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Shell Coal Gasification Process: An Integrated Solution For Efficient Coal-To-Products Value Chains

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111 views20 pages

Shell Coal Gasification Process: An Integrated Solution For Efficient Coal-To-Products Value Chains

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Umar Hayat
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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SHELL COAL GASIFICATION PROCESS

An integrated solution for efficient coal-to-products


value chains

Gasification India Conference


New Delhi, India
December 06-07, 2017

Presented by: Kapil Girotra, OKEngg, Representative India Shell Global


Made by: Rob van den Berg, Technology Manager Gasification
Shell Projects & Technology
Copyright of Shell Global Solutions International B.V.
Definitions & Cautionary Note

Reserves: Our use of the term “reserves” in this presentation means SEC proved oil and gas reserves.

Resources: Our use of the term “resources” in this presentation includes quantities of oil and gas not yet classified as SEC proved oil and gas reserves. Resources are consistent with the Society of Petroleum
Engineers 2P and 2C definitions.

Organic: Our use of the term Organic includes SEC proved oil and gas reserves excluding changes resulting from acquisitions, divestments and year-average pricing impact.

Shales: Our use of the term ‘shales’ refers to tight, shale and coal bed methane oil and gas acreage.

The companies in which Royal Dutch Shell plc directly and indirectly owns investments are separate legal entities. In this presentation “Shell”, “Shell group” and “Royal Dutch Shell” are sometimes used for
convenience where references are made to Royal Dutch Shell plc and its subsidiaries in general. Likewise, the words “we”, “us” and “our” are also used to refer to subsidiaries in general or to those who work
for them. These expressions are also used where no useful purpose is served by identifying the particular company or companies. ‘‘Subsidiaries’’, “Shell subsidiaries” and “Shell companies” as used in this
presentation refer to companies over which Royal Dutch Shell plc either directly or indirectly has control. Entities and unincorporated arrangements over which Shell has joint control are generally referred to
“joint ventures” and “joint operations” respectively. Entities over which Shell has significant influence but neither control nor joint control are referred to as “associates”. The term “Shell interest” is used for
convenience to indicate the direct and/or indirect ownership interest held by Shell in a venture, partnership or company, after exclusion of all third-party interest.

This presentation contains forward-looking statements concerning the financial condition, results of operations and businesses of Royal Dutch Shell. All statements other than statements of historical fact are, or
may be deemed to be, forward-looking statements. Forward-looking statements are statements of future expectations that are based on management’s current expectations and assumptions and involve
known and unknown risks and uncertainties that could cause actual results, performance or events to differ materially from those expressed or implied in these statements. Forward-looking statements include,
among other things, statements concerning the potential exposure of Royal Dutch Shell to market risks and statements expressing management’s expectations, beliefs, estimates, forecasts, projections and
assumptions. These forward-looking statements are identified by their use of terms and phrases such as ‘‘anticipate’’, ‘‘believe’’, ‘‘could’’, ‘‘estimate’’, ‘‘expect’’, ‘‘goals’’, ‘‘intend’’, ‘‘may’’, ‘‘objectives’’,
‘‘outlook’’, ‘‘plan’’, ‘‘probably’’, ‘‘project’’, ‘‘risks’’, “schedule”, ‘‘seek’’, ‘‘should’’, ‘‘target’’, ‘‘will’’ and similar terms and phrases. There are a number of factors that could affect the future operations of
Royal Dutch Shell and could cause those results to differ materially from those expressed in the forward-looking statements included in this presentation, including (without limitation): (a) price fluctuations in
crude oil and natural gas; (b) changes in demand for Shell’s products; (c) currency fluctuations; (d) drilling and production results; (e) reserves estimates; (f) loss of market share and industry competition; (g)
environmental and physical risks; (h) risks associated with the identification of suitable potential acquisition properties and targets, and successful negotiation and completion of such transactions; (i) the risk of
doing business in developing countries and countries subject to international sanctions; (j) legislative, fiscal and regulatory developments including regulatory measures addressing climate change; (k)
economic and financial market conditions in various countries and regions; (l) political risks, including the risks of expropriation and renegotiation of the terms of contracts with governmental entities, delays
or advancements in the approval of projects and delays in the reimbursement for shared costs; and (m) changes in trading conditions. All forward-looking statements contained in this presentation are
expressly qualified in their entirety by the cautionary statements contained or referred to in this section. Readers should not place undue reliance on forward-looking statements. Additional risk factors that
may affect future results are contained in Royal Dutch Shell’s 20-F for the year ended December 31, 2015 (available at www.shell.com/investor and www.sec.gov ). These risk factors also expressly qualify
all forward looking statements contained in this presentation and should be considered by the reader. Each forward-looking statement speaks only as of the date of this presentation, [insert date]. Neither
Royal Dutch Shell plc nor any of its subsidiaries undertake any obligation to publicly update or revise any forward-looking statement as a result of new information, future events or other information. In light
of these risks, results could differ materially from those stated, implied or inferred from the forward-looking statements contained in this presentation.

