Ten questions about how a terminal like the one being built in Brunsbüttel works
What exactly is being built in Brunsbüttel?
An LNG import and distribution terminal is to enter trial operation first and then regular operation in Brunsbüttel in 2027, making a significant contribution to the security of natural gas supplies in Germany and Europe.
As part of the gradual phase-out of fossil fuels, the Brunsbüttel site and the infrastructure then in place will also enable the continuous and future-oriented import and distribution of fossil-free forms of energy, probably hydrogen derivatives.
What does a normal day at a comparable LNG terminal look like?
The core of running a terminal is the operations department where men and women working in multiple shifts take care of operations around the clock, 7 days a week. They are responsible in particular for unloading LNG carriers – together with the crew of the arriving ship – loading tank trucks and rail tank cars, and feeding gas into the pipeline that connects the terminal to the gas network in Germany.
The operations department is directly supported by the maintenance team, which ensures that all systems function safely and efficiently. Throughout the day, they maintain the equipment and also supervise the subcontractors who perform specialised tasks.
In addition, there are many other areas of activity that support the overall functioning of the terminal: the human resources department, including training and further education; the safety department; the technical department for maintenance design and planning; the commercial department for customer service; and the finance department.
All workflows, routines, processes and responsibilities are described in a constantly updated terminal management manual and are part of the terminal’s safety management system (SMS).
All staff receive ongoing training in all relevant safety measures. This ensures that all employees are able to use the latest safety technology and equipment.
In total, the German LNG terminal will employ around 90 people in various roles.
What happens when an LNG carrier arrives at the terminal? How long does the unloading take?
Large and small LNG carriers will be able to berth at dedicated jetties at the terminal in Brunsbüttel. Jetty 1 will be equipped to handle LNG carriers with a total length of up to 345 metres and a capacity of around 267,000 m³ of LNG, known as Qmax tankers. Jetty 2 can handle smaller LNG barges and LNG bunker vessels with a total length of up to 180 metres.
Regardless of their size, all LNG carriers must notify the terminal of their arrival, present their loading documents and provide an estimated time of arrival (ETA). These relevant documents are exchanged in advance between the terminal and the skipper. This is necessary so that the terminal’s operating personnel can adequately prepare for the arrival of an LNG carrier. The LNG is unloaded and transported via pipelines to the tanks, where it is temporarily stored.
The terminal will have a maximum unloading rate of 14,000 m³/h LNG transfer to our LNG storage tanks on land. This means that a large ship could be unloaded in around 20 hours. However, activities such as docking, safety checks, paperwork, tug assistance, starting up the unloading process, etc. will increase the total berthing time for a large LNG carrier to around 30 hours. Accordingly, smaller LNG carriers will have a shorter berthing time.
The LNG is converted back into gas by heating (regasification) and fed into the national gas grid. Excess heat from the nearby industrial community at the ChemCoast Park is available for this purpose – a significant location advantage.
The LNG can be further distributed by LNG bunker ship, tank truck or even rail tank car to supply fuelling stations for LNG-powered trucks, or the LNG bunker ships provide ship-to-ship bunkering operations in ports in Germany and beyond. Like the loading of trucks, the loading of rail tank cars are prescribed by specific written procedures and manuals. Each tank truck or rail tank car will be carefully inspected before being handled at the terminal.
How often will LNG carriers arrive at the terminal?
That depends on customer demand. In general, more than one large LNG carrier can be handled per week. The maximum unloading rate will be 14,000 m³/h. Including mooring and the necessary paperwork, a large carrier will take around 30 hours to unload, with smaller carriers taking correspondingly less time.
How will LNG be loaded onto trucks or rail tank cars?
LNG tank trucks operate all over Europe and increasingly also in Germany, so that employees will have plenty of experience with the loading of LNG onto such trucks.
