Modeling Heavy Oils in Aspen HYSYS: Engineering Excellence Webinar Series 26 January 2010

Modeling Heavy Oils in
Aspen HYSYS
Engineering Excellence Webinar Series

26 January 2010
2010 Aspen Technology, Inc. All rights reserved
Modeling Heavy Oils in Aspen HYSYS

Dr. Mohammad Khoshkbarchi
Senior Project Manager, Process Ecology
Email: mohammad@processecology.com
Sanjeev Mullick
Director, Product Marketing, AspenTech
Email: Sanjeev.Mullick@aspentech.com
http://support.aspentech.com
Agenda
Heavy Oil Overview
Best Practices for Modeling Heavy Oils in Aspen HYSYS
Sample Applications
Recommendations and Conclusions
Q&A
What is Heavy Oil?

By definition, has API gravity < 20 & viscosity > 1,000 cP
Has over 60 carbon atoms, and hence, a high BP & MW
Mainly comprised of hydrocarbons heavier than pentanes,
with a high ratio of aromatics and
naphthenes to paraffins
High amounts of nitrogen, sulfur (~5%),
oxygen and heavy metals
Exists in a semi-solid state and may not
flow in its naturally occurring state
Comparative Oil Properties

Oil Viscosity:
Conventional Crude
<~ 30,000 cSt
Conventional Heavy
30,000 40,000 cSt
Thermal Heavy
200,000 250,000
cSt
0.5 11.0 cSt
Diluent
Oil API:
Conventional Crude
Conventional Heavy
> 25 API
25 18 API
Extra Heavy (Thermal)

Tar Sand
20 12 API
12 7 API
Where Does it Exist?

Heavy oil deposits total almost 5 trillion barrels (est.);
80% of deposits are in the Western Hemisphere
- In the U.S., heavy hydrocarbon deposits are estimated to be
more than eight times that of the nation's remaining reserves
of conventional crude oil
Where Does it Exist?

1. Western Canada
Mainly in the form of oil sands in Alberta
44% of Canadian oil production in 2007 was from oil sands, with an
additional 18% being heavy crude oil
Average density is API = 8

Viscosity within a range 5000-10,000 cP,
and higher (up to 100,000 cP)
2. Venezuela
Mainly heavy oil
Viscosity within a range of 1000-5000 cP
Challenges in Modeling Heavy Oils

Characterizing the oil
Defaults
Data
Bulk
Curves
Viscosity
Blending to match properties at wellhead

Emulsion viscosity
Phase entrainment/carryover
Foaming
Further effects of adding solvents
Implications of Poor Modeling

Incorrect wellhead conditions
Steam-Oil ratio
Properties prediction
Flash conditions: vapor when its really a liquid/vice versa,
trivial phases
Large pressure gradients

Unattainable separations
Products: SCO
Capacity
Yields
Over/under design of towers, drums
Misrepresented utilities
Over/under design of heat exchanger units
Agenda
Heavy Oil Overview
Sample Applications
Q&A
10
Best Practices Workflow

Assay Setup
Oil Properties
Build PFD
Enter Assay
lab data
Enter User
Cutpoint
ranges
Blend Oil &

Water streams
Check
Correlation set
Verify/alter
Extrapolation
& Conversion
Methods
Blend Assay &

Cut into Hypos
Alter emulsion
viscosity, if
necessary
Compare
Property Plots
Incorporate
entrainment
Install Oil
Use Utilities to
check products
11
Oil Characterization in Aspen HYSYS

Purpose: convert lab analyses Aspen HYSYS library and
hypothetical components
3 steps in Oil
Characterization:
1.
Characterize
the Assay
2.
Generate
Pseudo
Components
Cut/Blend
3.
Install the Oil in

the Flowsheet
12
True Boiling Point (TBP)

FBP
True Boiling Point Curve
1200
Bolining Point (C)
1000
IBPi
FBPi
800
600
400
200
0
IBP
20
40
Alternative Methods:
ASTM D86 (atmospheric batch distillation)
ASTM D1160 (vacuum batch distillation)
ASTM D2887 (chromatography)
Usually unsuitable for heavy crudes
13
60
Volum e % Distilled
80
100
1. Characterizing the Assay

Know how your lab handles its analysis:
Which analysis type?
Are they applying any corrections?
Are light-ends included? Or is it a separate analysis?
Input Composition
Auto Calculate
Ignore
14

Conventional Oil TBP
Heavy Oil TBP
700
1200
600
1000
Bolining Point (C)
Bolining Point (C)
800
500
400
300
200
100
800
600
400
200
0
-100
20
40
60
80
100
0
0
20
Volum e % Distilled
40
60
Volum e % Distilled
Heavy oil TBP has much fewer experimental points

