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

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