CFD APPLIED TO PETROBRAS REFINING PROCESS … · cfd applied to petrobras refining process development and optimization – present, future and chalenges – w. p. martignoni petrobras/ab-re/tr/ot

CFD APPLIED TO PETROBRAS REFINING PROCESS DEVELOPMENT AND OPTIMIZATION – PRESENT,

FUTURE AND CHALENGES–

W. P. MARTIGNONIPETROBRAS/AB-RE/TR/OT

[email protected]

CFD APPLIED TO PETROBRAS REFINING PROCESS DEVELOPMENT AND OPTIMIZATION – PRESENT,

FUTURE AND CHALENGES–

W. P. MARTIGNONIPETROBRAS/AB-RE/TR/OT

[email protected]

• PETROBRAS CS, PFCC CFD, TFCC, SIX and AB-

RE/TR/OT Team::

• José Mozart Fusco

• Raquel Coutinho

• Silvia Waintraub

• Solange Klein

• Washington Geraldelli

• Waldir P Martignoni

• Alessandra B. dos Santos

• Antonio Vicente de Castro

• Danilo Carneiro

• Francisco Barros

• Guilherme Pimentel

• Wilson Kenzo Huziwara

... with the help of the ESSS Team:

• Waldir P Martignoni

• Ricardo Serfaty

• Wilson Kenzo Huziwara

• Celso Murilo dos Santos

(Gorciex)

• Antonio Samel

• Carlos Eduardo Fontes

• Daniel Ribeiro

• Ricardo Damian

• Raphael Bacchi

• Fernando Feitosa

• Karolline Ropelato

• Marcus Reis

• Fabio Santos

Summary:Summary:

3

Summary:Summary:

:: Introduction

:: PETROBRAS R&D Overview

:: Refining Challenges and Applied Technologies

:: CFD Applied to Refining Technologies Development

:: CFD_NET on Refining: REDE CFD

:: Conclusions

1- INTRODUCTION1- INTRODUCTION

Computational Fluidynamics has been used as a very powerful tool forscience and academic development and also in industrial scales forsome specific tasks, even so, there are many aspects of CFD that stillnow need further development in order to be ready for an overall fullIndustrial scale application.

4

Industrial scale application.

Petroleum Refining deals with very complex flows, like multiphase, non-Newtonian, turbulent, high temperature and high pressure, reactiveflows, besides large and complex equipment.

Fully application of CFD to such processes is still not possible due tolack of trustful models, solvers and hardware, however carefully analyzedsituations allow us to take advantage of this technique for solvingrefining development and optimization problems.

1- INTRODUCTION - - CONT1- INTRODUCTION - - CONT

PETROBRAS started developing its own softwares in the eighties, for several applications, but in the nineties, in order to take advantage of large developing teams, switched to commercial codes.

5

Nowadays PETROBRAS is investing a large amount of human power and resources in CFD application to large Industrial equipment simulation, like, Cyclones, Risers, Regenerators, Prilling Towers, Reactors, multiphase flows in general, etc.

PETROBRAS is certainly one of the largest commercial CFD code users.

1- INTRODUCTION - CONT1- INTRODUCTION - CONT

In order to speed up this king of development, A CFD net has beencreated, involving several Brazilian Universities and Research Centers,furnishing them with experimental laboratories and suitable Instruments ,computational hardware and resources to hire high trained Experts.

Environmental issues have been the Oil Refining Industry development

6

driving force for last decades and will continue even more intensive inthe future, but economical issues due to the increase in oil consumptionvs shortage will play an important role in this new scenario.

New scientific developments in physical models and model solving,cheaper high performance computers are mandatory for achievingtrustful simulation.

