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6th Annual LNG TECH Global Summit 2011

De Doelen, Rotterdam 3rd-5th October

Liquefaction of Natural Gas


How can fundamental R&D help the industry?
Case studies from GTS
Geir Skaugen
SINTEF Energy Research,
Trondheim, Norway

Gas Technology Center NTNU-SINTEF

Content of the presentation

The Gas Technology Centre at NTNU - SINTEF


- What is GTS
- Research areas and capabilities

Case Studies:
- LNG Heat Exchanger Studies
Multilevel experiments and modelling
- Small scale LNG systems
From laboratory experiments to installation onboard a gas carrier
- LNG and Low temperature Energy chain
- Future research tasks within LNG at GTS
http://www.ntnu.no/gass/

Gas Technology Center NTNU-SINTEF

Gas Technology Centre NTNU - SINTEF


Cooperation
Virtual organisation
Tight links to industry
International network

Strategic partners
Statoil
Mission:
To act as a common
interface in gas technology
R&D between NTNUSINTEF and the marked:

Researchers
NTNU
75 professors
135 Ph.D. researchers
30 post.doc. researchers
SINTEF
200 research scientists
Students
Award 75% of all M.Sc. in
Norways gas-related industry

Gas Technology Center NTNU-SINTEF

The Norwegian University of Science & Technology (NTNU)


- and The SINTEF Group
Number of employees (2010):
NTNU
(Scientific

4.700
60%)

SINTEF
(Scientific

2.145
73%)

Students:
18.500
10.000 in Engineering & Science

A technological cluster with education, basic & applied


research, innovations and business developments
- of large importance for Norway
Gas Technology Center NTNU-SINTEF

SINTEF is a multidisciplinary research organisation with


international top level expertise in specific fields

SINTEF Building and


Infrastructure
SINTEF ICT
SINTEF Materials and
Chemistry
SINTEF Technology and Society

SINTEF Energy Research


SINTEF Fisheries and Aquaculture
SINTEF Petroleum Research
MARINTEK

Gas Technology Center NTNU-SINTEF

Disciplines around Gas Technology Centre

Gas Technology Center NTNU-SINTEF

R&D along the Natural Gas value chain


Reservoir technology (including CO2-injection)
Gas transport (multiphase pipelines, LNG, LPG,
energy markets)
Chemical conversion
Gas processing
Gas transport infrastructure and techno-economic
optimisation
Fossil fuel hydrogen production, storage and
usage

Gas Technology Center NTNU-SINTEF

Laboratory facilities
Refrigeration and Combustion Technology LAB
- Multiphase flow of oil and gas
- Heat transfer and pressure drop for gas mixtures in compact
geometries
- Small scale laboratory prototype for liquefaction of Natural
gas
- Oxy-fuel Combustion for Gas Turbines

Absorption LAB
- Absorption of CO2, H2S and NOx
- Catalysts and absorbents

Membrane technology LAB


- Membranes for hydrogen and CO2 separation

Hydrogen production, liquefaction and


storage
Fuel cell technology

Gas Technology Center NTNU-SINTEF

NTNU & SINTEF

A Strategic Model of Cooperation:


1. Common strategies
2. Industrial relevance and involvement
3. Basic scientific methodology
SINTEF-personnel
participates in
teaching at NTNU

NTNU-personnel
participates in
SINTEF-projects

Joint use of
laboratories and
equipment
Core Areas:
- Contract Research
- Applied Research

Core Area:
Strategic Research

Gas Technology Center NTNU-SINTEF

Core Areas:
- Education
- Basic Research

Strategic Research - Competence Building Projects for


the Industry
Some key characteristics:
Long term projects 3-5 years
Cooperation with leading international research partners and includes PhD
education
Results are to be published in open scientific journals
Minimum industry funding of 20% of total budget
The industry is represented in the steering committee of the project
"Enabling Low Emission LNG-systems"
Project figures:
Duration 2009-2014
Total budget: 44 million NOK (With 61% from the research council)
2 industry partners and support from the Gas Technology Centre
Educate 3 PhD candidates and 1 postdoc candidates within the field

Gas Technology Center NTNU-SINTEF

Enabling low-emission LNG systems


Fundamentals for multilevel modelling
Focus towards fundamental phenomena occurring in
LNG equipment
- Experimentally
- By modeling

