LNG Technology

Dr. S. Madhavan
Global Director, Plant Services (Retd.)
Kellogg Brown & Root (KBR), Inc.
Houston, TX, USA

Presented in Dehra Dun

09 August 2010
 Natural Gas Utilization

Distribution by Pipeline
Liquefaction and Regasification
Compressed gas (CNG)
or
Conversion to Liquid Hydrocarbons
Conversion to Methanol
Conversion to Fertilizer
Conversion to Electric Power
 The Hydrocarbon Trend

Hydrocarbon Ratio of Primary Energy

4
3
H/C

2
1
0
1700 1800 1900 2000 2100

Century
Stranded Gas and Major Consumer Markets

Legend
Stranded Gas
Major Markets
 Relative Costs of Gas Transportation

Pipeline vs. LNG

$5.00
$4.00
$ /M M B T U

$3.00
$2.00
$1.00
$0.00
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000
MILES

Offshore Pipeline Onshore Pipeline LNG

How not to transport gas !!
How not to transport gas !!
LNG Technology
 Typical Natural Gas Composition

Typical Composition at Inlet of LNG Plant

1.0 - 2.0 % Nitrogen
85.0 - 95.0 % Methane
5.0 - 10.0 % Ethane - - Feedstock for Ethylene
2.0 - 5.0 % Propane LPG
Petrochemical
2.0 - 3.0 % Total Butane+ Feedstock

1.0 - 4.0 % Carbon Dioxide

Trace: H2S, Hg, R-SH, COS
 LNG

Liquefied Natural Gas

o
- 161 C !!
 Typical LNG Product Specifications

Component Limits (maximum)

Carbon Dioxide 50 ppm
Mercury 0.01 micrograms per normal m3
Nitrogen 1 mol%
Water Vapor 1 ppmv
Benzene 1 ppmv
Ethane < 6 8 mol% (Feedstock for Ethylene!)
Propane < 3 mol% LPG
Petrochemical
Butane < 2 mol%
Feedstock
Pentane and heavier < 0.1 mol%
High Heating Value =1050 Btu/SCF (Europe and USA)
up to 1140 Btu/SCF (East Asia)
 LNG Train Capacities

Train capacities
Camel Plant, Algeria - 1964 - 0.4 MTPA
Sonatrach LNG, Algeria - 1970s - 1.0 - 1.4 MTPA
Malaysia LNG (Satu), Bintulu - 1983 - 2.6 MTPA
Bontang LNG Trains - 1980s-90s - 1.6-3.0 MTPA
Woodside LNG - 1980s-90s - 2.2 - 4.2 MTPA
SEGAS LNG - 2004 - 5.0 MTPA
Qatargas LNG, Qatar - 2007 - 7.8 MTPA
Future Trains - - - - - 2010 - 9.0 MTPA
 TYPICAL BLOCK DIAGRAM - LIQUEFACTION

FUEL
C2 C4

BY PRODUCT
GASOLINE
HYDROCARBON
FRACTIONATION FUEL

NATURAL C2 C3 C4
GAS
FEED DEHYDRATION LNG OFFSITE
CO2 & MERCURY CHILLING LIQUEFACTION NITROGEN
REMOVAL REJECTION LNG
REMOVAL
STORAGE

REFRIGERATION REFRIGERATION
SYSTEM SYSTEM
Typical Acid Gas Removal Scheme

Acid Gas
Reflux
Condenser

Treated Gas
Lean Amine

Lean
Absorber
Low-
Low-Pressure
Semi-
Semi-Lean Flash
Amine
Amine
Cooler

Bulk
Absorber Stripper

Flash Gas
Sour Gas
High-
High- Reboiler

Rich Amine Pressure

Flash
Lean/Rich
Exchanger
 Typical Dehydration Scheme Process Flow

Regeneration
Gas Compressor

Drier
Regeneration
Precooler
Cooler

Water Regeneration Gas

Saturated Knockout Drum
Natural
Gas

Driers Driers
(ABS) (Regen)
Water Hydrocarbon
Liquid Regeneration
Heater

Dry Gas To
Liquefaction
Filter
 Typical Mercury Removal Scheme
Process Flow

From Acid Gas Removal Section

Mercury Outlet Gas

Removal Specification is
Column generally 10
nanograms of
Mercury per cubic
meter of gas.

