Optimizing Bitumen Upgrading Scheme Modeling and Simulation Approach
Mugurel Catalin Munteanu, Jinwen Chen CanmetENERGY, Natural Resources Canada One Oil Patch Drive, Devon, AB, T9G 1A8, Canada
2012 AIChE Spring Meeting, April 1-5, 2012, Houston, TX, USA Topical 7: 15th Topical on Refinery Processing
Research Background
The production of Canadian bitumen is expected to increase significantly, from the current 1.3 MBPD to 3.0 MBPD by 2018 and 5.6 MBPD by 2030. The carbon footprints, or greenhouse gas (GHG) emission, related to bitumen production, upgrading and refining to produce clean transportation fuels is higher than those related to conventional crudes. Incremental or evolutional steps to improve process efficiency, reduce energy consumption and increase raw crude utilization to produce clean transportation fuels remain critically important to the industry. Process modeling and simulation can help refineries to improve hydrotreating performance and reduce energy consumption by optimizing operating conditions, hydrotreater configurations and catalyst utilizations.
Research Objectives
Conducting simulation and optimization of the entire bitumen upgrading schemes to optimize operation, improve process efficiency, y minimize energy gy consumption p Each process and unit involved in the whole upgrading and refining scheme (such as distillation, coking, hydrotreating, etc.) will be modeled and simulated ( (using g ASPEN-HYSYS ( (or) ) in-house developed programs) using relatively simple models Identify the most bottlenecking upgrading steps to provide guidance and directions for industrial retrofitting g g and future research and development.
What are Oil Sands and Bitumen?
Wikipedia: Oil sands are a type of bitumen deposit. The sands are naturally occurring mixtures of sand, clay, water, and an extremely dense and viscous form of petroleum called bitumen. Alberta Energy: Oil sand is a naturally occurring mixture of sand, clay or other minerals, water and bitumen, which is a heavy and extremely viscous oil that must be treated before it can be used by y refineries to produce usable fuels such as gasoline and diesel.
Wikipedia: Bitumen is a mixture of organic liquids that are highly viscous, black, sticky, entirely soluble in carbon disulfide, and composed primarily of highly condensed polycyclic aromatic hydrocarbons. Naturally occurring or crude bitumen is a sticky, tar-like form of petroleum which is so thick and heavy that it must be heated or diluted before it will flow. At room temperature, it is much like cold molasses. Alberta Energy: A heavy y black viscous oil that must be rigorously g y treated to convert it into an upgraded crude oil before it can be used by refineries to produce gasoline and diesel fuels. Until recently, Alberta's bitumen deposits were known as tar sands but are now referred to as oil sands.
Production of Canadian Bitumen from Oil Sands
Mining + In-situ
In-situ Two major technologies: Open Pit Mining In-Situ (Steam Assisted Gravity Drainage or SAGD) Current production: 1.6 Million bpd (2010) (53% mining; 47% in-situ) (all mined bitumen is upgraded in Canada) Forecast: 2.9 million bpd by 2020 3.5 million bpd p by y 2025
Recoverable with current technology: 173 billion barrels Potentially recoverable with technological advances: +315 billion barrels
Source: Alberta Energy and Utilities Board
Bitumen Production from Oil Sands Mining
Composition (wt%): Mineral solids: ~85 Bitumen: ~12 Water: ~3
Tailings management
~90% bitumen recovery from oil sands with mining and extraction 3-4 3 4 barrels of water consumed for one barrel of bitumen
Source: Bantrel Corp., www.bantrel.com
Bitumen Production from Oil Sands In-Situ/SAGD
Boiler Separator
Bitumen to upgrader
Bitumen recovery: 60%. Less than barrel of water is consumed for per barrel of bitumen bitumen.
Source: Alberta Energy Resources Conservation Board, www.ercb.ca
Why Bitumen Upgrading?
All petroleum refineries are designed to process conventional crude oils. Raw bitumen cannot be directly processed in refineries due to its much higher viscosity, sulphur, metal and asphaltene contents. Bitumen upgrading is an integrated process during which bitumen goes through a series of chemical and physical treatments to reduce it density, its d it viscosity, i it carbon, b sulphur l h and d metal t l contents, t t and d to t increase its hydrogen content. Such a bitumen-derived oil is called synthetic crude oil (SCO). Ultimate objective: to increase its processibility and market value.
