Odw Heavy Oils Slides[1]

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© 2010 Aspen Technology, Inc. All rights reserved© 2010 Aspen Technology, Inc. All rights reserved

Engineering Excellence Webinar Series

26 January 2010

Modeling Heavy Oils inAspen HYSYS


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© 2010 Aspen Technology, Inc. All rights reserved | 2

Modeling Heavy Oils in Aspen HYSYS

•

Dr. Mohammad Khoshkbarchi

−

Senior Project Manager, Process Ecology

−

Email: [email protected]

•

Sanjeev Mullick

−

Director, Product Marketing, AspenTech−

Email: [email protected]

•

http://support.aspentech.com

mailto:[email protected]://support.aspentech.com/mailto:[email protected]://support.aspentech.com/http://support.aspentech.com/mailto:[email protected]:[email protected]


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Agenda

Heavy Oil Overview

Best Practices for Modeling Heavy Oils in Aspen HYSYS

Sample Applications

Recommendations and Conclusions

Q&A


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What is Heavy Oil?

•

By definition, has API gravity < 20°

& viscosity > 1,000 cP

•

Has over 60 carbon atoms, and hence, a high BP & MW

•

Mainly comprised of hydrocarbons heavier than pentanes,with a high ratio of aromatics andnaphthenes to paraffins

•

High amounts of nitrogen, sulfur (~5%),oxygen and heavy metals

•

Exists in a semi-solid state and may not

flow in its naturally occurring state


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Comparative Oil Properties

Conventional Crude 25 °API

Conventional Heavy 25 –

18 °API

Extra Heavy (Thermal) 20 –

12 °API

Tar Sand 12 –

7 °API


6/59© 2010 Aspen Technology, Inc. All rights reserved | 6

Where Does it Exist?

•

Heavy oil deposits total almost 5½

trillion barrels (est.);80% of deposits are in the Western Hemisphere

-

In the U.S., heavy hydrocarbon deposits are estimated to be

more than eight

times that of the nation's remaining reservesof conventional crude oil



Where Does it Exist?

1.

Western Canada

–

Mainly in the form of oil sands in Alberta

•

44% of Canadian oil production in 2007 was from oil sands, with an

additional 18% being heavy crude oil

–

Average density is API = 8°

–

Viscosity within a range 5000-10,000 cP,and higher (up to 100,000 cP)

2.

Venezuela

–

Mainly heavy oil

–

Viscosity within a range of 1000-5000 cP



Challenges in Modeling Heavy Oils

•

Characterizing the oil

–

Defaults

–

Data Bulk

Curves

–

Viscosity

•

Blending to match properties at wellhead

–

Emulsion viscosity

•

Phase entrainment/carryover

•

Foaming

•

Further effects of adding solvents



Implications of Poor Modeling

•

Incorrect wellhead conditions

–

Steam-Oil ratio

–

Properties prediction

–

Flash conditions: vapor when it’s really a liquid/vice versa,trivial phases

•

Large pressure gradients

•

Unattainable separations–

Products: SCO

–

Capacity

–

Yields

–

Over/under design of towers, drums

•

Misrepresented utilities

–

Over/under design of heat exchanger units



Agenda

Heavy Oil Overview


Sample Applications


Q&A



Oil Properties Build PFD Assay Setup

Best Practices Workflow

Enter Assaylab data

Check

Correlation set

Enter UserCutpoint

ranges

Verify/alter

Extrapolation

& ConversionMethods

Blend Assay &Cut into Hypos

Compare

Property Plots

Install Oil

Blend Oil &Water streams

Alter emulsion

viscosity, ifnecessary

Incorporate

entrainment

Use Utilities to

check products



Oil Characterization in Aspen HYSYS

•

Purpose: convert lab analyses Aspen HYSYS library andhypothetical components

•

3 steps in Oil

Characterization:1.

Characterizethe Assay

2.

Generate

PseudoComponents –

Cut/Blend

3.

