Gas-to-Liquids

Realizing the vision

 Business Lines:

Gas-to-Liquids

LNG

Upstream Oil & Gas

Refining

Chemicals &
Petrochemicals

Pharmaceuticals
Biotechnology
Healthcare

Power
Turning vision
into reality
GTL has clearly come of age and
some of the engineering challenges
that have faced the experts over
recent years have been overcome.
In certain regions of the world GTL is
considered economically viable and
the first in the next generation of GTL
plants is taking shape in Qatar.
Foster Wheeler has led the way in
developing complete GTL
solutions, working with different
technologies, for a number of
clients, in difficult locations. We've
helped major international and
national oil companies develop their
GTL strategies.
Our significant contribution to the
ORYX GTL plant in Qatar started with
the development of a feasibility study
and a high quality FEED and
continues with provision of our
expertise as members of the Project
Management Team.
GTL projects require the 'top team'.
The challenges to be faced even at
the feasibility stage go well beyond
the process engineering that
typifies most feasibility studies, into
solutions for utilities and offsites
integration, some 40-50% of Foster Wheeler
project costs, construction leads the way in
philosophy, risk management and
environmental impact. gas-to-liquids
solutions. No other
contractor has the
same breadth and
depth of experience
or talented GTL
engineering
resource.
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 Why

GTL is the term

given to a number
of gas-to-liquids
processes, primarily
the formation
of liquid
hydrocarbons,
dimethyl ether or
methanol, from
natural gas.

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gas-to-liquids?
GTL processes offer
attractive alternatives for
monetizing gas. There is
a significant potential
market for high quality,
low impurity synthetic
hydrocarbon transportation
fuels and chemical
feedstocks, which meet
high environmental
standards.
There are a number of reasons for Technology used in GTL projects
using GTL technology to convert includes syngas production,
natural gas into liquid products: Fischer-Tropsch (FT) synthesis,
methanol synthesis and dimethyl
· Many of the world's gas reserves ether (DME) conversion.
are considered 'stranded', being Foster Wheeler has expertise in
too far from consumers and
all of these technologies and is
difficult or expensive to transport
able to provide a complete project
· Associated gas (with oil service to deliver exceptional
production) in quantities too
great to utilize at the site
engineering solutions.
• The need to end flaring
· Diversifying market risks,
converting natural gas into
something other than LNG
· Legislation driving demand
for high quality, cleaner
transport fuels
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 Commitment

We have the right We add value for our clients throughout the project lifecycle:
people with the · Technology selection and We work closely with our clients to
right expertise, optimization turn ideas and concepts into safe,
· Feasibility studies successful, high quality facilities.
commitment and
· Front-end engineering design
experience to deliver (FEED) We understand the drivers and
challenges of GTL projects and have
high quality complete · Utility and offsite system definition worked with our clients through the
and integration
GTL solutions. various project phase stages to
· Project management overcome these challenges and
· Detailed engineering develop cost-effective, optimized
· Environmental engineering solutions. We are particularly skilled
at integrating GTL process units with
· Procurement
offsites and utilities.
· Construction management
· Commissioning
· Operations and maintenance
management
· Training

