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tk
A company
of ThyssenKrupp
Technologies
Uhde
The Shell Gasification Process
Contents
1. Company Profile
2. Introduction
3. Process Configuration
3.1 Basic Reactions
3.2 Main Technology Steps
3.3 Advantages of the Shell Gasification Process (SGP)
3.4 Reliability Data
1. Company Profile
Uhde provides more than 250 different processes covering many different
sectors and providing intelligent solutions for the refining, petrochemical and
chemical industries.
Shell Global Solutions International B.V. is owner and licensor of the Shell
Gasification Process (SGP). Uhde is Shells engineering partner for the SGP,
which can be applied for the production of synthesis gas from all liquid and
gaseous feedstocks.
... / 2
2. Introduction
The growing demand for lighter and cleaner fuel products, the heavier crude oil
sources for the refineries and the economical situation inside the refineries to
downgrade the bottom more and more are changing the configuration of the
refineries.
Refineries are also searching for a global solution to their emission problems and
are gradually replacing the old furnaces used for the production of power, steam
and heat.
During the refining stages, heavy metals in particular, vanadium, iron and nickel,
which are present in all crude oils are accumulated in the bottom products. In
fact, these residues, which have the highest metal concentration, are the cheapest
feedstocks for gasification units.
... / 3
This gas can subsequently be used to produce hydrogen, power, fuel gas or steam
for any refinery purposes, as well as producing gases for the chemical industries
(Fig. 1).
Uhde has built worlds largest IGCC Power Plant (318 MW e, net) in Puertollano,
Spain
... / 5
3. Process Configuration
The Shell Gasification Process has a long track record of optimum performance
over many years of operation.
The SGP process, initially developed in the 1950s, was primarily used with fuel oil
and bunker C oil as feedstocks. By the 1970s vacuum (short) residue had become
the standard feed. In the 1980s vacuum residues were concentrated even further
by visbreaking and C4/C5 deasphalting. Over time, the feed became heavier and
more viscous, and contained higher levels of sulphur and heavy metals. Shells
continuous developments in this field over the years underpin its dedication to this
particular technology.
is exothermic and produces a gas which containing mainly CO and H2. The raw
synthesis gas (or syngas) contains small quantities of CO2, H2O and H2S and
impurities, such as CH4, NH3, COS, HCN, N2, Ar and ash, the quantities being
determined by the composition of the feedstock, the oxidant and the actual
gasification temperature (1300 1400 C). A small amount of unconverted carbon
is also present and ranges from 0.5 to 1.0 %wt in liquid feedstocks or 50 200 ppm
wt in gaseous feedstocks.
Hydrocarbon fuels, such as natural gas, refinery gas, bunker C-oil, vacuum residue,
vacuum-flashed cracked residue, asphalt, liquid waste and orimulsion can all be
used as feedstock for the gasification process.
... / 6
The Shell Gasification Process consists of three principal stages (Fig. 2):
PROCESS FEEDSTOCK
STEAM SYNGAS
HP STEAM FILTRATE
OXYGEN BOILER
FEED WATER
SOOT
SCRUBBER
SYNGAS
REACTOR EFFLUENT
COOLER
SOOT
QUENCH
SOOT WATER
Fig. 2: The Shell Gasification Process (Gasifier and Syngas Effluent Cooler
manufactured by Standard Fasel Lentjes B.V., The Netherlands)
The final stage involves a soot water processing section, Naphtha Soot Recycling
Unit (NSRU) or Soot Ash Removal Unit (SARU), which recovers carbon from the
... / 7
wash water and separates the metal ash from the carbon to yield a valuable
product.
Both the feedstock and the gasification agent, oxygen, are preheated prior to being
fed to the burner which is a proprietary co-annular burner specially designed for
viscous feedstocks.
The reactors optimal design allows for complete gasification reactions. The burner
is controlled by a managing system which includes a safeguarding system and a
sequence logic block to enable fully automated start and stops and normal
operation during all plant operating conditions.
