1st Intl. Conference on
TECHNOLOGICAL OPPORTUNITIES IN OIL & GAS INDUSTRY 4 MAY 2014
MINISTRY of
PETROLEUM
GAS
(NIGC)
REFINING
(NIORDC) PETROCHEMICAL
(NPC)
OIL
(NIOC)
RIPI
2
RIPI PRESIDENT
Technology & Intl. Affairs
Procurement
Strategic Planning Energy & Environment
Downstream Technologies
Upstream Technologies
RESEARCH CENTERS
Research & Technology Development
DIRECTORATES
Policy & Commercialization
Organization
3
Sites
1. Pardis (Tehran)
Rey (Tehran)
2. Kermanshah (Downstream)
3. Ahvaz (Upstream)
4. Qeshm Island (E&E)
5. Pars - Asaluyeh (E&E)
4
RIPI's Mission Statement
Our Mission is continuous value creation for the stakeholders through developing technologies and offering technological solutions.
We rely on our core competencies and exploiting of open innovation mechanisms to accomplish our mission.
Our intellectual capital is our main asset in moving toward excellence and
We are committed to professional ethics and sustainable development.
RIPI's 2020 vision The pioneer in technology development and offering
technological solutions in Oil (Petroleum) Industry and committed to sustainable development.
5
International Collaborations OVERVIEW
RUSSIA Demercaptanization Technologies Crude upgrading Engineering & Consultancy Services
GERMANY Intellectual Properties Environmental Problems (Decontamination) Engineering Services
FRANCE Seismic Interpretation Intellectual Properties
UK CDM (PDD validation) Engineering Services Environmental Solutions
AUSTRIA Reservoir Studies Software Development Fuel & Combustion
POLAND Laboratory Services
CHINA Hydrate Studies EOR/IOR PVT, Core & Geological Studies Corrosion Evaluation
JAPAN Technology Development Environmental Studies Clean Fuel Production
S. KOREA Engineering Services Pilot plants
IRAQ Training Courses Exchange of Experts
CANADA Technology Commercialization
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Content
Software Services Products Technologies
Cooperation
potentials Offers Achievements
7
achievements
Integrated Reservoir Characterization
based on:
Geology
Geophysics
Petrophysics (Full set logs, Special Image Logs, Cut offs,
Facies Modeling)
Basic Reservoir Engineering (SCAL, RCAL, PVT, MBAL,
Welltest)
Production Engineering (PLT, Production Data, well
flow performance)
Static and Dynamic Modeling
Structural Modeling
Property Modeling
Model Initialization
Single well/ Sector/ Full Field Modeling
History Matching
Technological Achievements
9
Production Prediction Scenarios
Natural Depletion Scenarios
EOR Scenarios
Water Injection
Gas Injection (Miscible/ Immiscible)
WAG
Drilling and Completion
Well Trajectory
Well Completions
EPD
Surface Facilities Design
Economic Evaluation
Technological Achievements
10
Marun
Ahwaz
Bibi Hakimeh
Azadegan
Kushk
Hosseinieh
Reservoir technology
Technological Achievements
11
Bibi Hakimeh oil production and IOR potential
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
200000
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
2013
2015
2017
2019
2021
2023
2025
2027
2029
mb
bls
/d
Khami condensate
Bangestan
Tight sectors
Gas Inj.