Properties of Bitumen and Conventional Crude Oil
Bitumen (Cold Lake, Alberta) Density(16C), g/ml (API gravity) Viscosity @ 15C/ 40C, cp Boiling range, C Sulphur/nitrogen content, wt% Metal content (nickel/ vanadium), ppm Carbon content, wt% Hydrogen content, wt% Saturates, wt% Aromatics, wt% Asphaltenes 1.00 (10.0) 235000/1050 250 to over 800 4.0/0.42 69/190 84.0 10.5 30 70 10
Conventional crudes (Arabian) 0.86 (32.5) 14.0/8.6 30 to 550 1.9/0.09 14/3.7 84.0 13.5 80 20 <1
Source: Environment Canada database
Schematic Diagram of Bitumen Upgrading to SCO
Diluent Naphtha Diluent Recovery Unit Naphtha H ydrotreater Naphtha Treated N aphtha
Diluted Bitumen
Light Gasoil Vacuum Distillation Unit LGO Hydrotreater
Treated LGO
Synthetic Crude Oil
Bitumen
HGO Heavy Gasoil Hydrotreater LGO Oil R esidue Separator Treated HGO
TLP
HGO
Coker
Coke
Residue
H2
Hydroconversion
H2
Hydrogen Plant
Bitumen upgrading scheme
Properties of Typical Athabasca Bitumen and Its Distilled Products
Property Density @15C API gravity Sulfur Nitrogen Hydrogen Carbon H/C atomic ratio
Unit g/mL API wt% wppm wt% wt% -
Bitumen 0.9960 10.57 4 30 4.30 5423 10.45 82.82 1.53
Bitumen Atm Bottoms 0.9957 10.62 4 27 4.27 5421 12.31 85.30 1.75
Vacuum Bottoms 1.0670 1.10 5 97 5.97 10590 10.57 82.5 1.43
Naphtha 0.782 49.4 1 68 1.68 237 12.36 85.1 1.74
Light Gas Oil 0.941 18.9 3 64 3.64 1600 10.87 84.8 1.54
Heavy Gas Oil 1.002 9.8 4 33 4.33 3780 10.17 84.2 1.45
Synthetic Crude Oil 0.865 32 0 15 0.15 0.06-0.10 12.63 86.6 1.75
Simulation of Coking-Based Upgrading Scheme
Coker
Hysys Bitumen upgrading flowsheet coking based
Simulation of Coking-Based Upgrading Scheme
Coking-based scheme streams properties
Diluent Recovery Unit Bitumen Properties Units Diluent DilBit Diluent Return Atmospheric Bottoms
Mass flow Nitrogen content Sulfur content Aromatics Density API CCR
kg/h wppm % vol% g/ml API wt%
494800 5423.00 4 30 4.30 61.45 0.9960 10.57 9.53
126600 0.00 0 00 0.00 0.53 0.7643 53.63 0.00
620800 4318.00 3 43 3.43 46.22 0.9381 19.34 7.59
126600 10.80 0 15 0.15 3.40 0.7670 52.99 0.00
494300 5420.00 4 27 4.27 60.44 0.9949 10.72 9.53
Simulation of Coking-Based Upgrading Scheme
Coking-based scheme streams properties
Vacuum distillation Napht ha Properties Mass flow Nitrogen content Sulfur content Aromatics Density API CCR Units kg/h wppm wt% vol% g/ml API wt% 6672 14 68 14.68 0.20 4.30 0.7802 49.87 0 00 0.00 75720 202 80 202.80 1.53 26.14 0.8836 28.64 0 00 0.00 188000 1552 3.48 54.61 0.9753 13.58 1 41 1.41 223900 10590 5.98 82.08 1.0670 1.10 19 86 19.86 19140 0 00 0.00 0.00 0.00 0.6500 86.20 0 00 0.00 33590 88 0.95 11.00 0.7535 56.28 0 00 0.00 26870 1132 3.83 50.00 0.8814 29.05 0 10 0.10 78370 3100 3.93 57.00 0.9798 12.92 1 50 1.50 60460 18370 7.92 89.00 1.0690 0.89 20 35 20.35 Vacuum Bottoms Coker Lights Ends Coker Naphtha Coker Diesel Coker Gas Oil Coke Coker
LVGO
HVGO
Simulation of Coking-Based Upgrading Scheme
Coking-based scheme streams properties
Naphtha Hydrotreater Mixed Naphtha Properties Mass flow Nitrogen content Sulfur content Aromatics Density API CCR Units kg/h wppm wt% vol% g/ml API wt% 40260 75.85 0.83 9.92 0.7578 55.22 0.00 37290 21.96 0.08 5.98 0.7591 54.91 0.00 Hydrotreated Naphtha
Diesel Hydrotreater Mixed Diesel Hydrotreated Diesel
Gas Oil Hydrotreater Mixed Gas Oil Hydrotreated Gas Oil
102600 446.2 2.13 32.40 0.8830 28.74 0.03
102000 432.2 0.14 26.37 0.8516 34.66 0.00
266400 2007.0 3.61 55.31 0.9766 13.39 1.44
261200 319.2 0.11 50.28 0.8811 29.09 0.00