2- PETROBRAS – OVERVIEW

PETROBRAS MAIN ACTING AREAS

Production

DistributionTransport

7

Exploitation

GásEnvironmental Management

Refining and Petrochemisty

Products

Energy

2- PETROBRAS – OVERVIEW

TECHNOLOGICAL DEVELOPMENT PROGRAMS

PROTERPROTERRefining

PROFEX Exploration

PROAMB

EnvironmentalINOVAINOVA

Innovation on Fuel

PROCAP

Deep Water

8

Refining

PROPES

Heavy Oils

Fuel

PRORECPROREC

Optimization an Reliability

PRODUTDucts and Pipelines

PROGAS Gás

PROGER Renewable Energies

PRAVAP

Advanced Recuperation

RESEARCH CENTER – CENPES –

ORGANIZATION - DOWNSTREAMS

PDABPDABR&D REFR&D REF

PROTERPROTERINOVAINOVA PRORECPROREC

PRODUTPRODUT

PILOT PLANTS PILOT PLANTS

(CENPES AND (CENPES AND SIXSIX))FCC FCC

9

FUELSFUELS

FUEL PERFORMANCEFUEL PERFORMANCE

LUBRICANTS ANDLUBRICANTS AND

SPECIAL PRODUCTSSPECIAL PRODUCTS HYDROREFININGHYDROREFINING

DISTRIBUTION, LOGISTICSDISTRIBUTION, LOGISTICS

AND TRANSPORTATIONAND TRANSPORTATION

PETROCHEMISTRYPETROCHEMISTRY

Refining Challenges and Applied TechnologiesRefining Challenges and Applied Technologies

Time evolution of Refining Technologies - Hardware and Products

10

“Starting of Barril Bottom Program”

Starting FCC Catalyst Production-FCCSA

Fluid Catalytic Cracking Technological Evolution Fluid Catalytic Cracking Technological Evolution Delayed Coking Technological Evolution Delayed Coking Technological Evolution

1ª application o BR HDT Technology

Qav: REDUC


Naftênic Oil:LUBNOR

Hydrotreatment Technological Evolution Hydrotreatment Technological Evolution


Qav: REDUCInstáveis: RPBC

2ª application o BR HDT Technology to

de Instáveis: REPLAN

2ª application o BR RFCC Technology to

: RLAM

Process Optimization and Automation Technological Evolution:

Process Optimization and Automation Technological Evolution:

Introduction of BR Reneable Technology:

HBIO

Renewable Sources Technological Evolution. Renewable Sources Technological Evolution.

New Diesel HDT´sl-REGAP,

REDUC, REPLAN& REPAR

BR REFINING Technological Evolution: BR REFINING Technological Evolution:

Implementation o SIX Technological Park.

Starting of PROTERStratefic Refining

Technological Program

Heavy Oil UFCC’s

1ª application of BR RFCC Technology: RECAP

New series of Catalysts of high accessibility for

Catalytic Cracking.

11

81 0199

REFAPs Modernization:

0695 0582

3º RFCC

1ª Application of BRCoke Technology:

RPBC

2ª Application of BR

Coke Technology : REGAP


Coke Technology : REPLAN



2º Plan of Metalurgic Suitability.

5º COQUE

86

8º HDT

89 94 03 0498

Starting of SDCDsREDUC e REVAP

87

Starting of The MainIndustrial Automation Plan:

PDAI

90

Starting of OptimizationPrograma at AB

Starting BLENDING ofGasolina-REVAP and

Diesel-REPLAN

00

Startign of the Center Of Excelenc on Studies and Dynamic Analysis

of AB : CEAD

Startign of The Technological Program:PROREC

Begining of New Meterials For heavy

Oil Processing

1ª application ofBR Real Time

Optimization Technology: REVAP

“Starting of Barril Bottom Program”

Starting of FCC Catalyst ProductionFCCSA


Qav: REDUC


Naftênic Oil:LUBNOR


Qav: REDUCInstáveis: RPBC

2ª application o BR HDT Technology to

de Instáveis: REPLAN

2ª application o BR RFCC Technology to

: RLAM Introduction of BR Reneable Technology:

HBIO

New Diesel HDT´sl-REGAP,

REDUC, REPLAN& REPAR

Implementation o SIX Technological Park.

Starting of PROTERStratefic Refining

Technological Program

Heavy Oil UFCC’s

1ª application of BR RFCC Technology: RECAP

New series of Catalysts of high accessibility for

Catalytic Cracking.

Refining Chalenges and Applied Technologies – AB-RERefining Chalenges and Applied Technologies – AB-RE

12

Startign of The Technological Program:PROREC

81 0199

REFAPs Modernization:

0695 0582

3º RFCC

1ª Application of BRCoke Technology:

RPBC


Coke Technology : REGAP





2º Plan of Metalurgic Suitability.

