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Society of Petroleum Engineers Distinguished Lecturer Programwww.spe.org/dl

1

LNG Basicsfor Petroleum Engineersfor Petroleum Engineers

Michael Choi

2

Present an Overview of LNG Plantese Ove v ew o NG• Why LNG?• Typical Multi Trains Plant• Typical Multi-Trains Plant• Pre-Treatment Required• Unique Auxiliary Facilitiesq y• Natural Gas Liquefaction

Thermodynamics• Commercial Liquefaction

Oman LNG Plant

• Commercial Liquefaction Processes

• Equipment for LiquefactionOman LNG Plant • Novel Plant Concepts

• Concluding Remarks

3

Stranded Gas Looking for Markets• LNG Proved to be Most Economic for Distances >1,500 Mile• Transported in Insulated Tankers @ -162C & 1 atm.

V l R d ti f 600 1• Volume Reduction of 600:1

SupplyDemandDemand

4

LNG Process & Equipment ?q p

Big Refrigeration System

• Compressor/DriverR f i C d

Big Refrigeration System

• Refrigerant Condenser• Evaporator (Process

Heat Exchanger)Heat Exchanger)

Similar to the AC Systemi O H !in Our Home!

5

Typical 2-Train LNG PlantFuelMake-

Up FuelGas

Gathering Train 1

Inlet Gas Reception

Inlet Gas Treating

NGL Recovery

Liquefaction LNG Storage

LNG

Gas

Liquid

g

1.7 Bcfd

NGL Fractionation

Train 2

9 Mtpa (1.2 Bcfd)

Condensate Stabilization

Propane Storage

Butane

Propane

Butane

.73 Mtpa(27 Mbpd)

Butane Storage

Condensate Storage

Butane

Condensate

(17 Mbpd).5 Mtpa

1 2 MtStorage(34 Mbpd) 1.2 Mtpa

6

Typical 2-Train LNG PlantFuelMake-

Up FuelGas

Gathering Train 1

Inlet Gas Reception

Inlet Gas Treating

NGL Recovery

Liquefaction LNG Storage

LNG

Gas

Liquid

g

1.7 BcfdInlet Gas Reception

NGL Fractionation

Train 2

9 Mtpa (1.2 Bcfd)

Inlet Gas Reception• Pipeline Manifold• Pig Receivers• I l t S t

Condensate Stabilization

Propane Storage

Butane

Propane

Butane

.73 Mtpa(27 Mbpd)

• Inlet Separator• Slug Catcher

Condensate Stabilization Butane Storage

Condensate Storage

Butane

Condensate

(17 Mbpd).5 Mtpa

1 2 Mt

Condensate Stabilization• Multi-Stage Column• Vapor Compressor

10 12 i RVP Storage(34 Mbpd) 1.2 Mtpa • 10-12 psia RVP

• De-Odorized7

Typical 2-Train LNG PlantFuelMake-

Up FuelGas

Gathering Train 1

Inlet Gas Reception

Inlet Gas Treating

NGL Recovery

Liquefaction LNG Storage

LNG

Gas

Liquid

g

1.7 Bcfd

NGL Fractionation

Train 2

9 Mtpa (1.2 Bcfd)NGL Fractionation

• DeethanizerV C i

Condensate Stabilization

Propane Storage

Butane

Propane

Butane

.73 Mtpa(27 Mbpd)

• Vapor Compression• Depropanizer & Treating

• 95% & 200 psig VP Butane Storage

Condensate Storage

Butane

Condensate

(17 Mbpd).5 Mtpa

1 2 Mt

• <.5ppm H2S & <15ppm S• Debutanizer & Treating

• 95% & 70 psig VP @100F Storage(34 Mbpd) 1.2 Mtpa

7

95% & 70 psig VP @100F• <.5ppm H2S & <15ppm S

Typical 2-Train LNG PlantFuelMake-

Up FuelGas

Gathering Train 1

Inlet Gas Reception

Inlet Gas Treating

NGL Recovery

Liquefaction LNG Storage

LNG

Gas

Liquid

g

1.7 Bcfd Inlet Gas Treating

NGL Fractionation

Train 2

9 Mtpa (1.2 Bcfd)

Inlet Gas Treating• Amine for CO2 & H2S Removal

• <50 ppm & < 4 ppm• S lf R U it if H S

Condensate Stabilization

Propane Storage

Butane

Propane

Butane

.73 Mtpa(27 Mbpd)