Simulation of Hydroconversion-Based Upgrading Scheme
Hydroconverter Ebullated bed reactor
Hysys y y Bitumen upgrading pg g flowsheet hydroconversion based
Simulation of Hydroconversion-Based Upgrading Scheme
Hysys Bitumen upgrading flowsheet f hydroconversion based
Simulation of Hydroconversion-Based Upgrading Scheme
H d Hydroconversion-based i b d scheme h streams t properties ti
Diluent Recovery Unit Bitumen Properties Mass flow Nitrogen content Sulfur content Aromatics Density API CCR Units kg/h wppm wt% vol% g/ml API wt% 494800 5423.00 4.30 61.45 0.9960 10.57 9.53 126600 0.00 0.00 0.53 0.7643 53.63 0.00 620800 4318.00 3.43 46.22 0.9381 19.34 7.59 126600 9.95 0.14 3.23 0.7653 53.39 0.00 494300 5421.00 4.27 60.53 0.9957 10.62 9.53 Diluent DilBit Diluent Return Atmospheric p Bottoms
Simulation of Hydroconversion-Based Upgrading Scheme
Hydroconversion-based scheme streams properties
Vacuum Distillation Vacuum Bottoms EB Lights Ends EB Naphtha Hydrocracker EB Diesel EB Gas Oil EB Residue (goes to Residue) 1781 12.75 0.18 3.83 0.7723 51.72 0.00 80990 194. 1.47 25.13 0.8805 29.20 0.00 187500 1553. 3.48 54.63 0.9754 13.57 1.41 224000 10590 5.97 82.07 1.0670 1.10 19.85 348400 9202 4.21 69.19 1.0780 -0.30 17.72 16230 0.6495 86.35 17150 8.0 0.12 21.5 0.7423 59.13 0 76370 162 0.64 29.0 0.8783 29.61 0 86880 1220 1.12 41.1 0.9767 13.38 0.85 124600 9895 1.74 57.2 1.1000 -2.82 21.8
Naphtha Properties Mass flow Nitrogen content Sulfur content Aromatics Density API CCR Units kg/h wppm % vol% g/ml API wt%
LVGO
HVGO
Residue
Simulation of Hydroconversion-Based Upgrading Scheme
H d Hydroconversion-based i b d scheme h streams t properties ti
Naphtha Hydrotreater Mixed Naphtha Properties Mass flow Nitrogen content Sulfur content Aromatics Density API CCR Units kg/h g wppm % vol% g/ml API wt% 18930 8.45 0.13 19.87 0.7450 58.43 0.00 16690 0.39 0.01 10.23 0.7465 58.04 0.00 157400 178.47 1.07 27.01 0.8794 29.40 0.00 159900 21.18 0.16 16.41 0.8516 34.66 0.00 274400 1447.56 2.45 40.50 0.9758 13.51 0.96 277500 126.9 0.07 29.93 0.8664 31.82 0.00 Hydrotreated Naphtha Diesel Hydrotreater Mixed Diesel Hydrotreated Diesel Gas Oil Hydrotreater Mixed Gas Oil Hydrotreated Gas Oil
SCO Properties Comparison
SCO Coking-based scheme Properties Mass flow Nitrogen content Sulfur content Aromatics Density API CCR Yield Yield Units kg/h wtppm % vol% g/ml API % vol% wt% 400500 320.30 0.12 39.45 0.8607 32.91 0.00 93.65 81.01 454100 85.02 0.10 20.35 0.8561 33.78 0.00 106.80 91.86 SCO Hydroconversion-based scheme
Diluent Recovery and Vacuum Distillation Column Operating Conditions
Diluent Recovery Unit Number of stages Feed stage Diluent return stage Atmospheric bottoms stage Pressure (top) Pressure (bottom) Diluent D86 90% Temperature 24 24 Overhead liquid outlet Bottom liquid outlet 120 kPa 140 kPa 206.1C Vacuum Distillation Column Number of stages Feed stage Naphtha withdraw stage Light vacuum gas oil Withdraw stage Heavy vacuum gas oil Withdraw stage Vacuum bottoms Withdraw stage Pressure top Pressure bottom Naphtha D86 90% temperature Light vacuum gas oil D86 90% temperature Light vacuum gas oil D86 90% temperature N hth yield Naphtha i ld Light vacuum gas oil yield Heavy vacuum gas oil yield Vacuum bottoms yield 24 8 Overhead liquid outlet 2 7 Bottom liquid outlet 2 kPa 5 kPa 221C 345C 524C 1 4 t% 1.4wt% 15.3wt% 38.0wt% 45.3wt%
Coker and Hydrocracker Operating Conditions
