Scalable capacity liquefied natural gas plant

US 20070193303A1
Filed: 06/10/2005
Published: 08/23/2007
Est. Priority Date: 06/18/2004
Status: Abandoned Application

First Claim

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1. A method of producing liquefied natural gas using a LNG liquefaction plant, wherein the LNG liquefaction plant includes a plurality of process unit module types, said plurality of process unit module types including at least a first process unit module type comprised of one or more first process unit modules and a second process unit module type comprised of two or more integrated second process unit modules, wherein further at least one of said first process unit modules and at least one of said second process unit modules are sized at their respective substantially maximum processing efficiency, said LNG liquefaction plant including two or more integrated process unit module types, said method comprising producing liquefied natural gas from said LNG liquefaction plant.

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Abstract

The current invention is related to hydrocarbon fluid processing plants, methods of designing hydrocarbon fluid processing plants, methods of operating hydrocarbon fluid processing plants, and methods of producing hydrocarbon fluids using hydrocarbon fluid processing plants. More particularly, some embodiments of the invention are related to natural gas liquefaction plants, methods of designing natural gas liquefaction plants, methods of operating natural gas liquefaction plants and methods of producing LNG using natural gas liquefaction plants. One embodiment of the invention includes a hydrocarbon fluid processing plant including a plurality of process unit module types, the plurality of process unit module types including at least a first process unit module type including one or more first process unit modules and a second process unit module type including two or more integrated second process unit modules wherein at least one of the first process unit modules and at least one of the second process unit modules are sized at their respective substantially maximum processing efficiency.

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406 Claims

1. A method of producing liquefied natural gas using a LNG liquefaction plant, wherein the LNG liquefaction plant includes a plurality of process unit module types, said plurality of process unit module types including at least a first process unit module type comprised of one or more first process unit modules and a second process unit module type comprised of two or more integrated second process unit modules, wherein further at least one of said first process unit modules and at least one of said second process unit modules are sized at their respective substantially maximum processing efficiency, said LNG liquefaction plant including two or more integrated process unit module types, said method comprising producing liquefied natural gas from said LNG liquefaction plant.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 385, 394)
- - 2. The method according to claim 1, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 3. The method according to claim 2, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 4. The method according to claim 3, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 5. The method according to claim 4, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 6. The method according to claim 4, wherein said LNG liquefaction plant is further comprised of a third process unit module type comprised of one or more third process unit modules.
  - 7. The method according to claim 4, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 8. The method according to claim 7, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 9. The method according to claim 6, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 10. The method according to claim 9, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 11. The method according to claim 6, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 12. The method according to claim 6, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 13. The method according to claim 12, wherein at least some of said respective equipment types are substantially equally configured.
  - 14. The method according to claim 13, wherein at least some of said respective equipment types are substantially equally sized.
  - 15. The method according to claim 6, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 16. The method according to claim 15, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 17. The method according to claim 15, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 18. The method according to claim 16, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 19. The method according to claim 17, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 20. The method according to claim 15, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 21. The method according to claim 15, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 22. The method according to claim 6, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 23. The method according to claim 22, wherein at least two of said plurality of compressors are arranged in parallel.
  - 24. The method according to claim 23, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 25. The method according to claim 24, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 26. The method according to claim 25, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 27. The method according to claim 26, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 28. The method according to claim 27, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 29. The method according to claim 27, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 30. The method according to claim 6, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 31. The method according to claim 30, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 32. The method according to claim 31, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 33. The method according to claim 6, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 34. The method according to claim 6, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 35. The method according to claim 34, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 36. The method according to claim 1, wherein said LNG liquefaction plant contains three or more integrated process unit module types.
  - 37. The method according to claim 36, wherein said LNG liquefaction plant contains four or more integrated process unit module types.
  - 385. A method according to claim 1, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 394. A method according to claim 1, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

38. A method of designing a LNG liquefaction plant, comprising:
- A) providing the identity of a plurality of process unit module types included in said LNG liquefaction plant, said plurality of process unit module types including at least a first process unit module type and a second process unit module type;
  
  B) determining a first maximum processing efficiency for a first process unit module of said first process unit module type and a second maximum processing efficiency for a second process unit module of said second process unit module type; and
  
