Evaluation of LNG Production Technologies

Ayema Aduku Oluwaseun Harris Valerie Rivera Miguel Bagajewicz

University of Oklahoma

Outline
LNG Background Objective Simulation Specifications Liquefaction Techniques Heat Exchanger Types Simulation Method Results

Flow Diagram for a Typical LNG Plant

LNG (Liquefied Natural Gas) Basics

Combustible mixture of hydrocarbons

Dry

VS. Wet

NGL Extraction Dehydration/Scrubbing Liquefied Natural Gas

temperature for Natural gas:-260F Reduces volume by a factor 600
Target

Objective

Main Objectives Simulate Processes Optimize Processes Minimize compressor work Compare Processes based on Capital cost Energy cost Total cost per capacity(Ton)

Liquefaction Processes
Mixed Refrigerants Pure Refrigerants Both Other

Linde Process Axens Liquefin Process Dual Mixed Refrigerant

CoP Simple Cascade CoP Enhanced Cascade

APCI C3 MR APCI AP-X Linde 2006

Technip-TEALARC
ExxonMobil Dual Multi-component Black and Veatch Prico Process Technip- Snamprogetti

BP Self refrigerated process ABB Randall TurboExpander Williams Field Services co. Mustang Group

* Italicized processes signify Patent searched processes. * Bolded processes signify processes not included in scope of project.

Flow diagrams

Black and Veatchs PRICO Process

Axens Liquefin Process

C3MR: Air Products and Chemical Inc

ExxonMobil Dual Multi-Component Cycle

AP-X: Air Products and Chemical Inc.

Technip- TEALARC System

BP- Self Refrigerated Process DMR- Dual Mixed Refrigerant

Linde/Statoil -Mixed Fluid Cascade Process

Linde- CO2 MFCP

ConocoPhilips Simple Cascade

Simulation Specifications

Natural Gas composition

Methane: 0.98 Ethane: 0.01 Propane: 0.01

Inlet conditions Pressure: 750 psia Temperature: 1000F Outlet conditions Pressure: 14.7 psia Beihai City, China o Temperature: -260 F Capacity: Common min. to max. capacity of process Common min. Capacity: 200,000 lbs/hr

Liquefaction Techniques

Different Liquefaction techniques include:

Single

Refrigeration cycle Multiple Refrigeration cycles Self Refrigerated cycles Cascade Processes

The cooling of natural gas involves the use of refrigerants which could either be pure component refrigerants or mixed component refrigerants.

Liquefaction Techniques
Schematic of a Simple Refrigeration Cycle

Expander

Compressor

Heat Exchanger

Liquefaction Techniques

Mixed refrigerants are mainly composed of hydrocarbons ranging from methane to pentane, Nitrogen and CO2. Pure component Refrigerants
Specific

operating ranges for each component

Mixed Refrigerants
Modified

to meet specific cooling demands. Helps improve the process efficiency

Liquefaction Techniques
T-Q Diagrams
Natural gas cooling curve

Area between curves represents work done by the system

Liquefaction Techniques Single Refrigeration Cycle

One

refrigeration loop that cools the natural gas to its required temperature range. Usually requires fewer equipment and can only handle small base loads. Lower capital costs and a higher operating efficiency

Black and Veatch: PRICO Process

Condenser Compressor

Inlet Gas

100oC

Cold Box Residue

-260oC

Single mixed refrigerant loop and single compression system Limited capacity (1.3 MTPA) Low capital cost Great Pilot Process

Expander

LNG

Refrigeration Cycles and Natural Gas Liquefaction

Compressor

Inlet Gas

Simple Refrigeration Cycle

Cold Box

LNG

Black and Veatch- PRICO Process

Liquefaction Techniques Multiple Refrigeration cycles

Contains

two or more refrigeration cycles. Refrigerants involved could be a combination of mixed or pure component refrigerants. Some cycles are setup primarily to supplement cooling of the other refrigerants before cooling the natural gas. More equipment usually involved to handle larger base loads.

Air Products and Chemical Inc: C3-MR

LNG

Inlet Gas

APCI processes are used in almost 90% of the industry Good standard by which to judge the other processes Capacity of about 5 MTPA Utilizes Propane (C3) and Mixed Refrigerants (MR)

Mixed Refrigerant

Liquefaction Techniques Self Refrigerated Cycles

Takes

advantage of the cooling ability of hydrocarbons available in the natural gas to help in the liquefaction process. Numerous expansion stages are required to achieve desired temperatures. Considered as a safer method because there are no external refrigerants needing storage.

BP Self Refrigerated Process

Residue Gas

Neither refrigerants, compressor, nor expanders present in setup. Cost include mainly capital costs and electricity. Low Production rate (51%) Capacities of over 1.3MTPA attainable .

Inlet gas LNG

Liquefaction Techniques Cascade Processes

A

series of heat exchangers with each stage using a different refrigerant. Tailored to take advantage of different thermodynamic properties of the refrigerants to be used. Usually have high capital costs and can handle very large base loads.

