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LIQUEFIED NATURAL GAS (LNG) – An Introduction 14 th  April 2009 P resented By: N. MA NIK ANDAN  
Transcript

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LIQUEFIEDNATURAL GAS

(LNG) – 

An Introduction

14th

 April 2009

Pr e s e n t e d B y : N . MA N I K ANDAN 

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2Liquefied Natural Gas - An Introduction

I. LNG OVERVIEW

II. TECHNIP’S LNG CAPABILITY

III. LNG MANUFACTURING PROCESS

IV. LIQUEFACTION TECHNOLOGIES

V. CRITICAL EQUIPMENT

VI. LNG REGASIFICATION

Contents

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3Liquefied Natural Gas - An Introduction

LNG OVERVIEW

►LNG is Natural Gas reduced to liquid state by cooling it to –162ºC

►LNG is colorless, odorless, non-toxic and the gaseous form is lighter

than air 

►Natural gas required to manufacture LNG – from gas reservoirs often

offshore

►Gas produced from two different kinds of reservoirs, each requiring a

different processing technique.

 – Gas reservoirs – produced at High Pressure

 – Oil reservoirs – oil-gas dispersion/mixed phase or oil reservoir

gas caps; relatively lower pressure

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4Liquefied Natural Gas - An Introduction

LNG OVERVIEW

Ethane (C2H6)

HEAVIER FRACTIONS also referred to as:

C5+

Pentanes Plus

Natural Gasoline

Condensate

NGL

Propane (C3H8)

Butane (C4H10)LPG

NATURAL

GASex-well

Methane (CH4 )

Non-Hydrocarbons

H2O, CO2, H2S, N2, Hg, etc.

LIQUID AT 1 Bar 

n-Butane –0.5ºC

i-Butane –12ºC

Propane –42ºC

Ethane –88ºC

Ethylene –103ºC

Methane –161ºC

Oxygen –184ºC

Nitrogen –196ºCH2 –253ºC

Helium –269ºC

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5Liquefied Natural Gas - An Introduction

Why should Natural Gas be liquefied?

►Liquefaction reduces gas volume by approx. 600 times.

►More economical for liquid transport

 – through ship – between countries/continents

 – through road carriers – in land.

►For remote gas fields (especially offshore) pipeline transportationof gas is expensive – hence natural gas is liquefied before

transportation

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6Liquefied Natural Gas - An Introduction

WHY WE NEED LNG?

Growing power demand in the world and forecast

that by 2050 energy needs will double that of today –

gas is a cheaper source of fuel.Oil companies under pressure to reduce gas flaring

 – develop strategies for dealing with gas.

Growing demand for cleaner fuels – gas is thepreferred choice for large-scale power plants.

Reservoir recovery – on an average about 60% of

the gas in the reservoir is recoverable, as comparedto 33% of an oil deposit.

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7Liquefied Natural Gas - An Introduction

NG – A CLEAN FUEL COMPARED TO DIESEL

Values in grams/kWH power generation

0.050.15PM

0.51HC

17NOx

415.5CO

Flue gas from

NG burning

Flue gas from

Diesel burning

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8Liquefied Natural Gas - An Introduction

How is LNG/NG Measured?

►Natural Gas is measured in• Volume units, i.e. cubic feet or cubic meters

• Energy Units, i.e. Million BTU or Million kCalories

►VOLUME UNITS

• Supplies to Power plants measured in Million standard cubic feet/day (MMSCFD)

or Million standard cubic meter/day (MMSCMD).• Resources and reserves calculated in Trillions of standard cubic feet (Tcf).

A Gas field containing 3.65 TCF ≡ around 12 MMSCMD gas for 25 years

A rough way of visualizing a trillion cubic feet of gas ≡ imagine enough of

product to fill a cube with its sides two miles long►ENERGY VALUES

•  Amount of energy obtained from the burning unit volume of Natural Gas measured inBritish Thermal Unit (BTU) or kCalorie or kJoule.

At sea level, it takes about 75 BTU (19 kCal) to make a cup of tea.►A cubic feet of natural gas gives off about 1050 BTU (depends on quality of

gas) » one cubic feet of Natural Gas may make 14 cups of tea

► 1 BTU = 0.252 kCalories = 1.055 kJoules

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9Liquefied Natural Gas - An Introduction

How is LNG/NG Measured?

