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October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale www.fieldupgrading.com 1 John Gordon Javier Alvare Neil Camarta

October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale 1 John Gordon Javier Alvare

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Page 1: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com1

Upgrading Bitumen using Molten Sodium

Enabling Cost Effective Upgrading at Modest Scale

John GordonJavier

AlvareNeil

Camarta

Page 2: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com2

Molten Sodium Upgrading

Breakthrough Upgrading

…Significantly Less Complex

…One-Half the Capital Intensity

…Twice the Net Margin

…Less Hydrogen Required

…Greatly Improved Economics

…Lower emissions

Page 3: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com3

Molten Sodium Upgrading

Reactor Separator

Electrolytic regenerationSeparator

H2 or CH4

Ni, V, Fe

Electrical Power

Na saltNa

Sulfur

Make up Na

Simple Process

Page 4: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com4

Diluent loop

Bitumen production

Market

Sodium Upgrading

DilbitMix

Diluent StripperSweet

20 APILow resid

8 API36

API

18 API

20 API

Diluent return

Page 5: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com5

Major Equipment Comparison

Molten Sodium CokingReactor Atmospheric Unit

Solids Separator 1 Vacuum Unit

Condensate Stripper

Cokers

Solids Dryer Coker Fractionator

Solids Separator 2 Gas Recovery Unit

Electrolysis Unit Hydrogen Plant

Tank Farm Naphtha Hydrotreater

Utilities Distillate Hydrotreater

Gasoil Hydrotreater

Amine and SRU

Tank Farm

Utilities

Page 6: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com6

MSU Treatment ExampleFractions boil at lower temperature

“Resid” fraction is reduced

0 0.10.20.30.40.50.60.70.80.9 10

100

200

300

400

500

600

700

800

Dilbit treatedDilbit AR

Fraction Boil offSim

dis

t T

em

p (

C )

Page 7: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com7

Electro Regeneration

Page 8: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com8

Electrolysis Cells

+ +

Na2S Solution

Molten Sodium

Molten Sulfur

Anolyte

Cathode

NaSICON tube

AnodeNa2S Solids

DepletedNa2SSolution

Na2SDepletedSolids

Page 9: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com9

Tubular Commercial Cells

For sodium waste recovery

Page 10: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com10

Cell Life Tests Very Encouraging

Anolyte Replacement

Page 11: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com11

Example Metrics & Economics

Page 12: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com12

Key Crude Valuation Metrics

PropertyAthabasca Bitumen

Feed

MSU Product

Best Run

MSU ProductPotential

DelayedCoking Sweet SCO

API Gravity 8.3 27.3 29 34.8

Sulphur, wt% 4.9% <0.1% <0.1% 0.2%

TAN, mg KOH/g

2.8 <0.1 <0.1 <0.1

Olefins wt% 0% 1.1% <1.0% 0%

MCRT, wt% 13.2% 0.3% <0.3% 0%

C5 Asphaltenes

16.6% <0.3% <0.3% 0%

Ni+V, wppm 289 <1 <1 <1

Page 13: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com13

Key Crude Valuation Metrics

PropertyAthabasca Bitumen

Feed

MSU Product

Best Run

MSU ProductPotential

Delayed

Coking Sweet SCO

Distillation

IBP – 350 F 0% 4% 4% 17%

350 – 650 F 14% 34% 36% 58%

650 – 1000 F 35% 43% 45% 25%

1000 F + 51% 19% 15% 0%

Yield (LV%) N/A 90% 95% 82%

Edmonton Price $US/bbl

$42.76 $74.52 $75.65 $80.01

Page 14: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com14

Economics - Margin

MSU ProductPotential

DelayedCoking Sweet

SCO

Feedstock Price, US$/bbl $42.76 $42.76

Product Price, US$/bbl $75.65 $80.01

Product Yield, LV% 95% 82%

Gross Margin, US$/bbl $29.93 $23.67

Operating Cost, US$/bbl $8.85 $16.30

Net Margin, US$/bbl $21.08 $7.37

Page 15: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com15

Economics – Capital & Return

MSU ProductPotential

DelayedCoking Sweet

SCO

Net Margin, US$/bbl $21.08 $7.37

Capital Cost, US$/bbl $30,000 $60,000

Capital Cost, US$MM $750 $1,500

IRR, % 18.4% 1.1%

NPV (10%), US$MM $602 ($835)

Profitability Index 1.80 0.44

Page 16: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com16

Emissions

45% Lower CO2 Emissions

Zero SO2 Emissions

Page 17: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com17

Niches

Smaller operationsDiluent scarceDecentralizedRemote

Page 18: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com18

Next Steps

Pre-pilot investigation 20121st Pilot scale installation and operation 2013 – 2014

Page 19: October 11, 2012 Upgrading Bitumen using Molten Sodium Enabling Cost Effective Upgrading at Modest Scale  1 John Gordon Javier Alvare

October 11, 2012 www.fieldupgrading.com19

Contact Information

John Gordon…[email protected]…(801) 631-5961

Neil Camarta…[email protected]…(403) 470-0141