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Gas-to-Liquids Realizing the vision

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Page 1: Gas-to-Liquids - · PDF fileWhy GTL is the term given to a number of gas-to-liquids processes, primarily the formation of liquid hydrocarbons, dimethyl ether or methanol, from natural

Gas-to-LiquidsRealizing the vision

Page 2: Gas-to-Liquids - · PDF fileWhy GTL is the term given to a number of gas-to-liquids processes, primarily the formation of liquid hydrocarbons, dimethyl ether or methanol, from natural

Business Lines:

Gas-to-Liquids

LNG

Upstream Oil & Gas

Refining

Chemicals &Petrochemicals

PharmaceuticalsBiotechnology

Healthcare

Power

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Turning vision into reality

GTL has clearly come of age andsome of the engineering challengesthat have faced the experts overrecent years have been overcome.In certain regions of the world GTL isconsidered economically viable andthe first in the next generation of GTLplants is taking shape in Qatar.

Foster Wheeler has led the way indeveloping complete GTL solutions, working with differenttechnologies, for a number of clients, in difficult locations. We'vehelped major international andnational oil companies develop theirGTL strategies.

Our significant contribution to theORYX GTL plant in Qatar started withthe development of a feasibility studyand a high quality FEED andcontinues with provision of ourexpertise as members of the ProjectManagement Team.

GTL projects require the 'top team'.The challenges to be faced even atthe feasibility stage go well beyondthe process engineering that typifies most feasibility studies, intosolutions for utilities and offsitesintegration, some 40-50% of project costs, constructionphilosophy, risk management andenvironmental impact.

Foster Wheelerleads the way ingas-to-liquidssolutions. No othercontractor has thesame breadth anddepth of experienceor talented GTLengineeringresource.

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Page 4: Gas-to-Liquids - · PDF fileWhy GTL is the term given to a number of gas-to-liquids processes, primarily the formation of liquid hydrocarbons, dimethyl ether or methanol, from natural

Why

GTL is the termgiven to a numberof gas-to-liquidsprocesses, primarilythe formation of liquidhydrocarbons,dimethyl ether ormethanol, fromnatural gas.

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Page 5: Gas-to-Liquids - · PDF fileWhy GTL is the term given to a number of gas-to-liquids processes, primarily the formation of liquid hydrocarbons, dimethyl ether or methanol, from natural

There are a number of reasons forusing GTL technology to convertnatural gas into liquid products:

· Many of the world's gas reservesare considered 'stranded', beingtoo far from consumers anddifficult or expensive to transport

· Associated gas (with oilproduction) in quantities toogreat to utilize at the site

�• The need to end flaring

· Diversifying market risks,converting natural gas intosomething other than LNG

· Legislation driving demand for high quality, cleaner transport fuels

Technology used in GTL projectsincludes syngas production,Fischer-Tropsch (FT) synthesis,methanol synthesis and dimethylether (DME) conversion. Foster Wheeler has expertise in all of these technologies and is able to provide a complete projectservice to deliver exceptionalengineering solutions.

GTL processes offer

attractive alternatives for

monetizing gas. There is

a significant potential

market for high quality,

low impurity synthetic

hydrocarbon transportation

fuels and chemical

feedstocks, which meet

high environmental

standards.

gas-to-liquids?

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We have the rightpeople with the right expertise,commitment andexperience to deliverhigh quality completeGTL solutions.

Commitment

· Technology selection andoptimization

· Feasibility studies

· Front-end engineering design(FEED)

· Utility and offsite system definitionand integration

· Project management

· Detailed engineering

· Environmental engineering

· Procurement

· Construction management

· Commissioning

· Operations and maintenancemanagement

· Training

We work closely with our clients toturn ideas and concepts into safe,successful, high quality facilities.

We understand the drivers andchallenges of GTL projects and haveworked with our clients through thevarious project phase stages toovercome these challenges anddevelop cost-effective, optimizedsolutions. We are particularly skilledat integrating GTL process units withoffsites and utilities.

