VOL.

2:
PEAK SHAVING WITH
SYNTHETIC NATURAL GAS
A Handbook from the
SNG Academy™

Tulsa, Oklahoma, USA

Understanding Peak Shaving
and Synthetic Natural Gas
Table of Contents
History & Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Business Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
The Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Why Use SNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Distance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SNG Mixture Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SNG Mixing Process: An Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Design and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Construction Times and Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Design — Material Supplier Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LPG Delivery Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LPG Storage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LPG Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LPG Vaporizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SNG Mixing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Peak Shaver Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Security Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Training and Technical Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Feasibility Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Appendix Contents
Percentage of Propane in an SNG Mixture vs. Dewpoint . . . . . . . . . . . . . . . . . . . . . . . . 18
Percentage of Isobutane in an SNG Mixture vs. Dewpoint . . . . . . . . . . . . . . . . . . . . . . . 19
Percentage of N-Butane in an SNG Mixture vs. Dewpoint . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure-Temperature Diagram for Various Propane-Air Mixtures . . . . . . . . . . . . . . . . . . 21
Product Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Various LPG Compositions: Vapor Pressures of Typical Butane-Propane Mixtures . . . . . 23
Thermodynamic Properties of Saturated Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thermodynamic Properties of Saturated Butane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Physical Constants of Hydrocarbons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Vaporization Rate from a 30,000 Gallon Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pressure Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Propane Vaporization Rates at 0°F at Varying Tank Levels . . . . . . . . . . . . . . . . . . . . . . . . 30
Properties of Liquified Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electric Currents for Specific Countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Ethylene Glycol Freeze Protection Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Please Read — Disclaimer of Responsibility

Ely Energy Inc. does not warrant or assume any legal liability or responsibility for the accuracy, completeness,
or usefulness of any information, apparatus, product, or process described herein. Ely Energy Inc. assumes no
liability for the misuse, abuse, or incorrect application of data presented. Ely Energy Inc. intent is lawful and if
any information presented breaks applicable local or national law, in any country, it is not intended for you.
 Ely Energy, Inc.

History & Abstract

Synthetic Natural Gas (SNG), plays a niche role, yet a critical role in meeting the energy
needs of nations around the world. SNG is a term that describes a variety of “manufactured
gases”. In our language, SNG is a blend of Liquefied Petroleum Gas (LPG) and air which
provides a direct replacement for natural gas.
This handbook provides basic information important to sales personnel and end users for
designing and understanding SNG Peak Shaving systems. It describes concepts and equipment
common to the industry.

History of Ely Energy, Inc.

From 1898 to the 21st-Century…
In 1898, Energy Systems, Inc. (ESI) began as a mechanical contractor located in Minnesota
(USA). By the 1950’s ESI had branched out into associated mechanical engineering activities
that grew to include the design and manufacture of Synthetic Natural Gas (SNG) systems.
Their applications included peak shaving for natural gas utilities and industry, backup fuel
systems and CityGas distributed gas systems. Around 1980 ESI was acquired by the RJ Ely
Company of Tulsa, Oklahoma (USA) and began operations as Ely Energy Systems, and later as
Ely Energy Inc. — a subsidiary of the RJ Ely Company. In 1998, under a corporate consolida-
tion, the corporation formally changed to Ely Energy, Inc. (EEI).

General Business Description

EEI specializes in specific niche market energy opportunities that typically involve LPG (liqui-
fied petroleum gases), NH3 (ammonia), aqueous ammonia (NH4OH) and a variety of hydro-
carbons. A cornerstone of EEI’s business is the so-called synthetic natural gas (SNG) group that
offers solutions to assist in natural gas management. Most people have heard of natural gas.
Some have heard of liquefied petroleum gas (LPG). Few outside the energy sector, however,
understand SNG. We create SNG by blending LPG with air to a specific ratio that results in a
fuel with combustion characteristics essentially identical to natural gas. This controlled mixing
of LPG and air allows it to be used as an alternative to natural gas for backup use, peak shaving,
and CityGas supply in regions where natural gas is not yet available. No orifice changes, pressure
changes or any other changes are required for the natural gas consuming equipment! SNG is a
direct replacement for natural gas (NG)!
The technology of blending LPG and air to simulate natural gas is not new. Use of SNG
extends back to the 1950’s. What is new is our ability to provide much higher degrees of control,
gas quality consistency and safety to the process.
Our SNG solutions assist in natural gas energy management for private industry, the federal
government, the U.S. military, municipalities, educational and correctional institutions and the
medical-health care sector.
With ancestral roots that trace to 1898, EEI is easily one of the most respected SNG equip-
ment and service providers in the world. Our commitment is to optimize our available resource
base to make every project successful. We provide a variety of SNG energy services including:

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Introduction to Synthetic Natural Gas

■ SNG Backup Systems: Allows the industrial natural gas customer to change from a
FIRM to an INTERRUPTIBLE Natural Gas rate structure. The savings will often pay for
an installation within 6 mo. or less, up to 4 years.

■ SNG Peak Shaving Systems of NG: Allows both NG Companies and Industrial Clients
to augment their NG demand during peak demand periods.