5º COQUE

86

8º HDT

89 94 03 0498

Starting of SDCDsREDUC e REVAP

87

Starting of The MainIndustrial Automation Plan:

PDAI

90

Starting of OptimizationPrograma at AB

Starting BLENDING ofGasolina-REVAP and

Diesel-REPLAN

00

Startign of the Center Of Excelenc on Studies and Dynamic Analysis

of AB : CEAD

Begining of New Meterials For heavy

Oil Processing

1ª application ofBR Real Time

Optimization Technology: REVAP

Introduction of Extra Quality

BR QAV

Metropolitan Diesel

Production

Production of F1

Gasoline

Antecipation of Diesel

500 ppm Production

de Diesel 500 ppm

(RJ, MG e SP)97

Starting Of Quality Strategic Management

(SGQ): Diesel & Gasoline

02

06

00

99

Refining Chalenges and Applied Technologies – AB-RERefining Chalenges and Applied Technologies – AB-RE

Production of

PODIUM

Gasoline

Starting Diesel

PODIUM

05

13

86

Lead Free Gasoline

Production of PREMIUM Gasoline

92

Starting op the Product

Technological Program (INOVA)

Starting Of Quality

Strategic Management

(SGQ): QAV

87

89

97

Starting of Technological Programs: Lubs (PROLUB),

Diesel (PRODIESEL), Gasoline (PROGASOLINA)

and High Value Products (PROPAG)

96

Implementation of

Engine Lab at The South

94


14

Applied Refining Technologies in Order to Achieve 2002-2006 Goals.


77,877,776,9

80,0

90,0

Refining Applied Technologies in order to Achieve the Goals: 2002 –2006:

Main Goal: Increasing in National Oil Processing Capacity:

15

22,224,1

26,7

22,3

23,125,826,329,8

37,541,043,0

44,048,647,946,5 48,1

77,875,973,3

77,776,974,273,7

70,262,559,0

57,056,0

51,451,952,153,5

10,0

20,0

30,0

40,0

50,0

60,0

70,0

1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

PERCENTUAL imp (%) PERCENTUAL nac (%)


Refining Applied Technologies in order to Achieve the Goals: 2002 – 2006:

:: Petrobras RFCC Technology and High Accessibility Catalysts;

:: Increasing of Hardware Reliability;

16

:: High Metalurgic Standard Able to Process Marlin Heavy Oil;

:: Petrobras Technology of Vacuum and Atmospheric Residumm Coking.

:: PETROBRAS Hydrotreatment Technologies to REPLAN, REGAP, REPAR, REDUC E REFAP;


17

The PE 2015: New Technologies for New Challenges

RELIABILITY TECHNOLOGIES & HARDWARE (ASSETS) OPTIMIZATION

NEW TECHNOLOGIES FOR CONVENTIONAL PROCESSES AND PRODUCTS

EMISSION REDUCTION TECHNOLOGIES AND USE OF NATURAL RESOURSE


The PE 2015: New Technologies for New Challenges

STRATEGIC PLAN STRATEGIC PLAN -- 20152015

2007 2011 2015

18

RENEWABLE SOURCES TECHNOLOGIES (Bio-Technologies, ...)RENEWABLE SOURCES TECHNOLOGIES (Bio-Technologies, ...)

ULTRA LOW SULFUR CONTEND FUEL TECHNOLOGIES

TECHNOLOGIES FOR USING NATURAL GAS AS FEEDSTOCK (Gasification ...)

INOVATION AND ADVANCED TECHNOLOGIES (Mecatronics, Nanotechnology, Slurry-beds R)

EMISSION REDUCTION TECHNOLOGIES AND USE OF NATURAL RESOURSE

TECHNOLOGIES OF NEW TRAINING STANDARDS (Simulation)

FUTURISTIC VIEW (Cars, Refineries R)

INVESTMENT PORTFOLIO

CFD Applied to Refining Technologies DevelopmentCFD Applied to Refining Technologies Development

19

CFD applied to Refining Technologies Development in Order to Achieve 2002-2021 GOALS.


:: Development and Application of Reliable Fluidynamics Models andSolving Techniques for:

• Operating Problems Diagnosis;

• Existing Processes Optimization

CFD CFD –– COMPUTATIONAL FLUID DYNAMICSCOMPUTATIONAL FLUID DYNAMICS

0.

