Bestech Industrial & Technical Training Center, Inc .

APPLICATION OF
REFRIGERATION IN OIL AND
GAS AND PETROCHEMICAL
INDUSTRY
 PRESENTER

V EJ IEH J IM , SU M A G A YSA Y
PROFESSIONAL MECHANICAL ENGINEER
License Welding Engineer – Japan Welding Engineering Society
Certified Welding Inspector – Philippine Welding Society
 Understand the Concept of Heat
Transfer and Laws of Refrigeration
Technical
Understand the Thermodynamic Properties
Training applied in Refrigeration System

Outcomes Familiarize with different terminologies used

in Refrigeration

I Understand the Basis Principle of

Refrigeration System
Identify the refrigeration system components
and its function

Familiarize with common problem encountered

during operation of refrigeration system
Understand the HSE impact of
Refrigeration System Operation
LAWS OF REFRIGERATION
▪ Heat travels from Hot to Cold

▪ Refrigerant absorbs heat when changing

from liquid to vapor

▪ Refrigerant release heat when changing

vapor or gas to liquid
HEAT TRANSFER METHODS
THERMODYNAMIC PROPERTIES
BASIC STATE OF MATTER
THERMODYNAMIC PROPERTIES
▪ Mass – Quantity of substance ( kg or lb. )
▪ Volume – Space occupied by substance (m3 or ft3)

▪ Density – Ratio of mass to volume (kg/m3 or lb./ft3)

▪ Temperature – Degree of hotness or coldness of substance .

➢ Temperature Scale : 0Celsius and O Fahrenheit

➢ Absolute Temperature Scale : Kelvin and Rankine

▪ Pressure – Force acting normal to an area.

➢ Gauge Pressure (KPag, Barg ,PSIg, )

➢ Atmospheric Pressure ( KPaa, Bara, PSIa)

➢ Absolute Pressure ( Kpa, Bar, PSI)

THERMODYNAMIC PROPERTIES

▪ Internal Energy (U) – energy within the substance brought about by

molecular movement ( KJ or BTU).

▪ Enthalpy (H) – The sum of internal energy and flow work ( KJ or BTU).

▪ Entropy (S) – The property of substance that remains constant when

there is no heat added to or taken away from the substance (KJ/K or
BTU/R).
THERMODYNAMIC PROPERTIES

▪ Internal Energy (U) – energy within the substance brought

about by molecular movement ( KJ or BTU).

▪ Enthalpy (H) – The sum of internal energy and flow work

( KJ or BTU).

▪ Entropy (S) – The property of substance that remains constant

when there is no heat added to or taken away from the substance
(KJ/K or BTU/R).
THERMODYNAMIC PROPERTIES
▪ Heat – Energy in motion.

▪ Latent Heat – The amount of heat or energy required to change

the phase of substance without change in temperature .

▪ Sensible Heat – The amount of heat required to change the

temperature of a given mass of a substance.

▪ Heat of Fusion – Latent heat absorbed when solid melts into

liquid or latent heat release during liquid solidifies.
THERMODYNAMIC PROPERTIES
LATENT HEAT
REFRIGERATION TERMINOLOGIES
▪ Refrigeration – The transfer of heat from lower temperature
region to higher temperature region.

▪ Refrigerant – The working fluid used in refrigeration system.

▪ Refrigeration Cycle – the process of changing refrigerant

liquid into vapor or gas by absorbing the heat from evaporator
coils and dissipating the absorbed heat into the condenser to the
surrounding atmosphere.
REFRIGERATION TERMINOLOGIES

Conventional Refrigerant used in Oil and Gas and Petrochemical Industry

Refrigerant Temperature Range
▪ Methane – 185 0C to – 130 0C
▪ Ethane/Ethylene – 115 0C to – 60 0C
▪ Propane/Propylene – 45 0C to +4 0C
▪ Mixed Refrigerant ( Methane, Ethane, Propane and N2)
REFRIGERATION TERMINOLOGIES
REFRIGERATION TERMINOLOGIES
▪ TON of Refrigeration (TR) – The amount of heat
required to freeze a ton (2000 pounds) of water at 32 0F
in 24 hours .

