First greenfield application of Durasorb LNG MAX: operation with unexpected heavy feed

The challenges of processing lean feed gas to produce LNG using standard plant designs are well known.  Many existing LNG plants, which were designed with a traditional LNG pre-treatment line-up relying on vapor liquid separation to remove heavy hydrocarbons (HHCs), struggle with HHC freezing in the cold section of the plant.  With these challenges known, Shell took a new and innovative approach to LNG plant design by implementing Durasorb LNG MAX adsorptive HHC and water removal in the pre-treatment section of the plant.  Following Shell’s qualification of Durasorb in 2020, plant design commenced and this greenfield LNG plant, DLNG, started up in April of 2024.

Shell selected Durasorb LNG MAX at the conception of the DLNG plant because the grid gas processed is expected to contain a heavy tail.  With this technology in place, other unique design features were also implemented to ensure world-class operation and consistent LNG production.  These features include continuous or online monitoring of water and HHC concentrations in feed and treated, condensate (water and HHC) handling.

In this paper, Shell and BASF will jointly discuss the technology selection, plant design, plant operation, including the unique features of the plant, and performance to date.  Utilization of Durasorb LNG MAX technology ensures removal of HHCs under a wider design envelop, which has already proven important due to the feed gas source switching from lean Russian gas at the onset of plant design to heavier Norwegian gas at start up.  This flexibility allows for consistent plant operation and performance.  To date, the DLNG plant has been delivering on spec gas and does not shut down or reduce LNG production due to HHC freezing.  This approach to a greenfield LNG plant provides a roadmap for other LNG projects on how to avoid well known challenges using new and innovative approaches to plant design.