Odw Heavy Oils Slides

Modeling Heavy Oils in Aspen HYSYS
Engineering Excellence Webinar Series 26 January 2010
2010 Aspen Technology, Inc. All rights reserved
Modeling Heavy Oils in Aspen HYSYS

Dr. Mohammad Khoshkbarchi
Senior Project Manager, Process Ecology Email: mohammad@processecology.com
Sanjeev Mullick
Director, Product Marketing, AspenTech Email: Sanjeev.Mullick@aspentech.com
http://support.aspentech.com
Agenda
Heavy Oil Overview Best Practices for Modeling Heavy Oils in Aspen HYSYS Sample Applications Recommendations and Conclusions Q&A
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
Comparative Oil Properties

Oil Viscosity:
Conventional Crude Conventional Heavy Thermal Heavy Diluent

Oil API:
<~ 30,000 cSt 30,000 40,000 cSt 200,000 250,000 cSt 0.5 11.0 cSt > 25 API 25 18 API 20 12 API 12 7 API
|
Conventional Crude Conventional Heavy Extra Heavy (Thermal) Tar Sand
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
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
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
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
Agenda
10
Best Practices Workflow Assay Setup

Enter Assay lab data Check Correlation set Verify/alter Extrapolation & Conversion Methods
Oil Properties
Enter User Cutpoint ranges Blend Assay & Cut into Hypos Compare Property Plots Install Oil
Build PFD
Blend Oil & Water streams Alter emulsion viscosity, if necessary Incorporate entrainment Use Utilities to check products
11
Oil Characterization in Aspen HYSYS

Purpose: convert lab analyses hypothetical components 3 steps in Oil Characterization:
1. 2. Characterize the Assay Generate Pseudo Components Cut/Blend Install the Oil in the Flowsheet
Aspen HYSYS library and
3.
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True Boiling Point (TBP)

FBP
True Boiling Point Curve
1200 1000 Bolining Point (C) 800 600 400 200 0
IBPi
FBPi
Alternative Methods: ASTM D86 (atmospheric batch distillation) ASTM D1160 (vacuum batch distillation) ASTM D2887 (chromatography) Usually unsuitable for heavy crudes
2010 Aspen Technology, Inc. All rights reserved |
IBP
20
40
60
80
100
Volum e % Distilled
13
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
14
True Boiling Point (TBP)

Conventional Oil TBP
800 700 600 Bolining Point (C) 500 400 300 200 100 0 -100 0 20 40 60 80 100
Heavy Oil TBP

1200 1000 Bolining Point (C) 800 600 400 200 0 0 20 40 60 80 100 Volum e % Distilled
Volum e % Distilled
Heavy oil TBP has much fewer experimental points No FBP or close point to it
15
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
16
Best Practices Specify Properties for Heavy Oils
Bulk property options include:

Molecular Weight > 16 Mass Density = 250 ~ 2000 kg/m3 Watson K Factor = 8 ~ 15 Bulk Viscosity, @ 100F and @210F Required Recommended Required
Add other property curves

Molecular Weight curve Density curve Viscosity curve (two curves) Recommended Recommended
17
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
18
Best Practices Creating Hypotheticals for Heavy Oils

When generating pseudocomponents for heavy oil fractionation, recommend using User Points or User Defined Ranges How many?
Minimum of 4 pseudocomponents 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?

19
True Boiling Point (TBP) 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
1200 1000 B o lin in g Po in t (C ) 800 600 400 200 0 0 20 40 60 80 100 Volume % Distilled
Solution: Use a guide point such as FBP or IBP Use other distribution
20
Best Practices Predict Heavy Oil Fractions

Use the Distribution Plot to help predict crude products
Enter custom cuts to 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?

21
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!
22
Best Practices Stream 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
23
Aspen HYSYS Can Accurately Predict Important Heavy Crude Properties 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
24
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
25
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 can result 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.
26
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.
27
Curve Fitting Options For each input curve, can specify:

Curve Includes L.E. Bulk Value Bulk Value Incl. L.E. Head % Head Adjust Weight Main % Main Adjust Weight Tail Adjust Weight
28
Curve Fitting Options Example 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)
29
Curve Fitting Options Example
30
Curve Fitting Options Example 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 readjust the curve to the overall crude
Solution: Choose to fit with or without light ends, as appropriate:

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
31
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.
32
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
33
Heavy Crude Viscosity Trends
Full Crude Viscosity vs. Temperature

120000 Viscosity (cSt) 100000 80000 60000 40000 20000 0 0 50 100 150 Temperature (C)
Viscosity (cSt) 250000000 200000000 150000000 100000000 50000000 0
Cut Viscosity vs. Final Boiling Point
200
400
600 FBP (C)
800
1000 1200
Use two points from full crude viscosity curve. High FBP viscosities are usually a result of extrapolation using a log(log) approach.
34
Viscosity Curves Example Problem and Solution Problem: Calculated and inputted viscosity values dont 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 extrapolation 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
35
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
36
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
37
Example: Improving Thermal Conductivity
Alter coefficients
Regress data
38
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 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
39
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
40
Agenda
41
Steam Assisted Gravity Drainage (SAGD)
RECOVERED DILUENT/SCO DILUENT/ SYNTHETIC CRUDE
Gas Treating
SOUR GASES GAS
SWEET GASES
Well Pad Emulsion
Gas-OilWater Separation
WATER
OIL [DILBIT/ SYNBIT]
To Upgrader or Pipeline
STEAM/HEAT
Steam Generation
42
Steam Assisted Gravity Drainage (SAGD)

