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
© 2010 Aspen Technology, Inc. All rights reserved | 2

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
Diluent 0.5 – 11.0 cSt
Oil API:
Conventional Crude > 25 °API
Conventional Heavy 25 – 18 °API
Extra Heavy (Thermal) 20 – 12 °API
Tar Sand 12 – 7 °API

Where Does it Exist?
• Heavy oil deposits total almost 5½ 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 it’s 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

Best Practices Workflow
Assay Setup Oil Properties Build PFD
Enter Assay Enter User Blend Oil &

lab data Cutpoint Water streams
ranges
Check Alter emulsion
Correlation set Blend Assay & viscosity, if
Cut into Hypos necessary
Verify/alter
Extrapolation Compare Incorporate
& Conversion Property Plots entrainment
Methods
Install Oil Use Utilities to
check products

Oil Characterization in Aspen HYSYS
• Purpose: convert lab analyses Æ 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

True Boiling Point (TBP)
FBP
True Boiling Point Curve
1200
1000
IBPi FBPi
Bolining Point (C)

800
600
400
200
0
0 20 40 60 80 100
IBP Volum e % Distilled
• Alternative Methods:
− ASTM D86 (atmospheric batch distillation)
− ASTM D1160 (vacuum batch distillation)
− ASTM D2887 (chromatography)
• Usually unsuitable for heavy crudes
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

Conventional Oil TBP Heavy Oil TBP

800
700 1200
600 1000
Bolining Point (C)
Bolining Point (C)

500
800
400
600
300
200 400
100
200
0
0 20 40 60 80 100 0
-100
0 20 40 60 80 100
Volum e % Distilled
Volum e % Distilled
• Heavy oil TBP has much fewer experimental points

• No FBP or close point to it

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

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, @ 100°F and @210°F Required
• Add other property curves

– Molecular Weight curve
– Density curve Recommended
– Viscosity curve (two curves) Recommended

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

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 pseudo-
components 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”?
• In the absence of high FBP

experimental data the True Boiling Point Curve
extrapolation of the curve 1200
could result in abnormalities.
This will have a great impact 1000
on the set up of some unit
B o lin in g Po in t (C )
800
operations such as
distillation.
600
400
• The undershoot in the 200

extrapolation could change to
overshoot as well 0
0 20 40 60 80 100
Volume % Distilled
• Solution:
− Use a guide point such as FBP or IBP
− Use other distribution

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”?

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!

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

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

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

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.

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.

Curve Fitting Options
• For each input curve, can specify: – Curve Includes L.E.

– Bulk Value
– Bulk Value Incl. L.E.
– Head %
– Head Adjust Weight
– Main %
– Main Adjust Weight
– Tail Adjust Weight

• 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)

Curve Fitting Options Example

• 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 re-
adjust 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

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.

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

Heavy Crude Viscosity Trends
Full Crude Viscosity vs. Temperature Cut Viscosity vs. Final Boiling Point
120000 250000000
100000 200000000
Viscosity (cSt)
Viscosity (cSt)
80000
150000000
60000
100000000
40000
20000 50000000
0 0
0 50 100 150 0 200 400 600 800 1000 1200
Temperature (C) FBP (C)
• Use two points from full crude viscosity curve.

• High FBP viscosities are usually a result of extrapolation
using a log(log) approach.

Viscosity Curves
• Problem: Calculated and inputted viscosity values don’t

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 extra-
polation 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
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

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

Example: Improving Thermal Conductivity
Alter coefficients
Regress data

Checklist for Modeling Heavy Oils
9 Enter lab data—distillation 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

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

Agenda
Heavy Oil Overview

Sample Applications
Q&A

Steam Assisted Gravity Drainage (SAGD)
Gas SWEET
Treating GASES
RECOVERED
DILUENT/SCO
SOUR
GASES
DILUENT/
SYNTHETIC
CRUDE GAS
Gas-Oil- OIL [DILBIT/ To

Well Pad Water Upgrader
Emulsion Separation
SYNBIT] or Pipeline
WATER
STEAM/HEAT Steam
Generation

Aspen HYSYS Model

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

DESIGN OPERATIONS
• Model wellpad characteristics • Use model to make decisions
• Model separation of water, in all phases of operation—
oil, and gas phases preheat, steam injection & oil
production, and blowdown
– Additions of diluent and/or
solvents, their flow conditions, • Track and report key
separation scheme & recovery components—sulfur, etc.
– Bitumen treatment and recovery
• Determine how operating
– Steam generation improvements
– Water treatment (incl. softening) – Increase bitumen separation/
• Perform profit calculations recovery
(upgrade to SCO or sell) – Reduce energy requirements
• Consider new technology— – Improve water usage
partial upgrading in-situ,
combustion, VAPEX, etc.

