Baseload LNG Production in Xin Jiang

7/31/2019 Baseload LNG Production in Xin Jiang

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BaseloadLNG Productionin Xin Jiang


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2

Contents.

3 Introduction

4 The basics

Design basisBasic data or the process design o the plant

Feed gas composition

Specifcation o the product LNG

Process eatures

Utilities

Block diagramm o the Shan Shan LNG plant

6 Features IAmbient conditions at the site

Overall process and utility description

Natural gas treatmentNatural gas liqueaction

Block diagram o the liqueaction

8 Features IIRerigerant system

Gas turbine

LNG storage and loading system

Block diagram o the LNG storage tank and loading system

11 Features III

Fuel system

Hot oil unit

Main cryogenic heat exchanger

Project execution

13 Project execution

14 Closing remarksSelected reerences

16 Contact

Xiang Dong

PresidentXin Jiang Guanghui Liqueied Natural Gas Development Co. [email protected], 838202 Shan Shan, PRC

Thilo Schiewe

Sales Manager, Natural Gas [email protected], Linde AG, Engineering DivisionDr.-Carl-von-Linde-Str. 6-14, 82049 Pullach, Germany

Albert Meffert

Project [email protected], Tractebel Gas EngineeringMildred-Scheel-Str.1, 53175 Bonn, Germany

Li Wei Bin

LNG Chie [email protected], SSEC, SINOPEC Shanghai Engineering Co. Ltd.,769 Zhangyang Road, Pudong New Area, Shanghai, PRC


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The gas is treated and liqueied in an LNG plant

near Shan Shan in the Xin Jiang Province o

China. The plant is operated in baseload mode

and employs intermediate storage o the LNG

product in an insulated tank beore it is loaded

into LNG road tankers. These trucks then carry

the LNG over long distances to satellite and caruelling stations in various cities o China. Ater

revaporization o the LNG at these stations the

natural gas is inally distributed to a variety o

industrial and private consumers.

As LNG is considered the most environmentally

riendly hydrocarbon uel, it is expected that

this domestic natural gas initiative through LNG

creates new gas markets and provides a great

improvement to the tight energy supply situa-

tion in China. This paper describes the Shan Shan

LNG acilities rom gas treatment, liqueactionwith a single mixed rerigerant cycle in coil-

wound heat exchangers, through storage, to

unloading and to the distribution o the LNG

to various cities in China.

3

Introduction.

Baseload LNG production in Xin Jiang - a remote sourceo clean energy or gas consumers in China.

In 2004 Xin Jiang Guanghui Liqueied Natural Gas DevelopmentCo. Ltd. established a unique LNG chain. The result is that gas,which until recently has been lared at the Tuha oilields some300 km south-west o Urumqi, can now be utilized as a cleanprimary energy source.

This new LNG scheme is a easible and workable alternativeto existing peak shaving and conventional baseload plants.With a LNG production capacity o 0.4 MTPA (million tons perannum) the plant represents a new category o LNG planttypes, with which a speciic demand can be ulilled.


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Design basis

The baseload LNG plant is designed or the pro-

duction o LNG equivalent to 1,500,000 Nm3/d.

The plant consists o natural gas treatment, gas

liqueaction, LNG storage tank and LNG distribu-

tion systems. The liqueaction process is based on

a highly eicient single mixed rerigerant cycle.

Basic data for the process design of the plant

The design o the LNG plant or the Xin Jiang

project is based on state-o-the-art natural gas

liqueaction technology.

The LNG production capacity o the plant is

equivalent to 1,500,000 Nm3/d with an ex-

pected on-stream time o 330 days per year.Design hourly liqueaction capacity is 54 t/h.

Storage capacity is 30,000 m3 o LNG, which is

the equivalent o 12 days production. The ca-

pacity o the LNG send-out and distribution

system meets the requirement o loading the

100 trucks and movable containers within 16

hours. Approx. 30 % o the LNG product is load-

ed in trucks and 70 % in movable containers.