■ SNG Base-Load Systems: Provide SNG in regions where NG is currently not available.
SNG typically functions as a bridge fuel while either an NG or LNG solution is being
implemented.

The Company
We can be contacted at fax (918) 254-5412 (USA) or at our e-mail: sales@elyenergy.com.
Our telephone switchboard is at (918) 250-6601. Touch ‘0’ for the Operator to direct your call.
Or visit us on the Internet at www.elyenergy.com. Our physical address is 11385 East 60th
Place South, Tulsa, Oklahoma 74146 (U.S.A.).

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Introduction to Synthetic Natural Gas Ely Energy, Inc.

Introduction
SNG peak shaving facilities (See Figure 1), are asset management tools for both the demand side
and supply side of the natural gas (NG) market. Peak shaving facilities are similar to traditional SNG
Backup Systems, but are typically larger in capacity, operate at higher discharge pressures, require
more storage and are more sophisticated. Most utilize specialized equipment for flow measurement
and control.
For the demand side, or “end user” side of the NG market, SNG helps manage natural gas costs.
For example, an SNG mixing system can allow a client to switch from a higher cost firm tariff (FT)
gas rate, to a lower cost interruptible tariff (IT) service. The SNG facility provides the fuel supply on
those days when the natural gas supply is interrupted. The SNG facility can also provide MDQ or
nomination management by allowing the use of SNG to augment the amount of nominated NG.
On the supply side of the NG market a Local Distribution Company (LDC) can help support
the natural gas flow or pressure demands during peak consumption periods by peak shaving with
SNG. Peak consumption demand typically occurs during the winter when NG purchases are
expensive, or when NG is simply not available. In addition, the peak shaving system provides “fuel
availability insurance” during emergency crisis situations.

Figure 1: Typical modern, modular SNG Peak Shaving Facility (USA)

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Introduction to Synthetic Natural Gas

Why Use SNG?

Most natural gas utilities offer their customers both firm and interruptible service. Firm and inter-
ruptible incentives vary by region, mainly as a function of demographics, weather and deliverability
of gas. The firm tariff (FT) price (per decatherm or Mcf-used) is priced higher than the interruptible
tariff. This firm tariff may also include a demand charge and other charges. Using interruptible gas,
a client may realize savings in both the cost of the gas and the associated demand charges. However,
if a client opts for interruptible gas, an alternative fuel must be available during those interruptions
For a demand side industrial client, it may be economically advantageous to maintain some firm
natural gas supply and convert only part of their total load to the interruptible rate schedule. In this
case, SNG can be used for the load peaks that exceed the contracted firm gas availability. Hence the
term “peak shaving.”

Code Requirements
Regulatory Criteria
Before we go too far, lets mention local jurisdictional codes.
These vary widely. Typically state, local and sometimes fed-
eral regulatory agencies must review the plans for a proposed
SNG facility. At the federal and state level in the USA,
various NFPA (Figure 2) documents including Pamphlet
58 (Liquefied Petroleum Gas Code), NFPA 54 (National
Fuel Gas Code), and NFPA Pamphlet 59 (Utility LP Plant
Code) are basic codes generally followed by authorities.
NFPA Pamphlet 59, as the title implies, is a sister document
to NFPA Pamphlet 58 and addresses fire protection and
other safety measures for utility peak shaving facilities. The
requirements are based on an analysis of the hazards identi-
fied within and near the proposed facility. The guidelines
to meet these requirements can include preparation of an
emergency-response plan, appropriate training of personnel,
fire protection devices and other safety measures.
Figure 2

Distance Criteria
Both NFPA Pamphlet 58 and NFPA Pamphlet 59 suggest minimum design criteria for LPG facilities.
As mentioned above, NFPA Pamphlet 59 specifically addresses criteria for utility-owned peak shaving
facilities. As always, other codes and technical standards can impact construction of an SNG facility.
Distance guidelines provided by NFPA Pamphlet 59 include such issues as storage tank capacities,
allowable distances from buildings or property lines, vaporizer distances from unloading facilities, tank
groupings and so forth. These distances may be modified by local jurisdictional authorities. In addition,
some insurance companies (e.g. FM Global and Industrial Risk Insurers) can require distances more
stringent than NFPA recommendations.

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 Ely Energy, Inc.

Table 1 Shows the respective installation distance requirements for storage per NFPA 59.
Minimum distances stated are from an LPG tank to the nearest important building not associated
with the utility gas facility, or, an adjoining buildable property line.

Standard Fire Protection

Modern SNG peak shaving facilities
Table 1 typically use an integrated Emergency
NFPA Pamphlet 59 Distances (2004 Edition) Shutdown System (ESS) to allow auto-
Water capacity Minimum matic closure of key valves in the SNG
per container in Distances in ft. system. ESS systems utilize air or nitro-
US gal. (M3) and (m) gen to actuate valves in the storage
2,001 to 30,000 50 ft. tanks, at the unloading stations (both
vehicular and rail) as well as other
(7.6 to 114 m3) 15m
points in the system. The ESS can also
30,001 to 70,000 75 ft.
be configured to activate alarms both
(114 to 265 m3) 23m local to the facility as well as at remote
70,001 to 90,000 100 ft. locations. Other types of gas leak detec-
(265 to 341 m3) 30m tion devices and fire detection devices
90,001 to 120,000 125 ft. may be installed to further bolster the
overall facility monitoring systems as
(341 to 454 m3) 38m
necessary.
120,001 to 200,000 200 ft. Additional protection can take the
(454 to 747 m3) 61m form of fire retardant insulation, deluge
200,001 to 1,000,000 300 ft. water systems, or mounding or burying
(747 to 3,875 m3) 91m the LPG storage tanks. Deluge and
1,000,001 or more 400 ft.
buried storage tanks are expensive and
(over 3,785 m3) 122m relatively uncommon. Both techniques
can detrimentally affect the economics
of a proposed facility.

