Petrobras Technology 2011

7/28/2019 Petrobras Technology 2011

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Petrobras is internationally recognized orits history o achievements and currentlyranks among the worlds most innovativecompanies in the oil and energy sector.Our capacity goes beyond the creationo solutions or the challenges posed

by the market. We attempt to anticipatescenarios, expand rontiers in the use o traditional energy sources, and diversi yenergy generation with new raw materi-als and products, always emphasizingsustainability in the production and con-sumption o energy. And, or that, tech-nological innovation is critical.

For the greater part, our per ormanceresults rom the signi cant investments

in technology development and technicalskills made throughout the companyshistory. These are investments that growconsistently. In 2011, Petrobras investedUS$1.5 billion in R&D a 47% increaseover 2010.

In addition to boosting the results o Petrobras itsel , investments and e ortsdedicated to technology leveraged theentire oil, gas and bio uels industry chain.We invest in our internal research capac-ity and, in parallel, we maintain intense,productive exchanges with the external

environment, acting in cooperation withBrazilian and oreign institutions, universi-ties and suppliers, which also stand outor their innovation capacity. The per or-mance in networks enables joint growthtowards development o local content or

our industry, which improves its ability toprovide, with increasing excellence, goodsand services demanded by the sector,with sa ety, speed, and e cacy.

This 2011 Petrobras Technology reportgathers the main results obtained in theareas o basic engineering and researchand development throughout 2011. Bypublishing these results to our investorsand partners, we are showing some o the

trends in which we are investing to ensurethe sustainable growth that Petrobras hasdemonstrated throughout its history.

Maria das Graas Silva Foster Petrobras CEO


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TECHNOLOGY

STRATEGY10 11 12 14

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2011 RESULTS

e x p a n s i o n o

l i m i t s

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t d i v e r s

i f c a

t i o n

s u s t a

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b i l i t yexploration o

new rontiers

maximization o oil recovery

development o pre-salt

production, operationsand logistics

development o a newgeneration o o shoreand subsea productionsystems

classi cation o rocksand fuids in pre-salt andother complex reserves

logistic solutions ornatural gas in remoteareas

operational optimization

and reliabilityfexibilization o there ning park

innovation inuels, lubricants andspecial products

petrochemicals

gas-chemicals

bio uels

energy rom otherrenewable sources

management o water ande fuents

management o CO2 and other emissions

energy e ciency

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As the largest Brazilian company and one

o the principal organizations in the world in

the areas where it operates, Petrobras has

a clear vision o the importance o innova-

tion to its businesses. The results achievedthroughout its history are largely due to

continuous investments in technology and

innovation. Since its early years, the com-

pany has maintained a technology strategy

that is constantly renewed and adapted

to the national historical context and the

companys goals.

A brie history o this strategy is presented

here, starting with the creation o Petrobras,

in 1953. Petrobras resources or innovation,

based on pro essional quali cation, invest-

ments and cutting-edge experimental in ra-

structure, are also highlighted in this report,which includes technological partnerships

with suppliers and Science & Technology

Institutions.


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HISTORYFrom the ormation o the company, in

1953, to the mid -1970s, the implemen-tation o re ning industry was the maindriver. In this period, Brazil imported oil,and the main objective was to promotethe national capability o processing andproduction o uel to supply the domesticmarket. Petrobras needed to learn there ining technologies available in theworld to improve and adapt them to the

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national demands. That was a period

o great emphasis on the quali cationo human resources or this industry.Petrobras Research & DevelopmentCenter (CENPES) was created in 1963,within this context.

In 1974, the Garoupa eld openedup the recently discovered exploratoryrontier o the Campos Basin, beginningthe various discoveries o the rst giant

o shore elds o the company, such as

Albacora, Marlim and Roncador. Thisoil province changed the scenario o theoil and gas industry in Brazil and madePetrobras signi cantly change its inno-vation strategy: it was no longer possibleto learn only rom oreign experiences.The challenges or the development o these elds were unprecedented and wewould have to develop new technologies

Semisubmersible plat orm Sedco 135D in operation in the Enchova ield, in the Campos Basin 1977

Construction o Gabriel Passos Refnery (REGAP), in Betim (MG) 1960s


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to achieve that much desired o shore

production, rom increasingly deepwaters. We searched or partners withcompetence, both in Brazil and abroad.We were internationally recognized orour pioneering work in the productionrom deep waters. We have received twomaximum recognitions at the O shoreTechnology Con erence (OTC), the maintechnology orum in the industry.

Construction o Petrobras Research Center 1970s


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PRE-SALTAND PETROBRAS

TECHNOLOGYSTRATEGY

With the discovery o the Lula ield in2006, and the consequent con irma-tion o the new exploration rontiero the pre-salt, we witnessed a newmilestone in the oil and gas industryin Brazil. With extensive previous ex-

perience in deep waters, the companyhad amiliarity with the technologicalsolutions necessary or this scenarioand vast knowledge to develop the pro-duction in this new province. However,given the scale o these reserves, evenminor process and technology im-provements may generate signi icantcost reduction and e iciency gains.

This is a great market opportunityor the development o a new gen-

eration o technologies or o shore oiland gas production, with a signi icantapplication scale. The Brazilian regu-latory environment, associated withthis opportunity, strongly encouragesend-to-end conception, developmentand application in Brazil, and we haveseen this in our actions and in theactions o our suppliers and partners.The country has become attractive to

the leading players o this industry.Conditions have been created

or Brazil to increase not only its hy-drocarbon production, but also thegeneration o technologies. Brazil o ersa variety o opportunities or large sup-pliers and service providers. These arenot simply installing their productionunits in the country. They are ndingways to generate technology locally,through captive research centers andin partnership with national science andtechnology institutions which are highlyencouraged by investments in the

sector. Innovation at Petrobras directsthe companys e orts to the manage-ment o a large network o technologydevelopment in Brazilian territory whichis articulated with the main technologycenters o excellence in the energyindustry worldwide.

The amount o business generatedby the pre-salt to suppliers o equip-ment and services and to operators o

the oil and gas industry is the driveror the consolidation, in Brazil, o oneo the biggest technology centers o the sector in the 21st century. Thismovement is related to the BusinessPlan o Petrobras a company thathas historically operated in partnershipwith well known institutions around theglobe, as well as Brazilian universities,national suppliers and others. Thus, alarge network o cooperation has beenconsolidated and directed to local inno-vation capability, aiming at the scenarioon which Petrobras technology strategy

is currently grounded.The results presented in this re-

port are the consequence o this strat-egy and generated, to a large extent,by this broad network o innovationcreated by Petrobras and its partners.

Three pillars are essential to en-able this technology strategy: peoplewith excellent quali ications; properinancial resources in relation to the

challenges; laboratories and cutting-edge in rastructure or experiments.These three pillars are materialized byPetrobras resources and the network o partnerships established with universi-ties and suppliers. Leopoldo AmricoMiguez de Mello Research & Develop-ment Center (CENPES) manages thetechnology unction at Petrobras; itis responsible or the coordinationo research, development and basicengineering activities at the companyand also the articulation with partnersor technological development.

Illustration o pre-salt layers

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Some o CENPES employees recognized or important associations,

companies, institutes and congresses in Brazil and abroad in 2011

HUMAN RESOURCES

CENPES has today 1,814 employees,70% o which are exclusively dedicatedto research and development. Thesepro essionals have a high quali cationpro le: 24% o the researchers havea doctorate degree and 43% havea masters degree. In addition, theResearch and Development Centerhas 314 engineers dedicated to basicengineering activities at Petrobras; theyare responsible or the irst phaseso large development projects. Thisarrangement places designers closer

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to researchers, acilitating the applica-tion o technological innovations toengineering projects o the company.

