Cleaner Petroleum Production and Refining Technologies

Reduce environmental impacts across petroleum production, refining, and fuel use Liquid fuel demand is projected to increase by more than 20% over the next three decades, yet petroleum remains the prime source of manmade carbon and methane greenhouse emissions. Cleaner Petroleum Production and Refining Technologies addresses this tension directly, detailing methods to produce and refine crude oils and gas into quality fuels while minimizing environmental impacts throughout the entire production-to-consumption chain. This edited volume includes authoritative discussions of carbon capture and storage, fugitive methane emissions reduction, and technologies to reduce energy intensity and green house gas emissions for heavy oil production and oil sands operations. It examines refinery reconfiguration to convert carbon residuals into middle distillates and light olefins for petrochemical feed, gas-to-liquid processes including Fischer-Tropsch synthesis, and the use of renewable feedstock in hydrogen production. Key topics include: Production and processing technology for oil and gas with specific focus on pollution minimization during production, processing, and fuel consumption Integration of refinery with petrochemical plant processes providing alternative pathways when demand for petroleum-based fuels declines Gas-to-liquid processes including Fischer-Tropsch synthesis to produce liquid fuels from syngas or CO2 for middle distillate production Deep conversion and desulfurization technologies alongside renewable feedstock applications for more sustainable hydrogen production in refineries Identification of prospects, issues, and gaps in the path toward more sustainable petroleum production, refining, and consumption Cleaner Petroleum Production and Refining Technologies serves engineers, scientists, and managers in the petroleum production and refining industries, as well as researchers at government organizations and research centers. University faculty and students working in petroleum production and processing will also find this volume a substantive technical reference.

List of Contributors xvii Preface xix 1 Introduction 1 M. R. Riazi and Harvey W. Yarranton 1.1 Historical Perspective on Petroleum 2 1.2 Future Demand for Petroleum and Its Products 5 1.3 Petroleum Production 9 1.4 Petroleum Refining 12 Part I Cleaner Petroleum Production 23 2 Carbon Capture, Storage, and Enhanced Oil Recovery 25 Eduardo Manrique 2.1 Introduction 25 2.2 CCUS: Main Steps 26 2.3 Geologic CO2 Storage 28 2.4 Enhanced Oil Recovery 30 2.5 CCUS: Challenges and General Economics 38 2.6 Closing Remarks 55 3 Fugitive Methane Emissions 77 Stuart Riddick 3.1 Methane Oil and Gas Emission Sources 77 3.2 Methane 79 3.3 Micrometeorology 81 3.4 Methane Emission Quantification Methodologies 86 3.5 Measuring Methane Concentrations 95 3.6 Full System Solutions 101 3.7 Challenges and Needs for Future Work 101 4 Technologies to Reduce GHG Emissions from Heavy Oil Production 117 Dr. Bruce S. Carey 4.1 Introduction 117 4.2 Current Commercial Thermal Methods 122 4.3 New Solvent-based Recovery Processes with Improved Environmental Metrics 133 4.4 Other Recovery and Associated GHG Intensity Reduction Technologies 163 4.5 Summary of GHG Reduction Estimates 177 4.6 Key Takeaways and Concluding Comments 177 5 Energy Intensity in Mineable Oil Sands 189 Danuta M. Sztukowski and Elco D. Hollander 5.1 Introduction to Mineable Oil Sands 189 5.2 Evolution of Process Flowsheets 196 5.3 Continuous Improvement Opportunities 212 5.4 Step-out Technologies 221 