Model Predictions for the C-SOS Oil Shale Process L Douglas Smoot, - - PowerPoint PPT Presentation

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Model Predictions for the C-SOS Oil Shale Process L Douglas Smoot, - - PowerPoint PPT Presentation

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Model Predictions for the C-SOS Oil Shale Process L Douglas Smoot, Robert E Jackson, Ambar M Ochoa Combustion Resources Inc., Provo, UT 30 th International Oil Shale Symposium Golden Colorado, 18-22 October 2010 Acknowledgements n Department

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SLIDE 1

Model Predictions

for the

C-SOS Oil Shale Process

L Douglas Smoot, Robert E Jackson, Ambar M Ochoa

Combustion Resources Inc., Provo, UT 30th International Oil Shale Symposium

Golden Colorado, 18-22 October 2010

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SLIDE 2

2 Combustion Resources, Inc.

Acknowledgements

n Department of Energy/SBIR

n Phase II Contract n Chandra M. Nautiyal, Project Officer

n BLM/OSEC (Dan Elcan) / Sage Geotech (Gary Aho)

– 150 tons of oil shale

n CR Colleagues [other paper – The Clean, Shale Oil

Surface (C-SOS) Pilot Plant Process]

n Dr. Craig Eatough n Mr. Steven Eatough n Mr. Kent Hatfield

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SLIDE 3

3 Combustion Resources, Inc.

Objectives

n Contract Objective – Demonstrate and

characterize the C-SOS oil shale pilot plant

n Modeling Analysis Objective – Develop and

apply an oil shale process model for the kiln and the aft-end collection system

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SLIDE 4

4 Combustion Resources, Inc.

C-SOS General Flow Diagram

  • 2. Shale Oil Production
  • 1. H2 Production
  • 3. Shale Oil Upgrading

5 ton/day Pilot Plant

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SLIDE 5

5 Combustion Resources, Inc.

Two Element Model

n Front-end: Kiln n Aft-end: Recovery & Separation

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SLIDE 6

6 Combustion Resources, Inc.

Front-End: Kiln

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7 Combustion Resources, Inc.

Front-End: Kiln (continued)

Feed Hopper Spent Shale Removal Oil Vapor/Gas Outlet

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SLIDE 8

8 Combustion Resources, Inc.

Aft-end: Shale Oil Recovery and Separation Unit

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SLIDE 9

9 Combustion Resources, Inc.

Source of Shale White River Mine Stockpile

White River oil shale mine site near Bonanza, UT

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10 Combustion Resources, Inc.

Kiln Model Configuration

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11 Combustion Resources, Inc.

Kiln Model Parameters

SHALE PROPERTIES

n Particle size n Moisture content n Density (v. porosity, particle size) n Heat capacity (v. temperature) n Thermal conductivity (v. porosity,

temp.)

n Heat of pyrolysis n Oil yield / mass shale n Oil heat capacity (v. temperature) n Gas yield / mass shale n Gas heat capacity ( v. temperature) n Pyrolysis reaction rate (v.

temperature)

n Oil cracking rate (v. temperature)

KILN THROUGHPUT

n Inside diameter n Length n Fill fraction or fill angle n Angle of repose n Slope n Rotation Rate n Shale bulk density

SHALE SURFACE HEAT TRANSFER

n Bulk density n Bulk heat capacity n Bulk thermal conductivity n Mean particle dia. n Kiln interface gas film thickness

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SLIDE 12

12 Combustion Resources, Inc.

PRO II Model (aft end) Elements

Gas Oil Heavy Diesel Diesel Gasoline Light Gasoline

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SLIDE 13

13 Combustion Resources, Inc.

Pilot Plant Reference Case Model Inputs

SHALE

n 4.2 ton/day n Western Shale (Miknis &

Robertson*)

n 27.5 gal/ton n 1.62% water n Gas 4.6%

KILN

n Inside dia.

0.83 (ft)

n Length

7.00 (ft)

n Volume

4.0 (ft3)

n Rotation Rate 20.00 (rpm) n Slope

1.0º

n Angle of repose 40.0º

* Data taken from tables in: F.P. Miknis, R.E. Robertson, "Characterization of DOE Reference Oil Shales", DE88005703, September 1987

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14 Combustion Resources, Inc.

Reference Case Inputs (continued)

Boiling Point (F) Mw Wgt % NBP1 251 145 0.436 NBP2 433 175 0.452 NBP3 487 196 0.458 NBP4 543 219 0.472 NBP5 597 247 0.476 NBP6 656 278 0.485 NBP7 708 312 0.490 NBP8 733 329 0.490 NBP9 758 339 0.498 NBP10 788 360 0.499 NBP11 818 382 0.506 NBP12 849 407 0.514 NBP13 880 432 0.523 NBP14 915 464 0.518 NBP15 949 498 0.521 NBP16 983 535 0.521 NBP17 1020 734 2.218

OIL

Gas

Boiling Point (F) Mw Wgt % H2O 212 18.015 6.62 H2

  • 423

2.016 0.0729 C0

  • 313

28.01 0.1657 CH4

  • 259

16.042 0.2355 CO2

  • 70

44.01 2.8232 C2H4

  • 155

28.053 0.0499 C2H6

  • 128

30.069 0.1477 H2S

  • 77

34.081 0.2335 C3H6

  • 54

42.08 0.0669 C3H8

  • 44

44.096 0.1038 C4H10 31 58.12 0.6287

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15 Combustion Resources, Inc.

Kiln Model Predictions

(4.2 tons/day)

Reference ¡Case ¡-­‑ ¡4.2 ¡Tons/day ¡(CH4 ¡Fuel)

100 200 300 400 500 600 0.0 0.2 0.4 0.6 0.8 1.0 0.00 0.20 0.40 0.60 0.80 1.00 1.20 Ts, ¡C Tg, ¡C Tw,C Fraction reacted

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16 Combustion Resources, Inc.