►1 Ton LNG ≡

~1420 Std. m3 Gas

~51.7 Million BTU

~13 Million kCal

~54.5 Giga Joules

►100 MW power plant requires ~ 0.5

MMSCMD Gas(~ 352 Tons/day)

►15 MMTPA LNG Plant requires ~ 1 TCFNatural Gas Per Annum

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10Liquefied Natural Gas - An Introduction

Upstream

Treatment andLiquefaction

Transportation

Regasification

Marketing

LNG Chain

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11Liquefied Natural Gas - An Introduction

NG

LNG

LNG

LNGLNG

LNG

LNG

Raw Gas

Gas Wells

Land/Offshore

Pretreatment

Liquefaction &

Fractionation

Storage

Extracted NGL

Loading

(Ship/Road tanker)Transportation Unloading

Storage

Vaporization

Natural gas

distributionnetwork

FEATURES OF LNG CHAIN

Sweet Gas

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TYPICAL COMPOSITION OF LNG

0.01 ppbMercury

<3ppmH2S

<1.25Nitrogen

<0.5 ppmWater 

<50ppm

<0.25

<2.0

<3.0

<9.2

>85

COMPOSITION (vol %)

Carbon Dioxide

Pentanes

Butanes

Propane

Ethane

Methane

COMPONENT

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TECHNIP’SLNG Capability

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Technip in the LNG chain

GAS FIELDS►Nigeria

• Obite

•  Amenam

Brunei• OPP

►Qatar • Qatargas

• QGII

► Indonesia• Tunu

• Peciko

►Egypt• Samian Sapphire

TERMINALS► Freeport

► Enagas

Barcelona

► Gulf LNG

LIQUEFACTION► Algeria

► Nigeria• NLNG Tr 1+2

• NLNG Tr 3

• NLNG Tr 4+5• NLNG Tr 6

• NLNG Tr 7+8

• OK LNG

► Qatar • Qatargas expansion

• QGII

• QGIII/IV

• Rasgas III

► Yemen

► Iran

► Indonesia• Bontang I

Turnkey solutions for reduced cost marine works

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Technip and LNG in short

►We built the first ever LNG Plant, 45 yearsago...

►We have been active ever since,introducing many concepts that arewidely used

►Tealarc process abandoned in 1993 infavour of APCI liquefaction technologyunder license

► YLNG and OK LNG confirm our position

in the first tier of EPC contractors in LNG

Camel, Algeria, 1964

QGII, Qatar, 2008

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Camel, Algeria, 1964

Camel, Algeria , 1964

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Three Mega LNG Projects in Qatar 

► Qatargas II: construction of 2 of the world’s

largest LNG trains (4 & 5) with a total capacity of

15.6 million tons/year 

► Qatargas III and IV: construction 2 additional

trains (6 & 7)

► Rasgas III: construction 2 trains (6 & 7)

Technip, in a joint venture,

is building the 6 largest LNG trains in the

world, with a capacity of 7.8 milliontons/year each.

Qatargas II

SaudiArabia

Qatar 

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LNG plants are huge!Qatargas II – View from Flare stack 24th May 2007

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 Yemen LNG

► Client: Total, Yemen Gas &

partners

► Capacity: 2 x 3.35 milliontons/year 

► Execution: Technip leader of Yemgas JV

► Commissioning: 2009

Using its LNG expertise and supported by

its presence in the Middle East, Technip andits partners are building Yemen’s first LNG

plant.

 Yemen LNG

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Aerial view of Balhaf plant (Yemen LNG), Oct 2008

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Shtokman LNG (FEED)► Client: Shtokman Development AG

► Gazprom 51%• Total 25%

• StatoilHydro 24%

► Location: Teriberka, near Murmansk

• One 7.5 Mt/y LNG train, APCI C3/MCR

• One gas export train

► FEED by Technip to be completed mid-2009

Technip is engineering the

LNG and gas plant facilities

for the first phase of

development of the largestundeveloped gas field in the

world.

