LNG Process ReliabilityLNG几种工艺的选择及其可靠性ppt课件.ppt

ImpactsofProcessSelectiononLNGPlantReliability AttilioJ Praderio 1920 Airliquefactioncryogenicsdeveloped1930s early Heliumrecoveryfromnaturalgasformilitarypurposes militaryballoons AfterHeliumrecovery NaturalGaswasrevaporizedandsoldaspipelinegas 1934 W J Podbielniakfiledandreceivedapatentforamixedcomponentrefrigerantsystemhavingthreestagesoffluidthrottlingandasinglecompressorinaclosedsystem 1939 firstLNGmanufacturingandstorageplantbuiltbyHopeNaturalGasCo asubsidiaryofConsolidatedNaturalGasSystems 1941 EastOhioGasCo builtapeakshavingplantinCleveland 1944 Accidentin2ndStoragetankofClevelandplantarrestedthegrowthofUSALNGindustryfor20years Thefailurewascausedbyinadequatemetallurgyusedinthetank 1956 Haseldenconsideredamixedrefrigerantprocessutilizingtwocompressorsinaclosedcycleforliquefactionofnaturalgas Hepointedouttheadvantageofobtainingtherefrigerantcomponentsfromnaturalgasitself 1959 A P KleemenkooftheInstituteofGasResearchAcademyofSciences U S S R describedaworkingapparatusemployingeitheranopenorclosedsinglefluid mixedcomponentrefrigeration LNGHistoricalDevelopment 2 1964 Oct7 firstcargoexportfromthevanguardplantCamellocatedinArzew Algeria Cascade TEAL LNGexportedtoU K 1965 fisrttwoU S LNGplantscommissioned21yearsafterClevelandincident builtbyAlabamaGasandTranscontinentalGasPipelineCorp 1966 J Perret Technip sScientificDirectordescribedmixedrefrigerantprocessesfornaturalgas1969 Kenaiplant Alaska usingCascade PhillipsOptimized GasTurbinesusedasdriversforthefirsttime 1970 GaumerandNewtowndescribedaMultiComponentRefrigerantAPCI MCR 1970 MarsaElBregaplant Libya usingSingleMixedRefrigerant APCIMCR lowthermalefficiency 1972 Skikda Algeria plantusingDualPressureMR TEAL1972 Lumutplant Brunei usingC3 MR APCI1972 1981 6plantsC3 MR APCI1981 1982 Skikda Algeria usingPRICO Pritchard1983 1999 14plantsC3 MR APCI1999 AtlanticLNG1 TrinidadCascade PhillipsOptimizedCascade LNGHistoricalDevelopment 3 1964 Cascade 1969ClosedLoopOptimizedCascade 1970 72 81 82 SingleMixedRefrigerant 3processes 1972 C3 MRpredominance Mid90sOpenLoopOptimizedCascade processchangesdiscussedlater 4 1964 Cascade 1969ClosedLoopOptimizedCascade 1970 72 81 82 SingleMixedRefrigerant 3processes 1 2 1 2 3 1972 C3 MRpredominance 3 4 Mid90sOpenLoopOptimizedCascade processchangesdiscussedlater C3 MRCycleisinrealityaCascade BUT 3Compressorswithout 2in1 configuration LessAvailability LessTonnes Year LessIncome 3Refrigerants 1pureand2mixed LMR7HMR MoreComplicatedOperation BiggerOPEX 5 1964 FirstLNGPlantusingClassicalCascadeat0 3mmtpa train Camel 1969 PhillipsOptimizedCascadeat1 5mmtpa train Kenai FirstGasTurbinesasdriversFirst 2in1 ConfigurationSignificantCostReductionsandReliabilityimprovements 2in1 TechnologyReservedto EquityProjects LNGHistoricalDevelopment Cont Processselectionbasedon Properties behaviorofrefrigerantswellknownandeasytocontrolHeatexchangedesignisstraightforwardCycleiseasytodesignandoperate 6 Early70s SingleMixedRefrigerants SMR LNGHistoricalDevelopment Cont Goals ReducenumberofcompressorsReducenumberofheatexchangersProcessChanges UseofONEsinglemixedrefrigerant