Basic Engineering & Technology Of LNG

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 Liquefied Natural Gas (LNG)

What is the LNG

Liquefied of gas (methane) at -160 Deg.C
High incentive project
Involvement of technology
No added value (require re-gas process)
Specification based on gas composition
(heating value) Transportation
Efficiency

Why LNG
As an option to transport gas to the market
Provide gas volume ratio of 1/600
(cost efficient)

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Feed Gas Condition & Target Quality

SHELL NA LNG

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 The LNG Plant

HIGH INCENTIVE PROJECT

Process & technology

Acid gas removal unit (AGRU)

Liquefaction & energy to drive

Heat rejection system

Utilities

Electrical, steam, N2, water

Storage & Loading Facility

Containment

Jetty
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 Heat Rejection System

To facilitate heat transfer process between two different

temperature fluids which are close to one another

Require in the process to control property of the fluid, rate of

mass transfer & rate of chemical reaction

Various heat exchanger types (heater, fluid-fluid, air cooler)

Selection based on operating variable, condition (pressure drop,

corrosion) & fluid characteristic (process efficiency)

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 The LNG Plant

LNG process uses same principle as a refrigerator or AC, but

.. larger size and more colder

Min 5 Deg C Min 160 Deg C

Temp

1 2 HP Power > 80,000 HP

Component of
Refrigerant
Freon or CO2 C1, C2, C3, N2

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 Heat Rejection System

expansion valve

Cooling & Heating Process

compressor

evaporator

condenser

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 Heat Exch. Eff.
LNG Liquefaction Process Turbo mach. Eff.

Sea Water/Air Refrigerant Gas LNG

LNG Plant
Performance

Cascade Cooling Process

Classical cascade Mixed refrigerant Expander cycle

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 Heat Rejection System
(to environment)

Resources
Availability &
Process Efficiency

Sea water

Air
Options

Fresh water

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 Heat Rejection System

Air Cooler Exchanger

Sea water Shell & Tube exchanger

Kettle Type exchanger

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Heat Rejection System (Main Cryogenic Heat Exchanger)

Specially designed for very low process temperature

Uses material of copper, aluminum alloys or stainless steels

Very sensitive to abnormal operating condition

(pressure surge, temperature shock, frequent start-stop)

Coiled tubes or spool wound exchanger type by Linde, Air Liquide

technic & APCI (approx. cost US$ 50 ~ 1250 Million)

Brazed aluminum exchanger, cool box, plate-fin by Linde, Nordon,

Altec, (approx. cost US$ 200 -300 Million)

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Heat Rejection System (Main Cryogenic Heat Exchanger)

Spiral/Wound cryogenic Spiral/Wound cryogenic

exchanger (APCI) exchanger (Linde)

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Heat Rejection System (Main Cryogenic Heat Exchanger)

Coil Wound MCHE (APCI)

Coil Wound MCHE (Linde)

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Heat Rejection System (Main Cryogenic Heat Exchanger)

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 Energy For The Refrigeration

Centrifugal, reciprocating, & axial

Compressor
Concern of compression ratio, flow
capacity vs Mach number limitation

Steam, gas turbine, electrical motor,

or combination among them
Driver
Equipment selection will impact to
utility unit size

30% - 50% of liquefaction unit capex

Others
Indication for plant performance
(reliability & availability factor)
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 Energy For The Refrigeration (Compressor)

Centrifugal Axial Reciprocating

Availability to meet process requirement (compressor ratio)

Compressor efficiency

Driver heat rate

Limited by Mach number

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 Energy For The Refrigeration (Steam Turbine)

11 of 13 base load project (1963 -1983)

High capital & operating expenses

(requires support of steam generation unit, boiler & water treatment)
The capacity could meets process specification / requirement
(but not available for big size capability)
Proven & reliable for LNG plant
(30 years life & achieved nonstop 3 years operation)

Thermal efficiency is 30% - 35% (boiler & steam turbine)

No correlation between output power & ambient temperature

More choices of vendor / manufacturer

Install as a gas turbine helper/tandem (e.g. Tangguh LNG train)

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Energy For The Refrigeration (Steam Turbine)

