Tony Purcell, Honeywell UOP: Maintaining FLNG operations in rough seas
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Transcript of Tony Purcell, Honeywell UOP: Maintaining FLNG operations in rough seas
© 2013 UOP LLC. All rights reserved. UOP 6195-1
Tony Purcell UOP LLC, A Honeywell Company
Maintaining FLNG Operations in Rough Seas
The FLNG Forum December 3-4, 2013 Perth, Western Australia
Take-away from This Presentation
UOP has a complete portfolio of Gas Processing Technologies also applicable for FLNG
UOP Integrated FLNG Pretreatment
Multiple technology building blocks to meet varied feed properties over the life of the gas field
Optimized pretreatment scheme designed to minimize weight and space with flexible operation
Provided as modules to load on ship
Multiple execution models to meet client needs
One Honeywell approach to capture value
UOP Integrated Offerings Reduce Schedule and Lifecycle Costs 2
UOP 6195-2
Overall Agenda
Introduction
Specifications
Unique Design Challenges
– Space and Weight Considerations
– Motion Effects
Gas Pretreatment Solutions for FLNG
Heavy Hydrocarbon Removal from Lean Gas
3
UOP 6195-3
Honeywell’s Businesses
$37.6 billion in revenues in 2012, 50% outside of U.S.
Nearly 122,000 employees operating in 100 countries
19,000 engineers and scientists
A Fortune 100 company with Morristown, NJ global corporate headquarters
Aerospace Automation &
Control Solutions
Performance Materials &
Technologies Transportation
Systems
4
UOP 6195-4
UOP Company Profile Serving the Gas Processing, Refining & Petrochemical Industries
Profile — Significant Technology Position
Business Units: • Gas Processing and Hydrogen (GP&H)
• Process Technology & Equipment (PT&E)
• Catalysts, Adsorbents & Specialties (CA&S)
• Renewable Energy and Chemicals (RE&C)
Offering: • Technology, catalyst & services to the refining,
petrochemical and gas processing industries
• Supplier of molecular sieve adsorbents to process and manufacturing industries
UOP Facilities — Global Footprint Sales: Geographic
Sales: Breakdown
North
America
32%
Asia Pacific
19%
China
12%
Middle East
9%
South
America
9%
E&A 9%
CIS 5%India
5%
UOP Offices
UOP Manufacturing Sites
• 20 Offices
• 17 Countries
• 12 Manufacturing Facilities
• 5 Engineering Centers
Worldwide Headquarters Des Plaines, Illinois (suburban Chicago)
3,500+ Employees
Global
Customers
Equipment
45%
Licensing
7%
Services
13%
Products
35%Equipment
Products
Services
Licensing
5
UOP 6195-5
Well/Reservoir Monitoring &
Control
• Production Well Monitoring
& Choke Control
• Gas Lift Control
• Gas/Water Injection Well Monitor
& Choke Control
• Down-hole Monitoring Advanced Applications
• Production Optimization
• Power Management
• Gas Lift Optimization
Acid Gas Treating and Dehydration
• Membrane CO2 Removal Systems
• Bulk, selective or trace acid gas removal
• Gas Dehydration Systems
• Mercury Removal
Safety Systems
• Process Shutdown
• Security
• Emergency Shutdown
• Fire and Gas detection
• Heating, Ventilation and
Air
Conditioning Topside Process Control
• Gas Processing Control
• Flow Control & Metering
• Compressor Control
• Gas/Oil Pipeline Monitor &
Control
• Turbo Generator Control
• Gas/Oil/Water Separation
Control
• Well Test Control
• Water Treatment Control Marine Systems
• Propulsion & Dynamic Positioning
• Loading Computer
• Cargo & Ballast Control
Power Applications
• Power management
• Load Shedding
• Turbo Generator Control
Other Systems
• Personnel Address
• Drilling
• Communications
Business and Other
Applications
• Well Test Accounting
• Production Accounting
• Data Warehousing
• Equipment Health Management
• Operator Training
• Aero
• UOP
• Automation & Control
Solutions
Honeywell
FPSO Solutions
Honeywell is uniquely situated
to provide a full suite of
technology solutions for
the FPSO vessel. Our
Technology employed can
provide significant
increase In yield and
operational efficiency to
the owners/ operators.
