1st intl. conference on technological opportunities in oil ... final compress.pdf · in oil &...

1st Intl. Conference on

TECHNOLOGICAL OPPORTUNITIES IN OIL & GAS INDUSTRY 4 MAY 2014

MINISTRY of

PETROLEUM

(NIGC)

REFINING

(NIORDC) PETROCHEMICAL

(NIOC)

RIPI PRESIDENT

Technology & Intl. Affairs

Procurement

Strategic Planning Energy & Environment

Downstream Technologies

Upstream Technologies

RESEARCH CENTERS

Research & Technology Development

DIRECTORATES

Policy & Commercialization

Organization

1. Pardis (Tehran)

Rey (Tehran)

2. Kermanshah (Downstream)

3. Ahvaz (Upstream)

4. Qeshm Island (E&E)

5. Pars - Asaluyeh (E&E)

RIPI's Mission Statement

Our Mission is continuous value creation for the stakeholders through developing technologies and offering technological solutions.

We rely on our core competencies and exploiting of open innovation mechanisms to accomplish our mission.

Our intellectual capital is our main asset in moving toward excellence and

We are committed to professional ethics and sustainable development.

RIPI's 2020 vision The pioneer in technology development and offering

technological solutions in Oil (Petroleum) Industry and committed to sustainable development.

International Collaborations OVERVIEW

RUSSIA Demercaptanization Technologies Crude upgrading Engineering & Consultancy Services

GERMANY Intellectual Properties Environmental Problems (Decontamination) Engineering Services

FRANCE Seismic Interpretation Intellectual Properties

UK CDM (PDD validation) Engineering Services Environmental Solutions

AUSTRIA Reservoir Studies Software Development Fuel & Combustion

POLAND Laboratory Services

CHINA Hydrate Studies EOR/IOR PVT, Core & Geological Studies Corrosion Evaluation

JAPAN Technology Development Environmental Studies Clean Fuel Production

S. KOREA Engineering Services Pilot plants

IRAQ Training Courses Exchange of Experts

CANADA Technology Commercialization

Content

Software Services Products Technologies

Cooperation

potentials Offers Achievements

achievements

Integrated Reservoir Characterization

based on:

Geology

Geophysics

Petrophysics (Full set logs, Special Image Logs, Cut offs,

Facies Modeling)

Basic Reservoir Engineering (SCAL, RCAL, PVT, MBAL,

Welltest)

Production Engineering (PLT, Production Data, well

flow performance)

Static and Dynamic Modeling

Structural Modeling

Property Modeling

Model Initialization

Single well/ Sector/ Full Field Modeling

History Matching

Technological Achievements

Production Prediction Scenarios

Natural Depletion Scenarios

EOR Scenarios

Water Injection

Gas Injection (Miscible/ Immiscible)

Drilling and Completion

Well Trajectory

Well Completions

Surface Facilities Design

Economic Evaluation

Bibi Hakimeh

Azadegan

Hosseinieh

Reservoir technology

Bibi Hakimeh oil production and IOR potential

100000

120000

140000

160000

180000

200000

Khami condensate

Bangestan

Tight sectors

Gas Inj.

WO / Infill

Baseline

Integrated reservoir studies and development plan for Azadegan,Yadavaran, Ahvaz, Marun,

Bibi Hakimeh Balal ,Tusan…..oil fields

International best practice reservoir management and optimum reservoir management

models for Iranian reservoirs

Integrated reservoir study of the field in the Arvandan Area

3D petroleum system modeling for the South Pars field

Regional study of Asmari formation in Dezful Embayment

• Development of pars reservoir Simulator(PRS) software for the simulation of carbonate reservoir

• Development of Pars basin Modeling(PBM) software for petroleum basin modeling

NeoResVol (Initial Fluid In-Place )

Estimation of reservoirs’ oil in place using artificial neural networks

Well Test Analysis (Gas Condensate and Gas Reservoirs)

Asphaltene Deposition Modeling (Static Condition, Thermodynamic Modeling)

Core Flow Modeling (USS Test Modeling, Water-oil)

Compositional Grading

Software achievements

• Designing Ultra light weight cement

Nanotechnology

Particle Size Distribution (PSD)

