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WO2006058107A1 - Systeme mobile de transformation de gaz en liquides et procede correspondant - Google Patents

Systeme mobile de transformation de gaz en liquides et procede correspondant Download PDF

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Publication number
WO2006058107A1
WO2006058107A1 PCT/US2005/042520 US2005042520W WO2006058107A1 WO 2006058107 A1 WO2006058107 A1 WO 2006058107A1 US 2005042520 W US2005042520 W US 2005042520W WO 2006058107 A1 WO2006058107 A1 WO 2006058107A1
Authority
WO
WIPO (PCT)
Prior art keywords
lpg
fpso
natural gas
synthetic crude
movable platform
Prior art date
Application number
PCT/US2005/042520
Other languages
English (en)
Inventor
H. Lynn Tomlinson
Kenneth Agee
E. Gary Roth
Original Assignee
Syntroleum Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/994,857 external-priority patent/US20050106086A1/en
Application filed by Syntroleum Corporation filed Critical Syntroleum Corporation
Priority to PCT/US2005/042520 priority Critical patent/WO2006058107A1/fr
Priority to EP05852095A priority patent/EP1827959A1/fr
Publication of WO2006058107A1 publication Critical patent/WO2006058107A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B35/00—Vessels or similar floating structures specially adapted for specific purposes and not otherwise provided for
    • B63B35/44—Floating buildings, stores, drilling platforms, or workshops, e.g. carrying water-oil separating devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B35/00—Vessels or similar floating structures specially adapted for specific purposes and not otherwise provided for
    • B63B35/44—Floating buildings, stores, drilling platforms, or workshops, e.g. carrying water-oil separating devices
    • B63B2035/4473—Floating structures supporting industrial plants, such as factories, refineries, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B35/00—Vessels or similar floating structures specially adapted for specific purposes and not otherwise provided for
    • B63B35/44—Floating buildings, stores, drilling platforms, or workshops, e.g. carrying water-oil separating devices
    • B63B2035/448—Floating hydrocarbon production vessels, e.g. Floating Production Storage and Offloading vessels [FPSO]
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40—Characteristics of the process deviating from typical ways of processing
    • C10G2300/4062—Geographical aspects, e.g. different process units form a combination process at different geographical locations