5.5 Concluding Remarks 225 6 Tailings and Waste Management in Mineable Oil Sands 233 Elco D. Hollander and Danuta M. Sztukowski 6.1 Introduction to Tailings and Waste Management 233 6.2 Tailings Mass Balance and Waste Material Types 236 6.3 The Tailings Management Challenge 243 6.4 Tailings Technology Trade-offs 253 6.5 Technologies Deployed 257 6.6 Concluding Remarks 267 Part II Cleaner Petroleum Refining 275 7 Refining of Unconventional and Heavy Oil 277 M. R. Riazi and Dicho Stratiev 7.1 Introduction 277 7.2 Heavy and Extra Heavy Oil Refining Technologies 277 7.3 Shale Oil Production and Processing 309 8 Petroleum Refining with Deep Conversion and Deep Desulfurization 333 George Hoekstra, Marcio Wagner da Silva, and Thomas Murphy 8.1 Heavy Oil Process Overview 333 8.2 A Closer Look at Heavy Oil Upgrading Reactors and Catalysts 338 8.3 Economic Analysis of Gasoline Sulfur Reduction Investment 349 9 Hydrogen Production Using Renewable Feedstock 363 Gabriela Nascimento da Silva, Clarissa Bergman-Fonte, Pedro R. R. Rochedo, Frédéric Lantz, and Alexandre Szklo 9.1 Introduction 363 9.2 Hydrogen Production in Oil Refineries 367 9.3 Hydrogen Produced from Water Electrolysis 370 9.4 Conclusion 375 10 Closer Integration Between Refining and Petrochemical Assets and Their Role in the Future of the Downstream Industry 383 Marcio Wagner da Silva, George Hoekstra, and Thomas Murphy 10.1 Introduction and Context 383 10.2 What Is the Petrochemical Integration Concept? 385 10.3 The Crude Oil to Chemicals – Maximum Added Value to the Processed Crude 387 10.4 Available Crude-to-chemicals Routes 400 10.5 Refining Technologies and Relatively Low-cost Alternatives to Integration 402 10.6 Closing the Sustainability Cycle – Plastics Recycling Technologies 406 10.7 Conclusion 407 11 Greening Existing Petroleum Refineries via Biomass Processing 411 Clarissa Bergman-Fonte, Aline T. Carvalho, Gabriela Nascimento da Silva, Pedro R. R. Rochedo, Frédéric Lantz, and Alexandre Szklo 11.1 Introduction 411 11.2 General Concepts 412 11.3 Oily Crops, Used Cooking Oils, Residual Fats 414 11.4 Lignocellulosic Biomass 420 11.5 Sugary and Starchy Biomass 427 11.6 Opportunities and Challenges for Biomass Co-processing – A Case Study Application 428 11.7 Conclusion 434 12 Liquid Fuels from Syngas and CO2 443 Chike George Okoye-Chine and B. Frank Gupton 12.1 Introduction 443 12.2 Syngas Production 444 12.3 Liquid Fuel Production from Syngas via FT Synthesis 456 12.4 Conversion of CO2 into Liquid Fuels 459 12.5 Conclusion 466 13 Syngas Production Beyond Petroleum Feedstock Toward LCA 481 Amol A. Inamdar, Francisco O. Aguirre, Olubayo O. Oginni, Heidi A. Taboada, and Lucy Mar Camacho 13.1 Introduction 481 13.2 Other Syngas Production Pathways 482 13.3 Valuable Syngas Subproducts and Their Environmental Footprint 483 13.4 Feedstock Alternatives for Syngas Production 485 13.5 Process Optimizations to Improve Environmental Performance 488 13.6 Environmental Impact of Syngas Production 490 13.7 Life Cycle Assessment of Syngas Production 494 13.8 Final Considerations from Syngas LCA 498 14 Investment Required for Upgrading Petroleum Refineries – Simplified Approach 507 Thomas Murphy, George Hoekstra, and Marcio Wagner da Silva 14.1 Introduction 508 14.2 Derivatives 510 14.3 Model Risk 513 14.4 Quantitative Models 515 14.5 Model Audits and Critique 516 14.6 Systems Thinking 517 14.7 Assessment of Model Risk Fits into a DSM Framework 520 14.8 Real Option Strategy Assessment Example – Evaluating CTL Technology 521 14.9 Environmental Compliance: Environmental Credits and Offsets 526 14.10 Conclusion 527 Index 529