LNG Process Overview
C Poh
PTU/L - LNG
June 2012
Shell Projects & Technology
RESTRICTED
June 2012
1
Agenda
LNG Characteristics
Terminology
Why LNG?
LNG Value Chain
The LNG Plant
MMLS
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
2
LNG Characteristics
What are the key characteristics of LNG?
LNG consists mainly of methane (C1)
Liquefied Natural Gas (LNG) is a colourless, cryogenic liquid
LNG has an atmospheric boiling point of –163 ºC to –160 ºC
Depending on composition, LNG has a density of 450 – 465 kg/m3
1 m3 of LNG at atmospheric pressure equals 600 sm3 of gas
… and what are the consequences of these characteristics?
LNG is very cold → when spilt, it will cause frostbite on your skin
LNG in ambient conditions vaporizes quickly → it needs to be kept
in cryogenic insulated storage (= expensive and heavy)
Even when stored in a cryogenic tank, some LNG will vaporize →
this should be addressed in any design
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
3
Terminology
Sales Gas
LNG Feed
GTL Feed
Impurities
WATER
CO2 H2S HG
NITROGEN
Associated
Gas
METHANE
NGLs
Ethane
80 - 95 MOL%
LNG
/ Grid
Propane
Wellhead
Fluid
Butane
ETHANE
Condensate
NGL
Crude Oil
SHELL – PROJECTS & TECHNOLOGY
LPG’s
PROPANE
BUTANE
C5+
RESTRICTED
4
Why LNG?
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
5
Gas schemes
Pipeline gas scheme
treating
Transmission
& recompression
distribution
LNG chain
transmission
distribution
Deep treating
& Liquefaction
SHELL – PROJECTS & TECHNOLOGY
LNG storage
& loading
Shipping
Receiving terminal
& re-gasification
RESTRICTED
6
Cost
Comparison of transportation methods
VLCC
Distance
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
7
LNG Value Chain
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
8
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
9
The LNG PLant
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
10
Block Flow Diagram: LNG plant
CO2, Sulphur,
ACID GAS
INCINERATOR
Natural
gas
H2O,
Mercury
Inlet
Station
Treating &
Drying
Field
Condensate
Water
Air or water
Cooling
Storage &
Loading
Liquefaction
LNG
Fractionation
LPG
Plant
Condensate
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
11
Slug catcher
Gas to
AGRU
Liquids to
Fractionatio
n Unit
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
12
Fractionation / NGL extraction
C1/C2
reinjected
back to LNG
or routed to
Fuel gas
system
LPG /
Condensate to
storage
Typical fractionation unit: Demethanizer-Deethanizer-Depropanizer-Debutanizer
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
13
Acid gas removal – Molsieve dehydration – Mercury
removal
Gas from
Slug
catcher
Wet gas to
Molsieve
Hg
guard
bed
SHELL – PROJECTS & TECHNOLOGY
Dry mercury free
gas to liquefaction
RESTRICTED
14
Liquefaction unit
Main Cryogenic Heat
Exchanger (MCHE)
Typical liquefaction circuit
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
15
LNG storage & loading
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
16
LNG Technology
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
17
Principle of mechanical refrigeration
Heat
Example:
first level of
propane cooling
Cooler
Air, 30 °C
Power
propane
20 bar
80 °C
57 °C
Compressor
Gasturbine
4.7 bar
0 °C
J-T value
Heat
46 °C
SHELL – PROJECTS & TECHNOLOGY
Natural
gas
Heat exchanger
3 °C
RESTRICTED
18
C3/MR
LNG
LNG
-161 C
-161 C
-120 C
-120 C
-30 C
Ethane
Methane
-123 C
….
