Ten Years of Field Experience with Flashing Two-Phase LNG Expanders GASEX 2012

Transcription

1 Ten Years of Field Experience with Flashing Two-Phase LNG Expanders Hans E. Kimmel Research & Development Ebara International Corporation Sparks, Nevada, USA GASEX 2012 Conference & Exhibition October 9-11, 2012 Bali, Indonesia

2 Company Profile EBARA Headquarters and Factory, Nevada, USA

3 EBARA International Corporation Cryodynamics Division Company Profile Established in 1973 Manufacturer of custom engineered liquefied gas pumps and expanders Located in Sparks, Nevada, USA Division of Ebara Corporation of Japan 5000 M2 factory with a modern, dedicated liquefied gas test facility ISO 9001 Certified

4 Ebara LNG Test Facility in Nevada

5 The liquefaction of Natural Gas requires a significant amount of energy for the refrigeration process

6 Cryogenic LNG Expanders reduce this amount of energy for the liquefaction process by replacing the Joule-Thomson throttling valve with a near isentropic expansion across a cryogenic liquid expander

7 The pressure reduction across the J-T valve produces 10% undesirable LNG vapour and only 90% of the liquid LNG is delivered to the storage tank

8 Liquefaction Process without LNG Expander for an Existing Plant with 100% Liquefaction Capacity. Only 90% of LNG are produced.

9 By replacing the J-T Valve with a cryogenic LNG Expander the amount of undesirable LNG vapour is reduced from 10% to only 5%, and 95% instead of 90% of the liquid LNG is delivered to the storage tank

10 Liquefaction Process with LNG Expander for an Existing Plant with 100% Liquefaction Capacity. The LNG production increases from 90% to 95%

11 Sgl & Two Ph

12 What is Single Phase Expansion?

13 Historic water tower in Louisville, KY built in One of the oldest water towers in the USA. The tower expands 5 bar of single phase water

14 Water Tower Expands Single Phase Flow of Water

15 What is Two-Phase Expansion?

16 Two-Phase Expansion at Home

17 Two-Phase Expansion in Nature

18 Hero of Alexandria, a Greek engineer, invented the first two-phase turbine 2000 years ago Hero s Two-Phase Turbine

19 The concept of Hero s turbine applied to today s technology: The Two-Phase LNG Expander

20 LNG Expander for Single Phase Expansion for Two-Phase Expansion

21 Existing Field Proven Two-Phase Expanders Cross section of a Two-Phase Liquefied Gas Expander inside pressurized containment vessel with lower inlet and upper outlet nozzle

22 Two-Phase hydraulic assembly with nozzle ring (red), turbine runner (yellow), jet exducer (green) and two-phase draft tube (metallic)

23 Nozzle Ring with converging nozzles generates high-velocity vortex flow

24 Reaction turbine runner converts angular fluid momentum into shaft torque

25 A radial outflow turbine for power generation by isentropic two-phase expansion to lower pressure

26 Two-Phase Expander with Two-Phase Draft Tube for Pressure Recovery and Condensation

27 Thermodynamic Expansion with Two-Phase Draft Tube P 1 Saturation Curve P 2 Pressure P 3 Joule Thomson Valve Expander Two Phase Expander w/jet Exducer Two Phase Expander w/two-phase Draft Tube Enthalpy

28 Single Phase and Flashing Two-Phase LNG Expanders are Field Proven Equipment in Existing LNG Liquefaction Trains

29 Two-Phase Liquefied Gas Expander at Ebara Manufacturing

30 2002 Testing of the First Flashing Two-Phase LNG Expander at the Ebara LNG Test Stand in Nevada, USA

31 2002 First Two-Phase LNG Expander after the Successful Test in Nevada, USA 31 Field Experience

32 Tested Performance Differential Pressure [MPa] Differential Pressure and Efficiency vs. Mass Flow % % no load % % % % DP D rated rated flow % % % % % % % % % % 80.00% 60.00% 40.00% 20.00% 0.00% Turbine Efficiency [%] Mass Flow [kg/s] inlet density: 494 kg/m^3

33 Tested Performance Differential Pressure and Efficiency vs. Volumetric Flow Differential Pressure [MPa] no load rated flow DP rated Volumetric Flow [m^3/hr] % % % % % % % % % % % % % % % % 80.00% 60.00% 40.00% 20.00% 0.00% Turbine Efficiency [%]

34 Tested LNG Temperature Reduction 0 Temperature Drop vs Power Output 2800 rpm temperature drop -2-4 Temperature Drop [C] Power Output [kw]

35 The KRIO Nitrogen Rejection Plant Location

36 Turbine before insertion into casing

37 January 2003 Installation of the Two-Phase Expander at Krio Polish Oil & Gas Odolanow, Poland

38 Location of Turbine

39 Expander Discharge Pipe with 30 meter Upward LNG Two-phase Flow to Heat Exchanger

40 Two-Phase Expander Mounted Near Main Heat Exchanger

41 Two-Phase Expander Mounted Inside Insulated Pressure Vessel

42 The flashing two-phase LNG Expanders installed in Poland in January 2002 are operating without failure for more than 30,000 hours with only scheduled maintenance

43 Thank You Hans E. Kimmel