Shtokman LNG site

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II. LNG MANUFACTURING

PROCESS

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LNG Manufacturing Process

Receiving gas from wells and manifolds Pressure control/reduction

Inlet gas-condensate-water separation

Feed gas compression

Acid gas removal

Gas Dehydration

Mercury removal

Liquefaction

LIQUEFACTION FORMS THE HEART OF ANY LNG

MANUFACTURING FACILITY

End flash

LNG Storage and loading

Fractionation of C1, C2, C3, C4 and NGL (i.e. Demethanizer, Deethanizer,

Depropanizer and Debutanizer)

Condensate/NGL Storage and loading

Feed gas pretreatment

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24Liquefied Natural Gas - An Introduction

LNG PLANT BLOCK DIAGRAM

Sulphur 

Recovery

Liquefaction

Field

Facilities

Non Associated

Natural Gas

Associated

GasLNG Storage

Loading

Fractionation (LPG)C5+ Gasoline

Dehydration

Condensate

Stabilisation

MercuryRemoval

NGLExtraction

Refrigeration

Refrigerant Make up

LNG

Field condensate

N2 RejectionPipeline

Reception

Acid Gas

RemovalFuel gas

Liquefaction Process License

LNG Train

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III. NG LIQUEFACTION

TECHNOLOGIES

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Available Technologies for Liquefaction

Mixed Refrigerant Cycle (MRC) Single Mixed Refrigerant

Propane + Mixed Refrigerant

Dual Mixed Refrigerant

Cascade Refrigeration Cycle (CRC) Simple/pure component cascade

Mixed Fluid Cascade

Expander Cycle (EC) Nitrogen Cycle (different versions to suit plant capacity)

Technology selection based on Plant Capacity,type of facil ity, feed gas composition changes,trade-off between operating cost versus capitalcost.

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CYCLE EFFICIENCY COMPARISON

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Main Liquefaction Technologies

LindeSnohvit (never reachedcapacity)

1. C2, C3

2. C1, C2, C3

3. N2, C1, C2

Statoil/LindeMFCP

NonePars LNG(Technip/JGC FEED)

1. C2, C3

2. N2, C1, C2, C3

AxensLiquefin

None1 under constructionSakhalin s/u 2008

1. C2, C3

2. N2, C1, C2, C3

SGSIDMR

None6 under construction inQatar 

QG Tr4 s/u 2008

1. C3

2. C1, C2, C3

3. N2

APCIAP-X

BechtelTrinidad, Egypt Idku,Darwin Australia, Eq.Guinea

1. C3

2. C2=3. C1

Conoco-Phillips

CoP LNGProcess

None90% market

 Yemen, Nigeria (Bonny &OK), Brunei, Indonesia,Malaysia, Australia,Qatargas, Rasgas, Oman,

1. C3

2. N2, C1, C2, C3

APCIC3/MCR

ExclusiveContractor Plants in OperationCyclesLicensor Process

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29Liquefied Natural Gas - An Introduction

Types of refrigeration cycles for Liquefaction

Reverse Rankine Cycles

Used in large liquefaction plants

Mixed Refrigerant Cycles

Pure Component Cycles

Hybrid e.g. pure propane cycle and one mixed refrigerant cycle

Reverse Brayton Cycles

Small peak shaving units, LNG carrier boil off gas re-liquefaction

Nitrogen cycles

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30Liquefied Natural Gas - An Introduction

MIXED REFRIGERANT CYCLE (MRC)

► Sweet gas pre-cooling done by propane

► Liquefaction done by main mixed refrigerant (MR)

►Mixture comprises of Nitrogen and hydrocarbons (C1to C3).

► Mixture composition specified such that liquid

refrigerant evaporates over a temperature range

similar to that of liquefaction.

 Advantages

Simple configuration

Higher thermodynamic efficiency

Fewer items of machinery

Only one or two compressors for refrigerant compression

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31Liquefied Natural Gas - An Introduction

TYPICAL NATURAL GAS – REFRIGERANT COOLING CURVE

►Basic principles for cooling and liquefying the gas using refrigerants

involve matching as closely as possible the cooling & heating curves of

the process gas and refrigerant.