-33 C MR
-30 C
…. ……
Methane
-123 C
-33 C MR
Ethane
Propane
Propane
NG
SHELL – PROJECTS & TECHNOLOGY
NG
RESTRICTED
19
MMLS
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
20
MMLS – Movable Modular Liquefaction System
Unique Shell concept, developed in US
Containerised mini-scale LNG facility
 Limited site preparation work required, simple to install and to redeploy
 Capacity around 0.25 Mtpa (multiple units for higher capacity)
 Generally international standards applied with Shell safety requirements and LNG experience
overlayed
 Costs similar to ‘conventional’ mini-scale LNG
Designed in collaboration with fabrication company with track record in mini/micro scale LNG
FEED for generic MMLS completed
 Standardized design allows global deployment
 Plug & Play functionality with optional units allows tailoring to individual opportunities without
design change (e.g. power generation, LPG & condensate export, feed-gas compression)
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
21
MMLS: Combination of Shell’s world leading LNG experience
and cost effective small scale equipment packaging.
• Combination of Shell’s world leading LNG experience and
cost effective small scale equipment packaging
Moveable Modular Liquefaction System (Full system
• Capacity 0.1-0.25 mtpa (15-40 mmscfd feed gas)
• Standardized design for range of gas compositions and air
temperatures using only proven technology.
• Requires very limited site/country specific adaptation. Allows
pre-ordering before permits.
• fully packaged on road transportable skids including pipe
racks and utilities.
• Fully pre-commissioned at Vendor
• 24 month or less design/fabricate/install/Commission
schedule
• Completed all design and project maturation and internal
safety reviews and assurance activities to similar depth as
“large Shell LNG project”.
Typical equipment skid
• Production Performance guarantee by Shell similar to “large”
LNG
• Final Investment Decision for Canada Fuels project taken. To
be announced Sept 9.
• Same plant will work at Cameron with addition of optional
C5+ stripping column.
• Shell has priced options for additional units.
• Shell has mechanism in place to manage and assure delivery
of multiple
packages.
SHELLplant
– PROJECTS
& TECHNOLOGY
RESTRICTED
22
DESIGN FEATURES
Basic features
Optional features
Capacity 15-30 MMSCFD feed gas (0.10.25 mtpa LNG)
Feed gas compression (up to 60 bar)
Feed gas source: raw well gas, pipeline gas
TSA molsieve for CO2 removal (up to 0.25
mol%)
Simple inlet separation (no slugcatcher)
Fractionation units (Deethaniser,
Debutaniser)
Operating pressure 40 bar – 60 bar
LPG, condensate storage
Amine system to remove up to 3% CO2 and
34 ppm H2S
Power generation facilities
TSA molsieve dehydration
Guard beds for trace contaminants removal
Cold box and demethaniser
MR compressor
LNG storage
Flare system
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
23
Chart Cold Box
Brazed fin aluminum heat exchanger
used in majority of small scale LNG
and peak shaving plants.
Chart is major supplier of this type
exchanger.
Many units in service in Shell in NGL
plants, etc
LNG Plant design by Salof and Shell.
Shell have gone thru full review of
Chart equipment according to internal
technology release process for use in
LNG service.
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
24
MMLS – Process Block FLOW Diagram
Blue blocks, in several cases not required
Full MMLS contains about 100 container size modules
Typical application requires about 60 modules
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
25
Layout
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
26
MMLS – LNG
For Transport
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
27
Conventional Supply Chain versus LNG in Transport
LNG Carrier
Regas Terminal
CONVENTIONA
L
Power Plant
LNG Refuelling
Station
LNG
Trailer Truck
Small Scale
Liquefaction
LNG
Fuelled Truck
ROAD
Small Terminal
LNG
Bunker Vessel
Small LNG Carrier
SHELL – PROJECTS & TECHNOLOGY
LNG
Fuelled Vessel
RESTRICTED
MARINE
28
Canadian Green Corridor Project
1 MMLS unit near Calgary at existing Shell site
Process pipeline gas into LNG fuel for Trucks, Drill rigs, Mining,
Rail.