Agenda
Heavy Oil Overview

Sample Applications
Q&A

Recommendations for Heavy Oils
1. For Assay data, generally suggest entering Gravity, Boiling

Point Range, Watson K;
For Heavy Crudes, recommend including Viscosity—Bulk 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: Peng Robinson with Lee-Kesler Enthalpies
Light Hydrocarbons: Peng Robinson
Hydrogen Rich: Peng Robinson
Sour Water: Peng Robinson Sour

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

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 Manager—Chapter 4, Aspen HYSYS Oil
Manager—provides 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

Agenda
Heavy Oil Overview

Sample Applications
Q&A

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Web: http://www.aspentech.com/aspenoneglobalconference
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

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Modeling Heavy Oils in

Engineering Excellence Webinar Series

© 2010 Aspen Technology, Inc. All rights reserved

• Dr. Mohammad Khoshkbarchi

© 2010 Aspen Technology, Inc. All rights reserved | 2

 Heavy Oil Overview

© 2010 Aspen Technology, Inc. All rights reserved | 3

• Has over 60 carbon atoms, and hence, a high BP & MW

• Mainly comprised of hydrocarbons heavier than pentanes,

• High amounts of nitrogen, sulfur (~5%),

• Exists in a semi-solid state and may not

© 2010 Aspen Technology, Inc. All rights reserved | 4

© 2010 Aspen Technology, Inc. All rights reserved | 5

• Heavy oil deposits total almost 5½ trillion barrels (est.);

© 2010 Aspen Technology, Inc. All rights reserved | 6

– Average density is API = 8°

© 2010 Aspen Technology, Inc. All rights reserved | 7

• Characterizing the oil

© 2010 Aspen Technology, Inc. All rights reserved | 8

• Incorrect wellhead conditions

© 2010 Aspen Technology, Inc. All rights reserved | 9

 Heavy Oil Overview

© 2010 Aspen Technology, Inc. All rights reserved | 10

Assay Setup Oil Properties Build PFD

Enter Assay Enter User Blend Oil &

© 2010 Aspen Technology, Inc. All rights reserved | 11

• Purpose: convert lab analyses Æ Aspen HYSYS library and

© 2010 Aspen Technology, Inc. All rights reserved | 12

Bolining Point (C)

• Know how your lab handles its analysis:

© 2010 Aspen Technology, Inc. All rights reserved | 14

Conventional Oil TBP Heavy Oil TBP

Bolining Point (C)

• Heavy oil TBP has much fewer experimental points

© 2010 Aspen Technology, Inc. All rights reserved | 15

• Light Ends handling and Bulk Property fitting:

• Understand the correlations used

© 2010 Aspen Technology, Inc. All rights reserved | 16

• Bulk property options include:

• Add other property curves

© 2010 Aspen Technology, Inc. All rights reserved | 17

• Blending is used to blend a number of assays. It provides a

– Auto Cut: based

– User Range: specify boiling point ranges and the number of

© 2010 Aspen Technology, Inc. All rights reserved | 18

• When generating pseudocomponents for heavy oil

“How well does my data

• In the absence of high FBP

on the set up of some unit

• The undershoot in the 200

© 2010 Aspen Technology, Inc. All rights reserved | 20

• Use the Distribution Plot to help predict crude products

© 2010 Aspen Technology, Inc. All rights reserved | 21

• Installing the oil in the flowsheet is done by providing a

© 2010 Aspen Technology, Inc. All rights reserved | 22

• Use stream Utilities to check individual streams against the

© 2010 Aspen Technology, Inc. All rights reserved | 23

The following section looks at special considerations in

n Specific Gravity/Standard Density

o Extrapolation Methods & Fitting Options

q General Oil Properties, i.e., Thermal Conductivity

© 2010 Aspen Technology, Inc. All rights reserved | 24

• Specific gravity is an extremely important data point for the

© 2010 Aspen Technology, Inc. All rights reserved | 25

Heavy Oil Overview

Heavy Oil Overview

Heavy Oil Overview

Heavy Oil Overview

Heavy Oil Overview