Simulation and Enhancement in the Existing LNG Refrigeration Cycle

A REPORT

in
CHE 4001- Equilibrium Staged Operations
By

Pranav Pahade (16BCM0008)

Nandini Malik (16BCM0040)
Ratnika Gupta (16BCM0041)
Nandini Jain (16BCM0046)
Shreyasi Dutta(16BCM0048)

Under the guidance of

Dr. Nirmala G.S

DEPARTMENT OF CHEMICAL ENGINEERING

School of Chemical Engineering

April 2019

1
 INTRODUCTION
LNG is one of the costly processes in oil and gas industries from aspects of installation and
operation costs. Energy is consumed about 250 to 800 kWh per ton of LNG production in most
plants all around the world. Approximately 60% of cost is related to the onshore and main part of
it can be the refinery of LNG, and LNG unit. Approximately 30% of cost is onshore cost. This
indicates that type of liquefaction processes play an important role in LNG production projects.
The most important problem for dealing with LNG production technologies is their high energy
consumption. The major portion is related to turbine, and operation of refrigeration cycles
compressors. The liquefaction processes can dramatically improve the energy efficiency of LNG
to increase efficiency and reduce the fuel consumption and carbon emissions. In the refrigeration
cycles used in the production of LNG, for the refrigerant cooling by environmental air or water to
the desired temperature, the high-pressure compressors with very high energy consumption are
used. It can be said that the most important way to reduce LNG production costs and increase the
cost of this energy carrier is suitable approaches to reduce the amount of consumed energy.
Numerous articles for reducing energy consumption and optimization process are provided. The
articles show integrated and optimized processes as well as appropriate way to reduce energy
consumption.
An integrated structure of natural gas liquids, liquefied natural gas and natural gas for domestic
and industrial consumption based on C3MR refrigeration cycle with the specific power of 0.41
kWh.(kg LNG)-1 and ethane recovery of 93% is developed. APCI Company introduced a method
for the production of these two products in which the kettle type heat exchanger, separation and
absorption tower and external refrigeration cycle are used. The simulation has shown that the use
of vapor phase and condensation have better results than the liquid phase purification section [9].
ConocoPhillips, APCI, and Ortloff have proposed some plans in order to integrate LNG and NGL
units. In design firms based on ConocoPhillips cascade cycle, lean ethane is employed for better
separation in the column. Pre-cooling in this process has been conducted by pure propane or a
mixture of propane and ethane.
Company APCI has proposed a method for LNG and NGL co-production in which heat
exchanger (kettle type), absorption tower, separation tower and external refrigeration cycle are
employed used. Input gas is first cooled using propane cycle and then is entered into the
separation unit. Rich methane gas from the top of the column and non-methane-rich liquid from

2
bottom of the column are sent out. After cooling gas, exited from the top of the tower, part of it is
condensed and as liquid and detergent stream goes back to the tower. This process is occurred in
special kettles exchanger using the mixed refrigerant refrigeration cycle. The liquid stream,
exited from bottom of the column is also sent to the purification section. The aforementioned
process has been amended and improved several times in 2008 to 2010, yet the process is carried
out according to above-mentioned explanation and description. Compression cooling cycles
widely used in various fields, especially used in oil and gas industry and extensive research has
been done to enhance their efficiency. Some of these studies have been used to optimize
operational characteristics such as pressure, flow rate cooling and combined cooling. Others
focused on the replacement expansion valves with liquid turbine. Also, some studies have been
conducted on the exergy analysis in the number of LNG production processes. A HYSYS
simulated model is investigated by exergy and exergoeconomic analyses for a propane mixed
refrigerant process. Exergy analysis is employed for optimization of a refrigeration cycle for
separation units in the petrochemical plants.

OBJECTIVE:
To study various refrigeration cycle processes involved in the liquefication of natural gas. To
study in depth about the C3MR and DMR refrigeration cycles. Conduct a literature survey and
list out the findings and to apply this collected information to continue the project further.
We have used Aspen-Hysys as simulator and Peng Robinson equation of state for phase
equilibrium analysis. The Peng Robinson equation of state because of its accuracy in the
extensive range of temperature and pressure conditions is used to predict properties of light
hydrocarbons, used in LNG production processes.

3
LITERATURE
There are best of four alternative processes, starting from basics and using the same conditions
like cooling medium, feed-gas, standards and cost basis.
The processes are:
 The Propane/Mixed Refrigerant process
 The Cascade process
 A version of the Dual Mixed Refrigerant (DMR) process
 A version of the Single Mixed Refrigerant (SMR) process
 The pre-cooled Nitrogen Expansion process.
For each of these processes several options exist in the configuration of the process that will
influence the capacity and overall attractiveness. This variation within a process results from the
hardware selected and the particular gas turbine drivers and cryogenic heat exchangers.
The differences in capacity, refrigerant make-up, power consumption, etc. of the various
liquefaction units are also reflected in the fractionation and utility requirements. It was therefore
decided to extend the scope of the study to include all process facilities and related utilities in a
combined liquefaction package. Each package consists of 2 complete LNG trains with a common
fractionation/refrigerant make-up unit and utilities like electrical power, process heat, etc. Such a
liquefaction package can be added to an existing LNG plant or form the heart of a new LNG
plant.

