Method of natural gas liquefaction on LNG carriers storing liquid nitrogen
10551117 ยท 2020-02-04
Assignee
Inventors
Cpc classification
F25J1/0072
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0204
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0265
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0277
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0042
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0223
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2240/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2210/62
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0015
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0278
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2240/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2270/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2230/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0221
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2210/60
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2210/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2290/60
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2290/72
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F25J1/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method for producing liquefied natural gas (LNG). A natural gas stream is transported to a liquefaction vessel. The natural gas stream is liquefied on the liquefaction vessel using at least one heat exchanger that exchanges heat between the natural gas stream and a liquid nitrogen stream to at least partially vaporize the liquefied nitrogen stream, thereby forming a warmed nitrogen gas stream and an at least partially condensed natural gas stream comprising LNG. The liquefaction vessel includes at least one tank that only stores liquid nitrogen and at least one tank that only stores LNG.
Claims
1. A method for producing liquefied natural gas (LNG), comprising: transporting liquid nitrogen in the liquefaction vessel; transporting a natural gas stream to the liquefaction vessel; liquefying the natural gas stream on the liquefaction vessel using at least one heat exchanger that exchanges heat between the natural gas stream and a liquid nitrogen stream from the transported liquid nitrogen, to at least partially vaporize the liquefied nitrogen stream, thereby forming a warmed nitrogen gas stream and an at least partially condensed natural gas stream comprising LNG; and storing and transporting the LNG in the liquefaction vessel in a tank exclusively reserved for LNG storage therein; wherein the liquefaction vessel further includes at least one tank that exclusively stores and transports liquid nitrogen therein and at least one tank that stores either LNG or liquid nitrogen therein; wherein the tank exclusively reserved for LNG storage does not store liquid nitrogen when liquid nitrogen is transported in the liquefaction vessel, and wherein the at least one tank that exclusively stores liquid nitrogen does not store LNG when LNG is transported in the liquefaction vessel.
2. The method of claim 1, further comprising: obtaining the natural gas stream from a floating production unit (FPU) vessel that produces natural gas from a reservoir and treats the produced natural gas to remove at least one of water, heavy hydrocarbons, and sour gases therefrom prior to transporting the natural gas stream to the liquefaction vessel.
3. The method of claim 2, further comprising: transporting the warmed nitrogen gas stream to the FPU vessel; and using the warmed nitrogen gas stream within a process on the FPU vessel.
4. The method of claim 3, further comprising: compressing the warmed nitrogen gas stream on the FPU; and injecting the compressed warmed nitrogen gas stream into a reservoir for pressure maintenance.
5. The method of claim 1, further comprising: reducing a pressure of the warmed nitrogen gas stream to produce at least one additionally cooled nitrogen gas stream; and exchanging heat between the at least one additionally cooled nitrogen gas stream and the natural gas stream to form at least one additional warmed nitrogen gas stream.
6. The method of claim 5, wherein the pressure of the warmed nitrogen gas stream is reduced using at least one expander service.
7. The method of claim 6, further comprising generating electrical power from at least one generator coupled to the at least one expander service.
8. The method of claim 1, further comprising: transporting the natural gas stream to the liquefaction vessel via a moored floating disconnectable turret configured to be connected, disconnected, and reconnected to the liquefaction vessel.
9. The method of claim 8, further comprising docking the liquefaction vessel at an export terminal while the natural gas stream is being liquefied.
10. The method of claim 8, wherein a single liquefaction vessel is used for LNG production and storage at the export terminal, and further comprising: storing LNG at an export terminal and transporting the LNG to an import terminal using more than one of LNG carriers, liquid nitrogen carriers and dual-purpose carriers.
11. The method of claim 1, further comprising: transporting the natural gas stream to the liquefaction vessel via a loading arm connected to an onshore gas pipeline, the loading arm being configured to be connected, disconnected, and reconnected to the liquefaction vessel.
