LNG PLANT

1. World-wide LNG Liquefaction Plants

2. Baseload LNG Plant
3. LNG Complex Scheme
4 Typical Cost Breakdown
5. Gas Reception
6. Pre Treatment
7. Liquefaction
8. Fractionation & LPG Recovery
9. LNG Storage & Loading

Jan-2008

1. Worldwide LNG Liquefaction Plant

Snohvit, Norway

Skikda, Algeria
Arzew, Algeria

Qatargas, Qatar
RasLaffan, QatarTombak, Iran

Kenai
Sakhalin, Russia

Das Island, Abu Dhabi

Bintulu, Malaysia
Damietta, Egypt
Brunei
Oman
Yemen
Bonny, Nigeria
Arun, Indonesia
Tangguh, Indonesia
Bontang, Indonesia
Angola
Woodside, Australia
Namibia
Libya

Existing
Existing
Planned or Construction

Jose, Venezuela
Atlantic, Trinidad

Camisea, Peru

2. Baseload LNG Plant

2.1 General Profile

Project

Country
Year

Start
mtpa

Capacity
Nos.

Trains Liquefaction
Process Media

Driver
Media

Cooling

Heating

EPC Contractor

Camel
Kenai
Libya
Brunei
Skikda,Ph1
Adgas,Tr1&2
Bontang,A/B
Arun,No1-3
Arzew,No1
Arzew,No2
Skikda,Ph2
Buntulu,Satu
Bontang,C/D
Arun,No4&5
Arun,No6
Woodside,Tr1-3
Bontang,E
Bontang,F
Adgas,Tr3
Buntulu,Dua
QatarGas,Tr1&2
Bontang,G
Atlantic,Tr1
Bontang,H
Nigeria,Tr1& 2
RasLaffan,Tr1&2
Oman,Tr1&2
Atlantic,Tr2&3
Nigeria,Tr3
Buntulu,Tiga
QatarGas,Tr3
RasLaffan,Tr3
SEGas,Tr1
Woodside,Tr4
Atlantic,Tr4
Idku,Tr1&2
Nigeria,Tr4
RasLaffan,Tr4
Darwin

Algeria
USA
Libya
Brunei
Algeria
UAE
Indonesia
Indonesia
Algeria
Algeria
Algeria
Malaysia
Indonesia
Indonesia
Indonesia
Australia
Indonesia
Indonesia
UAE
Malaysia
Qatar
Indonesia
Trinidad T
Indonesia
Nigeria
Qatar
Oman
Trinidad T
Nigeria
Malaysia
Qatar
Qatar
Egypt
Australia
Trinidad T
Egypt
Nigeria
Qatar
Australia

1964
1969
1970
1972
1972
1977
1977
1978
1978
1980
1980
1983
1983
1984
1987
1988
1990
1993
1994
1995
1997
1998
1999
1999
1999
1999
2000
2002
2002
2003
2003
2004
2004
2004
2005
2005
2005
2005
2006

0.44
0.95
0.64
1.44
1.0
1.23
1.67
1.67
1.22
1.22
1.21
2.53
1.67
1.67
1.67
2.43
2.3
2.3
2.3
2.65
2.2
2.6
3.0
2.95
2.95
2.9
3.3
3.3
2.95
3.87
4.7
4.7
5.0
4.2
5.2
3.6
4.0
4.7
3.5

3
2
4
5
1
2
2
3
6
6
2
3
2
2
1
3
1
1
1
3
2
1
1
1
2
2
2
2
1
2
1
1
1
1
1
2
1
1
1

Stm/T
G/T
Stm/T
Stm/T
Stm/T
Stm/T
Stm/T
F5x3
Stm/T
Stm/T
Stm/T
Stm/T
Stm/T
F5x3
F5x3
F5x4
Stm/T
Stm/T
Stm/T
F6+F7
F5x4
Stm/T
F5x6
Stm/T
F6+F7
F7x2
F6+F7
F5x6
F6+F7
F7+F7
F5x5
F7x2
Fr7x2
F7x2
F5x8
F5x5
F7x2
F7x2
LM2500x6

SW
CW
SW
CW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
Air
SW
SW
SW
SW+Air
SW
SW
Air
SW
CW
SW+CW
SW
Air
CW
Air
SW
SW+CW
Air
Air
Air
Air
Air
SW+CW
Air

Steam
?
Steam
Steam
Steam
Steam
Steam
Steam
Steam
Steam
Steam
Steam
Steam
Steam
Steam
HotWater
Steam
Steam
Steam
Steam
Steam
Steam
HotOil
Steam
HotOil
Steam
HTF
HotOil
HTF
HotOil
Steam
Steam
HotOil
HotWater
HotOil
?
HTF
Steam
?