4
C3MR PROCESS

The C3MR process consists of two refrigeration cycles: a propane-refrigeration cycle to cool
from ambient conditions to 235° C., and MR cycle to liquefy the natural gas stream and subcool
it to 2160° C.
With an end-flash system, the degree of subcooling is reduced to 2150° C. With extended end
flash, subcooling is reduced to 2145° C.
The propane cycle has four pressure levels for precooling the natural gas and MR streams. The
MR stream is separated into a light stream and a heavy liquid stream after it is cooled to the low-
pressure propane temperature level.
The heavy MR stream is subcooled in the warm and middle bundles of the main cryogenic heat
exchanger (MCHE). The stream is then let down in pressure in a liquid expander and routed to
the MCHE's shell side.
The light MR stream is liquefied and subcooled in the MCHE's warm, middle, and cold bundles.
The stream is then let down in pressure and routed to the MCHE's shell side.
NGLs are separated from relatively rich gas in the scrub column. Low-pressure propane and the
warm MCHE bundle provide overhead cooling. NGLs are then routed to the fractionation unit.
In the base case, the C2- cut is used as high-pressure fuel gas. In the extended end-flash cases, it
combines with the main natural gas stream.
Propane, butane, and condensate from the fractionation unit proceed to the storage and loading
area for export. A liquid expander reduces the pressure of subcooled natural gas from the MCHE.
The natural gas stream is flashed to atmospheric pressure in the extended end-flash cases. The
process recovers cold from the generated vapor and compresses the gas to high-pressure fuel
level. The main difference between the Shell DMR and the C3MR process is the precooling
mixed-refrigerant (PMR) cycle. In the DMR process, the precool refrigerant is a mixture of
ethane, propane, and small amounts of methane and butane.
Spool-wound heat exchangers replace most of the kettles in the C3 cycle. The scrub column
overhead requires no additional MR cooling since the PMR cycle can reach a precool
temperature of 240° C., which leads to a simpler line up.

5
The DMR process has less equipment than the C3MR process. The process has more flexibility,
which allows a wide range of operating conditions.

Process advantage:

• The use of a single component pre-cooling fluid with a staged pressure let-down provides
for an efficient, easy to control pre-cooling step.
• The use of a mixed refrigerant for liquefaction and sub-cooling in a single exchanger
permits boiling of the refrigerant over a temperature range, leading to high efficiency
when it is most crucial.
• The C3MR cycle minimizes the number of equipment items and control loops while
maintaining the highest efficiency on the market. These advantages lead to minimal plant
complexity, easier operation, and high availability.

6
DMR PROCESS

Dual mixed refrigerant process called DMR, including technologies which is are half American
and half European patents, registered by the Shell Company.
Process arrangement of this technology is similar to the C3MR process, except in its refrigeration
cycle, pure propane as refrigerant is employed instead of a mixture of ethane and propane. Table1
presents the composition of feed and product of the mixed refrigerant refrigeration and absorption
cycles in the integrated process with AR-MR1 refrigeration cycle.
In order to achieve the low temperature needed for the liquefaction of the natural gas, the dual
mixed refrigerant process uses two different mixtures of refrigerants. Usually, a first mixed
refrigerant is compressed and expanded at different pressure levels in the pre-cooling stage of the
liquefaction process, while a second mixed refrigerant goes through compression and expansion
in the liquefaction stage. The mixed refrigerants have different inlet pressures; usually the one
with the lower pressure is called the low level mixed refrigerant and the one with the higher
pressure is called the high level mixed refrigerant
The four DMR alternatives that were subject to optimization are the following:
1. Shell DMR Process
2. Air Products and Chemicals, Inc. (APCI)
3. Axens-IFP – “Liquefin” DMR with plate-in heat exchangers
4. Tealarc LNG Process
The Shell DMR process uses a low pressure mixed refrigerant in the pre-cooling stage and a high
pressure mixed refrigerant in the liquefaction stage. The low level refrigerant goes through two
pressure level changes before leaving the pre-cooling stage to the compression stage. The high
pressure refrigerant, leaves the pre-cooling stage at a lower temperature, and enters a phase
separator where liquid and vapor are separated, at the beginning of the second stage, the
liquefaction part. Here, the mixed refrigerant goes through one pressure level change, and then
leaves the liquefaction stage in order be compressed and sent back to the pre-cooling stage of the
process.

7
At atmospheric pressure LNG has a temperature of approximately -162°C, so the process of
cooling and condensing the NG requires large amounts of energy. Several different process
designs are used and they can be grouped roughly as follows:
• Mixed refrigerant: The refrigerant composition is adjusted to match the cooling curve of NG.
Some are designed with a separate pre-cooling cycle
• Cascade process (pure fluid): Several refrigerant cycles are used to limit the mean temperature
difference in the heat exchange
• Mixed fluid cascade process: Energy eflaciency is further improved by using several mixed
refrigerant cycles

8
9
DMR CYCLE Results obtained from Aspen-Hysys flowsheet

Name M1 to Cooler Mix Ref-1 in Mix Ref-2 in Mix Ref-1 out Mix Ref-2 out
Pressure [kPa] 347 120 120 500 190
Temperature [C] 47.04699427 -108 -174 -97 -132
Mass Flow [kg/h] 494.9587015 1500 1560 1500 1560
Std Ideal Liq Vol Flow [m3/h] 0.743983926 2.546735386 2.26218002 2.546735386 2.26218002
Vapor / Phase Fraction 1 1 1 0.983947252 1
Molar Enthalpy [kJ/kgmole] -14332.36374 -28263.96025 -18091.68328 -28270.49629 -16871.34395

Name Natural Gas Feed Propane in Cool NG Hot Propane Propane Out Natural Gas to LNG H.X.
Pressure [kPa] 5740 130 5710 150 180 5690
Temperature [C] 47.74 -35 16 -20.91818332 28 7.949365689
Mass Flow [kg/h] 222.4381339 233.7141006 222.4381339 233.7141006 233.7141006 222.4381339
Std Ideal Liq Vol Flow [m3/h] 0.705206824 0.461267504 0.705206824 0.461267504 0.461267504 0.705206824
Vapor / Phase Fraction 1 1 1 1 1 1
Molar Enthalpy [kJ/kgmole] -76796.47361 -108238.9622 -78270.48463 -107341.4832 -103865.0421 -78651.01569

Name Propane to Cool MR-2 Hot out MR-1 Hot out MR-1 Cold in MR-2 Cold out
Pressure [kPa] 140 339.8 200 120 720
Temperature [C] 27.40399792 -17 -10 -176 -10.58002944
Mass Flow [kg/h] 233.7141006 23 494.9587015 494.9587015 23
Std Ideal Liq Vol Flow [m3/h] 0.461267504 0.034571834 0.743983926 0.743983926 0.034571834
Vapor / Phase Fraction 1 1 1 1 1
Molar Enthalpy [kJ/kgmole] -103865.0421 -16292.98568 -16064.1373 -21001.66319 -16142.41953
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow Molar Flow

