LNG
February 10, 2017 | Author: Rama Moorthy | Category: N/A
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LNG Technology Dr. S. Madhavan Global Director, Plant Services (Retd.) Kellogg Brown & Root (KBR), Inc. Houston, TX, USA
Presen Pre sented ted in Dehra Dehra Dun
Natural Gas Utilization • Distribution by Pipeline • Liquefaction and Regasification • Compressed gas (CNG)
or • • • •
Conversion to Liquid Hydrocarbons Conversion to Methanol Conversion to Fertilizer Conversion to Electric Power
Natural Gas Utilization • Distribution by Pipeline • Liquefaction and Regasification • Compressed gas (CNG)
or • • • •
Conversion to Liquid Hydrocarbons Conversion to Methanol Conversion to Fertilizer Conversion to Electric Power
The Hydrocarbon Trend Hydrocarbon Hydrocarbon Rati atio of Primar Primary y Energy E nergy 4 3 C / H
2 1 0 1700
1800
1900
Century
2000
2100
Stranded Gas and Major Consumer Markets
Legend Stranded Gas Major Markets
Relative Costs of Gas Transportation Pipeline vs. LNG $5.00 $4.00
U T B
$3.00
M
$2.00
M / $
$1.00 $0.00 0
1 ,0 0 0 2 ,0 0 0
3 ,0 0 0
4,000 5,000
6,000
7,000 8,000
MILES Of f sho sho re Pipeli elin e
On sho shore Pipeli eline
LNG
9,000
How not to transport gas !!
How not to transport gas !!
LNG Technology
Typical Natural Gas Composition Typical Composition at Inlet of LNG Plant 1.0 - 2.0 %
Nitrogen
85.0 - 95.0 %
Methane
5.0 - 10.0 %
Ethane - - Feedstock for Ethylene
2.0 - 5.0 %
Propane
LPG
2.0 - 3.0 %
Total Butane+
Petrochemical Feedstock
1.0 - 4.0 %
Carbon Dioxide
Trace:
H2S, Hg, R-SH, COS
LNG Liquefied Natural Gas
o
- 161 C !!
Typical LNG Product Specifications
• • • • • • • • • •
Component
Limits (maximum)
Carbon Dioxide Mercury Nitrogen Water Vapor Benzene Ethane Propane Butane Pentane and heavier High Heating Value
50 ppm 0.01 micrograms per normal m3 1 mol% 1 ppmv 1 ppmv < 6 – 8 mol% (Feedstock for Ethylene!) LPG < 3 mol% Petrochemical < 2 mol% Feedstock < 0.1 mol% =1050 Btu/SCF (Europe and USA) up to 1140 Btu/SCF (East Asia)
LNG Train Capacities Train capacities •
Camel Plant, Algeria - 1964 - 0.4 MTPA
•
Sonatrach LNG, Algeria - 1970’s - 1.0 - 1.4 MTPA
•
Malaysia LNG (Satu), Bintulu - 1983 - 2.6 MTPA
•
Bontang LNG Trains - 1980’s-90’s - 1.6-3.0 MTPA
•
Woodside LNG - 1980’s-90’s - 2.2 - 4.2 MTPA
•
SEGAS LNG - 2004 - 5.0 MTPA
•
Qatargas LNG, Qatar - 2007 - 7.8 MTPA
•
Future Trains - - - - -
2010 - 9.0 MTPA
TYPICAL BLOCK DIAGRAM - LIQUEFACTION
C2
FUEL
C4
HYDROCARBON FRACTIONATION
C2
NATURAL GAS FEED
CO2 REMOVAL
DEHYDRATION & MERCURY REMOVAL
C3
BY PRODUCT GASOLINE FUEL
C4
CHILLING LIQUEFACTION NITROGEN REJECTION
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
LNG
OFFSITE LNG STORAGE
Typical Acid Gas Removal Scheme Acid Gas
Reflux Condenser
Treated Gas Lean Amine Lean Absorber SemiSemi-Lean Amine
Amine Cooler
Bulk Absorber
LowLow-Pressure Flash
Stripper Flash Gas
Sour Gas
Rich Amine
HighHighPressure Flash
Reboiler
Lean/Rich
Typical Dehydration Scheme Process Flow Regeneration Gas Compressor
Drier Precooler
Regeneration Cooler Regeneration Gas Knockout Drum
Water Saturated Natural Gas
Driers (ABS) Water
Hydrocarbon Liquid
Driers (Regen) Regeneration Heater
Filter
Dry Gas To Liquefaction
Typical Mercury Removal Scheme Process Flow
From Acid Gas Removal Section
Mercury Removal Column
To Liquefaction Section
Outlet Gas Specification is generally 10 nanograms of Mercury per cubic meter of gas.
