BEST Processes for SAGD

WHY UPGRADE BITUMEN?

  • Bitumen is not considered to be an acceptable oil to most US refineries.
  • Diluted Bitumen is also still not considered to be an acceptable oil to most US refineries.
  • Environmentalists do not want the “Dirty” oil produced because of the greenhouse gas emissions released in the SAGD bitumen production.
    • Their most effective deterrent so far is opposing pipelines out of Alberta.
    • Now, the Alberta Government and the Canadian Government are trying to tax the SAGD Production out of business because of high CO2 emissions.

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WHAT CAN BE DONE ABOUT IT?

  • Upgrade the bitumen so that it can be processed in any refinery with a 2,500 psig hydrotreater in front of their cat cracker. (Most of them in the US)
  • Stop releasing greenhouse gas emissions to produce the bitumen. At 87 kg of CO2 for every barrel of SAGD Production, only a modest amount of additional SAGD Production could be added.

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REMOVE THE ASPHALTENES

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WHAT ARE ASPHALTENES AND WHY ARE THEY BAD?

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HOW DO WE UPGRADE THE BITUMEN?

  • Take out the Asphaltenes.

  • The DAB®¹ Oil is all hydrotreater feedstock. 13% of Dilbit will be burned as fuel with CO2 released into the atmosphere.

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HYDROTREATED DAB OILtop of the page

HOW DO WE STOP RELEASING CO2 FROM SAGD?

  • Burn the asphaltene that were removed at the SAGD Facility and inject the flue gas into the reservoir.
    • The asphaltenes were going to be burned someplace else anyway, so that reduces someone else’s emissions by about 470 kg CO2 per barrel of dilbit produced.
    • 85% of the fuel value of asphaltenes is required to get the bitumen out of the ground.
    • The natural gas that would no longer have to be burned and this would save 87 kg CO2 per barrel of bitumen produced.
  • If the flue gas is sequestered underground, there will be no CO2 release per barrel of production, and 15% of the heat from the asphaltene burning will be used to make heat for the asphaltene removal process and clean electric power.

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BEST®¹ ASPHALTENE COMBUSTION PROCESS

  • Heat balance showed that asphaltene combustion would be at about 3,690°C. (ΔH of -393.4 vs -111.4 kJ/mol heat of combustion)
  • Needed to add water to cool the combustion. Found that enough additional water to make a 3:1 steam to oil ratio would cool the combustor down to about 1,230°C. (Typically 1,000-3,000°C)
  • Generate clean HP Steam with flue gas heat from 1,230ºC down to about 275ºC. First pass H&MB shows that about 341 t/hr of HP Steam can be produced after generating about 595 tonnes of HP Steam in the combustor, and enough hot diesel fuel for the Asphaltene Stripper Reboiler (only hot oil user in complex) in the first part of the Flue Gas Effluent Cooler.
  • 1 set of vessels, 4 heat exchanger services, and 1 turbine service is all that is required.
  • Patent application filed but claims and figure will be updated.

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HOW DOES IT ALL FIT TOGETHER?

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SIMPLE PAYOUT iN YEARS

  • Capacity, BPSD 30,000
    • Product Upgrade (41.67-31.14)  $10.53/bbl
    • Increased Operating Cost  $2.01/bbl
  • Net Upgrade Value   $8.52/bbl
  • Increased Value per day $255,499
  • Increased Value per year   $93,321,178
  • Capital Cost Estimate $100.6 million
  • Simple Payout 1.08 years
  • Decrease in natural gas charges and CO2 taxes would considerably shorten payout time
  • Expected increase in natural gas cost would increase product value if asphaltene value is related to natural gas value.

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LONG TERM PROJECTION

  • With very few asphaltenes in DAB®¹ Oil and most of it being converted to transportation fuels (jet, diesel, and automotive), and no CO2 emissions upon production, environmentalists will want every refinery to use DAB®¹ Oil.
  • Since the DAB®¹ Oil can be transported by pipeline it can be transported to the refinery from the SAGD Producer using only clean electricity (nuclear, hydroelectric, solar, wind or produced in the BEST®¹ Asphaltene Combustion Process).
  • Gasoline, Diesel, and Jet Fuel produced from DAB®¹ Oil will have a lower carbon footprint than any others.
  • With no CO2 emissions on production, and little to no asphaltenes to be burned elsewhere, even Canadian environmentalists should support using this oil all over North America.

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2016 YEAR END STATUS

  • Process Flow Diagrams & Heat and Material Balances
    • BEST®¹ Diluent Removal Process
    • BEST®¹ Asphaltene Removal Process
    • BEST®¹ Asphaltene Combustion Process
  • Piping and Instrument Diagrams (created in Microsoft Excel)
    • BEST®¹ Diluent Removal Process
    • BEST®¹ Asphaltene Removal Process
  • Plot Plan
    • BEST®¹ Diluent Removal Process
    • BEST®¹ Asphaltene Removal Process

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ALL WE NEED IS 5 MILLION DOLLARS AND 24 MONTHS

3 million dollars CAPEX

2 million dollars OPEX

Schedule:

License agreement signed

3 months later the process design is completed

9 months later the mechanical design is completed

9 to 12 months later the equipment purchases, and construction.

Usually the Pumps for the high pressure solvent circulation were ordered as soon as possible as they had a long lead time for delivery.  Ideally they would be ordered right after the process design was completed.  This is for a 30,000 barrel/day design.

The most recent 20 barrel/day plant was designed, constructed, and started up in less than 12 months.

Our 25 barrel/day demonstration unit would take 12-15 months after we received the money for the process design.

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