1、 Copyright of Shell Global Solutions International B.V. 壳牌煤气化技术及在中国的发展 SHELL COAL GASIFICATION TECHNOLOGY IN CHINA 2012.11 壳牌全球方案国际公司 Shell Global Solutions International B.V. 1 Shell Gasification China Licensing Department GM 壳牌气化技术中国技术许可部总经理 姜涛 Jiang Tao Copyright of Shell Global Solutions Interna
2、tional B.V. 目录 CONTENTS 01 壳牌气化技术的历史 Shell gasification technology history 02 壳牌煤气化技术在中国的应用 Shell coal gasification process application in China 03 壳牌水激冷气化技术 Shell water quench coal gasification development 04 设备国产化进程 , 强大的技术支持 Equipment Localization and Strong Technical Support 2 Copyright of Shell
3、 Global Solutions International B.V. 壳牌 - 世界最大的能源公司之一 在 2012年的财富五百强中名列第一名 3 Source: 2010 Annual Report and Form 20-F We are active in more than 我们活跃在 90 COUNTRIES 90多个国家 Worldwide, we have 全球范围，我们有 93,000 FULL-TIME EMPLOYEES 9.3万全职雇员 Our fuel retail network has around 我们油品销售网络有 43,000 SERVICE STATIO
4、NS 4.3万个加油服务站 In a year, we sell 一年里，我们销售 145 BILLION LITRES 1450亿升 of fuel to our customers 油品给我们的顾客 下游业务 Downstream 上游业务 Upstream 项目和技术部 P liquid hydrocarbon products： 140,000 b/d 、 两 系列 各有 9台 壳牌 天然气 气化 技术 (SGP)的气化装置 ， 合成气总产量为 95,400 KNm3/d。 9 SGP gasifiers in each of the 2 trains with syngas outp
5、ut 95,400 kNm3/d 18 SGP gasifiers 18台采用壳牌天然气气化工技术（ SGP）的气化装置 有史以来建成的最大的空分装置（ 28,800吨 /天） 世界上最大的优质润滑油生产装置 最大的零排放的工业水处理装置（ 45,000立方米 /天） Copyright of Shell Global Solutions International B.V. 国内首套 IGCC 气电氢联产装置 -中石化福建炼化一体化项目 (3台壳牌油气炉 ) FIRST IGCC CO-GENERATION UNIT IN CHINA SINOPEC FUJIAN WITH 3 SHELL
6、RESIDUE GASIFIERS 10 福建项目采用了三台壳牌渣油气化炉；所提供的氢气，蒸汽等达到设计要求，装置运行满足生产要求。 Three Shell residue oil gasifier were adopted in Fujian Project, the H2, steam reached designed requirement, the plant performance reach operation requirement. 全球有超过 125台气化炉用于炼厂 More than 125 Gasifiers used for refineries globally 20
7、12年 7月 ,壳牌被授予中东某项目的气化和酸气脱除的专利合同，这时迄今建设的最大的渣油气化项目，有 16台壳牌渣油气化炉。 In July, 2012, Shell was awarded the gasification unit and acid gas removal unit licenses for a project in Middle East, the largest residue gasification unit ever with 16 gasifiers Copyright of Shell Global Solutions International B.V. 壳
8、牌在煤气化技术的悠久发展历史，以及放大方面丰富的经验知识 LONG HISTORY AND RICH KNOWLEDGE /EXPERIENCE IN SCALING UP 壳牌于 1956年开始自己的油气化技术 Shell started its oil gasification technology in 1956 现在全球有 88台壳牌技术的油 /气气化装置在运行 88 oil / gas gasification units in operation 壳牌在 1976年开始煤气化试验装置 Shell Coal Gasification Process started in 1976 6
9、 t/d 150 t/d 250 t/d 1976 试验装置 ,阿姆斯特丹 Pilot Unit, Amsterdam, The Netherlands 1978 中试装置 ,汉堡 Demo Unit Harburg, Germany 1987 示范装置SCGP-1 休斯顿 Houston 1993 荷兰电厂 NUON IGCC 250MW Buggenum, The Netherlands 投煤量Coal intake T/d 2000 t/d 湖北双环 Hubei Shuanghau (900ton/day) 2000 Onwards Chinese coal gasification L
10、icensees 岳阳合资公司 Yueyang JV (2000ton/day) 云天化，大唐 YTH, Datang (2700ton/day) 澳大利亚项目 Australia project (4000ton/day) 11 Copyright of Shell Global Solutions International B.V. 壳牌 煤气化技术拥有的种不同炉型 (干法和湿法脱灰 ) 3 OPTIONS OF SHELL COAL GASIFICATION TECHNOLOGY (DRY/WET ASH REMOVAL) 12 气化炉 Gasifier 合成气冷却器 Syngas c