N2 C1 C2 C3 c4s C5 UseofONEexchanger multistream withoneortworefrigerationpressurelevel3technologies APCI TEALARC PRICOResults ProjectsfailedtoachievedesignLNGproductioncapacity Lowerthermalefficiency ProblemsrevealedaftercommissioningProductioncapacitybelowPhillipsCascade CostHigher 7 1972 mid90s APCIC3 MRpredominance nocompetition Goals OvercomeSingleMixedRefrigerantcapacityandinefficienciesProcessChanges PrecoolingsimilartoCascadeLiquefaction SubCooling SMRisdividedintwomixturesLight LMR andHeavy HMR ProcessLicenserequiresbuyingSpecialHeatExchanger SWHE fromthelicensor LNGHistoricalDevelopment Cont 8 1972 mid90s APCIC3 MRpredominance nocompetition Results IncreasedCapacityEfficiencybetterthanSMRbutnobetterthanCascadeVeryHighCapitalCostcomparedtoPhillipsCascadedueto MonopolisticsupplyofSWHEConservativeProcessDesignMarginsRestricted ofContractorswithLNGexperienceAppliedEPCbiddingstrategyTheoreticalthermalefficiencyimprovementgenerallynotachievedinrealoperations RealFeedConditionsrequireaconstantchangeinMRcompositionThermalEfficiencyverysensitivetoMRcompositionchangesPrecisecompositionLMRandHMRrequiremorecomplicatedcontrolandoperationLowerPlantAvailability onstreamdays thanPhillipsbecauseno 2in1 configuration Drivers Compressorsareinseries Ifonefails thewholetrainshutsdownHigheroperatingcostsduetoventingandmake upofrefrigerantsWhendrivers compressorstripToadjustMR almostnotdone NormallyplantfeediscontrolledtoavoidchangingLMRandHMRcompositions 9 MidtoLate90s EffectiveCostReductionisachieveddueto HigherGasPricesaroundtheworldpromotedLNGinterestduetobettereconomiesCompetitionamongstLicensorsresurges PhillipsTechnologyisopento3rdparties AtlanticLNG1 NewlicensorsappearandoldlicensorsdevelopscaleupsLindeMFC Snohvit ShellDMR Sakhalin APCI AP X Qatar Axens CompetitionamongstContractorsincreases BechtelbuildingPhillipsCascadeBechtelOpenBook EPCcontractstrategyMorerealisticplantdesignmarginsareused LNGHistoricalDevelopment Cont 10 LNGTrainSizes PastandFutureTrends LNGtrainsinstalledwithinthelasttenyearshaveacapacityrangingfrom2 0 4 5mtpa NewLNGprocessesarebeingdevelopedandhaveamongtheirprimaryobjectivesTodoublethecapacityofactualtrains 5 2 8 mmtpa ImproveprocessefficiencyReduceunitcapitalcostsandoperatingcosts economyofscale Nevertheless traincomplexitiesareincreasingalsoexponentiallyANDmostofthenewertechnologiesthathavebeendeveloped havestillnotbeenproveninacommercialproject 11 LNGProcessesPlantCapacityFlagships onlyplantsindicatingachangeinprocesscapacityorindicatinganewprocess 12 13 14 15 ConsiderationsforFutureLNGProjects FactorstendingtoincreaseCAPEXcost In2005 200675Billion areexpectedtoberequiredforLNGprojectsagainst27availablein2004 InternationalSteelPrice WorkloadonEPCcontractors ProjectFinanceDemands 16 CoPTechnologyReservedforProjectswhereCopcouldhaveparticipation C3 MRastheotheroptionforlargescaleplants C3 MRrequiringthepurchaseofthespecialHeatExchangerMonopolisticsupplyofSWHEReduced EPCcontractorswithexperience Competitionhascausedcapitalcosttoconverge CompetitiveFEEDStodayconsumetime approx1year andmoneyOptimizedCascadeisgettingapprox 50 