WO / Infill
Baseline
Technological Achievements
12
Integrated reservoir studies and development plan for Azadegan,Yadavaran, Ahvaz, Marun,
Bibi Hakimeh Balal ,Tusan…..oil fields
International best practice reservoir management and optimum reservoir management
models for Iranian reservoirs
Integrated reservoir study of the field in the Arvandan Area
3D petroleum system modeling for the South Pars field
Regional study of Asmari formation in Dezful Embayment
Technological Achievements
13
• Development of pars reservoir Simulator(PRS) software for the simulation of carbonate reservoir
• Development of Pars basin Modeling(PBM) software for petroleum basin modeling
NeoResVol (Initial Fluid In-Place )
Estimation of reservoirs’ oil in place using artificial neural networks
Well Test Analysis (Gas Condensate and Gas Reservoirs)
Asphaltene Deposition Modeling (Static Condition, Thermodynamic Modeling)
Core Flow Modeling (USS Test Modeling, Water-oil)
Compositional Grading
Software achievements
14
• Designing Ultra light weight cement
Using
Nanotechnology
and
Particle Size Distribution (PSD)
RIPI’s LWCem
With very high Compressive Strength
successfully commercialized
Drilling and Well Completion
Product Achievements
15
Achievements in Cementing Services
RIPI Elastic Cements
To solve casing collapse in
Maroun oil Field
By
Applying modifications to the cement
formula previously used
Cements with Optimized
Young’s Modulus
and Poisson's Ration
&
Reliable Compressive Strength
16
Product Achievements
17
Client: National Iranian Oil Company
Capacity: 240,000 BPD
Location: South Pars
Advantages: Sweetening of Sour
Condensate, Added Value
DMD & DMC
Technological Achievements
Naphtha Isomerization Unit of the Imam Khomeini Refinery
Client: Imam Khomeini Refinery
Location: Arak
Capacity: 8500 BPD
Start up: November, 2011
Advantage: High Octane Gasoline Production
Technological Achievements
18
Pentane Production Unit in Kermanshah
Client : Kermanshah Oil Refining Company Location : Kermanshah Unit Capacity: 5000 metric ton per year Start up : 2010 Advantage: Petrochemical solvent production
Technological Achievements
19
Client: National Iranian Oil Company
Capacity: 2,200(under construction) &
180,000 (designed)bbl/d
Location: Tehran, Bandarabbas and Abadan
Advantages: Converting Heavy residue to
API 30 or more syncrude
Volume yield : > 110%
Heavy Residue Hydroconversion (HRH)
Technological Achievements
20
Recovery Gasoline Refining of Kharg Petrochemical Complex
Client : Kharg petrochemical complex Location : Kharg Capacity: 1500 BPD Start up : 2005 Advantage: Converting waste cuts to export gasoline
Technological Achievements
21
Applications :oil and gas well drilling , cementing , completion and
production of Packings, Seals, Strippers, Plugs, Wipers , O-rings and …
Design and Manufacture of Polymeric Products for Oil and Gas Well Equipments
Product Achievements
22
-Special lubricating oils and greases
-Carbon Nano Tubes
-Catalysts & Nano materials
Product Achievements
23
-Crude oil evaluations labs
-Bitumen laboratories
-Catalyst evaluations labs
-Catalytic and non-catalytic pilot services
-Amine analysis and evaluation
Service Achievements
24
Technological Achievements
- Design, Installation and Classification of field atmospheric corrosion sites
- Atmospheric corrosion map for different industrial areas
Atmospheric corrosion map of
Bandar Abbass Oil Refinery
Atmospheric corrosion site installed on SPP1, gas flat at Persian Gulf
25
Technological Achievements
Engineering, procurement, construction and
commissioning (EPCC) of industrial and sanitary
wastewater and water treatment systems
Advanced wastewater treatment system of RIPI
EPCC of mobile water and
wastewater treatment
packages for industrial
applications
Mobile Treatment packages for sanitary wastewaters in Rafsanjan and Isfahan
26
Technological Achievements
• Bioremediation of oil-contaminated soil
Clean-up of a mud pit in Khangiran by combining microbial and phyto-remediation in biopile system
Remediation of sludge-contamiated soil through landfarming in Siri Island.
27
Technological Achievements
Monitoring and
modeling industrial air
pollutants
Simulation and modeling of pollution in Asalooyeh
28
Technological Achievements
Reuse of Reverse osmosis brine in Fajr Petrochemical Company
(the country's largest water reuse project)
29
Product Achievements
Formulation, evaluation and monitoring of corrosion inhibitor for:
Cooling Towers Fire Fighting water lines Gas Treatment(Amine) Systems
30
• Production of detection kits for sulfate-reducing
bacteria (SRB’s)
SRB’s detection and enumeration kits for water, soil and fuel.