Emergency procedures
NFPA Pamphlet 59 requires that emergency procedures be defined and available in the event of
an accident. The procedures should be prepared by a trained individual, be readily available at the
facility and be kept updated relative to any equipment or functional changes at the peak shaving
facility. EEI recommends annual training in both operational and emergency procedures.

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Introduction to Synthetic Natural Gas

Environmental Considerations
Environmental Protection Agency (EPA) requirements for leak detection or monitoring systems
are not generally required for an SNG facility. LPG is not an ozone depleting substance and LPG
released to atmosphere will vaporize immediately. However, LPG is heavier than air and precautions
must be taken to ensure the SNG facility is not located in a depression or surrounded by dikes or
berms. Investigate the state and local permitting requirements prior to proceeding with a project.

Noise
Noise associated with an SNG facility is primarily related to the air compression system. As most
peak shaving facilities utilize screw type compressors, sound attenuation enclosures typically reduce
the noise to within acceptable OSHA standards.
A noise level 74-79dbA is quite common in most screw air compressor specifications. Please note
this noise range is equivalent to something between a vacuum cleaner and being in a truck cab. (See
Tables 2 and 3 below).
For example, the dBA rating of the UTILI-PAK™ SNG System, equipped with the AFC™
Blender and Atlas-Copco™ air compressor, is in this range. If we refer to Table 2 this level is
below the OSHA limit. Table 3 illustrates permissible noise exposure and should also be taken into
consideration.

Table 2.
Sound intensity levels; Decibel Level (dB) Source
140 – threshold of pain: gunshot, siren at 100 feet
135 – jet take off, amplified music
120 – chain saw, jack hammer, snowmobile
100 – tractor, farm equipment
90 – OSHA limit - hearing damage if excessive exposure to noise levels above 90 dB
85 – inside acoustically insulated tractor cab
75 – average radio, vacuum cleaner
60 – normal conversation
45 – rustling leaves, soft music
30 – whisper
15 – threshold of hearing
0 – acute threshold of hearing - weakest sound

Table 3.
Permissible noise exposure scale Duration – hours per day Sound level (dBA)
8 Hours 90dBA
4 95
2 100
1 105
½ 110
¼ or less 115 Reference: OSHA Noise Standards.

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 Ely Energy, Inc.

SNG Mixture Characteristics

When LPG is vaporized and properly mixed with air, the resultant SNG can be used interchange-
ably with natural gas. LPG must be mixed with air because the density and heating value of LPG is
much higher than that of natural gas. The approximate ratio of dilution for propane and air is 45%
air and 55% LPG. The resulting mixture has a specific gravity of about 1.29–1.31 and a BTU value
of approximately 1400–1500 BTU/Ft3, which is compatible with typical natural gas.
Wobbe Index is one of the best indicators of the interchangeability of a specific natural gas com-
position and an SNG mixture. The Wobbe Index can be generally defined as “energy flow”. It is
calculated as the ratio of the calorific value to the square root of the specific gravity relative to air (i.e.
SG air = 1). Wobbe is used when “heat input” rather than “gas flow” is of interest. This is the case
for example, with a gas appliance. With an appliance, the gas input rate is controlled by the jet or
burner. If the gas is supplied at a constant pressure, the flow is proportional to the reciprocal of the
square root of the specific gravity. Hence, energy input is proportional to the Wobbe index. Such an
index is necessary in cases where the feedstock LPG (i.e. blends of propane and butane) varies and
can alter the calorific value.
If the natural gas and the SNG have an identical or nearly identical Wobbe Index, they produce
an equivalent amount of energy and require the same amount of combustion air. Burners operating
on SNG will not require pressure adjustments and the measured and observed combustion charac-
teristics show essentially complete acceptance.
The Wobbe Index relates the heating characteristics of interchangeable gases in a more usable way
than does classification by calorific value. Again, this is because Wobbe Index matching takes into
account fuel composition variations with the goal of matching “energy flow” rather than simply
maintaining a fixed set-point value.

SNG Mixing Process: An Overview…

Figure 3 depicts a typical SNG peak Figure 3: peak shaving Facility (Argentina)

shaving facility and Figure 4 on the

following page depicts a typical flow
process for an SNG system. Liquid
LPG is stored in tanks under pressure.
The amount of liquid LPG storage
required is determined based on the
output capacity of the proposed facility,
projected usage (i.e. number of hours or
days), logistical ability to replenish the
LPG consumed and so forth. When
the peak shaving system is in operation,
LPG is withdrawn from the tanks via a
rotary LPG pump. The LPG is pumped at pressure to an LPG vaporizer. As the LPG liquid passes through
the vaporizer, it is heated. A phase change from liquid to vapor results, with the vaporizer providing an
adequate amount of super-heat to prevent re-condensation to a saturated vapor or liquid.