11、ooler 适用不需要蒸汽的项目 . Suitable for project without steam demand ,流程简化 ,造价 降低 Simplified configuration, Capex reduction 污水易处理，水激冷工况温和 easy waste water handling mild condition in water quench 下行水激冷 Bottom quench 下行水激冷设计 Bottom flow water quench 流程简化 , 投资最低 simplified lineup Lowest Capex 利用成熟的水冷壁和烧嘴 , mat
12、ure membrane/burner, Simple configuration 激冷室 Quench chamber 上行水激冷设计 Top flow water quench 工业验证 , 技术成熟 ,适用大型项目。 Industrial proven, mature technology, suitable for large projects 热效率高 ,环境友好 High thermal efficiency, Environmental friendly 合成气冷却器设计 Syngas cooler design 气化炉 Gasifier 气化炉 gasifier 对置多喷嘴 O
13、pposite multiple-burners 不同炉型可根据客户的需要（费用，效率）来满足项目要求 Fit for purpose depending on clients requirement (Cost/Efficiency) Copyright of Shell Global Solutions International B.V. 应用于不同用途的全球业绩 GLOBAL EXPERIENCE WITH A WIDE RANGE OF APPLICATIONS 13 壳牌在全球已转让了 26个煤气化技术许可项目 , 应用在不同的领域中 Shell has 26 coal gasif
14、ication licenses globally for a wide range of applications including IGCC power plants With other 2 SCGP licenses: all for power (IGCC) Vietnam 越南 2 SCGP licenses Syngas for Ammonia 两 个项目 均 用于 合成氨生产 South Korea 韩国 1 SCGP license syngas for power (IGCC) 一个项目用于 IGCC China Equity 中国投资 50:50 JV with Sin
15、opec in Yueyang 岳阳 中石化壳牌煤气化公司 (50:50合资 ) Syngas for fertilizer production 合成气 用于化肥生产 Australia 澳大利亚 1 Syngas for Fertilizer 用于 化肥 生产 April 2012 Copyright of Shell Global Solutions International B.V. 壳牌全球气化总部和多个技术中心在 2012年移到中国 SHELL GASIFICATION HEADQUARTER AND TECHNICAL SERVICE CENTER MOVED TO CHINA
16、 IN 2012 14 Copyright of Shell Global Solutions International B.V. SECTION TWO 2.0 15 壳牌煤气化技术在中国的应用 Shell coal gasification process in China Copyright of Shell Global Solutions International B.V. 壳牌在中国的气化项目 THE SCGP PROJECTS IN CHINA 16 到 2012年 8 月国内共有 20台壳牌气化炉投入运行 Total 20 gasifiers started up till
17、 2012 Aug in China 1台寰球总包的越南第一套壳牌煤气化装置在 2012年 4月顺利投入运行。 One Vietnam gasifier started up in 2012 April, HQCEC is EPC contractor 云天化水富的气化装置在 2012年 6月 3日顺利开车 YTH Shuifu gasifier started up successfully in June 3rd 2012 Ammonia Methanol Hydrogen 合成气的用途 Syngas production for 13 10 8 14 5 2 1 3 7 6 15 4 1
18、2 11 17 18 16 9 19 1 Sinopec Shell Yueyang JV 2,000 t/d 2 Hubei Shuanghuan 900t/d 3 Guangxi Liuzhou 1,100t/d 4 Sinopec Hubei 2,000t/d 5 Sinopec Anqing 2,000t/d 6 Yunnan YunTianhua 2,700t/d 7 Yunnan Zhanhua 2,700t/d 8 Dalian Dahua 1,100t/d 9 Henan Longyu 2,100t/d 10 Shenhua DCL 2x2,200t/d 11 Henan Zh
19、ongyuan Dahua 2,100t/d 12 Henan Kaixiang 1,100t/d 13 Datang Power International 3x2,800t/d 14 Tianjin Soda 2x2,000t/d 15 Guizhou Tianfu 2,000t/d 16 Henan Hebi Zhongyuan 2,700t/d 17 Henan Longyu Phase II 2,100t/d 18 Datong Coal Mine Group 2,400t/d 19 Yunnan YunTianhua Phase II 1,100t/d Copyright of S
20、hell Global Solutions International B.V. 开车时间跟项目签订时间相关联，不是评价技术的标准 STARTUP TIME LINKED WITH SIGNED TIME, NOT TECHNOLOGY CRITERIA 17 13 10 8 14 5 2 1 3 7 6 15 4 12 11 17 18 16 9 19 1 Sinopec Shell Yueyang JV 2 Hubei Shuanghuan 3 Guangxi Liuzhou 4 Sinopec Hubei 5 Sinopec Anqing 6 Yunnan YunTianhua 7 Yu
21、nnan Zhanhua 8 Dalian Dahua 9 Henan Longyu 10 Shenhua DCL 11 Henan Zhongyuan Dahua 12 Henan Kaixiang 13 Datang Power International 14 Tianjin Soda 15 Guizhou Tianfu 16 Henan Hebi Zhongyuan 17 Henan Longyu Phase II 18 Datong Coal Mine Group 19 Yunnan YunTianhua Phase II 第一批是湖北双环，柳州，中石化湖北，中石化安庆，洞庭合资公司
22、。大部分签约在 2003年 ,施工开始于 2004， 2005年 ,在2006年年底， 2007年年初开车。 The 1st batch is Hunan Shuanghuan, Liuzhou, Sinopec Hubi, Sinopec Anqing and Dongting JV, most projects were signed in 2003, started construction in 2004,2005, started up mainly in end 2006 and early 2007. 第二批有神华 2套，永城，中原大化，云天化，云沾化，大体在 2004年签约 ,
23、 在 2005年开始施工 , 在 2008年中开车。 The 2nd batch is Shenhua, Yongcheng, ZYDH, Yima Kaixiang, YZH, most projects were signed in 2004, started construction in 2005, and started up in middle of 2008. 第三批有大唐 3套 ,天碱 2套 , 天福 , 分别在 2005/6年签约 , 2006/7年开始施工 ,2010/2011年开车。 The 3rd batch is Datang (3 gasifiers), Tianj
24、in Soda(2 gasifiers), Tianfu, contracts were signed in 2005/6, construction started up in 2006/7 and start up in 2010/2011 第四批云天化水富已经 2012年 6月 3日顺利开车，鹤壁和大同将分别在 2012年年中和 2013年开车。 The 4th batch is YTH shuifu, started up in June 3rd, 2012, Hebi and Datang is planned to start up in middle of 2012 and 20
25、13. Copyright of Shell Global Solutions International B.V. 壳牌气化的煤种适应性，消耗及环保优势 COAL SUITABILITY, CONSUMPTION AND ENVIRONMENTAL BENEFITS 18 干法除灰的环保优势 Environmental benefit of dry ash removal - 没有复杂的灰水处理系统 no complex waste water handling system - 耗水量低、废水排放少 low water consumption, less waste water bleed
26、, - 干灰用途多，可以增加企业效益 fly ash can be sold for many purpose, increasing economic return 测试项目 test items 典型消耗范围 typical consumption O2氧耗 /KNm3(CO+H2) 315390 Nm3 Coal 煤耗 /KNm3(CO+H2) 610650 kg 国内已有多台壳牌气化炉通过性能考核测试，氧耗 , 煤耗等指标均低于保证值，壳牌气化技术的先进性得到验证和认可； So far Many gasifiers in China have already signed Plant
27、Acceptance Certificate. Oxygen consumption and coal consumption of these gasifiers are all lower than guaranteed values: Benefits of SCGP are now being recognized 目前为止，壳牌气化技术已成功处理国内超过 120多种不同煤质的煤 , 包括具挑战性的褐煤和石油焦； Till now the SCGP has successfully handled over 120 types of Chinese domestic coal, inc
28、luding the very challenging feedstock lignite and petcoke; 壳牌技术处理过的原料 石油焦 Petcoke Ash 灰分 , wt% Moisture 水分 ,wt% FT 灰熔点 , 35.0% 3.8% 2000 100% 100% 无烟煤 Anthracite 烟煤 bituminous 次烟煤 Sub-bitu 褐煤 lignite Feed stock原料 36.4% 5.9% 1500 1140 大唐是首个使用壳牌气化技术已成功处理褐煤的装置，气化炉挂渣正常，废锅无结垢积灰。 Datang is the 1st SCGP pl
29、ant with lignite as feedstock, slag coverage is good and no fouling in syngas cooler. 天福是首个使用壳牌气化技术已成功处理石油焦的装置，40%石油焦掺混，连续高负荷运行 72天。 Tianfu is the 1st petcoke handling plant in China with SCGP and created a continuous 72 running days at high load with 40% petcoke blending. Copyright of Shell Global
30、Solutions International B.V. 壳牌煤气化的效率优势 EFFICIENCY ADVANTAGES OF SHELL COAL GASIFICATION 19 raw syngas Coal in 100% 82% 2.0% steam from reactor wall 12.8% steam from syngas cooler 0.5% unconverted carbon 2.7% low level heat ENERGY BALANCE 能量平衡 97% TOTAL thermal Efficiency 通过与低水气比变换技术集成，创造可观的额外经济效益。
