Innovation in gas treatment, mercury removal, CO/media/Files/A/Atkins-Corporate...Innovation in gas treatment, mercury removal, CO 2 handling and other approaches Introduction Steve

Innovation in gas treatment,

mercury removal, CO2 handling and

other approaches

Introduction

Steve Fogg

Formative Years

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Oil Price - $59

http://chartsbin.com/view/oau

http://chartsbin.com/view/oau

1971 – Houston We Have a Problem

A Safe Landing

Our Guest Speaker – Prof Martin Atkins

Chair of Chemical Innovation and Sustainability – Queen’s University of Belfast

Commercial Mentor for Spin Out Companies

P/T Commercial Director of QUILL – Queen’s University Ionic Liquid Laboratories

BP – China Chief Scientist

CTO - Petrona

Innovations in gas treatment

8

Aberdeen: 19.2.2015 Prof. Martin P Atkins

Outline Presentation

• Welcome remarks and background

• A fast-track development of Hg removal from

gas

• An emerging technology at demonstration

level for CO2 separation – challenges and

opportunities moving forward

Confidential (Commercially

Sensitive)

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Technology

Management.

Project

results and

progress

Conceptual

Design studies.

Provisional

CAPEX & OPEX

models

Business

Intelligence;

Market

Studies; BU

Input

TM

D

Fast-track development of a novel Ionic Liquid based Hg

removal technology – in collaboration with PETRONAS

Technology & Engineering Division 6

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PETRONAS operates a network of gas

production facilities at Malaysia Offshore

• Mercury has been discovered in the hydrocarbon stream delivered by

PETRONAS to the Gas Processing Plant (GPP) in Kerteh, Terengganu,

Malaysia• As mercury removal is becoming more challenging, there is a need to

find a more robust, new technology to reduce the content of mercury

to a much lower level.


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Fact: Mercury is present in our oil and

gas reservoirs

Estimated levels of Mercury in natural gas and condensate from around the globe.

Location Mercury Concentration

Gas (µg m -3)

Liquids(µg kg-1)

Europe 100 - 150 -

South America 50 - 120 50 - 100

Gulf of Thailand 100 - 400 400 - 1200

Africa 80 - 100 500 - 1000

Gulf of Mexico USA)

0.02 - 0.4 -

Overthrust Belt (USA)

5 - 15 1 – 5

North Africa 50 - 80 20 – 50

Malaysia 1- 200 10- 100

Indonesia 200 - 300 10 - 500

Bigham, M.D., " Field Detection and Implications of Mercury in Natural Gas", SPE Prod. Eng., May 1990, 120-124.

Wilhelm, S.M., and McArthur, A., "Removal and Treatment of Mercury Contamination at Gas Processing Plant", Soc. of Pet. Eng., (SPE No.

29721).


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The Problem with Mercury in our Operations- what is it and where is it located?

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The effect of mercury is threatening to the oil and gas

industry and hence a mitigation programme has been

developed

Confidential

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Energy Outlook to 2030 – Confirms Hg removal needs to be

addressed with Hydrocarbons making up 80% of the energy

pool in 2030

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Projections taken from BP’s Energy

Outlook 2030.


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Commercially Available Mercury

Removal Technologies (MRT)

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• Current commercial MRT uses supported sulphides, halides and silver as active materials.

• MRT can be used to treat gas, liquid hydrocarbon and water streams

• Depending on the applications, the targeted mercury levels at MRT outlets are:

• < 0.01 mg/m3 for gas stream• < 1 mg/l for liquid stream

Current Issues with MRT:• Fluctuation in the content of mercury in the streams• Analytical Accuracy - Issues in sampling, sample

treatment and analysis • MRT’s capability to remove all types of mercury

species.• Robustness of the MRT system when other

contaminants are present in the feed

• Handling of the spent MRT materials• Hefty Unit price of current MRT materials


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The IL Adsorbent Package is Innovative and Proprietary

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The material has to be resistant to water vapour

The active site is a Nano-engineered by-functionalmoiety comprising a molecular scaffold andactivated metal centre.

The in volatile nature of the IL makes supportedversions robust in plant operation. This approachopens up new avenues of research anddevelopment across catalysis and contaminantsremoval processes.


