Here, owners and operators of natural gas liquefaction facilities can realize substantial benefits during this re-inventory season.  Proven benefits of CBOP’s process modeling, performance monitoring and optimization include:

• Increased LNG production 5% to 10%, i.e., Top-off 10 to 20 days sooner
• Improved Specific Energy 5% to 10%, i.e., reduce fuel consumption
• Feed-Forward monitoring, i.e., catch problems before they happen
• Minimized risk of pipeline surcharges due to extended liquefaction season
• Potential for enhanced utilization of the facility, i.e., market excess capacity

CBOP represents a migration of standard high-value strategic technologies and services in the process industries to the world of LNG Peak Shaving.   CBOP provides a first principles chemical engineering service consisting of a staged and tiered programmed offering (introductory, mid-level and advanced) that provides a cost effective consultative solution.
Most U.S. LNG peakshavers are at least 20 years old, with some over 40.  Many of the exchangers and cold boxes are near the end of their expected life.  Almost every plant has a different feed gas compositions today than it did when it was first place into service.  Process modeling can quantify the real potential operating improvements of CH·IV optimization.  CH·IV is in a unique position to offer the value of process modeling technology to the LNG peakshaving industry. 
Process modeling for LNG peakshaving facilities is a perfect outsource solution.  Trying to capture the value of process modeling technology in-house requires a staff with years of experience, deep process knowledge and the software to turn the technology into savings.  CH·IV has the capability, the experience, and the customized software.
The first step in CBOP is to perform an independent diagnostic of the entire liquefaction section (Some of the diagnostic output is shown at right). 

 

 

 

 

 

 

 

 

 

 

 

 

The Diagnostic Phase includes some or all of the following steps:

1. Create a high fidelity model
2. Analyze actual current plant data (or in some cases projected changes in the free gas composition or pressure)
3. Perform gross error detection
4. Perform data reconciliation
5. Benchmark actual current performance against original design
6. Determine process equipment tuning parameters and constraints
7. Identify process stream sample points
8. Calculate actual compressor efficiencies
9. Calculate a Heat & Material Balance around each heat exchanger
10. Check drum sizing, when appropriate
11. Check hydraulics and line sizing for each stream
12. Generate composite heat exchanger cooling curves for the original design and existing operation (see graph below)
13. Calculate the original and existing liquefaction specific energy consumption
14. Generate optimized mixed refrigerant composition tables
15. Provide recommendations to improve and optimize operations for one or more feed gas streams

Typical Heat Exchanger Cooling Curve
Once the Diagnostic Phase has been completed with a comprehensive understanding of the possible and quantitative improvements, the owner/operator can implement the recommendations put forth by CH·IV. 
With the owner/operator’s concurrence, CBOP can then move to the Monitoring Phase where CH·IV performs regular rigorous model-based performance monitoring and off-line optimization to assure that the liquefaction plant continues to operate at peak efficiencies and optimized production rates.  Operating at the optimum set points and mixed refrigerant compositions can also prolong the life of equipment.