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GASTECH 2002 GTL Offshore: The Marine Perspective IZAR Abel Méndez, Joaquín López-Cortijo, Fernando Lago FW Steve Spicer, Simon C. Clarke F ene shipyard.

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Presentation on theme: "GASTECH 2002 GTL Offshore: The Marine Perspective IZAR Abel Méndez, Joaquín López-Cortijo, Fernando Lago FW Steve Spicer, Simon C. Clarke F ene shipyard."— Presentation transcript:

1 GASTECH 2002 GTL Offshore: The Marine Perspective IZAR Abel Méndez, Joaquín López-Cortijo, Fernando Lago FW Steve Spicer, Simon C. Clarke F ene shipyard 13th- 16th OCTOBER 2002 Sheraton Hotel & Qatar International Exhibition Centre, Doha

2 Foster Wheeler experience and capabilities Considerable experience in gas processing Considerable experience in gas processing –Technology optimisation –Studies –FEEDs –EPC –Project Management Consultancy Executed FEEDs for Executed FEEDs for –Sasol/Qatar Petroleum QGTL Project at Ras Laffan –Sasol/Chevron Nigeria Ltd EGTL Project at Escravos, Nigeria Extensive feasibility study work over last six years Extensive feasibility study work over last six years –Onshore plants –Offshore plants - barge or ship mounted Assistance with Starchem methanol technology Assistance with Starchem methanol technology Engineering contractor for OTM Alliance Engineering contractor for OTM Alliance Supplier of SMR units and proven technology Supplier of SMR units and proven technology Gastech GTL Offshore: The Marine Perspective

3 Agenda The offshore gas debate The offshore gas debate The challenge of offshore GTL The challenge of offshore GTL The way forward The way forward IZAR/FW: potential contribution to GTL projects IZAR/FW: potential contribution to GTL projects Gastech GTL Offshore: The Marine Perspective Summary and conclusions Summary and conclusions

4 Gastech GTL Offshore: The Marine Perspective The Offshore Gas Debate

5 Offshore Associated Gas Current FPSOs are targeted at oil production Current FPSOs are targeted at oil production Many deepwater fields have a large associated gas component Many 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 export –Re-injection - high cost, longer-term issues such as gas breakthrough –Flaring - generally not a long-term solution Associated gas can be a valuable resource Associated gas can be a valuable resource However, can we afford to use it? However, can we afford to use it? Gastech GTL Offshore: The Marine Perspective

6 Stranded gas utilisation alternatives Gastech GTL Offshore: The Marine Perspective Source: DEMO 2000, Statoil, Shell

7 The gas-to-liquids solution Physical processes Physical processes –LNG Chemical processes Chemical processes –Fischer-Tropsch, methanol and derivatives Gastech GTL Offshore: The Marine Perspective A process that converts natural gas into a transportable form Gas-to-liquids: a general term covering..... Gas-to-liquids: a general term covering.....

8 Gastech GTL Offshore: The Marine Perspective Gas utilisation options Methanol (chem grade) Chemicals Power DieselSubstitute Poly-Olefinsetc Syncrude Lubes / Waxes MiddleDistillates Gasoline / Naphtha User SyngasGeneration POXSMRATROTM/ITM GHR Hybrids Plasma O2O2O2O2 Air Steam ExistingTerminal Low Temp Fischer-Tropsch Water Hydro-Processing T T T T New Terminal / Phase Change Physical Process Process T OlefinsPolyConversion Solids High Temp Fischer-Tropsch T T NewTerminalOtherChemicalRoutes T WellheadPipeline Gas Processing HC Liquids Market LPGCondensate ExistingInfrastructure T MTO NewTerminal Methanol DME Large Scale MTG T T T NewTerminal T T = Transport (Special) = Transport (Normal)

9 The generic GTL chemical conversion flowscheme Gastech GTL Offshore: The Marine Perspective SyngasProductionNaturalGas Synthesis By- Products ProductWorkupLiquidProducts Offsites / Infrastructure Utilities Integration PowerSteamFuel

10 General GTL characteristics Syngas production Syngas production –Steam methane reforming - need to control H:CO ratio –Partial oxidation - oxygen fired or air blown –Autothermal reforming - combination of O 2 and steam Synthesis Synthesis –Fixed bed vs slurry bed reactors Product workup Product workup –Fischer-Tropsch - hydrocracking to diesel or hydrotreating to syncrude –Methanol - distillation –Methanol derivatives - further chemical conversion step e.g. to DME By-products By-products –Offgas disposal –Waste water Infrastructure, offsites and utilities Infrastructure, offsites and utilities Gastech GTL Offshore: The Marine Perspective