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 Energy For The Refrigeration (Electric Motor)

Less capital & maintenance expenses

Higher availability than gas turbine / steam turbine

Flexibility to match compressor & process requirement

Simple layout but not common in the existing LNG plant

Dependency to electric power supply availability

Consideration for offshore LNG plant or as a helper/tandem of gas

turbine (e.g Qatar LNG Plant)

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 Energy For The Refrigeration (Gas Turbine)

Implemented almost for all new LNG plant

Simple plant design & cost effective but requires start-up facility (helper)

Fuel gas quality is important (10% nominal value)

Industrial type & aero derivative type

(consideration of capex, space, maintainability, operability

Designed for certain nominal power & speed

(the capacity may not match to process requirement, or need strategy
to split the load to utilize all the capacity)
Thermal efficiency concern
(approx. 28% - 32% (industrial type), 38% - 42% (aero derivative type)

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Energy For The Refrigeration (Gas Turbine)

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 The LNG Process

Mercury CO2 (< 50 ppm) Water Fuel gas

(< 10 ng/NM3) H2S (< 4 ppm) (< 1 ppm)

Liquefaction LNG
Feed Gas
Inlet Mercury Purification Dehydration Separation
Facilities Removal
Feed Preparation Raw
Primary wet NGL
condensate
Fuel gas
Stabilization C3 Product
(Make-up/export)
LPG Plant
C4 Product
Fractionation (Make-up/export)

C5+ Product

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 Mercury (Hg) Removal

To avoid aluminum (MCHE material) corrosion

Spec. limitation < 10 ng/Nm3 (0.1 microgram/Nm3)

By chemisorption (glycol) & physics/adsorption

(Activated Carbon, macroporous alumina, Iodine loaded carbon)

Removal process optimum at temperature 30 80 Deg.C

(higher than 80 Deg.C will vaporized, less than 30 Deg.C will

reduce removal capacity)

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Mercury (Hg) Removal

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 Acid Gas Removal Unit (AGRU)

Mature
To remove impurities (CO2, H2S, Hg) & Water content Technology
Operation reason (to avoid plugging, corrosion)
Efficiency
Contractual limitation & environment concern
Operability &
Treatment process Maintainability

Solvent (chemical) or adsorption (solid bed, membrane)

Regeneration or Non-regeneration process cycle

Need energy to support treating process (for solvent)

Steam system or heating oil system (not common)

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2. LNG Process
Treating / Purification Unit

Amine chemical reaction

H2S + R2NH R2NH2+ + HS-

CO2 + 2R2NH R2NH2+ + R2NCO2-

CO2 + H2O + R2NH R2NH2+ + HCO3-

Carbonate chemical reaction

K2CO3 + H2S KHCO3 + KHS

K2CO3 + CO2 + H2O 2KHCO3 + heat

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 Acid Gas Removal Unit (AGRU)

Schematic Of Amine System

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 Acid Gas Removal Unit (AGRU)

Carbonate System DEA System

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 CO2 Removal Unit

CO2 corrosive & crystallized at 43 Deg. C

Contractual limitation < 50 ppm (environment issue)

Chemical process/absorption (Carbonate-amine/ Benfield) or

physics process/adsorption (solid bed / sulfinol shell)

Most likely using regenerated solvent (economical reason)

(Absorption at high pressure - low temperature & stripping

/regeneration at low pressure - high temperature)

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 Sulfur Removal Unit

H2S is corrosive & poisonous

Contractual limitation for H2S < 4 ppm

Contractual limitation for total sulfur < 30 mg/m3

Uses chemical process (amine) or physics mechanisms

(together with CO2 removal process or using bacteria)

H2S tolerant limit for human is 10 ppm

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 Dehydration (Water Removal)

Installed after treated gas washing tower

Below 20 oC, water & CH4 create hydrate (plug the MCHE tubes)

H2O specification is < 1 ppm

H2O remove by combining cooling & drying mechanism,

consist of 2 or 3 identical vessel (1 vessel on operation

mode, 1 vessel on regeneration mode, 1 vessel on stand by)

Adsorption using molecular sieve, activated alumina, silica gel

Glycol less optimum to achieve outlet < 1 ppm

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Dehydration (Water Removal)