This group o pro essionals dedi-cated to the activities o Research,Development and Engineering is only

one part o the broad network estab-lished by technological partnerships,signi cantly expanding the technologi-cal development capability o Petrobrasand Brazil. A recent study conductedby the Institute or Applied EconomicResearch (IPEA) estimated that, or

each researcher in CENPES, there arearound 18 external researchers, at uni-versities, suppliers and partners. Whenconsidering only Brazilian universitiesand research institutions, the estimateis o around 15 external researchersto each internal researcher, workingon projects to address the companystechnological challenges.


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Petrobras R&D Investment

R&D investment by large energy companies in 2011

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2006 2007 2008 2009 20102001 2002 2003 2004 2005 2011

million US$

0

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600

900

1,200

1,500

6x

2001-2003 average:US$ 160 million

2009-2011 average:US$ 1,041 million

A

B

C

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D

E

2.05 (0.7%*)

1.45 (1.0%*)

1.12 (0.2%*)

1.08 (0.5%*)

1.07 (2.7%*)

1.04 (0.2%*)

* % of Gross Revenue

Source: Evaluate Energy

billion US$

FINANCIAL RESOURCESThe inancial resources dedicated toR&D at Petrobras have constantly grown,especially in the last ve years. In 2011,Petrobras invested US$ 1.5 billion inR&D, a 47% increase in relation to 2010.Such consistent increase became moreintense in 2006. When comparing the

average investment in 2001-2003 tothe average value o 2009-2011, theamount o resources increased morethan six times.

In recent years, this amount hassystematically placed Petrobras amongthe top ve corporate R&D investors in

the energy area, worldwide.The R&D resources have a similarpro le to that o total Petrobras invest-ment distribution, allocated by businessarea.


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Investments oreseen by Petrobras by business area or 2011-2015 (billion US$)

R&D investments by area in 2009-2011

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127.5* (57%)

213.5 (95%)

11.2 (5%)2.4 (1%)3.1 (1%) 4.1 (2%)

3.8 (2%)

13.2 (6%)

70.6 (31%)

*US$ 22.8 billion in ExplorationBrazilAbroad

E&PRe ning,Transportation & TradeBiofuelsDistribution

PetrochemicalsGas, Energy& Gas-chemicalsCorporate

11%

47%

21%

4,5%

6%

10%

0,5%

Total: US$ 3.1 billion

ExplorationProductionDownstreamBiofuelsGas & EnergyEnvironmentOther R&D activities


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EXPERIMENTION INFRASTRUCTUREIn recent years, the resources invested by Petrobras in itsown R&D acilities and in the implementation o cutting-edgelaboratories at national R&D institutions have contributed tothe consolidation o a world-class experimentation park inBrazil or the industry o oil, gas and energy.

Petrobras R&D Center has one o the largest and mostmodern research acilities worldwide, occupying a total areao 300,000 m2 in Cidade Universitria, Rio de Janeiro. Thiscomplex has experimentation plants, modern laboratories

and a Visualization and Collaboration Center or simulations,interactivity and immersion o several processes related tothe energy industry. Besides the acilities in Rio de Janeiro,CENPES also has six experimentation centers (see below)near their related business areas, which per orm tests ona semi-industrial scale, an essential phase or technologyescalation and its uture availability to Petrobras.

R&D in rastructures o Petrobras and its partners

Experimentation Centerin Fortaleza (CE)

Experimentation Centerin Atalaia (Aracaju - SE)

Experimentation Centerin Miranga (BA)

SIX Re ning Technology(So Mateus do Sul - PR)

CENPES

Experimentation Centerin Taquipe (BA)

Technology Centers o BakerHughes, Schlumberger andFMC Technologies

Rio de Janeiro (RJ)

ExperimentationCenters

TechnologyCenters o large suppliers

R&D in rastructureprojects unded byPetrobras and implementedat Brazilian Science andTechnology Institutions

1 a 4

5 a 8

10 a 14

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Technology Park in Rio de Janeiro,

at UFRJ, where the technology centers

o Baker Hughes,

Schlumberger and FMC Technologies are installed. CENPES

may be seen in the upper part

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The research in rastructure is not limited to the com-panys acilities.

Since the creation, in 2006, o the Thematic Networks a model that promoted partnerships between Petrobrasand Brazilian universities and research institutions , theamount invested in laboratory in rastructure has consistentlyincreased. Twenty- our laboratories were inaugurated or ex-panded at universities and research institutions in Brazil in2011, with resources o around R$ 77 million spent duringthe construction and/or equipment acquisition phases.

The national technology park was urther enhancedwith the arrival in Brazil o some o the main suppliers o equipment and services in the energy sector. Attracted by thescenario o great opportunities involving the pre-salt reserves,some o the largest companies operating in this industry

decided to establish in Brazil not only their production plants,but also captive research centers and experimentation plants,to develop here in partnership with Petrobras and Brazil-ian science and technology institutions new technological

solutions.Some o them will have their research centers installed

in the Technology Park, in Cidade Universitria, at theFederal University o Rio de Janeiro (UFRJ), near PetrobrasResearch Center. Schlumberger, one o the worlds largestsuppliers o exploration and production services inauguratedits research center there in 2010. In 2011, Baker Hughes,an important competitor o Schlumberger, also installed itsacilities in the park. The company inaugurated its researchcenter in Cidade Universitria at the UFRJ so as to developsolutions and technologies that will optimize the productionin deep waters and in the pre-salt reserves. In 2011, FMCTechnologies also started to build its research center andexperimentation plants or the development and testing o subsea oil and gas production and processing systems.

In the coming years, other research centers o suppliersmay be inaugurated in both Cidade Universitria, at the UFRJ,and on the campuses o other Petrobras partner universities.


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The research projects are undertaken ac-

cording to the strategic business plan o the

company. Each project aims at o ering solu-

tions to support one or more business goals.

They are organized according to the three

main pillars o the companys technological

development: expansion o the current

Petrobras business limits; value addition and

product diversi cation and sustainability o

the energy industry.The key results o research and develop-

ment achieved in 2011 are presented in this

report or each o the companys principal

technological development pillars.


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EXPANSIONOF LIMITS

logisticsolutionso naturalgas in remoteareas

explorationo new rontiers

classi cationo rocks and fuidsin the pre-salt andother complexreserves

development o a new generation o o shore and subsea

production systems

developmento pre-salt production,operations and logistics

operationaloptimizationand reliability

fexibilizationo the re ning park

maximizationo oil recovery

This pillar includes all lines o research and projects or the expansion o Petrobras

conventional businesses: oil and natural gas exploration and production, processing,re ning and the production o uels and by-products, as well as transportation andlogistic systems required to per orm these activities. It includes all research projectsthat seek new techniques and methods, as well as constant improvements to ourproduction processes, intended to maximize business results.


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SUSTAINABILITY

VALUEADDITION AND PRODUCT DIVERSIFICATION

innovationin uels, lubricantsand specialproducts

management o water and e fuents

management o CO2 and otheremissions

energy e ciency

petrochemicals

gas-chemicalsbio uels

This pillar involves the R&D projects or sustainability in all Petrobras processesand products. The research activities included here are di erent rom those o theother two pillars, as the permanent objective is to mitigate possible negative impactsthat can be neutralized or even changed into positive environmental and economicresults, with the conversion o waste and emissions into products that add value tothe industry. The management o water, e fuents and emissions, as well as energye ciency improvement projects, are present here.

This pillar includes projects to expand the diversity o energy sources and port olio o

products o ered by Petrobras. It involves the constant search or quality and per or-mance o uels, lubricants and special products; the technologies or petrochemicalsand gas-chemicals to trans orm hydrocarbons into high-value industrial products; theconstant improvements o uels and other biomass originated products, as well as thedevelopment o new sources o renewable energy.