12. The method of claim 11, further comprising: transporting liquid nitrogen from a separate vessel to the liquefaction vessel via a cryogenic liquid loading arm configured to be connected, disconnected, and reconnected to the liquefaction vessel, the liquid nitrogen stream comprising the liquid nitrogen transported in the liquefaction vessel.
13. The method of claim 11, further comprising: transporting the LNG from the liquefaction vessel to a separate vessel via a cryogenic liquid loading arm configured to be connected, disconnected, and reconnected to the liquefaction vessel.
14. The method of claim 1, further comprising: at an LNG import terminal, liquefying nitrogen gas using available exergy from gasification of the LNG, thereby forming the liquefied nitrogen in the liquid nitrogen stream.
15. The method of claim 1, further comprising: cooling the natural gas stream to a temperature not less than about 40 C. prior to transporting the natural gas stream to the liquefaction vessel.
16. The method of claim 1, further comprising: obtaining the natural gas stream from an onshore facility that treats natural gas to remove at least one of water, heavy hydrocarbons, and sour gases therefrom to produce said natural gas stream.
17. The method of claim 1, further comprising: during liquefaction turndown and/or shutdown periods, maintaining a temperature of liquefaction equipment on the liquefaction vessel using one of liquid nitrogen and liquid nitrogen boil-off gas.
18. The method of claim 1, further comprising liquefying vaporized nitrogen gas using the liquid nitrogen.
19. The method of claim 1, further comprising the use of warm nitrogen gas to derime the at least one heat exchanger during periods between LNG production on the liquefaction vessel.
20. A system for liquefying a natural gas stream, comprising: a liquefaction vessel that transports liquefied natural gas from a first location to a second location and transports liquefied nitrogen (LIN) to the first location, the liquefaction vessel including; at least one tank that exclusively stores LIN, at least one tank exclusively reserved for storing LNG therein, at least one tank that stores either LIN or LNG therein, and an LNG liquefaction system including at least one heat exchanger that exchanges heat between a LIN stream from LIN stored on the natural gas liquefaction vessel and the natural gas stream, which is transported to the natural gas liquefaction vessel, to at least partially vaporize the LIN stream, thereby forming a warmed nitrogen gas stream and an at least partially condensed natural gas stream comprising LNG, the LNG configured to be stored on the natural gas liquefaction vessel in the at least one tank exclusively reserved for storing LNG therein, to be transported to the second location; wherein the at least one tank exclusively reserved for storing LNG does not store LIN when LIN is transported in the liquefaction vessel to the first location, and wherein the at least one tank that exclusively stores LIN does not store LNG when LNG is transported in the liquefaction vessel to the second location.
21. The system of claim 20, further comprising: a floating production unit (FPU) vessel configured to produce the natural gas stream from a reservoir and to remove at least one of water, heavy hydrocarbons, and sour gases from the natural gas stream prior to transporting the natural gas stream to the liquefaction vessel.
22. The system of claim 20, wherein a pressure of the warmed nitrogen gas stream is reduced to produce at least one additionally cooled nitrogen gas stream, and further comprising a second heat exchanger configured to exchange heat between the at least one additionally cooled nitrogen gas stream and the natural gas stream to thereby form additional warmed nitrogen gas streams.
23. The system of claim 22, further comprising at least one expander service configured to reduce a pressure of the warmed nitrogen gas stream.
24. The system of claim 23, further comprising at least one generator coupled to the at least one expander service, the at least one generator configured to generate electrical power.
25. The system of claim 24, further comprising motor driven compressors powered by the at least one generator, the motor driven compressors configured to compress the warmed nitrogen gas stream.
26. The system of claim 23, wherein the at least one expander service is coupled to at least one compressor to thereby compress the warmed nitrogen gas stream.
27. The system of claim 20, further comprising a moored floating disconnectable turret configured to be connected, disconnected, and reconnected to the liquefaction vessel, wherein the natural gas stream is transported to the liquefaction vessel via the moored floating disconnectable turret.