We add value for our clients throughout the project lifecycle:

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to deliver

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Page 8: Gas-to-Liquids - · PDF fileWhy GTL is the term given to a number of gas-to-liquids processes, primarily the formation of liquid hydrocarbons, dimethyl ether or methanol, from natural

Front-end

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Page 9: Gas-to-Liquids - · PDF fileWhy GTL is the term given to a number of gas-to-liquids processes, primarily the formation of liquid hydrocarbons, dimethyl ether or methanol, from natural

We have a reputation for

delivering high quality

conceptual, feasibility and

front-end packages, which lay

the foundations for a

successful project. We have

executed well over 150 major

FEEDs in the last 15 years.

We can provide advice to technologydevelopers to enable them tooperate their pilot plants, to gainuseful data and thus improve theengineering definition of a project.

Linking our process expertise andour project execution/estimatingskills and IT tools, we apply valueimprovement practices during theearly phases of a project, where theydeliver the greatest benefit.

"At this defining stage of the project,we note to our satisfaction aremarkably low level of designchanges and cost increasesassociated with the P&ID andHAZOP reviews to date. This is asignificant achievement, particularlyfor a new technology project suchas this. We directly associate thisachievement to the high quality andcompleteness of the front-endengineering design packagedeveloped by Foster Wheeler.�”

�“�…a significant achievement�…�”Following the 30% engineeringcompletion phase of the ORYX GTL project in Qatar, W J Swanepoel, GTL ProjectManager, on behalf of Sasol.

excellence

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Page 10: Gas-to-Liquids - · PDF fileWhy GTL is the term given to a number of gas-to-liquids processes, primarily the formation of liquid hydrocarbons, dimethyl ether or methanol, from natural

Our breadth of expertise in gastreatment and conversion processesis of particular benefit whenconsidering integrated upstream anddownstream projects. The integrationand optimization of the energy,offsites and utilities systems are keyto providing economic solutions toGTL ventures.

Our extensive experience providesmajor cost-saving opportunities forour clients in:

· Air separation· Heat integration and recovery· Steam generation and utilization· Hydrogen production· Waste water processing and

treated water re-use· Product quality optimization

We also provide expertise inminimizing plot plan and pipingarrangements, optimizingconstruction philosophy andschedule reductions.

Syngas productionWe have experience in a full range ofsynthesis gas generationtechnologies including:

· Partial oxidation (air and oxygen based)

· Catalytic partial oxidation· Autothermal reforming· Gas heated reforming/heat

exchange reforming· Steam methane reforming· Combination reforming and

other hybrids· Ceramic membranes

Foster Wheeler has its own steammethane reforming technology, andhas worked with other technologies.

Fischer-Tropsch synthesisThis process has been usedcommercially since the 1950s andhas since advanced considerably. A number of oil and chemicalcompanies and technologydevelopers license their owntechnology. We have developeddesigns with several of thesecompanies for fixed, moving andslurry bed technologies.

Taking

We have unrivalledexperience intechnology transfer.We work withleading internationalprocess licensorsboth in technologyevaluation andproject execution.

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technology further

Methanol conversionWe have worked with a number ofmethanol conversion technologiesfor production of fuel and chemicalgrade methanol. We can offeroxygen-blown, air-blown or enrichedair schemes.

Dimethyl ether conversionThis process provides anadvantage over methanolconversion by producing a non-toxic fuel with high calorificvalue as an alternative to LNG fora power-based value chain, or asa diesel replacement fuel.

Floating GTLWe have experience inbarge-mounted and floatingproduction storage offloading(FPSO) facilities for thedevelopment of integrated GTLoffshore facilities, via the SeagasJoint Industry Project, of which we are one of the founder members.

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Quality ideas into

Our projects areamong the safest inthe business, butwe continually striveto do even better.We have won morethan 50 safetyawards over the last 10 years.

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quality solutions

EngineeringWe deliver a high quality product,with engineering experts who designwith a focus on safety, cost,constructability and operability. Wethink it's important that engineersfollow the job through to site andtake an active role in constructionand commissioning.

ProcurementWith our global network ofprocurement centres and our localknowledge, supported by e-procurement, we have theexpertise, negotiating power andflexibility to match the supply ofmaterials and services to our clients'cost, schedule, quality, local contentand export credit needs.

Construction andcommissioningThere's a focus on construction andcommissioning from day one of ourprojects. Our constructionmanagement personnel are highly

experienced and culturally awareprofessionals with a 'can do'mentality, who expect the sameworld-class standards on theirconstruction sites, wherever theyare in the world.