Product Achievements
31
Product Achievements
Design and production of passive samplers
Nitrogen dioxide passive sampler
Sulfation plate
32
Service Achievements
Evaluation of various environmental impacts of industrial activities
• This group is certified by the Department of Environment of Iran
33
Service Achievements
Energy Audit and Feasibility Study, Optimization,
Engineering and consulting of utility systems
Reuse of High TDS wastewater and optimal use of excess LP steam in the
Shahid Hasheminejad (Khangiran) Gas Processing Company (SGPC)
34
Service Achievements
Design of Corrosion Monitoring Failure Analysis Selection of suitable coating systems Material Selection Cathodic Protection Design and Evaluation
Material selection Diagram for SRU Plant
35
Elemental analysis
instruments such as:
AAS, ICP, N,S analyzer,
CHNO analyzer
Service Achievements
Liquid, ionic and gas
chromatography systems
equipped with SCD، NPD، FPD،
SIM.DIS ، MS، FTIR، FID، TCD
Nanometric instruments
such as: SEM, XRF, XRD
and Nano-zetasizer
Molecular spectroscopy
instruments such as:
UV/VIS and FTIR(ATR)
36
Service Achievements
Crude oil finger printing
Analysis of environmental pollutants such as: Pesticides, BTEXs, PCBs, Methyl mercury and PAHs
measurement of Elemental sulfur in oil and gas samples Condensate assay
37
Software Achievements
Development of Software for energy performance
analyses in utilities and power plants
EPATTM
software based on ASME-PTC
and Operational Experience
38
Offer
Integrated Reservoir Study and modeling Technology
Field Development Planning Technology
Petroleum system study and basin modeling Technology
Laboratory study and research on EOR ,Drilling and production Technology
Upstream software development Technology
Offered Technologies
40
-Sedimentological, Paleontological and Structural Studeis -Sequence stratigraphy -Geological & Petrophysical Log Correlation -1D and 2D Facies Modeling
•Source rock Characterization •Organic chemistry Studies on oils and Bitumens •Organic Petrography Studies •Oil-Oil and Oil –Source Correlations •Fluid Inclusion study •1-3D basin Modeling
Offered Technologies
41
Survey Designing of 2D-3D Land and Supervision on 3D seismic data Acquisition
2D and 3D Seismic Data Processing Seismic Imaging Kirchhoff and Full Wave Solutions Study and Research on New methods in Seismic data Processing Structural Interpretation Velocity Model Building Depth Conversion Multi-Attribute Analysis and Classification Acoustic Impedance Inversion AVO and Elastic Inversion Reservoir Property Estimation Seismic Facies Analysis Stratigraphycal Interpretation Seismic Sequence Stratigraphy
Offered Technologies
42
• laboratories equipped with internationally well-known devices for both in-house and
well site services
Drilling Fluids Services Performing All API & OCMA Standard Tests
for evaluating Drilling fluid additives and
Formulating different drilling muds according to drilling requirements of operating company
Offered Services
Enhanced Oil Recovery services • Water Flooding and Water Injection Pressure
Maintenance
• Gas Injection, Miscible and Immiscible
Lab. Research
• Underground Gas Storage Studies
• Polymer, Surfactant and ASP Flooding
Cementing Services
43
Sep. oil & gas,water, H2S,CO2, HG…)) Surface sampling at well site
Subsurface sample validity and transferring at well site
Conventional Gas PVT Analysis (1000cc,up to 15000 psi & 350 o F (
Conventional Oil PVT Analysis (400cc&100cc,up to 15000 psi & 350 o F)
PVT sampling and analysis
Offered Services
44
Routine Rock Properties
– Natural gamma radiation and depth matching
– Consolidate and unconsolidated core plugging samples
– Fluids saturation measurement
– Helium porosity and grain density (ambient condition)
– Air and Klinkenberg permeability (ambient condition)
– Porosity, Air and Klinkenberg permeability at confining press
– Pore volume compressibility
– Hydraulic unit delineation
– X-ray computed tomography (CT) Scanning
– Sieve analysis
Offered Services
45
– Relative permeability
• Water-oil and gas-oil at ambient and reservoir conditions
• Unsteady state (constant rate or constant pressure)
• Steady state, X-Ray CT monitoring
• In-situ saturation monitored by attenuation of X-Ray
– Capillary pressure
• High-speed centrifuge (drainage & imbibition)
• Porous plate method
• Mercury injection and pore size distribution
– Wettability
• Wettability restoration
• Amott method
• USBM method
• Contact angle method
– Electrical properties
• Formation Resistivity Factor (FRF)
• Resistivity Index (RI) at ambient and reservoir conditions
– Interfacial tension
• Interfacial tension at ambient and reservoir conditions
• Determination of contact angle between fluid and rock
Reservoir Rock (SCAL)
Offered Services
46
Offered Technologies
Small and medium size condensate refinery Objective : Creating added value through processing of condensate
Feed: South Pars condensate
Products: Diesel – Gasoline
Economic considerations : Estimated investment for 20,000 barrels
per day, about 80 to 130 million dollar with a
rate of return of over 35 percent and for of
60,000 barrels per day to about 250 to 300 million
dollar investment with a rate of return of 48 percent.