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to deliver

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 Front-end

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excellence
"At this defining stage of the project,
we note to our satisfaction a
remarkably low level of design
changes and cost increases
associated with the P&ID and
HAZOP reviews to date. This is a
significant achievement, particularly
for a new technology project such
as this. We directly associate this
achievement to the high quality and
completeness of the front-end
engineering design package
developed by Foster Wheeler.”
“…a significant achievement…”
Following the 30% engineering
completion phase of the
ORYX GTL project in Qatar,
W J Swanepoel, GTL Project
Manager, on behalf of Sasol.
We have a reputation for
delivering high quality
conceptual, feasibility and
front-end packages, which lay
the foundations for a
successful project. We have
executed well over 150 major
FEEDs in the last 15 years.
We can provide advice to technology
developers to enable them to
operate their pilot plants, to gain
useful data and thus improve the
engineering definition of a project.
Linking our process expertise and
our project execution/estimating
skills and IT tools, we apply value
improvement practices during the
early phases of a project, where they
deliver the greatest benefit.
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We have unrivalled Our breadth of expertise in gas
treatment and conversion processes
experience in is of particular benefit when
technology transfer. considering integrated upstream and
downstream projects. The integration
We work with and optimization of the energy,
leading international offsites and utilities systems are key
to providing economic solutions to
process licensors GTL ventures.
both in technology
evaluation and Our extensive experience provides
major cost-saving opportunities for
project execution. our clients in:
· Air separation
· Heat integration and recovery
· Steam generation and utilization
· Hydrogen production
· Waste water processing and
treated water re-use
· Product quality optimization
We also provide expertise in
minimizing plot plan and piping
arrangements, optimizing
construction philosophy and
schedule reductions.
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Taking
Syngas production
We have experience in a full range of
synthesis gas generation
technologies including:
· Partial oxidation (air and
oxygen based)
· Catalytic partial oxidation
· Autothermal reforming
· Gas heated reforming/heat
exchange reforming
· Steam methane reforming
· Combination reforming and
other hybrids
· Ceramic membranes
Foster Wheeler has its own steam
methane reforming technology, and
has worked with other technologies.
Fischer-Tropsch synthesis
This process has been used
commercially since the 1950s and
has since advanced considerably.
A number of oil and chemical
companies and technology
developers license their own
technology. We have developed
designs with several of these
companies for fixed, moving and
slurry bed technologies.
technology further

Methanol conversion
We have worked with a number of
methanol conversion technologies
for production of fuel and chemical
grade methanol. We can offer
oxygen-blown, air-blown or enriched
air schemes.

Dimethyl ether conversion

This process provides an
advantage over methanol
conversion by producing a
non-toxic fuel with high calorific
value as an alternative to LNG for
a power-based value chain, or as
a diesel replacement fuel.

Floating GTL
We have experience in
barge-mounted and floating
production storage offloading
(FPSO) facilities for the
development of integrated GTL
offshore facilities, via the Seagas
Joint Industry Project,
of which we are one of the
founder members.

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 Quality ideas into

Our projects are

among the safest in
the business, but
we continually strive
to do even better.
We have won more
than 50 safety
awards over the
last 10 years.

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quality solutions
EPC expertise
As an EPC contractor or project
management consultant, we have
executed projects with a total
installed cost exceeding $50 billion.
Our network of execution centres
provides our clients with local access
to our global resources.
We have a long track record of
executing successful EPC projects,
completed on time, meeting
aggressive cost targets but with no
compromise on safety or quality.
Complex, large and difficult projects
are areas in which we excel.
Project management
Excellence underpins our project
management track record and
contributes significantly to our high
level of repeat business. We have a
reputation for providing world-class
project management, as an integral
part of our EPC project execution, or
working with our clients as their
project management consultant.
Engineering
We deliver a high quality product,
with engineering experts who design
with a focus on safety, cost,
constructability and operability. We
think it's important that engineers
follow the job through to site and
take an active role in construction
and commissioning.
Procurement
With our global network of
procurement centres and our local
knowledge, supported by
e-procurement, we have the
expertise, negotiating power and
flexibility to match the supply of
materials and services to our clients'
cost, schedule, quality, local content
and export credit needs.
Construction and
commissioning
There's a focus on construction and
commissioning from day one of our
projects. Our construction
management personnel are highly
experienced and culturally aware
professionals with a 'can do'
mentality, who expect the same
world-class standards on their
construction sites, wherever they
are in the world.
With significant modularization
experience, we have the
expertise to develop the optimum
construction strategy.
Plant operations
and maintenance
Our operations and maintenance
centre of excellence specialises
in the provision of management,
operations, maintenance, staff
development and training services.
Its expertise ranges from operating
an entire facility to provision of
specialist consultancy services.
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We have the Here are just a few examples of how we helped our clients solve
problems or do things differently:
expertise to provide
Utility integration
innovative solutions GTL plants are large consumers and
to complex producers of utilities. We have
problems, optimizing investigated and created solutions
for the reuse of available utilities in
project execution order to improve availability and
and reducing reduce capital costs.
capital costs. Fuel and tail gas
management
For unreacted syngas, light
hydrocarbons and CO2, we have
assessed their use as a stable
heating resource and developed
solutions for hydrocarbon and
hydrogen recovery, recycling
hydrogen and CO2, and using CO2
for syngas ratio adjustment.
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Adding
Water treatment
Water is by far the largest process
stream of a GTL plant. We have
developed solutions for simple
disposal and upgrading for irrigation,
cooling water and boiler feedwater
quality using reverse osmosis and
chemical/biological treatment.
Project implementation
We have reduced schedules by
developing construction
methodologies and sequencing,
improving the EPC bidding
process, making technology
selection during FEED phase,
and optimizing commissioning
and start-up procedures.
value

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 Project highlights

We have delivered a large number of gas-to-liquids projects since 1996:

over 20 technology development studies, 20 pre-feasibility studies,
eight detailed feasibility studies and two front-end engineering designs.

