Liquefaction Process to Extend Lifetime of Depleting Gas Fields
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1 Liquefaction Process to Extend Lifetime of Depleting Gas Fields Munir Amsyari Corporate Secretary P.T.Badak Jakarta, Indonesia Muljono Sutedjo Director P.T. Indobara Bahana Jakarta Pusat, Indonesia Hans E Kimmel Executive Director hkimmel@ebaraintl.com Ebara International Corporation Sparks, Nevada, USA World LNG Technology Summit th and 27 th April 2006 Barcelona Hilton Barcelona, Spain
2 To Extend the Lifetime of Depleting Gas Fields the Feed Gas has to be Reduced To Reduce the Feed Gas for a given LNG Output, the LNG Boil-Off Downstream the Main Heat Exchanger has to be minimized To Reduce the LNG Boil-Off the Condensed LNG has to be Sub Cooled
3 Sub Cooling of LNG using LNG Liquid Expanders and Two-Phase Expanders
4 Since the early days of refrigeration technology, it has been known that two-phase expanders improve the thermodynamic efficiency of gas liquefaction processes. Only in recent years is the technology available to reliably operate liquid-vapor Two-Phase LNG Expanders
5 Thermodynamics offers three methods to cool fluids Heat transfer Adiabatic Expansion Evaporation
6 All three methods are used in the liquefaction process of natural gas Heat Transfer Heat Exchanger Adiabatic Expansion Evaporation Gas Expander Liquid Expander Joule-Thomson Valve Joule-Thomson Valve Two-Phase Expander
7 To cool a fluid the enthalpy of the fluid has to be reduced Enthalpy is the Total Heat or Heat Content of a fluid Enthalpy is the amount of energy in a fluid capable of doing mechanical work
8 Heat Exchangers Gas Expanders Liquid Expanders Two-Phase Expanders reduce the enthalpy of the natural gas
9 Single-Phase and Two-Phase* Joule-Thomson Valves do not reduce the enthalpy of the natural gas *Two-Phase Joule-Thomson Valves are also called Flashing Joule-Thomson Valves
10 Two-Phase or Flashing Joule-Thomson Valves vaporize a certain part of the condensed LNG
11 The total enthalpy for the vaporized and liquid LNG remains constant across the Joule-Thomson Valve
12 The vaporization heat is removed from the liquid and reduces the enthalpy of the remaining LNG
13 By passing through a flashing Joule-Thomson Valve the remaining liquid LNG is cooled by evaporation
14 For the transitional non-steady state at the exit of the JT-Valve, the liquid portion is much colder than the vapor portion. This is an important benefit. It produces a colder LNG if the phase separation occurs close to the JT-Valve exit. In the steady state and without phase separation, the temperatures of liquid and vapor are equal.
15 Expanders cool the passing fluid by reducing the enthalpy through adiabatic expansion
16 Liquid Expanders utilize only one method to cool the liquefied gas: Adiabatic Expansion
17 Two-Phase Expanders utilize two methods to cool the liquefied gas: Adiabatic Expansion and Evaporation
18 A Two-Phase Expander operates like a Liquid Expander combined with a Flashing Joule-Thomson Valve
19 A Two-Phase Expander eliminates the Flashing Joule-Thomson Valve
20 Sgl & Two Ph
21 Three-Stage Liquid Expander Oman LNG June 1999 (Ebara Intl. Corp.)
22 Generator Rotor Generator Stator Thrust Equalization Mechanism (TEM) Fixed Geometry Inlet Guide Vanes Runners
23 Hero s s Two-Phase Turbine 2000 years ago, Hero of Alexandria, a Greek engineer, invented the first two-phase expander with jet exducer