11 The Challenge of Offshore GTL

12 Marine motion effects - process specific Natural gas treatment Natural gas treatment –Liquid removal - standard FPSO application –Sulphur removal - absorption, not solvents –CO 2 removal - economic, rather than technical, decision rather than technical, decision Oxygen production Oxygen production –Safety implications - prime focus area –Most issues largely resolved Syngas production Syngas production –Gas phase process –Mechanical stress is only concern Fischer-Tropsch synthesis Fischer-Tropsch synthesis –Impact dependent on reactor type - fixed bed vs slurry bed –Slurry bed - large vessels, heat removal via coils, liquid-liquid separation –Considerable challenges, but solutions available Gastech GTL Offshore: The Marine Perspective Source: IZAR FENE

13 Marine motion effects Product workup Product workup –No reactor impacts –Product quality issues –Unit not always required Other units Other units –Liquid inventory slopping –Mechanical stresses from movement Tall columns Tall columns –Air separation - able to tolerate variable quality O 2 for short periods –Water treatment - impact on discharge quality –Product workup - significant impact on naphtha/diesel quality General General –Significant advances in internals design for motion effects –More work on seakeeping behaviour –Locate impacted equipment near centre of gravity –Passive and active motion reduction or compensation Gastech GTL Offshore: The Marine Perspective Source: GREENLAB Software - MARIN

14 Safety New safety challenges New safety challenges –Large process equipment - impact on ship stability and structural integrity –O 2 production –Hazardous materials –High process temperatures and pressures –Fugitive emissions and leaks –Corrosion –Steam systems and rotating equipment Other specific marine issues Other specific marine issues –Hull integrity –Deck sealing –Void spaces Gastech GTL Offshore: The Marine Perspective

15 - Break - Launching of the EXMARs OFFSHORE FPSO FARWAH IZAR FENE Shipyard 07-Oct-2002

16 Hull type alternatives Gastech GTL Offshore: The Marine Perspective Concrete Structure Steel Structure - Conversion - Conversion - New built

17 Hull size Gastech GTL Offshore: The Marine Perspective For combined offshore production GAS + OIL two solutions are proposed: One single unit: ULFPS (Ultra Large Floating Production System) One single unit: ULFPS (Ultra Large Floating Production System) Two Combined Units connected by an Articulated Arm: CFPSO (Combined Floating Production Storage and Offloading unit) Two Combined Units connected by an Articulated Arm: CFPSO (Combined Floating Production Storage and Offloading unit)

18 Compactness of design Gastech GTL Offshore: The Marine Perspective High density of equipment is required High density of equipment is required Special attention should be given to: Special attention should be given to: Reserve of Buoyancy - ILLC Reserve of Buoyancy - ILLC Damaged Stability Damaged Stability Weight distribution (CoG) Weight distribution (CoG) Deck reinforcement Deck reinforcement Individual Module Weight Individual Module Weight Footprint Footprint Topsides Weight Topsides Weight Hull+Topsides Height Hull+Topsides Height Source: IZAR FENE

19 Fabrication and Class Approval Very complex projects (management, technical, fabrication, etc) Very complex projects (management, technical, fabrication, etc) Gastech GTL Offshore: The Marine Perspective Require the combied effort of a number of representatives of the offhore industry (interfaces) Require the combied effort of a number of representatives of the offhore industry (interfaces) Limited number of shipyard due to the dimension of the units Limited number of shipyard due to the dimension of the units Lack of specific regulations (a combination of existing ones should be used instead) Lack of specific regulations (a combination of existing ones should be used instead) A special effort from Regulatory Bodies and Classification Societies is required A special effort from Regulatory Bodies and Classification Societies is required Source: IZAR FENE

20 Gastech GTL Offshore: The Marine Perspective The way forward

21 Combined production GTL FPSOs Gastech GTL Offshore: The Marine Perspective Appropriate for benign environmental conditions combined with large oil reserves Appropriate for benign environmental conditions combined with large oil reserves 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 10,500 BPD (7,900 BPD Diesel and 2,600 BPD Naphtha. Net Gas Feed: 98 MMSCFD) GTL Production about 10,500 BPD (7,900 BPD Diesel and 2,600 BPD Naphtha. Net Gas Feed: 98 MMSCFD) ULFPS R One single unit: ULFPS R R Two Combined Units connected by an Articulated Arm: CFPSO R Two alternatives are proposed: Two alternatives are proposed:

22 ULFPS R : Ultra Large Floating Production System Gastech GTL Offshore: The Marine Perspective MAIN DIMENSIONS: MAIN DIMENSIONS: –350 m x 100 m x 32 m –4.5 MBBLS Storage Capacity PROCESS PLANT: PROCESS PLANT: –60,000 ton Topsides Weight –30,000 m 2 Available Deck Area