RIPI’s LWCem

With very high Compressive Strength

successfully commercialized

Drilling and Well Completion

Product Achievements

Achievements in Cementing Services

RIPI Elastic Cements

To solve casing collapse in

Maroun oil Field

Applying modifications to the cement

formula previously used

Cements with Optimized

Young’s Modulus

and Poisson's Ration

Reliable Compressive Strength

Client: National Iranian Oil Company

Capacity: 240,000 BPD

Location: South Pars

Advantages: Sweetening of Sour

Condensate, Added Value

DMD & DMC

Naphtha Isomerization Unit of the Imam Khomeini Refinery

Client: Imam Khomeini Refinery

Location: Arak

Capacity: 8500 BPD

Start up: November, 2011

Advantage: High Octane Gasoline Production

Pentane Production Unit in Kermanshah

Client : Kermanshah Oil Refining Company Location : Kermanshah Unit Capacity: 5000 metric ton per year Start up : 2010 Advantage: Petrochemical solvent production

Client: National Iranian Oil Company

Capacity: 2,200(under construction) &

180,000 (designed)bbl/d

Location: Tehran, Bandarabbas and Abadan

Advantages: Converting Heavy residue to

API 30 or more syncrude

Volume yield : > 110%

Heavy Residue Hydroconversion (HRH)

Recovery Gasoline Refining of Kharg Petrochemical Complex

Client : Kharg petrochemical complex Location : Kharg Capacity: 1500 BPD Start up : 2005 Advantage: Converting waste cuts to export gasoline

Applications :oil and gas well drilling , cementing , completion and

production of Packings, Seals, Strippers, Plugs, Wipers , O-rings and …

Design and Manufacture of Polymeric Products for Oil and Gas Well Equipments

-Special lubricating oils and greases

-Carbon Nano Tubes

-Catalysts & Nano materials

-Crude oil evaluations labs

-Bitumen laboratories

-Catalyst evaluations labs

-Catalytic and non-catalytic pilot services

-Amine analysis and evaluation

Service Achievements

- Design, Installation and Classification of field atmospheric corrosion sites

- Atmospheric corrosion map for different industrial areas

Atmospheric corrosion map of

Bandar Abbass Oil Refinery

Atmospheric corrosion site installed on SPP1, gas flat at Persian Gulf

Engineering, procurement, construction and

commissioning (EPCC) of industrial and sanitary

wastewater and water treatment systems

Advanced wastewater treatment system of RIPI

EPCC of mobile water and

wastewater treatment

packages for industrial

applications

Mobile Treatment packages for sanitary wastewaters in Rafsanjan and Isfahan

• Bioremediation of oil-contaminated soil

Clean-up of a mud pit in Khangiran by combining microbial and phyto-remediation in biopile system

Remediation of sludge-contamiated soil through landfarming in Siri Island.

Monitoring and

modeling industrial air

pollutants

Simulation and modeling of pollution in Asalooyeh

Reuse of Reverse osmosis brine in Fajr Petrochemical Company

(the country's largest water reuse project)

Formulation, evaluation and monitoring of corrosion inhibitor for:

Cooling Towers Fire Fighting water lines Gas Treatment(Amine) Systems

• Production of detection kits for sulfate-reducing

bacteria (SRB’s)

SRB’s detection and enumeration kits for water, soil and fuel.

Design and production of passive samplers

Nitrogen dioxide passive sampler

Sulfation plate

Evaluation of various environmental impacts of industrial activities

• This group is certified by the Department of Environment of Iran

Energy Audit and Feasibility Study, Optimization,

Engineering and consulting of utility systems

Reuse of High TDS wastewater and optimal use of excess LP steam in the

Shahid Hasheminejad (Khangiran) Gas Processing Company (SGPC)

Design of Corrosion Monitoring Failure Analysis Selection of suitable coating systems Material Selection Cathodic Protection Design and Evaluation

Material selection Diagram for SRU Plant

Elemental analysis

instruments such as:

AAS, ICP, N,S analyzer,

CHNO analyzer

Liquid, ionic and gas

chromatography systems

equipped with SCD، NPD، FPD،

SIM.DIS ، MS، FTIR، FID، TCD

Nanometric instruments

such as: SEM, XRF, XRD

and Nano-zetasizer

Molecular spectroscopy

instruments such as:

UV/VIS and FTIR(ATR)

Crude oil finger printing

Analysis of environmental pollutants such as: Pesticides, BTEXs, PCBs, Methyl mercury and PAHs

measurement of Elemental sulfur in oil and gas samples Condensate assay

Software Achievements

Development of Software for energy performance

analyses in utilities and power plants

EPATTM

software based on ASME-PTC

and Operational Experience

Integrated Reservoir Study and modeling Technology

Field Development Planning Technology

Petroleum system study and basin modeling Technology

Laboratory study and research on EOR ,Drilling and production Technology

Upstream software development Technology

Offered Technologies

-Sedimentological, Paleontological and Structural Studeis -Sequence stratigraphy -Geological & Petrophysical Log Correlation -1D and 2D Facies Modeling