. 2

=∇

∇+−∇=∇+∂

u

upuuut

ν

0.

. 2

=∇

∇+−∇=∇+∂

u

upuuut

ν

20

Contribution to Operational Refining Costs Optimization and Reduction of Failure

Probability due to Improvements in Operating Problems Diagnosis.

• Existing Processes Optimization

• New Processes Equipment and Components Conception, Design.


:: For a Single Phase Incompressible Flow the Generalized Navier StokesEquation contains all Information but Boundary and Initial Conditions(Frisch, 1995).


. 2∇+−∇=∇+∂ upuuut

ν

21

This includes Turbulence- DNS.

Initial and BC may not be the Problem.

The Main Problem, that remains for Centuries is Solving the Equation

0.

.

=∇

∇+−∇=∇+∂

u

upuuut

ν


:: For a Multiphase Phase Incompressible Flow the Generalized NavierStokes Equation needs, besides, Boundary and Initial Conditions for allPhases, Body Forces bk and Phase Interaction constitutive Equations.

CFD CFD ––MultiPhase FlowMultiPhase Flow

)().(

=∇

++∇∇+−∇=∇+∂ikkkkkkkkkt

bupuuu

ε

βνεεε

ikβ

22

The SECOND Phase (Particle, Droplet, Bubble or OtherContinuous Phase) Initial and Boundary Conditions may not be so clear,even for well design Experiments.

1

0).(

,1

=

=∇

∑= �k

k

kku

ε

ε


:: For Large Industrial Equipments, lots of Information, regarding BC andInitial Conditions are difficult to define;

:: Numerical Methods may not be Suitable, due to the Equipment Size;

CFD CFD –– DIFFICULTIESDIFFICULTIESikβ

23


:: In Real Operating Conditions We need to Consider Heat and MassTransfer, Phase Change, Reaction and Turbulence, all at once;

:: Normally a very Complex Geometry

CFD CFD –– UNDER DEVELOPMENTUNDER DEVELOPMENT

0.

. 2

=∇

∇+−∇=∇+∂

u

upuuut

ν

0.

. 2

=∇

∇+−∇=∇+∂

u

upuuut

ν

CFD Applied to Refining Technologies Development

SOLVERSOLVERMODELMODEL

24

HARDWAREHARDWARE

PROBLEM

piloto no CENPES, comprovada em escala


• Cyclone Inlet Conditions (PSRI data)

Blind Tee Disperses Solids Entering Cyclone(More Turbulence)

99.9

99.99

99.999

0 5 10 15 20

Material: FCC Eq. Catalyst

Cyclone Size: 19.75-in (50-cm)

Entry: Tangential

Li: 2 lb/ft

3 (32 kg/m

3)

Riser Termination:

Ov

era

ll 1

st

Sta

ge

Cy

clo

ne

Eff

icie

nc

y, %

Blind-Tee

Elbow

Inlet Gas Velocity, m/s

25

Elbow Causes Solids to Form a Coherent StrandBefore Entering the Cyclone (Less Turbulence)

0 10 20 30 40 50 60 70

99

99.5

Ov

era

ll 1

st

Sta

ge

Cy

clo

ne

Eff

icie

nc

y, %

Inlet Gas Velocity, ft/s

20 30 40 50 60 7099.5

99.9

99.990 5 10 15 20

Material: FCC Eq. CatalystCyclone Size: 21-in (53-cm)Cyclone Inlet Type: Tangential

Li: 1.9 lb/ft

3 (30 kg/m

3)

Riser Termination: Blind-Tee

Ov

era

ll 1

st

Sta

ge

Cy

clo

ne E

ffic

ien

cy, %

Inlet Gas Velocity, ft/s

shorter (2.5 ft) longer (6.5 ft)

Cyclone Inlet Length:

Inlet Gas Velocity, m/s

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.898

99

99.5

99.9

99.99

99.9990 5 10 15 20 25 30

Material: FCC Eq. CatalystCyclone Size: 21-in (53-cm)

Cyclone Inlet Type: Tangential

Ugi: 60 ft/s (18.2 m/s)

Riser Termination: Blind-Tee

Cyclone Inlet Length:

Ov

era

ll 1

st

Sta

ge

Cyc

lon

e E

ffic

ien

cy, %

Inlet Solids Loading, lb/ft3

shorter (2.5 ft) longer (6.5 ft)