Operating conditions Reactor catalyst density LHSV Reactor pressure Reactor temperature Sulphur conversio Conradson carbon residue conversion Nitrogen conversion Aromatics conversion p H2 consumption Total liquid product yield NH3 yield H2S yield g ends initial boiling gp point Light naphtha initial boiling point diesel initial boiling point gas oil initial boiling point gp point Residue initial boiling Light ends yield Naphtha yield Diesel yield yield Gas oil y Coke/Residue yield Residue conversion kg/m3 h-1 MPa C wt% wt% wt% wt% SCF/bbl wt% wt% wt% C C C C C wt% wt% wt% wt% wt% wt% Coker N/A N/A Atmospheric 482.2 N/A N/A N/A N/A N/A 70.6 0.45 2.0 -60.0 37.0 242.7 402.2 N/A 8.6 15.0 12.0 35.0 27.0 100.0 Hydroconverter 1500 0.48 16 430.0 71.5 48.5 51.6 39.1 1512 92.2 4.8 3.0 -60.0 37.0 204.0 371.0 565.0 5.1 5.3 23.8 27.0 38.8 61.2
Operating Conditions for Hydrotreaters in Coking-Based Scheme
Naphtha hydrotreater Number of reactors Number of beds/ reactor Reactor catalyst density Reactor ID Catalyst loading Bed voidage Reactor pressure Reactor temperature Gas/oil ratio Sulphur conversion Conradson carbon residue conversion Nitrogen conversion Aromatics conversion H2 consumption Product yield kPa C STD m3/m3 wt% wt% wt% wt% SCF/bbl wt% kg/m3 m kg/bed 2 2 1500 2.5 m 18,000 0.37 5,000 285.0 300.0 90.0 0.0 71.1 39.7 170.0 99.9 Diesel hydrotreater 2 2 1500 2.5 18,000 0.37 8,000 351.2 300.0 93.3 100.0 3.1 18.6 581.3 99.6 Gas oil hydrotreater 2 2 1500 2.5 m 18,000 0.37 13,260 365.6 584.2 96.8 100.0 84.1 9.1 912.6 99.4
Operating Conditions for Hydrotreaters in Hydroconversion-Based Scheme
Naphtha hydrotreater Number of reactors Number of beds/ reactor Reactor catalyst R l density Reactor ID Catalyst loading Bed voidage Reactor pressure Reactor temperature Gas/oil ratio Sulphur conversion Conradson carbon residue conversion Nitrogen conversion A Aromatics ti conversion i H2 consumption Product yield kPa C STD m3/m3 wt% wt% wt% wt% t% SCF/bbl wt% kg/m3 m kg/bed 2 2 1500 2.5 18,000 0.37 5,000 285.0 300.0 88.8 0.0 67.6 33 2 33.2 170.0 99.8 Diesel hydrotreater 2 2 1500 2.5 18,000 0.37 8,000 351.2 300.0 78.5 100.0 78.8 50 4 50.4 892.4 99.5 Gas oil hydrotreater 2 2 1500 2.5 18,000 0.37 13,260 365.6 584.2 97.0 100.0 88.0 26 1 26.1 1628.0 99.6
Conclusions
Two major commercially used bitumen upgrading schemes are simulated with HYSYS. The properties and flow rates of the intermediate and final products in each scheme are estimated and compared. Models M d l f for th the atmospheric t h i di distillation till ti column, l th the vacuum di distillation till ti column, l th the coker, k th the hydroconverter, and the hydrotreaters are calibrated according to the pilot plant and industrial data. Hydroconversion-based upgrading scheme has a SCO yield of about 92wt% which the coking-based ki b d upgrading di scheme h has h a SCO yield i ld of f about b t 81%, 81% which hi h are quite it close l t to commercial operation values. SCO generated from the hydroconversion-based scheme has higher quality (lower sulphur, nitrogen and aromatics contents) than that generated from coking-based scheme. The simulation is versatile and multiple options can be considered for different scenarios, and therefore can be considered as an important tool to guide bitumen upgrading process design and operation.
Acknowledgments
Partial funding for this study was provided by the Canadian I t d Interdepartmental t t l Program P of f Energy E Research R h and d Development (PERD 1.1.3).