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Mercury Removal Solid Support Ionic Liquid Journey

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Collaboration with QUILL, Belfast

- Start of collaboration

fundamental research

- Establish PETRONAS Ionic Liquid Laboratory in QUILL

- Additional R&D projects included in the program

- Large scale production and Pilot Plant

- Commercialization of R&D projects

2007

2008-2009

2010

2011

Global

commercial

marketing

alliance

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Several tasks were studied in parallel primarily to reduce

risks in commercialisation and speed the development

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A new tool to understand the “ageing profile” and screening of new

supports. High throughput experimentation tools applied and

validated.

Establish the right partnerships early. In our case with catalyst

manufacturers, support providers, ionic liquid manufacturer.

Strong support from site for implementation – commitment through

the organisation

Economics, commercialisation, corrosion, risk management, HSE, Due

Diligence, Patents & IP.

Critical path issues managed by central team drawn together from

manufacturing, technology, engineering and business development.

Key to success was “excellence” in project management. The

difference between success and failure.


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Mercury Capture Profile of SSILs

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The team developed a new tool to predict the commercial lifetime of new

supports.

The mercury captured by the SSILsapproach 70-75% of the theoreticalcapacity based on the oxidation tomercury(II) and incorporation intothe ionic liquid structure.

Laboratory results indicated betterperformance in terms of mercuryuptake as compared to commercialadsorbents.

Selection of the optimal ionic liquidcompositions and optimal supportfor the next stage pilotdemonstration.

Confidential (Commercially Sensitive) 22

Slip stream pilot plant

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The heart of the slip stream pilot plant ismultiple reactors fed direct from the mainplant gas feed.

The unit is set-up for “doping extra Hg” toallow adsorption capacity to be estimated(life of the adsorbent).

The unit sees all plant operational variancesand feed gas changes in the main plant.

Multiple beds allows comparison of differentadsorbents

Additional capability and understandinggenerated on site. Early opportunity fortraining on new technology.


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Commercial Trial Loading Activities at Gas Processing Plant

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It is possible to fast track R&D commercialization. It needs:

1. The “right project” – strategic fit to Company objectives

2. The right partners: catalyst manufacturer; support supplier, fundamental

support, in-house expertise and excellence (eg Petronas Hg analysis)

3. Commitment from industrial partner especially site management and personnel

3. TEAMWORK and FOCUS

An emerging CO2 separation

demonstration project


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Absorbent Absorbent

Natural gas

CH4

CO2

Natural gas purification by membrane contractor process

Membrane contactor combines conventional absorption process

with membrane technology

Promising technology: membrane contactor process

Porous membrane

Gaseous mixture Absorbent

N2 or CH4

CO2 or H2S or SO2


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Advantages of membrane contactors

Higher packing density:

500-1500 m2/m3 for membrane contactor

100-250 m2/m3 for absorption column

Less equipment size and weight:

Dry equipment weight reduction of 32% to 37%

Equipment height reduction of 60%

Operating equipment weight reduction of 34%

to 40 %

Capital cost reduction of 35 % to 40 %

Better operation flexibility:

No-foaming, flooding or entrainment

Independent control of gas and liquid phases

Insensitive to motion (critical for offshore)

Easy to scale-up

Traditional absorption column

Membrane contactor system


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Laboratory study

Hollow fiber membranes Membrane contactor testing system

CH4

CO2

LP Mixture

Gas Tank

HP Mixture

Gas Tank

Flash

evaporator

Fresh

Absorbent

tank

HP

Absorbent

Tank

Vacuum line

To GC

Purge

Vacuum

pump

MFC

MFC

PIT

P4

PIT

P3

PIT

P1

PIT

P2

PIT

P9

PIT

P11

LI

PIT

P10

PIT

P8

MFC

PIT

P6

PIT

P7 MFC

Y1

Y2

JI

J2

F1

F2 J3

J4

J5 J6

J7

PIT

P5

J13

Y5

Q5

Y4

W2

Q6

J10

J11

J9Y3J8

Q1

W1

Q3 Q4

F4

F3

Spent

Absorbent

Drum

PIT

PIT

Pulsation

dampener


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Development of PTFE membranes

• High hydrophobicity

• High chemical resistance

• Wetting resistance

• Good mechanical performance

PTFE is considered one of the most suitable materials for membrane contactor use in

CO2 removal from natural gas

C C

F

F

F

F

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Development of PTFE membrane and module

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Development of membrane contactor pilot systemThe commissioning for pilot scale hollow fiber membrane contactor on CO2 removal from natural gas was

successfully conducted in a gas process plant located at Malaysia east coast, which is jointly developed by Prof. Cao Group (DNL0905) of Dalian Institute of Chemical Physics CAS (DICP) and PETRONAS.

