tony purcell, honeywell uop: maintaining flng operations in rough seas

© 2013 UOP LLC. All rights reserved. UOP 6195-1

Tony Purcell UOP LLC, A Honeywell Company

Maintaining FLNG Operations in Rough Seas

The FLNG Forum December 3-4, 2013 Perth, Western Australia

Take-away from This Presentation

UOP has a complete portfolio of Gas Processing Technologies also applicable for FLNG

UOP Integrated FLNG Pretreatment

Multiple technology building blocks to meet varied feed properties over the life of the gas field

Optimized pretreatment scheme designed to minimize weight and space with flexible operation

Provided as modules to load on ship

Multiple execution models to meet client needs

One Honeywell approach to capture value

UOP Integrated Offerings Reduce Schedule and Lifecycle Costs 2

UOP 6195-2

Overall Agenda

Introduction

Specifications

Unique Design Challenges

– Space and Weight Considerations

– Motion Effects

Gas Pretreatment Solutions for FLNG

Heavy Hydrocarbon Removal from Lean Gas

3

UOP 6195-3

Honeywell’s Businesses

$37.6 billion in revenues in 2012, 50% outside of U.S.

Nearly 122,000 employees operating in 100 countries

19,000 engineers and scientists

A Fortune 100 company with Morristown, NJ global corporate headquarters

Aerospace Automation &

Control Solutions

Performance Materials &

Technologies Transportation

Systems

4

UOP 6195-4

UOP Company Profile Serving the Gas Processing, Refining & Petrochemical Industries

Profile — Significant Technology Position

Business Units: • Gas Processing and Hydrogen (GP&H)

• Process Technology & Equipment (PT&E)

• Catalysts, Adsorbents & Specialties (CA&S)

• Renewable Energy and Chemicals (RE&C)

Offering: • Technology, catalyst & services to the refining,

petrochemical and gas processing industries

• Supplier of molecular sieve adsorbents to process and manufacturing industries

UOP Facilities — Global Footprint Sales: Geographic

Sales: Breakdown

North

America

32%

Asia Pacific

19%

China

12%

Middle East

9%

South

America

9%

E&A 9%

CIS 5%India

5%

UOP Offices

UOP Manufacturing Sites

• 20 Offices

• 17 Countries

• 12 Manufacturing Facilities

• 5 Engineering Centers

Worldwide Headquarters Des Plaines, Illinois (suburban Chicago)

3,500+ Employees

Global

Customers

Equipment

45%

Licensing

7%

Services

13%

Products

35%Equipment

Products

Services

Licensing

5

UOP 6195-5

Well/Reservoir Monitoring &

Control

• Production Well Monitoring

& Choke Control

• Gas Lift Control

• Gas/Water Injection Well Monitor

& Choke Control

• Down-hole Monitoring Advanced Applications

• Production Optimization

• Power Management

• Gas Lift Optimization

Acid Gas Treating and Dehydration

• Membrane CO2 Removal Systems

• Bulk, selective or trace acid gas removal

• Gas Dehydration Systems

• Mercury Removal

Safety Systems

• Process Shutdown

• Security

• Emergency Shutdown

• Fire and Gas detection

• Heating, Ventilation and

Air

Conditioning Topside Process Control

• Gas Processing Control

• Flow Control & Metering

• Compressor Control

• Gas/Oil Pipeline Monitor &

Control

• Turbo Generator Control

• Gas/Oil/Water Separation

Control

• Well Test Control

• Water Treatment Control Marine Systems

• Propulsion & Dynamic Positioning

• Loading Computer

• Cargo & Ballast Control

Power Applications

• Power management

• Load Shedding

• Turbo Generator Control

Other Systems

• Personnel Address

• Drilling

• Communications

Business and Other

Applications

• Well Test Accounting

• Production Accounting

• Data Warehousing

• Equipment Health Management

• Operator Training

• Aero

• UOP

• Automation & Control

Solutions

Honeywell

FPSO Solutions

Honeywell is uniquely situated

to provide a full suite of

technology solutions for

the FPSO vessel. Our

Technology employed can

provide significant

increase In yield and

operational efficiency to

the owners/ operators.

