pres 02 1 aarna indrek

7/21/2019 PRES 02 1 Aarna Indrek

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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



Estonia as the Oil Shale Country



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



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



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



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)



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



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



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



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



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)



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



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



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



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



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

pres 02 1 aarna indrek

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