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Abstract—The disposition of waste heat in liquefied natural gas (LNG) plants has become increasingly
important as train sizes approach 5 million tons per annum (MTPA). A major contributor to this problem is the
large number of fin-fan, air-cooled heat exchangers (ACHEs) typically used to cool the gas to liquid phase.
Since ACHEs reject heat to the atmosphere, their effect on local ambient temperature and wind conditions
can contribute to loss of LNG production, particularly from the impact on the turbine drivers of refrigeration
compressors. To develop and optimize plant layouts that minimize the effects of air recirculation, Bechtel
uses computational fluid dynamics (CFD) models. This paper discusses typical air recirculation issues and
mitigation measures and presents case studies.
Keywords—air flow, air-cooled heat exchanger (ACHE), computational fluid dynamics (CFD), crosswind,
data comparison, heat exchanger, liquefied natural gas (LNG), mitigation, multi train, propane condenser,
self-recirculation, simulation methodology, skirts, stacks, temperature contamination, temperature rise,
validation, virtual reality, wind rose
A s the typical train size in liquefied thermally efficient designs employing combined
natural gas (LNG) plants has grown from cycle power and process integration, a large
2 million tons per annum (MTPA) in 1990 to multi-train facility releases a significant amount
Philip Diwakar 4.5 MTPA today, the disposition of waste heat of heat. Figure 1 illustrates how this waste
pmdiwaka@bechtel.com has become increasingly important. And solving heat can affect a facility’s ability to produce
this problem will only become more critical in at relative design capacities for all potential
the future, with trains of more than 5 MTPA ambient conditions.
Zhengcai Ye, PhD capacity being considered by several projects. The production rate at LNG plants can be very
zye@bechtel.com Thus, facility design economics will be driven sensitive to the inlet temperatures of compressor
not only by normal equipment and operating turbine drivers and plant air-cooling equipment.
costs, but also by the need to optimize design The inlet temperatures of this equipment depend
Ramachandra margin with overall facility arrangement and on the local wind conditions, terrain, and climate,
Tekumalla capacity requirements.
rptekuma@bechtel.com
60,000 3,000
m2
CFD
air-cooled heat exchanger
No
• Obtain component • Present temperature contours, animation, and write-up
specifications, flow rates, • Develop prototype drawings and detailed design process, • Benchmark
fan curve characteristics, review validation plan based on analysis, and develop and validate,
and heat requirements prototype build control plan if data available
• Use lessons learned to reduce costs, risks, and environmental effects
TYPICAL CFD STUDY OF AIR RECIRCULATION cooling equipment inlet temperature rises and
A process flow chart for an LNG air determine their variation with wind direction,
recirculation study using CFD simulation wind speed, and ambient temperature. Wind
is provided in Figure 2. The chart depicts and ambient temperature data and air-cooling
how mitigation measures are included in the equipment inlet temperatures were to be recorded
evaluation process to reduce inlet air temperatures every 15 minutes for 6 months. To collect the inlet
to the compressors and air-cooling equipment. temperature data, 25 sensors were installed on
the ethylene and propane condenser racks. The
condensers were located 12 to 18 m (39 to 59 ft)
VALIDATION OF CFD METHODOLOGY above ground. The sensors were mounted about
1.2 to 1.5 m (4 to 5 ft) below the tube bundles.
DT(C) – T2 Propane
4
2 P11. At location E11, the two cooling water pipes
0
that circulate water from the compressors to the
nearby vessel and air-cooling equipment may
–2
have contributed the higher local temperature
–4
The discrepancies rise measurements.