“Input from Honeywell during

the design phase of our FPSO

resulted in a

significant reduction of labor

costs.”

–Mike Baker

Project C&I Lead Texaco Captain

FPSO

Successful Projects Captain FPSO

Laminaria

Esso Norge Jotun FPSO

FPSO Cidade de Angra dos Reis

(MODEC)

FPSO Cidade de Sao Paulo

(MODEC)

FPSO Replicants (Petrobras)

FPSO Cessao Onerosa

(Petrobras)

UOP has been selected for 100%

of Petrobras pre salt FPSOs

tendered (Cidade de Angra dos

Reis, São Paulo, Replicants and

Cessão Onerosa)

Others

Integrated sub-sea

controls

Simulator

RMG Controls

Enraf Tankage

Scope

• Design

• Engineering

• Fabrication

Staging

Commissioning

Helipad Applications & Others

• Guidance and obstruction

lighting • (Condition-based Maintenance)

Source: Honeywell 6

UOP Natural Gas Solutions Flow Scheme

UOP Has Solutions to Help Maximize Gas Monetization

Sulfur Acid Gas

Mercury Removal

Dehydration

UOP Equipment UOP Equipment UOP Equipment

Natural Gas

Extraction

Sulfur Recovery UOP Offerings

Dry Sweet Gas

LNG

Raw Natural

Gas Liquids

Ethane

Propane

Mixed Butanes

Natural

Gasoline

UOP Petrochemical technology to further convert / upgrade NGLs

MOLSIV™ Separex™

Membrane

Systems

Amine Guard™

FS Process

Selexol™

Process

Twister™

Supersonic

Separator

Liquids Recovery

Fractionation

Liquefaction Acid Gas Removal

(CO2, H2S)

Adsorbents

Ortloff

Processes

SeparSIV ™

7

UOP 6195-7

Overall Agenda

Introduction

Specifications



– Motion Effects



8

UOP 6195-8

FLNG Pretreatment Requirements

Mooring System & Inlet Separation FLNG Pretreatment

UOP Gas Processing

Liquefaction & Unloading

Typical Gas Composition Gas Quality

for

Liquefaction

South

America

South

East Asia Australia

Middle

East

H2S, ppmv 5 - 1000 5 - 200 2 - 50 1000 - 2900 <2 - 4

Total Sulfur, ppmv 5 - 1000 5 - 250 2 - 60 0 - 400 RSH 1 - 40 COS < 10 - 50

CO2, % 2 - 55 9 - 50 2 - 30 2 - 7 < 50 ppmv

Hg, μg/Nm3 0 - 100 200 - 2000 50 - 200 0 - 50 < 0.01

H2O, ppmv Saturated Saturated Saturated Saturated < 0.1

C5+ Varies Varies Varies Varies < 0.1 mole%

9

UOP 6195-9

Overall Agenda

Introduction

Specifications



– Motion Effects



10

UOP 6195-10

Space and Weight Considerations

Land Based

Use Economies of Scale for larger plant

– Units over 1 BCFD (7MMTPA)

