Shipboard applications

Module 1.2 - EcoRel

General presentation

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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

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 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

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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

provide:
a robust & reliable system
easy operation
lowest possible power consumption

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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 172000m3 capacity, the boil-off represents
approximately 5200 kg/h BOG
A 3 week voyage could result in loss of appr. 2620 tons if not used
effectively

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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 172000 m3 LNG carrier.
How much is 0,15 %
172 000 m3 x 0,15 % x 98,5% (tank filling) # 254 m3 of liquid methane per day
254 m3 x 590 Nm3/m3 = 150000 Nm3/d
or 6250 Nm3/h
or 3750 m3/h (at -100C and 1.06 bara)
or 4500 kg/h of pure methane

Energy content
Methane LHV = 50 MJ/kg or 35.8 MJ/Nm3
=> 62 MW of thermal power or approx 31 MW electricity (with = 0.5)

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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

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Module 1.2 Ecorel general presentation

BRAYTON CYCLE
3

T
4

C
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:

10

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

T
4

C
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 T3 to T4.
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

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Module 1.2 Ecorel general presentation

BRAYTON CYCLE - EcoRel analogy
Heat rejection
3

N2 Loop
BOG
Condenser

N2 Counter Current
Exchanger

Cold production

N2 inter &
after coolers

2
3
4
N2 Compander

T
12

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Module 1.2 Ecorel general presentation

Sizing considerations

LNG Gorgon

35

N2 content

Design Case

30

Partial Reliq.

% N2 in BOG

25
20
15
10

Full Reliq.

5
0
0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

% N2 in LNG

The plant is designed to allow full reliquefaction up to a certain N2 content,

thereafter partial reliquefaction is applied

14

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0,8

Module 1.2 Ecorel general presentation

Sizing considerations

Mass of boil-off gas is primary capacity consideration

N2 content in the boil-off gas (NBO) is equipment sizing consideration

NBO with excessive N2 will be handled by partial reliquefaction

Cryostars EcoRel is designed to be operated with Full Reliquefaction as the

primary goal saving all the cargo

15

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Module 1.2 Ecorel general presentation

Sizing considerations
Definition of N2 cycle :
Nitrogen mass flow based on BOG flow
Nitrogen operating pressure based on BOG composition

Mass flow is a function of N2 loop pressure

Higher pressure = higher mass flow for a given volume flow (N2 loop
volume)

BOG Condensation temperature is a function of the N2 loop pressure

Higher pressure is the N2 loop = Higher will be the cold power production
and lower will be the condensate temperature

16

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Module 1.2 Ecorel general presentation

Simplified flow diagram N2 Loop

N2 Loop
N2 Counter Current
Exchanger
BOG
Condenser

N2 inter &
after coolers

N2 Compander

Tank 4

17

Tank 3

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Tank 2

Tank 1

Module 1.2 Ecorel general presentation

Simplified flow diagram BOG Loop

BOG
Compressor

BOG
Condenser

BOG Loop principle

Tank 4

18

Tank 3

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Tank 2

Tank 1

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

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Module 1.2 Ecorel general presentation

Operating modes: Reliquefaction operations
Full Reliquefaction: Up to 21.4% N2 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 N2 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

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Module 1.2 Ecorel general presentation

Operating modes: N2 loop/Compander in IDLE mode
N2 loop in IDLE mode corresponds to a status of the cooling system:
When reliquefaction unit is stopped (no BOG running on the reliquefaction)
The N2 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 N2 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

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Module 1.2 Ecorel general presentation

Process flow diagram: Full reliquefaction
T:-74C
P:6,51 bara

T: -120C
P:1,06 bara

BOG
Compressor

N2
Cold BOG
T:-112C
P:10,2 bara
T:-139C
P:10,5 bara

Warm BOG
BOG
Desuperheater
T:-126C
P:6,26 bara

Condensate

T:-128C
P:10,1 bara
T:-141C
P:9,6bara

N2 Counter Current
Exchanger

T:42C
P:9,8 bara

BOG
Condenser
T:43C
P:46,0 bara

T:-107C
P:45,6 bara

T-160C
P:6,1 bara

N2 Compander

T:-162C
P: 10,7 bara

Tank 4

22

Tank 3

Tank2

N2 inter &
after coolers

Tank 1

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Module 1.2 Ecorel general presentation

Process flow diagram: Partial reliquefaction
BOG
Compressor

GCU
Off gas Heater
N2
Cold BOG

BOG
Intercooler

Warm BOG
Condensate

BOG
Desuperheater

Vent gas

N2 Counter Current
Exchanger
BOG
Condenser

N2 inter &
after coolers

LNG Flash
Drum

N2 Compander
LNG Return Pump

Tank 4

23

Tank 3

Tank 2

Tank 1

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Module 1.2 Ecorel general presentation

