Liquid Assets: Custom-Made Catalyst For The World’s Largest Gas-To-Liquid Plant

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“Quality is critical during manufacturing because of the impact of the catalyst on operational performance in a plant the size of Pearl,” he says. “Through the use of a dedicated state-of-the-art manufacturing facility we are delivering the quality and consistency that is essential for the successful operation of the world’s largest GTL plant.”

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Gas–To–Liquid Products

What Liquefied Gas Can Do – Slate of Products

Gas-to-liquids technology enables major resource holders to monetise reserves of natural gas, through its conversion into higher value products normally derived from oil. Pearl GTL is the world’s largest source of gas-to-liquids products. It will produce 140,000 barrels of GTL products per day. Its slate of GTL products includes:

GTL Gasoil

A diesel-type fuel that will help diversify the supply of diesel fuels and can be blended easily with conventional, oil-based diesel and used in the existing diesel distribution system. GTL gasoil has a very high cetane number, is virtually free of sulphur and burns with lower sulphur dioxide, lower nitrogen oxides and particulate emissions than conventional oilbased diesel. Pearl GTL will produce around 50,000 barrels of GTL gasoil per day, enough to fill over 160,000 cars every day. Shell Chemicals will also market GTL gasoil into drilling fluids and other chemical applications globally.

GTL Kerosene

GTL kerosene can be used for heating and lighting but its main use will be for aviation fuel. Like GTL gasoil, it burns with lower local emissions than conventional oil-based kerosene.

GTL Base Oils

GTL base oils can be used for lubricants that keep vehicle engines and gearboxes operating smoothly. Pearl GTL will be one of the world’s largest sources of lubricant base oil with the capacity to produce about 30,000 barrels per day, enough to fill 225 million cars per year.

GTL Normal Parafin

Normal paraffin can be used in the production of detergent chemicals for washing powder and soaps. Traditionally, detergent manufacturers extract normal paraffin from oil-based kerosene. The GTL process eliminates this extraction stage.

GTL Naphtha

An alternative cracker feedstock to conventional naphtha. It has much higher paraffin content than conventional naphtha, which means each litre of GTL naphtha can yield more chemicals.

Second Generation GTL On Its Way

Continuous research and development, combined with experience gained from the Bintulu plant, is leading to further improvements in the HPS catalyst design that will allow faster processing and should enable Shell to produce even greater volumes of products at Pearl GTL. “A second generation HPS catalyst has already been proven at Bintulu and we have third and fourth generation versions in different stages of development,” explains Del Paggio. “With each new variant we are extending our knowledge and understanding of the chemical reaction at the heart of the GTL process and getting progressively higher yields and longer service life.”

A closed loop is also employed for the recovery of the cobalt precious metal used in HPS catalysts, once they reach the end of their service life. The recovered cobalt is recycled and used in the production of fresh catalyst, which contributes to a more sustainable and economically attractive catalyst life-cycle.

Pearl GTL will add almost 8% to Shell’s production worldwide — making it one of the main engines for growth. It has already shipped its first product and will reach full production in 2012. Building on its extensive experience marketing GTL products from Bintulu, Shell will export Pearl GTL’s high value, differentiated products – including chemical feedstocks and derivatives – around the globe. ●

* The author is a chemical industry writer for Shell.

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Gas To Liquid