Ton of Refrigeration
12000 BTU/hr
200 BTU/min
3.52 KW
REFRIGERATION TERMINOLOGIES
▪ Heat of Compression – The heat generated inside the
compressor while the gas is compressed at high speed and
pressure.

▪ Heat of Condensation – The heat required to liquefy gas

refrigerant into the surroundings .

▪ Heat Lag – The time consumed in travelling through the

conductor
 SYSTEM CLASSIFICATION
Refrigeration System Classification
High Temperature Refrigeration : Above 0 0C
Medium Temperature Refrigeration : 0 0C to – 25 0C
Low Temperature Refrigeration : – 25 0C to – 50 0C
Ultra Low Temperature Refrigeration : – 50 0C to – 100 0C

Cryogenic Refrigeration System

▪ Refrigeration System dealing with extremely low temperature
below – 150 0C.
 REFRIGERATION TECHNOLOGY
APPLIED TO OIL AND GAS AND PETRCOHEMICAL INDUSTRY
Refrigeration Approximate Temperature Refrigerant
Technology Range 0C
Steam Jet Ejector 2 0C to 200C Water
Absorption 4 0C to 200C Lithium Bromide
Solution
Absorption – 40 0C to – 1 0C Ammonia
Mechanical – 130 0C to – 4 0C Ammonia,
Compression Halogenated
Hydrocarbon,
Propane,
propylene, ethane
ethylene, MR etc.
VAPOR COMPRESSION CYCLE
PV Diagram
VAPOR COMPRESSION CYCLE
Ph Diagram
VAPOR COMPRESSION CYCLE
Deviation from Ideal Vapor
Compression Refrigeration Cycle

➢ Pressure drop across evaporator : P2 < P1

➢ Entropy increase across compressor : S3>S2
➢ Pressure drop across the condenser : P4 < P3

Other Factors
➢ Piping and Fittings : Flow resistance Pressure drop
➢ Surrounding Environment : Increase or decrease in Temperature
VAPOR COMPRESSION CYCLE
IDEAL T-S Diagram
VAPOR COMPRESSION CYCLE
ACTUAL T-S Diagram
Mechanical Refrigeration
Components
▪ COMPRESSOR

▪ CONDENSER

▪ EVAPORATOR

▪ EXPANSION VALVE

▪ LIQUID RECEIVER

▪ ACCUMULATOR
Refrigeration System Componets
MECHANICAL COMPONENTS
Compressor
The heart of refrigeration system. A mechanical device used to
compressed refrigerant vapor to increase its pressure and
temperature.

Types of Compressor used in Refrigeration System

▪Reciprocating Compressor – uses piston to squeeze the

refrigerant vapor or gas to initiate refrigeration cycle.

▪ Rotary Compressor – uses roller , lobe and vanes

Refrigeration Components
Reciprocating Compressor Parts Reciprocating Operation
Refrigeration Components
Reciprocating Compressor Construction
Hermitic Compressor Semi - Hermitic Compressor
Refrigeration Components
Reciprocating Compressor Construction
Open Type Compressor
Refrigeration Components
Parts of Reciprocating Compressor
External Parts Internal Parts
Refrigeration Components
Rotary Compressor Operation

3 Lobe Rotary Compressor 2 Lobe Rotary Compressor

Refrigeration Components
Screw Compressor Operation

3 Lobe Rotary Compressor 2 Lobe Rotary Compressor

Refrigeration Components
Rotary Compressor Operation

3 Lobe Rotary Compressor 2 Lobe Rotary Compressor

Refrigeration Components
Screw Compressor

Compressor Performance Compressor Operation

 Application of Refrigeration

SCREW COMPRESSORS
▪ Screw compressors are designed to be incorporated
with oil injection and have been used in industrial
applications since 1950
▪ Screw compressor can be classified as twin-screw
compressors or single - screw compressors
 Application of Refrigeration
SCREW COMPRESSORS CONTROLS
Status monitoring and specific controls
▪ Inlet and outlet chilled media temperature
▪ Evaporator and condenser refrigerant temperatures and
pressures
▪ Compressor suction Temperature
Safety Controls
▪ Monitor Overloading, high and low pressure cut-outs, oil
pressure
▪ Diagnostic: Operating conditions and diagnostic display
Application of Refrigeration
SREW COMPRESSOR LUBRICATION SYSTEM
Suction Filter from Chiller

