heavy oil simulation
DESCRIPTION
Heavy Oil SimulationTRANSCRIPT
© 2010 Aspen Technology, Inc. All rights reserved© 2010 Aspen Technology, Inc. All rights reserved
Engineering Excellence Webinar Series
26 January 2010
Modeling Heavy Oils in Aspen HYSYS
© 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
© 2010 Aspen Technology, Inc. All rights reserved | 3
Agenda
Heavy Oil Overview
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
© 2010 Aspen Technology, Inc. All rights reserved | 4
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 and naphthenes 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
© 2010 Aspen Technology, Inc. All rights reserved | 5
Comparative Oil Properties
Conventional Crude <~ 30,000 cSt
Conventional Heavy 30,000 – 40,000 cSt
Thermal Heavy 200,000 – 250,000 cSt
Diluent 0.5 – 11.0 cSt
Oil Viscosity:
Oil API:
Conventional Crude > 25 °API
Conventional Heavy 25 – 18 °API
Extra Heavy (Thermal) 20 – 12 °API
Tar Sand 12 – 7 °API
© 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 reserves of conventional crude oil
© 2010 Aspen Technology, Inc. All rights reserved | 7
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
© 2010 Aspen Technology, Inc. All rights reserved | 8
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
© 2010 Aspen Technology, Inc. All rights reserved | 9
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
© 2010 Aspen Technology, Inc. All rights reserved | 10
Agenda
Heavy Oil Overview
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
© 2010 Aspen Technology, Inc. All rights reserved | 11
Oil Properties Build PFDAssay Setup
Best Practices Workflow
Enter Assay
lab data
Check
Correlation set
Enter User
Cutpoint
ranges
Verify/alter
Extrapolation
& Conversion
Methods
Blend Assay &
Cut into Hypos
Compare
Property Plots
Install Oil
Blend Oil &
Water streams
Alter emulsion
viscosity, if
necessary
Incorporate
entrainment
Use Utilities to
check products
© 2010 Aspen Technology, Inc. All rights reserved | 12
Oil Characterization in Aspen HYSYS
• Purpose: convert lab analyses Aspen HYSYS library and hypothetical components
• 3 steps in Oil Characterization:
1. Characterize the Assay
2. Generate Pseudo Components –Cut/Blend
3. Install the Oil in the Flowsheet
© 2010 Aspen Technology, Inc. All rights reserved | 13
• 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
Volume % Distilled
Bo
lin
ing
Po
int
(C)
IBP
FBP
IBPi FBPi
True Boiling Point (TBP)
© 2010 Aspen Technology, Inc. All rights reserved | 14
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
© 2010 Aspen Technology, Inc. All rights reserved | 15
• 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
Volume % Distilled
Bo
lin
ing
Po
int
(C)
Heavy Oil TBP
0
200
400
600
800
1000
1200
0 20 40 60 80 100
Volume % Distilled
Bo
lin
ing
Po
int
(C)
True Boiling Point (TBP)
© 2010 Aspen Technology, Inc. All rights reserved | 16
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 property curves?
– 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
© 2010 Aspen Technology, Inc. All rights reserved | 17
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
© 2010 Aspen Technology, Inc. All rights reserved | 18
2. Generating Pseudocomponents
• Blending is used to blend a number of assays. It provides a general presentation of the whole crude. Cutting not only generates the pseudocomponents, but also determines their compositions in the crude
– Auto Cut: based on values specified internally
– User Points: specified cut points are proportioned based on internal weighting scheme
– User Range: specify boiling point ranges and the number of cuts per range
© 2010 Aspen Technology, Inc. All rights reserved | 19
Best PracticesCreating Hypotheticals for Heavy Oils
• When generating pseudocomponents for heavy oil fractionation, recommend using User Points or User Defined Ranges
• How many?
– Minimum of 4 pseudo-components per draw
– Use Composite plot to determine exact number for each temperature range Test accuracy of input
assay data against generated hypotheticals
―How well does my data match with Aspen HYSYS‖?
© 2010 Aspen Technology, Inc. All rights reserved | 20
• In the absence of high FBP experimental data the extrapolation of the curve could result in abnormalities. This will have a great impact on the set up of some unit operations such as distillation.
• The undershoot in the extrapolation could change to overshoot as well
True Boiling Point Curve
0
200
400
600
800
1000
1200
0 20 40 60 80 100
Volume % DistilledB
olin
ing
Po
int
(C)
• Solution:
− Use a guide point such as FBP or IBP
− Use other distribution
True Boiling Point (TBP)
© 2010 Aspen Technology, Inc. All rights reserved | 21
Best Practices Predict Heavy Oil Fractions
• Use the Distribution Plot to help predict crude products
– Enter custom cutsto slice oil as desired
– See product changes with temperature
– Use these fractions as initial product draw rates for converging the column (i.e., for front end of an upgrader)
―Approximately how much of every product will I get‖?
