A novel strategy for process optimization of a natural gas liquid recovery unit by replacing Joule–Thomson valve with supersonic separator

The natural gas liquid recovery is an important process in a gas plant to correct hydrocarbon dew point and earn profit. In this study, a natural gas liquid recovery unit operated based on the Joule–Thomson process was investigated and its performance was optimized. To improve the system performance, the plant configuration and intermediate pressure ratio were defined as the variables and maximization of the natural gas liquid recovery rate and maximization of exergy efficiency were defined as the objective functions. To improve the plant performance, the amount of natural gas liquid recovery rate should be increased. To achieve this goal, several scenarios for the intermediate pressure ratio and three new configurations were proposed for the investigated gas plant. In the proposed configurations, the supersonic separators with optimized structures were used instead of the Joule–Thomson process. It was observed that all three proposed configurations improved the natural gas liquid recovery rate compared to the existing configuration. For example, by installing two supersonic separators instead of second and third stage Joule–Thomson valve + low temperature separator, at the optimal operating condition, the natural gas liquid recovery rate increased about 390%. The influence of the intermediate pressure ratio on the phase envelope diagram, exergy efficiency, dew point depression and natural gas liquid recovery rate was also investigated. By comparing the influence of intermediate pressure ratio and modifying the plant configuration on the objective functions, it was observed that the system performance can be further improved by modifying the plant configuration.