Install the Oil in

the Flowsheet



•

Alternative Methods:

−

ASTM D86 (atmospheric batch distillation)

−

ASTM D1160 (vacuum batch distillation)

−

ASTM D2887 (chromatography)

•

Usually unsuitable for heavy crudes

True Boiling Point Curve

0

200

400

600

800

1000

1200

0 20 40 60 80 100

Volum e % Dist illed

B o l i n i n g

P o i n t ( C )

IBP

FBP

IBPi FBPi

True Boiling Point (TBP)



1. Characterizing the Assay

•

Know how your lab handles its analysis:

–

Which analysis type?

–

Are they applying any corrections?

–

Are light-ends included? Or is it a separate analysis?

Input Composition

Auto Calculate

Ignore


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•

Heavy oil TBP has much fewer experimental points

•

No FBP or close point to it

Conventional Oil TBP

-100

0

100

200

300

400

500

600

700

800

0 20 40 60 80 100


B o l i n i n g

P o i n t ( C )

Heavy Oil TBP

0

200

400

600

800

1000

1200

0 20 40 60 80 100


B o l i n i n g

P o i n t ( C )



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1. Characterizing the Assay

•

Light Ends handling and Bulk Property fitting:

–

Are Light-ends included in the input curves?

–

Are Light-ends included in the bulk properties?

–

What bulk data do you have? Do you also have propertycurves?

–

Do you want to control which part of the curve is tuned to

match the bulk property?

•

Understand the correlations used

•

Understand which conversion and extrapolation methods

are used


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Best PracticesSpecify Properties for Heavy Oils

•

Bulk property options include:

–

Molecular Weight > 16

–

Mass Density = 250 ~ 2000 kg/m3

Required

–

Watson K Factor = 8 ~ 15

Recommended

–

Bulk Viscosity, @ 100°F and @210°F

Required

•

Add other property curves

–

Molecular Weight curve

–

Density curve

Recommended–

Viscosity curve (two curves)

Recommended


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2. Generating Pseudocomponents

•

Blending is used to blend a number of assays. It provides ageneral presentation of the whole crude. Cutting not onlygenerates thepseudocomponents,but also determinestheir compositionsin the crude

–

Auto Cut: basedon values specifiedinternally

–

User Points:specified cut pointsare proportioned based on internal weighting scheme

–

User Range: specify boiling point ranges and the number of

cuts per range


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Best PracticesCreating Hypotheticals for Heavy Oils

•

When generating pseudocomponents for heavy oilfractionation, recommend using User Points or User DefinedRanges

•

How many?

–

Minimum of 4 pseudo-

components per draw

–

Use Composite plot todetermine exact numberfor each temperaturerange

Test accuracy of input

assay data againstgenerated hypotheticals

“How well does my data

match with Aspen HYSYS”?


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•

In the absence of high FBPexperimental data theextrapolation of the curvecould result in abnormalities.

This will have a great impacton the set up of some unitoperations such asdistillation.

•

The undershoot in theextrapolation could change toovershoot as well

True Boiling Point Curve

0

200

400

600

800

1000

1200

0 20 40 60 80 100


B o

l i n i n g P

o i n t ( C )

•

Solution:

−Use a guide point such as FBP or IBP

−

Use other distribution



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Best PracticesPredict Heavy Oil Fractions

•

Use the Distribution Plot to help predict crude products

–

Enter custom cuts

to slice oil as desired

–

See product changeswith temperature

–

Use these fractionsas initial productdraw rates forconverging thecolumn (i.e., forfront end of anupgrader)

“Approximatelyhow much of every

product will I get”?


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3. Installing the Oil

•

Installing the oil in the flowsheet is done by providing astream name on the Install Oil tab. This:

1.

Adds the pseudo components to the Fluid Package

2.

Transfers the pseudo component information into theFlowsheet

3.

Creates a stream on the Flowsheet with a definedcomposition

If you forget this step, you will not be able to see the oilcomposition in the flowsheet!


