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1、May 9 - 11, 2006“Impacts of Process Selection on LNG Plant Reliability” Attilio J. Praderio 1920, Air liquefaction cryogenics developed1930s, (early) Helium recovery from natural gas for military purposes (military balloons). After Helium recovery, Natural Gas was revaporized and sold as pipeline ga
2、s.1934, W.J. Podbielniak filed and received a patent for a mixed component refrigerant system having three stages of fluid throttling and a single compressor in a closed system.1939, first LNG manufacturing and storage plant built by Hope Natural Gas Co. a subsidiary of Consolidated Natural Gas Syst
3、ems.1941, East Ohio Gas Co. built a peak shaving plant in Cleveland.1944, Accident in 2nd Storage tank of Cleveland plant arrested the growth of USA LNG industry for 20 years. The failure was caused by inadequate metallurgy used in the tank.1956, Haselden considered a mixed refrigerant process utili
4、zing two compressors in a closed cycle for liquefaction of natural gas. He pointed out the advantage of obtaining the refrigerant components from natural gas itself.1959, A. P. Kleemenko of the Institute of Gas Research Academy of Sciences (U.S.S.R) described a working apparatus employing either an
5、open or closed single fluid, mixed component refrigeration. LNG Historical Development 2LNG Process ReliabilityLNG几种工艺的选择及其可靠性1964, Oct 7, first cargo export from the vanguard plant Camel located in Arzew (Algeria). Cascade - TEAL. LNG exported to U.K.1965, fisrt two U.S. LNG plants commissioned 21
6、years after Cleveland incident, built by Alabama Gas and Transcontinental Gas Pipeline Corp.1966, J. Perret, Technips Scientific Director described mixed refrigerant processes for natural gas 1969, Kenai plant (Alaska) using Cascade Phillips Optimized (Gas Turbines used as drivers for the first time
7、 )1970, Gaumer and Newtown described a Multi Component Refrigerant APCI (MCR)1970, Marsa El Brega plant (Libya) using Single Mixed Refrigerant APCI MCR (low thermal efficiency)1972, Skikda (Algeria) plant using Dual Pressure MR TEAL1972, Lumut plant (Brunei) using C3 / MR APCI1972 1981, 6 plants C3
8、/ MR APCI1981 & 1982, Skikda (Algeria) using PRICO Pritchard1983- 1999, 14 plants C3 / MR APCI1999, Atlantic LNG 1, Trinidad Cascade - Phillips Optimized CascadeLNG Historical Development 3LNG Process ReliabilityLNG几种工艺的选择及其可靠性600 psi600 psi300 psi300 psi-132 F-132 F-28 F-28 F50 F50 F200 psi200 psiT
9、reatedTreatedNaturalNaturalGasGas600 psi600 psi300 psi300 psi-132 F-132 F-28 F-28 F50 F50 F200 psi200 psiTreatedTreatedNaturalNaturalGasGas1964 (Cascade), 1969 Closed Loop Optimized Cascade1970, 72, 81,82 = Single Mixed Refrigerant (3 processes)1972 + = C3 /MR predominanceMid 90s Open Loop Optimized
10、 Cascade (process changes discussed later)4LNG Process ReliabilityLNG几种工艺的选择及其可靠性600 psi600 psi300 psi300 psi-132 F-132 F-28 F-28 F50 F50 F200 psi200 psiTreatedTreatedNaturalNaturalGasGas1964 (Cascade), 1969 Closed Loop Optimized Cascade1970, 72, 81,82 = Single Mixed Refrigerant (3 processes)600 psi
11、600 psi300 psi300 psi-132 F-132 F-28 F-28 F50 F50 F200 psi200 psiTreatedTreatedNaturalNaturalGasGas121231972 + = C3 /MR predominance34Mid 90s Open Loop Optimized Cascade (process changes discussed later)C3 MR Cycle is in reality a Cascade, BUT- 3 Compressors without “2 in 1” configuration = Less Ava
12、ilability = Less Tonnes/Year = Less Income ($)- 3 Refrigerants: 1 pure and 2 mixed (LMR 7 HMR) = More Complicated Operation = Bigger OPEX5LNG Process ReliabilityLNG几种工艺的选择及其可靠性1964: First LNG Plant using Classical Cascade at 0.3 mmtpa/train (Camel)1969: Phillips Optimized Cascade at 1.5 mmtpa/train
13、(Kenai) First Gas Turbines as drivers First “2 in 1” Configuration Significant Cost Reductions and Reliability improvements (“2 in 1”) Technology Reserved to “Equity Projects”LNG Historical Development (Cont.)Process selection based on: Properties / behavior of refrigerants well known and easy to co