“Input from Honeywell during
the design phase of our FPSO
resulted in a
significant reduction of labor
costs.”
–Mike Baker
Project C&I Lead Texaco Captain
FPSO
Successful Projects Captain FPSO
Laminaria
Esso Norge Jotun FPSO
FPSO Cidade de Angra dos Reis
(MODEC)
FPSO Cidade de Sao Paulo
(MODEC)
FPSO Replicants (Petrobras)
FPSO Cessao Onerosa
(Petrobras)
UOP has been selected for 100%
of Petrobras pre salt FPSOs
tendered (Cidade de Angra dos
Reis, São Paulo, Replicants and
Cessão Onerosa)
Others
Integrated sub-sea
controls
Simulator
RMG Controls
Enraf Tankage
Scope
• Design
• Engineering
• Fabrication
Staging
Commissioning
Helipad Applications & Others
• Guidance and obstruction
lighting • (Condition-based Maintenance)
Source: Honeywell 6
UOP Natural Gas Solutions Flow Scheme
UOP Has Solutions to Help Maximize Gas Monetization
Sulfur Acid Gas
Mercury Removal
Dehydration
UOP Equipment UOP Equipment UOP Equipment
Natural Gas
Extraction
Sulfur Recovery UOP Offerings
Dry Sweet Gas
LNG
Raw Natural
Gas Liquids
Ethane
Propane
Mixed Butanes
Natural
Gasoline
UOP Petrochemical technology to further convert / upgrade NGLs
MOLSIV™ Separex™
Membrane
Systems
Amine Guard™
FS Process
Selexol™
Process
Twister™
Supersonic
Separator
Liquids Recovery
Fractionation
Liquefaction Acid Gas Removal
(CO2, H2S)
Adsorbents
Ortloff
Processes
SeparSIV ™
7
UOP 6195-7
Overall Agenda
Introduction
Specifications
Unique Design Challenges
– Space and Weight Considerations
– Motion Effects
Gas Pretreatment Solutions for FLNG
Heavy Hydrocarbon Removal from Lean Gas
8
UOP 6195-8
FLNG Pretreatment Requirements
Mooring System & Inlet Separation FLNG Pretreatment
UOP Gas Processing
Liquefaction & Unloading
Typical Gas Composition Gas Quality
for
Liquefaction
South
America
South
East Asia Australia
Middle
East
H2S, ppmv 5 - 1000 5 - 200 2 - 50 1000 - 2900 <2 - 4
Total Sulfur, ppmv 5 - 1000 5 - 250 2 - 60 0 - 400 RSH 1 - 40 COS < 10 - 50
CO2, % 2 - 55 9 - 50 2 - 30 2 - 7 < 50 ppmv
Hg, μg/Nm3 0 - 100 200 - 2000 50 - 200 0 - 50 < 0.01
H2O, ppmv Saturated Saturated Saturated Saturated < 0.1
C5+ Varies Varies Varies Varies < 0.1 mole%
9
UOP 6195-9
Overall Agenda
Introduction
Specifications
Unique Design Challenges
– Space and Weight Considerations
– Motion Effects
Gas Pretreatment Solutions for FLNG
Heavy Hydrocarbon Removal from Lean Gas
10
UOP 6195-10
Space and Weight Considerations
Land Based
Use Economies of Scale for larger plant
– Units over 1 BCFD (7MMTPA)
Large Footprint
No major Weight Considerations
Floating
Minimal footprint
Smaller Capacities
– Ship Size limitations 1 to 4 MMTPA
Minimize Weight
– Additional Weight Requires Buoyancy
– Additional Buoyancy Reduces On-Board Storage
11
UOP 6195-11
Project Location Capacity, MMSCFD Technologies Application S/U Date
Indonesia 4 x 625 B, M3 LNG+NGL 80’s
Adgas 2 x 225 B, M3 LNG+NGL 85
Adgas 550 B, M3 LNG+NGL 95
RasGas 3 x 750 A, M, S, O (I) LNG 04/05/06
RasGas 750 A, M3, S, O (I) SG 05
Dolphin 4 x 800 A2, M3 SG+NGL 07/08
Gasco 2 x 625 A, O SG+NGL 08/09
Gasco 2 x 400 A, O SG+NGL 09