ofnewproventechnologyGrassrootProjectsNextTechnicalSelectionCriterias 1 TotalProduction Year Availability Maintainability Product RefrigerantsLossduringprocessupsetsandmaintenance2 ConstructionSchedule CoPTechnologyhastheshortestConstructionSchedule3 OperatingCosts belowindustryestimationsof3 ofCAPEX 17 Note Thecostof2LNGtanks 120 000m3 each isapprox 73MM 1 TotalProductionyear Availability 18 C3 MRCycleisinrealityaCascade BUT 3Compressorswithout 2in1 configuration LessAvailability LessTonnes Year LessIncome 3Refrigerants 1pureand2mixed LMR7HMR MoreComplicatedOperation BiggerOPEX 1 TotalProductionyear Availability 1 2 1 2 3 3 4 19 1 TotalProductionyear Availability 20 Source LNGTechnologySelection Dr TariqShukri HydrocarbonEngineering Feb2004 Source RelibilityStudyofanLNGComplex Hamad QatarLNG Wilson Brown Root Duchemin Total Vega KBR Source RelibilityandCapacityImprovementofaBaseLoadLNGPlant Hadiono Harsono Djamil Pertamina ArunLNG Source AvaiilabilityofRefrigerationProcessofBaseloadLNGPlants Kikkawa ChiyodaCorporation AIChESpringMeeting2005 1 TotalProductionyear Availability 21 Source C3 MRAvailability Oman 92 94 2 1 TotalProductionyear Availability 22 Source 20Years operatingexperienceofsteam drivenseawatercoolinginBadakLNGplant Sutopo Musamma LNG12Conference Note CapacityFactorsareabove100 duetoplantcapacitydebottleneckingprojectsincludingupratingpropaneandMCRcompressors Seesource 1 TotalProductionyear Availability C3 MRAvailability Badak 84 95 23 Sources 148 C3 MRAvailability Algeria GL 1Z 12years 60 1 TotalProductionyear Availability Source LNG1PlantRevampingProject Improvementanddebottlenecking LNG12Conference Bounouara Benmoulai Sonatrach Bethioua Algeria GL1ZLNGPlant 24 25 Source BGGroupplc CoPOptimizedCascadearetheshortest 2 ConstructionSchedules 26 EgyptIdku 2 CoP willbeconcluded6monthsahead 2 ConstructionSchedules TheValueof StandardizationTemplateDesignIncorporationofLessonsLearned Seepaper EgyptianLNG TheValueofStandardization Gastech2005 Redding Hernandez Qualls Avidan 27 C3 MRPowerConsumption SensitivitytoOptimumMRcomposition Source CoP BechtelLNGProductDevelopmentCenter Source LNGLiquefierCycleEfficiency Liu Daugherty Brofenbrenner APCI LNG12Conference PerthAustralia4 7May1998 Although indesign C3 MRrequiresalittlelessworkthanCascadetoproduceLNG AnysmallvariationinMRcompositionorFeedGascondition pressure temperature composition willoffsettheoptimumpointandtheC3 MRwillrequireevenmoreenergythancascade 3 OperatingExpenditures 28 Intheory the continuous closerapproaches reducestherequiredkW TonLNG Inpractice changesincompositionwillrequirechangesinMRcomposition hence 1 MRcompositionischanged affectingnegativelythethermalefficiency seereviewofthermalefficiencyabove Or2 MRcompositionisnotchanged affectingalsothethermalefficiency seeslidePowerConsumptionandMRComposition C3 MRPowerConsumption Continuous TemperatureApproachrequires continuous MRcompositionadjustment 3 OperatingExpenditures 29 Source AvailabilityandEfficiencyImprovementofBadakLNGPlant Makfud Sutopo Bontang EastKalimantan AIChe C3 MRThermalEfficiency Badak 85 89 3 OperatingExpenditures 30