14、ntrol Heat exchange design is straightforward Cycle is easy to design and operate6LNG Process ReliabilityLNG几种工艺的选择及其可靠性Early 70s: Single Mixed Refrigerants (SMR) LNG Historical Development (Cont.)Goals:Reduce number of compressorsReduce number of heat exchangersProcess Changes:Use of ONE single mix
15、ed refrigerant (N2, C1, C2, C3, c4s, C5)Use of ONE exchanger (multistream) with one or two refrigeration pressure level 3 technologies: APCI, TEALARC, PRICOResults:Projects failed to achieve design LNG production capacity (Lower thermal efficiency)Problems revealed after commissioningProduction capa
16、city below Phillips Cascade, Cost Higher.7LNG Process ReliabilityLNG几种工艺的选择及其可靠性1972 mid 90s: APCI C3-MR predominance (no competition) Goals: Overcome Single Mixed Refrigerant capacity and inefficiencies Process Changes: Pre cooling similar to Cascade Liquefaction/ SubCooling: SMR is divided in two
17、mixtures Light (LMR) and Heavy (HMR) Process License requires buying Special Heat Exchanger (SWHE) from the licensor. LNG Historical Development (Cont.)8LNG Process ReliabilityLNG几种工艺的选择及其可靠性 1972 mid 90s: APCI C3-MR predominance (no competition) Results: Increased Capacity Efficiency better than SM
18、R but no better than Cascade Very High Capital Cost compared to Phillips Cascade due to: Monopolistic supply of SWHE Conservative Process Design Margins Restricted # of Contractors with LNG experience Applied EPC bidding strategyTheoretical thermal efficiency improvement generally not achieved in re
19、al operations: Real Feed Conditions require a constant change in MR composition Thermal Efficiency very sensitive to MR composition changes Precise composition LMR and HMR require more complicated control and operation Lower Plant Availability (on stream days) than Phillips because no “2 in 1” confi
20、guration. Drivers / Compressors are in series. If one fails, the whole train shuts down Higher operating costs due to venting and make-up of refrigerants When drivers / compressors trip To adjust MR (almost not done). Normally plant feed is controlled to avoid changingLMR and HMR compositions.9LNG P
21、rocess ReliabilityLNG几种工艺的选择及其可靠性Mid to Late 90s: Effective Cost Reduction is achieved due to: Higher Gas Prices around the world promoted LNG interest due to better economies Competition amongst Licensors re surges: Phillips Technology is open to 3rd parties (Atlantic LNG 1) New licensors appear an
22、d old licensors develop scale ups Linde MFC (Snohvit), Shell DMR (Sakhalin), APCI (AP-X Qatar), Axens Competition amongst Contractors increases: Bechtel building Phillips Cascade Bechtel Open Book EPC contract strategy More realistic plant design margins are used.LNG Historical Development (Cont.)10
23、LNG Process ReliabilityLNG几种工艺的选择及其可靠性AlgeriaUSALibyaAlgeriaBruneiAbu DhabiAlgeriaIndonesiaIndonesiaMalaysiaIndonesiaAustraliaIndonesiaAbu DhabiIndonesiaMalaysiaQatarNigeria, Qatar & TrinidadNigeriaMalaysiaQatarEgyptAustraliaNigeriaEgyptOmanAustraliaTrinidadRussiaEq. GuineaAlgeriaIndonesiaTrinidadNo
24、rwayAverage Capacity (MTPA)LNG Trains Worldwide - Installed to date and Firm ProjectsLNG Train Sizes Past and Future TrendsLNG trains installed within the last ten years have a capacity ranging from 2.0 - 4.5 mtpa.New LNG processes are being developed and have among their primary objectivesTo double
25、 the capacity of actual trains (5.2 - 8+ mmtpa)Improve process efficiencyReduce unit capital costs and operating costs (economy of scale)Nevertheless, train complexities are increasing also exponentiallyAND most of the newer technologies that have been developed, have still not been proven in a comm
26、ercial project.11LNG Process ReliabilityLNG几种工艺的选择及其可靠性LNG Processes Plant Capacity Flagships(only plants indicating a change in process capacity or indicating a new process)12LNG Process ReliabilityLNG几种工艺的选择及其可靠性13LNG Process ReliabilityLNG几种工艺的选择及其可靠性14LNG Process ReliabilityLNG几种工艺的选择及其可靠性CoP Te