•Source rock Characterization •Organic chemistry Studies on oils and Bitumens •Organic Petrography Studies •Oil-Oil and Oil –Source Correlations •Fluid Inclusion study •1-3D basin Modeling

Survey Designing of 2D-3D Land and Supervision on 3D seismic data Acquisition

2D and 3D Seismic Data Processing Seismic Imaging Kirchhoff and Full Wave Solutions Study and Research on New methods in Seismic data Processing Structural Interpretation Velocity Model Building Depth Conversion Multi-Attribute Analysis and Classification Acoustic Impedance Inversion AVO and Elastic Inversion Reservoir Property Estimation Seismic Facies Analysis Stratigraphycal Interpretation Seismic Sequence Stratigraphy

• laboratories equipped with internationally well-known devices for both in-house and

well site services

Drilling Fluids Services Performing All API & OCMA Standard Tests

for evaluating Drilling fluid additives and

Formulating different drilling muds according to drilling requirements of operating company

Offered Services

Enhanced Oil Recovery services • Water Flooding and Water Injection Pressure

Maintenance

• Gas Injection, Miscible and Immiscible

Lab. Research

• Underground Gas Storage Studies

• Polymer, Surfactant and ASP Flooding

Cementing Services

Sep. oil & gas,water, H2S,CO2, HG…)) Surface sampling at well site

Subsurface sample validity and transferring at well site

Conventional Gas PVT Analysis (1000cc,up to 15000 psi & 350 o F (

Conventional Oil PVT Analysis (400cc&100cc,up to 15000 psi & 350 o F)

PVT sampling and analysis

Offered Services

Routine Rock Properties

– Natural gamma radiation and depth matching

– Consolidate and unconsolidated core plugging samples

– Fluids saturation measurement

– Helium porosity and grain density (ambient condition)

– Air and Klinkenberg permeability (ambient condition)

– Porosity, Air and Klinkenberg permeability at confining press

– Pore volume compressibility

– Hydraulic unit delineation

– X-ray computed tomography (CT) Scanning

– Sieve analysis

Offered Services

– Relative permeability

• Water-oil and gas-oil at ambient and reservoir conditions

• Unsteady state (constant rate or constant pressure)

• Steady state, X-Ray CT monitoring

• In-situ saturation monitored by attenuation of X-Ray

– Capillary pressure

• High-speed centrifuge (drainage & imbibition)

• Porous plate method

• Mercury injection and pore size distribution

– Wettability

• Wettability restoration

• Amott method

• USBM method

• Contact angle method

– Electrical properties

• Formation Resistivity Factor (FRF)

• Resistivity Index (RI) at ambient and reservoir conditions

– Interfacial tension

• Interfacial tension at ambient and reservoir conditions

• Determination of contact angle between fluid and rock

Reservoir Rock (SCAL)

Offered Services

Small and medium size condensate refinery Objective : Creating added value through processing of condensate

Feed: South Pars condensate

Products: Diesel – Gasoline

Economic considerations : Estimated investment for 20,000 barrels

per day, about 80 to 130 million dollar with a

rate of return of over 35 percent and for of

60,000 barrels per day to about 250 to 300 million

dollar investment with a rate of return of 48 percent.

Heavy crude oil refinery design with the purpose of bitumen production Purposes and achievements: Production of an extra light crude oil with the API=43, and providing opportunity to sale heavy crude oils in the presence of produced light crude oil Quality improvement of produced bitumen Taking the regional or even the world market of bitumen Economic consideration: Providing a net profit of approximately 3-5 dollars per barrel Low investment in the comparison with an ordinary refinery plant (approximately 2000-3000 dollars per barrel) Payback Period: less than 2 years.

Application The use of sulfiran process is regarded very significant for environmental protection and energy conservation .

Achievements A 450000 ft3/day demonstration unit was constructed and installed at Fajr-E-Jam gas refining. It became operational for periods of 3 months from 2008 to 2011.

