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Shell Gasification Technology: Generating Profit from the Bottom of the Barrel Joachim Wolff Jack Jones
Shell Global Solutions International BV

Presentation overview

Challenges facing refiners How gasification can help Suitable feedstocks Technical insights Typical process schemes Project lists and case studies Conclusions

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Challenges for the oil-refining industry

Refiners 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
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What is gasification?

Gasification converts hydrocarbon feedstocks into syngas It involves partial combustion

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2(CH2) + O2

2CO + 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
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Shell gasification feedstocks

The feed to the gasifier can be Solid Shell Coal Gasification Process (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

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SGP compared with SCGP key features

SGP Typical feedstock Operating temperature Operating pressure Slagging condition Gasifier Boiler Vacuum residue 1320C 3565 bar Non-slagging Refractory-lined Fired-tube SCGP Petroleum coke >1500C 2545 bar Slagging Membrane wall Water tube

Technologies can be tuned to a variety of refinery configurations

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Refinery residue options

Solvent deasphalting

Residue hydroprocessin g

Vacuum distillation (and deasphalting)

Heavy viscous residue

SG P

Crude oil

Distillation and vacuum distillation

(Deep) thermal cracking

Vacuum distillation (and deasphalting)

Delayed coking

Petroleum coke

SCG P

Helping refiners to convert the bottom of the barrel

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Why gasification for refineries?

Feed * Hydrogen Chemicals, ammonia, methanol Boilers Furnaces Liquid transportation fuels Electricity Steam

Gasification* and Gas treating*

Clean syngas (CO + H2)

Clean syngas for refinery use Synthesis of Hydrocarbons* Power generation IGCC Sulphur*

Oxygen Steam

Gasification offers attractive options for refiners

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* Shell Technology Application

SGP

Typical process scheme Key details Recent projects Pernis case study

Converting the bottom of the barrel into valuable products

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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

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SGP feedstock flexibility

Feedstock type Elementary analysis C H S N O Ash Total Vanadium Nickel Sodium Viscosity (100oC) %wt %wt %wt %wt %wt %wt %wt ppm wt ppm wt ppm wt cSt 85.27 10.08 4.00 0.30 0.20 0.15 100 270700 120 30 10,000 84.37 9.67 5.01 0.52 0.23 0.20 100 800 200 30 9.17 107 Units Visbreaker residue Butane asphalt

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SGP feedstock flexibility

Feedstock type H2 CO CO2 CH4 N2 Ar H2S COS Total HHV LHV Units %vol %vol %vol %vol %vol %vol %vol %vol %vol MJ/Nm3 MJ/Nm3 Raw gas from SGP unit 45.05 49.62 2.84 0.30 0.60 0.80 0.76 0.03 100 12.33 11.42 Clean gas after desulphurisation 45.43 50.04 2.82 0.30 0.60 0.81 5 to 20 ppm 5 to 20 ppm 100 12.23 11.33

SGP can process a wide range of feedstocks

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Typical SGP process scheme

High-pressure steam

Residue Oxygen Steam

Gasification
The feedstock is converted to syngas Raw syngas

Syngas effluent cooler

High-pressure steam is generated from the hot syngas Raw syngas

Carbon removal Residual carbon and

ash are removed from the syngas

Clean syngas

Ash and residual carbon

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SGP key details

Requires an integrated approach Can process virtually all refinery oil residues Enables refiners to use heavier crudes Can help refiners enhance their yield of high-value products

Tailor-made solutions are integrated into existing complexes

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Case study: Pernis refinery

Pernis business situation

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Required a performance step change

Solution integrating the SGP Resultant syngas is used to

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Produce hydrogen for the hydrocracker Fuel the IGCC plant

Business benefits

Benefiting from integrating a polygeneration plant into the refinery

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Shell Gasification Process & Refineries - Gasification

Plant Site Shell Pernis Feedstock HYCON+VFC R VFCR Asphalt Capacity 3 * 550 t/d Product Hydrogen (Power) Syngas (Hydrogen) Hydrogen Fuel gas (Power) Hydrogen (Power) Hydrogen Power Hydrogen (Power) Driver Business Case Emissions Hydrogen Heavier crude oil Residue disposal Hydrogen Steam for SAGD Hydrogen Hydrogen Residue disposal Hydrogen Residue disposal
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Agip Sannazzaro Opti Canada