28. The system of claim 27, wherein a single liquefaction vessel is used for LNG production and storage at the export terminal, and further comprising: storing LNG at an export terminal and transporting the LNG to an import terminal using more than one of LNG carriers, liquid nitrogen carriers and dual-purpose carriers.
29. The system of claim 20, further comprising a cryogenic liquid loading arm for transporting LIN from a separate vessel to the liquefaction vessel, the cryogenic liquid loading arm configured to be connected, disconnected, and reconnected to the liquefaction vessel.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other features, aspects and advantages of the disclosure will become apparent from the following description, appending claims and the accompanying drawings, which are briefly described below.
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(12) It should be noted that the figures are merely examples and no limitations on the scope of the present disclosure are intended thereby. Further, the figures are generally not drawn to scale, but are drafted for purposes of convenience and clarity in illustrating various aspects of the disclosure.
DETAILED DESCRIPTION
(13) To promote an understanding of the principles of the disclosure, reference will now be made to the features illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications, and any further applications of the principles of the disclosure as described herein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. For the sake clarity, some features not relevant to the present disclosure may not be shown in the drawings.
(14) At the outset, for ease of reference, certain terms used in this application and their meanings as used in this context are set forth. To the extent a term used herein is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Further, the present techniques are not limited by the usage of the terms shown below, as all equivalents, synonyms, new developments, and terms or techniques that serve the same or a similar purpose are considered to be within the scope of the present claims.
(15) As one of ordinary skill would appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name only. The figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. When referring to the figures described herein, the same reference numerals may be referenced in multiple figures for the sake of simplicity. In the following description and in the claims, the terms including and comprising are used in an open-ended fashion, and thus, should be interpreted to mean including, but not limited to.
(16) The articles the, a and an are not necessarily limited to mean only one, but rather are inclusive and open ended so as to include, optionally, multiple such elements.
(17) As used herein, the terms approximately, about, substantially, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numeral ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and are considered to be within the scope of the disclosure.
(18) The term heat exchanger refers to a device designed to efficiently transfer or exchange heat from one matter to another. Exemplary heat exchanger types include a co-current or counter-current heat exchanger, an indirect heat exchanger (e.g. spiral wound heat exchanger, plate-fin heat exchanger such as a brazed aluminum plate fin type, shell-and-tube heat exchanger, etc.), direct contact heat exchanger, or some combination of these, and so on.
(19) The term dual purpose carrier refers to a ship capable of (a) transporting LIN to an export terminal for natural gas and/or LNG and (b) transporting LNG to an LNG import terminal.
(20) As previously described, the conventional LNG cycle includes: (a) initial treatments of the natural gas resource to remove contaminants such as water, sulfur compounds and carbon dioxide; (b) the separation of some heavier hydrocarbon gases, such as propane, butane, pentane, etc. by a variety of possible methods including self-refrigeration, external refrigeration, lean oil, etc.; (c) refrigeration of the natural gas substantially by external refrigeration to form liquefied natural gas at or near atmospheric pressure and about 160 C.; (d) transport of the LNG product in ships or tankers designed for this purpose to a market location; and (e) re-pressurization and regasification of the LNG at a regasification plant to a pressurized natural gas that may distributed to natural gas consumers. The present disclosure modifies steps (c) and (e) of the conventional LNG cycle by liquefying natural gas on a liquefied natural gas (LNG) transport vessel using liquid nitrogen (LIN) as the coolant, and using the exergy of the cryogenic LNG to facilitate the liquefaction of nitrogen gas to form LIN that may then be transported to the resource location and used as a source of refrigeration for the production of LNG. The disclosed LIN-to-LNG concept may further include the transport of LNG in a ship or tanker from the resource location (export terminal) to the market location (import terminal) and the reverse transport of LIN from the market location to the resource location.
