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Maximising every molecule - compositional constraints optimisation.

Number: 38

Author(s) : WHITELAW L.

Summary

The Karratha Gas Plant (KGP) is a complex integrated site with four liquified natural gas (LNG) processing trains; two domestic gas trains; four condensate stabilisation units and three liquified petroleum gas (LPG) fractionation units. In response to declining output from existing fields, KGP transitioned to tolling operations in March 2022, introducing other resource owner (ORO) gases via new pipeline connections. This shift required KGP to process feed gas compositions beyond its original design envelope.
Evaluating the processing capacity for this new range of feed compositions began with establishing limits across the site for key components including nitrogen, carbon dioxide, LPG and heavies (C5+). The historical phased expansion of KGP over 40 years has made this more complex with differing constraints across the disparate processing trains.
Technical studies and process simulations were used to determine initial component limits which were then expanded through plant trials and operational optimisation assessing the impacts on unit processing capacity. Processing modifications to further extend limits were also scoped and investigated. The objective was to maximise production within existing constraints and avoid costly modifications.
Optimising production requires a multifaceted approach, including targeted processing and feed blending to adhere to component limits. Ongoing assessment of plant operations and blend gas availability was essential, especially as declining field profiles and unit retirements further tightened constraints.
The final phase focused on operationalising these limits through robust production planning, ensuring day-to-day maximisation of processing volumes and adaptability to planned shutdowns. This adaptive strategy has enabled KGP to safely and efficiently expand its operational envelope, sustaining value and production.
The KGP is a complex integrated site encompassing multiple LNG trains, a domestic gas plant, LPG plant and condensate stabilisation units. In recent years, declining output from the North West Shelf (NWS) offshore fields supplying KGP has created spare processing capacity, presenting a strategic opportunity to introduce other resource owners ORO gas through tolling arrangements. This shift has enabled the plant to generate additional value by leveraging its infrastructure for external feedstocks.
However, the compositional profiles of these new imported gases often fall outside the original design specifications of the plant. Addressing this challenge has required a comprehensive program of technical studies, plant trials, and process optimization. This paper details the systematic approach undertaken to maximise the value of these new processing opportunities.
The initial phase began in March 2022 with the introduction of Woodside Burrup (WB) gas through the Pluto to North West Shelf interconnector pipeline (PNI). This was followed by further expansion, when Waitsia gas was integrated via backhaul from the domestic pipeline network. Since then, ORO production has continued to grow, supported by contract extensions for PNI and ongoing
evaluation of additional opportunities from a diverse range of third-party sources.

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Details

  • Original title: Maximising every molecule - compositional constraints optimisation.
  • Record ID : 30034651
  • Languages: English
  • Subject: Technology
  • Source: 21st International Conference & Exhibition on Liquefied Natural Gas (LNG2026)
  • Publication date: 2026/02/05

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