Transcript Document

SINTEF Energy Research
Compact LNG Heat Exchangers
Seminar for NFR sitt Olje og gass program
3 - 4 april 2003
Mona J. Mølnvik
SINTEF Energy Research
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SINTEF Energy Research
Compact LNG Heat Exchangers
Outline of presentation
 LNG in general
 The project
 Conclusions
Spiral Wound LNG heat Exchanger
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SINTEF Energy Research
LNG TRADE
Map of major gas trade movements (BP Amoco, 2002)
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SINTEF Energy Research
LNG
 LNG – Natural gas at –162oC
 A base-load LNG plant usually comprises the
following elements:
 Inlet facilities
 CO2 removal
 Dehydration
 Natural gas liquefaction
 LNG storage
 LNG loading facilities
 Fractionation
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SINTEF Energy Research
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Base Load Plants
Existing Baseload LNG plants
Licensor
Process
Technology
Total
number of
trains
Total
production
[MTPA]
% of market
production
Start up
date
Largest
train
[MTPA]
APCI
C3/MR
52
104.5
87.8
1972present
3.3
APCI
SMR
4
2.6
2.2
1970
0.65
TechnipL’Air Liquid
Teal (dual
pressure SMR)
3
2.85
2.4
1972
0.95
TechnipL’Air Liquid
Classical
cascade
3
1.2
1.0
1964
0.4
Pritchard
Prico (SMR)
3
3.6
3.0
1981
1.2
Phillips
Cascade
2
4.3
3.6
1969-1999
3.0
Total
-
67
119.05
100
-
-
APCI
C3/MR
Cascade
DMR
SMR
MTPA
=
=
=
=
=
=
Air Products and Chemicals Inc
Propane precooled/ mixed refrigerant
Combined Propane, Ethylene, Methane refrigeration system
Dual mixed refrigerant
Single mixed refrigerant
Million tonnes per annum
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Base Load Plants
Current LNG projects
LNG Plant / Current
Project
Selected Technology
Largest train [MTPA]
Planned start-up
Nigeria Expansion train 3
APCI C3/MR
3.0
2002
Atlantic LNG Expansion
train 2 and 3, Trinidad
Phillips Cascade
3.3
2003
MLNG Tiga Expansion
train 7 and 8, Malaysia
APCI C3/MR
3.6
2003
Northwest Shelf
Expansion, train 4
Australia
APCI C3/MR
4.2
2004
RASGAS Expansion,
train 3 and 4, Qatar
APCI C3/MR
4.7
2004-5
Egypt SEGAS LNG
APCI C3/MR
5.0
2004
Nigeria Plus, train 4 and 5
APCI C3/MR
3.1
2005
Snøhvit, Hammerfest,
Norway
Statoil/Linde MFCP
4.3
2006
MFCP = Mixed Fluid Cascade Process
SINTEF Energy Research
The coil-wound heat exchanger
 Produces by:
 Air Products and Chemicals Inc. in USA
 Linde in Germany
 The heat exchangers are made in aluminum.
 Dimensions of a the main LNG coil-wound heat
exchanger is as follows:





Height
Diameter
Core tube diameter
Tube length
Tube diameter
10-50 m
3-5 m
1m
70-100 m
10-15 mm
 The Statoil/Linde MFCP is a more flexible mixed
fluid process with two main coil-wound heat
exchangers.
