SIMULATION OF OIL SHALE RETORTING USING THE · PDF filePETRONAS – An Overview...
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© 2006 PETROLIAM NASIONAL BERHAD (PETRONAS)
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SIMULATION OF OIL SHALE RETORTING USING
THE ICON© STEADY STATE MODEL
Shahrul Azman Zainal Abidin
PETRONAS Group Technology Solution
Ahmad Junaidi Jalaludin
PETRONAS Group Technology Solution
Dr. Omar Bekri
CHAPEM Consultants, Morocco
PETRONAS – An Overview
PRESENTATION OUTLINE
Introduction to Malaysia
Shale Oil Modeling
Questions
INTRODUCING MALAYSIA
• A NATION AT THE HEART OF SOUTH EAST ASIA• NEIGHBOURING THAILAND, SINGAPORE AND INDONESIA• POPULATION OF ABOUT 25 MILLION
INTRODUCING MALAYSIA
• A MODERNIZING NATION BLENDED WITH A MULTICULTURAL SOCIETY RICH IN THE ARTS, TRADITION AND NATURAL BEAUTY
INTRODUCING MALAYSIA
• FULL OF NATURAL WONDERS
INTRODUCING MALAYSIA
• HISTORY & HERITAGE
INTRODUCING MALAYSIA
• MODERN INFRASTRUCTURE
PETRONAS and Formula 1
PETRONAS – An Overview
PRESENTATION OUTLINE
Introduction to Malaysia
Shale Oil Modeling
Questions
PETRONAS’ Corporate Profile
PETRONAS is the national oil corporation of Malaysia.
PETRONAS was incorporated on 17th August 1974, vested with the entire ownership and control of the petroleum resources in Malaysia.
PETRONAS also competes with other multinational oil companies operating in the downstream sector of the petroleum industry.
Over the last 32 years, PETRONAS has evolved into a fully integrated oil and gas multinational corporation with global presence in 31 countries.
1970s1970s 1980s1980s 1990s1990s 2000s2000s
PSC ManagerPSC Manager PSC & Project Manager/Operator PSC & Project Manager/Operator -- Integrated Oil CompanyIntegrated Oil Company Global PlayerGlobal Player
Vision: To be a leading oil and gas multinational of choice
We are a business entity
Petroleum is our core business
Our primary responsibility is to develop and add value to this national resource
Our objective is to contribute to the well being of the people and the nation
MISSION
PETRONAS – An Integrated Petroleum Company
LNGLNG
GasGas
MarketingMarketing
ShippingShipping
PetchemPetchem
ExplorationExploration
CorporateCorporate
OilOil
RefiningRefining
ProductionProduction
PETRONAS Group Comprises 127 Direct Subsidiaries and 54 Associated Companies
Wholly Owned Subsidiaries
105
Overseas Domestic
64 41
Associated Companies
54
Overseas Domestic
33 21
Partly Owned Subsidiaries
22
Overseas Domestic
4 18
Status as at 31.3.2006
PETRONAS – An Integrated Petroleum Company
EXPLORATION &PRODUCTION
CONDENSATESCONDENSATES
PROCESSINGPROCESSING
LIQUEFACTIONLIQUEFACTION LNG
REFININGREFINING
CRUDE OILCRUDE OIL
MARKETING FACILITIESMARKETING FACILITIES
PETROLEUM PRODUCTSPETROLEUM PRODUCTS
LPGLPG
SALES GASSALES GAS
FERTILISERSFERTILISERS
LNGLNG
OIL
GAS
AROMATICSAROMATICS PETROCHEMICALPETROCHEMICAL
PETRONAS has interests in 30 countries worldwidePETRONAS has interests in 30 countries worldwide
UPSTREAM (14 countries)
AlgeriaAngolaBenin
Equatorial GuineaEthiopia
IranMauritaniaMoroccoMyanmar
MozambiqueNiger
PakistanTurkmenistan
Yemen
ChadCameroonEgyptIndonesia
UPSTREAM & DOWNSTREAM(8 countries)
PhilippinesSudanVietnamMalaysia
Australia ArgentinaCambodiaChina
IndiaSouth AfricaThailandUnited Kingdom
DOWNSTREAM (8 countries)
Organisational Structure of PETRONASOrganisational Structure of PETRONAS
MANAGEMENT COMMITTEE
BOARD AUDIT COMMITTEE
EDUCATIONDIVISION
FINANCE DIVISION
HUMAN RESOURCE
DIVISION
RESEARCH & TECHNOLOGY
DIVISION
CORPORATE HSE
INTERNAL AUDIT
CORPORATE SECURITY
PRESIDENT’S OFFICE
LEGAL AND CORPORATE AFFAIRS
REGIONAL OFFICES
OILBUSINESS
GASBUSINESS
PETROCHEMICAL BUSINESS
