an update on shell licensed gasification projects and · pdf filean update on shell licensed...

Shell Global Solutions

An Update On Shell Licensed GasificationProjects and the Performance of Pernis IGCC

2000 Gasification Technologies Conference

8-11 October, San Francisco

J.D. de Graaf


Summary

• Introduction

• Shell Gasification Processes

• Recent Projects

• Feedback Pernis IGCC

• Conclusion


Shell Gasification Processes

• Gasification of (natural) gas

• Gasification of liquids

• Gasification of solids


Shell Gasification Processes

• Natural gas SGP @ ~1400 oC, ~50 bar

Refinery gas

• Vacuum Residue

Vacuum Flashed SGP @ ~1320 oC, 35-65 barCracked Residue

Asphalts

• Coke SCGP @ ~1600 oC, 25-45 bar

Bituminous Coal SCGP @ ~1500 oC, 25-45 bar

Anthracite SCGP @ ~1600 oC, 25-45 bar

5Shell Global Solutions

Oxygenmanufacture

Oxygenmanufacture

NaturalGas

100 MMSCF/d

CO + 2H2

SynthesisSynthesis

H2O

– CH2 –

HydrogenationHydrogenation

12,500bbl/d

MiddleDistillates

HydrocrackingHydrocracking

6*SGP6*SGP HPSHPS

HPCHPC

CH4

Syngasmanufacture

Syngasmanufacture

Lube oil feedstock

Solvents

Waxes

The SMDS process

ASUASU


ASU incident

• ASU explosion Dec 24th 1997

• Not related to SMDS technology or ops. error

• Extensive investigation - due to haze build up inAluminium reboiler

• Much more safe design prepared

• Plant rebuilt and started up May 2000


Developments Shell Gasification

• NG gasification for Shell Middle Distillate Synthesis inMalaysia. Rebuilt restarted.

• Large scale SMDS projects with multile large scale ShellGasification 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


Simplified flow scheme Shell Gasification Process

Residue Oxygen

HP steam

HP BFW

feedpump

syngaseffluentcooler

sootquench

sootseparator

sootscrubber

oxygenheater

feedvessel

gasifierreactor

Steam

FiltrationFilter cakework-up

Ni/V ash

Waste waterstripper

LP steam

Claus gas

Flue gas

To Biotreater



• NG gasification for Shell Middle Distillate Synthesis inMalaysia

• Large scale SMDS projects with multile large scale ShellGasification units for sygas manufacture







milling and drying

raw coalfly ash

recirculation

coal feeding

slagremoval

slag

MP steam

HP steam

dryfly ash

removal

fly ashsystem

fly ashrecirculation

waterwash

gasifier

syngas-cooler

coal gastogas treating

quench

quenchgas

Demkolec SCGP


Eastern India Refinery Project

SCGP(2+1)

syngasscrub.

H2S/COSremoval

2 stage shift

bulkCO2wash

PSA

gasification unit hydrogen plant

clean syngas to GT’sPower & Utilities

block

Hydrogen

offgas

Petcoke

ASU H2S toClaus unit

CO2 to atmosphere

Oxygen


Eastern India Refinery Project

SCGP(2+1)

syngasscrub.

H2S/COSremoval

2 stage shift

bulkCO2wash

PSA

gasification unit hydrogen plant

clean syngas to GT’s Power / Utilities

Hydrogen

offgas

Petcoke

ASU H2S toClaus unit

CO2 to atmosphere

Oxygen


SCGP for Dongting Fertiliser Plant

Fertiliserplant

SteamNaphthaReformer

NH3feedgas

preparation

Naphtha


SCGP for Dongting Fertiliser Plant

Fertiliserplant

SteamNaphthaReformer

NH3feedgas

preparation

Naphtha

ASU

SCGPSourShift

Desulph.

LocalCoal



• NG gasification for Shell Middle Distillate Synthesis inMalaysia

• Large scale SMDS projects with multile large scale ShellGasification units for sygas manufacture







Simplified flow scheme of Pernis Shell Gasification Hydrogen Plant

Residue Oxygen

HP steam

HP BFW

feedpump


sootquench

sootseparator

sootscrubber

oxygenheater

feedvessel

gasifierreactor

Steam

DesulphurizationHydrogen

Manufacture

FROM parr.TRAINS

Fuelgasto gasturbines


Ni/V ash

Hydrogenproduct

CO2

Waste waterstripper

LP steam

Claus gas

Flue gas

To Biotreater


250

275

300

325

350

375

0 5000 10000 15000 20000

Total Runtime [hrs]

Tem

pera

ture

Syn

gas

[°C

]

Maximum allowable level

Outlet Temperatures Syngas Coolers



Residue Oxygen

HP steam

HP BFW

feedpump


sootquench

sootseparator

sootscrubber

oxygenheater

feedvessel

gasifierreactor

Steam


Manufacture

FROM parr.TRAINS



Ni/V ash

Hydrogenproduct

CO2

Waste waterstripper

LP steam

Claus gas

Flue gas

To Biotreater


0%

25%

50%

75%

100%

08:30 08:45 09:00 09:15

Oil flow

Oxygenflow

SyngastoRectisol

System Pressure

0%

25%

50%

75%

100%

08:30 08:45 09:00 09:15

Time [hh:mm]

Syngas to gas turbines

Naturalto gasturbines

Syngas exreactors

Start of gasifier without flaring



Residue Oxygen

HP steam

HP BFW

feedpump


sootquench

sootseparator

sootscrubber

oxygenheater

feedvessel

gasifierreactor

Steam


Manufacture

FROM parr.TRAINS



Ni/V ash

Hydrogenproduct

CO2

Waste waterstripper

LP steam

Claus gas

Flue gas

To Biotreater


OXYGEN

RESIDUESGP

STEAM

SRU/SCOT

GASCLEAN UP

SYNGAS

H2CO SHIFTCO2REMOVAL

METHANATION

NATURAL GAS

SAT VHPSTEAM

HP STEAM

HEATRECOVERY

GG

ELECTRICPOWER

LP STEAM

MP STEAM

G ELECTRICPOWER

ST

ST

GTGT

Pernis SGP H2 Manufacture and Power generation


Hydrogen toHydorcracker

CO-Shift CO2 removal MethanationDesulfurization

Syngas

Gasturbine burner control in Pernis IGCC

PC

Y

FCF

PC

PC

Steam

Gas turbineburner 1 of 10

Natural gas

dPcontrol

Gas turbinecontrol system

Primarymanifold

Secondarymanifold


Performance of Gas Turbines in Pernis

GT-4700 GT-4800

• Availability till mid 2000 95.2 % 95.5 %

• Availability 1st half 2000 91.8 % 98.9 %

• Excluding planned stop 98.7 % 98.9 %


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


Conclusion

• Shell gasification processes selected for several key newapplications

• 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


Thank You.

an update on shell licensed gasification projects and · pdf filean update on shell licensed...

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