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SINTEF Energy Research
The Statoil - Linde Proprietary - Liquefaction Technology
 MFCP - The Mixed Fluid
Cascade Process
 Novel LNG liquefaction
technology
 Concept based on well known
elements
 Linde fabrication of heat
exchangers
 Plate fin heat exchangers in
the precooling
 Spiral wound heat exchangers
in the liquefaction and
subcooling
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Prosess Barge Hammerfest, Melkøya
 2006
 4,3 MTPA
 CO2 reinection
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Breakdown of Liquefaction Plant Capital Costs
6%
10 %
Gas liquefaction
LNG storage
16 %
50 %
Utilities
Loading facilities
Pre-treatment
18 %
(Finn et al. 1999)
SINTEF Energy Research
Compact LNG Heat Exchangers
Project: 156662/210
 Objective: to develop the next generation heat exchanging
technology for LNG plants, which compared to heat exchangers
used today is:
 more compact
 having higher efficiency
 reduced costs
 Applicants: SINTEF Energy Research, Norsk Hydro and Statoil
(project responsible/manager)
 Total budget: 14 MNOK (2003-2006), 50% from NFR
 The project shall lead to a strong international LNG
technology position for the project partners by
combining:
 Norsk Hydro’s experience in aluminium multiport
extruded tubes and components
 SINTEF’s experience in gas liquefaction and
development of compact automotive refrigeration heat
exchangers
 Statoil’s experience in heat exchanger development and
Spiral Wound LNG heat
theExchanger
development of the Hammerfest LNG plant
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Compact LNG Heat Exchangers
Necessity for new technology
 The propane pre-cooled mixed refrigerant process is the most
common refrigerant cycle for base-load natural gas liquefaction
plants.
 Both for future projects and for improvements and replacements
on existing plants this configuration will be central.
 Heat exchange equipment is applied in several parts of a LNG
plant. Especially in the liquefaction section, large and expensive
equipment is needed.
 For the liquefaction section the following heat-exchange
equipment is of special interest and importance:
 Condensation of natural gas in the multistream main cryogenic heat
exchanger, in heat exchange with evaporating mixed refrigerant
 Seawater or air cooling of refrigerant in pre-cooling section and
mixed refrigerant in the compressor train
 Cooling of mixed refrigerant and natural gas by evaporating precooling refrigerant
Spiral Wound LNG heat Exchanger
SINTEF Energy Research
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Compact LNG Heat Exchangers
R&D-challenges
 The first part of the project will be used to identify which heat
exchangers in the LNG process that has the largest potential for
improvements regarding size and cost reduction.
 Material selection - aluminum will put restrictions on possible
design due to manufacturing costs and challenges related to
corrosion.
 Performance of enhanced heat exchanger surfaces, heat transfer
and pressure drop. Important test data are missing within the
field of applications that will be addressed here.
 Distribution of the two-phase flow in the heat exchanger cores
and header systems, an area with major challenges, especially
for compact heat exchangers, which is the focus for this project.
Spiral Wound LNG heat Exchanger
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Compact LNG Heat Exchangers
R&D-challenges ...
 Heat exchanger manufacturing is a challenge since new
concepts are to be developed. In this project laboratory heat
exchangers will be manufactured and tested based on the
experience Hydro inherits from other application areas.
 Also, two PhD studies are planned; one will be focusing on
experimental measurements and new heat exchanger design
development. The second PhD will be focused on heat exchanger
modeling software development.
 The project is expected to give results that may contribute to a
technological shift within the area of heat exchanger technology
for LNG applications.
Spiral Wound LNG heat Exchanger
SINTEF Energy Research
Compact LNG Heat Exchangers
R&D-methodology
 Experimental work
 Skewed distribution in two-phase flows
 Heat transfer and pressure drop in advanced compact heat
exchangers with enhanced surfaces for improved performance.
 SINTEF Energy Research and NTNU have large and advanced
laboratory facilities and relevant experimental rigs and equipment.
 Modeling, simulation and software development
 Based on heat-transfer and pressure drop measurements on
advanced heat-exchangers, correlations for use in design and
simulation tools will be developed.
 Development of a design tool for compact heat exchangers for
LNG heat exchangers
 Based on the experimental and modeling activities.
 An important feature is the wide geometric flexibility in definition
and simulation of new designs, both regarding tube configuration
and tube and fin geometry.
Spiral Wound LNG heat Exchanger
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Compact LNG Heat Exchangers
Conclusions
MPE VV
DH = 0.8 mm
Coil VV
DH = 10 – 15 mm
Snøhvit 1
Snøhvit 2?