No FBP or close point to it
15
80
100
1. Characterizing the Assay

Light Ends handling and Bulk Property fitting:
Are Light-ends included in the input curves?
Are Light-ends included in the bulk properties?
What bulk data do you have? Do you also have property
curves?
Do you want to control which part of the curve is tuned to
match the bulk property?
Understand the correlations used

Understand which conversion and extrapolation methods
are used
16
Best Practices
Specify Properties for Heavy Oils
Bulk property options include:

Molecular Weight > 16
Mass Density = 250 ~ 2000 kg/m3
Required
Watson K Factor = 8 ~ 15
Recommended
Bulk Viscosity, @ 100F and @210F
Required
Add other property curves

Molecular Weight curve
Density curve
Recommended
Viscosity curve (two curves)
Recommended
17
2. Generating Pseudocomponents
Blending is used to blend a number of assays. It provides a
general presentation of the whole crude. Cutting not only
generates the
pseudocomponents,
but also determines
their compositions
in the crude
Auto Cut: based
on values specified
internally
User Points:
specified cut points
are proportioned based on internal weighting scheme
User Range: specify boiling point ranges and the number of
cuts per range
18
Best Practices
Creating Hypotheticals for Heavy Oils
When generating pseudocomponents for heavy oil
fractionation, recommend using User Points or User Defined
Ranges
How many?
Minimum of 4 pseudocomponents per draw
Use Composite plot to
determine exact number
for each temperature
range
Test accuracy of input

assay data against
generated hypotheticals
How well does my data

match with Aspen HYSYS?
19
The undershoot in the

extrapolation could change to
overshoot as well
True Boiling Point Curve

1200
1000
B o lin in g Po in t (C )
In the absence of high FBP

experimental data the
extrapolation of the curve
could result in abnormalities.
This will have a great impact
on the set up of some unit
operations such as
distillation.
800
600
400
200
0
0
20
40
60
Volume % Distilled
Solution:
Use a guide point such as FBP or IBP
Use other distribution
20
80
100
Best Practices
Predict Heavy Oil Fractions
Use the Distribution Plot to help predict crude products
Enter custom cuts
to slice oil as desired
See product changes
with temperature
Use these fractions
as initial product
draw rates for
converging the
column (i.e., for
front end of an
upgrader)
Approximately
how much of every
product will I get?
21
3. Installing the Oil

Installing the oil in the flowsheet is done by providing a
stream name on the Install Oil tab. This:
1. Adds the pseudo components to the Fluid Package
2. Transfers the pseudo component information into the
Flowsheet
3. Creates a stream on the Flowsheet with a defined
composition
If you forget this step, you will not be able to see the oil
composition in the flowsheet!
22
Best Practices
Stream Utilities for Oils
Use stream Utilities to check individual streams against the
composite oil
Boiling Point Curves: calculates simulated distillation data and
critical property data for each cut point and cold properties
Cold Properties: shows boiling point
curve and breakdown of Paraffins/
Naphthenes/Aromatics for the
installed oil
23
Aspen HYSYS Can Accurately Predict

Important Heavy Crude Properties
The following section looks at special considerations in
predicting heavy oil properties, including:
n Specific Gravity/Standard Density
o Extrapolation Methods & Fitting Options
p Viscosity
q General Oil Properties, i.e., Thermal Conductivity
24
n Specific Gravity
Specific gravity is an extremely important data point for the
accurate extrapolation of heavy oils, as well as an important
data point to generate a missing SG curve
Bulk SG is, by default, optional and part of the assay analysis
It is therefore
recommended
that the bulk density
(or density curve)
be supplied as an
input parameter
for the accurate
characterization of
a heavy oil
25
Specific Gravity
Example Problem and Solution
Problem: Range of discrepancy in estimated density
values is 6% at lower NBPs and up to 11% at
higher NBPs
Solution: Apply different correlation sets for multiple NBP
ranges
Inconsistent/unreliable SGs at heavy ends can
result especially if the SG is estimated from any
correlation where NBP is the only independent
variable, since SG might also be a function of MW
The SG curve generated from input data should be
consistent and follow the trend of the boiling point curve
Watson K method creates a Watson K curve based on boiling curve
and average SG. This Watson K curve is used to generate component
SG boiling point, then moved up and down to match bulk SG.
26
o Curve Extrapolation
Available mathematical extrapolation methods (for both
ends) include:
Probability
Least squares
Lagrange
Recommended
selections for heavy
oils are shown here
The linear
extrapolation method
is not appropriate for extrapolating the SG, MW and viscosity
curves for heavy ends. The least squares (2nd order
polynomial), applied at both ends, is recommended.
27
Curve Fitting Options

Curve Includes L.E.
For each input curve, can specify:
Bulk Value
Bulk Value Incl. L.E.
Head %
Head Adjust Weight
Main %
Main Adjust Weight
Tail Adjust Weight
28

