Zero Emission Power Production for LNG Regasification

Transcription

1 part of Aker Zero Emission Power Production for LNG Regasification A concept for new environmental friendly regasication technology Suthan Vivekananthan MEng CEng MIChemE (UK) Senior Process Engineer System Design Dept. Presented at the 2 nd Trondheim Gas Technology Conference 3 rd November Aker Solutions

2 CONTENTS 1. Introduction to Aker Solutions & BAs 2. Study Background 3. Reference Case 4. Study Results 5. Future work Slide 2

3 Aker Solutions Operating businesses Engineering solutions Product solutions Field life solutions Engineering Subsea Well Intervention Services Drilling Technologies Oilfield Services & Marine Assets Mooring & Loading Systems Maintenance, Modifications & Operations Process Systems Slide 3

4 Business Management Corporate structure Executive Chairman Øyvind Eriksen President 1 and Chief Financial Officer Leif Borge Corporate Centre Chief Operating Officer Chief of Staff Chief Strategic Marketing Chief Technology Officer Chief HR Officer Engineering (ENG) Subsea (SUB) Umbilicals (UMB) Drilling Technologies (DRT) Mooring & Loading Systems (MLS) Process Systems (PRS) Well Intervention Services (WIS) Oilfield Services & Marine Assets (OMA) Maintenance, Modifications & Operations (MMO) Valborg Lundegaard Alan Brunnen Tove Røskaft Thor Arne Håverstad Leif Haukom Michael Hambly Wolfgang Puennel Karl Erik Kjelstad Tore Sjursen 1 President of Aker Solutions ASA Slide 4 Slide 4

5 Engineering BA Management Head of Engineering Valborg Lundegaard Chief of Staff Gry Braathen CFO Merete Åsenden QM & HSE Knut Støle Hanssen Business Development Petter Urdahl Future hubs Engineering UK (AET Ltd) Erik Sjølie Engineering India (APG) Sanjay Joshi Engineering Malaysia (AEM) Ravi Kashyap AET Engineering &Project Mgmt Astrid S. Onsum AET Front-End &Technology Henning Østvig System Design Dept. Slide 5

6 CONTENTS 1. Introduction to Aker Solutions & BAs 2. Study Background: Introduction Study Motivation Study aims 3. Reference Case: Comparision with Adriatic LNG Terminal 4. Study Results: Equipment design Technology status Layout design Weight / Cost estimates 5. Future work Slide 6

7 Study Background: Introduction LNG Regasification Process turns the cold LNG into Natural Gas so that it can be given to the End User. LNG feed LNG Vaporiser Natural Gas Traditionally 2 different methods are used for LNG Regasification: Submerged Combustion Vaporisers (SCVs) using a burner as the heat source Rack Vaporisers (ORVs) using sea water as the heat source But both methods have a negative impact on the environment: SCVs: Emission of flue gases containing NO x, CO, CO 2 ORVs: Discharge of large volumes of seawater containing hypochlorite and at up to 10 C colder than the seawater intake temperature Slide 7

8 Study Motivation (External) Global warming due to increase in human emissions of CO 2 require new environmentally friendly products Kyoto agreement EU 2020 Goal There is an existing and growing market on offshore and onshore LNG Regas terminals There are restrictions on planning and building of LNG Regas terminals due to environmental regulations Upcoming new technology for environmentally friendly large scale energy production: Post-combustion (ACC) Available technology Pre-combustion Future Technology Oxyfuel Emerging Technology Slide 8

9 Study Motivation (Internal) Aker Solutions controls the entire CO 2 value chain Aker Clean Carbon (ACC) owns technology on CO 2 capture CO 2 from NG CO 2 injection (Subsea/platform) Aker Solutions has built two-third of world s offshore GBS structures This Regas terminal is assumed to be built on GBS Experience on major onshore LNG regasification terminals Slide 9

10 Study Aims Design a NEW environmental friendly LNG Regas terminal that does not produce any emission or effluents Power generation with CO2 separation (minimal harmful emissions) No discharges to sea This new technology will be a real competitor to the traditional LNG Regas market, in the areas where stricter environmental restrictions are enforced. Slide 10

11 CONTENTS 1. Introduction to Aker Solutions & BAs 2. Study Background: Introduction Study Motivation Study aims 3. Reference Case: Comparision with Adriatic LNG Terminal Base Case Process 4. Study Results: Equipment design Technology status Layout design Weight / Cost estimates 5. Future work Slide 11

