GASTECH 2002
“GTL Offshore: The Marine Perspective”
IZAR Abel Méndez, Joaquín López-Cortijo, Fernando LagoFW Steve Spicer, Simon C. Clarke
F ene shipyard
13th- 16th OCTOBER 2002Sheraton Hotel & Qatar International Exhibition Centre, Doha
Foster Wheeler experience and capabilities
Considerable experience in gas processingConsiderable experience in gas processing– Technology optimisationTechnology optimisation– StudiesStudies– FEEDs FEEDs – EPC EPC – Project Management ConsultancyProject Management Consultancy
Executed FEEDs for Executed FEEDs for – Sasol/Qatar Petroleum QGTL Project at Ras LaffanSasol/Qatar Petroleum QGTL Project at Ras Laffan– Sasol/Chevron Nigeria Ltd EGTL Project at Escravos, Nigeria Sasol/Chevron Nigeria Ltd EGTL Project at Escravos, Nigeria
Extensive feasibility study work over last six yearsExtensive feasibility study work over last six years– Onshore plantsOnshore plants– Offshore plants - barge or ship mountedOffshore plants - barge or ship mounted
Assistance with Starchem methanol technologyAssistance with Starchem methanol technology Engineering contractor for OTM AllianceEngineering contractor for OTM Alliance Supplier of SMR units and proven technologySupplier of SMR units and proven technology
Gastech 2002 - GTL Offshore: The Marine Perspective
Agenda
The offshore gas debateThe offshore gas debate
The challenge of offshore GTLThe challenge of offshore GTL
The way forwardThe way forward
IZAR/FW: potential contribution to GTL projectsIZAR/FW: potential contribution to GTL projects
Gastech 2002 - GTL Offshore: The Marine Perspective
Summary and conclusions Summary and conclusions
Gastech 2002 - GTL Offshore: The Marine Perspective
The Offshore
Gas Debate
Offshore Associated Gas
Current FPSOs are targeted at oil productionCurrent FPSOs are targeted at oil production
Many deepwater fields have a large associated gas componentMany deepwater fields have a large associated gas component
Associated gas has to be handled Associated gas has to be handled
– Power generation - usually not for exportPower generation - usually not for export
– Re-injection - high cost, longer-term issues such as gas breakthrough Re-injection - high cost, longer-term issues such as gas breakthrough
– Flaring - generally not a long-term solutionFlaring - generally not a long-term solution
Associated gas can be a valuable resourceAssociated gas can be a valuable resource
However, can we afford to use it? However, can we afford to use it?
Gastech 2002 - GTL Offshore: The Marine Perspective
Stranded gas utilisation alternatives
Gastech 2002 - GTL Offshore: The Marine Perspective
GTL
Source: DEMO 2000, Statoil, Shell
The gas-to-liquids solution
Physical processes Physical processes – LNGLNG
Chemical processesChemical processes– Fischer-Tropsch, methanol and derivatives Fischer-Tropsch, methanol and derivatives
Gastech 2002 - GTL Offshore: The Marine Perspective
A process that converts natural gas into a transportable form
A process that converts natural gas into a transportable form
Gas-to-liquids: a general term covering ..... Gas-to-liquids: a general term covering .....