  C) designing said LNG liquefaction plant, said LNG liquefaction plant design including one or more first process unit modules sized to substantially meet said first maximum processing efficiency and one or more second process unit modules sized to substantially meet said second maximum processing efficiency.
- View Dependent Claims (39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 386, 395)
- - 39. The method of claim 38, wherein said substantially meeting said maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 40. The method of claim 39, wherein said substantially meeting said maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 41. The method of claim 40, wherein said substantially meeting said maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 42. The method of claim 41, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 43. The method of claim 41, wherein said LNG liquefaction plant design further includes a third process unit module type comprised of one or more third process unit modules.
  - 44. The method of claim 41, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 45. The method of claim 44, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 46. The method of claim 43, wherein said LNG liquefaction plant design includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 47. The method of claim 46, wherein said LNG liquefaction plant design includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 48. The method of claim 43, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 49. The method of claim 43, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 50. The method of claim 49, wherein at least some of said respective equipment types are substantially equally configured.
  - 51. The method of claim 50, wherein at least some of said respective equipment types are substantially equally sized.
  - 52. The method of claim 43, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 53. The method of claim 52, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 54. The method of claim 52, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 55. The method of claim 53, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 56. The method of claim 54, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 57. The method of claim 52, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 58. The method of claim 52, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 59. The method of claim 43, wherein said LNG liquefaction plant design includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 60. The method of claim 59, wherein at least two of said plurality of compressors are arranged in parallel.
  - 61. The method of claim 60, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 62. The method of claim 61, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 63. The method of claim 62, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 64. The method of claim 63, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 65. The method of claim 64, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 66. The method of claim 64, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 67. The method of claim 43, wherein said LNG liquefaction plant design has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 68. The method of claim 67, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 69. The method of claim 68, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 70. The method of claim 43, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 71. The method of claim 43, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 72. The method of claim 71, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 73. The method of claim 43, wherein said LNG liquefaction plant design contains two or more integrated process unit module types.
  - 74. The method of claim 73, wherein said LNG liquefaction plant design contains three or more integrated process unit module types.
  - 75. The method of claim 74, wherein said LNG liquefaction plant design contains four or more integrated process unit module types.
  - 386. A method according to claim 38, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 395. A method according to claim 38, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

76. A method of designing an expanded processing capacity of a LNG liquefaction plant having an existing plant maximum feed processing capacity, comprising:
- A) providing the existing configuration of said LNG liquefaction plant, said LNG liquefaction plant including a plurality of process unit module types;
  
  B) determining a first process unit module type requiring additional maximum feed processing capacity to increase said existing plant maximum feed processing capacity;
  
  C) determining the maximum processing efficiency of a first process unit module of said first process unit module type; and
  
  D) designing an expanded LNG liquefaction plant, said design including the addition of one or more first process unit modules sized to substantially meet said maximum processing efficiency.
- View Dependent Claims (77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 387, 396)
- - 77. The method of claim 76, wherein said substantially meeting said maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 78. The method of claim 77, wherein said substantially meeting said maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 79. The method of claim 78, wherein said substantially meeting said maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 80. The method of claim 79, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 81. The method of claim 80, wherein said LNG liquefaction plant design further includes a second process unit module type comprised of one or more second process unit modules and a third process unit module type comprised of one or more third process unit modules.
  - 82. The method of claim 81, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 83. The method of claim 82, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 84. The method of claim 81, wherein said LNG liquefaction plant design includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 85. The method of claim 84, wherein said LNG liquefaction plant design includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 86. The method of claim 81, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 87. The method of claim 81, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 88. The method of claim 87, wherein at least some of said respective equipment types are substantially equally configured.
  - 89. The method of claim 88, wherein at least some of said respective equipment types are substantially equally sized.
  - 90. The method of claim 81, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 91. The method of claim 90, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 92. The method of claim 90, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 93. The method of claim 91, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 94. The method of claim 92, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 95. The method of claim 90, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 96. The method of claim 90, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 97. The method of claim 81, wherein said LNG liquefaction plant design includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 98. The method of claim 97, wherein at least two of said plurality of compressors are arranged in parallel.
  - 99. The method of claim 98, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 100. The method of claim 99, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 101. The method of claim 100, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 102. The method of claim 101, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 103. The method of claim 102, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 104. The method of claim 102, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 105. The method of claim 81, wherein said LNG liquefaction plant design has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 106. The method of claim 105, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 107. The method of claim 106, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 108. The method of claim 85, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 109. The method of claim 81, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 110. The method of claim 109, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 111. The method of claim 81, wherein said LNG liquefaction plant design contains two or more integrated process unit module types.
  - 112. The method of claim 111, wherein said LNG liquefaction plant design contains three or more integrated process unit module types.
  - 113. The method of claim 112, wherein said LNG liquefaction plant design contains four or more integrated process unit module types.
  - 387. A method according to claim 76, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 396. A method according to claim 76, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

114. A method of operating a LNG liquefaction plant having a plurality of process unit module types, said plurality of process unit module types including at least a first process unit module type comprised of one or more first process unit modules and a second process unit module type comprised of two or more integrated second process unit modules wherein at least one of said first process unit modules and at least one of said second process unit modules are sized at their respective substantially maximum processing efficiency, said method comprising:
- A) determining a first plant feed processing rate;
  
