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Shell Global Solutions
Shell Global Solutions
Overview of Shell Global Solutions’ Worldwide Gasification Developments
Piet Zuideveld
Shell Global Solutions International BV, Amsterdam, the Netherlands
Gasification Technologies 2003San Francisco,
October 12–15, 2003
Shell Global Solutions 2
SGP/SCGP inputs and outputsFeedstock End product
SGP
or
SCGP
Coal
Petroleum coke
Heavy oil residues
Asphaltenes
Natural gas
(Biomass)
Chemicals
Hydrogen
Power
Clean fuels
(Carbon dioxide)
Oxo-alcohols
Methanol
Ammonia
Urea
Shell Global Solutions 5
SGP projects – recently completed, in progress or planned
2006Hydrogen/power4.71600AsphaltGdansk, PolandRafineriaGdańska SA
2006Steam/hydrogen7.53100AsphaltAlberta, CanadaOpti/Nexen
2005Hydrogen/power
3.41200Cracked residue
Sannazzaro, ItalyEni SpA
2001Chemicals0.7225Vacuum residue
Naju, KoreaLucky Goldstar
2001Chemicals/hydrogen
3.61250Cracked residue
Litvinov, Czech Republic
Chemopetrolrevamp
1998Chemicals2.1700Vacuum residue
Lanzhou, People�s Republic of China
LanzhouChemical
1997Hydrogen/power/steam
4.71650Cracked residue
Rotterdam, Netherlands
Shell Nederland Raffinaderij
Start-up date
End productSyngas output(106Nm3/d)
Input, t/dFeedstockLocationOwner
Shell Global Solutions 6
Challenges for the oil-refining industry
• Increase the production of lighter, higher-value products
• Improve competitiveness
• Reduce export of high-sulphur fuel
• Reduce refinery emissions
• Produce cleaner products
• Meet future environmental legislation
Shell Global Solutions 7
Shell Pernis gasification project
• Cost-effective hydrogen production
• Alternative outlet for residue
• Increased feedstock flexibility
• Investment largely independent of residue quality
Shell Global Solutions 8
Pernis – SGP
H2Sremoval
COshift
CO2removal
Heatrecovery
Gasturbine
Residue
H2S
Methanation
HP steam
MP/LP steam H2
Electric power
Steam cycle
Electric power
CO2
SGP
Refinery
O2
ASU
Shell Global Solutions 9
Sannazzaro – SGP
Syngastreating
Sootfiltration
Residue
H2SHydrogenrecovery
ASU
Flue gas
SGP
Refinery
O2
H2
Syngas to power plantturbines
SuperheatedHP steam
Ni/V ashSoot coke
combustion
Shell Global Solutions 10
Gdańska – SGP
H2Sremoval
COshift
CO2removal
Heatrecovery
Gasturbine
H2S Methanation
HP steam
H2
ASU
Steam cycle
Electricpower
CO2
SGP
Refinery
Vacuum residue
HCU
O2
Deasphalting
Asphaltenes
H2Electric power
DAO
Shell Global Solutions 11
OPTI/Nexen Long Lake project
Athabascaoil sands
SAGD
OrCrudeTM
process
Hydro-cracking
Bitumen
Sour synthetic crude
Premium synthetic crude
SGP Power
Hydrogen
Fuel gas
Asphaltene
Shell Global Solutions 15
Nuon – coal gasificationPlant owner Nuon
Location Buggenum, the Netherlands
Coal gasification 2000 t/d
Syngas production 4.0 x 106 Nm3/d
End product 253 MWe
Successful operation
Test run with biomass as feedstock
Technical and operational feedback for future projects
Shell Global Solutions 16
SCGP projects planned for the People’s Republic of China
2006Chemicals3.42000CoalQujing, Yunnan
YunzhanhuaChemicals
2006Chemicals3.42000CoalAnning, Yunnan
YuntianhuaChemicals
2006Chemicals1.51000CoalDalian, Liaoning
DahuaChemical
2005Chemicals3.42000CoalAnqing, Anhui
Sinopec
2005Chemicals3.42000CoalZhijiang, Hubei
Sinopec
2005Chemicals3.42000CoalYueyang, Hunan
Sinopec-Shell
2005Chemicals2.11200CoalLiuzhou, Guangxi
LiuzhouChemical
2004Chemicals1.3900CoalYingcheng, Hubei
ShuanghuanChemical
Start-up date
End product
Syngas output(106 Nm3/d)
Input, t/dFeedstockLocationOwner
Shell Global Solutions 17
Typical scheme SCGP for chemicals productionCrude syngas
ASU SCGPShift,
gas treatingAmmoniasynthesis
Coal Urea plant
H2O2
Shell Global Solutions 18
Yingcheng coal gasification projectPlant owner Shuanghuan Chemical Group
Location Yingcheng, Hubei
Coal gasification 900 t/d
Syngas production 1.3 x 106 Nm3/d
End product Fertiliser
Project engineering and construction China Wuhan Chemical Engineering Company
Status Gasifier delivered
Ready for start-up Second half 2004
Shell Global Solutions 19
Dongting coal gasification projectPlant owner Sinopec–Shell
Location Yueyang, Hunan
Coal gasification 2000 t/d
Syngas production 3.4 x 106 Nm3/d
End-product Fertiliser
Project engineering and construction Sinopec Lanzhou Design Institute
Status Implementation started
Ready for start-up End 2005
Shell Global Solutions 20
Coal gasification projects in China
Produce low-cost feedstock (syngas) to
• Reduce cost of fertiliser manufacture
• Improve competitiveness with imported fertiliser
Invest in cleaner fuel technology to replace existing, older and environmentally unfriendly facilities
Shell Global Solutions 21
Landed cost of urea in China – existing plants
Chinaexisting naphtha
$300/t
Chinaretrofit naphtha to coal
$25/t
Middle Eastgreenfield natural gas
$0.5/MMBtu
250
200
150
100
50
0
Import price range
Coalgasification
Transport costs
Feedstock costs
Operating costs (excluding feedstock)
Capital charge
$/t
Shell Global Solutions 22
Gasification of waste coal
Coal-to-clean fuels and power co-productionOwner WMPI
Location Gilberton, Pennsylvania, USA
Coal gasification 4000 t/d anthracite culm (40%)
Syngas production 6.0 x106 Nm3/d
Power production 40 MWe
The first commercial-scale waste coal gasification project in the USA
Shell Global Solutions 24
SMDS – process scheme
ASU
Natural gas
CO + 2H2
Synthesis
– CH2 –
Hydrogenation
Middle distillates
Hydrocracking
CH4
Lube oil feedstock
SGPSolvents
Waxes
O2
Shell Global Solutions 25
Shell gas-to-liquids technologyFirst generation – Bintulu, Malaysia
Feedstock 100 MMscf/d
Syngas production 12,500 bbl/d
Second generation
Feedstock 600 MMscf/d
Syngas production 70,000 bbl/d
Shell Global Solutions 26
Features of SGP and SCGP technologies:
• Strong environmental credentials• Efficient and reliable operation• Wide-ranging feed flexibility• New feedstock options
• Biomass• Waste coal• Asphaltenes from tar sands
• A large variety of syngas outlets • Cost-effective solution
The demand for these Shell technologies is increasing