Technip/Prichard
Phillips/Bechtel/SW
Esso R&E/Snam/Bechtel
JGC/Procon
Technip
CCEC/Bechtel
Bechtel
Bechtel
Bechtel
Pullman Kellogg
Prichard/ Pullman kellogg
JGC/Kellogg
Bechtel
CCEC
JGC
JGC/Kellogg/Kaiser
CCEC
CCEC/IKPT
CCEC
JGC/Kellogg
CCEC
CCEC/IKPT
Bechtel
Kellogg/IKPT
JGC/Kellogg/Technip/Snam
JGC/Kellogg
CCEC/FW
Bechtel
JGC/Kellogg/Technip/Snam
JGC/Kellogg
CCEC
CCEC
JGC/Kellogg/Technicas
Kellogg/JGC/Hatch/Clough
Bechtel
Bechtel
JGC/Kellogg/Technip/Snam
CCEC
Bechtel

TEAL,Cascade
Phillips,Cascade
APCI,MR
APCI,PP+MR
TEAL,2Pressure
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
Prichard,PRICO
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
Phillips,Cascade
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
Phillips,Cascade
APCI,PP+MR
Shell,PP+MR
APCI,PP+MR
APCI,PP+MR
APCI,PP+MR
Shell,PP+MR
Phillips,Cascade
Phillips,Cascade
APCI,PP+MR
APCI,PP+MR
Phillips,Cascade

2. Baseload LNG Plant

2.1 General Profile (update)

Project

Country

Start
Year

Capacity
mtpa

Trains
Nos.