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Introduction to Synthetic Natural Gas

Figure 4: Typical process flow for SNG system

The super-heated LPG vapor
is then blended with air supplied
from an air compressor to a
specific ratio thus, creating the
SNG. This mixing occurs in a
proportional blending system
such as our AFC™ Blender.
The peak shaving system’s flow
control system then allows
injection of the SNG into the
natural gas distribution grid as
required.
There are two common control methods of peak shaving: Ratio Control (Figure 5) and Pressure
Control (Figure 6).
When peak shaving in Ratio Control, a pressure and temperature corrected flow signal from a
meter in the natural gas line upstream of the SNG tie-in is required. A similar flow signal is required
from an SNG meter. These signals allow
Figure 5: Ratio Control
a Flow Control Valve installed after the
AFC™ Blender to regulate a volumetric
ratio up to ~40% of SNG to Natural Gas
in the pipeline. This ratio ensures the
overall specific gravity of the SNG/NG
will remain below 1.00 (lighter than air).
The control system also allows the SNG
Figure 6: Pressure Control
flow to vary as necessary, in a fixed ratio,
as the natural gas demand varies.
An alternate method of peak shaving
control is Pressure Control. When peak
shaving in Pressure Control, the amount
of SNG replacement of NG can vary from
minimal to 100%. The role of the SNG is
simply to maintain line pressure and flow
in the NG pipeline — regardless of SNG/
NG ratio! During operation, a pressure
transmitter provides a flow control bias
that will reduce the SNG flow rate as the
natural gas pressure in the pipeline approaches some fixed pressure setpoint. If the natural gas system
pressure rises above that set value, the flow control valve closes and SNG injection will stop. When the
line pressure drops, the flow process will begin again.
Both systems have various safeties that ensure safe operation. These will be discussed in a following
section.

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Design And Construction

The design and construction activities associated with an SNG peak shaving facility can be sub-
divided into discrete activity blocks. These include:
1. Economic feasibility confirmation
2. Site selection
3. System design and specification
4. Site permit / Fire Safety Analysis completion
5. Manufactured Equipment ordered
> Liquid LPG unloading facility
> Liquid LPG storage facility
> Liquid LPG transfer systems (storage to vaporizer)
> Liquid LPG vaporization system
> SNG mixing system (i.e. LPG and Air blending)
> SNG flow Control System
> Control philosophy and hardware
4. Field preparatory work ( as necessary)
5. Field concrete / foundations
6. Tanks and manufactured equipment set
7. Field interconnecting piping completed
8. Field interconnecting electrical completed
9. Field “tie-in” to Natural Gas Grid completed
10. Site security and landscaping
11. Commissioning / Training / Hand-over to Client

Construction Times/Costs
The amount of time required to design
and construct a peak shaving facility can vary.
Depending on the size of the system, four
to eight months are reasonable construction
estimates. This estimate includes the design,
manufacturing, field erection and commis-
sioning activities.
Costs vary dramatically depending on sys-
tem capacity and sophistication. A primary
Figure 7: Modular factory-built SNG peak shaving Plant
cost center is liquid storage. As storage require-
ments increase — costs increase significantly. Estimates from $400,000 to $5+ million USD are reasonable.
Storage capacities, soil conditions and amount of field piping have the most direct impact on costs.
EEI offers modular “plug and play” designs for peak shaving requirements. This includes pre-pack-
aged, wired, piped and tested UTILI-PAK™ (see Figure 7) mixing modules. These modules reduce
overall construction costs, field piping costs, field electrical costs, commissioning costs and overall PO
to commissioning time.

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Introduction to Synthetic Natural Gas

Design – Material Supplier Qualifications

Designing an SNG facility requires expertise and experience in the field of gas engineering. Select
a firm that specializes in both the design and manufacture of “3rd Party Approved” equipment. This
will include, for example FM GLOBAL (FM) listed (see Figure 8) or UNDERWRITERS LAB (UL)
LISTED equipment. This helps guarantee safety while also making permitting and approval issues
easier. LOOK FOR THIS SYMBOL!
Figure 8

Warning! For utility peak shaving facilities, avoid LPG equipment that does not
carry 3rd Party Safety Approvals. This is especially important for the Vaporization
and SNG Blender portion of the system.

