Heat integration analysis based on recycle split vapor ethane recovery process

Recovering ethane from natural gas involves significant energy consumption. Globally, the recycle split vapor process (RSV) is widely adopted as an efficient method for ethane recovery. Nonetheless, one major challenge faced by the RSV process is the lack of adequate heat integration, despite its overall effectiveness. In this article, we investigate the heat integration of the RSV process and propose two novel ethane recovery processes: the recycle split vapor process with direct heat integration of the feed gas (RSV‐DTI) and the recycle split vapor process with split heat integration of the feed gas (RSV‐SHI). A comparative analysis is conducted among these three processes, focusing on integrated energy consumption, exergy efficiency, and economic investment. The study's findings reveal the following: (1) The RSV‐DTI process distinguishes itself with its reduced energy consumption, enhanced stability, and minimized refrigerant usage. In comparison to the RSV process, the RSV‐DTI process achieves a reduction of over 15% in total compression duty and a remarkable decrease of 68% in propane usage. (2) Electricity emerges as the predominant energy consumed in the ethane recovery process, and the RSV‐DTI process significantly improves upon this aspect. Notably, the RSV‐DTI process incurs the lowest investment cost, yielding a swift payback period of approximately 1 year for the plant. The characteristics of the RSV‐DTI process are investigated, and the effect of changes in feed gas conditions on the heat integration of the RSV‐DTI process is analyzed. The characteristics of the RSV‐DTI process show the following: (1) Different pressures of feed gas existing in the main cold box have different minimum heat integration temperatures (MHIT). When the feed gas temperature is lower than the MHIT, heat integration becomes difficult, and the heat energy can be supplied by hot liquid propane at 48°C. When the feed gas temperature is higher than the MHIT, changes in feed gas temperature have little effect on the process, only affecting the external gas temperature. (2) The heat transfer duty of the demethanizer sideline outlet stream is affected by the feed gas pressure. To enhance heat integration, it is recommended to set the heat transfer duty of the low‐temperature sideline outlet stream (DLTSS) between 40% and 90% of the reboiler duty and the heat transfer duty of the high‐temperature sideline outlet stream (DHTSS) between 40% and 75% of the reboiler duty.