  B) determining the number of process unit modules of each process unit module type required to meet said first plant feed processing rate;
  
  C) commissioning at least the number of each process unit module of each process unit module type required to meet said first plant feed processing rate determined in step (B); and
  
  D) producing LNG.
- View Dependent Claims (115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 228, 229, 230, 388, 397)
- - 115. The method of claim 114, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 116. The method of claim 115, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 117. The method of claim 116, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 118. The method of claim 117, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 119. The method of claim 117, wherein said LNG liquefaction plant further includes a third process unit module type comprised of one or more third process unit modules.
  - 120. The method of claim 117, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 121. The method of claim 120, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 122. The method of claim 117, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 123. The method of claim 122, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 124. The method of claim 119, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 125. The method of claim 119, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 126. The method of claim 125, wherein at least some of said respective equipment types are substantially equally configured.
  - 127. The method of claim 126, wherein at least some of said respective equipment types are substantially equally sized.
  - 128. The method of claim 119, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 129. The method of claim 128, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 130. The method of claim 128, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 131. The method of claim 129, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 132. The method of claim 130, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 133. The method of claim 128, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 134. The method of claim 128, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 135. The method of claim 119, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 136. The method of claim 135, wherein at least two of said plurality of compressors are arranged in parallel.
  - 137. The method of claim 136, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 138. The method of claim 137, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 139. The method of claim 138, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 140. The method of claim 139, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 141. The method of claim 140, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 142. The method of claim 140, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 143. The method of claim 119, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 144. The method of claim 143, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 145. The method of claim 144, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 146. The method of claim 119, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 147. The method of claim 119, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 148. The method of claim 147, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 149. The method of claim 119, wherein said LNG liquefaction plant contains two or more integrated process unit module types.
  - 150. The method of claim 149, wherein said LNG liquefaction plant contains three or more integrated process unit module types.
  - 151. The method of claim 150, wherein said LNG liquefaction plant contains four or more integrated process unit module types.
  - 152. The method of claim 119, further comprising;
    - E) determining a second plant feed processing rate;
      
      F) determining the number of process unit modules of each process unit module type required to meet said second plant feed processing rate; and
      
      G) commissioning at least the number of each process unit module of each process unit module type required to meet said second plant feed processing rate determined in step (F).
  - 228. The method of claim 118, wherein said LNG liquefaction plant contains two or more integrated process unit module types.
  - 229. The method of claim 228, wherein said LNG liquefaction plant contains three or more integrated process unit module types.
  - 230. The method of claim 229, wherein said LNG liquefaction plant contains four or more integrated process unit module types.
  - 388. A method according to claim 114, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 397. A method according to claim 114, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

153. A method of producing LNG using a LNG liquefaction plant, said LNG liquefaction plant comprised of a plurality of process unit module types, each of said plurality of process unit module types comprised of one or more process unit modules, said method comprising:
- A) providing at least one original process unit module for each process unit module type included in said plurality of process unit module types, one or more of said original process unit modules sized at their respective substantially maximum processing efficiency, thereby providing a first phase LNG liquefaction plant;
  
  B) providing one or more additional process unit module(s) for one or more process unit module type(s) included in said first phase LNG liquefaction plant, said additional process unit module being integrated with said original process unit module within said process unit module type, thereby providing a second phase LNG liquefaction plant; and
  
  C) producing LNG from said second phase LNG liquefaction plant.
- View Dependent Claims (154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 389, 398)
- - 154. The method of claim 153, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 155. The method of claim 154, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 156. The method of claim 155, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 157. The method of claim 156, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 158. The method of claim 156, wherein said LNG liquefaction plant further includes a third process unit module type comprised of one or more third process unit modules.
  - 159. The method of claim 156, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 160. The method of claim 159, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 161. The method of claim 156, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 162. The method of claim 161, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 163. The method of claim 158, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 164. The method of claim 158, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 165. The method of claim 164, wherein at least some of said respective equipment types are substantially equally configured.
  - 166. The method of claim 165, wherein at least some of said respective equipment types are substantially equally sized.
  - 167. The method of claim 158, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 168. The method of claim 167, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 169. The method of claim 167, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 170. The method of claim 168, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 171. The method of claim 169, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 172. The method of claim 167, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 173. The method of claim 167, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 174. The method of claim 158, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 175. The method of claim 174, wherein at least two of said plurality of compressors are arranged in parallel.
  - 176. The method of claim 175, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 177. The method of claim 176, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 178. The method of claim 177, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 179. The method of claim 178, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 180. The method of claim 179, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 181. The method of claim 179, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 182. The method of claim 158, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 183. The method of claim 182, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 184. The method of claim 183, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 185. The method of claim 158, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 186. The method of claim 158, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 187. The method of claim 186, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 188. The method of claim 158, wherein said LNG liquefaction plant contains two or more integrated process unit module types.
  - 189. The method of claim 188, wherein said LNG liquefaction plant contains three or more integrated process unit module types.
  - 190. The method of claim 189, wherein said LNG liquefaction plant contains four or more integrated process unit module types.
  - 389. A method according to claim 153, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 398. A method according to claim 153, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

