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12/07/2015
FLNG Essentials
World Bank estimates 140 billion standard cubic metres of gas was
flared in 2011 (about 40% of the LNG traded), producing 360 million
tonnes of CO2 without any beneficial heat or power production
Energy intensive
Capital intensive
Purity Requirements
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While most of the easy onshore gas fields have been tapped, there are
considerable stranded gas reserves offshore
There is growing opposition to locating LNG plants onshore (e.g. James
Price Point in Australias Kimberley Region) for environmental or land
use zoning factors. Floating LNG import terminals are already gaining
popularity for this reason
Environmental impacts may be reduced one example is reduction of
dredging in harbours for laying gas pipelines and for entry of LNG
carriers
Possible cost and schedule advantages, though FLNG operating
expense may be high
As with any novel application of technology, some risk is associated with
initial application of FLNG. Teething problems can be expected with
the first FLNG applications, but subsequent FLNG projects can be
expected to become more straightforward
Experience gained by first FLNG operators will provide a competitive
advantage
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Development History
1964: First base load LNG export plant begins operation in Arzew, Algeria
using a cascade process designed and constructed by Technip/Air Liquid.
Exports were initially to Canvey Island, UK and Le Havre, France.
The first LNG cargo from Arzew was transported to Canvey Island on the
River Thames in England on board the first purpose-built LNG carrier
Methane Princess, which had a capacity of 27,000 m3.
1968: The mixed refrigerant concept was presented in a paper at the LNG-1
conference in Chicago
1969: Kenai LNG plant comes on stream in Alaska USA, designed and
constructed by Phillips Petroleum and Bechtel, exporting to Japan. The
Kenai plant was mothballed for a while in 2012 but is currently back in
production with licence to export until 2015
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Development History
Air Products developed the SMR process into the C3/MR process which
was first applied in Brunei, starting up in 1972
In 2004, Shell began to license its own version of the C3/MR process (a
long-held ambition) starting with the Australian North West Shelf Train 4
at 4.2 MTPA
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Development History
At Gastech in 2002, APCI rolled out its large train APX process. After
much development, the first 7.8 MTPA APX train was started up in Qatar in
2009. Six APX trains were built in total, all in Qatar, for RasGas and
QatarGas. The last, QatarGas IV, started up in 2011
Construction of new liquefaction capacity slowed, with Pluto being the only
new train added in 2012. Angola LNG joined the ranks of LNG exporters
in 2013. PNG LNG started up in 2014, along with an Algerian expansion
train and the first train using Queensland coal seam gas (QCLNG).
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In 2013, Petronas achieved FID for its PFLNG1 floating LNG project.
PFLNG1 will use a nitrogen expander process with a capacity of 1.2
MTPA and will be positioned off Sarawak
In 2014, Petronas announced that FID had been reached for its PFLNG2
facility to be positioned offshore Sabah with a capacity of 1.5 MTPA
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Refrigerant
Import
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Liquefaction
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Utilities
Power Generation
Other infrastructure:
buildings, drainage,
security, emergency
response, fire and gas
systems
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Gas Pre-Treatment
Equipment required for pre-treatment of feed gas is common to all
LNG process technologies (depending on feed gas composition)
Acid Gas Removal Prevent freezing of CO2 during liquefaction
Typically amine processes are used
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Liquefaction
Q:
A:
By using refrigeration
Q:
A:
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Refrigeration
Carnot Cycle
1.
2.
3.
4.
Isentropic compression
A real engine (left) compared to the Carnot cycle (right). The entropy of a real material changes
with temperature.
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Refrigeration
Reverse Carnot Cycle
For liquefaction of natural gas, the
warm air in the diagram is replaced
by warm natural gas which is cooled
and liquefied by the refrigerant
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odourless,
non-corrosive,
The vapours formed at an LNG liquid pool surface are always fuel rich.
