Gasification Technology
Monetise low-value refinery residues, asphaltenes, heavy oils, gas or biomass by converting them into syngas. Shell Catalysts & Technologies’ Residue and Natural Gas Gasification process upgrades the bottom-of-the-barrel and other low-value streams into synthesis gas (carbon monoxide and hydrogen), for refinery consumption, power generation or use in other high-value processes.
Upgrade Low-Value Streams with High-Value Processes
Monetise low-value refinery residues, asphaltenes, heavy oils, gas or biomass by converting them into syngas. Shell Catalysts & Technologies’ Residue and Natural Gas Gasification process upgrades the bottom-of-the-barrel and other low-value streams into carbon monoxide and hydrogen, for refinery consumption, power generation or use in other high-value processes.
Integrating the Shell Gasification Process with other upgrading and treating technologies enables you to process a wide range of feedstocks including highly viscous, high-sulphur residues. The technology functions with low oxygen and fresh water consumption resulting in low soot formation, and uses enhanced thermal efficiency that reduces operating costs while resulting in an enhanced syngas yield to supply the refinery with hydrogen, power or other usages.
Reduce Plant Emissions and Capture CO2
An integrated Shell Gasification Process results in a high syngas (carbon monoxide and hydrogen) yield with low soot levels and high thermal efficiency that reduces plant emissions. Capture CO2 created during the process instead of releasing it into the environment, storing it for later processes, such as enhanced oil recovery, or for use in greenhouses.
Process Low-Value and Heavy Materials
Use the Shell Gasification Process to handle heavy high sulphur viscous residues such as thermal cracked residue, Solvent de-Asphalter residue (DoA), the bottom streams of Ebullated bed units, and heavy fuel oil from the fluidised catalytic cracker (FCC) unit.
Reduce Operating Costs and Improve Margins
Refiners can use gasification to reduce operating costs through the production of high-pressure saturated process steam, while petrochemical companies can convert refinery residue to syngas for the production of ammonia, methanol, oxo-alcohols, and other petrochemicals to increase margins.
Shell Gasification Process (SGP)
Title: Shell Gasification Process Video
Duration: 03:02
Description:
SGP or Shell Gasification Process animation features this overlooked technology and how it can help address challenges that refiners face.
[Background music plays]
Techy, modern music.
[Animated sequence]
‘SHELL CATALYSTS & TECHNOLOGIES TRANSFORMING ENERGY TOGETHER’ logo on a white screen.
[Male voiceover]
Refiners face significant challenges as they work to remain profitable in an increasingly competitive market.
[Animated sequence]
Camera zooms out to reveal white 3D model of a petrochemical refinery over a green textured background. Camera moves and centers on one particular white 3D model of four tanks. ‘PROFITABILITY’ yellow text and arrow animate upward above petrochemical tanks, while ‘COMPETITIVE MARKET’ text animates below them.
[Male voiceover]
Upgrading low-value, bottom-of-the-barrel molecules, creating petrochemicals feedstock and increasing crude flexibility are just a few examples.
[Animated sequence]
Slide transition to an orange textured background with ‘UPGRADING LOW-VALUE MOLECULES’ text next to a white 3D model of low-value molecules and a yellow arrow behind them, pointing up. Slide transition to the same orange textured background with ‘CREATING PETROCHEMICALS FEEDSTOCK’ text next to a white 3D model of a petrochemical unit. Slide transition to the same orange textured background, with ‘INCREASING CRUDE FLEXIBILITY’ text above a white 3D model of three crude barrels. The top of the front crude barrel squiggles right to left to symbolize ‘flexibility.’
[Male voiceover]
At the same time, many refiners are looking for ways to reduce their carbon footprint and create their own low-cost hydrogen source.
[Animated sequence]
Transition to a blue textured background with ‘REDUCE CARBON FOOTPRINT’ text above five footprints that animate in with a ‘step by step’ motion. Slide transition to the same blue textured background, with ‘CREATE LOW-COST HYDROGEN SOURCE’ text below an ‘H2’ icon. 3D hydrogen molecules fly out from ‘H2’ icon.
[Male voiceover]
Shell can help overcome all of these challenges with the Shell Gasification Process, or SGP.
[Animated sequence]
Transition to a red textured background. Parts of a Shell Gasification Process 3D model spin around and come together to form an SGP unit. White dotted dash lines animate over red background and ‘SHELL GASIFICATION PROCESS’ text scrolls in under the unit. ‘SGP’ text animates next to the SGP unit.
[Male voiceover]
Using our experience as an owner-operator and having licensed over 100 gasification units, we’ve continuously improved this technology, making it highly reliable and efficient.
[Animated sequence]
Camera moves up to reveal world map on the same red textured background with white dots throughout. We see ‘PERNIS’ and ‘RHINELAND’ text highlighting these two locations on the map. ‘EXPERIENCED OWNER-OPERATOR’ text animates at the center of the frame, over the map. A row of multiple white 3D models of the SGP unit slides left, in and out of frame, while increasing and decreasing size, along with ‘OVER 100 GASIFICATION UNITS’ text. A 3D model of a full-size latest generation SGP unit slides into frame and opens up to reveal white arrows flowing throughout the unit. ‘HIGHLY RELIABLE & EFFICIENT’ text animates next to the unit.