31、By integrating with Low-steam Shift, considerable extra economic benefits can be achieved 壳牌废锅流程可副产中压或高压过热蒸汽，冷煤气效率和热效率分别可达 82%和 97%。 The SCGP by-produces high/medium pressure steam; cold gas efficiency and thermal efficiency can reach 82% and 97% respectively; 案例： 某年产 26万 吨合成氨装置，采用壳牌废锅 +低水气比变换流程，年 运
32、行时间已连续 3年超过8000小时，副产蒸汽每年有六千多万的回报 。 One Chinese 260kt/a Ammonia plant adopted SCGP and integrated with Low-steam Shift process, achieved over 8000 annual operating hours in the past 3 years gaining 68 million RMB profits from byproducts and steam each year; 产品 Products 元 /吨 RMB/ton 吨 /时 Ton/Hr 百万人民币
33、/年 (8000小时 ) Million RMB/A (8,000 hrs) 飞 灰 Fly ash 300 3.5 8.4 灰渣 Slag 150 9.0 10.80 蒸汽 ( 外送 ) Steam (to B.L) 230 27 47.98 总收益 Total Income 68.88 Copyright of Shell Global Solutions International SHELL TECHNOLOGY COMPARISON WITH CRITERIA SET BY NDRC 壳牌技术指标与国家发改委设定的入门指标对比 20 April 2012 煤制烯烃 Coal to o
34、lefin 项目能耗 Project efficiency 煤耗（标煤） Coal consumption (standard coal) 新鲜水耗 Fresh water consumption 壳牌废锅流程 SCGP 45.1% 3.91 2.31 发改委推荐的先进值 NDRC recommended values 44% 5 t/t olefin 3t/t standard coal Copyright of Shell Global Solutions International B.V. 国内壳牌煤气化技术工厂的可靠性迅速提高 CHINA SCGP PLANT RELIABILITY
35、 STEADILY IMPROVED 21 壳牌煤气化中国客户的平均技术可靠性迅速提高 Average Reliability for Chinese SCGP clients is improved rapidly % of time lost due to outage SCGP SCGP范围以内的原因引起的停车 稳步提高性能 Steadily improving performance Copyright of Shell Global Solutions International B.V. 22 91% 93% 83% 20% 40% 60% 80% 100% 2006 2007 2
36、008 2009 2010 2011 在线率1100吨每天规模装置在线率趋势 1000t/d coal gasification learning curve L Y Y2 90% 94% 88% 20% 40% 60% 80% 100% 2007 2008 2009 2010 2011 在线率20003000吨每天规模装置在线率趋势 2000t/d3000t/d gasification learning curve D E1 T Y1 87% 多套国内壳牌煤气化装置实现高负荷长周期运行 MANY CHINESE SCGP PLANTS ACHIEVED VERY HIGH LOAD WIT
37、H LONG RUNS 0% 20% 40% 60% 80% 100% 120% 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 2011 one 1000t/d ammonia plant weekly Load 2011年 某 1000吨 /天合成氨装置 周 运行负荷 load 102% 0% 20% 40% 60% 80% 100% 120% 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 2011 one 2000t/d Methanol plant Weekly Load 20
38、11年 某 2000吨 /天甲醇厂 周 运行负荷 Copyright of Shell Global Solutions International B.V. 某壳牌用户过去 5年里运行表现 TOP QUARTILE CLIENT IN PAST 5 YEARS 23 63.0% 7.1% 9.4% 19.1% 1.4% 2007 Running time Plant shutdown Gasification equipment failure Process issue Downstream issue 78.1% 10.0% 2.2% 1.9% 4.7% 3.0% 2008 Runnin
39、g Time Power failure Gasification Equipment failure HPHT filter failure ASU failure Process Issue 2007 2008 2009 2010 2011 Total running days 总运行天数 221 285 331 329 338 Longest running days最长运行天数 44 109 114 59 142 用户已经连续 3年实现单炉 330+天的累计运行时间 , 2011年运行达到 338天 。 One client has reached 330day accumulated
40、 running day in the past 3 years. 2011 reach 338 days 93% 2% 1% 2% 1% 1% 2011 Running days 运转时间 Burner muffle leakage 烧嘴罩漏 Coal flange leakage 煤烧嘴法兰泄露 Transfer duct leakage 传导管泄漏 ASU shutdown 空分停车 Downstream down 下游停车 90.4% 5.8% 2.2% 0.0% 0.0% 0.3% 1.4% 2010 Running days HPHT Filter failure Burner m