© 2010 Aspen Technology, Inc. All rights reserved | 22
3. Installing the Oil
• Installing the oil in the flowsheet is done by providing a stream name on the Install Oil tab. This:
1. Adds the pseudo components to the Fluid Package
2. Transfers the pseudo component information into the Flowsheet
3. Creates a stream on the Flowsheet with a defined composition
If you forget this step, you will not be able to see the oil composition in the flowsheet!
© 2010 Aspen Technology, Inc. All rights reserved | 23
Best PracticesStream Utilities for Oils
• Use stream Utilities to check individual streams against the composite oil
– Boiling Point Curves: calculates simulated distillation data and critical property data for each cut point and cold properties
– Cold Properties: shows boiling point curve and breakdown of Paraffins/Naphthenes/Aromatics for the installed oil
© 2010 Aspen Technology, Inc. All rights reserved | 24
The following section looks at special considerations in predicting heavy oil properties, including:
Specific Gravity/Standard Density
Extrapolation Methods & Fitting Options
Viscosity
General Oil Properties, i.e., Thermal Conductivity
Aspen HYSYS Can Accurately Predict Important Heavy Crude Properties
© 2010 Aspen Technology, Inc. All rights reserved | 25
Specific Gravity
• Specific gravity is an extremely important data point for the accurate extrapolation of heavy oils, as well as an important data point to generate a missing SG curve
– Bulk SG is, by default, optional and part of the assay analysis
• It is therefore recommended that the bulk density(or density curve) be supplied as an input parameter for the accurate characterization of a heavy oil
© 2010 Aspen Technology, Inc. All rights reserved | 26
Specific Gravity Example Problem and Solution
• Problem: Range of discrepancy in estimated density values is 6% at lower NBPs and up to 11% at higher NBPs
• Solution: Apply different correlation sets for multiple NBP ranges
– Inconsistent/unreliable SGs at heavy ends canresult especially if the SG is estimated from any correlation where NBP is the only independent variable, 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 curve and average SG. This Watson K curve is used to generate component SG boiling point, then moved up and down to match bulk SG.
© 2010 Aspen Technology, Inc. All rights reserved | 27
Curve Extrapolation
• Available mathematical extrapolation methods (for both ends) include:
– Probability
– Least squares
– Lagrange
• Recommended selections for heavy oils are shown here
– The linear extrapolation method is not appropriate for extrapolating the SG, MW and viscosity curves for heavy ends. The least squares (2nd order polynomial), applied at both ends, is recommended.
© 2010 Aspen Technology, Inc. All rights reserved | 28
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:
© 2010 Aspen Technology, Inc. All rights reserved | 29
Curve Fitting OptionsExample Problem and Solution
• Problem: Property curves are shifted along y-axis
• Solution: To correct discrepancies, you have 3 options:
− Change Bulk Value (least accurate), or
− Adjust Main % and Tail Adj Wt. to correspond with data entry points (manual), or
− Apply Smart Bulk Fitting (automatic)
© 2010 Aspen Technology, Inc. All rights reserved | 31
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 was obtained from a light-ends free sample, Aspen HYSYS can re-adjust the curve to the overall crude
• Solution: Choose to fit with or without light ends, asappropriate:
– In situations when only partial light ends analysis data is available, Aspen HYSYS can generate overlapping hypothetical components to compensate the missing portion of the light ends, making the output stream matching both the partial light ends input and the other input curves
© 2010 Aspen Technology, Inc. All rights reserved | 32
Viscosity
• Viscosity is key to both successfully understanding the fluid properties 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 when compared to the temperature effect; but large pressure gradients tend to occur with high viscosity oils. At higher flow rates, frictional heating effects can become significant, and the heating tends to reduce the oil viscosity, which in turn, affects the pressure gradient. The net result is that the predicted pressure gradient may be higher than should actually be expected.
© 2010 Aspen Technology, Inc. All rights reserved | 33
Viscosity Options in Aspen HYSYS
• Since viscosity is the key property to proper heavy oils characterization, we do not recommend omitting this variable
• 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 at different temperatures
© 2010 Aspen Technology, Inc. All rights reserved | 34
Heavy Crude Viscosity Trends
Full Crude Viscosity vs. Temperature
0
20000
40000
60000
80000
100000
120000
0 50 100 150
Temperature (C)
Vis
co
sit
y (
cS
t)
Cut Viscosity vs. Final Boiling Point
0
50000000
100000000
150000000
200000000
250000000
0 200 400 600 800 1000 1200
FBP (C)
Vis
co
sit
y (
cS
t)• Use two points from full crude viscosity curve.
• High FBP viscosities are usually a result of extrapolation using a log(log) approach.
© 2010 Aspen Technology, Inc. All rights reserved | 35
Viscosity CurvesExample Problem and Solution
• Problem: Calculated and inputted viscosity values don’t match. Depending on the application, bulk values are good, but in other cases (like heavy oils) the cuts value (i.e., residue) is better.
