Aker Solutions

part of Aker

2008 Aker Solutions

Separation Solutions for Heavy Oil

Morten Hana, PhD

Product and Technology Manager

Aker Process Systems AS

Aker Solutions

2008 Aker Solutions part of Aker2-Oct-09 Slide 2

The low API crude problem

How to make export quality oil from low API crudes without heating to 120 -140C and without using enormous vessel sizes.

Some of the challenges:

Strong Stabilisation WiO Emulsions by Asphalthenic Particles

High polarity components

High phase inversion -> high emulsified water content

Entrapment of Water into Oil Phase

Heavy crudes can be highly conductive


Aker Solutions Heavy Oil Specialists

In the heavy oil business for over 30 years Canadian SAGD we are on every operating

lease

Horizontal electrostatic treater installed on Grane CEC qualified for Heavy Oil First ever full-scale CySep Processing heavy crude in Russia and South

America

Proven product portfolio covering the entire oil treatment flow-sheet

Electrostatic Coalescers for treaters and desalters Diluent Injection & Recovery Systems Produced water deoiling

Experienced EPC partner: skid-based to modules

Fabrication capabilities inhouse and/or with qualified fabricators to provide schedule certainty and right quality

Cold & Hot weather and modular plant experience to compliment our heavy oil capabilities

Vast Offshore & Onshore Experience

Crude: 26.7 API

Viscosity: 21cP at 60 C

110cP at 25 C

Forms strong emulsions

The preferred partner for heavy oil processing solutions!


World Leading Technologies in Heavy Oil Processing

Canada - 600,000 bpd

Middle East - 300,000 bpd

Russia - 76,000 bpd

South America - 50,000 bpd

Aker Process Systems equipment is used to treat

well over one million barrels per day of heavy oil

> 20% of world heavy oil production!

North Sea

200,000 bpd


APS Technology portfolio and locationsProducts & Technologies

Separation technologies

Separator trains & packages

Separation and scrubber internals

Heavy oil/Ultra heavy oil

Desalting solutions

Sand & solid solutions

Produced water solutions

Compact Technologies

CEC

CySep

Hydrate inhibition - MEG reclamation

Water injection - SRU solutions

Lifecycle management

Integrated solutions Topsides

Gas dehydration/TEG & Fuel gas

Fired heaters

VOC Crude

VOC Gasoline Utility skids to power turbines

Diluent Injection & Recovery Systems

Locations

Oslo, Norway

Aberdeen, UK

Paris, France

Calgary, Canada

Copenhagen, Denmark

Perth, Australia

Rio de Janeiro, Brazil

Singapore

+ additional 60 locations of Aker Solutions!


Crude treatment The Challenge

Produced crude oil contains sediment produced water (BS&W), salt and other impurities

How to remove them?


Crude Treatment

Water separation from Oil is governed by Stokes Law:

oil

oilwaters

dgV

18

2

We manipulate this equation


What can we manipulate?

Aker Solutions have proprietary and patented components to coalesce/increase the water size d using:

Mechanical impingement

Turbulent & cyclonic flow

Electrostatics


Mechanical coalescing Patented matrix packing

1 triangular sections with a 45downward slope.

How it Works

Water droplets hit the corrugated plates, collide with each other & grow

Larger droplets slide down the plate channels, flow to the bottom water phase of the vessel.

Advantages

Self cleaning action that prevents plugging and is self draining

Enhances coalescing

Increases buoyancy drive between the oil and water


Turbulent coalescing Patented Adjustable Flow Distribution baffles

Horizontal flow distribution

Ensures even flow for heavy oil thus even temperature profile in the separator

Turn down to 25%

Promotes coalescing via impingement & turbulence


Cyclonic Coalescing Patented Compact Cyclonic Inlet (CCI) device Anti Foaming Cyclonic Inlet Device

Promotes separation & coalescing via centrifugal forces and impingement on the cyclone wall

Vast reference list

Heavy Oil: Surmont Phase 1, FWKO and Treaters, 16 API, 2005

CCI


Electrostatic treaters for heavy oil

Patented Horisontal 3D Vertical Grids

Compact Electrostatic Coalescer (CEC)

Horisontal 3D Vertical GridsCEC


Electrostatic Coalescing Patented 3-D Vertical Grids For Horizontal Flow Treating

