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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. MølnvikSINTEF 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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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

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 IncC3/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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SINTEF Energy Research

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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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 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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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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SINTEF Energy Research

Prosess Barge Hammerfest, Melkøya

2006 4,3 MTPA CO2 reinection

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SINTEF Energy Research

50 %

18 %

16 %

10 %6 %

Gas liquefactionLNG storageUtilitiesLoading facilitiesPre-treatment

Breakdown of Liquefaction Plant Capital Costs

(Finn et al. 1999)

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SINTEF Energy Research

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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SINTEF Energy Research

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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SINTEF Energy Research

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?