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NGL Recovery Project at Badak LNG Plant by Rahmat Safruddin and Abdul Gafar PT Badak NGL Bontang-Indonesia 23 rd World Gas Conference 5-9 June 2006 Amsterdam – The Netherlands

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Page 1: NGL Recovery Project at Badak LNG Plantmembers.igu.org/html/wgc2006pres/data/wgcppt/pdf/PGC Programme... · NGL Recovery Project at Badak LNG Plant by ... Material Balance LEX PLANT

NGL Recovery Project at Badak LNG Plant

byRahmat Safruddin and Abdul Gafar

PT Badak NGLBontang-Indonesia

23rd World Gas Conference5-9 June 2006

Amsterdam – The Netherlands

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Safety Massage

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Agenda

• Background and Objective

• Project Scope

• Plant Location

• Material Balance

• Project Staging

• Conclusions

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East Kalimantan Gas Gathering and Pipeline System

C

F

G

Gas Pipelines

Oil Pipelines

SENIPAH

PECIKO

BEKAPAI

HANDIL

TAMBORA

TUNU

BontangDomestic Plants

LNG Plant

Santan (LEX Plant)

Mah

akamR

iver

Muara Badak (VICO)

57 km

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Background

East Kalimantan Gas Distribution

LNG Plant

Domestic Plants

BontangKM-57

Chevron Liquid

Extraction (LEX) Plant

VICO

MuaraBadakKM-0 Santan

From TotalIndonesie

Rich Gas1109.2 btu/scf

Lean Gas1017 btu/scf

300 mmscfd

KM-53

3,320 mmscfd

150 mmscfd

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Background

Domestic Plants

• Fertilizer Plant: 4 Trains• Ammonia Plants: 2 Plants• Methanol Plant• Gas delivery Contract: 457,055 mmbtu/d• Supplied by 2 x 16”, 20” rich gas, and 16” lean gas p ipelines

Badak LNG Plant

• Train Number: 8 (A-H)• Production Capability: 22.1 mtpa LNG, 1 mtpa LPG, 10 million

bbl/yr condensate• Supplied by 2 x 36” and 2 x 42” gas pipelines

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Feed Gas Condition

Background

950−12001109.2HHV

0.437C6+

0.167nC5

0.261iC5

0.823nC4

0 − 50.718iC4

0 − 83.482C3

0 − 125.215C2

70 − 9983.285C1

5.528CO20 − 9

0.084N2

Domestic Contract

From Pipeline

Component

• Pressure: 35-40 kg/cm 2g• Temp : 27-32 oC

Background

Composition (Vol%)

• Pressure: 45-47 kg/cm 2g• Temp : 27-32 oC

To LNG Plant

To Domestic Plants

HHV in BTU/SCF

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Current Situations

• Feed Gas price to Domestic Plants is cheap

• Domestic Plants require primarily methane

• Price of heavier HC components is higher than metha ne

• Condensed hydrocarbon in pipeline transmission to D omestic Plants is flared

• Part of LPG Component is recombined with LNG to mai ntain LNG heating value (LPG price is higher than LNG pri ce)

• So, supplying lean gas instead of rich gas to Domes tic Plants will benefit from:

replacing LPG component in LNG with C2recovering LPG & Condensate from rich gaseliminating flared condensed HC

Background

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LNG Plant Process Overview

FEED GAS

K.O.D.

CO2

LNG

MARINE LOADING

MARINE LOADING

FRACTIONATION

C5+

BOIL OFF TOPLANT FUEL

PROPANEREFRIGERATION

M C RREFRIGERATION

DEETHANIZERDEPROPANIZERDEBUTANIZER

LNGSTORAGE

LPG

LPGSTORAGE

CO2 REMOVAL

(ABSORBER & REGENERATOR)

DEHYDRATION FRACTIONATION LIQUEFACTION(MCHE) STORAGE TANK(SCRUB COLUMN)(H2O & Hg REMOVAL)

4KT-1 4KT-2 4KT-3

4E-54E-6

4E-124E-10

4E-14

Background

LPG

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• To recover 99.2% of ethane and 100% components heavie r than ethane from pipeline rich gas delivered to Domest ic Plants

• To eliminate the flared condensed hydrocarbon in pipel ine to Domestic Plant

Objective

NGL Recovery Ethane Plus Extraction Plant (EPEP) Project

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CO2 Removal Unit Dehydration