Major manufactured equipment include the: LPG storage system, LPG unloading facilities, LPG
transfer pumping system, LPG vaporization system, SNG blending system, control systems and
ancillary safety systems (e.g. ESS or Emergency Shutdown Systems).
Proper selection of equipment requires the following information be provided by the client:
> Maximum hourly output for the system (in MMBTU/h or MCF of SNG)
> Heating value of the Natural Gas (to allow Wobbe matching)
> System pressure of the NG system (e.g. to define pressure for the SNG)
> Site information (e.g. site plan of area to allow equipment layout design)

LPG Delivery Facilities

Truck Delivery
LPG delivery via truck transport is
the most common method of LPG
product delivery to most small to
medium sized peak shaving facili-
ties. Transport capacities range from
9,000 to 11,500 (water) gallons and
typically unload via a PTO driven
pump mounted on the transport. A
level unloading area is required to
ensure effective transfer of the liquid
LPG from the transport to the stor-
age facility.
LPG is transferred using what is
called a TTU or Truck Transport
Unloading station. (See Figure 9).
The TTU has two hose connections; Figure 9

one is a vapor line connection piped

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Figure 9: Storage Tanks

to the vapor connection of the storage tanks. The second connection is the liquid transfer connection,
which is piped to the liquid connection on the storage tanks (shown above). During the transfer
process, high pressure hoses connect the transport to the storage tanks creating a circuit. As liquid is
transferred from the transport to the storage tanks, vapor is displaced from the storage tanks to the
transport.
After completion of the liquid transfer, from the transport, the unloading process is complete.
The vapor remaining in the transport can constitute up to ~3% of the load. However, recovery of
the vapor phase requires use of a specialized LPG transfer/recovery compressor. Such compressors
are typical for rail car off-loading but not typical in the USA for most transport off loading facilities
simply due to additional costs. We discuss compressors under “Rail Delivery”.

Rail Delivery
Rail tanker deliveries require different equipment than road tankers — and we don’t just mean the
track! Rail tank cars generally are not “bottom drop” like LPG delivery trucks. Rather — the LPG is
off loaded via connections on the top of the rail car. To accomplish this, rail unloading facilities must
have a railroad unloading tower unloading transfer compressor. The stationary LPG transfer compres-
sor (Figure 10) is used to “push” the liquid LPG out of the rail car. This is accomplished by drawing
vapor from the (“empty”) storage tank(s), compressing the vapor to a slightly higher pressure while
adding some heat from compression, and
then pushing the compressed vapor into the
rail car. This vapor volumetrically displaces
the liquid LPG in the rail tanker, forcing the
liquid to transfer out of the rail car to the
storage tanks.
After most of the liquid has been removed
from the rail tanker, the process is reversed
enabling the vapor in the rail car to be recov-
ered and transferred to the storage tanks as Figure 10

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Introduction to Synthetic Natural Gas

well. To accomplish this, the compressor flow path is reversed using a 4-way valve arrangement. Vapor
is sucked from the rail car and discharges to the storage tanks via the liquid line connection. During
this process the rail tanker’s liquid outlet valve is closed. The LPG vapor is discharged through the
liquid inlet of the storage tanks allowing the vapor to cool and condense as it enters the tank. Recovery
of the LPG vapor is typically conducted until approximately 25% of the original vapor pressure is
remaining. Beyond that, the economics of recovery are not favorable. More energy is spent in recover-
ing the LPG than there is energy in the LPG itself!

LPG Storage System

LPG is stored under pressure in the liquid form. The size of the pressure vessels (i.e. tanks) for a
peak shaving facility can vary from 30,000 to 90,000 gallon storage tanks — or larger. The LPG stor-
age tanks must be manufactured in compliance with the applicable codes of the American Society of
Mechanical Engineers (ASME). Arguably, the most common size range for tanks is 30,000 – 60,000
gallons. Sizing of the storage facility depends upon the demands on the process and the availability of
LPG supply. An analysis of the projected use can define the minimum appropriate storage required.
Example: A peak shaving facility has a projected usage operating 24 hours per day, at an average of
300 million BTU/hr for up to 3 consecutive days. The LPG this requires at peak flow will be approxi-
mately 3,300 gallons per hour. A 60,000 gallon storage tank will provide a 16-hour supply. (A 60,000
gallon storage tank can only be filled to ~88% capacity at 60°F.) For three days (24h x 3 = 72h), 72/16
= 4.5 or a requirement for five (5) 60,000 gallon tanks.
The storage tanks require the following
tank trim items: (See Figure 11).
1. Liquid fill valve
2. Liquid outlet port valve
3. Vapor space valve
4. Pressure gauge
5. Liquid level gauge
6. Thermometer
7. Relief valves
8. Excess flow valves
9. 85% value
10. Internal valves
11. Rotary level gauge

Although LPG storage tanks can be installed

underground, costs are high relative to above
ground tanks. Underground tanks can have
additional requirements including protective
coatings, ballasts, special types of pumping
scenarios, top penetrations versus bottom and
so forth. Figure 11

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 Ely Energy, Inc.

LPG Pumps
LPG is delivered to the SNG mixing system at a pressure elevated above equilibrium pressure.
Vapor pressure in the tank is dependent upon the “percent full” and ambient temperature of the
LPG. As the LPG temperature drops and/or the storage tank level drops as with use, the vapor
pressure in the tank will also drop. Hence, liquid pumps ensure sufficient LPG flow and pressure
are available at the SNG mixing systems. LPG pumps are rotary pumps, generally either positive
displacement or turbine type.

