Technology Integration to Maximize Technology Integration to Maximize Value of Oil Sands ProductsValue of Oil Sands Products
Gasification Technology ConferenceGasification Technology ConferenceOctober 3, 2006October 3, 2006Washington DCWashington DC
Dave HolbrookDave HolbrookUOP LLCUOP LLC
AgendaAgenda
Oil Sands Processing ChallengesOil Sands Processing ChallengesUpgrading ConsiderationsUpgrading ConsiderationsSyngas Treating and Processing SolutionsSyngas Treating and Processing SolutionsIncremental Hydrogen StudiesIncremental Hydrogen StudiesIntegrated Integrated FlowschemeFlowscheme ExamplesExamples
Oil Sands Processing ChallengesOil Sands Processing ChallengesProcessing StrategyProcessing Strategy
–– Targeted product slateTargeted product slate–– Residue conversion approachResidue conversion approach–– Hydroprocessing severityHydroprocessing severity
Project ChallengesProject Challenges–– Total costsTotal costs–– Hydrogen requirements and sourcesHydrogen requirements and sources–– Energy demandsEnergy demands
COCO22 ManagementManagement–– Current or future considerationsCurrent or future considerations
Bitumen Upgrading Bitumen Upgrading Typical FlowTypical Flow--SchemeScheme
Residues
Distillates / Gas OilsDistillates / Gas Oils
ResidueUpgrading
Hydroprocessing
Synthetic Crude
UOP 4446I-43
HydrogenHydrogen
Dis
tilla
tion
Naphtha
DilutedBitumen
UnconvertedResidues
PSAPSASteam Methane
Reforming
NaturalNaturalGasGas
UOP Technologies
Tail GasTail Gas
Bitumen Upgrading with Gasification Bitumen Upgrading with Gasification FlowFlow--SchemeScheme
Residues
Distillates / Gas OilsDistillates / Gas Oils
ResidueUpgrading
UOP 4446I-43
HydrogenHydrogen
SyngasTreatingGasification PSAPSAPSA
Tail GasAcid Gas
Naphtha
DilutedBitumen D
istil
latio
n
UnconvertedResidues
Hydroprocessing
Synthetic Crude
UOP Technologies
Hydrogen BalanceHydrogen BalanceA Key to Upgrading SuccessA Key to Upgrading Success
Knowing how much and Knowing how much and where to put hydrogenwhere to put hydrogenHow to produce low cost How to produce low cost HydrogenHydrogenIntegrating both consumers Integrating both consumers and producers of hydrogenand producers of hydrogen
Knowing how much and where to put Knowing how much and where to put Hydrogen Impacts:Hydrogen Impacts:
Integration OpportunitiesIntegration Opportunities
–– Product Quality Selection and FlexibilityProduct Quality Selection and Flexibility
–– Capital CostsCapital Costs
–– Operating CostsOperating Costs
UOP Integrated Hydroprocessing UOP Integrated Hydroprocessing FlowFlow--SchemeScheme
HotHotSeparatorSeparator
HotHotFlashFlashDrumDrum
ColdColdSeparatorSeparator
ColdColdFlashFlashDrumDrum
AmineAmineScrubberScrubber
Vacuum Gas Oil Vacuum Gas Oil
HH22RecoveryRecovery
UOP 4267A-19
HotHotSeparatorSeparator
withwithPost Post ––TreatTreat
BedBed
DistillatesDistillates
DeasphaltedDeasphaltedOilOil
FractionatorFractionator
Synthetic CrudeSynthetic Crudeoror
Finished productsFinished products
MakeMake--upup
H2H2
ReactorsReactors
Recycle H2Recycle H2
SteamSteam
Gasification
Claus Sulfur Plant
Combined Cycle Unit
Air Separation Unit
Gas Cooling &CO Shift
Residue Residue FeedFeedStockStock
OO22
NN22
SulfurSulfurHH22SS
HH22,, CO,CO, COCO22 PowerPower
HH22Syngas treating& Separation
H2S, HH2S, H2 2 CO,CO, COCO22
COCO22
Typical Gasification Complex Can Typical Gasification Complex Can Produce Steam, Power, and HydrogenProduce Steam, Power, and Hydrogen
Regions of Use for Acid Gas TechnologiesRegions of Use for Acid Gas Technologies10001000
100100
1010
1.01.0
0.10.1Part
ial p
ress
ure
of a
cid
gas i
n fe
ed, p
sia
Part
ial p
ress
ure
of a
cid
gas i
n fe
ed, p
sia
Partial pressure of acid gas in product, psiaPartial pressure of acid gas in product, psia0.0010.001 0.010.01 0.10.1 1.01.0 1010 100100
Amine GuardTM FS
Process
MOLSIVTM
Scavengers
SelexolTM
ProcessBenfieldTM
ProcessSeparexTM
Membrane
UOP 4446I-11
PolybedTM
PSA
Syngas Treating TechnologiesSyngas Treating Technologies10001000
100100
1010
1.01.0
0.10.1Part
ial p
ress
ure
of a
cid
gas i
n fe
ed, p
sia
Part
ial p
ress
ure
of a
cid
gas i
n fe
ed, p
sia
Partial pressure of acid gas in product, psiaPartial pressure of acid gas in product, psia0.0010.001 0.010.01 0.10.1 1.01.0 1010 100100
Amine GuardTM FS
Process
SelexolTM
Process
UOP 4446I-12
What is the SelexolWhat is the Selexol Process? Process?