With significant modularizationexperience, we have the expertise to develop the optimumconstruction strategy.

Plant operations and maintenanceOur operations and maintenancecentre of excellence specialisesin the provision of management,operations, maintenance, staffdevelopment and training services.Its expertise ranges from operatingan entire facility to provision ofspecialist consultancy services.

EPC expertiseAs an EPC contractor or projectmanagement consultant, we haveexecuted projects with a totalinstalled cost exceeding $50 billion.Our network of execution centresprovides our clients with local accessto our global resources.

We have a long track record ofexecuting successful EPC projects,completed on time, meetingaggressive cost targets but with nocompromise on safety or quality.Complex, large and difficult projectsare areas in which we excel.

Project managementExcellence underpins our projectmanagement track record andcontributes significantly to our highlevel of repeat business. We have areputation for providing world-classproject management, as an integralpart of our EPC project execution, orworking with our clients as theirproject management consultant.

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Adding

Utility integrationGTL plants are large consumers andproducers of utilities. We haveinvestigated and created solutionsfor the reuse of available utilities inorder to improve availability andreduce capital costs.

Fuel and tail gasmanagementFor unreacted syngas, lighthydrocarbons and CO2, we haveassessed their use as a stableheating resource and developedsolutions for hydrocarbon andhydrogen recovery, recyclinghydrogen and CO2, and using CO2

for syngas ratio adjustment.

Water treatmentWater is by far the largest processstream of a GTL plant. We havedeveloped solutions for simpledisposal and upgrading for irrigation,cooling water and boiler feedwaterquality using reverse osmosis andchemical/biological treatment.

Project implementationWe have reduced schedules bydeveloping constructionmethodologies and sequencing,improving the EPC bidding process, making technologyselection during FEED phase, and optimizing commissioning and start-up procedures.

We have theexpertise to provideinnovative solutionsto complex problems, optimizingproject execution and reducing capital costs.

Here are just a few examples of how we helped our clients solveproblems or do things differently:

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value

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Chevron Nigeria Ltd Escravos GTL ProjectNigeria

New 34,000 bpd gas-to-liquidsplant, producing premium qualityGTL fuels and naphtha products.

Pre-feasibility and feasibility studies,single point licensing on behalf ofSasol Technology comprising basicengineering of licensor units,process facilities, steam systemsand licensor co-ordination. Alsoawarded FEED, long leadprocurement, preparation of biddocuments for EPC bidders andassistance with EPC evaluationand project award.

Marathon Gas-to-Liquids ProjectQatar

Project Management Consultant(PMC), assisting Marathon incompleting pre-FEED feasibility studies for design optimization andcost reduction.

The study included assessment ofthe application of Fischer-Tropschgas-to-liquids technology, operabilityand hazards evaluation, waterhandling and disposal, plant layoutoptimization, contract strategydevelopment, operating andmaintenance philosophy, andpreparation of a total installed cost estimate.

Project highlights

Sasol/Qatar Petroleum ORYX GTL ProjectRas Laffan, Qatar

New 34,000 bpd gas-to-liquidsplant processing 330 mmscfdlean natural gas, producing:· 24,000 bpd fuel· 9,000 bpd naphtha· 1,000 bpd LPG

Pre-feasibility and feasibilitystudies, fast-track FEED, long leadprocurement, preparation of biddocuments for EPC bidders andassistance with EPC evaluationand project award. Contributing todriving EPC progress as part ofthe Project Management Team.With unrivalled experience intechnology transfer, we work withleading international processlicensors both in technologyevaluation and project execution.

We have delivered a large number of gas-to-liquids projects since 1996:over 20 technology development studies, 20 pre-feasibility studies, eight detailed feasibility studies and two front-end engineering designs.

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Seagas JIPOffshore GTL

Seagas is a joint industry projectset up to examine the possibilitiesfor developing commercially viableoffshore GTL facilities involving fourcontractors: Foster Wheeler, asengineering and processspecialist, Spanish shipbuilder Izar,Dutch floating production operatorBluewater, and certification agencyDen Norske Veritas.

Having developed a deepunderstanding of the key issuesand possible solutions for a WestAfrican scenario, the team is now seeking a real field development project on which to apply its expertise.

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100%commitment

to meeting your

safety, cost, schedule,quality and

plant performanceobjectives

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[email protected] www.fwc.com

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