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Dehydration (Water Removal)

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 Separation & Fractionation

Hydrocarbon separation through fractionation column Mature

Technology

Adjustment for LNG heating value specification Efficiency

Provide refrigerant for liquefaction process, or Operability &

Maintainability

Monetizing C3 & C4 for LPG business opportunity

Need energy to support separation process

Steam (common) or heating oil (not common)

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 Separation & Fractionation
Number of columns depends on
Rigid product specification
Number of products to be made
Characters of feed
Methane & Ethane (C1, C2) Propane (C3) Butane (C4)

Inlet Gas

C1, C2, C3, C4, C5+

Condensate (C5+)
C3, C4, C5+ C4, C5+

De-ethanizer De-propanizer De-butanizer

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Separation & Fractionation

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 Liquefaction

1. Change the behavior of hydrocarbon molecules from gas to liquid

2. Cooled down the gas (methane) to approx. 161 Deg.C (@ 1 atm)

3. Combination several methods of heat removal techniques

Conventional two-fluid heat exchanger & innovation equipment

Free expansion of pressurized liquid through a valve (Joule Thomson

Effect)

Expansion of pressurized gas through a machine which produce external

work (expander)

Require a huge amount of energy

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 Methane (C1) Phase Behavior Diagram

Gas

Enthalpy/heat is transfered from natural

gas to the refrigerant
(Single or Mixed component)

Require support of continuous

cooling/refrigeration system
Liquid

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 Highest thermal eff. Is
when refrigerant has
Liquefaction / Cooling Curves near identical boiling
curve to feed gas
condensing curve

100 %
low boiling temp
refrigerant Precooling
80 %
(C2, C3)
Liquefaction
60 %
Enthalpy

Refrigerant
Methane
40 %
Very low boiling
temp refrigerant
Subcooling
20 % (N2, C1)

0%
-180 - 160 - 120 - 90 - 60 - 30 0 30 60
Temperature ( Deg C)

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 Liquefaction Process Selection

Propane
Pre-cooled Axens Liquefin
Black & Veatch
Mixed Refrigerant Process
PRICO process
(APCI)

Double Mixed
Cascade Process Mixed Fluid Cascade Refrigerant Process
(Philips) Process (Shell)
(Statoil/Linde)

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 LNG Liquefaction Process (Classical Cascade)

Modification of common refrigeration / cooling process

Combination of more than 2 refrigerants (Phillips), such as

propane/ethane/ methane, propane/ethylene/methane or
ammonia/freon 13/methane

Complexity of different process cycle for each refrigerant (Phillips) &

need external sources for the specific refrigerant

Previously designed as 2 train in 1 reliability (Phillips)

Able to monetize small gas reserve approx. 3 ~ 4 TCF

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 ConocoPhillips Optimized Cascade Process

1. Three pure refrigerant component (methane, ethane or ethylene, propane)

2. Applied on 7 of 31 based load LNG plant . Cap. up to 3.5 mtpa/train
3. No proprietary equipment

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Plate Fin Heat Exchanger

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Plate Frame Heat Exchanger

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 LNG Liquefaction Process (Mixed Refrigerant Cycle)

Modification of classical cascade cycle

Using mixture of components as one refrigerants (MCR)

(nitrogen, methane, ethane & propane)
Used only a single mixed refrigerant /Prico process
(First LNG based load plant Skikda Algeria)

Consideration to add propane pre-cooled is to enhance the

liquefaction performance, pre cooling gas temperature from 40
Deg.C to 30 Deg.C (APCI process)

Further enhance cooling mechanism by APCI using pure

nitrogen in the end of sub cooling process (AP-XTM)

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 Black & Veath PRICO Process

1. Single mixed refrigerant cycle (nitrogen, methane, ethane, propane, i-pentane)

2. Modular concept & multiple individual train (no proprietary equipment)
3. Applied on Skikda LNG Base load plant, Algeria (Mid 70s). Cap. 1.2 mtpa/train)

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ASR-2 Technology In The LNG Business 46
 Mixed Fluid Cascade Process (Statoil/Linde)