Feed gas composition

Composition (mole %):

Nitrogen 3.81

Methane 81.02

Ethane 9.99

Propane 4.10

Butanes 0.93

Pentanes 0.05

C6+ < 0.0021

In addition, CO2 as well as traces o H2S and

sulur are present in the eed gas. The eed gas

operating pressure ranges rom about 0.6 MPag

to 1.1 MPag. The design pressure is 0.7 MPag.

The eed gas operating temperature can range

rom -15C to 40C. The design temperatureis 28C.

Specification of the product LNG

Composition (mole %):

Nitrogen 0.8 (max 1.0)

Methane 82.4

Ethane 11.1

Propane 4.6

Others 1.1

Pressure and temperature at LNG tank:

0.01MPag, 163C. The design LNG hasa density o about 490 kg/m3 in the LNG

tank.

Process features

The main process and utility units are illustrated

in the block diagram in Fig1. The mixed reriger-

ant cycle liqueaction process requires the com-

ponents nitrogen, methane, ethylene, propane

and pentane. Rerigerant nitrogen and purge

nitrogen are identical and case both generated

in a nitrogen package.

Utilities

Make-up water or the ollowing are provided

rom outside the plant: closed cooling water

cycle, machinery cooling and demineralized

water as make-up water or the MEA in the CO

wash unit.

A mixture o compressed LNG tank return gas

and eed gas is used as normal uel gas;

start-up uel gas is eed gas. A closed hot oil

cycle is used as heating medium. A MEA

(monoethanolamine)-water solution is used

as solvent or the CO2 wash unit.

The liqueaction process is based on a highlyeicient single mixed rerigerant cycle,

4

The Basics.


5/16

Fig1: Block diagram o the Shan Shan LNG plant with

process and utility units

5

which contains the components nitrogen,methane, ethylene, propane and pentane.

Waste

water

Hot oil

system

Natural gas

Sour

gas

Exhaust

gas

Waste heat

recoveryGas turbine

Solvent

regeneration

Rerigeration

system

Boil o gas

(uel gas)

compression

Feed gas

compression

NG purication

CO2 removal

NG purication

dryer

NG

liqueaction

LNG

storage

LNG loading

station

container

MCR

make-up unitFire ghting Utilities Flare

LNG loading

station

special cont.

LNG loading

station truck

LNG meters

LNG meters

NG

puri-edNG

hotoil

hotoil

hotoil

fuelgas

hotoil

fuelgas

r

ich

solvent

vap

.refr.

lean

solvent

liqu

idr

efr.

hotoil

fuegas

dryNG LNG LNG

LNG

LNG

LNG


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Ambient conditions at the site

The average ambient temperatures ranges rom

37.1C in the warmest month to -15.6C in the

coldest month. The design temperature or gas

turbine air inlet and or air-cooling is 30C. The

average temperature in the hottest month is 37C,

the extreme maximum temperature is 75C. The

plant elevation above sea level is about 790 m.

Overall process and utility description

The production capacity o Shan Shan LNG lies

between the two principle type o LNG plants:

Baseload and peakshaving plants. LNG peak-

shaving or back-up plants with intermittent

operation and production have capacities up

to about 500,000 Nm3/d. LNG baseload plantswith continuous operation and production

have capacities between 5,000,000 Nm3/d and

17,000,000 Nm3/d. With 1,500,000 Nm3/d LNG

production capacity the Shan Shan LNG plant is

about three times larger than the largest exist-

ing peakshaving plants, but about three times

smaller than existing baseload plants. The eed

gas has a low pressure at battery limit, which

is too low or an eicient liqueaction process.

Thereore, the natural gas is compressed in

three compressor stages.

The natural gas is cooled, liqueied and sub-

cooled in a coil-wound heat exchanger by a

highly eicient single mixed rerigerant cycle.

This cycle provides cold temperatures by Joule-

Thomson expansion at three dierent pressure

levels.