Liquefaction
Process

Driver

Cooling
Media

Heating
Media

EPC Contractor

Nigeria,Tr5
RasLaffan,Tr5
Equatorial Guinea
Snohvit

Nigeria
Qatar
Guinea
Norway

2006
2007
2007
2007

4.1
4.7
3.4
4.1

1
1
1
1

APCI,PP+MR
APCI,PP+MR
Phillips,Cascade
Linde MFC

F7x2
F7x2
F5x6
Motor

Air
SW+CW
?
SW

HTF
Steam
?
HTF

JGC/Kellogg/Technip/Snam
CCEC
Bechtel
Linde

Sakhalin
Qatar Gas II
Nigeria,Tr6
Tangguh
Woodside, Tr5
Yemen
RasGas II

Russia
Qatar
Nigeria
Indonesia
Australia
Yemen
Qatar

2008
2008
2008
2008
2009
2009
2009

4.8
7.8
4.1
3.8
4.2
3.4
7.8

2
2
1
2
1
2
2

Shell DMR
APCI,APX
APCI,PP+MR
APCI,PP+MR
Shell,PP+MR
APCI,PP+MR
APCI,APX

F7x2
F9x3
F7x2
F7x2
F7x2
F7x2
F9x3

2. Baseload LNG Plant

2.2 Evolution of LNG Train Capacity

8
QGII

GE Fr.9

Gas Turbine Driven

Egypt SEGAS

GE Fr.5

Brunei

0
1960

Kenai

1970

Qatargas

Tangguh

Woodside Exp
Oman
Atlantic

Ras
Laffan

Arun 6

Badak

Lybia

Camel

Australia

Malaysia

Snohvit

Egypt Idku
Ras Laffan Exp
Malaysia Tiga

Malaysia Dua Nigeria

Arun

GE Fr. 6&7

Helper Motor

Motor Drive

Elec Motor Driven

Power Export

Million Ton/Yr

Steam Turbine Driven

Arzew

Abu Dhabi

Abu Dhabi
Skikda

1980

1990

2000

2010

3. LNG Complex Scheme

End Flash gas
LNG TRAIN
ACID
GAS
REMOVAL

BOG
HANDLING
LNG

DEHYDRATION

MERCURY
REMOVAL

SCRUB
COLUMN

LIQUEFACTION

TANK
REFRIG. STORAGE

FUEL GAS
SYSTEM
NG

FRACTIONATION

C3 & MR
REFRIGE-RANT

RECIEVING
&
METERING

TANK
LP
G
TANK

CONDENSATE
RECOVERY

CONDENSATE

RAW
WATER
WATER
TREATMENT

STEAM
GENERATION

COOLING
WATER

INERT GAS

ELECT.
GENERATOR

INSTRUMENT
& SERVICE AIR

FIRE
PROTECTION

FLARE &
LIQ.DISPOSAL

WET /COLD/ OPERATIONAL/

LIQUID /TANK/ SPARE FLARES

4. Plant Cost

4.1 Typical Cost Breakdown

LNG Train 48%

Liquefaction
36%

Dehydration
3%
Gas
Treating
7%

Fractionation
2%

Jetty
3%
Offsite
Facility

Utility
14%

G/T, Air Cooled LNG Plant

13%

Storage
& Loading
22%

4. Plant Cost

4.2 Historical Cost of LNG Plant

100
90
80
70
60
50
40
30
20
10
0
1960

Brunei
Malaysia
Australia
Nigeria
Ras Laffan
Trinidad
Oman

1970

1980

1990

2000

Design Year

Robert G. Ryan et.al., Special Report LNG Evolution, Oil&Gas J July 16,2001

4. Plant Cost

4.3 Historical Cost of LNG Plant (update)

5. LNG Plant Projects

5.1 Particulars of LNG Plant Projects

High Quality & Reliability Required
LNG Chain (Long term contract between
Seller and Buyer, LNG Ship)
Large CAPEX
High Grade Material for HP /LT conditions
Merit of Scale
Finance
Completion Reliability
Long-term PJ Schedule
Phased Development Required
Remote Sites

5. LNG Plant Projects

5.2 Technologies

Particular Aspects of LNG Technology

Process Licensers Limited
LNG Equipment
Long Delivery
Large Size
Technical Complexity
- Main Cryogenic
Exchangers
- Gas Turbines &
Compressors
- Liquid Expanders
- LNG Tanks

5. LNG Plant Projects

5.3 Current Requirements

Lower Investment & Operation Costs

Shorter Completion Schedules

Higher Availability

More Environmentally Friendly

5. LNG Plant Projects

5.4 Typical Schedule

1st year

DEFINITION
BOD/BDP
BCE
FRONT END DESIGN
LICENSORS DESIGN
FEED PACKAGE
EPC COST ESTIMATE(10%)
EPC BIDDING
PROPOSAL
EVALUATION
IMPLEMENTATION
PROC. CRITICAL ITEMS
SITE PREPARATION
EPC
START UP

2nd year

3rd year

4th year

5th year

6th year

7th year

6. Gas Reception & Pre Treatment

6.1 Slug Catcher & Stabilizer

Feed Gas
&
Condensate
(Two Phase)

Feed Gas
Separator

Feed Gas
Recovery
Compressor

Pig
Receiver
Slug
Catcher
Stabilizer

Condensate

6. Gas Reception & Pre Treatment

6.2 Metering & Feed Gas Compression
F

Metering Skid
Inlet Separator

After
Cooler

Booster
Compressor

To LNG
Train

F
Feed Gas
Metering Skid
Inlet Separator

After
Cooler

Booster
Compressor

F
After
Cooler

Metering Skid
Inlet Separator

Booster
Compressor

6. Gas Reception & Pre Treatment

6.3 Acid Gas Removal Scheme

Sweet
Gas
Lean
Amine
Absorber

Acid Gas to
Downstream

Regenerator

Feed Gas
Rich
Amine

6. Gas Reception & Pre Treatment

6.4 Comparison of Solvents

MEA
MDEA Sulfinol
(Benfield)
H2S

CO2
Mercaptans Partial Partial
Degradation COS No
CO2 No
CO2
CS2
CS2
H2S select

X
Q duty large large small
small

Adsorption chem. chem.

chem. chem.
physic.

