zeus cgtl 2011 final -...

© 2011 CompactGTL plc

Real title

Iain BaxterDirector of Business Development

CompactGTL plc

Latest Advancements in Compact GTL Technology

Zeus 2011 Modular GTL SeminarHouston23rd June 2011


Stranded

Oil !


Engineering Partners

Client Sponsor

Technology Development

Support Partners

2006: Challenges for CompactGTL

Supply Chain Partners

Market Opportunity

• Strong project economics needed for attractive ROI

• Vision of CompactGTL as a solution provider to Upstream industry

• Partnership model necessary for successful execution


2011: Vision Realised

Delivering a turnkey associated gas solution

to enable oilfield development

Client commercial plant studies & pre-FEED’s at 200 bpd to 2,000 bpd

Volume manufacturing supply chain established

CompactGTL Brazil subsidiary established in Rio de Janeiro

Continuously strengthening team with World-scale GTL experience

Petrobras plant commissioned and now running under test


Real title

Market Opportunity & The Modular GTL Solution


Flared6 TCF

Associated gas is a huge global problem

Source: International Energy Annual 2005 World Bank GGFR 2006,2007

> 10 TCF (= 4.6 mmboe per day)

= 27%of annual US gasconsumption !

~4 TCFNot used to enhance

oil recovery

Asia

North America

Africa

Middle East

Central & S America

Europe

Russia

Re-injected14 TCF


Associated gas particularly problematic at < 50 MMscf/d

E&P TRENDSMore development in deepwater

More development remote from gas markets

250 km

Satellite image of gas flaring in Nigeria

0

50

100

150

200

5-10 11-50 51-100 101-150

Offshore

Onshore

Associated gas production [MMscf/day]

Number of Fields

Image courtesy of Chris Elvidge, National Geophysical Data Centre, Bouder, CO, USA


Emerging gas utilization options

• FLNG

– High infrastructure cost

– Economics favourable at 400+ MMscfd

– Project studies underway

• CNG– High infrastructure cost

– Economics favourable at 200+ MMscfd

– Concepts being developed– Economics dependent on distance to shore

• Gas to Wire

– High cost for deep water and remote fields

– Needs local market for power

– Economics dependent on distance to shore


Distinct market for modular GTL

Reinjection

Associated Gas MMscf/d

Distance to market for converted product

[km]

150

75

40020050

500

FLNG

CNG

PipelineGas to Wire

Modular

GTL


CompactGTL solution @ 2-50MMscf/d

• Incremental NPV of >$100MM possible

• Early production – Standalone unit

• Increased revenue from syncrude

• Savings in gas re-injection wells or pipelines

• Gas can be booked as reserves

• No separate storage, transportation or market access required for syncrude

Concept Design10MMscfd GTL plant on FPSO

Modular GTL :Convert the associated gas into syncrude

Co-mingle and transport with the natural crude

Image courtesy of SBM Offshore


Commercial plant conceptual design

29 m48 m

• 10 MMscfd gas feed

• 1,000 bbl/d syncrude production

• 2,400 T operating weight

• Configurable for :

• Aframax

• Suezmax

• VLCC

SMR modules

FT modules


Modular plant design gives scaleability, inherent reliability & operability

• Modules can be removed as production falls

• Modules re-furbished and catalyst replaced onshore

• Modules can go on-line and off-line to accommodate production variability

• Multiple modules provide inherent reliability


Basis for enhanced oilfield NPV

Facilities Capital Cost PV

Gas Disposal

Crude Revenue

PV

OilfieldNPV

Operations & Tax PV

Penalties or Delay

Operations & Tax PV

GTL Opex

OilfieldNPV

SyncrudePV

Crude Revenue

PV

Gas Re-Injection or Pipeline to Market

Facilities Capital Cost PV

GTL Plant

Integrated CompactGTL


Indicative economics

$ 150 MMPRE-TAX Incremental Oilfield NPV

$ 75 / bblOil price [assume natural crude]

$ 50 MMIncremental capex

5 MMscfd

[converts to 500 bpd syncrude]Feed gas at end of field life [15 years]

20 MMscfd

[converts to 2,000 bpd syncrude]Feed gas at first oil

PRE-TAX Incremental Economics – Oilfield FPSO Project

GTL module replaces $250 MM Re-injection well

Pre-Tax IRR Sensitivity

40.0%

45.0%

50.0%

55.0%

60.0%

65.0%

70.0%

-20% -15% -10% -5% 0% 5% 10% 15% 20%

Incre

menta

l G

TL IR

R

Oil Price

Capex

Opex


Real title

Commercialisation Route & Key Milestones Achieved


Partnership approach critical to success

FPSO

Expertise

Catalyst

Supplier

Reactor

Supplier

FEED

Partners

Technology

Support


Amagasaki Head Office

Overseas Offices

New York

Major Subsidiaries

STS(UK), MET(JPN), SE(JPN)