Grounded

Diffusion

Baffle

Developed specifically for Heavy

Oil

Adjustable spacing between

ground & energized grid

3-D Grid provides coalescing

between the vessel shell and grid

Wings

Energized Grid


Electrostatic Coalescing Patented 3-D Vertical Grids For Horizontal Flow Treating

Adjustable spacing between

ground & energized grid

3-D Grid provides coalescing between

the vessel shell, water phase and grid

Wings


Selected References for Horizontal-Flow Electrostatic Treater

Project Year API Equipment

Husky - Tucker Lake SAGD 2005 18 API FWKOs,

Treaters (Electrostatic coalescers)

PetroCanada MacKay River SAGD

2000 8.7 API Inverted High Temperature Separators (FWKOs & Treaters)

Petrobank Energy White Sands SAGD

2005 14-19 API FWKO, Treaters

PetroAndina CHOP 2008 17.7 API FWKO, Treater, Electrostatic Desalter (all with integral Fire tubes)

LukOil Komi CHOP 2008 14.3 API Two stage Electrostatic Desalters

StatoilHydro Grane 2003 19 API Electrostatic Treater

part of Aker

2008 Aker Solutions

Compact Electrostatic CoalescerCEC


Compact Electrostatic Coalescer (CEC)Compact Offshore High Performance Technology

Proprietary, patented solution for improvement of separation of water from oil Compact and standardized design

Large operating window, high performance

Robust and highly offshore suitable

Debottlenecking for existing production facilities:Enhances performance of existing downstream separation equipment

Electrostatic field and turbulence make droplets coalesce: Electrostatic field

Water droplets become polarized (e.g. dipoles)

Emulsifying films are distorted and weaken => contributing to emulsion breaking

Droplets vibrate collisions

Mild Turbulence

Random droplet collisions

Increase droplet to droplet contact => higher coalescing efficiency


CEC Technology

Configuration Number of concentric electrodes depending

on liquid production rate Intense AC electrostatic field, voltage

modulation Energized electrodes are coated

Unique dynamic power control Rapid modulation and better control

Larger water droplets rapidly settling in separator, shorter residence time, hence smaller separator vessel

Comparing CEC to traditional equipment: Typical conventional up-flow EC:

20 350 BPD/ft2 CEC + Separator:

400 BPD/ft2 Reduction in size, footprint, weight Typical CEC size: 5.5 m height, OD

1.2m + skid structure

CEC internals


CEC Flowloop testing (StatoilHydro MPFL) Rapid coalescing and emulsion breaking with heavy oil

19 API crude @ 80 C


CEC Flowloop testing (StatoilHydro MPFL) Rapid coalescing and emulsion breaking with heavy oil

Emulsified water in oil after centrifugation, measured before and after CEC with

CEC turned ON (demulsifier > 125ppm)

0,0

0,5

1,0

1,5

2,0

2,5

3,0

0,0 0,5 1,0 1,5 2,0 2,5 3,0

Emulsified water in oil after centrifugation, measured before CEC [%]

Em

uls

ifie

d w

ate

r in

oil a

fter

cen

trif

ug

ati

on

,

mea

su

red

aft

er

CE

C

[%

]

Am

ou

nt

of

em

uls

ifie

d w

ate

r

AF

TE

RC

EC

p

roc

es

s

Amount of emulsified

water INTO the CEC

FLOWLOOP TEST DATA

19 API @ 60 80 C

Req: < 0.5% BS& W

Achieved with only

20% of demulsifier

compared to live

conditions


CEC References STATOILHYDRO Glitne (65,000 BPD)

API 32 Operational since 2002 , 100% uptime

part of Aker

2008 Aker Solutions

Cyclonic Separation - CySepAker Solutions has been awarded a contract for a CySep separation unit.