• Sulfur Recovery Unit if H2S• Mol Sieve Dehydration*

• < 100 ppbButane Storage

Condensate Storage

Butane

Condensate

(17 Mbpd).5 Mtpa

1 2 Mt

• Mercury Vapor Removal*• Activated Carbon Adsorber

Storage(34 Mbpd) 1.2 Mtpa

7

Typical 2-Train LNG PlantFuelMake-

Up FuelGas

Gathering Train 1

Inlet Gas Reception

Inlet Gas Treating

NGL Recovery

Liquefaction LNG Storage

LNG

Gas

Liquid

g

1.7 Bcfd NGL Recovery

NGL Fractionation

Train 2

9 Mtpa (1.2 Bcfd)

NGL Recovery• Scrub Column/KO after C3 Pre-Cool• Primarily C4+ to Prevent Freezing• LNG H t V l I t t f US &

Condensate Stabilization

Propane Storage

Butane

Propane

Butane

.73 Mtpa(27 Mbpd)

• LNG Heat Value Important for US & European Markets• 1,070 btu/scf Max

Butane Storage

Condensate Storage

Butane

Condensate

(17 Mbpd).5 Mtpa

1 2 Mt

• Need Turbo-Expander for High C3+ Removal

Storage(34 Mbpd) 1.2 Mtpa

7

180,000 M3 LNG Tank180,000 M3 LNG Tank

• Full-Containment Tank to Reduce Impound Area & Improve SafetyImpound Area & Improve Safety

• Approx. 75M Dia x 40M H• Insulated for <.05%/D of Boil-off

• Total Capacity Based on Tanker Size (135,000 M3)

• Plus 4+-Days Production• Top Entry In-Tank Pumpsp y p

8

Inside the Tanks

Single-Stage Multi-Stage

Tank with Pump Caissons9

LNG Loading System

• 16” Chiksan Typeyp• 3+1 – LNG Arms

• 3,500 M3/Hr/Ea.• 10,500 M3/Hr• 140K M3 Tanker

• 4+1 – Systems• 14,000 M3/Hr• Qmax & Qflex• Qmax & Qflex• 200K+ M3

• 1 – Vapor Return1 Vapor Return

10

Cost of Refrigeration

MethaneMethaneor Nitrogen

Cost/BtuRemovedRemoved

Air/WaterPropaneEthylene

-162C 25CTemperature

p

11

Natural Gas Liquefaction Processes25C

Gas Cooling

TemperatureCondensation

Min. DT

Liquid

-162C

Sub-cooling

H (Enthalpy - Heat Removed)12

Cascade LNG Process• Most Straight Forward of All Processes• Kenai Plant Continuous Operation 1969

80F PropaneRefrig.

1st Stage

2 d SCoP Optimized

80F PropaneRefrig.

1st Stage

2 d SCoP Optimized

PropaneRefrig.

1st Stage

2 d S

PropaneRefrig.

1st Stage

2 d SCoP OptimizedKenai Plant Continuous Operation 1969

• CoP License, Plant Build by Bechtel

Tem

pera

ture

2nd Stage

3th Stage

1st Stage

2nd Stage

Cascade Refrigerant Cycle

Tem

pera

ture

2nd Stage

3th Stage

1st Stage

2nd Stage

Cascade Refrigerant Cycle2nd Stage

3th Stage

2nd Stage

3th Stage

Ethylene Refrig1st Stage

2nd Stage

Cascade Refrigerant Cycle

1st Stage

-260F

H (Enthalpy - Heat Removed)

Methane Refrig. .-260F

H (Enthalpy - Heat Removed)

..2nd Stage

3th Stage

Kenai AlaskaKenai, Alaska

13

C3 Precooled – Mixed Refrigerant Process80F Propane

Refrig.