Inlet Solids Loading, kg/m3


• Cyclones – Usual Boundary Conditions

26


••Cyclones Cyclones –– TroubleshootingTroubleshooting••Cyclones Cyclones –– TroubleshootingTroubleshooting

27



28

Refining Challenges and Applied Technologies


29


:: For Large Industrial Equipments, lots of Information, regarding BC andInitial Conditions are difficult to define;



EXAMPLEEXAMPLE –– FCC RISERSFCC RISERSikβ

30


:: In Real Operating Conditions We need to Consider Heat and MassTransfer, Phase Change, Herogeneous Reaction and Turbulence, all atonce;

:: Normally it varies from Dense (Moving Bed) to very Dilute Flow (10-06)

:: Up to now We considered only Cold Flows

:: Probably one of the largest World effort in Solving Industrial Problems.


:: Radial and Axial Gas Solid Mixing – LES Model


EXAMPLEEXAMPLE –– FCC RISERSFCC RISERS

31

Modelε−Κ ModelLES ModelLES

CENPES

PETROBRAS Research Center


32

FCC and Gasoline

Divisions

DesaltingDistillation

CS and PFCC


33

Deasphalting

Delayed Coking

CS and PFCC

Research and Development

CFD

2 Passes 4 Passes2 Passes 4 Passes

• Baffles design studies

– Optimize the first baffle height, above vapor inlet

– Uniformity of vapor flow after the last baffle


34

baffle

• Case studies

– Coker fractionators


CFD

• Inlet device studies

– Establish criteria for new designs

– Understand the vapor distribution

– Evaluate baffles spacing

• Case studies

Case 3

35

• Case studies

– FCC main fractionator

vaporvaporinletinlet

inlet

details

Case 1

Case 2

Case 3

Case 1 Case 2


• Empty spray section design

– Inlet characteristics studies

• Axial velocity profiles

– Heat and Mass transfer

• Case studies

CFD

High


36

• Case studies

– Vacuum towers

– Coker fractionators

Low

High

vaporvaporinletinlet

spray spray sectionsection

Low


• Inlet Feed Device

– Reduce the liquid drag and velocity peak

– Improve the vapor distribution

– Modifying the feed nozzles

• Case studies

CFDCFD Applied to Refining Technologies DevelopmentCFD Applied to Refining Technologies Development

37

• Case studies

– Vacuum towers Detailed Detailed numerical numerical discretizationdiscretization

Liq.Volume Fraction

0.0e+0

1.0e- 4


• Liquid Distributors

– The effect of the previous section in liquid distribution

• Advantages: Evaluate geometric arrangement in distributors previous section

• Case studies

– Atmospheric towers

CFD

liquid inlet nonliquid inlet non--uniformityuniformity


38

– Atmospheric towers

Downbox A

Downbox H

liquid inlet uniformityliquid inlet uniformity

CFD_NET APPLIED TO REFINING: REDE CFDCFD_NET APPLIED TO REFINING: REDE CFD

•• Objectives:Objectives: The Computational Fluidynamics NET on Refining Processes, Applied to Oil, Gas and Renewable Energy Sources has as main objectives to Implement Actions in order to Elaborate Studies, Develop R&D Projects, Define and Create Infra Structure, and Develop Human Resources on Fluid Dynamics Through the Associated Institutions.

39

::

• INFRASTRUCTURE and P&D PROJECTS

Members Members –– Infrastructure Projects:Infrastructure Projects:

– UNICAMP, UFSC, UFRJ (EQ ), UFU (MEC), UFMG, PUC-RIO - OK

– USP (CHEM, MEC, MAT APL), UnB, UNESP, ITA, IME, CTA UFRJ(COPPE ), UFU (MEC), – ON THE WAY

G-S-L (i) G-S (ii) COMB in ENGINES (ii)INDUSTRIAL COM. (i)

Multiphase Flow (I) Combustion and Fuels (II)ÁREAÁREA

SUBSUB--AREAAREA

CFD_NET APPLIED TO REFINING: REDE CFDCFD_NET APPLIED TO REFINING: REDE CFD

CFD APPLIED TO REFININGCFD APPLIED TO REFINING

40

::

EXP (1) NUM (2) EXP (1) NUM (2)