Definitions

  • the invention relates to a movable gas-to-liquid system and process, and more particularly, to a gas-to-liquid system constructed on a marine vessel, such as an FPSO.
  • Fischer-Tropsch processes for converting synthesis gas into higher carbon number hydrocarbons are well known.
  • the hydrocarbon products of a Fischer-Tropsch synthesis generally include a wide range of carbon number, ranging from between about 1 and about 100.
  • the end products which may be recovered from the Fischer-Tropsch synthesis product, following separation, hydroprocessing or other upgrading, include but are not limited to liquified petroleum gas ("LPG"), naphtha, middle distillate fuels, e.g. jet and diesel fuels, and lubricant basestocks.
  • the desirability of an end product of a Fischer-Tropsch synthesis may also be dependent upon geographic location of the Fischer-Tropsch plant.
  • GTL Gas to liquid
  • synthesis gas is generated from natural gas via partial oxidation with oxygen, requiring an air separation plant to provide the oxygen.
  • nitrogen is eliminated from the synthesis gas stream as an unwanted inert.
  • synthesis gas is produced by oxidation of hydrocarbons using air- or oxygen enriched air-carried oxygen, rather than separated oxygen. This eliminates the expense, as well as the extra space requirment, of an air separation plant. It thus reduces capital costs, making possible plants with considerably smaller footprints, and also provides for a safer operating environment.
  • Fischer-Tropsch plants of at least about 50,000B/d production are generally required in order to lower the capital cost per barrel of daily capacity to an acceptable level.
  • such Fischer-Tropsch plants require about 500 Mmcf/d of feed gas, or 5.4 trillion cubic feet over a thirty year period. Only about 2% of the known gas fields outside of North America are of such size.
  • Stranded natural gas reserves also may produce condensates and liquified petroleum gasses (LPGs), i.e. propanes and butanes, which may be recovered. Isolation of LPG components, with or without combination with Fischer-Tropsch produced LPGs, is not typically practiced in gas to liquid processes. However, failure to monetize LPG components further lowers the economic feasibility of accessing and producing stranded gas reserves.
  • LPGs liquified petroleum gasses
  • the invention provides a movable gas to liquids system and process.
  • a synthesis gas production unit, a synthetic crude production unit and a product upgrading unit are located on a movable platform wherein the units are operationally connected to each other.
  • a process for converting natural gas to hydrocarbon liquids wherein the process occurs on one or more movable platforms operationally connected to each other.
  • Fig. 1 is a schematic drawing of a GTL FPSO embodiment of the present invention.
  • Fig. 2 is a schematic drawing of an Oil/GTL FPSO embodiment of the present invention.
  • Fig. 3 is a schematic diagram showing an alternative embodiment of the invention wherein Wellhead Natural Gas and Fischer-Tropsch synthesis product are blended in the production of LPG products, Naphtha products and transportation fuel products.
  • Fig. 4 is a schematic diagram showing an alternative embodiment of the invention wherein Wellhead Natural Gas, Fischer-Tropsch synthesis product, and imported offsite Natural Gas are co-processed in the production of a transportation fuel.
  • C x refers to a hydrocarbon compound having predominantly a carbon number of x.
  • C x may be modified by reference to a particular species of hydrocarbons, such as, for example, C 5 olefins.
  • the term means an olefin stream comprised predominantly of pentenes but which may have impurity amounts, i.e. less than about 10%, of olefins having other carbon numbers such as hexene, heptene, propene, or butene.
  • C x + refers to a stream wherein the hydrocarbons are predominantly those having a hydrocarbon number of x or greater but which may also contain impurity levels of hydrocarbons having a carbon number of less than x.
  • Ci 5+ means hydrocarbons having a carbon number of 15 or greater but which may contain impurity levels of hydrocarbons having carbon numbers of less than 15.
  • C x -C y where x and y are numbers greater than zero, refers to a mixture of hydrocarbon compounds wherein the predominant component hydrocarbons, collectively about 90% or greater by weight, have carbon numbers between x and y.
  • C 5 - C 9 hydrocarbons means a mixture of hydrocarbon compounds which is predominantly comprised of hydrocarbons having carbon numbers between 5 and 9 but may also include impurity level quantities of hydrocarbons having other carbon numbers.
  • Synthesis gas (or "syngas”) useful in producing a Fischer-Tropsch product useful in the invention may contain gaseous hydrocarbons, hydrogen, carbon monoxide and nitrogen with H 2 :CO ratios from between about 0.8: 1 to about 3.0:1.
  • the hydrocarbon products derived from the Fischer-Tropsch reaction may range from methane to high molecular weight paraffinic waxes containing more than 100 carbon atoms.
  • Operating conditions and parameters of an autothermal reactor for producing a syngas useful in the process of the invention are well known to those skilled in the art. Such operating conditions and parameters include but are not limited to those disclosed in U.S. 4,833,170; 4,973,453; 6,085,512; 6,155,039, the disclosures of which are incorporated herein by reference.
  • Fischer-Tropsch catalysts are also known in the art and include, those based upon for example, cobalt, iron, ruthenium as well as other Group VIIIB transition metals or combinations of such metals, to prepare both saturated and unsaturated hydrocarbons.
  • the Fischer-Tropsch catalyst may also include a support, such as a metal-oxide support, including but not limited to silica, alumina, silica-alumina or titanium oxides.
  • a cobalt (Co) catalyst on transition alumina with a surface area of approximately 100-200 m 2 /g may be used in the form of spheres of 50-150 ⁇ m in diameter.
  • the Co concentration on the support may be between about 5 wt% to about 30 wt%.
  • the stabilizers include Group IIA or Group HIB metals, while the promoters may include elements from Group VIII or Group VIIB.