AAbsorption/regeneration process for selective bsorption/regeneration process for selective removal removal of Hof H22S, COS, & COS, COS, & CO22
–– PhysPhysical solventical solvent–– Typical solventTypical solvent--extraction flowextraction flow--schemescheme
Product QualityProduct Quality–– Can be essentially sulfur freeCan be essentially sulfur free–– Project specific COProject specific CO22 slip or captureslip or capture–– Project specific acid gas HProject specific acid gas H22S concentrationS concentration
UOP 4446I-18
Selexol ProcessSelexol ProcessHydrogen Production FlowHydrogen Production Flow--SchemeScheme
HH22S AbsorberS Absorber
Acid GasEnrichment
StripperStripper
COCO22 AbsorberAbsorberXXXXX
Acid Acid GasGas
ExportExportWaterWater
FeedFeedGasGas
RawRawHH22
RawRawCOCO22
UOP 4446I-39
Selexol ProcessSelexol ProcessCommercial ExperiencesCommercial Experiences
56 operating units56 operating units–– Both Natural Gas and Gasification applicationsBoth Natural Gas and Gasification applications
Recent Gasification ApplicationsRecent Gasification Applications–– Sarlux IGCC Sarlux IGCC -- Sardinia, ItalySardinia, Italy–– API IGCC API IGCC –– Falconara, ItalyFalconara, Italy–– Coffeyville Resources NHCoffeyville Resources NH33/UAN /UAN -- USAUSA–– Syngas treating Syngas treating -- Alberta, CanadaAlberta, Canada
Coal to Power Applications Coal to Power Applications –– US locationUS location–– Presently being designed for multiple UnitsPresently being designed for multiple Units
UOP 4446I-22
UOP Syngas Processing SolutionsUOP Syngas Processing Solutions
PolysepMembrane
PolysepPolysepMembraneMembrane
Fischer TropschFischer Fischer TropschTropsch
Polybed PSAPolybed PSAPolybed PSA
UnicrackingUnicrackingUnicracking
PowerPower
PolysepTM
MembranePolysepPolysepTMTM
MembraneMembrane PolybedTM PSAPolybedPolybedTMTM PSAPSA Power + HPower + H22
Ammonia Ammonia
TransportationTransportationFuelsFuels
Methanol Methanol
Polybed PSAPolybed PSAPolybed PSA HH22 OnlyOnly
-- COCO22-- COCO-- HH22-- HH22SS-- COSCOS
Syngas Syngas
HH22SS
SelexolSelexol
UOP 4446I-24
Hydrogen BalanceHydrogen BalanceA Key to Upgrading SuccessA Key to Upgrading Success
Knowing how much Knowing how much hydrogen is neededhydrogen is needed
How to produce low cost How to produce low cost HydrogenHydrogen
Integrating both consumers Integrating both consumers and producers of hydrogenand producers of hydrogen
For Increased Hydrogen For Increased Hydrogen Production RequirementsProduction Requirements
CO shift added on syngas:CO shift added on syngas:–– Increased hydrogenIncreased hydrogen–– Increased COIncreased CO2
COCO22 Absorber included in SelexolAbsorber included in Selexol–– COCO22 recovered at high pressurerecovered at high pressure–– Minimizes COMinimizes CO22 content of treated gascontent of treated gas
Reduces PSA SizeReduces PSA Size–– Minimizes tail gasMinimizes tail gas
Gasification for Power and Gasification for Power and Hydrogen ProductionHydrogen Production
Polysep Membrane
Gas Cooling& COS
Hydrolysis
ElectricElectricPowerPower
Raw HydrogenRaw Hydrogen
ElementalElementalSulfurSulfur
SteamSteamforfor
ExportExport
OO22
FeedFeedClaus Plant
AirAir
High Purity HydrogenHigh Purity Hydrogen
Gasifierwith Quench& Scrubbing
Selexol
Air Separation Unit
Combined Cycle Power
Plant
PolybedPSA
Tail GasTail Gas
Purified SyngasPurified Syngas
UOP 4375F-12
Gasification for Max Hydrogen Gasification for Max Hydrogen and COand CO22 Capture Capture
Air SeparationUnit
AmmoniaSynthesis
NN22
PolybedPSA
UAN Plant
NHNH3 3 ProductProduct
UANUANProductProduct
OO22 High Purity HydrogenHigh Purity Hydrogen Purified COPurified CO22
QuenchGasification
SyngasScrubbing
CO Shift & Gas Cooling
Selexol2-stage
Petroleum Petroleum CokeCoke
Tail GasTail Gas
AirAir
Claus Plant
Acid GasAcid Gas
Raw CORaw CO22
CO2Purification
COCO22 VentVentRaw HRaw H22
UOP 4446I-38UOP Technologies
