Athabasca Assay

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OIL S.4NT.G~'FOR.V..~,T;ON E V F . S R I _S C

UPGRADER OPTIMIZATION

A N W LOOK AT THE R GO A U G A E E E I N L P RDR

WITH SELECTEDADDm0NS

A C A B R OF R S U C S , HME EORE L SANDS TASK F R E O C WH I T A B R A D P R M N OF E E G LE T EA T E T NR YAND

E E G MINES A D R I R , :; CA A"A NR Y N E OJ CF.' . N I) '

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Alberta Energy 96-03611/

ACKNOWLED(~EMENT AND DISCLAIMER

The research project for which this report is submitted was funded (in part) from the Alberta Department of Energy. This report and its contents, the project in respect of which it is submitted and the conclusion and recommendations arising from it do not necessarily reflect the view of the Government of Alberta, its officers, employees or agents. The Government of Alberta, its officers, employees or agents and consultants make no warranty, express or implied, representation or otherwise, in respect of this report or its contents. The Government of Alberta, its officers, employees and agents and Consultants are exempted, excluded and absolved from all liability for damage for injury, howsoever caused, to any ~rson in connection with or arising out of the use by that person for any purpose of this report or its contents.

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TABLE OF CONTENTS

Table of Contents Ust of Tables Lost of F,gures Admowtedgements Executwe Summary 10 INTRODUCTION 11 12 13 14 20 PREAMBLE STUDY ORGANIZATION ECONOMIC BASES TECHNOLOGY BASES

II VII IX X Xl

1-1 1 1-1 1-1 12 1-2 2-1 21 2-2 2--4 2-4 2-5 2-631 3-I 3-2 3-3 33 3-5 3-5 3-6 3-74-1 4-1 4-2 4-7 4-15

CASES-CONSIDERED2 .I

2.2. 23 24 25 26 30

PREAMBLE BASECASE EXPANDEDBASE CASE FISCHER-TROPSCH CASE PARTIALREFINING CASE REFININGCASES

FEED,INTERMEDIATE AND PRODUCT PRICING 31 32 33 34 3S PRICING AND COST SUMMARY ECONOMIC ANALYSES BASES COMMENT F-T MIDDLE DISTILLATE VALUATION PURCHASED HYDROGEN 3 5 1 AVAILABILITY 3 S 2 BALANCE 3 S 3 PURCHASED HYDROGEN COSTING

4O

BASE CASE 41 42 43 44

INTRODUCTION DESIGN BASES DESCRIPTION OF OVERALL DESIGN PRODUCT YIELDS AND PROPERTIES

Page Ja

TABLE OF CONTENTS

4.5 4.6 4.7 4.85.0

UTILITY BALANCE CAPITAL COST ESTIMATES WORKING CAPITAL ESTIMATES OPERATING COST ESTIMATES

4-15 4-16 4-19 4-195-1 - ' ;'~5-1

EXPANDED BASE CASE

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.86.0

INTRODUCTION DESIGN BASES DESCRIPTION OF DESIGN PRODUCT YIELDS AND PROPERTIES UTILITY BALANCES CAI~TAL COST ESTIMATES WORKING CAPITAL ESTIMATES OPERATING COST ESTIMATES

5-1 5-1 .5-2 5-2 5-2 5-2 5-3 6-I 6-1 6-3 6-4 6-4 6-7 6-7 6-7 6-8 6-11 6-12 6-14 6-15 6-15 6-15 6-17 6-19 6-20 6-20 6-20

F|SCHER-TROPSCH CASE 6.1 6.2 6.3 6.4 6.5 6.6 INTRODUCTION DESIGNBASES STEAMMETHANE REFORMING CO2 RECOVERY HYDROGEN SEPARATION FISCHER-TROPSCHSYNTHESIS 6.6.1 PREAMBLE 6.6.2 FISCHER-TROPSCHPROCESS DESCRIPTION 6.6.3 CATALYST SPECIFICATIONS 6.6.4 CATALYST LIFE AND REGENERATION 6.6.5 CATALYST INSITU ACTIVATION 6.6.6 F-T PURGE GAS PROCESSING F-T PRODUCT FINISHING 6.7.1 PREAMBLE 6.7.2 HYDROCRACKING 6.7.3 MIDDLE DISTILLATE IMPROVEMENT 6.7.4 PRODUCT FRACTIONATION 6.7.5 FURTHER WORK F-T AREA WASTE TREATMENT

