Hydrogen liquefaction with stored hydrogen refrigeration source
A system and method for liquefying a hydrogen gas feed stream uses a high-pressure hydrogen stream from a storage source to provide refrigeration to the system. After providing refrigeration to the system, the hydrogen from the high-pressure storage source is at a pressure not lower than the pressure of a cold box feed stream of the system, where the cold box feed stream includes the hydrogen gas feed stream and at least one recycle stream, and is not recycled back through the system but instead exits the system.
1 . A system for liquefying a hydrogen gas feed stream comprising:
a. a cold box feed line configured to receive a cold box feed stream having a cold box feed stream pressure where the cold box feed stream includes at least the hydrogen gas feed stream;
b. a heat exchanger system having a liquefier cooling passage in fluid communication with the cold box feed line and configured to receive and cool a liquefier feed stream so that a product stream is formed;
c. a product expansion device in fluid communication with an outlet of the liquefier cooling passage and configured to receive the product stream so that an expanded product stream is formed;
d. said heat exchanger system including a first refrigerant cooling passage configured to receive a refrigerant feed stream so that a cooled refrigerant feed stream is formed;
e. a first refrigerant expansion device in fluid communication with the first refrigerant cooling passage of the heat exchanger system so that a first expanded refrigerant stream is formed, said heat exchanger system further including:
i. second liquefier cooling passage in fluid communication with the liquefier cooling passage and the product expansion device;
ii. a second refrigerant cooling passage in fluid communication with the first refrigerant cooling passage and the first refrigerant expansion device;
iii. a second refrigerant warming passage;
f. said heat exchanger system including a first refrigerant warming passage in fluid communication with an outlet of the first refrigerant expansion device so that cooling is provided in the heat exchanger system;
g. said heat exchanger system including a first hydrogen high-pressure refrigerant cooling passage configured to receive and cool a high-pressure hydrogen supplemental refrigerant feed stream from a stored hydrogen source that is external to the system so that a cooled hydrogen supplemental refrigerant stream is formed;
h. a supplemental refrigerant expansion device having an inlet in fluid communication with the first hydrogen high-pressure refrigerant cooling passage so that an expanded hydrogen supplemental refrigerant stream is produced having a pressure not lower than the cold box feed stream pressure; and
i. said heat exchanger system including a high-pressure hydrogen refrigerant warming passage in fluid communication with an outlet of the supplemental refrigerant expansion device and configured to receive the expanded hydrogen supplemental refrigerant stream so that cooling is provided in the heat exchanger system and a high-pressure hydrogen product stream is formed that is at a pressure higher than the cold box feed stream pressure;
j. a product separator having a product separator vapor outlet and a product separator liquid outlet, said product separator configured to receive the mixed-phase expanded product stream from the product expansion device and produce a liquid hydrogen product stream that exits the product separator through the product separator liquid outlet and a hydrogen vapor stream that exits the product separator through the product separator vapor outlet;
k. said heat exchanger system including a first product separator vapor recycle passage in fluid communication with the product separator vapor outlet so that cooling is provided in the heat exchanger system and a first recycle stream is formed;
l. a first recycle compressor having an inlet configured to receive the first recycle stream so that a compressed first recycle stream is formed;
wherein the cold box feed stream includes at least the compressed first recycle stream and the hydrogen gas feed stream;
m. a second refrigerant expansion device configured to receive a first portion of the cooled refrigerant stream exiting the first refrigerant cooling passage so that a second expanded refrigerant stream is formed;
n. said second refrigerant cooling passage configured to receive and cool a second portion of the cooled refrigerant stream;
o. said second refrigerant warming passage in fluid communication with an outlet of the second refrigerant expansion device so that cooling is provided in the heat exchanger system;
p. a second recycle compressor having an inlet configured to receive the hydrogen gas feed stream downstream from the first recycle compressor and in fluid communication with the second refrigerant warming passage and an outlet of the first recycle compressor so that a compressed second recycle stream is formed, said second recycle compressor having an outlet in fluid communication with the cold box feed line and wherein the inlet or the outlet of the second recycle compressor is configured to receive the hydrogen gas feed stream so that the second recycle compressor receives the hydrogen gas feed stream or the cold box feed stream contains the hydrogen gas feed stream;
q. a split in fluid communication with the cold box feed line and configured to divide the cold box feed stream into the liquefier feed stream and the refrigerant feed stream;
r. said first refrigerant expansion device configured so that the expanded refrigerant stream is mixed-phase and further comprising a refrigerant separator configured to receive and separate the expanded refrigerant stream into a vapor refrigerant stream and a liquid refrigerant stream, said refrigerant separator having a refrigerant separator vapor outlet and a refrigerant separator liquid outlet and wherein the refrigerant separator vapor outlet is in fluid communication with the inlet of the first recycle compressor;
s. said heat exchanger system further including a product heat exchanger including a product liquefier cooling passage in fluid communication with the liquefier cooling passage and the product expansion device and a product vapor warming passage configured to receive and warm the hydrogen vapor stream from the product separator vapor outlet of the product separator, said product vapor warming passage having an outlet in fluid communication with an outlet of the refrigerant separator vapor outlet.
2 . The system of claim 1 further wherein the heat exchanger system includes a feed stream cooling passage in fluid communication with the cold box feed line and configured to receive and cool the cold box feed stream so that a first absorber feed stream is formed and further comprising a first absorber configured to receive the first absorber feed stream so that the liquefier feed stream is formed.
3 . The system of claim 1 wherein the second refrigerant expansion device is a turbine.