We may have used certain terms, such as resources, in this presentation that United States Securities and Exchange Commission (SEC) strictly prohibits us from including in our filings with the SEC. U.S.
Investors are urged to consider closely the disclosure in our Form 20-F, File No 1-32575, available on the SEC website www.sec.gov.

Copyright of Shell Global Solutions International B.V. January 2017 2


Shell Gasification technology portfolio

SHELL GASIFICATION PROCESS (SGP) SHELL COAL GASIFICATION PROCESS (SCGP)

with natural gas with residue feedstock with solid feedstock (coal, petcoke and biomass) e.g.
feedstock e.g. for GTL e.g. for refineries for chemicals, hydrogen and power generation

“One proven technology, two line-ups”

Syngas cooler

Bottom water
quench

Copyright of Shell Global Solutions International B.V. January 2017 3


Residue gasification: from the bottom-of-the-barrel to light products

Proven track record since 1950s Shell Pernis


1997
>125 gasifiers in operation Cracked Residue

Wide residue feedstock range from vacuum residue to highly ENI Sannazzaro
viscous residues, such as thermal cracked residue, solvent de- 2006
asphalter residue; later retrofit to heavier feedstock possible Residue/Asphalt

Safe and reliable operation: automated and fully safeguarded Nexen (Opti)
2008
heat-up, start-up, shutdown sequences; reliability >99.5% Asphalt

Extensive experience in start-up, operation and maintenance Sinopec Fujian


2009
of own units and licensed units. Asphalt

Copyright of Shell Global Solutions International B.V. January 2017 4


SCGP – A proven technology on an ever-increasing scale

3200 t/d
Coal Lu’an (3200 t/d)
feed
ton/day YTH, Datang (2700 t/d)

Datong (2400 t/d)


2000 t/d
Yueyang JV (2000 t/d)

Guangxi Liuzhou (1200 t/d)


YTH Jinxin (1100 t/d)
Wison Nanjing BQ (1000 t/d)
Hubei Shuanghuan (900 t/d
250 t/d
150 t/d
6 t/d

1976 1978 1987 1993 2000


Pilot unit, Demo unit, SCGP-1 NUON Onwards
Amsterdam, Harburg, Houston, IGCC Coal
NL Germany USA Buggenum, gasification
NL licensees

Copyright of Shell Global Solutions International B.V. January 2017 5


SCGP licensing reference in China

>15 years of commercialisation in China


22 license projects, 24 gasifiers in operation, 5 gasifiers to start-up

Pulverized coal intake capacity

> 3,000 t/d


> 2,000 t/d
< 2,000 t/d

17 gasifiers with >2000t/d coal intake capacities


Largest gasifier delivered 3,200t/d, start-up Q1 2017

Copyright of Shell Global Solutions International B.V. January 2017 6


Mature core of the technology: reactor and burners

Syngas and
flyash leave at
the top
GASIFIER
SPACE
(1500-1600oC
Membrane wall 40-45 barg)
protected by slag
layer

Multiple (4-6)
opposed
molten slag
burners
flows downwards

Slag leaves at
the bottom
solid slag on tube wall

BOILER FEED
WATER TUBE
(50-60 bar
270-300oC)
Protection against high operating temperatures via a slag layer on a
membrane (water) wall

Copyright of Shell Global Solutions International B.V. January 2017 7


Shell Coal Gasification: a single proven technology, two line-ups
SYNGAS COOLER BOTTOM WATER QUENCH

Syngas Gasifier
cooler

Water
quench
Gasifier

Industrially proven, mature technology Same basic design as syngas cooler line-up
Carbon efficiency >98-99% Carbon efficiency >98-99%
Highest energy efficiency, lowest consumption Simplified line-up, reduced Capex
High-level steam as a very useful ‘byproduct’ Even wider coal flexibility
Low water consumption, less wastewater to treat: Easier operation and maintenance (less
environmentally friendly equipment)

Copyright of Shell Global Solutions International B.V. January 2017 8


Bottom Quench technology: a simplified line-up

COAL/PETCOKE SYNGAS TO
SHIFT
MILLING/DRYING T~200°C

PROCESS
Gasifier WET WATER
SCRUBBER
COAL FEEDING
FEEDING/PRESS. MP STEAM
1,600°C

Syngas cooler replaced


with a mature, ‘industry-
standard’ water quench T~210°C
technology
PROCESS
Same membrane wall WATER

Same multiple burner


WATER TREATMENT
Same dry feed system

Copyright of Shell Global Solutions International B.V. SLAG FILTER CAKE January 2017 9
SCGP – Syngas cooler process line-up
SCGP line-up with Syngas Cooler (SGC) offers high efficiency and
small environmental footprint

COAL/PETCOKE QUENCH GAS (200°C)

MILLING/DRYING Gasifier
HP STEAM
900°C

MP STEAM

COAL FEEDING 1,600°C RAW


HPHT WET
FILTER SCRUBBING SYNGAS

FLYASH WATER
SYSTEM TREATMENT
SLAG

FLYASH TO SALTS
STORAGE

Copyright of Shell Global Solutions International B.V. January 2017 10


Performance and reliability: wide coal suitability

FEED FLEXIBILITY
Property range of feedstocks operated in SCGP
Handled over >150 different kinds of coal incl.
challenging feedstocks like lignite and petcoke 100% 2000℃ 100%