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Best PracticesStream Utilities for Oils

•

Use stream Utilities to check individual streams against thecomposite oil

–

Boiling Point Curves: calculates simulated distillation data andcritical property data for each cut point and cold properties

–

Cold Properties: shows boiling pointcurve and breakdown of Paraffins/

Naphthenes/Aromatics for theinstalled oil


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The following section looks at special considerations inpredicting heavy oil properties, including:

Specific Gravity/Standard Density

Extrapolation Methods & Fitting Options

Viscosity

General Oil Properties, i.e., Thermal Conductivity

Aspen HYSYS Can Accurately PredictImportant Heavy Crude Properties


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Specific Gravity

•

Specific gravity is an extremely important data point for theaccurate extrapolation of heavy oils, as well as an importantdata point to generate a missing SG curve

–

Bulk SG is, by default, optional and part of the assay analysis•

It is thereforerecommendedthat the bulk density

(or density curve)be supplied as aninput parameterfor the accurate

characterization ofa heavy oil

f


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Specific GravityExample Problem and Solution

•

Problem: Range of discrepancy in estimated densityvalues is 6% at lower NBPs and up to 11% athigher NBPs

•

Solution: Apply different correlation sets for multiple NBPranges

–

Inconsistent/unreliable SGs at heavy ends can

result especially if the SG is estimated from anycorrelation where NBP is the only independentvariable, since SG might also be a function of MW

–

The SG curve generated from input data should be

consistent and follow the trend of the boiling point curve–

Watson K method creates a Watson K curve based on boiling curveand average SG. This Watson K curve is used to generate componentSG boiling point, then moved up and down to match bulk SG.


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Curve Extrapolation

•

Available mathematical extrapolation methods (for bothends) include:

–

Probability

–

Least squares–

Lagrange

•

Recommendedselections for heavy

oils are shown here–

The linearextrapolation methodis not appropriate for extrapolating the SG, MW and viscosity

curves for heavy ends. The least squares (2nd orderpolynomial), applied at both ends, is recommended.


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Curve Fitting Options

–

Curve Includes L.E.

–

Bulk Value

–

Bulk Value Incl. L.E.

–

Head %–

Head Adjust Weight

–

Main %

–

Main Adjust Weight–

Tail Adjust Weight

•

For each input curve, can specify:

C Fitti O ti


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Curve Fitting OptionsExample Problem and Solution

•

Problem: Property curves are shifted along y-axis

•

Solution: To correct discrepancies, you have 3 options:

−

Change BulkValue (leastaccurate), or

−

Adjust Main %and Tail Adj Wt.

to correspondwith data entrypoints (manual),or

−

Apply SmartBulk Fitting(automatic)


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Curve Fitting Options Example

C Fitti O ti


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Curve Fitting OptionsExample Problem and Solution

•

Problem: TBP Curve is shifted along the liq. vol. x-axis

–

A TBP, by default, includes light ends; however, if the TBP wasobtained from a light-ends free sample, Aspen HYSYS can re-

adjust the curve to the overall crude

•

Solution:Choose to fitwith or without

light ends, as

appropriate:

–

In situations when only partial light ends analysis data is

available, Aspen HYSYS can generate overlapping hypotheticalcomponents to compensate the missing portion of the lightends, making the output stream matching both the partial lightends input and the other input curves


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Viscosity

•

Viscosity is key to both successfully understanding the fluidproperties of a heavy oil and for predicting oil recovery

•

Both viscosity reduction and thermal expansion are the key

properties to increase productivity of heavy oils–

Viscosity influences every aspect of a heavy oil development

•

Effect of viscosity on pressure gradients

–

For real liquids, the effect of pressure is relatively small whencompared to the temperature effect; but large pressuregradients tend to occur with high viscosity oils. At higher flow

rates, frictional heating effects can become significant, and theheating tends to reduce the oil viscosity, which in turn, affects

the pressure gradient. The net result is that the predictedpressure gradient may be higher than should actually beexpected.


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Viscosity Options in Aspen HYSYS

•

Since viscosity is the key property to proper heavy oilscharacterization, we do not recommend omitting thisvariable

•

Optional to use:–

Bulk viscosity values (recommended)

–

Only viscosity curve

–

Two viscosity curves (optimal)

•

Higher flexibility on temperature extrapolation

•

Note: Bulk viscosity and viscosity curves can be input atdifferent temperatures


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Heavy Crude Viscosity Trends

Full Crude Viscosity vs. Temperature

0

20000

40000

60000

80000

100000

120000

0 50 100 150

Temperature (C)

V i s c o s i t y ( c S t )

Cut Viscosity vs . Final Bo iling Point

0

50000000

100000000

150000000

200000000

250000000

0 200 400 600 800 1000 1200

FBP (C)

V i s c o s i t y ( c S t )

•

Use two points from full crude viscosity curve.