Sulfiran The usual method to eliminate H2S for capacities higher than 20 ton/day of sulfur, is absorption by amine process which followed by incinerator or Cluse process. Sulfiran process is economical for gas streams containing 0.2 to 15 ton/day of sulfur. In this process the absorption and conversion of H2S to sulfur is carried out in a single stage

Real Time Optimization (RTO)

Main Objectives:

Decreasing Energy Consumption of Plants

Improvement of plant stability and reliability

Automatically optimizing plant’s performance

Calculating and reporting

consumption/production of feed and

products at any time

Advantages :

High added value with minimum investment

RTO CASE STUDY:

BANDARABBAS HYDROTREATING PLANT

Million Rials Description Item

10223.70 Fix investment 1

21785.11 Revenue 2

156456.55 NPV (12%) 3

207.12 (IRR)% 4

0.54 Payback Period(year) 5

ECONOMIC RESULTS

Description IRR %New IRR %

Fix investment +100% 103.05 207.12

Production cost +100% 201.09 207.12

Fix investment +100% and

Production cost +100%

100.05

207.12

Fix investment +100% and

Production cost +100% and Revenue -50%

207.12

Sensitivity Analysis

Online Blending

Online blending provide the opportunity to diversify the Crude oil type upon the

client requirement .Afghanistan market and numerous available Iraq hydrocarbon

resources make this plant very attractive in Iran.

Economic aspects:

The economic features of this plant is very attractive and the payback period is

less than a year.

Mobile DMC Plant

Mobile DMC plant provide unique opportunity

to make added value through sweetening of

condensate in different locations in Persian Gulf

Economic aspects:

High added value makes this plant

very feasible with a payback period

of about one year

RIPI Gas To Liquid Technology (3000 bbl/d GTL) Objective : creating added value through Natural Gas to Liquid

Feed: Natural Gas

Products: Diesel – Gasoline

Economic aspects : Estimated investment for a capacity of 3,000 barrels per day, about 130to 150 million dollar with

rate of return over 30 percent

Carbon Management Research Topics

Carbon Capture & Storage (CCS/ CO2-EOR)

Emission Inventory Software Development

Emission Reduction Policy & Action Plan

Clean Development Mechanism Projects(CDM)

Global Environmental Facility Projects( GEF)

National Appropriate Mitigation Actions( NAMAs)

Climate Technology Center & Network (CTC&N)

Carbon Tax and Trading

- Design of coating natural weathering

station in industrial units

- Developing technologies for improving

the performance and lifetime of

industrial coatings

Natural weathering paint exposure station

Diagnosis and control of biological corrosion

Offered Products

Synthesis and formulation of

corrosion-resistant

intelligent nanocoatings

Synthesis and formulation of

fire retardant nanocoatings

Fire retardant nanocoating

Cooperation potentials

Technological Cooperation potentials

technology Exploration technology Development

technology ERO/IOR technology Production technology Reservoir management

IOR and Green field development significance for Iran

Development- The EOR Roadmap

INCRESED KNOWLEDGE, UNDERESTANDING, INVESTMENT, AND RECOVERY OVER TIME

Propose at FDP Stage

Screen EOR Methods

Test in laboratory

Model Field and Process

Design Field Test

Perform Pilot: Monitor and Analyze

Design Field Implementation

Efficient EOR Decision making: Feedback loops to Improve design are Implemented rapidly

Ref. : www.slb.com

Success of EOR operations: Optimizing the EOR project Continues throughout its life

Implement in Field

Additional recovery

Monitor and Control

Project

Fine Tune Field Development Plan Expand Field

Development

• Advance Reservoir Study and Modeling Technology

• Optimum Field Development Scenarios Technology

• IOR/EOR Advance Technologies:

Hydraulic Fracturing

Hybrid EOR

• Advance Reservoir Imaging and 4D Seismic Technology

Drilling and well stimulation technologies

• Advance drilling Technology and drilling cost reduction

• Smart completion

• Artificial lifting technology

• Laser drilling

• Multi zone stimulation technology (MZST) in low

permeable reservoirs

Drilling technology

• Technical know-how of the procedure for the production of additives used in drilling, well completion and stimulation

• Advance drilling and well completion technologies

• RIPIs ultra light weight and elastic cements

• RIPIs ultra light weight drilling fluids

Production- Hydraulic fracturing

• Improvement of Productivity Index • Hydraulic fracturing usually used when the permeability of a reservoir is

below 1 md (for gas reservoirs) / 10 md (for oil reservoirs).

• Areas of Collaboration

• Experimental study of hydraulic fluid and proppants efficiency using modified API conductivity test

• Operation design • Preparation of chemicals • Field operation

Production- Well Production Enhancement Methods

• Water Control Management

• Sand Production Management

• Hydraulic Fracturing

• Artificial Lift

Lab Setup Modeling Designing Implementation

Productivity improvement technology

• water and gas control in reservoir

Gel polymer formulation (Lab research and field implementation)

intelligent well technology application and development

• Asphaltane precipitation, inhibitation and removal in the well

investigation on asphaltane precipitation

( Lab. research and software development)

inhibitor and solvent synthesis

Production- Polymer Gel Treatment for Water Shut-Off

• using polymer gel treatment for water shut off in fractured reservoirs

which are the most common reservoirs in Iran.