     T     E     M     P     E     R     A     T     U     R     E

HEAT

Nat. Gas Cooling curve

Refrigerant Cooling curve

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32Liquefied Natural Gas - An Introduction

APCI PROPANE PRECOOLED MIXED REFRIGERANT PROCESS (C3/MCR)

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HP-MRPROPANE

 

HP-MRPROPANE

NG Liquefaction with Mixed Refrigerant (C3/MCR)

0

20

-20

-60

-40

-80

-120

-100

-140

-180

-160

        2        0        0

        6        0        0

        1        0        0        0

        1        4        0        0

        1        8        0        0

        2        2        0        0

        2        6        0        0

        3        0        0        0

        3        4        0        0

Temperature (°C)

 H (kcal/kmole)

Water or Air 

Propane Cycle

Dew Pt

B Pt   Liquefaction Refrigerant

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LICENSOR’S FOCUS

THREE ASPECTS OF LNG PRODUCTION

► COMPRESSION REQUIRED FOR REFRIGERATION CYCLES

► POWER TO DRIVE REFRIGERATION CYCLES

- EARLIER PLANTS USED STEAM TURBINES

- CURRENT INDUSTRY NORM IS COMBUSTION GAS TURBINES OR

ELECTRIC MOTORS

► MAIN CRYOGENIC HEAT EXCHANGER TO CHILL THE INCOMING GAS

- SPIRAL WOUND HEAT EXCHANGER (SWHE) DOMINATED MARKET

- BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGERS CHALLENGE

DOMINANCE OF SWHE

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IV.CRITICAL EQUIPMENT

C C Q G

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CRITICAL EQUIPMENT IN LNG PLANT

►CRYOGENIC HEAT EXCHANGERS

►LARGE COMPRESSORS – CENTRIFUGAL AND/OR AXIAL

►LARGE DRIVERS FOR COMPRESSORS (>50MW DRIVERS) –

GAS TURBINES OR MOTORS

►LARGE COOLERS FOR COMPRESSOR INTERSTAGE (AIR

COOLED OR SEA WATER COOLED)

►LARGE UTILITY SYSTEMS

►LARGE CRYOGENIC STORAGE TANKS

T f H t E h f Li f ti

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Types of Heat Exchangers for Liquefaction

(Main Cryogenic Heat Exchangers – MCHE)

Spiral wound Heat Exchangers

(SWHE)Cylindrical tall tower, packed with spiral wound

bundle of narrow tubes.

Transportation constraint limit the size – max size

4.5m dia x 30m tall, as a single piece.

Flexible to operateProprietary item – less competition

Ai P d t M i C i H t E h

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APCI documents

Air Products Main Cryogenic Heat Exchanger 

REFRIGERATION COMPRESSORS

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REFRIGERATION COMPRESSORS

Propane pre-cooling• Centrifugal compressor

• Side-streams at 3 or 4 pressure levels

• Typically 50 MW

• Gas Turbine plus Starter/Helper Motor 

Mixed refrigerant liquefaction and sub-cooling

• Large volumetric flows

• Two casing arrangements (LP and HP)

• Axial LP / centrifugal HP compressor (45 – 48 bar)

• Typically 80 MW Gas Turbine (e.g. Frame 7) plus Starter/Helper Motor 

• LP compressor - axial or centrifugal

• HP centrifugal compressor 

Centrifugal Compressors

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Centrifugal Compressors

PROPANE COMPRESSOR (CENTRIFUGAL)

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PROPANE COMPRESSOR (CENTRIFUGAL)

Gas Turbines General Electric

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Gas Turbines - General Electric

Frame 9

Heat rejection – air and water cooling

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Heat rejection – air and water cooling

► Liquefaction plants reject a large amount of heat to the surroundings toprovide cooling for the refrigeration compressor systems

Water coolingTypical cooling water requirement

 – about 70,000m3/h

Air cooling

Typical Utilities for LNG Production

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Typical Utilities for LNG Production

Electric power 

• typical power requirement – about 300 MWe for 5 MMTPA LNG plant

using all motor driven refrigeration compressors,.

• Depending on Train Capacity each Refrigeration Compressor in MRC

consumes 50 to 75MW power (turbine or motor driven)

Hot water/Hot oil as heating medium in

• fractionation section, glycol regeneration, solvent recovery in acid gas

removal unit.

