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Simulation and Optimization of Primary Oil and Gas Processing Plant of FPSO Operating in Pre-Salt Oil Field

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Simulation and Optimization of Primary Oil and Gas Processing Plant of FPSO Operating in Pre-Salt Oil Field ALI ALLAHYARZADEH BIDGOLI Simulation and Optimization of Primary Oil and Gas Processing Plant of FPSO Operating in Pre-Salt Oil Field. São Paulo 2018 ALI ALLAHYARZADEH BIDGOLI Simulation and Optimization of Primary Oil and Gas Processing Plant of FPSO Operating in Pre-Salt Oil Field. Thesis presented at the Polytechnic School of the University of São Paulo in support of the candidature for the Degree of Doctor in Science of Mechanical Engineering. São Paulo 2018 ALI ALLAHYARZADEH BIDGOLI Simulation and Optimization of Primary Oil and Gas Processing Plant of FPSO Operating in Pre-Salt Oil Field. Thesis presented at the Polytechnic School of the University of São Paulo in support of the candidature for the Degree of Doctor in Science of Mechanical Engineering. Field of Study: Mechanical Engineering - Energy and Fluids. Supervised by: Prof. Dr. Jurandir Itizo Yanagihara São Paulo 2018 Este exemplar foi revisado e alterado em relação à versão original, sob responsabilidade única do autor e com a anuência de seu orientador. São Paulo, ....... de ...................de 2018 Assinatura do autor..................................... Assinatura do orientador..................................... Catalogação-na-publicação Allahyarzadeh Bidgoli, Ali Simulation and Optimization of Primary Oil and Gas Processing Plant of FPSO Operating in Pre-Salt Oil Field / A. Allahyarzadeh Bidgoli -- versão corr. -- São Paulo, 2018. 206 p. Tese (Doutrado) - Escola Politécnica da Universidade de São Paulo. Departamento de Engenharia Mecânica. 1.Plataforma offshore de processamento de óleo e gás 2.Análise termodinâmica 3.Análise de sensibilidade 4.Método híbrido 5. Otimização I.Universidade de São Paulo. Escola Politécnica. Departamento de Engenharia Mecânica II.t. ﻘﺪﻢ ﺮ م، ﺪر و ﻣﺎم To my wife and my parents Á minha Família ACKNOWLEDGEMENTS I would like to thank my great loving Creator as a First and Foremost Teacher who gave me the thirst for science, the best family, the best teachers and the opportunity to write this thesis. I can do nothing without believing in Him. I am very much thankful to my wife, for her love, for staying by my side and following my moments of difficulties. I could not complete this research work without your support. I am extremely appreciative to my parents, for their love, prayers, motivating and sacrifices for educating and preparing me for my future. I would like to extend my thanks to my sisters and also my father and mother-in-law, Mohammad and Maryam. I would like to express my sincerest thanks and gratitude to my advisor, Prof. Dr. Jurandir Itizo Yanagihara for his advices and guidances. Every time I needed him, he was present and after every discussion, I had a new motivation that helped me to make a significant progress in my work. I would also like to thank Prof. Silvio de Oliveira Jr., for providing valuable discussions and support during the project. A special thanks to my friends and colleagues from Universidade de São Paulo: Alencar Migliavacca, Eduardo Suzuki, Felipe Malta, João Gouveia, Prof. Daniel Dezan, Yamid Sanchez, Felipe D’Aloia, Rafael Nakashima, Daniel Flórez-Orrego, Tomas Mora, Milton Gallo, Antonio Fernando Maiorquim, Ehsan Heidaryan, Esther Siroky, Paulo Faggioni Filho e Sidney Carneiro . I wish to acknowledge the support from PPGEM/POLI/USP, CAPES and BG/Shell Brasil. "Buscai o conhecimento, do berço à sepultura!" Profeta Mohammad (S.A.A.S) RESUMO As plantas FPSO (Floating, Production, Storage e Offloading) , assim como outras plataformas de processamento offshore de petróleo e gás, são conhecidas por terem processos com uso intensivo de energia. Portanto, qualquer aplicação de procedimentos de otimização para consumo de energia e/ou produção pode ser útil para encontrar as melhores condições de operação da unidade, reduzindo custos e emissões de CO2 de empresas que atuam na área de petróleo e gás. Uma planta de processamento primário de uma plataforma FPSO típica, operando em um campo de petróleo em águas profundas brasileiras e em áreas do pré-sal, é modelada e simulada usando seus dados operacionais reais: (i) Teor máximo de óleo / gás (modo 1), (ii) 50 % de teor de BSW no óleo (modo 2) e (iii) teor elevado de água / CO2 no óleo (modo 3). Além disso, uma turbina a gás aeroderivativa (RB211G62 DLE 60Hz) para aplicação offshore é considerada para a unidade de geração da potência eletrica e calor, através dos seus dados reais de desempenho. O impacto de oito parâmetros termodinâmicos de entrada no consumo de combustível e na recuperação de hidrocarbonetos líquidos da unidade FPSO são investigados pelo método SS-ANOVA (Smoothing Spline ANOVA). A partir do SS-ANOVA, os parâmetros de entrada que apresentaram o maior impacto no consumo de combustível e na recuperação de hidrocarbonetos líquidos foram selecionados para aplicação em um procedimento de otimização. Os processos de análise da triagem (usando SS-ANOVA) e