New Refinery Applications of Shell Gasification Technology Joachim Wolff Piet Zuideveld Gasification Technologies Conference San Francisco, October 9-12, 2005
Shell Gasification Process & Refineries - Content 1. Refinery Challenges 2. Refinery Crude Upgrading and Consequences 3. Refinery Gasification Projects with SGP 4. Fujian Refinery Ethylene Project 5. LOTOS, Gdansk (Update) 6. Discussion 2
Shell Gasification Process & Refineries: Challenge (1) Oil to be main feedstock for a long time to come Possible introduction of bio-crudes Product slate will have to change Refinery hydrogen balance Cutting deeper into the barrel Achieving zero-sulphur products while maintaining throughput New routes to gasoline Responding to falling demand for heavy fuel oil Upgrading residue more efficiently Shell Pulau Bukom Refinery Singapore 3
Shell Gasification Process & Refineries: Challenge (2) Advances in combustion engine technology Pace of introduction of new technologies, like fuel cells The stance to be taken by governments Tax and fiscal measures Energy, transport and environmental legislation Public opinion Regional variations Shell Pernis Refinery Rotterdam 4
Shell Gasification Process & Refineries Upgrading Ways for liquid Residue Technology Plus Minus Comment Blending Simple; cheap No upgrading; No contribution to quality and to environmental Thermal conversion (DTC) Cost effective; distillates good HT feed Removes 10 % (VB) to 40 % (DTC) of sulphur Depending on location of the refinery Difficult to store and to blend Solvent Deasphalting Maximum recovery of non-black products Not selective for CCR Difficult to store and to blend 5
Shell Gasification Process & Refineries Consequences of Upgrading Distillates Crude CD LR Diluent HV SR Diluent TC/DTC Liquid coke SGP Bunker! More viscous residue! More heavy metals and sulphur in the residue! Difficulties in blending! Difficulties achieving fuel oil quality Bunker 6
Shell Gasification Process & Refineries - Gasification Plant Site Feedstock Capacity Product Driver Business Case Shell Pernis HYCON+VFCR 3 * 550 t/d Hydrogen Emissions (Power) Hydrogen Heavier crude oil Agip Sannazzaro VFCR 2 * 600 t/d Syngas (Hydrogen) Residue disposal Opti Canada Asphaltenes 4 * 1033 t/d Hydrogen Hydrogen Fuel gas Steam for SAGD (Power) Fujian Refinery Asphaltenes 3 * 1200 t/d Hydrogen Hydrogen Ethylene Project (Power) Lotos, Gdansk Asphaltenes 3 * 550 t/d Hydrogen Hydrogen Power Residue disposal Heavier crude oil Upgrading and residue disposal Hydrogen balance Refinery energy utilisation and emissions 7
Shell Gasification Process & Refineries Projects Plant Site Shell Pernis Agip Sannazzaro (GTC 2004: Guido Collodi) Opti Canada (GTC 2004: Phil Rettger) Fujian Refinery Ethylene Project Lotos, Gdansk (GTC 2004: Joachim Wolff) Special aspects Gasifier fuel Gas turbine fuel Superheated steam ex Syngas Cooler Syngas substitutes natural gas Chemical site; Very high pressure steam (121 bara; 1755 psia) Import of cheap crude oil Integration Full refinery integration Limited integration (low pressure BFW, cooling water etc.) Full integration to upgrader and SAGD Full integration between refinery, gasification and chemical complex Full refinery integration Develop (tailor-made) solutions integrated with existing refinery complexes 8
Shell Gasification Process & Refineries FREP, China Fujian Refinery Ethylene Project (FREP) JV: 50% - Fujian Petrochemical Co., Ltd. 25% - Exxon-Mobil China Petrochemical Co., Ltd. 25% - Aramco Overseas Company B.V. Refinery expansion (80,000 -> 240,000 bpd) Sour Arabian Crude 800,000 t/a ethylene steam cracker Polyethylene and polypropylene units 700,000 t/a paraxylene Shell Gasification Unit 9