Removal of Trace Mercury Contaminants
Mercury has to be removed from natural gas and its associated condensate to prevent: • corrosion in aluminum equipment
Removal of mercury in the gas phase is by: Ê
Ê
adsorption on sulfur impregnated carbon or alumina carrier molecular sieve
Refrigeration Cycles Types of Licensed Processes: • Propane Precooled Mixed Refrigerant Cycle (APCI) • Pure Component Cascade Cycle – Phillips Optimized Cascade
• Dual Mixed Refrigerant Cycle – Technip & Snamprogetti
• Single Mixed Refrigerant Cycle – PRICO
• Linde Technology
Basic Refrigeration - Simple PFD (Process Flow Diagram) Q High Temperature Condenser
Work
Compressor
(Ambient)
Air-cooled or water-cooled
Refrigeration Loop Accumulator
Suction Drum Heat Exchanger
J-T Valve
Q Low Temperature
Propane Precooled Mixed Refrigerant Cycle Ê
Pure propane refrigerant cycle Ambient to -40oC Ê Three or four pressure levels Ê
Ê
Mixed component refrigerant cycle -40oC to -160oC Ê Typical MCR Composition: Ê
2 - 10 % Nitrogen Ê 35 - 45 % Methane Ê 30 - 45 % Ethane Ê 10 - 15 % Propane Ê
Typical Propane Circuit Scheme Process Flow SW
PC
To MCHE MR
SW
Reinjection Chiller DC2 Condenser
To Scrub Column
Feed from Acid Gas Removal Feed Gas
APCI C3/MCR Process NRU
MR LIQ LIQ EX EXP MR P
HP HP CC 33
MP MP CC33
LP LP CC33
LOWBTU BTU LOW FUELGAS GA FUEL
LLP LLP CC33
LNG LNG EXP EXP
LNG LNG RUNDOW RUNDOWN
REFLUX REFLUX DRUM DRUM
MCHE MCHE
HP HP MR MR TREATED TREATED FEED FEED GAS GAS
MP MP MR MR
LP LP MR MR
LPG LPG REINJECTION REINJECTION
DEHY/Hg DEHY/Hg REMOVAL REMOVAL HP HP CC33
MP MP CC33
LP LP CC33
LLP LLP CC33
SCRUB SCRUB COLUMN COLUMN
ToFRACTIONATION FRACTIONATION To
Thermal Efficiency
Compressor Driver Selection • Economic driver selection possibilities: – Steam Turbines – Industrial Gas Turbines – Aeroderivative Gas Turbines – Electric Motors
Typical LP MR Compressor Axial Compressor Rotor Lifted From Casing
Propane Compressor
Frame 6 Gas Turbine
Propane Compressor driven by Frame 6 Gas Turbine
Axial Compressor
Frame 7 Cutaway Single Shaft Design
Power Turbine
Air Compressor
COIL WOUND EXCHANGER CONSTRUCTION
Main Cryogenic Heat Exchanger (MCHE)
LNG Tank
Vapour Release
Double Metal Wall LNG Storage Tank Design: To Boiloff Gas Recovery RV
LNG Rundown Bottom Fill
LNG to Ship
Top Fill
Carbon Steel Light LNG Heat Leak from Perlite Insulation
Ambient Heavy LNG
9% Ni Steel 32 month Construction Insulation
Schedule (Typical)
Double Containment Tanks
Full Containment Tanks
LNG Storage Tank Selection Full Integrity Tank •
For Spacing and Security Concerns Malaysia LNG Storage Tanks
LNG Contractors Liquefaction Plants
Top Tier • KBR/JGC • Chiyoda • Bechtel
Next Tier • Technip • Foster-Wheeler • Snamprogetti
LNG Shipping
Typical LNG Ships
Shipping and Typical Ship Parameters • Ship Size = 125,000 - 135,000 m3 nominal capacity • Design Speed = 18 - 20 knots • Boil-off rate = 0.15% of contents per day • Length = 300 m ; Breadth = 50 m • Draft = 11 m • Cost = $160 MM (highly dependent on market) • To ship 5 MMTPA a distance of 3500 miles, approximately 6 x 135,000 m3 ships are needed
LNG Receiving Terminals
LNG Terminal Flow Diagram
Vapor Return Line
Boil-Off Gas Compressor
LNG Unloading Arm Recondenser LNG Tanker
1st Stage Sendout Pumps LNG Storage Tanks
Fuel Gas Vaporizer
2nd Stage Sendout Pumps
To Pipeline
Open Rack Type
Features – Low running cost. Sea water used as heat source. – Easy to operate and maintain. – Tube Panels--made of aluminum alloy, coated outside with zinc alloy to provide corrosion resistance from sea water. – Return sea water is 4-5 deg. C cooler. Environmental consideration.