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EXPANSIONOF LIMITS

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explorationo new rontiers

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the integration o geologicalsimulators improves the studyo oil system evolution

Petrobras has recently developed its own computer

simulator, named SimBR, to model hydrocarbon genera-tion and accumulation processes in sedimentary basins.This so tware simulates the evolution o sedimentarylayers, reproducing physical and chemical processeso the interaction o rocks and luids over geologicaltime. In 2011, researchers incorporated into SimBR astratigraphic modeling so tware called Steno, which canmore precisely estimate the distribution o

Computer simulator SimBR applied to studies into the evolution o sedimentary layers over geological time

di erent types o sediments during the ormation o lay-

ers. For instance, Steno simulates the process o sanddeposition in distinct parts o a basin. Then, a morerealistic representation o the occurrence in rocks in thegeological layers is obtained, which is later incorporatedinto SimBR. The utilization o these two applicationsenables Petrobras to better understand the evolutiono oil systems which is essential or the reduction o exploratory risks.


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Petrobras has implemented Reverse Time Migration (RTM),to improve seismic imaging

This is the most popular technology in the oil industryto obtain seismic imaging o good quality in geologi-cally complex areas. This methodology implemented inPetrobras uses the ull wave equation, while traditionalseismic processing considers only the vertical propa-gation. The representation o more complex orms o

the seismic wave enables better imaging quality and

The first sampling of gas hydrates has been performed off the Brazilian coast

Gas hydrates are compounds that occur in nature inthe orm o ice, where gas molecules are surrounded bywater molecular structures under high pressure and lowtemperature conditions. They are ound in sedimentswith high gas concentrations on the sea loor, startingat 500 meters o water depth and below, and underthe perma rost in polar regions. These compoundsmay constitute a new non-conventional source o energy, whose commercial use has not been proven.In a partnership with Ponti ical Catholic University o Rio Grande do Sul (PUC-RS), marine sediments were

Seismic section o the pre-salt, in the Santos Basin, processed with

RTM technology

collected rom the Pelotas Basin (RS, Brazil) tens o meters below the sea loor, to check or occurrence o hydrates. Depending on the results, high-resolutiongeochemical and geophysical data will be collected inthe irst hal o 2012 using an autonomous underwatervehicle, or a more accurate mapping o the region.Petrobras is investing around R$ 23 million in thesestudies, whose objective is to characterize these oc-currences and enable uture exploration o this newenergy resource. R E

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provides support to estimate physical properties o rocks, in search o reserves with the best characteristicso porosity and permeability. The implementation o RTM technology by Petrobras will enable the develop-ment, in 2012 and 2013, o unique improvements orexclusive use by the company, such as the inclusiono anisotropy e ects (variation o seismic propertieso rocks along the measurement direction), whichare essential or obtaining better images o areas o complex geology, such as the carbonate reservoirs o

the pre-salt.


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Conclusion of basic designs and upgrade

FEED for semisubmersible drilling rigs P-14 and P-17

The project or P-14 includes modernization with increasein drilling capacity, rom 350 meters to a maximum o 1,100 meters o water depth. The project or P-17 in-cludes increase in drilling capacity, rom 700 meters toa maximum o 2,000 meters o water depth. In pioneerwork, the upgrade in rig hulls will be per ormed withthe rigs foating, providing savings o R$ 32 million tothe company. This innovation may be applied to other

upgrade projects o Petrobras semisubmersible rigs. Bothprojects have been certi ed by the Certi cation SocietyBureau Veritas (BV).

Virtual model o plat orms P-14 and P-17, a ter upgrade

Maximizationo oil recovery


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The irst well in the world drilled withthe Liner Conveyed Gravel Pack (LCGP)technology, which reduces drilling time o horizontal wells in mature sandstone ields

With investments o US$ 4 million made by Petrobras and

in partnerships with Baker Drilling Fluids and Halliburton,a synthetic fuid was developed or wells in sandstone eldsthat enables the installation o a sand production controlsystem to prevent problems associated with erosion,especially in the horizontal portions , ollowed by the 7

Project evaluates glycerin injectionor enhanced recovery o oil in Pojuca

River ield

The biodiesel production scale oreseen or the comingyears may generate a large amount o glycerin by-product,well above the estimated consumption o the Brazilian andinternational markets. To prevent excess glycerin avail-

ability, Petrobras has developed a technology that injectsthis by-product, combined with a special sur actant, orenhanced oil recovery. As a consequence, a new eco-nomic application has been created or this compound,

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liner cementation in only one maneuver. This pioneer

application was success ully per ormed in 7-MRL-212-RJS well (Marlim eld), and it has enabled single-phasewell drilling with gains in angle and horizontal portions,in existing wells rom mature elds o the Campos Basin,reducing these operations by up to seven days.

which may use its entire additional estimated production.Glycerin combined with a sur actant was injected in theeld o Pojuca River in 2010 and 2011, where it helpedrecover 36,000 barrels o oil that would otherwise nothave been recovered. This is an additional recovery o 2% o Original Oil in Place o the reservoir. In the next ewyears, this method will be used in the Fazenda Malaquiaseld (RN, Brazil), or additional testing and a more preciseeconomic evaluation.


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Conclusion o the installation at theFazenda Alegre o a pilot DistributedTemperature Sensing (DTS) system orcontinuous monitoring o well temperature

The system was installed in six onshore wells in theFazenda Alegre ield (ES, Brazil). DTS operates throughoptical iber cables that act as distributed sensors,monitoring the temperature in oil reservoirs alongthe entire well extension unlike the occasional sen-sors currently used by the company. This tool bringsadvantages especially in heterogeneous reservoirs. AtFazenda Alegre, this detailed analysis o well operationmay help increase the e iciency o steam injection withconsequent increase in oil recovery. I success ullyused at high temperatures, this technology will enableuture applications in the pre-salt scenario, where the

DTS tool may be installed during well conclusion orreal-time production monitoring. The tests at FazendaAlegre should last one year.

Oil pump in an onshore Fazenda Alegre eld, in Esprito Santo,Brazil

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The sa ety parameters have beende ined or water injection into awell in the Lula ield

Pre-salt reservoirs have salts such as halite and anhydriteas cap rocks (non-permeable rock overlying the oil reser-voir that traps oil, water or gas). Such salts dissolve whenin contact with injection water, and one o the engineerstasks is to de ne parameters to minimize such occurrence.Data rom laboratory studies and analysis with Codebrightso tware, developed by Politcnica de Catalua (Spain),

Developmento pre-salt production,operations and logistics

with contributions rom the Federal University o Per-nambuco (UFPE), were used to simulate these scenarios,involving fuids fows, chemical and mechanical interac-tions. Similar studies are planned to be developed in 2012or other scenarios in pilot wells o the Lula eld.

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Schematic illustration o water injection in carbonate reservoirs


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Success ul conclusion o high-inclinationdirectional well drilling

Petrobras has success ully concluded the saline portion

drilling with angle gains o 53 at 7-LL2D-RJS well in thepre-salt region o the Santos Basin. Due to high mobility,this acts like a luid in drilling operations, which makesit di icult to obtain angle gains in saline well intervals.This technology is the main challenge or horizontal welland extended reach well (ERW) drilling in the pre-saltarea, to increase productivity o each well and conse-quently minimize the number o wells and associatedcosts. The irst project phase was per ormed in the Agu-ilhada ield, when numerical simulators were developed

Schematic illustration o vertical and directional wells in the pre-salt region

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and calibrated to estimate saline de ormation and salt

dissolution, and special luids (100% synthetic luids)were created or drilling, as well as cement pastes. Inthe ollowing phase, two directional wells were drilled,in Marlim (Brava) and Crealb (East Albacora), achiev-ing inal angles o 23 and 30, respectively. In the lastphase, already in progress, an almost horizontal well isbeing drilled, with angle gain o 84. It is planned to beconcluded in February 2012.


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at the Experimentation Center in Taquipe, Bahia,Brazil, or the so tware calibration and per ormanceevaluation. The technology has already been usedin the injection well o the Subsea Water and OilSeparator (SSAO) project, in the Marlim ield, andin the 3-PPT-6-RJS well, in the Papa-Terra ield. Inthe irst hal o 2012, the simulation o luid drain-age in turbulent situations will be incorporated intothe so tware.

