1. No category

New Frontiers in Oil & Gas Research
Vishnu Pareek, Tejas Bhatelia & Moses Tade
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Future Oil and Gas Plants
Safer
Modular
Cheaper
Future
Oil and
Gas
Plants
Leaner
Smaller
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Cleaner
Smarter
Artificial
Intelligence
Novel
Sensors
Data
Analysis
3D Virtual
Reality
Robotics
Process Intensification (PI)
“The development of innovative apparatuses and techniques that offer drastic
improvements in chemical manufacturing and processing, substantially
decreasing equipment volume, energy consumption, or waste formation, and
ultimately leading to cheaper, safer, sustainable technologies”- Moulijn (2000)
Classic PI Example-Methyl acetate production
 Up to 7 unit operations combined
into one single unit
 Replaces series of azeotropic
distillation columns, extraction
units, separators, decanters, and
mass transfer agents
 Higher conversions by LeChatelier’s principle
 Commercially operating since the
1980’s by Eastman Chemicals
Co.
Conventional Plant
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Intensified unit
Principles of PI
1) Kinetic events: improve the conversions, selectivity
and productivity of the system
Ultimately we
2) Minimize non-uniformity in terms
of temperature
want
to go fromand
concentration gradients within reactive
systems.
this size
to …..
3) Maximum possible interface area and driving forces
across these interfaces at all scales
4) Synergistic effect to improve the performances.
Small intensified plants……
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Images courtesy – Water corporation and BIC-IWHR
Examples in GTL industries
ORYX GTL
34 kbo/d of products
Total foot print of 0.75 km2
Diameters 10 m Length 60 m
Pearl GTL
140 kbo/d of products
Total foot print of 2.5 km2
Reactor tubes can run from Perth to Sydney twice
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Multiphase reactors
Fluidized bed reactor
Slurry bubble
column reactor
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Fixed bed reactor
PI-Multiphase reactors
 Decreased linear dimensions
 Increased surface to volume ratio
 Superior Heat and mass transfer characteristics
 Low pressure drops, Low residence time and reduced hold-up
 Modular
 Safe in operation
Micro reactors
Spinning Disc reactors
Outlet
Shaft
Liquid Inlet
Disc
Liquid Outlet
Inlet 2
Inlet 1
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Steps in CFD Analysis
control
volume
Fluid region of
pipe flow
discretized into
finite set of
control volumes
(mesh).
Geometry Creation
and Meshing
Domain is
discretized into a
finite set of control
volumes or cells.
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Models &
Solution
Conservation equations
for mass, momentum,
energy, discretized into
algebraic equations.
Visualization of
Results
Geometry Meshing
Structured Mesh with
boundary layer
Unstructured
T-Grid Mesh
Thank you.
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Structured Mesh with
boundary layer
MICRO REACTORS
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Micro Reactors
Hydrodynamics
Bubble rise
velocities
Geometrical
parameters
Length of
liquid slugs
• Capillary number
• Angle of inlets
Superior
Mass transfer
Physical
properties
of fluids
Thickness
of liquid
films
• Reynolds number
• Viscosity ratio
• Wall contact
angle
Diffusivity
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Flow Regimes in Micro-Channels
1.00E-03
Annular flow
Ql/(Ql+Qg)
1.00E-02
Cappilary Slug flow
1.00E-01
Tansitional
Slug/
Churn flow
1.00E+00
0.05 0.07 0.09 0.10 0.12 0.13 0.15 0.19 0.21 0.20 0.26 0.28 0.30 0.34 0.35 0.40
