baseload lng production · with a lng production capacity of 0.4 mtpa (million tons per annum) the...
TRANSCRIPT
BaseloadLNG Productionin Xin Jiang
2
Contents.
3 Introduction
4 The basics
Design basis
Basic data for the process design of the plant
Feed gas composition
Specification of the product LNG
Process features
Utilities
Block diagramm of the Shan Shan LNG plant
6 Features I Ambient conditions at the site
Overall process and utility description
Natural gas treatment
Natural gas liquefaction
Block diagram of the liquefaction
8 Features II Refrigerant system
Gas turbine
LNG storage and loading system
Block diagram of the LNG storage tank and loading system
11 Features III Fuel system
Hot oil unit
Main cryogenic heat exchanger
Project execution
13 Project execution
14 Closing remarks Selected references
16 Contact
Xiang DongPresidentXin Jiang Guanghui Liquefied Natural Gas Development Co. [email protected], 838202 Shan Shan, PRC
Thilo SchieweSales Manager, Natural Gas [email protected], Linde AG, Engineering DivisionDr.-Carl-von-Linde-Str. 6-14, 82049 Pullach, Germany
Albert MeffertProject [email protected], Tractebel Gas EngineeringMildred-Scheel-Str.1, 53175 Bonn, Germany
Li Wei BinLNG Chief [email protected], SSEC, SINOPEC Shanghai Engineering Co. Ltd.,769 Zhangyang Road, Pudong New Area, Shanghai, PRC
The gas is treated and liquefied in an LNG plant
near Shan Shan in the Xin Jiang Province of
China. The plant is operated in baseload mode
and employs intermediate storage of the LNG
product in an insulated tank before it is loaded
into LNG road tankers. These trucks then carry
the LNG over long distances to satellite and car
fuelling stations in various cities of China. After
revaporization of the LNG at these stations the
natural gas is finally distributed to a variety of
industrial and private consumers.
As LNG is considered the most environmentally
friendly hydrocarbon fuel, it is expected that
this domestic natural gas initiative through LNG
creates new gas markets and provides a great
improvement to the tight energy supply situa-
tion in China. This paper describes the Shan Shan
LNG facilities from gas treatment, liquefaction
with a single mixed refrigerant cycle in coil-
wound heat exchangers, through storage, to
unloading and to the distribution of the LNG
to various cities in China.
3
Introduction.
Baseload LNG production in Xin Jiang - a remote sourceof clean energy for gas consumers in China.
In 2004 Xin Jiang Guanghui Liquefied Natural Gas Development Co. Ltd. established a unique LNG chain. The result is that gas, which until recently has been flared at the Tuha oilfields some 300 km south-west of Urumqi, can now be utilized as a cleanprimary energy source. This new LNG scheme is a feasible and workable alternativeto existing peak shaving and conventional baseload plants.With a LNG production capacity of 0.4 MTPA (million tons perannum) the plant represents a new category of LNG planttypes, with which a specific demand can be fulfilled.
Design basisThe baseload LNG plant is designed for the pro-
duction of LNG equivalent to 1,500,000 Nm3/d.
The plant consists of natural gas treatment, gas
liquefaction, LNG storage tank and LNG distribu-
tion systems. The liquefaction process is based on
a highly efficient single mixed refrigerant cycle.
Basic data for the process design of the plantThe design of the LNG plant for the Xin Jiang
project is based on state-of-the-art natural gas
liquefaction technology.
The LNG production capacity of the plant is
equivalent to 1,500,000 Nm3/d with an ex-
pected on-stream time of 330 days per year.
Design hourly liquefaction capacity is 54 t/h.
Storage capacity is 30,000 m3 of LNG, which is
the equivalent of 12 days production. The ca-
pacity of the LNG send-out and distribution
system meets the requirement of loading the
100 trucks and movable containers within 16
hours. Approx. 30 % of the LNG product is load-
ed in trucks and 70 % in movable containers.
Feed gas compositionComposition (mole %):
– Nitrogen 3.81
– Methane 81.02
– Ethane 9.99
– Propane 4.10
– Butanes 0.93
– Pentanes 0.05
– C6+ < 0.0021
In addition, CO2 as well as traces of H2S and
sulfur are present in the feed gas. The feed gas
operating pressure ranges from about 0.6 MPag
to 1.1 MPag. The design pressure is 0.7 MPag.
The feed gas operating temperature can range
from -15°C to 40°C. The design temperature
is 28°C.
Specification of the product LNGComposition (mole %):
– Nitrogen 0.8 (max 1.0)
– Methane 82.4
– Ethane 11.1
– Propane 4.6
– Others 1.1
Pressure and temperature at LNG tank:
0.01MPag, –163°C. The design LNG has
a density of about 490 kg/m3 in the LNG
tank.
