LNG AND METHYL FUELS PROCESS ECONOMICS PROGRAM. METHYL FUELS---- by GEORGE E. HADDELAND. Report No by GEORGE T. STEVENIN.

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1 Report No. 103 LNG AND METHYL FUELS LNG by GEORGE T. STEVENIN METHYL FUELS---- by GEORGE E. HADDELAND September 1976 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION PART A--LIQUEFIED NATURAL GAS SUMMARY... Cost Estimates INDUSTRY STATUS Major Markets Consumption Pattern Production and Growth Rates Production Capacity CASCADE REFRIGERANT CYCLE... Review of Processes... Introduction.... Discussion of Cascade Refrigerant Patents... Process Description... Process Discussion.... Cost Estimates.... Capital Costs... Production Costs MIXED REFRIGERANT CYCLE Review of Processes Introduction Discussion of Mixed Refrigerant Patents Mixed Refrigerant Processes Offered for License Air Products and Chemicals Technip J. F. Pritchard and Company Linde (LOT0 PRO) Phillips Pullman-Kellogg Other Plants Process Description Process Discussion Cost Estimates Capital Costs Production Costs Vii

3 CONTENTS 6 LNG TRANSPORTATION Introduction Transportation Requirements Requirements Discussion Cost Estimates Capital Costs Transportation Cost LEG REGASIFICATION Introduction Process Description Process Discussion Cost Estimates Capital Costs Production Costs Production Costs Discussion PART B--METHYLFUEL METHYL FUEL Introduction summary Methyl Fuel Uses Process Methyl Fuel Capital and Operating Costs Alternative Methyl Fuel Applications Methyl Fuel Methyl Fuel Applications Boiler Fuel Automotive Fuel Status of Applications Process Description Process Discussion Cost Estimates Capital Investment Production Costs Shipping Costs Upgrading Methyl Fuel to Chemical Methanol Conclusion viii

4 CONTENTS APPENDICES, REFERENCES, AND FLOW SHEETS FOR PARTS A AND B APPENDIX A DESIGN AND COST BASIS APPENDIX B PHYSICAL AND THERMODYNAMIC DATA APPENDIX C HANDLING AND SAFETY CITED REFERENCES ix

5 4.1 Liquefaction of Natural Gas by a Cascade Refrigerant Process Process Flow Sheet Effect of Liquefaction Plant Capacity on Total Fixed Capital Investment for a Cascade Refrigerant Process Effect of Liquefaction Plant Capacity on Production Cost for a Cascade Refrigerant Process Liquefaction of Natural Gas by a Mixed Refrigerant Process Process Flow Sheet Effect of Liquefaction Plant Capacity on Total Fixed Capital Investment for a Mixed Refrigerant Process Effect of Liquefaction Plant Capacity on Production Cost for a Mixed Refrigerant Process Effect of liquefaction Plant Capacity on Transportation Cost Receiving Terminal and LNG Vaporization Process Flow Sheet Effect of Liquefaction Capacity on Receiving and Regasification Total Fixed Capital Effect of Liquefaction Plant Capacity on Receiving and Regasification Cost Process Flow Sheet Energy Distribution per 5,000 tpd Methyl Fuel Train xi

6 TABLES 2.1 LNG Shipped to the United States or Japan from a Mixed Refrigerant Liquefaction Plant in a Remote Area Summary of Economics Worldwide LNG Plants Operating, Under Construction, or Planned, Listed by Licenser Natural Gas Liquefaction (Cascade System) Summary of Patents Cascade Refrigerant Cycle Process Stream Flows Cascade Refrigerant Cycle Refrigerant Stream Flows Cascade Refrigerant Cycle Total Capital Investment--Indices 250/ Cascade Refrigeration Cycle Total Capital Investment--Indices 325/ Cascade Refrigerant Cycle Total Capital Investment--Indices 450/ Cascade Refrigerant Cycle Major Equipment and Utilities Summary Cascade Refrigerant Cycle Production Costs, Indices 250/ Cascade Refrigerant Cycle Production Costs, Indices Cascade Refrigerant Cycle Production Costs, Indices 450/ Xiii

7 TABLES 4.11 Cascade Refrigerant Cycle Production Costs, Indices 250/ Cascade Refrigerant Cycle Production Costs, Indices 325/ Cascade Refrigerant Cycle Production Costs, Indices 450/ Natural Gas Liquefaction (Mixed Refrigerant Cycle) Summary of Patents Mixed Refrigerant Cycle Process Stream Flows Mixed Refrigerant Cycle Refrigerant Stream Flows Mixed Refrigerant Cycle Total Capital Investment--Indices 250/ Mixed Refrigerant Cycle Total Capital Investment--Indices 325/ Mixed Refrigerant Cycle Total Capital Investment--Indices 450/ Mixed Refrigerant Cycle Major Equipment and Utilities Summary Mixed Refrigerant Cycle Production Costs, Indices 250/ Mixed Refrigerant Cycle. Production Costs, Indices 325/ xiv

8 TABLES 5.10 Mixed Refrigerant Cycle Production Costs, Indices 450/ Mixed Refrigerant Cycle Production Costs, Indices 250/ Mixed Refrigerant Cycle Production Costs, Indices 325/ Mixed Refrigerant Cycle Production Costs, Indices LNG Transportation--4,000 Miles (250 Million scfd) LNG Transportation --4,000 Miles (1 Billion scfd) LNG Transportation--6,600 Miles (250 Million scfd) LNG Transportation--6,600 Miles (1 Billion scfd) T.NG Regasification Process Stream Flows LNG Receiving Terminal Major Equipment and Utilities Summary....," LNG Receiving Terminal Total Capital Investment--Indices 220/220 (232 Million scfd) LNG Receiving Terminal Total Capital Investment--Indices 250/250 (237 Million ecfd) LNG Receiving Terminal Production Costs--Indices 220/220 (232 Million scfd) LNG Receiving Terminal Production Costs--Indices 220/220 (927 Million scfd) xv

9 TABLES LNG Receiving Terminal Production Costs--Indices 250/250 (238 Million scfd) LNG Receiving Terminal Production Costs--Indices 250/250 (948 Million scfd) Capital and Operating Cost Summary for Methyl Fuel Plants Major Equipment and Utilities Summary Stream Flows A Total Capital Investment--Saudi Arabian Coast li9 8.4B 8.4C 8.5A 8.5B 8.5C 8.6' 8.7 Total Capital Investment--Iranian Coast Total Capital Investment--U.S. Gulf Coast Production Costs--Saudi Arabian Coast Production Costs--Iranian Coast Production Costs--U.S. Gulf Coast Methyl Fuel Ocean Transportation, Storage, and Transfer Additional Cost to Upgrade Methyl Fuel to Chemical Grade Methanol xvi