An Update On Shell Licensed Gasification Projects and the Performance of Pernis IGCC
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1 An Update On Shell Licensed Gasification Projects and the Performance of Pernis IGCC 2000 Gasification Technologies Conference 8-11 October, San Francisco J.D. de Graaf
2 Summary Introduction Shell Gasification Processes Recent Projects Feedback Pernis IGCC Conclusion
3 Shell Gasification Processes Gasification of (natural) gas Gasification of liquids Gasification of solids
4 Shell Gasification Processes Natural gas ~1400 o C, ~50 bar Refinery gas Vacuum Residue Vacuum Flashed ~1320 o C, bar Cracked Residue Asphalts Coke ~1600 o C, bar Bituminous Coal ~1500 o C, bar Anthracite ~1600 o C, bar
5 The SMDS process Natural Gas CH 4 Oxygen Oxygen manufacture manufacture ASU 100 MMSCF/d Syngas Syngas manufacture manufacture 6*SGP CO + 2H 2 Synthesis Synthesis HPS H 2 O CH 2 Hydrogenation Hydrogenation Hydrocracking Hydrocracking HPC Solvents Waxes Middle Distillates Lube oil feedstock 12,500 bbl/d 5
6 ASU incident ASU explosion Dec 24th 1997 Not related to SMDS technology or ops. error Extensive investigation - due to haze build up in Aluminium reboiler Much more safe design prepared Plant rebuilt and started up May
7 Developments Shell Gasification NG gasification for Shell Middle Distillate Synthesis in Malaysia. Rebuilt restarted. Large scale SMDS projects with multile large scale Shell Gasification units for sygas manufacture planned Oil Residue in Pernis refinery for hydrogen and power Oil Residue for Power in Sannazzaro, Italy Petcoke gasification for IOCL, Paradip, India Coal gasification for Sulcis, Sardinia, Italy Coal gasification for Dong Ting fertiliser, Hunan, China
8 Simplified flow scheme Shell Gasification Process HP steam soot scrubber syngas effluent cooler Claus gas feed pump soot quench Waste water stripper To Biotreater gasifier reactor LP steam feed vessel oxygen heater soot separator Flue gas Steam Ni/V ash Residue Oxygen HP BFW Filtration Filter cake work-up
9 Developments Shell Gasification NG gasification for Shell Middle Distillate Synthesis in Malaysia Large scale SMDS projects with multile large scale Shell Gasification units for sygas manufacture Oil Residue in Pernis refinery for hydrogen and power Oil Residue for Power in Sannazzaro, Italy Petcoke gasification for IOCL, Paradip, India Coal gasification for Sulcis, Sardinia, Italy Coal gasification for Dong Ting fertiliser, Hunan, China
10 Demkolec SCGP raw coal fly ash recirculation quench gas milling and drying gasifier HP steam coal feeding syngascooler MP steam dry fly ash removal quench water wash coal gas to gas treating slag removal fly ash system slag fly ash recirculation 10
11 Eastern India Refinery Project ASU Oxygen H2S to Claus unit clean syngas to GT s Power & Utilities block offgas Petcoke SCGP (2+1) syngas scrub. H2S/ COS removal 2 stage shift bulk CO2 wash PSA gasification unit hydrogen plant CO2 to atmosphere Hydrogen
12 Eastern India Refinery Project ASU Oxygen H2S to Claus unit clean syngas to GT s Power / Utilities offgas Petcoke SCGP (2+1) syngas scrub. H2S/ COS removal 2 stage shift bulk CO2 wash PSA gasification unit hydrogen plant CO2 to atmosphere Hydrogen
13 Eastern India Refinery Project ASU Oxygen H2S to Claus unit clean syngas to GT s Power / Utilities offgas Petcoke SCGP (2+1) syngas scrub. H2S/ COS removal 2 stage shift bulk CO2 wash PSA gasification unit hydrogen plant CO2 to atmosphere Hydrogen
14 Eastern India Refinery Project ASU Oxygen H2S to Claus unit clean syngas to GT s Power / Utilities offgas Petcoke SCGP (2+1) syngas scrub. H2S/ COS removal 2 stage shift bulk CO2 wash PSA gasification unit hydrogen plant CO2 to atmosphere Hydrogen
15 Eastern India Refinery Project ASU Oxygen H2S to Claus unit clean syngas to GT s Power / Utilities offgas Petcoke SCGP (2+1) syngas scrub. H2S/ COS removal 2 stage shift bulk CO2 wash PSA gasification unit hydrogen plant CO2 to atmosphere Hydrogen
16 SCGP for Dongting Fertiliser Plant Naphtha Steam Naphtha Reformer NH3 feedgas preparation Fertiliser plant
17 SCGP for Dongting Fertiliser Plant Naphtha Steam Naphtha Reformer NH3 feedgas preparation Fertiliser plant ASU Local Coal SCGP Sour Shift Desulph.