–6
between the
–8
CFD model results –10 CATEGORIZING AIR RECIRCULATION
and the 22 24 26 28 30 32 34 CONTAMINATION
W
temperature Ambient Temperature, °C
hen a large amount of heat generating
measurements equipment is located in a limited plot
are shown space, interactions among that equipment are
Figure 4. Measured Air-Cooling Equipment Inlet
Temperature Rise (Measured Inlet Temperature unavoidable. Many types of equipment at an
to be within
Minus Ambient Temperature) Versus Wind Direction, LNG plant involve air intake and exhaust. When
1 ºC (1.8 ºF). Wind Speed, and Ambient Temperature the pieces of equipment are close together, a
limited amount of fresh air is available and some
pieces may start to draw in exhaust air from
these criteria. The corresponding wind speeds other pieces or themselves. Such contamination
and ambient temperatures were averaged, and results in loss of cooling surface area and/or
the results (east wind, 1.9 m/sec [6.2 ft/sec]; higher inlet temperature above the ambient. The
ambient temperature, 25.2 °C [77.4 °F]) were used temperature contamination can be classified
as inputs to the CFD model. The air-cooling into two categories:
equipment inlet temperature data for these
• Contamination from self-recirculation
wind conditions was then used for comparison
with the CFD model results. • Contamination from other exhausts
9
8 Within 2 Sigma
7 CFD
All Measured Data
Temperature Rise, °C
6
5
4
3
2
1
0
–1
E11 E12 P11 P12 P13 P14 P15 P16 P17 E31 E32 P31 P32 P33 P34 P35 P36
Measurement Locations
Figure 5. Comparison of CFD Results with Inlet Temperature Measurements for East Wind Direction
Based on
Temperature, °C
simulations,
the LNG plant
28.5 29.5 30.9 31.5 32.5+ may be reoriented
or mitigation
measures studied
Figure 6. Temperature Profile Underneath Double-Bank Propane Condensers
to minimize
self-recirculation
Temperature Contamination from narrow plume and causing more lift with less
during crosswinds.
Self-Recirculation possibility of recirculation back into the inlet.
Because of site layout or wind conditions, While the same amount of fan throughput is
exhaust air can sometimes recirculate to the predicted in both cases, the horizontal skirt
inlets of the same unit. To illustrate this activity, results in a lower inlet recirculation temperature
a CFD model was constructed based on the into the air-cooling equipment. In the crosswind
use of a double bank of air-cooled propane case, the vertical skirt offers larger resistance to
condenser units. Different wind speeds and airflow, accelerating flow below the first one or
directions were tested, and the effects on the two rows of fans. As seen in the vector plot, the
propane condensers were studied. downward pull of the airflow upstream of the
vertical skirt renders the first row of fans nearly
Figure 6 shows the temperature profile just
dysfunctional. Moreover, since the crosswind
underneath the propane condensers’ fans. The
simulations predicted that when wind direction
is perpendicular to the length of the propane
condensers (crosswind), the largest heated zone
is created (Figure 7), resulting in the greatest
self-recirculation. But when the wind blows along
the length of the propane condensers, much less
self-recirculation occurs because the edge facing
the wind is shorter. However, under strong
wind conditions, the turbulence created from Z
the corners can swirl back into the inlets of the X Y
propane condensers, as shown in Figure 7. Based
on these simulations, the plant can be reoriented
or mitigation measures studied to minimize the
self-recirculation during crosswinds.
5.7
35.0
15.7
7.9
7.9
30.5
0.0
0.0
26.0
Z Z
Y X Y X
Horizontal skirt
pushes pull-down further
upstream, preventing
recirculation.
35.0
35.0
30.5
30.5
35.0
26.0
26.0
26.0
30.5
26.0
26.0
Z Z
Y X Y X
Horizontal Vertical
approaches the air-cooling equipment from one performance gradually improves as the
side, the entire airflow has to enter the coolers skirt width is increased to 4.5 m (15 ft).
from that side, resulting in higher average and Increase in flow and decrease in inlet
peak velocity below the skirts. temperature are also apparent as skirt
width increases. However, structural
What, then, should be the size of the skirt?
stability, flutter, and fatigue limit skirts
Figure 9 shows a comparison of 1.5, 3, and
to a maximum of about 3 m (10 ft).
