Upload
phamphuc
View
387
Download
11
Embed Size (px)
Citation preview
The Shell GTL Process:
Towards a World Scale Project in Qatar: the Pearl Project
Arend Hoek
Shell Global Solutions International, Amsterdam
DGMK-Conference “Synthesis Gas Chemistry”October 4-6, 2006, Dresden
2
Contents
Introduction
F-T catalysis
Hydroprocessing
Bintulu learning
Evolution
The Pearl project (Qatar)
Conclusions
3
What is Gas To Liquids (GTL)?
LPG GTL Naphtha
GTL Gas Oil
n-ParaffinsGTL Base Oils
RawNatural
GasFischer Tropsch
SynthesisProductsWork-up
CO + 2H2 -CH2-
CH SyngasManufacturing
4 SyngasManufacturing
O 2
GasProcessing
Syngas
Methane Oxygen+ Hydrogen Carbon monoxid
e
WaterFischer-Tropsch distillates+ +
Catalyst
Condensate
LPGEthane
Sulphur
Conversion of natural gas to clean, high quality fuels & products via the Fischer Tropsch process
Bintulu SMDS
4
SGP Upscaling: Experience + Modelling
Upscaling based on design criteria used for 50 years
Upscaling evaluated by fluid flow and reaction modelling
• High quality Syngas:H2/CO 1.8 mol/molCH4 slip < 0.5 vol % dryCO2 content ~ 2 vol % dryCarbon to CO ~94 vol %
• Modelling tested against Bintulu
• Sufficient reactant mixing time
• Minimum temperature fluctuations near the refractory wall and no hot spots
• Dimensioning to achieve long refractory lifetime
• Burner front design checked by finite element stress analysis
5
Technical challenges
Carbon efficiency- selectivity of catalysts
Capex- process intensity
Availability- catalyst stability- robustness
Materials- resistance against corrosion, erosion, metal dusting
A GTL plant is mainly a UTILITY complex- efficient use of steam
6
Advantages
All in house technology
No boundary issues between process step
In house catalyst manufacturing
No secrecy issues
7
Contents
Introduction
F-T catalysis
Hydroprocessing
Bintulu learning
Evolution
The Pearl project (Qatar)
Conclusions
8
Fischer-Tropsch synthesis
Promoted Co catalyst
Fixed bed multi-tubular reactors
9
CO
CH3
C2H5
CnH2n+1
CH4
C2H6
CnH2n+2
= probability of chain growth
1 - = probability of chain termination
n-1
Cn =n
1 − α
1 − α
(1 − α)α
(1 − α)
α
α
α
(1 − α)α
α
1−α
αα
(1 − α)
1 − α
Probability
Schulz Schulz -- FloryFlory FT KineticsFT Kinetics
10
0.75 0.80 0.85 0.90 0.950
20
40
60
80
100%m
Probability of chain growth
New catalystsFe (classic)
Co (classic)
C 20+
Wax
C12-19
Gasoil
C
3-4 LPG
1-2 Fuel gas
C5-12 Tops/Naphtha
C
The Relevance of Catalyst Selectivity
Wax
Producewax
Crack back
11
Preferred process lay-out
Producing max. heavy wax (max. chain growth probability leads to:
High efficiency (liquid yield)
High gas oil and base oil yield
High degree of isomerisation of gas oil and base oil
12
Fischer-Tropsch catalyst R&D
80
85
90
95
100
0 50 100 150 250 300 350
relative reactor productivity
Liqu
id s
elec
tivity
, %w
200
Design pointPearl GTL
200
Bintuludesign
capex down
FutureGTL?
2nd gen.Pearl GTL
BintuluDBN
efficiency up
1st gen.
R&D cat.
