Innovation in gas treatment, mercury removal, CO 2 handling and - PowerPoint PPT Presentation

Innovation in gas treatment, mercury removal, CO 2 handling and other approaches Introduction Steve Fogg

Formative Years

Oil Price - $59

1971 – Houston We Have a Problem

A Safe Landing

Our Guest Speaker – Prof Martin Atkins Chair of Chemical Innovation and Sustainability – Queen’s University of Belfast Commercial Mentor for Spin Out Companies P/T Commercial Director of QUILL – Queen’s University Ionic Liquid Laboratories BP – China Chief Scientist CTO - Petrona

Innovations in gas treatment Aberdeen: 19.2.2015 Prof. Martin P Atkins 8

Outline Presentation • Welcome remarks and background • A fast-track development of Hg removal from gas • An emerging technology at demonstration level for CO2 separation – challenges and opportunities moving forward Confidential (Commercially 9 Sensitive)

Fast-track development of a novel Ionic Liquid based Hg removal technology – in collaboration with PETRONAS Business Conceptual Intelligence; Design studies. Market Provisional Studies; BU CAPEX & OPEX Input models Technology & Engineering Division 6 Technology TM Management. D Project results and progress Confidential (Commercially 10 Sensitive) 10 10

PETRONAS operates a network of gas production facilities at Malaysia Offshore • Mercury has been discovered in the hydrocarbon stream delivered by PETRONAS to the Gas Processing Plant (GPP) in Kerteh, Terengganu, Malaysia • As mercury removal is becoming more challenging, there is a need to find a more robust, new technology to reduce the content of mercury Confidential (Commercially 11 to a much lower level. Sensitive)

Fact: Mercury is present in our oil and gas reservoirs Location Mercury Concentration Gas Liquids (µg m -3 ) (µg kg -1 ) Europe 100 - 150 - South America 50 - 120 50 - 100 Gulf of Thailand 100 - 400 400 - 1200 Africa 80 - 100 500 - 1000 Gulf of Mexico 0.02 - 0.4 - USA) Overthrust Belt 5 - 15 1 – 5 (USA) North Africa 50 - 80 20 – 50 Malaysia 1- 200 10- 100 Indonesia 200 - 300 10 - 500 Estimated levels of Mercury in natural gas and condensate from around the globe. Bigham, M.D., " Field Detection and Implications of Mercury in Natural Gas", SPE Prod. Eng. , May 1990, 120-124. Wilhelm, S.M., and McArthur, A., "Removal and Treatment of Mercury Contamination at Gas Processing Plant", Soc. of Pet. Eng ., (SPE No. 29721). Confidential (Commercially 12 Sensitive)

The Problem with Mercury in our Operations - what is it and where is it located? Confidential (Commercially 13 Sensitive) 13

The effect of mercury is threatening to the oil and gas industry and hence a mitigation programme has been developed Confidential (Commercially 14 Sensitive)

Energy Outlook to 2030 – Confirms Hg removal needs to be addressed with Hydrocarbons making up 80% of the energy pool in 2030 Projections taken from BP’s Energy Confidential 15 Outlook 2030. (Commercially Sensitive) 15

Commercially Available Mercury Removal Technologies (MRT) • Current commercial MRT uses supported sulphides, halides and silver as active materials. • MRT can be used to treat gas, liquid hydrocarbon and water streams • Depending on the applications, the targeted mercury levels at MRT outlets are: • < 0.01 mg/m3 for gas stream • < 1 mg/l for liquid stream Current Issues with MRT: • Fluctuation in the content of mercury in the streams • Analytical Accuracy - Issues in sampling, sample treatment and analysis • MRT’s capability to remove all types of mercury species. • Robustness of the MRT system when other contaminants are present in the feed • Handling of the spent MRT materials • Hefty Unit price of current MRT materials Confidential (Commercially 16 Sensitive) 16

The IL Adsorbent Package is Innovative and Proprietary  The material has to be resistant to water vapour  The active site is a Nano-engineered by-functional moiety comprising a molecular scaffold and activated metal centre.  The in volatile nature of the IL makes supported versions robust in plant operation. This approach opens up new avenues of research and development across catalysis and contaminants removal processes. Confidential (Commercially 17 Sensitive) 17

Mercury Removal Solid Support Ionic Liquid Journey Confidential (Commercially 18 Sensitive) 18

