Review on the design and optimization of natural gas liquefaction processes for onshore and offshore applications

Single mixed refrigerant biomethane liquefaction plant integrated with solar energy: Dynamic simulation for the decarbonization of the heavy road transport sector

This works proposes a dynamic thermoeconomic analysis of a liquefied biomethane production plant to meet the fuel demand of a fleet of heavy duty trucks in the south of Italy. The biomethane is obtained from the upgrading of the biogas produced by means of anaerobic digestion through a plug flow reactor fed by organic fraction of municipal solid waste. The upgrading of the biogas is realized using a three-stage membrane compression process, producing a 96 % pure biomethane. The biomethane liquefaction is realized using a single-mixed refrigerant process and compared to a Linde cycle process. The whole system is assisted by solar energy to reduce the fossil energy consumption of the process and feed-in tariffs are considered as funding policy. The models for the anaerobic digestion, the biogas upgrading, and the biomethane liquefaction are in detail developed in MatLab. The anaerobic digestion model is based on the ADM1 biological model, integrated with a suitable heat transfer model. The biogas upgrading model is based on a simplified Fick model. The liquefaction model is based on an equivalent two heat-exchangers model, taking into account the transient heat transfer. All the components are then integrated in TRNSYS to perform the dynamic simulation for one operating year of the whole system. Results from the thermoeconomic analysis are outstanding in terms of profitability, showing a payback period of less than 2 years and a Net Present Value of the system of 402 M€. The great environmental impact is also confirmed by a Primary Energy Saving of 91 % and a dramatic reduction of 86 % of the CO2 equivalent emissions.

Reliable sustainable management strategies for flare gas recovery: technical, environmental, modeling, and economic assessment: a comprehensive review

The gas flaring network is an inseparable constituent commonly present in most of the oil and gas refineries and petrochemical facilities conferring reliable operational parameters. The improper disposal of burn-off gases improperly results in environmental problems and loss of economic resources. In this regard, waste to energy transforming nexus, in accord with the "carbon neutrality" term, has potentially emerged as a reasonable pathway to preserve our planet. In a transdisciplinary manner, the present review article deeply outlines the different up-to-date strategies developed to recover the emitted gases (flaring minimization) into different value-added products. To analyze the recovery potential of flare gases, different technologies, and decision-making factors have been critically reviewed to find the best recovery methods. We recommend more straightforward recovery methods despite lower profits. In this regard, electricity generation seems to be an appropriate option for application in small amounts of flaring. However, several flare gas utilization processes such as syngas manufacturing, reinjection of gas into petroleum reservoirs, and production of natural gas liquid (NGL) are also recommended as options because of their economic significance, technological viability (both onshore and offshore), and environmental benefits. Moreover, the adopted computational multi-scale data assimilation for predictive modeling of flare gas recovery scenarios has been systematically reviewed, summarized, and inspected.

A novel strategy for process optimization of a natural gas liquid recovery unit by replacing Joule-Thomson valve with supersonic separator

The natural gas liquid recovery is an important process in a gas plant to correct hydrocarbon dew point and earn profit. In this study, a natural gas liquid recovery unit operated based on the Joule-Thomson process was investigated and its performance was optimized. To improve the system performance, the plant configuration and intermediate pressure ratio were defined as the variables and maximization of the natural gas liquid recovery rate and maximization of exergy efficiency were defined as the objective functions. To improve the plant performance, the amount of natural gas liquid recovery rate should be increased. To achieve this goal, several scenarios for the intermediate pressure ratio and three new configurations were proposed for the investigated gas plant. In the proposed configurations, the supersonic separators with optimized structures were used instead of the Joule-Thomson process. It was observed that all three proposed configurations improved the natural gas liquid recovery rate compared to the existing configuration. For example, by installing two supersonic separators instead of second and third stage Joule-Thomson valve + low temperature separator, at the optimal operating condition, the natural gas liquid recovery rate increased about 390%. The influence of the intermediate pressure ratio on the phase envelope diagram, exergy efficiency, dew point depression and natural gas liquid recovery rate was also investigated. By comparing the influence of intermediate pressure ratio and modifying the plant configuration on the objective functions, it was observed that the system performance can be further improved by modifying the plant configuration.