Optimizing bitumen upgrading scheme modeling and simulation approach Jinwen Chen and Mugurel Munteanu CanmetENERGY, Natural Resources Canada One Oil Patch Drive, Devon, AB, T9G 1A8, Canada Abstract The present study focuses on modeling and simulation of the bitumen upgrading and refining schemes using the HYSYS modeling software in conjunction with pilot plant experimental data obtained at CanmetENERGY, as well as any available commercial operation data. Two existing upgrading schemes were investigated: coking-based and hydroconversion-based, which are commonly used by oil sands companies. The major upgrading units, such as atmospheric and vacuum distillation columns, coker/hydroconverter, and hydrotreaters, were depicted in detail and the commercial operating conditions for each of them were identified. The coking-based upgrading scheme was simulated under various operating scenarios. Using existing data, mass balance was performed and a synthetic crude oil yield close to 82wt% was achieved based on the initial diluted bitumen feedstock. The hydroconversionbased upgrading scheme was also studied in this work by replacing the coker with a hydroconverter (an ebullated bed reactor) and by utilizing commercially available data under different operating conditions. Introduction About 1.6 million barrels of combined mining and in-situ based bitumen is currently produced. Over 50% of this production is upgraded to synthetic crude oil (SCO). To date, virtually all of the mining based bitumen is upgraded. Much of the synthetic crude is processed in Canadian refineries today, but increasingly large volumes will be marketed in the northern tier US states as the industry expands its output1. Production of transportation fuels from Canadian bitumen feedstocks requires either new integrated upgrading and refining facilities, or converting existing refineries that use conventional crudes to allow higher input of bitumen feedstocks. In either case, it is important and useful to optimize the entire upgrading and refining scheme under different process configurations and product scenarios to minimize the process related energy intensity/ consumption, at the same time to achieve the best economic benefits. Such optimization can provide guidelines to either existing upgrading and refining operations or process design for new upgraders and refineries. There are two major commercial primary bitumen upgrading processes: coking and hydroconversion. Historically coking has predominated as the choice for primary upgrading. As the first step to produce a bottomless (zero residue) SCO, it handles the higher solids and water content in mining based bitumen more easily. The by-product coke helps to trap solids, and concentrate and remove metals as well as some of the sulphur and nitrogen. However, the total liquid product yield is relatively low due to the formation of coke. In comparison, ebullated bed catalytic hydroconversion process has much higher total liquid product yield due to the hydrogen addition. In some commercial operations the conversion of bitumen is not 100% in
the hydroconversion unit, generating a small portion of residue that is further processed with a coking unit. Both of the two primary processes produce liquid products with boiling ranges similar to conventional crudes. However they have high concentrations of impurities, such as sulphur and nitrogen. The secondary hydrotreating processes remove these impurities to produce sweet blending stocks for the SCO without changing much the boiling range of the liquid. The SCO boiling range is essentially controlled by the primary upgrading step. In reviewing some of the major challenges that the oil sands industry is facing, bitumen upgraders need to capitalize on, or address, the following: (a) Take advantage of some relatively minor upgrading at the recovery stage (b) Take advantage of the necessity to move to alternative energy and hydrogen sources, particularly internally generated residues, which is a trend with very large impact on main upgrading process selection (c) Address major environmental concerns in an integrated way (d) Meet future crude quality requirement with existing facilities The oil sands industry by its very size is in a position to influence technology development for their relatively unique needs. It is important to identify the possible avenues for better upgrading technology for current and future projects. The most important technology developments for existing commercial processes are: coking, ebullated bed hydroconversion, moderate primary upgrading, hydrotreating, hydrocracking, and catalyst development. The objective of this study is to identify the technologies and different operating conditions that directly meet the future trends in current upgrader performances. Improvement in process efficiency and bitumen utilization will benefit from advanced modeling techniques. Advanced modeling can also help to achieve better process control. Advanced simulation results also provide valuable information for understanding bitumen processabilities and increasing marketability, reducing GHG emissions and other related environmental impacts in bitumen upgrading and refining. Modeling and Simulation Bases Figure 1 presents a simplified generic flow diagram of current upgrading process. The diluted bitumen from the extraction and froth treatment plant is distilled in the diluent recovery unit (DRU), or atmospheric distillation unit (ADU). The diluent is recovered and recycled to the extraction plant. The bitumen constitutes the feed for the vacuum distillation unit (VDU). The distilled products from the VDU are routed directly to naphtha, light gas oil and heavy gas oil hydrotreaters, and the vacuum-topped bitumen is either thermally cracked in the coker or catalytically hydroconverted in the ebullated bed hydroconverter. The total liquid product (TLP) from the coker or hydroconverter is fractionated into naphtha, light gas oil and heavy gas oil, which are combined with the corresponding fractions from the VDU. The combined naphtha, light gas oil and heavy gas oil are further hydrotreated in three individual hydrotreaters. The liquid products from the hydrotreaters are blended to form the final upgrading product SCO, which is shipped to refineries in Canada and the US by pipeline for further refining2,3. Table 1 summarizes the properties of typical Athabasca bitumen and its distilled products. The bitumen contains about 4.3wt% of sulfur and the API gravity is about 10.6.