191. A method of producing liquefied natural gas, comprising:
- A) providing an LNG liquefaction plant comprising a plurality of product sized process unit module types, said LNG liquefaction plant having a first plant maximum feed processing capacity;
  
  B) expanding the maximum feed processing capacity of at least one but less than all of said product sized process unit module types to achieve a second plant maximum feed processing capacity that is 10 percent or greater than said first plant maximum feed processing capacity, wherein the expanding includes adding at least one additional process unit module; and
  
  C) producing LNG in said LNG liquefaction plant after initiation of said expanding step (B).
- View Dependent Claims (192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219, 220, 221, 222, 223, 224, 225, 226, 227, 390, 399)
- - 192. The method of claim 191, wherein said product sized process unit module types are selected from acid gas removal contactor units, dehydration units, deethanizer units, cryogenic heat exchanger units, refrigerant compressor units, nitrogen rejection units, liquefaction units, helium recovery units, and combinations thereof.
  - 193. The method of claim 192, wherein said product sized process unit module types include at least a first process unit module type comprised of one or more first process unit modules and a second process unit module type comprised of two or more integrated second process unit modules wherein at least one of said first process unit modules and at least one of said second process unit modules are sized at their respective substantially maximum processing efficiency.
  - 194. The method of claim 193, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 195. The method of claim 194, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 196. The method of claim 195, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 197. The method of claim 196, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 198. The method of claim 196, wherein said LNG liquefaction plant further includes a third process unit module type comprised of one or more third process unit modules.
  - 199. The method of claim 196, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 200. The method of claim 199, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 201. The method of claim 196, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 202. The method of claim 201, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 203. The method of claim 198, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 204. The method of claim 198, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 205. The method of claim 204, wherein at least some of said respective equipment types are substantially equally configured.
  - 206. The method of claim 205, wherein at least some of said respective equipment types are substantially equally sized.
  - 207. The method of claim 199, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 208. The method of claim 207, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 209. The method of claim 207, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 210. The method of claim 208, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 211. The method of claim 209, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 212. The method of claim 207, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 213. The method of claim 207, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 214. The method of claim 198, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 215. The method of claim 214, wherein at least two of said plurality of compressors are arranged in parallel.
  - 216. The method of claim 215, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 217. The method of claim 216, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 218. The method of claim 217, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 219. The method of claim 218, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 220. The method of claim 219, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 221. The method of claim 219, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 222. The method of claim 198, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 223. The method of claim 222, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 224. The method of claim 223, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 225. The method of claim 198, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 226. The method of claim 198, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 227. The method of claim 226, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 390. A method according to claim 191, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 399. A method according to claim 191, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

231. A method of producing liquefied natural gas using an LNG liquefaction plant, said LNG liquefaction plant comprised of a plurality of process unit module types, each of said plurality of process unit module types comprised of one or more process unit modules, said method comprising:
- A) providing at least one original process unit module for each process unit module type included in said plurality of process unit module types, thereby providing a first phase LNG liquefaction plant;
  
  B) producing first LNG from said first phase LNG liquefaction plant;
  
  C) constructing one or more additional process unit modules for one or more process unit module types included in said first phase LNG liquefaction plant while completing at least a portion of said producing step (B);
  
  D) placing said one or more additional process unit modules in service, said additional process unit modules being integrated with said original process unit module within said process unit module type, thereby providing a second phase LNG liquefaction plant; and
  
