Innovation in gas treatment, mercury removal, CO 2 handling and - - PowerPoint PPT Presentation

Innovation in gas treatment, mercury removal, CO2 handling and

• ther approaches

Introduction

Steve Fogg

Formative Years

Oil Price - $59

1971 – Houston We Have a Problem

A Safe Landing

Our Guest Speaker – Prof Martin Atkins

Chair of Chemical Innovation and Sustainability – Queen’s University of Belfast Commercial Mentor for Spin Out Companies P/T Commercial Director of QUILL – Queen’s University Ionic Liquid Laboratories BP – China Chief Scientist CTO - Petrona

Innovations in gas treatment

8

Aberdeen: 19.2.2015 Prof. Martin P Atkins

Outline Presentation

• Welcome remarks and background
• A fast-track development of Hg removal from

gas

• An emerging technology at demonstration

level for CO2 separation – challenges and

• pportunities moving forward

Confidential (Commercially Sensitive) 9

Confidential (Commercially Sensitive) 10

10

Technology Management. Project results and progress Conceptual Design studies. Provisional CAPEX & OPEX models Business Intelligence; Market Studies; BU Input TM D

Fast-track development of a novel Ionic Liquid based Hg removal technology – in collaboration with PETRONAS

Technology & Engineering Division

6

10

Confidential (Commercially Sensitive) 11

PETRONAS operates a network of gas production facilities at Malaysia Offshore

• Mercury has been discovered in the hydrocarbon stream delivered by

PETRONAS to the Gas Processing Plant (GPP) in Kerteh, Terengganu, Malaysia

• As mercury removal is becoming more challenging, there is a need to

find a more robust, new technology to reduce the content of mercury to a much lower level.

Confidential (Commercially Sensitive) 12

Fact: Mercury is present in our oil and gas reservoirs

Estimated levels of Mercury in natural gas and condensate from around the globe.

Location Mercury Concentration Gas (µg m -3) Liquids (µg kg-1) Europe 100 - 150

• South America

50 - 120 50 - 100 Gulf of Thailand 100 - 400 400 - 1200 Africa 80 - 100 500 - 1000 Gulf of Mexico USA) 0.02 - 0.4

• Overthrust Belt

(USA) 5 - 15 1 – 5 North Africa 50 - 80 20 – 50 Malaysia 1- 200 10- 100 Indonesia 200 - 300 10 - 500

Bigham, M.D., " Field Detection and Implications of Mercury in Natural Gas", SPE Prod. Eng., May 1990, 120-124. Wilhelm, S.M., and McArthur, A., "Removal and Treatment of Mercury Contamination at Gas Processing Plant", Soc. of Pet. Eng., (SPE No. 29721).

Confidential (Commercially Sensitive) 13

The Problem with Mercury in our Operations

• what is it and where is it located?

13

Confidential (Commercially Sensitive) 14

The effect of mercury is threatening to the oil and gas industry and hence a mitigation programme has been developed

Confidential (Commercially Sensitive) 15

Energy Outlook to 2030 – Confirms Hg removal needs to be addressed with Hydrocarbons making up 80% of the energy pool in 2030

15 Projections taken from BP’s Energy Outlook 2030.

Confidential (Commercially Sensitive) 16

Commercially Available Mercury Removal Technologies (MRT)

16

• Current commercial MRT uses supported

sulphides, halides and silver as active materials.

• MRT can be used to treat gas, liquid

hydrocarbon and water streams

• Depending on the applications, the targeted

mercury levels at MRT outlets are:

• < 0.01 mg/m3 for gas stream
• < 1 mg/l for liquid stream

Current Issues with MRT:

• Fluctuation in the content of mercury in the streams
• Analytical Accuracy - Issues in sampling, sample

treatment and analysis

• MRT’s capability to remove all types of mercury

species.

• Robustness of the MRT system when other

contaminants are present in the feed

• Handling of the spent MRT materials
• Hefty Unit price of current MRT materials

Confidential (Commercially Sensitive) 17

The IL Adsorbent Package is Innovative and Proprietary

17  The material has to be resistant to water vapour  The active site is a Nano-engineered by-functional

moiety comprising a molecular scaffold and activated metal centre.

 The in volatile nature of the IL makes supported

versions robust in plant operation. This approach

• pens

up new avenues

• f

research and development across catalysis and contaminants removal processes.

