Shell Coal Gasification Process Update

Pete Parker

US Gasification Service Manager

Shell Global Solutions (US) Inc
GTC 06 MHernandezCopyright:Copyright:
10/4/2006 SIPC Shell Exploration & Production Ltd.
Agenda

Shell coal/coke gasification process

Comparison of low rank US coals to ongoing projects
SCGP availability
Syngas availability strategies
Shell Oil Gasification vs. Shell Coal Gasification
liquid refinery residues, coal, lignite,
natural gas petroleum coke
SGP SCGP

Differences:
non-slagging condition slagging condition
refractory lined gasifier membrane wall gasifier
liquid/gas feed system dry feed system
fired tube boiler water tube boiler
soot water handling solid slag handling
 Shell Coal Gasification Simplified Flow Scheme
COAL/PETCOKE Fly ash
Recirc.
Recirc. QUENCH GAS

1650 F
Milling/Drying GASIFIER HP STEAM

2900 F
MP STEAM

Coal feeding Wet Gas

CLEAN
DSR Scrubbing Treating SYNGAS

Fly ash Water

SLAG Treatment
system

FLY ASH TO SALTS SULPHUR

MILLING AND DRYING
Shell Coal Gasification Features

Entrained flow, dry coal feed,

compact
equipment, good scale-up possibility
Membrane-wall gasifier
Long life time of membrane wall (
>25 yrs)
and coal burners ( >20,000 hrs)
High carbon conversion ( >99%)
Applicable to most coals
Low coal consumption, and
low oxygen consumption

High cold gas efficiency ( >80 %

LHV)
10/4/2006 GTC 06 MHernandezCopyright:Copyright:
SIPC Shell Exploration & Production Ltd.

US coals compared to non-US projects

Range of Coal Properties Tested and Accepted
(at SCGP-1, Houston)

Proximate, wt % Ultimate, wt % MF

Moisture (AR) 3.7 35.6 Carbon 56.4 88.7

Ash (MAF) 0.5 24.5 Hydrogen 3.6 5.7

VM (MF) 10.6 45.6 Nitrogen 1.1 1.7

Fixed C (MF) 39.1 88.5 Sulphur 0.3 5.2

Chlorine 0.01 0.41
Oxygen 0.1 18
(by difference)
HHV (MBtu/lb) 9.9 14.3

Shell (dry feed) coal gasification technology is

also suitable for gasifying low rank sub-bituminous coal and lignite.
Comparative Coal Properties

Texas North
PRB
Lignite China

Carbon 48.2 35.0 36.9

Hydrogen 3.3 2.7 2.5

Oxygen 11.9 11.3 10.4

Chlorine 0.0 0.1 0.1

Sulfur 0.4 1.2 1.6

Nitrogen 0.7 0.8 0.6

Ash 5.3 15.9 13.0

Moisture 30.2 33.0 35.0

HHV, BTU/LB 8,340 6,018 6,229

Comparative Coal Ash Properties
Texas North
PRB
Lignite China

Silicon Dioxide 31.4 45.2 52.9

Aluminum Oxide 15.1 21.9 20.2

Ferric Oxide 5.4 7.0 7.7

Titanium Oxide 1.1 1.6 1.0

Phosphorus Pentoxide 0.9 0.8 0.4

Calcium Oxide 23.6 16.4 4.9

Magnesium Oxide 4.7 3.3 2.1

Sodium Oxide 1.5 0.8 2.5

Potassium Oxide 0.3 0.8 1.6

Sulfur Trioxide 14.7 1.3 4.5

10/4/2006 GTC 06 MHernandezCopyright:Copyright:
SIPC Shell Exploration & Production Ltd.

SCGP Availability
SCGP Availability

Nuon Power Buggenum 2002 - New designed Shell Gasifier:

2004:
Unplanned outage 6%
Unplanned outage 14.0 Gasification Island:
% Buggenum problems designed out N.A.
Gasification island: Miscellaneous items 4.5 %
Related to equipment/system failures 4.7 % ASU and Gas-treating related* 1.5 %
Miscellaneous items 5.8 %
ASU and Gas-treating related 3.4 % Planned outage 6%
Shell expectation based on current maintenance
Planned outage 13.1 % philosophy

Relatively high as Buggenum is less time constraint

because of available spare power capacity in the
Netherlands Total outage 12 %

Total outage 27.1 %

*: Based on current industry standards (ASU: 99.0%; Gas-treating: 99.5%)
SCGP Availability

Factors for improved availability of latest SCGP designs:

Design modifications implemented in new designs:

HTHP filter; candle support grid
Improvement of SGC water tube flexibility
Material of slag bath water circulation system
Cooled wall heat skirt (not implemented in
Buggenum)
Minimization of coal switches; In Buggenum, the coal
feed switched frequently, requiring significant retuning
of the plant.
10/4/2006 GTC 06 MHernandezCopyright:Copyright:
SIPC Shell Exploration & Production Ltd.

Syngas Availability Options

Product Availability Needs

Power Limit in GT

Hydrogen 98 99.5 %

Chemicals 98 + %
Syngas Availability Options

Spare Gasifiers
2 x 100%
3 x 50%

Other Technologies
Natural gas (Power)
Natural gas or vacuum resid gasification (SGP)
Steam methane reforming (Hydrogen)
The Shell Gasification Process with Natural Gas

Bintulu Gas-to-Liquids
Qatar GTL
Clear Lake, TX
SGP in Hot Standby

For unit to produce 100 mm SCFD

Startup time < one hour
CAPEX < $15 mm
Natural gas consumption in standby = 70 mscfd
Natural gas consumption in operation = 37 mmscfd
Availability basis Bintulu experience = 97%
SCGP Availability with 100% Spare Gasifier

365 Days
Planned Maintenance No Planned Maintenance
Gasification
Availability
43.8 321.2
=
1 Up 0 Up 2 Up 1 Up 0 Up
99.0 %

41.2 2.6 283.8 36.2 1.2

Gasification Island Availability for Different Backup
Options

Configuration Availability

Single train 88%

2 x 100% 99.0%

77.8% full capacity

2 x 50%
21.2% half capacity

97.0% full capacity

3 x 50%
2.9% half capacity

Natural gas ~100%

Natural gas gasifier 99.6%

Economic Impact of Backup Choice

2 x 100%

3 x 50%
Cost of Production

2 x 50%

1 X 100%

SGP
Natural
Gas

Natural Gas Price

Final Thoughts
High availability of product is often needed
Need to consider availability options carefully
and in project context
Natural gas is likely the preferred backup if
practical for your project
SGP on hot standby is a good, low CAPEX option
for hydrogen and chemical applications