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Shipboard applications Module 1.2 - EcoRel General presentation www.cryostar.com
Shipboard applications
Module 1.2 - EcoRel
General presentation
www.cryostar.com
Module 1.2 – Ecorel general presentation The following document contains partly confidential information, and is
Module 1.2 – Ecorel general presentation
The following document contains partly confidential
information, and is provided for training purposes to
selected shipyards and their customers.
It must not be used for any other purpose, and may not
be provided to a third party without our consent.
This document contains representative data only, and
does not replace the manuals or technical
documentation issued for the vessel.
© Cryostar 2014
2 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation COURSE SYLLABUS Ecorel Primary objective Gas transport Reason for
Module 1.2 – Ecorel general presentation
COURSE SYLLABUS
Ecorel
Primary objective
Gas transport
Reason for reliquefaction
System description
Brayton Cycle
Sizing consideration
Simplified flow diagram
System description
Operating modes
Process flow diagram
Sparing philosophy
On board reliquefaction
Equipments
Process Overview
Reliquefaction plant operation: Principle
Ecorel key data
3 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation EcoRel , the Eco nomic Rel iable Eco logical
Module 1.2 – Ecorel general presentation
EcoRel , the
Eco nomic
Rel iable
Eco logical
Rel iquefaction system
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Module 1.2 – Ecorel general presentation The 6 years of development primary objective was to
Module 1.2 – Ecorel general presentation
The 6 years of development primary objective was to
provide:
a robust & reliable system
easy operation
lowest possible power consumption
5 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Reason for reliquefaction LNG boil-off gas should be consumed,
Module 1.2 – Ecorel general presentation
Reason for reliquefaction
LNG boil-off gas should be consumed, disposed of or retained in the tank
For a vessel of 172’000m 3 capacity, the boil-off represents
approximately 5’200 kg/h BOG
A 3 week voyage could result in loss of appr. 2620 tons if not used
effectively
7 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation BOG rate 0,15 % vol / day (expressed in
Module 1.2 – Ecorel general presentation
BOG rate
0,15 % vol / day (expressed in pure methane) is a standard value used for the laden
case for 172’000 m 3 LNG carrier.
How much is 0,15 %
172
000 m 3 x 0,15 % x 98,5% (tank filling) # 254 m 3 of liquid methane per day
254
m 3 x 590 Nm 3 /m 3 = 150’000 Nm 3 /d
or 6’250 Nm 3 /h
or 3’750 m 3 /h (at -100°C and 1.06 bara)
or 4’500 kg/h of pure methane
Energy content
Methane LHV = 50 MJ/kg or 35.8 MJ/Nm 3
=> 62 MW of thermal power or approx 31 MW electricity (with  = 0.5)
8 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation SYSTEM DESCRIPTION Cooling provided by a closed nitrogen loop
Module 1.2 – Ecorel general presentation
SYSTEM DESCRIPTION
Cooling provided by a closed nitrogen loop using the Brayton Cycle
Boil-off gas is compressed to facilitate liquefaction process
Condensation takes place in an aluminum plate fin Heat Exchanger
Liquefied LNG is returned to the tanks
Excessive boil-off gas is incinerated in a Gas Combustion Unit
100% redundancy of equipment is normally applied
9 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation BRAYTON CYCLE 3 2 T C 4 1 This
Module 1.2 – Ecorel general presentation
BRAYTON CYCLE
3
2
T
C
4
1
This is an important cycle frequently employed in gas cycle refrigeration
systems.
Process 1-2: adiabatic compression in a compressor
Gas at low pressure is compressed from state 1 to state 2.
Process 2-3:
heat rejection in a heat exchanger
Hot and high pressure gas flows through a heat exchanger
and rejects heat sensibly to a heat sink. The enthalpy and
temperature of the gas drop during the process due to
heat exchange.