Ca
Bubbly
Churn
Annular
Slug
This type of flow is characterized by alternate bullet shaped bubbles (Taylor
bubbles) separated by free gas-entrained liquid slugs.
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Model Geometry
Geometry configurations
2mm
No
θ1
θ2
θ3
1
120°
120°
120°
2
180°
60°
120°
3
180°
90°
90°
4
90°
180°
90°
50 mm
Operating Conditions
θ3
θ1
10 mm
10 mm
θ2
Schematic of Y- junction MicroChannel
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Structured Mesh
Superficial
Gas and Liquid
Velocity
0.01 0.1 m/s
Gas Phase
Air
Liquid Phase
Water
Methodology
Characterise Hydrodynamics of
Capillary Micro-Channel
Effect of Simulation
Parameters
Effect of
Grid Size
Comparison
of 2D and
3D Model
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Effect of Operating
Parameters
Effect of
Gravity
Effect of Superficial
Velocity
Effect of
Liquid Wall Contact Angle
Effect of Geometric
Parameters
Effect of
Angle of Entry
Effect of
Channel Diameter
Effect of Grid Size
146
144
ΔP Pascal
142
140
Δp (pa)
Laplace = 175
Theory
138
136
134
0.4
0.3
0.25
Grid Size in mm
0.4mm
0.3mm
0.25mm
Air
0.2mm
Water
Slugs at different mesh resolution
(Ug = 0.1 m/s, Ul = 0.1 m/s, t = 0.5 s)
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ΔP Simulation compared for various
grid size
0.2
Comparison of 2D and 3D Model
2D
Lg = 6.36mm
3D
Lg = 4.96mm
Ug & Ul = 0.1 m/s
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Type of
Geometry
Lg
Simulation
Lg Exp (Qian and Lawal (2006)
2D
6.36 mm
4.7 mm
3D
4.96 mm
4.7 mm
Effect of Gravity
1.6
0.5
1.5
Ld (Horizontal) / Ld(Vertical)
0.6
Bo
0.4
0.3
0.2
1.4
1.3
1.2
0.1
1.1
0
1
0.5
1
2
4
Channel Diameter in mm
Bond Number Versus Effective Radius
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0.5
1
2
Channel Diameter in mm
Deviation Length ΔL (mixing zone)
of horizontal and vertical channel
Ug = 0.1 m/s, Ul = 0.1 m/s, t = 0.5s.
4
Effect of Superficial Velocity
20
Lg Qian and Lawal (2006)
Lg this work
Mean Gas Slug Length mm a
18
16
14
12
10
8
6
4
2
0
0.01
Contours of Volume Fraction of Air
Ul = 0.1, 0.05, 0.025 & 0.01 m/s
Ug = 0.1 m/s, @t = 0.5s
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0.025
0.05
0.1
0.15
0.2
0.25
Channel Diameter in mm
Influence of Liquid Velocity on
Mean Gas Slug Length.
0.3
Effect of Liquid Wall Contact Angle
6
Mean Gas and Liquid Slug Length a
mm
Lg
Ll
5
4
3
2
1
0
0°
30°
60°
Channel Diameter in mm
90°
120°
Effect of Contact Angle on Mean Gas and Liquid Slug Length
Ug = 0.1 m/s, Ul = 0.1 m/s
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Effect of Angle of Entry
4.5
9
Lg
Ll
4
8
3.5
7
3
6
2.5
5
2
4
1.5
3
1
2
0.5
1
0
0
180,60,120
120,120,120
180,90,90
90,180,90
Inlet Entry Configuration
Contours of Vorticity Magnitude
for Gas at Different Angles of Entry
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Influence of Angle of Entry
Number of Gas Slugs
Mean Gas and Liquid Slug Length a
mm
No of Slugs
Effect of Channel Diameter
7
35
Lg
6
30
5
25
4
20
3
15
2
10
1
5
0
0
Number of Gas Slugs
Mean Gas Slug Length
Lg mm
No of Slugs
0.5
1
2
4
Channel Diameter in mm
Mean Gas Slug Length and Number of Gas Slugs for Varying Channel Diameter
Ug = 0.1 m/s, Ul = 0.1 m/s, t = 0.5s.
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Pressure Drop
Variable
Value
Parameter
Length, Lc
Value
50mm
Diameter, d
2mm
Channel type
InvertedY/Vertical
Ug
0.1 m/s
Ul
0.1 m/s
ρg
1.225 kg/m3
ρl
1000 kg/m3
177 Pa
σ
0.0729 N/m
± 13.46 Pa
µl
1×10-3 Pa.s
g
± 9.81 m/s2
Correlations
Ub
0.216 m/s
P Ls P
 P 3.74
 Pmm  P
tot
fric
acc
grav
B
εg
0.53
Pfric
16 
d
2
f 
1  0.17
ε Lc f l  lU 2 ; U  U g  U0.47
l;
Re 
Ls
l
d
ΔPfric


