5 MTPA LNG Plant Design and Simulation
Budget: $30 – $250 USD
LNG Plant Aspen HYSYS Project – Brief Overview
Project Objective
Design and simulate a 5 MTPA LNG plant using Aspen HYSYS.
The goal is to:
* Model the full process from raw natural gas to LNG
* Include pre-treatment, liquefaction, and storage
* Evaluate and optimize energy consumption (mainly refrigeration power)
* Compare liquefaction technologies
* Deliver a conceptual, realistic plant design
⸻
Basis of Design (Key Inputs)
* Feed: Raw natural gas (with CO₂, H₂S, water, mercury, heavy hydrocarbons)
* Product: LNG meeting standard specifications
* Assumptions: Steady-state operation, typical LNG plant conditions
* Simulation package: Suitable EOS (e.g., Peng–Robinson)
⸻
Main Process Units to Model
1. Feed Gas Pre-Treatment Section
Purpose: Prepare gas before cryogenic cooling
Include:
* Inlet Separation → remove free liquids
* Acid Gas Removal Unit (AGRU) → remove CO₂, H₂S
* Dehydration Unit → remove water (prevent hydrates/freezing)
* Mercury Removal Unit
* Hydrocarbon Conditioning / NGL removal → control heavies
⸻
2. Liquefaction Section (Core of the Plant)
Purpose: Convert treated gas to LNG (~ -160°C)
Model:
* Main Cryogenic Heat Exchanger (MCHE)
* Refrigeration System
Technologies to consider:
* Primary Case: Propane Pre-cooled Mixed Refrigerant (C3MR)
* Comparison Case: Dual Mixed Refrigerant (DMR)
⸻
3. Refrigeration System
Most energy-intensive part
Include:
* Propane cycle (pre-cooling)
* Mixed refrigerant loop(s)
* Compressors, coolers, expanders/valves
Optimization targets:
* Minimize compressor power
* Optimize refrigerant composition & pressures
* Improve temperature matching in heat exchangers
⸻
4. LNG Storage & Boil-Off Gas (BOG) Handling
Include:
* LNG storage tanks
* Boil-off gas generation
BOG handling options:
* Recompression and recycle
* Use as fuel gas
* Re-liquefaction
* Flare (emergency only)
⸻
Simulation Approach in HYSYS
* Define components and property package
* Build flowsheet step-by-step
* Use:
* Separators/splitters for early-stage simplification
* Logical unit operations for each treatment step
* Perform:
* Mass & energy balances
* Sensitivity/optimization studies
⸻
Key Performance Targets
* LNG production: 5 MTPA
* LNG product quality (methane-rich, minimal impurities)
* Minimum specific power consumption
* Stable and realistic operating conditions
⸻
Safety & Environmental Considerations (Conceptual)
* Include placeholders for:
* Relief valves
* Flare system
* Emergency shutdown
* Minimize:
* Flaring
* Energy consumption
* Ensure proper handling of:
* Acid gases
* Boil-off gas
⸻
Expected Deliverables
* Complete Aspen HYSYS flowsheet
* Stream results (composition, temperature, pressure)
* Energy consumption (especially compressors)
* LNG product specifications
* Equipment list (major units)
* Comparison: C3MR vs DMR
* Recommended operating conditions
Project Objective
Design and simulate a 5 MTPA LNG plant using Aspen HYSYS.
The goal is to:
* Model the full process from raw natural gas to LNG
* Include pre-treatment, liquefaction, and storage
* Evaluate and optimize energy consumption (mainly refrigeration power)
* Compare liquefaction technologies
* Deliver a conceptual, realistic plant design
⸻
Basis of Design (Key Inputs)
* Feed: Raw natural gas (with CO₂, H₂S, water, mercury, heavy hydrocarbons)
* Product: LNG meeting standard specifications
* Assumptions: Steady-state operation, typical LNG plant conditions
* Simulation package: Suitable EOS (e.g., Peng–Robinson)
⸻
Main Process Units to Model
1. Feed Gas Pre-Treatment Section
Purpose: Prepare gas before cryogenic cooling
Include:
* Inlet Separation → remove free liquids
* Acid Gas Removal Unit (AGRU) → remove CO₂, H₂S
* Dehydration Unit → remove water (prevent hydrates/freezing)
* Mercury Removal Unit
* Hydrocarbon Conditioning / NGL removal → control heavies
⸻
2. Liquefaction Section (Core of the Plant)
Purpose: Convert treated gas to LNG (~ -160°C)
Model:
* Main Cryogenic Heat Exchanger (MCHE)
* Refrigeration System
Technologies to consider:
* Primary Case: Propane Pre-cooled Mixed Refrigerant (C3MR)
* Comparison Case: Dual Mixed Refrigerant (DMR)
⸻
3. Refrigeration System
Most energy-intensive part
Include:
* Propane cycle (pre-cooling)
* Mixed refrigerant loop(s)
* Compressors, coolers, expanders/valves
Optimization targets:
* Minimize compressor power
* Optimize refrigerant composition & pressures
* Improve temperature matching in heat exchangers
⸻
4. LNG Storage & Boil-Off Gas (BOG) Handling
Include:
* LNG storage tanks
* Boil-off gas generation
BOG handling options:
* Recompression and recycle
* Use as fuel gas
* Re-liquefaction
* Flare (emergency only)
⸻
Simulation Approach in HYSYS
* Define components and property package
* Build flowsheet step-by-step
* Use:
* Separators/splitters for early-stage simplification
* Logical unit operations for each treatment step
* Perform:
* Mass & energy balances
* Sensitivity/optimization studies
⸻
Key Performance Targets
* LNG production: 5 MTPA
* LNG product quality (methane-rich, minimal impurities)
* Minimum specific power consumption
* Stable and realistic operating conditions
⸻
Safety & Environmental Considerations (Conceptual)
* Include placeholders for:
* Relief valves
* Flare system
* Emergency shutdown
* Minimize:
* Flaring
* Energy consumption
* Ensure proper handling of:
* Acid gases
* Boil-off gas
⸻
Expected Deliverables
* Complete Aspen HYSYS flowsheet
* Stream results (composition, temperature, pressure)
* Energy consumption (especially compressors)
* LNG product specifications
* Equipment list (major units)
* Comparison: C3MR vs DMR
* Recommended operating conditions