47
Heavy crude oil refinery design with the purpose of bitumen production Purposes and achievements: Production of an extra light crude oil with the API=43, and providing opportunity to sale heavy crude oils in the presence of produced light crude oil Quality improvement of produced bitumen Taking the regional or even the world market of bitumen Economic consideration: Providing a net profit of approximately 3-5 dollars per barrel Low investment in the comparison with an ordinary refinery plant (approximately 2000-3000 dollars per barrel) Payback Period: less than 2 years.
Offered Technologies
48
Application The use of sulfiran process is regarded very significant for environmental protection and energy conservation .
Achievements A 450000 ft3/day demonstration unit was constructed and installed at Fajr-E-Jam gas refining. It became operational for periods of 3 months from 2008 to 2011.
Offered Technologies
Sulfiran The usual method to eliminate H2S for capacities higher than 20 ton/day of sulfur, is absorption by amine process which followed by incinerator or Cluse process. Sulfiran process is economical for gas streams containing 0.2 to 15 ton/day of sulfur. In this process the absorption and conversion of H2S to sulfur is carried out in a single stage
49
Real Time Optimization (RTO)
Main Objectives:
Decreasing Energy Consumption of Plants
Improvement of plant stability and reliability
Automatically optimizing plant’s performance
Calculating and reporting
consumption/production of feed and
products at any time
Advantages :
High added value with minimum investment
Offered Technologies
50
RTO CASE STUDY:
BANDARABBAS HYDROTREATING PLANT
Million Rials Description Item
10223.70 Fix investment 1
21785.11 Revenue 2
156456.55 NPV (12%) 3
207.12 (IRR)% 4
0.54 Payback Period(year) 5
ECONOMIC RESULTS
51
Description IRR %New IRR %
Fix investment +100% 103.05 207.12
Production cost +100% 201.09 207.12
Fix investment +100% and
Production cost +100%
100.05
207.12
Fix investment +100% and
Production cost +100% and Revenue -50%
47.04
207.12
Sensitivity Analysis
52
Online Blending
Online blending provide the opportunity to diversify the Crude oil type upon the
client requirement .Afghanistan market and numerous available Iraq hydrocarbon
resources make this plant very attractive in Iran.
Economic aspects:
The economic features of this plant is very attractive and the payback period is
less than a year.
