· PDF fileUpgrading of Bitumen by using Supercritical Water Tomoki Kayukawa JGC Corporation 5th NCUT Upgrading and Refining Conference 2009

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Upgrading of Bitumen

by using Supercritical Water

Tomoki Kayukawa

JGC Corporation

5th NCUT Upgrading and Refining Conference 2009

Copyright 2009 JGC all rights reserved

Source NexantReport

Light & Middle

Crudes (API 22o~ 31

o)

Heavy & Ex. Heavy

Crudes (API <22o)

Bitumen

Vis. >10,000CP

Bitumen

Heavy & Ex. Heavy Crudes

Billion bbl

North

America

South

AmericaAfrica Europe

Middle

EastAsia Russia

600

500

400

300

200

100

0

2

21%

47%32%

World’s Proven Reserves


Transportation of Ex. Heavy Oil and Bitumen

Well

Diluent

Dilution Refinery Low availability of diluentSoaring diluentprice

Full Upgrading

RefineryW ell Upgrader

Dilution

Pipelinetransportation

Complex schemeLarge-scale upgrader

(Thermal &

Hydro cracking)


Dil-Bit

Sweet SCO

3

Copyright 2009 JGC all rights reserved 4

Conventional Bitumen Upgrading Process

DilutedBitumen

Diluent

AR

VR

Bottom

Virgin LGO

Vacuum HGO

H2

Amine &SulfurPlant

SweetSCO

Sour Gas

Sweet GasTo Utilities

H2

H2

H2

Coke

Sulfur

(Oil & Gas Journal / April 23, 2001)


Partial Upgrading by using Supercritical Water

Well

Dil-BitRefinery

Full Upgrading

RefineryW ell Upgrader

Sweet SCO

Dilution


(Thermal &

Hydro cracking)


Simple schemeSmall-scale upgraderNo diluent

Partial Upgrading by using Supercritical Water (SCW )

RefineryW ell Partial

Upgrader Sour SCO


5

Diluent

Low availability of diluentSoaring diluentprice

Complex schemeLarge-scale upgrader

Dilution


HighPress.Steam

BoilerFacility

BitumenRecoveryFacilities

Oil Sands

Reserves

(underground)

Supercritical Water

CrackingFacilities

Sour SCOSour SCO

(API 19~25(API 19~25oo))

Bitumen

API 8.5o

Hot Water

Residue (Liquid)

Drain

SAGD*

* Steam Assisted Gravity Drainage

Integration of SAGD and SCW Cracking

No hydrogenNo hydrogen

No natural gasNo natural gas

No catalystNo catalyst

Small quantities ofSmall quantities of

byby--productsproducts

Upgrader

6


Gas SC Fluid Liquid

Density kg/m3 1 100~1,000 1000

Viscosity mPa s 0.01 0.1 1

Diffusion

Coefficientm

2/s 10

-510

-7~10

-810

-10

Thermal

ConductivitymW/mK 5~30 20~150 50~200

Water at a temperature

and under a pressure

above its critical point

SCWSCWPress.

Critical Pressure

(=22.1Mpa)

Temp.

Critical

Temperature

(=374oC)

Solid(Ice)

Liquid(Water)

Gas(Vapor)

CriticalCriticalPointPoint

Water T-PPhase Diagram

7

What is Supercritical Water?

SCW has physical

properties between liquid

and gas


SCW has a low dielectricconstant somewhere in the range of 2 to 10

SCW has characteristicsof non-polar solvent

Roles of Supercritical Water

SolventDielectric

Constant

Water @20oC 81.1

Methanol 32.7Ethanol 25.8Acetone 20.7Propanol 20.3

Methylene Chloride 8.93THF 7.58

Chloroform 4.81Diethylether 4.33Toluene 2.38Benzene 2.27Heptane 1.92Hexane 1.88

Non-polar

Polar

[-]

Press. [MPa]

SaturationCurve

CPCP

Dielectric Constant [-] of Water

8


Injection of samples

Videocamera

Monitoring & Recordering

! Temperature

change

Pressure change

Phase change

Temperature

change

Pressure change

Phase change

Temperature

change

Pressure change

Phase change

SetupSetup

Temp. range: 430oC

(Heating rate: ~ 3 oC/min)

Press. range: 30 MPa

Temp. range: 430oC



Temp. range: 430oC



Direct Observation of Reaction and Extraction Phenomena

9


Water,W ater,Distillate,Distillate,VGOVGO

Water,Residue

SCW forms layers in SCW forms layers in

asphalteneasphaltene micellemicelle

1. Thermal Cracking of VR

3. Inhibiting polymerization of asphaltene (coking)

2. Extracting Distillate and VGO

Results of Direct Observation

Roles of Supercritical W ater

10


Test Apparatuses

& Test Results

11


Feedstock Properties

Bitumen (produced by SAGD)

12

Density (@15oC) g/cc 1.012

API o 8.3

Sulfur wt% 5.15

CCR wt% 13.8

Viscosity (@40oC) cSt 17,000

Nickel wtppm 75

Vanadium wtppm 194

-360oC wt% 17

360-540oC wt% 33

540oC+ wt% 50

Metals

Distillation (SimDis)