2nd gen. Bintulu
13
Shell FT: Heavy Paraffins Synthesis (HPS) Configuration: Multi-tubular, water/steam cooled
Performance: Automated, fast catalyst loading, In situ catalyst regeneration
High productivity: 7,000 - 9,000 bbl/d per reactor
Liquid Selectivity (CO to liq.): >90%
Easy operation, including start-up, shut-down and transients
Heavy product
Synthesis gas
Light Product
CoolingSteam
Water
14
Contents
Introduction
F-T catalysis
Hydroprocessing
Bintulu learning
Evolution
The Pearl project (Qatar)
Conclusions
15
Hydroprocessing step
Dedicated catalyst and conditions
Hydrogenation of oxygenates and olefins
Hydrocracking/isomerisation of paraffins
Bifunctional catalyst: noble metal and acid function
Low gas make, product flexibility
7.5 years in service
16
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500 600 700 800
atm.bp, °C
reco
very
, %w
total feed
total product
TBP-GLC of hydroprocessing feed and prod.
17
Screening of hydroconversion catalysts
0
10
20
30
40
50
60
70
C1-C4 sel C5-150 sel 150-200 sel 200-370 sel
sele
ctiv
ity, %
w
catalyst 1catalyst 2catalyst 3catalyst 4catalyst 5
18
Contents
Introduction
F-T catalysis
Hydroprocessing
Bintulu learning
Evolution
The Pearl project (Qatar)
Conclusions
19
SARAWAK
BintuluShell MDS Plant
SABAH
PENINSULARMALAYSIA
Kuala Lumpur
Head Office
INVESTMENTInitial capital investmentof US$850 million2003 debotteneckinginvestment of US$50 million
STRUCTUREShell MDS (Malaysia) Sdn. Bhd.Shareholders: Shell, Mitsubishi, Petronas, Sarawak State
SCOPEConversion of 110 mmscf/d NG into 575 kt/a (14,700 b/d) of GTL productsProduces clean fuels and specialityproductsWorldwide marketing
Shell MDS in Malaysia
20
SMDS SMDS -- BintuluBintulu -- schemescheme
O2O2
NaturalGas
100 MMSCF/d
CO + 2H2
SynthesisSynthesis
H2O
– CH2 –
HydrogenationHydrogenation
14,700 bbl/d
Middle DistillatesHydrocrackingHydrocracking
ASUASU
SGPSGP HPSHPS
HPCHPC
CH4
Lube oil feedstock
Syngasmanufacture
Syngasmanufacture
Solvents
Waxes
21
Shell MDS Plant in Bintulu
Bintulu SMDS:One train of 14,700 b/d
Malaysia LNG: 6 trains, total of 16.5 mln tpa
22
Boilers
HMU
SGP
HPS
HPC/HGU/Distillation
Wax plant/Specialties
ASU
Compressors
Air coolers
Waste water plant
SMDS SMDS -- BintuluBintulu
23
• SMDS research started 1973
• Pilot plant 1983
• SMDS-M project approved 1989
• SMDS-M start-up 1993
• ASU explosion: ingress of combustibles 1997ex forest fires
• Restart 2000
• Debottlenecking 2003
• 1 year of operation without complex trip 2004
SMDS Bintulu story
24
90919293949596979899
100
1994 1995 1996 1997 2001 2002Air Separation UnitShell Gasification Process
FT Synthesis
Bintulu: Invaluable learning for Plant reliability
Huge challenges at start-up
“You don’t know what you don’t know”
Has proven catalyst & reactor systems, procedures for start-up, shut-down, regeneration, emergencies and operability of complex integrated system
Plant Reliability (% on-stream)
2003 2004
25
75
100
2001 2002 Pre-DBN(2003)
Post-DBN **
(2003)
100
energy consumed/tonneproduced
9693
88
steady state (no statutory shutdown)
Overall 18% improvement in NG efficiency
Achieved by improved utilities integration
2004
85
Continuous Improvement in S-MDS Bintulu Natural Gas Efficiency
Proj. 2005
~84
80
85
90
95
(relative scale)
** DBN = Debottlenecking
26
LPG(0 – 5%)
GTL Products, yields and applicationsCracker complex
Shell Pura: Thailand
Shell V-Power: Germany
Shell Helix Ultra: Global
GTL Naphtha
(30 – 40%)GTL Gasoil(40 – 70%)
GTL Base Oils
(0 – 30%)
GTL plant (Shell Bintulu)
Maximum value from GTL products is derived from an understanding of the fully integrated value chain
Patent portfolio covering GTL products in high-value applications
Marketing GTL products for 10 years
Plastic products
27
Launch of Shell-VW GTL Test : Berlin, 6th May 2003
Synthetic diesel based on SMDS Gasoil - Bintulu
28
GTL Fuel can improve air quality in Mega Cities
Dieselisation will improve the CO2 emissions of the transport sector.