Process flow diagram: N2 cycle & N2 system
TCV34

N2 from cycle
From BOG
coolers

N2 from N2 system
FCV10

To BOG
Condenser

N2 inter & after coolers

N2 Counter Current
Exchanger

PDCV23

N2 Compander

ATM

PCV25

PCV15

PCV54

PCV01

N2
Production
N2 supply

PCV04

N2 Buffer

N2 Buffer
seal gas

PCV55

N2 Drum

The N2 seal gas system for compander is not represented

24

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Module 1.2 Ecorel general presentation

Sparing philosophy:
Redundant system
BOG
Compressor

Two installed (2x100 %)

N2 from cycle
Cold BOG
Warm BOG
Condensate
Vent gas
N2 from N2 system

BOG
Intercooler

BOG
Desuperheater

BOG
Condenser

N2 inter & after coolers

GCU

N2 Counter Current
Exchanger
LNG Flash
Drum

LNG
TANKS

N2 Compander
LNG Return
Pump

ATM

N2
Production

25

The N2 seal gas system for compander is not represented

N2 supply

N2 Buffer

N2 Buffer
seal gas
N2 Drum

For training purpose only 2014 CRYOSTAR SAS. All rightsConfidential

reserved.
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 flow diagram

GCU
N2 loop
Cold BOG
Warm BOG
BOG Heater

BOG
Compressor
11 & 12.K.01

Condensate
LNG

Off gas Heater

10.E.02

Vent gas

BOG
Intercooler
11 & 12.E.01

BOG
Desuperheater
10.E.03

N2 Drum
20.V.01
N2 Counter Current
Exchanger
20.E.01

BOG
Condenser
10.E.01

Liq Main

N2 Production
20.Z.01

N2 inter &
after coolers
21 & 22.E.01~03

LNG
Drum
10.V.01
N2 Compander
21 & 22.C.01
LNG Return Pump
10.P.01/02
Vent Mast

Tank 4

26

Tank 3

Tank 2

Tank 1

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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

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Module 1.2 Ecorel general presentation

Cryostar provides a single source for:
the Overall Plant Concept
the Liquefaction Process
the Cryogenic Turbo machinery (N2 Compander and 2 stages BOG
Compressor)
the Plant Engineering
the Project Management

28

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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

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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

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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

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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

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Module 1.2 Ecorel general presentation

Process: Cooling
Power Control
BOG
Compressor
N2 from cycle
Cold BOG
Warm BOG
Condensate
Vent gas
N2 from N2 system

BOG
Intercooler

BOG
Desuperheater

BOG
Condenser

N2 inter & after coolers

GCU

N2 Counter Current
Exchanger
LNG Flash
Drum

LNG
TANKS

N2 Compander
LNG Return
Pump

ATM

N2
Production

33

The N2 seal gas system for compander is not represented

N2 supply

N2 Buffer

N2 Buffer

N2 Drum

For training purpose only 2014 CRYOSTAR SAS. All rights

reserved.
seal
gasit, relate its contents to other persons, or to misuse it in any other way
Confidential Information. This document is the property of Cryostar. It is not permitted
to copy

Module 1.2 Ecorel general presentation

Process: OutletBOG
Temperature and Load Control on the
Compressor
compander
TCV34
N2 from cycle
N2 from N2 system
From BOG
coolers
FCV10
To BOG
Condenser

N2 inter & after coolers

N2 Counter Current
Exchanger

PDCV23

N2 Compander

Compander load,
flow and
temperature
control in the N2
loop

ATM

20PCV25

20PCV15

20PCV54

N2
Production
N2 supply

20PCV04

N2 Buffer

N2 Buffer
seal gas

N2 Drum

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34

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20PCV01

Module 1.2 Ecorel general presentation

Reliquefaction plant operation: Principle

BOG flowrate

Excess BOG

Low BOG

Full reliq

Partial
reliq

No reliq

Full reliq
(a)

Partial
reliq

No reliq

Full reliq

Partial
reliq (d)

No reliq

BOG
compressor

1 or 2 (b)

1 or 2 (b)

1 or 2 (b)

1(e)

1 (c)

Compander

GCU

Mode of operation

Number of
operating
equipment

Normal BOG

(a) Reliquefaction plant additional capacity will be limited by plant design figures and is a
function of flow rate and N2 content in BOG,
(b) Number of running equipment is function of BOG flow rate and N2 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

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Module 1.2 Ecorel general presentation

Reliquefaction plant operation: Functioning modes

Modes
Low Flow mode
Normal flow
mode

37

BOG LOOP

N2 LOOP

No BOGC running to reliquefaction

IDLE MODE

Low flow

Low flow mode control

Partial reliquefaction

Load control mode

Full reliquefaction

Load control mode

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Module 1.2 Ecorel general presentation

38

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Module 1.2 Ecorel general presentation

EcoRel: Unit key data

39

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 N2 in BOG

Water consumption

~ 460 m3/h

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Module 1.2 Ecorel general presentation

THANK YOU FOR YOUR ATTENTION !

ANY QUESTION?

40

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