University scientists have developed software to increase the productivity of small-scale LNG plants.

Scientists from Gubkin Russian State University of Oil and Gas (National Research University) have developed software that can increase the productivity of small-scale LNG plants by up to 7% and reduce their energy consumption by up to 5%. The development will help increase the yield of finished products and reduce gas losses.

"This development is not just a calculation program, but a digital simulation model—a 'tomography' of the process—that identifies bottlenecks in production processes and suggests targeted solutions, as well as a decision-making system for the operator," explained Roman Barashkin, Associate Professor of the Department of Process Automation at Gubkin University.

In the first phase of the project, the scientists conducted research at a plant with a capacity of 21,500 tons per year, using software developed at Gubkin University.

Engineers created a digital copy of the process—a simulation model—that identified issues reducing the plant's efficiency. These included high gas losses during adsorber regeneration, insufficient refrigeration cycle efficiency, inaccurate instrumentation readings, and inadequate pipeline insulation.

Based on the data obtained, the specialists proposed specific modernization measures: using boil-off gas (the evaporated gas generated in liquid natural gas tanks) for internal needs, installing an adjustable throttle (a device that reduces gas pressure), replacing the thermal insulation, calibrating the instrumentation, and adjusting the LNG storage pressure.

"As calculations show, adjusting the throttle alone will increase LNG production by 2-4% without purchasing new equipment. Replacing the refrigerant will allow the gas to be cooled further—from -50 to -55 degrees Celsius. This means more gas will be converted to liquid." Another potential solution is eliminating losses during loading: due to poor insulation of the hose used to load LNG into tanks, up to 4% of the product is lost,” said Roman Barashkin.

The new software allows for real-time loss tracking, simulating equipment operation and suggesting optimal settings to maximize finished product yield.

In addition to technical solutions, the scientists developed a decision support system for operators – a program with a graphical user interface connected to a digital model of the plant. A training complex was also created – a program simulating the operation of a real plant for practicing plant control in various modes without risking production.

“We saw that the actual performance of the LNG plant under consideration was lower than the design. To address this, we created a digital model that allowed us to analyze the process and understand where exactly efficiency was being lost. This can be compared to a tomography scan of a complex organism, allowing us to identify problem areas and propose targeted solutions that do not require production shutdowns or significant investment,” noted Roman Barashkin.

The development is ready for implementation at other enterprises, which opens the way for the growth of LNG production in Russia.