QatarGas 2 x 1400 M3, S, O (I) LNG+NGL 08/09
RasGas 2 x 1500 A, M3, S, O (I) LNG+NGL 09
RasGas 1600 A, M4, S, O (I) SG+NGL 09
QatarGas 2 x 1400 M3, S, O (I) LNG+NGL 09/10
Gasco (SGD) 2x900 M, S, O (I) SG+NGL 12/15
RasGas (Barzan) 3x980 A, M, S, O (I) SG+NGL 12/15
26.69 Bcfd A - UOP Amine Guard FS Unit M - UOP Molecular Sieve System
B – UOP Benfield Unit O – Ortloff NGL Unit
S - UOP Selexol Unit
I – Integrated
Land Based LNG & NGL Integrated Approach UOP World Scale Experience
12
UOP 6195-12
UOP LNG Experience
13
UOP 6195-13
FLNG Motion Effect on Column Performance
Uniform countercurrent gas and liquid flow is disturbed by motion leading to reduced heat and mass transfer efficiency
Column efficiency drops for distillation/absorption have been documented in the literature
Column performance suffers with motion and permanent tilt
Column efficiency decreases at very long or very short period
The taller the bed height, or H/D ratio, the higher the loss in efficiency
List angle
α
Significant concerns to meet 50 ppm CO2 product spec for
FLNG pretreatment when amine process applied 14
UOP 6195-14
Effect of Mal-distribution on Column Performance
The lower the CO2 product spec required, the more sensitive the amine
column to mal-distribution, or motion For FLNG pretreatment
15
UOP 6195-15
0%
1%
2%
3%
4%
5%
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Maldistribution Factor
Ou
tlet
CO
2 C
on
cen
trati
on
Outlet CO2 spec = 3%
Outlet CO2 spec = 1%
50 ppmv CO2 spec is required for FLNG (very sensitive to mal-distribution)
Right design margin is applied to guarantee
treated gas meeting 50 ppmv CO2 spec
Increasing Solvent Rate to Overcome the Effect of Mal-distribution: Solvent Circulation Margin
• At high liquid rates the absorber is less sensitive to mal-distribution
• Design margin in solvent circulation rate needs to be added for offshore service
Margin: The extra solvent circulation rate applied above land base amine design
16
UOP 6195-16
8.E-04
7.E-04
6.E-04
5.E-04
4.E-04
3.E-04
2.E-04
1.E-04
0.E+00
CO
2 C
on
ce
ntr
ati
on
in
Tre
ate
d G
as
0 0.05 0.1 0.15 0.2 0.25 0.3
Maldistribution Factor
Land Based
10% Margin
23% Margin
We have developed a design procedure for
marinization of amine unit
UOP Design Procedure for Offshore Amine Units
• Set the feed basis and solvent circulation rate from land based design • Motion amplitude
• Period
• Permanent tilt angle
• Worst case maldistribution sets the design case
Motion/tilt Data For the Project
Land Based Design
CFD Simulations
Maldistribution Parameters
Rigorous Heat & Mass Transfer Model
AGRU Design <50 ppm CO2
Pilot Plant Data For Rocking
Column
17
UOP 6195-17
MolSiv Adsorber under Tilt Condition
Tilt Angle α
Liquid Level
High Liquid Flow
Low Liquid Flow
Amine Column
Tilt Angle α
Solid Level
Uniform Gas Flow
• In amine units, liquid level will stay horizontal, and not perpendicular to the flow path, resulting in flow mal-distribution
• In MolSiv units, solid adsorbent will stay perpendicular to the flow path resulting in uniform gas flow.
