HEAVY CRUDE UPGRADING: AN OPTION FOR GASIFICATION · 2016. 1. 25. · Heavy Crude Upgrading: An Opportunity for Gasification Gasification Technology Council Conference – S.Francisco,

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HEAVY CRUDE UPGRADING:AN OPTION FOR GASIFICATION

Luigi Bressan – Foster Wheeler Italiana CorporationMichael J. McGrath - Foster Wheeler USA Corporation

Gasification Technologies Council ConferenceSan Francisco, CA - October 2007

Heavy Crude Upgrading: An Opportunity for Gasification

Gasification Technology Council Conference – S.Francisco, CA – October 2007

Agenda

• Heavier crudes• Upgrading schemes • Crude Atmospheric and Vacuum Distillation• Delayed Coking Unit • Solvent Deasphalting• Combination of Deasphalting and Coking• Byproducts Gasification and conversion to power• Material balances• Economic analysis• Conclusions



Heavier Crudes

• Global demand for crude increasing

• Light crudes becoming more expensive

• Crudes becoming heavier and higher in sulfur

• Large light/heavy price differential



Heavy ArabianWhole Crude

Heavy MEWhole Crude

Gravity, oAPI 28.2 13.9

Viscosity, cs. at 70oF 35.8 1,033

Viscosity, cs. at 100oF 18.9 286

Pour Point, oF -30 0

Sulfur, wt. % 2.8 5.17

Nitrogen, wt. % 0.15 0.19

Neut. No. mgKOH/gm 0.03 0.92

Upgrading Schemes

Typical Heavy Crudes



CDU

VDU

IGCC

Synthetic Crude

Electric Power

Upgrading Schemes

CASE 1: CDU+VDU+IGCC



CDU

VDU

DCU

IGCC

Synthetic Crude

Electric Power

Upgrading Schemes

CASE 2: CDU+VDU+DCU+IGCC



CDU

VDU

SDA

IGCC

Synthetic Crude

Electric Power

Upgrading Schemes

CASE 3: CDU+VDU+SDA+IGCC



CDU

VDU

ASCOT

IGCC

Synthetic Crude

Electric Power

Upgrading Schemes

CASE 4: CDU+VDU+ASCOT+IGCC



Crude and Vacuum Distillation

• Typical refinery units used to separate products according to distillation range• Simple, well proven and reliable units• Capacities selected are in the highest range of units built worldwide• In crude upgrading application can simplified and optimized to reduce investment and operating costs



Delayed Coking

Delayed Coking – SYDECSM



• Full conversion of residue to distillates- Full range of lighter products- Complete decarbonization of residue feed- Complete metals removal

• Fuel-grade Coking: - Maximum yield of clean liquid products

- Low pressure coking / ultra-low recycle coking• Proven technology

- Past experience: large available knowledge base ondesign, operations and maintenance

• Strong 3rd party support services and equipment vendors• Long turnaround periods: 5 years +• Fast execution of projects: <28 months

- Fewer budget surprises: $3,600 / BPSD - Short period of negative cash flow

• Modern designs are safe and clean

Delayed Coking



Delayed Coking



Picture Picture Picture

Solvent Deasphalting (FW/UOP Technology)

Experience Extensive pilot plant and crude data base Well-proven technology 50+ units licensed (500 to 45,000 BPD) Excellent correlations of pilot plant runs and prediction of commercial

operations

Solvent Deasphalting



• Physical Separation of residues into: Deasphalted oil (DAO) Highly viscous, asphaltene-rich stream

(Pitch) • Separation is by density differences• Light liquid paraffins precipitate asphaltenes

and resins from heavy oils• Non thermal process• Utility optimization

Upstream integration Eliminate heaters, hot oil heating system

• Extraction technologies Countered current designs utilizing

structured packing• Separation of DAO and solvent by:

Sub-critical Super-critical




DAODAOSeparatorSeparator

VacuumResidueCharge

DAODAOStripperStripper

DAODAOPitchPitch

PitchPitchStripperStripper

ExtractorExtractor




1009080706050403020100

1009080706050403020100

Sulfu

r, N

itrog

en a

nd M

etal

sA

ppea

ring

in D

easp

halte

d O

il, %

Deasphalted Oil Yield, Vol-%

Sulfur & Nitro

gen

CCR

Nickel

Vanad

ium




• Well-proven separation process

• Lower capital costs

• Light feeds

• Small sizes

• Lower operating costs

Supercritical DAO-solvent separation




• The potential benefits of combining Solvent Deasphalting and Delayed Coking

ASCOTSM

ASCOT – Combination of deasphalting and coking



Fuel GasCoker LPG

Naphtha

LCGO

HCGO & DAO

Asphalt

DAO

Coke

VacuumResidue

Heat

Integration

Solvent

Makeup

SolventDeasphalter

Del

ayed

Cok

er

ASCOTASCOT – Combination of deasphalting and coking



IGCC

Byproducts Gasification and Conversion to Power



Integrated Gasification Combined Cycle

• A way to dispose efficiently of heavy products regardless of their quality• Outstanding environmental performance• Allows full carbon rejection• Proven technology• Multi-unit complex with different peculiarities• The gasification process leads to a syngas from which either hydrogen