•

High FBP viscosities are usually a result of extrapolationusing a log(log) approach.

Viscosity Curves


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Viscosity CurvesExample Problem and Solution

•

Problem: Calculated and inputted viscosity values don’tmatch. Depending on the application, bulk values aregood, but in other cases (like heavy oils) the cuts value

(i.e., residue) is better. –

Quite a typical case:

Low quality viscositycurves for extra-

polation purposes It is a measure range

problem

Inconsistent data

leads to a mismatchof input to calculated

•

Solution: Manipulatebulk value by trial anderror to match residue viscosity


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Indexed Viscosity

•

Viscosity cannot be blended linearly, so a methodology isadopted that substitutes a function of the measured viscositythat is approximately linear with temperature. A linearizedequation for viscosity is given by Twu and Bulls (1980).

•

On the Parameters tab for equation of state methods, youcan change the viscosity calculation method from HYSYSViscosity to Indexed Viscosity to determine the blended liquid

viscosity


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General Oil Properties

•

When comparing Aspen HYSYS-predicted property valuesagainst vendor, lab, or plant data, for properties such asliquid density, viscosity, thermal conductivity and heatcapacity, there can be some discrepancies, since:

–

They are generated from general thermodynamic models

–

It is not realistic to expect model predicted results to exactly

match real data

•

To improve the accuracy of these properties, use the Tabularfeature in Aspen HYSYS to:

–

Edit the coefficients for property correlation

–

Regress lab data directly in Aspen HYSYS


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Example: Improving Thermal Conductivity

Alter coefficients

Regress data


39/59


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Checklist for Modeling Heavy Oils

Blend water and oil streams; check emulsion properties

Build flowsheet

Incorporate phase entrainment in separators (usingcarryover function) and columns (via efficiencies)

Use stream utilities (BP curves, Cold Properties) to checkindividual streams against the composite oil


41/59


Agenda

Heavy Oil Overview


Sample Applications


Q&A


42/59


Well PadEmulsion

DILUENT/

SYNTHETICCRUDE

STEAM/HEAT

ToUpgraderor Pipeline

Gas-Oil-

Water

Separation

[DILBIT/

SYNBIT]

OIL

GAS

GasTreating

RECOVEREDDILUENT/SCO

SOURGASES

SWEETGASES

Steam Assisted Gravity Drainage (SAGD)

SteamGeneration

WATER


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STEAM GENERATION

GAS TREATMENT

Well Pad

Diluent

OIL TREATMENT

To Upgrader

or Pipeline

DilBit

Make up Streams

WATER TREATMENT


Aspen HYSYS Model


44/59


OPERATIONSDESIGN

•

Use model to make decisionsin all phases of operation—

preheat, steam injection & oilproduction, and blowdown

•

Track and report keycomponents—sulfur, etc.

•

Determine how operatingimprovements

•

Model wellpad characteristics

•

Model separation of water,oil, and gas phases

•

Perform profit calculations(upgrade to SCO or sell)

•

Consider new technology—

partial upgrading in-situ,

combustion, VAPEX, etc.


–

Additions of diluent and/orsolvents, their flow conditions,separation scheme & recovery

–

Bitumen treatment and recovery

–

Steam generation

–

Water treatment (incl. softening) –

Increase bitumen separation/recovery

–

Reduce energy requirements

–

Improve water usage


45/59


Agenda

Heavy Oil Overview


Sample Applications


Q&A


46/59


Recommendations for Heavy Oils

1.

For Assay data, generally suggest entering Gravity, BoilingPoint Range, Watson K;

For Heavy Crudes, recommend including Viscosity—Bulk or

Curve

2.

When generating Pseudo-Components, Auto-Cut option isnot the best choice for heavy oil fractionation; recommendusing User Points or User Defined Ranges; generate aminimum of 4 pseudo-components per draw

3.

