The LUKOIL Neftohim Burgas hybrid reformer has experienced unusual reformate octane drop from 100 down to 98.7 (research octane) and from 89 down to 87.5 (motor octane) during its eighth cycle and 16-year operation with the same catalytic system. Several hypotheses have been checked to identify the reason for the octane reduction over a period of five months. Finally, it was established that the basic nitrogen containing chemical substituting caustic to neutralize the chlorides in the crude distillation units upstream of the reformer in order to decrease the sodium content in the vacuum residue had been carried over to the reformer and subsequently poisoned its catalyst. Poisoning of the reformer catalytic system led to both octane reduction and reformate yield decrease.
It was observed in the LUKOIL Neftohim Burgas refinery that the employed 2-ethyl hexil nitrate cetane improver treating rate increased by a factor of two for the last 17 months. An analysis performed using intercriteria analysis revealed that the main culprit for cetane improver treating rate augmentation is the deterioration of the cetane index of the finished automotive diesel fuel as a result of the increased H-Oil severity of operation. The estimation of the cetane number (index) of the refinery diesel fuel employing the linear blending rule established that the high severity mode of operation of H-Oil leads to production of refinery diesel having about 1 point lower cetane index (number). The slope of enhancement of diesel fuel with magnification of cetane improver treating rate indicated that 1 point lower diesel cetane number (index) will need about 370 ppm higher cetane improver treating rate.
Polymer flooding as well as other chemical flooding operations have to be well considered and researched for each reservoir. Adding to the research efforts are the economical calculations to deliberate about if the investments can be assimilated by the higher oil recovery in a production period. A cost reducing measure would be the reinjection of produced polymer. This article presents first basic experiments to test the influence of separation techniques, fluid -fluid and rock-fluid interactions on an alkaline polymer surfactant (ASP) system. Furthermore, parameters and lab experiments for an intensive study to perform a numerical simulation for different possible scenarios are discussed. Those include the commonly applied analysis for polymer evaluation as well as new issues that have to be considered in an additional experimental test series and the adjustment of simulation tools.
Reduction carbon and valorizing of CO2 rich gases are of increasing for many industries. Methanol is a perfect fit for energy storage, for producing clean fuels and is already one of the essential building blocks for producing high value chemicals. Air Liquide Engineering and Construction (ALE&C) offers a first generation of CO2 to methanol plant based on the well-referenced Lurgi (TM) Methanol technology with some specific optimizations regarding CO2 conversion [1]. It follows the classic synthesis loop design utilizing high recycle ratios to achieve overall high conversion rates. Typically, a recycle ratio of around 4 is foreseen. This technology is commercially offered with commercial guarantees on catalyst lifetime and methanol production. Commercially available electrolyzers or other low carbon hydrogen sources will result in first methanol plants based on CO2 with a capacity up to 1000 mtpd. The most efficient synthesis solution for large scale plants is a Lurgi Megamethanol (TM) loop with two reaction steps in series to reach single train capacities up to 10,000 mtpd. Air Liquide developed and is further optimizing further a second generation "CO2 to Methanol" plant setup (Fig. 1). This integrated synthesis loop consists of a "12 in 1" reactor with multiple stages of reaction, gas to gas heat exchange, condensation and inter-stage product removal (Fig. 2). The new multi-stage solution allows very effective conversion rates at reduced recycle rates (down to similar to 1), reduced costs (CAPEX & OPEX) for low reactive gases like CO2. The key features of the "12 in 1" Air Liquide CO2 to methanol approach can be summarized in the following points: - reactor design based on plates - higher per pass conversion and lower recycle ratio (1 instead 4) - longer catalyst lifetime - small footprint and low equipment count - approximately 20% lower CAPEX of the synthesis section - scalability, for a wide range of capacities and feedstock The multi-stage reactor concept offers high potential in the conversion of gases with high inert content. To develop a tailor-made solution for these carbon sources, a new pilot plant has been constructed at the Air Liquide Innovation Campus, Frankfurt (Fig. 3).
