carbon management in heavy oil refinery · case study – heavy oil refinery refinery feedstock :10...
TRANSCRIPT
›Middle East Refining Technology Conference›January 23-24, Bahrain
›Carbon Management in Heavy Oil Refinery
›Syamal Sen, Director - Engineering
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OUR WORKFORCE COUNTS OVER
40,000
EMPLOYEES
SPEAKS
60 LANGUAGES
REPRESENTS SOME
80 NATIONALITIES
AND WORKS FROM OFFICES IN OVER
50 COUNTRIES.
Who we are
› Founded in 1911
› Leading engineering and construction firm
› Major player in infrastructure ownership
› End-to-end solutions: EPC, EPCM, financing, operations & maintenance services
› Over 40,000 employees working in 50 countries
› Listed on the Toronto stock exchange
› Operating in 4 key sectors
Discover Our Markets
Our four key markets are Infrastructure, Mining & Metallurgy, Oil & Gas and Power. By consolidating our operating units into these four sectors, we have improved market focus and efficiency, and enhanced teamwork.
Mining & Metallurgy Oil & Gas Infrastructure Power
Services
We are one of very few firms with top-tier expertise in engineering, construction, procurement, financing & asset management, and operations & maintenance. This is a key differentiator in our industry, and a powerful vehicle for delivering outstanding value to our stakeholders.
ICI Engineering Procurement Construction O&M
SNC-Lavalin Corporate Overview
GHG Emissions in Refinery - Overview
Well to tank (WTT) is on average
20% of the well to wheel emission.
Refining is ~10 kg CO2/MMBtu LHV
of gasoline.
Refining emission varies widely.
Industry has proactively reduced GHG
emissions.
Recent changes e.g. COP 21 -- early
consideration in project lifecycle.
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Stage #1
Production (7.5%)
Stage #2
Transportation (1.5%)
Stage #3
Refining (10%)
Stage #4
Transportation (1%)
Stage #5
Combustion (80%)
Carbon Management – Path Forward
For an Oil Refinery, what will be the most economic
approach to reduce carbon emission in near future?
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1. Don’t install the refinery.
2. Use CO2 for greenhouses/ grow plants.
3. Reduce fossil fuel consumption.
4. Convert CO2 to chemicals.
5. Reduce power consumption.
6. Capture flue gas CO2 & sequester.
Emissions Contributions – Sectors
As per EPA Report, October 2010.
Combustion
63.3%
Hydrogen
Plant
5.8%
Sulfur Plant
1.8%
Flaring
2.5%
FCC Coke
23.5%
Others
3.1%
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Emissions Contributions – Units
Different units contributions*of a typical refinery :
• Distillation: 16.8%
• FCC: 35.1%
• Distillate Hydrotreater: 20.3%
• Kerosene Hydrotreater: 7.4%
• Naphtha Hydrotreater: 20.2%
• Others: 0.1%
* Estimated.
Based on a light feedstock of 38.5 oAPI and 0.6 wt% S.
Can we focus our attention only on heating and FCC for
CO2 emission reduction?
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Emissions -- Feedstock
0
10
20
30
40
50
60
70
80
90
#1 #2 * #3 #4 #5
Em
issi
on
kg
pe
r B
bl
of
Fee
dst
ock CO2 Emission Rates Comparison for
Various CrudesCO2 emission-Medium Conversion
CO2 emission-High Conversion
oAPI 38.5 33.5 27.4 20.7 18.3
Sulfur wt% 0.6 0.2 2.3 3.9 5.3
Long Residue V/V% 24.1 2.6 31.9 35.2 54.5 7
Co-Products Contribution
CO2 Emission Carbon Rejection
(Coking)
H2 Addition
(Hydrocracking)
kg/Bbl of feed Base 185%
kg/MJ of products * Base 125%
Emission from co-products combustion
kg/MJ of products * Base 68%
Emission from co-products combustion (credit from NG)
kg/MJ of products * Base 71%
Results are for a 21 oAPI feedstock with 3.9 wt% sulphur and
35 vol% vacuum residue.
* Refined Products only.
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Case Study – Heavy Oil Refinery
Refinery feedstock :10 oAPI with 5.4 wt% S, 53 V% VR.
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Hydrocracking
/Treating
Naphtha
Block
Light Ends
Recovery
Gasification
Block
Hydrogen
Production
Heavy
Feed
Blendstock
Sulphur
Block
Natural Gas Hydrogen
Sulphur
Diesel
Gasoline
Butanes
LPG
REFINERY CONFIGURATION –
MAJOR PROCESS BLOCKS
Jet A-1
Methanol
Gas Oil
Distillate
Hydrotreating
Case Study – Emissions
10
Heat
(Heating &
Steam)
19%
Hydrogen
Production
Unit
53%
Power
Plant
4%
Residue
Gasificatio
n
24%
Emission Sources in Heavy Oil Refinery
• High yield - ~3-4% unconverted residue or ‘pitch’;
• Emission much higher than a light crude Refinery.
Options for Emissions Reduction
�Alternate fuel for heating?
�Lower conversion of residue?
� ‘Pitch’ processing for carbon conversion?
� `Pitch` processing for hydrogen production?
�Alternate power supply source?
�Carbon mineralisation?
�Carbon capture from hydrogen production?
�Carbon capture from flue gas?
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Residue to Methanol
Oxygen
Steam
Steam
BFW
BFW
Off-gas
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Carbon capture from SMR Plant
Reference: National Energy Technology Laboratory, August 2010.
Steam
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‘Pitch’ Processing Options
• Light crude 38.5 oAPI, 0.6 wt% S and 24.1 v% VR; Coking;
• No emission from coke as co-product.
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4
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10
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0.00
5000.00
10000.00
15000.00
20000.00
25000.00
Sale Power
Generation
Methanol
Production
Hydrogen
Production
Reference
Light Crude
Em
issi
on
inte
nsi
ty, g
m/M
J o
f R
efi
ne
d P
rod
uct
s
CO
2E
mis
sio
ns
in M
TP
D
Emission for 'Pitch' Processing Options
Residue/ FCC for Light Crude
Power Plant
Hydrogen Production Unit
Heat (Heating & Steam)
CO2 Intensity, gm/MJ
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Process CO2 Recovery Option
0
2
4
6
8
10
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18
20
0.00
5000.00
10000.00
15000.00
20000.00
25000.00
Sale Power
Generation
Methanol
Production
Hydrogen
Production
Reference
Light Crude
Em
issi
on
inte
nsi
ty, g
m/
MJ
of
Re
fin
ed
Pro
du
cts
CO
2E
mis
sio
ns
in M
TP
DEmission with Process CO2 Recovery
Residue/ FCC for Light Crude
Power Plant
Hydrogen Production Unit
Heat (Heating & Steam)
CO2 Intensity, gm/MJ
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Selected Options
0
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10
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20
0.00
5000.00
10000.00
15000.00
20000.00
25000.00
Sale Methanol
Production
Reference Light
Crude
Em
issi
on
inte
nsi
ty, g
m/M
J o
f R
efi
ne
d P
rod
uct
s
CO
2E
mis
sio
ns
in M
TP
DProcess & Selected Flue CO2 Recovery
Selected Options for further work:
- All Process, selective Flue CO2 Recovery;
- Methanol Production (most economic);
- 25 MW Bio-mass power.
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Q & A
THANK YOU
For questions, please contact:
Syamal SenDirector (Engineering)SNC-Lavalin Oil & Gas
Telephone: [email protected]
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