6. Gas Reception & Pre Treatment

6.5 Dehydrator

Recycle Gas
Compressor

Water
Regeneration
Gas Heater

Propane
Refrigerant
Wet Gas

Dehydrator

Dry
Gas

7. Liquefaction

7.1 Process Classification

External Refrigerant type
Cascade
Mixed Refrigerant Process (MR Process)
- Single MR
- Dual MR
- C3 Pre-cooled
Self-refrigerant Process
Expander Process
Nitrogen Cycle (Peak-shaving & On-board)

7. Liquefaction

7.2 Existing Process

Single MR Process (PRICO)

TEALARC Dual MR (Technip)
CASCADE Process (Phillips)
C3 Pre-cooled MR Process (APCI, Shell)

7.2.1 Single MR (PRICO)

Low Pressure Refrigerant

Treated Feed Gas

High Pressure Refrigerant

Inter
Cooler

Refrigerant
Heat Exchanger

Inter Stage
Scrubber

Inter Stage
Pump
Heavy Liquid
Separator

Refrigerant
Condenser
Refrigerant
Compressor

Heavy Liquid
to Processing
LNG
Refrigerant
Pump

To Storage

GASTECH 1998

7.2.2 TEALARC Dual MR (Technip)

Treated Feed Gas

Mixed Refrigerant

Refrigerant
Heat Exchanger

Pre-refrigeration
Cycle

Fractionators
Mixed
Refrigerant

C2+
Refrigerant
Heat Exchanger

Liquefaction Cycle

LNG
to Storage

by LNG9 1989

7.2.3 Cascade Process (Phillips)

C3 Surge Drum

Treated Feed Gas

Refrigerant Heat
Exchanger
After
Cooler

C3
Compressor

C2= Surge Drum

After Cooler
C2+
to Fractionation
C2=
Compressor
After Cooler

Fuel Gas

Refrigerant Heat
Exchanger
C1
Compressor

LNG to Storage
Ship and Tank Vapor

by GASTECH 1996

7.2.4 Propane Pre-cooled MR (APCI)

Fuel Gas

N2
Reject

LNG

C3
Pre-cooling

to Storage
C3
Compressor

LP
C3

MR
Compressor

Scrub Column

MP C3
Mixed
Refrigerant
Refrigerant
Heat
Exchanger
HHP HP
C3 C3

MP
C3

LP
C3

LPG Fractionation

HP C3
Treated
Feed Gas
LPG
Condensate

7.2.5 Cooling Curve of Cascade Process

20
0

Natural Gas

-20

Temperature (C)

-40

Propane
-60
-80
-100

Ethylene

-120
-140

Methane

-160
1000

2000

Enthalpy difference (kcal/mol)

3000

7.2.6 Cooling Curve of C3 Pre-cooled MR

20
0

Natural Gas

Temperature (C)

-20
-40
C3 Cycle
-60
-80
-100

MR Cycle

-120
-140
-160
1000

2000

3000

Enthalpy difference (kcal/mol)

7. Liquefaction

7.3 New Process

Dual MR Process (Shell)

Liqeufin Process (Axens)
MFC Process (Linde)
AP-X Process (APCI)

