TECH CORNER SMALL-SCALE LNG PLANTS Using mixed refrigerants for small-scale LNG plants Several factors responsible for increasing demand for plants . By Cristiana Guastaroba ‘supply. Within this sector, the demand for Cocco works 2¢ proposal manager of Cees Cd Se eens ey eer ae na Pee ene eee eed ee Se ee iy eins z & E z = 8 a Ss 5 = 138 compaessoareote UL" 2019 easily to remote regions that would be impractical to service with fixed pipelines; LNG vessels can be diverted easly thereby providing higher confidence in security of ‘supply for major gas-importing nations 1m Power generators aready favor gas over coal asi emits around half the CO to the ‘atmosphere. At the same time, companies ate finding new markets for LNG for use in toad vehicles, ships and many other applications (see Fi: ‘SSLNG applications GEX's capability and technology inthis, ‘market covers mini-medium-size iquification ants, those supplying up to 1 SMTA (miion tons per annum) of ING (see Fig:2). These serve applications such as: peak shaving plants -typicaly used for storing surplus natural gas to meet the sudden consumption requirements due to extreme cold weather or heat waves: satelite LNG plants forges transport where there sno pipeline: on- board ship liquefaction Bo-off Gas (806) re-iquefaction coal bed methane recovery ‘and biogas and bio-methane, landfill gas and ‘shale gas liquefaction, The technology used fo iquetying natural ‘92s for easy storage and transportation is not new. However, as with so many other industrial processes, itis the experience behind the process that helps to ensure that the design, building, commissioning ‘and continued operation of a new SSLNG Plants smooth tis alsa essential to ‘standarclize technology and processes ‘a far as possible to minimize design and construction costs and to allow plants tobe ‘supplied as pre-assembled modular units, SSING plant design ‘The design objectives of a SSING piant are process simplicity, safety, easy operation low cost, reliability and quick delivery time. ‘The processes for quefying natural gas can be classified into three groups: cascade, mixed refrigerant (MR) and expansion-ased processes. Each typehas its own strengths Gas Reserves Gas Pretreatment a Small-scale LNG PlantSen iter eer) refrigeration loop that RECUR Reng RUC deele inet ace} BS yer eens (hell CL ‘and weaknesses so the choice for each ‘application depends the plant size and capacity (train size), safety considerations ‘and space constraints, ‘GEA considers the use of MR to.be one of the most efficent options for many ‘applications. Using MR creates a efigeration loop that matches very closely the cooling curve of atypical gas liquefaction, to ‘achieve high refrigeration efficiency and reduce energy consumption. GEA's prefered solution for natural gas liquefaction uses aretrigeration unt with multiple operation pressure levels, lash drums and a heat ‘exchanger to liquify the gas (see Fig: 8). The refigerant of choice isa mixture of hydrocarbons and nitrogen, that can ‘approach the methane cooing curve. ‘Toreach the extremely cold or cryogenic temperatures required to produce LNG (around -160°C (-256°F), ts necessary to ‘Compress the MR and remove excess heat through air or water coolers The primary Se lila tains en igs. LNG transport TECH CORNER ‘SMALL-SCALE LNG PLANTS 7 ery oe cen ere Mata 2 3 340 (2x170) 34 290.000 140 (2x70) 14 120.000 2 : 0 7 eno 2@ 70 (2x35) 7 60.000 2 E B35 om 4508350 Based on 8000 hiy objectives are to optimize the efficiency ofthe process while keeping costs toa minimum. Composition of the refrigerant mixture The choice ofthe optimum blend of refrigerant depends on the composition of thenatural gas. the utes avaiable forthe condensation of the refrigerant and the final product requirements, For example, higher molecular weight componentsin the mixed refrigerant tend Fueling vehicles sha Industrial users Residential users to.condense during the compression stage. ‘The WRis composed largely from the ‘same elements that are used in cascade processes Ci, C2 and C3.Tolower the minimum temperature, necessary for the cooling inthe final part of the curve of the natural gas, tis necessary to introduce a {action of an even lower baling component ‘of methane. in contrast, to improve heat, ‘exchange conditions at the stat of the process.i's necessary to add a higher boling hydrocarbon C4 andlor C5. Ingeneral, the MR wil comprise around 10% nitrogen. Tis willincrease as the required output temperature ofthe LNG decreases. This may be necessary if there is high level of nitrogen in the natural gas rif the process requires a significant break ‘down of the re-evaporation after the final lamination. Less nitrogen may be used if the natural gas does not contain ritrogen and is sufficiently ich in ethane. In principle, as the nitragen leven the natural gas increases so the ratio (R) between the molar lw rates of the MR, ‘compared with that ofthe natural gas, increases. This, in turn, increases the cost of liquiication Ratio (R)= motar flow ofthe MR molar flow of the natural gas uty 2019) CoMPRESsORTECH" 38TECH CORNER ‘SMALL-SCALE LNG PLANTS GEA oil injected screw compressor Compression Train Reserve/ Associated NG from Wellipeline Refrigeration Unit . Mixed refrigerant (Na, Methane, Ethylene, Butane...) Methane and nitrogen together usually form around one third of the MR. This can be as low as one quarter ofthe total If theres alow evel of nitrogen and a very high ethane levet in the natural gas. Ethylene is the most important Component of the MR asit can exchange ‘most ofthe latent heat of condensation from the natural gas. Propane, butanes and pentanes represent around one quarter ofthe MR. MERU Pee aa RUE dU cor lis ( TORU dai 40) compeessoarect JULY 2019, eu GAS TREATMENT Section Dew point control COs, HaS Sweetening AGRU (H:S 4 ppm & CO 50 ppm) ‘Dehydration (0,1 ppm) Hg Removal (0,01 ua/Hms) ate Liquefaction Train Gia injected screw compressor ‘As the molecular weight of the [MR increases, so (R) decreases and, witht, the costs of quification. Unfortunately, however, an excessive Increase in molecular weight can create Incipient thermal crossing zones that cause the overallheat exchange capacity of the ‘main exchanger to collapse. This results na fallin the overall capacity of the plant. Experience to support innovation In perfecting the techniques for efficient SSSING production, at GEA we have ‘combined decades of experience in process refrigeration design, manufacture and ‘operation, with extensive testing using process simulation techniques. ‘Asan example, for aliquetaction ‘capacity of 35 tons per hour, we have found ‘our own cilflooded screw compressors and cryogenic brazed aluminum heat NGL d Refrigerar BOG Gea oil injected sre ‘compressor LNG Storage = 170°C, P atm. or different storage conditions exchangers tobe most effective. ‘The process design and auxiiay oil ‘removal system guarantee negigible al evel inthe compressor discharge. This prevents the carryover through the cryogenic system ‘and avoids blockages ofthe channels within the main heat exchanger. The ‘choice of the operative parameters is 2 delicate balance between operative and investment cost andthe utities present at the site. The compressor selected depends ‘onthe duty required and the specific ‘application. GEA engineers will make precise recommendations in each case. In simulations using specialized ‘software to determine power consumption ‘and ta quide compressor selections, GEA thas shown that optimizing the quitying of natural gas with MR consumes approximately 400 kW of energy per ton of LNG, inline with expected values. cre