Adsorber
18
UOP 6195-18
Overall Agenda
Introduction
Specifications
Unique Design Challenges
– Space and Weight Considerations
– Motion Effects
Gas Pretreatment Solutions for FLNG
Heavy Hydrocarbon Removal from Lean Gas
19
UOP 6195-19
Water Sour Gas CO2 + H2S
UOP GB™ Adsorbent Mercury Removal Unit
UOP Amine Guard FS™ Process Unit
XXXX
Treated Gas to LNG
Feed Gas
Conventional Pretreatment Scheme UOP MOLSIVTM Adsorbent
Dehydration Unit
Large solvent system in off-shore environment
– Logistics (permanent solvent/water make-up)
– HSE issues related to use of amines
Limited flexibility
– For variations in feed over life of field
– Limit on CO2 content of feed gas due to limit on size of unit
Impact of rocking motion has to be accounted for
20
UOP 6195-20
Water
Permeate Gas
Sour Gas CO2 + H2S
UOP GB™ Adsorbent Mercury Removal Unit
UOP Amine Guard FS™ Process Unit
Feed Gas
XXXX
Sour Gas CO2 + H2S
Treated Gas to LNG
Treated Gas to LNG
Feed Gas
Hybrid Scheme
Conventional Scheme
Water
XXXX
UOP Separex Membrane System
Hybrid Pretreatment Scheme
Smaller amine unit
More flexible for variation over life of field
System can handle gas streams with higher CO2 content
UOP MOLSIVTM Adsorbent Dehydration Unit
21
UOP 6195-21
22
Solvent-free Pretreatment Scheme
Water
Permeate Gas
Sour Gas CO2 + H2S
UOP GB™ Adsorbent Mercury Removal Unit
UOP Amine Guard FS™ Process Unit
Feed Gas
XXXX
Sour Gas CO2 + H2S
Treated Gas to LNG
Treated Gas to LNG
Feed Gas
Hybrid Scheme
Conventional Scheme
Water
XXXX
UOP Separex Membrane System
UOP MOLSIVTM Adsorbent Dehydration Unit
Final FLNG pretreatment lay-out depends
on feed gas composition UOP 6195-22
22
Solvent-free Pretreatment Scheme
Regeneration Gas Water, CO2 & H2S
UOP GB™ Adsorbent Mercury Removal Unit
UOP Amine Guard FS™ Process Unit
Feed Gas
UOP MOLSIVTM Adsorbent Acid Gas Removal/ Dehydration Unit
Treated Gas to LNG
Treated Gas to LNG
Feed Gas
Membranes + Adsorbents
Adsorbent-Only
Water
UOP Separex Membrane System
Permeate Gas Water, CO2 & H2S
Solvent-free eliminates motions effects
Permeate Gas (Membranes) or Regeneration Gas (MolSiv) can be
used to meet the ship’s utility needs
23
UOP 6195-23
Adsorbents in LNG Service & Off-shore
UOP Molsiv Adsorbents have been used in > 1,400 units
for dehydration and acid gas removal
Extensive Experience in CO2 Removal for LNG Pretreatment
– 30 + references in LNG Peak Shavers
– Pipeline Quality Gas (2-3%) to LNG Quality Gas (50 ppmv)
UOP Molsiv Adsorbents have been used in off-shore units
(Brasil, Thailand, Indonesia, Nigeria, Angola, Australia…)
Molsiv Adsorbents can also be used
for CO2 removal in FLNG pretreatment 24
UOP 6195-24
UOP’s Offshore Separex Experience
Location Type of
Unit MMSCFD CO2
Removal Stages
Pretreatment
Thailand Platform 32 50% - 20% 1 MG
Malaysia Platform 680 44% - 8% 2 MG
Thailand Platform 580 40% - 23% 1 MG
Thailand FPSO 11 28% - 3% 1 J-T
Thailand Platform 480 35% - 23% 1 MG
Brazil FPSO 176 25% - 5% 2 J-T
Brazil FPSO 176 35% - 5% 1 C3R
UOP is extending its land based experience to offshore
by courtesy of Talisman by courtesy of Petrobras
25
UOP 6195-25
Overall Agenda
Introduction
Specifications
Unique Design Challenges
– Space and Weight Considerations
– Motion Effects
Gas Pretreatment Solutions for FLNG
Heavy Hydrocarbon Removal from Lean Gas
26
UOP 6195-26
Heavy Hydrocarbon Removal from Lean Gas
Heavy hydrocarbon removal is desirable, but light hydrocarbon removal is not
– Keep C2-C4 in the LNG to raise BTU value
Concern:
– Heavy hydrocarbons freezing in LNG exchangers
– Desirable to remove BTEX and heavier components