Diluent Naphtha Diluent Recovery Unit Naphtha Hydrotreater Naphtha Treated Naphtha
Diluted Bitumen
Light Gasoil Vacuum Distillation Unit LGO Hydrotreater
Treated LGO
Synthetic Crude Oil
Bitumen
HGO Heavy Gasoil Hydrotreater LGO Oil Residue Separator Treated HGO
TLP
HGO
Coker
Coke
Residue
H2
Hydroconversion
H2
Hydrogen Plant
Figure 1. Simplified generic schematic diagram of upgrading process Table 1. Properties of typical Athabasca bitumen and its distilled products
Bitumen atmospheric bottoms 0.9957 10.6 4.3 5421 12.3 85.3 1.8 Vacuum bottoms 1.0670 1.1 6.0 10590 8.5 83.7 1.4 Light gas oil 0.9410 18.9 3.6 1600 10.9 84.8 1.5 Heavy gas oil 1.0020 9.8 4.3 3780 10.2 84.2 1.5 Synthetic crude oil 0.8650 32.0 0.15 800 12.6 86.6 1.8
Property Density API gravity Sulfur Nitrogen Hydrogen Carbon H/C atomic ratio
Unit g/cm3 API wt% wppm wt% wt% -
Bitumen 0.9960 10.6 4.3 5423 10.5 82.82 1.53
Naphtha 0.7820 49.4 1.7 237 12.4 85.1 1.7
The present work focuses on modeling and simulation of the bitumen upgrading and refining schemes using the HYSYS modeling software in conjunction with pilot plant experimental data obtained at CanmetENERGY, as well as any available commercial operation data and published literature data4-12. Two existing upgrading schemes are investigated: coking-based and hydroconversion-based. The major upgrading units, atmospheric and vacuum distillation columns, coker/hydroconverter, and hydrotreaters, are depicted in detail and the commercial operating conditions for each of them were identified.
Results and Discussions Simulations are performed for both schemes, coking-based and hydroconversion-based with the same bitumen-to-diluent ratio as feedstock (75:25 vol/vol). The processing capacities are assumed to be the same at 100K barrel/day diluted bitumen. The properties of the bitumen feed, intermediate streams and the final SCO for both simulated schemes are presented in Tables 2 to 4 (coking-based scheme), Tables 5 to 7 (hydroconversion-based scheme), and Table 8 (synthetic crude oil), respectively. The upgrading units are modeled and calibrated adequately in order to simulate commercial operating conditions and to generate data of industrial interest. Since there are no available models for coking and ebullated bed hydroconversion in HYSYS, pilot plant experimental data obtained at CanmetENERGY and published in literature are used to develop the coker and hydroconverter models. Simulation results show that a SCO yield of about 81wt% can be achieved based on the initial diluted bitumen feedstock for the coking-based scheme. In contrast, the hydroconversion-based upgrading scheme generates a SCO yield of about 92wt%. The difference in the SCO yield between the two schemes is due to the fact that the ebullated bed hydroconversion unit completely converts the vacuum bottoms into gaseous and liquid products without generating any solid residual material. As seen in Table 8, the SCO from hydroconversion-based scheme has slightly lower concentrations of sulfur, nitrogen and aromatics than that from coking-based scheme. This results from the hydrodesulphurization, hydrodenitrogenation and hydrogenation, in addition to the hydrocracking of heavy molecules, occurring in the ebullated bed hydroconverter. The major upgrading units are investigated in detail and calibrated accordingly to commercial operating conditions. In this paper, the authors present only one set of operating conditions and parameters for the two above mentioned upgrading schemes as shown in Table 10. It is noted that the atmospheric distillation column, the vacuum distillation column and the hydrotreaters are operated under the same conditions for both schemes. The only difference is that one uses coking and the other one uses hydroconversion. The operating conditions are summarized in Table 9. As seen in Tables 11 and 12, even if the hydrotreaters are operated under the same conditions, the hydrogen consumptions for diesel and gas oil in the hydroconversion-based upgrading are significantly higher than those in the coking-based upgrading. This is because feed flow rates to these two units in the hydroconversion-based scheme are much higher than those in the coking-based scheme (Tables 4 and 7). Consequently the hydroconversion-based upgrading scheme has a higher SCO yield at the cost of higher hydrogen consumption. Table 2. Coking-based scheme streams properties