Offered Technologies
53
Offered Technologies
Mobile DMC Plant
Mobile DMC plant provide unique opportunity
to make added value through sweetening of
condensate in different locations in Persian Gulf
Economic aspects:
High added value makes this plant
very feasible with a payback period
of about one year
54
RIPI Gas To Liquid Technology (3000 bbl/d GTL) Objective : creating added value through Natural Gas to Liquid
Feed: Natural Gas
Products: Diesel – Gasoline
Economic aspects : Estimated investment for a capacity of 3,000 barrels per day, about 130to 150 million dollar with
rate of return over 30 percent
Offered Technologies
55
Carbon Management Research Topics
Carbon Capture & Storage (CCS/ CO2-EOR)
Emission Inventory Software Development
Emission Reduction Policy & Action Plan
Clean Development Mechanism Projects(CDM)
Global Environmental Facility Projects( GEF)
National Appropriate Mitigation Actions( NAMAs)
Climate Technology Center & Network (CTC&N)
Carbon Tax and Trading
Offered Technologies
56
- Design of coating natural weathering
station in industrial units
- Developing technologies for improving
the performance and lifetime of
industrial coatings
Natural weathering paint exposure station
Offered Technologies
57
Offered Technologies
Diagnosis and control of biological corrosion
58
Offered Products
Synthesis and formulation of
corrosion-resistant
intelligent nanocoatings
Synthesis and formulation of
fire retardant nanocoatings
Fire retardant nanocoating
59
Cooperation potentials
Technological Cooperation potentials
technology Exploration technology Development
technology ERO/IOR technology Production technology Reservoir management
61
Technological Cooperation potentials
62
IOR and Green field development significance for Iran
Technological Cooperation potentials
63
Technological Cooperation potentials
64
Development- The EOR Roadmap
Technological Cooperation potentials
INCRESED KNOWLEDGE, UNDERESTANDING, INVESTMENT, AND RECOVERY OVER TIME
RED
USE
D U
NC
ERA
INTY
AN
D R
ISK
Propose at FDP Stage
Screen EOR Methods
Test in laboratory
Model Field and Process
Design Field Test
Perform Pilot: Monitor and Analyze
Design Field Implementation
Efficient EOR Decision making: Feedback loops to Improve design are Implemented rapidly
Ref. : www.slb.com
Success of EOR operations: Optimizing the EOR project Continues throughout its life
Implement in Field
Additional recovery
Monitor and Control
Project
Fine Tune Field Development Plan Expand Field
Development
65
• Advance Reservoir Study and Modeling Technology
• Optimum Field Development Scenarios Technology
• IOR/EOR Advance Technologies:
Hydraulic Fracturing
WAG
Hybrid EOR
• Advance Reservoir Imaging and 4D Seismic Technology
66
Technological Cooperation potentials
Drilling and well stimulation technologies
• Advance drilling Technology and drilling cost reduction
• Smart completion
• Artificial lifting technology
• Laser drilling
• Multi zone stimulation technology (MZST) in low
permeable reservoirs
Technological Cooperation potentials
67
Drilling technology
• Technical know-how of the procedure for the production of additives used in drilling, well completion and stimulation
• Advance drilling and well completion technologies
• RIPIs ultra light weight and elastic cements
• RIPIs ultra light weight drilling fluids
Technological Cooperation potentials
68
Production- Hydraulic fracturing
• Improvement of Productivity Index • Hydraulic fracturing usually used when the permeability of a reservoir is
below 1 md (for gas reservoirs) / 10 md (for oil reservoirs).
• Areas of Collaboration
• Experimental study of hydraulic fluid and proppants efficiency using modified API conductivity test
• Operation design • Preparation of chemicals • Field operation
Technological Cooperation potentials
69
Production- Well Production Enhancement Methods
• Water Control Management
• Sand Production Management
• Hydraulic Fracturing
• Artificial Lift
Lab Setup Modeling Designing Implementation
Technological Cooperation potentials
70
Productivity improvement technology
• water and gas control in reservoir
Gel polymer formulation (Lab research and field implementation)
intelligent well technology application and development
• Asphaltane precipitation, inhibitation and removal in the well
investigation on asphaltane precipitation
( Lab. research and software development)
inhibitor and solvent synthesis
Technological Cooperation potentials
71
Production- Polymer Gel Treatment for Water Shut-Off
• using polymer gel treatment for water shut off in fractured reservoirs
which are the most common reservoirs in Iran.
• Area of Collaboration
• Field operation
• Chemical providing
Technological Cooperation potentials
72
Reservoir Management Technology
• Real time reservoir monitoring and
optimization (RTO) technology
• Real time reservoir management technology
Smart well
Smart reservoir
• Full integration between surface and
sub surface technology
• Software development for reservoir
simulation technology
Technological Cooperation potentials
73
Zero Flaring: an Engineering, Control and Automation Approach
• Thorough the study and evaluation of the process in order to indentify major flare gas generator
• Modifying and optimization of the process (through improving equipment technology or process changes) in order to reduce the permanent flare gas load
• Design a Flare Gas Recovery Unit (FGRU)
• Improving the flare system operation reliability via upgrading automation and instrumentation technologies
• Minimizing the flare pilot gas consumption using new-developed pilot technologies
• Reducing purge gas injection using design of liquid seals and molecular seals in flare stack
Technological Cooperation potentials
74
Upgrading of heavy residue/crude oil
The upgrading of heavy residue/crude oil is an international challenge
and RIPI has its own technologies, beside , we are interested on
developing new ideas that is partially developed to make feasible
plant preferably in small and medium scale.