Nonlinear Reactor Design Optimization With Embedded Microkinetic Model Information

Despite the success of multiscale modeling in science and engineering, embedding molecular-level information into nonlinear reactor design and control optimization problems remains challenging. In this work, we propose a computationally tractable scale-bridging approach that incorporates information from multi-product microkinetic (MK) models with thousands of rates and chemical species into nonlinear reactor design optimization problems. We demonstrate reduced-order kinetic (ROK) modeling approaches for catalytic oligomerization in shale gas processing. We assemble a library of six candidate ROK models based on literature and MK model structure. We find that three metrics—quality of fit (e.g., mean squared logarithmic error), thermodynamic consistency (e.g., low conversion of exothermic reactions at high temperatures), and model identifiability—are all necessary to train and select ROK models. The ROK models that closely mimic the structure of the MK model offer the best compromise to emulate the product distribution. Using the four best ROK models, we optimize the temperature profiles in staged reactors to maximize conversions to heavier oligomerization products. The optimal temperature starts at 630–900K and monotonically decreases to approximately 560 K in the final stage, depending on the choice of ROK model. For all models, staging increases heavier olefin production by 2.5% and there is minimal benefit to more than four stages. The choice of ROK model, i.e., model-form uncertainty, results in a 22% difference in the objective function, which is twice the impact of parametric uncertainty; we demonstrate sequential eigendecomposition of the Fisher information matrix to identify and fix sloppy model parameters, which allows for more reliable estimation of the covariance of the identifiable calibrated model parameters. First-order uncertainty propagation determines this parametric uncertainty induces less than a 10% variability in the reactor optimization objective function. This result highlights the importance of quantifying model-form uncertainty, in addition to parametric uncertainty, in multi-scale reactor and process design and optimization. Moreover, the fast dynamic optimization solution times suggest the ROK strategy is suitable for incorporating molecular information in sequential modular or equation-oriented process simulation and optimization frameworks.

Status and prospects of the decentralised valorisation of natural gas into energy and energy carriers

We critically review the recent advances in process, reactor, and catalyst design that enable process miniaturisation for decentralised natural gas upgrading into electricity, liquefied natural gas, fuels and chemicals.

Membrane-Assisted Removal of Hydrogen and Nitrogen from Synthetic Natural Gas for Energy-Efficient Liquefaction

Synthetic natural gas (SNG) production from coal is one of the well-matured options to make clean utilization of coal a reality. For the ease of transportation and supply, liquefaction of SNG is highly desirable. In the liquefaction of SNG, efficient removal of low boiling point impurities such as hydrogen (H2) and nitrogen (N2) is highly desirable to lower the power of the liquefaction process. Among several separation processes, membrane-based separation exhibits the potential for the separation of low boiling point impurities at low power consumption as compared to the existing separation processes. In this study, the membrane unit was used to simulate the membrane module by using Aspen HYSYS V10 (Version 10, AspenTech, Bedford, MA, United States). The two-stage and two-step system designs of the N2-selective membrane are utilized for SNG separation. The two-stage membrane process feasibly recovers methane (CH4) at more than 95% (by mol) recovery with a H2 composition of ≤0.05% by mol, but requires a larger membrane area than a two-stage system. While maintaining the minimum internal temperature approach value of 3 °C inside a cryogenic heat exchanger, the optimization of the SNG liquefaction process shows a large reduction in power consumption. Membrane-assisted removal of H2 and N2 for the liquefaction process exhibits the beneficial removal of H2 before liquefaction by achieving low net specific power at 0.4010 kW·h/kg·CH4.

Shuffled Complex Evolution-Based Performance Enhancement and Analysis of Cascade Liquefaction Process for Large-Scale LNG Production

