Classification: Internal Status: Draft

Natural Gas Liquefaction

TEP 10 Gas Processing and LNG Fall 2008

Jostein Pettersen

Simplified LNG plant block diagram Fuel

gas

CH4/N2

End
flash

HHC
Extraction

Power
&
heat

1
 3

Hammerfest LNG plant - block flow diagram

N2 to atm.
CO2 reinjection
(to pipeline)

CO2 drying
and Nitrogen
recompression removal
Fuel gas
system LNG
Storage

Feed from
pipeline Slug Inlet facilities/ CO2 De- Mercury Natural gas LNG
catcher Metering removal hydration removal liquefaction Storage

C1 / C2 / C3 Refrig. Make
-up
Fractionation
MEG (Refrigerant LPG
Recovery Make-up) Storage

Lean MEG
(to pipeline)
Condensate Condensate
treatment Storage
Utility Flare Control
Systems Facilities room

Gas conditioning (pre-treatment)

Acid Gas (CO2 and H2S) removal
Acid gas causes corrosion, reduces heating value, and may freeze and create solids in cryogenic
process
Typical requirements for LNG: Max 50 ppmv CO2, Max 4 ppmv H2S
(ppmv - parts per million by volume)

Dehydration (water removal)

Water will freeze in cryogenic process
Typical requirement: Max 1 ppmw (weight) H2O

Mercury removal
Mercury can cause corrosion problems, especially in aluminium heat exchangers
Requirement: Max 0.01 g/Nm3

2
 5

Gas quality constraints for gas liquefaction

Source: Advantica

Natural gas and LNG composition

Design data for Hammerfest LNG plant
Composition mol %
Component Slug catcher Liquefaction plant LNG
Nitrogen 2,51 2,67 1,10
Methane 80,02 86,34 91,92
Ethane 4,97 6,54 5,59
Propane 2,50 2,68 1,11
Butane 1,22 1,23 0,23
Pentane 0,58 0,35 0,04
C6+ 1,62 0,15 0
Aromatics 0,23 0,02 0
CO2 5,20 0,005 0,005
H2S 0,0005 0 0
Water 0,81 0 0
MEG 0,35 0 0
Total 100 100 100

3
 7

Example of ageing/weathering during LNG transport

40.55

40.5
GCV (MJ/Sm)

40.45

40.4
Calculated ageing
40.35 effect during the
voyage from Melkya
to USA, Cove Point
40.3

40.25
0 2 4 6 8 10 12 14 16
Day

Calculated according to ISO 6976 based on real gas

Nitrogen Removal
Nitrogen need to be removed from LNG in order to meet
Storage and transport specification (Roll Over)
Fuel gas requirements
LNG Heating Value requirements

Systems to handle N2 will vary in complexity, from simple end flash drums, to
complex distillation columns systems for separating N2 from the LNG

4
 9

Example of end flash with LNG turbine

Flash gas (containing nitrogen) used as fuel gas

High-pressure LNG
from cryogenic HE

Gen Set M

LNG
EXPANDER HP
END FUEL GAS
FLAS H

Gen Set LNG

RUNDOWN

LNG at near-
atmospheric pressure
pumped to storage tank

10

Qatargas LNG plant layout

Utility power
Sulphur and steam
recovcery
Utilities

Slugcatch Condensate
er stabilization

5
 11

MCR Heat
Exchanger CCR

Gas turbines
and CO2
compressors absorber

Qatargas

12
Jetty

Atlantic LNG Trinidad

(Air cooled)

Jetty

Compressors

Air cooled
condenser
s Cold boxes
(Heat exchangers)

6
 Classification: Internal Status: Draft

LAYOUT - HAMMERFEST LNG

Area 1 Area 2 Area 3
PLANT HP flare

Grid substation LP flare

Subsea road Camp area
tunnel
Administration building / control
room
Sea water outlet /sea water
Holding basin / waste waterinlet
treatment
Utility
MDEA storage / substation
fuel gas
Compressed air and inert gas Condensate storage
facilities
Landfall tank
Offshore utility substation
MEG process LNG storage
MEG substation area tanks
Product jetty
MEG storage tank
LPG storage tank
area
Hot oil and Storage & loading
chemical storage N2substation
cold box
tanks NG Cold box
Pig receiver
Process
substation
Electrical power generation
Compression area, barge
Process area, barge

