Shell Gasification Technology

Shell Global Solutions

Shell Gasification Technology:

Generating Profit from the Bottom of the

Barrel

Joachim Wolff

Jack Jones

Shell Global Solutions International BV

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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Challenges for the oil-refining industry

Refiners 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


What is gasification?

• Gasification converts hydrocarbon feedstocks

into syngas

• It involves partial combustion

- 2(CH2) + O2 2CO + 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


Shell gasification feedstocks

The feed to the gasifier can be

• Solid – Shell Coal Gasification

Process (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


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

1320°C

35–65 bar

Non-slagging

Refractory-lined

Fired-tube

Petroleum coke

>1500°C

25–45 bar

Slagging

Membrane wall

Water tube


Refinery residue options

Helping refiners to convert the bottom of the barrel

Distillation and

vacuum

distillation

Residue

hydroprocessin

g

(Deep) thermal

cracking

Delayed coking

Solvent

deasphalting

Vacuum distillation

(and deasphalting)

Vacuum distillation

(and deasphalting)Crude oil

Petroleum

coke

Heavy

viscous

residue

SG

P

SCG

P


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 of

Hydrocarbons*

Liquid

transportation fuels

Power generation

IGCC

Electricity

Steam

Sulphur*

* Shell Technology Application


SGP

• Typical process scheme

• Key details

• Recent projects

• Pernis case study

Converting the bottom of the barrel into

valuable products


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


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

270–700

120

30

10,000

9.67

5.01

0.52

0.23

0.20

100

800

200

30

9.17 107

SGP – feedstock flexibility


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


Typical SGP process scheme

Gasification

The feedstock

is converted

to syngas

High-pressure

steam is generated

from the hot syngas

Syngas effluent

coolerResidual carbon and

ash are removed

from the syngas

Carbon

removal

Residue

Oxygen

Steam

Raw syngas Raw syngas

High-pressure steam

Clean syngas

Ash and residual carbon


SGP – key details

• Requires an integrated approach

• Can process virtually all refinery oil

residues

• Enables refiners to use heavier

crudes

• Can help refiners enhance their

yield of high-value products

Tailor-made solutions are integrated into existing complexes


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


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/dVFCRAgip

Sannazzaro

Emissions

Hydrogen

Heavier crude oil

Hydrogen

(Power)

3 * 550 t/dHYCON+VFC

R

Shell Pernis

Driver –

Business Case

ProductCapacityFeedstockPlant Site


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 between

refinery, gasification

and chemical complex

Chemical site;

Very high pressure

steam (121 bara; 1755

psia)

Fujian Refinery

Ethylene 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


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


SCGP

• Typical process scheme

• Key details

• Recent projects

• Buggenum case study

For sustainable utilisation of petroleum

coke and other solid feedstocks


Typical SCGP process scheme

Coal

Milling/drying

Coal feeding

Oxygen

Quench gas

900°C

>1500°C

Dry solids

removalWet scrubbing Gas treating

Clean syngas

Sulphur

Water

treatmentFly-ash system


SCGP – petcoke gasification

Excellent carbon conversion

Fuel

Water in feed wt%, a.r. 1.5

C

H

O

N

S

Ash

LHV

Oxygen, 95.5% O2

Steam

Crude gas, dry

H2

CO

CO2

CO+H2

Gasifier outlet temperature

Cold gas efficiency

wt%, dry

wt%, dry

wt%, dry

wt%, dry

wt%, dry

wt%, dry

MJ/kg, dry

kg/kg, dry

vol%, dry

m3/kg feed, dry

° C

%, 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 %

2.34

1600

82.7

Petroleum coke,

dried


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


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 SCGP–IGCC combination


SCGP Water Quench – A change for the

better…Allow 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 saturator

cycle in the shift section


…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 an

efficient 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


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

Quenc

h


General IGCC SGC vs WQ

Disadvantages Water Quench (WQ) for IGCC

applications

IGCC 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)


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


Questions / Contact

Liquid Refinery Residue Gasification - SGP

Jack M. Jones, Market DevelopmentShell Global Solutions (US) Inc.

Work: +1-281-544 6342

Mobile: +1-281-468 8677

Email: [email protected]

Solid Gasification - SCGP

Kevin J. Lanier, Business Development ManagerClean Coal Energy, Shell US Gas & Power

Work: +1 713 241 4381

Mobile: +1 832 661 9579

Email: [email protected]

www.shell.com/globalsolutions

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