Confidential (Commercially Sensitive) 18

Mercury Removal Solid Support Ionic Liquid Journey

18

Confidential (Commercially Sensitive) 19 19

Collaboration with QUILL, Belfast

• Start of

collaboration fundamental research

• Establish

PETRONAS Ionic Liquid Laboratory in QUILL

• Additional

R&D projects included in the program

• Large scale

production and Pilot Plant

• Commercialization
• f R&D projects

2007 2008- 2009 2010 2011

Global commercial marketing alliance

20

Several tasks were studied in parallel primarily to reduce risks in commercialisation and speed the development

20

 A new tool to understand the “ageing profile” and screening of new supports. High throughput experimentation tools applied and validated.  Establish the right partnerships early. In our case with catalyst manufacturers, support providers, ionic liquid manufacturer.  Strong support from site for implementation – commitment through the organisation  Economics, commercialisation, corrosion, risk management, HSE, Due Diligence, Patents & IP.  Critical path issues managed by central team drawn together from manufacturing, technology, engineering and business development.  Key to success was “excellence” in project management. The difference between success and failure.

Confidential (Commercially Sensitive) 21

Mercury Capture Profile of SSILs

21

The team developed a new tool to predict the commercial lifetime of new supports.  The mercury captured by the SSILs approach 70-75% of the theoretical capacity based on the oxidation to mercury(II) and incorporation into the ionic liquid structure.  Laboratory results indicated better performance in terms of mercury uptake as compared to commercial adsorbents.  Selection of the optimal ionic liquid compositions and optimal support for the next stage pilot demonstration.

Confidential (Commercially Sensitive) 22

Slip stream pilot plant

22

 The heart of the slip stream pilot plant is multiple reactors fed direct from the main plant gas feed.  The unit is set-up for “doping extra Hg” to allow adsorption capacity to be estimated (life of the adsorbent).  The unit sees all plant operational variances and feed gas changes in the main plant.  Multiple beds allows comparison of different adsorbents  Additional capability and understanding generated on site. Early opportunity for training on new technology.

Confidential (Commercially Sensitive) 23

Commercial Trial Loading Activities at Gas Processing Plant

23

Confidential (Commercially Sensitive) 24 24

 It is possible to fast track R&D commercialization. It needs: 1. The “right project” – strategic fit to Company objectives 2. The right partners: catalyst manufacturer; support supplier, fundamental support, in-house expertise and excellence (eg Petronas Hg analysis) 3. Commitment from industrial partner especially site management and personnel

• 3. TEAMWORK and FOCUS

An emerging CO2 separation demonstration project

Confidential (Commercially Sensitive) 25

Confidential (Commercially Sensitive) 26 Absorbent Absorbent Natural gas

CH4 CO2 Natural gas purification by membrane contractor process

Membrane contactor combines conventional absorption process with membrane technology

Promising technology: membrane contactor process

Porous membrane

Gaseous mixture Absorbent N2 or CH4 CO2 or H2S or SO2

Confidential (Commercially Sensitive) 27

Advantages of membrane contactors

 Higher packing density:  500-1500 m2/m3 for membrane contactor  100-250 m2/m3 for absorption column  Less equipment size and weight:  Dry equipment weight reduction of 32% to 37%  Equipment height reduction of 60%  Operating equipment weight reduction of 34% to 40 %  Capital cost reduction of 35 % to 40 %  Better operation flexibility:  No-foaming, flooding or entrainment  Independent control of gas and liquid phases  Insensitive to motion (critical for offshore)  Easy to scale-up

Traditional absorption column Membrane contactor system

Confidential (Commercially Sensitive) 28

Laboratory study

Hollow fiber membranes Membrane contactor testing system

Confidential (Commercially Sensitive) 29

Confidential (Commercially Sensitive) 30

Development of PTFE membranes

• High hydrophobicity
• High chemical resistance
• Wetting resistance
• Good mechanical performance

PTFE is considered one of the most suitable materials for membrane contactor use in CO2 removal from natural gas

C C F F F F n

Confidential (Commercially Sensitive) 31

Development of PTFE membrane and module

Confidential (Commercially Sensitive) 32

Development of membrane contactor pilot system

The commissioning for pilot scale hollow fiber membrane contactor on CO2 removal from natural gas was successfully conducted in a gas process plant located at Malaysia east coast, which is jointly developed by Prof. Cao Group (DNL0905) of Dalian Institute of Chemical Physics CAS (DICP) and PETRONAS. The system operated continuously and stably for 72 hours, the results indicated that all process parameters met the contract requirements. It is the world`s first system to purify the high pressure natural gas by hollow fiber membrane contactor. The unit adopted firstly the PTFE hollow fiber high-pressure membrane absorber jointly developed by DICP and Shanghai Bi Ke Clean Energy Technology Co., Ltd (“CECC”), the performance indicators of which also satisfied the contract requirements for the membrane development.