Sasol/Qatar Petroleum Chevron Nigeria Ltd Marathon

ORYX GTL Project Escravos GTL Project Gas-to-Liquids Project
Ras Laffan, Qatar Nigeria Qatar

New 34,000 bpd gas-to-liquids
plant processing 330 mmscfd
lean natural gas, producing:
· 24,000 bpd fuel
· 9,000 bpd naphtha
· 1,000 bpd LPG
Pre-feasibility and feasibility
studies, fast-track FEED, long lead
procurement, preparation of bid
documents for EPC bidders and
assistance with EPC evaluation
and project award. Contributing to
driving EPC progress as part of
the Project Management Team.
With unrivalled experience in
technology transfer, we work with
leading international process
licensors both in technology
evaluation and project execution.
New 34,000 bpd gas-to-liquids
plant, producing premium quality
GTL fuels and naphtha products.
Pre-feasibility and feasibility studies,
single point licensing on behalf of
Sasol Technology comprising basic
engineering of licensor units,
process facilities, steam systems
and licensor co-ordination. Also
awarded FEED, long lead
procurement, preparation of bid
documents for EPC bidders and
assistance with EPC evaluation
and project award.
Project Management Consultant
(PMC), assisting Marathon in
completing pre-FEED feasibility
studies for design optimization and
cost reduction.
The study included assessment of
the application of Fischer-Tropsch
gas-to-liquids technology, operability
and hazards evaluation, water
handling and disposal, plant layout
optimization, contract strategy
development, operating and
maintenance philosophy, and
preparation of a total installed
cost estimate.

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Seagas JIP
Offshore GTL

Seagas is a joint industry project

set up to examine the possibilities
for developing commercially viable
offshore GTL facilities involving four
contractors: Foster Wheeler, as
engineering and process
specialist, Spanish shipbuilder Izar,
Dutch floating production operator
Bluewater, and certification agency
Den Norske Veritas.

Having developed a deep

understanding of the key issues
and possible solutions for a West
African scenario, the team is
now seeking a real field
development project on which
to apply its expertise.

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 100%
commitment
to meeting your

safety, cost, schedule,

quality and
plant performance
objectives
gtl@fwc.com www.fwc.com

Engineering Centers
France
92 Quai de Bercy, 75597 Paris Cedex 12, France
T +33 1 43 46 40 00 F +33 1 43 46 47 00

Italy
Via Sebastiano Caboto 1, 20094 Corsico, Milan, Italy
T +39 02 44861 F +39 02 4486 3131

Singapore
991E Alexandra Road, Block 7 #01-25, Singapore 119973
T +65 6501 8888 F +65 6273 1015

South Africa
(Location) 2nd Road, Halfway House, Midrand, 1685, South Africa
(Correspondence) PO Box 76, Halfway House, Midrand, 1685, South Africa
T +27 11 690 0400 F +27 11 315 0243

Spain
Edificio Foster Wheeler, Calle Gabriel Garcia Marquez, 2, 28230 Las Rozas, Madrid, Spain
T +349 1 336 2500 F +349 1 336 2555

Thailand
217 Moo 12, Sukhapiban 8 Road, Tungsukhla, Sriracha, Cholburi 20230, Thailand
T +66 38 352 200/6, 768 400/3 F +66 38 352 226/444

Turkey
Kozyatagi-Sari Kanarya Sokak 22, Yolbulan Plaza, B-Blok, 34742, Istanbul, Turkey
T +90 216 445 1335 F +90 216 445 1336

UK
Shinfield Park, Reading, Berkshire, RG2 9FW, UK
T +44 (0)118 913 1234 F +44 (0)118 913 2333

USA
585 Dairy Ashford, Houston, Texas 77079
T +1 713 929 5000 F +1 713 929 5170