18 Developments Shell Gasification NG gasification for Shell Middle Distillate Synthesis in Malaysia Large scale SMDS projects with multile large scale Shell Gasification units for sygas manufacture Oil Residue in Pernis refinery for hydrogen and power Oil Residue for Power in Sannazzaro, Italy Petcoke gasification for IOCL, Paradip, India Coal gasification for Sulcis, Sardinia, Italy Coal gasification for Dong Ting fertiliser, Hunan, China
19 FROM parr. TRAINS Fuelgas to gasturbines CO2 HP steam Desulphurization Hydrogen Manufacture Hydrogen product soot scrubber syngas effluent cooler Claus gas feed pump soot quench Waste water stripper To Biotreater gasifier reactor LP steam feed vessel oxygen heater soot separator Flue gas Steam Ni/V ash Residue Oxygen HP BFW Filtration Filter cake work-up Simplified flow scheme of Pernis Shell Gasification Hydrogen Plant
20 Outlet Temperatures Syngas Coolers 375 Maximum allowable level Temperature Syngas [ C] Total Runtime [hrs]
21 FROM parr. TRAINS Fuelgas to gasturbines CO2 HP steam Desulphurization Hydrogen Manufacture Hydrogen product soot scrubber syngas effluent cooler Claus gas feed pump soot quench Waste water stripper To Biotreater gasifier reactor LP steam feed vessel oxygen heater soot separator Flue gas Steam Ni/V ash Residue Oxygen HP BFW Filtration Filter cake work-up Simplified flow scheme of Pernis Shell Gasification Hydrogen Plant
22 Start of gasifier without flaring 100% Oil flow 75% Oxygen flow 50% 25% 0% 100% 75% 08:30 08:45 09:00 09:15 Syngas to Rectisol System Pressure Syngas ex reactors 50% Syngas to gas turbines 25% 0% 08:30 08:45 09:00 09:15 Time [hh:mm] Natural to gas turbines 22
23 FROM parr. TRAINS Fuelgas to gasturbines CO2 HP steam Desulphurization Hydrogen Manufacture Hydrogen product soot scrubber syngas effluent cooler Claus gas feed pump soot quench Waste water stripper To Biotreater gasifier reactor LP steam feed vessel oxygen heater soot separator Flue gas Steam Ni/V ash Residue Oxygen HP BFW Filtration Filter cake work-up Simplified flow scheme of Pernis Shell Gasification Hydrogen Plant
24 Pernis SGP H2 Manufacture and Power generation OXYGEN ST G ELECTRIC POWER STEAM MP STEAM RESIDUE SGP SAT VHP STEAM NATURAL GAS HEAT RECOVERY HP STEAM ST LP STEAM GAS CLEAN UP SRU/SCOT SYNGAS GT GT G G ELECTRIC POWER CO SHIFT CO2 REMOVAL METHANATION H 2
25 Natural gas Gas turbine control system Primary manifold dp control Steam Gas turbine burner 1 of 10 PC Secondary manifold Y F PC FC PC Desulfurization CO-Shift CO2 removal Methanation Syngas Hydrogen to Hydorcracker Gasturbine burner control in Pernis IGCC
26 Performance of Gas Turbines in Pernis GT-4700 GT-4800 Availability till mid % 95.5 % Availability 1st half % 98.9 % Excluding planned stop 98.7 % 98.9 %
27 Gas turbines with SGP in Pernis Normal running behaviour No vibrations Normal run hours between inspection stops Flexible in accepting a wide range of feeds Can run on syngas only Switch over from full NG to full syngas in minutes Load following
28 Conclusion Shell gasification processes selected for several key new applications in gas to liquids for coal to fertiliser for petroleum coke to hydrogen and power for heavy refinery residue to power SGP application in Pernis refinery very successful hydrogen for hydrocracking clean fuel gas for gasturbines
29 Thank You.
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