The recovery of sensible heat from the syngas is an integral feature of the SGP
process. Primary heat recovery takes place in the Syngas Effluent Cooler (SEC)
where high-pressure saturated steam is generated. Secondary heat recovery
occurs in a boiler feed water economiser immediately downstream of the SEC.
The SGP process suspends the carbon (soot) produced by the partial oxidation of
hydrocarbons in the gasifier, in a carbon slurry, which is an aqueous suspension
containing up to 20 g/l of soot and ash. The soot particles and the ash are removed
from the gas in the two-stage water scrubber, comprising:
About 95% of the soot is removed by a direct water spray in the quench pipe.
The gas then enters the scrubber where it is scrubbed in counter-current flow in a
packed bed using condensate return water and the filtrate from the soot water
processing section. After leaving the scrubber the syngas has a residual soot
content of less than 4 mg/Nm.
The heavy metals and alkaline-earth metals entering the reactor are transformed
into oxides, sulphides and carbonates, and because these compounds are only
slightly soluble the ash follows the soot water process flow.
... / 8
The SGP process has been used successfully with two different technologies for
separating soot from soot water; the most recent ones is shown in Fig. 3.
Water Recycle
+ Scrubbing
Water Recycle
Steam
Steam
Soot Water
Soot Water
Oil/Carbon
Carbon/
Naphtha Soot Water
Oil Part Stream
Extraction Filtration
Waste Water
(Soot + Heavy Metals) Filter Cake
Waste
Filter cake
Water
Burn-off
Treatment
Fig. 3: Naphtha Soot Recovery Unit vs. Soot Ash Removal Unit
In the Naphtha Soot Recovery Unit, NSRU, the soot water is mixed with liquid
hydrocarbons (naphtha) in a proprietary extractor. The hydrocarbons force the soot
particles to agglomerate and to rise and these agglomerates are then sieved-off in
a special rotating sieve. The purified water is recycled back to the scrubbing
section. The naphtha is recovered and the soot becomes a pumpable suspension
in the fresh feedstock (soot oil) which can be recycled and used as feedstock for
the reactor.
The final stage of the NSRU comprises a Waste Water Treatment Unit in which the
heavy metal compounds and the remaining soot are extracted from a small bleed
stream leaving the NSRU.
The latest SGP development in this field is the Soot Ash Removal Unit. This unit
consists of a Soot Water Filtration section and a section for filter cake incineration.
The soot water coming from the scrubber is depressurised and routed to a filter
... / 9
press. Filter cakes with a solid content of approx. 17 20 %wt can be attained. The
filter cake is dried in a special incineration section and the remaining carbon is
burnt off. The final product is a highly valuable heavy metal ash, which is sold to the
metal reclaimer market.
R E L IAB IL IT Y .
SGPs optimum process availability and reliability is the result of more than 40
years experience in the design and operation of gasification units and a dedication
to continuous technological developments.
Key developments in the SGP process have resulted in high on-stream factors
which are now routine in a variety of services.
soot formation and consequently there are fewer deposits on the refractory of the
reactor and less fouling in the SEC. Another result of the moderate gasification
temperature is the comparably low oxygen consumption. Furthermore, the superior
efficiency of the SGP process results in a high CO content and a low CO2 content.
One of the key elements of the SGP process is the Syngas Effluent Cooler (SEC)
which produces high-pressure steam (Fig. 4).