CySep for Petrobras Pampo PPM-1


CySep

Three stage compact cyclonic separation

Qualified for high water cut (> 75%) and 13 API

Substitutes traditional inlet separator

First full-scale unit under construction for Petrobras, delivery mid 2010

DEGASSING

STAGES

CYCLONIC

SEPARATION

BOW

PV002

PDC

PV003

DC

PV004

LV001

GAS FROM

PRODUCTION

HEADER

TO SECOND STAGE

SEPARATOR

TO PRODUCED

WATER DEGASSER

PDIT

002

FIT 001

PDIT

001

FIT

002

PDR

001

FIT 003

PDR 002

PDIT

004

PDIT

003

FIT

004

PDR

003

PDIT 005

PDIT

006

PIT 001

PIC

001

PCV001

LIT 001

LIC

001

TO GAS TREATMENT

SYSTEM

CYCLONIC

DEGASSER


Oil Sands/SAGDAPS value chain for technology solutions for the separation

Provider of:

Studies

Technology

Solutions

APS has provided equipment

to all operational SAGD leases


Heavy Oil Typical APS solution (PFD)

1st stage

2nd stage

APS Compact high

performance Solutions

CEC

PW treatment


Heavy Oil Separation with Wash Tanks

HP DEG

LP DEG

Wash Tank

Dehydration

Desalting

PW treatment


Case study on Heavy Oil

Process Design Basis: SAGD FWKO

Diluted Bitumen (Dilbit)

2/3 Bitumen

1/3 Diluent

Oil Feed Rate: 8000 sm3/day

Water Rate: 18500 sm3/day

Water Cut 69.8%

Gas Flow Rate: 180000 sm3/d

Sand 12 m3/d

Crude Specific Gravity: 16 API @ 15 C

H2O Specific Gravity 1.0037

Operating Temperature: 110 - 125 C

Operating Pressure: 6 barg


Process Design Basis FWKO Continued:

FWKO Outlet Specifications:

Crude Quality

10% BS&W @ 125 C

20% BS&W @ 110 C

Water quality

1000 ppm oil in water


Approximate Viscosity - Temperature Chart for various API Crude Oils

Temperature

Vis

co

sit

y

50,000

7

6

5

4

3 cSt

1,000

2,0003,0005,000

10,000

20,000

100

75

5040

30

20

15

1098

500400300

200150

460

345

230185

137

97

77

59555249

45

42

39

36

SSU

-10 oC 11010080706050403020100 90 140130120 150

14,0009,000

4,600

2,3001,8001,350

900640

230,000

95,000

47,000

24,000

2482302121941761581401221048668503214 oF 302284266

6 API13 12 11 10 9 8 719 18 17 16 15 14

2827

26

25242322 21 20

40 API

36

33

30

29

Color Key: Plot - Inlet Condition - Operating Condition

Given Viscosity Data:

Pt 1: 25 cP @ 110 C

Pt 2: 16 cP @ 125 C

Pt 3: 11 cP @ 140 C

Dilbit behalves closer

to a 14 API oil

Viscosity Behavior


Design Analysis

Traditional FWKO Design Separation of free (non-emulsified) water from crude oil

The Problem: Typical 16 API Heavy oil holds more than 30% water as

emulsion

Typical Dilbit blend of 1/3 Diluent and 2/3 SAGD Bitumen blended to 16 API would typically hold ~22% water

Emulsions are not broken in FWKOs unless heat is applied

and/or coalescence inducing internals are utilized

and demulsifying chemicals are used.

Conclusions: SAGD Dilbit FWKOs with better than ~20% outlet performance

are actually high temperature coalescing separators


Aker Solutions from concept to operation

Concept studies Evaluation of crude Screening evaluation Qualification of systems and/or equipment

FEED Establish PFD, P&IDs Layout

Project Execution Engineering Purchasing Construction Installation

Lifecycle Operational support Spare parts


Contact deatils

Morten Hana, PhD

Product and Technology Manager

Separation Technologies

Tel: +47 67 83 77 49

Mob: +47 907 85 905

E-mail:[email protected]

Mika Tienhaara

Vice President Separation Technologies

Tel: +47 67 83 77 87

Mob: +47 454 11 459

E-mail: [email protected]

Espen Bostadlkken

International Sales Manager

Tel: +47 67 83 78 24

Mob: +47 91 11 88 67

E-mail: [email protected]


Copyright

Copyright of all published material including photographs, drawings and images in this document remains vested in Aker Solutions and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.


Disclaimer

This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions of the regions and industries that are major markets for Aker Solutions ASA and Aker Solutions ASAs (including subsidiaries and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements containing words such as expects, believes, estimates or similar expressions. Important factors that could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that are or will be major markets for Aker Solutions businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Aker Solutions ASA believes that its expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation. Aker Solutions ASA is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation, and neither Aker Solutions ASA nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use.

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