Applications of CFD in the Oil Sand Industry
Transcript of Applications of CFD in the Oil Sand Industry
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Securing Canada's Energy Future1
Applications of CFD in the Oil Sand Industry
NETL Workshop on Multiphase Flow SciencePittsburgh, PA
May 4th-6th, 2010Kevin Reid
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Securing Canada's Energy Future2
• First Point– Sub Point
Syncrude is located in Northern Alberta and has 8 oil sand leases with significant reserves.
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Securing Canada's Energy Future3
Who and What are the Oil Sands and Syncrude?
Syncrude here and how
• Largest oil sands producer in the world
• Largest single source of oil in Canada
• Major employer
• Top researcher
• Multi-billion dollar, triple bottom line business
The Canadian Oil Sands are a rich and vast resource• 1.7 trillion barrels in-place
• 300+ billion barrels recoverable
• More than 30% of Canada’s oil production is from the oil sands
• Slated to increase to 50% by 2020
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Securing Canada's Energy Future4
Who is Syncrude? Joint venture undertaking among:
ConocoPhillips Oilsands Partnership
II9%
Nexen Oil Sands Partnership
7%
Mocal Energy Limited5%
Imperial Oil Resources
25%
Canadian OilSands Limited
37%
Murphy Oil Company Ltd.5%
Petro-Canada Oil & Gas 12%
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Syncrude operates mining, extraction, upgrading and utilities plants in order to produce synthetic crude from
oil sand
Mining
Extraction
Upgrading
SSB
Utilities
Bitumen Production Operations
Bitumen Processing Operations
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History of CFD at Syncrude
• 1984-1990– Simple 2-D single phase projects contracted out
• 1990 - 2000– Obtained first commercial code (Flow3D from AEA)– Ran two Unix computers– 3-D multiphase transient problems– Primarily used external contractors– Mostly exploring CFD capability – not integrated into research
projects• 2000 – Present
– Larger and more complicated 3-D multiphase transient problems– Done in-house as well as through external consultants– Integrated into research projects to compliment experimental work
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Securing Canada's Energy Future7
History of CFD at Syncrude
CFD Growth at Syncrude
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
4000000
4500000
5000000
1984
1993
1994
1995
1997
1998
2000
2002
2003
2005
2006
2008
Year
No.
of C
ontr
ol V
olum
es
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Securing Canada's Energy Future8
Primary Separation Vessels
Aurora PSV
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Securing Canada's Energy Future9
Full Bustle Design (Current)
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Full Bustle Design (Current)
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Full Bustle Design (Current)
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Half Bustle Design (Proposed)
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Half Bustle Design
Left Middlings Inlet Right Middlings Inlet
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Half Bustle Elbow Design
•90o / 1.5D Elbow• rotated 10o towardscenter of vessel
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Radial (X = 0 m) PlaneTime Averaged Velocity
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Commercial Bustle Pipe
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Securing Canada's Energy Future17
FLUID COKINGTM Unit Overhead Line
Reactor
Burner
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FLUID COKING Unit Overhead Line
Burner O/H Line
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Commercial Orifice Plate & Coanda R&D Model
Commercial Scale Coanda Model Scale
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CFD Validation – PV23
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PV23 / MHO Spacing
20’ Spacing 30’ Spacing
PV23
FO 205
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FLUID COKING Units
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Solid Flows
Scouring Coke Line
Hot Coke Line
Dense Phase
Stripper
Sore Thumb
Cyclones
Scrubber Grid
Scrubber
Reactor
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Gas Flows
Scrubber
Reactor
Scrubber Grid
Scouring Coke Line
Hot Coke Line
Cyclones
Dense Phase
Stripper
Sore Thumb
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FLUID COKING Unit Scrubber Improvements to Reduce Clay Carryover
• CFD Simulations– Performed at CSIRO– Led Cold Flow Work1. Gas Phase Only
• Swirl Noted• Baffles Disrupted
2. G\L Phase • Droplet
breakup/coalescence model• Heat transfer and flashing
included
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FLUID COKING Unit Scrubber Improvements to Reduce Clay Carryover:
CFD Simulations
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FLUID COKING Unit Scrubber Improvements to Reduce Clay Carryover:
CFD Simulations
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FLUID COKING Unit Scrubber Improvements to Reduce Clay Carryover
Commercial Installation
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Conclusion• How does Syncrude use CFD Today?
Innovation Cycle
Commercial
Cold Flow Model CFD Model
Industry Support
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Acknowledgements
• Thanks to the following people who provided support for this presentation– Larry Hackman– Craig McKnight– Barry Bara– Michael Wormsbecker– CSIRO– PSRI– ExxonMobil