Construction jetty

Slug catcher

14

Gas liquefaction process - ideal

Example: Natural gas at 60 bar, 10oC ambient temperature
50
Heat is removed as the gas is 100 60

cooled at gliding temperature 10

Ambient temperature 10oC 20 bar

-30 W
Heat removed during liquefaction
Temperature, C

-70 p=1.3 bar

(Q), and ideal work (W), are shown
as areas -110

Gas pressure has a large influence -150

on work
-190
Ideal work of liquefaction: Natural gas Q
at 60 bar: 0.11 kWh/kg -230
(0.8 % of Lower Heating Value)
-273
-270
-6 -4 -2 0
Entropy, kJ/(kgK)

7
 15

Energy (fuel gas) use for liquefaction

20
Liquefaction process 2nd law
Efficiency of power generation: (exergy) efficiency typically
Energy input as % of LHV

30 % around 50%
15
50 %
100 %
Typical fuel use 5-10% of feed
10
Ambient temperature and feed
gas pressure has large effect
Hammerfest
5

0
0 20 40 60 80 100
Exergy efficiency of liquefaction cycle, %

16

Natural gas cooling

Cooling of natural gas stream occurs T, oC
over large temperature span Ambient temperature (air / sea water)
10oC
Heat must be removed from natural gas
stream at varying temperature NG
Pumping of heat
Temperature of evaporating refrigerant
must be as high as possible to reduce
power need for heat pumping

Close match between NG temperature

curve and refrigerant temperature can
be achieved by
- using many stages of
evaporation temperature
(cascade process), or
- using a refrigerant that -160oC
evaporates at gliding
temperature (mixed refrigerant
process) Heat transferred

8
 17

Temperature difference in heat exchangers is increasingly

important at lower temperatures
Consequence: T need to be
W = T0 S = To(SC - SH) reduced as much as possible at
To
low temperatures

10

W/Q - Change in work (MW) per MW

heat transferred, for 1 K delta T
T T = 1 K

1
Q

Ambient temp 10oC

SC S
0,1
SH
Increased work Reduced work
input output
Sub-ambient temperature
W = extra power input needed to 0,01
compensate for heat transfer across -250 -150 -50 50 150
a temperature difference of T = 1 K Temperature, deg C
W grows more than exponentially
as temperature level T is reduced

18

Natural gas path through liquefaction

pressure-enthalpy diagram (C1:89.7% C2:5,5% C3:1.8% N2:2.8%)
100
-200oC -150oC -100oC -50oC 0 oC 50oC

Liquefaction Precooling
Subcooling

Expansion
Pressure [bara]

10

JT Throttling

1
-900 End
-800 flash -700 -600 -500LNG -400 -300 -200 -100 0 100 200
Enthalpy [kJ/kg]

9
 19

Simple vapour compression refrigeration system

Flow circuit Condensing refrigerant

Heat sink
(Air/water) Condenser
High pressure

Compressor

Expansion valve
Low pressure

Evaporator Fluid to
be cooled

Evaporating
refrigerant

20

Refrigeration cycle in ph-coordinates (propane)

3
40oC at
Evaporation at -30oC Condensation at 30oC
Compressor
discharge
2
T [oC]: -60 -40 -20 0 20 40 60 80 100
100,0

3
10,0 2
4
Pressure [bara]

4 1
Evaporating 1,0

temperature 30oC

Condensing
temperature 30oC
0,1
-700 -600 -500 -400 -300 -200 -100 0 100 200 300
Enthalpy [kJ/kg]

10
 21

Refrigeration cycle in Th-coordinates (propane)

120

100

80
25
60 20
15
Temperature [C]

40
10
20
2 bar
0

-20

p = 1 bar
-40

-60

-80
-700 -600 -500 -400 -300 -200 -100 0 100 200 300
Enthalpy [kJ/kg]

22

Vapour pressure of pure fluids relevant for LNG

processes
Refrigerant Vapour Pressure

100

CO2
C1 Ethylene
N2 C2

C3
Pressura(Bara)

10

n-C4

LNG Range

1
-200 -150 -100 -50 0 50
Temp(C)

