HEAVY CRUDE UPGRADING: AN OPTION FOR GASIFICATION
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1 / HEAVY CRUDE UPGRADING: AN OPTION FOR GASIFICATION Luigi Bressan Foster Wheeler Italiana Corporation Michael J. McGrath - Foster Wheeler USA Corporation Gasification Technologies Council Conference San Francisco, CA - October 2007 Insert file path on the 'Header and Footer' menu 1
2 Agenda Heavier crudes Upgrading schemes Crude Atmospheric and Vacuum Distillation Delayed Coking Unit Solvent Deasphalting Combination of Deasphalting and Coking Byproducts Gasification and conversion to power Material balances Economic analysis Conclusions
3 Heavier Crudes Global demand for crude increasing Light crudes becoming more expensive Crudes becoming heavier and higher in sulfur Large light/heavy price differential
4 Upgrading Schemes Typical Heavy Crudes Heavy Arabian Whole Crude Heavy ME Whole Crude Gravity, o API Viscosity, cs. at 70 o F ,033 Viscosity, cs. at 100 o F Pour Point, o F Sulfur, wt. % Nitrogen, wt. % Neut. No. mgkoh/gm
5 Upgrading Schemes CDU Synthetic Crude VDU IGCC Electric Power CASE 1: CDU+VDU+IGCC
6 Upgrading Schemes CDU Synthetic Crude VDU DCU IGCC Electric Power CASE 2: CDU+VDU+DCU+IGCC
7 Upgrading Schemes CDU Synthetic Crude VDU SDA IGCC Electric Power CASE 3: CDU+VDU+SDA+IGCC
8 Upgrading Schemes CDU Synthetic Crude VDU ASCOT IGCC Electric Power CASE 4: CDU+VDU+ASCOT+IGCC
9 Crude and Vacuum Distillation Typical refinery units used to separate products according to distillation range Simple, well proven and reliable units Capacities selected are in the highest range of units built worldwide In crude upgrading application can simplified and optimized to reduce investment and operating costs
10 Delayed Coking Delayed Coking SYDEC SM
11 Delayed Coking Full conversion of residue to distillates - Full range of lighter products - Complete decarbonization of residue feed - Complete metals removal Fuel-grade Coking: - Maximum yield of clean liquid products - Low pressure coking / ultra-low recycle coking Proven technology - Past experience: large available knowledge base on design, operations and maintenance Strong 3 rd party support services and equipment vendors Long turnaround periods: 5 years + Fast execution of projects: <28 months - Fewer budget surprises: $3,600 / BPSD - Short period of negative cash flow Modern designs are safe and clean
12 Delayed Coking
13 Heavy Crude Upgrading: An Opportunity for Gasification Solvent Deasphalting Solvent Deasphalting (FW/UOP Technology) Experience Extensive pilot plant and crude data base Well-proven technology 50+ units licensed (500 to 45,000 BPD) Excellent correlations of pilot plant runs and prediction of commercial operations Picture Picture Picture
14 Heavy Crude Upgrading: An Opportunity for Gasification Solvent Deasphalting Physical Separation of residues into: Deasphalted oil (DAO) Highly viscous, asphaltene-rich stream (Pitch) Separation is by density differences Light liquid paraffins precipitate asphaltenes and resins from heavy oils Non thermal process Utility optimization Upstream integration Eliminate heaters, hot oil heating system Extraction technologies Countered current designs utilizing structured packing Separation of DAO and solvent by: Sub-critical Super-critical
15 Solvent Deasphalting Vacuum Residue Charge Extractor DAO Separator Pitch Stripper DAO Stripper Pitch DAO
16 Solvent Deasphalting Sulfur, Nitrogen and Metals Appearing in Deasphalted Oil, % Sulfur & Nitrogen CCR Nickel Vanadium Deasphalted Oil Yield, Vol-%
17 Heavy Crude Upgrading: An Opportunity for Gasification Solvent Deasphalting Well-proven separation process Lower capital costs Light feeds Small sizes Lower operating costs Supercritical DAO-solvent separation
18 ASCOT Combination of deasphalting and coking The potential benefits of combining Solvent Deasphalting and Delayed Coking ASCOT SM
19 ASCOT Combination of deasphalting and coking Solvent Makeup Heat Integration Delayed Coker Fuel Gas Coker LPG Naphtha LCGO HCGO & DAO Vacuum Residue Solvent Deasphalter DAO Asphalt Coke