Suggested Thermodynamic Methods are:

Heavy Hydrocarbons:

Peng Robinson with Lee-Kesler Enthalpies

Light Hydrocarbons:

Peng Robinson

Hydrogen Rich: Peng Robinson

Sour Water:

Peng Robinson Sour


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4.

Verify usage of:

–

Correlations set

–

Extrapolation methods for property curves

–

Fit option with light ends

5.

Use Plots and Utilities to match data to model and correctfor any deficiencies in data

–

Plots: Composite, Oil Distribution–

Utilities: Cold Properties, BP Curves

6.

Integrate lab/plant data into thermodynamic parameters


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7.

Aspen HYSYS can match Heavy Oils data for simulationstudies as validated in three papers

–

Hyprotech, HYSYS, and Oils

–

Technical Audit of Heavy Oil Characterization Methods–

Heavy Crude Oil Handling

8.

Simulation Basis Manager—Chapter 4, Aspen HYSYS OilManager—provides all the technical details and options

9.

Support Knowledge Base offers many solutions on this topic

–

Sample files

–

Technical tips: keywords such as, viscosity, thermal conductivity,

density–

Example file: The usage of Indexed Viscosity option in HYSYSwith an example


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Agenda

Heavy Oil Overview


Sample Applications


Q&A


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•

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•

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53/59


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•

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•

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57/59


Focused sessions including:

•

Aspen Process Modeling

–

Chemicals -

Aspen Plus and ACM

–

Energy -

Aspen HYSYS Family

•

Aspen Exchanger Design & Rating (HTFS)

•

Capital Project Engineering

–

Aspen Economic Evaluation (Icarus)

–

Aspen Basic Engineering (Zyqad)

•

Batch and Pharma Process Development

Format:

•

In-depth sessions on product families,solution areas and industry verticals

•

Panel discussions

•

Share best practices and experiences

with other users and AspenTech experts•

Open discussions to share new ideas and

provide feedback to AspenTech

•

Tutorials and training on latest capabilities

•

Clear understanding of future productdirection

3-5 May 2010 Boston, MA, USA

Westin Copley Place

For more information:

Email:

[email protected]

or [email protected]

Web: http://www.aspentech.com/aspenoneglobalconference



mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.aspentech.com/aspenoneglobalconferencehttp://www.aspentech.com/aspenoneglobalconferencemailto:[email protected]:[email protected]


58/59


Focused sessions including:

•

Aspen Process Modeling

–

Chemicals -

Aspen Plus and ACM

–

Energy -

Aspen HYSYS Family

•

Aspen Exchanger Design & Rating (HTFS)

•

Capital Project Engineering

–

Aspen Economic Evaluation (Icarus)

–

Aspen Basic Engineering (Zyqad)

•

Batch and Pharma Process Development

Format:

•

In-depth sessions on product families,solution areas and industry verticals

•

Panel discussions

•

Share best practices and experiences

with other users and AspenTech experts•

Open discussions to share new ideas and

provide feedback to AspenTech

•

Tutorials and training on latest capabilities

•

Clear understanding of future productdirection

3-5 May 2010 Boston, MA, USA

Westin Copley Place

For more information:

Email:

[email protected]

or [email protected]

Web: http://www.aspentech.com/aspenoneglobalconference


•

More User Presentations….Track agendas are incorporating additional user presentations slots—up to 100 total—so

attendees can see and learn how best practitioners are implementing the latest solutions.

•

More Networking Connections...The 2010 program wil l make it easier for attendees to connect with their peers, giving moreopportunities to exchange ideas that are relevant to their specific business needs.

•

More Integrated Solutions and Product Updates...Back by popular demand, the AspenTech Plenary Session, the Solutions Center, and

dedicated product update sessions will bring more focus on integrated solut ions, product

news and what's ahead in product development.

mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.aspentech.com/aspenoneglobalconferencehttp://www.aspentech.com/aspenoneglobalconferencemailto:[email protected]:[email protected]


59/59

Dr. Mohammad Khoshkbarchi

Senior Project Manager, Process EcologyEmail: [email protected]

Dr. Glenn DissingerDirector, Product Management, AspenTechEmail: [email protected]

Sanjeev MullickDirector, Product Marketing, AspenTechEmail: [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

Documents

Odw Heavy Oils Slides[1]