shell-gasification technology.pdf
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Shell Global Solutions
Shell Gasification Technology:
Generating Profit from the Bottom of the
Barrel
Joachim Wolff
Jack Jones
Shell Global Solutions International BV
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2Shell Global Solutions
Presentation overview
Challenges facing refiners
How gasification can help Suitable feedstocks
Technical insights
Typical process schemes
Project lists and case studies
Conclusions
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3Shell Global Solutions
Shell Global Solutions
Combining the operating experience of over 4500 staffwith
proven implementation skills and advanced technologies
Diverse cultures andnationalities
Over 50 years ofimplementing businessand engineering solutions
Continued investment in
innovation
Houston
Chester
Hamburg
Amsterdam/
The Hague
Rouen
Kuala Lumpur
Beijing
Tokyo
Buenos Aires
Moscow
Dubai
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4Shell Global Solutions
Challenges for the oil-refining industryRefiners are looking for solutions that will help them to
Reduce plant emissions
Meet environmental legislation Cut deeper into the barrel
Increase their hydrogen supplies.
It is vital that they develop cost-effective strategies for
Disposing of their crude oil residues
Use own feedstocks like petcoke
Increasing the yield of lighter, high-value products(low sulphur, low aromatics).
Gasification may be able to help refiners rise to these challenges
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5Shell Global Solutions
What is gasification?
Gasification converts hydrocarbon feedstocks
into syngas
It involves partial combustion
- 2(CH2) + O22CO + 2H2
Syngas is a mixture of carbon monoxide and
hydrogen Syngas can be
- Converted into products such as ammonia,
methanol, oxo-chemicals, synthetic hydrocarbons
or hydrogen
- Used as a fuel
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6Shell Global Solutions
Shell gasification feedstocks
The feed to the gasifier can be
Solid Shell Coal GasificationProcess (SCGP) including coal,
lignite and petroleum coke
Liquid Shell Gasification Process(SGP) including oil distillates,
residues and natural gas
Converting a wide range of feedstocks into hydrogen and power
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SGP compared with SCGP key features
Technologies can be tuned to a variety of refinery
configurations
SGP SCGP
Typical feedstock
Operating temperature
Operating pressure
Slagging condition
Gasifier
Boiler
Vacuum residue
1320C
3565 bar
Non-slagging
Refractory-lined
Fired-tube
Petroleum coke
>1500C
2545 bar
Slagging
Membrane wall
Water tube
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8Shell Global Solutions
Refinery residue options
Helping refiners to convert the bottom of the barrel
Distillation andvacuum
distillation
Residue
hydroprocessin
g
(Deep) thermalcracking
Delayed coking
Solvent
deasphalting
Vacuum distillation
(and deasphalting)
Vacuum distillation(and deasphalting)
Crude oil
Petroleum
coke
Heavy
viscous
residue
SG
P
SCG
P
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9Shell Global Solutions
Why gasification for refineries?
Gasification offers attractive options for refiners
Feed
*
Gasification*
and
Gas treating*
Oxygen
Steam
Clean
syngas
(CO + H2)
Hydrogen Chemicals, ammonia,
methanol
Clean syngas for
refinery use
Boilers
Furnaces
Synthesis ofHydrocarbons*
Liquid
transportation fuels
Power generation
IGCC
Electricity
Steam
Sulphur*
* Shell Technology Application
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10Shell Global Solutions
SGP
Typical process scheme
Key details Recent projects