BOARD OF DIRECTORS
PRESIDENT AND CHIEF EXECUTIVE
E & P BUSINESS
CORPORATE PLANNING & DEVELOPMENT
DIVISION
Organisational Structure of PETRONASOrganisational Structure of PETRONAS
MANAGEMENT COMMITTEE
BOARD AUDIT COMMITTEE
EDUCATIONDIVISION
FINANCE DIVISION
HUMAN RESOURCE
DIVISION
RESEARCH & TECHNOLOGY
DIVISION
CORPORATE HSE
INTERNAL AUDIT
CORPORATE SECURITY
PRESIDENT’S OFFICE
LEGAL AND CORPORATE AFFAIRS
REGIONAL OFFICES
OILBUSINESS
GASBUSINESS
PETROCHEMICAL BUSINESS
BOARD OF DIRECTORS
PRESIDENT AND CHIEF EXECUTIVE
E & P BUSINESS
CORPORATE PLANNING & DEVELOPMENT
DIVISION
RESEARCH & TECHNOLOGY DIVISION
Group Research & Technology Mgt
Policy, strategy & directionTechnology Condition
DiagnosticsConsolidation of business
technology requirementsTechnology fore-sightingVenture capital management
Group Technical Capability MgtPolicy, strategy, guidelines &
systemTechnical staff development
plan, career progression and movement
Technical knowledge sharingGroup Research
Applied researchFundamental research
Group Technology SolutionPlant Performance
ManagementPlant Project StudiesEngineering ExpertiseKnowledge Management
Note : * Plant include E&P facilities, pipelines, and downstream plants
GroupTechnicalCapability
Mgmt
GroupResearch
Group Technology
Solution
VP Office
OGPTSSB
PRSSSB
AERSB
PTSSB
Legal Entities Research and Technology Division
PETRONAS GROUP TECHNOLOGY SOLUTION
Group *Plant Performance Mgt
Engineering *Plant Project Studies
Knowledge Mgt (KM)
Performance Improvement Mgt
Process & Hydrocarbon Value
Chain Mgt
Asset Reliability & Integrity Mgt
Process Engineering
Plant Engineering
Process Automation & Optimisation Technology
Development
Technical Studies
Technical Assurance
KM Strategy, Planning & Dev’t.
KM Asset Mgt
Group Technology Solution
Plant modelling
Advanced Process Control
Real Time Optimization
PETRONAS – An Overview
PRESENTATION OUTLINE
Introduction to Malaysia
Shale Oil Modeling
Questions
SHALE OIL MODELLING: INTRODUCTION
• Why model shale oil?– To pursue knowledge and expertise in shale oil– To provide fundamental understanding in shale oil reactions and
processing capabilities• The necessity to understand the basic reaction mechanism/ discarding other
side reactions to ensure proper development in shale oil program– Use of iCON, PETRONAS’s own steady state process simulation
software
• PETRONAS direction in acquiring alternative sources of fuel– Potential of shale oil– Opportunities in developing new technology
INTRODUCTION TO ICON
Steady state process simulator
VMGThermo
Open source simulation kernel Microsoft
productivity tools
PRSS simulation kernel- Membrane- LNG Exchanger- Shortcut distillation- Vessel sizing- Vacuum pump- ……. etc
Proprietary & customized
Non-proprietary & literature based
PRSS GUI
METHODOLOGY
Modeling Approach
Experimental Methodology Mathematical Modeling
EXPERIMENTAL METHODOLOGY
• Thermo Gravimetric Analyzers (TGA) are used to obtain processed data for model (require sample of <50mg and crushed to <300μm)– Isothermal and non-isothermal operation possible– Non-isothermal TGA used
• Fast • Simple• Easier to manage information• Disadvantage is no detailed compositional analysis
N2
T~260-550ºC
Oil Vapor + N2
Oil Shale
Modeled Area
MATHEMATICAL MODELLING
• The modeling is based on the equation:
• Where– k1 and k2 are reaction rate constants – Arrhenius equations k1=k10e-E1/RT
– f1 represents the conversion of kerogen to oil & gas– f2 represents the conversion of bitumen to oil &gas
• Follows a 6-step process including an iteration procedure• Step 1
– Plot versus 1/V will provide
carbonresidualgasoil
bitumengasoil
Kerogen kk &&21 ⎯→⎯⎯→⎯
( )V
eERTk
kfMoRTE
dTdPV RTE 1..
1.
