ZENTRIFUGALE TRENNTECHNIK IN DER ROHÖLENTWÄSSERUNG UND -ENTSALZUNG

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1 69. BHT - FREIBERGER UNIVERSITÄTSFORUM 2018 KOLLOQUIUM 3 EINHEIMISCHE ENERGIERESSOURCEN GEWINNUNG UND SPEICHERUNG AM 7. UND 8. JUNI 2018 Flach, Andree (GEA Westfalia Separator Group GmbH) ZENTRIFUGALE TRENNTECHNIK IN DER ROHÖLENTWÄSSERUNG UND -ENTSALZUNG Seit vielen Jahrzehnten werden Zentrifugen in der Rohölentwässerung und entsalzung erfolgreich eingesetzt. Hier vor allem in Bereichen, in denen herkömmliche Technologien an ihre physikalischen und kommerziellen Grenzen stoßen. Heute werden Zentrifugen von der Petrochemischen Industrie jedoch nur sehr selten als alternative Lösung zu statischen Systemen gesehen, wobei sie in anderen Industrien schon deutlich weiter etabliert sind. Anhand von Erfahrungen durch erfolgreiche Tests auf Ölfeldern und vor allem einer kommerziellen Großinstallation die in Jahr 2017 in Betrieb genommen wurde, sollen die Chancen und Herausforderungen offen gelegt werden.

2 Fachkolloquium Zentrifugale Trenntechnik in der Rohölentwässerung und -entsalzung ANDREE FLACH

3 Introduction in mineral oil application ~ Centrifuges sold p.a.

4 Centrifuges in mineral oil applications *approx. 20 GW installed capacity x 250g/kW (GEA assumption) ** *** **** Gas Turbine & Diesel Engine Power Marine Crude Oil Production Refineries Oil Flow Market Share Centrifuges 80% 750 TBPD* TBPD** TBPD*** 99% 0,1% 0% TBPD****

5 Introduction of a newcomer A forgotten technology? Crude Oil Production Refineries Disc Stack Centrifuge Oil Flow Market Share Centrifuges TBPD*** 0,1% TBPD**** 0% Asking my colleagues: O&G is a very conservative area Too little references No tender specifications available Asking potential customers: Not reliable due to rotating equipment Tricky to operate Expensive

6 Introduction of a newcomer A forgotten technology? 110 Years of Oil Separation Technology 1907: first separator for treating lube oils based on a milk centrifuge Disc Stack Centrifuge 1920: Oklahoma Oil Field 1982: Crude Oil Purification Arar Power Plant (KSA) 1967: Canadian Oil Sands

7 Fundamental Principles of Centrifugal Separation Density difference: disk stack and decanter centrifuges can be used for separating mixtures of the following types: Working Principle of a modern disc stack centrifuge: Product feed Liquid/Solid Liquid/Liquid Liquid/Liquid/Solid Discharge, heavy phase Discharge, light phase Solids discharge

8 Static vs. centrifugal settling velocitiy Sample Case: De-watering of Oil Basic Product Data Density water droplet ρ w 1000 kg/m³ Diameter water droplet d 0,00005 m (50µm) Density oil ρ o 900 kg/m³ Oil 50 C 380 cst Static Oil 140 C (static Sep.) 11 cst = 12 density 900 kg/m³ Dynamic Viscosity C (static Sep.) 0,012 kg/ms (1cp = 0,001 kg/ms) Formula for (theoretical) static settling velocity 400mm

9 Static vs. centrifugal settling velocitiy Sample Case: De-watering of Oil Basic Product Data Density water droplet ρ w 1000 kg/m³ Diameter water droplet d 0,00005 m (50µm) Density oil ρ o 900 kg/m³ Oil 50 C 380 cst Static Oil 98 C (static Sep.) 35 cst = 39 density 900 kg/m³ Dynamic Viscosity 98 C (static Sep.) 0,039 kg/ms (1cp = 0,001 kg/ms) Bowl Radius (Median) = 300 mm Bowl Speed = rpm ww = 2 ππ ss 60 Formula for (theoretical) centrifugal settling velocity 2mm 9

10 Field Experience Heavy Crude Oil De-Hydration Russian Federation Republic of Komi Crude Oil Characteristics (in wet tank) Capacity (phase 1): 440 m³/h or BPD Product characteristics: Heavy Crude Oil (API 16) Water Content up to 40 % by Vol. Solids Content: up to 0,07 % by Vol. Particle Size: max. 100 micron Gas Content: n.a. Export requirements (downstream of centrifuges) Water and solids content < 0,5 % BS&W GEA Supply 8 disc-stack centrifuges type WSD 200 (6 running, 2 standby) Process lines plug & play Control System 6 month operation and optimization support 10

11 Field Experience Heavy Crude Oil De-Hydration Russian Federation Republic of Komi Wells 1 Tanks [3 x C] Pumping [3 2barg] Heating [T out =95 C] Treated Oil Oily Water 3 Sludge Export Pipeline Water Treatment & Steam Generation Sludge Disposal

12 Centrifugal Separation A forgotten technology? Crude Oil Production Refineries Asking potential customers: Not reliable due to rotating equipment Tricky to operate Expensive Oil Flow TBPD*** TBPD**** Market Share 0,1% 0% 50 years of continous operation 1967: Canadian Oil Sands 2018: Canadian Oil Sands

13 Centrifugal Separation A forgotten technology? Crude Oil Production Refineries Asking potential customers: Not reliable due to rotating equipment Tricky to operate Expensive Oil Flow TBPD*** TBPD**** Market Share 0,1% 0% to Centrifugal Separators are operated by seamen every day. Especially in rough sea clean fuel may decide on live or die.

14 Centrifugal Separation A forgotten technology? Crude Oil Production Refineries Asking potential customers: Not reliable due to rotating equipment Tricky to operate Expensive Oil Flow Market Share TBPD*** TBPD**** 0,1% 0% What would it be worth to you.? Reduced Chemicals g Continuous solids removal Expandable and/or mobile API down to /24 Small footprint No pressure drop Quick response to feed drift No limitations in water cut Scalable from trial to full scale

15 Questions.?

16 gea.com 17