Gastech 2002 - GTL Offshore: The Marine Perspective
Gas utilisation options
MethanolMethanol(chem grade)(chem grade)
ChemicalsChemicals
PowerPower
DieselDieselSubstituteSubstitute
Poly-OlefinsPoly-Olefinsetcetc
SyncrudeSyncrude
Lubes / Lubes / WaxesWaxes
MiddleMiddleDistillatesDistillates
Gasoline /Gasoline /NaphthaNaphtha
UserUser
SyngasSyngasGenerationGeneration
POXPOXSMRSMRATRATROTM/ITMOTM/ITMGHR HybridsGHR HybridsPlasmaPlasma
OO22AirAir SteamSteam
ExistingExistingTerminalTerminal
Low TempLow TempFischer-Fischer-TropschTropsch
WaterWater
Hydro-Hydro-ProcessingProcessing
TTTT
TT
TT
New Terminal / New Terminal / Phase ChangePhase Change
PhysicalPhysical ProcessProcess TT
OlefinsOlefins PolyPolyConversionConversion
SolidsSolids
High TempHigh TempFischer-Fischer-TropschTropsch
TT
TT
NewNewTerminalTerminal
OtherOtherChemicalChemicalRoutesRoutes
TT
WellheadWellheadPipelinePipeline
Gas ProcessingGas Processing
HC LiquidsHC Liquids
MarketMarket
LPGLPGCondensateCondensate
ExistingExistingInfrastructureInfrastructure
TT
MTOMTO
NewNewTerminalTerminal
MethanolMethanol
DMEDME
Large ScaleLarge Scale
MTGMTG
TT
TT
TT
NewNewTerminalTerminal
TT
TT = Transport (Special)= Transport (Special)
= Transport (Normal)= Transport (Normal)
The generic GTL chemical conversion flowscheme
Gastech 2002 - GTL Offshore: The Marine Perspective
SyngasSyngasProductionProduction
NaturalNaturalGasGas
SynthesisSynthesis
By-Products
ProductProductWorkupWorkup
LiquidLiquidProductsProducts
Offsites / InfrastructureOffsites / Infrastructure
Utilities IntegrationUtilities IntegrationPowerPowerSteamSteamFuelFuel
General GTL characteristics
Syngas productionSyngas production– Steam methane reforming - need to control H:CO ratioSteam methane reforming - need to control H:CO ratio– Partial oxidation - oxygen fired or air blownPartial oxidation - oxygen fired or air blown– Autothermal reforming - combination of OAutothermal reforming - combination of O 2 2 and steamand steam
SynthesisSynthesis– Fixed bed vs slurry bed reactors Fixed bed vs slurry bed reactors
Product workup Product workup – Fischer-Tropsch - hydrocracking to diesel or hydrotreating to syncrudeFischer-Tropsch - hydrocracking to diesel or hydrotreating to syncrude– Methanol - distillationMethanol - distillation– Methanol derivatives - further chemical conversion step e.g. to DMEMethanol derivatives - further chemical conversion step e.g. to DME
By-productsBy-products– Offgas disposalOffgas disposal– Waste waterWaste water
Infrastructure, offsites and utilities Infrastructure, offsites and utilities
Gastech 2002 - GTL Offshore: The Marine Perspective
Gastech 2002 - GTL Offshore: The Marine Perspective
The Challenge of Offshore GTL
Marine motion effects - process specific
Natural gas treatmentNatural gas treatment– Liquid removal - standard FPSO applicationLiquid removal - standard FPSO application– Sulphur removal - absorption, not solventsSulphur removal - absorption, not solvents– COCO22 removal - economic, removal - economic, rather than technical, decisionrather than technical, decision
Oxygen productionOxygen production– Safety implications - prime focus area Safety implications - prime focus area – Most issues largely resolvedMost issues largely resolved
Syngas productionSyngas production– Gas phase processGas phase process– Mechanical stress is only concernMechanical stress is only concern
Fischer-Tropsch synthesisFischer-Tropsch synthesis– Impact dependent on reactor type - fixed bed vs slurry bedImpact dependent on reactor type - fixed bed vs slurry bed– Slurry bed - large vessels, heat removal via coils, liquid-liquid separationSlurry bed - large vessels, heat removal via coils, liquid-liquid separation– Considerable challenges, but solutions available Considerable challenges, but solutions available
Gastech 2002 - GTL Offshore: The Marine Perspective
Source: IZAR FENE
Marine motion effects
Product workupProduct workup– No reactor impactsNo reactor impacts– Product quality issuesProduct quality issues– Unit not always requiredUnit not always required
Other unitsOther units– Liquid inventory sloppingLiquid inventory slopping– Mechanical stresses from movementMechanical stresses from movement