4.5 m (5, 10, and 15 ft, respectively) horizontal
skirts in the crosswind case. As can be seen
in the figure, the widest skirt (4.5 m [15 ft]) Temperature Contamination from
results in the least amount of recirculation Other Exhausts
due to the downward flow being pushed When multiple large pieces of heat-
away from the air-cooling equipment, thus releasing equipment (such as ACHEs) are
preventing it from recirculating back into located within a limited plot area,
the inlet. The first rows of fans appear temperature contamination from these various
to be severely affected when exhausting sources is also possible in addition to
flow for the 1.5 m (5 ft) skirt case. The fan self-recirculation. Downstream equipment
3 m Skirt
4.5 m Skirt
Z Z Z
Y X Y X Y X
50.0
Compressor Building 48.5
with Turbine Stack 47.0
45.5
44.0
42.5
41.0
39.5
Air Coolers 38.0
36.5
35.0
33.5
30.5
Double Bank 29.0
27.5 Temperature
Propane Condensers 26.0
Z 24.5 Z Contours Cut Slice
Y 23.0 Y Through All Units,
X 21.5 X Scaled from 2–50 °C
20.0
Figure 11. SWW Wind Direction at 4.2 m/sec (13.7 ft/sec) – Stream Lines from All Units Colored by Temperature,
Scaled from 20–35 °C (68–95 °F)
CFD can be
a fast and
W ith multi-train LNG plants becoming more
common, the impacts from the surrounding
environment are a vital consideration for
REFERENCES
[1] A. Avidan, D. Messersmith, and B. Martinez,
economic way production. Large vessels, towers, and buildings “LNG Liquefaction Technologies Move
to analyze can block air feeding into air-cooled equipment. Towards Greater Efficiencies, Lower Emissions,”
Turbulence generated behind these structures Oil & Gas Journal, Vol. 100, Issue 33, August 19,
the fluid dynamics 2002, access via http://www.ogj.com/index/
can also create local recirculation zones. If air- current-issue/oil-gas-journal/volume-100/
around plants. cooling equipment is located within these zones, issue-33.html.
the equipment can be starved for fresh air. CFD
can be a faster, cheaper way to analyze the fluid
dynamics around plants. Using CFD in the ADDITIONAL READING
design phase can help to minimize recirculation Additional information sources used to develop
problems. In a simulation, the relationships this paper include:
among, and orientations of, open spaces and
buildings can be evaluated and different kinds • J. Berkoe, “Fluid Dynamics Visualization Solves
LNG Plant Recirculation Problem,” Oil & Gas
of weather conditions can be assessed. Different Journal, Vol. 97, Issue 13, March 29, 1999
mitigation measures can also be examined, such (access via http://www.ogj.com/index/current-
as changing the orientation of the plant or issue/oil-gas-journal/volume-97/issue-13.html).
relocating some of the equipment. Although • W.K. Yee, D. Lin, V. Mehrotra, and P. Diwakar,
no complete solutions exist for these problems, “Predicting Environmental Impacts on Multi-
Train LNG Facility Using Computation Fluid
analyzing different scenarios can minimize the Dynamics (CFD),” AIChE Spring National
effects of recirculation on LNG production. Meeting, Atlanta, GA, April 10–14, 2005,
access via http://www.aiche.org/
In the authors’ experience, recirculation
Publications/pubcat/0816909849.aspx.
effects can be minimized by using hoods or
• D. Lin, W.K. Yee, P. Diwakar, and V. Mehrotra,
horizontal or vertical skirts. The fluid dynamics “Validation of the Air Recirculation CFD
of the plume emanating from the air-cooling Simulations on a Multi-Train LNG Plant,”
equipment change significantly with the type AIChE Spring National Meeting,
New Orleans, LA, April 25–29, 2004, access via
of skirt (vertical/horizontal) and wind direction
http://www.aiche.org/Publications/pubcat/
(parallel/crosswind). A horizontal skirt is a listings/2004springmeetingcd.aspx.
more aerodynamic design that helps air flow
into the air-cooling equipment while reducing
air recirculation and improving air-cooling
equipment performance under all wind speeds
BIOGRAPHIES
and directions. However, as skirt width is
Philip Diwakar is a senior
increased beyond 10 feet, the return on improved
eng i neer i ng specia l ist
performance diminishes while the cost increases. for Bechtel Systems &
CFD can provide valuable insights to the plant Infrastructure, Inc.’s, Advanced
designers or engineers and enable informed Simulation and Analysis
Group. He employs state-of-
decisions to be made about these and similar
the-art technology to resolve
design factors. a wide range of complex
engineering problems on large-
As a mitigation tool, CFD enables various scale projects. Philip has more
parameters to be changed in the virtual space than 15 years of experience in CFD and finite element
so the most effective solution can be found. analysis for structural mechanics. His more recent
experience includes work on projects involving fluid-
Computing technology continues to advance,
solid interaction and explosion dynamics.
and increasingly complex problems can be