AIChE Spring Conference 2005 Topical Conference on Natural Gas Utilization

Transcription

1 AIChE Spring Conference 2005 Topical Conference on Natural Gas Utilization LNG Expander for Extended Operating Range In Large-Scale Liquefaction Trains Munir Amsyari Plant Coordinator Zudiharto Senior Process Engineer Joel V. Madison President Hans E. Kimmel Vice President P.T.Badak Indonesia Ebara International Corporation, USA LNG BADAK

2 Abstract The size of LNG liquefaction trains is steadily increasing due to economical reasons. As a consequence of the increase in the size of trains most of the equipment used in the liquefaction process have also to be increased in size. Particularly compressors, heat exchangers, gas expanders and liquid expanders have to be increased either in size or quantity. The paper presents the concept and design of LNG expanders for extended operating range in large-scale liquefaction trains.

3 Origin of LNG Expander Technology United States Patent 4,334,902 Inventor: Henri Paradowski Technip, Paris La Defense, France Method of and System for Refrigerating a Fluid to be Cooled Down to a Low Temperature Priority Date: Dec. 12, 1979 A A process of and an apparatus for saving energy in a method of liquefying a natural gas

4 LNG Expander Economics LNG Expander Power Output Increase in LNG Output Increase in Revenue For LNG Price $266.67/ton kw Tons/year $/year ,000 30,000 60, ,000 16,000 1,600,000 8,000,000 16,000,000 32,000,000 Reference: Gilbert Habets, Shell International Oil Products B.V. et al.: "Economics of Cryogenic Turbine Expanders" The International Journal of Hydrocarbon Engineering, December 1998

5 Oman LNG

6 Oman LNG Liquefaction Process Trains 1 and 2

7 Sakhalin LNG Liquefaction Trains and LNG & Oil Export Terminal

8 Typical LNG Plant Process Scheme

9 MLNG Dua Malaysia First generation LNG expander with air- cooled generator and rotating shaft seal 1996 (Flowserve Corp.)

10 NLNG Nigeria First generation LNG and HMR expanders with air-cooled generator and rotating shaft seal 1999 (Flowserve Corp.)

11 Comparison in AIR COOLED GENERATOR size and weight between first 7000 mm SEAL, COUPLING & THRUST BEARING and second generation LNG TURBINE SUBMERGED TURBINE GENERATOR 3370 mm expanders First Generation Power Output = 900 kw Total Weight = 27,000 kg. (Flowserve Corp.) Second Generation Power Output = 1000kW Total Weight = 7,600 kg. (Ebara Intl. Corp.)

12 Second Generation Three-Stage Liquid Expander Oman LNG June 1999 (Ebara Intl. Corp.)

13 MLNG Tiga, Malaysia December 2000 Second-generation LNG expander with submerged generator and variable speed (Ebara Intl. Corp.)

14 Generator Rotor Generator Stator Thrust Equalization Mechanism (TEM) Fixed Geometry Inlet Guide Vanes Runners

15 Three-Stage Liquid Expander for Ras Laffan LNG 2002 (Ebara Intl. Corp.)

16 Since the early days of the cryogenic technology it has been known that two-phase cryogenic expanders improve thermodynamic efficiency of gas liquefaction processes. Only in recent years is the technology available to operate reliably liquid-vapour LNG expanders

17 What is Two-Phase Expansion?

18 Two-Phase Expansion at Home

19 Two-Phase Expansion in Nature

20 Hero s s Two-Phase Turbine Hero of Alexandria, a Greek engineer, invented the first two-phase turbine 2000 years ago

21 The concept of Hero s s turbine applied to today s s technology: The Jet Exducer

22 Two-Phase Expander with Jet Exducer

23 Hydraulic Assembly

24 Two-Phase Jet Exducer

25 Two-Phase Jet Exducer

26 Krio Polish Oil & Gas Two-Phase Exducer Turbine 2003

27 January 2003 Installation of Two-Phase Expander at Krio Polish Oil & Gas Odolanow, Poland

28 The following six slides are part of the presentation Improved LNG Production Process Using Two-Phase Expanders Christian Fischer Shell Sakhalin Energy SE-LNG Yokohama, Japan Hans E Kimmel Ebara International Corporation Sparks, Nevada, USA hkimmel@ebaraintl.com 5th Annual 'Rome' World LNG Summit 1 st st - 3 rd December 2004, Rome, Italy The CWC Group

29 Sgl & Two Ph

30 Fig 1 Curve

31 Fig 2 Curve

32 Expander Rotor Runner

33 Fig 3 Curve

34 Radial and Axial Converging Nozzle Ring

35 Generator Rotor Generator Stator Thrust Equalization Mechanism (TEM) Fixed Geometry Inlet Guide Vanes Runners

36 Two-Phase Expander with Jet Exducer

37 Two-Phase Expander with Compact Assembly Configuration

38 Two-Phase Expander with Compact Assembly Configuration

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41 Operating Conditions Tf H C-3 Flow rate : kg/s Intake capacity : dm 3 /s Intake capacity : m 3 /hr Inlet pressure : bar abs Inlet density : kg/m Inlet temperature : C Outlet pressure : bar abs 2.7 P of Turbine : bar H of Turbine : m Number of Stages 2 Operating Conditions Tf H C-3 Flow rate : kg/s Intake capacity : dm 3 /s Intake capacity : m 3 /hr Inlet pressure : bar abs Inlet density : kg/m Inlet temperature : C Outlet pressure : bar abs 1.01 P of Turbine : bar H of Turbine : m Number of Stages 2

42 Operating Conditions Tf H C-3 Operational Speed :rpm 3000 Intake capacity :m 3 /hr H of Turbine : m Inlet density : kg/m Power Hydraulic In : kw 674 Efficiency Turbine : % 85 Efficiency Generator : % 96.5 Power Out Gen. : kw 553 BTU Removal/Hr : BTU/hr 1,888,180 Predicted Expander Eff: % 82 Reclaimed Cap. : dm 3 /s 2.41 Capacity Increase : % 0.97 Reclaimed Cap.: tons/day Revenue Incr. : $/Year $ 8,814,820 Operating Conditions Tf H C-3 Operational Speed :rpm 3000 Intake capacity :m 3 /hr H of Turbine : m Inlet density : kg/m Power Hydraulic In : kw 716 Efficiency Turbine : % 94 Efficiency Generator : % 96.5 Power Out Gen. : kw 652 BTU Removal/Hr : BTU/hr 2,226,208 Predicted Expander Eff: % 91 Reclaimed Cap. : dm 3 /s 2.84 Capacity Increase : % 1.14 Reclaimed Cap.: tons/day Revenue Incr. : $/Year $ 10,388,220

43 Thanks to Hero of Alexandria Our Turbine Engineering Forefather

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