Vaporizers
Vaporizers convert liquid LPG to
vapor by adding heat. For a utility appli-
cation, the vaporizer is typically a gas-
fired water-bath. An electrically heated
vaporizer is almost never used for utility
applications due to operating cost. The
choice of steam or gas-fired water-bath
type generally depends on the availabil-
ity or lack of steam. Without question,
the vast majority of utility SNG facilities
built worldwide use gas-fired water-bath
vaporizers.

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Introduction to Synthetic Natural Gas

Gas-fired water-bath vaporizers (See Figure 12) use either an atmospheric or forced draft power
burner system to heat a solution of ethylene-glycol and water. The ratio of water to ethylene-glycol
can be estimated from the Protection Curve on page 33. The waterbath indirectly heats the LPG via
the LPG heat exchanger. Factory Mutual (FM) Approved waterbath models are available up to 12,500
gallon/h in one unit. The distance requirements are 25 to 75 feet from a building or storage tank.

Figure 12

SNG Mixing Systems

SNG is created by blending LPG and air to achieve an appropriate natural gas replacement mixture.
The SNG is then injected into the natural-gas grid to replace up to about 25 to 40% of the total gas
flow. The “right” mixture quality (BTU/Ft3) for a peak shaving site involves several factors, including
the composition of the natural-gas and LPG streams and the interchangeability criteria to be met.
There are several techniques for blending LPG and air depending on the required SNG pressure. For
peak shaving, a “proportional blender” using an external compressed air source is most common.
The AFC™ Blender (See Figure 13) is a global standard used in many peak shaving applications.
Common SNG pressures for peak shaving range from 15 – 70 PSIG but 110 to 350 PSIG are avail-
able. The AFC™ Blender operates on a molar (volumetric) relationship wherein the percentage of
gaseous propane and compressed air are blended to maintain a specific SNG mixture. An optional
Wobbe Index meter (See Figure 14) monitors the SNG gas quality and determines its interchange-
ability with the natural gas. The AFC™ Blender uses the Wobbe Index signal to adjust the mixing
ratio to the desired gross WI value. Typical correlation is +/- 1.5% of setpoint. The Wobbe Index
meter also alarms any High or Low Wobbe value that might be measured.
In this system, propane is delivered to a mixing chamber under pressure (see Figure 15). The air is deliv-
ered to the same mixing chamber from an air compressor. The mix is then fed to the piping system.
The AFC™ discharge pressure is controlled by upstream pressure regulators. Therefore, the AFC™
Blender responds much like a regulator. SNG flow increases with falling Gas Distribution System
pressures, and, the reciprocal, SNG flow decreases as the Gas Distribution System pressure, increases.
Output pressures can range to 150 PSIG. This is the most common type of system at larger instal-
lations like military bases, due to the higher delivery pressures usually required.

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Introduction to Synthetic Natural Gas Ely Energy, Inc.

Figure 13

The AFC™ monitors the following conditions. If one of these process characteristics is out of
normal range, the AFC™ will alarm and shutdown as necessary.

• Low LPG Supply Pressure

• Low LPG Supply Temperature
• Low Air Supply Pressure
• Flow Control System Faulty — flow ratio of two gas streams are incorrect.
• Air Flow Control Valve Faulty — Air Control Valve is not responding. The Air valve includes
a position sensor that monitors the position of the valve. When the actual Air Control valve
position differs by more than 2% of the required theoretical position, this alarm will shutdown
the blender.
• Low Wobbe Index
• High Wobbe Index

The AFC™ has the capability of operating in

two different modes of operation as we previously
discussed for peak shaving. It can operate in Ratio
Mode, wherein a fixed ratio of the natural Gas flow
is displaced by SNG. Alternatively, the AFC™
can operate in so called Pressure Mode, wherein
ALL Natural Gas is displaced (or made up by…)
by SNG.
When in Pressure Mode, the AFC™ Blender
operates at 1" to 3" of water column pressure
higher than the regulated Natural Gas. This con- Figure 14: Operator stands near Wobbe Index meter. (Courtesy of Cammuzigas)

www.elyenergy.com 15
Introduction to Synthetic Natural Gas

Figure 15

figuration requires a check valve be installed in the Natural Gas piping up stream of the SNG injec-
tion point. When SNG is being injected at the slightly higher pressure, it will automatically close
this check valve shutting off the Natural Gas supply. SNG now supplys all the gas into the pipeline.
If the AFC™ were to shutdown, the Gas Distribution System pressure will fall allowing the Natural
Gas check valve to re-open and Natural Gas to flow back into the facility.
When in Ratio Mode, a Flow Control Valve is required on the discharge of the AFC™ Blender.
The AFC™ will operate similar to the Pressure Mode we described above with the SNG discharge
pressure 1" to 3" of water column higher than the regulated Natural Gas pressure at the point of
injection. The SNG Flow Control Valve will control the SNG injection rate using a dedicated PID
Process Controller that monitors the ratio of the corrected Natural Gas and SNG volumetric flows.
The natural gas flow signal will be provided from a meter installed upstream of the SNG Tie-in. The
AFC™ creates a corrected flow signal for controlling the SNG through normal programming. The
Flow Control Valve controller will only allow a volumetric ratio up to 40% SNG to Natural Gas.
This ensures that the overall specific gravity will remain below 1.00 (lighter than air), The control
system also allows for the SNG volume to adjust as necessary, in a fixed ratio, as the Natural Gas
Flow demand changes.