  E) producing second LNG from said second phase LNG liquefaction plant.
- View Dependent Claims (232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 255, 256, 257, 258, 259, 260, 261, 391, 400)
- - 232. The method of claim 231, wherein said placing step D is accomplished while producing first LNG in step B.
  - 233. The method of claim 231, wherein said placing step D is at least partially accomplished while producing first LNG in step B.
  - 234. The method of claim 231, wherein said placing step D is at least partially accomplished while not producing first LNG in step B.
  - 235. The method of claim 234, wherein said placing step D is at least partially accomplished while not producing first LNG in step B for less than 10 days.
  - 236. The method of claim 231, wherein at least one of said additional process unit modules is sized at its respective substantially maximum processing efficiency.
  - 237. The method of claim 236, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 238. The method of claim 237, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 239. The method of claim 238, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 240. The method of claim 239, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 241. The method of claim 240, wherein said original and additional process unit modules are substantially equally configured.
  - 242. The method of claim 241, wherein said original process unit module is comprised of original equipment types and said additional process unit module is comprised of additional process equipment types.
  - 243. The method of claim 242, wherein at least some of said respective equipment types are substantially equally configured.
  - 244. The method of claim 243, wherein at least some of said respective equipment types are substantially equally sized.
  - 245. The method of claim 244, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 246. The method of claim 245, wherein at least two of said plurality of compressors are arranged in parallel.
  - 247. The method of claim 246, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 248. The method of claim 247, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 249. The method of claim 248, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 250. The method of claim 249, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 251. The method of claim 250, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 252. The method of claim 250, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 253. The method of claim 244, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 254. The method of claim 243, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 255. The method of claim 253, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 256. The method of claim 244, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 257. The method of claim 244, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 258. The method of claim 257, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 259. The method of claim 244, wherein said LNG liquefaction plant contains two or more integrated process unit module types.
  - 260. The method of claim 259, wherein said LNG liquefaction plant contains three or more integrated process unit module types.
  - 261. The method of claim 260, wherein said LNG liquefaction plant contains four or more integrated process unit module types.
  - 391. A method according to claim 231, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 400. A method according to claim 231, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

262. An LNG liquefaction plant, comprised of one or more high construction cost product sized process unit module types and one or more low construction cost product sized process unit module types, at least one of said low construction cost product sized process unit module types having a maximum feed processing capacity that is at least 110 percent of the maximum feed processing capacity of at least one of said high construction cost product sized process unit module types.
- View Dependent Claims (263, 264, 265, 266, 267, 268, 269, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289, 290, 291, 292, 293, 294, 295, 296, 297, 298, 299, 300, 301, 302, 303, 403, 405)
- - 263. An LNG liquefaction plant according to claim 262, wherein said high construction cost product sized process unit module types have a total construction cost per unit of maximum feed processing capacity that is 1.25 times or greater the total construction cost per unit of maximum feed processing capacity of said low construction cost product sized process unit module types.
  - 264. An LNG liquefaction plant according to claim 262, wherein said low construction cost product sized process unit module types are selected from acid gas removal units, dehydration units, fractionation units, nitrogen rejection units, and helium recovery units.
  - 265. An LNG liquefaction plant according to claim 262, wherein said high construction cost product sized process unit module types are selected from inlet facilities units, refrigerant compression units, cryogenic heat exchanger units, and liquefaction units.
  - 266. The method of claim 262, wherein said product sized process unit module types include at least a first process unit module type comprised of one or more first process unit modules and a second process unit module type comprised of two or more integrated second process unit modules wherein at least one of said first process unit modules and at least one of said second process unit modules are sized at their respective substantially maximum processing efficiency.
  - 267. The method of claim 266, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 268. The method of claim 267, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 269. The method of claim 268, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 270. The method of claim 269, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 271. The method of claim 269, wherein said LNG liquefaction plant further includes a third process unit module type comprised of one or more third process unit modules.
  - 272. The method of claim 269, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 273. The method of claim 272, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 274. The method of claim 269, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 275. The method of claim 274, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 276. The method of claim 271, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 277. The method of claim 271, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 278. The method of claim 277, wherein at least some of said respective equipment types are substantially equally configured.
  - 279. The method of claim 278, wherein at least some of said respective equipment types are substantially equally sized.
  - 280. The method of claim 271, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 281. The method of claim 280, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 282. The method of claim 280, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 283. The method of claim 281, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 284. The method of claim 282, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 285. The method of claim 280, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 286. The method of claim 280, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 287. The method of claim 271, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 288. The method of claim 287, wherein at least two of said plurality of compressors are arranged in parallel.
  - 289. The method of claim 288, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 290. The method of claim 289, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 291. The method of claim 290, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 292. The method of claim 291, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 293. The method of claim 292, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 294. The method of claim 292, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 295. The method of claim 271, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 296. The method of claim 295, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 297. The method of claim 296, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 298. The method of claim 271, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 299. The method of claim 271, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 300. The method of claim 299, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 301. The method of claim 271, wherein said LNG liquefaction plant contains two or more integrated process unit module types.
  - 302. The method of claim 301, wherein said LNG liquefaction plant contains three or more integrated process unit module types.
  - 303. The method of claim 302, wherein said LNG liquefaction plant contains four or more integrated process unit module types.
  - 403. A LNG liquefaction plant according to claim 262, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 405. A LNG liquefaction plant according to claim 262, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

304. A method of producing liquefied natural gas, comprising:
- A) providing an LNG liquefaction plant comprising a plurality of process unit module types, said LNG liquefaction plant having at least a first refrigerant circuit, said first refrigerant circuit comprising at least one first refrigerant compressor service type, said first refrigerant compressor service type comprised of one or more original first refrigerant compressors in parallel, said LNG liquefaction plant having a plant maximum feed processing capacity;
  