Cove Point Terminal
LNG Projects in India •
Dahej LNG Terminal, Gujarat – Started up in Jan 2004
•
Kochi LNG Terminal – 2.5 MM Tonnes/Yr capacity
•
Hazira LNG Terminal, Gujarat is a JV of Shell and Total
•
Ratnagiri LNG Terminal at Dabhol (Ex-Enron) will start shipping pipeline gas starting from 2010
•
Many proposed LNG Terminals may be shelved due to competition from new gas finds/fields offshore in K-G Basin and Cauveri Basin
•
New LNG Terminals and new pipeline construction will need to be developed in tandem.
1997 World LNG Trade Major Producers Ê
Pacific Rim Ê Ê Ê Ê Ê
Ê
67.5% 47.7% 26.5% 11.0% 12.7% 2.1%
Middle East Ê Ê
Ê
Indonesia Malaysia Brunei Australia Alaska Qatar Abu Dhabi
9.3% 28.2% 71.8%
Atlantic Basin Ê Ê Ê Ê
Algeria Libya Trinidad Nigeria
83.8 Mmt/y
23.2% 94.9% 5.1%
1997 World LNG Trade Major Consumers Ê
Pacific Rim Ê Ê Ê Ê Ê
Ê
Japan Taiwan Korea China India
75.2% 76.4% 5.0% 18.6%
Atlantic Basin Ê Ê Ê Ê Ê Ê Ê
France Belgium Greece Italy Spain Turkey USA
83.8 Mmt/y
24.8% 33.2% 16.8% 6.7% 24.0% 11.1% 8.2%
LNG Producing Countries Operating LNG Plants 1. Algeria 2. Libya 3. Egypt 4. Nigeria 5. Qatar 6. Oman 7. UAE 8. Malaysia 9. Brunei 10. Indonesia 11. Australia 12. USA 13. Trinidad
Plants Under Construction 1.
Nigeria
Plants on the Drawing Board
2.
Qatar
1.
Algeria
3.
Indonesia
2.
Egypt
4.
Australia
3.
Nigeria
5.
Norway
4.
Qatar
6.
Russia
7.
Equatorial Guinea
5.
Australia
8.
Trinidad
6.
Russia
9.
Oman
7.
Angola
10. Yemen
A Clear Picture of the Future
Floating LNG Chain 22,000 MT topsides FPSO for LNG on field location
Offshore LNG Transfer 4,000 MT topsides
to shuttle LNG carriers
FPSO Receiving Terminal Gas distribution grid
Flare
Acid Gas Solvent Regenerator
Pantograph LNG Unloading Arm
Accommodations appr. 100 people
Acid Gas Absorber Refrig. Compressors
Main Cryogenic Heat Exchanger
Power Generation Fractionation Dehydration
Internal Turret & Risers
Typical Service Crane
Inlet Compressor
Knock Out Drums
LNG FPSO
LNG Plant on a Ship
--Modularization LNG plant on a barge---BLUE MARTIN – STAT OIL Norway [154 METERS LONG AND 60 METERS WIDE AND 50 METERS HEIGHT-- 350,000 TONS ] 50
Source: “The LNG Business: How Fast Will it Grow?” By Theo Oerlemans, Poten
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