43.9
 x g2Pa xl2  
xl2 

2 

 
Pacc  m 




  g  g  Pa
ΔPgrav

l  l  L 0 
  g  g  l  l  L  Lc± 232.66

x g2
ΔP
11.47 Pa
B
 p 
  g  g   l  l g sin 


 L ΔP
grav
±
Total
P Inlet
 3 (CFD)
2
PB  3.58
9C a
r
P Outlet
(CFD) ± 193.99 Pa
ΔP(CFD)
± 180.53 Pa
Error%
± 1.9-2.0 %
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 
1 0.33
Ca
U b

; C a  

Internal recirculation
Front
Interface
Stagnant
Zone
Back
Interface
rs
R
Front
Interface
Stagnant
Zone
Back
Interface
rs
R
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Assumptions:
• Front and back interface of each slug had same geometry
• 2D non-stationary model was assumed
• The slug size was the same for all flow velocities
• Lg = 4.7mm, Ls = 3.7mm, U(avg) = 0.2 m/s
Brief Summary
 The geometrical configurations of the mixing elements
and micro-channel dimensions showed a significant
effect on the slug size and its hydrodynamic behavior
 In comparison with conventional contactors superior
hydrodynamic performances were noted which includes
key features such as
 Well defined flow patterns,
 Minimal pressure losses, and
 improved interfacial and specific areas
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SPINNING DISK
REACTORS
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