– Quite a typical case:
Low quality viscosity curves for extra-polation purposes
It is a measure range problem
Inconsistent data leads to a mismatch of input to calculated
• Solution: Manipulate bulk value by trial and error to match residue viscosity
© 2010 Aspen Technology, Inc. All rights reserved | 36
Indexed Viscosity
• Viscosity cannot be blended linearly, so a methodology is adopted that substitutes a function of the measured viscosity that is approximately linear with temperature. A linearized equation for viscosity is given by Twu and Bulls (1980).
• On the Parameters tab for equation of state methods, you can change the viscosity calculation method from HYSYS Viscosity to Indexed Viscosity to determine the blended liquid viscosity
© 2010 Aspen Technology, Inc. All rights reserved | 37
General Oil Properties
• When comparing Aspen HYSYS-predicted property values against vendor, lab, or plant data, for properties such as liquid density, viscosity, thermal conductivity and heat capacity, 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 Tabular feature in Aspen HYSYS to:
– Edit the coefficients for property correlation
– Regress lab data directly in Aspen HYSYS
© 2010 Aspen Technology, Inc. All rights reserved | 38
Example: Improving Thermal Conductivity
Alter coefficients
Regress data
© 2010 Aspen Technology, Inc. All rights reserved | 39
Checklist for Modeling Heavy Oils
Enter lab data—distillation data, light ends, bulk properties, and/or curve data (MW, density, viscosity)
Verify correlation set used for assay over entire temperature range
Validate appropriate selections for assay extrapolation and conversion methods
Blend and cut assay using user cutpoint ranges
Compare plots of input data vs. calculated TBP curve, gravity, viscosities, etc.
Install oil
© 2010 Aspen Technology, Inc. All rights reserved | 40
Checklist for Modeling Heavy Oils
Blend water and oil streams; check emulsion properties
Build flowsheet
Incorporate phase entrainment in separators (using carryover function) and columns (via efficiencies)
Use stream utilities (BP curves, Cold Properties) to check individual streams against the composite oil
© 2010 Aspen Technology, Inc. All rights reserved | 41
Agenda
Heavy Oil Overview
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
© 2010 Aspen Technology, Inc. All rights reserved | 42
Well Pad Emulsion
DILUENT/SYNTHETIC CRUDE
STEAM/HEAT
To Upgrader or Pipeline
Gas-Oil-Water
Separation
[DILBIT/
SYNBIT]
OIL
GAS
Gas Treating
RECOVERED DILUENT/SCO
SOUR GASES
SWEET GASES
Steam Assisted Gravity Drainage (SAGD)
Steam Generation
WATER
© 2010 Aspen Technology, Inc. All rights reserved | 43
STEAM GENERATION
GAS TREATMENT
Well Pad
Diluent
OIL TREATMENT
To Upgrader
or Pipeline
DilBit
Make up Streams
WATER TREATMENT
Steam Assisted Gravity Drainage (SAGD)
Aspen HYSYS Model
© 2010 Aspen Technology, Inc. All rights reserved | 44
OPERATIONSDESIGN
• Use model to make decisions in all phases of operation—preheat, steam injection & oil production, and blowdown
• Track and report key components—sulfur, etc.
• Determine how operating improvements
• 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.
Steam Assisted Gravity Drainage (SAGD)
– Additions of diluent and/or solvents, 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
© 2010 Aspen Technology, Inc. All rights reserved | 45
Agenda
Heavy Oil Overview
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
© 2010 Aspen Technology, Inc. All rights reserved | 46
Recommendations for Heavy Oils
1. For Assay data, generally suggest entering Gravity, Boiling Point Range, Watson K;
For Heavy Crudes, recommend including Viscosity—Bulk or Curve
2. When generating Pseudo-Components, Auto-Cut option is not the best choice for heavy oil fractionation; recommend using User Points or User Defined Ranges; generate a minimum 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
© 2010 Aspen Technology, Inc. All rights reserved | 47
Recommendations for Heavy Oils
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 correct for any deficiencies in data
– Plots: Composite, Oil Distribution
– Utilities: Cold Properties, BP Curves
6. Integrate lab/plant data into thermodynamic parameters
© 2010 Aspen Technology, Inc. All rights reserved | 48
Recommendations for Heavy Oils
7. Aspen HYSYS can match Heavy Oils data for simulation studies 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 Oil Manager—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 HYSYS with an example
© 2010 Aspen Technology, Inc. All rights reserved | 49
Agenda
Heavy Oil Overview
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
© 2010 Aspen Technology, Inc. All rights reserved | 50
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aspenONE® Global ConferenceMay 3-5, 2010 in Boston, MA
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For more information:
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aspenONE® Global ConferenceMay 3-5, 2010 in Boston, MA
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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 product
direction
3-5 May 2010 Boston, MA, USA
Westin Copley Place
For more information:
Email: [email protected] or [email protected]: http://www.aspentech.com/aspenoneglobalconference
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© 2010 Aspen Technology, Inc. All rights reserved | 60
Dr. Mohammad KhoshkbarchiSenior Project Manager, Process EcologyEmail: [email protected]
Dr. Glenn DissingerDirector, Product Management, AspenTechEmail: [email protected]
Sanjeev MullickDirector, Product Marketing, AspenTechEmail: [email protected]