Reducing other diesel related emissions will be a key enabler.
Options available
Reduced sulphur content in diesel
Improved engine management systems
Exhaust after treatment (particle filter or chemical treatment)
Introduction of GTL fuel
Growing importance of clean public transport
Nitrogen Oxides - 6%Particulates (PM10) - 20%Hydrocarbon - 63%CarbonMonoxides - 91%
*Reference Fuel: Diesel < 10ppm sulphurSource: VW
Emission benefits* of Shell GTL fuel
Based on trial result of 100% Shell GTL Fuel in 25 Volkswagen Golfs without any vehicle modifications, Berlin, 2003.
29
Shell worked with Audi to build the first diesel racing car winning the Le Mans 24 hour race. The Audi R-10 is fueled by a diesel containing GTL Fuel, based on Shell V-Power technology.
Fuel and engine developments together deliver:Exceptional TorqueVery low noiseImproved fuel consumption
And…………GTL Fuel is by no means slow
Audi R-10 during its maiden victory at the 12 hours of Sebring
30
with the Courtesy of Volkswagen
31
Contents
Introduction
F-T catalysis
Hydroprocessing
Bintulu learning
Evolution
The Pearl project (Qatar)
Conclusions
32 1990 2000
Spec
ific
Cap
ex, a
.u.
Economiesof Scale
Bintulu
2nd generationcatalyst
GTL Plant Costs
Gas to Liquids coming of age
3rd generation catalyst
2010 2020
Brown FieldExpansion
Two trainsStart-up Year
012345678
1960 1970 1980 1990 2000 2010
Trai
n ca
paci
tyM
tpaExisting
ConstructionProposed
Spec
ific
cost
, a.u
.
compare: LNG
(12,500 bpd)
(140,000 bpd)
33
Contents
Introduction
F-T catalysis
Hydroprocessing
Bintulu learning
Evolution
The Pearl project (Qatar)
Conclusions
34
Qatar Shell GTL Project Overview
NORTH FIELD
Doha
Ras Laffan
EthanePropaneButaneCondens.Sulphur
C2/LPG Extr.Cond.Process.
Gas Treating
Sulphur Recov.NaphthaGasoiln-ParaffinsBaseOilsWater
GTLUtilitiesStorage
General Fac.
Two wellhead platforms
Two onshore phases
Two multiphasepipelines
Fully integrated project
Development Production Sharing Agreement (DPSA), 100% Shell
~1,600 MMscf/d well head gas
140,000 b/d GTL products
Two phases, start-up phase 1: 2009/2010
35
Tangible Progress in Qatar
Seismic800 km2 3 D seismics completed in 2003
Providing info for appraisal drilling and for subsurface modelling of allocated area
Appraisal Well DrillingFirst well spud on 14th February and completed31st August 2004
Second well spud on 4th September and completed 19th December 2004
Geotechnical Site InvestigationsFirst phase completed Dec.’03 – April ’04
36
Pearl GTL Project – Progress Continues…
2005: Front End Engineering Design (FEED) completedPermit to Construct grantedProject Management Contractor (PMC) appointedAll EPC contracts tenderedFT synthesis reactors orderedDevelopment drilling contract awarded
2006: Submission of Final Development PlanF-T catalyst production startedFinal project approvalsAward EPC contractsStart site activitiesIntense procurement activities
2002: Statement of Intent
2004: Development Production Sharing Agreement (DPSA)
2003: Heads of Agreement (HOA)
37
Tangible Progress: FEED and Contracting Activities
EPC Contracting:– Multiple contractor strategy– Several bids awarded (Sep. 2006)
Onshore FEED:
– Conducted by JGC, primarily in the London offices of MW Kellogg (joint venture of JGC & KBR), during March 2004 – May 2005
– Close to 500,000 man-hours
Offshore Front-End-Engineering-Design (FEED):
– Conducted in Shell offices, Aberdeen during March 2004 to February 2005
Investment Decision– July 2006
38
GeneralFacilities
SMDS capacity build-up configuration
Work-upincl HPC
ASUs SGPs HPS reactors
Modular sectionsC
onfig
urat
ion
for 7
0,00
0 bp
d
Single train Storage &Loading
CommonUtilities
Additional modules to build to capacity of 140,000 bbl/d
Work-upincl HPC
Single train
39
Watertreating
Utilities
Gas Processing GTL Process
ASUs
Storage
Pearl project (Qatar Shell GTL)
40
Type Quantity
Equipment 2,300 items
Equipment 100,000 tons
Piping 50,000 tons
Structural steel 30,000 tons
Concrete 200,000 m3
Cables 1,800 km
Insulation 700,000 m2
Control loops 3,500
1440 meters1610 meters
Onshore construction dimensions
41
Pearl will break many recordsThe world's largest capacity to produce premium quality base oils.
