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

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Shell Global Solutions
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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
- 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 SCGP
Typical feedstock Vacuum residue Petroleum coke
Operating temperature 1320°C >1500°C
Operating pressure 35–65 bar 25–45 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
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 Refinery residue options

Solvent
deasphalting

Residue Vacuum distillation Heavy

hydroprocessin (and deasphalting) SG
viscous
g P
residue

Distillation and (Deep) thermal Vacuum distillation

Crude oil vacuum cracking (and deasphalting)
distillation

Delayed coking Petroleum SCG

coke P

Helping refiners to convert the bottom of the barrel

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Why gasification for refineries?

Feed Hydrogen Chemicals, ammonia,

* methanol

Clean syngas for Boilers

Clean refinery use Furnaces
Gasification*
and syngas
Gas treating* (CO + H2) Liquid
Synthesis of
Hydrocarbons* transportation fuels

Power generation Electricity

Oxygen IGCC Steam
Steam
Sulphur*

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
Visbreaker Butane
Feedstock type Units residue asphalt
Elementary analysis
C %wt 85.27 84.37
H %wt 10.08 9.67
S %wt 4.00 5.01
N %wt 0.30 0.52
O %wt 0.20 0.23
Ash %wt 0.15 0.20
Total %wt 100 100
Vanadium ppm wt 270–700 800
Nickel ppm wt 120 200
Sodium ppm wt 30 30
Viscosity (100oC) cSt 10,000 9.17
107

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SGP – feedstock flexibility
Raw gas from Clean gas after
Feedstock type Units SGP unit 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

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 Typical SGP process scheme

High-pressure steam

Residue Gasification Syngas effluent Carbon

cooler removal
Oxygen The feedstock Raw syngas Raw syngas Residual carbon and Clean syngas
High-pressure ash are removed
is converted
steam is generated from the syngas
Steam to syngas
from the hot 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

- Required a performance step change
• Solution – integrating the SGP
• Resultant syngas is used to
- 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 Feedstock Capacity Product Driver –
Business Case
Shell Pernis HYCON+VFC 3 * 550 t/d Hydrogen Emissions
R (Power) Hydrogen
Heavier crude oil
Agip VFCR 2 * 600 t/d Syngas Residue disposal
Sannazzaro (Hydrogen)
Opti Canada Asphalt 4 * 1033 t/d Hydrogen Hydrogen
Fuel gas Steam for SAGD
(Power)
Fujian Asphalt 3 * 1200 t/d Hydrogen Hydrogen
Refinery (Power)
Ethylene
Lotos, Gdansk Asphalt 3 * 550 t/d Hydrogen Hydrogen
Project
Power Residue disposal
ConocoPhillips Asphalt 3 * 1150 t/d Hydrogen Hydrogen
, (Power) Residue disposal
Wilhelmshave
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 Shell Gasification Process & Refineries – Projects

Plant Site Special aspects Integration

Shell Pernis Gasifier fuel Full refinery integration

Gas turbine fuel
Agip Sannazzaro Superheated steam ex Limited integration
Syngas Cooler (low pressure BFW,
cooling water etc.)
Opti Canada Syngas substitutes Full integration to
natural gas upgrader and SAGD
Fujian Refinery Chemical site; Full integration between
Ethylene Project Very high pressure refinery, gasification
steam (121 bara; 1755 and chemical complex
Lotos, Gdansk psia)
Import of cheap crude Full refinery integration
oil
Conoco Phillips, Capacity increase of the Full refinery integration
Wilhelmshaven refinery

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

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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 900°C
Dry solids
Wet scrubbing Gas treating
removal
>1500°C
Coal feeding
Water
Fly-ash system
treatment

Oxygen Sulphur

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SCGP – petcoke gasification
Petroleum coke,
Fuel dried
Water in feed wt%, a.r. 1.5
C wt%, dry 88.3
H wt%, dry 4.8
O wt%, dry 0
N wt%, dry 2.9
S wt%, dry 3.7
Ash wt%, dry 0.4
LHV MJ/kg, dry 35.7

Oxygen, 95.5% O2 kg/kg, dry 1.04

Steam kg/kg, dry 0.23
Crude gas, dry
H2 vol%, dry 30 %
CO vol%, dry 63 %
CO2 vol%, dry 2%
CO+H2 m3/kg feed, dry 2.34
Gasifier outlet temperature °C 1600
Cold gas efficiency %, HHV based 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

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

Strong environmental credentials

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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 SCGP–IGCC 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 Duct

Reversal Chamber (GRC)

Quench
Full scale nozzle test
performed under pressure Quenc
SGC
Gasifier
h
Burners

CFD modeling based on Slagbath

actual quench nozzle design

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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

- 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: 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

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