The rerigerant cycle is recompressed in a three-

stage turbo-compressor, which is driven by a gas

turbine. In order to enhance plant eiciency, the

waste heat rom the gas turbine is recovered by

heating a hot oil cycle, which covers the heating

requirements o the process plant.

Natural gas treatmentNatural gas (eed gas) has a low pressure at the

battery limit. Solid and l iquid particles are re-

moved by the eed gas ilter separator beore it

is compressed in a three stage eed gas com-

pressor. Ater the irst-stage o the eed gas

compressor, the gas is cooled in an intercooler

against ambient air to about 40C. Any water

condensed in the intercooler is separated in the

eed gas compressor interstage drum and is ed

to the wash unit.

Ater this irst compression step the eed gas isurther compressed in the next two compressor

stages with inter- and ater-cooling in air-cool-

ers. The eed gas is routed to the wash unit or

removal o CO2. The sweet eed gas leaving the

CO2 wash column is then routed to the drier

station.

Natural gas liquefaction (Fig. 2)

Ater the CO2 and H2O removal, the natural gas

is routed to the cold part o the process, which

contains three coil-wound heat exchangers

integrated in one shell (rocket), as well as

several separation vessels. The natural gas is

irst cooled in the eed gas precooler E1. Poten-

tial o-spec heavy hydrocarbons are separated

in the eed gas heavy hydrocarbon separator D3,

where only marginal liquids during design eed

gas operation are expected. The gas is then con-

densed in eed gas liqueier E2 and subcooled in

eed gas subcooler E3. The required subcooling

temperature is maintained by adjusting the na-

tural gas low rate to the plant. Thus, a certain

power output o the gas turbine govering theplant capacity. Cooling is provided by the mixed

rerigerant cycle.

The Shan Shan LNG plant has amedium size production capacity,

6

Features I


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Fig 2: Natural gas liqueaction process o the

Shan Shan LNG plant

in between the two principle typeso LNG plants which are currently in

operation world-wide.

7

LNG to storage tank

E3Subcooler

D3

Cold MCRseparator

E1Precooler

E2

Liqueier

D3

Feed gasHHCseparator

Feed

gas

Feed gascompression,

CO2/H2Oremoval

CT1

Gas turbine

Cycle compressor coolers

Cycle compressorsuction drums

C1Cyclecompr. D2

Cycle HPseparator

D1

Cycle MPseparator


8/16

Fig 3: 30,000 m3 LNG storage tank

Refrigerant system

The rerigerant gas stream is withdrawn rom the

shell side o precooling section E1 o the cryo-

genic coil-wound heat exchanger set. The re-

rigerant is slightly super-heated.

The rerigerant is compressed in the irst stage o

the three-stage rerigerant cycle compressor. It

is than cooled against air in the inter- and ater-

cooler resulting in partial condensation. The

resulting liquid is separated in the cycle com-

pressor discharge drum D1.

The liquid rom the discharge drum D1 is routed

to the cryogenic heat exchanger E1, where it is

subcooled and then used or the precooling othe natural gas ater expansion in a Joule-Thom-

son valve.

The cycle gas rom the buer drum D2 is cooled

in E1 to the same temperature and partly conden-

sed and ed to the cold rerigerant separator D3.

The liquid rom this separator is subcooled in the

cryogenic heat exchanger section E2 to a low

temperature so that it can be used as a reri-

gerant in E2 ater expansion in a Joule-Thomson

valve.

The vapor rom the cold rerigerant separator D3

is condensed in E2 and subcooled in the cryo-

genic heat exchanger section E3 to a suiciently

low temperature. This provides the inal cold or

the natural gas subcooling ater throttling in a

Joule-Thomson valve. Ater expansion to the

lower pressure, the cycle gas streams are warmed

up in the common shell side o the cryogenic

coil-wound heat exchangers E3, E2 and E1 andreturn jointly to the suction side o the irst stage

o the rerigerant cycle compressor.

Gas turbine

Gas turbine GT1 is used as the primary driver or

the cycle gas compressor C1. Design tempera-

ture or gas turbine rating is an ambient air tem-

perature o 30C. The same design temperature

applies or air-cooling. The compressed boil-o,

lash and displacement gas rom the LNG storage

tank is used as regeneration gas and then as uel

gas or the gas turbine.