Unit design/operation in perspective of:


- Fundamental phenomena
- Robust modeling approach
- Integration with the process

LNG
systems
LNG heat
exchangers
LNG fundamental
phenomena

Process design and system analysis including:


- LNG process optimizing taking into account detailed unit models
- LNG process dynamics
- Process evaluation methodology

Gas Technology Center NTNU-SINTEF

Droplet and film phenomena (PhD and PostDoc)


To be able to model and predict heat exchanger shell-side flow, droplet and
bubble and film interaction needs to be better understood, hence both
experiments and numerical analysis is required.
Fundamental knowledge can
be applied to build more
accurate engineering models.

instabilities and heat transfer for two-phase flow in confined geometries


representing heat exchanger tube side phenomena.

Gas Technology Center NTNU-SINTEF

Droplet and film phenomena experimental setup

Experiments conducted with water and with n-Pentane


on a horizontal or a tilted flowing film

Gas Technology Center NTNU-SINTEF

General and modular heat exchanger modeling


framework
Generic tool with building blocks of:
fluid nodes
heat nodes
surfaces
thermal resistors

Example:
Counter-flow HX with wall heat conduction

splitters
mixers
flash units
flow restrictions
Surfaces:
geometry models
heat transfer/pressure drop models
Fluid nodes:
thermodynamic model
numerical and physical flow model

Gas Technology Center NTNU-SINTEF

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Use of detailed heat exchanger simulation


models in an engineering flow-sheeting
environment for static instability analysis

Gas Technology Center NTNU-SINTEF

Process optimisation
Heat exchanger representation in process simulation and
optimisation are most often:
- Black or grey boxes that provide the process input/output states
- Some degree of zone-analysis in a simplified manner
- Using lump, composite warm and cold streams

Using a detailed heat exchanger model, a chosen design can be


validated and the process operability can be investigated in a more
complete way
The focus of this presentation is to investigate heat exchanger
design in terms of steady state instability, also referred to in
literature as: Ledinegg type instability.

Gas Technology Center NTNU-SINTEF

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Industrial relevance
Increased focus on compact and
energy efficient solutions
Compact, optimized LNG
processes using are proposed and
presented in literature are often
based on using brazed aluminum
heat exchangers (BAHX) only
A recent example:
- The ExxonMobile EMR process.
- About 30 parallel cores
(Denton 2010)

The issues of potential instability


need to be addressed

Presented at: 89th Annual GPA Convention,


21-24 March 2010, Austin , TX (Denton et.al)

Gas Technology Center NTNU-SINTEF

Ledinegg instability in boiling services


N-shape for upward boiling in a heat exchanger

All

va

po

ur

An N-shape may occur in boiling


services if an increase in flow rate
results in a decrease in pressuredrop

Combination: increased flow ->


decrease in average void fraction
may give an N-shape

phas

Two-

Pressure drop

Counteracting effects:
- Increase in flow -> higher
pressure drop
- Decrease in average void
fraction -> lower pressure drop

uid

q
ll li

Flow rate

Gas Technology Center NTNU-SINTEF

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Case: Optimised SMR process for liquefaction of


natural gas
Cooling and liquefaction of 1 kmole/s NG from 25
to -155 C

External cooling to 25C


25C
Single phase vap
P2

1 kmol/s
( 64 t/h)
10K superheat

MITA=1.2 K

N2,C1,C2,C3,iC4 and nC4


flowrates

Optimisation of flow-rate, composition, and


pressure levels to obtain minimum energy
consumption with restrictions:

- 10 K superheat
- 1.2 K minimum temperature approach (MITA)

With specifications:
P1

- External cooling to 25C

-155C
Subcooled
single phase liq

Gas Technology Center NTNU-SINTEF

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Optimised process design with a fully designed heat


exchanger

T NG
T LP
P LP
P HP

-155
-157.1
5.34
25.88

N2
C1
C2
nC4

0.0929
0.2913
0.3887

MREFR (kmol/s)
MNG

Gas Technology Center NTNU-SINTEF

0.2271
3.15
1

20

Check for operability Pressure drop vs. flow rate for the evaporating stream

1.80

1.1

1.60

1.40

0.9

1.20

0.8

1.00

0.7

0.80

0.6

0.60

0.5

0.40

0.4
Pressure drop (bar)
Vapour fraction (kg/kg)

0.20

Outlet vapour fraction

Pressure drop (bar)

