Shell Gasification Technology

Shell Global Solutions
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

Combining the operating experience of over 4500 staff
with
proven implementation skills and advanced technologies
Diverse cultures and

nationalities
Over 50 years of
implementing business
and engineering solutions
Continued investment in
innovation
Chester
Amsterdam/
The Hague
Hamburg
Beijing
Moscow
Rouen
Houston
Tokyo
Dubai
Kuala Lumpur
Buenos Aires
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
What is gasification?
Gasification converts hydrocarbon feedstocks

into syngas
It involves partial combustion
-
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
-
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

SGP compared with SCGP key features

SGP
SCGP
Typical feedstock
Vacuum residue
Petroleum coke
Operating temperature
1320C
>1500C
Operating pressure
3565 bar
2545 bar
Slagging condition
Non-slagging
Slagging
Gasifier
Refractory-lined
Membrane wall
Boiler
Fired-tube
Water tube
Technologies can be tuned to a variety of refinery

configurations
Refinery residue options

Solvent
deasphalting
Crude oil
Distillation and
vacuum
distillation
Residue
hydroprocessin
g
Vacuum distillation
(and deasphalting)
(Deep) thermal
cracking
Vacuum distillation
(and deasphalting)
Delayed coking
Heavy
viscous
residue
Petroleum
coke
SG
P
SCG
P
Helping refiners to convert the bottom of the barrel

Why gasification for refineries?

Hydrogen
Feed
*
Gasification*
and
Gas treating*
Clean
syngas
(CO + H2)
Oxygen
Steam
Chemicals, ammonia,
methanol
Clean syngas for

refinery use
Boilers
Furnaces
Liquid
transportation fuels
Synthesis of
Hydrocarbons*
Power generation
IGCC
Electricity
Steam
Sulphur*
Gasification offers attractive options for refiners

* Shell Technology Application
SGP
Typical process scheme

Key details
Recent projects
Pernis case study
Converting the bottom of the barrel into

valuable products
10
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
11
SGP feedstock flexibility

Units
Visbreaker
residue
Butane
asphalt
%wt
85.27
84.37
%wt
10.08
9.67
%wt
4.00
5.01
%wt
0.30
0.52
%wt
0.20
0.23
Ash
%wt
0.15
0.20
Total
%wt
100
100
Vanadium
ppm wt
270700
800
Nickel
ppm wt
120
200
Sodium
ppm wt
30
30
Viscosity (100oC)
cSt
10,000
9.17 107
Feedstock type
Elementary analysis
12
SGP feedstock flexibility

Feedstock type
Units
Raw gas from

SGP unit
Clean gas after

desulphurisation
H2
%vol
45.05
45.43
CO
%vol
49.62
50.04
CO2
%vol
2.84
2.82
CH4
%vol
0.30
0.30
N2
%vol
0.60
0.60
Ar
%vol
0.80
0.81
H2S
%vol
0.76
5 to 20 ppm
COS
%vol
0.03
5 to 20 ppm
Total
%vol
100
100
HHV
MJ/Nm3
12.33
12.23
LHV
MJ/Nm3
11.42
11.33
SGP can process a wide range of feedstocks

13
Typical SGP process scheme
High-pressure steam
Residue
Gasification
Oxygen
The feedstock
is converted
to syngas
Steam
Syngas effluent
cooler
Raw syngas
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
14
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

15
Case study: Pernis refinery
Pernis business situation

-
Solution integrating the SGP

Resultant syngas is used to
-
Required a performance step change
Produce hydrogen for the hydrocracker

Fuel the IGCC plant
Business benefits
Benefiting from integrating a polygeneration plant into the

refinery
16
Shell Gasification Process & Refineries - Gasification

Plant Site
Feedstock
Capacity
Product
Driver
Business Case
Shell Pernis
HYCON+VFC
R
3 * 550 t/d
Hydrogen
(Power)
Emissions
Hydrogen
Heavier crude oil
Agip
Sannazzaro
VFCR
2 * 600 t/d
Syngas
(Hydrogen)
Residue disposal
Opti Canada
Asphalt
4 * 1033 t/d
Hydrogen
Fuel gas
(Power)
Hydrogen
Steam for SAGD
Fujian
Refinery
Ethylene
Lotos,
Gdansk
Project
Asphalt
3 * 1200 t/d
Hydrogen
(Power)
Hydrogen
Asphalt
3 * 550 t/d
Hydrogen
Power
Hydrogen
Residue disposal
3 * 1150 t/d
Hydrogen
(Power)
Hydrogen
Residue disposal
ConocoPhillips Asphalt
,
Wilhelmshave
n
17
Shell Gasification Process & Refineries Projects

Plant Site
Special aspects
Integration
Shell Pernis
Gasifier fuel
Gas turbine fuel
Full refinery integration
Agip Sannazzaro
Superheated steam ex
Syngas Cooler
Limited integration
(low pressure BFW,
cooling water etc.)
Opti Canada
Syngas substitutes
natural gas
Full integration to
upgrader and SAGD
Fujian Refinery
Ethylene Project
Full integration between

refinery, gasification
and chemical complex
Lotos, Gdansk
Chemical site;
Very high pressure
steam (121 bara; 1755
psia)
Import of cheap crude
Conoco Phillips,
Wilhelmshaven
oil
Capacity increase of the
refinery

18
Recent SGP projects

Owner
Location
Feedstock
Input, t/d
Syngas,
106Nm3/d
End product
Startup
date
Shell Nederland
Raffinaderij
Rotterdam,
Netherlands
Cracked
residue
1650
4.7
Hydrogen/
power/steam
1997
Lanzhou
Chemical
Lanzhou, China
Vacuum
reside
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
2006
Opti/Nexen
Alberta, Canada
Asphalt
3100
7.5
Steam/
hydrogen
2007
Fujian ethylene
project
Fujian, China
Asphalt
2180
5.7
Hydrogen/
power
2008
19
SCGP
Typical process scheme

Key details
Recent projects
Buggenum case study
For sustainable utilisation of petroleum

coke and other solid feedstocks
20
Typical SCGP process scheme

Coal
Quench gas
Clean syngas
Milling/drying
Coal feeding
900C
Dry solids
removal
Wet scrubbing
Fly-ash system
Water
treatment
Gas treating
>1500C
Sulphur
Oxygen
21
SCGP petcoke gasification

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

22
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
-
Features
Low oxygen consumption
- High efficiency, reliability and availability
- Meets environmental legislation
-
Strong environmental credentials

23
Case study: Buggenum power plant
SCGP produces fuel for commercial

power plant
Features
-
High efficiency
High availability
Robust technology
Feedback loop improves SCGP design
20% biomass co-feed
Successful operations prove the SCGPIGCC combination

24
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
25
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
26
Water Quench
Water spray quench in wide,
empty vessel below the Gas
Reversal Chamber (GRC)
Full scale nozzle test
performed under pressure
Duct
Quench
Gasifier
SGC
Quenc
Burners
CFD modeling based on

actual quench nozzle design
Slagbath
27
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)
28
Conclusions
SGP and SCGP can help refiners to

-
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

29
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: jack.jones@shell.com
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: kevin.lanier@shell.com
www.shell.com/globalsolutions
World wide presence of Shell Global Solutions
30

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