Process featuresThe main process and utility units are illustrated
in the block diagram in Fig1. The mixed refriger-
ant cycle liquefaction process requires the com-
ponents nitrogen, methane, ethylene, propane
and pentane. Refrigerant nitrogen and purge
nitrogen are identical and case both generated
in a nitrogen package.
UtilitiesMake-up water for the following are provided
from outside the plant: closed cooling water
cycle, machinery cooling and demineralized
water as make-up water for the MEA in the CO
wash unit.
A mixture of compressed LNG tank return gas
and feed gas is used as normal fuel gas;
start-up fuel gas is feed gas. A closed hot oil
cycle is used as heating medium. A MEA
(monoethanolamine)-water solution is used
as solvent for the CO2 wash unit.
The liquefaction process is based on a highly efficient single mixed refrigerant cycle,
4
The Basics.
Fig1: Block diagram of the Shan Shan LNG plant with
process and utility units
5
which contains the components nitrogen, methane, ethylene, propane and pentane.
Wastewater
Hot oil
system
Natural gas
Sourgas
Exhaustgas
Waste heat
recoveryGas turbine
Solvent
regeneration
Refrigeration
system
Boil off gas
(fuel gas)
compression
Feed gas
compression
NG purification
CO2 removal
NG purification
dryer
NG
liquefaction
LNG
storage
LNG loading
station
container
MCR
make-up unitFire fighting Utilities Flare
LNG loading
station
special cont.
LNG loading
station truck
LNG meters
LNG meters
NG
puri-fiedNG
hotoil
hot o
il
hot o
il
fuel
gas
hot o
il
fuel
gas
rich
solv
ent
vap.
refr.
lean
solv
ent
liqui
d re
fr.
hot o
il
fluegas
dryNG LNG LNG
LNG
LNG
LNG
Ambient conditions at the siteThe average ambient temperatures ranges from
37.1°C in the warmest month to -15.6°C in the
coldest month. The design temperature for gas
turbine air inlet and for air-cooling is 30°C. The
average temperature in the hottest month is 37°C,
the extreme maximum temperature is 75°C. The
plant elevation above sea level is about 790 m.
Overall process and utility descriptionThe production capacity of Shan Shan LNG lies
between the two principle type of LNG plants:
Baseload and peakshaving plants. LNG peak-
shaving or back-up plants with intermittent
operation and production have capacities up
to about 500,000 Nm3/d. LNG baseload plants
with continuous operation and production
have capacities between 5,000,000 Nm3/d and
17,000,000 Nm3/d. With 1,500,000 Nm3/d LNG
production capacity the Shan Shan LNG plant is
about three times larger than the largest exist-
ing peakshaving plants, but about three times
smaller than existing baseload plants. The feed
gas has a low pressure at battery limit, which
is too low for an efficient liquefaction process.
Therefore, the natural gas is compressed in
three compressor stages.
The natural gas is cooled, liquefied and sub-
cooled in a coil-wound heat exchanger by a
highly efficient single mixed refrigerant cycle.
This cycle provides cold temperatures by Joule-
Thomson expansion at three different pressure
levels.
The refrigerant cycle is recompressed in a three-
stage turbo-compressor, which is driven by a gas
turbine. In order to enhance plant efficiency, the
waste heat from the gas turbine is recovered by
heating a hot oil cycle, which covers the heating
requirements of the process plant.
Natural gas treatmentNatural gas (feed gas) has a low pressure at the
battery limit. Solid and liquid particles are re-
moved by the feed gas filter separator before it
is compressed in a three stage feed gas com-
pressor. After the first-stage of the feed gas
compressor, the gas is cooled in an intercooler
against ambient air to about 40°C. Any water
condensed in the intercooler is separated in the
feed gas compressor interstage drum and is fed
to the wash unit.
After this first compression step the feed gas is
further compressed in the next two compressor
stages with inter- and after-cooling in air-cool-
ers. The feed gas is routed to the wash unit for
removal of CO2. The sweet feed gas leaving the
CO2 wash column is then routed to the drier
station.
Natural gas liquefaction (Fig. 2)After the CO2 and H2O removal, the natural gas
is routed to the cold part of the process, which
contains three coil-wound heat exchangers
integrated in one shell (“rocket”), as well as
several separation vessels. The natural gas is
first cooled in the feed gas precooler E1. Poten-
tial off-spec heavy hydrocarbons are separated
in the feed gas heavy hydrocarbon separator D3,
where only marginal liquids during design feed
gas operation are expected. The gas is then con-
densed in feed gas liquefier E2 and subcooled in
feed gas subcooler E3. The required subcooling
temperature is maintained by adjusting the na-
tural gas flow rate to the plant. Thus, a certain
power output of the gas turbine govering the
plant capacity. Cooling is provided by the mixed
refrigerant cycle.