Pernis case study
Converting the bottom of the barrel into
valuable products
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11Shell Global Solutions
SGP residue gasification
Lower availability compared to Partial Oxidation using
NG
SGP co-annular burner for viscous feed with high ash
Stable operating condition key for reliability ( minimal
external disruptions like blackout, off take, O2, steam)
SGP: fully automated start up, normal ops, shut down
SGP: unique SARU design, does not affect availability
Refractory (& other equipment) maintenance cycle
matches well with refinery shutdown
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Elementary analysis
C
H
S
N
O
Ash
Total
Vanadium
Nickel
Sodium
Viscosity (100oC)
Feedstock type UnitsVisbreaker
residue
Butane
asphalt
%wt 85.27 84.37
%wt
%wt
%wt
%wt
%wt
%wt
ppm wt
ppm wt
ppm wt
cSt
10.08
4.00
0.30
0.20
0.15
100
270700
120
30
10,000
9.67
5.01
0.52
0.23
0.20
100
800
200
30
9.17 107
SGP feedstock flexibility
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SGP can process a wide range of feedstocks
H2
CO
CO2
CH4
N2
Ar
H2S
COS
Total
HHV
LHV
Feedstock type UnitsRaw gas from
SGP unit
Clean gas after
desulphurisation
%vol 49.62 50.04
%vol
%vol
%vol
%vol
%vol
%vol
%vol
MJ/Nm3
MJ/Nm3
2.84
0.30
0.60
0.80
0.76
0.03
100
12.33
11.42
2.82
0.30
0.60
0.81
5 to 20 ppm
5 to 20 ppm
100
12.23
11.33
%vol 45.05 45.43
SGP feedstock flexibility
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14Shell Global Solutions
Typical SGP process scheme
Gasification
The feedstock
is converted
to syngas
High-pressuresteam is generated
from the hot syngas
Syngas effluent
coolerResidual carbon and
ash are removedfrom the syngas
Carbon
removal
Residue
Oxygen
Steam
Raw syngas Raw syngas
High-pressure steam
Clean syngas
Ash and residual carbon
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SGP key details
Requires an integrated approach
Can process virtually all refinery oilresidues
Enables refiners to use heavier
crudes Can help refiners enhance their
yield of high-value products
Tailor-made solutions are integrated into existing complexes
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Case study: Pernis refinery
Pernis business situation
- Required a performance step change Solution integrating the SGP
Resultant syngas is used to
- Produce hydrogen for the hydrocracker- Fuel the IGCC plant
Business benefits
Benefiting from integrating a polygeneration plant into the
refinery
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Shell Gasification Process & Refineries - Gasification
Hydrogen
Residue disposal
Hydrogen
Power
3 * 550 t/dAsphaltLotos, Gdansk
Hydrogen
Residue disposal
Hydrogen
(Power)
3 * 1150 t/dAsphaltConocoPhillips
,
Wilhelmshave
n
HydrogenHydrogen
(Power)
3 * 1200 t/dAsphaltFujian
Refinery
Ethylene
Project
Hydrogen
Steam for SAGD
Hydrogen
Fuel gas
(Power)
4 * 1033 t/dAsphaltOpti Canada
Residue disposalSyngas
(Hydrogen)
2 * 600 t/dVFCRAgipSannazzaro
Emissions
Hydrogen
Heavier crude oil
Hydrogen
(Power)
3 * 550 t/dHYCON+VFC
R
Shell Pernis
Driver
Business Case
ProductCapacityFeedstockPlant Site
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18Shell Global Solutions
Shell Gasification Process & Refineries Projects
Full refinery integrationImport of cheap crude
oil
Lotos, Gdansk
Full refinery integrationCapacity increase of the
refinery
Conoco Phillips,
Wilhelmshaven
Full integration betweenrefinery, gasification
and chemical complex
Chemical site;Very high pressure
steam (121 bara; 1755
psia)
Fujian RefineryEthylene Project
Full integration to
upgrader and SAGD
Syngas substitutes
natural gas
Opti Canada
Limited integration
(low pressure BFW,cooling water etc.)