• Hot water generated by heat recovery from gas turbine exhaust

• Typical process demand of thermal energy from hot water is about

100MWth for a 5 MMTPA LNG plant.

►Nitrogen – high purity (99.9%) – used in refrigerant make-up

LNG STORAGE TANKS

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LNG STORAGE TANKS

►Capacity: 30,000 m3 ~200,000 m3

► Typically about 44 to 80m dia and 22 to 36m Height

► Types of Storage Tanks

•  Above-ground

 – Conventional single wall tank with Dike – Double containment tank (steel roof)

 – Full containment tank (concrete roof + steel )

►Under-ground

 – The UG tanks are of continuous membrane walls, sidewalls and Basementslabs and Roof.

► Design Pressure: 290 ~ 310 mbarg / -5 ~ -10 mbarg, Design Temperature: –166ºC to –170ºC.

►Storage Tank Protection (Vacuum & Relief Devices)

• Pressure relief valve: Set Pr 260 mbarg to flare

• Pressure relief valve: Set Pr 280 mbarg to Atm

• Vacuum relief valve: Set Pr -5 mbargIn breath N2

LNG STORAGE FACILITY C td

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►Storage Tank Selection

Criteria•Location

•Environmental considerations

•Operational conditions

•Safety and economic efficiency

LNG STORAGE FACILITY – Contd.

Full containment tankTANK DESIGN PRESSURE

TANK DESIGN PRESSURE

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Full containment tank

Liquid Gas at –160°C

POST-TENSIONED

CONCRETE SHELL

PERLITE

RESILIENT

BLANKET

9% Ni STEEL

INNER TANK

CELLULAR GLASS

SUSPENDED DECK

GLASSWOOL

CARBON STEEL VAPOUR BARRIER

CONCRETESLAB

Filling, Emptying, Instrumentation, …ALL PENETRATIONS THROUGH THE CONCRETE DOME

9% Ni THERMAL

CORNER PROTECTION

9% Ni SECONDARY BOTTOM

TANK DESIGN PRESSURE

 –15 to 300 mbarg

NG

HEATING SYSTEM

REINFORCED

CONCRETE ROOF

Liquid Gas at –160°C

POST-TENSIONED

CONCRETE SHELL

POST-TENSIONED

CONCRETE SHELL

PERLITEPERLITE

RESILIENT

BLANKET

RESILIENT

BLANKET

9% Ni STEEL

INNER TANK

9% Ni STEEL

INNER TANK

CELLULAR GLASSCELLULAR GLASS

SUSPENDED DECKSUSPENDED DECK

GLASSWOOLGLASSWOOL

CARBON STEEL VAPOUR BARRIERCARBON STEEL VAPOUR BARRIER

CONCRETESLAB

CONCRETESLAB

Filling, Emptying, Instrumentation, …ALL PENETRATIONS THROUGH THE CONCRETE DOME

9% Ni THERMAL

CORNER PROTECTION

9% Ni THERMAL

CORNER PROTECTION

9% Ni SECONDARY BOTTOM9% Ni SECONDARY BOTTOM

TANK DESIGN PRESSURE

 –15 to 300 mbarg

NG

HEATING SYSTEMHEATING SYSTEM

REINFORCED

CONCRETE ROOF

REINFORCED

CONCRETE ROOF

MATERIALS OF CONSTRUCTION

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MATERIALS OF CONSTRUCTION

► The MOC of major/critical Equipment in Pre-cooling and liquefaction units:

•  Aluminum and SS for MCHE

• Refrigeration Compressors – 3.5Ni/13Cr 

• LNG Expanders – SS

• Endflash unit – SS vessels and SS pumps

• SS-316 for columns/vessels

► The MOC of major/critical Equipment in LNG storage:

• Storage tank 9% Ni Steel

• LNG Pumps: Aluminum Alloy (Casting & Impeller)

LNG IMPORT FACILITY

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LNG IMPORT FACILITY

Unloading Jetty

Liquid Unloading Arms & Vapour Return Arms

Liquid Unloading & Vapour return pipelines

LNG Storage tanks

Boil-off Gas (BOG) Compressor 

LNG pumps (LP and HP Pumps)