11
 23

Data for some relevant fluids

Normal boiling point, at 1.013 bara

Enthalpy of evaporation at NBP

NBP dhNBP Triple point Critical point

[C] [kg/kJ]]
[kJ/kg [C] [bara] [C] [bara]
Nitrogen N2 -195,75 202,678 -210,0 0,125 -146,95 33,944
Methane CH4 -161,45 522,080 -182,5 0,117 -82,55 46,002
Ethylene C2H4 -103,71 487,132 -169,2 0,0012 9,20 50,359
Carbon dioxide CO2 -78,45 392,780 -56,6 5,170 31,05 73,765
Ethane C2H6 -88,65 496,999 -182,8 0,000013 32,25 48,839
Propane C3H8 -42,07 431,517 -187,6 1,960E-09 96,67 42,496
n-Butane C4H10 -0,45 389,746 -138,3 6,740E-06 152,05 37,997

Normal sublimation temperature (NBP lower than triple point temp)

24

Bubble Point Curve Boundary between liquid phase and 2-phase region
Phase envelope Dew Point Curve Boundary between gas phase and 2-phase region.
(for a given composition)
Critical Point Location where bubble point and dew-point curves meet.

Cricondentherm Highest T in phase envelope.

Cricondenbar Highest P in phase envelope.

Quality Lines Lines of constant volumetric or molar percentage of a phase.

Cricondenbar
Bubblepoint Curve
Critical

Dew Point Curve

Quality
Pressure

75% Lines

50%

Cricondentherm
25%

Temperature

12
 25

Tx-diagram example:
Cooling C2/C3 at a constant pressure of 5 bara
Equilibrium between
5
liquid and vapour
0 Bubble Dew
Superheated (Saturated)
-5 vapour
-10
Temp/concentration
-15 Two-phase
of last vapour to
T em p erature [C ]

condense
-20
-25
-30 T
-35
Temp/concentration
-40 of first liquid
-45 condensed

-50
Subcooled
-55 liquid
-60
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Weight-% Ethane

26

Mixed-fluid process in Th-coordinates

(50/50 w-% C2/C3)
120

100

80

60
T em p eratu re [C ]

40

25
20
20

0
15
10
-20
2 bar
-40

-60
p = 1 bar
-80
-800 -700 -600 -500 -400 -300 -200 -100 0 100 200 300
Enthalpy [kJ/kg]

13
 27

Process licensors Base load LNG plants

Air Products and Chemicals Inc (APCI)
World leader since since the 1970s More than 130 Mtpa installed, 50 Mtpa under construction,
more than 60 operating trains
C3MR process ( < 60 trains)
AP-XTM Hybrid (Qatar Gas II, 2 x 7.8 Mtpa, Start up 2008 and 2009)
ConocoPhillips (Optimised) Cascade
Trinidad: Atlantic LNG - 4 trains
Egypt: Idku
Alaska: Kenai (Operating since 1969!)
Australia: Darwin LNG
Equatorial Guinea
Shell DMR Double Mixed Refrigerant (Sakhalin, 2 x 4.8 Mtpa)
PMR (same as C3MR but parallel MR circuits) no references
Linde/Statoil MFC Mixed Fluid Cascade Process (Snhvit, 4.3 Mtpa start up 2007)
Axens Liquefin (No references)

Mtpa = Million tonnes per year

28

Cascade process for natural gas liquefaction

1.4 bar 45 bar

1.4 bar 19 bar

1.4 bar 7 bar

-96 C -32 C 12 C
LNG -155 C NG

Methane
Ethylene
Propane

14
 29

Mixed-fluid process in Th-coordinates

(50/50 w-% C2/C3)
120

100

80

60
T em p eratu re [C ]

40
25
20 20
15
0
10
-20
2 bar
-40

-60
p = 1 bar
-80
-800 -700 -600 -500 -400 -300 -200 -100 0 100 200 300
Enthalpy [kJ/kg]

30

Principles of mixed refrigerant cycle

(Prico single-mix cycle)

NG Composition:
12 C 30 bar
NG Refrig
C1 0.897 0.360
12 C 6,5 C
C2 0.055 0.280
99,8 C C3 0.018 0.110
nC4 0.001 0.150
-155 C 5 bar
LN
N2 0.028 0.100
-155 C -155,5 C
G

