Liquefaction Process to Extend LifetimeLiquefaction Process to Extend Lifetimeof Depleting Gas Fieldsof Depleting Gas Fields

Munir AmsyariMunir AmsyariCorporate SecretaryCorporate Secretary

munir@badaklng.co.idmunir@badaklng.co.idP.T.BadakP.T.Badak

Jakarta, Indonesia

Muljono SutedjoMuljono SutedjoDirectorDirector

muljono.sutedjo@indobara.co.idmuljono.sutedjo@indobara.co.idP.T. Indobara BahanaP.T. Indobara Bahana

Jakarta Pusat , IndonesiaJakarta, Indonesia Jakarta Pusat , Indonesia

Hans E KimmelHans E KimmelExecutive DirectorExecutive Director

hkimmel@ebaraintl.comhkimmel@ebaraintl.comEbara International CorporationEbara International Corporation

Sparks, Nevada, USASparks, Nevada, USA

World LNG Technology Summit 2006 World LNG Technology Summit 2006 2626thth and 27and 27thth April 2006 Barcelona Hilton Barcelona, Spain April 2006 Barcelona Hilton Barcelona, Spain

•• To Extend the Lifetime of Depleting Gas To Extend the Lifetime of Depleting Gas Fields the Feed Gas has to be ReducedFields the Feed Gas has to be Reduced

•• To Reduce the Feed Gas for a given LNG To Reduce the Feed Gas for a given LNG Output, the LNG BoilOutput, the LNG Boil--Off Downstream Off Downstream the Main Heat Exchanger has to be the Main Heat Exchanger has to be minimizedminimized

•• To Reduce the LNG BoilTo Reduce the LNG Boil--Off the Off the Condensed LNG has to be Sub CooledCondensed LNG has to be Sub Cooled

Sub Cooling of LNGSub Cooling of LNGusing using

LNG Liquid Expanders LNG Liquid Expanders and and

TwoTwo--Phase ExpandersPhase Expanders

Since the early days of refrigerationSince the early days of refrigerationtechnology, it technology, it has beenhas been known thatknown that

twotwo--phase expanders improve phase expanders improve the thermodynamic efficiencythe thermodynamic efficiencyof gas liquefaction processes.of gas liquefaction processes.

Only in recent years is Only in recent years is the technology availablethe technology available

to reliably operate liquidto reliably operate liquid--vapor vapor TwoTwo--Phase LNG ExpandersPhase LNG Expanders

Thermodynamics offers Thermodynamics offers three methods to cool fluidsthree methods to cool fluids

Heat transferAdiabatic Expansion

Evaporation

All three methods are used in the All three methods are used in the liquefaction process of natural gasliquefaction process of natural gas

••Heat TransferHeat Transfer→→ Heat ExchangerHeat Exchanger

••Adiabatic ExpansionAdiabatic Expansion

→→ Gas ExpanderGas Expander→→ Liquid ExpanderLiquid Expander→→ JouleJoule--Thomson ValveThomson Valve

••EvaporationEvaporation→→ JouleJoule--Thomson ValveThomson Valve→→ TwoTwo--Phase ExpanderPhase Expander

To cool a fluid the enthalpy of the To cool a fluid the enthalpy of the fluid has to be reducedfluid has to be reduced

Enthalpy is the Enthalpy is the Total Heat or Heat Content Total Heat or Heat Content

of a fluidof a fluid

Enthalpy is the amount of energy in a fluid Enthalpy is the amount of energy in a fluid capable of doing mechanical workcapable of doing mechanical work

Heat Exchangers Heat Exchangers Gas ExpandersGas Expanders

Liquid ExpandersLiquid ExpandersTwoTwo--Phase ExpandersPhase Expanders

reduce the enthalpy reduce the enthalpy of the natural gasof the natural gas

SingleSingle--Phase and TwoPhase and Two--Phase* Phase* JouleJoule--Thomson Valves Thomson Valves

do notdo not reduce the enthalpy reduce the enthalpy of the natural gasof the natural gas

*Two*Two--Phase JoulePhase Joule--Thomson Valves are also Thomson Valves are also called Flashing Joulecalled Flashing Joule--Thomson ValvesThomson Valves

TwoTwo--Phase or FlashingPhase or FlashingJouleJoule--Thomson ValvesThomson Valves

vaporize a certain part of vaporize a certain part of the condensed LNGthe condensed LNG

The total enthalpy for the The total enthalpy for the vaporized and liquid LNG vaporized and liquid LNG

remains constant across theremains constant across theJouleJoule--Thomson ValveThomson Valve

The vaporization heat The vaporization heat is removed from is removed from

the liquid and the liquid and reduces the enthalpy reduces the enthalpy

of the remaining LNGof the remaining LNG

By passing through By passing through a flashing a flashing

JouleJoule--Thomson Valve Thomson Valve the remaining liquid LNGthe remaining liquid LNGis cooled by evaporationis cooled by evaporation

For the transitional nonFor the transitional non--steady state at steady state at the exit of the JTthe exit of the JT--Valve, the liquid portion Valve, the liquid portion

is much colder than the vapor portion.is much colder than the vapor portion.