MR LP

Assumption for this simulation:


Constant warm stream flow rates

0.3

0.00

0.2
0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

Relative flow rate MR LP(-)

Gas Technology Center NTNU-SINTEF

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Consequences of Ledinegg instability


Equal cold stream pressure drop with flow-rate split 42/58 (+/- 8%)
Temperature profiles
40
20
0

Temperature

-20
-40

LP MR Under refrigerated

-60

LP MR Over refrigerated

-80
-100
-120
-140
-160
0

0.2

0.4

0.6

0.8

Relative length

Individual temperature profile


Gas Technology Center NTNU-SINTEF

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Remedies for avoiding Ledinegg instabilities

All

va

po

ur

N-shape for upward boiling in a heat exchanger

phas

Pressure drop

Two-

id

qu

li
All

Move the operating


point within the blue
line.
Get rid of the N-shape
-

Modify HX design,
Reduce outlet resistance
Increase inlet resistance
Avoid cold end pinch
(Reduce the heat load)

Flow rate

Gas Technology Center NTNU-SINTEF

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Example on modified design


Reduced heat flux for cold channels increased surface
while maintaining - or reducing the pressure drop
MR LP
0.40

1.1

0.35

Pressure drop (bar)

0.8

0.25

0.7

0.20

0.6

0.15

0.5

0.10

N-shape

Yes

No

0.4

Pressure drop (bar)


Vapour fraction (kg/kg)

0.05

Outlet vapour fraction

0.9

0.30

Core volume (m3)


Heat transfer surface (m2)
Average heat flux (W/m2)
Mass flux (kg/m2 s)
Design pressure drop (bar)

HX 1
HX 2
31.7 107.0
26502 70255
2911 1073
62.7
19.4
0.82
0.17

0.3

0.00

0.2
0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

Relative flow rate MR LP(-)

Gas Technology Center NTNU-SINTEF

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Summary on heat exchanger / process analysis


In cryogenic processes using fluids with low density and low latent
heat, instabilities are more likely to occur
The risk of ending up with a design operating point in an unstable
region is high, if
- processes are optimised based on composite curves and minimum
temperature differences,
- the pressure drop vs flowrate curve exhibits an N-shape

When equipment with a high degree of parallelism is used, this could


have serious consequences in terms of thermal stress or inefficient
operation
There are currently 3 PhD studies on the topic of instability in heat
exchangers at NTNU.

Gas Technology Center NTNU-SINTEF

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Small Scale LNG production


The SINTEF Mini-LNG concept from laboratory to
installation onboard a gas carrier

The Mini-LNG technology


General characteristics

Re-Liquefaction plant, application example


Full scale plant analysis

Contact person on Mini LNG: Petter Neks


(petter.neksa@sintef.no)

Gas Technology Center NTNU-SINTEF

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NG liquefaction plants, capacity range

Base-load
LNG production: 1500 5000 kT/year

Hammerfest/Snhvit 4300 kT/year (12500T/day)

Peak shaving
LNG production: 35 150 kT/year
Mini-LNG
LNG production: 3.5 35 kT/year
(10 100 T/day)
Gas Technology Center NTNU-SINTEF

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The cost challenge of


small scale LNG

Gas Technology Center NTNU-SINTEF

Energy efficency

The energy efficiency challenge


of small scale LNG
Magnetic cycle

SINTEF
Mini LNG

Mini LNG

Peak shaving

Baseload

Production
capacity

Gas Technology Center NTNU-SINTEF

The SINTEF mini-LNG concept - Liquefaction Unit


Using standard equipment for low investment cost and fast
manufacture of the liquefaction unit
- Copper brazed plate heat exchangers, withstands rapid temperature
changes
- Lubricant injected screw compressors
- Proven robust oil/lubricant management

Construction in steel frames:


- Lower manufacturing cost
- Faster manufacture time
- Modular movable plant elements

Refrigeration cycle with mixed refrigerant (N2,C1,C2,C3,C4) for


low energy demand
Adaptation of selected equipment, MR and operational
conditions to given application and NG composition
Gas Technology Center NTNU-SINTEF