15
 31

Temperature - Enthalpy
150

Mixed refrigerant dew point line

100 Mixed refrigerant 30 bar
Mixed refrigerant bubble point line

50
NG 60 bar
Temperature, C

NG dew point line

-50
Mixed refrigerant 5 bar
NG bubble point line
-100

-150

-200
-1500 -1000 -500 0 500 1000 1500
Enthalpy, x 10^6 kJ/hr

32

Mixed Fluid Cascade (MFC) process (Linde-Statoil)

NG
Three mixed refrigerant circuits

Pre-
Pre-cooling Precooling (Mainly: C2, C3)
Section

E1A Liquefaction (Mainly: C1, C2, C3)

Subcooling (Mainly: N2, C1, C2)

CW1
E1B
C1 Cascade connection of the circuits

Liquefaction Precooling in two (sometimes three)

Section
stages
E2 CW2

C2
No fractionation of the mixed
Sub-
Sub-cooling
refrigerant flows
Section

E3
Expander on subcooling cycle
CW
3A/B
G C3
LNG X1

16
 33

Heavy hydrocarbon extraction Natural gas

from pre-processing
Scrubber column (Snhvit)

Natural gas liquids (NGL/LPG) are formed during

precooling, and can/must be separated from the gas
Precooling
stream

Propane and butane are valuable products

-25oC -50oC
Extraction process is needed to reach lean gas
specifications, LNG specs demand that C3 and C4 is
removed

A relatively simple solution is to use a scrubber column

that separates out liquid components which are formed
during cooling of the natural gas
Scrubber column
Some LPG is fractionated to give pure C1, C2 and C3 for
refrigerant make-up

LPG Fractionation
Refrigerant make-up

34
Feedgas from
Natural Gas Liquefaction Circuiting

pre-processing

Precooling Lique- Subcooling

faction
CH4 from
nitrogen
removal
N2/CH4 to
nitrogen
removal

LPG Fractionation
Refrigerant make-up

LNG

17
 35

Natural gas circuiting

36

Composite temperature curves - Hammerfest

Overall Heat / Temperature Diagram for Cold Equipment in System 25
Snhvit A Plant Feed Stock
360

320

280

240 R Lique-
e faction
b Refri-
Heat [MW]

200 gerant
o
i
160 l
e
120 r
Subcooling Refrigerant
Precooling Refrigerant
80

40

0
110 130 150 170 190 210 230 250 270 290
Temperature [K]
Hot (sum) Cold (sum)