24 The concept of Hero s s turbine applied to today s s technology: The Jet Exducer
25 Two-Phase LNG Expander with Jet Exducer
26 Two-Phase Expander Hydraulic
27 Two-Phase Jet Exducer
28 Two-Phase Jet Exducer
29 Two-Phase Expander January 2003 Krio Polish Oil & Gas (Ebara Intl. Corp.)
30 January 2003 Installation of Two-Phase Expander at Krio Polish Oil & Gas Odolanow, Poland
31 Installation of Two-Phase Expander 2003
32 Tested Performance Two-Phase Expander Differential Pressure [MPa] Differential Pressure and Efficiency vs. Mass Flow % % no load % % % % DP D rated rated flow % % % % % % % % % % 80.00% 60.00% 40.00% 20.00% 0.00% Turbine Efficiency [%] Mass Flow [kg/s] inlet density: 494 kg/m^3
33 Specific Volume of LNG Liquid-Vapor Mixture Specific Volume vs. Differential Pressure Specific Volume Pressure Temperature inlet m^3/kg 2.06 MPa 115 K outlet m^3/kg.1 MPa 95.6 K Specific Volume [m^3/kg] Differential Pressure [MPa]
34 Tested Performance over Volumetric Flow Differential Pressure and Efficiency vs. Volumetric Flow Differential Pressure [MPa] no load rated flow DP rated Volumetric Flow [m^3/hr] % % % % % % % % % % % % % % % % 80.00% 60.00% 40.00% 20.00% 0.00% Turbine Efficiency [%]
35 Tested LNG Temperature Reduction 0 Temperature Drop vs Power Output 2800 rpm temperature drop -2-4 Temperature Drop [C] Power Output [kw]
36 Liquefaction Process to Reduce Boil-Off
37 Equipment Description MHE Main Heat Exchanger X1 Liquid Expander X2 Two-Phase Expander PHS Phase Separator LLNG Liquid Portion LNG VLNG Vapor Portion LNG M Mass Flow Measurement T Temperature Measurement P Pressure Measurement
38 Minimizing the Feed Gas Supply Variable speed Liquid Expander X1 expands the pressurized condensed LNG to the ideal inlet conditions for the variable speed Two-Phase LNG Expander X2 to achieve the maximum value for the ratio: T/ M T = Temperature Reduction ( T1 T3 ) M = Difference LNG mass flow ( M1 M3 ) M1 = LNG Mass Flow at Inlet Liquid Expander M3 = LNG Mass Flow at Outlet Phase Separator
39 Liquefaction Process to Reduce Boil-Off
40 Liquid Expander and Two-Phase Expander in Tandem Configuration Project P.T.Badak Ref. 108g AIChE Spring Conf Atlanta
41 Performance Comparison Liquid vs. Two-Phase Expander Project P.T.Badak Ref. 108g AIChE Spring Conf Atlanta 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
42 Performance Comparison Liquid vs. Two-Phase Expander Project P.T.Badak Ref. 108g AIChE Spring Conf Atlanta Two-Phase LNG Expander Performance Increase Differential Pressure 6.25% Expander Efficiency 11.00% Enthalpy Reduction % LNG Production 17.90% Revenue Increase Mill US $/Year
43 Feed Gas Reduction Liquid vs. Two-Phase Expander Project P.T.Badak Ref. 108g AIChE Spring Conf Atlanta Liquid Expander: Feed Gas Reduction: 0.97% Two-Phase LNG Expander Feed Gas Reduction: 1.14%
44 Thank You Munir Amsyari Muljono Sutedjo Hans E Kimmel
45 Liquefaction Process to Extend Lifetime of Depleting Gas Fields Appendix: Example for Use of Cold LNG Vapor Akihiro Ushitora CEO Ebara International Corporation Sparks, Nevada, USA Hans E Kimmel Executive Director hkimmel@ebaraintl.com Ebara International Corporation Sparks, Nevada, USA World LNG Technology Summit th and 27 th April 2006 Barcelona Hilton Barcelona, Spain
46 Certain LNG Liquefaction Plants are Powered by Gas Turbines The Fuel Gas for the Gas Turbines is Clean Vaporized LNG The Vaporized LNG is produced by a Two-Phase LNG Expander or by a Joule-Thomson Valve
47 The Vaporized LNG is at Cold Boiling Temperature The Cold LNG Vapor can be used to Cool the Air at the Inlet of the Air Compressor of the Gas Turbine The Vaporized LNG is produced by a Two-Phase LNG Expander or by a Joule-Thomson Valve
48 Air Cooling for Gas Turbine
49 Cold Compressed Air and Cold Natural Gas Fuel Increase the Performance and Efficiency of Gas Turbines The Portion of LNG Vapor Produced across the Two-Phase LNG Expander or across the Joule- Thomson Valve Sub Cools the LNG and Reduces the LNG Boil-Off
50 Thank You Akihiro Ushitora Hans E Kimmel
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