Collaboration with QUILL, Belfast Global commercial marketing alliance 2011 2010 2008- 2009 - Commercialization of R&D projects - Large scale 2007 production and Pilot Plant - Establish PETRONAS Ionic Liquid Laboratory in QUILL - Start of collaboration - Additional R&D projects fundamental included in the research program Confidential (Commercially 19 19 Sensitive)

Several tasks were studied in parallel primarily to reduce risks in commercialisation and speed the development  A new tool to understand the “ageing profile” and screening of new supports. High throughput experimentation tools applied and validated.  Establish the right partnerships early . In our case with catalyst manufacturers, support providers, ionic liquid manufacturer.  Strong support from site for implementation – commitment through the organisation  Economics, commercialisation, corrosion, risk management, HSE, Due Diligence, Patents & IP.  Critical path issues managed by central team drawn together from manufacturing, technology, engineering and business development.  Key “excellence” to success was in project management. The 20 difference between success and failure. 20

Mercury Capture Profile of SSILs The team developed a new tool to predict the commercial lifetime of new supports.  The mercury captured by the SSILs approach 70-75% of the theoretical capacity based on the oxidation to mercury(II) and incorporation into the ionic liquid structure.  Laboratory results indicated better performance in terms of mercury uptake as compared to commercial adsorbents.  Selection of the optimal ionic liquid compositions and optimal support for the next stage pilot demonstration. Confidential (Commercially 21 Sensitive) 21

Slip stream pilot plant  The heart of the slip stream pilot plant is multiple reactors fed direct from the main plant gas feed.  The unit is set-up for “doping extra Hg” to allow adsorption capacity to be estimated (life of the adsorbent).  The unit sees all plant operational variances and feed gas changes in the main plant.  Multiple beds allows comparison of different adsorbents  Additional capability and understanding generated on site. Early opportunity for training on new technology. Confidential (Commercially Sensitive) 22 22

Commercial Trial Loading Activities at Gas Processing Plant 23 Confidential (Commercially 23 Sensitive)

 It is possible to fast track R&D commercialization. It needs: The “right project” – strategic fit to Company objectives 1. 2. The right partners: catalyst manufacturer; support supplier, fundamental support, in-house expertise and excellence (eg Petronas Hg analysis) 3. Commitment from industrial partner especially site management and personnel 3. TEAMWORK and FOCUS Confidential (Commercially 24 Sensitive) 24

An emerging CO2 separation demonstration project Confidential (Commercially 25 Sensitive)

Promising technology: membrane contactor process N 2 or CH 4 CO 2 or H 2 S or SO 2 Natural gas Absorbent CO 2 Porous Gaseous mixture membrane CH 4 Membrane contactor combines Absorbent Absorbent conventional absorption process with membrane technology Natural gas purification by membrane contractor process Confidential (Commercially 26 Sensitive)

Advantages of membrane contactors  Higher packing density:  500-1500 m 2 /m 3 for membrane contactor  100-250 m 2 /m 3 for absorption column  Less equipment size and weight:  Dry equipment weight reduction of 32% to 37%  Equipment height reduction of 60%  Operating equipment weight reduction of 34% Traditional absorption column to 40 %  Capital cost reduction of 35 % to 40 %  Better operation flexibility:  No-foaming, flooding or entrainment  Independent control of gas and liquid phases  Insensitive to motion (critical for offshore) Membrane contactor system  Easy to scale-up Confidential (Commercially 27 Sensitive)

Laboratory study Vacuum Vacuum line pump J4 J7 PIT F1 P5 PIT PIT J5 J6 P1 P2 MFC PIT Y1 P6 JI CH4 LP Mixture HP Mixture F2 J3 Gas Tank Gas Tank PIT PIT P3 P4 MFC Y2 J2 CO2 J13 To GC Y5 W1 PIT P10 W2 PIT Purge P9 HP Absorbent Q5 Tank PIT F4 Y4 PIT Pulsation Fresh MFC P11 dampener Absorbent PIT Q3 Q4 P8 tank Flash LI Q1 evaporator F3 PIT PIT P7 MFC J8 J9 J10 Y3 Q6 Spent Absorbent Drum J11 Membrane contactor testing Hollow fiber membranes system Confidential (Commercially 28 Sensitive)

Confidential (Commercially 29 Sensitive)

Development of PTFE membranes • High hydrophobicity • High chemical resistance • Wetting resistance • Good mechanical performance F F C C n F F PTFE is considered one of the most suitable materials for membrane contactor use in CO 2 removal from natural gas Confidential (Commercially 30 Sensitive)