Enhancement of the efficiency of the Open Cycle Phillips Optimized Cascade LNG process

• Expanders replaced JT valves in the Phillips Optimized Cascade liquefaction process.
• Improvement in plant liquefaction efficiency was evaluated in presence of expanders.
• Comparison of the different optimum cases for the liquefaction process was presented.

This study aims to improve the performance of the Open Cycle Phillips Optimized Cascade Process for the production of liquefied natural gas (LNG) through the replacement of Joule–Thomson (JT) valves by expanders. The expander has a higher thermodynamic efficiency than the JT valve. Moreover, the produced shaft power from the expander is integrated into the process. The study is conducted using the Aspen HYSYS-V7 simulation software for simulation of the Open Cycle Phillips Optimized Cascade Process having the JT valves. Simulation of several proposed cases in which expanders are used instead of JT valves at different locations in the process as at the propane cycle, ethylene cycle, methane cycle and the upstream of the heavies removal column is conducted. The optimum cases clearly indicate that expanders not only produce power, but also offer significant improvements in the process performance as shown by the total plant power consumption, LNG production, thermal efficiency, plant specific power and CO2 emissions reduction. Results also reveal that replacing JT valves by expanders in the methane cycle has a dominating influence on all performance criteria and hence, can be considered as the main key contributor affecting the Phillips Optimized Cascade Process leading to a notable enhancement in its efficiency. This replacement of JT valves by liquid expanders at different locations of the methane cycle encounters power savings in the range of 4.92–5.72%, plant thermal efficiency of 92.64–92.97% and an increase in LNG production of 5.77–7.04%. Moreover, applying liquid expanders at the determined optimum cases for the different cycles, improves process performance and shows a plant power saving of 5.80%, plant thermal efficiency of 92.81% and an increase in LNG production of 7.0%.