Superheated steam ex
Syngas Cooler
Agip Sannazzaro
Full refinery integrationGasifier fuel
Gas turbine fuel
Shell Pernis
IntegrationSpecial aspectsPlant Site
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19Shell Global Solutions
Owner Location Feedstock Input, t/dSyngas,
106Nm3/dEnd product
Startup
date
Shell Nederland
Raffinaderij
Lanzhou
Chemical
Chemopetrol
revamp
Lucky Goldstar
Eni SpA
Opti/Nexen
Fujian ethylene
project
Rotterdam,
Netherlands
Lanzhou, China
Litvinov,
Czech Republic
Naju, Korea
Sannazzaro,
Italy
Alberta, Canada
Fujian, China
Cracked
residue
Vacuum
reside
Cracked
residue
Vacuum
residue
Cracked
residue
Asphalt
Asphalt
1650
700
1250
225
1200
3100
2180
4.7
2.1
3.6
0.7
3.4
7.5
5.7
Hydrogen/
power/steam
Chemicals
Chemicals/
hydrogen
Chemicals
Hydrogen/
power
Steam/
hydrogen
Hydrogen/
power
1997
1998
2001
2001
2006
2007
2008
Recent SGP projects
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SCGP
Typical process scheme
Key details Recent projects
Buggenum case study
For sustainable utilisation of petroleum
coke and other solid feedstocks
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21Shell Global Solutions
Typical SCGP process scheme
Coal
Milling/drying
Coal feeding
Oxygen
Quench gas
900C
>1500C
Dry solids
removalWet scrubbing Gas treating
Clean syngas
Sulphur
Water
treatmentFly-ash system
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22Shell Global Solutions
SCGP petcoke gasification
Excellent carbon conversion
Fuel
Water in feed wt%, a.r. 1.5
C
HO
N
S
Ash
LHV
Oxygen, 95.5% O2
Steam
Crude gas, dry
H2
CO
CO2
CO+H2Gasifier outlet temperature
Cold gas efficiency
wt%, dry
wt%, drywt%, dry
wt%, dry
wt%, dry
wt%, dry
MJ/kg, dry
kg/kg, dry
vol%, dry
m3/kg feed, dryC
%, HHV based
kg/kg, dry
vol%, dry
vol%, dry
88.3
4.8
0
2.9
3.7
0.4
35.7
1.04
0.23
30 %
63 %
2 %
2.341600
82.7
Petroleum coke,
dried
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SCGP key details
Versatile process converts coal and coke
into syngas
Syngas can be used for
- Chemical manufacturing
- Hydrogen production
- Production of synthetic hydrocarbons- Power generation
Features
- Low oxygen consumption
- High efficiency, reliability and availability
- Meets environmental legislation
Strong environmental credentials
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Case study: Buggenum power plant
SCGP produces fuel for commercial
power plant
Features
- High efficiency
-High availability
- Robust technology
- Feedback loop improves SCGP design
- 20% biomass co-feed
Successful operations prove the SCGPIGCC combination
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SCGP Water Quench A change for the
betterAllow gasification of coals, which cannot be
processed with a syngas cooler due to fouling
- high sodium/chlorine content
Reduce CAPEX
- no Syngas cooler
- no candle filter
- simpler shift line-up
Improve integration with a downstream shift for
chemical applications
- water is added directly to the syngas, not via a saturatorcycle in the shift section
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but stick to key advantages of SCGP
Membrane wall, heat protection of the gasifier via
water cooling and steam production
Separate gas outlet & slag outlet for processing
high ash coals
Multiple burners allowing large capacities and anefficient slag removal with only a small amount of
fines
Proven scale-up rules for gasifier
Dry flyash removal (as much as possible), limiting
the amount of black/grey wastewater/slurry
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Water spray quench in wide,
empty vessel below the Gas
Reversal Chamber (GRC)
Full scale nozzle test
performed under pressure
CFD modeling based on
actual quench nozzle design
Water Quench
Burners
Quench
SGCGasifier
Duct
Slagbath
Quench
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General IGCC SGC vs WQ
Disadvantages Water Quench (WQ) for IGCC
applicationsIGCC efficiency 2-4%-points less with WQ SCGP
and no Carbon Capture System
More Low Temperature syngas cooling (multiple
KT-reboilers)
More water handling (with absence Dry Flyash
Removal)
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29Shell Global Solutions
Conclusions
SGP and SCGP can help refiners to
- Produce steam, hydrogen and power
- Meet stringent product specifications
- Increase feedstock flexibility
Flexibility of integration into refineries
has been demonstrated
Potentially highly profitable
investments
Strong track record and proven technology
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Questions / Contact
Liquid Refinery Residue Gasif ication - SGP
Jack M. Jones, Market DevelopmentShell Global Solutions (US) Inc.
Work: +1-281-544 6342Mobi le: +1-281-468 8677
Email: jack.jones@shell.com
Solid Gasif ication - SCGPKevin J. Lanier, Business Development ManagerClean Coal Energy, Shell US Gas & Power
Work: +1 713 241 4381
Mobi le: +1 832 661 9579
Email: kevin.lanier@shell.com
www.shell.com/globalsolutions
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