  B) expanding the plant maximum feed processing capacity of said LNG liquefaction plant by adding at least one additional first refrigerant compressor to said first refrigerant compressor service type, said additional first refrigerant compressor being integrated with said one or more original first refrigerant compressors within said first refrigerant compressor service type; and
  
  C) producing LNG in said LNG liquefaction plant after initiation of said expanding step (B).
- View Dependent Claims (305, 306, 307, 308, 309, 310, 311, 312, 313, 314, 315, 316, 317, 318, 319, 320, 321, 322, 323, 324, 325, 326, 327, 328, 329, 330, 331, 332, 333, 334, 335, 336, 337, 338, 339, 340, 341, 342, 343, 344, 345, 347, 348, 349, 350, 351, 352, 392, 401)
- - 305. The method of claim 304, wherein at least one of said original first refrigerant compressors and at least one of said additional first refrigerant compressors are substantially equally sized.
  - 306. The method of claim 305, wherein at least one of said original first refrigerant compressors and at least one of said additional first refrigerant compressors are substantially equally mechanically configured.
  - 307. The method of claim 306, wherein said original first refrigerant compressors are comprised of a plurality of first refrigerant compressors, said plurality of original first refrigerant compressors having a maximum combined processing capacity.
  - 308. The method of claim 307, wherein said maximum combined processing capacity is less than the processing capacity of the largest commercially available compressor.
  - 309. The method of claim 307, wherein each of said plurality of original first refrigerant compressors has a processing capacity less than the processing capacity of the largest commercially available compressor.
  - 310. The method of claim 307, wherein said original first refrigerant compressors include electric drive compressors.
  - 311. The method of claim 306, wherein said original first refrigerant compressors include gas turbine drive compressors.
  - 312. The method of claim 306, wherein said first refrigerant circuit further includes one or more plate fin heat exchangers, said plate fin heat exchangers adapted to cool a natural gas stream through heat exchange with refrigerant compressed by said first refrigerant compressors.
  - 313. The method of claim 312, wherein said one or more plate fin heat exchangers includes a plurality of plate fin heat exchangers arranged in a cold box.
  - 314. The method of claim 306, wherein said first refrigerant circuit further includes one or more spiral wound heat exchangers, said spiral wound heat exchangers adapted to cool a natural gas stream through heat exchange with refrigerant compressed by said first refrigerant compressors.
  - 315. The method of claim 304, wherein said process unit module types include at least a first process unit module type comprised of one or more first process unit modules and a second process unit module type comprised of two or more integrated second process unit modules wherein at least one of said first process unit modules and at least one of said second process unit modules are sized at their respective substantially maximum processing efficiency.
  - 316. The method of claim 315, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 317. The method of claim 316, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 318. The method of claim 317, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 319. The method of claim 318, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 320. The method of claim 318, wherein said LNG liquefaction plant further includes a third process unit module type comprised of one or more third process unit modules.
  - 321. The method of claim 318, wherein the maximum feed processing capacity of said second process unit module type at least equals the maximum feed processing capacity of said first process unit module type.
  - 322. The method of claim 321, wherein said first and second process unit module types have first and second construction costs per unit of maximum feed processing capacity, said first construction cost per unit of maximum feed processing capacity exceeding said second construction costs per unit of maximum feed processing capacity.
  - 323. The method of claim 318, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally sized process unit modules in parallel.
  - 324. The method of claim 323, wherein said LNG liquefaction plant includes at least one of said process unit module types having a plurality of substantially equally configured process unit modules in parallel.
  - 325. The method of claim 320, wherein said third process unit module type includes third process unit modules sized at their substantially maximum processing efficiency.
  - 326. The method of claim 320, wherein said first process unit module is comprised of first equipment types, said second process unit module is comprised of second process equipment types and said third process unit module is comprised of third process equipment types
  - 327. The method of claim 326, wherein at least some of said respective equipment types are substantially equally configured.
  - 328. The method of claim 327, wherein at least some of said respective equipment types are substantially equally sized.
  - 329. The method of claim 320, wherein the maximum feed processing capacity of said first process unit module type differs by more than 10 percent from said second process unit module type.
  - 330. The method of claim 329, wherein said second process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 331. The method of claim 329, wherein said first process unit module type has a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 332. The method of claim 330, wherein said second process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said first process unit module type.
  - 333. The method of claim 331, wherein said first process unit module type has a maximum feed processing capacity less than 80 percent of the maximum feed processing capacity of said second process unit module type.
  - 334. The method of claim 329, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said first process unit module type.
  - 335. The method of claim 329, wherein at least two of said process unit module types have a maximum feed processing capacity less than 85 percent of the maximum feed processing capacity of said second process unit module type.
  - 336. The method of claim 320, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 337. The method of claim 326, wherein at least two of said plurality of compressors are arranged in parallel.
  - 338. The method of claim 337, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 339. The method of claim 338, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 340. The method of claim 339, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 341. The method of claim 340, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 342. The method of claim 341, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 343. The method of claim 341, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 344. The method of claim 320, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 345. The method of claim 344, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 347. The method of claim 320, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 348. The method of claim 320, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 349. The method of claim 348, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 350. The method of claim 320, wherein said LNG liquefaction plant contains two or more integrated process unit module types.
  - 351. The method of claim 350, wherein said LNG liquefaction plant contains three or more integrated process unit module types.
  - 352. The method of claim 351, wherein said LNG liquefaction plant contains four or more integrated process unit module types.
  - 392. A method according to claim 304, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 401. A method according to claim 304, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