... / 11
SYNGAS
REACTOR EFFLUENT
COOLER
Fig. 4.:
SGP Reactor with
Syngas Effluent Cooler
(manufatured by Standard
Fasel Lentjes B.V., The
Netherlands)
The SEC equipment operates with low fouling and high feedstock flexibility. In fact,
intensive investigations were carried out to ascertain the current availabilities of the
cooler, e.g. the special design of the inlet section of the cooler. Efficiency for
electric power generation increases by approx. 5 percentage points, if an SEC is
used instead of a gasifier operated with a direct water quench. The entire design of
the cooler is extremely cost effective, e. g. there is no additional steam drum. The
use of low-alloy steels combined with special design makes the investment costs
for the SEC very low and the return on investment therefore extremely good. As a
consequence, the SEC usually pays for itself within two years. Low maintenance
costs are achieved since the standard maintenance and cleam-outs usually are
required only after two years.
process uses a filter press and a carbon burn-off process which is completely
reliable and which does not affect the availability of the gasification unit. The Soot
Ash Removal Unit has the following advantages over a Naphtha Soot Recovery
Unit:
The SARU is a typical once-through system with spare capacity in cheap tanks
rather than in expensive filtering systems.
Lower capital requirements and operating costs (automated operation, no use
of naphtha)
Hardly any heavy metals in the waste water
No accumulation of heavy metals in the gasification feed. This prevents heavy
metals from attacking the refractory of the reactor. It also prevents increases in
the viscosity of the feedstock and creates less fouling of the Syngas Effluent
Cooler.
The final product (metal ash) is a valuable product which is sold to metal
reclaimers.
The latest development to the SGP process is the standardised Safeguarding and
Control System. This system includes all the safety measures, which have been
implemented during the development of gasification technology. The special
modular structure means that the commissioning and start-up of the gasification
plant is extremely efficient. The highly automated control system supports the
operator in all aspects of plant operation (start-up, shutdown, stand-by) and avoids
trips of non-safety nature. In fact, this system enables the plant to be started
automatically within 10 minutes and also minimises flaring of the gases produced
during the initial phase of plant operation.
It is even possible to replace the conventional blast burner with a co-annular burner
in existing SGP plants. The Safeguarding and Control System can be easily
adapted to the old plant configuration thanks to its unique modular structure.
... / 13
Data obtained from SGP units already in operation have provided the following
average figures for availability and replacements over a 10 year operating period:
Replacement schedule:
Replacement of burner/internals every year
Coils of the syngas effluent cooler 5 - 8 years
Refractory gasifier 5 - 8 years
Since the SGP IGCC/H2 cogeneration complex started operation in Pernis, further
improvements to its availability and reliability have been observed.
... / 14
Many different gaseous and liquid feedstocks are used for the SGP process.
Although the SGP process is standardised (see Table 1 specific raw gas
production data for the SGP process), any applications affecting the final product
are tailored to the customers requirements using an optimum route for treating and
purifying the syngas (Fig. 5).
Hydrogen
Chemicals
Feedstock
Boilers
Clean Syngas for
Furnaces
Refinery Use
(Electricity)
(Steam)
Gasification Clean
& Syngas
Gastreating (CO + H2) Synthesis of Liquid
Transportation
Hydrocarbons
Fuels
Oxygen Integrated
Gasification Electric Power
Steam
Combined Cycle
Oil/Heavy Residue
Gasification
Syngas
Air Separation Effluent Cooler
Oxygen
Soot Water
Water Soot Ash
Air Soot Scrubbing Filtrate Metal Ash
Removal Unit
Blow Down
H2 S Removal
Waste Water Water
Humidification Treatment
Syngas
Steam
BFW
Sour Gas T
C T G G
Gas
Air
Turbine Steam Turbine
Sulphur Heat
Recovery Recovery
Condenser
Sulphur Flue Gas
An Air Separation Unit (ASU) is also required for the gasifier operation. As a rule,
the oxygen for the gasification unit is more than 95 % pure which means the
equipment needed for the gas path can be reduced in size.
The nitrogen extracted is used in the gas turbine to reduce the NOx emissions
which are formed by the combustion of the clean syngas in the gas turbine for
power generation. The exhaust heat from the gas turbine is used to produce steam
... / 16
in a heat recovery steam generator, which, together with the steam generated in
the Syngas Effluent Cooler of the gasification section, is routed to a steam turbine
used to generate more power.