ConocoPhilips Simple Cascade

Methane Ethylene Propane

Residue Gas Sub-Cooling

3 stage pure refrigerant process

Propane Ethylene Methane

5 MTPA Capacity

Inlet Gas
Pre- Cooling Liquefaction

LNG

Equipment

Plate Fin Heat Exchanger

Spiral Wound Heat Exchanger

Spiral Wound Heat Exchanger

Equipment Comparison
Plate-Fin-Heat-Exchangers Coil-Wound-Heat-Exchangers

Characteristics

Extremely compact
Multiple streams Single and two-phase streams

Compact
Multiple streams Single and two-phase streams Clean Cross counter-flow 20 - 300 m/m Aluminum Stainless steel (SS) Carbon steel (CS) Special alloys

Fluid Flow-types

Very clean Counter-flow

Cross-flow
Heating-surface Materials

300 - 1400 m/m Aluminum

Temperatures Pressures Applications

-269C to +65 C (150 F) Up to 115 bar (1660 psi) Cryogenic plants Non-corrosive fluids Very limited installation space

All Up to 250 bar (3625 psi) Also for corrosive fluids Also for thermal shocks Also for higher temperatures

Our Evaluation Methods

Data on operating conditions (Temperatures, Pressures, Flowrates, etc) for all these processes is not widely available (Only some is reported). We decided to perform simulations using our best estimates. We used minimum compression work as guide. We identified non-improvable points

Details of methodology

Conditions after each stage of refrigeration were noted After making simple simulations mimic real process, variables were transferred to real process simulation Optimization- Refrigerant composition Optimization- Compressor work Restriction needed- Heat transfer area

All cells in LNG HX must have equal area Check temperature of streams Obtain cooling water flow rate

Restriction needed- Second law of thermodynamics

Utilities

CO2 Pre-cooled Linde Process

Inlet Gas

100oC
Pre- Cooling

-70oC

Liquefaction

-140oC

High Pressure

Low Pressure

Modification of the Mixed Fluid Cascade Process Three distinct stages using 3 mixed refrigerants with different compositions Carbon dioxide is sole refrigerant in pre-cooling stage Separate cycles and mixed refrigerants help in the flexibility and thermodynamic efficiency Process is safer because hydrocarbon inventory is less 8 MTPA Capacity

Sub-Cooling

-260oC
LNG

Results

Cost Basis

Economic Life of 20 years New train required at the documented maximum capacity of each specific process. Average cost of electricity and cooling water throughout the US used in analysis. Energy cost evaluated at a minimum capacity of 1.2 MTPA

Results

10

Results

10

Results

Process Prico Liquefin ExxonMobil DMR APX MFCP MFCP(CO2) TEALARC C3MR Conoco

Cost per ton ($) 5.12 3.41 4.83 12.58 19.20 31.73 24.77 25.35 12.93 20.15

Max capacity (MTPA) 1.20 6.00 4.80 4.80 7.80 7.20 7.20 6.00 4.80 5.00

Analysis

Our results may not match market trends

Operating

temperature and pressure range as well as flowrate information unavailable Precedents to compare results unavailable Information on cost to use process unavailable (licensing, proprietary production fees, etc.)

Analysis

We may be trapped in local minima and failed to identify better conditions

Work
Local Minimum

Global Minimum

Temperature

Conclusions

We successfully simulated several LNG production plants We obtained capital and operating costs and determined a ranking Some connection with existing trends were identified, but other results do not coincide with market trends We discussed why discrepancies may arise.

Questions?

References

"Overview: LNG Basics." Center for Liquefied Natural Gas. 2008. Center for Liquefied Natural Gas. 3 Feb 2008. <http://www.lngfacts.org/About-LNG/Overview.asp>. http://www.globalsecurity.org/military/systems/ship/tanker-lng-history.htm www.fpweb.com/200/Issue/Article/False/67449/Issue Fossil Energy Office of Communications. U.S. Department of Energy: Fossil Energy. 18 Dec 2007. U.S. Department of Energy. 3 Feb 2008. .<http://www.fossil.energy.gov/programs/oilgas/storage/index.html>. "Mustang receives U.S. patent for LNG liquefaction process." Scandanavian Oil and Gas Magazine. 14 Dec 2007. 3 Feb 2008. <http://www.scandoil.com/moxie-bm2/news/mustangreceives-us-patent-for-lng-liquefaction-pr.shtml>. Spilsbury, Chris; Yu-Nan Liu; et al. "Evolution of Liquefaction Technology for today's LNG business." Journees Scientifiques Et Techniques (2006) Process Selection is Critical to onshore LNG economics. World-Oil Magazine. February 2006 com <http://www.worldoil.com/Magazine/MAGAZINE_DETAIL.asp?ART_ID=2808&MONTH_YEAR=F eb-2006> Flynn, Thomas N. Cryogenic Engineering. Second edition. Marcel Dekker. New York- NY. 2005