[Male voiceover]
Here’s how it works: SGP partially oxidises a wide range of low-value molecules in the presence of oxygen and steam to produce 'syngas' - which is primarily hydrogen and carbon monoxide.
[Animated sequence]
Camera zooms into the unit to reveal a light blue textured background with a white 3D model of low-value molecules at the center of the frame. An arrow points to the molecules from the left with ‘O2’ text over it, while another arrow points to the molecules from the right with ‘STEAM’ text over it. Transition to the same light blue textured background with multiple 3D hydrogen and carbon monoxide molecules floating over ‘SYNGAS’ text. ‘HYDROGEN’ and ‘CARBON MONOXIDE’ text fades in behind molecules.
[Male voiceover]
The syngas can then be used to generate power, supply hydrogen and make a variety of petrochemicals, high-quality synthetic fuels or lubes.
[Animated sequence]
Camera zooms out while ‘SYNGAS’ text remains at the center of the frame with gas bubbles flying behind it. Four arrows animate from ‘SYNGAS’ toward each corner of the frame, pointing at a 3D power tower, a 3D hydrogen icon, 3D three crude barrels and a 3D motor, in that order. The 3D motor is running.
[Male voiceover]
Meanwhile, the high-purity CO2 is captured without the need for additional process units.
[Animated sequence]
Transition to a green textured background with multiple 3D CO2 molecules floating around. A dotted dash square animates to capture these molecules, while ‘CO2’ and ‘CAPTURE’ text animates in.
[Male voiceover]
It can be supplied to greenhouses to fast-track crop development, or injected underground for CO2 storage or enhanced oil recovery.
[Animated sequence]
Camera zooms out and moves to the right, while captured CO2 molecules remain at the left of the frame with ‘CO2’ text below them. We see a 3D model of a greenhouse next to the captured CO2 molecules, with a right pointed arrow in between them. The crops in the greenhouse grow while ‘FAST-TRACK CROP DEVELOPMENT’ text animates below it. Slide transition to a blue textured background with a white 3D model of a petrochemical refinery on the upper left corner and a white 3D model of a pumpjack on the upper right corner. We see yellow arrows going down from the petrochemical refinery to the captured CO2 molecules, which are moving underground from left to right, while ‘CO2 STORAGE’ text follows them. We see other yellow arrows going up from the captured CO2 molecules to the pumpjack, while ‘ENHANCED OIL RECOVERY’ text animates next to them.
[Male voiceover]
SGP is extremely flexible when it comes to feed type, processing heavy residues such as asphalt from solvent deasphalting units, ebullated bed residue or slurry hydrocracking pitch.
[Animated sequence]
Transition to an orange textured background with white 3D model of the SGP unit at the center of the frame. ‘EXTREMELY’ text slides left and ‘FLEXIBLE’ text slides right from behind the model. SGP model moves to the right of the frame, while ‘HEAVY RESIDUES’ text animates to the left of it, with a bracket and an arrow pointing at the unit in between them. Text fades out while ‘ASPHALT,’ ‘EBULLATED BED RESIDUE’ and ‘SLURRY HYDROCRACKING PITCH’ text animate to the left of the bracket, with 3D icons next to them.
[Male voiceover]
Its broad capabilities are great for future proofing, as refineries upgrade and change their configuration to meet market demands.
[Animated sequence]
Camera zooms out, flying away from the SGP unit, while a 3D model of a full petrochemical refinery fades in with the SGP unit remaining in place. ‘UPGRADE’ text animates in the upper left corner of the frame. ‘RECONFIGURE’ text animates in the bottom right corner of the frame.
[Male voiceover]
Natural gas can also be gasified into syngas through partial oxidation, providing opportunities to turn stranded gas into high-value, syngas-based products.
[Animated sequence]
Transition to a purple textured background with ‘NATURAL GAS’ text at the center of the frame and a gas cloud behind it. ‘NATURAL GAS’ text moves to the left of the frame while ‘SYNGAS’ text animates on the right side of the frame with gas bubbles behind it. The silhouette of a gasifier unit fades in, in between both text graphics, while ‘PARTIAL OXIDATION’ text and right pointed arrows animate over the gasifier unit. Arrows point from ‘NATURAL GAS’ TO ‘SYNGAS,’ circling the gasifier unit.
[Male voiceover]
Biomass or biogas can be gasified through the same method, helping refiners as they process increasing amounts of renewables.
[Animated sequence]
Slide transition to a green textured background with white 3D models of corn and tree logs next to ‘BIOMASS’ text, and a white 3D model of a gas cloud below them, next to ‘BIOGAS’ text. They all move to the left of the frame while an SGP 3D model slides into frame from the right with ‘SGP’ text next to it. A yellow bracket with a right pointed arrow animates in between ‘BIOMASS,’ ‘BIOGAS’ elements and SGP unit.