  • the Fischer-Tropsch catalyst and reaction conditions may be selected to be optimal for desired reaction products, such as for hydrocarbons of certain chain lengths or number of carbon atoms. Any of the following reactor configurations may be employed for Fischer-Tropsch synthesis: fixed bed, slurry bed reactor, ebullating bed, fluidizing bed, or continuously stirred tank reactor ("CSTR").
  • the FTR may be operated at a pressure from about 100 psia to about 800 psia and a temperature from about 300° F to about 600° F.
  • the reactor gas hourly space velocity may be from about 1000 hr "1 to about 15000 hr " ⁇
  • Operating conditions and parameters of the FTR useful in the process of the invention are well known to those skilled in the art. Such operating conditions and parameters include but are not limited to those disclosed in U.S. 4,973,453; 6,172,124; 6,169,120; and 6,130,259, the disclosures of which are incorporated herein by reference.
  • Some embodiments of the invention provide a movable system optimized for the monetization of stranded gas reserves.
  • the stranded gas reserves are located in or near submerged formations, such as those found off-shore.
  • the movable system may be moved, for example, by way of ocean- or sea-going vessels, such as a floating production, storage and offloading (FPSO) vessel.
  • FPSO floating production, storage and offloading
  • Movable vessels useful in the invention may be independently mobile or may require external mobility means, such as lift ship or tugboat.
  • the terms movable platforms and/or vessels include, without limitation, FPSOs, floating storage and offloading vessels (FSO), gravity based structures, spar platforms, tension leg platforms.
  • movable platforms are included in the scope of the invention, including trailer, truckbed, rail car or platform, or other movable forms on which the modules may be transported or moved from location to location.
  • the movable platform is maintained in place by any of a number of methods, including without limitation, fixed turret, removable turret, conventional mooring systems, anchoring, and/or suction piles.
  • a GTL FPSO 10 is located in a position accessible to an existing FPSO 12, generally accessible by pipeline.
  • Existing FPSO 12 may be an oil and or gas producing FPSO or any other type of FPSO from which natural gas may be obtained.
  • existing FPSO 12 is a crude oil production FPSO from which associated natural gas may be obtained.
  • Existing FPSO 12 is, in some embodiments, an FPSO which is in place and producing prior to the introduction of the GTL FPSO 10.
  • existing FPSO 12 and GTL FPSO 10 are placed in proximity at or substantially at the same time.
  • the GTL FPSO 10 receives natural gas from existing FPSO 12 through gas pipeline 14.
  • the GTL FPSO 10 converts the natural gas into a synthesis gas, and the synthesis gas into a synthetic crude using known processes.
  • the GTL FPSO 10 further includes product upgrading and recovery facilities for the conversion of synthetic crude into one or more products, such as naphtha and transportation fuels, including, for example, diesel fuel.
  • product upgrading means the refining of a synthetic crude that is waxy, into one or more hydrocarbon products, including for example, a single wide-boiling range product (e.g., C5 to C40) having a reduced pour point which is lower than the waxy synthetic crude which is sufficient to prevent wax crystallization during transshipment either as a separate product or blended with crude oil and/or condensate, naphthas, liquified petroleum gases, basestocks, solvents, kerosene, and hydrocarbon products meeting fuel specifications.
  • product upgrading eliminates all or all but trace amounts of oxygenated compounds.
  • the addition of some additives to the product upgrading products of kerosene and fuels may be required before end use.
  • any of the products may, in some embodiments, be blended with petroleum products prior to end use.
  • the term reduced pour point means having a pour point between about 100 0 F and about O 0 F, between about 7O 0 F and about 2O 0 F, between about 50 0 F and about 2O 0 F, or between about 4O 0 F and about 20 0 F.
  • a syngas production unit which may include those components and may be of a type known in the art.
  • a synthetic crude production unit of a type and including components known to those in the art is also located on the GTL FPSO 10.
  • product upgrading units including components known in the art, such as hydrocrackers, distillation columns, dehydration and oligomerization reactors, are located on the GTL FPSO 10.
  • product upgrading refers to the production of finished end user products, such as diesel fuel, and/or intermediate products, such as lubricant basestocks.
  • the synthesis gas and synthetic crude production units and, if present, the product upgrading units are mounted onto the GTL FPSO in a manner which causes such units to be substantially unmovable.
  • some or all of such units are mounted on skids or modules which may be interchanged and/or repositioned.
  • an Oil/GTL FPSO 20 is located at or near an oil or natural gas reserve.
  • the Oil/GTL FPSO 20 preferably includes oil production facilities as well as the GTL component units as discussed in connection with Fig. 1.
  • the Oil/GTL FPSO 20 includes those GTL components, i.e., synthesis gas production unit, Fischer-Tropsch unit, as discussed in connection with Fig. 1.
  • the Oil/GTL FPSO includes primary separation equipment to separate oil, gas and water which may all, or some, be produced from the wellhead.
  • the Oil/GTL FPSO 20 communicates with the wellhead through incoming production risers and umbilicals 22 and one or more outgoing water injection lines 24.
  • the synthesis gas and synthetic crude production units and, if present, the product upgrading units are mounted onto the GTL FPSO in a manner which causes such units to be substantially immovable.
  • some or all of such units are mounted on skids or modules which may be interchanged and/or repositioned.
  • the GTL FPSO 10 and the Oil/GTL FPSO 20 are configured to produce complete parcels, as that term is commonly used in the shipping field. That is, in preferred embodiments of invention, the storage capacity of the FPSO and the production capacity of oil production and/or gas to liquid production facilities are correlated so as to completely or nearly completely fill the storage capacity of the FPSO. Further, the storage tanks on the GTL FPSO are preferably sized to match as large a shipping parcel as possible. Shipping of product is a key financial consideration in any project that depends upon product reaching the final market in order to be profitable. In the hydrocarbon product market, shipping of products occurs in clean product tankers, typically.