20 Byproducts Gasification and Conversion to Power IGCC
21 Byproducts Gasification and Conversion to Power Integrated Gasification Combined Cycle A way to dispose efficiently of heavy products regardless of their quality Outstanding environmental performance Allows full carbon rejection Proven technology Multi-unit complex with different peculiarities The gasification process leads to a syngas from which either hydrogen or CO 2 can be derived for use and disposal
22 Byproducts Gasification and Conversion to Power Nitrogen Air Separation Air HP Steam MP Steam LP Steam Electric Power Asphalt Partial Oxydation Syngas Treatment Acid Gas Removal Syngas Gas Turbine HRSG Metals Recovery and Water Treatment Sulphur Recovery Utilities Steam Turbine Metal Cake Waste Water Sulphur
23 Material Balances Technical Data Case 1 Case 2 Case 3 Case 4 CDU + CDU + VDU + DC CDU + VDU + SDA CDU + VDU + Description VDU+IGCC + IGCC + IGCC ASCOT + IGCC CDU Feed BPSD VDU Feed BPSD DC Feed BPSD SDA Feed BPSD ASCOT Feed BPSD IGCC Feed t/h 536,0 201,3 284,3 203,1 Synthetic Crude BPSD , , , ,0 t/h 776, , , ,6 API 28,0 24,9 20,1 21,0 % S 3,6 3,7 4,1 4,1 Power Production MW 2.507,2 596, ,4 592,2 Synth. Crude yield % vol 42,6 90,5 82,7 93,0
24 Material Balances Economical Case 1 Case 2 Case 3 Case 4 CDU + CDU + VDU + DC CDU + VDU + SDA CDU + VDU + Description VDU+IGCC + IGCC + IGCC ASCOT + IGCC BRENT Crude API 38,06 factors 0,007 $/$ of Brent % S 0,37 0,056 $/$ of Brent $/Barrel 80,0 ME Crude API 13,90 % S 5,17 $/Barrel 45,0 Synthetic Crude API 28,00 24,90 20,10 21,00 % S 3,55 3,70 4,11 4,10 $/Barrel 60,1 57,7 53,2 53,7 Electric Power $/MWh Investment Cost MM US$ 5683,7 2608,1 3432,1 2933,7 Simple Payout Period Year 19,86 2,39 4,04 2,86
25 Economical Analysis Reference CRUDE Value = 40 $/Barrel CDU/VDU CDU/VDU /DCU CDU/VDU /SDA CDU/VDU /ASCOT 50 $/MWh n.a. 5,01 8,73 6,04 75 $/MWh 9,59 4,07 5,36 4, $/MWh 5,19 3,43 3,87 4, $/MWh 3,56 2,97 3,02 3,49 Reference CRUDE Value = 60 $/Barrel 50 $/MWh n.a. 3,80 9,18 4,60 75 $/MWh 30,10 3,24 5,53 3, $/MWh 8,23 2,82 3,95 3, $/MWh 4,77 2,50 3,08 2,96 Reference CRUDE Value = 80 $/Barrel 50 $/MWh n.a. 3,07 9,69 3,72 75 $/MWh n.a. 2,69 5,71 3, $/MWh 19,86 2,39 4,04 2, $/MWh 7,22 2,16 3,13 2,56
26 Conclusions All cases considered have been selected to fit the proposed gas turbine s appetite (GE7FB) and the size of power plant in order to have refinery units of similar capacities for comparison reasons. Over the four cases considered the following conclusions can be drawn: 1. It is expected this kind of units would be installed close to oil fields in order to avoid transportation of difficult crudes and to generate electric power and deliver lighter synthetic crude 2. The units foreseen are simple and reliable non-catalytic units 3. Case 1 solution is justified only when crude is at low cost level with high electric power selling prices 4. Case 2 solution (the delayed coker) looks the more convenient and the more effective in the case where reference crude value increases and electric power selling prices decrease 5. The quality of the crude considered may change the results of this analysis, but the delayed coking based solution is the preferred one with most difficult crudes
27 Conclusions 6. Delayed Coking scheme may lead to light products with a certain degree of insaturation; the installation of hydrotreaters (in this case catalytic units) may considerably increase the quality of synthetic crude 7. Both Delayed Coking and Solvent Deasphalting units are well proven and very reliable process units. 8. Solvent Deasphalting and Delayed Coking can be integrated to obtain the benefits of both 9. Upgrading provides an opportunity to utilize gasification to eliminate low-value by-product and produce higher-valued products such as: power for site and export hydrogen for further upgrading chemicals products (methanol, SNG,.. Etc.)
28 / THANK YOU. Foster Wheeler Insert file path on the 'Header and Footer' menu 28
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