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From theory laboratory - full scale


40

46

52

Theoretical

62

54

HA-01

60

58

Laboratory plant 1 tonnesLNG/d

HA-02
90

102 104

10

88

74
86

Simplified
concept

114

HA-04

20

HA-07

120

78

118

76

116

117

22
24 26

77

- Fully instrumented closed loop lab plant at SINTEF


- Operation since 2003, 2000 h (500 continuous)
- Lubricant tests, various operating conditions, rapid
start-up

28

LNG

40

50

20

45

40

Full scale test, 20 tonnesLNG/d


-

Design and construction


FAT test at SINTEF Tiller lab in Trondheim 2008
Analysis of results
Installation onboard a gas carrier 2009

temperature 'C

-20

35

-40

temperature

30

-60

flow

25

-80

20

-100

15

-120

10

-140

flow kg/h

- Process development and simplification


- Analysis

64
100

-160

0
0

10

20

30

40

50

60

70

minutes

start

Gas Technology Center NTNU-SINTEF

31

40

50

20

45

40

-20

35

-40

temperature

30

-60

flow

25

-80

20

-100

15

-120

10

-140

-160

0
0

10

20

30

40

50

60

m inutes

start
Gas Technology Center NTNU-SINTEF

70

flow kg/h

temperature 'C

Mini-LNG liquefaction unit


Rapid start and stop
Reading from laboratory plant 1 tonnes/d

Application example SINTEF Mini-LNG

Reliquefaction of boil-off gas from a small IMS Multigas carrier


using the Mini-LNG Techology

10.000 m3
Multigas

3D illustration of the tanker with the


refrigeration system on the top deck

Gas Technology Center NTNU-SINTEF

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Gas Technology Center NTNU-SINTEF

Plant design simulation results (mini-LNG)


BOG NG with 89 mol% CH4, 11 mol% N2 (18 bara)

Boil-off gas liquefaction capacity

20 tonnes/d

LNG exit temperature (before throttling to tank)

-155 oC

MR (at first vapour-liquid separator inlet) and NG precooling temperature

-35 oC

Mixed refrigerant compressor pressure ratio

9.3 -

Mixed refrigerant compressor power consumption

395 kW

Estimated compressor isentropic efficiency

0.65 1520 m3/h

Mixed refrigerant actual suction volume


Specific suction volume
Specific power consumption mini-LNG

1.8 m3/kg LNG


0.47 kWh/kg LNG

Gas Technology Center NTNU-SINTEF

Heat Exchanger HX 2, MR-HP/MR-LP, high temp


Duty vs. Temperature
0

Heat Exchanger HA2 Zones Analysis


-10
-20

Temperature, C

-30
-40
-50
-60
-70
-80
-90
-100
0

0,00005

0,0001

0,00015

0,0002

0,00025

0,0003

Duty, x 10^6 kW

Gas Technology Center NTNU-SINTEF

0,00035

0,0004
36

Heat Exchanger HX 7, NG/MR-LP


Duty vs. Temperature

Gas Technology Center NTNU-SINTEF

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Plant exergy loss analysis


LP MIXER
7%

FCV1
6%

FCV5
2%

HA2
21 %

FCV4
3%

HP MIXER
0%

HA7
27 %
HA4
34 %

Plant

Coldbox

- Still considerable potential for reducing losses


- Especially for compressor and heat exchangers
- Dependent on component availability

Gas Technology Center NTNU-SINTEF

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Full scale test results


Results from full scale tests and simulation model verification

Including simulation results for future plant operating conditions (corrects for off-design conditions at full scale tests)
Parameter
..

Liquefaction capacity

Simulation
..

Simulation
corrected 1)
(dp and leak)

Simulation
corrected 2)
(precooling t)

tonnes/d

14,4

14,4

17,1

18,8

Unit

LNG exit temperature before


throttling to tank

oC

-154,1

-154,1

-155

-155

MR precooling temperature at
vap-liq separtor

oC

-24,9

-24,9

-24,9

-35

NG precooling temperature

oC

-31,7

-31,7

-35

-35

Refrigerating capacity

kW

70,7

84,3

93,2

Volume flow LP MR out of


coldbox

m3/h

1436

1512

1517

Capacity difference relative to nominal (18.8 tonnes/d)


1)
2)

Measured
.