This is an important benefit. This is an important benefit. It produces a colder LNG if the phase It produces a colder LNG if the phase

separation occurs close to the JTseparation occurs close to the JT--Valve exit.Valve exit.

In the steady state and without phase In the steady state and without phase separation, the temperatures of liquid separation, the temperatures of liquid

and vapor are equal.and vapor are equal.

Expanders cool the Expanders cool the passing fluid by reducing passing fluid by reducing

the enthalpy through the enthalpy through adiabatic expansionadiabatic expansion

Liquid Expanders Liquid Expanders utilize only one method utilize only one method to cool the liquefied gas:to cool the liquefied gas:

Adiabatic ExpansionAdiabatic Expansion

TwoTwo--Phase Expanders Phase Expanders utilize two methods utilize two methods

to cool the liquefied gas:to cool the liquefied gas:

Adiabatic ExpansionAdiabatic Expansionandand

EvaporationEvaporation

A TwoA Two--Phase Expander Phase Expander operates like a operates like a

Liquid Expander Liquid Expander combined with a Flashing combined with a Flashing

JouleJoule--Thomson Valve Thomson Valve

A TwoA Two--Phase Expander Phase Expander eliminates the Flashing eliminates the Flashing JouleJoule--Thomson Valve Thomson Valve

Sgl & Two Ph

ThreeThree--Stage Stage Liquid ExpanderLiquid Expander

Oman LNGOman LNGJune 1999June 1999

(Ebara Intl. Corp.)(Ebara Intl. Corp.)

Generator RotorGenerator Rotor

Generator StatorGenerator Stator

Thrust EqualizationThrust Equalization

Mechanism (TEM)Mechanism (TEM)

Fixed GeometryFixed Geometry

Inlet Guide VanesInlet Guide Vanes

RunnersRunners

HeroHero’’s Twos Two--Phase TurbinePhase Turbine

2000 years ago,2000 years ago,Hero of Hero of

Alexandria,Alexandria,a Greek a Greek engineer, engineer,

invented the first invented the first twotwo--phase phase

expander with expander with jet exducerjet exducer

The concept of HeroThe concept of Hero’’s turbine s turbine

applied to todayapplied to today’’s technology:s technology:

The Jet ExducerThe Jet Exducer

TwoTwo--Phase Phase LNG LNG

ExpanderExpander

with with Jet ExducerJet Exducer

TwoTwo--Phase Expander HydraulicPhase Expander Hydraulic

TwoTwo--Phase Jet ExducerPhase Jet Exducer

TwoTwo--Phase Jet ExducerPhase Jet Exducer

TwoTwo--PhasePhase

ExpanderExpander

January 2003 January 2003

Krio Polish Oil & GasKrio Polish Oil & Gas(Ebara Intl. Corp.)(Ebara Intl. Corp.)

January 2003January 2003

Installation of Installation of TwoTwo--Phase Phase

Expander at Krio Expander at Krio Polish Oil & Gas Polish Oil & Gas

Odolanow, Odolanow, PolandPoland

Installation of TwoInstallation of Two--Phase Expander 2003Phase Expander 2003

Differential Pressure and Efficiency vs. Mass Flow

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

0 5 10 15 20 25 30

Mass Flow [kg/s]

Diff

eren

tial P

ress

ure

[MPa

]

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

140.00%

160.00%

180.00%

200.00%

220.00%

240.00%

260.00%

280.00%

300.00%

320.00%

340.00%

360.00%

380.00%

400.00%

Turb

ine

Effic

ienc

y [%

]

no load320028002400DP ratedrated flow

inlet density: 494 kg/m^3

D

Tested Performance TwoTested Performance Two--Phase ExpanderPhase Expander

Specific Volume of LNG LiquidSpecific Volume of LNG Liquid--Vapor MixtureVapor MixtureSpecific Volume vs. Differential Pressure

0

0.001

0.002

0.003

0.004

0.005

0.006

0.007

0.008

0 0.5 1 1.5 2 2.5 3

Differential Pressure [MPa]