Spinning Disk Reactors
Centrifugal accelerations to create thin highly sheared films on rotating surfaces.
Rapid mixing in the liquid film,
Short liquid residence time,
Superior liquid/vapour heat/mass transfer.
Reactions which are limited by mass transfer rates.
Continuous operations
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Image courtesy Protensive
Analytical and Computational Model
Parameter
Value
Multiphase Model
Volume of Fluid
Flow parameters
Laminar
Incompressible
Isothermal
Axis-symmetric Flow - 2D/3D
Boundary Conditions
Inlet - Velocity Inlet
Outlet – Pressure Outlet
Liquid Wall contact angle specified at
wall-disc
Other
*2D (MRF) Moving Reference frame
*3D Wall rotational
Volumetric flow rate
10-18 ml/sec
Rotational speed
0-84 rad/sec
Liquid wall contact angle
30°
Gravity orientation
Horizontal
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Comparison of 2D and 3D Models
Inlet
Liquid
Film
Disc
Computed volume fraction of water for 2D and 3D model.
Q = 18ml/sec, ω = 21 Rad/sec, 2D radius 15cm, 3D radius 3.5cm.
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Spinning Disk Contact Hydrodynamics
Disc Diameter 30 cm, Distance of Inlet from Disc 4 cm and Liquid flow
rate 10 ml/sec.
500 RPM
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1500 RPM
Average Film Thickness
0.015
Measured film thickness (Burns et al 2003)
Rauscher et al, 1973
Computed from 2D Model
Lepekhin and Riabchuk, 1975
h/r
0.01
0.005
0
10
14
18
23
Q in ml/sec
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27
37
48
Effect of Rotational Speed
0.024
0.04
Q = 14ml/sec
Q = 10 ml/sec
21 rad/sec
42 rad/sec
63 rad/sec
84 rad/sec
0.03
h/r
h/r
0.018
0.012
21 rad/sec
42 rad/sec
63 rad/sec
84 rad/sec
0.02
0.01
0.006
0
0.000
1
1
2
3
2
4
Radial position in cm
0.06
Q = 18 ml/sec
h/r
0.05
21 rad/sec
42 rad/sec
63 rad/sec
84 rad/sec
0.03
0.02
0.00
1
2
3
Radial position in cm
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3
Radial position in cm
4
4
Fully developed velocity profiles
Disc
5cm
15cm
5cm
0.8
z=12.5cm
z=0.25cm
Disc
z=7.5cm
Velocity Magnitude m/s c
0.7
Central mixing
Zone
0.6
Disengagement
Zone
0.5
0.4
Disc Spinup Zone
0.3
Disc Spinup Zone
Acceler
ation
Zone
0.2
0.1
0
-30
-25
-20
-15
-10
-5
0
5
Radial Position cm
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10
15
20
25
30
Conclusions
 CFD simulations predicted the liquid film thicknesses that
were in good agreement with previously published
experimental data.
 Fully developed velocity maps suggest that there are
immense centrifugal, shear and inertial forces acting on
the fluid disengaged from the disc surface.
 Both viscous and surface tension forces were negligible
compared to the coriolis and centrifugal forces, thus
macro and micro bubbles were formed freely, which
resulted in a enhancement in the specific interfacial
areas.
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OTHER PROJECTS
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Submerged Combustion Vaporizer (SCV)
 1.3 to 2% of LNG is
consumed as fuel4
 1 BCFD terminal costs
typically $60 million/yr
in gas usages
 70 tons/yr of NOx, 210
tons/yr of CO, 300,000
tons/yr of CO2
 $5-6 million/yr in CO2
costs
3http://www.cryonorm.nl/submergedcombustionvaporiser.html
4Dendy
and Nanda, 2008 American Institute of Chemical Engineers (AIChE) Spring Meeting
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Open Rack Vaporizer (ORV)
 For 1 BCFD gas4
appro. 570 million L of
seawater daily,
depending on
seawater temperature
 The ORV systems
may adversely impact
the marine life due to
mechanical, thermal,
and chemical effects
5http://www.tokyo-gas.co.jp/lngtech/orv/index.html
4Dendy
and Nanda, 2008 American Institute of Chemical Engineers (AIChE) Spring Meeting
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Ambient Air Vaporizer (AAV)
 Simply uses air so no
environmental impact
 Minimal energy
consumptions
 Green Technology
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Fog formation and flow around AAVs
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Fluid Catalytic Cracking Stripper
Packing
Baffles
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Particle Tracks (50 m)
t = 1.05 s
Vx = Vy = 0
Vx = Vy = 2 m/s
t = 4.00 s
Vx = Vy = 0
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Vx = Vy = 2 m/s
ROLE OF
GOVERNMENT
AND INDUSTRY
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The Evolving Concept of University
Provide trained
professionals
Support structure for
innovation
Provide research
results
Create and
disseminate
knowledge
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Combine
fundamental
research with
application
Understand the
value of intellectual
capital
Collaboration Models
Government
Government
Business
University
Business
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University
Triple Helix
Government
Business
University
“Competing” interests of industry and academia are slowly turning into “complementing” interests
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Australian Government Scheme
 Australian Research Council Linkage Grant Scheme
 Excellent scheme to work with industry
 Typically ARC funds may help in doubling the industrial commitments
(cash + in-kind)
 Achieves the objective of application driven research
 Facilitates university-industry collaborations
 Overseas industry may also particiapate
 Overseas Government Partnerships
 Australian Development Research Awards Scheme
 AISRF
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Conclusions
 The partnerships between government-academia-industry
is essential for meaningful research
 Australian government has schemes to facilitates such
partnerships
 Overseas partners are welcome to solve research
problems of common interests
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About Curtin University
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Curtin Engineering
Organizational Structure
Civil Engineering
Mechanical Engineering
Chemical Engineering
Petroleum Engineering
SCME
SCPE
Department of Chemical Engineering
Centre for Process Systems Computations
Centre for Gas Technology Australia
Engineering
Schools
Centre for Corrosion Engineering
Fuels and Energy Technology Institute
WASM
Western Australian
School of Mines
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SEEC
Electrical Engineering
Computing
Degree Programs
Bachelor of Engineering (Chemical Engineering)
Chemical Engineering Stream
Oil & Gas Stream
Double Degrees ( >= 5 years)
BEng (Chemical Engineering)/BSc (Extractive Metallurgy)
BEng (Chemical Engineering)/BSc (Chemistry)
BEng/ BCom
Postgraduate Course Work
Chemical Engineering
Corrosion Engineering
Process Safety and Loss Prevention
HDR Master and PhD
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The People
500 undergraduate
students
(~ 40% from overseas)
50 Masters by course
work students
Postdoc Research
Fellows(25)
90 PhD students
10 Master by research
students
DCE
Technical &
Administration
(13)
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Professors(9)
Assoc/Professors(2)
Senior Lecturers(3)
Lecturers(7)
Key Research Area
Fuels and Energy
This is a placeholder text.
Colloidal Systems
Polymer Systems
Biosystems Engineering
Corrosion Engineering
Process Systems Engineering
Engineering Education
Process Development
and Modelling
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Nanomaterials
Research Income
School of Chemical and Petroleum Engineering Research Grants and Application
Year
2010
2011
$812,881
$860,287
$2,192,373
$2,309,606
$2,568,813
$962,740
Category 3: I&O - Industry and Other Funding
$404,468
$24,785
$1,844,071
Category 4: CRC - Cooperative Research
Centres
Number of ACG Applications
$306,740
$424,483
$637,140
Category 1: ACRG - Australian Competitive
Research Grants
Category 2: OPS - Other Public Sector Funding
Value of ACG Applications
Number of Successful ACG Applications
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13
$1,354,000
6
12
$1,525,000
5
2012
15
$1,885,000
6
Summary of Publications
Over 2005-2010 period
• Chemical engineering has
achieved an average World
CPP of 17.92 (world average of
9.65)
(Australian Research Council ERA report)
• The total apportioned papers
are 378 with citations of 6767.
Field of Publication
Journal Publications based on Scopus data (2000+)
Classified using Journal FoR1 Code
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• 78.29% of the papers were
published in A*/A/Bonus (ERA
rank) journals.
Thank you
Acknowledgement
All staff and colleagues in Department of Chemical Engineering, Curtin University
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