Peak Shaver Controls

Advances in controls technology allows peak shaving operations to be extremely flexible, user
friendly and safe at affordable prices. Generally a centralized control station is either a traditional
relay based system or more commonly handled via a PLC utilizing either an Ethernet or Data
Highway design. Either way, the controls allow integration of the entire process — from storage
and unloading through to flow control and gas quality maintenance. System design should focus on
achieving a coherent operating strategy that, ensures a safe, simple and reliable process.

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Introduction to Synthetic Natural Gas Ely Energy, Inc.

Security Protection
Standard security at an LPG facility should include perimeter fencing and other device to keep
unauthorized personnel out of the facility. The facility should be restricted to authorized and trained
personnel.

Training And Technical Documentation

System operators must understand the basic properties and associated hazards of LPG. It is impor-
tant that the differences between natural gas and LPG be understood.
EEI offers both operator training and safety training as part of their complete package. As safety
is the ultimate key to success, training and safety measures are fully integrated into the overall SNG
Peak shaver proposal.

Feasibility Analysis
Consideration of a peak shaving system, either for a government facility, an LDC or a public
institution requires both a plan and the ability to analyze and evaluate the proposed investment.
EEI can help you address the feasibility of constructing a new Peak Shaver, or expanding or
rehabilitating an existing plant. EEI is focused towards a practical approach using our extensive
knowledge of both natural gas pricing options and SNG technologies.
We will be happy to schedule a time when we can meet at your facility or ours for a discussion
on feasibility planning.

Thank You
Thanks for taking the time to read this booklet and for being interested. When we can help — call
us. We’re dedicated to serving your needs.

www.elyenergy.com 17
Appendix

Percentage of Propane in an SNG Mixture vs. Dewpoint

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Appendix Ely Energy, Inc.

Percentage of Isobutane in an SNG Mixture vs. Dewpoint

www.elyenergy.com 19
Appendix

Percentage of N-Butane in an SNG Mixture vs. Dewpoint

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Pressure-Temperature Diagram for Various Propane-Air Mixtures

www.elyenergy.com 21
Appendix

Product Definitions

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 Ely Energy, Inc.

Various LPG Compositions:

Vapor Pressures of Typical Butane-Propane Mixtures

www.elyenergy.com 23
Appendix

Thermodynamic Properties of Saturated Propane

Enthalpies and Entropies are referred to saturated liquid at -200°F. where the values are zero.
Temp. Pressure Specific Volume Density Enthalpy** Latent** Entropy**
F. Lb. Per Sq. In. Cu. Ft. per Lb. Lb. Per Cu. Ft. Btu per Lb. Heat Btu per Lb. Deg. F.
Btu per
Absolute Gauge Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor
t P g.p. v V l/v l/V hƒ hg L sƒ sg