  • Some embodiments of the invention further provide for cooled storage of LPG products, the production of which is discussed in more detail below in connection with Figs. 3 and 4.
  • Such cooled storage facility is preferably correlated with production capacity of LPG and LPG components so as to achieve complete parcel shipping amounts.
  • FIGs. 1 and 2 describe the use of an FPSO vessel as the movable platform for the production and GTL facilities, other embodiments of the invention include other land and marine based platforms, such as ships, gravity based structures, and platforms.
  • the movable platform may have a multi- vessel configuration.
  • Multi-vessel configurations permit the use of any of the component vessels to be used for a single or multiple purposes.
  • one of the two vessels may be used, for example, for oil production equipment, primary separation, and crude oil storage.
  • the second vessel could be employed, for example, for synthesis gas and synthetic crude production along with storage of LPG components, i.e., butane and propane, LPG, end user products, and/or intermediate products.
  • both vessels would preferably be FPSOs.
  • one vessel could function for all production activities, including for example, oil production, oil/gas separation, LPG recovery, synthesis gas and synthetic crude production.
  • the other two vessels could be floating storage and offloading vessels (FSOs).
  • FSOs floating storage and offloading vessels
  • the FSOs may be such so as to allow cold and or warmed storage.
  • Yet other compartments of the FSOs could be temperature untreated.
  • end user and/or intermediate GTL products could be stored in appropriate tanks located on either of the FSO vessels.
  • one of the vessels may be dedicated to crude oil storage and one of the vessels dedicated to end user, intermediate, LPG, or LPG component storage.
  • FIG. 3 one embodiment of the invention is shown in which wet sour gas from a wellhead is processed in a gas sweetening/liquids separation unit 40.
  • An LPG fraction is obtained overhead from unit 40 ("NG-LPG" hereinafter)
  • a natural gas liquids (“NGL” hereinafter) fraction is obtained as an upper side stream from unit 40 containing primarily hydrocarbons having a carbon number greater than 5 is recovered.
  • the bottoms fraction known in the art as "residue gas” containing primarily hydrocarbons having a carbon number equal to or greater than 9 is recovered.
  • the bottoms fraction is sent to synthesis gas production.
  • the synthesis gas so produced may then be used in a GTL production, such as a Fischer-Tropsch synthesis.
  • the Fischer-Tropsch synthesis product may then be fractionated to recover a light Fischer-Tropsch liquid, also commonly referred to as a Fischer-Tropsch oil, (“LFTL”) and a heavy Fischer-Tropsch liquid, also commonly referred to as a Fischer-Tropsch wax, (“HFTL”).
  • LFTL Fischer-Tropsch oil
  • HFTL Fischer-Tropsch wax
  • Fig. 3 the synthesis gas production, Fischer-Tropsch synthesis and Fischer-Tropsch product fractionation processes are jointly illustrated in unit 41.
  • the Fischer- Tropsch LFTL may then be dehydrated, or otherwise treated for removal of oxygenates, or hydrotreated, as indicated in Fig. 4 in unit 42.
  • the HFTL may be hydrocracked in unit 43 to produce lower molecular weight hydrocarbons.
  • the products of units 42 and 43 may then be recombined and fed into a product fractionator 44.
  • a Fischer-Tropsch LPG product (“FT- LPG” or “GTL-LPG” hereinafter)) may be recovered from Fractionator 44 and combined with the LPG obtained overhead from unit 40.
  • the combined LPG may then be further processed into a variety of known LPG products.
  • any of the FT-LPG product, NG-LPG, or a combination of FT-LPG and NG-LPG products may be separated into butane and propane fractions.
  • a Fischer-Tropsch or GTL Naphtha may also be recovered from fractionator 44 and combined with the NGL recovered from unit 40.
  • the combined NGL and Fischer-Tropsch Naphtha may then be further processed into a variety of known naphtha products.
  • Transportation fuels, or blending stocks therefor, such as jet fuel and diesel fuel may also be recovered from fractionator 44.
  • Fig. 4 illustrates yet another embodiment of the invention in which liquified petroleum gas is imported from an off-site location and co-processed with the LPG fraction recovered from unit 40 and the Fischer-Tropsch LPG fraction recovered from fractionator 44.
  • the embodiment of the invention shown in Fig. 4 could be used with stranded reserves providing even less than 100 Mmcf/d but which may provide feasible economics due to the ability to supplement the stranded gas reserve with imported natural gas.
  • a synthesis gas module may include a gas sweetening/liquids separation unit for removal of certain contaminants, such as sulfur, and separation of liquids from gaseous hydrocarbon components.
  • synthesis gas module would generally also include an autothermal reactor for conversion of the gaseous hydrocarbons into synthesis gas.
  • the synthesis gas module may also include one or more Fischer-Tropsch reactors.
  • the Fischer-Tropsch reactor(s) may be combined with one or more Fischer-Tropsch product fractionators to form a Fischer-Tropsch module.
  • One or more product modules may be connected to the synthesis gas module or Fischer-Tropsch module for upgrading the product of the Fischer-Tropsch synthesis into one or more higher value products.
  • One example product module, a transportation fuel product module would include dehydration or hydrotreatment units for the processing of an LFTL fraction as well as a hydrocracking unit for the processing of an FIFTL fraction to obtain a synthetic transportation fuel.
  • Other product modules include, for example, a hydrotreatment plus hydroisomerization unit and a dehydrogenation plus oligomerization units.
  • off-site or imported natural gas feed may be piped directly into a product unit.
  • Table 1 shows three possible arrangements of the invention using standard crude oil tanker hulls as a base hull for the Oil/FPSO and/or GTL FPSO.
  • Table 2 shows an alternate embodiment of the invention whereby a new or existing FPSO associated with crude oil production is connected to a GTL FPSO.