1. Three mixed refrigerant cycles (nitrogen, methane, ethane, propane)

2. Proprietary equipment (Spiral Wound Heat Exchanger by Linde)
3. Applied on Snohvit LNG Base load plant, Norway. Cap. 4 mtpa/train)

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 Axens Liquefin Process

1. Double mixed refrigerant cycle (nitrogen, methane, ethane, propane, butane)

2. No proprietary equipment
3. The design has not been implemented
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 LNG Liquefaction Process (Expander Cycle)

To gain the mechanical work produced by decreasing gas

pressure

Installed in the pipeline system, let down the gas pressure for
local gas distribution system

Commonly installed for peak shaving plant

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Medium / Mini LNG Plant

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 Liquefaction Technology Comparison

Selection Criteria Cascade SMR C3-MR DMR N2

Expander
Thermal Efficiency High Medium High High Low
Equipment Count High Low Medium Medium Medium
Hydrocarbon Large Medium Large Medium None
Refrigerant
Storage
Offshore Medium High Medium High High
Suitability
Compactness Low Medium Low Medium High
Motion Impacts Medium Medium High Medium Low

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 Physical properties of Nitrogen & Paraffin Hydrocarbon
(used for refrigerant)

Components Nitrogen Methane Ethane Propane i-Butane n-Butane i-Pentane

Molecular Weight 28 16 30 44 58 58 72

Boiling point, -195 -161 -88 -41 -12 0 28

(1 Atm, o C)
Density of gas 0.96 0.55 1.03 1.52 2 2 2.49
(1 Atm, 15 o C)
GCV or HHV 0 1016 1769 2516 3252 3262 4000
(Btu/ft3), ideal gas
Flammability Limits 0 5 - 15 2.9 - 13 2 9.5 1.8 8.5 1.5 - 9 1.3 - 8
(Volume % in air)

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 Liquefaction Process License
(Selection Approach)

Safety Operation
Maturity - Reliability
Proven tech. (performance) - Availability
Environment impact - Flexibility
Design Integrity - Thermal Eff.
Specific power Inlet Maintainability
Life cycle cost Feed Gas
- Capex
- Opex
Energy for LNG
Refrigeration Production

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 Off Shore LNG Plant

Integrity &
safety of gas
Monetizing non associated Robust,
/ stranded gas
production
Special
efficientdesign
&
facility & LNG
Monetizing associated vessel
flexible
gas & FOB
design
(flare gas)
processing
Commercial limitation
Subject to project economic viability

Reduce cost & construction time

Selection of FPSO technology

Selection of LNG process license

Technical
Challenge LNG Off loading operation mechanism

Safety & environment concerns

Lender & buyer concerns for production &

Others
delivery sustainability

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 The FLNG Plant

The Plant Reserves

The Hull Volume & deliverability
Containment system Technology readiness
Turret & Mooring
Living quarter
>25 years before dry dock

The philosophy Capital Investment

Stringent safety concept Management Model
(less Hydrocarbon refrigerant inventory)
Cost intensive project ($ billion)
System (availability, reliability & redundancy)
Efficiency

Economic Viability
The Equipment Market
Process & technology (against motion) Investment
Storage & off loading facility Life cycle cost
Utilities (power generation, N2, water, etc) Fiscal regime
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 The On-Shore Vs FLNG Concept

Opportunity to develop stranded

and remote gas reserve (as a cost
effective option)

Reduce cost
(platform, pipe line to shore, land
acquisition, environment issue)

Mobile facility to develop another

gas reserve

Coordination of producing gas,

processing & loading activities in
one facility ASR - LNG Technology 56
The FPSO LPG Belanak

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 The FLNG

The LNG Plant

Floating LNG
The LNG Vessel (FLNG)
The FPSO

Benchmark to facilities performance

Safety
Operability & maintenance ability
Constructability

Integrated
Risk
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 To Select An Appropriate FLNG Safe Concept