18
 37

Precooling cicruit

25-133 25-133
38
25-122
SW SW
25-198 25-HA-112
25-HA-111
25-210

25-263
25-207

25-103
25-VD-103 SW
25-LV-1007

OVERVIEW
25-193 MIN. FLOW LINE
25-263.2 25-263.1
25-104 25-266 25-172
25-HA-114
25-202

25-195

25-265 25-PV-1626
25-PV-1464 25-269
25-171
25-UV-1011

25-UV-1012

25-278 25-279
25-VD-115

25-VD-116

25-251 25-277

25-HG-104 25-HG-105
MIN. FLOW
25-273
25-249

25-HA-104
25-201

SW
25-UV-1009
25-UV-1010
25-270

25-HA-101 25-247 SW
25-VD-102

25-264 25-274
25-196.1
25-196.3

21 21-102 25-138
25-110
25-111 25-FV-1550
MIN. FLOW

25-200

25-LV-1463
25-252
26-112

25-LV-1448
26-184

25-UV-1879
25-173

25-248 ANTISURGE
25-272
MIN. FLOW
26A

25-196.2

25-LV-1321A 25-LV-1430A
26C
26D
26C

25-LV-1321B 25-LV-1430B
25-812
25-271

25-268
26-175

25-802 25-813 START UP RECYCLE

25-803

25-168
26-140

25-FV-1549

26D
25-811

25-801
25-205

25-VD-101
25-804

26-180

25-UV-1308
25-VD-109

25-109
25-102

25-196
25-VD-111

25-106
25-HG-102 A-F SW
26-102
25-190
25-FV-1219A
25-FV-1219B

25-196.4
25-132.1
25-121.1

25-131

25-132

25-HA-113
25-FV-1224A
25-FV-1224B

25-139 ANTISURGE
25-114
25-805
25-121
26B
25-108

25-130

25-HG-101 A-D
25-815
M PC
ANTISURGE

25-112
25-105
25-UV-1878

25-KA-101
25-FV-1546

SC II

M
25-117
LC
SC I

25-LV-1327A
25-117

25-189 27A 25-UV-1548

M
25-LV-1327B ANTISURGE
25-807 25-808
25-114 25-118 25-203 25-202
25-LV-1435A
25-KA-102
25-UV-1877

25-LV-1435B 25-818 25-KA-103

25-809
25-819 25-817
25-PV-1560A
25-806 25-816
25-129
25-121.2

25-120

25-122.2 25-122.1
25-VD-110

25-VD-112
25-142

25-116 25-PV-1561A
25-113

25-133.2 25-133.1
25-FV-1221A
25-FV-1221B

25-VD-105

25-258
25-223

25-209
25-820
25-810
27A
25-280

25-FV-1227A 25-177
25-FV-1227B
25-140
25-115
25-VD-106
25-259

25-PV-1282B
25-206

25-211
25-183 25-VD-114 25-140.1 25-140.2
27A
46A 25-FV-1543
25-PV-1561C
25-PV-1561B

START-UP LINE
G 25-143
25-132.2
25-261

26-174
42 25-144.1 26B 25-CT-101
25-EG-101 25-PV-1282A
25-141
25-FV-1562A
25-FV-1562B

25-HV-1138
25-179
25-136

26-139
26A 25-137
27A 25-PV-1255B
25-VD-107

25-VD-107A

25-260

25-219 42 42-104 25-169

25-165
25-FV-1451

25-262

25-155
25-163 25-164 27
25-PV-1559
25-HX-102
25-141 25-253
25-HX-103
25-127
25-281.1

25-166
25-225

25-158
25-254
25-148

25-VD-104
46A
25-TV-1268

25-181
25-PV-1560C
25-PV-1560B

25-128

25-PA-102 A/B
25-256

25-162
25-154
25-135
25-FV-1236A
25-FV-1236B

25-167
25-HG-103 A/B
25-VE-102

26-205 26 25-124 27-131

27-FV-1025
27-130
27
25-255

25-149.1

25-FV-1203 25-161
25-257
25-VE-101

25-156

25-HV-1302

25-215 25-149
25-HX-101
25-125

25-FV-1531
25-FV-1654
25-FV-1657

25-153 25-156.1 25-156.2

25-159

25-HA-105
HO 25-123 G
25-126
25-212

25-152

25-134 25-EG-102 25-CT-102

25-PV-1316
25-PA-101 25-160
42
25-157
25-PA-103 A/B 25-144
A/B
25-FV-1725A

25-150 25-151 26

19
 26-VE-101 25-HA-105 25-VE-101 25-CT-102

25-HG-101

27-VE-102

25-HX-102

25-HX-101

25-HX-103

25-VD-107

25-HG-103
25-PA-103

25-VE-102
25-HA-101

27-VE-101
25-PA-101

25-PA-102

PROSESS STRM

Classification: Internal 39
Status: Draft 27-KA-101

26-VE-101 25-HA-105 25-VE-101 25-CT-102

25-HG-102

25-HG-101

27-VE-102

25-HX-102

25-HX-101

25-HX-103

25-VD-107

25-HG-103
25-PA-103

25-VE-102
25-HA-101

27-VE-101
25-PA-101

25-PA-102

25-VD-105

25-HA-114

PROSESS STRM
VSKEDANNINGSKRETS
Classification: Internal 40
Status: Draft 25-KA-102 27-KA-101

20
 26-VE-101 25-HA-105 25-VE-101 25-CT-102 25-VD-109
25-HG-102

25-HG-101

25-VD-112

25-VD-110

27-VE-102

25-HX-102

25-HX-101

25-HX-103

25-VD-107

25-HG-103
25-PA-103

25-VE-102
25-HA-101

27-VE-101
25-PA-101

25-PA-102

25-VD-105

25-HA-112

25-HA-111

25-HA-114
25-HG-105

25-HG-104

25-VD-101
PROSESS STRM
25-VD-115 VSKEDANNINGSKRETS
Classification: Internal 41
FORKJLINGSKRETS
Status: Draft 25-VD-103
25-VD-116 25-VD-102 25-KA-101 25-KA-102 27-KA-101

