Академический Документы
Профессиональный Документы
Культура Документы
a r t i c l e i n f o a b s t r a c t
Article history: Natural gas liquefaction process using mixed and/or cascade refrigerant is popular in onshore LNG (liq-
Received 29 December 2014 uefied natural gas) plant. Similar attempt has been adopted for FLNG (floating LNG) but still needed for
Received in revised form the improvement of the process to enhance its efficiency as well as reliability. The dynamic modeling of
27 September 2015
cold box which is a core equipment in LNG/FLNG plant enabling to liquefy natural gas is crucial in order
Accepted 28 September 2015
to develop or improve a liquefaction process concerning operability and controllability. A decomposition
Available online 9 October 2015
methodology for dynamic modeling of cold box in the case of lack of internal design data at early design
stage is presented. The proposed methodology is validated through the industrial application of offshore
Keywords:
Cold box
natural gas liquefaction process and expected to be extensively applied to the various process designs
LNG which require dynamic simulation of cold box unit.
FLNG © 2015 Elsevier Ltd. All rights reserved.
Liquefaction
Dynamic simulation
Decomposition approach
http://dx.doi.org/10.1016/j.compchemeng.2015.09.020
0098-1354/© 2015 Elsevier Ltd. All rights reserved.
C.-J. Lee et al. / Computers and Chemical Engineering 84 (2016) 546–557 547
kn1 = kn2 = · · · = knm = kn for all n, where knm is the k value for a layer
n and a zone m. Even though the exact k value of each zone in the
same layer may differ due to the phase change occurring in the
channel inside the heat exchanger, the final k value obtained after
parameter estimation should meet the target flow rate.
The initial value of kn for layer n is estimated and then manipu-
lated by a parameter estimation technique. The choice of a proper
initial point is crucial. Therefore, we propose herein to estimate
the initial k value with the density at the mean temperature of the
inlet and outlet temperatures, and the pressure drop as the total
pressure drop divided by the number of zones, m.
Table 1
Heat and material balance.
Table 2
k and UA values at each step for Core 1.
Stream Variable Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8
Core 2 exchanges heat between one cold stream and three hot Fig. 4. Exchanger geometry and layer configuration of Core 2.
streams. Without internal design data of the PFHE, ASPEN MUSE
is used to estimate the exchanger geometry and number of layers. must be specified for dynamic modeling of Core 3. The variables are
Core 2 has dimensions of 2600 mm × 600 mm (length × width) with defined as ki and UAi for i = I, J, K.
800 layers. The pattern of EHEHEHFHGHGHGHGH (E = NG2–NG3,
F = MR3–MR4, G = MR9–MR10, H = MR12–MR13) is configured as a
4. Results and discussion
set, hence with 16 layers in a set, and 50 sets in total. Cold and hot
layers flow in counter directions. The total length of the exchanger
4.1. Dynamic models of each core
is partitioned into 10 zones (Fig. 4).
Here, we also assume that equal k and UA values are used for
4.1.1. Core 1
layers with the same feed stream. Equal k and UA values are used
The k and UA values at each step are shown in Table 2. At Step
for all zones in a layer too. So, four k values and 4 UA values must be
1, the mass flow rate values of streams A and B are lower than the
specified for dynamic modeling of Core 2. The variables are defined
PFD values, while those of stream C and D are greater than the PFD
as ki and UAi for i = E, F, G, H.
Core 3 exchanges heat between one cold stream and two hot
streams. Without internal design data of the PFHE, ASPEN MUSE is
used to estimate the exchanger geometry and the number of lay-
ers. Core 2 has dimensions of 1640 mm × 600 mm (length × width)
with 120 layers. The pattern of IKIKJK (I = NG3–NG4, J = MR4–MR5,
K = MR6–MR7) is configured as a set, hence with six layers in a set,
and 20 sets in total. Cold and hot layers flow in counter direc-
tions. The total length of the exchanger is partitioned into 10 zones
(Fig. 5).