Commercialisation route

Lab Reactors Commercial PlantBrazil PlantUK Pilot Plant

Commercial Plant Studies

Requirements

Reactor & Catalyst Supplier

Engagement

Prototype Reactor & Catalyst Evaluation

Requirements

Supplier Selection

Pilot Reactor & Catalyst Manufacture

Commercial Supply Chain Establishment


UK Pilot plant operational for > 2.5 years

PlantcommissionedJuly 2008

Installation atWilton, NEEngland

• Confirming catalyst & reactor performance from manufacturers

• Integrated operation – ‘gas in to liquids out’

• Operational stability, start-up & shut down procedures

• Variable feed gas composition & CO2 content

• Operator training for larger plants


Petrobras GTL demonstration plant contract

• Contract confirmed with CompactGTL in July 2008

• Funded by Petrobras

• Capacity of 200,000 scf gas (20 bpd)

• Plant required to demonstrate all aspects needed for commercial application


Plant constructed in Canada & Japan

Plant constructed by ZetonInc, Burlington, Canada

SMR & FT Reactors fabricated by Sumitomo Precision Products, Osaka, Japan


Complete set of GTL reactors despatched by air-freight to Brazil


Final commissioning December 2010Plant running and

under test

• Gas pre-treatment

• Pre-reforming

• Reforming

• Waste heat recovery

• Process steam generation

• Syngas compression

• Fischer Tropsch synthesis

• FT cooling water system

• Tail gas recycling

World’s first small scale fully integrated

GTL facility !

Image shown courtesy of Petrobras


Real title

Process & Technology Overview


HC rich tail-gas

H2 rich tail-gasGT drivers

watertreatment

steam

FT 1reactormodules

FT 2reactormodules

FT cooling System

product flash

syncrude

SMR 2reactormodules

steamgeneration(WHB)

syngascompressor

SMR 1reactormodules

No OxygenRequired !

Process overview

gas treatment Syngas production FT synthesis

pre-wash

mercuryremoval

heating

sulphurremoval

gasfeed

pre-reformer

High CO2Possible !


FT 1 FT 2

Inherent reliability & flexibilityPlant stays on stream during module replacement

steamgeneration(WHB)

syngascompressor

gastreatment

FT 1 FT 2

FT 1 FT 2

pre-reformer SMR 2SMR 1 FT 1 FT 2

SMR 2SMR 1steam

generation(WHB)

SMR 2SMR 1steam

generation(WHB)

SMR 2SMR 1steam

generation(WHB)

SMR 2SMR 1steam

generation(WHB)

module control

FT 1 FT 2

module control


Compact mini-channel reactors are key

Conventional

Tubular steam

Reformer / ATR

CompactFT

Reactor

CompactSMR

Reactor

Conventional

FT reactor

e.g. slurry phase

10x increase in specific

throughput

• High heat transfer plate & fin reactor construction :

• High specific heat input to SMR reaction

• High specific heat removal from FT reaction


Mini-channel CompactGTL reactors

Catalysts :

• Removable metallic inserts

• Established automotive mass production techniques

Reactors :

• High specific heat transfer

• Established heat exchanger mass production techniques

• High reactor ‘voidage’ using pressed fin plates, minimising metal content, cost & weight

Automated catalyst insertion & removal at point of manufacture


Model based reactor design & scale up methodology

Catalyst screening

Reaction modelling

Reactormodelling

Modelvalidation

Reactor design& scale up

Lab reactors for all process steps

Reactor models withdetailed kinetics

Process heat and mass balances


Mini-channel SMR reactor

CompactSMR

Reactor

SMR Stream

Combustion Stream

High heat transfer fromCombustion stream intoSMR process stream

SMR catalyst foil inserts

Combustion catalyst foil inserts


SMR mini-channel reactor layout

FUEL & COMBUSTION AIR

COMBUSTION EXSHAUST

COMBUSTION LAYER

METHANE & STEAM

SYNGAS

REFORMING LAYER

COMPLETE SMR REACTOR

BLOCK


Mini-channel FT reactor

CompactFT

Reactor

FT Stream

Coolant Stream

High heat transfer fromFT process stream intocoolant stream

FT catalyst foil inserts


FT mini-channel reactor layout

SYNGAS IN

FT PRODUCT OUT

FT PROCESS LAYER

COOLANT IN

COOLANT OUT

COOLANT LAYER

COMPLETE FT REACTOR

BLOCK


Stranded Oil

Onshore &

Offshore

Client commercial plant studies & pre-FEED’s at 200 bpd to 2,000 bpd

In: Russia, Africa, South America, SE Asia

Commercial projects


Status today………

Manufacturing route & partners established

UK pilot plant operational for >2.5 years

CompactGTL structuring as a TURNKEY SOLUTION PROVIDER

‘Standalone’ solution for oilfield development

Petrobras plant commissioned and now running under test

With special thanks to Petrobras and all our

partners for their valued contribution


Real title

Iain BaxterDirector of Business Development

CompactGTL plc

Latest Advancements in Compact GTL Technology

Zeus 2011 Modular GTL SeminarHouston23rd June 2011

zeus cgtl 2011 final -...

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