Among all large-scale natural gas (NG) liquefaction processes, the mixed fluid cascade (MFC) process is recognized as a best-alternative option for the LNG production, mainly due its competitive performance. However, from a thermodynamic point of view, the MFC process is still far from its potential maximum energy efficiency due to non-optimal execution of design variables. Therefore, the energy efficiency enhancement of the MFC process remains an ongoing issue. The design optimization after fixing the main configuration of the process is one of the most economic, but challenging exercises during the design stages. In this study, shuffled complex evolution (SCE) is studied to find the optimal design of the MFC process corresponding to minimal energy consumption in refrigeration cycles. The MFC process is simulated using Aspen Hysys® v10 and then coupled with the SCE approach, which is coded in MATLAB® 2019a. The refrigerant composition and operating pressures for each cycle of the MFC process were optimized considering the approach temperature inside the LNG heat exchanger as a constraint. The resulting optimal MFC process saved 19.76% overall compression power and reduced the exergy destruction up to 28.76%. The thermodynamic efficiency (figure of merit) of the SCE-optimized process was 25% higher than that of the published base case. Furthermore, the optimization results also imply that there is a trade-off between the thermodynamic performance improvement and the computational cost (no. of iterations). In conclusion, SCE exhibited potential to improve the performance of highly nonlinear and complex processes such as LNG processes.

Single-Solution-Based Vortex Search Strategy for Optimal Design of Offshore and Onshore Natural Gas Liquefaction Processes

Propane-Precooled Mixed Refrigerant (C3MR) and Single Mixed Refrigerant (SMR) processes are considered as optimal choices for onshore and offshore natural gas liquefaction, respectively. However, from thermodynamics point of view, these processes are still far away from their maximum achievable energy efficiency due to nonoptimal execution of the design variables. Therefore, Liquefied Natural Gas (LNG) production is considered as one of the energy-intensive cryogenic industries. In this context, this study examines a single-solution-based Vortex Search (VS) approach to find the optimal design variables corresponding to minimal energy consumption for LNG processes, i.e., C3MR and SMR. The LNG processes are simulated using Aspen Hysys and then linked with VS algorithm, which is coded in MATLAB. The results indicated that the SMR process is a potential process for offshore sites that can liquefy natural gas with 16.1% less energy consumption compared with the published base case. Whereas, for onshore LNG production, the energy consumption for the C3MR process is reduced up to 27.8% when compared with the previously published base case. The optimal designs of the SMR and C3MR processes are also found via distinctive well-established optimization approaches (i.e., genetic algorithm and particle swarm optimization) and their performance is compared with that of the VS methodology. The authors believe this work will greatly help the process engineers overcome the challenges relating to the energy efficiency of LNG industry, as well as other mixed refrigerant-based cryogenic processes.

Overall Performance Evaluation of Small Scale LNG Production Processes

The liquefied natural gas (LNG) is considered a viable solution to replace oil-based engines (common in heavy-duty truck and naval industry) reducing the environmental impact in the transport sector. Since liquefaction plants represent energy intensive processes, the best configurations/operation assessment is of primary importance. In this paper, a novel general procedure for the thermodynamic design and optimization, engineering design and off-design evaluation for small-scale LNG production systems is presented. The procedure can be used for the complete design and performance evaluation of plug & play facilities at filling stations for vehicles/boats, with the contemporary benefits of reducing pollutant emission in the city/port area and operating as electrical storage, coupled with renewable generators. Furthermore, the procedure has been applied to a case study (ferry boat operating at the main canal in the port of Ravenna, Italy), evaluating the optimal size for the integrated wind plant by minimizing the electricity introduction into the grid. The obtained results show 78 kW as optimal wind size, allowing the LNG plant to operate 187 h/year in design and 4720 h/year in off-design conditions, with electricity surplus around 33 MWh/year. A prototype will be installed to reduce pollutant emissions and test this technology as a storage option for renewable sources.

Potential of District Cooling Systems: A Case Study on Recovering Cold Energy from Liquefied Natural Gas Vaporization

District cooling systems (DCSs) are networks able to distribute thermal energy, usually as chilled water, from a central source to industrial, commercial, and residential consumers, to be used for space cooling/dehumidification. As cooling demand will increase significantly in the next decades, DCSs can be seen as efficient solutions to improve sustainability. Although DCSs are considered so relevant for new city developments, there are still many technical, economic, and social issues to be overcome to let such systems to spread out. Thus, this paper aims to highlight the advantages and issues linked to the adoption of DCSs for building cooling when cold is recovered from a specific application. A case study based on liquified natural gas (LNG) cold energy recovery from the transport sector is presented. Starting from the estimation of the free cooling availability, a DCS design method is proposed and the potential energy saving is investigated. Results show that a DCS using the cold waste derived from LNG can provide a relevant amount of electricity saving (about 60%) for space cooling compared to traditional solutions, in which standard air conditioning systems are installed in every building.