So tware or simulation andvisualization o luid drainage in wellcementation process is now available

Inter aces 1.0, developed in partnership withPonti ical Catholic University o Rio de Janeiro(PUC-Rio), optimizes operational p arameters tominimize the mixture o luids (drilling, spacer andcement paste), enabling the cementing operationin a aster and sa er manner. This application cansimulate, in one or two hours, compared with dayso simulation using conventional so tware. In theirst hal o 2011, tests were per ormed in the well,

Tank park at the Experimentation Center in Taquipe, Bahia

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Utilization o acid racturing techniquedeveloped in laboratory or wellstimulation in carbonate rocks

The technique consists o injecting a solution o hydro-chloric acid under pressures above racture propagationpressure. This solution chemically reacts with the rock,causing racture ace stress and promoting hydraulic con-ductivity. Besides costing 40% less than the conventionaltechnique (hydraulic racturing) and reducing operationalrisks (as fuid does not contain solid materials), acid rac-turing may achieve high conductivity levels, enabling asigni cant increase in well productivity. With investments

o R$ 7 million, the project established a partnershipwith the State University o Campinas (UNICAMP) orphysical test equipment, and with Texas A&M Universityor laboratory trial expertise. In the ollowing phase,

mathematical models will be developed that incorporatethe parameters analyzed in laboratory trials to orecastthe conductivity obtained in the acid racturing processin carbonate rocks o the pre-salt.

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New technologies and operationalimprovements reduce well drillingtime to one third in the Lula pre-salt ield

The reduction obtained when comparing the drillingtime o the vertical pilot well in the Lula ield, in 2006,

to the average drilling time o Lula wells drilled in 2011,which were all directional wells, is the result o a numbero improvements, including the insertion o technologi-cal developments, best practice sharing between drillingteams, optimization in well projects, and selection o best drill bits, among others. The main cost o o shorewell construction is the rent o drillships, whose con-tracts require payment according to the number o daysthe rig is allocated to the activity. Decreasing the drillingtime directly reduces the costs o such contracts. Anddrilling directional wells will enable greater productivity

per well, reducing the total number o wells required orthe production systems being implemented.


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Rigid Riser Technologycon irmed or pre-salt plat orms

The Steel Lazy Wave Riser (SLWR) system hasreceived new materials (mixing lined and claddedpipes), to make it resistant to fuids with high CO2 content present in the pre-salt region. It employs rigidrisers made o steel coupled to the foating unit, creat-ing one more option to pre-salt riser systems, suchas Riser Tower, Sel -Supporting Hybrid Riser (RHAS)and the Sel -supporting Buoy Riser (BSR), besidesenabling the utilization o larger diameters (up to 24inches). The intention is to increase competitivenessin the market o riser supply, reducing the companysriser acquisition costs. It is a technically easiblealternative or the application in the ollowing elds:North Guar, South Cernambi, Lula Alto and CentralLula, all in the pre-salt area in the Santos Basin. The

result o the bidding process, that is planned to beannounced by June 2012, may have the new systemo rigid risers as the winning alternative.

SLWR technology scheme

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Tool enables selection o luid withlowest damage to the salt layer,ensuring better cementing and greaterintegrity o pre-salt wells

Simulao de Solubilizao Salina (4Sal) is so twarethat calculates the increase in well diameter accord-

ing to the dissolution o saline ormation in the drillingluid. The objective is to select the drilling luid thatminimizes salt solubility, preventing excessive wid-ening o the well diameter and ensuring cementingquality and well integrity. Developed by Petrobras ina partnership with ESSS, the project had investmentso R$ 800,000 and was used in the 9-RJS-681(ADR-Iracema Alto) and P3 Lula pilot wells, both inthe pre-salt region.


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Chromium 17 approvedor utilization in pre-salt elds

A ter Petrobras con irmed the potential o chromium17 stainless steel or the coating o production wellsand columns o the pre-salt region, or its resistanceto corrosion in environments with a high content o contaminants, pipes o this material were producedwith several diameters to attest the technical viabilityo the product making process on a commercial scaleby JFE Steel Corporation, a Japanese company. In

Laboratory analysis o Chromium 17

2011, mechanical tests were per ormed on thesepipes, which enabled the approval o the usage o Cr17 by Petrobras in its well projects. Besides it s highresistance to corrosion, the new material costs up to30% less than SuperDuplex, so ar the most requentsolution in pre-salt wells. In 2012, corrosion tests willcommence with alternative materials to SuperDuplex,under development by Brazilian companies.

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Wettability inversion agent or pre-salt eldstested in laboratory

Success ully tested in laboratory, the chemical product canincrease up to 10% o the oil recovery actor when added tothe injection water at the concentration o 500 ppm. A teranalyzing more than 70 products rom various suppliers,CENPES researchers identi ed the potential applicability o the selected chemical product, compatible with the char-acteristics o pre-salt reservoirs. With wettability inversionensured by the chemical product, making the rock releaseoil more easily, the process o natural resource exploitation

has been optimized, as more oil is recovered when injectingless water. In the second project phase, the team per ormedan evaluation on a eld scale, using the Carioca eld, withthe help o mathematical reservoir simulators. Parameterso the wettability inversion process determined in the rstphase in laboratory were entered into this simulator (CMG-STARS). In the next phase, the interactions o this productduring the primary processing o oil and water, re ningprocesses and the environment will be analyzed.


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Tests quali y Multi unctional Bell Mouthtechnology or pre-salt FPSOs

The Multi unctional Bell Mouth makes the riser sus-pension system fexible in FPSOs through modulariza-tion and standardization o the principal components.The new bell mouth enables the connection o fexibleor rigid pipes o a wide diameter range (2.5 to 16inches, depending on the environmental conditions) toFPSOs and the replacement o pipes on the high seas,which allows the selection o risers a ter the FPSOdesign. This is an important characteristic to enhancethe rst amily o replicated pre-salt FPSOs available,or the construction and rapid assembly o these unitsenabling a quick start to production in the elds thatwill receive them. It has already been incorportated inthe engineering speci cations o these units.

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Tests with Super Chromium 13 ensurereduced costs with processing inCernambi wells, in the pre-salt region,in the Santos Basin

The results show that using Supermartensitic Stain-less Steel (Super Chromium 13) in conditions o low

contents o contaminants (CO2 and H2S), in productioncolumns and coating materials, does not a ect thewell integrity in the Cernambi eld. As a consequence,a reduction o R$40 million in the well costs o therst Cernambi module alone is expected, as well asreduced supply deadline. This material will replace thecurrently used SuperDuplex Stainless Steel, conven-tionally used in high corrosion conditions.


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Conclusion o basic design or NorthCernambi ield plat orm

The basic design or the North Cernambi ield wasconcluded in November. The plat orm retains thestandardization and simpli ication principles and thelowest CAPEX o pre-salt replicated FPSOs (with stan-dardized modules), using the same critical equipment.The design considers CO2 contents below 10%, low o

Virtual model o an FPSO

or the North Cernambi eld

150,000 barrels o oil a day and 8 million m3 o gas aday. The plant plans to use the unit o selective aminesor H2S removal, interconnection o Gas-Fluid Subsea

Separation System (SSGL) and a portable pull-in systemthat will enable the installation and replacement o riserswith improved sa ety and operational lexibility.

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Improvements in computer toolsensure improved reliability andsa ety in pre-salt well construction

Computer tools, such as Sigma (PUC-Rio), or theproduction o geomechanical models, and Anvec(UFRJ), or the simulation o these models, used by thecompany since 1986, have received improvements or3D simulation o geomechanical stability o directionalwells, especially in saline intervals. These simulationsare per ormed in two stages. The irst one involvesthe drilling luid density speci ication, to provide asa e operational margin or per oration, running in and

coating cementation phases. The second stage allowsus to design the coating to bear the stress rom saltluidity over the well li e. As a result, it was possible to

help design and build directional wells in the pre-saltregion, minimizing operational risks and oil ield devel-opment costs. The same so tware was used in 2011 inwells drilled in salt regions by Petrobras, both in Braziland abroad.


