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The Marine Perspective”

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Presentation on theme: "The Marine Perspective”"— Presentation transcript:

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

2 Foster Wheeler experience and capabilities
Considerable experience in gas processing Technology optimisation Studies FEEDs EPC Project Management Consultancy 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 Onshore plants Offshore plants - barge or ship mounted Assistance with Starchem methanol technology Engineering contractor for OTM Alliance Supplier of SMR units and proven technology Gastech GTL Offshore: The Marine Perspective

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

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

5 Offshore Associated Gas
Current FPSOs are targeted at oil production Many deepwater fields have a large associated gas component 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 However, can we afford to use it? Gastech GTL Offshore: The Marine Perspective

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

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

8 Gas utilisation options
Methanol (chem grade) Chemicals Power Diesel Substitute Poly-Olefins etc Syncrude Lubes / Waxes Middle Distillates Gasoline / Naphtha User Syngas Generation POX SMR ATR OTM/ITM GHR Hybrids Plasma O2 Air Steam Existing Terminal Low Temp Fischer- Tropsch Water Hydro- Processing T New Terminal / Phase Change Physical Process Olefins Poly Conversion Solids High Temp New Other Chemical Routes Wellhead Pipeline Gas Processing HC Liquids Market LPG Condensate Infrastructure MTO DME Large Scale MTG = Transport (Special) = Transport (Normal) Gastech GTL Offshore: The Marine Perspective

9 Utilities Integration Offsites / Infrastructure
The generic GTL chemical conversion flowscheme Synthesis By- Products Syngas Production Natural Gas Product Workup Liquid Products Utilities Integration Power Steam Fuel Offsites / Infrastructure Gastech GTL Offshore: The Marine Perspective

10 General GTL characteristics
Syngas production Steam methane reforming - need to control H:CO ratio Partial oxidation - oxygen fired or air blown Autothermal reforming - combination of O2 and steam Synthesis Fixed bed vs slurry bed reactors 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 Offgas disposal Waste water Infrastructure, offsites and utilities Gastech GTL Offshore: The Marine Perspective

11 The Challenge of Offshore GTL
Gastech GTL Offshore: The Marine Perspective

12 Marine motion effects - process specific
Natural gas treatment Liquid removal - standard FPSO application Sulphur removal - absorption, not solvents CO2 removal - economic, rather than technical, decision Oxygen production Safety implications - prime focus area Most issues largely resolved Syngas production Gas phase process Mechanical stress is only concern 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 Source: IZAR FENE Gastech GTL Offshore: The Marine Perspective

13 Marine motion effects Product workup Other units Tall columns General
No reactor impacts Product quality issues Unit not always required Other units Liquid inventory slopping Mechanical stresses from movement Tall columns Air separation - able to tolerate variable quality O2 for short periods Water treatment - impact on discharge quality Product workup - significant impact on naphtha/diesel quality 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 Source: GREENLAB Software - MARIN Gastech GTL Offshore: The Marine Perspective

14 Safety New safety challenges Other specific marine issues
Large process equipment - impact on ship stability and structural integrity O2 production Hazardous materials High process temperatures and pressures Fugitive emissions and leaks Corrosion Steam systems and rotating equipment Other specific marine issues Hull integrity Deck sealing Void spaces Gastech GTL Offshore: The Marine Perspective

15 - Break - EXMAR’s OFFSHORE FPSO ‘FARWAH’ Launching of the
IZAR FENE Shipyard 07-Oct-2002 Gastech GTL Offshore: The Marine Perspective

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

17 Hull size For combined offshore production GAS + OIL two solutions are proposed: 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) Gastech GTL Offshore: The Marine Perspective

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

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

20 The way forward Gastech GTL Offshore: The Marine Perspective

21 Combined production GTL FPSOs
Appropriate for benign environmental conditions combined with large oil reserves 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) Two alternatives are proposed: One single unit: ULFPSR Two Combined Units connected by an Articulated Arm: CFPSOR Gastech GTL Offshore: The Marine Perspective

22 ULFPSR : Ultra Large Floating Production System
MAIN DIMENSIONS: 350 m x 100 m x 32 m 4.5 MBBLS Storage Capacity PROCESS PLANT: 60,000 ton Topsides Weight 30,000 m2 Available Deck Area Gastech GTL Offshore: The Marine Perspective

23 ULFPSR : Ultra Large Floating Production System
Takes advantage of the economies of scale: Compact Solution High Flexibility: Bow External Turret Research is performed in cooperation with MARIN in order to investigate: Roll Motion Weathervaning capabilities Drift Forces Mooring Gastech GTL Offshore: The Marine Perspective

24 CFPSOR : The Standard-Size Solution
MAIN DIMENSIONS: Two units (300 m x 58 m x 32 m) 4.5 MBBLS Storage Capacity PROCESS PLANT: 60,000 ton Topsides Weight 30,000 m2 Available Deck Area Gastech GTL Offshore: The Marine Perspective

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

26 CFPSOR - Combined FPSO Research is performed in co-operation with in order to investigate: Diffraction calculation for both vessels 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 Operational Limits Model testing Gastech GTL Offshore: The Marine Perspective

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

28 Seakeeping aspects Turret Moored vs. Spread Moored Critical Motions:
- Pitch - Roll Auxiliary Thrusters Source: GREENLAB Software - MARIN Process Plant Layout Offloading Green Waters Source: FLOW-JIP - MARIN

29 The SEAGAS JIP Gastech GTL Offshore: The Marine Perspective

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

31 Structure Participants IZAR FENE (Marine Leader) FOSTER WHEELER
(Topsides Leader) Leading Partners Marine Engineering Company Classification Society Topsides Operator Partners Participants Group I: Suppliers,Consultants, Learning & Regulatory Bodies, Research Institutes & Universities Group II: Oil & Gas Cos, Energy Cos, and Ship Owners Group III: Governmental Bodies, National Institutes, Banks, etc Gastech GTL Offshore: The Marine Perspective

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

33 Budget: Man-Hours: 1.4 MMeuro 23 MONTHS 10,000 Duration:
Participation Duration: 23 MONTHS Budget: 1.4 MMeuro Man-Hours: 10,000 Participation Fees (EURO): Gastech GTL Offshore: The Marine Perspective

34 IZAR experience and capabilities
Result of the Merger of and in 2001 2nd biggest marine group in Europe and 9th in the world 19 business centres. IZAR Fene is the former ASTANO 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 SEAGAS JIP - Sponsored by Marin: DP FPSO Safeflow CFPSO Roll JIP ULFPS DP JIP FPSO Research Forum Boil-Off Relicuefaction Gastech GTL Offshore: The Marine Perspective

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 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 The SEAGAS JIP is aimed in the development of a ‘basis for design’ for such type of units Gastech GTL Offshore: The Marine Perspective

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


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