LNG Plant OptimisationLNG Plant OptimisationSeptember 20 September 20 -- 21, 200521, 2005 ·· Sheraton Imperial HotelSheraton Imperial Hotel

Kuala Lumpur, MalaysiaKuala Lumpur, Malaysia

Using LNG Expanders for Using LNG Expanders for Optimised LNG ProductionOptimised LNG Production

Joel V. MadisonJoel V. MadisonPresidentPresident

Ebara International Corporation Ebara International Corporation USAUSA

Joel V. Madison is President of Joel V. Madison is President of Ebara International Corporation, Ebara International Corporation, Cryodynamics Division, Nevada, USA. Cryodynamics Division, Nevada, USA.

He graduated from Pennsylvania State University, USA He graduated from Pennsylvania State University, USA with a Masterwith a Master’’s Degree in Mechanical and Aerospace s Degree in Mechanical and Aerospace Engineering.Engineering.

Oman LNGOman LNG

Oman LNGOman LNGLiquefaction Process Trains 1 and 2Liquefaction Process Trains 1 and 2

Typical LNG Plant Process SchemeTypical LNG Plant Process Scheme

LNG Expander EconomicsLNG Expander Economics

LNG ExpanderPower Output

Increase inLNG Output

Increase in RevenueFor LNG Price

$266.67/tonkW Tons/year $/year

110050010002000

606,00030,00060,000120,000

16,0001,600,0008,000,00016,000,00032,000,000

Reference: Gilbert Habets, Shell International Oil Products B.V. et al.:

"Economics of Cryogenic Turbine Expanders"

The International Journal of Hydrocarbon Engineering, December 1998

MLNG Dua MLNG Dua MalaysiaMalaysia

First generation LNG First generation LNG expander with airexpander with air--

cooled generator and cooled generator and rotating shaft sealrotating shaft seal

19961996(Flowserve Corp.)(Flowserve Corp.)

NLNG NigeriaNLNG Nigeria

First generation LNG First generation LNG and HMR expanders and HMR expanders

with airwith air--cooled cooled generator and rotating generator and rotating

shaft sealshaft seal

19991999

(Flowserve Corp.)(Flowserve Corp.)

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.)

7000 mm

3370 mm

AIR COOLED GENERATOR

SEAL, COUPLING & THRUST BEARING

TURBINE SUBMERGED

TURBINE GENERATOR

Comparison in Comparison in size and weight size and weight between first between first and second and second

generation LNG generation LNG expandersexpanders

Ebara Intl. Corp.Ebara Intl. Corp.Second Generation Second Generation

ThreeThree--Stage Stage Liquid Expander Liquid Expander

Oman LNG, June 1999Oman LNG, June 1999developed in cooperation developed in cooperation

withwith

Gilbert Habets,Gilbert Habets,

Shell International Oil Shell International Oil

Products B.V.Products B.V.

MLNG Tiga, MLNG Tiga, MalaysiaMalaysia

December 2000December 2000

SecondSecond--generation generation LNG expander with LNG expander with

submerged generator submerged generator and variable speedand variable speed(Ebara Intl. Corp.)(Ebara Intl. Corp.)

Generator RotorGenerator Rotor

Generator StatorGenerator Stator

Thrust Equalization Thrust Equalization

Mechanism (TEM)Mechanism (TEM)

Fixed Geometry Fixed Geometry

Inlet Guide VanesInlet Guide Vanes

RunnersRunners

ThreeThree--Stage Stage Liquid Expander Liquid Expander

for Ras Laffan LNGfor Ras Laffan LNG20022002

(Ebara Intl. Corp.)(Ebara Intl. Corp.)

Since the early days of the Since the early days of the cryogenic technology it cryogenic technology it has beenhas been known thatknown that

twotwo--phase cryogenic expandersphase cryogenic expandersimprove thermodynamic efficiencyimprove thermodynamic efficiency

of gas liquefaction processes.of gas liquefaction processes.

Only in recent years is Only in recent years is the technology availablethe technology available

to operate reliably to operate reliably liquidliquid--vapour LNG expandersvapour LNG expanders

What isWhat is

TwoTwo--Phase Expansion ?Phase Expansion ?