2 * 600 t/d 4 * 1033 t/d

Fujian Refinery Ethylene Lotos, Gdansk Project

Asphalt Asphalt

3 * 1200 t/d 3 * 550 t/d 3 * 1150 t/d

ConocoPhillips Asphalt , Wilhelmshave n

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Shell Gasification Process & Refineries Projects

Plant Site Shell Pernis Agip Sannazzaro 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) of cheap crude Import oil Capacity increase of the refinery 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 Full refinery integration

Opti Canada Fujian Refinery Ethylene Project Lotos, Gdansk Conoco Phillips, Wilhelmshaven

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Recent SGP projects

Owner Shell Nederland Raffinaderij Lanzhou Chemical Chemopetrol revamp Lucky Goldstar Eni SpA Opti/Nexen Fujian ethylene project Location Rotterdam, Netherlands Lanzhou, China Litvinov, Czech Republic Naju, Korea Sannazzaro, Italy Alberta, Canada Fujian, China Feedstock Cracked residue Vacuum reside Cracked residue Vacuum residue Cracked residue Asphalt Asphalt Input, t/d 1650 700 1250 225 1200 3100 2180 Syngas, 106Nm3/d 4.7 2.1 3.6 0.7 3.4 7.5 5.7 End product Hydrogen/ power/steam Chemicals Chemicals/ hydrogen Chemicals Hydrogen/ power Steam/ hydrogen Hydrogen/ power Startup date 1997 1998 2001 2001 2006 2007 2008

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SCGP

Typical process scheme Key details Recent projects Buggenum case study

For sustainable utilisation of petroleum coke and other solid feedstocks

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Typical SCGP process scheme

Coal Quench gas

Clean syngas Milling/drying

900C

Dry solids removal Coal feeding

>1500C

Wet scrubbing

Gas treating

Fly-ash system

Water treatment

Oxygen

Sulphur

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SCGP petcoke gasification

Fuel Water in feed C H O N S Ash LHV Oxygen, 95.5% O2 Steam Crude gas, dry H2 CO CO2 CO+H2 Gasifier outlet temperature Cold gas efficiency wt%, a.r. wt%, dry wt%, dry wt%, dry wt%, dry wt%, dry wt%, dry MJ/kg, dry kg/kg, dry kg/kg, dry vol%, dry vol%, dry vol%, dry m3/kg feed, dry C %, HHV based Petroleum coke, dried 1.5 88.3 4.8 0 2.9 3.7 0.4 35.7 1.04 0.23 30 % 63 % 2% 2.34 1600 82.7

Excellent carbon conversion

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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
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Features
Low oxygen consumption - High efficiency, reliability and availability - Meets environmental legislation
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Strong environmental credentials

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Case study: Buggenum power plant

SCGP produces fuel for commercial power plant Features

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High efficiency High availability Robust technology Feedback loop improves SCGP design 20% biomass co-feed

Successful operations prove the SCGPIGCC combination

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SCGP Water Quench A change for the better

Allow 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 saturator cycle in the shift section
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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 an efficient 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
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Water Quench
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
Duct

Quench SGC Quenc

Gasifier
Burners

Slagbath

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General IGCC SGC vs WQ

Disadvantages Water Quench (WQ) for IGCC applications IGCC 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)

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Conclusions

SGP and SCGP can help refiners to

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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

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Questions / Contact
Liquid Refinery Residue Gasification - SGP Jack M. Jones, Market Development
Shell Global Solutions (US) Inc. Work: +1-281-544 6342 Mobile: +1-281-468 8677 Email: [email protected]

Solid Gasification - SCGP Kevin J. Lanier, Business Development Manager

Clean Coal Energy, Shell US Gas & Power Work: +1 713 241 4381 Mobile: +1 832 661 9579 Email: [email protected]

www.shell.com/globalsolutions

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