Aspen HYSYS Model
GAS TREATMENT Make up Streams
Well Pad
DilBit Diluent To Upgrader or Pipeline
OIL TREATMENT
STEAM GENERATION
WATER TREATMENT
43
Steam Assisted Gravity Drainage (SAGD) DESIGN

Model wellpad characteristics Model separation of water, oil, and gas phases
Additions of diluent and/or solvents, their flow conditions, separation scheme & recovery Bitumen treatment and recovery Steam generation Water treatment (incl. softening)
OPERATIONS
Use model to make decisions in all phases of operation preheat, steam injection & oil production, and blowdown Track and report key componentssulfur, etc. Determine how operating improvements
Increase bitumen separation/ recovery Reduce energy requirements Improve water usage
Perform profit calculations (upgrade to SCO or sell) Consider new technology partial upgrading in-situ, combustion, VAPEX, etc.
44
Agenda
45
Recommendations for Heavy Oils

1. For Assay data, generally suggest entering Gravity, Boiling Point Range, Watson K; For Heavy Crudes, recommend including ViscosityBulk 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: Light Hydrocarbons: Hydrogen Rich: Sour Water: Peng Peng Peng Peng Robinson with Lee-Kesler Enthalpies Robinson Robinson Robinson Sour
46

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
47

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 ManagerChapter 4, Aspen HYSYS Oil Managerprovides 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
48
Agenda
49
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Consider a training class from AspenTech
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50
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51
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For more information: Email: sanjeev.mullick@aspentech.com or dan.mccarthy@aspentech.com Web: http://www.aspentech.com/aspenoneglobalconference

59
Dr. Mohammad Khoshkbarchi Senior Project Manager, Process Ecology Email: mohammad@processecology.com Dr. Glenn Dissinger Director, Product Management, AspenTech Email: glenn.dissinger@aspentech.com Sanjeev Mullick Director, Product Marketing, AspenTech Email: sanjeev.mullick@aspentech.com
60

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Modeling Heavy Oils in Aspen HYSYS

Engineering Excellence Webinar Series 26 January 2010

2010 Aspen Technology, Inc. All rights reserved

Modeling Heavy Oils in Aspen HYSYS

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

What is Heavy Oil?

2010 Aspen Technology, Inc. All rights reserved

Comparative Oil Properties

Conventional Crude Conventional Heavy Thermal Heavy Diluent

Conventional Crude Conventional Heavy Extra Heavy (Thermal) Tar Sand

2010 Aspen Technology, Inc. All rights reserved

Where Does it Exist?

2010 Aspen Technology, Inc. All rights reserved

Where Does it Exist?

2010 Aspen Technology, Inc. All rights reserved

Challenges in Modeling Heavy Oils

Blending to match properties at wellhead

Phase entrainment/carryover Foaming Further effects of adding solvents

2010 Aspen Technology, Inc. All rights reserved

Implications of Poor Modeling

Large pressure gradients Unattainable separations

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

Best Practices Workflow Assay Setup

2010 Aspen Technology, Inc. All rights reserved

Oil Characterization in Aspen HYSYS

Aspen HYSYS library and

2010 Aspen Technology, Inc. All rights reserved

True Boiling Point (TBP)

1. Characterizing the Assay

2010 Aspen Technology, Inc. All rights reserved

True Boiling Point (TBP)

Heavy Oil TBP

2010 Aspen Technology, Inc. All rights reserved

1. Characterizing the Assay

2010 Aspen Technology, Inc. All rights reserved

Best Practices Specify Properties for Heavy Oils

Bulk property options include:

Add other property curves

2010 Aspen Technology, Inc. All rights reserved

Best Practices Creating Hypotheticals for Heavy Oils

Test accuracy of input assay data against generated hypotheticals

How well does my data match with Aspen HYSYS?

Best Practices Predict Heavy Oil Fractions

Approximately how much of every product will I get?

3. Installing the Oil

2010 Aspen Technology, Inc. All rights reserved

Best Practices Stream Utilities for Oils

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

2010 Aspen Technology, Inc. All rights reserved

Recommended selections for heavy oils are shown here

2010 Aspen Technology, Inc. All rights reserved

Curve Fitting Options For each input curve, can specify:

2010 Aspen Technology, Inc. All rights reserved

Curve Fitting Options Example Problem and Solution

2010 Aspen Technology, Inc. All rights reserved

Curve Fitting Options Example

2010 Aspen Technology, Inc. All rights reserved

Curve Fitting Options Example Problem and Solution

Solution: Choose to fit with or without light ends, as appropriate: