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Petroleum
Unconventional
sources
Colloidal Fuel Bituminous sands Natural gas liquid Oil shale Biofuel
a. k. a.
Produced
by
Same geological process as natural gas. Hence, commonly found together with natural gas. Anaerobic decomposition or organic material and usually produced from organic sediments at
Greater
Theory of Formation
Biogenic
First proposed by Georg Agricola Widely accepted petroleum formation theory First proposed by Alexander von Humboldt Not acknowledged by most geologists due to limited scientific basis and inability in prediction for oil deposits
Fuel Technology by Andrew Benedict Tengkiat
Abiogenic
Accumulation
Gelatinous vegetal matter Animal Microscopic plant or bacterial organism like zooplankton, plankton or algae
Oil
formation would require formation of organic matter-rich layer of mud or sediment. Favorable conditions are:
Stagnant sea or lake bottom Anoxic condition or very low oxygen level results in partial decay
Geological
movement/deposition of sediment, i.e. sand, stone and mud, on the seabed or lakebed compresses organic matter due to its weight. Increases in depth result in increase of pressure and temperature. Oil formation starts at temperature > 70oC. Initial formation of waxy material known as kerogen.
Fuel Technology by Andrew Benedict Tengkiat
Kerogen
Mixture of organic material derived from geopolymers, i.e. degraded biomaterial Age or maturity is due to changes brought about by
which are associated with increasing depth of burial having the corresponding color changes
With the passage of time, sediment hardens into sedimentary rock. Oil window is temperature range at which oil forms (60-160oC).
Below minimum temperature, kerogen does not change to oil Within oil window, kerogen is converted to oil Above maximum temperature, oil is converted to natural gas by thermal cracking (> 160oC), i.e. gas window
High pressure and temperature (~ 100oC to 160oC) broke down (catagenesis, i.e. semidestructive distillation) long hydrocarbons to shorter chains by an endothermic reaction.
Fuel Technology by Andrew Benedict Tengkiat
10
Oil
formed in the source rock migrates through pores of permeable rocks. Process takes millions of years for oil/gas to migrate a few kilometers.
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Oil/gas
12
Oil-retaining cap rock is penetrated by drilling and continued until bottom of the well, i.e. richest part of the oil-bearing rock, is located Natural pressures of reservoir will force the oil, gas and some water out to the surface As the oil is removed, water moves in to take the place of the oil Reservoir pressure is lowered by water displacement A point will be reach when the reservoir pressure is too low to force out the oil Gas or water is injected to the well to increase reservoir pressure
13
Base
Paraffinic Naphthenic or Asphaltic Mixed Paraffinic (1560%) Naphthenic (3060%) Aromatics (3-30%) Asphaltic (Remainder)
Composition
Sulfur
Content
Sweet Sour
Fuel Technology by Andrew Benedict Tengkiat
14
Hydrocarbons
Paraffins (Alkanes)
Saturated hydrocarbons Stable compound Normal (straight chain) and iIso (branched) forms Unsaturated paraffinic hydrocarbons like alkenes, alkynes, dienes, trienes, etc Unstable and chemically reactive Form from cracking Smoky when burned Causes gum formation when oxidized Base material for polymerization
Fuel Technology by Andrew Benedict Tengkiat
Olefins
15
Naphthenes
Saturated ring hydrocarbons, i.e. cycloparaffins Unsaturated stable ring hydrocarbons Has good antiknock quality Smoky when burned Good solvent
Aromatics
Traces of
Impurities
16
Light
Ends
Whites
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Blacks
Light Fuel Oil (C28C50) Heavy Fuel Oil (C40C70) Residue and Asphalt
18
Atmospheric Vacuum
Hydrogenation
Process similar to cracking but in the presence of hydrogen environment Unsaturated hydrocarbons becomes saturated
19
Fractional
Distillation (Separation)
Atmospheric Vacuum
Cracking
(Hydrocarbon Breakdown)
Thermal Catalytic
Polymerization
Reverse of cracking Creation of heavier compounds from lighter compounds through chain elongation
20
Absorption
Removal of heavier hydrocarbons from lighter compounds by contact process Vapors are removed by heating absorbing medium Process similar to cracking but in the presence of hydrogen environment Unsaturated hydrocarbons becomes saturated
Hydrogenation
21
Dehydrogenation
Hydrogen removal process Maximum octane number that can be produced is about 100 Production of isoparaffin by reacting olefin and paraffin Product is high octane fuel with high boiling point and low vapor pressure
Alkylation
Blending
of Finished Products
22
Density
Air 15oC or 60oF a. k. a. API Gravity Created as API Gravity Scale in 1921 by American Petroleum Institute, which is an oil industry standard for density measurement Measure of how heavy or light a petroleum liquid is compared to water (10oAPI), i.e. < 10, heavier than water > 10, lighter than water
Fuel Technology by Andrew Benedict Tengkiat
oAPI
23
Usually ranges between 10 and 70 Low specific gravity has high API gravity Obtained by Direct Measurement (Hydrometer Method)
Liquid is to poured into a tall cylinder Hydrometer is gently lowered into the liquid like graduated cylinder Hydrometer is allowed to float freely until stabilized Point at which the surface of the liquid touches the stem of the hydrometer is noted and reading made directly
24
Density is measured using hydrometer or oscillating U tube Density adjustment made due to Temperature difference from standard of 60oF to account for sodalime glass expansion/contraction Meniscus correction for opaque oil Specific gravity is calculated 141.5 API gravity calculated using o API 131.5
SG (60 / 60 o F )
API at 60o F
Reid
Absolute vapor pressure exerted by 100mL liquid exposed to air 4 times its volume in a bomb immersed at 100oF bath Applies to volatile crude oil and volatile nonviscous petroleum liquid except LPG Measure of fuel volatility that affects
Engine start up and warm up Easy acceleration Vapor lock tendency, i.e. combustion failure due to vaporization of fuel in fuel lines or delivery system
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Sulfur
Forms SO2 and/or SO3 when burned that reacts with water vapor to form sulfurous acid or in some cases sulfuric acid Determined by analytical chemical tests
Corrosion
Test
Measures presence of sulfur and sulfur compounds by reacting sample with copper Test is done either done by copper-strip or copper-dish method Clean brightly polished copper surface changes to gray or black
Fuel Technology by Andrew Benedict Tengkiat
27
Doctor
Test
Used to determine presence of sulfur compounds like hydrogen sulfide and mercaptans in light distillate based on color change Reaction Na2PbO2 + H2S PbS + 2 NaOH
Sodium Plumbite Black Color
28
Gum
Content
a. k. a. Existent Gum Measures presence of gum and gum forming potential due to presence of olefins or cracked material Process
50 mL sample is exposed at temperature of 320oF to evaporate volatile compounds Air is blown to promote low temperature oxidation of the fuel resulting to gum formation Result is reported as milligrams gum per 100 mL sample
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Octane
Number
Knock or detonate when burned in a spark ignition engine Burned on a controlled manner
Knocking (or detonation) is the very rapid and uncontrollable burning of a fuel-air mixture in a cylinder which results in an abnormally rapid pressure rise and shock wave generates a sound. Intensity of knock is measured by a knockmeter, which indicates the rate of pressure rise during combustion.
Fuel Technology by Andrew Benedict Tengkiat
30
Determined by comparing the performance of the fuel with the performance of a mixtures of isooctane and n-heptane with iso-octane arbitrarily set at 100 and n-heptane at 0. Does not relate to
High performance engine require octane number of at least 93 Can be boosted by addition of
Organometallic additives like TEL Hydrocarbons like isooctane and toluene Oxygenates like MTBE, ETBE and EtOH
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Measurement method
Research Octane Number (RON) Most common rating used around the world Determined by running the fuel in a test engine with variable compression ratio under controlled conditions, i.e. low to medium speed knock or at 600 rpm Motor Octane Number (MON) a. k. a. aviation lean octane rating Measure how fuel behaves under load, i.e. high speed knock Has no relation to RON but is around 8 to 10 points below RON
Fuel Technology by Andrew Benedict Tengkiat
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Preheated fuel mixture High engine speed, i.e. 900 rpm Variable ignition timing
AntiKnock Index (AKI) a. k. a. Pump Octane Number (PON) Average of RON and MON Around to 4 to 5 points below RON Observed Road Octane Number (RdON) Developed in the 1920s Determined by testing fuel over a stretch of level road using a multicylinder engine car at open throttle or a chassis dynamometer under conditions simulating highway driving
Fuel Technology by Andrew Benedict Tengkiat
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Neutralization Number
a. k. a. acid number Measures the amount of acidity present in fuel specifically naphthenic acid, which result to corrosiveness of fuel Parameter is measured in terms of mg KOH required to neutralize a gram of sample
Smoke Point
Measures tendency of a liquid fuel to form soot Higher smoke point result in lower soot forming tendency Experimentally determined by burning the fuel in a special wick lamp and slowly increasing the height of the flame until smoke begins to appear
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Distillation Curve/Test
Used to determine volatility of fuel by measuring temperature at which a certain volume of liquid is evaporated Measurements taken are
Initial Boiling Point (IBP) Increments of 10% Fuel Evaporated Final Boiling Point (FBP)
D86 for petroleum products at atmospheric pressure D 1160 for petroleum products at reduced pressure
Freeze Point
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Cloud
Point
Temperature below which wax in diesel or biowax in biodiesel form a cloudy appearance due to crystal formation Tendency to plug filters and/or small orifices at cold operating temperature Presence of solidified waxes result in
Thickens fuel and clogs filters and injectors in engines Wax accumulation on cold surfaces (e.g. pipeline or heat exchanger fouling) and forms fuel- or oil-water emulsion
Wax crystals typically first form at the lower circumferential wall with the appearance of a whitish or milky cloud
Fuel Technology by Andrew Benedict Tengkiat
36
Cold
Lowest temperature, expressed in 1C, at which a given amount of fuel still passes through a standardized filtration device at a specified time when cooled under certain conditions Gives estimate for the lowest temperature that a fuel will give trouble free flow in certain fuel systems, which is important as in cold temperate countries Fuel with high cold filter plugging point will clog up vehicle engines more easily Generally around 3oC lower than cloud point
Fuel Technology by Andrew Benedict Tengkiat
37
Flash
Point
Lowest temperature at which a fuel will vaporize sufficiently to form a combustible mixture of fuel vapor and air above the fuel and requires ignition source At flash point, vapor will cease to burn when ignition source is removed Characterize the fire hazard of liquid fuel, i.e. both flammable and combustible liquids
Fire
Point
Temperature (higher than flash point) at which a fuel will have enough vapors that will rise to produce a continuous flame above the liquid
Fuel Technology by Andrew Benedict Tengkiat
38
Autoignition
Temperature
a. k. a. kindling point Indication of the relative difficulty of combusting a fuel Lowest temperature required to initiate selfsustained combustion, i.e. spontaneous ignition, in atmospheric air in the absence of a spark or flame Temperature supply activation energy needed for combustion
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Pour
Point
Liquid will flow or pour Crude oil be readily pumpable Formation of paraffin wax crystals Viscosity effect Thermal history
40
Pour point range can be observed for sample to be between upper and lower pour points. Between the upper and lower pour points, fuel sample may appear liquid or solid because wax crystals form more readily when it has been heated within the past 24 hours and contributes to the lowering of pour point Measure resistance of fluid to flow Standard measured of viscosity is in terms of kinematic viscosity
Viscosity
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Cetane
Measure of ignition delay, i.e. time between start of injection and onset of combustion in compression-ignition engine Determined by comparing performance of a fuel with the performance of a mixtures of
42
Ignition delay is measured in a standardized prechamber diesel engine at 900 rpm with
Water temperature of 100oC Inlet air temperature of 150oF Test is questionable at low cetane (CN < 35).
Formula
Cetane Number (CN) = % ncetane + 0.15 * % isocetane
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Aniline point (temperature at which aniline and the fuel are miscible) API gravity (G) Midboiling point temperature in oF (TM) using ASTM D86 Distillation test
44
Metal content
Pollution Scale formation Catalyst poisoning/deactivation Vanadium Nickel Lead Sodium Calcium Iron Silicon Aluminum
Fuel Technology by Andrew Benedict Tengkiat
45
Carbon
Residue
Weight percent of carbon deposit that will remain after evaporating the fuel Used as a gauge in comparing fuel with regard to
Clean burning property Tendency of oils to crack and form hard carbon deposits upon heating
Fore heavy fuel, 10 grams of a fuel is heated to a very high temperature in a covered crucible For light fuels with less than 5% carbon residues, the last 10% residuum from distillation test can be tested. For such case, the percentage is done with respect to the weight of 10% residuum
Fuel Technology by Andrew Benedict Tengkiat
46
Carbon
Residue
Weight percent of carbon deposit that will remain after evaporating the fuel Used as a gauge in comparing fuel with regard to
Clean burning property Tendency of oils to crack and form hard carbon deposits upon heating in an inert atmosphere Ramsbottom Carbon Residue Conradson Carbon Residue Micro Carbon Residue
Can be expressed as
47
Fore heavy fuel, fuel is heated to a very high temperature and cooled afterwards. Percentage is based on weight difference. For light fuels with less than 5% carbon residues, the last 10% residuum from distillation test can be tested. For such case, the percentage is done with respect to the weight of 10% residuum
Solid matter that remains after complete combustion of the fuel Quantity is measured similar to Conradson Carbon Residue test except that temperatures are sufficiently high enough to ensure complete carbon combustion.
Fuel Technology by Andrew Benedict Tengkiat
Ash
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Asphaltene
content
Primarily composed of
Carbon Hydrogen Nitrogen Oxygen Sulfur Trace amounts of Vanadium and Nickel
C:H ratio is approximately 1:1.2, depending on source Operationally defined as n-heptane-insoluble, toluene-soluble component carbonaceous material like crude oil, bitumen or coal
Fuel Technology by Andrew Benedict Tengkiat
49
(Bottoms)
Conducted to determine the percentage of impurities in the fuel Liquid fuel is dissolved in benzol and centrifuged for 10 minutes at a speed of 1500 rpm
Heating
Value
Higher Lower
50
API
Gravity ASTM Distillation Sulfur Trace Metals Pour Point Salt Content Naphthenic acid or Neutralization number Water and Sediment
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LPG
Specific gravity Hydrocarbon composition Corrosion, Cu strip Hydrogen sulfide
Gasoline
Specific gravity Aromatics and Benzene Content RON, MON, DON Corrosion, Cu strip Doctor Test RVP Distillation Recovery at 10%, 50% and 90%
Fuel Technology by Andrew Benedict Tengkiat
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Kerosene/Jet
Fuel
Specific gravity Freeze point Smoke point Distillation Corrosion, Cu strip Aromatics, % vol
Diesel
Sulfur content Flash point Pour point Cloud point Cold filter plugging point Distillation at 90% recovery Specific gravity Viscosity Cetane number/Diesel index
Industrial
Fuel Oil
Sulfur content Flash point Pour point Specific gravity Viscosity Bottoms, Sediment and Water Metals
Bitumen/Asphalt
Emulsion
of powdered solid fuel and a liquid fuel/medium like coal in water or coal in kerosene Additive may be added to ensure emulsified state Fuel has high viscosity High velocity required to move solution
57
a.
k. a.