Spec

ific

Volu

me

[m^3

/kg]

Specific Volume Pressure Temperatureinlet .002024 m^3/kg 2.06 MPa 115 Koutlet 0.005475 m^3/kg .1 MPa 95.6 K

Tested Performance over Volumetric FlowTested Performance over Volumetric Flow Differential Pressure and Efficiency vs. Volumetric Flow

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

0 100 200 300 400 500

Volumetric Flow [m^3/hr]

Diff

eren

tial P

ress

ure

[MPa

]

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

140.00%

160.00%

180.00%

200.00%

220.00%

240.00%

260.00%

280.00%

300.00%

320.00%

340.00%

360.00%

380.00%

400.00%

Turb

ine

Effic

ienc

y [%

]

no load320028002400rated flowDP ratedD

Tested LNG Temperature ReductionTested LNG Temperature Reduction

Temperature Drop vs Power Output

-16

-14

-12

-10

-8

-6

-4

-2

0

0 10 20 30 40 50 60 70 80

Power Output [kW]

Tem

pera

ture

Dro

p [C

]

2800 rpm temperature drop

Liquefaction Process to Reduce BoilLiquefaction Process to Reduce Boil--Off Off

Equipment DescriptionEquipment Description

MHE Main Heat ExchangerMHE Main Heat ExchangerX1 Liquid ExpanderX1 Liquid ExpanderX2 TwoX2 Two--Phase Expander Phase Expander PHS Phase SeparatorPHS Phase SeparatorLLNG Liquid Portion LNGLLNG Liquid Portion LNGVLNG Vapor Portion LNG VLNG Vapor Portion LNG M Mass Flow MeasurementM Mass Flow MeasurementT Temperature Measurement T Temperature Measurement P Pressure Measurement P Pressure Measurement

Minimizing the Feed Gas SupplyMinimizing the Feed Gas SupplyVariable speed Liquid Expander X1 Variable speed Liquid Expander X1 expands the pressurized condensed LNG to expands the pressurized condensed LNG to the ideal inlet conditions for the variable the ideal inlet conditions for the variable speed Twospeed Two--Phase LNG Expander X2 to Phase LNG Expander X2 to achieve the maximum value for the ratio:achieve the maximum value for the ratio:

∆∆ T/T/ ∆∆ MM∆∆ T = Temperature Reduction ( T1 T = Temperature Reduction ( T1 –– T3 ) T3 ) ∆∆ M = Difference LNG mass flow ( M1 M = Difference LNG mass flow ( M1 –– M3 )M3 )M1 = LNG Mass Flow at Inlet Liquid ExpanderM1 = LNG Mass Flow at Inlet Liquid ExpanderM3 = LNG Mass Flow at Outlet Phase SeparatorM3 = LNG Mass Flow at Outlet Phase Separator

Liquefaction Process to Reduce BoilLiquefaction Process to Reduce Boil--Off Off

Liquid Expander Liquid Expander andand

TwoTwo--Phase Expander Phase Expander in in

Tandem ConfigurationTandem Configuration

Project P.T.Badak Project P.T.Badak

Ref. 108g AIChE Spring Conf. 2005 AtlantaRef. 108g AIChE Spring Conf. 2005 Atlanta

Performance Comparison Liquid vs. TwoPerformance Comparison Liquid vs. Two--Phase ExpanderPhase ExpanderProject P.T.Badak Ref. 108g AIChE Spring Conf. 2005 AtlantaProject P.T.Badak Ref. 108g AIChE Spring Conf. 2005 Atlanta Operating Conditions Tf H C-3 Operational Speed :rpm

3000

Intake capacity :m3/hr

897.30

∆ H of Turbine : m

615.49

Inlet density : kg/m3

448.00

Power Hydraulic In : kW

674

Efficiency Turbine : %

85

Efficiency Generator : %

96.5

Power Out Gen. : kW

553

BTU Removal/Hr : BTU/hr

1,888,180

Predicted Expander Eff: %

82

Reclaimed Cap. : dm3/s

2.41

Capacity Increase : %

0.97

Reclaimed Cap.: tons/day

93.28

Revenue Incr. : $/Year

$ 8,814,820

Operating Conditions Tf H C-3 Operational Speed :rpm

3000

Intake capacity :m3/hr

897.30

∆ H of Turbine : m

653.94

Inlet density : kg/m3

448.00

Power Hydraulic In : kW

716

Efficiency Turbine : %

94

Efficiency Generator : %

96.5

Power Out Gen. : kW

652

BTU Removal/Hr : BTU/hr

2,226,208

Predicted Expander Eff: %

91

Reclaimed Cap. : dm3/s

2.84

Capacity Increase : %

1.14

Reclaimed Cap.: tons/day

109.93

Revenue Incr. : $/Year

$ 10,388,220

Performance Comparison Performance Comparison Liquid vs. TwoLiquid vs. Two--Phase ExpanderPhase Expander