Four projects successfully used petcoke Lignite

blended with coal, with one reaching >1500℃ Sub-bituminous


-
328 days at full operation load 1140℃ Bituminous
38.6%
35.0%
Based on extensive operating experience, -
-
Anthracite
8.2%
3.8%
several modelling tools were developed Petcoke
to confidently assess novel coals and optimise Ash + flux FT, ℃ Moisture wt% Feedstock
coal blends (MF) wt%

Copyright of Shell Global Solutions International B.V. January 2017 11


Broad operating experience on many different kinds of coal
SiO2

FEED FLEXIBILITY
Handled over >200 different kinds of coal
covering the whole reactivity spectrum from
lignite to anthracite, ash contents from 6-37%
Four projects successfully used petcoke
blended with coal, with excellent operational
results

45
40 CaO Al2O3
35
Ash content, %

30
DEEP INSIGHT IN PROCESS
25
Based on extensive operating
20
experience, several modelling
15 Operational data from a Chinese customer tools were developed
10 to confidently assess novel coals
0 and optimise coal blends
21 Jun 5 Jul 19 Jul 2 Aug 16 Aug 30 Aug
Copyright of Shell Global Solutions International B.V. October 2017 12
Example of actual operation of a Chinese customer

45
Operational data from a Chinese customer

40

35

30
Ash content, %

25

20

15 Typical ash content design window


DESIGN WINDOW
10

0
21 Jun 5 Jul 19 Jul 2 Aug 16 Aug 30 Aug

Copyright of Shell Global Solutions International B.V. January 2017 13


Rich operational experience on petcoke/coal blends

Tianfu was the first dry-feed


gasification plant in China that Now four SCGP plants in China
successfully demonstrated have operational experience on
petcoke/coal blending petcoke

1987 2010 NOW

Gasified 100% petcoke in Petcoke blending gives good


SCGP-1 plant in Houston US operational performance and
reliability: YZH operated
continuously for 291 days
and Tianfu for186 days.
Annual longest accumulated
running days: 341.

Copyright of Shell Global Solutions International B.V. January 2017 14


RELIABILITY DATA 2016

产量
Capacity
可靠性 最长运行天数 平均氧负荷
平均氧负荷
Rt (%) Longest cont. Average O2 load
累计运行天数
(Nm3/hr) Acc. Run days
(Note 1) run (days) (%)
CO+H2

1 140,000 100 348 196 94


2 140,000 98.4 347 234 97
3 70,000 100 336 207 100
4 140,000 100 336 171 101
5 140,000 96.7 335 167 96
6 140,000 95.6 331 173 100
7 70,000 87.4 320 117 89*
8 70,000 88.0 317 88 88
9 70,000 97.3 316 212 103
10 140,000 98.6 315 131 94
11 140,000 97.5 315 178 76*
12 140,000 97.8 313 208 75*
13 140,000 90.7 307 127 91
14 140,000 96.4 300 254 77*
96% *) Limited by downstream demand

Copyright of Shell Global Solutions International B.V. January 2017 15


Top quartile operation performance in 2016

SAFE OPERATION HIGH RELIABILITY


Dongting JV achieved 10 million Overall SCGP plant reliability in 2016 is 96.3%:
man-hours without LTI on December 14 plants clocked more than 300 accumulative
25, 2015 (since 9th Feb 2006) running days, the longest one 348 days

AVERAGE TECHNOLOGY RELIABILITY

LATEST START-UP: ANOTHER SCGP-BQ


Jinxin coal to ammonia/fertilizer plant in Inner Mongolia successfully started
up in June 2016, reached 90% load, and produced on-spec end-use product
within the first month of operation. First BQ operation on lignite

Copyright of Shell Global Solutions International B.V. January 2017 16


SCGP - SGC Korea Western POwer (KOWEPO) IGCC project

The first IGCC project in South Korea, located in


Taean, approximately 150 km south-west of Seoul,
started-up end of 2015.
IGCC is supported as new energy under the Korean
government Renewable Portfolio Standard.
Gasification (a single SCGP unit)
Feedstock: 2,650 ton/day sub-bituminous coal
Syngas capacity:175,000 Nm3/hr CO+H2
IGCC power output 380 MW (gross), net
efficiency 42% HHV, with good air quality
emissions of
SOx < 15 ppm
NOx < 30 ppm
Dust < 1 mg/Nm3

Copyright of Shell Global Solutions International B.V. January 2017 17


Looking to the future

Shell’s world-class gasification technologies can


contribute to a cleaner energy future.
Continuous improvement has seen the reliability of
Shell’s gasification technologies steadily improve in
recent years.
Shell has a strong, global reference list in
gasification
Coal gasification offers a single proven
technology in two line-ups: SCGP syngas cooler
and bottom water quench depending on your
business objectives.
Our dedicated gasification technical and services
team offers comprehensive and experienced
support.

Copyright of Shell Global Solutions International B.V. 18


Thanks for your attention

Copyright of Shell Global Solutions International B.V.


Copyright of Shell Global Solutions International B.V.

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