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Module 1.2 – Ecorel general presentation BRAYTON CYCLE 3 2 T C 4 1 Process
Module 1.2 – Ecorel general presentation
BRAYTON CYCLE
3
2
T
C
4
1
Process 3-4:
adiabatic expansion in a turbine
High pressure gas from the heat exchanger flows through a turbine, and
delivers net work output. The temperature of the gas drops during the process
from T 3 to T 4 .
Process 4-1:
heat absorption in a heat exchanger.
Cold and low pressure gas from turbine flows through the low temperature
heat exchanger and extracts heat sensibly
from a heat source, providing a useful refrigeration effect.
11 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation BRAYTON CYCLE - EcoRel analogy Heat rejection 3 2
Module 1.2 – Ecorel general presentation
BRAYTON CYCLE - EcoRel analogy
Heat rejection
3
2
C
4
1
N 2 Loop
BOG
Condenser
N 2 Counter Current
Exchanger
N 2 inter &
Cold production
2 after coolers
1
3
4
N 2 Compander
T
C
12 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Sizing considerations N 2 content LNG Gorgon Design Case
Module 1.2 – Ecorel general presentation
Sizing considerations
N 2 content
LNG Gorgon
Design Case
35
30
25
Partial Reliq.
20
15
10
Full Reliq.
5
0
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
% N 2 in LNG
The plant is designed to allow full reliquefaction up to a certain N 2 content,
thereafter partial reliquefaction is applied
14
For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
% N 2 in BOG
Module 1.2 – Ecorel general presentation Sizing considerations Mass of boil-off gas is primary capacity
Module 1.2 – Ecorel general presentation
Sizing considerations
Mass of boil-off gas is primary capacity consideration
N 2 content in the boil-off gas (NBO) is equipment sizing consideration
NBO with excessive N 2 will be handled by partial reliquefaction
Cryostar’s EcoRel is designed to be operated with Full Reliquefaction as the
primary goal – saving all the cargo
15 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Sizing considerations Definition of N 2 cycle : Nitrogen
Module 1.2 – Ecorel general presentation
Sizing considerations
Definition of N 2 cycle :
Nitrogen mass flow based on BOG flow
Nitrogen operating pressure based on BOG composition
Mass flow is a function of N 2 loop pressure
Higher pressure = higher mass flow for a given volume flow (N 2 loop
volume)
BOG Condensation temperature is a function of the N 2 loop pressure
Higher pressure is the N 2 loop = Higher will be the cold power production
and lower will be the condensate temperature
16 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Simplified flow diagram – N 2 Loop N 2
Module 1.2 – Ecorel general presentation
Simplified flow diagram – N 2 Loop
N 2 Loop
N2 Counter Current
Exchanger
BOG
Condenser
N2 inter &
after coolers
N2 Compander
Tank 4
Tank 3
Tank 2
Tank 1
17 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Simplified flow diagram – BOG Loop BOG Compressor BOG
Module 1.2 – Ecorel general presentation
Simplified flow diagram – BOG Loop
BOG
Compressor
BOG
Condenser
BOG Loop principle
Tank 4
Tank 3
Tank 2
Tank 1
18 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation System description Natural Gas Plant – additional equipment Desuperheater
Module 1.2 – Ecorel general presentation
System description
Natural Gas Plant – additional equipment
Desuperheater
to protect the BOG Condenser from rapid temperature changes
BOG compressor interstage cooler
to reduce compressor power
19 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Operating modes: Reliquefaction operations Full Reliquefaction: Up to 21.4%
Module 1.2 – Ecorel general presentation
Operating modes: Reliquefaction operations
Full Reliquefaction: Up to 21.4% N 2 content in BOG, EcoRel plant provides
Full Reliquefaction of the BOG at design heat ingress.
Partial Reliquefaction: If Full Reliquefaction can no more be achieved due to
too high N 2 content in BOG, Partial Reliquefaction is initiated.
The Partial Reliquefaction mode consists in operating the reliquefaction system
in “LNG drum operation” mode. During this mode of operation the
Condensates are routed to a LNG drum.