-75 6.37 *17.0 0.0266 14.5 37.59 0.069 65.5 255.5 190 0.142 0.625
-70 7.37 *14.9 0.02674 12.9 37.4 0.0775 68 257 189 0.148 0.623
-65 8.48 *12.7 0.02688 11.3 37.2 0.0885 71.5 258 186.5 0.154 0.621
-60 9.72 *10.1 0.02703 9.93 37 0.111 74 259.5 485.5 0.16 0.62
-55 11.1 *7.3 0.02717 8.7 36.8 0.115 77 261 184 0.167 0.618
-50 12.6 *4.3 0.02732 7.74 36.6 0.129 79.5 262.7 183.2 0.173 0.617
-45 14.4 *0.6 0.02748 6.89 36.39 0.145 82.3 2644 181.9 0.179 1615
-40 16.2 1.5 0.02763 3.13 36.19 0.163 85 265.8 180.8 0.185 0.614
-35 18.1 3.4 0.02779 5.51 35.99 0.181 87.5 264.2 179.7 0.19 0.613
-30 20.3 5.6 0.02795 4.93 35.78 0.203 90.2 268.9 178.7 0.196 0.612
-25 22.7 8 0.02811 4.46 35.58 0.224 92.8 270.3 177.5 0.202 0.61
-20 25.4 10.7 0.02827 4 35.37 0.25 95.6 271.8 176.2 0.208 0.608
-15 28.3 13.6 0.02844 3.6 35.16 0.278 98.3 273.2 174.9 0.214 0.607
-10 31.4 16.7 0.0286 3.26 34.96 0.307 101 274.9 173.9 0.22 0.607
-5 34.7 20 0.02878 2.97 34.75 0.337 103.8 276.2 172.4 0.226 0.606
0 38.2 23.5 0.02895 2.71 34.54 0.369 106.2 277.7 171.5 0.231 0.605
5 41.9 27.2 0.02913 2.48 34.33 0.403 108.8 279 170.2 0.236 0.604
10 46 31.3 0.02931 2.27 34.12 0.441 111.3 280.5 167.2 0.246 0.603
15 50.6 35.9 0.0295 2.07 33.9 0.483 114 281.8 167.8 0.248 0.602
20 55.5 40.8 0.0297 1.9 33.67 0.526 116.8 283.1 166.3 0.254 0.601
25 60.9 46.2 0.02991 1.74 33.43 0.575 119.7 284.4 164.7 0.269 0.6
30 66.3 51.6 0.03012 1.6 33.2 0.625 122.3 285.7 163.4 0.266 0.599
35 72 57.3 0.03033 1.48 32.94 0.676 125 287 162 0.272 0.598
40 78 63.3 0.03055 1.37 32.73 0.73 128 288.3 160.3 0.278 0.597
45 84.6 69.9 0.03078 1.27 32.49 0.787 131.1 289.5 158.4 0.285 0.596
50 91.8 77.1 0.03102 1.18 32.24 0.847 134.2 290.7 156.5 292 0.596
55 99.3 84.6 0.03125 1.1 32 0.0909 137.2 292 154.8 0.298 0.596
60 107.1 92.4 0.0315 1.01 31.75 0.99 140.6 293.2 152.6 0.306 0.595
65 115.4 100.7 0.03714 0.945 31.5 1.06 143.8 294.5 150.7 0.313 0.594
70 124 109.3 0.03201 0.883 31.24 1.13 147.5 295.8 148.3 0.321 0.594
75 133.2 118.5 0.03229 0.825 30.97 1.21 150.3 296.9 146.6 0.327 0.594
80 142.8 128.1 0.03257 0.77 30.7 1.3 154 299.1 145.1 0.335 0.593
85 153.1 138.4 0.03284 0.722 30.42 1.39 157 299.2 142.2 0.342 0.593
90 164 189 0.03317 0.673 30.15 1.49 160.3 300.3 140 0.349 0.593
95 175 160 0.03348 0.632 29.84 1.58 163.4 301.3 137.9 0.356 0.592
100 187 172 0.03381 0.591 29.58 1.69 166.8 302.4 135.6 0.363 0.592
105 200 185 0.03416 0.553 29.27 1.81 169.8 303.2 133.4 0.37 0.592
110 212 197 0.03453 0.52 28.96 1.92 172.8 304 131.2 0.376 0.591
115 226 211 0.03493 0.488 28.63 2.05 176.2 304.7 128.5 0.383 0.59
120 240 225 0.03534 0.0459 28.3 2.18 179.2 305.2 125.4 0.391 0.589
125 254 239 0.03575 0.432 27.97 2.31 183.5 305.8 122.3 0.399 0.588
130 272 257.3 0.03618 0.404 27.64 2.48 183.8 306.1 119.3 0.406 0.587
135 288 273.3 0.03662 0.382 27.32 2.62 190 306.3 116.3 0.413 0.583
140 305 290.3 0.03707 0.36 27 2.78 194 306.5 112.5 0.422 0.505
† Based on material from Dana, Jenkins, Burdick and Timm, published originally in REFRIGERATING ENGINEERING, June,
1926, Vol. 12, No. 12, Page 403.
* Inches of mercury below one standard atmosphere (29.92 in.).
** From Mollier Diagrams for Propane, W.C. Edmister, Standard Oil Co. (Indiana).

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Thermodynamic Properties of Saturated Butane

www.elyenergy.com 25
Appendix

Physical Constants of Hydrocarbons

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Physical Constants of Hydrocarbons

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Appendix

Vaporization Rate from a 30,000 Gallon Tank

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 Ely Energy, Inc.

www.elyenergy.com 29
Appendix

Propane Vaporization Rates at 0° F at Varying Tank Levels

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 Ely Energy, Inc.

www.elyenergy.com 31
Appendix

Electric Currents for Specific Countries

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Appendix Ely Energy, Inc.

Ethylene Glycol Freeze Protection Curve

www.elyenergy.com 33
Appendix

Sources of Additional Information

National Fire Protection Association Factory Mutual (FM Global)
Association, PO Box 9101 1151 Boston-Providence Turnpike
Quincy, MA 02269-9101 PO Box 9102
www.nfpa.org Norwood, MA 02062
www.fmglobal.com
ANSI Publications
American National Standards Institute ICBO Publication
1430 Broadway, New York, NY 10018 International Conference of Building Officials
www.ansi.org 5360 S. Workman Mill Road, Whittier, CA
90601
API Publications www.icbo.com
American Petroleum Institute
2102 L St. NW, Washington, DC 20037 UL Laboratories
www.apioil.com Underwriters Laboratories, Inc.
333 Pfingsten Rd., Northbrook, IL 60062
ASCE Publications www.ul.com
American Society of Civil Engineers
345 East 47th St., New York, NY 10017 U.S. Government Publication
www.asce.org Superintendent of Documents
U.S. Government Printing Office, Washington,
ASME Publications DC 20401
American Society for Mechanical Engineers www.gpo.gov
345 East 47th St., New York, NY 10017
www.asme.org

ASTM Publications
American Society for Testing and Materials
1916 Race St., Philadelphia, PA 19103
www.metalinfo.com

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 11385 E. 60th Place So.
Tulsa, Oklahoma 74146
Phone: (918) 250-6601
Fax: (918) 254-5412
Visit us at: www.elyenergy.com
Email: sales@elyenergy.com
Copyright 2004 - Ely Energy, Inc.
Publication: SNG-HB/03-04