Corrected for leak in safety valve by-pass from high p to low p and
undersized stop valve in suction tube
~ 14 %-points
Corrected to nominal precooling temperature (-35C)
~ 9 %-points

Some maldistribution in first secondary hx (HX 2) observed


-

Estimated influence on capacity 5 - 7 %

Gas Technology Center NTNU-SINTEF

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Constraints and possible improvements


Some constraints today

- NG pressure from BOG handling system 18 bar (balance BOG


compr./Mini-LNG)
- Storage pressure in chain, carrier tanks can handle 5 bara
- Design for high ambient temperatures - Sea water temperatures in north
of Europe relatively low
- Availability of components

Efficiency improvements

- Improved compressor efficiency


- Reduced temperature differences in hx
- Optimisation of MR composition

Plant operation without pre-cooling could be possible


- Existing refrigeration system on-board is used for precooling today

Gas Technology Center NTNU-SINTEF

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Liquid Energy Chain Optimization

Contact person: Prof. Truls.Gundersen


(truls.gundersen@ntnu.no)

Aspelund A. and Gundersen T. A Liquefied Energy Chain for Transport and Utilization of Natural Gas for
Power Production with CO2 Capture and Storage Part 1, Journal of Applied Energy, vol. 86, pp.
781-792, 2009 .

Gas Technology Center NTNU-SINTEF

A Liquefied Energy Chain (LEC)

LNG

LNG

LNG

LIN

CO2

CO2

Aspelund A. and Gundersen T. A Liquefied Energy Chain for Transport and Utilization of Natural Gas for
Power Production with CO2 Capture and Storage Part 1, Journal of Applied Energy, vol. 86, pp.
781-792, 2009 .

T. Gundersen

Gas Technology Center NTNU-SINTEF

A Liquefied Energy Chain (LEC)

Key Features of the LEC Concept

Utilization of Stranded Natural Gas for Power Production


High Exergy Efficiency of 46.4% (vs. 42.0% for traditional)
Elegant and Cost Effective solution to the CCS Problem
CO2 replaces Natural Gas injection for EOR
Combined Energy Chain (LNG) and Transport Chain (CO2)
T. Gundersen

Gas Technology Center NTNU-SINTEF

Simulation-Optimization of the entire LEC


LNG
NG

LNG

S
t
The field
o
site
LIN
r
process
a
LCO2 g
e

N2
CO2

LNG

LNG

S LNG
NG
t
The market
o
site
r LIN
process CO2
a
g LCO2
e

LNG
P3

LIN
P2

P1

F2

LCO2

F1

Electricity

Power
process
with CO2
capture

Water

N2
LIN

LCO2

LCO2

The simple chain


The complete chain
CO2-Recycle

T2

CO2-7
CO2-9

N2-7

EXP-101

T3
N2-8

T4

P6
N2-12

N2-9

LCO2
N2-13

EXP-102

V-101

T5

N2-11

CO2-3

P-102

HX-101
K-100

P4

N2-12

N2-2
NG-5

NG-4

LIQ-EXP-101

Offshore

P-101

N2-11

NG-PURGE

P2

CO2-1

LIQ-EXP-102

CO2-12

CO2-13

VF1
NG-1

HX-102

NG @ 25

P1

LNG

P3

NG-5

P-101

T. Gundersen

F3

2 stage compression
K105-K106

N2-0

P-102

LNG

F1

F1

NG-4

V-101

P-100

CO2-1

N2-1

N2-8

4 stage compression
K101-K104

HX-101

P3

CO2-4

N2-16

N2-9
NG-3

LIN

NG-6

CO2-0

CO2-10

CO2-11

NG-2

V-102

HX-102

T1

K-107

N2-15
T7

N2-10

N2-1

CO2-2
NG-3

NG-2

T6

F2

N2-3

CO2-4

CO2-5

F4

N2-10

P2

CO2-6

CO2-8

EXP-102

N2-5

N2-6

NG-1

K-108

P1

P5

K-101

N2-4

N2-14

Onshore

Gas Technology Center NTNU-SINTEF

EXP-101

F2

Optimizing the Liquefied Energy Chain

First: Near-Optimal Design established by

Domain Knowledge related to LNG


Heuristic Design rules (new and old)
Pinch Analysis (the Composite Curves)
Exergy Analysis (calculating Exergy)
Rigorous Simulation by HYSYS (testing the Concept)