LNG storage and loading system

LNG rom the liqueaction unit with the cryo-

genic heat exchanger set E1, E2 and E3 is sent to

the storage tank via the tank illing line, Fig. 3.

The 30,000 m3 LNG tank (Fig. 5) is a lat bottom,double wall, perlite insulated type installed in

an endiked area. The tank will be illed continu-

ously during operation o the liqueaction sys-

tem at a illing rate o about 111 m3/h. A discon-

tinuous send out o LNG product to the truck and

container illing acilities is scheduled or 16

hours per day.

8

Features II


9/16

Fig. 5: LNG storage tank and loading systemo the Shan Shan LNG plant

Fig. 4: LNG truck loading station

For send-out operation, two submerged in-tankpumps are installed. Each designed or 320 m3/h

capacity, suitable or 100 % o send-out capac-

ity. One pump is installed as a spare. The pumps

are installed in pump columns inside the tank

and equipped with oot valves. Each pump is

equipped with a kickback line to the tank to

control the minimum low o the pump during

the period when no illing operation takes place.

The send out lines to the truck and container

illing station are permanently illed with LNG.

A small circulation low keeps the system atcryogenic temperatures. The trucks are weighed

prior to illing. Trucks are connected manually

to the loading arm illing and vapor return lines.

The initial LNG into the warm tanks truck eva-

porates The resulting vapor returns to the stor-

age tank. Ater cooling the truck tank, the illing

rate increases to the maximum illing rate.

The low meter stops the illing operation auto-

matically via the automatic control valve at the

loading station. The truck leaves the plant via

the weighbridge ater disconnection rom the

loading arm. Fig. 4 shows the LNG truck loading

station with our trucks each with a storage

capacity o 44 m3. The loading capacity o the

9

stations is suicient to match the send out ca-pacity by operationg 16 hours a day.

The same operation applies to the container

illing system. The only dierence is that trucks

are mobile by themselves and the container

must be moved by gantry crane and trailers.

The container is ixed on rail-platorm cars andtransported as train o 40 to 70 cars in length.

The illing time or one container or one truck is

estimated to be about 1.2 hours including con-

nection and disconnection time. The system capa-

city is designed to ill 100 trucks or containers

within 16 hours. The illing system consists o

six loading stations or containers and our load-

ing stations or trucks.

P-411LNG transer pump

LNG rom liqueier Vapor return containerilling station

Boil-off/flash/displacement gasto re-compression

Container and truck filling station

D-411LNG storage tank

L-421

A/B/C/D/E/F

L-431

L-441A/B/C


10/16

Fig. 6: Three stage 43 m high coil-wound heat

exhanger with separator in the steel rame

Fuel system

The net lash, boil-o and displacement gas

coming rom the LNG storage tank is com-

pressed, cooled against ambient air and used

as regeneration gas in the dehydration section

beore it is sent as uel to the gas turbine, which

drives the cycle compressor. To allow or pres-

sure control o the uel gas, an additional

uel stream is taken rom the eed gas ollowing

the second stage o the eed gas compressor.

Hot oil unit

The hot oil system provides the process heat or

the plant at two temperature levels. In order

to keep constant low rates in the system, two

cycles are used: a medium temperature cycle

and a high temperature cycle. The heat or both

cycles is provided by a hot oil heater package, a

waste heat recovery unit in the exhaust stack o

the cycle gas turbine. The hot oil is heated to ap-

prox. 260C to supply heat or the regeneration

gas heating. To allow or start-up during winter

conditions, the system is heat traced.

10

Features III


11/16

Fig. 7: Precooling section o the coil-wound heat

exchanger in the Linde workshop

11

Main cryogenic heat exchangerA special eature o the cryogenic section o the

process plant is the coil-wound heat exchanger

which is designed and built by Linde.