23 ULFPS R : Ultra Large Floating Production System Gastech 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 cooperation with MARIN in order to investigate: Research is performed in cooperation with MARIN in order to investigate: Roll Motion Roll Motion Weathervaning Weathervaning capabilities capabilities Drift Forces Drift Forces Mooring Mooring

24 CFPSO R : The Standard-Size Solution Gastech GTL Offshore: The Marine Perspective MAIN DIMENSIONS: MAIN DIMENSIONS: –Two units (300 m x 58 m x 32 m) –4.5 MBBLS Storage Capacity PROCESS PLANT: PROCESS PLANT: –60,000 ton Topsides Weight –30,000 m 2 Available Deck Area

25 CFPSO R - The Articulated Spring Arm (ASL) Gastech GTL Offshore: The Marine Perspective –Resembles the mooring hawsers used for tandem offloading – Piping / Cabling routing. Enclosed gangway for Enclosed gangway for personnel access personnel access – The spring-damper element provides adequate dynamic provides adequate dynamic behaviour to the system behaviour to the system – Gas Transfer: Conventional Floating hose Floating hose –Undesired degrees of freedom are released by means of hinged joints –Tension/ Compression capability is incorporated to limit the clearance between the Units

26 CFPSO R - Combined FPSO Gastech GTL Offshore: The Marine Perspective Diffraction calculation for both vessels Diffraction calculation for both vessels Numerical time domain simulation with 2 bodies Numerical time domain simulation with 2 bodies Modelling of ASL element as a spring- damper combination dependent on the relative distance in 3D between the connections Modelling of ASL element as a spring- damper combination dependent on the relative distance in 3D between the connections Research is performed in co-operation with in order to investigate: Research is performed in co-operation with in order to investigate: Model testing Model testing Operational Limits Operational Limits

27 CFPSO R - Combined FPSO Gastech GTL Offshore: The Marine Perspective Work in progress...

28 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

29 The SEAGAS JIP Gastech GTL Offshore: The Marine Perspective

30 ... through chemical gas conversion processes A recently established Joint Industry Project to INVESTIGATE SOLUTIONS for the exploitation of Stranded and Associated Gas offshore... Initially focus will be on Associated Gas in Benign Waters Objectives

31 Gastech 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 Partners Participants Structure

32 Gastech GTL Offshore: The Marine Perspective Main Show Stoppers The JIP will result in a basis for design for GTL FPSOs Suitability for Ship Installation Suitability for Ship Installation Safety / hazard potential Safety / hazard potential Potential environmental non-compliance Potential environmental non-compliance Ease of modularization Ease of modularization Energy and hydrocarbon conversion efficiency Energy and hydrocarbon conversion efficiency Ease of start-up and operation Ease of start-up and operation Installation difficulties, e.g. heavy-lifts Installation difficulties, e.g. heavy-lifts Topsides / Ships systems integration Topsides / Ships systems integration

33 Gastech GTL Offshore: The Marine Perspective Participation Participation Fees (EURO): Duration: Budget: Man-Hours:

34 IZAR experience and capabilities Gastech GTL Offshore: The Marine Perspective Result of the Merger of and in 2001 Result of the Merger of and in nd 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 ASTANO 19 business centres. IZAR Fene is the former ASTANO Izar Fene is fully dedicated to Offshore construction since 1987 Izar Fene is fully dedicated to Offshore construction since 1987 –FSU and FPSOs (Alba, Gryphon A, Texaco Captain, Petrojarl Foinaven, Farwah) –Drilling Units (Drillmar, Discoverer Enterprise, Spirit and Deep Seas) –Topsides (Texaco Captain, Discoverer Enterprise, Spirit and Deep Seas) –Other Offshore facilities and Various civil works Deeply involved in research activities Deeply involved in research activities –SEAGAS JIP- Sponsored by Marin: –DP FPSO - Safeflow –CFPSO - Roll JIP –ULFPS - DP JIP –FPSO Research Forum –Boil-Off Relicuefaction

35 Summary and conclusions Environmenal and Regulatory concerns will force Oil Companies and Operators to provide integrated solutions for processing offshore oil and gas in order to avoid flaring Environmenal and Regulatory concerns will force Oil Companies and Operators to provide integrated solutions for processing offshore oil and gas in order to avoid flaring Gastech GTL Offshore: The Marine Perspective GTL Technologies may be a solution in some instances GTL Technologies may be a solution in some instances IZAR and FW have skills to deliver in the field of design and construction of floating GTL facilties IZAR and FW have skills to deliver in the field of design and construction of floating GTL facilties The SEAGAS JIP is aimed in the development of a basis for design for such type of units The SEAGAS JIP is aimed in the development of a basis for design for such type of units

36 Questions and answers Gastech GTL Offshore: The Marine Perspective For further information, please contact: Foster Wheeler Tel: +44 (0) IZAR Tel:


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