Bitumen 494800 5423.0 4.3 61.5 0.9960 10.6 9.5 Diluent 126600 0.0 0.0 0.5 0.7643 53.6 0.0 DilBit 620800 4318.0 3.4 46.2 0.9381 19.3 7.6 Diluent return 126600 10.8 0.15 3.4 0.7670 53.0 0.0 Atmospheric bottoms 494300 5420.0 4.3 60.4 0.9949 10.7 9.5
Mass flow Nitrogen content Sulfur content Aromatics content Density API gravity Conradson carbon residue
kg/h wppm Wt% vol% g/cm3 API wt%
Table 3. Coking-based scheme streams properties
Vacuum distillation Light Heavy vacuum vacuum gas oil gas oil 75720 188000 202.8 1.5 26.1 0.8836 28.6 1552.00 3.5 54.6 0.9753 13.6 Coker Vacuum bottoms 223900 10590.0 6.0 82.1 1.0670 1.1 Coker lights ends 19140 0.0 0.0 0.0 0.6500 86.2 Coker naphtha 33590 88.0 0.9 11.0 0.7535 56.3 Coker diesel 26870 1132.0 3.8 50.0 0.8814 29.1 Coker gas oil 78370 3100.0 3.9 57.0 0.9798 12.9
Mass flow Nitrogen content Sulfur content Aromatics content Density API gravity Conradson carbon residue
kg/h wppm wt% vol% g/cm3 API
Naphtha 6672 14.68 0.20 4.3 0.7802 49.9
Coke 60460 18370.0 7.9 89.0 1.0690 0.9
wt%
0.0
0.0
1.4
19.9
0.0
0.0
0.1
1.5
20.4
Table 4. Coking-based scheme streams properties
Naphtha hydrotreater Mixed Hydrotreated naphtha naphtha 40260 37290 75.9 0.8 9.9 0.7578 55.2 22.0 0.08 6.0 0.7591 54.9 Diesel hydrotreater Mixed Hydrotreated diesel diesel 102600 102000 446.2 2.1 32.4 0.8830 28.7 432.2 0.14 26.4 0.8516 34.7 Gas oil hydrotreater Mixed Hydrotreated gas oil gas Oil 266400 261200 2007.0 3.6 55.3 0.9766 13.4 319.2 0.1 50.3 0.8811 29.1
Mass flow Nitrogen content Sulfur content Aromatics content Density API gravity Conradson carbon residue
kg/h wppm wt% vol% g/cm3 API
wt%
0.00
0.00
0.03
0.00
1.44
0.00
Table 5. Hydroconversion-based scheme streams properties
Bitumen 494800 5423.0 4.3 61.5 0.9960 10.6 9.5 Diluent 126600 0.0 0.0 0.5 0.7643 53.6 0.0 DilBit 620800 4318.0 3.4 46.2 0.9381 19.3 7.6 Diluent return 126600 9.9 0.14 3.2 0.7653 53.4 0.0 Atmospheric bottoms 494300 5421.0 4.3 60.5 0.9957 10.6 9.5
Mass flow Nitrogen content Sulfur content Aromatics content Density API gravity Conradson carbon residue
kg/h wppm wt% vol% g/cm3 API wt%
Table 6. Hydroconversion-based scheme streams properties
Vacuum distillation Light vacuum gas oil 80990 194.0 1.5 25.1 0.8805 29.2 Heavy vacuum gas oil 187500 1553.0 3.5 54.6 0.9754 13.6 Residue (vacuum bottoms + recycle) 348400 9202.0 4.2 69.2 1.0780 -0.3 Hydroconverter
Mass flow Nitrogen content Sulfur content Aromatics content Density API gravity
kg/h wppm wt% vol% g/cm3 API
Naphtha 1781 12. 0.2 3.8 0.7723 51.7
Vacuum bottoms 224000 10590.0 6.0 82.1 1.0670 1.1
Lights ends 16230 0.0 0.0 0.0 0.6495 86.4
naphtha 17150 0.0 0.0 0.0 0.7423 59.1
diesel 76370 0.0 0.0 0.0 0.8783 29.6
gas oil 86880 0.0 0.2 10.0 0.9767 13.4
Residue (recycle) 124600 6645.0 0.9 44.0 1.1000 -2.8
Conradson carbon residue
wt%
0.0
0.0
1.4
19.9
17.7
0.0
0.0
0.0
0.0
14.6
Table 7. Hydroconversion-based scheme streams properties
Naphtha hydrotreater Mixed naphtha 18930 1.2 0.02 0.4 0.7450 58.4 Hydrotreated naphtha 16690 0.4 0.00 0.2 0.7465 58.0 Diesel hydrotreater Mixed diesel 157400 99.9 0.8 12.9 0.8794 29.4 Hydrotreated diesel 159900 21.2 0.16 6.4 0.8516 34.7 Gas oil hydrotreater Mixed gas Oil 274400 1061.0 2.5 40.5 0.9758 13.5 Hydrotreated gas oil 277500 126.9 0.07 29.9 0.8664 31.8
Mass flow Nitrogen content Sulfur content Aromatics content Density API gravity Conradson carbon residue
kg/h wppm wt% vol% g/cm3 API
wt%
0.00
0.00
0.00
0.00
0.96
0.00
Table 8. Synthetic crude oil properties
SCO Coking-based scheme 400500 320.3 0.12 39.5 0.8607 32.9 0.0 93.7 81.0 SCO Hydroconversion-based scheme 454100 85.0 0.10 20.5 0.8561 33.8 0.0 106.8 91.9
Mass flow Nitrogen content Sulfur content Aromatics content Density API gravity Conradson carbon residue Yield Yield
kg/h wppm wt% vol% g/cm3 API wt% vol% wt%
Table 9. Diluent recovery and Vacuum distillation column operating conditions