Hull design
Hull dictated by the weight/complexity of top side equipment
Containment system (SPB, membrane, etc)
long life utilization before dry docking (>25 yrs) Safe, Compactness
Sensitivity &
Robustness Again
Top side design
Motion
Gas pre-treatment & AGRU selection for LNG spec.
LNG cap. constrained by the power (compressor, driver) Operability and
Liquefaction process (licensor) selection Maintainability
(minimize HC refrigerant inventory) Reliability &
Main equipment selection (driver, utilities, etc) Availabity
Safety classification area layout & safety gap
Compactness, less equipment & process flexibility
Structural integrity & robustness design (against motion)

Mooring & loading philosophy

Turret
Side by side or tandem system
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 Shell Prelude FLNG Project

Shipyard : Samsung Heavy Idustry

Design : Shell, Technip, Samsung
Cost : > $12 Billion
Dimensi : 488 mtr x 74 mtr
Capacity : 4 mtpa
Storage : LNG, LPG, Condensate
LNG Tech.: Shell DMR

Weight : > 260.000 ton

Membrane LNG Containment
Life time 25 yrs
Start up operation 2017

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 Petronas1 FLNG Project

Shipyard : Daewo Shipbuilding & Marine

Design : Petronas, Daewo, Technip
Dimensi : 365 mtr x 60 mtr
Capacity : 1,2 mtpa
Storage : LNG, Condensate
LNG tech. : Nitrogen Expander APCI

Membrane LNG Containment

Start up operation 2015

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 FLNG Development Concept Alternative

Reserve
Composition
Market Technology Viability
Timing

Onshore LNG Offshore LNG

Schematic Schematic

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 PUSHING FRONTIERS IN
DEEPWATER

Shell Eastern Petroleum Pte Ltd 17 June 2014 63

 Caribbean FLNG

72.0 MMSCFD (+/- 0,5 Mtpa) ,for temporary storage and export.
EPCIC by Wison Contractor, uses the barge based FSRU
Black & Veatch Liquefaction Technology
Dimension,
Length 144m, Breadth 32m, Depth 20m,
Draft 5,4 M

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 LNG Storage

Retention liquid

Gas tightness

Thermal Insulation

Environmental safety

Buffer Storage Seasonal Storage

- To support plant continues operation - To anticipate peak demand

( Base load LNG plant ) ( Peak shaving plant )

- Short resident time (10 15 days) - Long resident time (100 days)

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 Tank Mechanical Design
(Ref. CEN TC 265)

Self Supporting Tank Membrane Tank

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 LNG Tank location

Above ground In ground Under ground

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LNG Boil Off

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Tank Comparison

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 Tank Useful Capacity

Laden voyage
S = C + (Td Tu) Qm + Cm
where :
10,000
S = storage M3/hr 12,000 M3/hr, loading rate
capacity
Mode
C = useful & condition
unloading of loading operation
capacity
Approx
Td = max. berthing time
24 hr of vessel
(loading time, custody, paper work)
Tu = min. berthing time of vessel
Qm = max. flow rate required
Cm = min. of LNG remaining Ballast voyage

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Materials For LNG Insulation

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 Loading Facilities
(Ref. SIGTTO)

Approach channels & turning cycle

Vessel movement (tugs power, traffic control,

Port Design
speed limit, etc)
Operation limits (wind, current, etc)

Exclusion of ignition source

Mooring layout (fender, dolphin, etc)

The Jetty
Safety (quick release hook, emergency ship
shore release system/ESD system, powered
emergency release couplers)

SIGTTO : Society of International Gas Tankers & Terminal Operators LTD

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 Loading Facilities

Loading Arm
3 loading arm & 1 vapor return arm

Extreme working environment

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 What Makes LNG Shipping Unique

1. Design & technology

Double hull design (insulated to prevent leakage & rupture)

Containment system

Hazardous cargo (sub cool, boil off arrangement)

2. High capital cost (about twice VLCC)

3. Few experienced ship owners

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ASR - LNG Technology 75
 I.M.O Gas Code (IGC Code)

LNG CARRIERS

Self Supporting Tanks Membrane Tanks

Type A Type B Stainless Steel , 18% Ni Invar , 36% Ni

Non Computable Computable Perpendicular Plane

Structure Structure corrugations

Full Secondary Splash barrier Full Secondary Full Secondary

barrier barrier barrier

Prismatic Spherical Prismatic

Tanks Tanks Tanks

MOSS IHI SPB TECHNIGAZ GAZ TRANPORT

CONCH
TECHNIGAZ
SENER
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 I.M.O Gas Code (IGC Code)