This approach has the potential to raise the conversion efficiency above that of the
conventional steam cycle if all elements of the plant are integrated optimally, that is:
integration of extracted air for the Air Separation Unit from the gas turbine air
compressor for reducing internal power consumption
integration of nitrogen as a by-product for reducing the NOx emissions
integration of the heat from the steam produced in the Syngas Effluent Cooler
into the CCGT steam cycle for increasing conversion efficiency
optimum use of low-level heat from both the CCGT and the gas treatment
section for preheating and saturation (moisturing) of the syngas for increasing
conversion efficiency.
This optimum integration of the major elements in the power station results in high-
level efficiency (approx. 45 %, LHV-based). As far as environmental acceptability is
concerned, this type of power station can compete with the most efficient
conventional power stations based on other fuels (e.g. coal-fired power stations).
The power stations ability to supply clean gas for a number of applications
(hydrogen, oxo-gas, carbon monoxide etc.), as well as the low-value feedstock
used (high in sulphur and heavy metals), provides the plants with a much stronger
market potential than cheap natural gas power generation.
The integration of the IGCC into refineries leads to additional synergies for both
plants less emissions and lower investment cost by optimum integration of steam,
power and fuel gas produced by the IGCC.
The following atmospheric emissions recorded for an IGCC with the SGP process
emphasise its environmental advantages:
... / 17
Despite the poor quality feedstocks, the emissions are still extremely low. The
sulphur recovery efficiency, defined as a ratio between the liquid sulphur recovered
and the sulphur in the feedstock, is > 99.5 %.
In refineries, the SGP is particularly attractive when used in conjunction with power
generation:
... / 18
- Refineries which are under pressure to invest mainly in SO2 and NOx reduction
may find that the use of clean syngas in furnaces or boilers is a very cost-
effective way to avoid having to make investments for environmental reasons.
- A key factor in solving the global CO2 problem in the future will be linked to true
energy pricing and competition. Improved efficiencies, closed product cycles
and cogeneration are just some of the solutions to this problem. Cogeneration
of Power and Hydrogen should be a must for any refinery wishing to solve
future problems with heavy crude wastes, cleaner automotive fuels and
emission reduction.
- Refinery heat is often distributed at the level of MP steam. This heat can be
supplied from the steam turbine process either directly from the heat recovery
steam generator or by extracting heat from the steam turbine.
- The SGP can handle any heavy feedstock. Consequently the refineries can
utilise deeper conversion (see DTC) which leaves a residue that can yet be
processed by SGP. It is possible for the refineries to increase their profits by
using heavier sulphur and, consequently, cheaper crude.
The SGP process was first used for the production of syngases used in the
chemical industry (primarily ammonia and methanol). The following examples of
various SGP process applications demonstrate its versatility:
The advantage of using the SGP for methanol production is that the gas can be
produced at a pressure level suitable for modern low pressure synthesis
processes without requiring further compression. The total production capacity
of SGP-based methanol plants around the world exceeds 10 million Nm
(H2+CO) per day.
- SGP for CO and Oxo-Gas
The high CO content (approx. 45 %) in raw synthesis gas makes the SGP a
natural choice for the production of oxo-syngas and pure CO. The total
production capacity of SGP based oxo-syngas and CO production plants is over
5 million Nm (H2+CO) per day.
Which gas treatment and purification systems are to be used depends on the purity
requirements and the economics of the particular application.
The SGP process provides an excellent opportunity for turning low-value liquid
residues into high-value products by cogenerating electrical power and gaseous
products. The use of syngas for refinery-based power generation increases the
synergy with other refinery needs. In general, less than 10 % of refinery fuel is
required to cover the hydrogen and energy demand of a typical refinery when using
the SGP process.
... / 20
The Shell Gasification Process used in the Shell Pernis Refinery in the Netherlands
is a fine example of state-of-the-art technology (Fig. 7).
The Shell Pernis plant is the first IGCC in the world to operate using heavy oil
residue gasification. It produces about 115 MW electric power and 285 t/d of pure
hydrogen.