Factory Acceptance test: inlet 10 %, outlet <0.1 % GPP3 on-site test: inlet 5%,outlet 0.02%-0.2%

Development of membrane contactor pilot system

The MBC system integrates the advantages of membrane separation technology and traditional adsorption process and is proved to be low energy consumption, high separation efficiency, high recovery rate of natural gas, compact device with small footprint, operation friendly, and other superior properties. The innovative technology can be used not only for acidic gas removal from natural gas (especially on offshore platform), but also for other areas like biogas purification and CO2 capture of flue gases. Confidential (Commercially Sensitive) 33

34

Caribbean FLNG 下水

 全球第一艘投入商业运营的FLNG，Caribbean FLNG为非自航驳船，2014年11月下水，2015年下半年交付至哥伦比亚投运  144m长，32m宽，0.5mt/a LNG，72亿cf/d，2亿Nm^3/d，90KNm^3/h  Exmar和加拿大Pacific Rubiales Energy公司（PRE）的全资子公司Pacific Midstream Holding各出资50%成立的合资公司所有  惠生海工负责总承包建设 EPCIC，Black & Veatch负责提供工艺技术及工艺设备采购，北京华福负责该工艺生产装置的详细设计

CARIBBEAN 设计参数 吸收塔 40寸MBC 设计处理量/Nm3/h 90000 设计进口CO2含量 ppm 2000 2000 设计出口CO2含量 ppm 50 50 单根膜组件处理量 Nm3/h / 6400 需要数量 1 14 所需膜面积/m2 / 56.25 K 尺寸 Φ1500mm×20.3m Φ1000mm×2.6m 单位设备体积处理量 2510 3135 SHELL设计参数 吸收塔 40寸MBC 设计处理量 Nm3/h 580000 设计进口CO2含量 ppm 2000 2000 设计出口CO2含量 ppm 50 50 单根膜组件处理量 Nm3/h / 6400 需要数量 1 91 所需膜面积 m2 / 362.5 K 单位设备体积处理量 / 3135

34

Confidential (Commercially Sensitive) 35

Evaluation

Gas‐liquid contactor

• -- Data by PoroGen

Specific surface area (cm2/cm3) Volumetric mass transfer coefficient, (sec)-1 Packed column (Countercurrent) 0.1 –3.5 0.0004 –0.07 Bubble column (Agitated) 1 –20 0.003 –0.04 Spray column 0.1 –4 0.0007 –0.075 Membrane contactor (PEEK) 1 –70 >0.1

• Capital cost by 35 -40%;
• Operating costs of 38% -42%;
• Dry equipment weight of 32% -37%;
• Operating equipment weight of 34% -40%;
• Total operating weight of 44% -50%;
• Footprint requirement of 40%.

Reduction & Savings

• -- Data by Aker Process System
• Capex reduction of 35-40% due to smaller equipment, Smaller footprint

(floating LNG is possible)

• Opex savings between 30-40% due to Lower energy requirement for

regeneration, higher pressure operation (less compression required),Minimal hydrocarbon losses, Reduced foaming

Reduction & Savings

• -- Data by WP

Conclusions

• Despite falling oil prices and uncertainties in the short

term, innovations and improvements to our daily

• perations are key for stability and safe, economic
• perations
• Gas is proving to be a feedstock of choice for power

and is resilient in the market place with LNG markets remaining strong and durable in the current crisis

• With remote gas, FLNG production is proving a

useful vehicle for marginal fields.

• The larger gas complexes (e.g. shale) are now taking

advantage of novel gas conversion opportunities.

36

Q&A

Thank You

Next event ‘O&G decommissioning: Learning from

• ther industries’ is on 26 March 2015 at Gordon

Highlander Museum