The Use of MPG Gasification for Upgrading Canadian Oil Sands"

Transcription

1 The Use of MPG Gasification for Upgrading Canadian Oil Sands" Ulrich Wolf, Holger Schlichting, Stefan Walter, Lurgi AG Jim Quinn, North West Upgrading Inc Gasification Technology Conference JW Marriott, Washington, DC October 1-4, 2006 Lurgi AG

2 Overview Basics of Heavy Oil and Oils Sands Business Products produced from syngas NWU-Hydrogen Unit Technology Selection Acid Gas Removal Challenges CO-Shift Variants 2

3 World Reserves Currently, 90% of production is from conventional oil Production of heavy oil and bitumen are growing rapidly Canada and Venezuela together have >35% of the non-conventional oil reserves in sands Source: SPE International Conventional Oil - 30% Heavy Oil 15% Extra Heavy and Bitumen 55% World Oil in Place Conventional <100 cp Heavy Oil cp Bitumen >10,000 cp 3

4 Future of Conventional Oil 2001 predictions: Demand +1.5%/yr Less replacement World production peaks in ~ Middle East now at 30%, 50% by 2011 Conventional Oil Prediction in Red Total Need Prediction in Blue Dots Q- BB/yr 20 ~29-31 Heavy oil, bitumen, & other sources Campbell and Laherrère March Campbell 1998 and Scientific Laherrère American, March 1998 p. Scientific 78 ff American, p. 78 ff Source: SPE International 4

5 Process routes from heavy oil gasification Fuel Gas Fischer Tropsch Synthesis Upgrading LPG Naphtha Diesel Megammonia Waxes Ammonia Gasification Mega- Methanol Lurgi proprietary process MTC MtSynfuels MTP MTO MtPower MTH Acrylic Acid Fuel Cells Chemicals (MTBE, Acetic Acid, Formaldehyde,...) Diesel, transport. fuels Propylene/Polypropylene Acrylic Acid/Acrylates Ethylene/Propylene Power/Fuel/DME(Diesel) Hydrogen 5

6 MPG: Waste Heat Boiler Configuration 6

7 MPG: Quench Configuration Feedstock O 2 / Steam Gas Scrubbing CO-Shift MP-Boiler Final Cooler Raw Gas to AGR Metals Ash Process Water 7

8 Soot water handling Lurgi Mars System 8

9 The North West Upgrader Diluent Recycle to Wellhead Fuel Gas / LPG Bitumen Feed Atmospheric Distillation Light End Recovery Acid Gas Removal Vacuum Distillation Hydrotreating Unit Product Stabilization SynCrude to Pipeline Hydrocracker Unit Hydrogen Claus Unit Sulfur Hydrocracked Heavy Residue Hydrogen Unit Carbon Dioxide 9

10 Objectives of Hydrogen Unit Maximize Hydrogen Production Minimize Investment No HP-Steam Consumers Low Value of Fuel Gas Keep Open Options for CO 2 Usage 10

11 North West Upgrading Licensor Selection Criteria All Required Technologies from One Licensor Gasification, Acid Gas Removal, CO-Shift, H 2 -Purification Single Line Responsibility for Hydrogen Unit Multi Purpose Gasification (MPG) Lurgi s Experience and Commercial References of MPG Large Feedstock Flexibility Robust Burner Quick Restart Option Acid Gas Removal (AGR) } High Availability and Reliability Lurgi s Know-How to select most suitable process 11

12 Sulfur Balance of Upgrader Determines AGR Process Selection Diluent Recycle to Wellhead Fuel Gas / LPG Bitumen Feed Sulfur = 15 t/h Atmospheric Distillation Vacuum Distillation Hydrocracker Unit Sulfur = 2 t/h Carbon = 44 t/h Light End Recovery Hydrotreating Unit Hydrogen Hydrogen Unit Product Stabilization Acid Gas Removal Claus Unit SynCrude to Pipeline Sulfur = 13 t/h Feed to Claus H 2 S < 12% Carbon Dioxide CO 2 = 155 t/h Sulfur 12

13 Selection of Appropriate Gas Purification Process Product Gas Purity Rectisol ppm H 2 S + COS ppm CO 2 Selective AGR 5 50 ppm H 2 S, no COS removal Purisol / Selexol Selective Amine Treating MDEA 3 50 ppm H 2 S, no COS removal Bulk Amine Treating amdea 1 50 ppm H 2 S 5 50 ppm CO 2 13

14 MPG based H 2 Plant Feedstock LP-Steam Pure Impure CO 2 CO 2 Low High BTU BTU S > Low 100 Sulfur ppm Fuel Fuel Gas Gas Steam MPG Quench Raw Gas Shift Gas Cooling Selective Rectisol AGR Methanation PSA 97% Hydrogen O 2 H 2 S+CO 2 Sulfur Carbon Slurry O 2 OxyClaus Claus Off-Gas ASU MARS Waste Water Treatment Process Water Air Metals/Ash 14

15 Clean Shift vs. Raw Gas Shift Raw Gas Shift Quench mode of gasifier Complete Gas Stream Steam Generation and low grade Heat Supply Process Condensate Clean Shift Split of syngas WHB downstream of gasification Almost no Waste Water Internal Reaction Heat Recovery 15

16 CO-Shift Experience? 133 CO-Shift Units built 18 Clean CO-Shift Units downstream of Oil Gasification Total capacity 1.7 Mio Nm3/h syngas (=1 500 MMSCFD) (equivalent to 1.6 Mio Nm3/h hydrogen = MMSCFD) Largest train Nm3/h syngas (= 170 MMSCFD) (equivalent to Nm3/h hydrogen = 155 MMSCFD) 9 Raw Gas Shift units Total capacity 1.9 Mio Nm3/h syngas (= MMSCFD) (equivalent to 0.8 Mio Nm3/h hydrogen = 710 MMSCFD) Largest train Nm3/h syngas (= 420 MMSCFD) (equivalent to Nm3/h hydrogen = 140 MMSCFD) 16

17 Contact : Ulrich Wolf Director Syngas Technology Phone ulrich.wolf@lurgi.com Jim Quinn Vice President Engineering North West Upgrading Inc. Calgary, Alberta, Canada Comments? Stefan Walter Process Manager MPG Phone stefan.walter@lurgi.com Lurgi AG Frankfurt am Main, Germany Internet: 17