Second: Mathematical Programming and a novel (and


innovative) Superstructure

Offshore and Onshore Processes Optimized separately

Third: Stochastic Search with Rigorous Simulation

Referred to as SimulationOptimization
Taboo Search (global) and Nelder Mead (local)
HYSYS providing Objective Function Values
Applied Simultaneously to the entire Chain
T. Gundersen

Gas Technology Center NTNU-SINTEF

Progress of the Optimization


1

36
35
34
33
32
31
30
29
28

0
0

50

100

150

200

Best known objective

250

Current best

300

350

400

Local search

Myklebust J., Aspelund A., Tomasgard, A., Nowak M. and Gundersen T., An Optimization-Simulation
Model of a Combined Liquefied Natural Gas and CO2 Value Chain, INFORMS Annual Meeting, Seattle,
November 2007

T. Gundersen

Gas Technology Center NTNU-SINTEF

Future research tasks Rapid Phase Transition (RPT)


What is RPT?
- can occur if liquid natural gas is spilled on / and mixed with water
- a physical explosion where unstable, superheated liquid instantaneously
expands to vapour phase and creates overpressure and pressure
waves
- explosion impact often converted to tons of TNT

Increased attention in recent safety studies


-

increased use and transport of LNG


well researched, but still difficult to predict
complex chain of various physical phenomena
challenging in terms of scale-up from laboratory tests

Gas Technology Center NTNU-SINTEF

Physics of RPT single component

Gas Technology Center NTNU-SINTEF

Future research tasks Rapid Phase Transfer (RPT)


Plan to start up new 3 mill EUR project in 2012
awaiting governmental financial support still open for
industry participation
- Both experimental and modelling approach are planned

2 PhD from NTNU from the mid 90's


-

pool boiling of hydrocarbon on water surface


mixing of cryogenic jet in water
fragmentation
modelling
spreading

Now: Utilize advances in measurement and visualization


techniques and advances in modelling experience on
fast transients on pressure wave propagation
Gas Technology Center NTNU-SINTEF

Thank you for


your attention!

Gas Technology Centre:


www.ntnu.no/gass
www.sintef.no

Gas Technology Center NTNU-SINTEF

Some selected references


Neks, P., Brendeng, E., Drescher, M. and Norberg, B. (2010): Development and
analysis of a natural gas reliquefaction plant for small gas carriers, J. of Natural Gas
Science and Engineering, ISSN1875-5100, Vol 2 (2-3), pp 143-149
Neks P., Brendeng E., Norberg B., Brndum P., Drescher M. (2008), Development of
a small scale natural gas reliquefaction plant for gas tankers, Proc. of the 8th IIR Gustav
Lorentzen Conference on Natural Working Fluids, Copenhagen, Sept 8-10, ISBN
9782913149632, ISSN 0151-1637
Brendeng E., Neeraas B.O. (2000), Method and device for small scale liquefaction of
product gas, E.P. patent no. 1255955, priority date 2000-02-10
Zhao, H., A. Brunsvold, et al. (2011). "Investigation of droplets impinging on a deep
pool: transition from coalescence to jetting." Experiments in Fluids 50(3): 621-635.
Zhao, H., A. Brunsvold, et al. (2010). "An experimental method for studying the discrete
droplet impact phenomena in a flammable gas environment." Journal of Natural Gas
Science and Engineering 2(5): 259-269.
G. Skaugen*, G.A. Gjvg, P. Neks, P.E. Wahl, "Use of sophisticated heat exchanger
simulation models for investigation of possible design and operational pitfalls in LNG
processes", Journal of Natural Gas Science and Engineering 2(5) 235-243
Aspelund A. and Gundersen T. A Liquefied Energy Chain for Transport and Utilization
of Natural Gas for Power Production with CO2 Capture and Storage Part 1, Journal of
Applied Energy, vol. 86, pp. 781-792, 2009

Gas Technology Center NTNU-SINTEF

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