The gas generated in this drum (if any) is:
either sent to GCU
either returned to tank (if GCU is not available)
both
20 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Operating modes: N 2 loop/Compander in IDLE mode “N
Module 1.2 – Ecorel general presentation
Operating modes: N 2 loop/Compander in IDLE mode
“N 2 loop in IDLE mode” corresponds to a status of the cooling system:
When reliquefaction unit is stopped (no BOG running on the reliquefaction)
The N 2 loop is maintained in cold conditions to anticipate any reliquefaction
start. No cold energy being exchanged with the BOG cycle, the cold
produced is mainly reduced with the N 2 loop/Compander bypasses.
In this mode, the power of the Compander is minimized and the system status
is:
loop pressure at minimum (minimum mass flow rate)
pressure ratio equal to design value
expander flow rate controlled
Counter current HTX bypass opened
21 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Process flow diagram: Full reliquefaction T:-74°C T: -120°C P:6,51
Module 1.2 – Ecorel general presentation
Process flow diagram: Full reliquefaction
T:-74°C
T: -120°C
P:6,51 bara
P:1,06 bara
BOG
Compressor
N 2
Cold BOG
T:-112°C
Warm BOG
P:10,2 bara
BOG
Condensate
T:-128°C
Desuperheater
T:-139°C
P:10,1 bara
P:10,5 bara
T:-126°C
T:-141°C
P:6,26 bara
P:9,6bara
N 2 Counter Current
Exchanger
T:42°C
P:9,8 bara
BOG
Condenser
T:43°C
N 2 inter &
after coolers
T-160°C
T:-107°C
P:46,0 bara
P:6,1 bara
P:45,6 bara
N 2 Compander
T:-162°C
P: 10,7 bara
Tank 4
Tank 3
Tank2
Tank 1
Confidential Information. This document is the property of Cryostar. It is not permitted to copy it, relate its contents to other persons, or to misuse it in any other way
22
For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Process flow diagram: Partial reliquefaction BOG Compressor GCU Off
Module 1.2 – Ecorel general presentation
Process flow diagram: Partial reliquefaction
BOG
Compressor
GCU
Off gas Heater
N 2
Cold BOG
BOG
Intercooler
Warm BOG
BOG
Condensate
Desuperheater
Vent gas
N 2 Counter Current
Exchanger
BOG
Condenser
N 2 inter &
after coolers
LNG Flash
Drum
N 2 Compander
LNG Return Pump
Tank 4
Tank 3
Tank 2
Tank 1
Confidential Information. This document is the property of Cryostar. It is not permitted to copy it, relate its contents to other persons, or to misuse it in any other way
23
For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Process flow diagram: N 2 cycle & N 2
Module 1.2 – Ecorel general presentation
Process flow diagram: N 2 cycle & N 2 system
TCV34
N 2 from cycle
From BOG
N 2 from N 2 system
coolers
FCV10
To BOG
N 2 inter & after coolers
Condenser
PDCV23
N 2 Counter Current
Exchanger
N 2 Compander
ATM
PCV25
PCV15
PCV54
PCV01
N 2
Production
N 2 supply
PCV04
N 2 Buffer
PCV55
N 2 Drum
N 2 Buffer
seal gas
The N2 seal gas system for compander is not represented
Confidential Information. This document is the property of Cryostar. It is not permitted to copy it, relate its contents to other persons, or to misuse it in any other way
24 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Sparing philosophy: Redundant system BOG Compressor N 2 from
Module 1.2 – Ecorel general presentation
Sparing philosophy:
Redundant system
BOG
Compressor
N 2 from cycle
Two installed (2x100 %)
Cold BOG
Warm BOG
Condensate
Vent gas
N 2 from N 2 system
BOG
BOG
Intercooler
Desuperheater
BOG
Condenser
N 2 inter & after coolers
GCU
N 2 Counter Current
Exchanger
LNG Flash
Drum
N 2 Compander
LNG
TANKS
LNG Return
Pump
ATM
N 2
Production
N 2 Buffer
seal gas
N 2 supply
N 2 Buffer
N 2 Drum
The N2 seal gas system for compander is not represented
25