APL (a) FUND (b) APL (a) FUND (b)

EXP (1) NUM (2) EXP (1) NUM (2)

APL (a) FUND (b) APL (a) FUND (b)

GAS-LIQUID-SOLID and GAS-LIQUID FLOWS,

HEAT AND MASS TRANSFER,CHEMICAL REACTION,

COALESC. AND BREAKUP, POPULATION BALANCE,

DRAG AND DEFORMATION,HDT/HCC

BUBBLE COLUMS, SLURRY BEDSFLUIDIZATION,

DISTIL. TOWERS

GAS-SOLID FLOWS: MODELS, DRAG, EXTRA FORCES,

TURBULENCE, HEAT AND MASSTRANSPORT, CHEMICAL REACTION,

MULTIPHASES, EROSION,MODEL SCALEUP,

MEASURING TECHNIQUES,RISERS, CYCLONES, REGEN.,

STRIPPERSSTAND-PIPES, BENDS,

VALVES

COMBUSTION MECHANISMSAND KINETIC PARAM. DETERM.,

REDUCED MODELS, MEASURING TECNHIQUES,

TURBULENCE, EVAPORATION, MULTIPHASE COMBUST.,

BURNERS, FLAMES, DATA BASE,ALTERNAT. FUELS, GASEF.

AND

OXICOMBUST.

COMBUSTION MECHANISMSAND KINKETIC PARAM. DETERM.,

REDUCED MODELS, MEASURING TECNHIQUES,

TURBULENCE, EVAPORATION, MULTIPHASE COMBUST.,

IGNITION/EXTINTION, DETONATION

MODERN FUELS – BIO/GTL.ENGINE DYNAMICS.

GROUPGROUP

SUBSUB--GROUPGROUP

CFD_NET TO REFINING: R&D SUBMITED PROJECTSCFD_NET TO REFINING: R&D SUBMITED PROJECTS

PROJECT UNIVERSITY

1 CFD Evaluation of coke formation inside tubes - Delayed Coking Process UNICAMP 10

2 Fischer Tropsch and Hydrocracking Bubbling Bed Fluidynamics Evaluation FURB/UNICAMP

3 Development of Turb. Comb. Models Based on Eulerian/Lagrangean Tech.on the Immersed Boundaries Meth.PUC/UFU

4 Development of Numerial and Experimental Gas-Liquid Multiphase Flows UFSC/FURB

5 Development of Numerial and Experimental Gas-Solid Multiphase Flows UNICAMP/FURB

6 Improvement and Application of CFD Techniques for Adaptative Characterization of Petroleum FractionsCOPPE_1

7 Development of Methods for the Solution of Multivariate CFD-PEB Models COPPE_3

8 Simulation of The Combustion of Petroleum Coke in a Fast Fluidized Bed UNICAMP

41

::

8 Simulation of The Combustion of Petroleum Coke in a Fast Fluidized Bed UNICAMP

9 Numerical Simulation of Multiphase Liquid Sheet Formation UFU

10 Numerical Simulation of Multiphase Flow in Pipes UFU

11 Numerical Analysis of Multtiphase Pipe and Cyclone Erosion UFU

12 Application of LES to Gas-Solid Flows UNICAMP

13 Residual (Bunker) Oil Combustion Studies PUC

14 HydroCyclones for Water Oil-Separation UFRJ-EQ

15 DNS Solution of Turbulent Complex Flows in Refining Processes UFRJ-EQ/UFU

16 Optimization of Oxi-Gasification Process UFRJ-EQ

17 Analysis of Coalescence in Dessalting Units UFRJ-EQ

18 Development of a Methodology based on CFD for Industrial Burners Optimization PUC

19 Optimization of Mixing Time in Tanks UNICAMP

20 Development of a Measuring Divice based on Optic Fibers Probe for Gas-Solid Systems UNICAMP

PETROBRAS Supporting Tools-

• SUPPORTING LABORATORIES AND PILOT PLANTS – CLUSTERS (800)

42

• Basic Engineering introduces innovation, generated by Design and R&D

people interaction, in new and existing units;

• CS and PFCC division from CENPES/PETROBRAS rely on CFD tools to increase

equipment life-time, safety, efficiency and mechanical integrity in order to

minimize problems and increase reliability!

