Natural gas saving opportunities in gas supply system of Iran. 22 April 2014
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1 Natural gas saving opportunities in gas supply system of Iran 22 April 2014
2 PROJECTS New design of gas compressor stations Energy integration in the existing compressor stations Power recovery by Turbo expander Advanced technologies for export gas pipelines
3 1- New design of gas compressor stations Main concept $ Fuel Gas Station Outlet Industrial Gas Turbine Centrifugal Compressor Recycle system J-T valve Heater Station Inlet
4 1- New design of gas compressor stations Main concept condenser GT4ST GC4 GT3 GC3 Heat Recovery Steam Generator GT2 GC2 It decreases the station fuel consumption by 30% GT1 GC1 Stand by
5 1- New design of gas compressor stations Main concept: COMBINED CYCLE LAYOUTS
6 1- New design of gas compressor stations Power generation unit concept
7 1- New design of gas compressor stations First step screening between IGAT8 stations Parameter NG saving per annum Investment cost CO2 reduction Unit MMSCM MUS$ Ton/year KHONJ JAHROM ARSANJAN ARDESTAN DEHSHIR NODOOSHAN KASHAN Total
8 1- New design of gas compressor stations Case study ARSANJAN 4 STATION ARSANJAN 8 STATION 108 MMSCMD 3+1 SGT600 BASED 100 MW TOTAL INSTALLED POWER 100 MUS$ 3*16.1MW POWER GENERATION
9 1- New design of gas compressor stations CASE STUDY 2GT FLUE GAS
10 1- New design of gas compressor stations CASE STUDY
11 1- New design of gas compressor stations CASE STUDY-PROJECT GROSS BUDGET ELIMINATING ONE GT COST, ADDITIONAL COST WOULD BE ABOUT 28 MUS$ 100MUS$ 128 MUS$
12 1- New design of gas compressor stations CASE STUDY-ECONOMIC EVALUATION
13 1- New design of gas compressor stations International experience
14 1- New design of gas compressor stations Outlook 1- At least, 75 new compressor stations is planed by With the 3+1 layout, the new concept concept is applicable for all 3- The new concept increases total investment from 7.5 BUS$ to about 9.6 BUS$ MMSCM per annum saving is forecasted totally. It would be about 30% of one Asalooyeh standard phase production 5- In case of export, it is worth about 1.4 BUS$ per year 6- About 30% emission reduction as a by product should be appreciated a well
15 2- Energy integration in the existing compressor stations Motivation WASTE MORE THAN 80% FOR OLD ONES ABOUT 65% FOR NEW ONES Fuel Gas ENERGY Station Outlet Industrial Gas Turbine Centrifugal Compressor Recycle system J-T valve Heater Station Inlet
16 2- Energy integration in the existing compressor stations Motivation At the moment, 70 compressor stations are in operation 30 out of the them are new and the others are old The old ones efficiency is poor indeed (about 18%) that waste a plenty of NG There would be some stations complex that the old and new ones are constructed in the same location Is it possible to improve the transmission efficiency in this stations? Yes, it is possible if one could make retrofit them energy integrated So, while the old ones driver is replaced by variable speed electric motors, the required power can be supplied by heat recovery from the flue gas of new ones. Therefore the old stations fuel consumption reaches to zero!
17 2- Energy integration in the existing compressor stations First step screening in some stations Station Name Power Generation Available Space Electrical Grid Power Matching Construction Simplicity Estimated Payback Time (Y) PATAVEH Excellent Fine Poor Poor Poor 1.89 DORAHAN Excellent Fine Fine Poor Poor 1.87 POLKALEH Excellent Fine Fine Poor Poor 1.93 DEHAGH Excellent Fair/Poor Fine Poor Poor 1.85 QOM Excellent Poor Fine Poor Poor 1.83 SAVEH Excellent Fine/Fair Fine Poor Fine 1.73 QAZVIN Excellent Fine Excellent Excellent Excellent 1.72 TABRIZ Excellent Fair Excellent Fine Excellent 4.41
18 2- Energy integration in the existing compressor stations Case study
19 2- Energy integration in the existing compressor stations Case study QAZVIN 1 COMPRESSORS NORMAL POWER DEMAND = = 14.7 MW QAZVIN 2 COMPRESSORS NORMAL POWER DEMAND = 2*14.7 MW
20 2- Energy integration in the existing compressor stations Case study Electrical grid GT3 MOTOR3 GC3 ST GEN GT2 MOTOR 2 GC2 GT3 GC3 GT1 MOTOR1 GC1 HRSG GT2 GC2 QAZVIN OLD STATION GT1 GC1 QAZVIN NEW STATION
21 2- Energy integration in the existing compressor stations Case study: ENERGY BALANCE 14.7 MW FOR QAZVIN 1 NEW DRIVERS FROM 2 SGT600
22 2- Energy integration in the existing compressor stations Case study: MONTHLY SAVING Current situation fuel consumption (Kg/sec) NEVSKY LP Energy Integrated station fuel consumption (kg/sec) NEVSKY HP 2*SGT600 QAZVIN I 2*SGT600 HRSG Saving (MMSCM) January February March April May June July August September October November December Annual Design Point
23 2- Energy integration in the existing compressor stations Case study: CONNECTION TO ELECTRICAL GRID
24 2- Energy integration in the existing compressor stations Case study: PROJECT COST SUMMARY Project Cost Summary Estimated Cost I Specialized Equipment 37,030,850 USD II Other Equipment 2,828,165 USD III Civil 3,695,046 USD IV Mechanical 4,574,301 USD V Electrical Assembly & Wiring 1,043,527 USD VI Buildings & Structures 1,029,165 USD VII Engineering & Plant Startup 6,273,549 USD Subtotal - Contractor's Internal Cost 56,474,602 USD VIII Contractor's Soft & Miscellaneous Costs 9,769,627 USD Contractor's Price 66,244,229 USD IX Owner's Soft & Miscellaneous Costs 4,971,981 USD Total - Owner's Cost 71,216,210 USD
25 2- Energy integration in the existing compressor stations Case study: ECONOMIC EVALUATION
26 2- Energy integration in the existing compressor stations OUTLOOK Considering connection to electrical grid, Such a concept would be applicable for all existing stations. To integrate all compressor stations, in fact the gas compressor stations and power plants will be interconnected. if so, some additional electrify generated in the stations will be injected to electrical network. It needs to invest about 3 BUS$ to make existing stations energy integrated. It leads to about 3 BSCMY or 8 MMSCMD in average. It would be about 30% of one Asalooyeh standard phase production. Such a saving will be equal to 1.3 BUS$A income for the country.
