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Upgrader Optimization: A New Look at the Regional Upgrader with Selected Additions

Alberta Department of Energy

In this pdf format, this document has 174 pages and is 6.5MB

Table of Contents II
List of Tables VII
List of Figures IX
Acknowledgements X
Executive Summary XI
1.0 INTRODUCTION 1-1
  1.1 PREAMBLE 1-1
1.2 STUDY OF ORGANIZATION 1-1
1.3 ECONOMIC BASES 1-2
1.4 TECHNOLOGY BASES 1-2
2.0 CASES CONSIDERED 2-1
  2.1 PREAMBLE 2-1
2-2 BASE CASE 2-2
2.3 EXPANDED BASE CASE 2-4
2.4 FISCHER-TROPSCH CASE 2-4
2.5 PARTIAL REFINING CASE 2-5
2.6 REFINING CASES 2-6
3.0 FEED, INTERMEDIATE AND PRODUCT PRICING 3-1
  3.1 PRICING AND COST SUMMARY 3-1
3.2 ECONOMIC ANALYSES BASES 3-2
3.3 COMMENT 3-3
3.4 F-T MIDDLE DISTILLATE VALUATION 3-3
3.5 PURCHASED HYDROGEN 3-5
  3.5.1 AVAILABILITY 3-5
3.5.2 BALANCE 3-6
3.5.3 PURCHASED HYDROGEN COSTING 3-7
4.0 BASE CASE 4-1
  4.1 INTRODUCTION 4-1
4.2 DESIGN BASES 4-2
4.3 DESCRIPTION OF OVERALL DESIGN 4-7
4.4 PRODUCT YIELDS AND PROPERTIES 4-15
4.5 UTILITY BALANCE 4-15
4.6 CAPITAL COST ESTIMATES 4-16
4.7 WORKING CAPITAL ESTIMATES 4-19
4.8 OPERATING COST ESTIMATES 4-19
5.0 EXPANDED BASE CASE 5-1
  5.1 INTRODUCTION 5-1
5.2 DESIGN BASES 5-1
5.3 DESCRIPTION OF DESIGN 5-1
5.4 PRODUCT YIELDS AND PROPERTIES 5-2
5.5 UTILITY BALANCES 5-2
5.6 CAPITAL COST ESTIMATES 5-2
5.7 WORKING CAPITAL ESTIMATES 5-2
5.8 OPERATING COST ESTIMATES 5-3
6.0 FISCHER-TROPSCH CASE 6-1
  6.1 INTRODUCTION 6-1
6.2 DESIGN BASES 6-3
6.3 STEAM METHANE REFORMING 6-4
6.4 CO2 RECOVERY 6-4
6.5 HYDROGEN SEPARATION 6-7
6.6 FISCHER-TROPSCH SYNTHESIS 6-7
  6.6.1 PREAMBLE 6-7
6.6.2 FISCHER-TROPSCH PROCESS DESCRIPTION 6-8
6.6.3 CATALYST SPECIFICATIONS 6-11
6.6.4 CATALYST LIFE AND REGENERATION 6-12
6.6.5 CATALYST INSITU ACTIVATION 6-14
6.6.6 F-T PURGE GAS PROCESSING 6-15
6.7 F-T PRODUCT FINISHING 6-15
  6.7.1 PREAMBLE 6-15
6.7.2 HYDROCRACKING 6-17
6.7.3 MIDDLE DISTILLATE IMPROVEMENT 6-19
6.7.4 PRODUCT FRACTIONATION 6-20
6.7.5 FURTHER WORK 6-20
6.8 F-T AREA WASTE TREATMENT 6-20
6.9 F-T AREA UTILITIES 6-21
  6.9.1 REFRIGERATION 6-21
6.9.2 CHILLED WATER 6-21
6.9.3 STEAM SYSTEMS 6-21
6.9.4 CONDENSATE AND BOILER FEED WATER 6-22
6.9.5 COOLING WATER 6-22
6.9.6 INSTRUMENT AIR 6-22
6.9.7 FUEL GAS 6-22
6.9.8 FLARES 6-23
6.9.9 PIPELINES 6-23
6.9.10 TANKAGE 6-23
6.10 PRODUCT YIELDS AND PROPERTIES 6-23
6.11 UTILITY BALANCE 6-23
6.12 CAPITAL COST ESTIMATE 6-26
6.13 WORKING CAPITAL COST ESTIMATE 6-26
6.14 OPERATING COST ESTIMATES 6-26
7.0 PARTIAL REFINING CASES 7-1
  7.1 INTRODUCTION 7-1
7.2 DESIGN BASES 7-2
7.3 DESCRIPTION OF OVERALL DESIGN 7-2
7.4 PRODUCT QUALITIES 7-9
7.5 UTILITY BALANCES 7-9
7.6 CAPITAL COST ESTIMATES 7-9
7.7 WORKING CAPITAL ESTIMATES 7-10
7.8 OPERATING COST ESTIMATES 7-10
8.0 INTEGRATED CASE 8-1
  8.1 INTRODUCTION 8-1
8.2 DESIGN BASES 8-1
8.3 DESCRIPTION OF DESIGN 8-3
8.4 PRODUCT YIELDS AND PROPERTIES 8-3
8.5 UTILITY BALANCES 8-3
8.6 CAPITAL COSTS 8-3
8.7 WORKING CAPITAL 8-3
8.8 OPERATING COSTS 8-3
9.0 FULL REFINING CASES 9-1
  9.1 INTRODUCTION 9-1
9.2 DESIGN BASES 9-2
9.3 DESCRIPTION OF OVERALL DESIGN 9-6
9.4 PRODUCT YIELDS 9-24
9.5 UTILITY BALANCES 9-24
9.6 CAPITAL COST ESTIMATES 9-24
9.7 WORKING CAPITAL 9-26
9.8 OPERATIONAL COST ESTIMATES 9-26
10.0 SPECIAL CASES 10-1
  10.1 PREAMBLE 10-1
10.2 BUY OR MAKE HYDROGEN 10-1
10.3 PARTIAL OXIDATION FOR SYNTHESIS GAS 10-2
10.4 METHANOL VERSUS FISCHER-TROPSCH 10-3
11.0 ECONOMIC COMPARISONS 11-1
  11.1 PREAMBLE 11-1
11.2 EXPANDED BASE CASE DISCUSSION 11-4
11.3 FISCHER-TROPSCH CASE 11-4
11.4 PARTIAL REFINING CASES 11-6
11.5 INTEGRATED CASE 11-7
11.6 FULL REFINING CASE 11-8
12.0