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Basic projects or thetreatment and processing o pre-salt gas rom the Santos Basin:Cabinas Pipeline project

The projects will enable the treatment and process-ing o up to 13 million m3 o natural gas per day,which will low through a gas pipeline connectingthe pre-salt area in the Santos Basin to CabinasTerminal, in Maca (RJ). The units covered by theproject are: Mercury Removal Unit; two Units o

CO2 Removal rom natural gas through activationo amines these units are the irst o this type atPetrobras; Natural Gas Processing Unit II; NaturalGas Condensate Processing Unit IV; and one LPG(Lique ied Petroleum Gas) Caustic Treatment Unit.

Cabinas Terminal, which will have new units to receive gas rom the pre-salt region o the Santos Basin


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Conceptual designs started orthe Stationary Unit o FutureProduction (UEP)

Petrobras is designing a new generation o produc-tion units in order to anticipate and systematize theapplication o new technologies in basic engineeringdesigns or o shore production units. These concep-tual designs will ensure the ollowing bene ts: projectcost reduction and simpli cation, increased revenue,energy e ciency, reduced environmental impact andintegrated operation management. In the rst phase,technologies or sur ace processing were selected,which are ready to be used and that will be part o therst conceptual design.

Conclusion o conceptual and basicdesigns or the new units o theExperimentation Center o Miranga(BA)

Pre-salt ields have high amounts o natural gascombined with oil (with initial contents o CO2 ranging

rom 8% to 15%), which may be used to increase oilrecovery actors. For this reason, the separation o theCO2 rom the associated gas will be carried out as tore-inject it into the elds to be developed. Separationprocesses can be developed or optimized, and, orthis reason, the Experimentation Center o Miranga(BA, Brazil) will receive new units to test Brazilian andinternational technologies. These are complementarynatural gas treatment and CO2 compression technolo-gies: (a) dehydration with molecular sieves (to removeH2O rom the produced gas, important to reduce the

corrosion e ects generated by coexistence o corro-sion with CO2, an acid component); (b) CO2 separationthrough membranes (to test the utilization o hollowber membranes and spiral membranes); (c) removalo H2S through xed bed (to test the utilization o metaloxides and other absorbent agents); (d) removal o acidgases using amines, or complementary separationo CO2, and (e) CO2 compression to be injected intodepleted gas reservoirs.

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Pipes with metallic liner quali ied oruse in risers and subsea pipelines o special metallurgical construction

The new solution, a result rom extensive evalua-tion o material atigue, enables a 60% reduction in

manu acturing costs o risers when compared to theconventional solution o cladded pipes. Resonancetests achieved class E in atigue resistance, accord-ing to the classi cation o Det Norske Veritas (DNV),which was considerably above the requirements orsubsea pipeline applications (class F1). In 2012, newtests will be per ormed, reproducing the winding andunwinding process o pipes in reels, a method that willbe used or the installation o risers. The solution willbe applied to the pre-salt pilots in the Sapinho andNortheast Lula elds.


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Conceptual designs orthe treatment and processingo pre-salt gas in the Santos Basin,at COMPERJ Pipeline 3

The conceptual designs or the third gas pipeline o

the pre-salt region in the Santos Basin have beenconcluded. The solution approved in October 2011selected the Maric alternative, to be served byCOMPERJ. This alternative oresees an onshore ando shore gas pipeline o 14 million m3 o gas per day,with subsequent treatment and processing.

Petrochemical Complex Construction COMPERJ, Itabora (RJ)

The basic project o the Maric alternative has al-

ready been started and is planned to be concludedin 2012, covering two Natural Gas Treatment Units,two Natural Gas Processing Units, two Natural GasCondensate Processing Units and one LPG (Lique edPetroleum Gas) Caustic Treatment Unit.

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Installation o Subsea Water-OilSeparation Station (SSAO) in theMarlim ield

On November 9th the prototype o the rst Petrobrassubsea water-oil separation system was installed. Theequipment, which will be interconnected to plat ormP-37, was developed in a joint e ort with FMC Tech-nologies. It is the rst in the world to separate, in deepwaters, the produced water, re-injecting it into thereservoir as a secondary recovery mechanism. Thetechnology employed in the subsea prototype wasthe tubular separation, which enables the re-injectiono at least 70% o the water produced through the

Developmento a new generation o o shore and subseaproduction systems

Transportation rom the Subsea Water-Oil Separation Station (SSAO) to the Marlim eld

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equipment. The prototype installed in the Marlimeld will allow us to use the process plant capacityon P-37, previously occupied by the produced water,enabling increased oil production and recovery actor.Once the tests are concluded, Petrobras intends toprovide this technology or usage by its operationalunits. The prototype is 29 meters long, 10.8 meterswide, 8.4 meters high and its total weight is 392 tons.The system is planned to start operating in May 2012.


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Startup o Skid-mounted SubseaCentri ugal Pump System (S-BCSS)

The system started operating in late December 2011, inthe Espadarte eld, in the Campos Basin. Installed on the

seafoor, 1,200 meters deep, 200 meters rom EPS-23 welland 11 km rom the Cidade de Rio das Ostras plat orm, thesystem will produce during one o the Extended Well Testso the Espadarte Field (EWT o Arauan). The S-BCSS isthe rst skid-mounted subsea centri ugal pump systemand it produces around 2,000 m3 o oil a day, 100%more than the amount that would be obtained without theequipment installation. The S-BCSS was manu actured byFMC Technologies and the pumps were supplied by BakerHughes. Integration tests were per ormed by Petrobrasat the Experimentation Center o Atalaia, in Aracaju (SE).The validation o this technology in subsea environmentsprovides one more alternative to existing pumping systemsinside production wells.

Conclusion o Subsea Helical-Axial Multi-Phase Pump manu actureand testing or installation in theBarracuda ield

The pump, manu actured by Framo Engineering AS, willbe connected to the P-48 plat orm and will start operatingin the rst hal o 2012. This is the multi-phase pump withthe highest di erential pressure worldwide 65 bar ,which enables increased production fow o 6,300 barrelsper day in the Barracuda eld.

Transportation o the Skid-mounted Subsea Centri ugal Pump System

Subsea Helical-Axial Multi-Phase Pump

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Facial (litho acial and petro acial) 3Dmodeling created or improved simulationo fuid fow in pre-salt reservoirs

The model makes a 3D representation o geological

heterogeneities o microbial carbonate reservoirs inthe pre-salt Lula eld, allowing fuid fow simulationsconsidering capillary e ects. Initially, rocks wereclassi ed according to the geological description o samples (litho acies) and later using pore geometry(petro acies or rock types). With the new 3D modelo litho acies and petro acies, it will be possible tosimulate with higher precision the di erent schemeso well arrangement and geometry, optimizing pre-saltproduction estimates.

Geochemical classi cation explains thedi erent types o oil in the pre-salt region

Petrobras has identi ied a speci ic biomarker (molecularossil that preserves the characteristics o oil-generatingrocks) that speci ies two groups o oil in the areas o Tupi and Carioca. Data obtained now show that theaccumulated oil in the Carioca area has the contribu-tion o a source rock with particular characteristics interms o depositional paleoenvironment and thermalhistory, resulting in a higher concentration o para in

Classi cation o rocks and fuids inthe pre-salt and othercomplex reserves

Example o 3D representation o acies

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with high molecular weight and high WAT (Wax Appear-ance Temperature) value. Understanding the origin andphenomena related to the occurrence o para inic oilshelps identi y probable areas o oil incidence, whichis an important element in planning the continuity o exploration and production processes in the pre-saltregion.