27、chnology Reserved for Projects where Cop could have participation C3-MR as the other option for large scale plants. C3-MR requiring the purchase of the special Heat Exchanger Monopolistic supply of SWHE Reduced # EPC contractors with experience- Competition has caused capital cost to converge = Comp
28、etitive FEEDS today consume time (approx 1 year) and money- Optimized Cascade is getting approx. 50% of new proven technology Grassroot Projects- Next Technical Selection Criterias: 1.- Total Production / Year = Availability, Maintainability, Product & Refrigerants Loss during process upsets and mai
29、ntenance 2.- Construction Schedule = CoP Technology has the shortest Construction Schedule 3.- Operating Costs = annual operating expenses below industry estimation of 3% total capital expenditures15LNG Process ReliabilityLNG几种工艺的选择及其可靠性Considerations for Future LNG Projects: Factors tending to incr
30、ease CAPEX cost In 2005, 2006 75 Billion$ are expected to be required for LNG projects against 27 available in 2004International Steel Price Workload on EPC contractors Project Finance Demands 16LNG Process ReliabilityLNG几种工艺的选择及其可靠性CoP Technology Reserved for Projects where Cop could have participa
31、tion C3-MR as the other option for large scale plants. C3-MR requiring the purchase of the special Heat Exchanger Monopolistic supply of SWHE Reduced # EPC contractors with experience- Competition has caused capital cost to converge = Competitive FEEDS today consume time (approx 1 year) and money- O
32、ptimized Cascade is getting approx. 50% of new proven technology Grassroot Projects- Next Technical Selection Criterias: 1.- Total Production / Year = Availability, Maintainability, Product & Refrigerants Loss during process upsets and maintenance 2.- Construction Schedule = CoP Technology has the s
33、hortest Construction Schedule 3.- Operating Costs = below industry estimations of 3% of CAPEX17LNG Process ReliabilityLNG几种工艺的选择及其可靠性Note: The cost of 2 LNG tanks (120.000 m3/each) is approx. 73 MM$ 1.- Total Production year Availability18LNG Process ReliabilityLNG几种工艺的选择及其可靠性C3 MR Cycle is in reali
34、ty a Cascade, BUT- 3 Compressors without “2 in 1” configuration = Less Availability = Less Tonnes/Year = Less Income ($)- 3 Refrigerants: 1 pure and 2 mixed (LMR 7 HMR) = More Complicated Operation = Bigger OPEX1.- Total Production year Availability600 psi600 psi300 psi300 psi-132 F-132 F-28 F-28 F5
35、0 F50 F200 psi200 psiTreatedTreatedNaturalNaturalGasGas121233419LNG Process ReliabilityLNG几种工艺的选择及其可靠性Typical “2 x 1” configuration applied in Kenay and Trinidad600 psi600 psi300 psi300 psi-132 F-132 F-28 F-28 F50 F50 F200 psi200 psiTreatedTreatedNaturalNaturalGasGas1.- Total Production year Availab
36、ility20LNG Process ReliabilityLNG几种工艺的选择及其可靠性Source: “LNG Technology Selection”, Dr. Tariq Shukri, Hydrocarbon Engineering, Feb 2004Source: “Relibility Study of an LNG Complex” Hamad (Qatar LNG), Wilson (Brown &Root), Duchemin (Total), Vega (KBR)Source: Relibility and Capacity Improvement of a Base
37、Load LNG Plant” Hadiono, Harsono, Djamil, Pertamina, Arun LNGSource: “Avaiilability of Refrigeration Process of Baseload LNG Plants”, Kikkawa, Chiyoda Corporation, AIChE Spring Meeting 20051.- Total Production year Availability21LNG Process ReliabilityLNG几种工艺的选择及其可靠性Source: C3- MR Availability: Oman
38、 = 92 94.2%1.- Total Production year Availability22LNG Process ReliabilityLNG几种工艺的选择及其可靠性Source: “20 Years operating experience of steam-driven sea water cooling in Badak LNG plant”. Sutopo, Musamma, LNG 12 Conference.Note: Capacity Factors are above 100% due to plant capacity debottlenecking projec
39、ts including uprating propane and MCR compressors. See source.1.- Total Production year AvailabilityC3- MR Availability: Badak = 84 95 %23LNG Process ReliabilityLNG几种工艺的选择及其可靠性Sources:=148C3- MR Availability: Algeria, GL-1Z, 12 years 60 %1.- Total Production year AvailabilitySource: “LNG 1 Plant Rev