In Pernis, the three-train gasification plant has a capacity of 1,650 t/d (approx.
11,000 b/d) and uses a heavy, vacuum-flashed, visbroken residue as feedstock.
About 1,600 t/d oxygen are supplied by a third-party source nearby. The main
... / 21
reason for having three gasification trains is that if one gasifier needs to be taken
off-line, the hydrogen requirement for the hydrocracker can still be provided by the
two remaining trains.
The scrubber water (containing soot and ash) from the three trains is filtered and
returned to the scrubber. Excess water is fed to water treatment facilities and the
filter cake is processed for metal recovery.
The Pernis SGP plant has been in operation since the end of 1997 and has been
extremely successful in using the latest technological developments in the Shell
Gasification Process, which are:
2. The combination of the specific SGP reactor design with the co-annular burner
permits the operation of the gasification unit with low soot make and relatively
low operating temperatures resulting in a relatively low oxygen demand and CO2
production.
W i n k le r
192 6
= E,P,C by Uhde
K T- 19 41
D e v e lo p m e n t
= Milestone for reference
K T- 19 51
M a z in g a rb e , F
K T ( o il) - 1 9 5 2
Tex aco - 19 53 S h e ll - 1 9 5 3 O u lu , F in la n d
T G P L ic e n s e S G P ( O il)
K T- 1 956
T o ky o , J a p a n
K T- 19 57
P u e n t e s , S p a in
K T ( o il) - 1 9 5 7
Z a n d v o o rd e , B
Tex aco - 19 60 S G P - 1 96 4 K T - 19 62
L is b o n , P o rt u g a l K U s f irs t S G P P t o le m a is , G r.
K T (g a s ) - 1 9 6 5
T a lk h a , E g y p t
K T - 19 65
M a e M o h , T h a il.
K T ( o il) - 1 9 6 8
Z e it z , G e rm a n y
Tex aco - 19 71 K T - 19 68
K ta h ya , T u r ke y
168 SGP Reactors (Shell reference)
L a v e r a , F ra n c e
K T - 19 78 H TW - 1 978
TC G P - 1 978 T a lc h e r, In d ia F re c h e n
D e m o H o lt e n , D
S h e ll -K o p p e r s - 1 9 8 0 K T - 19 78
D e m o H a m b u rg , D R am ag unda m , I.
K T - 19 84
K ta h ya , T u r ke y H TW - 1 985
S C G P -1 9 8 5 B e rre n ra th
TC G P - 1 986 H ous ton, U S A P RE NFLO -198 6 K T - 19 86
O b e rh a u s e n , D F r ste n h a u s e n , D Z e it z , G e rm a n y
K T - 19 88 H TW - 1 988
I n d e c o , Z a m b ia
O u lu , F in la n d
H TW - 1 989
W e s s e lin g
Tex aco - 19 91
O b e r h a u se n , D H TW - 1 993
S C G P -1 9 9 4 K o B ra ( n o t re a l. )
B ugg enum , NL
P RE NFLO -199 7
P u e rt o lla n o , S p a in
S G P - 1 997
Tex aco - 19 98 P e rn is , N L
B h a r u c h , I n d ia
S G P - 1 998
S G P C o o p e ra tio n S C G P - 19 99
S h e ll / K U R e - u n if ie d C o o p e r a t io n H TW - 2 000
S h e ll / K U S H I, J apa n
H TW - 2 002
V re s o v a , C z .
As shown in Fig. 8, Uhde has designed and built about 100 gasifiers worldwide
based on 5 different gasification technologies (Shell, PRENFLO, Koppers-Totzek,
High-Temperature Winkler, Texaco) catering to almost all feedstocks - solid, liquid
and gaseous. These technologies include upstream and downstream processes,
such as heat recovery, gas treatment, waste water treatment, and subsequent
processes for the production of methanol, ammonia, hydrogen, oxo-chemicals and
electrical power.
