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7/21/2019 PRES 02 1 Aarna Indrek
http://slidepdf.com/reader/full/pres-02-1-aarna-indrek 1/16
New Solid Heat Carrier Technology forProcessing Different Shales
Dr. Indrek Aarna and Dr. Andreas OrthEnefit Outotec Technology OÜ
October 19-23, 200929th Oil Shale SymposiumGolden, CO
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Estonia as the Oil Shale Country
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Enefit Oil & Gas – Narva Oil PlantEnefit biggest competitive advantage is the existing commercial scale shale oil extraction technology
Enefit Oil & Gas Commissioned in 1980
Since its initial design, 70% of the equipmenthas been replaced and improved by the plant
engineers Two unique production units of Enefit140 (140
t/h oil shale throughput each)
Maximum capacity 820 t/d of oil (5,300 bbl/d)
Retort gas production of 43 million Nm3/year (utilized for power production)
Established as a limited company by Enefit in2007
Sales numbers have increased by over 25% ayear
Enefit technology is proven technology
Enefit has many years of operational history Successful results over last 25 years –
successful industry in Estonia
Enefit technology has potential to becomeleading technology
Narva Oil Plant – 2x Enefit140 units in operation
Eesti Energia Shale Oil Production (th bbl)
270
390
490
655
820
900
1018
0
200
400
600
800
1000
1200
1990 1995 2000 2003 2005 2007 2008
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New Generation of Enefit Technology – Cooperation with Outotec
Develops and supplies technologies for mining and metalsindustries as well as other process industries
Market leadership in several markets and segments
Expertise covers the whole process chain from mine to metal
Comprehensive R&D resources
Some 2,500 employees in 21 countries Flexible and cost-efficient use of resources and subcontractors
Global operations and presence in all the key markets
556
740
1000
1218
469426
0
200
400
600
800
1000
1200
1400
2004 2005 2006 2007 2008 Q2/2009
Sales figures of Outotec
€ million
Outotec has long experience in development of technologies for processing of ores
Comprehensive expertise and R&D support
Proven scale-up capabilities
Market ready product portfolio
Leading provider of fluidizing technologies for over60 years
Strong global set-up and experience in projectimplementation
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New Generation of Enefit Technology – cooperation with OutotecTo develop the new generation of Enefit technology a cooperation has been established with Outotec Oyj from Finlan
&
Current Narva Oil Plant
Detailed design in progress-construction started:• Enhanced heat recovery
• Reduced mechanical equipment• Reduced emissions• Higher oil yields• Designed for highest availability
Current Production:Oil - 170,000 tonnes/year
New Plant adds:
Oil - 290,000 tonnes/year
Total Production 2012:Oil - 460,000 tonnes/year
Future Enefit280
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Development of Enefit Technology
950 1960 1980
× 2,5 × 6
Capacity:500 t/d
1970 2000
Commissioning ofEnefit280 in 2012
20101990
× 2
1953: Introduction of solid heat carrier process in Estonia (the Galoter process)
1980: Start-up of UTT-3000 in Narva
1980- To Date: Replacement of 70% of equipment of UTT - 3000
2001: Acquisition of patent for Enefit-process (Enefit140)
2009: Commencement of Enefit280 construction (280 t/h)
UTT-3000 Capacity:140 t/h (3000 t/d)
The solid heat carrier (Galoter) was introduced in Estonia in 1953, it has undergone remarkable development since
2016
30 000 bbl/dayEstonian fuels
industry
apacity:200 t/d
Enefit280 Capacity:280 t/h (6000 t/d)
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Enefit140 Process
o Enefit140 units are operated by Enefit Oil & Gas
efit140 technology consists of the followingeps: Oil shale feed preparation (0-20mm) Oil shale drying in lift-pipe dryer Pyrolysis of oil shale in rotary kiln
Separation of vapor-gas mixture and spent shale Combustion of spent shale in lift-pipe combustor
Flue gas cleaning
Oil condensation and fractionation
Enefit140 is the only solid heat carrier based plant in commercial operation
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Advantages of the Enefit ProcessEnefit units convert efficiently and in an environmentally sound way all mined oil shale into high quality oil
Almost 80 years of shale oil expertise
More than 50 years of experience developing the solid heat carrier process
Almost 30 years of operation experience of Enefit140 plant
ProvenTechnology
Shale oil:
- low viscosity (1.2 centistokes +15°C)
- low sulphur content (< 0.7%)
- low pour point (-15 °C)
High calorific value of retort gas
Retort gas can be used for hydrogen production and in power generation
Product Quality
The process chemical efficiency is 80%
The product yield against Fischer Assay is 103%
Thermal efficiency over 80%
High Efficiency
Uses fine-grained shale (from 0 to 25 mm) with a low heating value
All mined shale can be used in the process – no wasted resource No requirement to use external fuel (i.e. natural gas, oil, power)
Easily adaptable to other oil shales
Flexible Fuel