The system operated continuously and stably for 72 hours, the results indicated that all process parameters met the contract requirements. It is the world`s first system to purify the high pressure natural gas by hollow fiber membrane contactor. The unit adopted firstly the PTFE hollow fiber high-pressure membrane absorber jointly developed by DICP and Shanghai Bi Ke Clean Energy Technology Co., Ltd (“CECC”), the performance indicators of which also satisfied the contract requirements for the membrane development.

Factory Acceptance test: inlet 10 %, outlet <0.1 %

GPP3 on-site test: inlet 5%,outlet 0.02%-0.2%

Development of membrane contactor pilot system

The MBC system integrates the advantages of membrane separation technology and traditional adsorption process and is proved to be low energy consumption, high separation efficiency, high recovery rate of natural gas, compact device with small footprint, operation friendly, and other superior properties. The innovative technology can be used not only for acidic gas removal from natural gas (especially on offshore platform), but also for other areas like biogas purification and CO2 capture of flue gases.


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Caribbean FLNG 下水全球第一艘投入商业运营的FLNG，Caribbean FLNG为非自航驳船，2014年11月下水，2015年下半年交付至哥伦比亚投运 144m长，32m宽，0.5mt/a LNG，72亿cf/d，2亿Nm^3/d，90KNm^3/h

Exmar和加拿大Pacific Rubiales Energy公司（PRE）的全资子公司Pacific Midstream Holding各出资50%成立的合资公司所有惠生海工负责总承包建设 EPCIC，Black & Veatch负责提供工艺技术及工艺设备采购，北京华福负责该工艺生产装置的详细设计

CARIBBEAN 设计参数吸收塔 40寸MBC

设计处理量/Nm3/h 90000

设计进口CO2含量 ppm 2000 2000

设计出口CO2含量 ppm 50 50

单根膜组件处理量 Nm3/h / 6400

需要数量 1 14

所需膜面积/m2 / 56.25 K

尺寸 Φ1500mm×20.3m Φ1000mm×2.6m

单位设备体积处理量 2510 3135

SHELL设计参数吸收塔 40寸MBC

设计处理量 Nm3/h 580000

设计进口CO2含量 ppm 2000 2000

设计出口CO2含量 ppm 50 50

单根膜组件处理量 Nm3/h / 6400

需要数量 1 91

所需膜面积m2 / 362.5 K

单位设备体积处理量 / 3135

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Confidential (Commercially Sensitive)

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Evaluation

Gas‐liquid contactor

--- Data by PoroGen

Specific surface area

(cm2/cm3)

Volumetric mass transfer

coefficient, (sec)-1

Packed column (Countercurrent) 0.1 –3.5 0.0004 –0.07

Bubble column (Agitated) 1 –20 0.003 –0.04

Spray column 0.1 –4 0.0007 –0.075

Membrane contactor (PEEK) 1 –70 >0.1

• Capital cost by 35 -40%;

• Operating costs of 38% -42%;

• Dry equipment weight of 32% -37%;

• Operating equipment weight of 34% -40%;

• Total operating weight of 44% -50%;

• Footprint requirement of 40%.

Reduction & Savings

--- Data by Aker Process System

• Capex reduction of 35-40% due to smaller equipment, Smaller footprint

(floating LNG is possible)

• Opex savings between 30-40% due to Lower energy requirement for

regeneration, higher pressure operation (less compression

required),Minimal hydrocarbon losses, Reduced foaming

Reduction & Savings

--- Data by WP

Conclusions

• Despite falling oil prices and uncertainties in the short

term, innovations and improvements to our daily

operations are key for stability and safe, economic

operations

• Gas is proving to be a feedstock of choice for power

and is resilient in the market place with LNG markets

remaining strong and durable in the current crisis

• With remote gas, FLNG production is proving a

useful vehicle for marginal fields.

• The larger gas complexes (e.g. shale) are now taking

advantage of novel gas conversion opportunities.36

Q&A

Thank YouNext event ‘O&G decommissioning: Learning from

other industries’ is on 26 March 2015 at Gordon

Highlander Museum

Documents

Innovation in gas treatment, mercury removal, CO/media/Files/A/Atkins-Corporate...Innovation in gas treatment, mercury removal, CO 2 handling and other approaches Introduction Steve