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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
Shell Global Solutions
Summary
• Introduction
• Shell Gasification Processes
• Recent Projects
• Feedback Pernis IGCC
• Conclusion
Shell Global Solutions
Shell Gasification Processes
• Gasification of (natural) gas
• Gasification of liquids
• Gasification of solids
Shell Global Solutions
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
6Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
Developments Shell Gasification
• NG gasification for Shell Middle Distillate Synthesis inMalaysia
• Large scale SMDS projects with multile large scale ShellGasification units for sygas manufacture
• 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
10Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
SCGP for Dongting Fertiliser Plant
Fertiliserplant
SteamNaphthaReformer
NH3feedgas
preparation
Naphtha
Shell Global Solutions
SCGP for Dongting Fertiliser Plant
Fertiliserplant
SteamNaphthaReformer
NH3feedgas
preparation
Naphtha
ASU
SCGPSourShift
Desulph.
LocalCoal
Shell Global Solutions
Developments Shell Gasification
• NG gasification for Shell Middle Distillate Synthesis inMalaysia
• Large scale SMDS projects with multile large scale ShellGasification units for sygas manufacture
• 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
Shell Global Solutions
Simplified flow scheme of Pernis Shell Gasification Hydrogen Plant
Residue Oxygen
HP steam
HP BFW
feedpump
syngaseffluentcooler
sootquench
sootseparator
sootscrubber
oxygenheater
feedvessel
gasifierreactor
Steam
DesulphurizationHydrogen
Manufacture
FROM parr.TRAINS
Fuelgasto gasturbines
FiltrationFilter cakework-up
Ni/V ash
Hydrogenproduct
CO2
Waste waterstripper
LP steam
Claus gas
Flue gas
To Biotreater
Shell Global Solutions
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
Shell Global Solutions
Simplified flow scheme of Pernis Shell Gasification Hydrogen Plant
Residue Oxygen
HP steam
HP BFW
feedpump
syngaseffluentcooler
sootquench
sootseparator
sootscrubber
oxygenheater
feedvessel
gasifierreactor
Steam
DesulphurizationHydrogen
Manufacture
FROM parr.TRAINS
Fuelgasto gasturbines
FiltrationFilter cakework-up
Ni/V ash
Hydrogenproduct
CO2
Waste waterstripper
LP steam
Claus gas
Flue gas
To Biotreater
22Shell Global Solutions
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
Shell Global Solutions
Simplified flow scheme of Pernis Shell Gasification Hydrogen Plant
Residue Oxygen
HP steam
HP BFW
feedpump
syngaseffluentcooler
sootquench
sootseparator
sootscrubber
oxygenheater
feedvessel
gasifierreactor
Steam
DesulphurizationHydrogen
Manufacture
FROM parr.TRAINS
Fuelgasto gasturbines
FiltrationFilter cakework-up
Ni/V ash
Hydrogenproduct
CO2
Waste waterstripper
LP steam
Claus gas
Flue gas
To Biotreater
Shell Global Solutions
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
Shell Global Solutions
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
Shell Global Solutions
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 %
Shell Global Solutions
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
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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
Shell Global Solutions
Thank You.
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