(21) The disclosure more specifically describes a method for liquefying natural gas on a liquefaction vessel having multiple storage tanks associated therewith, where at least one tank exclusively stores liquid nitrogen used in the liquefaction process, and at least one tank stores LNG exclusively. Treated natural gas suitable for liquefaction may be transported to the liquefaction vessel via a moored floating disconnectable turret which can be connected and reconnected to the liquefaction vessel. The treated natural gas may be liquefied on the liquefaction vessel using at least one heat exchanger that exchanges heat between a liquid nitrogen stream and the natural gas stream to at least partially vaporize the liquefied nitrogen stream and at least partially condense the natural gas stream. The LNG stream may be stored in the liquefaction vessel either in the at least one tank reserved for LNG storage or in other tanks onboard the liquefaction vessel configured to store either LNG or LIN.
(22) In an aspect of the disclosure, natural gas may be produced and treated using a floating production unit (FPU). The treated natural gas may be transported from the FPU to a liquefaction vessel via one or more moored floating disconnectable turrets which can be connected and reconnected to one or more liquefaction vessels. The liquefaction vessel may include at least one tank that only stores LIN. The treated natural gas may be liquefied on the liquefaction vessel using at least one heat exchanger that exchanges heat between a liquid nitrogen stream and the natural gas stream to at least partially vaporize the liquefied nitrogen stream and at least partially condense the natural gas stream. The liquefied natural gas stream may be stored in at least one tank that only stores LNG within the liquefaction vessel. The FPU may contain gas processing equipment to remove impurities, if present, such as water, heavy hydrocarbons, and sour gases to make the produced natural gas suitable for liquefaction and or marketing. The FPU may also contain means to pre-cool the treated natural gas prior to being transported to the liquefaction vessel, such as deep sea-water retrieval and cooling and/or mechanical refrigeration. Since the LNG is produced on the transporting tanker, over-water transfer of LNG at the production site is eliminated.
(23) In another aspect, natural gas processing facilities located at an onshore production site may be used to remove any impurities present in natural gas, such as water, heavy hydrocarbons, and sour gases, to make the produced natural gas suitable for liquefaction and or marketing. The treated natural gas may be transported offshore using a pipeline and one or more moored floating disconnectable turrets which can be connected and reconnected to one or more liquefaction vessels. The treated natural gas may be transferred to one or more liquefaction vessels that includes at least one tank that only stores LIN and at least one tank that only stores LNG. The treated natural gas may be liquefied on the liquefaction vessel using at least one heat exchanger that exchanges heat between a LIN stream and the treated natural gas stream to at least partially vaporize the LIN stream and at least partially condense the natural gas stream. The LNG stream produced thereby may be stored either in the at least one tank that only stores LNG, or in another tank onboard the liquefaction vessel that is configured to store either LNG or LIN. Since the LNG is produced on the liquefaction vessel, which also serves as a transportation vessel, over-water transfer of LNG at the production site is eliminated.
(24) In yet another aspect of the disclosure, onshore natural gas processing facilities may remove impurities, if present, such as water, heavy hydrocarbons, and sour gases, to make the produced natural gas suitable for liquefaction and/or marketing. The treated natural gas may be transported near-shore via a pipeline and gas loading arms connected to one or more berthed liquefaction vessels. Conventional LNG carriers, LIN carriers and/or dual-purpose carriers may be berthed alongside, proximal, or nearby the liquefaction vessels to receive LNG from the liquefaction vessel and/or transport liquid nitrogen to the liquefaction vessel. The liquefaction vessels may be connected to cryogenic loading arms to allow for cryogenic fluid transfer between liquefaction vessels and/or the LNG/LIN/dual-purpose carriers. The liquefaction vessel may include at least one tank that only stores liquid nitrogen and at least one tank that only stores LNG. The treated natural gas may be liquefied on the liquefaction vessel using at least one heat exchanger that exchanges heat between a LIN stream and the natural gas stream to at least partially vaporize the liquefied nitrogen stream and at least partially condense the natural gas stream. The LNG gas stream produced thereby may be stored in the at least one tank that only stores LNG and/or in at least one tank onboard the liquefaction vessel configured to store either LIN or LNG. In a further aspect, one permanently docked liquefaction vessel may liquefy the treated natural gas from onshore. The produced LNG may be transported from the liquefaction vessel to one or more dual-purpose carriers. LIN may be transported from the one or more dual-purpose carriers to the liquefaction vessel.