Design Temp. : 480oC

Design Press. : 30MPaCapacity : 0.15BPDMaterial : SUS316

PG

Pump

Pump

VerticalReactorVessel

TI

PG

Heater

Heater

PG

Back PressureRegulating Valve

Flow Meter

Condenser

VENT

Heavy ResidualProducts

Condenser

Schematic Diagram of Test Unit

Bitumen

W ater

Light Products

W ater

13


Light Products (75.7 vol%)

100 vol%

APIo

22.9

Viscosity@10oC cSt 26.0

Distillation Characteristics

~360oC wt% 57

360-540oC wt% 39

540oC+ wt% 4

Heavy Residual Products (25.2 vol%)

API -6.5

Viscosity@310oC cSt 17.5

Distillation Characteristics

~360oC wt% 5

360-540oC wt% 27

540oC+ wt% 68

Test Results

Bitumen

Light Products

SCW

W ater

14

Heavy ResidualProducts


0

20

40

60

80

100

120

FeedstockBitumen

SCW Cracking Products

Delayed CokerProducts*1

Yield vol%

Distillate & Lighter

VGO

VR100% 101%

80%(+Coke 20wt%

19

34

47

46

36

19

40

40

*1 Feedstock for Delayed Coker is VR from Bitumen. Products include Coker products and straight run Distillate & Naphtha.

Higher Liquid Yield by SCW Cracking

15


! Bitumen was successfully cracked by using SCW

" 60% of VR was converted to Distillate & VGO.

! SCW cracking system involves the functions of

reaction and extraction. SCW worked as a solvent for

the separation of light and heavy residual products.

!The kinematic viscosity and density of light products

satisfied the Canadian pipeline specifications.

! The heavy residual products satisfied the boiler fuel

specifications in terms of kinematic viscosity.

Summary of Reaction Tests

16


Economic Evaluations

17


Base x 3 Base Base x 0.50

50

100

150

200

10.0

Capacity : 30,000BPD of Bitumen (8oAPI)

CAPEX includes on-site facilities, utility facilities, power plant,

off-site facilities and owner cost.

Reactor Volume

Economic Efficiency vs. Residence timeWaterRecycle15%

Others3%

Reactor27%

High Press.Equipment

54%

Rela

tive Index o

fC

AP

EX

, N

et

Ma

rgin

IRR

[%]

18

IRR [%] 6.6 8.1

0

5

10

CAPEX

Net Margin


Bitumen

30KBD

8oAPI

SCO

24KBD

21oAPI

Naphtha

HDS

D. Coker

15KBD

SCW Cracking

30KBD

Coke

990 tpd

D. Coker-based plant

Visbreaker

30KBD

(*) D. Coking and Vis Breaking tests

were conducted by PARC.(*)

Pitch6KBD

Economic Comparison

Visbreaker-based plant

SCW Cracking-based

plant

Bitumen

30KBD

8oAPI

SCO

24KBD

21oAPI

CDU

VDU

Bitumen

30KBD

8oAPI

SCO

30KBD

11oAPI

(*)

19


Results of Economic Comparison

20

SCWCracking

Coker(30KBD)

Coker(60KBD)

Visbreaker

0

25

50

75

100

125

Rela

tive Index o

fC

AP

EX

an

d N

et

Ma

rgin

IRR [%] 10.0

0

5.5 8.5 8.3

5

10

IRR

[%]

CAPEX

Net Margin

Capacity : 30,000BPD of Bitumen (8oAPI)

CAPEX includes on-site facilities, utility facilities, power plant,

off-site facilities and owner cost.

In the case of Coker (60KBD) above, its CAPEX is estimated at half of that of whole plant.

15


! SCO value of SCW cracking was higher than other

thermal operations because of lower density and

higher liquid yield.

! Pitch from SCW is more valuable than solid coke,

as Pitch is usable as boiler fuel oil for SAGD Boiler.

! Lower capital cost due to simple process

! Lower plant complexity without crude distillation

columns and hydro-finishing process

! Lower operating cost without consumption of

hydrogen and catalyst

Summary of Economic Evaluations

21

Economic efficiency of SCW cracking-based plant

has proved to be higher than

that of D. Coker- or Visbreaker-based plant


Foot Print(excl. Tank Yard)

Solid Waste(By-Product)

CokeSulfur

Sulfur

EnergyConsumption(API 8

o# 21

o)

SCW (30KBD) D. Coker (30KBD)

SCW~ Simple,Clean, minimal Waste ~

22

1 4

1 12.5 25

1 1.4

Copyright 2009 JGC all rights reserved 23

~Acknowledgment ~

JGC Corporation owes JOGMEC(Japan Oil, Gas and Metals National Corporation)

a great deal for this research.


“Energy”, “Environment”, “Engineering”

for the quality of human life

Thank you for your Thank you for your

kind attention!!kind attention!!

TomokiTomoki KayukawaKayukawakayukawa.tomoki@ jgc.co.jpkayukawa.tomoki@ jgc.co.jp

24

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· PDF fileUpgrading of Bitumen by using Supercritical Water Tomoki Kayukawa JGC Corporation 5th NCUT Upgrading and Refining Conference 2009