Syngas Treating/Separation Syngas Treating/Separation Relative Hydrogen ProductionRelative Hydrogen Production
0
20
40
60
80
100
IGCCApplication
H2 + LowPress Fuel
H2 + MedPress Fuel
High H2 Max H2
Unshifted GasUnshifted Gas ShiftedShifted GasGas
% recovery % recovery of of
available available HH
22
Syngas Treating/SeparationSyngas Treating/SeparationRelative OpexRelative Opex
0
0.5
1
1.5
2
2.5
3
IGCC H2 + LowPress Fuel
H2 + MedPress Fuel
High H2 Max H2
Unshifted GasUnshifted Gas ShiftedShifted GasGas
Purification Options ImplicationsPurification Options Implications
+2%+2%
+5%+5%
99.399.3
98%98%
PSA with PSA with (Tail Gas (Tail Gas Recycle)Recycle)
+10%+10%BaseBaseImpact on Impact on Hydrocracker Hydrocracker PressurePressure
+20%+20%BaseBaseImpact on Impact on Hydrocracker Hydrocracker Catalyst Catalyst VolumeVolume
97%97%99.999.9HydrogenHydrogenPurityPurity
9797--98%98%8888--90%90%Hydrogen Hydrogen RecoveryRecovery
MethanationMethanationPSAPSA(Conventional)(Conventional)
Hydrogen BalanceHydrogen BalanceA Key to Upgrading SuccessA Key to Upgrading Success
Knowing how much Knowing how much hydrogen is neededhydrogen is needed
How to produce low cost How to produce low cost HydrogenHydrogen
Integrating both consumers Integrating both consumers and producers of hydrogenand producers of hydrogen
Selexol
Upgrading and GasificationUpgrading and GasificationConventional Hydrogen Supply Conventional Hydrogen Supply FlowschemeFlowscheme
Residues
Distillates / Gas OilsDistillates / Gas OilsUnionfiningUnicrackingResidue
Upgrading
Gasification
Synthetic Crude / Refined Fuels
Syngas Polybed PSA
Syngas Polybed PSA
UOP 4446I-43
PlantPolybed PSA
PlantPolybed PSA
High Purity HHigh Purity H22
CO2 RichTail Gas
To PlantFuel System
Flash Gas
RichAcid Gas
SelexolCOShift
Upgrading and Gasification Upgrading and Gasification UOP Proprietary Maximum Hydrogen SupplyUOP Proprietary Maximum Hydrogen Supply
Residues
UnionfiningUnicracking
ResidueUpgrading
Gasification
Synthetic Crude / Refined Fuels
UOP 4446I-43
High Purity HHigh Purity H22
Tail Gas
Flash GasFlash Gas
RichAcid Gas
Polybed PSA(96-98% Recovery)
Polybed PSAPolybed PSA(96(96--98% Recovery)98% Recovery)SelexolCO
ShiftRawRaw
SyngasSyngas
Distillates / Gas OilsDistillates / Gas Oils
CO2 CO2
Purification Options ImplicationsPurification Options Implications
+2%+2%
+5%+5%
99.399.3
98%98%
PSA with PSA with (Tail Gas (Tail Gas Recycle)Recycle)
BaseBase
BaseBase
99.999.9
9696--98%98%
PSAPSA(Integrated)(Integrated)
+10%+10%BaseBaseImpact on Impact on Hydrocracker Hydrocracker PressurePressure
+20%+20%BaseBaseImpact on Impact on HydrocrackerHydrocrackerCatalystCatalystVolumeVolume
97%97%99.999.9HydrogenHydrogenPurityPurity
9797--98%98%8888--90%90%Hydrogen Hydrogen RecoveryRecovery
MethanationMethanationPSAPSA(Conventional)(Conventional)
Value of Integrated ApproachValue of Integrated Approach
SummarySummary
Integrated solutions provide the best Integrated solutions provide the best opportunities to maximize marginsopportunities to maximize margins
UOP’s Hydroprocessing technologies UOP’s Hydroprocessing technologies offer unique and optimal solutions to offer unique and optimal solutions to meet product objectivesmeet product objectives
UOP has the complete technology UOP has the complete technology package for syngas treating, hydrogen package for syngas treating, hydrogen recovery and purificationrecovery and purification
UOP has commercial experience for UOP has commercial experience for gasification applicationsgasification applications
Technology Integration to Maximize Technology Integration to Maximize Value of Oil Sands ProductsValue of Oil Sands Products
Gasification Technology ConferenceGasification Technology ConferenceOctober 3, 2006October 3, 2006Washington DCWashington DC
Thanks for your time and attentionThanks for your time and attention