RESEARCH AND DEVELOPMENT FACTORS

12-1
13.0

ENVIRONMENTAL FACTORS

13-1
  13.1 PREAMBLE 13-1
13.2 AIR 13-1
13.3 WATER 13-2
13.4 LAND 13-3
13.5 NEIGHBORS 13-3
13.6 APPROVALS 13-3
14.0 CONCLUSIONS AND RECOMMENDATIONS 14-1
  14.1 CONCLUSIONS 14-1
14.2 RECOMMENDATIONS 14-1
APPENDICES
A PRICE FORECASTS
B CAPITAL AND OPERATING COSTS

C

CASE COMPARISONS

List of Tables

2.1.1 LIGHT/SYNTHETIC CRUDE QUALITY COMPARISON 2-3
3.5.1-1 REGIONAL BYPRODUCT HYDROGEN AVAILABILITY 3-5
4.2-1 CRUDE ASSAY OF COLD LAKE BITUMEN 4-3
4.2-2 CRUDE ASSAY OF ATHABASCA BITUMEN 4-4
4.2-3 COLD LAKE BASE CASE - OVERALL MASS BALANCE 4-10
4.2-4 BASIC UPGRADER TANKAGE 4-14
4.2-5 BASE CASE WORKING CAPITAL 4-22
4.2-6 BASE CASE OPERATING COST ESTIMATES 4-22
5.8-1 EXPANDED CASE OPERATING COST ESTIMATES 5-3
6.7-1 FISCHER-TROPSCH PRODUCT FINISHING BALANCE 6-18
6.9.10-1 F-T CASE TANKAGE 6-24
6.12-1 FISCHER TROPSCH PROCESS UNIT DIRECT FIELD COST 6-27
6.13-1 F-T CASE WORKING CAPITAL 6-27
6.14-1 F-T CASE OPERATING COST ESTIMATES 6-28
7.3.1 PARTIAL REFINING CASE TANKAGE 7-6
7.7-1 PARTIAL REFINING CASES WORKING CAPITAL 7-10
7.7-2 PARTIAL RI~FINING SUB CASES OPERATING COST ESTIMATES 7-11
8.3-1 INTEGRATED CASE TANKAGE 8-5
8.7-1 INTEGRATED CASE WORKING CAPITAL 8-6
8.8-1 INTEGRATED CASE OPERATING COST ESTIMATES 8-6
9.3-1 REFINING CASE ANALYSIS SUMMARY 9-8
9.3-2 FULL REFINING CASE TANKAGE 9-13
9.4-1 GASOLINE AND MIDDLE DISTILLATE POOL COMPOSITION ESTIMATES 9-25
9.7-1 FULL REFINING CASE WORKING CAPITAL 9-28
9.8-1 FULL REFINING SUB CASES OPERATING COST ESTIMATES 9-28
10.2-1 BUY OR MAKE HYDROGEN COST BASES 10-4
10.3-1 DRY RAW SYN GAS COMPOSITIONS 10-4
10.3-2 PARTIAL OXIDATION VERSUS STEAM METHANE REFORMING 10-5
10.4-1 F-T VERSUS METHANOL TO INCREMENTAL LIQUIDS 10-8
11.1-1 CASE ANNUAL REVENUE AND COST SUMMARY 11-2
11.1-2 ANNUAL DIFFERENTIALS VERSUS BASE CASE SUMMARY 11-3
11.1-3 FISCHER-TROPSCH SENSITIVITIES INCREMENTAL TO BASE CASE 11-5
11.1-4 PARTIAL REFINING SUB CASE SENSITIVITIES INCREMENTAL TO BASE CASE 11-5
  FULL REFINING CASE SENSITIVITIES LOW GASOLINE PRODUCTION 11-9

List of Figures

4.2-1

BASE CASE SMR PROCESS FLOW SHEET

4-6

4.3-1

BASE CASE UPGRADER/EDMONTON TRANSFER SYSTEM

4-13

6.1.1

OVERALL FISCHER-TROPSCH SYSTEM

6-2

6.3-1

F-T CASE SMR PROCESS FLOW SHEET

6-5

6.4-1

CO2 RECOVERY SYSTEM

6-6

6.6-1

FISCHER-TROPSCH SYNTHESIS

6-9

6.7-1

F-T PRODUCT FINISHING SYSTEM

6-16

6.9.10-1

F-T CASE UPGRADER/EDMONTON TRANSFER SYSTEM

6-25

7.3-1

PARTIAL REFINING CASE S. C. O FRACTIONATION

7-4

7.3-2

OPTIONAL NAPHTHA HYDROTREATER IN PARTIAL REFINING CASE

7-5

7.3-3

PARTIAL REFINING CASE UPGRADER/EDMONTON TRANSFER SYSTEM

7-7

8.1-1

INTEGRATED CASE PRODUCT BLENDING

8-2

8.3-1

INTEGRATED CASE UPGRADER/EDMONTON TRANSFER SYSTEM

8-4

9.3-1

FULL REFINING PROCESS SCHEME

9-7

9.3-2

FULL REFINING CASE UPGRADER/EDMONTON TRANSFER SYSTEM

9-15

9.3-3

TAME COMPLEX

 

10.4-1

METHANOL TO NAPHTHA AND MIDDLE DISTILLATE

10-7