1st Stage Propane PreCooledMixed Refrigerant Cycle

80F80F PropaneRefrig.

1st Stage Propane PreCooledMixed Refrigerant Cycle

PropaneRefrig.

1st Stage

PropaneRefrig.

1st Stage Propane PreCooledMixed Refrigerant Cycle

• Most Widely Used Licensed by APCI• 1st Plant in Algeria Operating Since 1972

Tem

pera

ture

2nd Stage

3th Stage

Mixed Refrigerant

Tem

pera

ture

Tem

pera

ture

2nd Stage

3th Stage

Mixed Refrigerant

2nd Stage

3th Stage

2nd Stage

3th Stage

Mixed Refrigerant

g p g• Plants Built by KBR, Chiyoda, JGC, FW

-260F

H (Enthalpy - Heat Removed)

-260F

H (Enthalpy - Heat Removed)

-260F

H (Enthalpy - Heat Removed)

QatarGas LNG PlantQ

14

APCI AP-X Process

• Largest Train Capacity @ 8 Mtpa• Overcome Spiral Wound MCHE Limit APCI Suppliesp• First Unit Started in 2009 (QG-II)• No Plants Outside of Qatar

• Process Design• Cold Boxes• Spiral Wound Exchangerp g• Turbo-Expanders

15

All Processes Use Similar Equipment

GE MS7001 FB Gas Turbine• Most New Plants Use Large Gas Turbine (& Combined

Cycle) to Drive Refrigerant Compressors• Some Older & Smaller Trains Have Steam Turbine DrivesSome Older & Smaller Trains Have Steam Turbine Drives• Many Peak Shaving Plants on Electric Drives• Use Large Process Type Centrifugal Compressorsg yp g p• Main Difference is in the Cryogenic Heat Exchangers

16

Main Cryogenic Heat ExchangerMain Cryogenic Heat ExchangerUse by Mixed Refrigerant ProcessUse by Mixed Refrigerant Process

Ai P d t & Ch i lAir Products & Chemicals& Linde: Spiral Wound Ex.• Max. Diameter: 5,030mma . a ete : 5,030• Height: ~55m• Stainless Steel Core• 25mm Aluminum Tubing• Externally Insulated• Chill & Liquefy GasChill & Liquefy Gas

– From –34ºC to –152ºC– At 55 to 69 Barg

17

APCI’s MR Main Cryogenic Heat Exchanger (MCHE)Spiral Wound DesignSpiral Wound Design

18

Heat Exchanger for Cascade Process

Plate FinExchangerExchanger

• Many Manufacturers• Use Extensively in Air Separation• Cascade & Other LNG Processes

Cold Box ConfigurationCascade & Other LNG Processes

19

Advances in LNG PlantsOnshoreConventional Design

Near-shore

g

GBS Design

OffshoreSteel or ConcreteSteel or Concrete

Floater20

Conclusions• LNG Liquefaction Process Same as AC System in Our Home• Pre-Treatment Facilities Can Dwarf Liquefaction System

– Mole Sieve Dehydration & Mercury Removal RequiredMole Sieve Dehydration & Mercury Removal Required– Gas Treating & NGL Extraction May be Needed– Stabilized Condensate & Fractionated NGL Add Value

LNG E h St & L di S t A U i• LNG Exchangers, Storage & Loading Systems Are Unique• Commercial Liquefaction Processes Well Proven, Robust & Can

be Optimized for Plant Size, Gas Composition, Sales & Commercial NeedsCommercial Needs

• Novel Near-Shore & Offshore Floating Concepts Are Developed

21

LNG ?

22

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