Here, we also assume that equal k and UA values are used for
layers with the same feed stream. Equal k and UA values are used
for all zones in a layer too. So, three k values and three UA values Fig. 5. Exchanger geometry and layer configuration of Core 3.
C.-J. Lee et al. / Computers and Chemical Engineering 84 (2016) 546–557 551
Fig. 6. Flow rate and temperature conditions at each step for Core1.
values. Therefore, we can say that k values for streams A and B providing more heat duty to the hot streams. Then, the outlet tem-
should be higher, and those for C and D should be lower. perature at stream MR14 is lowered (Fig. 6 and Table 3).
At Step 2, the temperature of the hot streams A and B are higher
than the PFD values. This means that the UA values should be higher 4.1.2. Core 2 and Core 3
for these streams, hence more heat duty provided to lower the In the case of Core 2, we can see that the initial k and UA val-
outlet temperature. Meanwhile, the temperature of the cold outlet ues were poorly given. It is not easy to estimate the k value of the
stream D is lower than the PFD value. Thus, UAD should be higher, cold stream in particular, because the cold MR is vaporizing in the
552 C.-J. Lee et al. / Computers and Chemical Engineering 84 (2016) 546–557
Table 3
Flowrate and temperature conditions at each step for Core 1.
Stream Conditions Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8
NG2 (A) Flowrate 104.6 117.9 121.1 117.9 118.1 117.7 118.2 118.0
Temperature −60.4 −59.3 −63.2 −63.6 −63.9 −63.9 −64.0 −64.0
MR3 (B) Flowrate 37.6 40.3 40.6 40.5 40.3 40.3 40.5 40.4
Temperature −62.1 −61.0 −63.4 −63.9 −64.1 −64.1 −64.0 −64.0
MR9 (C) Flowrate 187.6 187.2 185.4 187.0 186.4 187.1 186.9 187.1
Temperature −65.6 −65.1 −63.9 −64.3 −64.1 −64.4 −64.0 −64.0
MR14 (D) Flowrate 230.8 227.7 221.1 227.5 226.3 227.6 227.4 227.5
Temperature −53.0 −52.4 −33.1 −35.1 −33.1 −33.4 −33.1 −33.1
Table 4
k and UA values at each step for Core 2.
Table 5
Flowrate and temperature conditions at each step for Core 2.
Table 6
k and UA values at each step for Core 3.
Stream Variable Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8
cold box and the density of the fluid changes greatly. With poor ini- values of the hot streams decrease, the density values are increased,
tial estimates, stream conditions at Step 1 were far away from the and hence the flow rates are also increased. Therefore, adjustment
design points. At Step 3, UA values for the hot streams (E, F and G) of the k values is needed again. After five adjustments, the final val-
were at maximum limits but still could not meet the temperature ues of k and UA were obtained (Figs. 7 and 8 and Tables 4–7). PI
condition. This is because of the increased flow rates of hot streams control parameters to obtain k and UA parameters are summarized
and the lowered flow rate of the cold stream. As the temperature in Table 8.
Table 7
Flowrate and temperature conditions at each step for Core 3.
Stream Conditions Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8
NG4 (I) Flowrate 116.6 118.0 118.1 118.0 118.0 118.0 118.0 118.0
Temperature −141.5 −144.9 −146.5 −147.0 −147.4 −147.5 −147.7 −147.8
MR5 (J) Flowrate 39.9 40.4 40.3 40.4 40.4 40.4 40.4 40.4
Temperature −143.9 −147.2 −147.1 −147.6 −147.8 −147.9 −147.8 −147.8
MR7 (K) Flowrate 26.5 40.4 38.1 40.4 39.7 40.4 40.2 40.4
Temperature −130.0 −135.9 −132.7 −133.7 −132.7 −133.0 −132.7 −132.7
Fig. 7. Flow rate and temperature conditions at each step for Core 2.