12 Adriatic LNG Terminal Overview Design Gravity-base structure (GBS) designed by Aker Solutions Technical Features The structure is 180 m x 88 m LNG Regas process using four ORVs (seawater) + one SCV (waste heater boiler) Located 15 km off the east coast of Italy. Placed on the seabed in a water depth of approximately 30 metres. Pipes which transport gas to land Adriatic LNG Regas Process 25 million Sm 3 /day of sales gas Equals 8 billion Sm 3 /year 5.9 MTPY Other existing Regas terminals are: 0 5 MTPY *MTPY = Million Tonnes Per Year Slide 12

13 Overall Block Flow Diagram - Base Case N 2 to Export Electric Power 32MW Water Air Air Separation Unit (ASU) 55 O 2 Steam & Power Generation 55 Flue gas N 2/ O 2 /CO 2 Vent CO 2 Dehydration & Compression 23 CO 2 Product to Export / Injection 773t/d ( tonnes/year) LP Steam LP Steam to users Fuel gas for Power Sales Gas Export LNG Feed LNG Pumps CO 2 Capture Cooling Flue Gas Cooling LNG Vaporising (by Condensed Steam) LNG Vaporising (by LP Steam) 25 Mill. Sm 3 /day Slide 13

14 Design Features New LNG Regas Process Systems: Air Separation Unit Produce Oxygen Oxygen Fired Burner (Oxyfuel) Clean combustion Onboard Steam & Power System Power plant CO 2 Removal System Flue gas (CO 2 / Water) CO 2 Compression / Export CO 2 for EOR/Injection Regas Facility Features: Utilises the heat integration between the LNG gasification process and the power generation and CO 2 separation process Slide 14

15 CONTENTS 1. Introduction to Aker Solutions & BAs 2. Study Background: Introduction Study Motivation Study aims 3. Reference Case: 4. Study Results: Equipment design Technology status Layout design Weight / Cost estimates 5. Future work Slide 15

16 Equipment Design: LNG Regas Process Electric Vertical pump Power Produced 5 operating + 1 spare Water Spiral wounded tubes Steam N 2 to Export BFW Npassing Condensate 2/ O 2 /COthrough 2 a water Vent bath Flue Heating medium: CO 2 Product Steam/ to gas Condensate CO 2 Clean Up Export / Injection Air Separation O 2 Steam & Power 4 exchangers in parallel Unit (ASU) Generation & Compression Air LNG Vaporisers Designed & Supplied by Cryostar / Linde LP Steam LP Steam to users Fuel gas for Power 1688 m 3 /hr (Actual flow) Nat. Gas Export LNG Feed LNG Pumps CO 2 Dehydration & compression Cooling Flue Gas Condensing LNG Vaporising (by Condensed Steam) LNG Vaporising (by LP Steam) 25 Million Sm 3 /day Slide 16

17 Equipment Design: Air Separation Unit Air Gaseous O 2 production Produced Possible N 2 (gas) production Water N 2 to Export Steam Air cooled BFW water circulation N Condensate 2/ O 2 /CO 2 intercooling system Vent Air Separation Unit (ASU) 47 O 2 Designed & Supplied by Linde Oxygen plant (95% purity) Based on onshore design can be tailor Steam made & Power for Offshore Generation 55 Flue gas CO 2 Clean Up & Compression 23 CO 2 Product to Export / Injection LP Steam LP Steam to users 0,4 Mill. Sm 3 /day Fuel gas for Power 1688 m 3 /hr (Actual flow) Nat. Gas Export LNG Feed LNG Pumps CO 2 dehydration Cooling Flue Gas Condensing LNG Vaporising (by Condensed Steam) LNG Vaporising (by LP Steam) 25 Million Sm 3 /day Slide 17

18 Air Equipment Design: Steam & Power System Produced Flue gas Fans: Howden Water N 2 to Export Electric Steam BFW N Condensate 2/ O 2 /CO 2 Power Vent Both fans (FG Fan and FG Recycle Fan) commercially available Air Separation Unit (ASU) 47 O 2 Steam & Power Generation 55 Flue gas CO 2 dehydration & Compression 23 CO 2 Product to Export / Injection LP Steam LP Steam to users Fuel gas for Power 1688 m 3 /hr (Actual flow) Boiler design: Ålborg boilers LNG Feed Offshore boiler design w/ econ Economizers reduce CO 2 fuel Clean cons. up by 10% Cooling LNG Pumps 40 bara & 400 o C MP steam Can be modified to fit Oxyfuel burner Oxyfuel burner: Vendor TBC Separate study by SINTEF Burners Flue not Gas commercially available LNG Vaporising Major Condensing developments ongoing (by Condensed Steam) 3 suppliers tested natural gas fired oxyfuel burners: Air Liquide, Jupieter Oxygen Corp & Clean Energy Systems Nat. Gas ST design : Alstom Power Export Condensing Steam Turbine 25 Million Commercially LNG Vaporising available Sm 3 /day Condensate (by LP Steam) cooled by LNG cold (Cryostar/Linde s Waterbath technology) Slide 18