40、amping Project: Improvement and debottlenecking”, LNG 12 Conference, Bounouara, Benmoulai, Sonatrach, Bethioua, Algeria, GL1Z LNG Plant24LNG Process ReliabilityLNG几种工艺的选择及其可靠性CoP Technology Reserved for Projects where Cop could have participation C3-MR as the other option for large scale plants. C3-
41、MR requiring the purchase of the special Heat Exchanger Monopolistic supply of SWHE Reduced # EPC contractors with experience- Competition has caused capital cost to converge = Competitive FEEDS today consume time (approx 1 year) and money- Optimized Cascade is getting approx. 50% of new proven tech
42、nology Grassroot Projects- Next Technical Selection Criterias: 1.- Total Production / Year = Availability, Maintainability, Product & Refrigerants Loss during process upsets and maintenance 2.- Construction Schedule = CoP Technology has the shortest Construction Schedule 3.- Operating Costs = annual
43、 operating expenses below industry estimation of 3% total capital expenditures25LNG Process ReliabilityLNG几种工艺的选择及其可靠性Source: BG Group plcCoP Optimized Cascade are the shortest2.- Construction Schedules26LNG Process ReliabilityLNG几种工艺的选择及其可靠性Egypt Idku-2 (CoP ) will be concluded 6 months ahead2.- Co
44、nstruction SchedulesThe Value of: Standardization Template Design Incorporation of Lessons Learned(See paper “Egyptian LNG, The Value of Standardization”, Gastech 2005, Redding, Hernandez, Qualls, Avidan)27LNG Process ReliabilityLNG几种工艺的选择及其可靠性C3- MR Power Consumption: Sensitivity to Optimum MR comp
45、ositionSource: CoP Bechtel LNG Product Development CenterSource: LNG Liquefier Cycle Efficiency, Liu, Daugherty, Brofenbrenner, APCI, LNG 12 Conference, Perth Australia 4-7 May 1998Although, in design, C3/MR requires a little less work than Cascade to produce LNGAny small variation in MR composition
46、 or Feed Gas condition (pressure, temperature, composition) will offset the optimum point and the C3/MR will require even more energy than cascade3.- Operating Expenditures28LNG Process ReliabilityLNG几种工艺的选择及其可靠性- In theory, the “continuous” closer approaches, reduces the required kW/Ton LNG- In pra
47、ctice, changes in composition will require changes in MR composition, hence:1.- MR composition is changed, affecting negatively the thermal efficiency (see review of thermal efficiency above)Or2.- MR composition is not changed, affecting also the thermal efficiency (see slide Power Consumption and M
48、R Composition)C3- MR Power Consumption: “Continuous” Temperature Approach requires “continuous” MR composition adjustment.3.- Operating Expenditures29LNG Process ReliabilityLNG几种工艺的选择及其可靠性Source: Availability and Efficiency Improvement of Badak LNG Plant”, Makfud, Sutopo, Bontang, East Kalimantan, A
49、IChe.C3- MR Thermal Efficiency: Badak = 85 - 89%3.- Operating Expenditures30LNG Process ReliabilityLNG几种工艺的选择及其可靠性Non Proven Technologies = Increased Technological Risks = Increased Construction and Startup Schedules-Despite the extended experience of the Compressor Manufacturer with MR mixtures,- S
50、ome adjustments (delays) were required to match compressors to performance specifications31LNG Process ReliabilityLNG几种工艺的选择及其可靠性Sources:-“Indonesias Arun LNG plant nears completion”, O&GJ, Mar 13, 1978, pag. 62- “Badak LNG plants first two years is impressive operating experience”- “Comparing five
51、LNG processes”, Paradowski, Hydrocarbon Engineering, October 2003, pag.33- “PRICO A proven, low cost liquefaction alternative”, LNG Conference, Boumaza (Skikda), Rousset (Sofragaz), Price (Pritchard)- “MFCs3 the formula for high capacity LNG base load plants”, Bauer, Franke, Schier, Linde, AIChE 200
52、4 Spring Meeting. -Cascade compositions, several articles and Product Development Center StudiesRange of Feed Compositions for Proven TechnologiesCoP Optimized Cascade: is the only technology proven in very dry (lean) gases where refrigerant imports / manufacture is critical and the liquefaction process is more difficult. consistently produces more LNG per MMSCFD received 32LNG Process ReliabilityLNG几种工艺的选择及其可靠性Thank You!33LNG Process ReliabilityLNG几种工艺的选择及其可靠性Questions?34LNG Process ReliabilityLNG几种工艺的选择及其可靠性