Large Footprint

No major Weight Considerations

Floating

Minimal footprint

Smaller Capacities

– Ship Size limitations 1 to 4 MMTPA

Minimize Weight

– Additional Weight Requires Buoyancy

– Additional Buoyancy Reduces On-Board Storage

11

UOP 6195-11

Project Location Capacity, MMSCFD Technologies Application S/U Date

Indonesia 4 x 625 B, M3 LNG+NGL 80’s

Adgas 2 x 225 B, M3 LNG+NGL 85

Adgas 550 B, M3 LNG+NGL 95

RasGas 3 x 750 A, M, S, O (I) LNG 04/05/06

RasGas 750 A, M3, S, O (I) SG 05

Dolphin 4 x 800 A2, M3 SG+NGL 07/08

Gasco 2 x 625 A, O SG+NGL 08/09

Gasco 2 x 400 A, O SG+NGL 09

QatarGas 2 x 1400 M3, S, O (I) LNG+NGL 08/09

RasGas 2 x 1500 A, M3, S, O (I) LNG+NGL 09

RasGas 1600 A, M4, S, O (I) SG+NGL 09

QatarGas 2 x 1400 M3, S, O (I) LNG+NGL 09/10

Gasco (SGD) 2x900 M, S, O (I) SG+NGL 12/15

RasGas (Barzan) 3x980 A, M, S, O (I) SG+NGL 12/15

26.69 Bcfd A - UOP Amine Guard FS Unit M - UOP Molecular Sieve System

B – UOP Benfield Unit O – Ortloff NGL Unit

S - UOP Selexol Unit

I – Integrated

Land Based LNG & NGL Integrated Approach UOP World Scale Experience

12

UOP 6195-12

UOP LNG Experience

13

UOP 6195-13

FLNG Motion Effect on Column Performance

Uniform countercurrent gas and liquid flow is disturbed by motion leading to reduced heat and mass transfer efficiency

Column efficiency drops for distillation/absorption have been documented in the literature

Column performance suffers with motion and permanent tilt

Column efficiency decreases at very long or very short period

The taller the bed height, or H/D ratio, the higher the loss in efficiency

List angle

α

Significant concerns to meet 50 ppm CO2 product spec for

FLNG pretreatment when amine process applied 14

UOP 6195-14

Effect of Mal-distribution on Column Performance

The lower the CO2 product spec required, the more sensitive the amine

column to mal-distribution, or motion For FLNG pretreatment

15

UOP 6195-15

0%

1%

2%

3%

4%

5%

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Maldistribution Factor

Ou

tlet

CO

2 C

on

cen

trati

on

Outlet CO2 spec = 3%

Outlet CO2 spec = 1%

50 ppmv CO2 spec is required for FLNG (very sensitive to mal-distribution)

Right design margin is applied to guarantee

treated gas meeting 50 ppmv CO2 spec

Increasing Solvent Rate to Overcome the Effect of Mal-distribution: Solvent Circulation Margin

• At high liquid rates the absorber is less sensitive to mal-distribution

• Design margin in solvent circulation rate needs to be added for offshore service

Margin: The extra solvent circulation rate applied above land base amine design

16

UOP 6195-16

8.E-04

7.E-04

6.E-04

5.E-04

4.E-04

3.E-04

2.E-04

1.E-04

0.E+00

CO

2 C

on

ce

ntr

ati

on

in

Tre

ate

d G

as

0 0.05 0.1 0.15 0.2 0.25 0.3

Maldistribution Factor

Land Based

10% Margin

23% Margin

We have developed a design procedure for

marinization of amine unit

UOP Design Procedure for Offshore Amine Units

• Set the feed basis and solvent circulation rate from land based design • Motion amplitude

• Period

• Permanent tilt angle

• Worst case maldistribution sets the design case

Motion/tilt Data For the Project

Land Based Design

CFD Simulations

Maldistribution Parameters

Rigorous Heat & Mass Transfer Model

AGRU Design <50 ppm CO2

Pilot Plant Data For Rocking

Column

17

UOP 6195-17

MolSiv Adsorber under Tilt Condition

Tilt Angle α

Liquid Level

High Liquid Flow

Low Liquid Flow

Amine Column

Tilt Angle α

Solid Level

Uniform Gas Flow

• In amine units, liquid level will stay horizontal, and not perpendicular to the flow path, resulting in flow mal-distribution

• In MolSiv units, solid adsorbent will stay perpendicular to the flow path resulting in uniform gas flow.