Name LNG to JT M1 To Cool-1 M2 To Cool-2 LNG To Separator Flashes Final LNG

Pressure [kPa] 300 190 120 101.3 101.3 101.3
Temperature [C] -162.7788907 -107.4245782 -132.7361426 -162.6973384 -164.2298068 -164.2298068
Mass Flow [kg/h] 222.4381339 1500 1560 222.4381339 0 222.4381339
Std Ideal Liq Vol Flow [m3/h] 0.705206824 2.546735386 2.26218002 0.705206824 0 0.705206824
Vapor / Phase Fraction 0 1 1 0 1 0
Molar Enthalpy [kJ/kgmole] -92433.42463 -28270.49629 -16871.34395 -92433.42463 -81377.69032 -92518.67263

10
FEED STREAM
Name Natural Gas Feed
Pressure [kPa] 5740
Temperature [C] 47.74
Mass Flow [kg/h] 222.4381339
Std Ideal Liq Vol Flow [m3/h] 0.705206824
Vapor / Phase Fraction 1
Molar Enthalpy [kJ/kgmole] -76796.47361

PRODUCT STREAM
Name Flashes Final LNG
Pressure [kPa] 101.3 101.3
Temperature [C] -164.2298068 -164.2298068
Mass Flow [kg/h] 0 222.4381339
Std Ideal Liq Vol Flow [m3/h] 0 0.705206824
Vapor / Phase Fraction 1 0
Molar Enthalpy [kJ/kgmole] -81377.69032 -92518.67263
COOLER
Name E-100 E-101 E-102 E-103 E-104
Duty [kJ/h] 23181.77616 128850.8654 4523.11167 -369.6015763 73029.39433
Pressure Drop [kPa] 10 227 261.109942 70 0
LNG
Name LNG-100 LNG-101 LNG-102 LNG-103
Number of Sides 2 2 5 3
LMTD [C] 39.79652357 26.84697868 18.99232433 6.365677069
UA [kJ/C-h] 119.5239637 686.3021012 5312.855788 11472.36869
Hot Pinch Temperature [C] 16 47.74 -1.899198401 -131.8069902
Cold Pinch Temperature [C] -20.91818332 28 -10.58002944 -132.2118989
Side Pressure Drop [kPa] 20 30 5120 -380
Number of Hot Sides 1 1 3 1
Number of Cold Sides 1 1 2 2
Hot Inlet Eqm. Temp. [C] 16 47.74 7.949365689 -108
Cold Inlet Eqm. Temp. [C] -35 -20.91818332 -176 -174
Exchanger Cold Duty [kJ/h] 4756.638239 18425.13788 100903.4803 73029.39432

11
SEPERATOR
Name V-100
Vessel Temperature [C] -164.2298068
Vessel Pressure [kPa] 101.3
Vessel Pressure Drop [kPa] 0
Vapour Outlet Pressure Drop [kPa] 0
Liquid Volume Percent [%] 50
Duty [kJ/h] -1065.6
Compressor
Name K-100 K-101
Power [kW] 9.293851427 0.082164847
Capacity (act feed vol flow) [ACT_m3/h] 210.8179833 5.599937082
Adiabatic Efficiency 75 75
Polytropic Efficiency 76.7679694 75.39228823
Compressor Volume [m3] 0 0
Delta T [C] 57.04699427 11
Delta P [kPa] 147 41.309942
Polytropic Head [m] 5291.620003 988.7055316
Adiabatic Head [m] 5169.753673 983.5610131
Dynamic Head [m] 5291.620003 988.7055316
Polytropic Fluid Head [kJ/kg] 51.8930653 9.695889101
Adiabatic Fluid Head [kJ/kg] 50.69796486 9.645438609
Dynamic Fluid Head [kJ/kg] 51.8930653 9.695889101
Polytropic Head Factor 1.000159963 1.000004837
Polytropic Exponent 1.557146065 1.584962924
Isentropic Exponent 1.38048768 1.386167935
Fluid Power [kW] 9.293851427 0.082164847
Duty [kJ/h] 33457.86514 295.7934507

Valve:
Name VLV-100 VLV-101 VLV-102 VLV-103 VLV-104 VLV-105
Pressure Drop [kPa] 40 370 30 70 310 198.7
Percentage open [%] 50 50 50 50 50 50
Friction pressure Drop [kPa] 40 370 30 70 310 198.7
Resistance (Cv or K) [USGPM(60F,1psi)] 17.22565775 79.60728409 28.72494663 0.538895014
Cg 576.4807709 2664.169297 961.3205845 18.03487666
C1 33.46640106 33.46640106 33.46640106 33.46640106 33.46640106 33.46640106
Km 0.9 0.9 0.9 0.9 0.9 0.9
Pipe roughness [m] 0.000259 0.000259 0.000259 0.000259 0.000259 0.000259
Pipe Velocity [m/s] 10.12495126 0.381638764 25.04349115 51.35390793 22.20505288 0.068565527
Reynolds Number 199247.7473 10872.79847 233430.5395 1275478.517 1083150.375 10375.11693
Pipe Feed Diameter [m] 0.05 0.05 0.05 0.05 0.05 0.05

12
ECONOMICS FOR DMR CYCLE
Name Summary
Total Capital Cost [USD] 4654760
Total Operating Cost [USD/Year] 1671660
Total Raw Materials Cost [USD/Year] 0
Total Product Sales [USD/Year] 0
Total Utilities Cost [USD/Year] 42327.2
Desired Rate of Return [Percent/'Year] 20
P.O.Period [Year] 0
Equipment Cost [USD] 928900
Total Installed Cost [USD] 1358900

Utilities
Name Fluid Rate Rate Units Cost per Hour Cost Units
Electricity 62.259 KW 4.825073 USD/H
Refrigerant - Propane Refrigerant 0.120292 KLB/H 0.003488 USD/H

Unit
Operations
Name Equipment Cost [USD] Installed Cost [USD] Equipment Weight [LBS] Installed Weight [LBS] Utility Cost [USD/HR]
E-100 8300 66900 490 7130 0.003488
LNG-102 0 0 0 0 0
K-100 522200 635800 6600 16651 0.867225
LNG-103 0 0 0 0 0
E-101 0 0 0 0 0
K-101 383200 493700 5400 14961 0.006975
LNG-100 0 0 0 0 0
VLV-104 0 0 0 0 0
E-102 0 0 0 0 0
E-104 0 0 0 0 0
VLV-105 0 0 0 0 0
VLV-100 0 0 0 0 0
VLV-101 0 0 0 0 0
VLV-103 0 0 0 0 0
V-100 15200 162500 2600 20437 0

