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Upgrading Bitumen using Molten Sodium. Enabling Cost Effective Upgrading at Modest Scale. John Gordon Javier Alvare Neil Camarta. Molten Sodium Upgrading. Breakthrough Upgrading …Significantly Less Complex …One-Half the Capital Intensity …Twice the Net Margin …Less Hydrogen Required - PowerPoint PPT Presentation
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October 11, 2012 www.fieldupgrading.com 1
Upgrading Bitumen using Molten Sodium
Enabling Cost Effective Upgrading at Modest Scale
John GordonJavier
AlvareNeil
Camarta
October 11, 2012 www.fieldupgrading.com 2
Molten Sodium UpgradingBreakthrough Upgrading…Significantly Less Complex…One-Half the Capital
Intensity…Twice the Net Margin…Less Hydrogen Required…Greatly Improved
Economics…Lower emissions
October 11, 2012 www.fieldupgrading.com 3
Molten Sodium Upgrading
Reactor Separator
Electrolytic regenerationSeparator
H2 or CH4
Ni, V, Fe
Electrical Power
Na saltNa
Sulfur
Make up Na
Simple Process
October 11, 2012 www.fieldupgrading.com 4
Diluent loop
Bitumen production
Market
Sodium Upgrading
DilbitMix
Diluent StripperSweet
20 APILow resid
8 API36 API
18 API
20 API
Diluent return
October 11, 2012 www.fieldupgrading.com 5
Major Equipment Comparison
Molten Sodium CokingReactor Atmospheric UnitSolids Separator 1 Vacuum UnitCondensate Stripper
Cokers
Solids Dryer Coker FractionatorSolids Separator 2 Gas Recovery UnitElectrolysis Unit Hydrogen PlantTank Farm Naphtha
HydrotreaterUtilities Distillate
HydrotreaterGasoil HydrotreaterAmine and SRUTank FarmUtilities
October 11, 2012 www.fieldupgrading.com 6
MSU Treatment ExampleFractions boil at lower temperature
“Resid” fraction is reduced
0 0.10.20.30.40.50.60.70.80.9 10
100200300400500600700800
Dilbit treatedDilbit AR
Fraction Boil offSim
dist
Tem
p ( C
)
October 11, 2012 www.fieldupgrading.com 7
Electro Regeneration
October 11, 2012 www.fieldupgrading.com 8
Electrolysis Cells
+ +
Na2S Solution
Molten Sodium
Molten Sulfur
Anolyte
Cathode
NaSICON tube
AnodeNa2S Solids
DepletedNa2SSolution
Na2SDepletedSolids
October 11, 2012 www.fieldupgrading.com 9
Tubular Commercial CellsFor sodium waste recovery
October 11, 2012 www.fieldupgrading.com 10
Cell Life Tests Very Encouraging
Anolyte Replacement
October 11, 2012 www.fieldupgrading.com 11
Example Metrics & Economics
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Key Crude Valuation Metrics
PropertyAthabasca Bitumen
Feed
MSU Product
Best Run
MSU ProductPotential
DelayedCoking Sweet SCO
API Gravity 8.3 27.3 29 34.8Sulphur, 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
October 11, 2012 www.fieldupgrading.com 13
Key Crude Valuation Metrics
PropertyAthabasca Bitumen
Feed
MSU Product
Best Run
MSU ProductPotential
Delayed
Coking Sweet SCO
DistillationIBP – 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 $80.01
October 11, 2012 www.fieldupgrading.com 14
Economics - Margin
MSU ProductPotential
DelayedCoking Sweet
SCOFeedstock Price, US$/bbl $42.76 $42.76Product Price, US$/bbl $75.65 $80.01Product Yield, LV% 95% 82%Gross Margin, US$/bbl $29.93 $23.67Operating Cost, US$/bbl $8.85 $16.30Net Margin, US$/bbl $21.08 $7.37
October 11, 2012 www.fieldupgrading.com 15
Economics – Capital & Return
MSU ProductPotential
DelayedCoking Sweet
SCONet Margin, US$/bbl $21.08 $7.37Capital Cost, US$/bbl $30,000 $60,000Capital Cost, US$MM $750 $1,500IRR, % 18.4% 1.1%NPV (10%), US$MM $602 ($835)Profitability Index 1.80 0.44
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Emissions45% Lower CO2 EmissionsZero SO2 Emissions
October 11, 2012 www.fieldupgrading.com 17
NichesSmaller operationsDiluent scarceDecentralizedRemote
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Next StepsPre-pilot investigation 20121st Pilot scale installation and operation 2013 – 2014
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Contact InformationJohn Gordon
…[email protected]…(801) 631-5961
Neil Camarta…[email protected]…(403) 470-0141