Low air emissions All organic matter is fully utilised
Waste is a stable ash, <1% organic content
Oil extraction process itself is water free
Possibility to add CCS capability
LowEnvironmental
Impact
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New Generation of Enefit Technology – Enefit280To meet future environmental requirements and apply process to other oil shales, technology had to be improved
Design basis for Enefit280
Double unit capacity – 280 t/h
High availability - >90%
Meets strict EU environmental standards
CO2~ 0,2…0,3 t/t Oil Shale SO2 <50 mg/Nm3
Solid particles <25 mg/Nm3
NOx <200 mg/Nm3
TOC ~0
High thermal efficiency Complete combustion of semi coke in
CFB
Waste heat boiler
Ash cooler
Power production
Enefit280
A new Enefit280 unit iscurrently under construction
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New Enefit280 processEnefit280 process diagram and the main improvements to the process
• The Enefit280 has twice thecapacity of its predecessorEnefit140
Unit size
• The availability of the unit has
been increased from 75% tomore than 90%
Availability
• The Enefit280 unit will recoverheat from the ash and fluegases
• The heat can be utilized forpower production
Efficiency
• The lift pipe combustor hasbeen replaced by CFB boilerwhich will result in a morecomplete combustion of thespent shale and cleaner fluegases
Lower environmental impact
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Prospects of Enefit280
• Annual oil shale consumption 2,26 mil. tons
• Annual shale oil production 290 000 tons
• Annual retort gas production 75 mil. m³
• Power production 35 MWe
• Designed lifetime of the plant 30 years• Start-up of the plant: 2012
• Investment cost 200 mil. €
Enefit280 technology has advantages that allow easy adaptation to other oil shales
Enefit Technology has major advantages compared to other existing industrial technologies
Unit Separation Easier control
FlexibilityBuilt with flexibility with respect to variation in fuel properties
No technical constraints regarding oil content of oil shale
Easier to design according to specific oil shale properties
Easier to modify the process if certain units are not needed (e.g. drying)
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Enefit Outotec Technology Capabilities
Testing: Characterization of oil shale
Bench-scale unit for solid heat carrier process 20 kg/h
Bench-scale units to test fluidizing behavior of material
Pilot plant for combustion of spent shale or oil shale in CFB (upto 200 mm)
Pilot plant for drying of oil shale
Modeling: Enefit process model in AspenPlus
CAD drawings
Engineering: Conceptual engineering
Basic process and plant engineering
Detailed plant design (layout, piping, electrical, instrumentation,automation, mechanical, structural)
Approach: Conceptual study – 3 month
Testing and basic engineering – 6 -12 month
Detailed engineering – 9-12 month
Bench-scale unit of Enefit process
Enefit Outotec Technology is able to design shale oil production plant based on Enefit process for your oil shale
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Application of Enefit280 on other oil shales
Enefit Outotec Technology OÜ has started conceptual studies on USand Chinese oil shales:
Process block diagram and description
Plant description and plot plan List of main equipment
Preliminary project schedule
Estimated Investment Costs (with accuracy of +/- 30%)
Minimum Technology Package
Enefit Outotec Technology OÜ will soonstart basic engineering on Enefit’s project in
Jordan
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Evaluation of oil shale projects
Shale oil production projects are primarily evaluated onoil production – other benefits are important:
Oil yield Energy production
Steam production Power production
Gas production Hydrogen production Sulfur production Power production
Ash utilization
In cement industry as clinker substitute Building industry Road construction
Process efficiency Resource utilization efficiency Thermal efficiency
Chemical efficiency Use of external energy sources
Environmental performance
Selection of technology should be based oil yield, energy efficiency and utilization of byproducts
Enefit280 is the only technologycurrently maximizing:• oil production
• energy efficiency• utilization of byproducts
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Conclusions
Enefit140 is the only solid heat carrier based plant in commercial operation
Enefit’s long operational experience and Outotec’s technology development experience was
used to develop new, more efficient and environmentally friendly Enefit280 technology
Cost of oil produced in Enefit280 process is competitive with conventional oils
Enefit280 technology has advantages that allow easy adaptation to other oil shales around theworld
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Thank you!Dr. Indrek Aarna Dr.-Ing. Andreas OrthHead of R&D Department Vice President, Metals Processing, EnergyEesti Energia AS Outotec GmbH
Laki 24 Ludwig- Erhard-Strasse 21,12915 Tallinn D- 61440 OberurselEstonia GermanyTel: +3727152301 Tel. +49(6171) 9693-0E-mail: [email protected] E-mail: [email protected] www.outotec.com