Propane Refrigeration Unit LPG Product Refrigeration

LNG Plant

StorageTanks

EPEP Project Scope

C5+

Pipeline Distribution System

C2Vapor

EPEP Plant Utility

To DomesticPlants

Turboexpander + Fractionation Unit

KOD

Project Scope

C3C4

Field

StabilizerResidue Gas (C1)

ExistingKM-53

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Turboexpander Unit

Project Scope

C2 Product

Residue GasExport

Fuel

NGL Product

PretreatmentUnit

Raw Gas From Pipeline

Recycle Compressor

Residue Gas Compressor

Demethanizer

De-ethanizer

Booster Compressor

Expander

Ethane Compressor

TURBO EXPANDER TECHNOLOGY FOR

ETHANE PLUS EXTRACTION PROJECT

-106oC19 kg/cm 2

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EPEP Plant Characteristics

• High NGL recovery: 99.2% of C2 and 100% of other heavier HC components

• Highly Energy-efficient plant: fuel consumption 4.2% of its feed (Plant thermal efficiency of 95.8%)

Project Scope

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EPEP Plant Utilities

• Hot Oil: 5,000 m 3/h, WHRU Preheater + Furnace

• Electricity: Gas Turbine Generator, 3 x 50%

• Air : Instrument, Utility (compressor 3 x 100%)

• Nitrogen: Cryogenic and PSA Units (2 x 100%)

• Fuel Gas: High, Medium and Low Pressures

• Wastewater Treatment

• Smokeless Flares and Blowdown: LTCS, LTSS, Wet Flar es, Liquid Drain Collection and burnpit

• Water Storage ( supplied from LNG Plant ) : Amine water makeup, Potable, Utility & Fire Suppression Water S ystem

• Air cooling system

Project Scope

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R 1,830m

R 3,354m

R 1830m

Conical

zone

SWL 38m

Location

Condensate

stab unit

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Before EPEP Project

LEX PLANT LEAN GAS 150 MMSCFDHHV 1,017.0 BTU/SCF

DELIVERY CONTRACT

FEED GAS 457,055 MMBTU/D

DISTRIBUTION 275 MMSCFDPRODUCTS :

LNG 365 std cargoes

LPG C3 500,657 tons/year

FROM FIELD 3,595 MMSCFD 3,320 MMSCFD LPG C4 477,006 tons/year

HHV 1,109.2 BTU/SCF CONDENSATE 10,849,417 bbl/year

BADAK LNGPLANT

DOMESTICPLANTS

Material Balance

1 LNG std cargo = 125,000 m 3

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After EPEP Project

Material Balance

LEX PLANT LEAN GAS 150 MMSCFDHHV 1,017.0 BTU/SCF

DELIVERY CONTRACT

457,055 MMBTU/DRESIDUE 304 MMSCFD

HHV 1,000.3 BTU/SCFNGL RECOVERIES :

FEED GAS C2 261,285 tons/year

DISTRIBUTION C3 257,901 tons/yearC4 150,444 tons/year

TO EPEP 385 MMSCFD i-C5+ 1,043,683 bbl/year

(Addition 110 MMSCFD)

PRODUCTS : Net GainLNG 4.37 std cargoes

FROM FIELD 3,705 MMSCFD 3,320 MMSCFD LPG C3 257,901 tons/year

HHV 1,109.2 BTU/SCF LPG C4 150,444 tons/year

CONDENSATE 1,043,683 bbl/year

BADAK LNGPLANT

DOMESTICPLANTS

EPEPPLANT

110 mmscfd additional rich gas to EPEP Plant is req uired for• Makeup for energy shrinkage : 94 mmscfd• EPEP Fuel consumption : 16 mmscfd (4.2% of EPEP Feed)

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Project Staging

Feb’06

Sep'06Dec'07

EPC

FEED TenderEPC Tender

May’05

Aug ‘05

FEEDJun'06

Prep’n

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Conclusions

• EPEP Plant will be capable of recovering 99.2% of C 2 and 100% of heavier HC components from rich gas by Turbo-exp ander technology

• EPEP Project will gain additional production up to 4.4 std cargoes LNG, 0.4 mtpa LPG and 1 M bbl condensate by NGL recovery from rich gas delivered to Domestic Plants

• EPEP Plant is energy efficient with fuel consumptio n of 4.2% from its feed

• EPEP Plant will require 110 mmscfd additional gas su pply for residue gas energy shrinkage and plant fuel consump tion

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Thank You