27 3- power generation in the gas pressure reduction stations concept
28 4- power generation in the gas pressure reduction stations concept J-T Valve = 1MP C Power = + Power Turbo Expander 1MP C
29 4- power generation in the gas pressure reduction stations First step screening
30 4- power generation in the gas pressure reduction stations Case study Turboexpander with Conventional Hydrodynamic Bearing Parameter Symbol Unit Value Station / Turboexpander Inlet Pressure P 1 bar 70 Station / Pre-heater Inlet Temperature T 0 C 24 Pre-heater Exit / Turboexpander Inlet Temperature T 1 C 66.5 Gas Turbines Fuel / Turboexpander Flow m f kg/s Gas Turbines Fuel / Turboexpander Discharge Pressure P 2 bar 24.5 Gas Turbines Fuel / Turboexpander Discharge Temperature T 2 C 10 Required Input Heat to Gas Q 0 kw Input Heat Considering Pre-heater Efficiency Q kw Turboexpander Speed N rpm Turboexpander Specific Speed N S Turboexpander Efficiency η TE % Electrical Power Generation W kw First-Law Thermal Efficiency η th % 61.13
31 4- power generation in the gas pressure reduction stations Case study Turboexpander with Modern Magnetic Bearing Parameter Symbol Unit Value Station / Turboexpander Inlet Pressure P 1 bar 70 Station / Pre-heater Inlet Temperature T 0 C 24 Pre-heater Exit / Turboexpander Inlet Temperature T 1 C 73.9 Gas Turbines Fuel / Turboexpander Flow m f kg/s Gas Turbines Fuel / Turboexpander Discharge Pressure P 2 bar 24.5 Gas Turbines Fuel / Turboexpander Discharge Temperature T 2 C 10 Required Input Heat to Gas Q 0 kw Input Heat Considering Pre-heater Efficiency Q kw Turboexpander Speed N rpm Turboexpander Specific Speed N S Turboexpander Efficiency η TE % Electrical Power Generation W kw First-Law Thermal Efficiency η th % 61.86
32 3- power generation in the gas pressure reduction stations Case study: financial issues
33 4- power generation in the gas pressure reduction stations OUTLOOK There are so many gas pressure reduction in the oil and gas sector that can be adapted by TE In addition to the Oil & gas sector, such a concept also is applicable broadly for MOE and MOI The normal payback time of such a power generation units is about 2.5 years The normal power generation efficiency of such units would be even higher than 80%.
34 4- Advanced technologies for export gas pipelines motivation World energy outlook(source IEA) NG is exported by Pipeline, LNG, GTL and GTW
35 5- Advanced technologies for export gas pipelines motivation Gas transmission price for a 30 BSCM per year export (Source ENI)
36 5- Advanced technologies for export gas pipelines Case study: igat km, 56 pipeline to export 110MMSCMD with 0.8 thickness and 47µm roughness -17 gas compressor stations (100 MW total installed capacity) - Total power consumption is 17*50 MW=850MW - Total EPC Investment = 5BUS$ - With no local take off, about MMSCMD is exported - Emission= 5 Million ton CO2 per annum How it can be improved?
37 5- Advanced technologies for export gas pipelines Case study: igat 9 1- Improvement methods on pipeline to reduce line size, stations number, friction loss 2-1- Improvement methods on compressor stations to minimize stations fuel consumption Final solution: Line pressure increase together with internal coated pipe and combined cycle compressor stations
38 5- Advanced technologies for export gas pipelines Total solution 1- Pipeline MOP increases to 1950 psi 2- The pressure drop increases about 600 psi between stations 3- Pipe material ; API 5L X80 4- roughness decreases from 47 to 7 µ meter 5- Combined cycle compressor stations
39 5- Advanced technologies for export gas pipelines Igat 9 Total solution 110 MMSCMD MMSCMD 56 (X65), 1320psi, 17 stations, 5 BUS$ 110 MMSCMD 105 MMSCMD 48 (X80),1950psi, 13 stations, 4.1 BUS$, 260M$/y additional export 110 MMSCMD MMSCMD 48 (X80), 1950psi, 9 stations,4bus$, 520M$/y additional export 110 MMSCMD MMSCMD 48 (X80),1950psi, 9 stations (efficient), 4.3BUS$, 700M$/y additional export
40 5- Advanced technologies for export gas pipelines INTERNATIONA EXPERIENCE: ALLIANCE
41 5- Advanced technologies for export gas pipelines OUTLOOK
42 Free discussion
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