19 Equipment Design: CO 2 Removal Unit Air Produced N 2 to Export BFW Steam Water N Condensate 2/ O 2 /CO 2 Vent Air Separation Unit (ASU) 47 O 2 Steam & Power Generation 55 Flue gas CO 2 Dehydration & Compression 23 CO 2 Product to Export / Injection LP Steam LP Steam to users 0,4 Mill. Sm 3 /day Fuel gas for Power 1688 m 3 /hr (Actual flow) Compressor design: Man Turbo / Dresser Rand LNG Feed Centrifugal 3-stage compressor CO 2 Clean up Commercially available Cooling LNG Pumps Vendor can also supply CO 2 pump Intercoolers design: in-house As described Flue Gas before Condensing ST type Using LNG cold MEG/Water as heat transfer medium for cooling to +5 o C for compressor intercooling Cold separator design: inhouse Separates condensed CO 2 LNG from Vaporising nitrogen / oxygen at - LNG Vaporising 40 o C. (by Condensed (by LP Steam) Commercially Steam) available separation technology N 2 Nat. Gas Export 25 Million Sm 3 /day Methanol as heat transfer medium for cooling CO 2 to - 40 o C for cryogenic separation CO 2 Slide 19

20 Process Technology Status Process System Air Separation Unit Oxygen Fired Burner (Oxyfuel) Steam Generation System Power Generation system Cryogenic CO 2 Liquefaction System Heat Integration System Utilities and off sites Status Existing Technology for onshore plats Semi commercial. Small scale pilot plants NG 30MW exists. Ref. to Statoil Kårstø, BIGCCS Existing Technology Steam Generator Technology Exists Known Technology Elements New Application Ref. to Statoil Kårstø, BIGCCS Some heat exchanger equipment NOT off the shelf available Existing Technology Required work Qualification for offshore use Technology development for larger scale. Technology Qualification required. Boiler vendor and Oxyfuel Burner vendor liaising with each other to develop the steam generation technology None Application and System Integration needs to be Qualified Equipment and System Integration needs to be Qualified None Overall system need: Identification and verification of the plant operation and flexibility. Slide 20

21 Layout Design Basis for layout: GBS dimensions based on Adriatic (180m long x 88m wide) 2 x LNG storage tanks of 125,000m 3 / tank Equipment list developed by process Layout philosophy: Topsides design to be inherently safe with segregation of hazardous and non hazardous system LQ and utility areas located upwind of process facilities Fire / blast wall provided between process and utility areas Topsides modules split into system packages to reduce interface and hook-up and allow parallel fabrication activities Slide 21

22 Layout Design Iso view of Regas Topsides Slide 22

23 Weight/Cost Estimate: Reference Case is As-Built figures for a comparable Regasification facility, scaled to 2010 price-level figures. The above figures exclude the cost of GBS: The GBS size for the Base Case is same as for Reference case hence GBS costs are excluded for comparision Evaluation Summary : The cost of new Regasification terminal (with CO 2 separation) is comparable with the existing Regas terminals without CO 2 capture. Slide 23

24 CONTENTS 1. Introduction to Aker Solutions & BAs 2. Study Background: Introduction Study Motivation Study aims 3. Reference Case: 4. Study Results: Equipment design Technology status Layout design Weight / Cost estimates 5. Future Work Slide 24

25 Future Work Further development of the Patented Regas Technology Assistance with technology maturity To feasibility stage with operational, functional description and safety Detailed benchmarking against Adriatic Identify marketing challenges for the New Regas Technology Identify potential partners for joint-development / Govt. bodies for funding the following tasks: Technology Verification Pilot Test Programs FEED Develop Technology Qualification Plan with partners Involve potential test sites in further planning Identify relevant proposed projects for the New Regas Terminal Possible Locations / prospects Slide 25

26 THANK YOU! ANY QUESTIONS? Contact details: Slide 26

27 Copyright Copyright of all published material including photographs, drawings and images in this document remains vested in Aker Solutions and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction. Slide 27