The Shan Shan LNG plant has a medium size production capacity,
6
Features I
Fig 2: Natural gas liquefaction process of the
Shan Shan LNG plant
in between the two principle types of LNG plants which are currently in operation world-wide.
7
LNG to storage tank
E3Subcooler
D3Cold MCRseparator
E1Precooler
E2Liquefier
D3Feed gasHHCseparator
Feed
gas
Feed gas compression,
CO2/H2Oremoval
CT1Gas turbine
Cycle compressor coolers
Cycle compressorsuction drums
C1Cyclecompr. D2
Cycle HPseparator
D1Cycle MPseparator
Fig 3: 30,000 m3 LNG storage tank
Refrigerant systemThe refrigerant gas stream is withdrawn from the
shell side of precooling section E1 of the cryo-
genic coil-wound heat exchanger set. The re-
frigerant is slightly super-heated.
The refrigerant is compressed in the first stage of
the three-stage refrigerant cycle compressor. It
is than cooled against air in the inter- and after-
cooler resulting in partial condensation. The
resulting liquid is separated in the cycle com-
pressor discharge drum D1.
The liquid from the discharge drum D1 is routed
to the cryogenic heat exchanger E1, where it is
subcooled and then used for the precooling of
the natural gas after expansion in a Joule-Thom-
son valve.
The cycle gas from the buffer drum D2 is cooled
in E1 to the same temperature and partly conden-
sed and fed to the cold refrigerant separator D3.
The liquid from this separator is subcooled in the
cryogenic heat exchanger section E2 to a low
temperature so that it can be used as a refri-
gerant in E2 after expansion in a Joule-Thomson
valve.
The vapor from the cold refrigerant separator D3
is condensed in E2 and subcooled in the cryo-
genic heat exchanger section E3 to a sufficiently
low temperature. This provides the final cold for
the natural gas subcooling after throttling in a
Joule-Thomson valve. After expansion to the
lower pressure, the cycle gas streams are warmed
up in the common shell side of the cryogenic
coil-wound heat exchangers E3, E2 and E1 and
return jointly to the suction side of the first stage
of the refrigerant cycle compressor.
Gas turbine Gas turbine GT1 is used as the primary driver for
the cycle gas compressor C1. Design tempera-
ture for gas turbine rating is an ambient air tem-
perature of 30°C. The same design temperature
applies for air-cooling. The compressed boil-off,
flash and displacement gas from the LNG storage
tank is used as regeneration gas and then as fuel
gas for the gas turbine.
LNG storage and loading system LNG from the liquefaction unit with the cryo-
genic heat exchanger set E1, E2 and E3 is sent to
the storage tank via the tank filling line, Fig. 3.
The 30,000 m3 LNG tank (Fig. 5) is a flat bottom,
double wall, perlite insulated type installed in
an endiked area. The tank will be filled continu-
ously during operation of the liquefaction sys-
tem at a filling rate of about 111 m3/h. A discon-
tinuous send out of LNG product to the truck and
container filling facilities is scheduled for 16
hours per day.
8
Features II
Fig. 5: LNG storage tank and loading system
of the Shan Shan LNG plant
Fig. 4: LNG truck loading station
For send-out operation, two submerged in-tank
pumps are installed. Each designed for 320 m3/h
capacity, suitable for 100 % of send-out capac-
ity. One pump is installed as a spare. The pumps
are installed in pump columns inside the tank
and equipped with foot valves. Each pump is
equipped with a kickback line to the tank to
control the minimum flow of the pump during
the period when no filling operation takes place.
The send out lines to the truck and container
filling station are permanently filled with LNG.
A small circulation flow keeps the system at
cryogenic temperatures. The trucks are weighed
prior to filling. Trucks are connected manually
to the loading arm filling and vapor return lines.
The initial LNG into the “warm” tanks truck eva-
porates The resulting vapor returns to the stor-
age tank. After cooling the truck tank, the filling
rate increases to the maximum filling rate.
The flow meter stops the filling operation auto-
matically via the automatic control valve at the
loading station. The truck leaves the plant via
the weighbridge after disconnection from the
loading arm. Fig. 4 shows the LNG truck loading
station with four trucks each with a storage
capacity of 44 m3. The loading capacity of the
9
stations is sufficient to match the send out ca-
pacity by operationg 16 hours a day.
