part of Aker

2008 Aker Solutions

Separation Solutions for Heavy Oil
Morten Hana, PhD
Product and Technology Manager
Aker Process Systems AS
Aker Solutions
2008 Aker Solutions part of Aker 2-Oct-09 Slide 2
The low API crude problem
How to make export quality oil from low API crudes without heating
to 120 -140C and without using enormous vessel sizes.
Some of the challenges:
Strong Stabilisation WiO Emulsions by Asphalthenic Particles
High polarity components
High phase inversion -> high emulsified water content
Entrapment of Water into Oil Phase
Heavy crudes can be highly conductive
2008 Aker Solutions part of Aker 2-Oct-09 Slide 3
Aker Solutions Heavy Oil Specialists
In the heavy oil business for over 30 years
Canadian SAGD we are on every operating
lease
Horizontal electrostatic treater installed on Grane
CEC qualified for Heavy Oil
First ever full-scale CySep
Processing heavy crude in Russia and South
America
Proven product portfolio covering the entire oil
treatment flow-sheet
Electrostatic Coalescers for treaters and desalters
Diluent Injection & Recovery Systems
Produced water deoiling
Experienced EPC partner: skid-based to modules
Fabrication capabilities inhouse and/or with qualified
fabricators to provide schedule certainty and right
quality
Cold & Hot weather and modular plant experience to
compliment our heavy oil capabilities
Vast Offshore & Onshore Experience
Crude: 26.7 API
Viscosity: 21cP at 60 C
110cP at 25 C
Forms strong emulsions
The preferred partner for heavy oil processing solutions!
2008 Aker Solutions part of Aker 2-Oct-09 Slide 4
World Leading Technologies in Heavy Oil Processing
Canada - 600,000 bpd
Middle East - 300,000 bpd
Russia - 76,000 bpd
South America - 50,000 bpd
Aker Process Systems equipment is used to treat
well over one million barrels per day of heavy oil
> 20% of world heavy oil production!
North Sea
200,000 bpd
2008 Aker Solutions part of Aker 2-Oct-09 Slide 5
APS Technology portfolio and locations
Products & Technologies
Separation technologies
Separator trains & packages
Separation and scrubber internals
Heavy oil/Ultra heavy oil
Desalting solutions
Sand & solid solutions
Produced water solutions
Compact Technologies
CEC
CySep
Hydrate inhibition - MEG reclamation
Water injection - SRU solutions
Lifecycle management
Integrated solutions Topsides
Gas dehydration/TEG & Fuel gas
Fired heaters
VOC Crude
VOC Gasoline Utility skids to power
turbines
Diluent Injection & Recovery Systems
Locations
Oslo, Norway
Aberdeen, UK
Paris, France
Calgary, Canada
Copenhagen, Denmark
Perth, Australia
Rio de Janeiro, Brazil
Singapore
+ additional 60 locations of Aker
Solutions!
2008 Aker Solutions part of Aker 2-Oct-09 Slide 6
Crude treatment The Challenge
Produced crude oil
contains sediment
produced water (BS&W),
salt and other impurities
How to remove them?
2008 Aker Solutions part of Aker 2-Oct-09 Slide 7
Crude Treatment
Water separation from Oil is governed by Stokes
Law:
oil
oil water
s
d g
V
18
2
We manipulate this equation
2008 Aker Solutions part of Aker 2-Oct-09 Slide 8
What can we manipulate?
Aker Solutions have proprietary and patented components to
coalesce/increase the water size d using:
Mechanical impingement
Turbulent & cyclonic flow
Electrostatics
2008 Aker Solutions part of Aker 2-Oct-09 Slide 9
Mechanical coalescing Patented matrix packing
1 triangular sections with a 45
downward slope.
How it Works
Water droplets hit the
corrugated plates, collide with
each other & grow
Larger droplets slide down the
plate channels, flow to the
bottom water phase of the
vessel.