Tall columnsTall columns– Air separation - able to tolerate variable quality OAir separation - able to tolerate variable quality O2 2 for short periodsfor short periods– Water treatment - impact on discharge qualityWater treatment - impact on discharge quality– Product workup - significant impact on naphtha/diesel qualityProduct workup - significant impact on naphtha/diesel quality
General General – Significant advances in internals design for motion effectsSignificant advances in internals design for motion effects– More work on seakeeping behaviourMore work on seakeeping behaviour– Locate impacted equipment near centre of gravityLocate impacted equipment near centre of gravity– Passive and active motion reduction or compensationPassive and active motion reduction or compensation
Gastech 2002 - GTL Offshore: The Marine Perspective
Source: GREENLAB Software - MARIN
Safety
New safety challengesNew safety challenges– Large process equipment - impact on ship stability and structural integrityLarge process equipment - impact on ship stability and structural integrity– OO22 production production
– Hazardous materialsHazardous materials– High process temperatures and pressuresHigh process temperatures and pressures– Fugitive emissions and leaksFugitive emissions and leaks– CorrosionCorrosion– Steam systems and rotating equipmentSteam systems and rotating equipment
Other specific marine issuesOther specific marine issues– Hull integrityHull integrity– Deck sealingDeck sealing– Void spacesVoid spaces
Gastech 2002 - GTL Offshore: The Marine Perspective
Gastech 2002 - GTL Offshore: The Marine Perspective
- Break -Launching of the
EXMAR’s OFFSHORE
FPSO ‘FARWAH’
IZAR FENE Shipyard 07-Oct-2002
Hull type alternatives
Gastech 2002 - GTL Offshore: The Marine Perspective
Concrete StructureConcrete StructureSteel StructureSteel Structure
- Conversion- Conversion- New built- New built
Hull size
Gastech 2002 - GTL Offshore: The Marine Perspective
For combined offshore production For combined offshore production GAS + OILGAS + OIL two solutions are proposed: two solutions are proposed: One single unit:One single unit: ULFPS ULFPS (Ultra Large Floating (Ultra Large Floating Production System)Production System)
Two Combined Units connected Two Combined Units connected by an Articulated Armby an Articulated Arm: CFPSO : CFPSO (Combined Floating Production (Combined Floating Production Storage and Offloading unit)Storage and Offloading unit)
Compactness of design
Gastech 2002 - GTL Offshore: The Marine Perspective
High density of equipment is requiredHigh density of equipment is required
Special attention should be given to:Special attention should be given to:
Reserve of Buoyancy - ILLCReserve of Buoyancy - ILLC Damaged StabilityDamaged Stability Weight distribution (CoG)Weight distribution (CoG) Deck reinforcementDeck reinforcement Individual Module WeightIndividual Module Weight
FootprintFootprint
Topsides WeightTopsides Weight
Hull+Topsides HeightHull+Topsides Height
Source: IZAR FENE
Fabrication and Class Approval
Very complex projects Very complex projects (management, technical, fabrication, (management, technical, fabrication, etc)etc)
Gastech 2002 - GTL Offshore: The Marine Perspective
Require the combied effort of a Require the combied effort of a number of representatives of the number of representatives of the offhore industry (interfaces)offhore industry (interfaces)
Limited number of shipyard due to the dimension of the unitsLimited number of shipyard due to the dimension of the units
Lack of specific regulations (a combination of existing ones should Lack of specific regulations (a combination of existing ones should be used instead)be used instead)
A special effort from Regulatory Bodies and Classification Societies is A special effort from Regulatory Bodies and Classification Societies is requiredrequired
Source: IZAR FENE
Gastech 2002 - GTL Offshore: The Marine Perspective
The way forward
Combined production GTL FPSOs
Gastech 2002 - GTL Offshore: The Marine Perspective
Appropriate for benign environmental conditions combined with large oil Appropriate for benign environmental conditions combined with large oil reservesreserves