4 . The system of claim 1 further comprising a higher-temperature hydrogen expander configured to receive a portion of a cooled refrigerant stream exiting the first refrigerant cooling passage so that a hydrogen expander refrigerant expanded stream is formed and directed to the first product separator vapor recycle passage, the second refrigerant warming passage or both the first product separator vapor recycle passage and the second refrigerant warming passage of the heat exchanger system.
5 . The system of claim 1 wherein the heat exchanger system is configured to receive and warm a liquid stream from a refrigerant separator so that a mixed-phase hydrogen refrigerant stream is formed and to return the mixed-phase hydrogen refrigerant stream to the refrigerant separator.
6 . The system of claim 1 wherein the second liquefier cooling passage and the product liquefier cooling passage each contain an ortho-para conversion catalyst or is in fluid communication with one or more catalytic reactors.
7 . The system of claim 1 wherein the heat exchanger system includes a first heat exchanger configured to receive and cool the cold box feed stream and a second heat exchanger having the liquefier cooling passage and the refrigerant cooling passage and the first, second and product heat exchangers are each separate individual heat exchanger devices.
8 . The system of claim 1 further comprising a second absorber configured to receive the cooled hydrogen supplemental refrigeration stream, and wherein said heat exchanger system includes a second hydrogen high-pressure refrigeration cooling passage in fluid communication with an outlet of the second absorber and the inlet of the supplemental refrigerant expansion device.
9 . The system of claim 1 wherein the supplemental refrigerant expansion device is a turbine.
10 . The system of claim 1 wherein each of the product expansion device and the refrigerant expansion device is a Joule-Thomson valve.
11 . The system of claim 1 wherein the liquefier cooling passage of the heat exchanger system contains an ortho-para conversion catalyst or is in fluid communication with one or more catalytic reactors.
12 . The system of claim 1 wherein the heat exchanger system includes a first supplemental refrigerant passage configured to receive a non-hydrogen supplemental refrigerant.
13 . The system of claim 1 wherein the cold box feed stream pressure is approximately 200-600 psig.
14 . The system of claim 1 wherein the cold box feed stream pressure is approximately 250-400 psig.
15 . The system of claim 1 further comprising a first closed-loop compressor having an inlet in fluid communication with the refrigerant warming passage and an outlet in fluid communication with the refrigerant cooling passage and a closed-loop expansion device having an inlet in fluid communication with the refrigerant cooling passage and an outlet in fluid communication with the refrigerant warming passage.
16 . The system of claim 2 wherein the heat exchanger system includes a first heat exchanger having the feed stream cooling passage and a second heat exchanger having the liquefier cooling passage and wherein the first and second heat exchangers are each individual and separate heat exchanger devices.
17 . The system of claim 15 wherein the refrigerant includes helium or neon.
18 . A method for liquefying a hydrogen gas feed stream comprising the steps of:
a. receiving a cold box feed stream including at least the hydrogen gas feed stream into a heat exchanger system, said cold box feed stream having a cold box feed stream pressure;
b. cooling a liquefier feed stream that includes the cold box feed stream in the heat exchanger system to form a product stream;
c. expanding the product stream to form an expanded product stream;
d. cooling a refrigerant stream in the heat exchanger system to form a cooled refrigerant stream;
e. expanding the cooled refrigerant stream to form a first expanded refrigerant stream;
f. warming the first expanded refrigerant stream so that cooling is provided in the heat exchanger system;
g. cooling a high-pressure hydrogen supplemental refrigerant feed stream from an external stored hydrogen source in the heat exchanger system so that a cooled hydrogen supplemental refrigerant stream is formed;
h. expanding the cooled hydrogen supplemental refrigerant stream to form an expanded hydrogen supplemental refrigerant stream having a pressure not lower than the cold box feed stream pressure; and
i. warming the expanded supplemental hydrogen refrigerant stream so that cooling is provided in the heat exchanger system and a high-pressure hydrogen product stream is formed that is at a pressure higher than the cold box feed stream pressure.
19 . The method of claim 18 wherein step c. includes forming a mixed-phase product stream and further comprising the steps of;
j. separating the mixed-phase product stream into a liquid hydrogen product stream and a hydrogen vapor stream;
k. warming the hydrogen vapor stream to provide cooling in the heat exchanger system and to form a first recycle stream;
l. Compressing the first recycle stream to form a compressed first recycle stream and combining the compressed first recycle stream with the hydrogen gas feed stream to form the cold box feed stream.
20 . The method of claim 18 wherein the liquefier feed stream includes approximately 20-25% of a purified cooled cold box feed stream.
21 . The method of claim 18 wherein the cold box feed stream pressure is approximately 200-600 psig.
22 . The method of claim 18 wherein the cold box feed stream pressure is approximately 250-400 psig.
23 . The method of claim 18 further comprising the step of converting a portion of the liquefier feed stream from ortho-hydrogen to para-hydrogen.
24 . The method of claim 18 further comprising the steps of cooling and purifying the cold box feed stream to form the liquefier feed stream.
25 . The method of claim 18 wherein the refrigerant stream includes hydrogen.
26 . The method of claim 18 wherein step f. produces a warmed refrigerant stream and further comprising the step of compressing the warmed refrigerant stream to provide the refrigerant stream that is cooled in step d.
27 . The method of claim 19 further comprising the steps of:
m. splitting the cold box feed stream into the liquefier feed stream and the refrigerant stream;
n. dividing the refrigerant stream into a first portion and a second portion, where the first portion is expanded to form the first expanded refrigerant stream;
o. expanding the second portion of the refrigerant stream to form a second expanded refrigerant stream;
p. warming the second expanded refrigerant stream to provide cooling in the heat exchange system and to form a second recycle stream;
q. combining the second recycle stream with the compressed first recycle stream and the feed gas stream to form the cold box feed stream.
28 . The method of claim 26 wherein the refrigerant includes helium.