Reference for the following four slides:Reference for the following four slides:

Improved LNG Production Process Improved LNG Production Process Using TwoUsing Two--Phase ExpandersPhase Expanders

Christian FischerChristian FischerShell Sakhalin Energy SEShell Sakhalin Energy SE--LNGLNG

Yokohama, JapanYokohama, Japancfischer@ykh.chiyoda.co.jpcfischer@ykh.chiyoda.co.jp

Hans E KimmelHans E KimmelEbara International CorporationEbara International Corporation

Sparks, Nevada, USASparks, Nevada, USAhkimmel@ebaraintl.comhkimmel@ebaraintl.com

5th Annual 'Rome' World LNG Summit5th Annual 'Rome' World LNG Summit11stst -- 33rdrd December 2004, Rome, ItalyDecember 2004, Rome, Italy

The Strategic Implications of Technological AdvanceThe Strategic Implications of Technological Advance

The CWC Group www.thecwcgroup.comThe CWC Group www.thecwcgroup.com

Sgl & Two Ph

Fig 1 Curve

Fig 2 Curve

Fig 3 Curve

TwoTwo--Phase Phase Expander Expander

with with Jet ExducerJet Exducer

Hydraulic AssemblyHydraulic Assembly

TwoTwo--Phase Jet ExducerPhase Jet Exducer

TwoTwo--Phase Jet ExducerPhase Jet Exducer

Krio Polish Oil & GasKrio Polish Oil & Gas

TwoTwo--Phase Exducer Phase Exducer Turbine Turbine

20032003

January 2003January 2003

Installation of Installation of TwoTwo--Phase Phase

Expander at Krio Expander at Krio Polish Oil & Gas Polish Oil & Gas

Odolanow, Odolanow, PolandPoland

Generator RotorGenerator Rotor

Generator StatorGenerator Stator

Thrust Equalization Thrust Equalization

Mechanism (TEM)Mechanism (TEM)

Fixed Geometry Fixed Geometry

Inlet Guide VanesInlet Guide Vanes

RunnersRunners

TwoTwo--Phase Phase Expander Expander

with with Jet ExducerJet Exducer

TwoTwo--Phase Phase Expander Expander

with with Compact Compact Assembly Assembly

ConfigurationConfiguration

TwoTwo--Phase Phase Expander Expander

with with Compact Compact Assembly Assembly

ConfigurationConfiguration

Operating Conditions

Tf H C-3

Flow rate : kg/s

111.7

Intake capacity : dm3/s

249.25

Intake capacity : m3/hr

897.30

Inlet pressure : bar abs

29.75

Inlet density : kg/m3

448

Inlet temperature : C°

-146.93

Outlet pressure : bar abs

2.7

∆ P of Turbine : bar

27.05

∆ H of Turbine : m

615.49

Number of Stages

2

Operating Conditions

Tf H C-3

Flow rate : kg/s

111.7

Intake capacity : dm3/s

249.25

Intake capacity : m3/hr

897.30

Inlet pressure : bar abs

29.75

Inlet density : kg/m3

448

Inlet temperature : C°

-146.93

Outlet pressure : bar abs

1.01

∆ P of Turbine : bar

28.74

∆ H of Turbine : m

653.94

Number of Stages

2

Operating Conditions

Tf H C-3

Operational Speed :rpm

3000

Intake capacity :m3/hr

897.30

∆ H of Turbine : m

615.49

Inlet density : kg/m3

448.00

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. : dm3/s

2.41

Capacity Increase : %

0.97

Reclaimed Cap.: tons/day

93.28

Revenue Incr. : $/Year

$ 8,814,820

Operating Conditions

Tf H C-3

Operational Speed :rpm

3000

Intake capacity :m3/hr

897.30

∆ H of Turbine : m

653.94

Inlet density : kg/m3

448.00

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. : dm3/s

2.84

Capacity Increase : %

1.14

Reclaimed Cap.: tons/day

109.93

Revenue Incr. : $/Year

$ 10,388,220

This presentation is based on the following publications:G.L.G.M. Habets, Shell International Oil Products B.V.H.E.Kimmel, Ebara International Corporation"Economics of Cryogenic Turbine Expanders"The International Journal of Hydrocarbon Engineering, Dec. 1998

GG.L.G.M. Habets, Shell International Oil Products B.V.H.E.Kimmel, Ebara International Corporation“Development of a Hydraulic Turbine in Liquefied Natural Gas”7th European Congress on Fluid Machinery, The Hague, The Netherlands, April 1999

R.J.A.N. van den Handel, Shell International Oil Products B.V. H.E.Kimmel, Ebara International Corporation“A New Generation of Liquid Expanders in Operation at Oman LNG”GASTECH 2000, Houston, Texas, USA, November 2000

Munir Amsyari, Zudiharto, P.T.Badak, IndonesiaJ.V.Madison, H.E.Kimmel, Ebara International Corporation“LNG Expander for Extended Operating Range in Large-Scale Liquefaction Trains”AIChE 2005 Spring National Meeting, April 10-14, Atlanta, Georgia, USA

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