Pearl GTL: The World's Largest Gas-to-Liquids Plant Set for Production
By Royal Dutch Shell Plc, PRNETuesday, March 22, 2011
THE HAGUE, March 23, 2011 - The world's largest plant to turn natural gas into cleaner-burning fuels
and lubricants took a major step closer to production today when gas began
flowing from a giant offshore field.
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Pearl GTL will process around 3 billion barrels of oil equivalent over
its lifetime from the world's largest single gas field, the North Field in
the Arabian Gulf. The field stretches from Qatar's coast and contains more
than 900 trillion cubic feet of gas, equivalent to 150 billion barrels of
oil, or over 10% of worldwide gas resources.*
The gas-to-liquids (GTL) plant - a joint development by Qatar Petroleum
and Shell (NYSE: RDS.A) (NYSE: RDS.B) - will add almost 8% to Shell's
production worldwide - making it the company's main engine for growth for
2012. It has a capacity of 260,000 barrels oil equivalent a day and is
expected to ship its first product in 2011 and reach full production in 2012.
"We're on the verge of starting up a project that will be a foundation
for Shell's future growth for decades to come," says Shell's Country Chairman
in Qatar, Andy Brown. "For Qatar it means another way to generate revenues
from gas reserves, in addition to selling pipeline gas or liquefied natural
gas. It diversifies the country's revenue streams and provides long-term
income."
The plant will produce cleaner-burning diesel and aviation fuel, oils for
advanced lubricants, naphtha used to make plastics and paraffin for
detergents. It will make enough diesel to fill over 160,000 cars a day and
enough synthetic oil each year to make lubricants for more than 225 million
cars. The products will reach customers in every major energy market through
Shell's global retail network.
In bringing Pearl to production, Shell engineers have built on more than
30 years of experience in gas-to-liquids technology. We built the world's
first commercial-scale GTL plant in Bintulu, Malaysia, in 1993. Pearl's
output of GTL products will be 10 times greater than Bintulu's.
Safety record
Building Shell's biggest engineering project to date in Ras Laffan, a
vast industrial zone on Qatar's coast some 90 kilometres north of Doha, was a
major feat. At the peak of construction, it involved more than 52,000 workers
from over 50 nations.
Despite the massive number of workers involved and the complexity of
Pearl's construction, a strong safety culture helped Qatar and Shell achieve
a record-breaking 77 million hours worked onshore without injuries leading to
time off work.
Preparing for a smooth start-up
Getting the huge plant into full operation will take a series of
carefully executed system start-ups. Pearl GTL's control room - the nerve
centre of one of the largest and most sophisticated plants ever built in the
energy industry - has powered up.
The first turbines and auxiliary steam systems have begun to generate
steam and electricity to power the plant. The first two oxygen separation
units are up and running.
Drilling record
Sixty kilometres offshore, natural gas from the North Field - discovered
by Shell in 1971 - is now flowing from to two platforms standing in water up
to 40 metres deep to feed Pearl GTL. Eleven wells were drilled for each
platform in record drilling times for the field.
Two underwater 76-centimetre (30-inch) diameter pipelines are carrying
the natural gas to a gas separation plant onshore that extracts natural gas
liquids: ethane for industrial processes, liquefied petroleum gas (LPG) for
domestic heating and cooking and condensates as a feedstock for refineries.
The separation process also removes contaminants like metals and sulphur. The
sulphur is turned into pellets and shipped to the nearest market to make
hydrosulphuric acid, fertiliser or other valuable products.
Turning gas into liquid fuel
The pure gas, or methane, that remains will then flow to the GTL section
of the plant, where it will be converted in a three-stage process into a
range of gas-to-liquids products using Shell proprietary technology.
Finally, the liquid hydrocarbon wax is upgraded using specially developed
technology involving new catalysts into the range of products. It takes some
2,000 steps to prepare all GTL systems for production.
In Qatar, summer temperatures exceed 40degreesC (104degreesF) and
rainfall is slight. Conserving water is critical. Pearl was designed to be
self-sufficient in its use of water.
Pearl, the largest investment by Shell in any single project, is a fully
integrated project spanning production from an offshore gas field to finished
marketable products. Shell is funding 100% of the development costs under a
profit- sharing agreement with the state of Qatar.
*source: Oil & Gas Journal
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More information: For more information, interview requests or photography, please contact: Shell Media Relations, The Netherlands, Wendel Broere: +31(0)70-377-8750, International, Jonathan French: +31(0)70-377-3600.
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