Cargo press.
Personnel
Survival & temp. control, venting system
protection
capability

Operating
Containment
requirements
Environmental/ cargo tanks
control

System
Cargo & materials
Fire protection
handling &arrangements
extinction

Instrumentation

Operation Survey & certification

Control & Safety Construction

77
Membrane Vessel

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LNG Carrier (Moss & Membrane)

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LNG Containment System

80
Independent Self Supporting Tank

- Moss/Spherical , IHI Prismatic

- Longer cool down time (> 12 hrs)
- 40 to 150 mm aluminum alloy or
9% nickel steel
- 12 inches of balsa wood
insulation encased outside steel skin
- Parallel construction both hull & tank

- Fixed to the hull by a cylindrical

support structure/skirt (Moss)

81
 Membrane Containment System

GTT No 96 with 0.7 mm Invar Membrane

GTT Mark III with SS Membrane
- Gas transport system,
Technigaz system & CS-1

- 0.5 ~ 0.7 mm invar (36% Ni) or

1.2 mm (18% Ni) corrugated SS

- Backed by layer of plywood

insulation boxes (balsa or perlite)

- Less cool down time (< 10 hours)

- Dimension is smaller
(for same capacity)

82
 Marine Access Requirement

Considerations of vessel dimension

Access channel (approx. 300 m width & 14 m depth)

Mooring area & turning circle diameter (> 600 m)

Mooring basin at berth

Mooring position (ships bow in open sea direction)

Note : ship dimension for 125.000 carrier capacity

280 m length, 42 m breadth, & 12 m draught

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 Offshore Installation

Energy Bridge System Platform Conversion

FSRU FSRU

84
 LNG Safety

Employee

Community Environment

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 LNG Safety

Five Elements of LNG Safety

Suitable material for storage tank and

Primary Containment
other equipment

If leak or spills occurs, LNG can be

Secondary Containment
contained and isolated

Minimize the release of LNG & mitigate

Safe Guards System
the effect of a release

Safe distance for the community, spacing

Separation Distance
arrangement inside the facility

Appropriate operating/maintenance
Industry Standard &
Regulatory compliance SOP & competence/well trained personil

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 LNG Plant Security Zone

Red Zone
Unit facilities / equipment where
hydrocarbon are processed

Blue Zone
Supported facilities/building where
hydrocarbon are not processed

Green Zone (Buffer Zone)

The area between the plant fence
and the nearest public facilities

LNG Plant Fence ASR - LNG Technology 87

 LNG Properties

Liquid phase at -160 oC (-259 oF)

(clear , colorless & odorless)

LNG density lighter than water

NG gas density lighter than air

Hazard material

Cause cracking/brittle

Combustible

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LNG Properties

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LNG Properties

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LNG Properties

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 LNG Properties

Characteristic Unit LNG LPG (Propane)

Methane C1 % 82 - 99 0.05
Ethane C2 % 1 13 1 2.8
Propane C3 % 0.1 3 87 98.6
Butane % 0.2 - 1 0.1 1
Boiling point Deg.C -162 -42
Auto Ignition Temp Deg.C 537 450
Flammability limit in air (by Vol) LFL - UFL 5 15 2.1 9.5
Vapor Density (21 Deg C) Kg/m3 0.55 1.52
Liquid to Vapor Expansion % 1 - 600 1 267
Heat of Vaporation Btu/lb 218 185
Vapor cloud Comparison
Maximum size, Down wind M 375 110
Maximum size, Cross wind M 60 120
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 Lay Out & Spacing Of LNG Plant

Centralization Lay Out Modular Lay Out

(Camel LNG Plant) (SKIKDA, Arun LNG Plant)

Inside Battery Limit

Inside Battery Limit

A - Treating unit D - Steam generation G - Utilities K General services

B - Refrigerant unit E - Sea water pumping station H - LNG storage
C - Liquefaction unit F Control room J LNG loading station

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Lay Out & Spacing Of LNG Plant

Arun LNG Plant

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