Advantages
Self cleaning action that
prevents plugging and is self
draining
Enhances coalescing
Increases buoyancy drive
between the oil and water
2008 Aker Solutions part of Aker 2-Oct-09 Slide 10
Turbulent coalescing Patented Adjustable Flow Distribution baffles
Horizontal flow distribution
Ensures even flow for heavy oil
thus even temperature profile in
the separator
Turn down to 25%
Promotes coalescing via
impingement & turbulence
2008 Aker Solutions part of Aker 2-Oct-09 Slide 11
Cyclonic Coalescing Patented Compact Cyclonic Inlet (CCI)
device Anti Foaming Cyclonic Inlet Device
Promotes separation & coalescing via centrifugal forces and impingement
on the cyclone wall
Vast reference list
Heavy Oil: Surmont Phase 1, FWKO and Treaters, 16 API, 2005
CCI
2008 Aker Solutions part of Aker 2-Oct-09 Slide 12
Electrostatic treaters for heavy oil
Patented Horisontal 3D Vertical Grids
Compact Electrostatic Coalescer (CEC)
Horisontal 3D Vertical Grids
CEC
2008 Aker Solutions part of Aker 2-Oct-09 Slide 13
Electrostatic Coalescing Patented 3-D Vertical
Grids For Horizontal Flow Treating
Grounded
Diffusion
Baffle
Developed specifically for Heavy
Oil
Adjustable spacing between
ground & energized grid
3-D Grid provides coalescing
between the vessel shell and grid
Wings
Energized Grid
2008 Aker Solutions part of Aker 2-Oct-09 Slide 14
Electrostatic Coalescing Patented 3-D Vertical
Grids For Horizontal Flow Treating
Adjustable spacing between
ground & energized grid
3-D Grid provides coalescing between
the vessel shell, water phase and grid
Wings
2008 Aker Solutions part of Aker 2-Oct-09 Slide 15
Selected References for Horizontal-Flow Electrostatic Treater
Project Year API Equipment
Husky - Tucker Lake SAGD 2005 18 API FWKOs,
Treaters (Electrostatic
coalescers)
PetroCanada MacKay
River SAGD
2000 8.7 API Inverted High Temperature
Separators (FWKOs & Treaters)
Petrobank Energy White
Sands SAGD
2005 14-19 API FWKO, Treaters
PetroAndina CHOP 2008 17.7 API FWKO, Treater, Electrostatic
Desalter (all with integral Fire
tubes)
LukOil Komi CHOP 2008 14.3 API Two stage Electrostatic
Desalters
StatoilHydro Grane 2003 19 API Electrostatic Treater
part of Aker
2008 Aker Solutions
Compact Electrostatic Coalescer
CEC
2008 Aker Solutions part of Aker 2-Oct-09 Slide 17
Compact Electrostatic Coalescer (CEC)
Compact Offshore High Performance Technology
Proprietary, patented solution for improvement of
separation of water from oil
Compact and standardized design
Large operating window, high performance
Robust and highly offshore suitable
Debottlenecking for existing production facilities:
Enhances performance of existing downstream
separation equipment
Electrostatic field and turbulence make droplets
coalesce:
Electrostatic field
Water droplets become polarized (e.g. dipoles)
Emulsifying films are distorted and weaken =>
contributing to emulsion breaking
Droplets vibrate collisions
Mild Turbulence
Random droplet collisions
Increase droplet to droplet contact => higher
coalescing efficiency
2008 Aker Solutions part of Aker 2-Oct-09 Slide 18
CEC Technology
Configuration
Number of concentric electrodes depending
on liquid production rate
Intense AC electrostatic field, voltage
modulation
Energized electrodes are coated
Unique dynamic power control
Rapid modulation and better control
