Pilot-scale study of methane-assisted catalytic bitumen partial upgrading
The direct utilization of heavy and extra-heavy crude oils presents a formidable challenge due to their inherent physical and chemical properties such as high C/H ratio, extremely high viscosity and density, low APIo, super low mobility, high asphaltene and impurity (Fe, Ni, Co, S, N, etc.) contents...
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Elsevier
2024-11-01
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| Series: | Fuel Processing Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0378382024001085 |
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| author | Zhaofei Li Ali Omidkar Hua Song |
| author_facet | Zhaofei Li Ali Omidkar Hua Song |
| author_sort | Zhaofei Li |
| collection | DOAJ |
| description | The direct utilization of heavy and extra-heavy crude oils presents a formidable challenge due to their inherent physical and chemical properties such as high C/H ratio, extremely high viscosity and density, low APIo, super low mobility, high asphaltene and impurity (Fe, Ni, Co, S, N, etc.) contents. To tackle these problems cost-effectively, we have proposed and established a novel technique, distinct from conventional hydrotreating, for catalytic partial upgrading of extra heavy crudes with co-fed methane and a multi-functional catalyst. This technique has been further optimized using lab-scale batch reactors (100 mL, 300 mL), bench-scale and pilot-scale fixed bed reactors with their processing capacity of 250 mL/day and 20 L/day, respectively. The feasibility, stability, and profitability of this technique have been successfully verified using all these facilities and a wide variety of feedstock. Yet, further scale-up is necessary to advance this technique towards commercialization in industry. In this study, a pilot-scale prototype unit (processing capacity of 1 barrel/day) was designed and manufactured based upon the previous achievements, and a bitumen sample recovered from the Steam Assisted Gravity Drainage (SAGD) process was chosen as a typical extra heavy crude for the upgrading. A 30-day upgrading has been conducted smoothly without clogging and a liquid yield of 96.7 % was observed with remarkable enhancements in product quality. The notable decreases in density, viscosity, TAN, asphaltene content, and sulfur content were confirmed and consistent with previous results. A low olefin content implies excellent stability and compatibility of the liquid product. Additionally, a preliminary TEA (Techno-Economic Assessment) and LCA (Life-Cycle Analysis) have been conducted and the beneficial features of this novel technique have been confirmed with higher profitability, lower cost, and lower carbon footprint. This study further consolidates the advantages of this promising technique as a cost-effective and environmentally friendly alternative to hydrotreating for processing extra heavy crudes. |
| format | Article |
| id | doaj-art-bd2ed70957cf47ce94fb22b2bec14fc5 |
| institution | OA Journals |
| issn | 0378-3820 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Fuel Processing Technology |
| spelling | doaj-art-bd2ed70957cf47ce94fb22b2bec14fc52025-08-20T02:17:08ZengElsevierFuel Processing Technology0378-38202024-11-0126410813810.1016/j.fuproc.2024.108138Pilot-scale study of methane-assisted catalytic bitumen partial upgradingZhaofei Li0Ali Omidkar1Hua Song2Department of Chemical and Petroleum Engineering, University of Calgary, 2500 University Dr. NW, Calgary, Alberta T2N 1N4, CanadaDepartment of Chemical and Petroleum Engineering, University of Calgary, 2500 University Dr. NW, Calgary, Alberta T2N 1N4, CanadaCorresponding author.; Department of Chemical and Petroleum Engineering, University of Calgary, 2500 University Dr. NW, Calgary, Alberta T2N 1N4, CanadaThe direct utilization of heavy and extra-heavy crude oils presents a formidable challenge due to their inherent physical and chemical properties such as high C/H ratio, extremely high viscosity and density, low APIo, super low mobility, high asphaltene and impurity (Fe, Ni, Co, S, N, etc.) contents. To tackle these problems cost-effectively, we have proposed and established a novel technique, distinct from conventional hydrotreating, for catalytic partial upgrading of extra heavy crudes with co-fed methane and a multi-functional catalyst. This technique has been further optimized using lab-scale batch reactors (100 mL, 300 mL), bench-scale and pilot-scale fixed bed reactors with their processing capacity of 250 mL/day and 20 L/day, respectively. The feasibility, stability, and profitability of this technique have been successfully verified using all these facilities and a wide variety of feedstock. Yet, further scale-up is necessary to advance this technique towards commercialization in industry. In this study, a pilot-scale prototype unit (processing capacity of 1 barrel/day) was designed and manufactured based upon the previous achievements, and a bitumen sample recovered from the Steam Assisted Gravity Drainage (SAGD) process was chosen as a typical extra heavy crude for the upgrading. A 30-day upgrading has been conducted smoothly without clogging and a liquid yield of 96.7 % was observed with remarkable enhancements in product quality. The notable decreases in density, viscosity, TAN, asphaltene content, and sulfur content were confirmed and consistent with previous results. A low olefin content implies excellent stability and compatibility of the liquid product. Additionally, a preliminary TEA (Techno-Economic Assessment) and LCA (Life-Cycle Analysis) have been conducted and the beneficial features of this novel technique have been confirmed with higher profitability, lower cost, and lower carbon footprint. This study further consolidates the advantages of this promising technique as a cost-effective and environmentally friendly alternative to hydrotreating for processing extra heavy crudes.http://www.sciencedirect.com/science/article/pii/S0378382024001085SAGD bitumenPartial upgradingMethanePilot-scale1 barrel/day |
| spellingShingle | Zhaofei Li Ali Omidkar Hua Song Pilot-scale study of methane-assisted catalytic bitumen partial upgrading Fuel Processing Technology SAGD bitumen Partial upgrading Methane Pilot-scale 1 barrel/day |
| title | Pilot-scale study of methane-assisted catalytic bitumen partial upgrading |
| title_full | Pilot-scale study of methane-assisted catalytic bitumen partial upgrading |
| title_fullStr | Pilot-scale study of methane-assisted catalytic bitumen partial upgrading |
| title_full_unstemmed | Pilot-scale study of methane-assisted catalytic bitumen partial upgrading |
| title_short | Pilot-scale study of methane-assisted catalytic bitumen partial upgrading |
| title_sort | pilot scale study of methane assisted catalytic bitumen partial upgrading |
| topic | SAGD bitumen Partial upgrading Methane Pilot-scale 1 barrel/day |
| url | http://www.sciencedirect.com/science/article/pii/S0378382024001085 |
| work_keys_str_mv | AT zhaofeili pilotscalestudyofmethaneassistedcatalyticbitumenpartialupgrading AT aliomidkar pilotscalestudyofmethaneassistedcatalyticbitumenpartialupgrading AT huasong pilotscalestudyofmethaneassistedcatalyticbitumenpartialupgrading |