The same operation applies to the container
filling system. The only difference is that trucks
are mobile by themselves and the container
must be moved by gantry crane and trailers.
The container is fixed on rail-platform cars and
transported as train of 40 to 70 cars in length.
The filling time for one container or one truck is
estimated to be about 1.2 hours including con-
nection and disconnection time. The system capa-
city is designed to fill 100 trucks or containers
within 16 hours. The filling system consists of
six loading stations for containers and four load-
ing stations for trucks.
P-411LNG transfer pump
LNG from liquefier Vapor return containerfilling station
Boil-off/flash/displacement gasto re-compression
Container and truck filling station
D-411LNG storage tank
L-421A/B/C/D/E/F
L-431
L-441A/B/C
Fig. 6: Three stage 43 m high coil-wound heat
exhanger with separator in the steel frame
Fuel systemThe net flash, boil-off and displacement gas
coming from the LNG storage tank is com-
pressed, cooled against ambient air and used
as regeneration gas in the dehydration section
before it is sent as fuel to the gas turbine, which
drives the cycle compressor. To allow for pres-
sure control of the fuel gas, an additional
fuel stream is taken from the feed gas following
the second stage of the feed gas compressor.
Hot oil unit The hot oil system provides the process heat for
the plant at two temperature levels. In order
to keep constant flow rates in the system, two
cycles are used: a medium temperature cycle
and a high temperature cycle. The heat for both
cycles is provided by a hot oil heater package, a
waste heat recovery unit in the exhaust stack of
the cycle gas turbine. The hot oil is heated to ap-
prox. 260°C to supply heat for the regeneration
gas heating. To allow for start-up during winter
conditions, the system is heat traced.
10
Features III
Fig. 7: Precooling section of the coil-wound heat
exchanger in the Linde workshop
11
Main cryogenic heat exchangerA special feature of the cryogenic section of the
process plant is the coil-wound heat exchanger
which is designed and built by Linde.
The coil-wound heat exchangerThe robust design of the coil-wound heat ex-
changer is ideally suited for the pre-cooling,
liquefaction and sub-cooling processes. During
these processes, the refrigerant and product
streams reach temperatures as low as -160°C.
Fig. 7 shows the precooling section of the coil-
wound heat exchanger in the Linde workshop
prior to transport.
The outer dimensions (length x diameter) of the
three coil-wound heat exchanger sections are:
Precooler: 15 m x 3 m
Liquefier: 17 m x 3 m
Subcooler: 11 m x 2 m
All three heat exchanger sections were trans-
ported separately to the site. After concentric
stacking and welding in a steel structure, the
combined coil-wound heat exchangers have an
overall height of 43 m. Fig. 6 (page 10) shows
the cryogenic section with the coil-wound
heat exchanger together with the separator in
the permanent steel frame. In comparison to
plate-fin heat exchangers, the coil-wound heat
exchanger can with stand significant thermal
shocks. Thermal shocks may occur during start-
up or shut-down or mal-operations.
Fig: 8: Part of the fleet of LNG trucks for the
road transportation of the Shan Shan LNG
12
Project execution.The execution of the Shan Shan project is an ex-
ample for the excellent cooperation between
the owner of the plant, the liquefaction and tank
technology providers, and the local design insti-
tute.
SPIDI in Shanghai, China was responsible for the
entire plot plan of the plant and detail engineer-
ing with utilities. Tractebel Gas Engineering in
Bonn, Germany was responsible for the design
of the LNG storage tank and the loading facilities
and the procurement of the relevant imported
equipment and material as well as for the con-
struction and commissioning supervision of the
tank and loading units.
The Engineering Division in Munich, Germany
was responsible for the natural gas treatment
and liquefaction process design and for the pro-
curement of the imported process related equip-
ment as well as for the supervision of plant con-
struction and commissioning.
Fig. 9 (page 13) shows a section of the Shan
Shan LNG plant with the compressor shelter
building, the gas turbine exhaust stack, the
coil-wound heat exchanger in the rack, the
LNG tank and the air coolers on the pipe rack.
The plant was mechanically completed in 2004
followed by commissioning. The equipment and
piping was arranged in such a way as to take
into account the relevant safety regulations as
well as short pipeline lengths. The required
plant area is about 58 m x 130 m. The LNG stor-
age tank is connected to the process plant by a
pipe rack, which supports the product and the
vapor return line.
A large fleet of LNG trucks, Fig. 8, is now perma-
nently transporting the LNG over long distances
to the satellite stations in the vicinity of the con-
sumers.
