GASTECH 2002

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


Summary and conclusions Summary and conclusions


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?


Stranded gas utilisation alternatives


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


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 .....


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


MethanolMethanol

DMEDME

Large ScaleLarge Scale

MTGMTG

TT

TT

TT


TT

TT = Transport (Special)= Transport (Special)

= Transport (Normal)= Transport (Normal)

The generic GTL chemical conversion flowscheme


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



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


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


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



- Break -Launching of the

EXMAR’s OFFSHORE

FPSO ‘FARWAH’

IZAR FENE Shipyard 07-Oct-2002

Hull type alternatives


Concrete StructureConcrete StructureSteel StructureSteel Structure

- Conversion- Conversion- New built- New built

Hull size


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


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)


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


The way forward

Combined production GTL FPSOs


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


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


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


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)


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


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


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



... 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


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


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


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


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


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


For further information, please contact:

Foster Wheeler

[email protected][email protected][email protected]: +44 (0) 118 913 1234

[email protected]

[email protected]@izar.es

Tel: +34 981 338 563

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GASTECH 2002

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