To Liquefaction Section
 Removal of Trace Mercury Contaminants

Mercury has to be removed from natural gas and its

associated condensate to prevent:
corrosion in aluminum equipment

Removal of mercury in the gas phase is by:

adsorption on sulfur impregnated carbon or alumina
carrier
molecular sieve
 Refrigeration Cycles

Types of Licensed Processes:

Propane Precooled Mixed Refrigerant Cycle (APCI)
Pure Component Cascade Cycle
Phillips Optimized Cascade
Dual Mixed Refrigerant Cycle
Technip & Snamprogetti
Single Mixed Refrigerant Cycle
PRICO
Linde Technology
 Basic Refrigeration - Simple PFD
(Process Flow Diagram)
Q High Temperature
(Ambient)
Condenser

Work Air-cooled or
water-cooled

Compressor Refrigeration Loop

Accumulator

Suction Drum
J-T Valve
Heat Exchanger
Q Low Temperature
8/19/2010
(SubP.-19Ambient)
Propane Precooled Mixed Refrigerant Cycle

Pure propane refrigerant cycle

Ambient to -40oC
Three or four pressure levels

Mixed component refrigerant cycle

-40oC to -160oC
Typical MCR Composition:
2 - 10 % Nitrogen
35 - 45 % Methane
30 - 45 % Ethane
10 - 15 % Propane
Typical Propane Circuit Scheme
Process Flow SW

PC

To MCHE
MR SW

Reinjection
Chiller

DC2 Feed from

Condenser Acid Gas
Removal
To Scrub Feed Gas
Column

8/19/2010 P. 21
 APCI C3/MCR Process LOWBTU
LOW BTU
FUELGAS
FUEL GAS

MR LIQ
MR LIQ EXP
EXP NRU
HP
HP MP
MP LP
LP LLP
LLP LNG
LNG
CC
33 CC33 CC33 CC33 EXP
EXP LNG
LNG
RUNDOWN
RUNDOWN

REFLUX
REFLUX
MCHE
MCHE DRUM
DRUM

HP
HP MP LP
MP LP
MR
MR MR MR
MR MR LPG
LPG
REINJECTION
REINJECTION
TREATED
TREATED
FEED DEHY/Hg
DEHY/Hg
FEED
REMOVAL
REMOVAL
GAS
GAS SCRUB
SCRUB
HP
HP MP
MP LP
LP LLP
LLP COLUMN
COLUMN
CC33 CC33 CC33 CC33

ToFRACTIONATION
To FRACTIONATION
8/19/2010 P. 22
Thermal Efficiency
 Compressor Driver Selection

Economic driver selection possibilities:

Steam Turbines

Industrial Gas Turbines

Aeroderivative Gas Turbines

Electric Motors
Typical
LP MR
Compressor
Axial Compressor
Rotor Lifted From
Casing

P.
 Propane Compressor

Frame 6 Gas Turbine

Propane Compressor driven by

Frame 6 Gas Turbine
 Axial
Compressor Frame 7
Cutaway
Single Shaft Design

Power
Turbine

Air
Compressor
COIL WOUND
EXCHANGER
CONSTRUCTION
P.
Main Cryogenic
Heat Exchanger
(MCHE)
LNG Tank Vapour
Release

Double Metal Wall LNG Storage Tank Design:

To Boiloff Gas Recovery
RV
LNG Rundown LNG to Ship
Bottom Fill
Top Fill

Carbon Steel
Light LNG
Heat Leak from
Perlite Insulation Ambient
Heavy LNG
9% Ni Steel
32 month Construction
Insulation
Schedule (Typical)
 Double
Containment
Tanks
 Full
Containment
Tanks
 LNG Storage Tank Selection

Full Integrity Tank

For Spacing and Security Concerns
Malaysia LNG Storage Tanks
 LNG Contractors
Liquefaction Plants

