PIPELINE TRANSPORTATION OF HEAVY OILS, A STRATEGIC, ECONOMIC
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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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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
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Where Does it Exist?
Heavy oil deposits total almost 5
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
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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
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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
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Implications of Poor Modeling
Incorrect wellhead conditions
Steam-Oil ratio
Properties prediction
Flash conditions: vapor when its 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
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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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Oil Properties Build PFDAssay 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
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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/Blend3.
Install the Oil in
the Flowsheet
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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
Bolining
Point(C)
IBP
FBP
IBPi FBPi
True Boiling Point (TBP)
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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
Volum e % Dist illed
Bolining
Point(C)
Heavy Oil TBP
0
200
400
600
800
1000
1200
0 20 40 60 80 100
Volum e % Dist illed
Bolining
Point(C)
True Boiling Point (TBP)
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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, @ 100F and @210F
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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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 theFlowsheet3.
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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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 flowrates, 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)
Viscosity(cSt)
Cut Viscosity vs . Final Bo iling Point
0
50000000
100000000
150000000
200000000
250000000
0 200 400 600 800 1000 1200
FBP (C)
Viscosity(cSt)
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 dontmatch. 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
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Checklist for Modeling Heavy Oils
Enter lab datadistillation 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 andconversion methods
Blend and cut assay using user cutpoint ranges
Compare plots of input data vs. calculated TBP curve,
gravity, viscosities, etc.
Install oil
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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
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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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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
Steam Assisted Gravity Drainage (SAGD)
Aspen HYSYS Model
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OPERATIONSDESIGN
Use model to make decisionsin all phases of operation
preheat, steam injection & oilproduction, and blowdown
Track and report keycomponentssulfur, 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.
Steam Assisted Gravity Drainage (SAGD)
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
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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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Recommendations for Heavy Oils
1.
For Assay data, generally suggest entering Gravity, BoilingPoint Range, Watson K;
For Heavy Crudes, recommend including ViscosityBulk 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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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 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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Recommendations for Heavy Oils
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 ManagerChapter 4, Aspen HYSYS OilManagerprovides 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
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
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Aspen HYSYS Training
Process Modeling (Refining Industry Focus) (EHY102)February 8, 2010 -- Virtual Americas
March 15, 2010 Houston, Texas
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY102
Optimize engineering work processes using the full power and
flexibility of Aspen HYSYS to build, evaluate and optimizeflowsheets.
Learn the shortcuts for efficient use of the software to build steadystate simulations for refining processes.
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY102http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY102 -
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Aspen HYSYS Training
Use and apply advanced modeling techniques to enhance exist ing
Aspen HYSYS flowsheets.
Create custom columns, including non-standard configurations.
Perform complex calculations on flowsheet variables.
Create models that emulate plant conditions.
Process Modeling Additional Topics (EHY201)February 4, 2010 Seoul, Korea
February 19, 2010 Virtual Americas
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY201
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY201http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY201http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY201http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY201 -
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AspenTech Training: Making it easy
Simply by participating today you have earned a training discountto help you get started
You do nothing AspenTechs Training Groupwill contact you to:
1. Provide you with the promotional discount codefor this event2. Review training dates and options with you3. Answer any questions you have
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On-Demand and Up-coming Webinars
On-Demand Webinars:
Over 50 recordings of past webinars on Engineering
Visit:
http://www.aspentech.com/events/ondemand_webinar.cfm Future Webinars:
Improving FEED Business Processes and Handover toDetailed Engineering Featuring: Guest speaker Eascon (Italy)
February 2, 2010
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Register at:
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aspenONE Global Conference
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pMay 3-5, 2010 in Boston, MA
Guest keynote speakers
Customer case studies
Roundtable discussions
Networking opportunities
Plus a few surprises!
Agenda includes
Early Bird Rate Now Available $1200 Expires March 27 *
* Regular rate = $1500; On-site rate = $1800 http://www.aspentech.com/aspenoneglobalconference/
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Focused sessions including:
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Format:
In-depth sessions on product families,solution areas and industry verticals
Panel discussions
Share best practices and experiences
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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:
Web: http://www.aspentech.com/aspenoneglobalconference
pMay 3-5, 2010 in Boston, MA
aspenONE Global Conference
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] -
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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 productdirection
3-5 May 2010 Boston, MA, USA
Westin Copley Place
For more information:
Email:
Web: http://www.aspentech.com/aspenoneglobalconference
pMay 3-5, 2010 in Boston, MA
More User Presentations.Track agendas are incorporating additional user presentations slotsup to 100 totalso
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
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news and what's ahead in product development.
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8/12/2019 Model Heavy Oils Slides
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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]
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