de otimização, que consiste em um Algoritmo Híbrido (método NSGA-II + SQP), utilizaram o software Aspen HYSYS como simulador de processo. As funções objetivo utilizadas na otimização foram: minimização do consumo de combustível das plantas de processamento e utilidade e a maximização da recuperação de hidrocarbonetos líquidos. Ainda utilizando SS-ANOVA, a análise estatística realizada revelou que os parâmetros mais importantes que afetam o consumo de combustível da planta são: (1) pressão de saída da primeira válvula de controle (P1); (2) pressão de saída do segundo estágio do trem de separação (e antes da mistura com água de diluição) (P2); (3) pressão de entrada do terceiro estágio do trem de separação (P3); (4) pressão de entrada da água de diluição (P4); (5) pressão de saída do compressor principal de gás (Pc); temperatura de saída de petróleo no primeiro trocador de calor (T1); (7) temperatura de saída de petróleo no segundo trocador de calor (T2); e (8) temperatura da água de diluição. Os parâmetros de entrada de P1, P2, P3 e Pc correspondem a 95% da contribuição total para a recuperação de hidrocarbonetos líquidos da planta para os modos 1. Analogamente, os três parâmetros de entrada P3, Pc e T2 correspondem a 97% e 98% do contribuição total para o consumo de combustível para os modos 2 e 3, respectivamente. Para a recuperação de hidrocarbonetos líquidos da plant, os parâmetros de entrada de P1, P2, P3 e T2 correspondem a 96% da contribuição total para o consumo de combustível para o modo 1. Da mesma forma, os três parâmetros de entrada P3, P2 e T2 correspondem a 97% e 97% da contribuição total para a recuperação de hidrocarbonetos líquidos para os modos 2 e 3, respectivamente. Os resultados do caso otimizado indicaram que a minimização do consumo de combustível é obtida aumentando a pressão de operação no terceiro estágio do trem de separação e diminuindo a temperatura de operação no segundo estágio do trem de separação para todos os modos de operação. Houve uma redução na demanda de potência de 6,4% para o modo 1, 10% para o modo 2 e 2,9% para o modo 3, em comparação com o caso base. Consequentemente, o consumo de combustível da planta foi reduzido em 4,46% para o modo 1, 8,34% para o modo 2 e 2,43% para o modo 3, quando comparado com o caso base. Além disso, o procedimento de otimização identificou uma melhora na recuperação dos componentes voláteis, em comparação com os casos baseline. A condição ótima de operação encontrada pelo procedimento para otimização da recuperação de hidrocarbonetos líquidos apresentou um aumento de 4,36% para o modo 1, 3,79% para o modo 2 e 1,75% para modo 3, na recuperação líquida de hidrocarbonetos líquidos (e estabilização), quando comparado com as condições operacionais convencionais das suas baseline. Palavras-chave: Plataforma offshore de processamento de óleo e gás, Análise termodinâmica, Análise de sensibilidade, Método híbrido, Otimização. ABSTRACT FPSO (Floating, Production, Storage e Offloading) plants, similarly to other oil and gas offshore processing plants, are known to be an energy-intensive process. Thus, any energy consumption and production optimization procedures can be applied to find optimum operating conditions of the unit, saving money and CO2 emissions from oil and gas processing companies. A primary processing plant of a typical FPSO operating in a Brazilian deep-water oil field on pre-salt areas is modeled and simulated using its real operating data. Three operation conditions of the oil field are presented in this research: (i) Maximum oil/gas content (mode 1), (ii) 50% BSW oil content (mode 2) and (iii) high water/CO2 in oil content (mode 3). In addition, an aero-derivative gas turbine (RB211G62 DLE 60Hz) with offshore application is considered for the heat and generation unit using the real performance data. The impact of eight thermodynamic input parameters on fuel consumption and hydrocarbon liquids recovery of the FPSO unit are investigated by the Smoothing Spline ANOVA (SS-ANOVA) method. From SS-ANOVA, the input parameters that presented the highest impact on fuel consumption and hydrocarbon liquids recovery were selected for an optimization procedure. The software Aspen HYSYS is used as the process simulator for the screening analysis process and for the optimization procedure, that consisted of a Hybrid Algorithm (NSGA-II +SQP method). The objective functions used in the optimization were the minimization of fuel consumption of the processing and utility plants and the maximization of hydrocarbon liquids recovery. From SS-ANOVA, the statistical analysis revealed that the most important parameters affecting the fuel consumption of the plant are: (1) output pressure of the first control valve (P1); (2) output pressure of the second stage of the separation train before mixing with dilution water (P2); (3) input pressure of the third stage of separation train (P3); (4) input pressure of dilution water (P4); (5) output pressure of the main gas compressor (Pc); (6) output petroleum temperature in the first heat exchanger (T1); (7) output petroleum temperature in the second heat exchanger (T2); (8) and dilution water temperature (T3).
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