13
Equipment:
Name Equipment Cost [USD] Installed Cost [USD] Equipment Weight [LBS] Total Installed Weight [LBS]
E-100 8300 66900 490 7130
K-100 522200 635800 6600 16651
K-101 383200 493700 5400 14961
VLV-104 0 0 0 0
VLV-105 0 0 0 0
VLV-100 0 0 0 0
VLV-101 0 0 0 0
VLV-103 0 0 0 0
V-100 15200 162500 2600 20437
VLV-102 0 0 0 0

TEMA HEX
Name DHE TEMA EXCH E-100
User tag number E-100
Remarks 1 Equipment mapped from 'E-100'.
Number of identical items 1
Heat transfer area [m2] 1.465798444
Front end TEMA symbol B
Shell TEMA symbol E
Rear end TEMA symbol M
Tube design temperature [C] 121.1111111
Tube operating temperature [C] -40
Tube outside diameter [m] 0.0254
Shell design gauge pressure [kPag] 243.42108
Shell design temperature [C] 121.1111111
Shell operating temperature [C] 27.40399778
Tube length extended [m] 6.096
Tube pitch [m] 0.03175
Number of tube passes 1
Number of shell passes 1

Vertical Vessel
Name DVT CYLINDER V-100
User tag number V-100
Remarks 1 Equipment mapped from 'V-100'.
Liquid volume [m3] 2.401932948
Vessel diameter [m] 0.9144
Vessel tangent to tangent height [m] 3.6576
Design gauge pressure [kPag] 103.425
Operating temperature [C] -162.6973378

14
Gas Compressor
Name DGC CENTRIF K-100 DGC CENTRIF K-101
User tag number K-100 K-101
Remarks 1 Equipment mapped from 'K-100'. Equipment mapped from 'K-101'.
Actual gas flow rate Inlet [ACT_m3/h] 210.660455 5.595831121
Design gauge pressure Inlet [kPag] 98.67107677 238.4710768
Design temperature Inlet [C] -10 -17
Design temperature Outlet [C] 47.04699389 -6
Design gauge pressure Outlet [kPag] 245.6710771 279.7810213
Driver power [kW] 9.297023085 0.082192581
Molecular weight 25.61898 25.61898
Specific heat ratio 1.378546 1.377543
Compressibility factor Inlet 0.997471 0.995221

SUMMARY OF ACTIVATED ENERGY ANALYSIS RESULTS

15
Property Actual Target
Total Utilities [kJ/h] 231000 231000
Heating Utilities [kJ/h] 0 0
Cooling Utilities [kJ/h] 231000 231000
Carbon Emissions [kg/h] 25.82 25.82

COST ANALYSIS:

Summary Table
Property Actual Target Available Savings % of Actual
Total Utilities [Millions /Yr] 0.0169 0.01357 0.00333 19.69
Heating Utilities [Millions /Yr] 0 0 0 0
Cooling Utilities [Millions /Yr] 0.0169 0.01357 0.003327 19.7

16
CASCADE PROCESS
The Optimized Cascade process is based on three multi-staged, cascading refrigerant circuits
using pure refrigerants, brazed aluminum heat exchangers and insulated cold box modules.
ConocoPhillips has optimized the heat integration to closely approach the natural gas and
refrigerant cooling curves, resulting in a highly efficient process. Pure refrigerants of propane (or
propylene), ethylene and methane are utilized, since their physical properties are ideal for heat
integration. The refrigerant properties are also well known and predictable, contributing to
unrivaled operating ease and flexibility.

Brazed aluminum heat exchangers and cold box modules allow for highly efficient heat transfer
and can be designed to accommodate a wide range of LNG plant sizes. Depending on the natural
gas feed stream characteristics, the LNG train can be designed with a customized and integrated
heavies removal unit (HRU) and/or nitrogen rejection unit (NRU) to achieve optimal LNG plant
performance and maximize the net present value of the facility. To ensure superior reliability and
availability, the process is typically configured in a proven “two trains-in-one” arrangement. This
approach, now widely accepted within the LNG industry as a design that provides the highest
plant availability, was pioneered by ConocoPhillips, where one train of highly reliable heat

17
exchangers and other process equipment is served by parallel refrigeration turbine/compressor
sets. As an owner and operator of the Optimized Cascade technology, ConocoPhillips provides a
unique technical expertise and depth in understanding the operation of an LNG plant. Subject
matter experts in every critical discipline required to design, operate, and maintain liquefaction
facilities are readily available to Optimized Cascade process licensees.The raw gas is first treated
to remove carbon dioxide (CO2), Hydrogen Sulfide (H2S) and other sulfur compounds, water
(H2O), organometallic mercury compounds, particulates, and other contaminates before it is
routed to the liquefaction section of the plant. The treated gas is then chilled and condensed to
approximately -162°C in successively colder heat exchangers, using pure propane (or propylene),
ethylene, and methane as refrigerants. The LNG product is then pumped into insulated storage
tanks where it remains until shipment. Boil-off gas and ship return vapors are captured and
recycled through the Optimized Cascade process for efficient re-liquefaction.