LNG Vaporizers

Metering Systems for gas distribution/send-out

LNG REGASIFICATION

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LNG REGASIFICATION

►LIQUID PRODUCT VAPORIZED/REGASIFIED BEFORE

TRANSMISSION AND DISTRIBUTION BY PIPELINE

►PHYSICAL TRANSFORMATION FROM LIQUID STATETO GASEOUS STATE REQUIRES HEAT INPUT INTO

THE LNG

►THE VAPORIZATION EQUIPMENT ACCOMPLISHESHEAT TRANSFER IN A SAFE, EFFICIENT MANNER.

►WIDELY USED VAPORIZATION EQUIPMENT

•OPEN RACK VAPORIZER

• SUBMERGED COMBUSTION VAPORIZER

LNG REGASIFICATION – BLOCK FLOW

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LNG REGASIFICATION BLOCK FLOW

DIAGRAM

BOG COMPR

BOG

RECONDENSER

STORAGETANK

LNG BOOSTER

PUMP

LNG VAPORISER *

EXPORT GAS

METERINGUNLOADING

ARMS

LNG

VAP

SEA WATER

INTAKESEA WATER

DISCHARGE

TO GAS

DISTRIBUTION

PIPELINE

VAPOUR

RETURN

ARM

M

IN TANK

PUMPS

BOG Compressor 

 –151 to –105ºC0 – 150 mbarg

0 – 19000 Nm3/h FSRU PROCESS

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52Liquefied Natural Gas - An Introduction

 – 145 to –

150ºC3 – 6 Barg

PROPANE

DRUM

 Vapour Return Arm

LNGUnloading Arms

Hybrid Arm M

TO VENT MAST

M

HP Send Out Pump

Metering

To 32”

Subsea Pipeline

(via turret,

PLEM)

Intermediate Fluid

Vaporiser 

Sea water from power plant

turbine condenser 

Sea water

return

LNG Storage Tanks

(MOSS Spheres)

4 x 34250 m3

Recondenser 

Natural Gas

0ºC; 84 Barg

14.7 MMSCMD

5.37 BCM/Yr 

 – 155ºC87 Barg

 – 30 to 0ºC3 – 6 Barg

  –   1   6   0 .   5

   º   C

   6  -   7   B  a  r  g

(NET BOG)

SCHEMATIC

 – 157ºC

2 Barg12,000 m3 /h

LNG Vaporizers

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LNG Vaporizers

LNG re-gasified in vaporizing units by heating,through heat exchange with seawater or byburning gas.

Open-Rack type LNG Vaporizer (ORV) uses seawater as the heat source.

Submerged Combustion Vaporizer (SCV) uses NG

as the heat sourceSCV used when ORV is under maintenance or for

peak shaving.

Multiple ORVs and only one SCV are used.

SCV capacity is generally 15 to 25% of ORVcapacity.

Open-Rack Vaporizer

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Open Rack Vaporizer 

ORV composed of panel-shaped heat transfer tubesmade of aluminum alloy.

LNG flows upward inside the finned heat transfer tubes,sea water flows down along the outer surfaces of the

tubes. Performance Improvement and reduction of sea water

flow rate for conventional ORVs are limited due to iceformation on the outer surface of heat transfer tubes.

Approx. sea water requirement: 32 m3 /ton LNGevaporated at 5ºC T

To protect the ORV against corrosion by seawater, analuminum-zinc alloy is thermal-sprayed on the panels andupper and lower headers exposed to seawater.

Open-Rack Vaporizer 

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Submerged Combustion Vaporizer 

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Distribution Facility

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►Gas Distribution by Pipeline

• Power Plants

• Petrochemical/Fertilizer Plants• Heavy/Light Industries (Steel/Automobile)

• City Domestic Consumption

►Liquid Distribution by Road Tanker 

• Small Consumers• Remote Housing Facility

SUCCESS OF AN LNG PLANT DEPENDS ON

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►STRONG THERMODYNAMIC

FUNDAMENTALS

►SOUND ENGINEERING

PRACTICES

►WELL DEFINED EVALUATION

CRITERIA

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Thank you

for

your attention


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