Top Tier
KBR/JGC
Chiyoda
Bechtel

Next Tier
Technip
Foster-Wheeler
Snamprogetti
LNG Shipping
Typical LNG
Ships

P.
 Shipping and Typical Ship Parameters

Ship Size = 125,000 - 135,000 m3 nominal capacity

Design Speed = 18 - 20 knots
Boil-off rate = 0.15% of contents per day
Length = 300 m ; Breadth = 50 m
Draft = 11 m
Cost = $160 MM (highly dependent on market)
To ship 5 MMTPA a distance of 3500 miles,
approximately 6 x 135,000 m3 ships are needed
LNG Receiving Terminals
 LNG Terminal Flow Diagram

Boil-Off Gas
Compressor
Vapor Return Line

LNG Unloading
Arm
Recondenser
Fuel Gas

LNG Tanker
1st Stage Vaporizer
Sendout
Pumps
To Pipeline
LNG Storage Tanks 2nd Stage
Sendout Pumps
 Open Rack Type

Features
Low running cost. Sea water used as heat source.
Easy to operate and maintain.
Tube Panels--made of aluminum alloy, coated outside with
zinc alloy to provide corrosion resistance from sea water.
Return sea water is 4-5 deg. C cooler. Environmental
consideration.
Cove Point Terminal
P.
 LNG Projects in India
Dahej LNG Terminal, Gujarat Started up in Jan 2004

Kochi LNG Terminal 2.5 MM Tonnes/Yr capacity

Hazira LNG Terminal, Gujarat is a JV of Shell and Total

Ratnagiri LNG Terminal at Dabhol (Ex-Enron) will start shipping

pipeline gas starting from 2010

Many proposed LNG Terminals may be shelved due to

competition from new gas finds/fields offshore in K-G Basin
and Cauveri Basin

New LNG Terminals and new pipeline construction will need to

be developed in tandem.
1997 World LNG Trade
Major Producers 83.8 Mmt/y
Pacific Rim 67.5%
Indonesia 47.7%
Malaysia 26.5%
Brunei 11.0%
Australia 12.7%
Alaska 2.1%
Middle East 9.3%
Qatar 28.2%
Abu Dhabi 71.8%
Atlantic Basin 23.2%
Algeria 94.9%
Libya 5.1%
Trinidad
Nigeria
1997 World LNG Trade
Major Consumers 83.8 Mmt/y
Pacific Rim 75.2%
Japan 76.4%
Taiwan 5.0%
Korea 18.6%
China
India
Atlantic Basin 24.8%
France 33.2%
Belgium 16.8%
Greece
Italy 6.7%
Spain 24.0%
Turkey 11.1%
USA 8.2%
 LNG Producing Countries

Operating LNG Plants Plants Under Construction Plants on the

1. Algeria
1. Nigeria Drawing Board
2. Libya
3. Egypt 2. Qatar 1. Algeria
4. Nigeria 3. Indonesia 2. Egypt
5. Qatar 4. Australia 3. Nigeria
6. Oman
5. Norway 4. Qatar
7. UAE
8. Malaysia 6. Russia
5. Australia
9. Brunei 7. Equatorial Guinea
6. Russia
10. Indonesia 8. Trinidad
11. Australia 7. Angola
9. Oman
12. USA
10. Yemen
13. Trinidad
A Clear Picture of the Future
 Floating LNG Chain
22,000 MT topsides
FPSO for LNG
on field location

Offshore LNG
Transfer
4,000 MT topsides to shuttle LNG carriers

FPSO Receiving
Terminal

Gas distribution grid

 Flare Pantograph LNG Accommodations
Acid Gas Unloading Arm
Solvent appr. 100 people
Regenerator
Acid Gas
Absorber
Main Cryogenic
Refrig. Heat Exchanger
Compressors

Power
Generation
Fractionation

Dehydration

Knock Out
Drums
Inlet
Internal Turret & Compressor
Risers
Typical Service
Crane LNG FPSO
P.
 LNG Plant on a Ship

--Modularization LNG plant on a barge---BLUE MARTIN

STAT OIL Norway
[154 METERS LONG AND 60 METERS WIDE AND 50 METERS
HEIGHT-- 350,000 TONS ] 50
Source: The LNG Business: How Fast Will it Grow? By Theo Oerlemans, Poten
& Partners, presented at Gastech 2005.
 Thank You

Questions - Discussion