• Area of Collaboration

• Field operation

• Chemical providing

Reservoir Management Technology

• Real time reservoir monitoring and

optimization (RTO) technology

• Real time reservoir management technology

Smart well

Smart reservoir

• Full integration between surface and

sub surface technology

• Software development for reservoir

simulation technology

Zero Flaring: an Engineering, Control and Automation Approach

• Thorough the study and evaluation of the process in order to indentify major flare gas generator

• Modifying and optimization of the process (through improving equipment technology or process changes) in order to reduce the permanent flare gas load

• Design a Flare Gas Recovery Unit (FGRU)

• Improving the flare system operation reliability via upgrading automation and instrumentation technologies

• Minimizing the flare pilot gas consumption using new-developed pilot technologies

• Reducing purge gas injection using design of liquid seals and molecular seals in flare stack

Upgrading of heavy residue/crude oil

The upgrading of heavy residue/crude oil is an international challenge

and RIPI has its own technologies, beside , we are interested on

developing new ideas that is partially developed to make feasible

plant preferably in small and medium scale.

Methanol to gasoline conversion process (MTG)

Current Situation: the bench scale system for MTG process using a fixed bed reactor

has been set up

Development of technology concept of Alkylation process

with solid catalyst

Alkylation of isobutane with n-butenes (C3-C5 olefins) to form highly branched

isoparaffins (Alkylate) is an important process in gasoline manufacture. Alkylate is a

high octane gasoline that contains high octane number (RON 94-97).

It is the cleanest of all major gasoline components and, as restrictions on fuel

emissions become more stringent and pressure for

environmental responsiveness increases, the

demand for it is rising.

Mega GTL

We have nearly 21 years experience in the field of converting natural gas to liquid (GTL) fuels. Also RIPI has a process design package (PDP) for a commercial plant with a capacity of 3000 bbl/day. Invitations of companies participating in erecting up a Mega GTL plant

We hereby invite the specialized companies from home and abroad to participate in building a Mega factory of GTL plants in IRAN. The location of factory will be in south of Iran where there are deposits of huge amounts of natural gas recourses.

Oil and gas equipment technologies

The Process Development and Equipment Technology Division

has a wealth experience in this field and any new cooperations to transfer and

localization of these technologies specially in upstream equipments is

interested. Having private Iranian companies as the potential client or partner

paves the way for making units to produce to local and regional demand.

Renewable Fuels

Te drawback of worldwide huge emission of toxic exhaust gases from fossil fuels have

led to inevitable and mandatory use and market growth of clean, formulated fuels

as well as advanced renewable fuels such as nanoemulsion biofuels, biodiesel,

biogasoline, wood-based solid fuels and bio-SynGas. For a decade, RIPI has been

working on liquid biofuels and other biomass-based fuels processes at pilot-scale

and is willing to cooperate internationally regarding technology

development/transfer and joint efforts in all areas of biofuels and clean fuel

additives.

Chemicals for Enhanced Oil Recovery (C-EOR)

Water Shut-off with gel polymer

Polymeric Additives applied in Petroleum Upstream Industry

-CCR Process and Catalyst

-Fuel Additives

-RFCC Catalyst

-Polymer additives

-Surfactants(emulsifiers, demulsifiers ,co solvents..)

Product Development Potentials

• NDT and corrosion monitoring Technologies

• Production of oil and gas drilling equipments

• Coatings Technologies

- Development of technologies for the pipe line internal coatings

Internal Pipe line Coating

Summary

• Advance reservoir simulation technology for giant Iranian oil fields:

Reservoir simulation

Software development

• Optimum Field Development and production improvement Technology:

Water Control Management

Sand Production Management

Artificial Lift

• IOR/EOR advance technologies:

Hydraulic Fracturing

Hybrid EOR

Chemical EOR

Upstream Sector

• Drilling and well completion technologies:

Smart completion Laser drilling Multi zone stimulation technology (MZST) in low permeable reservoirs • Reservoir monitoring and

management technologies: Advance reservoir Imaging and 4D seismic Technology Smart well Smart reservoir

• Chemicals, gel polymer & Polymeric Additives for

Enhanced Oil Recovery (C-EOR)

• Small and medium size condensate refinery

• Upgrading of heavy residue/crude oil-GTL

• Oil and gas equipment technologies

Downstream Sector

Energy & Environment Sector

• NDT and Corrosion Monitoring Technologies

• Petroleum Biotechnology

• Environmental Pollutants control

• Energy Optimization

1st intl. conference on technological opportunities in oil ... final compress.pdf · in oil &...

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