Problem: Property curves are shifted along y-axis
Solution: To correct discrepancies, you have 3 options:
Change Bulk
Value (least
accurate), or
Adjust Main %
and Tail Adj Wt.
to correspond
with data entry
points (manual),
or
Apply Smart
Bulk Fitting
(automatic)
29
Curve Fitting Options Example
30

Problem: TBP Curve is shifted along the liq. vol. x-axis
A TBP, by default, includes light ends; however, if the TBP was
obtained from a light-ends free sample, Aspen HYSYS can readjust the curve to the overall crude
Solution:
Choose to fit
with or without
light ends, as
appropriate:
In situations when only partial light ends analysis data is
available, Aspen HYSYS can generate overlapping hypothetical
components to compensate the missing portion of the light
ends, making the output stream matching both the partial light
ends input and the other input curves
31
p Viscosity
Viscosity is key to both successfully understanding the fluid
properties of a heavy oil and for predicting oil recovery
Both viscosity reduction and thermal expansion are the key
properties to increase productivity of heavy oils
Viscosity influences every aspect of a heavy oil development
Effect of viscosity on pressure gradients

For real liquids, the effect of pressure is relatively small when
compared to the temperature effect; but large pressure
gradients tend to occur with high viscosity oils. At higher flow
rates, frictional heating effects can become significant, and the
heating tends to reduce the oil viscosity, which in turn, affects
the pressure gradient. The net result is that the predicted
pressure gradient may be higher than should actually be
expected.
32
Viscosity Options in Aspen HYSYS

Since viscosity is the key property to proper heavy oils
characterization, we do not recommend omitting this
variable
Optional to use:
Bulk viscosity values (recommended)
Only viscosity curve
Two viscosity curves (optimal)
Higher flexibility on temperature extrapolation

Note: Bulk viscosity and viscosity curves can be input at
different temperatures
33
Heavy Crude Viscosity Trends
Cut Viscosity vs. Final Boiling Point
120000
250000000
100000
200000000
Viscosity (cSt)
Viscosity (cSt)
Full Crude Viscosity vs. Temperature
80000
60000
40000
20000
150000000
100000000
50000000
50
100
150
200
400
Temperature (C)
600
800
1000 1200
FBP (C)
Use two points from full crude viscosity curve.

High FBP viscosities are usually a result of extrapolation
using a log(log) approach.
34
Viscosity Curves
Problem: Calculated and inputted viscosity values dont
match. Depending on the application, bulk values are
good, but in other cases (like heavy oils) the cuts value
(i.e., residue) is better.
Quite a typical case:
Low quality viscosity
curves for extrapolation purposes
It is a measure range
problem
Inconsistent data
leads to a mismatch
of input to calculated
Solution: Manipulate
bulk value by trial and
error to match residue viscosity
35
Indexed Viscosity
Viscosity cannot be blended linearly, so a methodology is
adopted that substitutes a function of the measured viscosity
that is approximately linear with temperature. A linearized
equation for viscosity is given by Twu and Bulls (1980).
On the Parameters tab for equation of state methods, you
can change the viscosity calculation method from HYSYS
Viscosity to Indexed Viscosity to determine the blended liquid
viscosity
36
q General Oil Properties

When comparing Aspen HYSYS-predicted property values
against vendor, lab, or plant data, for properties such as
liquid density, viscosity, thermal conductivity and heat
capacity, there can be some discrepancies, since:
They are generated from general thermodynamic models
It is not realistic to expect model predicted results to exactly
match real data
To improve the accuracy of these properties, use the Tabular

feature in Aspen HYSYS to:
Edit the coefficients for property correlation
Regress lab data directly in Aspen HYSYS
37
Example: Improving Thermal Conductivity
Alter coefficients
Regress data
38
Checklist for Modeling Heavy Oils

9 Enter lab datadistillation data, light ends, bulk properties,
and/or curve data (MW, density, viscosity)
9 Verify correlation set used for assay over entire
temperature range
9 Validate appropriate selections for assay extrapolation and
conversion methods
9 Blend and cut assay using user cutpoint ranges
9 Compare plots of input data vs. calculated TBP curve,
gravity, viscosities, etc.
9 Install oil
39
Checklist for Modeling Heavy Oils

9 Blend water and oil streams; check emulsion properties
9 Build flowsheet
9 Incorporate phase entrainment in separators (using
carryover function) and columns (via efficiencies)
9 Use stream utilities (BP curves, Cold Properties) to check
individual streams against the composite oil
40
Agenda
Heavy Oil Overview
Sample Applications
Q&A
41
Steam Assisted Gravity Drainage (SAGD)
RECOVERED
DILUENT/SCO
DILUENT/
SYNTHETIC
CRUDE
Gas
Treating
SWEET
GASES
SOUR
GASES
GAS
Well Pad
Emulsion
Gas-OilWater
Separation
OIL [DILBIT/
SYNBIT]
WATER
STEAM/HEAT
Steam
Generation
42
To
Upgrader
or Pipeline