7.3.1 Dual MR Process (Shell)

Fuel Gas
LNG

N2
Reject

to Storage

Mixed
Refrigerant
Spool wound
Heat Exchangers

MR Compressor

Compressor

Scrub Column

Mixed
Refrigerant
Refrigerant
Heat
Exchanger

LPG Fractionation

Treated
Feed Gas

LPG
Condensate
by LNG12 1998

7.3.2 Liquefin Dual MR (IFP-Axens)

Treated Feed Gas

After
Cooler

Refrigerant
Heat Exchanger
Fuel Gas
After
Cooler

MR 1
Compressors

Inter
Cooler

LNG
to Storage

MR2
Compressors
Expander
by GASTECH 1998

7.3.3 Mixed Fluid Cascade (LINDE)

Treated Feed Gas

Refrigerant
Heat Exchanger
Fuel Gas
Pre-cooling Cycle

Liquefaction
Cycle

Refrigerant
Heat Exchanger

Refrigerant
Heat
Exchanger

End Flash
LNG
to Storage

Sub-cooling Cycle

7.3.4 AP-XTM Process (APCI)

Coil Wound
Sub-cool Heat Exchanger
Propane Pre-cool Compressor

Feed
Gas

Propane Pre-cool
Heat Exchangers

MR Compressor

Nitrogen Gas Expander

Coil Wound
MCHE

Nitrogen Cold-box

Nitrogen Compressor

7. Liquefaction

7.4 Evolution of LNG Train Capacity

8
QGII

GE Fr.9

Gas Turbine Driven

Egypt SEGAS

GE Fr.5

Brunei

0
1960

Kenai

1970

Qatargas

Tangguh

Woodside Exp
Oman
Atlantic

Ras
Laffan

Arun 6

Badak

Lybia

Camel

Australia

Malaysia

Snohvit

Egypt Idku
Ras Laffan Exp
Malaysia Tiga

Malaysia Dua Nigeria

Arun

GE Fr. 6&7

Helper Motor

Motor Drive

Elec Motor Driven

Power Export

Million Ton/Yr

Steam Turbine Driven

Arzew

Abu Dhabi

Abu Dhabi
Skikda

1980

1990

2000

2010

7. Liquefaction

7.5 Driver for Refrigerant Compressor

Plant Capacity (MTPA)

25.00
20.00
15.00

First Single Shaft

GT Application

10.00
5.00

19
64
19
70
19
77
19
80
19
84
19
89
19
93
19
95
19
98
20
00
20
03

0.00

Gas Turbine
Steam Turbine

7. Liquefaction

7.6 Compressor & Driver Configuration

Large Size Gas Turbine
Application of Three Frame 7s or Frame 9s
Combined Cycle
Increase Plant Efficiency
Large Size Compressor
Limitation of Suction Volume
Parallel Configuration of Refrigerant Compressor
Train in Liquefaction Train
Relaxed by New Liquefaction Process
Motor Drive
Future Possible Option

7. Liquefaction

7.7 Train Size & Driver Configuration

G/T
Configuration

Plant
Capacity

Before 1990
1990 - 1999
2000 - 2005

(3 or 4) x F5
F7 + F6
2 x F7

1.6 - 2.5
3.0
3.9 - 4.8

Near Future

3 x F7
or 2 x F9
or 3 x F9
or Motor Drive

6.0 7.8

7. Liquefaction

7.8 Driver Type vs. Efficiency

Type
Steam Turbine 60 kg/cm2G 440 deg. C
Steam Turbine 105 kg/cm2G 510 deg. C
Gas Turbine for Industrial Use
Combined Cycle (G/T for Industrial Use)
Gas Turbine for Aircraft
Combined Cycle (G/T for Aircraft)

Efficiency %
25.3
28.5
27 31
33.5
33.4
39

7. Liquefaction

7.9 Cooling Medium

Air Cooling

Sea Water Cooling

Cheap

Expensive
(sea water intake &
required high
quality material)

Corrosion
Problem

No

Yes
(lower availability)

Temperature

High
(larger refrig.
compressor
power)

Low
(smaller refrig.
compressor
power)

Investment
cost

8. Fractionation and LPG Recovery

8.1 Simple LPG Re-injection System
Liquefaction
MCHE Section

Treated
Feed Gas

Scrub
Column

C1

LNG

Refrigerant
Storage

C2

C4

C3

C5+
To Condensate
Storage

Demethanizer

Deethanizer

Depropanizer

Debutanizer

8. Fractionation and LPG Recovery

8.2 Associated LPG Recovery
Liquefaction
MCHE Section

Treated
Feed Gas

C1

LNG

Refrigerant
Storage

C2

LPG Storage

C4

C3

Scrub
Column

Deeper
Sub-cooling
C5+
To Condensate
Storage

Increase LPG
Recovery
Demethanizer

Deethanizer

Depropanizer

Debutanizer

8. Fractionation and LPG Recovery

Pre-Cooling

LNG
Residue Gas

Stabilization
& Treating

Scrub Column Ovhd

8.3 Combined LPG Extraction

Liquefaction

LNG

MCHE Section

Gas
Re-injection

LPG Extraction Unit

NGL Extraction

LPG

LPG

Extraction

Fractionation

C3, C4 and Heavier

Maximize LPG Recovery

Sweet Feed Gas

C3
C4

Condensate

9. LNG Storage and Loading

9.1 Configuration

Suction
Drum

TC

To Fuel

BOG Compressor
PC

BOG
From Loading
Jetty
LNG Tank

LNG Rundown

LNG
To Loading
Jetty

9. LNG Storage and Loading

9.2 LNG Tank

One of Critical Equipment in Cost and Schedule

Recent Technological Trend
Type : Full Containment
Size : Greater than 140,000 m3
Number : Minimized
Possible Application of Single Containment
Site location : Sufficient Safe distance
Risk Assessment : Allowable Option