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(28) The use of LIN in the LNG liquefaction process as disclosed herein provides additional benefits. For example, LIN may be used to liquefy LNG boil off gas from the LNG tanks and/or the multipurpose tanks during LNG production, transport and/or offloading. LIN and/or liquid nitrogen boil off gas may be used to keep the liquefaction equipment cold during turndown or shutdown of the liquefaction process. LIN may be used to liquefy vaporized nitrogen to produce an idling-like operation of the liquefaction process. Small helper motors may be attached to the compressor/expander combinations found in the expander services to keep the compressor/expander services spinning during turndown or shutdown of the liquefaction process. Nitrogen vapor may be used to derime the heat exchangers during the periods between LNG production on the liquefaction vessel. The nitrogen vapor may be vented to the atmosphere.
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(35) The aspects described herein have several advantages over known technologies. For example, the power requirement for the liquefaction process disclosed herein is less than 20%, or more preferably less than 10%, or more preferably less than 5% the power requirement of a conventional liquefaction process used on a liquefaction vessel. For this reason, the power requirement for the liquefaction process disclosed herein may be much lower than the required propulsion power of the liquefaction vessel. The liquefaction vessel according to disclosed aspects may have the same propulsion system as a conventional LNG carrier since natural gas liquefaction is predominantly accomplished by the vaporizing of the stored liquid nitrogen and not by the onboard power production of the liquefaction vessel.
(36) Another advantage is that the liquefaction process disclosed herein is capable of producing greater than 2 MTA of LNG, or more preferably producing greater than 4 MTA of LNG, or more preferably producing greater than 6 MTA of LNG on a single liquefaction vessel. In contrast to known technologies, the LNG production capacity of the disclosed liquefaction vessel is primarily determined by the storage capacity of the liquefaction vessel. A liquefaction vessel with an LNG storage capacity of 140,000 m.sup.3 can support a stream day annual production of LNG of approximately 6 MTA at a liquefaction vessel arrival frequency of 4 days. The tank or tanks that only store liquid nitrogen may have a total volume of less than 84,000 m.sup.3, or more preferably a volume of approximately 20,000 m.sup.3, to provide a liquefaction vessel with a total storage capacity of 160,000 m.sup.3.
(37) Additionally, the liquefaction process according to disclosed aspects has the additional advantage of allowing for fast startup and reduced thermal cycling since a fraction of the stored liquid nitrogen can be used to keep the equipment of the liquefaction module cold during periods of no LNG production. Additionally, the overall cost of the disclosed liquefaction module is expected to be significantly less than the cost of a conventional liquefaction module. The LIN-to-LNG liquefaction module may be less than 50% of the capital expense (CAPEX) of an equivalent capacity conventional liquefaction module, or more preferably less than 20% the CAPEX of an equivalent capacity conventional liquefaction module. The reduced cost of the liquefaction module may make it economical to have the liquefaction vessels transport the LNG to market rather than having to transfer its cargo to less expensive ships in order to reduce the number of liquefaction vessels.
(38) It should be understood that the numerous changes, modifications, and alternatives to the preceding disclosure can be made without departing from the scope of the disclosure. The preceding description, therefore, is not meant to limit the scope of the disclosure. Rather, the scope of the disclosure is to be determined only by the appended claims and their equivalents. It is also contemplated that structures and features in the present examples can be altered, rearranged, substituted, deleted, duplicated, combined, or added to each other.