Shells expertise in refinery processes is unbeaten and the company can provide
in-depth assistance throughout the project cycle, from the design studies to after-
sales service.
Both Shell Global Solutions International B.V. and Uhde are world leaders in the
development, design, construction and commissioning of their gasification
technologies. Both companies have been involved not only in the technology
development and front-end basic design of the plants, but also in the detailed
engineering, commissioning, start-up and operation of gasification facilities for
decades.
This unique set-up ensures that the feedback essential for further process
improvements and developments is readily available. This is further supported by
extensive research and development work on all components in the gasification,
gas treatment, refinery and chemical plants.
Uhde is dedicated to providing its customers with a wide range of services and to
supporting them in their efforts to succeed in business.
The policy of the Uhde group and its subsidiaries is to ensure utmost quality in the
implementation of our projects. Our head office and subsidiaries worldwide work to
the same quality standard, certified DIN / ISO 9001 / EN29001.
We remain in contact with our customers even after project completion. Partnering
is our byword. We promote active communication between customers, licensors,
partners, operators and our specialists by organising and supporting technical
... / 25
symposia. This enables our customers to benefit from the development of new
technologies and the exchange of troubleshooting information.
We like to cultivate our business relationships and learn more about the future
goals of our customers. Our after-sales service includes regular consultancy visits
which keep the owner informed about latest developments or revamping
possibilities.
For more information contact one of the Uhde offices near you or see Internet:
www.thyssenkrupp.com/uhde
... / 26
The following list summarises all plants applying the Shell Gasification Process currently in
operation. The total amount of SGP gasifiers licensed amounts to over 160.
Hoechst Celanese Ltd. Houston, USA natural gas oxo 2,100,000 3 1977
Fertiliser Corp. of India Sindri, New Delhi, India heavy fuel oil ammonia 2,100,000 3 1977
Ltd.
National Fertiliser Ltd. Nangai, New Delhi, bunker C oil ammonia 2,100,000 3 1978
India
Hindustan Fertiliser Haldia, New Delhi, India bunker C oil ammonia + 2,100,000 3 1978
Corp. Ltd. methanol
Exxon Chemical Baton Rouge, USA heavy fuel oil oxo 570,000 3 1978
Company
National Fertiliser Ltd. Bathinda, India bunker C oil ammonia 2,100,000 3 1978
National Fertiliser Ltd. Bathinda, India bunker C oil ammonia 2,100,000 3 1979
Neyvell Lignite Corp. Neyvell, Tamil Nadu, bunker C oil syngas 800,000 2 1979
Ltd. India
Qilu Petrochemical Ind. Zibu, Shandong, China vacuum methanol + 715,000 2 1987
residue oxo
Shell MDS (Malaysia) Bintulu, Malaysia natural gas middle 7,552,000 6 1993
distilates
JiuJiang Petr. Chem. JiuJiang City, Jiangxi, vacuum ammonia 2,100,000 2 1996
Fertil. Comp. China residue
Inner Mongolia Chem. Hohot, Inner Mongolia, vacuum ammonia 2,100,000 2 1996
Fertiliser Plant China residue
Lanzhou Chem. Industry Lanzhou, Gansu, China vacuum ammonia 2,100,000 2 1997
Co. residue
Further SGP licenses have been granted since 1997. These have not yet been added
to the reference list. These plants are in various phases of realisation.
Uhde GmbH
Friedrich-Uhde-Strasse 15
D-44141 Dortmund
Tel.: +49 2 31 5 47-0
Fax: +49 2 31 5473032
www.thyssenkrupp.com/uhde
A company of
ThyssenKrupp Technologies
Fields of activity:
Refineries
Gas generation
Gas treatment
Synthesis processes
Ammonia, methanol, hydrogen
Fertilisers
Plastics and synthetic fibres
Organic chemicals
Aromatics
Electrochemicals
Bleaching chemicals (H2O2,CIO2 )
Oil and coal gasification
Energy technology
Pharmaceuticals
Infrastructures
General Contracting
Services