Conclusions

43

minimize problems and increase reliability!

• So, it is possible to take advantage of CFD tools to Develop, Design and

Optimize Processes in the Refining Industry;

• However we need more reliable Models, Solvers and more powerful

Computers in order to solve Real Large Problems,

• Therefore, PETROBRAS is doing its part on the Game, Investing.

• We should hurry up with our Simulations before Crude Oil finishes.

THANK YOUTHANK YOUTHANK YOUTHANK YOUTHANK YOUTHANK YOUTHANK YOUTHANK YOU

2020Perspectives for the future Refining Industry

FUTURISTICFUTURISTICFUTURISTIC VIEW (Cars, Refineries R)VIEW (Cars, Refineries R)VIEW (Cars, Refineries R)FUTURISTICFUTURISTICFUTURISTIC VIEW (Cars, Refineries R)VIEW (Cars, Refineries R)VIEW (Cars, Refineries R)

45

2000

New Emissions Standards

CO2 Balance– “well to wheel analysis”

Fuel Economy

The Car of the FutureThe Car of the Future

OBD- Automatic Driving

Objectives:

Demands:

46

Spark Ignition Direct Injection - GDICompression Ignition D.I.Hybrid VehiclesElectric VehiclesFuel Cells

OBD- Automatic DrivingField Performance ViabilityLong LastingAfter-Treatment

Means:

� Steam Reforming Hydrogen Production

Cost Reduction;

� Alternative Hydrogen Production

HydrogenHydrogen ProductionProduction

REFINING & PETROCHEMICAL

47

� Alternative Hydrogen Production

Processes: Reform With CO2, gasification

Catalytic Gasification of Residues, Direct

Methane Decomposition,

� Ceramic Membranes Applied to Synthesis

Gas Production

Fossil Resources:Fossil Resources:

• Ultra Low Sulfur fuels

• Synthetic fuels - GTL

Alternatives:Alternatives:

Fuel of The FutureFuel of The Future

48

Alternatives:Alternatives:

Natural Gas

Bio- oxygenated: Ethanol, Biodiesel

Emulsions

Di Methil Ether

Di Methoxi Methane

Hydrogen

Means:Means:

• Fuel Design

• Engine CFD Simulation and Optimization

Petrobras Downstream ChallengesPetrobras Downstream Challenges

49

56%

49.3

56%

49.3

Petrobras Investment PlanPetrobras Investment Plan(2007 (2007 –– 2011)2011)

US$ 87.1 billion

50

4%9%

3%

26%3%

E&P Downstream G&EPetrochemical Distribution Corporate

23.1

7.53.3

2.31.8

4%9%

3%

26%3%

E&P Downstream G&EPetrochemical Distribution Corporate

23.1

7.53.3

2.31.8

Note: Includes International

US$ 23.1 billion in the Downstream segment ...

61%

14%

US$ 3.219%

14%

26%

US$ 3.7

... of which US$ 14.2 billion in Refining

Investment Plan for DownstreamInvestment Plan for Downstream(2007(2007--2011)2011)

51

61%

13%

12%

Refining Pipelines

Sea Transport Petrochemical

US$ 14.2

31%

10%

Fuel Quality CapEx

Maintenance/HSE Conversion

Others

US$ 4.4

BioBio--fuels Productionfuels Production

Refinery

Hydrogen Diesel

fractionsAgribusiness

Farming Crushing

Seeds

Processed Oil

DieselDiesel

H-BIO

Or

Or

52

BiodieselBiodiesel

Glycerin + OthersGlycerin + Others Stations

Distributors

B2 or B5 Diesel

TransesterificationEthanol Ethanol

or

MethanolMethanol

Or

HBIOHBIO

HBIO is a process of:HBIO is a process of:

Oil refining that utilizes vegetable oils as raw material in order to obtain diesel oil

Hydrogenation of a blend of diesel and vegetable oils

53

diesel and vegetable oils

Castor-Oil Plant Sun-flower African Oil PalmSoy CottonCastor-Oil Plant Sun-flower African Oil PalmSoy Cotton

Documents

CFD APPLIED TO PETROBRAS REFINING PROCESS … · cfd applied to petrobras refining process development and optimization – present, future and chalenges – w. p. martignoni petrobras/ab-re/tr/ot