New Frontiers in Oil & Gas Research
New Frontiers in Oil & Gas Research Vishnu Pareek, Tejas Bhatelia & Moses Tade Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Future Oil and Gas Plants Safer Modular Cheaper Future Oil and Gas Plants Leaner Smaller Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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…… Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Multiphase reactors Fluidized bed reactor Slurry bubble column reactor Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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. Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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. Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Structured Mesh with boundary layer MICRO REACTORS Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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. Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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) Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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. Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 % Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J SPINNING DISK REACTORS Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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. Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Spinning Disk Contact Hydrodynamics Disc Diameter 30 cm, Distance of Inlet from Disc 4 cm and Liquid flow rate 10 ml/sec. 500 RPM Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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. Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J OTHER PROJECTS Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Ambient Air Vaporizer (AAV) Simply uses air so no environmental impact Minimal energy consumptions Green Technology Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Fog formation and flow around AAVs Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Fluid Catalytic Cracking Stripper Packing Baffles Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Particle Tracks (50 m) t = 1.05 s Vx = Vy = 0 Vx = Vy = 2 m/s t = 4.00 s Vx = Vy = 0 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Vx = Vy = 2 m/s ROLE OF GOVERNMENT AND INDUSTRY Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J The Evolving Concept of University Provide trained professionals Support structure for innovation Provide research results Create and disseminate knowledge Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J Combine fundamental research with application Understand the value of intellectual capital Collaboration Models Government Government Business University Business Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J University Triple Helix Government Business University “Competing” interests of industry and academia are slowly turning into “complementing” interests Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J About Curtin University Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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) Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J • 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 Curtin University is a trademark of Curtin University of Technology CRICOS Provider Code 00301J
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