Rotary Compressor

Slider Valve Oil Free Gas to Condenser

Discharge Gas

Oil Separator Circulating Pump

Filters
Refrigeration Components
Evaporator/ Chiller
▪ Mechanical device used to absorbed the heat from the
product to be cooled.

Accumulator
▪ Passive tube that store un-boiled refrigerant not to
proceed to the compressor while in liquid form.

Filter/Drier
▪ Cleans and dries the refrigerant before entering the
capillary tube to avoid clogging.
Refrigeration Components
Chiller/ Evaporator
Refrigeration System
Accumulator
▪ Located at the LP side of the
system
▪ Store excess liquid refrigerant
from the evaporator in an orifice
expansion tube system
Refrigeration System
Accumulator
Refrigeration Components
Liquid Receiver Drier
RECEIVER DRIER
▪ Located at the HP side of the
system
▪ Store excess refrigerant receive
from the condenser going to
expansion valve
Refrigeration Components
Condenser
▪ Mechanical device used to rejects heat from the
refrigerant vapor.
Types of Condenser
▪ Air Cooled Condenser : A fin and tube type heat
exchanger that utilizes air as cooling medium to remove
heat from the refrigerant vapor.
▪ Water Cooled Condenser : A shell and tube type
heat exchanger that utilizes water as cooling medium to
remove heat from the refrigerant vapor.
Refrigeration Components
Water Cooled Condenser
Refrigeration Components
Air Cooled Condenser
 Refrigeration System
Thermal Expansion Valve

Parts Name
(1)Membrane housing,
(2)Interchangeable adapter,
(3) Valve housing,
(4)Spindle for adjusting static superheat,
(5) Refrigerant-filled bulb,
(6)Port for external equalization.
 Refrigeration System
Thermal Expansion Valve Principle of Operation
 Refrigeration System
Types of Expansion Valve

TXV AXV Capillary Tube

MECHANICAL REFRIGERATION
VAPOR COMPRESSION REFRIGERATION
CYCLE
APPLICATION OF
REFRIGERATION IN
OIL AND GAS
INDUSTRY

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
Application of Refrigeration
LNG PROCESS PLANT
LNG REFRIGERATION PROCESS
C3-MCR LNG LIQUIFACTION PROCESS
Application of Refrigeration
Composition of Natural Gas
Application of Refrigeration
LNG Process – Cooling of Natural Gas
(mostly C1) to its Boiling Point
HYDROCARBON PROPERTIES
SYMBOL NAME BOILING POINT AIT
C1 METHANE -160 0C 600 0C
C2 ETHANE -58 0C 515 0C
C3 PROPANE -42 0C 505 0C
C4 BUTANE -0.5 0C 365 0C
C5 PENTANE +35 0C 260 0C
Application of Refrigeration
Mechanical Refrigeration System

Vapor compression refrigeration is the most common

mechanical refrigeration process.
Various of applications of Mechanical Refrigeration in the
Oil and Gas Processing Industry:

►Chilling natural gas for hydrocarbon dewpoint control

►Chilling natural gas for NGL extraction
►Condensation of reflux in de-ethanizers
►NGL product storage and transportation
►Natural gas liquefaction (LNG)
Application of Refrigeration
Natural Gas Treating Plant
▪ Refrigeration serves as a dual Dew Point Control Function
➢ To achieve HC Dew Point Temperature
➢ Water Dew Point Temperature for residue or sales gas

Dew Point Control by Refrigeration

➢ Chilling the gas to colder temperature such as – 29 0C to –
34 0C
➢ Contacting the gas stream with lean oil in an absorption
tower
 Application of Refrigeration
LNG REFRIGERATION PROCESS
Air Cooler P =1750 KPa
PRV r T = 60 0Cr
To Flare
Drum r