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Compact GTL technology quali ied orusage in o shore Extended Well Tests

Pilot plant tests were concluded in November 2011 at the

Atalaia Experimentation Center, in Aracaju (SE, Brazil),to quali y the technology or the chemical conversion o natural gas into synthetic oil, using milichannel reactorsor application in o shore extended well tests. It is the rstcompact GTL plant worldwide. CompactGTL was Petrobraspartner in this project. The tests veri ed the technology,which may be incorporated into Petrobras extended welltests, such as those planned or the Santos Basin pre-salt,so as to avoid gas burning. During 2012, urther tests will

Logistic solutionso natural gas inremote areas

be conducted to increase conversion e ciency and li etime

o the conversion unit, or the possible application in urtherscenarios. Other GTL technology with even smaller reactors(microchannels) is in test at the Fortaleza ExperimentationCenter, at the Northeast Lubri cant Re nery (LUBNOR).This second technology route, developed by Petrobras inpartnership with the companies Velocys, Modec and Toyo,will be available or usage by Petrobras in the second hal o 2012, i the tests are positive. A total o R$ 185 millionwas invested in the two pilot plants.

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GTL Plant in the Experimentation Center or Flow Assurance and Processing in Atalaia, Aracaju (SE, Brazil)


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New re ractory concrete witherosion resistance installed inREVAP FCC cyclone

Petrobras, in a partnership with the So Carlos Fed-eral University, has developed a new nanobondedre ractory concrete or application as internal coatingo FCC risers. Besides presenting greater resistanceto the erosive action o the catalyst , the material thathas been developed can be applied using a simplermethod and presents lower density and thermalconductivity than conventional solutions. During theresearch, still in progress, a new ormulation to be

Operationaloptimizationand reliability

REVAP FCC unit that received the regenerator cyclone and re ractory cement

used in the FCC separation cyclones was identi ed. InMarch 2011, this new material was used in the REVAPFCC regenerator cyclones, with nal evaluation to bemade in 2015, when the next planned interruption o the plant may take place. A ter its technical easibilityis con rmed and the material is implemented in allo the companys FCCs, this solution may generatesavings o over US$ 10 million a year.

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First inspection with ultrasonic pigconcluded 100% Brazilian technology

In November 2011, the rst inspection was concludedin two o Transpetros pipelines in Cubato (SP, Brazil),per ormed with the ultrasonic pig prototype or pipelineintegrity inspection and control. This inspection, conducteda ter real-scale testing at the Pipeline Technology Center(CTDUT), attests the pig operation, developed in a part-nership with the Ponti cal Catholic University o Rio deJaneiro (PUC-Rio) and the University o So Paulo (USP).The pig can be operated autonomously (without constanthuman intervention) and without an umbilical, allowing the

Ultrasonic pig prototype used in pipeline integrity inspection and control

inspection o long pipeline extensions (up to 200 km). Thisway, Petrobras o ers a national technological alternative,with cost reduction o around US$ 200,000/pipeline relatedto the imported service o pipeline inspection, with thepossibility o fexible operation in the inspection o othersubsea accessories, such as plat orm ties and mani olds.The technology has already been licensed by Pipeway, aBrazilian company, and may be o ered to the market in2012.


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New nanocomposite materials or pipelineand riser coatings and junctions aresubmitted to laboratory testing

Produced rom carbon nanotubes in a partnership withthe Federal University o Minas Gerais (UFMG), nano-composites, based on polyurethane, presented highpotential or application to pipeline and riser coatings and

junctions, with good mechanical per ormance. Petrobrasand UFMG are negotiating with possible suppliers toincrease the production scale o nanocomposites, or aeld test in the rst hal o 2013.Carbon nanotube

Credit: Thinkstock

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Integrated production management system implemented in Urucu

To maximize the oil and gas production in the three eldso Urucu (Urucu River (RUC), East Urucu (LUC) andSoutheast Urucu (SUC)), Petrobras has developed, in apartnership with Norwegian Petroleum Engineering Res-ervoir Analysts (PERA), a system that helps to optimize oiland gas production. All production models are gathered

Onshore base o the Urucu eld (AM, Brazil) oil province

in Pipe-It, a so tware that automatizes calculations andintegrates data rom reservoirs, wells and lines, o eringaggregated data that go rom the three elds and Araraprocess plant to individual visualization o wells andmani olds. The result enables engineers and geologists tomake decisions with a view o all the disciplines involved.

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Bench tests validate nanosensors orhydrogen sul ide (H2S) detection usinghigh sensitivity and selectivity

Through a partnership established between the FederalUniversity o So Carlos (UFSCAR) and Petrobras, a nano-

sensor was produced that can detect hydrogen sul de(H2S). The sensor principle is based on nanoribbons o metal oxides, and its detection range is 1 to 100 parts

per million, at ambient temperature, compatible with thecommercial systems o ered in the market today. It o ers

the possibility o reducing the detection range down to100 to 500 parts per billion. In the second project phase,orecast or 2012, the building o a prototype is planned.

System to measure the sensing properties o nanostructures. Close-up gure shows the measurement chamber


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Incrustation Management Planimplemented in gas production ieldsassociated with extremely saline waters

The elds o Urugu, Tamba and Mexilho, in the SantosBasin, and Camarupim and Canapu, in the Esprito Santo

Basin, present three determining actors or incrusta-tion build-up: pressure variation, high temperature andpresence o water with high salinity. Petrobras hasdeveloped the Incrustation Management Plan to preventincrustation build-up rom the early development phaseo these elds. The applied complementary technologiesuse chemical products that inhibit incrustation and wereespecially developed or highly saline environments. Therst solution uninterruptedly injects the chemical inhibitorvia umbilical until the end o the vertical portion o thewell, resulting in low concentration dosages, to protect

the portion rom the production well up to the production

unit. I complementary inhibition is required, the secondsolution - an inhibitor squeeze treatment - directly applies

the inhibitor to the reservoir, through a special ormulationinjected into the production well. The inhibitor is xed tothe rock and later slowly released by water production,preventing incrustation build-up rom the reservoir tothe production unit. The Incrustation Management Planhas already been implemented at the Mexilho plat orm(PMXL-1) or the production o our wells, at Cidade deSantos FPSO or one well and at Cidade de So MateusFPSO or our wells. The continuous application o thisincrustation inhibitor has started in all o these wells andis in operation at Cidade de So Mateus FPSO.

Men working at the Mexilho xed plat orm in the Santos Basin

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VALUEADDITION AND PRODUCT DIVERSIF

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and greater engine protection. Protection is ensured byits most modern complementary ltration system, whichremoves particles larger than 5 m and ensures maximumwater content o 200 mg/kg, as well as a pack o additivesthat minimize build-ups, reduce wear and oaming, withlower maintenance cost. The new ormulation also o ersthe advantage o lexible production, without requiringsegregated lines any more, thereby promoting an annualcost reduction o R$ 3 million. The study results enabledPetrobras to launch Podium S-50 diesel in July 2011.

Innovationin uels, lubricantsand special products

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New Podium diesel with low sul ur andimproved per ormance

The development o this new ormulation required labora-tory trials and per ormance tests in vehicles and engines,which attested the product bene ts. Besides its lower sul urcontent reduction rom 200 to a maximum o 50 mg/kg ,the new ormulation presents low contents o polyaromaticcompounds, reduced emissions o SOx and particulate mat-ter, and high quality ignition. Podium S-50 diesel rein orcesthe intrinsic values o the Podium brand: high technology,superior quality and respect or the environment, bringinglower emission o pollutants, better vehicle per ormance


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Start-up o Catalyst R&D PrototypePlant (PROCAT)With 1,660 m2 o constructed area and investments o R$ 27 million, PROCAT is a multipurpose plant or pilotscale studies, ocused on the manu acture o catalystsand related products. Coordinated by the Federal Univer-sity o Rio de Janeiro, the unit is part o the TechnologyCenter o Santa Cruz, next to the Fbrica Carioca deCatalisadores S.A. With this new in rastructure whichenables the scale increase in the R&D process, Petrobras

supports partner universities in the development o newtechnologies in the area o catalysis. At PROCAT, the

Petrochemicals

Catalyst R&D Prototype Plant (PROCAT), Rio de Janeiro (RJ)

orecast activities include the development o catalystsand their components or the area o polymers, FCCand CO2 emission reduction in industrial processes research lines that obtained good results at laboratorylevel within the Thematic Network o Catalysis and thePetrochemical Network. PROCAT started to operate inthe second hal o 2011, with a study or the productiono high-density polyethylene catalyst support. In total, R$

