Upgrading Bitumen using Molten Sodium

Report
Upgrading Bitumen using
Molten Sodium
Enabling Cost Effective Upgrading at
Modest Scale
John Gordon
Javier Alvare
Neil Camarta
October 11, 2012
www.fieldupgrading.com
1
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
October 11, 2012
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2
Molten Sodium Upgrading
Reactor
H2 or
CH4
Separato
Na salt r
Na
Ni, V, Fe
Electrolytic regeneration
Make up Na
Electrical Power
Separator
Sulfur
Simple Process
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3
Diluent loop
Bitumen
production
8 API
Dilbit
Mix
18 API
Sodium
Upgrading
36
API
Sweet
20 API
Low resid
Diluent Stripper
20 API
Market
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4
Major Equipment Comparison
Molten Sodium
Coking
Reactor
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
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5
MSU Treatment Example
Fractions boil at lower temperature
“Resid” fraction is reduced
Simdist Temp ( C )
800
700
600
500
400
Dilbit treated
Dilbit AR
300
200
100
0
0
0.5
1
Fraction Boil off
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6
Electro Regeneration
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7
Electrolysis Cells
Cathode
Molten Sodium
NaSICON tube
Anode
Anolyte
+
+
Na2S Solids
Depleted
Na2S
Solution
Molten Sulfur
Na2S Solution
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Na2S
Depleted
Solids
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8
Tubular Commercial Cells
For sodium waste recovery
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9
Cell Life Tests Very Encouraging
Anolyte Replacement
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10
Example Metrics & Economics
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11
Key Crude Valuation Metrics
Athabasca
Bitumen
Feed
MSU
Product
Best Run
MSU
Product
Potential
Delayed
Coking
Sweet
SCO
8.3
27.3
29
34.8
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%
289
<1
<1
<1
Property
API Gravity
Sulphur, wt%
Ni+V, wppm
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Key Crude Valuation Metrics
Athabasca
Bitumen
Feed
MSU
Product
Best Run
MSU
Product
Potential
Delayed
Coking
Sweet
SCO
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%
N/A
90%
95%
82%
$42.76
$74.52
$75.65
$80.01
Property
Distillation
Yield (LV%)
Edmonton
Price $US/bbl
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13
Economics - Margin
MSU
Product
Potential
Delayed
Coking Sweet
SCO
Feedstock Price, US$/bbl
$42.76
$42.76
Product Price, US$/bbl
$75.65
$80.01
95%
82%
Gross Margin, US$/bbl
$29.93
$23.67
Operating Cost, US$/bbl
$8.85
$16.30
Net Margin, US$/bbl
$21.08
$7.37
Product Yield, LV%
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14
Economics – Capital & Return
MSU
Product
Potential
Delayed
Coking Sweet
SCO
Net Margin, US$/bbl
$21.08
$7.37
Capital Cost, US$/bbl
$30,000
$60,000
Capital Cost, US$MM
$750
$1,500
18.4%
1.1%
NPV (10%), US$MM
$602
($835)
Profitability Index
1.80
0.44
IRR, %
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Emissions
45% Lower CO2 Emissions
Zero SO2 Emissions
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Niches
Smaller operations
Diluent scarce
Decentralized
Remote
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17
Next Steps
Pre-pilot investigation 2012
1st Pilot scale installation and operation 2013 –
2014
October 11, 2012
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18
Contact Information
John Gordon
[email protected]
…(801) 631-5961
Neil Camarta
[email protected]
…(403) 470-0141
October 11, 2012
www.fieldupgrading.com
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