6.7

6.8

Page iii

TABLE OF CONTENTS

6.9

6.10 6.11 6.T2 6.13 6.14 7'.0

F-T AREA UTILITIES 6.9.1 REFRIGERATION 6.9.2 CHILLED WATER 6.9.3 STEAMSYSTEMS 6.9.4 CONDENSATE AND BOILER FEEDWATER 6.9.5 COOLING WATER 6.9.6 INSTRUMENTAIR 6.9.7 FUEL GAS 6.9.8 FLARES 6.9.9 PIPELINES 6.9.10 TANKAGE PRODUCT YIELDS AND PROPERTIES UTILITY BALANCE CAF~TAL COST ESTIMATE WORKING CAPITAL COST ESTIMATE OPERATING COST ESTIMATES

6-21 6-21 6-21 6-21 6-22 6-22 6-22 6-22 6-23 6-23 6-23 6-23 6-23" 6-26 6-26 6,26

PARTIAL REFINING CASES

7-1 7-1 7-2 7-2 7-9 7-9 7-9 7-10 7-108-1 8-I 8-I 8-3 8-3 8-3 8-3 8-3 8-3

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.88.0

INTRODUCTION DESIGN BASES DESCRIPTION OF OVERALL DESIGN PRODUCT QUALITIES UTILITY BALANCES CAPITAL COST ESTIMATES WORKING CAPITAL ESTIMATES OPERATING COST ESTIMATES

INTEGRATED CASE8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

INTRODUCTION DESIGN BASES DESCRIPTION OF DESIGN PRODUCT YIELDS AND PROPERTIES UTILITY BALANCES CAPITAL COSTS WORKING CAPITAL OPERATING COSTS

Page iv

TABLE OF CONTENTS

9.0

FULL REFINING CASES 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 INTRODUCTION DESIGN BASES DESCRIPTION OF OVERALL DESIGN PRODUCT YIELDS UTILITY BALANCES CAPITAL COST ESTIMATES WORKING CAPITAL OPERATING COST ESTIMATES

9-1 9-1 9-2 9-6 9-24 9-24 9-24 9-26 9-2610-1 I0-I I0-I 10-2 10-3 11.1

I 0.0

SPECIALCASES 10.1 10.2 10.3 "0.4 PREAMBLE BUY OR MAKE HYDROGEN PARTIAL OXIDATION FOR SYNTHESIS GAS METHANOL VERSUS FISCHER-TROPSCH

11.0

ECONOMIC COMPARISONS 11.1 11.2 11.3 11.4 11.5 11.6 PREAMBLE EXPANDED BASECASE DISCUSSION FISCHER-TROPSCH CASE PARTIAL REFINING CASES INTEGRATED CASE FULL REFINING CASE

1 1-1 1 1-4 1 1-4 1 1-6 1 1-7 1 1-8

12.0 13.0

RESEARCH A N D DEVELOPMENT FACTORS

12-1 13-1 13-1 13-1

ENVIRONMENTAL FACTORS 13.1 PREAMBLE 13.2 AIR 13.3 WATER 13.4 LAND 13.5 NEIGHBOURS 13.6 APPROVALS

i3-213-3 13-3 13-3

Page v

TABLE OF CONTENTS

14.0

CONCLUSIONS AND RECOMMENDATIONS14.1 14.2 CONCLUSIONS RECOMMENDATIONS

14-1 14-1 14-1

APPENDICESA. B. C. PRICE FORECASTS CAPITAL AND OPERATING COSTS CASE COMPARISONS

Page vi

LIST OF TABLES

2.1-1 3.5.1-1 4.2-1 4.2-2 4.3-1 4.3-3 4.7-1 4.8-1 S.8-1 6.7-1 6.9.10-1 6.12-1 6.t3-L . 6.T4-17.3-1 7.7-1 7.8-I

LIGHT/SYNTHETIC CRUDE QUALITY COMPARISON REGIONAL BYPRODUCT HYDROGEN AVAILABILITY CRUDE ASSAY OF COLD LAKE BITUMEN CRUDE ASSAY OF ATHABASCA BITUMEN COLD LAKE BASE CASE - OVERALL MASS BALANCE BASIC UPGRADER TANKAGE BASE CASE WORKING CAPITAL BASE CASE OPERATING COST ESTIMATES EXPANDED CASE OPERATING COST ESTIMATES FISCHER-TROPSCH PRODUCT FINISHING BALANCE F-T CASE TANKAGE FISCHER.TROPSCH PROCESSUNIT DIRECT FIELD COST F-T CASE WORKING CAPITAL F-T CASE OPERATING COST ESTIMATES PARTIAL RE'FI'NING CASE TANKAGE PARTIAL REFINING CASESWORKING CAPITAL PARTIAL RI~FINING SUB CASES OPERATING COST ESTIMATES INTEGRATED CASE TANKAGE INTEGRATED CASE WORKING CAPITAL INTEGRATED CASE OPERATING COST ESTIMATES