18
19
DMR CASCADE cycle in Aspen-Hysys was made with the following specifications
Feed Stream

Name Distillation Feed-1 Feed-2 Distillation Feed-2 Distillation Feed-3

Pressure [kPa] 2500 2290 2790 1690
Temperature [C] -95 -85 20.05 67.46
Mass Flow [kg/h] 34455.66706 4691.562114 17522.78744 8594.6897
Std Ideal Liq Vol Flow [m3/h] 102.5993193 13.24400521 42.7774388 16.33365863
Vapor / Phase Fraction 0 0.518529184 0 1
Molar Enthalpy [kJ/kgmole] -92828.40017 -90146.89106 -105017.2317 -109917.8095
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow

Name Methane Ethane Liquids-1 Propane Liquids-2

Pressure [kPa] 2275 2275 2275 1585 1585
Temperature [C] -85.79659834 -1.782048188 -1.782048184 45.86005558 45.86005558
Mass Flow [kg/h] 23577.20031 10083.96589 0.000156198 0.000161974 5722.392722
Std Ideal Liq Vol Flow [m3/h] 77.62174726 28.30767082 4.37232E-07 3.21537E-07 11.30266931
Vapor / Phase Fraction 1 1 0 1 0
Molar Enthalpy [kJ/kgmole] -80020.35674 -88194.73233 -97613.67786 -104062.0774 -117549.1935
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow Molar Flow

Product stream details:

Name Bottom-1 Bottom-2 M-to cooler E-to Cooler P-to Cooler
Pressure [kPa] 1585 1655 99.99998276 700.0026028 600.0009273
Temperature [C] 45.86005409 18.63749364 -115.577196 -31.03072518 29.11723686
Mass Flow [kg/h] 5722.392878 25881.14708 23577.20031 10083.96589 0.000161974
Std Ideal Liq Vol Flow [m3/h] 11.30266975 57.72233382 77.62174726 28.30767082 3.21537E-07
Vapor / Phase Fraction 0 0.220713437 1 1 1
Molar Enthalpy [kJ/kgmole] -117549.1927 -110698.8969 -80020.35674 -88194.73233 -104062.0774
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow Molar Flow

Name Natural Gas Feed Methane in Ethane in Propane in Pure Methane

Pressure [kPa] 5870 100 130 12.5 100
Temperature [C] 25 -72 -82 -40.43021041 -72
Mass Flow [kg/h] 375 850 1503.495026 9701.340027 849.9528465
Std Ideal Liq Vol Flow [m3/h] 1.190605812 2.839068133 4.227064456 19.146953 2.838910637
Vapor / Phase Fraction 1 1 1 1 1
Molar Enthalpy [kJ/kgmole] -77731.03932 -78276.89011 -89925.42552 -108396.5803 -78276.89011
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow Molar Flow

20
Name Pure Ethane Pure Propane Methane to Comp NG-1 Comp Methane
Pressure [kPa] 130 12.5 140 5628.683432 152.3812094
Temperature [C] -82 -40.44 -34.63022416 -37 -28
Mass Flow [kg/h] 1503.495026 9701.340027 850 375 850
Std Ideal Liq Vol Flow [m3/h] 4.227064456 19.146953 2.839068133 1.190605812 2.839068133
Vapor / Phase Fraction 1 1 1 1 1
Molar Enthalpy [kJ/kgmole] -89925.42552 -108397.191 -77020.6452 -80878.03714 -76795.62714
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow Molar Flow

Name M-1 Methane to Valve Ethane to Comp NG-2 Comp Ethane

Pressure [kPa] 130 140 178.2633136 5318.419273 260
Temperature [C] -109 -71.61294818 -42 -96.92362366 -20.33562835
Mass Flow [kg/h] 850 850 1503.495026 375 1503.495026
Std Ideal Liq Vol Flow [m3/h] 2.839068133 2.839068133 4.227064456 1.190605812 4.227064456
Vapor / Phase Fraction 1 1 1 0 1
Molar Enthalpy [kJ/kgmole] -79527.59969 -78276.89011 -88182.8553 -88130.68625 -87214.42954
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow Molar Flow

Name Ethane to Valve Propane to Comp LNG Comp Propane Cold Propane
Pressure [kPa] 267.8951817 80 5100 100 30
Temperature [C] -68.45752447 -40 -160 -30.62087705 -40
Mass Flow [kg/h] 1503.495026 9701.340027 375 9701.340027 9701.340027
Std Ideal Liq Vol Flow [m3/h] 4.227064456 19.146953 1.190605812 19.146953 19.146953
Vapor / Phase Fraction 0.968063941 1 0 1 1
Molar Enthalpy [kJ/kgmole] -89925.42552 -108477.1649 -91995.5859 -107907.6796 -108396.5803
Stream Price Basis Molar Flow Molar Flow Molar Flow Molar Flow Molar Flow

Name LNG to Sep Flashs Final LNG

Pressure [kPa] 101 101 101
Temperature [C] -160.60925 -160.6093827 -160.6093827
Mass Flow [kg/h] 375 6.009072655 368.9909273
Std Ideal Liq Vol Flow [m3/h] 1.190605812 0.020070167 1.170535645
Vapor / Phase Fraction 0.017958671 1 0
Molar Enthalpy [kJ/kgmole] -91995.5859 -81253.74634 -92191.3315
Stream Price Basis Molar Flow Molar Flow Molar Flow
Heater specifications

Name E-100
Duty [kJ/h] 2087278.272
Pressure Drop [kPa] -1.72369E-05

21
LNG Details
Name LNG-100 LNG-101 LNG-102
Number of Sides 2 3 4
LMTD [C] 44.73798182 5.37992215 2.721376579
UA [kJ/C-h] 1487.763754 28512.45371 36552.05208
Hot Pinch Temperature [C] -37 -53.35712368 -160
Cold Pinch Temperature [C] -72 -55.69298889 -160
Side Pressure Drop [kPa] -40 -48.26331361 -67.5
Number of Hot Sides 1 1 1
Number of Cold Sides 1 2 3
Hot Inlet Eqm. Temp. [C] 25 -37 -40.43021041
Cold Inlet Eqm. Temp. [C] -72 -109 -160
Exchanger Cold Duty [kJ/h] 66559.54777 153394.7812 99471.89843

Separator
Name V-100
Vessel Temperature [C] -160.6093827
Vessel Pressure [kPa] 101
Vessel Pressure Drop [kPa] 0
Vapour Outlet Pressure Drop [kPa] 0
Liquid Volume Percent [%] 50
Duty [kJ/h] -43.609

