from bintulu shell mds to pearl gtl in qatar conferences/2005/sd… · from bintulu shell mds to...
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From Bintulu Shell MDS to
Pearl GTL in Qatar
Bilbao, 15 March 2005
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Shell MDS in Malaysia
Shell GTL Technology
Bintulu Learnings
Marketing of GTL Products
From Bintulu Shell MDS to Pearl GTL in Qatar
Progress of Pearl GTL Project
Conclusions
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SARAWAK
BintuluShell MDS Plant
SABAH
PENINSULARMALAYSIA
Kuala Lumpur
Head Office
INVESTMENTInitial capital investmentof US$850 million2003 debotteneckinginvestment of US$50 million
STRUCTUREShell MDS (Malaysia) Sdn. Bhd.Shareholders: Shell, Mitsubishi, Petronas, Sarawak State
SCOPEConversion of 110 mmscf/d NG into 575 kt/a (14,700 b/d) of GTL productsProduces clean fuels and specialityproductsWorldwide marketing
Shell MDS in Malaysia
4Byproducts: Nitrogen, Water, Biosludge
Air
Air Separation
NG Feed
Gasification
Synthesis
Conversion
Separation
- Specialities- Chemicals- Waxes
HydrocarbonProducts
- Naphtha- Kerosene- Gasoil- Waxy Raffinate
Shell GTL Technology Processes
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Challenges in Industrial Scale GTL
Gas processes without intermediate storage
Extreme conditions
Exothermic processes
High degree of process and utilities integration
Large-scale equipment
Specific HSE challenges
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LTI-free man-hours: 12.2 mlnRC-free man-hours: 1.7 mln(Status December, 2004)
FAT0
LTI0
Restricted Work Case0
Medical Treatment Case0
First Aid Case6
Near Misses6
LMHRisk potential
67%99.4%94.4%
33%0.5%2.2%
00.1%3.4%
61HSE Audit findings1027Unsafe Conditions356Unsafe Acts
HSE Achievements – 2004 Performance
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Fundamental Lessons Learned in Bintulu
Achieving high catalyst performance
Scale-up of reactors and other equipment
Proving reactor internals and systems for heat removal
Proving the suitability of construction materials
Proving the suitability of many prototype pieces of equipment
Proving the operability and dynamic control of the integrated complex
8 Max
imum
day
s be
twee
n co
mpl
ex s
hutd
owns
0
50
100
150
200
250
300
350
400
450
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
5679
141
8571
114
157
270
430
Continous Reliability Improvements
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L-P
Wax
Solvents, LDF,WR, waxes
Solvents
LDF,HDF
Naphtha
L-P
Wax
WaxWRHDF
Gasoil
Solvents, LDF,WR, waxes
Wax
LDF,HDF
Naphtha
LDF = Light Detergent Feedstock (n-paraffins)HDF = Heavy Detergent FeedstockWR = Waxy Raffinate
Gasoil
Worldwide GTL Products Marketing
10 10
Retail Sales of Shell GTL Blends
Shell Pura
Diesel
Thailand
Shell V-Power
Diesel
GermanyNetherlands
Shell Diesel2004
Athens
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Shell GTL Fuel Trials
Daimler Chrysler bus Trial
Toyota Trial
Volkswagen Trial
Berlin
Tokyo
ShanghaiLondon
California
Mitsubishi Trial
Pudong Bus Trial
Yosemite Waters Trial
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NOx Partikel·10 HC CO
0,1
0
0,2
0,3
Em
issi
onsw
erte
[g/
km]
Grenzwerte EU IV Diesel < 10ppm SShell GTL∆NOx= - 6,4% ∆Part. = - 26%
∆HC = - 63% ∆CO = - 91%
EU IV
Emissions Performance – Volkswagen Test
Berlin Fleet test 2003 - VW Golf with Shell GTL Fuel
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North Field
Pearl GTL - Project Overview
RasLaffan
Doha
Fully integrated project: “From Reservoir to Market’
Development & Production Sharing Agreement
1,600 MMscf/d well head gas
140,000 b/d GTL products
Substantial volumes LPG & condensate
Two phases, start-up end 2009 and ~ one year later
Capital costs to implement ~ USD 6 bln
EthanePropaneButaneCondensateSulphurGTL NaphthaGTL Gasoiln-ParaffinsBaseOilsWater
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Tangible Progress in QatarSeismic
800 km2 3 D seismics completed in 2003
Providing info for appraisal drilling and for subsurface modelling of allocated area
Appraisal Well DrillingFirst well spud on 14th February and completed31st August 2004
Second well spud on 4th September and completed 19th December 2004
Geotechnical Site InvestigationsFirst phase completed Dec.’03 – April ’04
Detailed FEED work in progress
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Tangible Progress: FEED Activities
Onshore EPC Contracting:– Strategy: single Lump Sum– EPC pre-qualification completed and ITB
issued January 2005
Onshore FEED:
– Conducted by JGC, primarily in the London offices of MW Kellogg (joint venture of JGC & KBR), during March 2004 – May 2005
– Close to 500,000 man-hours
Offshore Front-End-Engineering-Design (FEED):
– Conducted in Shell offices, Aberdeen during March 2004 to February 2005
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Onshore Project Scope: Huge Dimensions
1440 meters 1610 meters
FEED:Number P&IDs ~ 900Number documents ~ 4,000
Number Volumes ~ 140
Construction:Plot area: 230 haEquipment number 2,300 itemsEquipment weight 100,000 tons Piping 50,000 tons Structural steel 30,000 tons Concrete 200,000 m3
Cables 1,800 kmInsulation 700,000 m2
Heavy lifts > 1,200 tons > 24
Commissioning & Start-up:Mitigation of ~ 2000 ‘flaws’Checks > 2 millionActivities: ~15,000
Process:Shaft power consumption 1,100 MWHeat consumption 850 MWSteam generation 8,000 tons/hrCatalysts (5 processes) 5,630 tonsControl loops 4,000
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Construction ChallengesConcurrent Projects in Ras Laffan:
– Dolphin, RasGas 5,6&7, QatarGas II, QatarGas III, Oryx II, AKG II & III, Sasol/Chevron GTL, Methanol, DME, Exxon GTL, Marathon GTL, ConocoGTL, harbour & other infrastructure expansion, ….
– During 2005 – 2008 potentially several billions USD per quarter
0
10000
20000
30000
40000
50000
60000
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q
2004 2005 2006 2007 2008 2009 2010
Total (incl. Shell)
Shell only
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From Bintulu Shell MDS to Pearl GTL in Qatar
Shell has obtained vast commercial GTL experience through elevenyears of operation of the Shell MDS plant in Bintulu, a period of continuous learning
Bintulu has demonstrated that GTL technology on a commercial scale can be safe, efficient, reliable and profitable
The Pearl GTL project is fully underpinned by the Bintulu experience
The Pearl GTL project has already seen sustained progress in many areas and the resources are in place to ensure this progress is maintained through to the planned completion date
The Pearl GTL project is of huge dimensions and poses many challenges – but challenges that are manageable
As the first world-scale GTL plant, Pearl GTL signifies the birth of an exciting, new growth industry based on unique products that will deliver long-term value for both Qatar and Shell
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