Electricity-based synthetic fuels (e-fuels) close the gap for short-term achievement of national and international CO2 reduction targets, insofar as the CO2 originates from non-avoidable sources or the atmosphere. Since a widespread expansion of electromobility is not progressing fast enough either for all forms of transportation or in all regions of the world, and thus the share of internal combustion engines in transportation will remain dominant for the foreseeable future, these synthetic fuels offer an important way out to make mobility sustainable even in the short term. Proven technologies for the production of synthetic gasoline are market-ready for implementation on an industrial scale and operate every gasoline engine worldwide in a climate-neutral manner and in compliance with standards. For the production of synthetic fuels based on electricity from renewable energy sources (power-to-liquid, PtL), there are various possible solutions via water electrolysis and CO2 capture and the downstream synthesis technologies. In this paper, the main distinguishing features of the methanal-based synthesis routes are analyzed, An example process is then used to calculate the actual CO2 savings patential for synthetic gasoline produced in this way, and a market outlook for it is given.
This study analyzes the performance of the LUKOIL Neftohim Burgas (LNB) fluid catalytic cracking unit (FCCU) after commissioning of the H-Oil vacuum residue hydrocracker. It makes a parallel with the performance of the LNB FCCU experiencing high catalyst losses long before the commissioning of the H-Oil hydrocracker, revealing that the operation of the FCC unit at higher than design throughput and higher than design air rate impairs cyclone efficiency. It is shown that the overloading of the FCCU may result in damaging of reactor-re-generator internals, that in turn may lead to exceptionally high Delta coke and regenerator temperatures, restricting the possibility to increase through-put. The effect of poor cyclone performance on catalyst aging and its effect on inventory micro-activity is discussed.
In recent years, there have been repeated incidents of damage to wells at various locations while-they were in operation. These were due to an increase in the tensile force in the riser pipe, up to the critical axial load, caused by changes in temperature, changes in pressure, hydromechanics, alternating loads and rock mechanical processes, and were the impetus for developing a weight monitoring system for riser pipe rigs. The purpose of this weight monitoring system is to prevent damage to riser pipe rigs during operation by detecting load changes early and both measuring and monitoring the axial loads upon them. The weight monitoring system's "intelligent" support element can be used with all common landing bolts and tension and tubing spool rams at wellheads from different manufacturers, to suspend and monitor riser pipe rigs that are under mechanical pre-tension.
The article presents a comparative service life analysis for Novikov gears of mechanical drives of sucker-rod pumps according to various failure criteria. The dependence of the service life ratio according to the criteria of bending strength and contact strength of teeth on the geometric and kinematic transmission parameters, as well as on the mechanical characteristics of materials, was investigated. Calculations have established that the probability of failure of Novikov gears of mechanical drives of sucker-rod pumps as a result of bending stresses is significantly lower than the probability of damage to working surfaces as a result of contact stresses. Therefore, damage to the teeth occurs primarily in their working surfaces, and non-working surfaces remain almost intact. On the basis of this, the possibility of increasing the life of the Novikov gears of the sucker-rod pumps by replacing working surfaces with non-working ones after a certain period of operation was confirmed. Further, methods of replacing the working profiles of gear teeth of existing sucker-rod pumps were presented. Keywords: sucker-rod pumps; Novikov gears; bending stress; contact stress; pitting; service life ratio.
The BrineMine Project is a German-Chilean multidisciplinary research project realized by research and industry partners. The focus is developing strategies for raw material and water extraction from geothermal springs (Brine Mining) in Chile. The topics can be separated into a geological/geochemical part and a mechanical engineering part, which are processed in close cooperation by the project consortium. In the first part, the economic potential of the dissolved raw materials in thermal spring waters in Chile is assessed by analyzing existing geochemical data of different sites. This is complemented by hydrogeochemical and geophysical exploration campaigns. The second part focuses on the development, construction and implementation of a prototype for pre-treatment and concentration of geothermal brines. With the comprehensive expertise of the team, a treatment strategy was developed and tested in a geothermal power plant, enabling controlled silica precipitation in order to overcome this limiting factor for geothermal energy production and associated raw material extraction. In this study, successful milestones of the BrineMine project are presented. The economic potential of elements in Chilean thermal waters is demonstrated. Additionally, the global potential of Brine Mining is outlined. The development of the silica treatment strategy is further described, as well as a possible integration of a prototype into an operating geothermal power plant. Finally, the construction and implementation of a large-scale first-generation prototype are presented with promising field results.