Valve
Name VLV-100 VLV-101 VLV-102 VLV-103 VLV-104 VLV-105 VLV-106
Pressure Drop [kPa] 2175.000017 1574.997397 984.9990727 40 137.8951817 17.5 4999
Percentage open [%] 50 50 50 50 50 50 50
Friction pressure Drop [kPa] 2175.000017 1574.997397 984.9990727 40 137.8951817 17.5 4999
Pipe k [kg/hr/sqrt(kPa-kg/m3)] 0 0 0 0 0 0 0
Resistance (Cv or K) [USGPM(60F,1psi)] 101.3770655 38.40121247 5.33297E-07 3081.234284 0.181354122
Cg 3392.725533 1285.150378 1.78475E-05 103117.8223 6.069269767
C1 33.46640106 33.46640106 33.46640106 33.46640106 33.46640106 33.46640106 33.46640106
Km 0.9 0.9 0.9 0.9 0.9 0.9 0.9
Pipe roughness [m] 0.000259 0.000259 0.000259 0.000259 0.000259 0.000259 0.000259
Pipe length [m] 0 0 0 0 0 0 0
Pipe Velocity [m/s] 104.4608433 32.40153234 6.47947E-07 88.82558041 40.7430628 1992.074349 0.115881897
Reynolds Number 20488978.91 7295634.567 0.117967426 762011.2153 1575968.221 10885659.15 18598.95302
Pipe Feed Diameter [m] 0.05 0.05 0.05 0.05 0.05 0.05 0.05
Compressor details:

22
Name K-100 K-101 K-102
Power [kW] 3.311699449 13.4503578 34.80187881
Capacity (act feed vol flow) [ACT_m3/h] 745.9033603 522.806524 5194.672956
Adiabatic Efficiency 75 75 75
Polytropic Efficiency 75.25624505 75.83407426 75.37101706
Compressor Volume [m3] 0 0 0
Delta T [C] 6.630224156 21.66437165 9.379122946
Delta P [kPa] 12.38120944 81.73668639 20
Polytropic Head [m] 1076.357047 2490.460557 992.5609472
Adiabatic Head [m] 1072.692091 2463.059653 987.6749802
Dynamic Head [m] 1076.357047 2490.460557 992.5609472
Polytropic Fluid Head [kJ/kg] 10.55545683 24.42307502 9.733697813
Adiabatic Fluid Head [kJ/kg] 10.5195159 24.15436395 9.685782844
Dynamic Fluid Head [kJ/kg] 10.55545683 24.42307502 9.733697813
Polytropic Head Factor 1.000047018 1.000285367 1.000098814
Polytropic Exponent 1.477605081 1.289925247 1.192172741
Isentropic Exponent 1.320921998 1.20026185 1.132751519
PD Number of Cylinders 0 0 0
Transient Rotational Power [kW] 0 0 0
Friction Loss Power [kW] 0 0 0
Fluid Power [kW] 3.311699449 13.4503578 34.80187881
Duty [kJ/h] 11922.11802 48421.28806 125286.7637

Column sub-flowsheet
Name T-100 T-101 T-102
Number of Stage 10 14 24
Top Stage Temperature [C] -86.66666667 -4 38
Bottom Stage Temperature [C] -62.22222222 95 120
Top Stage Pressure [kPa] 2275 2275 1585
Bottom Stage Pressure [kPa] 2310 2292 1655
Reflux Flow/Total Liq Flow 0.976099828 2.500063736 2.384543119
Reboiler Duty [kJ/h] 10072361.01 11275510.02 3374897.511

Column 1 material stream:

Name Methane To Reboiler Boilup Distillation Feed-1 Feed-2
Pressure [kPa] 2275 2310 2310 2500 2290
Temperature [C] -85.79659834 7.835697901 14.43026225 -95 -85.00006842
Mass Flow [kg/h] 23577.20031 46805.39788 31235.36901 34455.66706 4691.562114
Std Ideal Liq Vol Flow [m3/h] 77.62174726 120.7095055 82.48792819 102.5993193 13.24400521
Vapor / Phase Fraction 1 0 1 0 0.518529871
Molar Enthalpy [kJ/kgmole] -80020.35674 -101936.8258 -90280.71984 -92828.40017 -90146.89106

Column 2 material stream:

23
Name Reflux To Condenser Boilup To Reboiler Ethane Liquids-1 Distillation Feed-2
Pressure [kPa] 2275 2275 2292 2292 2275 2275 2790
Temperature [C] -1.782048188 -1.215895752 67.69346356 65.36010662 -1.782048188 -1.782048188 20.05
Mass Flow [kg/h] 25288.24526 35372.21131 45345.78869 52784.61008 10083.96589 0.000156198 17522.78744
Std Ideal Liq Vol Flow [m3/h] 70.78750393 99.09517519 88.98813014 103.4578977 28.30767082 4.37232E-07 42.7774388
Vapor / Phase Fraction 0 1 1 0 1 0 0
Molar Enthalpy [kJ/kgmole] -97613.67786 -88257.42092 -105670.5091 -117078.4737 -88194.73233 -97613.67786 -105017.2317

Column 3 material stream:

Name Reflux To Condenser Boilup To Reboiler Propane Liquids-2 Distillation Feed-3
Pressure [kPa] 1585 1826.316568 1655 1655 1585 1585 1690
Temperature [C] 45.86005558 53.2895182 95.37914338 94.14675323 45.86005558 45.86005558 67.46
Mass Flow [kg/h] 13645.29258 19367.68546 13703.36245 16575.65927 0.000161974 5722.392722 8594.6897
Std Ideal Liq Vol Flow [m3/h] 26.9517031 38.25437274 24.07483861 29.1058276 3.21537E-07 11.30266931 16.33365863
Vapor / Phase Fraction 0 1 1 0 1 0 1
Molar Enthalpy [kJ/kgmole] -117549.1935 -104270.1119 -125182.234 -139361.0293 -104062.0774 -117549.1935 -109917.8095

ECONOMICS FOR CASCADE CYCLE:

Name Summary
Total Capital Cost [USD] 10959000
Total Operating Cost [USD/Year] 4490310
Total Utilities Cost [USD/Year] 2268620
Desired Rate of Return [Percent/'Year] 20
Equipment Cost [USD] 1932300
Total Installed Cost [USD] 3839100
Utilities
Name Fluid Rate Rate Units Cost per Hour Cost Units
Electricity 168.208 KW 13.03612 USD/H
Cooling Water Water 0.033099 MMGAL/H 3.97188 USD/H
Refrigerant - Propylene Refrigerant 0.593584 KLB/H 0.040364 USD/H
Refrigerant - Ethane Refrigerant 3.41391 KLB/H 0.06145 USD/H
Refrigerant - Freon 12 Refrigerant 104.4827 KLB/H 8.88103 USD/H
Steam @100PSI Steam 28.60041 KLB/H 232.807337 USD/H

24
Unit
Operations:
Name Equipment Cost [USD] Installed Cost [USD] Equipment Weight [LBS] Installed Weight [LBS] Utility Cost [USD/HR]
T-102 142200 461000 30900 79720 33.278094
E-104 10800 108600 1400 8530 0.011903
VLV-100 0 0 0 0 0
BAL-2 0 0 0 0 0
BAL-1 0 0 0 0 0
LNG-101 0 0 0 0 0
LNG-102 0 0 0 0 0
K-100 442400 572200 5800 18203 0.289075
VLV-102 0 0 0 0 0
K-101 493900 617200 6300 17566 1.1563
VLV-106 0 0 0 0 0
LNG-100 0 0 0 0 0
BAL-3 0 0 0 0 0
T-101 174100 513400 49900 104632 106.792887
MIX-100 0 0 0 0 0
E-102 0 0 0 0 0
E-105 11100 140700 1600 10535 0.040364
VLV-103 0 0 0 0 0
E-101 12700 148000 2100 12403 0.049548
T-100 102800 346400 28200 62027 87.46421
E-100 10700 95900 1300 8521 18.125061
VLV-101 0 0 0 0 0
K-102 516400 673200 7000 25484 2.89075
VLV-104 0 0 0 0 0
MIX-101 0 0 0 0 0
V-100 15200 162500 2600 20437 0
VLV-105 0 0 0 0 0
E-103 0 0 0 0 0

25
Equipment costing:
Name Equipment Cost [USD] Installed Cost [USD] Equipment Weight [LBS] Total Installed Weight [LBS]
E-104 10800 108600 1400 8530
E-102 0 0 0 0
E-105 11100 140700 1600 10535
VLV-103 0 0 0 0
E-101 12700 148000 2100 12403
E-100 10700 95900 1300 8521
VLV-101 0 0 0 0
K-102 516400 673200 7000 25484
VLV-104 0 0 0 0
MIX-101 0 0 0 0
V-100 15200 162500 2600 20437
VLV-105 0 0 0 0
Reboiler_@T-100 13900 78200 2500 13461
Main Tower_@T-100 88900 268200 25700 48566
Main Tower_@T-101 110600 280800 32100 54365
Reboiler_@T-101 18500 85200 4100 16042
Condenser_@T-101 45000 147400 13700 34225
Reboiler_@T-102 13100 78500 2200 13557
Condenser_@T-102 31800 114400 9000 24895
Main Tower_@T-102 97300 268100 19700 41268

TEMA HEX
Name DHE TEMA EXCH E-104 DHE TEMA EXCH E-102 DHE TEMA EXCH E-105
User tag number E-104 E-102 E-105
Remarks 1 Equipment mapped from 'E-104'. Equipment mapped from 'E-102'. Equipment mapped from 'E-105'.
Number of identical items 1 1 1
Heat transfer area [m2] 10.8384045 6.50324E-07 15.55146096
Front end TEMA symbol B B B
Shell TEMA symbol E E E
Rear end TEMA symbol M M M
Tube design gauge pressure [kPag] 243.42108 413.5883631 243.42108
Tube design temperature [C] -48.11340556 121.1111111 -58.398655
Tube operating temperature [C] -90 -45.55555556 -45.55555556
Tube outside diameter [m] 0.0254 0.0254 0.0254
Shell design gauge pressure [kPag] 243.42108 671.047008 128.504411
Shell design temperature [C] -48.11340556 121.1111111 -58.398655
Shell operating temperature [C] -20.33562778 29.11723722 -30.62087722
Tube length extended [m] 6.096 6.096 6.096
Tube pitch [m] 0.03175 0.03175 0.03175
Number of tube passes 1 1 1
Number of shell passes 1 1 1

26
Name DHE TEMA EXCH E-101 DHE TEMA EXCH E-100 DHE TEMA EXCH Reboiler_@T-100
User tag number E-101 E-100 Reboiler_@T-100
Remarks 1 Equipment mapped from 'E-101'. Equipment mapped from 'E-100'. Equipment mapped from 'Reboiler_@T-100'.
Number of identical items 1 1 1
Heat transfer area [m2] 18.29482618 8.908865169 23.05563016
Front end TEMA symbol B B B
Shell TEMA symbol E E E
Rear end TEMA symbol M M M
Tube design gauge pressure [kPag] 480.2561456 760.54608 1668.504412
Tube design temperature [C] -58.80850278 192.1111111 192.1111111
Tube operating temperature [C] -90 164.3333333 164.3333333
Tube outside diameter [m] 0.0254 0.0254 0.0254
Shell design gauge pressure [kPag] 771.0486819 473.254411 2553.421082
Shell design temperature [C] -58.80850278 -99.77777778 21.11111111
Shell operating temperature [C] -31.030725 -72 14.43026222
Tube length extended [m] 6.096 6.096 6.096
Tube pitch [m] 0.03175 0.03175 0.03175
Number of tube passes 1 1 1
Number of shell passes 1 1 1
Name DHE TEMA EXCH Reboiler_@T-101 DHE TEMA EXCH Reboiler_@T-102 DHE TEMA EXCH Condenser_@T-102
User tag number Reboiler_@T-101 Reboiler_@T-102 Condenser_@T-102
Remarks 1 Equipment mapped from 'Reboiler_@T-101'. Equipment mapped from 'Reboiler_@T-102'. Equipment mapped from 'Condenser_@T-102'.
Number of identical items 1 1 1
Heat transfer area [m2] 40.42274426 18.55435666 113.7435297
Front end TEMA symbol B B B
Shell TEMA symbol E E E
Rear end TEMA symbol M M M
Tube design gauge pressure [kPag] 1656.504416 1116.921078 1231.132126
Tube design temperature [C] 192.1111111 192.1111111 121.1111111
Tube operating temperature [C] 164.3333333 164.3333333 35
Tube outside diameter [m] 0.0254 0.0254 0.0254
Shell design gauge pressure [kPag] 2535.421078 1726.046083 1897.362646
Shell design temperature [C] 121.1111111 123.1569206 121.1111111
Shell operating temperature [C] 67.69346389 95.37914278 53.28951778
Tube length extended [m] 6.096 6.096 6.096
Tube pitch [m] 0.03175 0.03175 0.03175
Number of tube passes 1 1 1
Number of shell passes 1 1 1