Working example for a West African field (GOR 700)Working example for a West African field (GOR 700)
Oil production : 200,000 BOPD / 2 MBBLS FPSO storage capacity
GTL Production about GTL Production about 10,500 BPD10,500 BPD (7,900 BPD Diesel and 2,600 BPD (7,900 BPD Diesel and 2,600 BPD Naphtha. Net Gas Feed: Naphtha. Net Gas Feed: 98 MMSCFD98 MMSCFD))
One single unit: ULFPS ULFPSRR
Two Combined Units connected by an Articulated Arm: CFPSORR
Two alternativesTwo alternatives are proposed: are proposed:
ULFPSR : Ultra Large Floating Production System
Gastech 2002 - GTL Offshore: The Marine Perspective
MAIN DIMENSIONS:MAIN DIMENSIONS:– 350 m x 100 m x 32 m350 m x 100 m x 32 m– 4.5 MBBLS Storage Capacity4.5 MBBLS Storage Capacity
PROCESS PLANT:PROCESS PLANT:– 60,000 ton Topsides Weight60,000 ton Topsides Weight– 30,000 m30,000 m22 Available Deck Area Available Deck Area
ULFPSR : Ultra Large Floating Production System
Gastech 2002 - GTL Offshore: The Marine Perspective
Takes advantage of the economies of scale: Compact Solution Takes advantage of the economies of scale: Compact Solution
High Flexibility: Bow External Turret High Flexibility: Bow External Turret
Research is performed in Research is performed in cooperation with MARIN cooperation with MARIN in order to investigate: in order to investigate:
Roll MotionRoll Motion Weathervaning Weathervaning capabilitiescapabilities Drift ForcesDrift Forces MooringMooring
CFPSOR : The Standard-Size Solution
Gastech 2002 - GTL Offshore: The Marine Perspective
MAIN DIMENSIONS:MAIN DIMENSIONS:– Two units (300 m x 58 m x 32 m)Two units (300 m x 58 m x 32 m)– 4.5 MBBLS Storage Capacity4.5 MBBLS Storage Capacity
PROCESS PLANT:PROCESS PLANT:– 60,000 ton Topsides Weight60,000 ton Topsides Weight– 30,000 m30,000 m22 Available Deck Area Available Deck Area
CFPSOR - The Articulated Spring Arm (ASL)
Gastech 2002 - GTL Offshore: The Marine Perspective
X
Y
Z
– Resembles the mooring hawsers used for tandem offloadingResembles the mooring hawsers used for tandem offloading
– Piping / Cabling routing. Piping / Cabling routing. Enclosed gangway for Enclosed gangway for personnel accesspersonnel access
– The spring-damper element The spring-damper element provides adequate dynamic provides adequate dynamic behaviour to the systembehaviour to the system
– Gas Transfer: ConventionalGas Transfer: Conventional Floating hose Floating hose
– Undesired degrees of freedom are released by means of hinged jointsUndesired degrees of freedom are released by means of hinged joints
– Tension/ Compression capability is incorporated to limit the clearance Tension/ Compression capability is incorporated to limit the clearance
between the Unitsbetween the Units
CFPSOR - Combined FPSO
Gastech 2002 - GTL Offshore: The Marine Perspective
Diffraction calculation for both vesselsDiffraction calculation for both vessels Numerical time domain simulation with 2 bodiesNumerical time domain simulation with 2 bodies
Modelling of ASL Modelling of ASL element as a spring-element as a spring-damper combination damper combination dependent on the dependent on the relative distance in relative distance in 3D between the 3D between the connectionsconnections
Research is performed in co-operation with in order to Research is performed in co-operation with in order to investigate:investigate:
Model testingModel testing
Operational LimitsOperational Limits
CFPSOR - Combined FPSO
Gastech 2002 - GTL Offshore: The Marine Perspective
Work in progress...
Seakeeping aspects
Source: FLOW-JIP - MARIN
• Turret Moored vs. Spread Moored• Critical Motions:
- Pitch
- Roll• Auxiliary Thrusters
• Offloading
• Process Plant Layout
• Green Waters
Source: GREENLAB Software - MARIN
The SEAGAS JIP
Gastech 2002 - GTL Offshore: The Marine Perspective
Gastech 2002 - GTL Offshore: The Marine Perspective
... through chemical gas conversion ... through chemical gas conversion processesprocesses
A recently established Joint Industry Project to A recently established Joint Industry Project to INVESTIGATE SOLUTIONSINVESTIGATE SOLUTIONS for the exploitation of Stranded and Associated Gas offshore ...for the exploitation of Stranded and Associated Gas offshore ...