Larger water droplets rapidly settling
in separator, shorter residence time,
hence smaller separator vessel
Comparing CEC to traditional
equipment:
Typical conventional up-flow EC:
20 350 BPD/ft2
CEC + Separator:
400 BPD/ft2
Reduction in size, footprint, weight
Typical CEC size: 5.5 m height, OD
1.2m + skid structure
CEC internals
2008 Aker Solutions part of Aker 2-Oct-09 Slide 19
CEC Flowloop testing (StatoilHydro MPFL)
Rapid coalescing and emulsion breaking with heavy oil
19 API crude @ 80 C
2008 Aker Solutions part of Aker 2-Oct-09 Slide 20
CEC Flowloop testing (StatoilHydro MPFL)
Rapid coalescing and emulsion breaking with heavy oil

Emulsified water in oil after centrifugation, measured before and after CEC with
CEC turned ON (demulsifier > 125ppm)
0,0
0,5
1,0
1,5
2,0
2,5
3,0
0,0 0,5 1,0 1,5 2,0 2,5 3,0
Emulsified water in oil after centrifugation, measured before CEC [%]
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s
s
Amount of emulsified
water INTOthe CEC
FLOWLOOP TEST DATA
19 API @ 60 80 C
Req: < 0.5% BS& W
Achieved with only
20% of demulsifier
compared to live
conditions
2008 Aker Solutions part of Aker 2-Oct-09 Slide 21
CEC References
STATOILHYDRO Glitne (65,000 BPD)
API 32
Operational since 2002 , 100% uptime
<0.3% BS&W
MRSK Al Shaheen (38,000 BPD)
Operational since 2006
4 times better than conventional
API 22-24
MARATHON Alvheim (130,000 BPD)
In operation since September 2008
API 36
PETROBRAS Jubarte (5,000 BPD)
In commissioning
API 14
CEC in addition tested and qualified for:
19 API Captain crude (Chevron)
19 API Maya crude (Pemex)
19 API Marlim crude (Petrobras)
Planned qualification testing 2009:
14 API crude
19 API crude
Portable lab-scale CEC
available for screening test
part of Aker
2008 Aker Solutions
Cyclonic Separation - CySep
Aker Solutions has been awarded a contract
for a CySep separation unit.
CySep for
Petrobras Pampo PPM-1
2008 Aker Solutions part of Aker 2-Oct-09 Slide 23
CySep
Three stage compact cyclonic separation
Qualified for high water cut (> 75%) and 13 API
Substitutes traditional inlet separator
First full-scale unit under construction for Petrobras, delivery mid 2010
DEGASSING
STAGES
CYCLONIC
SEPARATION

BOW
PV002
PDC
PV003
DC
PV004
LV001
GAS
FROM
PRODUCTION
HEADER
TO SECOND STAGE
SEPARATOR
TO PRODUCED
WATER DEGASSER
PDIT
002
FIT
001
PDIT
001
FIT
002
PDR
001
FIT
003
PDR
002
PDIT
004
PDIT
003
FIT
004
PDR
003
PDIT
005
PDIT
006
PIT
001
PIC
001
PCV001
LIT
001
LIC
001
TO GAS TREATMENT
SYSTEM
CYCLONIC
DEGASSER
2008 Aker Solutions part of Aker 2-Oct-09 Slide 24
Oil Sands/SAGD
APS value chain for technology solutions for the separation
Provider of:
Studies
Technology
Solutions
APS has provided equipment
to all operational SAGD leases
2008 Aker Solutions part of Aker 2-Oct-09 Slide 25
Heavy Oil Typical APS solution (PFD)
1st stage
2nd stage
APS Compact high
performance Solutions
CEC
PW treatment
2008 Aker Solutions part of Aker 2-Oct-09 Slide 26
Heavy Oil Separation with Wash Tanks
HP DEG
LP DEG
Wash Tank
Dehydration
Desalting
PW treatment
2008 Aker Solutions part of Aker 2-Oct-09 Slide 27
Case study on Heavy Oil
Process Design Basis: SAGD FWKO
Diluted Bitumen (Dilbit)
2/3 Bitumen
1/3 Diluent
Oil Feed Rate: 8000 sm3/day
Water Rate: 18500 sm3/day
Water Cut 69.8%
Gas Flow Rate: 180000 sm3/d
Sand 12 m3/d