or CO2 can be derived for use and disposal




Air Separation

Partial Oxydation

Metals Recovery and

Water Treatment

Syngas Treatment

Acid Gas Removal

Sulphur Recovery

HP SteamMP Steam

LP SteamElectric Power

SulphurMetal Cake

Waste Water

SyngasAsphaltHRSGGas

Turbine

SteamTurbineUtilities

Air

Nitrogen

Air Separation

Partial Oxydation

Metals Recovery and

Water Treatment

Syngas Treatment

Acid Gas Removal

Sulphur Recovery

HP SteamMP Steam


HP SteamMP Steam


SulphurMetal Cake

Waste Water

SyngasAsphaltHRSGGas

Turbine

SteamTurbineUtilities

Air

Nitrogen




Material Balances

Technical Data Case 1 Case 2 Case 3 Case 4

DescriptionCDU +

VDU+IGCCCDU + VDU + DC

+ IGCCCDU + VDU + SDA

+ IGCCCDU + VDU +

ASCOT + IGCCCDU Feed BPSD 212.397 248.332 218.210 330.464VDU Feed BPSD 152.239 172.317 151.416 229.309DC Feed BPSD 85.699

SDA Feed BPSD 75.304ASCOT Feed BPSD 114.043IGCC Feed t/h 536,0 201,3 284,3 203,1

Synthetic Crude BPSD 90.443,0 224.849,0 180.558,0 307.490,0t/h 776,3 1.207,1 1.000,2 1.688,6°API 28,0 24,9 20,1 21,0% S 3,6 3,7 4,1 4,1

Power Production MW 2.507,2 596,6 1.236,4 592,2Synth. Crude yield % vol 42,6 90,5 82,7 93,0



Material Balances

Economical Case 1 Case 2 Case 3 Case 4

DescriptionCDU +

VDU+IGCCCDU + VDU + DC

+ IGCCCDU + VDU + SDA

+ IGCCCDU + VDU +

ASCOT + IGCCBRENT Crude ° API 38,06 factors 0,007 $/$ of Brent

% S 0,37 0,056 $/$ of Brent$/Barrel 80,0

ME Crude ° API 13,90% S 5,17$/Barrel 45,0

Synthetic Crude ° API 28,00 24,90 20,10 21,00% S 3,55 3,70 4,11 4,10$/Barrel 60,1 57,7 53,2 53,7

Electric Power $/MWh 100 100 100 100Investment Cost MM US$ 5683,7 2608,1 3432,1 2933,7

Simple Payout Period Year 19,86 2,39 4,04 2,86



Economical Analysis

Reference CRUDE Value = 40 $/Barrel CDU/VDU

CDU/VDU/DCU

CDU/VDU/SDA

CDU/VDU/ASCOT

50 $/MWh n.a. 5,01 8,73 6,04 75 $/MWh 9,59 4,07 5,36 4,85100 $/MWh 5,19 3,43 3,87 4,06125 $/MWh 3,56 2,97 3,02 3,49

Reference CRUDE Value = 60 $/Barrel 50 $/MWh n.a. 3,80 9,18 4,60 75 $/MWh 30,10 3,24 5,53 3,88100 $/MWh 8,23 2,82 3,95 3,36125 $/MWh 4,77 2,50 3,08 2,96

Reference CRUDE Value = 80 $/Barrel 50 $/MWh n.a. 3,07 9,69 3,72 75 $/MWh n.a. 2,69 5,71 3,24100 $/MWh 19,86 2,39 4,04 2,86125 $/MWh 7,22 2,16 3,13 2,56



Conclusions

All cases considered have been selected to fit the proposed gas turbine’s appetite(GE7FB) and the size of power plant in order to have refinery units of similar capacities for comparison reasons.Over the four cases considered the following conclusions can be drawn:1. It is expected this kind of units would be installed close to oil fields in order to

avoid transportation of difficult crudes and to generate electric power and deliver lighter synthetic crude

2. The units foreseen are simple and reliable non-catalytic units3. Case 1 solution is justified only when crude is at low cost level with high electric

power selling prices4. Case 2 solution (the delayed coker) looks the more convenient and the more

effective in the case where reference crude value increases and electric power selling prices decrease

5. The quality of the crude considered may change the results of this analysis, butthe delayed coking based solution is the preferred one with most difficult crudes



6. Delayed Coking scheme may lead to light products with a certain degree ofinsaturation; the installation of hydrotreaters (in this case catalytic units) mayconsiderably increase the quality of synthetic crude

7. Both Delayed Coking and Solvent Deasphalting units are well provenand very reliable process units.

8. Solvent Deasphalting and Delayed Coking can be integrated to obtain the benefits of both

9. Upgrading provides an opportunity to utilize gasification to eliminate low-value by-product and produce higher-valued products such as:

• power for site and export• hydrogen for further upgrading• chemicals products (methanol, SNG,.. Etc.)

Conclusions

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THANK YOU.Foster Wheeler

[email protected][email protected]

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HEAVY CRUDE UPGRADING: AN OPTION FOR GASIFICATION · 2016. 1. 25. · Heavy Crude Upgrading: An Opportunity for Gasification Gasification Technology Council Conference – S.Francisco,