Unconventional
petroleum deposit found in sand containing bitumen, clay, sand and water Formed by migration of oil to sand reservoir Costly due to energy intensive processes of bitumen extraction and upgrading Largest deposits are in
58
Bitumen
Hydrogendeficient, i.e. unsaturated, oil which has a mix of hydrocarbon (primarily polycyclic aromatics) of chain length of up to 2,000 carbon atoms that makes it
Impossible to burn Extremely viscous and does not flow unless Heated Diluted Tarry
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Sand is mixed with hot caustic solution and agitated. Additional heating can be provided by steam. Bitumen floats to the top when small air bubbles attach to bitumen droplets during frothing Centrifugation separates oil, water and fine solids (~ 75% recovery) Oil recovery is further enhanced to > 90% by secondary process, i.e. Tailings oil recovery Naphtha recovery from froth Settling and Centrifugation
Fuel Technology by Andrew Benedict Tengkiat
60
Cycling
a. k. a. huffandpuff method Used since 1950s in Californian oil fields Accidentally discovered by Shell while doing steam flooding in Venezuela when one of its steam injectors blew out Process is effective for the first few cycles Recovery range is around 20% to 25% Economic viability is dictated by cost of steam injection versus oil revenues
61
Process
Steam at 300340oC is injected into wells for weeks to months (Injection Stage) Sand is soaked for days to weeks (Soaking Stage) In the production stage, hot oil flows out by Natural flow due to increased reservoir pressure caused by steam injection Artificial lift or using pumps when reservoir pressure goes down Process is repeated when production rate falls
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Steam
Developed in the 1980s by Alberta Oil Sands Technology and Research Authority Cheaper than Cycling Steam Stimulation (CCS) Recovers up to 60% of the oil in situ Process
Two horizontal wells are drilled in the oil sand, i.e. At the bottom of formation Five meters above the bottom Steam is injected at the upper well, which melts the bitumen Bitumen is collected at the lower well and pump to the surface
Fuel Technology by Andrew Benedict Tengkiat
63
Vapor
Similar to SAGD but hydrocarbon solvents are injected instead of steam Process
Has better energy efficiency than SAGD Partially upgrades bitumen to oil in situ Economic viability is dictated by cost of steam injection versus oil revenues
Steam at 300340oC is injected into wells for weeks to months Sand is soaked for days to weeks Hot oil is pumped out for weeks to months Process is repeated when production rate falls
Fuel Technology by Andrew Benedict Tengkiat
Process
64
Derived from upgrading of bitumen and require approximately 1 to 1.25 GJ per barrel of bitumen 1st commercial production of synthetic crude in 1967 by Great Canadian Oil Sands Properties is dependent on upgrading processes used and typically has low sulfur and around 30oAPI Requires approximately 1 to 1.25 GJ energy Can be used to produce
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Bitumen
conversion process
Removal of
Water Sand Physical waste if any Lighter products Hydrodemetallization Hydrodesulfurization Hydrodenitrogenation Coking (Removal of carbon) Hydrogenation (Addition of hydrogen) Hydrocracking
Fuel Technology by Andrew Benedict Tengkiat
Catalytic purification by
Upgrading by
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a. k. a.
Casing head gasoline Drip gas Natural gasoline Raw gas White gas
Cleaner Denaturing additive for fuel alcohol Lantern fuel Solvent Stove fuel
Fuel Technology by Andrew Benedict Tengkiat
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Typical
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Fractionation
Debutanizer
NGL Feed
C5 plus mixture
Fuel Technology by Andrew Benedict Tengkiat
isoButane
69
Sweetening
Separation Conversion Desulfurization Molecular Sieve NGL is passed through a membrane to selectively remove mercaptans based on pore diameter
Process used
70
Mercaptan is extracted by caustic solution containing Merox catalyst Mercaptan is oxidized to disulfide by catalyst with air Disulfide is decanted Caustic solution is recycled
71
Flow Diagram
Disulfide
Extracted Product
Contactor
Reactor
Feed
Merox-Caustic Solution
72
Pyrolysis
of coal Catalytic gas reforming (FischerTropsch Process) Hydrogenation of coal (Bergius Process)
Partial
combustion of coal at substoichiometric air yields carbon monoxide and hydrogen rich gas Gas is fed in a catalytic reactor to reform carbon monoxide and hydrogen to hydrocarbons (paraffins and olefins) and alcohols
Contains
kerogen Process requires lots of water Expensive process and there is difficulty in disposal Yields 7 to 50 gallons per ton Largest deposit in the Colorado Plateau
75
Shale
is mined, crushed and conveyed to recovery plant Shale is heated to break open the shale and recover the kerogen by passing heated air through the raw shale in a retort Crude shale oil is coke to produce hydrocarbon gases, distillates and heavy residues
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Distillate
77