The worlds largest producer of GTL based normal paraffin and will be the worlds lowest cost normal paraffins producer.
The largest single train Hydrocracker in Shell and the worlds largest Hydrocracking capacity in one location.
The worlds largest ASU in terms of high purity Oxygen and the worlds largest overall Oxygen production on one location.
The worlds largest ever catalyst supply contract.
The worlds largest system for full recovery of industrial process water, achieving 'zero-liquid discharge‘.
One of the worlds largest and most advanced Fieldbus instrumentation and control systems.
One of the worlds most advanced multipurpose, multi plant dynamic process simulators.
The largest steam generation capacity of any hydrocarbon processing plant in the world (or indeed ... in the Petroleum Industry).
42
Project Implementation:
• Process technology• Utilities technology• Offsites technology• C, M, E, I
engineering• Process control• Rotating equipment• QA/QC• HSE management• Materials&Corrosion• Project engineering• Logistics• Value engineering• Contracting&Procur.• Commissioning& SU• Operations
GTL R&D:• Surface sciences• Adv. analytical tools• FT catalyst
development• Reactor engineering• CFD modelling• Syngas
development• Hydro conversion• Bench scale testing• Pilot plant testing• IP protection• Process modelling
GTL Challenges: ‘From Reservoir to Market’
Upstream:• Seismics• Geology• Petrophysics• Reservoir
engineering• Production
technology• Well engineering• Well testing• Offshore structures• Pipelines• Materials&Corrosion• Operations
Commercial etc:• Economics• Financing• Legal• Taxation• Authority
engineer.• Marketing• Trading• Shipping• Accounting• HR management• IT management• Traning&Devel.• Risk
management• Project
integration
.. excellence over huge span of skills
NaphthaLPG
Gasoil
LDFBaseoils
43
Contents
Introduction
F-T catalysis
Hydroprocessing
Bintulu learning
Evolution
The Pearl project (Qatar)
Conclusions
44
Why Gas to Liquids?