6.7 million are planned to be invested in R&D projectsat PROCAT. R

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Gas-chemicals

A technician operates the Pilot Plant o Mixed Fertilizers at the Nitrogen Fertilizer Plant in Sergipe (FAFEN-SE)

Pilot Plant o Mixed Fertilizersstarts operating

Installed in the Nitrogen Fertilizer Plant in Sergipe(FAFEN-SE), the plant will produce urea-based ertilizers,

which contain only the nitrogen nutrient. With the invest-ment o R$ 17 million, the plant production capacity is500 kg /h, with pastille technology, innovative in the areao ertilizers. This technology o ers the advantage o generating particles with excellent uni ormity and goodphysical properties, as well as lower costs o production

and investment than the alternative solidi cation tech-niques (granulation or prilling). This plant will enable the

development o new products rom urea enriching withother nutrients (such as sul ur and potassium), resultingin a product with improved quality and added value. A terthe tests to adjust the operation, the plant will start theproduction o ertilizers with mixed urea, sul ur or am-monium sul ate, in the rst hal o 2012.

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First phase o tests concludedor second-generation ethanol

production in Upton (USA)Through an agreement o joint development established in

2010 with KL Energy Corp. (KLE), 80,000 liters o second-generation ethanol have been produced rom sugarcanebagasse at KLE demonstration plant in Upton, Wyoming(USA). Thirteen batches o 25 to 60 tons o dry bagasseeach were processed, producing 290 liters o ethanol perton o dry bagasse. Petrobras initially invested US$ 5.6million in the adaptation and operation o the demonstra-tion plant, which was originally built to test wood ethanolproduction as well as its previously acquired technicalexpertise. The promising results encouraged a new phase

Bio uels

KLE demonstration plant o ethanol production rom sugarcane bagasse in Upton, Wyoming (USA)

o process optimization, with additional investments o US$

8.6 million, which will be undertaken in the rst hal o 2012to improve per ormance and consolidate the technology.With these complementary actions, Petrobras intends tohave all required data to start, also in 2012, the basic designo an industrial plant or second-generation ethanol, andto start operating in 2015. The second-generation ethanoltechnology may increase the production o ethanol rom15% to 40%, without increasing the sugarcane plantationarea, with sugarcane bagasse collection and processing.

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Energyrom otherrenewablesources

The largest wind power park in Brazilstarts commercial operation inRio Grande do Norte

The commercial operation o the Mangue Seco wind powerpark started in October 2011. With investments o R$424 million, the wind power park has the largest installedcapacity in Brazil, with 52 aerogenerators o 2 megawatts(MW), enough to provide electric power to 350,000 people.Environmental data, such as wind speed and direction atseveral heights, temperature, air humidity and atmosphericpressure, collected by Petrobras since 2002, were es-sential or the evaluation o wind power potential and thecompanys participation in the park concession auction.

Mangue Seco wind power park (RN)

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SUSTAINABILIT

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Managemento water ande fuents

First mobile e luent treatment unit is inaugurated aiming at water reuse

In June 2011, CENPES inaugurated the rst PetrobrasMobile Unit o Water Reuse, to support initiatives o thecompanys operational units (re neries and terminals, orinstance) in the selection o the best technology solutionor e fuent treatment. With investments o R$ 10 million,the station has two haul trucks with equipment operat-ing on a pilot scale that can test up to 90 technologicalsolutions. It is possible to test at the companys re ner-ies, or example, processes to remove solid materialsand organic load, as well as demineralization and polish

processes, simulating speci c operational conditions orthe various water and e fuent characteristics. A ter testson location, it will be possible to recommend the bestoption or water reuse at each unit, rom technical andeconomic perspectives. As a result, it will be possibleto plan industrial installations with shorter times andreduced costs. The Mobile Station is currently at theGabriel Passos Re nery (REGAP), in Betim (MG), andother applications have already been planned or thecoming years at the companys re neries and terminals.

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E fuent Treatment Station at Almirante Barroso Terminal (TEBAR), So Sebastio (SP)

Industrial unit or high salinitye luent treatment starts operating

The E fuent Treatment Station at So Sebastio Terminal(TEBAR So Sebastio, SP, Brazil), in pre-operationsince September 2011, is the rst unit in the world totreat high-salinity produced water (up to 80,000 mg/litero NaCl sea water has 35,000) using a biological pro-cess, with high e ciency in pollutant removal, above theenvironmental legislation requirements. When compared

to the conventional physico-chemcial process, the bio-logical process o ers a more e ective treatment, withlower cost and using ecologically adequate products. Theplant, whose treatment capacity is 300 m3 /h, receivedinvestments o R$ 480 million. The start-up o a similarplant, with production capacity o 150 m3 /h, is plannedto occur in May 2013 at TEBIG (Angra dos Reis, RJ).

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Water reuse plants start operatingat REVAP and REGAP

The membrane bioreactor technology was adopted orthe rst time at Petrobras in the Henrique Lage Re nery(REVAP), in So Jos dos Campos (SP, Brazil). A ter thebiological treatment, the e fuent is ltered by membranesor microorganism removal. The improved e luent qual-ity o this new station, which can treat up to 300 m3 /h,combined with the modernization o existing treatmentstation, enabled 25% savings due to water reuse, whichallowed the REVAP to obtain an expansion licensing.Other units using the same technology o membranebioreactors will be inaugurated at the Presidente Getlio

Bioreactor technology with solid separation through membranes

Vargas Re inery (REPAR) and at CENPES in 2012, and atthe Northeast Re inery (RNEST) in 2013. At the GabrielPassos Re inery (REGAP), the prototype plant or salinityremoval started operating using reversed electrodialysis,with treatment capacity o 60 m3 /h, or water reusetests. Reversed electrodialysis per orms water desali-nization by membrane separation. This technology isplanned to be applied at the Paran Re inery (REPAR)in the second hal o 2012, at the Northeast Re inery(RNEST) and at the Petrochemical Complex in Rio deJaneiro (COMPERJ).

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Managemento CO2 andother emissions

First test per ormed with oxy-combustiontechnology or CO2 capture in FCC units

This test was the rst on a demonstration scale in theworld. At the FCC multipurpose unit U-144 in SIX (the

Shale Industrialization Unit, in So Mateus do Sul, PR,Brazil), it applied oxy-combustion or CO2 capture in FCCunits. Per ormed in June 2011, the test is part o the CO2 Capture Project world consortium (www.co2capturepro- ject.org), the association o seven large energy companiesin search or industrial technologies o CO2 capture andstorage. The oxy-combustion technology replaces theair used in coke burning in the FCC regenerator with theCO2 produced in the burn, mixed with pure oxygen. The

Multipurpose unit o FCC at SIX, So Mateus do Sul (PR)

process enables us to obtain a CO2 chain o higher purity,ready or capture, and has the potential or reducing CO2

emissions by up to 32% in the re ning area, with 50% costreduction when compared to the current technology thatuses amine absorption. The test also demonstrated thatthe technology can ensure greater operational fexibilityor the FCC unit, with the possibility o increasing theprocessed load or improving the load conversion, whichmay bring urther cost reduction. This is the rst o a serieso tests that will be per ormed by March 2012. A ter that,the possibility o technology escalation will be evaluated.

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Basic design or the production o S-10 Diesel at REDUC

The purpose was to adjust the hydrore ning park o RE-DUC to meet the new speci cation o S-10 Diesel (10

ppm o sul ur), including the units or hydrotreatment,generation o hydrogen, treatment with amines, sul urrecovery and acid water. With the production capacityo 7,500 m3 o diesel per day, the new hydrotreatmentunit or unstable products (UHDT-5200) has the largestreactor ever designed by Petrobras (38 meters high).The unit is planned to start operating in 2016, and hasollowed project simpli cation and cost reduction guide-lines (in 2010 REMAN was the rst Petrobras re neryto receive a basic design or S-10 Diesel production).