[Male voiceover]
SGP also enables versatility in subsequent syngas applications.
[Animated sequence]
All elements slide left, off frame, while SGP 3D model remains at the center of the frame. ‘ENABLES’ text slides left and ‘VERSATILITY’ text slides right from behind the model.
[Male voiceover]
Historically, syngas provided steam, power and hydrogen at a low cost.
[Animated sequence]
Transition to a light blue textured background with ‘SYNGAS’ text at the center of the frame, with gas bubbles floating behind it. A hierarchy diagram animates below ‘SYNGAS’ to show ‘STEAM,’ ‘POWER’ and ‘HYDROGEN’ text and 3D icons connected to it. 3D icons are a steam cloud, a power tower and a hydrogen molecule.
[Male voiceover]
But as market dynamics shift, refiners continue to evaluate the use of syngas as a building block for ammonia, oxo-alcohols, methanol and other petrochemicals.
[Animated sequence]
Camera zooms out while texture background splits in half and rotates, ending up with a half light blue (upper side of frame), half dark blue (lower side of frame) background. ‘SYNGAS’ text and hierarchy diagram with ‘STEAM,’ ‘POWER’ and ‘HYDROGEN’ remain in frame. Another hierarchy diagram animates above ‘SYNGAS’ to show ‘AMMONIA,’ ‘OXO-ALCOHOLS’ and ‘METHANOL’ text and 3D icons connected to it. 3D icons are a detergent bottle, a hand soap bottle, a generic alcohol bottle and three crude barrels.
[Male voiceover]
The Shell Gasification Process is a powerful technology to consider in any modern downstream complex to process heavier crudes, especially if you want to...
[Animated sequence]
Transition to a red textured background, while camera zooms out to reveal SGP 3D model landing in the middle of a petrochemical facility, with ‘SGP’ text above the unit. We can see part of a yellow textured background underground. Petrochemical refinery and SGP unit slide up to reveal the rest of the yellow textured background.
[Male voiceover]
...turn bottom-of-the-barrel molecules into petrochemical feedstock...
[Animated sequence]
A white 3D model of low-value molecules with ‘LOW-VALUE MOLECULES’ text below it animates on the left side of the frame. A vertical dotted dash line and a right pointed arrow split the frame down the center. A white 3D model of three crude barrels and ‘PETROCHEMICAL FEEDSTOCK’ text animates on the right side of the frame.
[Male voiceover]
...generate hydrogen, while facing a high natural gas price...
[Animated sequence]
Slide up transition to reveal hydrogen icon with 3D hydrogen molecules floating around it and ‘GENERATE HYDROGEN’ text below it, all located on the left side of the frame. Dotted dash line remains in frame. A 3D flame and dollar sign animate on the right side of the frame with ‘HIGH NATURAL GAS PRICE’ text below it.
[Male voiceover]
...or capture and use CO2, instead of emitting it into the atmosphere.
[Animated sequence]
Slide up transition to reveal floating 3D carbon dioxide molecules, captured in a dotted dash square and ‘CAPTURE CO2’ text below it, all located on the left side of the frame. Dotted dash line remains in frame. A 3D flare stack with a red no symbol over it, animate on the right side of the frame with ‘EMISSIONS’ text below it.
[Male voiceover]
Our experts and masterplanners can advise you on how to incorporate the Shell Gasification Process to maximise profitability and reduce your carbon footprint.
[Animated sequence]
Camera zooms out to reveal an SGP 3D model closing at the center of the frame, on a red textured background. We see a dotted dash circle with diverse people 2D icons, ‘EXPERTS’ and ‘MASTERPLANNERS’ text around the SGP unit. ‘SHELL GASIFICATION PROCESS’ text flies in and lands at the center of the frame, over the SGP unit. Dotted dash circle with people icons and text fades out to reveal ‘MAXIMISE PROFITABILITY’ text on the upper left corner of the frame, and ‘REDUCE CARBON FOOTPRINT’ at the lower right corner of the frame. SGP unit and ‘SHELL GASIFICATION PROCESS’ text remain in frame.
[Animated sequence]
Camera zooms into the SGP 3D model to transition to a white screen, with Shell pecten at the center of the frame. ‘www.shell.com/ct’ text fades in below Shell pecten.
[Background music plays]
Shell mnemonic.
Continuous Improvement that Increases Runs and Reduces Maintenance Costs
As an owner and operator with close partnerships with other users, Shell’s gasification process and designs were created and refined over half a century dealing with real-time challenges. Our continuous improvement and innovation translates to longer continuous runs and lower maintenance costs for licensees.
Residue Upgrading
Shell Catalysts & Technologies assists refineries through the energy transition with flexible solutions like residue hydrocracking and upgrading.
CANSOLV SO₂ Capture
Gas absorptions solutions that help meet product specifications and restrictive emissions limits within a lower cost structure.
Refining Technologies
Shell Catalysts & Technologies’ has a wide range of solutions to lessen effects for refiners of crude prices being unstable.