For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Confidential Information. This document is the property of Cryostar. It is not permitted to copy it, relate its contents to other persons, or to misuse it in any other way
Module 1.2 – Ecorel general presentation GCU Process flow diagram N 2 loop Cold BOG
Module 1.2 – Ecorel general presentation
GCU
Process flow diagram
N 2 loop
Cold BOG
Warm BOG
BOG Heater
Condensate
BOG
Compressor
11 & 12.K.01
LNG
Off gas Heater
Vent gas
10.E.02
BOG
Intercooler
11 & 12.E.01
N 2 Drum
BOG
N 2 Production
20.V.01
Desuperheater
20.Z.01
10.E.03
N 2 Counter Current
Exchanger
20.E.01
BOG
Condenser
Liq Main
10.E.01
N 2 inter &
after coolers
21 & 22.E.01~03
LNG
Drum
10.V.01
N 2 Compander
21 & 22.C.01
LNG Return Pump
10.P.01/02
Vent Mast
Tank 4
Tank 3
Tank 2
Tank 1
26
Confidential Information. This document is the property of Cryostar. It is not permitted to copy it, relate its contents to other persons, or to misuse it in any other way
For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation On board LNG board reliquefaction provides: A viable mean/way
Module 1.2 – Ecorel general presentation
On board LNG board reliquefaction provides:
A viable mean/way of cargo conservation for longer voyages
The ability to hold cargo for spot trading
Vessel fuel costs less dependent on the gas price
Cargo composition maintained during the voyage
The ability to deliver a full cargo
27 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Cryostar provides a single source for: the Overall Plant
Module 1.2 – Ecorel general presentation
Cryostar provides a single source for:
the Overall Plant Concept
the Liquefaction Process
the Cryogenic Turbo machinery (N 2 Compander and 2 stages BOG
Compressor)
the Plant Engineering
the Project Management
28 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Equipments: Refrigeration unit Refrigeration Compander skid including: 3
Module 1.2 – Ecorel general presentation
Equipments: Refrigeration unit
Refrigeration Compander skid including:
3 stage Nitrogen compressor
1 stage expansion turbine
Common gearbox and L/O system
Cooler rack skid
Counter-current heat exchanger
Installed in the safe area (Motor Room)
29 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Equipments: Refrigeration unit Nitrogen buffer tank Nitrogen make-up system
Module 1.2 – Ecorel general presentation
Equipments: Refrigeration unit
Nitrogen buffer tank
Nitrogen make-up system
Interconnection to Natural Gas plant in cargo machinery room with only
two cold pipes through bulkhead
30 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Equipments: Reliquefaction unit Two 2-stages boil-off gas compressors
Module 1.2 – Ecorel general presentation
Equipments: Reliquefaction unit
Two 2-stages boil-off gas compressors
Compressors in cargo machinery room with proven bulkhead seal and drive
motors in motor room
De-superheater
Inter-stage cooler
Condenser (in cargo machinery room)
Flash drum skid
Gas analyzer
31 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Process Accurate process and operating mode Reliable liquefaction process
Module 1.2 – Ecorel general presentation
Process
Accurate process and operating mode
Reliable liquefaction process
Most ecological ship operation with no waste gas release
Most economical ship operation with no loss of cargo and lowest power
consumption
Simple and safe operation allowing fast start of the unit
32 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Process: Cooling Power Control BOG Compressor N 2 from
Module 1.2 – Ecorel general presentation
Process: Cooling Power Control
BOG
Compressor
N 2 from cycle