346. The method of claim 346, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.

353. A method of producing liquefied natural gas using an LNG liquefaction plant, said LNG liquefaction plant comprised of a plurality of process unit module types, each of said plurality of process unit module types comprised of one or more process unit modules, said method comprising:
- A) providing at least one original process unit module for each process unit module type included in said plurality of process unit module types, thereby providing a first phase LNG liquefaction plant;
  
  B) providing at least one second process unit module for each process unit module type included in said plurality of process unit module types, thereby providing a second phase LNG liquefaction plant;
  
  C) integrating one or more of said original process unit modules with one or more of said second process unit modules for two or more respective process unit module types; and
  
  D) producing LNG from said LNG liquefaction plant after initiation of said integrating step (C).
- View Dependent Claims (354, 355, 356, 357, 358, 359, 360, 361, 362, 363, 364, 365, 366, 367, 368, 369, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 393, 402)
- - 354. The method of claim 353, wherein said integrating step C includes integrating one or more of said original process unit modules with one or more of said second process unit modules of three or more respective process unit module types.
  - 355. The method of claim 354, wherein said integrating step C includes integrating one or more of said original process unit modules with one or more of said second process unit modules of four or more respective process unit module types.
  - 356. The method of claim 355, wherein said integrating step C includes integrating one or more of said original process unit modules with one or more of said second process unit modules of all of said plurality of process unit module types.
  - 357. The method of claim 353, wherein at least one of said second process unit modules is sized at its respective substantially maximum processing efficiency.
  - 358. The method of claim 357, wherein said substantially maximum processing efficiency is within 25 percent of the actual maximum processing efficiency.
  - 359. The method of claim 358, wherein said substantially maximum processing efficiency is within 15 percent of the actual maximum processing efficiency.
  - 360. The method of claim 359, wherein said substantially maximum processing efficiency is within 10 percent of the actual maximum processing efficiency.
  - 361. The method of claim 360, wherein said maximum processing efficiency is the process unit module capacity size for each process unit module type that minimizes total process unit module life cycle cost per unit of process unit module capacity.
  - 362. The method of claim 360, wherein said original and second process unit modules of the same process unit module type are substantially equally configured.
  - 363. The method of claim 362, wherein said original process unit module is comprised of original equipment types and said second process unit module is comprised of second process equipment types.
  - 364. The method of claim 363, wherein at least some of said respective equipment types are substantially equally configured.
  - 365. The method of claim 364, wherein at least some of said respective equipment types are substantially equally sized.
  - 366. The method of claim 365, wherein said LNG liquefaction plant includes a liquefaction unit, said liquefaction unit comprised of one or more cryogenic heat exchangers and a plurality of refrigerant compressors of like service.
  - 367. The method of claim 366, wherein at least two of said plurality of compressors are arranged in parallel.
  - 368. The method of claim 367, wherein said liquefaction unit includes a plurality of cryogenic heat exchanges of like service, said cryogenic heat exchanges arranged in parallel.
  - 369. The method of claim 368, wherein each of said plurality of compressors is in fluid communication with two or more cryogenic heat exchangers.
  - 370. The method of claim 369, wherein said liquefaction unit is configured so that each of said plurality of compressors may be placed in fluid communication with any of said cryogenic heat exchangers.
  - 371. The method of claim 370, wherein said plurality of cryogenic heat exchangers includes one or more modular heat exchangers.
  - 372. The method of claim 371, wherein said plurality of cryogenic heat exchangers includes one or more plate-fin heat exchangers.
  - 373. The method of claim 371, wherein said plurality of cryogenic heat exchangers includes one or more spiral wound heat exchangers.
  - 374. The method of claim 360, wherein said LNG liquefaction plant has a plant maximum feed processing capacity and a plant minimum feed processing capacity, said plant minimum feed processing capacity being 75 percent or less of said plant maximum feed processing capacity.
  - 375. The method of claim 374, wherein said plant minimum feed processing capacity is 65 percent or less of said plant maximum feed processing capacity.
  - 376. The method of claim 375, wherein said plant minimum feed processing capacity is 55 percent or less of said plant maximum feed processing capacity.
  - 377. The method of claim 360, wherein at least one of said process unit module types includes variable speed compressors, variable speed expanders, or combinations thereof.
  - 378. The method of claim 360, wherein said plant maximum feed processing capacity is greater than 4 million tons per year.
  - 379. The method of claim 378, wherein said plant maximum feed processing capacity is greater than 6 million tons per year.
  - 393. A method according to claim 353, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 402. A method according to claim 353, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

