Heavy Oil Simulation

2010 Aspen Technology, Inc. All rights reserved 2010 Aspen Technology, Inc.
All rights reserved

Engineering Excellence Webinar Series
26 January 2010
Modeling Heavy Oils in
Aspen HYSYS
2010 Aspen Technology, Inc. All rights reserved |
2
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
3
Agenda
Heavy Oil Overview
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
4
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
5
Comparative Oil Properties
Conventional Crude <~ 30,000 cSt
Conventional Heavy 30,000 40,000 cSt
Thermal Heavy 200,000 250,000
cSt
Diluent 0.5 11.0 cSt
Oil Viscosity:
Oil API:
Conventional Crude > 25 API
Conventional Heavy 25 18 API
Extra Heavy (Thermal) 20 12 API
Tar Sand 12 7 API
6
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
7
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
8
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
9
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
10
Agenda
Heavy Oil Overview
Sample Applications
Q&A
11
Oil Properties Build PFD Assay Setup
Best Practices Workflow
Enter Assay
lab data
Check
Correlation set
Enter User
Cutpoint
ranges
Verify/alter
Extrapolation
& Conversion
Methods
Blend Assay &
Cut into Hypos
Compare
Property Plots
Install Oil
Blend Oil &
Water streams
Alter emulsion
viscosity, if
necessary
Incorporate
entrainment
Use Utilities to
check products
12
Oil Characterization in Aspen HYSYS
Purpose: convert lab analyses Aspen HYSYS library and
hypothetical components
3 steps in Oil
Characterization:
1. Characterize
the Assay
2. Generate
Pseudo
Components
Cut/Blend
3. Install the Oil in
the Flowsheet
13
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
Volume % Distilled
B
o
l
i
n
i
n
g

P
o
i
n
t

(
C
)
IBP
FBP
IBPi FBPi
True Boiling Point (TBP)
14
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
15
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
Volume % Distilled
B
o
l
i
n
i
n
g

P
o
i
n
t

(
C
)
Heavy Oil TBP
0
200
400
600
800
1000
1200
0 20 40 60 80 100
Volume % Distilled
B
o
l
i
n
i
n
g

P
o
i
n
t

(
C
)
16
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
17
Best Practices
Specify Properties for Heavy Oils
Bulk property options include:
Molecular Weight > 16
Mass Density = 250 ~ 2000 kg/m
3
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
18
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
19
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 pseudo-
components 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?
20
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
0
200
400
600
800
1000
1200
0 20 40 60 80 100
Volume % Distilled
B
o
l
i
n
i
n
g

P
o
i
n
t

(
C
)
Solution:
Use a guide point such as FBP or IBP
Use other distribution
21
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?
22
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!
23
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
24
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
Aspen HYSYS Can Accurately Predict
Important Heavy Crude Properties
25
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
26
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.
27
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.
28
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:
29
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)
30
Curve Fitting Options Example
31
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 re-
adjust 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
32
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.
33
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
34
Heavy Crude Viscosity Trends
Full Crude Viscosity vs. Temperature
0
20000
40000
60000
80000
100000
120000
0 50 100 150
Temperature (C)
V
i
s
c
o
s
i
t
y

(
c
S
t
)
Cut Viscosity vs. Final Boiling Point
0
50000000
100000000
150000000
200000000
250000000
0 200 400 600 800 1000 1200
FBP (C)
V
i
s
c
o
s
i
t
y

(
c
S
t
)
Use two points from full crude viscosity curve.
High FBP viscosities are usually a result of extrapolation
using a log(log) approach.
35
Viscosity Curves
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 extra-
polation 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
36
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
37
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
38
Example: Improving Thermal Conductivity
Alter coefficients
Regress data
39
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
40
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
41
Agenda
Heavy Oil Overview
Sample Applications
Q&A
42
Well Pad
Emulsion
DILUENT/
SYNTHETIC
CRUDE
STEAM/HEAT
To
Upgrader
or Pipeline
Gas-Oil-
Water
Separation
[DILBIT/
SYNBIT]
OIL
GAS
Gas
Treating
RECOVERED
DILUENT/SCO
SOUR
GASES
SWEET
GASES
Steam Assisted Gravity Drainage (SAGD)
Steam
Generation
WATER
43
STEAM GENERATION
GAS TREATMENT
Well Pad
Diluent
OIL TREATMENT
To Upgrader
or Pipeline
DilBit
Make up Streams
WATER TREATMENT
Aspen HYSYS Model
44
OPERATIONS DESIGN
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
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.
Additions of diluent and/or
solvents, 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
45
Agenda
Heavy Oil Overview
Sample Applications
Q&A
46
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: Peng Robinson with Lee-Kesler Enthalpies
Light Hydrocarbons: Peng Robinson
Hydrogen Rich: Peng Robinson
Sour Water: Peng Robinson Sour
47
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
48
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
49
Agenda
Heavy Oil Overview
Sample Applications
Q&A
50
50
Want to see similar results?
http://support.aspentech.com/supportpublictrain/TrainHome.htm
Consider a training class from AspenTech
51
Aspen HYSYS Training
Aspen HYSYS: Process Modeling (EHY101)
February 16, 2010 -- Virtual Americas
February 23, -- Pune, India
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY101
Optimize engineering work processes using the full power and
flexibility of Aspen HYSYS to build, evaluate and optimize flowsheets.
Learn the shortcuts for efficient use of the software to build steady
state simulations for processes.
52
Process Modeling (Refining Industry Focus) (EHY102)
February 8, 2010 -- Virtual Americas
March 15, 2010 Houston, Texas
Optimize engineering work processes using the full power and
flexibility of Aspen HYSYS to build, evaluate and optimize
flowsheets.
Learn the shortcuts for efficient use of the software to build steady
state simulations for refining processes.
53
Use and apply advanced modeling techniques to enhance existing
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
1
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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,
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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 product
direction
3-5 May 2010 Boston, MA, USA
Westin Copley Place
For more information:
Email: sanjeev.mullick@aspentech.com or dan.mccarthy@aspentech.com
Web: http://www.aspentech.com/aspenoneglobalconference
aspenONE
Global Conference
59
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 product
direction
3-5 May 2010 Boston, MA, USA
Westin Copley Place
For more information:
Email: sanjeev.mullick@aspentech.com or dan.mccarthy@aspentech.com
Web: http://www.aspentech.com/aspenoneglobalconference
aspenONE
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60
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

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