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Revised April 2016
PROCESS OPTIMIZATION
FOR SMALL-SCALE LNG PLANTSKED – The Woodlands
Shilpa Dubey | Process Engineering
Tom Maramba | Process Dept. Manager
Bill Schaefer | Senior Process Manager
Dipanjan Bhattacharya | Technology Manager
3PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
KIEWIT OVERVIEW
5PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
OPERATING STRUCTURE
WESTERNREGION
CENTRALREGION
EASTERNREGION
US
OPERATIONS
CANADA OPERATIONS
BUILDING MININGAUSTRALIA
OPERATIONS
KIEWIT MINING GROUP
KIEWIT BUILDING GROUP
KIEWIT ENERGY GROUPKIEWIT INFRASTRUCTURE
GROUP
KIEWIT CORPORATIONBruce Grewcock, President & CEO
KIEWIT CORPORATIONBruce Grewcock, President & CEO
KED - The
WoodlandsKED - Lenexa
2PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
Kiewit Overview
Small-Scale LNG Business Opportunities
CapEx vs. OpEx
Small-Scale LNG Process Flow
Feed Gas Pre-Treatment
Liquefaction & Storage
Liquefaction Technology Selection
Main Utilities
Other Considerations
Summary
OUTLINE
6PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
SMALL-SCALE LNG BUSINESS
OPPORTUNITIES
7PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
BUSINESS OPPORTUNITIES
Technology Licensing
Engineering & Design
Project Management
Procurement
Commissioning& Start Up
Construction
Peak Shavers
Base Load Plants
High Horse Power
Machines(e.g. Drilling)
LNG Marine & Truck Fuel
Stranded Gas & Satellite Plants
Locomotive Fuel
Small-Scale
LNG Projects
8PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
CAPEX VS. OPEX
Tend to prioritize low CAPEX over reduced EFFICIENCIES and increased OPEX
9PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
LNG PROCESS FLOW
10PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
LNG PROCESS FLOW
Feed Gas Pipeline
Feed Gas Metering
Booster Compressor
Mercury Removal
Acid Gas Removal
Unit (AGRU)
DehydrationHeavy HC RemovalLiquefactionLNG StorageShip / Truck
Loading
Boil-Off-Gas,
(BOG)
Wet
Regeneration
Gas
Internal
Fuel Gas
Re-Liquefied
BOG
Internal
Fuel Gas
Return to Pipeline
Domestic
Fuel Gas
BOG
Compressor
S
T
A
R
T
F
I
N
I
S
H
11PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
FEED GAS PRE-TREATMENT
12PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
FEED GAS PRE-TREATMENT
Mercury Removal
< 0.01 µg/Nm3
Acid Gas Removal
CO2 < 50ppmv H2S< 4ppmv
Dehydration
H2O < 0.1 ppmvHeavy HC Removal
NO ONE-SIZE-FITS-ALL SOLUTION
• Sulfur Impregnated
Activated Carbon
• Metal Oxides (needs
H2S)
• Metal Sulfides
• Temperature Swing
Adsorption (TSA)
• Amine
• Mol. Sieve
TSA
• TSA
• Cryogenic Separation
CAN BE COMBINED INTO A SINGLE VESSEL
13PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
FEED GAS PRE-TREATMENT
Feed Gas Pipeline
Feed Gas Metering
Booster Compressor
(as required)
Mercury Removal
Acid Gas Removal
Unit (AGRU)
DehydrationHeavy HC RemovalLiquefactionLNG StorageShip / Truck
Loading
Boil-Off-Gas,
(BOG)
Wet
Regeneration
Gas
Internal
Fuel Gas
Re-Liquefied
BOG
Internal
Fuel Gas
Return to Pipeline
Domestic
Fuel Gas
S
T
A
R
T
F
I
N
I
S
H
14PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
LNG LIQUEFACTION & STORAGE
15PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
LNG LIQUEFACTION & STORAGE
Liquefaction LNG StorageBoil-Off-Gas (BOG)
Handling
• Single Mixed Refrigerant
Loop
• Nitrogen Recycle Loop
BOG Disposition:
• Pipeline
• Re-liquefy, return to LNG
Tank
• Fuel Gas
• Single / Double / Full
Containment
• In-Tank or Ex-Tank Pumps
• Pressurized Bullets (NFPA
59A permit as maximum of
280,000 US gal.)
16PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
LIQUEFACTION TECHNOLOGY SELECTION
FOR SMALL-SCALE LNG
Summary of Process Technology Selection Criteria
Liquefaction
Efficiency
Plant
Location
Ease of
Operation
Reduction
of BOG
Refrigerant
Availability &
Handling
Environmental
ImpactCapEx OpEx
Advantage
SMR� �
Advantage N2
Recycle � � � � � � �
Adapted from: “Plant Design Considerations for Small-Scale LNG Plants” Dipanjan Bhattacharya & Jason Yong (Kiewit), Scott Trautmann (APCI)(submitted for publication in LNG Industry Journal, June 2016)
17PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
LNG LIQUEFACTION & STORAGE
Feed Gas Pipeline
Feed Gas Metering
Booster Compressor
(as required)
Mercury Removal
Acid Gas Removal
Unit (AGRU)
DehydrationHeavy HC RemovalLiquefactionLNG StorageShip / Truck
Loading
Boil-Off-Gas,
(BOG)
Wet
Regeneration
Gas
Internal
Fuel Gas
Re-Liquefied
BOG
Internal
Fuel Gas
Return to Pipeline
Domestic
Fuel Gas
S
T
A
R
T
F
I
N
I
S
H
18PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
MAIN UTILITIES & OTHER
CONSIDERATIONS
19PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
MAIN UTILITIES
Hot Oil Heater
Direct-Fired Heater
Electric Heater
Heating
Medium
Feed Gas
Boil-Off-Gas
Vaporized Heavy
HCs
Fuel Gas
SMR vs. Nitrogen
Flare
System
SMR vs. Nitrogen
Refrigerant
Storage
Electric Motor Driven
Gas Turbine Driven
Refrigerant Comp. Driver
20PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
OTHER CAPEX REDUCTION CONSIDERATIONS
Skid-Mounting
vs. Stick Building
Pipe Rack
vs.
Sleepers
Minimum
Area Paving
21PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
• In SSLNG owners tend to prioritize lower CapEx over minimizing OpEx
• N2 Cycle technology offers overall CapEx benefits for Small-Scale LNG
• N2 Cycle Liquefaction provides greater simplicity of operation
• No ONE-SIZE-FITS-ALL solution for SSLNG Feed Gas Pre-Treatment
SUMMARY
22PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
• Plant Design Considerations for Small-Scale LNG Plants, Dipanjan Bhattacharya & Jason Yong (Kiewit), Scott Trautmann (APCI). Submitted for publication in LNG Industry Journal, June 2016.
• Small-Scale LNG 2012-2015 Triennium Work Report June 2015, International Gas Union
REFERENCES
23PROCESS OPTIMIZATION FOR SMALL-SCALE LNG PLANTS
QUESTIONS
TOM MARAMBAProcess Engineering Dept. Manager
KIEWIT ENGINEERING & DESIGN CO.3831 Technology Forest Blvd. The Woodlands, TX [email protected]
SHILPA DUBEYProcess Engineering
KIEWIT ENGINEERING & DESIGN CO.3831 Technology Forest Blvd. The Woodlands, TX [email protected]
DIPANJAN BHATTACHARYAManager of Technology
KIEWIT ENGINEERING & DESIGN CO.3831 Technology Forest Blvd. The Woodlands, TX [email protected]
BILL SCHAEFERSr. Process Engineering Manager
KIEWIT POWER & ENERGY9401 Renner Blvd. Lenexa, KS [email protected]