27
Gas compressor

Name DGC CENTRIF K-100 DGC CENTRIF K-101 DGC CENTRIF K-102
User tag number K-100 K-101 K-102
Remarks 1 Equipment mapped from 'K-100'. Equipment mapped from 'K-101'. Equipment mapped from 'K-102'.
Actual gas flow rate Inlet [ACT_m3/h] 745.3429251 522.4147253 5190.775246
Design gauge pressure Inlet [kPag] 38.67108326 76.93439621 -21.32891716
Design gauge pressure Outlet [kPag] 51.05228996 158.6710772 -1.328921615
Driver power [kW] 3.312829703 13.45494834 34.81375631
Molecular weight 16.0429 30.069901 44.097
Specific heat ratio 1.319725 1.217135 1.151678
Compressibility factor Inlet 0.993856 0.969867 0.974459
Compressibility factor Outlet 0.993829 0.965262 0.971083

Vertical vessel:
Name DVT CYLINDER V-100
User tag number V-100
Remarks 1 Equipment mapped from 'V-100'.
Liquid volume [m3] 2.401932948
Vessel diameter [m] 0.9144
Vessel tangent to tangent height [m] 3.6576
Design gauge pressure [kPag] 103.425
Operating temperature [C] -160.60925

Multi diameter tower:

Name DTW TOWER Main Tower_@T-100 DTW TOWER Main Tower_@T-101 DTW TOWER Main Tower_@T-102
User tag number Main Tower_@T-100 Main Tower_@T-101 Main Tower_@T-102
Remarks 1 Equipment mapped from 'Main Tower_@T-100'. Equipment mapped from 'Main Tower_@T-101'. Equipment mapped from 'Main Tower_@T-102'.
Diameter Bottom section [m] 1.3716 1.3716 0.9144
Bottom tangent to tangent height [m] 9.7536 12.192 18.288
Design gauge pressure Bottom [kPag] 2553.421082 2535.421078 1897.362646
Design temperature Bottom [C] 21.11111111 121.1111111 121.9245306
Operating temperature Bottom [C] 7.835697778 65.36010722 94.14675278
Number of trays Bottom section 10 14 24
Bottom Tray type SIEVE SIEVE SIEVE
Bottom Tray spacing [m] 0.6096 0.6096 0.6096
Molecular Wt Overhead Prod. 32.172268 45.035428 57.630978

28
COST ANALYSIS RESULTS

29
ENERGY ANALYSIS RESULTS:

Summary Table
Property Actual Target Available Savings % of Actual
Total Utilities [kJ/h] 43740000 25840000 17900000 40.94
Heating Utilities [kJ/h] 29020000 20070000 8950000 30.85
Cooling Utilities [kJ/h] 14720000 5770000 8950000 60.82
Carbon Emissions [kg/h] 2445 1445 1000 40.92

30
PROCESS ADVANTAGES:
• The DMR process has less equipment than the C3MR process.
• The process has more flexibility, which allows a wide range of operating conditions.
• Can be used in comparatively colder regions.
• More train capacity as compared to C3MR

31
CONCLUSION
The cascade process appears to be the best choice within the premises of this comparison study,
viz. large capacity LNG trains, employing air cooling in a tropical climate. Other promising
processes are the Dual Mixed Refrigerant process and the Single Mixed refrigerant process. Shell
is further investigating several variations of these three processes.
The pre-cooled Nitrogen Expansion process is not an economic choice for a large, onshore
application. It may be an alternative for smaller scale offshore applications (absence of
hydrocarbon refrigerants).

The Optimized Cascade process is based on three multi-staged, cascaded refrigerant circuits
using pure refrigerants, brazed aluminum heat exchangers and insulated cold box modules.
ConocoPhillips has optimized the heat integration to closely approach the natural gas and
refrigerant cooling curves, resulting in a highly efficient process. Pure refrigerants of propane,
ethylene and methane are utilized, since their physical properties are ideal for heat integration.
The refrigerant properties are also well known and predictable, contributing to unrivaled
operating ease and flexibility.

Brazed aluminum heat exchangers and cold box modules allow for highly effi cient heat transfer
and can be designed to accommodate a wide range of LNG plant sizes. Depending on the natural
gas feed stream composition, the design of your LNG train can include an integrated heavies
removal unit (HRU) and/or a nitrogen rejection unit (NRU) to achieve your LNG plant
performance and economic targets.

32
REFERENCES:
• Inkyu Lee, Kyungjae Tak, Hweeung Kwon, Junghwan Kim, Daeho Ko,Il Moon,Design
and Optimization of a Pure Refrigerant Cycle for Natural Gas Liquefaction with
Subcooling.
• Bahram Ghorbani, Mohammad-Hossein Hamedi, Majid, Implementing Absorption
Refrigeration Cycle in Lieu of DMR and C3MR cycles in the Integrated NGL, LNG and
NRU Unit
• Ji-Hyun Hwanga,1, Myung-Il Rohb,∗, Kyu-Yeul Leec, Determination of the optimal
operating conditions of the dual mixed refrigerant cycle for the LNG F
• Meiqian Wang, Jian Zhang, Qiang Xu∗PSO topside liquefaction process. Optimal design
and operation of a C3MR refrigeration system for natural gas liquefaction
• Raluca Iolanda Manescu, Optimization of Dual Mixed Refrigerant (DMR) Processes for
Natural Gas Liquefaction
• Youtube Video: https://www.youtube.com/watch?v=dv1q1y1lmqa
• Youtube Video: https://www.youtube.com/watch?v=z8LNMQz0s6U

33