Diluent Recovery Unit Number of stages Feed stage Diluent return stage Atmospheric bottoms stage Pressure (top) Pressure (bottom) Diluent D86 90% Temperature 24 24 Overhead liquid outlet Bottom liquid outlet 120 kPa 140 kPa 206.1C Vacuum Distillation Column Number of stages Feed stage Naphtha withdraw stage Light vacuum gas oil Withdraw stage Heavy vacuum gas oil Withdraw stage Vacuum bottoms Withdraw stage Pressure top Pressure bottom Naphtha D86 90% temperature Light vacuum gas oil D86 90% temperature Light vacuum gas oil D86 90% temperature Naphtha yield Light vacuum gas oil yield Heavy vacuum gas oil yield Vacuum bottoms yield 24 8 Overhead liquid outlet 2 7 Bottom liquid outlet 2 kPa 5 kPa 221C 345C 524C 1.4wt% 15.3wt% 38.0wt% 45.3wt%
Table 10. Coker (coking-based scheme) and Hydrocracker (hydroconversion-based scheme) operating conditions
Operating conditions Reactor catalyst density LHSV Reactor pressure Reactor temperature Sulphur conversion Conradson carbon residue conversion Nitrogen conversion Aromatics conversion H2 consumption Total liquid product yield NH3 yield H2S yield Light ends initial boiling point Coker kg/m3 h
-1
Hydroconverter 1500 0.48 16 430.0 71.5 48.5 51.6 39.1 1512 92.2 4.8 3.0 -60.0
N/A N/A Atmospheric 482.2 N/A N/A N/A N/A N/A 70.6 0.45 2.0 -60.0
MPa C wt% wt% wt% wt% SCF/bbl wt% wt% wt% C
Table 10 - continued
naphtha initial boiling point diesel initial boiling point gas oil initial boiling point Residue initial boiling point Light ends yield Naphtha yield Diesel yield Gas oil yield Coke/Residue yield Residue conversion C C C C wt% wt% wt% wt% wt% wt% 37.0 242.7 402.2 N/A 8.6 15.0 12.0 35.0 27.0 100.0 37.0 204.0 371.0 565.0 5.1 5.3 23.8 27.0 38.8 61.2
Table 11. Operating conditions for hydrotreaters in coking-based scheme
Naphtha hydrotreater Number of reactors Number of beds/ reactor Reactor catalyst density Reactor ID Catalyst loading Bed voidage Reactor pressure Reactor temperature Gas/oil ratio Sulphur conversion Conradson carbon residue conversion Nitrogen conversion Aromatics conversion H2 consumption Product yield kPa C STD m3/m3 wt% wt% wt% wt% SCF/bbl wt% kg/m3 m kg/bed 2 2 1500 2.5 m 18,000 0.37 5,000 285.0 300.0 90.0 0.0 71.1 39.7 170.0 99.9 Diesel hydrotreater 2 2 1500 2.5 18,000 0.37 8,000 351.2 300.0 93.3 100.0 3.1 18.6 581.3 99.6 Gas oil hydrotreater 2 2 1500 2.5 m 18,000 0.37 13,260 365.6 584.2 96.8 100.0 84.1 9.1 912.6 99.4
Table 12. Operating conditions for hydrotreaters in hydroconversion-based scheme
Naphtha hydrotreater Number of reactors Number of beds/ reactor Reactor catalyst density Reactor ID Catalyst loading Bed voidage Reactor pressure Reactor temperature Gas/oil ratio Sulphur conversion Conradson carbon residue conversion Nitrogen conversion Aromatics conversion H2 consumption Product yield kPa C STD m /m wt% wt% wt% wt% SCF/bbl wt%
3 3
Diesel hydrotreater 2 2 1500 2.5 18,000 0.37 8,000 351.2 300.0 78.5 100.0 78.8 50.4 892.4 99.5
Gas oil hydrotreater 2 2 1500 2.5 18,000 0.37 13,260 365.6 584.2 97.0 100.0 88.0 26.1 1628.0 99.6
2 2 kg/m3 m kg/bed 1500 2.5 18,000 0.37 5,000 285.0 300.0 88.8 0.0 67.6 33.2 170.0 99.8
Summary In this work, two major commercially used bitumen upgrading schemes are simulated with HYSYS. The properties and flow rates of the intermediate and final products in each scheme are estimated and compared. Models for the atmospheric distillation column, the vacuum distillation column, the coker, the hydroconverter, and the hydrotreaters are calibrated according to the pilot plant and industrial data. It is shown that the hydroconversion-based upgrading scheme has a SCO yield of about 92wt% which the coking-based upgrading scheme has a SCO yield of about 81%, which are quite close to commercial operation values. In addition, the SCO generated from the hydroconversion-based scheme has higher quality (lower sulphur, nitrogen and aromatics contents) than that generated from coking-based scheme. The simulation is versatile and multiple options can be considered for different scenarios, and therefore can be considered as an important tool to guide bitumen upgrading process design and operation. Acknowledgments Partial funding for this study was provided by the Canadian Interdepartmental Program of Energy Research and Development (PERD 1.1.3).
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