Shell Gasification Process & Refineries FREP, China (2) 3 x SGP Gasifier with Syngas Effluent Cooler 1 x Filtration unit with multiple filter presses 1 x Sour Water Stripper 2 x Multiple Hearth Furnace Residue Feed vessel Oxygen heater Feed pump Oxygen Syngas cooler HP steam Syngas product Soot scrubber Soot quench Waste Water stripper Claus gas To Bio-treater LP steam Flue gas Steam/CO 2 Gasifier reactor ECO Soot separator Soot filter Filter cake Work-up Ni/V ash BFW 10
Shell Gasification Process & Refineries FREP, China (3) Distillates Hydrocracker feed Crude CD Component De-asphalt Rock Carbon %wt, MAF 84.0 LR HV SDU Hydrogen %wt, MAF 8.0 Oxygen %wt, MAF 0.2 SR Asphalt Nitrogen %wt, MAF 1.0 Sulphur %wt, MAF 6.8 Ash %wt 0.18 Diluent X Diluent SGP Viscosity @ 270 C cst 300-350 HHV MJ/kg 40.7 Bunker X Bunker Vanadium ppmwt 275 Nickel ppmwt 79 Reliable disposal of De-asphalt Rock 11
Shell Gasification Process & Refineries FREP, China (4) Route to Power Acid Gas Removal (Rectisol) Route to Hydrogen Sour CO-Shift Acid Gas Removal (Rectisol) PSA Component Design Case mol% Component Design Case mol% CO 2 4.2 N 2 0.3 CO 50.2 Ar 0.1 H 2 43.1 H 2 O 0.2 CH 4 0.3 HCN, NH 3 Traces H 2 S 1.5 COS 0.1 Stream Design t/h (st/h) De-aspahlt Rock 100.0 (110.2) Oxygen (Purity 99.5 mol%) 92.2 (101.6) Syngas 221.6 (244.2) Saturated Steam 241.7 (266.4) Metal ash (V, Ni) 0.19 (0.21) 12
SGP & Refineries FREP, China (5) Shell s experience with Syngas Cooler @ high steam pressure: National Fertiliser Limited, Batinda, India 107 bara (1550 psia) National Fertiliser Limited, Panipat, India 107 bara (1550 psia) Total Spergau, Leuna, Germany 105 bara (1525 psia) Fujian requirement: 121 bara (1755 psia) at BL (into steam system integrated with Ethylene Cracker) SGP requirement: Syngas pressure always higher than steam pressure Differential pressure design of inlet section & coils Specification of set pressure for Pressure Safety Relief Valves Shell s modular Flat Front design (Courtesy Standard Fasel-Lentjes B.V.) 13
Shell Gasification Process & Refineries FREP, China (7) Fujian requirement: - 4 years operating cycle with no major capacity reduction - Maintenance while plant in operation - Chinese Codes and Standards (Hazardous area requirements) - Gasification & SARU @ different locations (based on Pernis experience) Shell s experience gained in Pernis with line-up, operation and maintenance 14
Shell Gasification Process & Refineries FREP, China (8) Basic Time Schedule: 2004 Founding of JV 12/2004 Licensor Selection 01/2005 Start Process Design 07/2005 Groundbreaking Ceremony 09/2005 Deliver of SGP PDP Standard 3D- Module 15
Shell Gasification Process & Refineries LOTOS, Gdansk (update) Component Asphaltenes Carbon %wt, MAF 85.9 Hydrogen %wt, MAF 8.8 Oxygen %wt, MAF 0.5 Nitrogen %wt, MAF 1.2 Sulphur %wt, MAF 3.6 Ash %wt 0.2 VVVVVVVVVVVVvV Viscosity @ 280 C cst 300-350 HHV MJ/kg 40.4 (Courtesy LOTOS, Gdansk Refinery) Component Design Case mol% Component Design Case mol% CO 2 4.7 N 2 0.3 CO 49.4 Ar 0.0 H 2 44.3 H 2 O 0.1 CH 4 0.3 HCN, NH 3 Traces H 2 S 0.8 COS 0.0 Stream Design t/h (st/h) Asphaltenes 68.0 (75.0) Oxygen (Purity 99.5 mol%) 67.0 (73.8) Syngas 152.4 (168.0) Saturated Steam 148.2 (163.4) Metal ash (V, Ni) 0.14 (0.16) SGP process design finished; Basic Engineering completion in 01/2006 16
Shell Gasification Process & Refineries Discussion Liquid routes to enhance refinery capacity: Deeper Conversion (DTC) Solvent De-asphalting Key strategic drivers for a strong business case: " Meet future product specifications " Increase crude flexibility (lower cost crudes) " Eliminate high-sulphur fuel oil export " Replace obsolete facilities, improve refinery environmental performance & enhance energy utilisation " Cost effective hydrogen production " Secure or expand employments and regional business opportunities Flexibility of SGP for an optimal refinery integrated solution! 17 Joachim.wolff@shell.com