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Mixed Cascade Fluid Process

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Mixed Fluid Cascade Process- Liquefaction process

Overview

The mixed Fluid Cascade Process is a process which was developed by Linde/statoil LNG technology Alliance. It was implemented in order to reduce the cost and construction time of producing the plant. (Berger,E, Forg, W...2003 pg 12) The process is a single train 4 million tpy LNG plant (Shukre,F and Wheeler,F 2004 pg 3). The main factors of introducing this process to be used in Northern Australia is because it consists of a better procedure and strategy required for the production of LNG, it costs less to assemble the plant with the equipment purchased in order to liquefy the gas and also construction time is reduced (Berger,E, Forg, W...2003 pg 12). Not only can it be economically effective but it is also environmentally friendly.

Description /Procedure

The below diagram is of how the mixed fluid cascade process operates. The referigerents are made up of methane, ethane, propane and nitrogen (Shukre,F and Wheeler,F 2004 pg 3). Firstly, the natural gas (fed stream) comes in from the top and goes through three mixed refrigerants cycles (red stream).

The pre-cooling cycle (green stream) consists of a mixture of Methane and Propane which is compressed in C1 according to the below diagram. It then is liquefied (purple stream) in sea water cooler C1 and sub cooled (blue stream) in E1A (Forg,W, Bach,W, Stockmann,R… 1999 pg5).

One part is then throttled to an intermediate pressure and used as refrigerant in E1A. The other part is further sub cooled in heat exchanger E1B, throttled to the suction pressure of compressor C1 and used as refrigerant in E1B(Forg,W, Bach,W, Stockmann,R… 1999 pg5).

The liquefaction cycle is compressed in C2, cooled in sea water cooler CW2A/2B. It is then further cooled in heat exchanger E1A, E1B and E2 (Forg,W, Bach,W, Stockmann,R… 1999 pg5).

It is then throttled and used as a refrigerant in liquefier E2. The sub cooling cycle is compressed ion compressor C3 cooled in seawater coolers CW3A and CW3B, cooled further in E1A,E1B, E2 and E3 (Forg,W, Bach,W, Stockmann,R… 1999 pg5).

It is then expanded in liquid turbine X1 and used as refrigerant in sub cooler E3. Note that all compressor suction fluids are slightly superheated above dew points (Forg,W, Bach,W, Stockmann,R… 1999 pg5).

Note: The SWHE can be used for the pre-cooling stage but the only reason it isn’t because it doesn’t cost as much as the PFHE. Also, a cold box insulation is used in order to enclose the heat exchangers and its piping’s (Berger,E, Forg, W...2003 pg 14)

[pic]

Figure 1 Mixed Fluid Cascade Process (Berger,E, Forg, W...2003 pg 13)

Advantages/Limitations of the MFC process

The following describes the advantages and limitations of the process. While considering those advantages and disadvantages the factors that are covered are equipment, environmental and economical considerations. The following are also compared to alternative processes which are also considered in this literature review.

Advantages:

Many advantages come with using the MFC process, they include;

- The process reduces cycle compressor shaft power requirements, thus reducing investment costs and becoming friendlier to the environment as there are lower emissions from fuel gases (Berger,E, Forg, W...2003 pg 12)

- By minimizing the shaft power the benefits are the reduction of the cycle compressors, the drivers (gas turbines) and cooling system are minimized. This shows that a large portion of the investment to produce a MFC is minimized through not having a lot of instrumentation, electrical, construction work etc. Therefore not a lot of space is used in constructing the process (Berger,E, Forg, W...2003 pg 12).

- The mixed fluid process can be distinguished from other processes through not having a separator; this is a large piece of equipment and costs a lot to operate ((Berger,E, Forg, W...2003 pg 13).

- There is Less circulating hydrocarbons are needed, this is more safe as there are less flammable hydrocarbons which can affect the environment around us (Berger,E, Forg, W...2003 pg13).

- The loop portion of the liquefier heat exchanger doesn’t need to be overheated out of its sub cooling meaning that it has lower heat exchanger dimensions and lower costs (Berger,E, Forg, W...2003 pg 13)

- An advantage also comes with the size and complexity of the heat exchangers. The SWHE in the MFC process has much less complexity and smaller size compared to single unit heat exchangers in the APCI or DMR to install and operate (Forg,W, Bach,W, Stockmann,R… 1999 pg5).

- N2 is released in to the atmosphere (as it is no really reactive in the atmosphere) , whilst CO2 can be returned by a subsea reservoir (Berger,E, Forg, W...2003 pg16).

- The other processes have an advantage over the MFCP when comparing shaft power and adiabatic efficiencies of the compressors as there is no axial machine applied in the MFCP which lowers the adiabatic efficiency. However, since the two heat exchangers are of similar size in the MFCP it isn’t a limiting factor for the size produced for one liquefaction train, meaning the production can be optimized (Forg,W, Bach,W, Stockmann,R… 1999 pg5).

- The first LNG plant to use electric motors to drive refrigeration compressors and thus will be able to increase production rates but higher costs of the electric system (negative due to costs) (Berger,E, Forg, W...2003 pg14).

Limitations:

Alongside many benefit, there are also disadvantages that can be found within the process:

- There is a limitation when it comes to get the maximum production of LNG when using the MFC process, the cycle compressors only allows a shaft power of up to 90MW (Forg,W, Bach,W, Stockmann,R… 1999 pg5).

- Due to the small size of compressors there is a limited of achieving the maximum temperature compared to a larger single compressor unit.

- The MFCP was meant to have similar heat transfer surface for all processes within cooling water and cryogenic section. This is not possible due to the limitation of maximum temperature.

- The conditions in Northern Australia may cause problems during construction phase and plant operation. This may include humidity, rainfall, cyclones, droughts, wind etc.

- Other processes use steam turbines which has an advantage of having any capacity available, but due to low efficiency, large equipment and larger cooling system, direct gas turbine drives had to be used (Berger,E, Forg, W...2003 pg 13).

MFC process with Power heated coupling

[pic]

Process with power heat coupling

This process is used in order to reduce the consumption of feed gas or fuel gas.

References

- Forg,W, Bach,W, Stockmann,R, Heiersted,R, Paurola,P and Freidheim,A.. (1999). A New LNG Baseload Process and Manufacturing of the Main Heat Exchanger. Linde. p 4-6.

(Forg,W, Bach,W, Stockmann,R… 1999 pg)

- Berger,E, Förg,W, Heiersted,R and Paurola,P.. (2003). The Snøhvit Project. Linde Technology. p12-23.

(Berger,E, Forg, W...2003 pg

- Shukri,F and Wheeler,F.. (2004). LNG technology selection. Hydrocarnon engineering. p3.

(Shukre,F and Wheeler,F 2004 pg

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