41、uffle leakage Coal control valve Slag crusher X1401 leakage ASU shutdown SGC inlet plugging 90.7% 1.4% 2.7% 2.7% 1.1% 1.4% 2009 Running days Manual shutdown ASU failure HPHT Filter failure SGC plugging Downstream down Copyright of Shell Global Solutions International B.V. 壳牌煤气化技术的运行可靠性 -2011年的优秀运行业绩
42、 Reliability -Top Quartile Performance in 2011 24 经过初始的摸索和操作管理水平的提高，多家用户实现了 连续运行百日常态化，全年累计三百天常态化。 Through initial learning curve and improvement of operation and management skill, many clients realized continuous 100+ days and accumulated 300+ days per year as normal operational runs. 多套采用壳牌煤气化工艺（ S
43、CGP）的气化装置年累计运行 300天上下。 Several SCGP run around or above 300 days. 2台壳牌煤气化工艺（ SCGP）的气化装置年累计运行 330余天，最高达到 338天。 2 SCGP running above 330 days , longest one reached 338 days. 2012年 6月 14日，云天安创造了新的壳牌煤气化装置连续满负荷运行纪录 157天。 In June 14th, 2012, Yun Tianan created a new continuous running record for SCGP at 1
44、57 days 中石化安庆实现 152天连续运行 -创下 2011年行业纪录，到 9月 27日连续运行 185天 -创造了 2012年行业纪录。 Sinopec Anqing achieved a record of 152 continuous running days dry feed gasification record in 2011; till 2012, Sept 27, AQ create new record 185 days. 贵州天福 TIANFU (GUIYANG) Copyright of Shell Global Solutions International B.
45、V. 中石化壳牌岳阳气化公司的运行不断突破记录 SINOPEC SHELL YUEYANG GASIFICATION JV BREAK RECORD PERFORMANCE 25 中石化壳牌岳阳煤气化有限公司 (Sinopec Shell Yueyang Gasification Co.） 中石化壳牌合资公司在原煤供应、生产运营、设备管理和工艺优化等方面，取得了长足的进步： Significant improvement achieved in Dongting Sinopec Shell JV in coal supply, operations, equipment management
46、and process optimization: 至 2012年 7月 21日，在 201日历天实现 195天高负荷运行，在线率高达 97%，连续运行 145天。 Till July 20, 2012, JV achieved 195days high load running day among 201 calendar days, continuous running day reached 145days, 2011年实现 304天商业运行。 304 days commercial running day in 2011 在高负荷下处理百种不同类型的煤。 Processed 100+
47、different types of coals at high load 自 2006年 2月到 2012年 5月，累计 700万人时无工时损失事故的安全纪录。 Clocked 7mln man-hours without a LTI since 2006 Feb to 2012 May. Copyright of Shell Global Solutions International B.V. 实现长周期运行的关键要素 KEY FACTS THAT IMPACT LONG TERM STABLE OPERATIONS 26 煤化工装置实现长周期稳定运行的 4个关键要素 : 4 key e
48、lements for coal chemical plants to achieve long-term and stable running are: 1. 选择成熟可靠，得到工业验证，适合煤种的气化工艺 . Select reliable and mature gasification technology with industrial proven and suitable for the coal properties. 2. 良好的设计 , 采购和施工质量 (EPC) Good Engineering, Procurement and Construction quality 3
49、. 生产管理水平，包括煤质管理，在设计窗口操作，主动维护检查关键设备。 Operational expertise， including coal management, operation within design window, proactive monitoring and repair of critical equipment etc. 4. 懂得操作诀窍的操作 ，维护，工艺技术 人员 Well trained operations, maintenance, technology and engineering team; Copyright of Shell Project & Technology Confidential 保密材料 , 壳牌设备可靠性 管理体系 SHELL EQUIPMENT RELIABILITY MANAGEMENT SYSTEM 27 随着运行经验的提高 ， 设备的可靠性越来越成为影响工厂运行可靠性的关键因素 。 With long op
