1 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
Dec 26, 2015
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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 ExchangersOutline of presentation
Spiral Wound LNG heat Exchanger
LNG in general The project Conclusions
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LNG TRADE
Map of major gas trade movements (BP Amoco, 2002)
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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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Base Load PlantsExisting 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 1972-
present 3.3
APCI SMR 4 2.6 2.2 1970 0.65
Technip-
L’Air Liquid
Teal (dual
pressure SMR) 3 2.85 2.4 1972 0.95
Technip-
L’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 = Air Products and Chemicals Inc
C3/MR = Propane precooled/ mixed refrigerantCascade = Combined Propane, Ethylene, Methane refrigeration systemDMR = Dual mixed refrigerantSMR = Single mixed refrigerantMTPA = Million tonnes per annum
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Base Load PlantsCurrent 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
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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 10-50 m Diameter 3-5 m Core tube diameter 1 m Tube length 70-100 m Tube diameter 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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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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50 %
18 %
16 %
10 %6 %
Gas liquefaction
LNG storage
Utilities
Loading facilities
Pre-treatment
Breakdown of Liquefaction Plant Capital Costs
(Finn et al. 1999)
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Compact LNG Heat ExchangersProject: 156662/210
Spiral Wound LNG heat Exchanger
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 the development of the Hammerfest LNG plant
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
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Compact LNG Heat ExchangersNecessity for new technology
Spiral Wound LNG heat Exchanger
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 pre-
cooling refrigerant
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Compact LNG Heat Exchangers R&D-challenges
Spiral Wound LNG heat Exchanger
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.
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Compact LNG Heat Exchangers R&D-challenges ...
Spiral Wound LNG heat Exchanger
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.
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Compact LNG Heat Exchangers R&D-methodology
Spiral Wound LNG heat Exchanger
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.
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Compact LNG Heat ExchangersConclusions
Coil VVDH = 10 – 15 mm
MPE VVDH = 0.8 mm
Snøhvit 1
Snøhvit 2?