26-VE-101 25-HA-105 25-VE-101 25-CT-102 25-VD-109

25-HG-102

25-HG-101

25-VD-112

25-VD-110

27-VE-102

25-HX-102

25-HX-101

25-HX-103

25-VD-107

25-HG-103
25-PA-103

25-VE-102
25-HA-101

27-VE-101
25-PA-101

25-CT-101
25-PA-102

25-HA-104
25-VD-105

25-VD-106
25-HA-112

27-HA-113
25-HA-111

25-HA-114
25-HG-105

25-HG-104

25-VD-101
PROSESS STRM
25-VD-115 VSKEDANNINGSKRETS
Classification: Internal 42
FORKJLINGSKRETS
Status: Draft 25-VD-103
25-VD-116 25-VD-102 25-KA-101 25-KA-102 27-KA-101 25-KA-103 UNDERKJLINGSKRETS

21
 25-HG-102
25-VD-104

25-HX-102

25-HX-101

25-VD-105

25-HA-114

25-KA-102

VSKEDANNINGSKRETS
Classification: Internal 43
Status: Draft

25-VD-109
25-HG-102

25-HG-101

25-VD-112

25-VD-110

27-HG-101

25-HA-112

25-HA-111

25-HG-105

25-HG-104

25-VD-101

25-VD-115
Classification: Internal 44
FORKJLINGSKRETS
Status: Draft 25-VD-103
25-VD-116 25-VD-102 25-KA-101

22
 25-HG-102

25-VD-114

25-HX-102

25-HX-101

25-CT-101

25-HA-104

25-VD-106

27-HA-113

Classification: Internal 45
Status: Draft 25-KA-103 UNDERKJLINGSKRETS

46

Liquefaction technology present and prediction

(Source: Shell)

23
 47

Compressor driver alternatives

Steam turbine
Refrigerant compressor(s) driven by steam turbine

Common in older LNG plants

Steam plant needed, including boiler, feedwater treatment etc.

Gas turbine
Direct mechanical compressor drive using gas turbine

Small plot area, low CAPEX

Most common solution today

Capacity of plant determined by available gas turbine sizes

Electric
Only Snhvit so far, but considered in several current developments

Increased availability, potential use of high-efficiency combined-cycle technology

48

Compressor driver trends

24
 49

Mixed Fluid Cascade (MFC) process and energy system at Hammerfest

Cold box Cycle compression and Electric power generation
seawater cooling waste heat recovery,
hot oil cycle
Unit 25 Unit 25 Unit 81 and 50

Electric 5 x GE LM 6000 GT
Power with waste heat recovery
NG Gener.

G
Air
Plate Fin Fuel gas
Heat Sea
Exchangers Pre- water
cooling cooling
Cycle
G
M
PCC Compressor
Lique-
faction
Cycle Hot
G oil
cycle
Spiral Wound
Heat M
Exchangers
Generator LCC Compressor
Sub-
cooling G
Cycle

LNG Expander/
Generator SCC M
G G Exp./
LNG Gener.
SCC Compressor G
Electric Power
Process heat
from the Grid
consumers

50

Parallel drivers/compressors (increasing availability)

Two in one concept

25
 51

Process availability (on-stream time)

On-line Availability
Fraction of time

2 circuits GT GT = 0.96
0.98 * 0.98

GT
2 circuits
1 parallel
GT = 0.97
driver/compr
0.98 * GT
0.99

3 circuits GT GT GT = 0.94
0.98 * 0.98 * 0.98

52

Heat rejection
Air cooling Water cooling

Tube-in-shell
heat exchanger

26
 53

Heat rejection
Air cooling Water cooling
Large plot area needed More compact plant
Lower process efficiency (less LNG for given Costly corrosion-resistant materials needed
power input) (e.g. titanium)
Lower CAPEX than water cooling High process efficiency
Larger seasonal variation in capacity and May need chlorination to prevent fouling
efficiency

54

Air cooled condensers

27
 55

Cooling of LNG plants

28