2-3 3-5 4-3 :'_4-4 4-10 4-14 4-22 4-22

5-3 6-18 6-24 6-27 6-27 6-28 7-6 7-10 7-11

8.3-1 8.7-1 8.8-1 9.3-1 9.3-2 9.4-19.7-1

8-5 8-6 8-6

9.8-1 10.2-1 10.3-1 10.3-2 TO.4-1

REFINING CASE ANALYSIS SUMMARY 9-8 FULL REFINING CASE TANKAGE 9-13 GASOLINE AND MIDDLE DISTILLATE POOL COMPOSITION ESTIMATES 9-25 FULL REFINING CASE WORKING CAPITAL 9-28 FULL REFINING SUB CASESOPERATING COST ESTIMATES 9-29 BUY OR MAKE HYDROGEN COST BASES DRY RAW SYN GAS COMPOSITIONS PAARTIAL OXIDATION VERSUS STEAM METHANE REFORMING F-T VERSUS METHANOL TO INCREMENTAL LIQUIDS

10-4 10-4 10-5 10-8

Page vii

LIST OF TABLES Page11.1-I 11.1-2 11.3-I 11 ,~I

11.6-1

CASE ANNUAL REVENUE AND COST SUMMARY ANNUAL DIFFERENTIALSVERSUS BASE CASE SUMMARY FISCHER-TROPSCH SENSITIVITIES INCREMENTAL TO BASE CASE PARTIAL REFINING SUB CASE SENSITIVITIES INCREMENTAL TO BASE CASE FULL REFINING CASE SENSITIVITIES LOW GASOLINE PRODUCTION

11-2 11-3 11-5 11-5 11-9

Page viii

LIST OF FIGURES

4.2-1 4.3-1 6.1-1 6.3-1 6.4-1 6.6-1 6.7.1-1 6.9.10-1 7.3-1 7.3-2 7.3-3

BASE CASE SMR PROCESSFLOW SHEEr BASE CASE UPGRADER/EDMONTON TRANSFERSYSTEM OVERALL FISCHER-TROPSCH SYSTEM F-T CASE SMR PROCESS FLOW SHEET CO2 RECOVERY SYSTEM FISCHER-TROPSCH SYNTHESIS F-T PRODUCT FINISHING SYSTEM F-T CASE UPGRADER/EDMONTON TRANSFER SYSTEM PARTIAL REFINING CASE S.C.O. FRACTIONATION OPTIONAL NAPHTHA HYDROTREATER IN PARTIAL REFINING CASE PARTIAL REFINING C..)eSEUPGRADER/EDMONTON TRANSFER SYSTEM ~

4-6 4-13 6-2 6-5 6-6 6-9 6-16 6-25 7-4 7-5 7-7

8.1.1 8.3-1 9.3-1 9.3-2 9.3-3 10.4-1

INTEGRATED CASE PRODUCT BLENDING INTEGRATED CASE UPGRADER/EDMONTON TRANSFERSYSTEM FULL REFINING PROCESSSCHEME FULL REFINING CASE UPGRADEP~DMONTON TRANSFERSYSTEM TAME COMPLEX METHANOL TO NAPHTHA AND MIDDLE DISTILLATE

8-2 8-4 9-7 9-15 9-22 10-7

Page ix

ACKNOWLEDGEMENTS

The Technical Advisory Board provided appreciable advice and much assistance at the personal level. Bert Lang as the Alberta Chamber of Resources' Project Manager also provided many valuable comments and timely approvals. Manuel Tortes of the Alberta Department of Energy and Mr. Bill Dawson of CANMET also provided many in'puts as internal approvals. The CIBC's Rob Francis handled the major billing and fiscal management role very capably and the Alberta Chamber of Resources Don Currie provided administrative assistance. AOSTRA's Roger Bailey and Riaz Padamsey were always on call and of appreciable assistance, and ~he development of "upgraded" Cold Lake upgrader yield data by the latter was very much apl~eciatecL Purvin and Gertz' Tom Wise was also of much value beyond the provision of value forecasts and-Dennis Bobiy provided a number of comments beyond his brief report on alternate construction approaches. Mobil's Grant Karsner provided many useful comment on natural 8as conversion and Mobil processes, including middle distillate dewaxing.

Page x

EXECUTIVE SUMMARY 1. INTRODUCTION This study investigated a series of alternates to improving upgrader economics through adding onsite processes and in one case by expanding the Basic Upgrader from ~60,000 to 90,000 BPCD. The Diverse Interests case upgrader of the 1990 Regional Upgrader Business Plan Study of the Alberta Chamber of Resources' Oil Sands Task Force, was us~ foi the Base Case. That plant is based on a generic high conversion, high hydrogen addition primary upgr