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Implementation o new emissionevaluation methods

Petrobras has brought orward its studies into the e ectso diesel and biodiesel on emissions o pollutants not yet

regulated, such as aldehydes and polyaromatic and mono-aromatic hydrocarbons. For this reason, the company hasinvested around R$ 2.6 million in equipment acquisition,method implementation and testing at the laboratorieso the Development Technology Institute (LACTEC) andalso at the State University o Rio de Janeiro (UERJ). AtLACTEC, trials were per ormed with S-50 Diesel (with 50ppm sul ur) and B5 and B20 biodiesel (with 5% and 20%content respectively, with soybean oil and tallow) to analyzethe emission o aldehydes, while the UERJ laboratory

Tests in engines at a laboratory o the Development Technology Institute (LACTEC) at the Federal University o Paran (UFPR)

evaluated emissions o polyaromatic and monoaromatichydrocarbons. As a result, with the analyzed methods,

vehicles and uels used in the project did not presentsigni cant increases o these pollutants when adding upto 20% o biodiesel to S-50 Diesel. The aldehyde measure-ment method is being used in research, including the newormulation o Podium Diesel and biodiesel evaluation

projects, in a partnership with Petrobras Biocombustvel. Asstipulated in CONAMA P7 legislation, IBAMA will receive, byDecember 2012, the typical values o aldehyde emissionsrom diesel engine and vehicle manu acturers, to decideabout the possibility o regulating this pollutant.

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Advanced control implementedat hydrotreatment units (HDT) in thePaulnia (REPLAN), Presidente Bernardes

(RPBC) and Presidente Getlio Vargas(REPAR) re ineriesAdvanced control brings more operational stability,increased reliability and pro tability through control andoptimization algorithms that determine and keep the bestoperation points, based on predictive calculations o theproperties. Several bene ts are obtained with this tech-nology, including: reduced residual naphtha production,reduced emissions, reduced steam consumption, maxi-mized HDT load, optimization o the diesel sul ur content,

optimization o production time o catalysts and maximizedincorporation o unstable products into the diesel. Withannual return o US$ 7.8 million, the advanced controlproject o HDT at REPLAN has reduced CO2 emissionsrom this unit by more than 9,400 tons each year, alsoensuring the production o S-50 Diesel (with a maximumo 50 ppm o sul ur).

Energye ciency

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HDT Unit at REPLAN


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The most complete study o RegionalEnvironmental Characterization o theCampos Basin submitted to IBAMA

This unprecedented study collected environmental datarom a 100,000 km area o the Campos Basin. More than40,000 chemical analyses and 10,000 biological analyses

were per ormed, involving around 250 pro essionals,including researchers and laboratory technical sta romtwenty Brazilian universities and R&D institutions (UFRJ,UNIRIO, USU, UFES, UVV, UFPE, UFRPE, UFCG, ULFAL,UNIVALI, FURG, FIOCRUZ, UERJ, PUC-Rio, UENF, USP,UFF, IEAPM, UFPR and INPE). With investments o R$ 40million, the study was conducted over our years, totaling365 days o o shore data collection, with dedicated ves-sels and teams. The resulting scienti c characterizationenables more e cient environmental management by

Petrobras and IBAMA, including aster environmentallicensing in the Campos Basin region. Data were submit-ted to IBAMA in a database compatible with the system

used by the Ministry o the Environment. Sensitive areaswere identi ed, such as bird reproduction areas, physicaland environmental data (geomorphology), socioeconomicresources (ports, airports, shing areas) and biologicalresources ( auna mapping and identi cation o threatenedspecies). Such data supported the production o resultingsensitivity maps. Other similar studies will be started orare in progress or Sergipe/Alagoas, Santos and EspritoSanto Basins, and they are planned to be concluded in2014, 2016 and 2016, respectively.

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Species o crustacean,cnidarian and echinoderm identi ied in the study o Regional Environmental Characterization o the Campos Basin

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EXPERIMENTA INFRASTRUCTURE AT BRAZILIAN TECHNOLOGICAL AND SCIENT

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Most results presented up to here were obtained in partner-ships with national science and technology institutions.Besides the e ective results rom research projects, importantin rastructure deliveries occurred in 2011 at these institutions,the result o resources allocated to universities and researchcenters by means o associations that are part o the thematic

research and development networks coordinated by Petrobras.From January to December, 24 inaugurations were held

at several institutions that undertook research activities on stra-tegic themes or the companys businesses and the Brazilianenergy sector. The Thematic Networks enable the associatedinstitutions to acquire advanced technology, create world-classlaboratories, quali y researchers and develop R&D projects in

Petrobras areas o interest, such as oil and gas, bio uels andenvironmental preservation.

The resources allocated by Petrobras to national sci-ence and technology institutions ollow the ANP guidelines.In 2006, the agency regulated the clause o concessioncontracts that determines that 1% o the gross revenue o petroleum elds subjected to special participation (largeproduction or pro tability) should be allocated to researchand development, and at least hal o this value to externalBrazilian institutions accredited by ANP. The ollowing pagespresent the principal laboratories inaugurated in 2011unded by these resources.


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ENVIRONMENTAL RESEARCH LABORATORY (LAPAMClimate Change Mitigation Technologies NetworkWith 100m2 and located in Cachoeira Paulista (SP) this laboratory is part o a Brazilian atmospheric monitoring system that studies the air quality and

the climate, being implemented by the Weather Forecast and Climatic Stud-ies Center o the National Institute o Special Reasearch (CPTEC/INPE). In-augurated in February, the laboratory received investments o R$ 2 million.

BIOGECHEMISTRY LABORATORYBioproduct Research Network and Climate Change MitigationTechnologies NetworkWith investments o R$ 3.6 million, the laboratory, inaugurated in March by theFederal University o Rio de Janeiro (UFRJ), has 110 m2 and is used to evaluate theuse o di erent types o vegetation as CO2 sequestration agent as well as to per ormstudies into microalgae production in hypersaline waters, or biodiesel production.

PHYSICAL GEOTECHNICAL MODELING LABORATORUENF Regional CenterIn 180 m2, this laboratory has unique equipment in Latin America, such as ageotechnical centri uge to simulate situations o o shore plat orm anchoring bytorpedo piles and suction stakes, as well as pipeline anchoring. Built by the StateUniversity o North Fluminense (UENF), this laboratory received investments o R$ 1.7 million and was inaugurated in April.

PRINCIPAL LABORATORIESINAUGURATED IN 2011

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ENVIRONMENTAL SCIENCES LABORATORYUENF Regional CenterWith investments o R$ 1.7 million and inaugurated in April by the State Universityo North Fluminense (UENF), this laboratory per orms analyses o organic andinorganic pollutants, and molecular biomarkers or the Campos Basin.

APPLIED GEOPHYSICS LABORATORYApplied Geophysical Studies NetworkInaugurated in May 2011, the Applied Geophysics Laboratory was built by the

Federal University o Rio Grande do Norte (UFRN) with R$ 1.3 million investedby Petrobras. Located in Natal (RN, Brazil) and occupying 600 m2, this laboratorywill contribute to a better understanding o shallow oil accumulation structures located in depths o between 300 and 400 meters in the Potiguar Basin.

BRAZILIAN GEOPHYSICAL EQUIPMENT POOL (PEG-BGeotectonic Studies NetworkWith investments o R$ 14 million made by Petrobras and inaugurated in June2011, PEG-BR is the rst pool o geophysical equipment in Brazil and o ersinstrumental and sta support to Brazilian projects in the areas o seismology,gravimetry and geoelectricity. It occupies 320 m2, built by the National Observatoryin Rio de Janeiro (RJ, Brazil).

ENGINES LABORATORYVehicle Development NetworkBuilt by the Technological Research Institute (IPT) in So

Petrobras Technology 2011

Documents

Transcript of Petrobras Technology 2011