Cold BOG
Warm BOG
Condensate
Vent gas
N 2 from N 2 system
BOG
BOG
Intercooler
Desuperheater
BOG
Condenser
N 2 inter & after coolers
GCU
N 2 Counter Current
Exchanger
LNG Flash
Drum
N 2 Compander
LNG
TANKS
LNG Return
Pump
ATM
N 2
Production
N 2 supply
The N2 seal gas system for compander is not represented
33
N 2 Buffer
N 2 Drum
For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
N 2 Buffer
seal gas
Confidential Information. This document is the property of Cryostar. It is not permitted to copy it, relate its contents to other persons, or to misuse it in any other way
Module 1.2 – Ecorel general presentation Process: Outlet Temperature and Load Control on the BOG
Module 1.2 – Ecorel general presentation
Process: Outlet Temperature and Load Control on the
BOG
compander
Compressor
TCV34
N 2 from cycle
N 2 from N 2 system
From BOG
coolers
FCV10
To BOG
Condenser
N 2 inter & after coolers
PDCV23
N 2 Counter Current
Exchanger
N 2 Compander
Compander load,
flow and
temperature
control in the N 2
loop
ATM
20PCV25
20PCV15
20PCV54
20PCV01
N 2
Production
N 2 supply
20PCV04
N 2 Buffer
N 2 Drum
N 2 Buffer
seal gas
Confidential Information. This document is the property of Cryostar. It is not permitted to copy it, relate its contents to other persons, or to misuse it in any other way
34 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Reliquefaction plant operation: Principle BOG flowrate Normal BOG Excess
Module 1.2 – Ecorel general presentation
Reliquefaction plant operation: Principle
BOG flowrate
Normal BOG
Excess BOG
Low BOG
Partial
Full reliq
Partial
Partial
Mode of operation
Full reliq
No reliq
No reliq
Full reliq
No reliq
reliq
(a)
reliq
reliq (d)
BOG
1
1
1 or 2 (b)
2
1 or 2 (b)
1 or 2 (b)
1(e)
1 (c)
0
compressor
Number of
operating
equipment
Compander
1
1
0 1
1
0 1
1
0
GCU
0
1
1 1
1
1 0
0
1
(a) Reliquefaction plant additional capacity will be limited by plant design figures and is a
function of flow rate and N 2 content in BOG,
(b)
Number of running equipment is function of BOG flow rate and N 2 content in BOG
(c)
BOG compressor at low speed (half speed) reduced flow rate.
(d)
Partial mode configuration is used but full reliquefaction of BOG can occur (depending
on BOG composition)
(e) See (d) note, this mode is automatically reached after 30min in low flow mode on the
LNG drum operation
36 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation Reliquefaction plant operation: Functioning modes Modes BOG LOOP N
Module 1.2 – Ecorel general presentation
Reliquefaction plant operation: Functioning modes
Modes
BOG LOOP
N 2 LOOP
No BOGC running to reliquefaction
IDLE MODE
Low Flow mode
Low flow
Low flow mode control
Partial reliquefaction
Load control mode
Normal flow
mode
Full reliquefaction
Load control mode
37 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation 38 For training purpose only ©2014 CRYOSTAR SAS. All
Module 1.2 – Ecorel general presentation
38 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation EcoRel: Unit key data BOG flow rate up to
Module 1.2 – Ecorel general presentation
EcoRel: Unit key data
BOG flow rate
up to 6,5 t/h (Following gas composition)
Refrigeration capacity
~ 1 MW
Total electrical power
~ 5 MW
Specific power consumption
~ 0.725 kW/(kg/h of BOG)
Full reliquefaction
up to 21,4 %mol N 2 in BOG
Water consumption
~ 460 m 3 /h
39 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.
Module 1.2 – Ecorel general presentation THANK YOU FOR YOUR ATTENTION ! ANY QUESTION? 40
Module 1.2 – Ecorel general presentation
THANK YOU FOR YOUR ATTENTION !
ANY QUESTION?
40 For training purpose only ©2014 CRYOSTAR SAS. All rights reserved.