Initially focus will be on Associated Gas in Benign WatersInitially focus will be on Associated Gas in Benign Waters
Objectives
Gastech 2002 - GTL Offshore: The Marine Perspective
Group II:Oil & Gas Cos, Energy Cos,
and Ship Owners
Group I: Suppliers,Consultants, Learning & Regulatory Bodies,
Research Institutes & Universities
Group III: Governmental Bodies,
National Institutes, Banks, etc
IZAR FENE(Marine Leader)
FOSTER WHEELER (Topsides Leader)
Leading Partners
Marine Engineering
Company
Classification Society
Topsides Engineering
Company
Operator
PartnersParticipants
Structure
Gastech 2002 - GTL Offshore: The Marine Perspective
Main Show Stoppers
The JIP will result in a basis for design for GTL FPSOs
Suitability for Ship InstallationSuitability for Ship Installation Safety / hazard potentialSafety / hazard potential Potential environmental non-compliancePotential environmental non-compliance Ease of modularizationEase of modularization Energy and hydrocarbon conversion efficiencyEnergy and hydrocarbon conversion efficiency Ease of start-up and operationEase of start-up and operation Installation difficulties, e.g. heavy-liftsInstallation difficulties, e.g. heavy-lifts Topsides / Ship’s systems integrationTopsides / Ship’s systems integration
Gastech 2002 - GTL Offshore: The Marine Perspective
Participation
Participation Fees (EURO):
Cost Eng.Hours Applicable Group I Group II Group III
Phase 1 30,000 0 Early Jan 2002 - June 2002 54,000 108,000 108,000
Phase 2 670,000 4,449 Standard July 2002-June 2003 60,000 120,000 120,000
Phase 3 700,003 5,211 Late July 2003 - Dec.2003 20,000 50,000 50,000
TOTAL 1,400,003 9,660
Group I 2 5 7 408,000Group II 1.5 3.5 5 582,000Group III 1.5 2 3.5 402,000
Duration: Budget:
Man-Hours:
IZAR experience and capabilities
Gastech 2002 - GTL Offshore: The Marine Perspective
Result of the Merger of and in 2001Result of the Merger of and in 2001
2nd biggest marine group in Europe and 9th in the world 2nd biggest marine group in Europe and 9th in the world 19 business centres. IZAR Fene is the former ASTANO19 business centres. IZAR Fene is the former ASTANO Izar Fene is fully dedicated to Offshore construction since 1987Izar Fene is fully dedicated to Offshore construction since 1987
– FSU and FPSOs (Alba, Gryphon A, Texaco Captain, Petrojarl Foinaven, Farwah)FSU and FPSOs (Alba, Gryphon A, Texaco Captain, Petrojarl Foinaven, Farwah)– Drilling Units (Drillmar, Discoverer Enterprise, Spirit and Deep Seas)Drilling Units (Drillmar, Discoverer Enterprise, Spirit and Deep Seas)– Topsides (Texaco Captain, Discoverer Enterprise, Spirit and Deep Seas)Topsides (Texaco Captain, Discoverer Enterprise, Spirit and Deep Seas)– Other Offshore facilities and Various civil worksOther Offshore facilities and Various civil works
Deeply involved in research activitiesDeeply involved in research activities– SEAGAS JIPSEAGAS JIP - Sponsored by Marin:- Sponsored by Marin:– DP FPSODP FPSO - Safeflow - Safeflow– CFPSOCFPSO - Roll JIP - Roll JIP– ULFPS - DP JIPULFPS - DP JIP– FPSO Research ForumFPSO Research Forum– Boil-Off Relicuefaction Boil-Off Relicuefaction
Summary and conclusions
Environmenal and Regulatory concerns will force Oil Companies and Environmenal and Regulatory concerns will force Oil Companies and Operators to provide integrated solutions for processing offshore oil Operators to provide integrated solutions for processing offshore oil and gas in order to avoid flaringand gas in order to avoid flaring
Gastech 2002 - GTL Offshore: The Marine Perspective
GTL Technologies may be a solution in some instancesGTL Technologies may be a solution in some instances
IZAR and FW have skills to deliver in the field of design and IZAR and FW have skills to deliver in the field of design and construction of floating GTL faciltiesconstruction of floating GTL facilties
The SEAGAS JIP is aimed in the development of a ‘basis for design’ The SEAGAS JIP is aimed in the development of a ‘basis for design’ for such type of unitsfor such type of units
Questions and answers
Gastech 2002 - GTL Offshore: The Marine Perspective
For further information, please contact:
Foster Wheeler
[email protected]_Spi[email protected][email protected]: +44 (0) 118 913 1234
[email protected]@izar.es
Tel: +34 981 338 563
