Shell Global Solutions Overview of Shell Global Solutions Worldwide Gasification Developments Piet Zuideveld Shell Global Solutions International BV, Amsterdam, the Netherlands Gasification Technologies 2003 San Francisco, October 12 15, 2003 Shell Global Solutions
SGP/SCGP inputs and outputs Feedstock Coal Petroleum coke Heavy oil residues Asphaltenes Natural gas (Biomass) SGP or SCGP End product Oxo-alcohols Methanol Chemicals Ammonia Urea Hydrogen Power Clean fuels (Carbon dioxide) Shell Global Solutions 2
Shell gasification projects Shell Global Solutions 3
Gasification of liquid residues Shell Global Solutions 4
SGP projects recently completed, in progress or planned Owner Location Feedstock Input, t/d Syngas output (10 6 Nm 3 /d) End product Startup date Shell Nederland Raffinaderij Rotterdam, Netherlands Cracked residue 1650 4.7 Hydrogen/ power/ steam 1997 Lanzhou Chemical Lanzhou, People s Republic of China Vacuum residue 700 2.1 Chemicals 1998 Chemopetrol revamp Litvinov, Czech Republic Cracked residue 1250 3.6 Chemicals/ hydrogen 2001 Lucky Goldstar Naju, Korea Vacuum residue 225 0.7 Chemicals 2001 Eni SpA Sannazzaro, Italy Cracked residue 1200 3.4 Hydrogen/ power 2005 Opti/Nexen Alberta, Canada Asphalt 3100 7.5 Steam/hydrogen 2006 Rafineria Gdańska SA Gdansk, Poland Asphalt 1600 4.7 Hydrogen/power 2006 Shell Global Solutions 5
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 6
Shell Pernis gasification project Cost-effective hydrogen production Alternative outlet for residue Increased feedstock flexibility Investment largely independent of residue quality Shell Global Solutions 7
Pernis SGP Refinery Residue ASU O 2 MP/LP steam Electric power H 2 Steam cycle SGP Heat recovery HP steam H 2 S H 2 S removal Gas turbine CO 2 Electric power CO shift CO 2 removal Methanation Shell Global Solutions 8
Sannazzaro SGP Refinery Residue Superheated HP steam Flue gas H 2 SGP O 2 ASU Soot filtration Soot coke combustion Ni/V ash H 2 S Syngas treating Hydrogen recovery Syngas to power plant turbines Shell Global Solutions 9
Gdańska SGP Refinery Vacuum residue Electric power H 2 Deasphalting DAO HCU Asphaltenes HP steam SGP O 2 ASU Heat recovery Steam cycle Gas turbine CO 2 Electric power H 2 S H 2 S removal CO shift CO 2 removal Methanation H 2 Shell Global Solutions 10
OPTI/Nexen Long Lake project Premium synthetic crude Hydrocracking Hydrogen Sour synthetic crude OrCrude TM process Asphaltene SGP Power Bitumen SAGD Fuel gas Athabasca oil sands Shell Global Solutions 11
Long Lake project OPTI/Nexen Fort McMurray Long Lake Edmonton Calgary Shell Global Solutions 12
Long Lake project OPTI/Nexen Shell Global Solutions 13
Gasification of coal for power production Shell Global Solutions 14
Nuon coal gasification Plant owner Nuon Location Buggenum, the Netherlands Coal gasification 2000 t/d Syngas production 4.0 x 10 6 Nm 3 /d End product 253 MWe Successful operation Test run with biomass as feedstock Technical and operational feedback for future projects Shell Global Solutions 15
SCGP projects planned for the People s Republic of China Owner Location Feedstock Input, t/d Syngas output (10 6 Nm 3 /d) End product Start-up date Shuanghuan Chemical Yingcheng, Hubei Coal 900 1.3 Chemicals 2004 Liuzhou Chemical Liuzhou, Guangxi Coal 1200 2.1 Chemicals 2005 Sinopec-Shell Yueyang, Hunan Coal 2000 3.4 Chemicals 2005 Sinopec Zhijiang, Hubei Coal 2000 3.4 Chemicals 2005 Sinopec Anqing, Anhui Coal 2000 3.4 Chemicals 2005 Dahua Chemical Dalian, Liaoning Coal 1000 1.5 Chemicals 2006 Yuntianhua Chemicals Anning, Yunnan Coal 2000 3.4 Chemicals 2006 Yunzhanhua Chemicals Qujing, Yunnan Coal 2000 3.4 Chemicals 2006 Shell Global Solutions 16
Typical scheme SCGP for chemicals production Crude syngas ASU O 2 SCGP Shift, gas treating H 2 Ammonia synthesis Coal Urea plant Shell Global Solutions 17
Yingcheng coal gasification project Plant owner Location Coal gasification Shuanghuan Chemical Group Yingcheng, Hubei 900 t/d Syngas production 1.3 x 10 6 Nm 3 /d End product Project engineering and construction Status Fertiliser China Wuhan Chemical Engineering Company Gasifier delivered Ready for start-up Second half 2004 Shell Global Solutions 18
Dongting coal gasification project Plant owner Sinopec Shell Location Yueyang, Hunan Coal gasification 2000 t/d Syngas production 3.4 x 10 6 Nm 3 /d End-product Fertiliser Project engineering and construction Sinopec Lanzhou Design Institute Status Implementation started Ready for start-up End 2005 Shell Global Solutions 19
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 20
Landed cost of urea in China existing plants 250 200 150 Import price range $/t 100 50 Coal gasification Transport costs Feedstock costs Operating costs (excluding feedstock) Capital charge 0 China existing naphtha $300/t China retrofit naphtha to coal $25/t Middle East greenfield natural gas $0.5/MMBtu Shell Global Solutions 21
Gasification of waste coal Coal-to-clean fuels and power co-production Owner WMPI Location Gilberton, Pennsylvania, USA Coal gasification 4000 t/d anthracite culm (40%) Syngas production 6.0 x10 6 Nm 3 /d Power production 40 MWe The first commercial-scale waste coal gasification project in the USA Shell Global Solutions 22
Partial oxidation of natural gas Shell Global Solutions 23
SMDS process scheme CH 4 CO + 2H 2 CH 2 Natural gas SGP Synthesis Hydrogenation Solvents Waxes ASU O 2 Hydrocracking Middle distillates Lube oil feedstock Shell Global Solutions 24
Shell gas-to-liquids technology First generation Bintulu, Malaysia Feedstock 100 MMscf/d Syngas production 12,500 bbl/d Second generation Feedstock Syngas production 600 MMscf/d 70,000 bbl/d Shell Global Solutions 25
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 Shell Global Solutions 26
Looking to the future Shell Global Solutions 27