Because the LNG is boiling, the pool surface vapours contain near 100
% hydrocarbons consisting primarily of methane, especially early on
during the spill
The vapours need to mix with air in order to become flammable
LNG vapours will become flammable once mixed with enough air to a
concentration ranging from 5 to 15 % by volume
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Dilution therefore is one of the main methods used to control spills resulting
from a loss of containment of LNG
Water curtains and jets can be used to draw in air and dilute the cloud that is
generated (putting water directly onto liquid pools should be avoided)
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In one large scale field trial, a rapid phase transition may have
ignited the evolved vapours
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Loss of containment leading to the formation of LNG liquid pools can also be
caused by a phenomenon called rollover
LNG rollover refers to the rapid release of LNG vapours from a storage tank
caused by stratification. The potential for rollover arises when two separate
layers of different densities (due to different LNG compositions) exist in a tank
In the top layer, the liquid becomes warmer due to heat leaking into the tank and
rises up to the surface, where it evaporates
Lighter gases are preferentially evaporated and the liquid in the upper layer
becomes denser. In the bottom layer, the warmed liquid rises towards the
interface by free convection but does not evaporate due to the hydrostatic head
exerted by the top layer
As the densities of two layers approach each other, the two layers mix rapidly,
and the lower layer which has been superheated gives off large amounts of
vapour as it rises to the surface of the tank
For FLNG, rollover is unlikely to present a problem since sloshing due to sea
state motions ensures mixing of tank contents
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Other specifications are concerned with the end use of regasified LNG and are
related to pipeline specifications or the design of gas burners in the receiving
country. Examples are heating value, wobbe number, NGL/LPG content,
sulphur/H2S
Receiving terminals may import LNG outside of the normal specifications (such
as heating value) but then must modify the properties in the receiving terminal
so that the gas will be suitable for in-country use. For instance to reduce
heating value, LPG components may be extracted (before regasification) or
nitrogen may be added (after regasification). To increase heating value, a
terminal may be equipped to spike the LNG with LPG in order to raise heating
value
Other specifications common for pipeline gas such as dewpoint are not of
concern since the liquefaction process requirements are far more stringent
than pipeline specifications
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The process design for the liquefaction facilities must ensure that
LNG can be produced to meet the specifications for properties
such as heating value and compositions of hydrocarbon
components and nitrogen
The heat and material balances and high level process design to
meet the liquefaction process requirements are usually carried out
by the liquefaction process licensor such as APCI or
ConocoPhillips
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The LNG export facility may have separate SPAs with a number of
different customers, so it is important that the specifications in
each of these agreements should be compatible with the
specification provided for design of the plant.
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BTU/ Scf
% mol maximum
% mol minimum
% mol maximum
% mol maximum
mg/Nm3 maximum
mg/Nm3 maximum
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All predictions are for natural gas usage and LNG trade to grow substantially
over the coming decades. With recent developments, it seems increasingly
likely that FLNG will become a major contributor to the predicted increases in
LNG trade and production
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Cost effective way of monetising smaller and more remote gas reserves
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Some of the factors likely to be critical for success of the first FLNG
ventures are:
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LNG plants are relatively complex to operate and maintain, and doing this
in a marine environment with less available space adds additional
complexity
Motion of the FLNG carrier due to sea state makes operation and
maintenance operations more difficult, e.g. working on rotating equipment
and other machinery with precise tolerances
Compared with onshore LNG plants, staff live and work in a relatively
confined space
Escape and evacuation procedures and drills are more complex and
assume more importance compared with onshore plants
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The size of the FPSO, which must have room to accommodate the gas production,
processing and liquefaction facilities as well as living quarters for a crew of 200 to 300
people. However, due to economic considerations as well as construction constraints,
its dimensions must be as compact as possible
Integration, because the space limitations of a floating plant dictate a specific process
layout that requires some stacking of equipment. Installing the production facilities on
deck and the LNG storage in the hull of the vessel creates some architectural
challenges as well
Safety, because the close proximity of process units - and above all the living quarters
just adjacent to them - make safety issues even more acute than for an onshore plant.
Safety is also a central focus when it comes to offloading the LNG onto methane
carriers, and innovative transfer systems are being developed for this context
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