Adsorber

18

UOP 6195-18

Overall Agenda

Introduction

Specifications



– Motion Effects



19

UOP 6195-19

Water Sour Gas CO2 + H2S

UOP GB™ Adsorbent Mercury Removal Unit

UOP Amine Guard FS™ Process Unit

XXXX

Treated Gas to LNG

Feed Gas

Conventional Pretreatment Scheme UOP MOLSIVTM Adsorbent

Dehydration Unit

Large solvent system in off-shore environment

– Logistics (permanent solvent/water make-up)

– HSE issues related to use of amines

Limited flexibility

– For variations in feed over life of field

– Limit on CO2 content of feed gas due to limit on size of unit

Impact of rocking motion has to be accounted for

20

UOP 6195-20

Water

Permeate Gas

Sour Gas CO2 + H2S



Feed Gas

XXXX

Sour Gas CO2 + H2S

Treated Gas to LNG

Treated Gas to LNG

Feed Gas

Hybrid Scheme

Conventional Scheme

Water

XXXX

UOP Separex Membrane System

Hybrid Pretreatment Scheme

Smaller amine unit

More flexible for variation over life of field

System can handle gas streams with higher CO2 content

UOP MOLSIVTM Adsorbent Dehydration Unit

21

UOP 6195-21

22

Solvent-free Pretreatment Scheme

Water

Permeate Gas

Sour Gas CO2 + H2S



Feed Gas

XXXX

Sour Gas CO2 + H2S

Treated Gas to LNG

Treated Gas to LNG

Feed Gas

Hybrid Scheme

Conventional Scheme

Water

XXXX


UOP MOLSIVTM Adsorbent Dehydration Unit

Final FLNG pretreatment lay-out depends

on feed gas composition UOP 6195-22

22

Solvent-free Pretreatment Scheme

Regeneration Gas Water, CO2 & H2S



Feed Gas

UOP MOLSIVTM Adsorbent Acid Gas Removal/ Dehydration Unit

Treated Gas to LNG

Treated Gas to LNG

Feed Gas

Membranes + Adsorbents

Adsorbent-Only

Water


Permeate Gas Water, CO2 & H2S

Solvent-free eliminates motions effects

Permeate Gas (Membranes) or Regeneration Gas (MolSiv) can be

used to meet the ship’s utility needs

23

UOP 6195-23

Adsorbents in LNG Service & Off-shore

UOP Molsiv Adsorbents have been used in > 1,400 units

for dehydration and acid gas removal

Extensive Experience in CO2 Removal for LNG Pretreatment

– 30 + references in LNG Peak Shavers

– Pipeline Quality Gas (2-3%) to LNG Quality Gas (50 ppmv)

UOP Molsiv Adsorbents have been used in off-shore units

(Brasil, Thailand, Indonesia, Nigeria, Angola, Australia…)

Molsiv Adsorbents can also be used

for CO2 removal in FLNG pretreatment 24

UOP 6195-24

UOP’s Offshore Separex Experience

Location Type of

Unit MMSCFD CO2

Removal Stages

Pretreatment

Thailand Platform 32 50% - 20% 1 MG

Malaysia Platform 680 44% - 8% 2 MG


Thailand FPSO 11 28% - 3% 1 J-T


Brazil FPSO 176 25% - 5% 2 J-T

Brazil FPSO 176 35% - 5% 1 C3R

UOP is extending its land based experience to offshore

by courtesy of Talisman by courtesy of Petrobras

25

UOP 6195-25

Overall Agenda

Introduction

Specifications



– Motion Effects



26

UOP 6195-26


Heavy hydrocarbon removal is desirable, but light hydrocarbon removal is not

– Keep C2-C4 in the LNG to raise BTU value

Concern:

– Heavy hydrocarbons freezing in LNG exchangers

– Desirable to remove BTEX and heavier components

– May not have enough hydrocarbon for a typical NGL cryogenic recovery scheme – not enough reflux in the demethanizer

Potential Solution(s):