Technological Cooperation potentials
75
Methanol to gasoline conversion process (MTG)
Methanol to gasoline conversion process (MTG)
Current Situation: the bench scale system for MTG process using a fixed bed reactor
has been set up
Technological Cooperation potentials
76
Development of technology concept of Alkylation process
with solid catalyst
Alkylation of isobutane with n-butenes (C3-C5 olefins) to form highly branched
isoparaffins (Alkylate) is an important process in gasoline manufacture. Alkylate is a
high octane gasoline that contains high octane number (RON 94-97).
It is the cleanest of all major gasoline components and, as restrictions on fuel
emissions become more stringent and pressure for
environmental responsiveness increases, the
demand for it is rising.
Technological Cooperation potentials
77
Mega GTL
We have nearly 21 years experience in the field of converting natural gas to liquid (GTL) fuels. Also RIPI has a process design package (PDP) for a commercial plant with a capacity of 3000 bbl/day. Invitations of companies participating in erecting up a Mega GTL plant
We hereby invite the specialized companies from home and abroad to participate in building a Mega factory of GTL plants in IRAN. The location of factory will be in south of Iran where there are deposits of huge amounts of natural gas recourses.
Technological Cooperation potentials
78
Oil and gas equipment technologies
The Process Development and Equipment Technology Division
has a wealth experience in this field and any new cooperations to transfer and
localization of these technologies specially in upstream equipments is
interested. Having private Iranian companies as the potential client or partner
paves the way for making units to produce to local and regional demand.
Technological Cooperation potentials
79
Renewable Fuels
Te drawback of worldwide huge emission of toxic exhaust gases from fossil fuels have
led to inevitable and mandatory use and market growth of clean, formulated fuels
as well as advanced renewable fuels such as nanoemulsion biofuels, biodiesel,
biogasoline, wood-based solid fuels and bio-SynGas. For a decade, RIPI has been
working on liquid biofuels and other biomass-based fuels processes at pilot-scale
and is willing to cooperate internationally regarding technology
development/transfer and joint efforts in all areas of biofuels and clean fuel
additives.
Technological Cooperation potentials
80
Chemicals for Enhanced Oil Recovery (C-EOR)
Water Shut-off with gel polymer
Polymeric Additives applied in Petroleum Upstream Industry
-CCR Process and Catalyst
-Fuel Additives
-RFCC Catalyst
-Polymer additives
-Surfactants(emulsifiers, demulsifiers ,co solvents..)
Technological Cooperation potentials
81
Product Development Potentials
• NDT and corrosion monitoring Technologies
• Production of oil and gas drilling equipments
• Coatings Technologies
82
- Development of technologies for the pipe line internal coatings
Internal Pipe line Coating
Technological Cooperation potentials
83
Summary
• Advance reservoir simulation technology for giant Iranian oil fields:
Reservoir simulation
Software development
• Optimum Field Development and production improvement Technology:
Water Control Management
Sand Production Management
Artificial Lift
• IOR/EOR advance technologies:
Hydraulic Fracturing
Hybrid EOR
Chemical EOR
Upstream Sector
• Drilling and well completion technologies:
Smart completion Laser drilling Multi zone stimulation technology (MZST) in low permeable reservoirs • Reservoir monitoring and
management technologies: Advance reservoir Imaging and 4D seismic Technology Smart well Smart reservoir
85
• Chemicals, gel polymer & Polymeric Additives for
Enhanced Oil Recovery (C-EOR)
• Small and medium size condensate refinery
• Upgrading of heavy residue/crude oil-GTL
• Oil and gas equipment technologies
Downstream Sector
86
Energy & Environment Sector
• NDT and Corrosion Monitoring Technologies
• Petroleum Biotechnology
• Environmental Pollutants control
• Energy Optimization
87