Reliable and powerful solutions for xTL compression
- Description
- References
Finding the right air compression solution for your xTL process is vital to ensuring a profitable operation from day one. High power, volume and reliability are essential in order to feed the massive volumes of air required for such processes at the gas reforming stage or for the cryogenic separation process used to convert natural gas to syngas.
With its high-power, high-volume compressor trains at the heart of the conversion process, Siemens is not only a prime supplier to many current large-scale xTL projects around the world, but is also already capable of providing new machines for next-generation xTL plants. What’s more, Siemens products and services, all from a single source, help to integrate utilities, run plants at optimal levels of efficiency and ensure maximum availability:
- Power generation and distribution: Siemens is a supplier for the entire range of power transmission and distribution systems, including
Utilities are of particular concern with regard to the internal energy integration of a plant. For instance when matching the large amounts of heat energy available from the syngas and FT process stages with the plant’s power demand. One of the challenges is to reduce operational expenditure (OPEX) through an overall optimization of energy efficiency.
- Water management: Solutions for water management have to meet stringent specifications while being robust with regard to production swings – a factor of growing concern with increasing plant size and output. For over 70 years, Siemens has been providing water and wastewater treatment solutions for the petroleum industry and has developed/introduced many standard technologies used in the industry today.
- Automation and control: A unique array of automation and control products, systems and solutions for field, production and management levels. Designed to achieve maximum productivity while achieving substantial cost savings.
- Industrial IT:
Enterprise intelligence solutions for safe and reliable operation, planning and scheduling:
- Real-time operational intelligence
- Process modeling, simulation and optimization
- Asset management
- Life-cycle services:
A portfolio of life-cycle services, including - Feasibility studies
- Financial engineering
- Design and network studies
- All levels of preventive and corrective maintenance
- Performance enhancement programs, service level agreements
- Training
SASOL’s Secunda CTL plant, Johannesburg, South Africa
Demonstrating technical feasibility and the economies of scale demanded of commercially viable GTL/CTL front-end technology, this electric-motor driven compressor delivers approx. 700,000 cbm/h of air to the air separation unit of SASOL’s Secunda CTL plant near Johannesburg, South Africa, the largest of its kind worldwide. Scope of Siemens delivery:
- STC-SR very high volume main air compressor and STC-GV integrally geared booster air compressor, both driven by electric motors
- Process control system, including distributed redundant SCADA system
- Integrated leak detection and batch tracking
- Integration of various subsystems
- Fiscal metering systems
- Automation of pump stations with fault-tolerant programmable logic controllers (PLC)
- Pump surge protection
- System integration
- Large-scale compression solution for an air separation plant
Siemens has been contracted to supply a large-scale compression solution for an air separation plant in the Gulf region. Scope of Siemens delivery:
- 700,000-cbm/h main air compressor (STC-SR)
- Integrally geared booster air compressor (STC-GV)
- Both powered by a double-ended 81-MW steam turbine
all designed, manufactured and installed by Siemens. The unit was built as the most powerful of its kind in the Middle East and numbers among the largest worldwide, supplying some 100,000 cbm/h of oxygen to a petrochemical refining process.
- Leuna 2000, Leuna, Germany
Leuna 2000, Europe’s largest refinery located in Eastern Germany, relies on Siemens compressor trains. Scope of Siemens delivery:
- Six integrally geared compressors (STCGV)
- Two vertically split single-shaft compressors (STC-SV)
- One horizontally split single-shaft compressor (STC-SH)
- One single-shaft axial compressor (STC-SX)
- 110 kV gas-insulated switchgear
- Power transformers
- Medium-voltage switchgear
- Integrated local control panels for the high voltage switchgear with integrated field level automation, including substation control and protection systems in addition to the redundant battery system
- Tank farm automation systems, Saudi Aramco, Saudi Arabia
Helping Saudi Aramco integrate 19 sites in the eastern, western and central regions of Saudi Arabia, Siemens’ tank farm automation system reduces both operating costs and truck movements while ensuring accountability and traceability for transactions and inventory tracking. Scope of Siemens delivery:
- System integration
- Terminal management
- Process automation
- Safety systems
- Preset controllers
- Building equipment
- Intercom systems
- Data communication infrastructure
- Uninterruptible power supply
- Fluid Catalytic Cracking (FCC) plant
Recovering waste heat at a Shell Fluid Catalytic Cracking (FCC) plant, this double-ended steam turbine drives a power generator and an air compressor, greatly improving energy efficiency. Scope of Siemens delivery:
- Double-ended SST-600 steam turbine
- Power generator
- Air compressor
- Ras Laffan Industrial City, Qatar
ORYX GTL Limited, Ras Laffan Industrial City, Qatar. Scope of Siemens delivery:
- Two separate water treatment systems for water re-use
- Wastewater treatment system, including CPI separators
- Aeration system equipment
- Secondary clarifiers
- Dissolved air flotation separators
- Traveling bridge filters
- Pumping systems and gravity belt thickening equipment
- Follow-on sanitary wastewater biological treatment package plant, including
- Overall plant design
- Lift station pumps and controls
- Rotating biological contactor (RBC) with supplemental aeration
- Gravity clarification equipment
- Skid-mounted chlorination and dechlorination equipment
- Calcasieu Refining, Louisiana, USA
Calcasieu Refining in Lake Charles, Louisiana, USA, selected Siemens to design and supply a complete wastewater treatment plant and a follow-up upgrade to treat the increased wastewater flow resulting from major process expansions over the next few years. Saving time and costs, the single-source vendor approach proved to be mutually beneficial. Scope of Siemens delivery:
- Full-range design and installation of an entire water treatment plant
- Including oil/water separation
- Aeration and clarification
- Sludge handling
- VOC control equipment
- Support
- Service
- BP Bulwer Island refinery, Brisbane, Australia
This Siemens cogeneration/combined cycle power plant provides 90% of the electrical power and 75% of the process steam for the BP Bulwer Island refinery facility near Brisbane. In normal operation the plant is run in parallel with the grid, allowing the export of any surplus power during times of low production. In the event of a loss of power from the grid, the plant is able to disconnect and operate in island mode and allow the refinery to continue operations. Scope of Siemens delivery:
- Complete CHP plant, including two SGT-400 gas turbines
- Nanhai Petrochemicals Complex, Daya Bay, China
Four of these Siemens SST-600 steam turbines provide a total of 240 MW of power for the vast Nanhai Petrochemicals Complex at Daya Bay in southern China, operated by Shell Nanhai BV and its joint venture partner CNOOC Petrochemicals Investment Limited. Scope of Siemens delivery: - Four 60 MW SST-600 steam-turbine-driven gensets
- Dolphin GTL project at Ras Laffan Industrial City, Qatar
Superior performance characteristics and speed of delivery were among the key reasons for selecting Siemens to supply a 3 x 35 MW power plant for the natural gas cleaning and treatment facility in connection with the Dolphin GTL project at Ras Laffan Industrial City, Qatar. The turbosets are driven by steam turbines using waste heat recovered from gas turbine exhausts via HRSGs. Scope of Siemens delivery:
- A total of three SST-400 steam turbines
- Gearboxes
- Generators