Aspen HYSYS Model
GAS TREATMENT
Make up Streams
Well Pad
DilBit
Diluent
To Upgrader
or Pipeline
OIL TREATMENT
WATER TREATMENT
STEAM GENERATION
43

DESIGN
OPERATIONS
Model wellpad characteristics

Model separation of water,
oil, and gas phases
Use model to make decisions

in all phases of operation
preheat, steam injection & oil
production, and blowdown
Track and report key
componentssulfur, etc.
Determine how operating
improvements
Additions of diluent and/or

solvents, their flow conditions,
separation scheme & recovery
Bitumen treatment and recovery
Steam generation
Water treatment (incl. softening)
Perform profit calculations

(upgrade to SCO or sell)
Consider new technology
partial upgrading in-situ,
combustion, VAPEX, etc.
Increase bitumen separation/

recovery
Reduce energy requirements
Improve water usage
44
Agenda
Heavy Oil Overview
Sample Applications
Q&A
45
Recommendations for Heavy Oils

1. For Assay data, generally suggest entering Gravity, Boiling
Point Range, Watson K;
For Heavy Crudes, recommend including ViscosityBulk or
Curve
2. When generating Pseudo-Components, Auto-Cut option is
not the best choice for heavy oil fractionation; recommend
using User Points or User Defined Ranges; generate a
minimum of 4 pseudo-components per draw
3. Suggested Thermodynamic Methods are:
Heavy Hydrocarbons:
Light Hydrocarbons:
Hydrogen Rich:
Sour Water:
Peng
Peng
Peng
Peng
Robinson with Lee-Kesler Enthalpies

Robinson
Robinson
Robinson Sour
46

4. Verify usage of:
Correlations set
Extrapolation methods for property curves
Fit option with light ends
5. Use Plots and Utilities to match data to model and correct

for any deficiencies in data
Plots: Composite, Oil Distribution

Utilities: Cold Properties, BP Curves
6. Integrate lab/plant data into thermodynamic parameters
47

7. Aspen HYSYS can match Heavy Oils data for simulation
studies as validated in three papers
Hyprotech, HYSYS, and Oils

Technical Audit of Heavy Oil Characterization Methods
Heavy Crude Oil Handling
8. Simulation Basis ManagerChapter 4, Aspen HYSYS Oil

Managerprovides all the technical details and options
9. Support Knowledge Base offers many solutions on this topic
Sample files
Technical tips: keywords such as, viscosity, thermal conductivity,
density
Example file: The usage of Indexed Viscosity option in HYSYS
with an example
48
Agenda
Heavy Oil Overview
Sample Applications
Q&A
49
Want to see similar results?
Consider a training class from AspenTech
http://support.aspentech.com/supportpublictrain/TrainHome.htm
50
50
Aspen HYSYS Training
Aspen HYSYS: Process Modeling (EHY101)

February 16, 2010 -- Virtual Americas
February 23, -- Pune, India
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY101
Optimize engineering work processes using the full power and

flexibility of Aspen HYSYS to build, evaluate and optimize flowsheets.
Learn the shortcuts for efficient use of the software to build steady
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51
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Learn the shortcuts for efficient use of the software to build steady
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52
Process Modeling Additional Topics (EHY201)

February 4, 2010 Seoul, Korea
February 19, 2010 Virtual Americas
1
Use and apply advanced modeling techniques to enhance existing
Aspen HYSYS flowsheets.
Create custom columns, including non-standard configurations.
Perform complex calculations on flowsheet variables.
Create models that emulate plant conditions.
53
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to help you get started
You do nothing AspenTechs Training Group

will contact you to:
1. Provide you with the promotional discount code
for this event
2. Review training dates and options with you
3. Answer any questions you have
55
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On-Demand Webinars:
Over 50 recordings of past webinars on Engineering
Visit:
http://www.aspentech.com/events/ondemand_webinar.cfm
Future Webinars:
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Featuring: Guest speaker Eascon (Italy)
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Register at:
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56
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For more information:

Email: sanjeev.mullick@aspentech.com or dan.mccarthy@aspentech.com
Web:
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58

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59
Dr. Mohammad Khoshkbarchi

Senior Project Manager, Process Ecology
Email: mohammad@processecology.com
Dr. Glenn Dissinger
Director, Product Management, AspenTech
Email: glenn.dissinger@aspentech.com
Sanjeev Mullick
Director, Product Marketing, AspenTech
Email: sanjeev.mullick@aspentech.com
60

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