Joel V. Madison President

Transcription

1 LNG Expanders - 10th Anniversary Keynote Address AIChE Spring Annual Meeting Orlando, Florida April 25, 2006 Joel V. Madison President Ebara International Corporation Nevada, USA

2 Headquarters and Factory Sparks, Nevada

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 process of and an apparatus for saving energy in a method of liquefying a natural gas

4 Turbine Expander Applications Typically used in the LNG liquefaction process in the pressure let-down section for both LNG and MR services (APCI) process. Also used in Nitrogen Rejection. Replaces conventional Joule-Thomson valve Can be used in any liquid expansion situation to extract energy

5 Typical LNG Plant Process Scheme

6 Benefits of using a Turbine Expander Isentropic expansion resulting in a reduction in temperature of the process liquid and increase in liquid output For a typical system, a 5% increase in process efficiency can be realized Energy extracted is converted to electricity from the generator, which can be fed back into the plant system

7 Oman LNG Liquefaction Process Trains 1 and 2

8 LNG Expander Economics LNG Expander: Power Output 1000 kw Increase in LNG Production: 60,000 tons/year Increase in Revenues: 16 Mill US$ /year LNG Expander: Power Output 2000 kw Increase in LNG Production: 120,000 tons/year Increase in Revenues: 32 Mill US$ /year LNG price: $/ton

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

12 EBARA Second Generation Three-Stage Liquid Expander Oman LNG June 1999

13 MLNG Tiga, Malaysia EBARA Second-generation LNG expander with submerged generator and variable speed December 2000

14 Turbine Expander Design Features Radial Inflow Reaction Design Hydraulic Section and Induction Generator mounted on an Integral Shaft Lower Run-Away Speeds compared to mixed-flow or axial designs Compact Size

15 Cutaway of a Typical Liquid Expander

16 Inlet Housing Generator Stator Generator Rotor Single Shaft Runners Outlet

17 Nozzle Vane Thrust Plate First Stage Runner Return Vane Interstage Nozzle Vane Second Stage Runner Draft Tube

18 Nozzle Vane Product Lubricated Main Bearing Second Stage Runner Product Lubricated Tail Bearing

19 Return Passage Runner Passage Wear Ring Draft Tube Tail Bearing

20 Product Lubricated Main Bearing Upper Wear-ring TEM Gap Lower Wear-ring

21 Shaft Bushing Product Lubricated Main Bearing Nozzle Vane TEM Gap Upper Wear Ring Lower Wear Ring Return Passage

22 Ras Laffan LNG EBARA Three-Stage Liquid Expander 2002

23 Liquid Expanders Delivered To Date by EIC Liquid Expander Site Details Tangguh LNG LNG Tangguh LNG MR Statoil Hammerfest Spare LNG Statoil Hammerfest Spare MR Q atar Gas III LNG Q atar Gas III MR Q atar Gas II LNG Qatar Gas II MR Ras Gas Train 6 & 7 LNG Ras Gas Train 6 & 7 MR Ras Gas Train 5 LNG Ras Gas Train 5 MR Nigeria Train 6 LNG Nigeria Train 6 MR Sakhalin LNG Sakhalin MR Oman LNG Train 3 LNG Oman LNG Train 3 MR Statoil Hammerfest Train 1 LNG Statoil Hammerfest Train 1 MR N-LNG Train 4 & 5 LNG N-LNG Train 4 & 5 MR Damietta Train 1 LNG Damietta Train 1 MR Krio Poland (2 Phase Prototype) Ras Gas Train 3 & 4 LNG Ras Gas Train 3 & 4 MR Oman LNG Train 1 & 2 LNG Oman LNG Train 1 & 2 MR MLNG Tiga (Bintulu) LNG MLNG Tiga (Bintulu) MR Under Manufacture Delivered Power kw

24 TYPICAL PERFORMANCE FOR VARIABLE SPEED LNG EXPANDERS

25 TYPICAL PERFORMANCE FOR VARIABLE GEOMETRY TURBINE EXPANDERS

26 LIQUID EXPANDER PERFORMANCE TYPICAL OPERATING ENVELOPE

27 LIQUID EXPANDER PERFORMANCE TYPICAL CURVE Constant Isentropic Efficiency Curve

28 Hydraulic Performance of Variable Speed LNG Expanders Constant Shaft Power P and Constant Hydraulic Efficiency η (No - Load Characteristic) η = 0; P = 0 η 1 = η 2 P 1 < P 2 η1 = const. ηmax = const. P2 = const. P1 = const. η2 = const. (Locked Rotor Characteristic) η = 0; P = 0 Head Flow

29 Optimising Power Output for Reduced Flow

30 Optimising Power Output for Overflow

31 Since the early days of the cryogenic technology it has been known that two-phase cryogenic expanders improve thermodynamic efficiency of gas liquefaction processes.

32 Only in recent years is the technology available to manufacture and reliably operate liquid-vapor LNG expanders

33 What is Two-Phase Expansion?

34 Sgl & Two Ph

35 Fig 1 Curve

36 Fig 2 Curve

37 Fig 3 Curve

38 TYPICAL PERFORMANCE OF TWO-PHASE EXPANDER

39 TYPICAL PERFORMANCE FOR VARIABLE GEOMETRY TURBINE EXPANDERS

40 PERFORMANCE FIELD OF TWO-PHASE EXPANDER

41 Two-Phase Expander with Jet Exducer Hydraulic Assembly

42 Jet Exducer Helical fluid passage for volumetric vapor formation Geometrically fixed cross section Fluid acceleration through volumetric expansion inside helical fluid passage

43 Cavitation Free Two-Phase Jet Exducer

44 Cavitation Free Two-Phase Jet Exducer

45 Two-Phase Jet Exducer

46 Flow Passage of Two-Phase Jet Exducer with Continuous Pressure Drop

47 Krio Polish Oil & Gas Two-Phase LNG Expander 2003

48 Krio Testing of Two-Phase LNG Expander 2002

49 Krio Installation of Two-Phase Expander at Krio Polish Oil & Gas Odolanow Poland

50 Krio Two-Phase Expander Mounted Inside Insulated Pressure Vessel

51 Krio Two-Phase Expander Mounted Near Main Heat Exchanger

52 PROCESS FLOWSCHEME FOR THE CRYOGENIC SECTION

53 EXPANDER PERFORMANCE Differential Pressure and Efficiency vs Mass Flow

54 EXPANDER PERFORMANCE Differential Pressure and Efficiency vs Volumetric Flow Volumetric Flow M3/hr

55 LNG TEMPERATURE REDUCTION Temperature Drop vs Power Output

56 Next Generation Technology Two-Phase Expander with Compact Tandem Assembly Configuration

57 Next Generation Technology

58 Next Generation Technology

59 Next Generation Technology COMPACT LNG-MR EXPANDER Upper 2-Phase 2-Stage LNG Expander LNG Inlet Vessel Seal Arrangement GENERATOR HEAT SEPARATED FROM THE LNG SMALL INSTALLATION SPACE Single Shaft Generator MR Inlet Vessel Lower 2-Stage MR Expander

60 Next Generation Technology High-Efficiency Compact LNG- MR Expander GENERATOR HEAT COMPLETELY SEPARATED FROM THE LNG and MR SMALL INSTALLATION SPACE Upper 2-Phase 2-Stage LNG Expander LNG Inlet Vessel LN2 or Liquid Propane Coolant MR Inlet Vessel Lower 2-Stage MR Expander

61 Thank You for Your Attention