GTL Fuel has unique properties:
-Virtually free of sulphur and aromatics
-High cetane number
Energy security → Strategic diversification of energy supply
→ Biomass and Coal to Liquids
Environment → Trend towards cleaner fuels
Economic development → Remote gas reserves commercialisation
→ Most cost effective alternative fuel
→ Strategic diversification of gas market
45
Shell GTL Development
Laboratory1973
Pilot plant1983
Bintulu Malaysia14 700 b/d1993
World-scale plant: Shell Qatar GTL140 000 b/d2009
→ Integrated world scale Qatar project based on proven technology→ A platform for exciting new industry based on unique new products
Long lead times & entry hurdles characterise GTL development
46
The end
Thank you for your attention
47
Back-up slides
48
Unconstrained MarketSMDS75,000 bbl/day
Product carriers-spot/term
Distribution/Blending
600 MMSCF/D
LNG Plant~ 4 mtpa
RegasificationShipping ~ 3500 nm3 x 130,000 m3
600 MMSCF/D
Fixed Chain
GTL as Alternative to LNGGTL as Alternative to LNG
49
15 tcf gas over project life
LNG150 mln tpa
8%
Growth of GTL is not market constrained and complementary to pipelines and LNG
GTL product slate2,000 mln tpa
0.6%
Virtually
unrestricted
GTL Appeals to Gas Resource Holders
50
-30
-25
-20
-15
-10
-5
0
78 79 80 81 82 83 84 85 86 87Cetane number
CP
or C
FPP,
°C
Cloud
CFPP
changing process conditions
Cold flow properties of Shell GTL fuel (340°C endpoint)
51
0
0.2
0.4
0.6
0.8
1
1.2
0 20 40 60 80 100Shell GTL fuel content %
CO
g/k
m
CitroenXantia
M.BenzVWBora
POTENTIAL TO MEET REGULATIONS
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0 20 40 60 80 100Shell GTL fuel content %
PM g
/km
CitroenXantia
M.BenzVW BoraCitroenXantia
M.BenzVWBora
Euro III limit
Euro III limit
Euro IV limitEuro IV limit
52
Gas grows faster than oilGas grows faster than oil
mln boed
Gas
Gas for PowerGeneration
Oil
Gas growth driven by:
CCGT* economics and power liberalisationCustomer preference for clean fuelKyoto and CO2 constraints
0
20
40
60
80
100
120
1990 2000 20202010
Oil
& G
as d
eman
d
*CCGT = Combined cycle gas turbine
53
2000 million scf/d
20
1000
500
50
200
100
101000 2000 3000 4000 5000 km
Pipeline LNG
Quantity
Distance
Electricity
Chemicals
GtL
Gas Utilisation
54
Continuous operation of Bintulu complex without unplanned shutdown
0
50
100
150
200
250
300
350
400
450
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
Day
s be
twee
n co
mpl
ex s
hutd
own
15
5679
141
85 71
114
157
270
430
55
Targetting different markets
• LNG: Dedicated shipping and receiving terminalsLong term contractsPower generation and gas markets
• GtL: Viable for smaller gas reservesPotential to substitute for oil importsHigh quality, ultra clean fuel applications
LNG & GTL in comparisonLNG & GTL in comparison
56
Industry LCA studies show the GHG emissions of a GTL system to be comparable to a complex refinery system
Efforts are focused on GTL process efficiency through R&D programs, targeting up to 20% efficiency improvements
Advanced GTL engines are being developed, sponsored by governments, and targeting up to 10% efficiency improvements
The GTL system also has:– significant lower impact on air
acidification and smog formation– lower emissions of particulate matter– less hazardous waste production
Greenhouse Gases(CO2 equivalents)
System -Potential
(ProcessEfficiency)
0GTLREFINERY
100%
GTLGTL
Potential
(EngineEfficiency)
System -
Use of productsTransport to usersProduction of productsExtraction of feedstock
Life Cycle Analysis – GHG Emissions
57
NOx Partikel·10 HC CO
0,1
0
0,2
0,3
Em
issi
onsw
erte
[g/
km]
Grenzwerte EU IV Diesel < 10ppm SShell GTLΔNOx= - 6,4% ΔPart. = - 26%
ΔHC = - 63% ΔCO = - 91%
EU IV
Emissions Performance – Volkswagen Test
Berlin Fleet test 2003 - VW Golf with Shell GTL Fuel
58
Simplified GTL Process Overview
Natural Gas Shell
Gasification Process (SGP)
Heavy Paraffins Synthesis (HPS)
Heavy Paraffins
Conversion (HPC)
LPGNapthaGasoil
Lube Base Oils Units
(BO)
Lube Base Oils
Utilities
Off-sites & Common Facilities
Light Detergent
Feedstock unit (LDF)
NormalParaffins
Air Air Separation Unit (ASU)
Natural Gas Steam
Methane Reformer
(SMR)
Hydrogen Manuf. Unit (HMU) H2
Synthetic Crude Distiller
(SCD)
O2
Key Processes: Shell Proprietary Technology….. proven in Bintulu