Trained operators will be responsible for truck loading. Together with the truck driver they connect the hoses. The loading itself will be done by pumping LNG from the tank to the truck: this is a fully automated process with many safety precautions built into the system. The operator and the driver are always present near the filling station to supervise the loading. Once the truck is loaded, the operator and the truck driver will disconnect the hoses, print and accept the necessary paperwork and perform a last safety check before the truck leaves the terminal. Around 120 trucks will be loaded per week.
LNG transported by rail has advantages for some customers, e.g. a lower environmental impact compared to truck transport. With the option of railcar loading the terminal will already be future-proof. The railcar loading works in a similar way to the loading process for tank trucks. In the initial phase, up to 150 rail cars per week can be loaded at German LNG Terminal.
So no LNG is released?
No. During regular operation, LNG – and, after regasification, natural gas – is handled in a closed system at the terminal, i.e. from the LNG carrier to the LNG tanks and on through transport pipelines to the feed-in point into the natural gas grid. Or from the LNG tanks to the individual loading stations for trucks, railcars or bunker ships.
Even the so-called boil-off gas, which is produced within the terminal, is recondensed and fed back into the LNG stream. An additional flare would only be used for a short time during the commissioning of the terminal and as an emergency measure in the event of unusual incidents. The German LNG Terminal can therefore be classified as an emission-free terminal.
And how is the LNG regasified?
The LNG is stored at temperatures of around -162° C and at atmospheric pressure. Under these conditions, LNG is a boiling liquid.
Heat is required to carry out regasification. Brunsbüttel offers an unbeatable advantage here: heating water from the nearby industrial area, ChemCoast Park, can be used for the LNG vaporiser system with hot water on one side and cold LNG on the other. The result is reheated LNG, which can now be fed into the gas transport network in a gaseous state.
The water used to heat the LNG does not come into contact with the LNG and leaves the site as clean as it entered, but considerably colder. This cold water can then be used as cooling water in the neighbouring industrial area, creating a perfect synergy.
What safety precautions are taken at the terminal? How is the staff protected?
All parties involved take the safety of staff, surrounding communities, residential areas and industrial facilities very seriously. This is the top priority. The LNG terminal in Brunsbüttel is being built in accordance with the latest safety technology and designed to minimise the impact of an accident scenario on the surrounding area. This means that the terminal is being built according to the safety-first principle. As with any terminal, site-specific emergency plans are being developed in close cooperation with third-party emergency services such as the fire brigade.
Operators and all other employees will be equipped with all appropriate protective clothing and equipment and will receive regular internal training from relevant external experts in emergency response and the latest safety measures.
Nothing is left to chance at the terminal. All systems are extensively tested before they are put into operation. In addition, all systems have built-in redundancy: if one part fails, a backup is always available. All processes at the terminal are documented in various specific manuals and are binding for staff and all activities. Appropriate management systems, based on the latest findings and technological developments, also continuously monitor safety. In addition, internal and external audit programmes monitor all necessary improvements.
However, the highest priority is to prevent any accidents.
What would be the effect of a gas leakage at the terminal?
The basic design, operation and maintenance structure of the terminal prevents gas from escaping. However, if a gas leak does occur, it is detected immediately, as there are several monitoring systems, gas detection systems and cameras throughout the terminal to alert operators.
The terminal is designed as to automatically stop all operations, with emergency shut-down valves positioned to block in the leaking system and thereby minimising the potential leak. An in-built system will direct any leaked LNG to a location where it can safely evaporate.
In summary, well-trained personnel and a terminal-specific safety design minimise the risk and reduce the consequences should an accident actually occur.
What is being done in terms of environmental and climate protection?
A series of measures are planned to minimise waste disposal, reuse materials and resources, and save energy wherever possible. The gas molecules entering the terminal are all contained in a closed system. This means that all incoming gas is temporarily stored before it enters product delivery systems such as pipelines, tankers or ships.
State-of-the-art technologies are used and the terminal is designed in line with best practices.