Crude Specific Gravity: 16 API @ 15 C
H2O Specific Gravity 1.0037
Operating Temperature: 110 - 125 C
Operating Pressure: 6 barg
2008 Aker Solutions part of Aker 2-Oct-09 Slide 28
Process Design Basis FWKO Continued:
FWKO Outlet Specifications:
Crude Quality
10% BS&W @ 125 C
20% BS&W @ 110 C
Water quality
1000 ppm oil in water
2008 Aker Solutions part of Aker 2-Oct-09 Slide 29
Approximate Viscosity - Temperature Chart for various API Crude Oils
Temperature
V
i
s
c
o
s
i
t
y
50,000
7
6
5
4
3 cSt
1,000
2,000
3,000
5,000
10,000
20,000
100
75
50
40
30
20
15
10
9
8
500
400
300
200
150
460
345
230
185
137
97
77
59
55
52
49
45
42
39
36
SSU
-10
o
C
110 100 80 70 60 50 40 30 20 10 0 90 140 130 120 150
14,000
9,000
4,600
2,300
1,800
1,350
900
640
230,000
95,000
47,000
24,000
248 230 212 194 176 158 140 122 104 86 68 50 32
14
o
F
302 284 266
6 API 13 12 11 10 9 8 7 19 18 17 16 15 14
28
27
26
25
24
23
22 21 20
40 API
36
33
30
29
Color Key: Plot - Inlet Condition - Operating Condition
Given Viscosity Data:
Pt 1: 25 cP @ 110 C
Pt 2: 16 cP @ 125 C
Pt 3: 11 cP @ 140 C
Dilbit behalves closer
to a 14 API oil
Viscosity Behavior
2008 Aker Solutions part of Aker 2-Oct-09 Slide 30
Design Analysis
Traditional FWKO Design
Separation of free (non-emulsified) water from crude oil
The Problem:
Typical 16 API Heavy oil holds more than 30% water as
emulsion
Typical Dilbit blend of 1/3 Diluent and 2/3 SAGD Bitumen
blended to 16 API would typically hold ~22% water
Emulsions are not broken in FWKOs unless
heat is applied
and/or coalescence inducing internals are utilized
and demulsifying chemicals are used.
Conclusions:
SAGD Dilbit FWKOs with better than ~20% outlet performance
are actually high temperature coalescing separators
2008 Aker Solutions part of Aker 2-Oct-09 Slide 31
Aker Solutions from concept to operation
Concept studies
Evaluation of crude
Screening evaluation
Qualification of systems and/or equipment
FEED
Establish PFD, P&IDs
Layout
Project Execution
Engineering
Purchasing
Construction
Installation
Lifecycle
Operational support
Spare parts
2008 Aker Solutions part of Aker 2-Oct-09 Slide 32
Contact deatils
Morten Hana, PhD
Product and Technology Manager
Separation Technologies
Tel: +47 67 83 77 49
Mob: +47 907 85 905
E-mail:morten.hana@akersolutions.com
Mika Tienhaara
Vice President Separation Technologies
Tel: +47 67 83 77 87
Mob: +47 454 11 459
E-mail: mika.tienhaara@akersolutions.com
Espen Bostadlkken
International Sales Manager
Tel: +47 67 83 78 24
Mob: +47 91 11 88 67
E-mail: Espen.Bostadlokken@akersolutions.com
2008 Aker Solutions part of Aker 2-Oct-09 Slide 33
Copyright
Copyright of all published material including photographs, drawings and images in this document
remains vested in Aker Solutions and third party contributors as appropriate. Accordingly, neither the
whole nor any part of this document shall be reproduced in any form nor used in any manner without
express prior permission and applicable acknowledgements. No trademark, copyright or other notice
shall be altered or removed from any reproduction.
2008 Aker Solutions part of Aker 2-Oct-09 Slide 34
Disclaimer
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are subject to risks and uncertainties that could cause actual results to differ. These statements and
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