380-383. -383. (canceled)

384. A LNG liquefaction plant comprising:
- a plurality of process unit module types, said plurality of process unit module types including at least a first process unit module type comprised of one or more first process unit modules and a second process unit module type comprised of two or more integrated second process unit modules, wherein at least one of said first process unit modules and at least one of said second process unit modules are sized at their respective substantially maximum processing efficiency; and
  
  two or more integrated process unit module types.
- View Dependent Claims (404, 406)
- - 404. A LNG liquefaction plant according to claim 384, wherein said LNG liquefaction plant contains one or more internally integrated process unit modules.
  - 406. A LNG liquefaction plant according to claim 384, wherein said LNG liquefaction plant contains two or more parallel integrated process unit modules.

Specification

Resources

Litigation Campaign Assessment

Current Assignee
Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
Original Assignee
Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
Inventors
Stone, John, Hawrysz, Daniel

Application Number

US11/629,744
Publication Number

US 20070193303A1
Time in Patent Office

Days
Field of Search
US Class Current

62/612
CPC Class Codes

B01D 53/1406   Multiple stage absorption

B01D 53/1462   Removing mixtures of hydrog...

C10L 3/10   Working-up natural gas or s...

C10L 3/102   of acid contaminants

C10L 3/12   Liquefied petroleum gas liq...

E05Y 2800/205   forming a unit

F25J 1/0022   Hydrocarbons, e.g. natural gas

F25J 1/0042   by liquid expansion with ex...

F25J 1/0045   by vaporising a liquid retu...

F25J 1/0052   by vaporising a liquid refr...

F25J 1/0057   after expansion of the liqu...

F25J 1/0214   as a dual level refrigerati...

F25J 1/0242   Waste heat recovery, e.g. f...

F25J 1/0259   Modularity and arrangement ...

F25J 1/027   Inter-connecting multiple h...

F25J 1/0271   Inter-connecting multiple c...

F25J 1/0272   Multiple identical heat exc...

F25J 1/0274   Retrofitting or revamping o...

F25J 1/0283   Gas turbine as the prime me...

F25J 1/0284   Electrical motor as the pri...

F25J 1/0294 : Multiple compressor casings...

F25J 2200/02 : in a single pressure main c...

F25J 2200/38 : using pre-separation or dis...

F25J 2200/70 : Refluxing the column with a...

F25J 2200/78 : Refluxing the column with a...

F25J 2205/04 : in the feed line, i.e. upst...

F25J 2220/62 : Separating low boiling comp...

F25J 2220/66 : Separating acid gases, e.g....

F25J 2230/24 : Multiple compressors or com...

F25J 2230/60 : the fluid being hydrocarbon...

F25J 2235/60 : the fluid being (a mixture ...

F25J 2240/04 : Multiple expansion turbines...

F25J 2240/30 : Dynamic liquid or hydraulic...

F25J 2240/70 : Steam turbine, e.g. used in...

F25J 2240/82 : with waste heat recovery, e...

F25J 2270/12 : External refrigeration with...

F25J 2270/66 : Closed external refrigerati...

F25J 2290/10 : Mathematical formulae, mode...

F25J 2290/40 : Vertical layout or arrangem...

F25J 2290/50 : Arrangement of multiple equ...

F25J 2290/80 : Retrofitting, revamping or ...

F25J 3/0209 : Natural gas or substitute n...

F25J 3/0233 : separation of CnHm with 1 c...

F25J 3/0242 : separation of CnHm with 3 c...

F25J 3/0257 : separation of nitrogen from...

F25J 3/029 : of helium

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Scalable capacity liquefied natural gas plant

First Claim

0 Assignments

0 Petitions

Accused Products

Abstract

89 Citations

406 Claims

Specification

Solutions

Use Cases

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Scalable capacity liquefied natural gas plant

First Claim

0 Assignments

Subscription Required

Subscription Required

0 Petitions

Subscription Required

Accused Products

Subscription Required

Abstract

89 Citations

406 Claims

Specification

Subscription Required

Solutions

Use Cases

Quick Links