– Using cryogenic distillation to remove hydrocarbons

– Using a highly selective multilayer adsorbent system to remove sulfur species and hydrocarbons

27

UOP 6195-27 SeparSiv can remove C6+ to less than 1 ppmv

Technical Solutions for Hydrocarbon Removal

For the SeparSIV Process, hydrocarbons and water are removed from a

gas/liquid separator after cooling the regeneration gas

UOP MOLSIV

dehydration

TSA

Cryogenic separation

expander or JT

distillation column

compressor

Feed Product to

Liquefaction

Water

Hydrocarbons

SeparSIV Process

Feed Product to

Liquefaction

Hydrocarbons

UOP’s SeparSiv Process

Cryogenic temperature achieved by gas expansion

Recompression of the gas is generally needed after liquefaction

Current commercial Process

UOP MOLSIV

dehydration

TSA

Water

28

UOP 6195-28

Cryogenic Distillation Options

• Poor separation due to high pressure scrub column

• Lower scrub column temp to provide reflux

– condense C1, C2

– less efficient

• Add fractionation columns to provide reflux

– add CAPEX

Fractionation

Dehydration

Precool

Scrub Column LNG

Feed

Cold Box

• Better separation due to low pressure scrub column

• Need expander-compressor – add CAPEX and OPEX

• This integrated NGL-liquefaction option is believed to be more efficient than the option above

Condenser

Dehydration

Precool

Scrub Column LNG

Feed

Cold Box

Compressor

Expander

NGL

Cryo requires low pressure and temperature to meet

spec which increases CAPEX and OPEX 29

UOP 6195-29

Adsorbing Bed

Particle Filter

Filter Coalescer Regenerating

Bed

Regen Gas Cooler Regen Gas

Separator

Regen Gas Blower

Feed

Liquids

Clean Gas

Regen Heater

UOP SeparSIV Process/System

30

UOP 6195-30

31 UOP - CONFIDENTIAL File Number

Technical Approach

With a vast inventory of adsorbents and a library of control

schemes, UOP can match the requirements of your application

Remove C6 and below, water to <0.1 ppm

Remove C8 and above and BTX, trace water

(capable of bulk water removal)

31

UOP 6195-31

Heavy Hydrocarbon Management Options

• The UOP SeparSIV Process can be used for pipeline gas dew point specification

or before liquefaction after an AGRU to remove water and hydrocarbon

compounds that freeze.

Product specification also affects process selection

GPM = gallons of liquefiable hydrocarbons per 1,000 cubic feet of natural gas

32

5

6

7

8

9

Hyd

roc

arb

on

to

be

re

mo

ve

d

ca

rbo

n n

um

be

r

SeparSIV - layered adsorbents Cryogenics

2 GPM > 2 GPM < 2

UOP 6195-32

layered adsorbents SeparSIV -

Cost Comparison*

*Cryo only considers compressor power

* Over how many years?

Savings derived from • Compression required in the cryogenic scheme while SeparSIV

only has a blower

• Cryogenic BTEX removal requires more pressure drop and lower temperatures, which drive up CAPEX and OPEX

• Cryogenic system better suited for higher GPM and loose product specifications

Economic Basis: 810 MMSCFD Rich Feed (1.8 GPM)

Lifecycle Cost = CAPEX + (4 * OPEX)

*Estimated

33

$MM SeparSIV Cryogenic

CAPEX 1.0 1.5

OPEX (annual) 1.0 4.8

Lifecycle Cost 1.0 2.0

UOP 6195-33

Conclusions

UOP’s Integrated FLNG Pretreatment

• Flexible ‒ Multiple technology building blocks to meet varied feed

properties over life of the gas field

• Proven Technology ‒ Technology used in applications on land

and offshore for past 30 years

‒ Low lifecycle costs

• Multiple Execution Models ‒ Provided as single or multi-lift equipment modules

‒ Licensed with key mechanical equipment

‒ Licensed only

34

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UOP 6195-35