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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


• A MODERNIZING NATION BLENDED WITH A MULTICULTURAL SOCIETY RICH IN THE ARTS, TRADITION AND NATURAL BEAUTY


• FULL OF NATURAL WONDERS


• HISTORY & HERITAGE


• MODERN INFRASTRUCTURE

PETRONAS and Formula 1




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

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




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

-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




Shale Oil Modeling

Questions

simulation of oil shale retorting using the · pdf filepetronas – an overview...

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