Receiver
r
P =1650 KPa
Propane Refrigeration Circuit
T = 50 0Cr
RAW NATURAL GAS

Suction Drum Compressor

r r

JT Valve r
P =110 KPa
T = - 40 0Cr
Lower Heat Exchanger r LNG
Application of Refrigeration
Single Stage Mechanical Refrigeration Process

SIC – Short Interval Control

LC – Level Control
LT – Level Transmitter
TT – Temperature Transmitter
TC – Temperature Transmitter
PT – Pressure Transmitter
 Application of Refrigeration
2 STAGE LNG REFRIGERATION SYSTEM

Multistage Refrigeration
Process are used to
enhance efficiency of the
process
LNG REFRIGERATION PROCESS
HCDP Control Gas Cooling Using Propane
Refrigeration System
LNG REFRIGERATION PROCESS
E1- Propane Refrigeration Unit in LNG
LNG REFRIGERATION PROCESS
LNG SCRUB COLUMN UNIT
LNG REFRIGERATION PROCESS
LNG CRYOGENIC TOWER
LNG REFRIGERATION PROCESS
FLASH VESSELS
LNG REFRIGERATION PROCESS
LNG STORAGE TANK
APPLICATION OF
REFRIGERATION IN
PETROCHEMICAL
INDUSTRY

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
Application of Refrigeration
POLYETHYLENE PLANT PROCESS

HX UNIT
Application of Refrigeration
POLYETHYLENE VRS REFRIGERATION
 Application of Refrigeration
POLYETHYLENE VRS REFRIGERATION UNIT
Evaporator/ Chiller
Glycol Out

P1 = 135 KPag
T1 = -- 20 0Cr
Glycol In
P4 = 155 KPag
P 2 =1745 KPag T4 = -- 25 0Cr
PRV r
T2 = 74 0Cr TCV r
To Atmosphere r TXV r

Compressor r
Receiver R 507 Refrigeration Circuit
Cooling Water Out Condenser r

P 3 =1745 KPag
Cooling Water In LNG T3 = 40 0Cr
Refrigeration Cycle Diagram
R-507 Ref Unit Ph - Diagram

P 3 =1745 KPag 3 2 P 2 =1745 KPag

T3 = 40 0Cr T2 = 74 0Cr

P4 = 155 KPag
T4 = -- 25 0Cr 4 P1 = 135 KPag
1 T1 = -- 20 0Cr
Refrigerant Properties
R-507 Physical Properties
 Refrigerant Properties
R-507 TOXICOLOGICAL INFORMATION
 REF UNIT CAPACITY
REFRIGERATION SYSTEM OPERATING CONDITIONS
POINT PRESSURE TEMP h (KJ/kg) Delta h REF FLOW RATE
(KPag) 0C (KJ/kg) ( Kg/hr)
1 135 - 20 353.5 94.5 7425
2 1745 74 418.4 64.9 7425
3 1745 40 259.0 - 159.4 7425
4 155 - 25 259.0 0 7425
 REF UNIT CAPACITY
REFRIGERATION UNIT CALCULATION

Description Formula Calculation Result Design

KW
Compressor Power m (h2-h1) 7425(64.9) 134 KW 150

Refrigerating Effect m (h1-h4) 7425 (94.5) 195 KW 329

Evaporator
Heat Capacity m (h2-h3) 7425(159.4) 329 KW 329
Condenser
COP Heat Capacity 329/195 1.7 KW -
Ref Effect
Application of Refrigeration
POLYETHYLENE VRS REFRIGERATION SYSTEM

MOTOR COMP

OIL
RECEIVER
 THANK YOU!

Bestech Industrial & Technical

Training Center, Inc.
PHONE NUMBER
0949 889 4118
 APPLICATION OF
REFRIGERATION IN OIL AND
GAS AND PETROCHEMICAL
INDUSTRY
QUESTION
AND
ANSWER