– May not have enough hydrocarbon for a typical NGL cryogenic recovery scheme – not enough reflux in the demethanizer
Potential Solution(s):
– Using cryogenic distillation to remove hydrocarbons
– Using a highly selective multilayer adsorbent system to remove sulfur species and hydrocarbons
27
UOP 6195-27 SeparSiv can remove C6+ to less than 1 ppmv
Technical Solutions for Hydrocarbon Removal
For the SeparSIV Process, hydrocarbons and water are removed from a
gas/liquid separator after cooling the regeneration gas
UOP MOLSIV
dehydration
TSA
Cryogenic separation
expander or JT
distillation column
compressor
Feed Product to
Liquefaction
Water
Hydrocarbons
SeparSIV Process
Feed Product to
Liquefaction
Hydrocarbons
UOP’s SeparSiv Process
Cryogenic temperature achieved by gas expansion
Recompression of the gas is generally needed after liquefaction
Current commercial Process
UOP MOLSIV
dehydration
TSA
Water
28
UOP 6195-28
Cryogenic Distillation Options
• Poor separation due to high pressure scrub column
• Lower scrub column temp to provide reflux
– condense C1, C2
– less efficient
• Add fractionation columns to provide reflux
– add CAPEX
Fractionation
Dehydration
Precool
Scrub Column LNG
Feed
Cold Box
• Better separation due to low pressure scrub column
• Need expander-compressor – add CAPEX and OPEX
• This integrated NGL-liquefaction option is believed to be more efficient than the option above
Condenser
Dehydration
Precool
Scrub Column LNG
Feed
Cold Box
Compressor
Expander
NGL
Cryo requires low pressure and temperature to meet
spec which increases CAPEX and OPEX 29
UOP 6195-29
Adsorbing Bed
Particle Filter
Filter Coalescer Regenerating
Bed
Regen Gas Cooler Regen Gas
Separator
Regen Gas Blower
Feed
Liquids
Clean Gas
Regen Heater
UOP SeparSIV Process/System
30
UOP 6195-30
31 UOP - CONFIDENTIAL File Number
Technical Approach
With a vast inventory of adsorbents and a library of control
schemes, UOP can match the requirements of your application
Remove C6 and below, water to <0.1 ppm
Remove C8 and above and BTX, trace water
(capable of bulk water removal)
31
UOP 6195-31
Heavy Hydrocarbon Management Options
• The UOP SeparSIV Process can be used for pipeline gas dew point specification
or before liquefaction after an AGRU to remove water and hydrocarbon
compounds that freeze.
Product specification also affects process selection
GPM = gallons of liquefiable hydrocarbons per 1,000 cubic feet of natural gas
32
5
6
7
8
9
Hyd
roc
arb
on
to
be
re
mo
ve
d
ca
rbo
n n
um
be
r
SeparSIV - layered adsorbents Cryogenics
2 GPM > 2 GPM < 2
UOP 6195-32
layered adsorbents SeparSIV -
Cost Comparison*
*Cryo only considers compressor power
* Over how many years?
Savings derived from • Compression required in the cryogenic scheme while SeparSIV
only has a blower
• Cryogenic BTEX removal requires more pressure drop and lower temperatures, which drive up CAPEX and OPEX
• Cryogenic system better suited for higher GPM and loose product specifications
Economic Basis: 810 MMSCFD Rich Feed (1.8 GPM)
Lifecycle Cost = CAPEX + (4 * OPEX)
*Estimated
33
$MM SeparSIV Cryogenic
CAPEX 1.0 1.5
OPEX (annual) 1.0 4.8
Lifecycle Cost 1.0 2.0
UOP 6195-33
Conclusions
UOP’s Integrated FLNG Pretreatment
• Flexible ‒ Multiple technology building blocks to meet varied feed
properties over life of the gas field
• Proven Technology ‒ Technology used in applications on land
and offshore for past 30 years
‒ Low lifecycle costs
• Multiple Execution Models ‒ Provided as single or multi-lift equipment modules
‒ Licensed with key mechanical equipment
‒ Licensed only
34
UOP 6195-34
35
UOP 6195-35