october 11, 2012 upgrading bitumen using molten sodium enabling cost effective upgrading at modest...
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Upgrading Bitumen using Molten Sodium
Enabling Cost Effective Upgrading at Modest Scale
John GordonJavier
AlvareNeil
Camarta
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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
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Molten Sodium Upgrading
Reactor Separator
Electrolytic regenerationSeparator
H2 or CH4
Ni, V, Fe
Electrical Power
Na saltNa
Sulfur
Make up Na
Simple Process
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Diluent loop
Bitumen production
Market
Sodium Upgrading
DilbitMix
Diluent StripperSweet
20 APILow resid
8 API36
API
18 API
20 API
Diluent return
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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
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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 )
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Electro Regeneration
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Electrolysis Cells
+ +
Na2S Solution
Molten Sodium
Molten Sulfur
Anolyte
Cathode
NaSICON tube
AnodeNa2S Solids
DepletedNa2SSolution
Na2SDepletedSolids
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Tubular Commercial Cells
For sodium waste recovery
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Cell Life Tests Very Encouraging
Anolyte Replacement
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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 34.8
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
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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 $80.01
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Economics - Margin
MSU ProductPotential
DelayedCoking Sweet
SCO
Feedstock Price, US$/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 $7.37
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Economics – Capital & Return
MSU ProductPotential
DelayedCoking Sweet
SCO
Net Margin, US$/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
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Emissions
45% Lower CO2 Emissions
Zero SO2 Emissions
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Niches
Smaller operationsDiluent scarceDecentralizedRemote
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Next Steps
Pre-pilot investigation 20121st Pilot scale installation and operation 2013 – 2014
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Contact Information
John Gordon…[email protected]…(801) 631-5961
Neil Camarta…[email protected]…(403) 470-0141