Project P.T.Badak Project P.T.Badak Ref. 108g AIChE Spring Conf. 2005 AtlantaRef. 108g AIChE Spring Conf. 2005 Atlanta

TwoTwo--Phase LNG Expander Performance IncreasePhase LNG Expander Performance Increase

Differential Pressure Differential Pressure →→ 6.25%6.25%Expander Efficiency Expander Efficiency →→ 11.00%11.00%Enthalpy Reduction Enthalpy Reduction →→ 17.90 % 17.90 % LNG Production LNG Production →→ 17.90%17.90%Revenue Increase Revenue Increase →→ 1.573 Mill US $/Year1.573 Mill US $/Year

Feed Gas Reduction Feed Gas Reduction Liquid vs. TwoLiquid vs. Two--Phase ExpanderPhase Expander

Project P.T.Badak Project P.T.Badak Ref. 108g AIChE Spring Conf. 2005 AtlantaRef. 108g AIChE Spring Conf. 2005 Atlanta

Liquid Expander: Liquid Expander: Feed Gas Reduction: 0.97%Feed Gas Reduction: 0.97%

TwoTwo--Phase LNG Expander Phase LNG Expander Feed Gas Reduction: 1.14%Feed Gas Reduction: 1.14%

Thank YouThank YouMunir AmsyariMunir Amsyari

Muljono SutedjoMuljono Sutedjo

Hans E KimmelHans E Kimmel

Liquefaction Process to Extend LifetimeLiquefaction Process to Extend Lifetimeof Depleting Gas Fieldsof Depleting Gas Fields

Appendix:Appendix:Example for Use of Cold LNG VaporExample for Use of Cold LNG Vapor

Akihiro UshitoraAkihiro UshitoraCEOCEO

aushitora@ebaraintl.comaushitora@ebaraintl.comEbara International CorporationEbara International Corporation

Sparks, Nevada, USA

Hans E KimmelHans E KimmelExecutive DirectorExecutive Director

hkimmel@ebaraintl.comhkimmel@ebaraintl.comEbara International CorporationEbara International Corporation

Sparks, Nevada, USASparks, Nevada, USA Sparks, Nevada, USA

World LNG Technology Summit 2006 World LNG Technology Summit 2006 2626thth and 27and 27thth April 2006 Barcelona Hilton Barcelona, Spain April 2006 Barcelona Hilton Barcelona, Spain

•• Certain LNG Liquefaction Plants Certain LNG Liquefaction Plants are Powered by Gas Turbinesare Powered by Gas Turbines

•• The Fuel Gas for the Gas Turbines is The Fuel Gas for the Gas Turbines is Clean Vaporized LNG Clean Vaporized LNG

•• The Vaporized LNG is produced by The Vaporized LNG is produced by a Twoa Two--Phase LNG Expander or by a Phase LNG Expander or by a JouleJoule--Thomson Valve Thomson Valve

•• The Vaporized LNG is at Cold The Vaporized LNG is at Cold Boiling TemperatureBoiling Temperature

•• The Cold LNG Vapor can be used to The Cold LNG Vapor can be used to Cool the Air at the Inlet of the Air Cool the Air at the Inlet of the Air Compressor of the Gas Turbine Compressor of the Gas Turbine

•• The Vaporized LNG is produced by The Vaporized LNG is produced by a Twoa Two--Phase LNG Expander or by a Phase LNG Expander or by a JouleJoule--Thomson Valve Thomson Valve

Air Cooling for Gas TurbineAir Cooling for Gas Turbine

•• Cold Compressed Air and Cold Cold Compressed Air and Cold Natural Gas Fuel Increase the Natural Gas Fuel Increase the Performance and Efficiency of Gas Performance and Efficiency of Gas TurbinesTurbines

•• The Portion of LNG Vapor The Portion of LNG Vapor Produced across the TwoProduced across the Two--Phase Phase LNG Expander or across the JouleLNG Expander or across the Joule--Thomson Valve Sub Cools the LNG Thomson Valve Sub Cools the LNG and Reduces the LNG Boiland Reduces the LNG Boil--OffOff

Thank YouThank YouAkihiro UshitoraAkihiro Ushitora

Hans E KimmelHans E Kimmel