The coil-wound heat exchanger

The robust design o the coil-wound heat ex-

changer is ideally suited or the pre-cooling,

liqueaction and sub-cooling processes. During

these processes, the rerigerant and product

streams reach temperatures as low as -160C.

Fig. 7 shows the precooling section o the coil-wound heat exchanger in the Linde workshop

prior to transport.

The outer dimensions (length x diameter) o the

three coil-wound heat exchanger sections are:

Precooler: 15 m x 3 m

Liqueier: 17 m x 3 m

Subcooler: 11 m x 2 m

All three heat exchanger sections were trans-

ported separately to the site. Ater concentric

stacking and welding in a steel structure, the

combined coil-wound heat exchangers have an

overall height o 43 m. Fig. 6 (page 10) shows

the cryogenic section with the coil-wound

heat exchanger together with the separator in

the permanent steel rame. In comparison to

plate-in heat exchangers, the coil-wound heat

exchanger can with stand signiicant thermal

shocks. Thermal shocks may occur during start-

up or shut-down or mal-operations.


12/16

Fig: 8: Part o the leet o LNG trucks or the

road transportation o the Shan Shan LNG

12

Project execution.

The execution o the Shan Shan project is an ex-

ample or the excellent cooperation between

the owner o the plant, the liqueaction and tank

technology providers, and the local design insti-

tute.

SPIDI in Shanghai, China was responsible or the

entire plot plan o the plant and detail engineer-

ing with utilities. Tractebel Gas Engineering in

Bonn, Germany was responsible or the design

o the LNG storage tank and the loading acilities

and the procurement o the relevant imported

equipment and material as well as or the con-

struction and commissioning supervision o the

tank and loading units.

The Engineering Division in Munich, Germany

was responsible or the natural gas treatment

and liqueaction process design and or the pro-

curement o the imported process related equip-

ment as well as or the supervision o plant con-

struction and commissioning.

Fig. 9 (page 13) shows a section o the Shan

Shan LNG plant with the compressor shelter

building, the gas turbine exhaust stack, the

coil-wound heat exchanger in the rack, the

LNG tank and the air coolers on the pipe rack.

The plant was mechanically completed in 2004

ollowed by commissioning. The equipment and

piping was arranged in such a way as to take

into account the relevant saety regulations as

well as short pipeline lengths. The required

plant area is about 58 m x 130 m. The LNG stor-

age tank is connected to the process plant by a

pipe rack, which supports the product and the

vapor return line.

A large leet o LNG trucks, Fig. 8, is now perma-

nently transporting the LNG over long distances

to the satellite stations in the vicinity o the con-

sumers.

Most o the LNG satellite stations are located inthe more densely populated regions in the east-

ern provinces o China. An overview o the exist-

ing and planned LNG satellite stations is shown

in Fig. 10 (page 13).

As is evident rom the table, the one way dis-

tances mostly exceed 3,000 km, some are even

greater than 4,000 km.

The Dehua satellite station, Fig. 11 (page 15),

represents the longest distance rom the Shan

Shan LNG plant. This station comprises eight

vertically installed cylindrical LNG storage tanks,

each with a capacity o 150 m3. They are illed

regularly by the LNG trucks. The LNG is vaporized

by blocks o inned heat exchangers using natu-

ral convection o ambient air as heat source.

Small LNG containers are oten illed with LNG

rom these large satellite stations and trans-

ported to smaller satellite stations in order to

a limited residential areas.

One o the urgent needs or clean uel comes

rom public busses. Thereore, one o the LNGsatellite stations supplies the LNG directly to a

city bus leet.