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  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Ocean & Marine Engineering (AREA)
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Abstract

Cette invention concerne un système servant à convertir du gaz naturel en un ou plusieurs produits hydrocarbures liquides. Ce système comprend une plate-forme mobile (10) sur laquelle sont installées des unités de production de gaz de synthèse et de production de brut synthétique (41) et des unités de valorisation des produits (42, 43, 44). L'unité de production de gaz de synthèse peut utiliser l'air ou de l'air enrichi en oxygène pour produire du gaz de synthèse, et l'unité de production de brut synthétique peut comprendre un réacteur à combustible en suspension sur colonne de barbotage. Sur la plate-forme mobile (10) peut être disposée une unité d'adoucissement des gaz et de séparation des liquides (40) pour extraire un gaz de pétrole liquéfié (GPL) ou des composants de GPL. L'unité de production de gaz de synthèse comprend de préférence un réacteur autothermique. L'unité de production de brut synthétique comprend de préférence un réacteur de Fischer-Tropsch. La plate-forme mobile est de préférence de type FPSO (10) pouvant comporter des cuves refroidies, des cuves réchauffées et/ou des cuves non traitées thermiquement. Un des produits hydrocarbures liquides préférés est du carburant diesel. Cette invention propose également un procédé servant à convertir du gaz naturel en produits hydrocarbures liquides, ce procédé étant réalisé sur ladite plate-forme mobile.
PCT/US2005/042520 2004-11-22 2005-11-22 Systeme mobile de transformation de gaz en liquides et procede correspondant WO2006058107A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/US2005/042520 WO2006058107A1 (fr) 2004-11-22 2005-11-22 Systeme mobile de transformation de gaz en liquides et procede correspondant
EP05852095A EP1827959A1 (fr) 2004-11-22 2005-11-22 Systeme mobile de transformation de gaz en liquides et procede correspondant

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/994,857 US20050106086A1 (en) 2003-08-06 2004-11-22 Movable gas-to-liquid system and process
US10/994,857 2004-11-22
PCT/US2005/042520 WO2006058107A1 (fr) 2004-11-22 2005-11-22 Systeme mobile de transformation de gaz en liquides et procede correspondant

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Publication number Priority date Publication date Assignee Title
WO2009108242A1 (fr) * 2008-02-29 2009-09-03 Kyrogen Usa, Llc Procédé et appareil d'activation/régénération de catalyseur de synthèse de fischer-tropsch et d'oxygénat
US8614158B2 (en) 2008-02-29 2013-12-24 Schlumberger Technology Corporation Fischer-trospch and oxygenate synthesis catalyst activation/regeneration in a micro scale process
US8293805B2 (en) 2008-05-29 2012-10-23 Schlumberger Technology Corporation Tracking feedstock production with micro scale gas-to-liquid units

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