Shell-Gasification technology.pdf

7/29/2019 Shell-Gasification technology.pdf

1/30

Shell Global Solutions

Shell Gasification Technology:

Generating Profit from the Bottom of the

Barrel

Joachim Wolff

Jack Jones

Shell Global Solutions International BV


2/30

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


3/30


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


4/30


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


5/30


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


6/30


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


7/30


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


8/30


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


9/30


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


10/30


SGP

Typical process scheme

Key details Recent projects

Pernis case study

Converting the bottom of the barrel into

valuable products


11/30


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


12/30


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


13/30


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


14/30


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


15/30


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


16/30


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


17/30


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


18/30


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


19/30


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


20/30


SCGP

Typical process scheme

Key details Recent projects

Buggenum case study

For sustainable utilisation of petroleum

coke and other solid feedstocks


21/30


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


22/30


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


23/30


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


24/30


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


25/30


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


26/30


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


27/30


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


28/30


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)


29/30


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


30/30


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: [email protected]

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: [email protected]

www.shell.com/globalsolutions

World wide presence of Shell Global Solutions

Documents

Shell-Gasification technology.pdf