13/16

Fig. 9: Section o the Shan Shan LNG plant with compressor shelter,

gas turbine exhaust stack, coil-wound heat exchanger and LNG tankFig. 10: LNG transport in China from the Shan Shan LNG plant

13

Shan ShanLNG plant

LNGsatellite station

LNG

satellite station

Station Distance

Linyi 3,400 kmRizhao 3,520 kmLianyungang 3,450 kmQingdao 3,600 km

Weihai 3,700 kmJiangyan 4,100 kmQidong 3,400 kmTongxiang 3,700 kmYuyao 3,920 kmBeijing 3,170 km

Minqing 4,050 kmDehua 4,400 kmChangde 3,190 kmChangsha 3,450 kmZhuzhou 3,520 km

Jiujiang 3,250 km

Ji An 3,700 kmNanchang 3,400 kmGuangzhou 4,040 kmJiangyang 4,350 kmLongchuan 4,200 km

Dongguan 4,120 kmUrumqi 340 kmHami 340 km


14/16

With the introduction o such LNG plant typescombined with the respective transport inra-structure, natural gas markets can be dynami-cally introduced and developed.

Demand or natural gas in China is projected to

increase drastically in the uture. This Shan Shan

LNG plant will open a new era in meeting the

increasing demand.

With the introduction o such LNG plants, com-

bined with the respective transport inrastruc-

ture, natural gas markets can be dynamically

developed in the uture. It is evident that natural

gas, as a cleaner uel, will play an increasingly

important role in the primary energy mix.

The LNG rom the Shan Shan LNG plant will

contribute substantially to the economic devel-

opment and growth in China. With the LNG rom

Shan Shan, a high degree o lexibility in the

energy supply will be made available to the

beneit o all natural gas consumers with luc-

tuating or peak demand proiles.

The Shan Shan LNG plant provides a means to

commercialize indigenous natural gas resources.

This, in turn, supports the local economy and

provides jobs.

The Shan Shan LNG plant provide a rubber tyre

pipeline in China. The transport o LNG via tank-

er trucks makes the distribution o natural gas tointermediate-sized consumers possibel.

Some o the target regions have not yet been

connected to major gas pipelines due to eco-

nomic reasons, since the initial gas consumption

rate would not justiy such a large investment.

Thereore, the LNG supply will initiate the pene-

tration o these regional markets with environ-

mentally riendly uel.

This LNG scheme is unique in the world with

regard to plant type as well as plant and trans-

port capacity. It can be considered as an a

model or the commercialization o remote gas

resources.

14

Closing remarks.


15/16

Fig 11: Dehua LNG satellite station

15

Selected references

E. Berger, Engineering Division:

XiangDong,XinjiangGuanghuiIndustry

and Commerce Group Co. Ltd.

JinGuoQiang,ShanghaiPharmaceutical

Industry Design Institute o SINOPEC (SPIDI)

Naturalgasliquefaction-technical

and economic aspects

FirstIndianLNGconference,

Madras, India, 1996

LNGsatellitestationsinEurope

LNG10conferenceinKualaLumpur,

Malaysia, 1992

A. Meert, Tractebel Gas Engineering,

L. Atzinger, Engineering Division:

LNGbaseloadplantinXinjiang,China;

commercialization o remote gas resources

or an Eco-responsible Future

Worldgasconference,Tokyo,2003

W. Frg, W. Bach, R. Stockmann,

Engineering Division,

R.S. Heiersted, P. Paurola, A.O. Fredheim,

Statoil:

AnewLNGbaseloadprocessandmanu-

acturing o the main heat exchangers

LNG12conference,Perth,May1998


16/16

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Phone: +49.(0)89.7445-0

Fax: +49.(0)89.7445-4908

[email protected]

LNG/3.1.e

/09

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Hangzhou, P.R. o China

Phone +86.571.87858-222

Fax +86.571.87858-200

[email protected]

Linde Engineering Division

Beijing Representative OiceBeijing, P.R. o China

Phone +86.10.6437-7014

Fax +86.10.6437-6718

[email protected]

Linde AG Taiwan Branch


Taipei, Taiwan

Phone +886.2.2786-3131

Fax +886.2.2652-5871

[email protected]

Linde Australia Pty. Ltd.

Chatswood N.S.W., Australia

Phone +61.29411-4111

Fax +61.29411-1470

[email protected]

Designing Processes- Constructing Plants.

Documents

Baseload LNG Production in Xin Jiang