Most of the LNG satellite stations are located in
the more densely populated regions in the east-
ern provinces of China. An overview of the exist-
ing and planned LNG satellite stations is shown
in Fig. 10 (page 13).
As is evident from the table, the one way dis-
tances mostly exceed 3,000 km, some are even
greater than 4,000 km.
The Dehua satellite station, Fig. 11 (page 15),
represents the longest distance from the Shan
Shan LNG plant. This station comprises eight
vertically installed cylindrical LNG storage tanks,
each with a capacity of 150 m3. They are filled
regularly by the LNG trucks. The LNG is vaporized
by blocks of finned heat exchangers using natu-
ral convection of ambient air as heat source.
Small LNG containers are often filled with LNG
from these large satellite stations and trans-
ported to smaller satellite stations in order to
a limited residential areas.
One of the urgent needs for clean fuel comes
from public busses. Therefore, one of the LNG
satellite stations supplies the LNG directly to a
city bus fleet.
Fig. 9: Section of the Shan Shan LNG plant with compressor shelter,
gas turbine exhaust stack, coil-wound heat exchanger and LNG tankFig. 10: LNG transport in China from the Shan Shan LNG plant
Δ
Δ
13
Shan ShanLNG plant
LNGsatellite station
LNGsatellite station
Station Distance
Linyi 3,400 kmRizhao 3,520 kmLianyungang 3,450 kmQingdao 3,600 kmWeihai 3,700 kmJiangyan 4,100 kmQidong 3,400 kmTongxiang 3,700 kmYuyao 3,920 kmBeijing 3,170 kmMinqing 4,050 kmDehua 4,400 kmChangde 3,190 kmChangsha 3,450 kmZhuzhou 3,520 kmJiujiang 3,250 kmJi An 3,700 kmNanchang 3,400 kmGuangzhou 4,040 kmJiangyang 4,350 kmLongchuan 4,200 kmDongguan 4,120 kmUrumqi 340 kmHami 340 km
With the introduction of such LNG plant typescombined with the respective transport infra-structure, natural gas markets can be dynami-cally introduced and developed.
Demand for natural gas in China is projected to
increase drastically in the future. This Shan Shan
LNG plant will open a new era in meeting the
increasing demand.
With the introduction of such LNG plants, com-
bined with the respective transport infrastruc-
ture, natural gas markets can be dynamically
developed in the future. It is evident that natural
gas, as a cleaner fuel, will play an increasingly
important role in the primary energy mix.
The LNG from the Shan Shan LNG plant will
contribute substantially to the economic devel-
opment and growth in China. With the LNG from
Shan Shan, a high degree of flexibility in the
energy supply will be made available to the
benefit of all natural gas consumers with fluc-
tuating or peak demand profiles.
The Shan Shan LNG plant provides a means to
commercialize indigenous natural gas resources.
This, in turn, supports the local economy and
provides jobs.
The Shan Shan LNG plant provide a “rubber tyre
pipeline” in China. The transport of LNG via tank-
er trucks makes the distribution of natural gas to
intermediate-sized consumers possibel.
Some of the target regions have not yet been
connected to major gas pipelines due to eco-
nomic reasons, since the initial gas consumption
rate would not justify such a large investment.
Therefore, the LNG supply will initiate the pene-
tration of these regional markets with environ-
mentally friendly fuel.
This LNG scheme is unique in the world with
regard to plant type as well as plant and trans-
port capacity. It can be considered as an a
model for the commercialization of remote gas
resources.
14
Closing remarks.
Fig 11: Dehua LNG satellite station
15
Selected references– E. Berger, Engineering Division:
• XiangDong,XinjiangGuanghuiIndustry
and Commerce Group Co. Ltd.
• JinGuoQiang,ShanghaiPharmaceutical
Industry Design Institute of SINOPEC (SPIDI)
• Naturalgasliquefaction-technical
and economic aspects
• FirstIndianLNGconference,
Madras, India, 1996
• LNGsatellitestationsinEurope
• LNG10conferenceinKualaLumpur,
Malaysia, 1992
– A. Meffert, Tractebel Gas Engineering,
L. Atzinger, Engineering Division:
• LNGbaseloadplantinXinjiang,China;
commercialization of remote gas resources
for an Eco-responsible Future
• Worldgasconference,Tokyo,2003
– W. Förg, W. Bach, R. Stockmann,
Engineering Division,
R.S. Heiersted, P. Paurola, A.O. Fredheim,
Statoil:
• AnewLNGbaseloadprocessandmanu-
facturing of the main heat exchangers
• LNG12conference,Perth,May1998
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LNG
/3.
1.e/
09
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