The new technical discipline Reservoir Fluid Geodynamics (RFG) accounts for compositional redistributions and phase changes of reservoir hydrocarbons during and post charge to present day. RFG naturally couples with petroleum systems concepts which account for trap filing. With RFG, crude oils can now be treated in the same comprehensive manner that reservoir rocks are treated, where both depositional setting and post deposition alterations or structural geodynamics are always considered. The key scientific advance that enabled RFG has been the development of asphaltene thermodynamics, specifically the Flory-Huggins-Zuo equation of state (FHZ EoS) with its reliance on the Yen-Mullins model of asphaltenes. The asphaltene thermodynamics are required to determine whether reservoir fluids are equilibrated or are evolving in geologic time due to a dynamic process acting on the fluids. Evaluation of asphaltene gradients, best performed using down hole fluid analysis, provides data needed for this thermodynamic treatment. To date, roughly 55 oilfields have been evaluated through an RFG perspective, enabling classification of many RFG processes; the collection of these processes constitutes the field RFG. In addition, equilibrated reservoir fluids imply reservoir connectivity, thereby addressing a major reservoir concern. Moreover, consideration of the coherent evolution of rock and fluid over geologic time enables development of the reservoir 'geoscenario", which is the sequence of events that occurred in/to the reservoir over geologic time. The 'coherence' refers to the fluids responding to the changing nature of their container via post deposition alteration of the reservoir rock. A much more accurate characterization of the present-day reservoir is obtained by considering the fluid and rock processes that led to the reservoir. All existing and new data can be tested against the geoscenario; thus, the geoscenario provides an integration platform. The emergence of RFG enables comprehensive and coherent evaluation of reservoir rock and fluids over geologic time, greatly enhancing reservoir evaluation.
Europe has been influenced by mining for thousands of years. Structural change now demands solutions for re-cultivating, re-structuring and re-using former mining areas. One innovative option is the utilization of mine water to provide energy for heating and cooling demands. At some sites, e.g. in the Ruhr valley area in western Germany, it is highly imperative to actively pump the mine water even after mining has ended in order to prevent contamination of the groundwater and subsidence of the surface (eternity task). Mine water geothermal energy offers the possibility to draw positive benefits from the eternity task.An overview of existing, planned and decommissioned plants worldwide shows that so far plants have been installed mainly in Germany, Great Britain and the USA. A total of 42 operating mine water geothermal plants could currently be researched. These plants have a total heating capacity of about 195 MW and a total cooling capacity of 2.5 MW and are situated mainly in Europe and North America. For example one plant was established in Frei-berg (east Germany). With the former mine "Reiche Zeche", university buildings are supplied with heating and cooling all year round. Extensive measurements have been taken since 2015. It is shown that the combination of heat and cold supply results in a high system efficiency. The coefficients of performance of the overall system are above seven. Nevertheless, the monitoring also revealed problems with the use of mine water. Since the mine water is mineralized and carries freight (e.g. iron, manganese), this results in the formation of deposits in the heat exchanger between the mine water and intermediate circuits. Without countermeasures, the efficiency of the plant will be significantly reduced
With Osmodialysis, the Austrian company fluvicon GmbH has developed a continuously operating, extremely robust membrane process based on forward osmosis, that is capable of cleanly separating oil and salt water. Fouling and scaling - the two major problems of membrane separation technology - play no role. That enables extremely long membrane service lives despite high oil loads and water hardness. The range of applications extends from the treatment of produced waters, condensate and seepage water in the oil and gas industry, to the purification of contaminated seawater after tanker accidents, shipwrecks and well disasters, to the treatment of oily bilge water on ships.