Final investment decision taken August 2011
Plant contract award planned for Oct 2011
Part of Global LNG fuels strategy
Startup 2013
SHELL – PROJECTS & TECHNOLOGY
Typical equipment skid
RESTRICTED
29
CGC Project - First MMLS Application
EXAMPLE:
COMMERCIALISING LNG FOR
TRANSPORT
Fort Mc
Murray
Fort St
John
Grande
Prairie
Canada Green Corridor FID 2011
 FID for 0.3 mtpa LNG
 Long distance truck fuel
 LNG retail infrastructure
Edmonton
Calgary
Vancouve
r
Jumping Pound
ENGINES MODIFIED FOR LNG LNG POWERED TRUCK
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
30
ACCESS
TO KEY
STRATEGI
C
MARKETS
SHELL’S GLOBAL LNG PORTFOLIO
ALTAMIRA
BAJA
COVE POINT
ELBA ISLAND
DUBAI
HAZIRA
SPAIN
LNG FOR
TRANSPORT
SHIPPING
GREEN
CORRIDOR
ARKAT
EXPORT
BRUNEI LNG
MALAYSIA LNG
LNG - OPERATION
LNG - CONSTRUCTION
REGAS POSITION - OPERATION
NORTH WEST
SHELF
SAKHALIN II
PLUTO
(WOODSIDE)*
QATARGAS 4
NIGERIA LNG
OMAN LNG
QALHAT*
WHEATSTONE
LNG
PRELUDE
GORGON LNG
* Indirect Interest
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
31
Movie – MMLS
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
32
SHELL – PROJECTS & TECHNOLOGY
33
RESTRICTED
33
Cascade process
LNG
-161 C
-164 C
Methane
-100 C
Ethylene
-103 C
-30 C
Propane
NG
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
34
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
35
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
36
LNG Liquefaction technology
C3/MR [APCI, Shell] majority of the LNG plants
Optimised Cascade Process [Philips] [Darwin; Trinidad]
DMR [Shell] [Sakhalin]
SMR [APCI] [Libya]
MFCP [Linde] [Snohvit]
C3-MR-N2 (AP-X) [APCI ] [Qatar]
C3 PMR [Shell]
Liquefin [Axens]
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
37
LNG Regas Terminal
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
38
Block Flow Diagram: LNG Regas Terminal
Pipeline
Compressor
Vent/Flare
LNG
Carrier
BOG
Compressor
Vapour
Return Arm
N2
Injection
Unit
Unloading
Arms
Recondenser
In-tank
Pumps
Vaporisers
LNG
Tanks
HP
Pumps
Metering
Station
Odorization
N2 Injection
Unit
Instrument
Air
Electricity
Nitrogen
Potable
water
Seawater
Fuel gas
SHELL – PROJECTS & TECHNOLOGY
Firewater
Dotted lines indicate Optional Units
RESTRICTED
39
39
Regas Technology
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
40
Open Rack Vaporizer (ORV)
 Consists of panels with a large number of heat transfer tubes
 Excellent operating experience & safety record
 Heat medium is seawater, low energy consumption
 More susceptible to seawater quality
 Gas temperature limited by SW temp.
 Cannot be used in cold climates
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
41
41
Submerged Combustion Vaporizer (SCV)
 Proven experience
 Heat source is from burning NG
 Fuel rate: 1.3 – 1.5% of gas throughput – can be costly!
 Allows high gas sendout temperatures
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
42
42
Shell & Tube Vaporizer (STV)
•
Shell & tube heat exchanger with closed loop heating
medium
•
Heating medium – water/glycol heated by gas fired heaters
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
43
43
Ambient Air Vaporizer (AAV)
•
Air cooled heat exchanger
•
Heat source is air with supplemental heat
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
44
44
Hybrid Vaporizer (SPX/SCV)
•
Closed loop recirculation system with heat source from air
•
Air tower serves as heating function
•
Supplemental heat from SCV during winter
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
45
45
Intermediate Fluid Vaporizer (IFV)
•
•
•
•
•
•
Some operating experience
Low energy consumption
Less susceptible to seawater quality – titanium tubes
Gas temperature limited by SW temp.
Cannot used in cold climates
Require intermediate fluid – e.g. propane, butane
LNG Vaporizer
LNG Vaporization
I.F. Condensation
NG
I.F. Vaporization
NG Heating
LNG
I.F. Vaporizer
Sea
Water
NG Heater
Sea Water
SHELL – PROJECTS & TECHNOLOGY
RESTRICTED
46
46