Kiln Model Predictions

(4.2 tons/day – alternate burner firing)

Modified ¡Reference ¡Case ¡-­‑ ¡4.2 ¡Tons/day ¡(CH4 ¡Fuel)

100 200 300 400 500 600 0.0 0.2 0.4 0.6 0.8 1.0 0.00 0.20 0.40 0.60 0.80 1.00 1.20 Ts, ¡C Tg, ¡C Tw,C Fraction reacted

Final Values: Ts = 506 C Tg = 513 C FR = 0.996

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17 Combustion Resources, Inc.

Kiln Model - Summary

1 17 77 1000 12.6 12.6 Inputed Rates

Mw

Inputed Rates lbm/min lbm/min lb-mol/hr 5.836 18 0.2918 0.97269 6 18 77 1000 12.85 12.6

Mw

Inputed Rates

Mw

Inputed Rates lbm/min lb-mol/hr lbm/min lb-mol/hr 16 0.1566 0.58718 18 0.0050 0.01667 7 19 77 1000 12.6 12.6

Mw

Inputed Rates

Mw

Inputed Rates lbm/min lb-mol/hr lbm/min lb-mol/hr 28.964 2.693 5.57855 18 0.0050 0.01667 20 22 1022 970 12.6 12.6

Mw

Inputed Rates Inputed Rates lbm/min lb-mol / hr lbm/min 27.630 2.850 6.18802 4.889 25 1000 12.6

Mw

Inputed Rates lbm/min lb-mol/hr 1.2388 1.91292

Compound

Oil Vapors & Gas Stream Oil Vapors & Gas + Steam Temperature (F) Pressure (psia)

Compound

H2O Stream Raw Shale to Kiln Temperature (F) Pressure (psia)

Compound

CH4 Stream Rotary Valve Purge Steam Temperature (F) Pressure (psia) Pressure (psia)

Compound

H2O

Compound

Air Stream Temperature (F) Pressure (psia)

Compound

H2O Stream Combustion Fuel (CH4) to Kiln Stream Combustion Air to Kiln Temperature (F) Pressure (psia) Steam Purge for Kiln Kiln Valve Purge Steam Temperature (F) Pressure (psia)

Compound

CH4 Stream Temperature (F)

Compound

Flue Gas Stream

Compound

Spent Shale Stream Flue Gas Out Temperature (F) Pressure (psia) Spent Shale Out Temperature (F) Pressure (psia)

Kiln Inputs Kiln Ouputs

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18 Combustion Resources, Inc.

C-SOS Pilot Plant Diagram and Stream Properties

Stream Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Phase Solid Solid Vapor Solid Solid Vapor Vapor Vapor Water Water Water Water Water Water Vapor Vapor Water Water Water Total Molar Rate LB-MOL/H Total Mass Rate LB/H Temperature F Pressure PSIA Stream Name 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Phase Vapor S/V Solid Solid Solid Vapor Vapor Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor Liquid Liquid Liquid Liquid Total Molar Rate LB-MOL/H Total Mass Rate LB/H Temperature F Pressure PSIA Stream Name 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Phase Liquid Vapor Liquid Liquid Water Liquid Liquid Liquid Vapor Vapor Liquid Liquid Water Mixed Vapor Liquid Water Vapor Vapor Total Molar Rate LB-MOL/H Total Mass Rate LB/H Temperature F Pressure PSIA Title: Size Number Revision A Date: 05/12/2010 Sheet 1 of 1 File: Drawn by: Ambar Montero

C-SOS PROCESS FLOW DIAGRAM

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19 Combustion Resources, Inc.

Predicted Material & Energy Balances – Reference Case

Materials (lbs/day) Enthalpy (BTUx105/hr)

IN OUT IN OUT Dry Oil Shale 10080 Spent shale 8424 Dry Oil Shale 9.12 Spent Shale 1.09 Water 156 Kiln Fuel (CH4) 2.02 Process Water 0.02 Gas Oil 274 Electricity 0.1 Oil Product 6.59 Heavy diesel cut 446 Steam 0.22 Flue gas 0.42 Diesel cut 250 Flare gas 1.13 Gasoline cut 40 Burner & Heat Losses (10%) 2.02 Light gasoline cut 12 Flare gas 478

Total 10080 10080 11.46 11.27

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20 Combustion Resources, Inc.

Observations

n 2 component model describes C-SOS pilot plant

in detail

n Kiln parameters n Extent of oil release n Effects of key variables n Properties of 57 process streams n Production of gas oil, diesel, and gasoline cuts n Material balance n Energy balance

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21 Combustion Resources, Inc.

Preliminary Observations

n Computation for the Reference Case

n 10% shale ore goes to oil products n 5% of shale ore goes to useful gas product n Net Energy Production ≈ 3:1 n Energy Recovery = 72%

n Computations for Base Case (First Pilot Plant test)

n In process n Comparison with pilot plant test data

1 2 1 2

Energy in oil : process energy (w/o mining, transportation and crushing) Energy in oil / energy in the raw shale

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22 Combustion Resources, Inc.

Plans – Second Year – Phase II

n Pilot plant Tests

n Effect of key variables n Oil split and quality n Long duration test

n Oil fractions upgrading

n Hydro treating n Hydro cracking

n Comparison with Model Predictions n Demonstration/Commercial Scale

n Preliminary Design n Cost

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23 Combustion Resources, Inc.

Thank You

Robert Jackson Doug Smoot Ambar Ochoa Combustion Resources, Inc Provo, Utah