4.2. Model validation through feed load variation simulation rate of NG5 as the process variable source. TIC-100 is a tempera-
ture controller with the JT2 actuator position as the output target
For dynamic validation of the developed model, controllers are object, and the temperature of NG4 as the process variable source.
added. FIC-LNG VLV is a flow rate controller with the LNG-VLV actu- TIC-101 is also a temperature controller which varies the opening
ator position defined as the output target object, and the mass flow of JT1 to keep the temperature of NG3 at the specified set point.
554 C.-J. Lee et al. / Computers and Chemical Engineering 84 (2016) 546–557
Fig. 8. Flow rate and temperature conditions at each step for Core 3.
The process flow diagram with the added controllers is shown in changing the set point of FIC-LNG VLV from 118 ton/h to 94.4 ton/h.
Fig. 9. Controller tuning parameters used in the model validation Since the flow rate of natural gas is decreased, natural gas is
summarized in Table 8. cooled further. Thus, the temperature of both NG3 and NG4 is low-
At 5 min after the integration, the feed load of natural gas is ered. Then, the temperature controllers closed the JT valves, hence
decreased from 100% to 80% by manual action. This is done by attaining a lower mixed refrigerant flow rate. The total flow rate of
210
110
90
NG 80% → 100%
70
50
0 20 40 60 80 100 120 140 160 180
Time (min)
140
Valve opening (%)
45 100
JT1 opening
80
50% → 41.7%
40
60
40
35
20
30 0
0 20 40 60 80 100 120 140 160 180
Time (min)
35
Mass flow rate (ton/hr)
Valve opening (%)
50
30
45 25
JT2 opening
50% → 45.9% 20
40
15
10
35
5
30 0
0 20 40 60 80 100 120 140 160 180
Time (min)
MR decreased by 15.5%. The opening of JT1 changed the flow rate 4.3. Industrial case study of C3 MR process
from 50% to 41.7%, while the opening of JT2 changed the flow rate
from 50% to 45.9%. The general control structure for C3 MR process includes two
At 74 min after the integration, the feed load of natural gas is kinds of control logic in cold box operation (Sicinski et al., 2007).
increased back from 80% to 100% by manual action. This is also done One is LNG temperature control and the other is WEDT (warm
by changing the set point of FIC-LNG VLV from 94.4 to 118 ton/h. The end delta temperature) control. For LNG temperature control, the
temperature controllers open JT1 and JT2 to lower the temperature LNG temperature leaving cold box (‘LNG’ stream) should be main-
of NG3 and NG4. Soon, all the stream conditions are back at the tained at −148.7 ◦ C in order to satisfy LNG product temperature
initial conditions. Thus, the developed dynamic model exhibits the to −158.5 ◦ C after Joule–Thomson valve. The amount of light MR
expected performance as shown in Fig. 10. (LMR) is changed to keep this LNG temperature to −148.7 ◦ C. On
the other hand, WEDT means the temperature difference between
heavy MR (HMR) and MR leaving cold box (‘MR Mix-3’ stream).
Because the temperature of heavy MR is fixed to −29.9 ◦ C, con-
Table 8 stant WEDT means constant temperature of ‘MR Mix-3’ stream.
Controller tuning parameters. As the WEDT is assumed to about 1.5 ◦ C, the temperature of ‘MR
Type Item kC Ti Td Mix-3’ stream has to be −31.4 ◦ C. The amount of HMR was var-
ied to track this ‘MR Mix-3’ stream temperature of −31.4 ◦ C. The
Parameter estimation k Value 0.1 0.2 0
UA value 1 20 0 suggested process flow diagram with control structure is shown in
Model validation TIC-JT1 0.1 30 0 Fig. 11.
TIC-JT2 0.1 30 0 The set point tracking was conducted to validate the dynamic
FIC-LNG VLV 0.01 0.8 0 model. The temperature of ‘MR Mix-3’ stream was controlled to
C.-J. Lee et al. / Computers and Chemical Engineering 84 (2016) 546–557 557
[kg/h] [°C]
590000 -30
588000
-30 .5
586000
-31
584000 SP: -31.4°C
-31.5
582000
[min]
Fig. 12. Set point (SP) tracking in the case of increasing LNG production.