..ln1ln /12
10101 ⎟⎟
⎠
⎞⎜⎜⎝
⎛−+−=⎟
⎠⎞
⎜⎝⎛− −
tconsTdTdPV
tan
ln=
⎟⎠⎞
⎜⎝⎛−
RTEeRTEk
TA /1210 .1
)(1 −−=
)..ln()(1 101 kfMo1RTETB +−=
KEROGEN DECOMPOSITION
• Step 2: Find E1 and k10– Plot B1(T) vs. 1/T and obtain
• A2 = -E1/R so E1 = -A2.R• B2 = ln (Mo.f1k10)• Calculate k10= (E1.A1 (T)/RT2) eE1/RT from Step 1
• Step 3: Calculate f1
• Step 4: Refine values– Plot to obtain the slope & intercept
• Step 5: Use new k10 and E1 to calculate new f1• Step 6: Repeat Step 4 until achieve convergence
110
/1
1 Mofk
edTdPVP
RTE
−−=
( )V
eERTk
RTEkfMo
dTdPV RTE 1..
1.1..lnln /1
210
101 ⎟⎟⎠
⎞⎜⎜⎝
⎛−−=−⎟
⎠⎞
⎜⎝⎛− −
RTEeRTEk
TA /1210 .1
)(3 −−=
RTETB 1)(3 −=
BITUMEN DECOMPOSITION
• Need to find f2 in bitumen decomposition
• Plotting the LHS of equation as a function of 1/T gives a slope of – A4 = -E2/R – B4 = ln (k20)
• A value for f2 can be calculated
)ln(2.ln 20kRTE
dTdP
PoPV
+−=⎟⎠⎞
⎜⎝⎛
−−
)1.(.1
)1(11
12211 fMo
fMoPoforffMoMofPo
−−−
=−+=−
RESULTS
RESULTS
RESULTS
RESULTS
RESULTS
-Layer M1 Timahdit shale has an organic matter content of 15.28%-Fluidized bed on Timahdit sample utilizing 3kg/hr Hamburg continuous bench-scale facility-Layer Y Timahdit shale has an organic matter content of 24%
Sample Layer M1 Layer Y
TEST Fischer Assay TGA Fluidized Bed Fischer Assay
Sample Size 100 g 20mg 1.3 kg/hr 100g
Particle Size 3.3mm <150 µm 300-400 µm 3.3mm
Oil 7.2 16.5 11.3
Gas 1.7 6.0 3.7
Water 2.4 2.8 2.8
Carbon Residue 3.9 1.9 2.6 6.2
Spent Shale (Mineral) 84.3 84.8 72.1 76.0
Spent Shale (Total) 88.7 86.7 74.7 82.2
13.3
Results Summary
11.3 13.3
25.317.8
88.7 86.7
74.782.2
0.0
10.020.0
30.040.0
50.0
60.070.0
80.090.0
100.0
Fischer AssayM
TGA Model Fluidized Bed Fischer AssayY
Test Method
Wei
ght%
Oil+Gas+WaterSpent Shale(Total)
CONCLUSION
The model was based on the simplified kerogen and bitumen decomposition reactions – ignoring residual carbon in kerogen decomposition and carbonate decomposition reactions.
The main parameters from this model are the conversion of kerogen and bitumen into oil and gas which were represented by the values of f1 and f2.
The hydro-cracking and hydro-coking products from shale oil pyrolysis were discarded in the model.
The raw data obtained from TGA of Timahdit shale oil samples were used to validate the model that had been developed using Microsoft Visual Basic ®.
It was proven that the model is true for any type of heating.
CONCLUSION
The major limitation of the non-isothermal TGA analysis as the basis for this model was the inability to characterize the oil and gas composition due to the small sample mass used in the TGA.
Increase number of test data using different experiments to further validate the model and to ensure robustness of the shaleoil model.
Model embedded in iCON©, PETRONAS’ steady state process simulation software.
The model can be used as a tool to predict oil and gas production capacity for given shale sample.
WAY FORWARD
Extend study of the kerogen and bitumen decomposition reactions– To Include carbonate decomposition.– Varying the samples from different shale deposits to further validate the
model. – Validating model with existing shale mathematical models.
Consider results of isothermal operations or use of other retorting methods.
Include a more detailed reaction set as part of the model. – Most importantly hydro-coking and hydro-cracking reactions– Developing a new experimental methodology using other gas medium– More detailed mathematical derivation– Physical and chemical characterization with kinetics and reaction
mechanisms would also assist in the development of a more comprehensive model.
WAY FORWARD
Consider an extensive study on the effects of particle size, mass and heat transfer and reactor design on shale decomposition.
Consider the various aspects of shale oil upgrading such as oily fines and loss of oil along the line.
Improvements in the model to increase robustness and user friendliness.
The model would be tested using iCON© where further trials would be conducted and downstream processing of the shale oil (upgrading)would be possible.
ThankThankYouYou
PETRONAS – An Overview
PRESENTATION OUTLINE
Introduction to Malaysia
Shale Oil Modeling
Questions