Upgrading Oilsands Bitumen and Heavy Oil

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"The emphasis throughout is to link the fundamentals of the molecules through to the economic drivers for the industry, because this combination determines the technology used for processing."-From the Introduction The high demand for quality petroleum products necessitates ongoing innovation in the science and engineering underlying oilsands extraction and upgrading. Beginning with a thorough grounding in the composition, fluid properties, reaction behaviour, and economics of bitumen and heavy oil, Murray Gray then delves into current processing technologies, particularly those used at full commercial scale. The tables of data on composition, yield, and behaviour of oilsands bitumen and heavy oil fractions are extensive. Though the focus is on bitumen from Alberta's oilsands-the largest resource in the world-the science applies to upgrading of heavy oil and petroleum residue feeds worldwide. Upgrading Oilsands Bitumen and Heavy Oil lays out the current best practice for engineers and scientists in the oilsands and refining industries, government personnel, academics, and students.

Table des matières

Table des matières
Front cover	1
Title page	4
Copyright page	5
Dedication	6
Contents	8
Acknowledgements	12
Introduction	14
I.1 Crude Oil and Bitumen Definitions	15
I.2 Canadian Oilsands Resources	15
I.3 International Bitumen and Heavy Oil Reserves	18
I.4 Upgrading Bitumen and Heavy Oil	19
I.5 Economic Incentives for Upgrading	20
I.6 Outline of This Book	23
References	24
1 Density and Phase Behaviour	26
1.1 Density and API Gravity	28
1.2 Distillation Curves and Boiling Ranges	30
1.3 Average Molar Mass and Molar Mass Distribution	37
1.4 Vapour–Liquid Equilibrium	43
1.5 Solids in Crude and Processed Oils	54
1.6 Density and Average Molar Mass of Asphaltenes	59
1.7 Solubility Parameters of the Petroleum, Bitumen and Asphaltene Fractions	60
1.8 Water in Hydrocarbons	74
Abbreviations	78
Notation	78
References	80
2 Transport and Thermal Properties	84
2.1 Liquid Viscosity	85
2.2 Thermal Conductivity	91
2.3 Diffusion Coefficient	92
2.4 Surface Tension	93
2.5 Melting Point of Vacuum Residues and Asphaltenes	95
2.6 Thermal Properties of Bitumen Fractions	97
2.7 Heats of Combustion	100
Notation	100
References	102
3 Chemical Composition	104
3.1 Origins of Alberta Bitumens	106
3.2 Elemental Composition	106
3.3 Class Fractionation	112
3.4 Coke-Forming Tendency	117
3.5 Chemical Structures in Bitumen	120
3.6 Asphaltene Composition and Structure	134
3.7 Quality Issues with Bitumen, Heavy Oils and Oilsands Products	152
Abbreviations	155
References	155
4 Upgrading Reactions and Kinetics	162
4.1 Thermodynamics of Cracking	164
4.2 Mechanisms of Cracking Hydrocarbons	166
4.3 Overall Kinetics of Bitumen Cracking	184
4.4 Liquid- versus Vapour-Phase Cracking of Bitumen Components	191
4.5 Catalytic Reactions in Upgrading	193
4.6 Formation of Solids and Coke	203
4.7 Basic Equations for Reactor Analysis at Steady State	212
Abbreviations	215
Notation	215
References	217
5 Marketing of Bitumen Products	222
5.1 Crude Oil Exports	223
5.2 Crude Oil Pricing	224
5.3 Transportation of Bitumen and Upgraded Products	228
5.4 Trade-Offs Between Upgrading Cost and Product Quality	234
5.5 Natural Gas Supply and Properties	237
5.6 Natural Gas Condensate	241
5.7 Sulfur Transport and Marketing	241
References	242
6 Production of Bitumen and Heavy Oil	244
6.1 Mineable Oilsands	245
6.2 In Situ Production of Oilsands Bitumen	251
6.3 Improvements to In Situ Production	254
6.4 In Situ Upgrading Schemes	255
References	258
7 Overview of Upgrading Processing and Economics	260
7.1 Sequences of Upgrading Processes	261
7.2 Operating Costs of Upgrading Bitumen and Heavy Oil	269
7.3 Benchmarking of Production and Upgrading Strategies	272
7.4 Greenhouse Gas Emissions from Production and Upgrading Processes	275
7.5 Selection of a Primary Upgrading Technology	276
7.6 Relationships of Upgrading to Refining	279
7.7 Limits to Upgrading Heavy Oils and Bitumens	283
References	285
8 Separation Processes	288
8.1 Desalting	289
8.2 Atmospheric and Vacuum Distillation	295
8.3 Solvent Deasphalting	296
References	307
9 Thermal Cracking and Coking Processes	308
9.1 Visbreaking: Thermal Viscosity Reduction	309
9.2 Delayed Coking	318
9.3 Fluid Coking	325
9.4 Fluid Coking with Coke Gasification	328
9.5 Limits on Yield and Density for Coking and Thermal Cracking Products	329
9.6 Coke Yield and Composition	332
9.7 Recycle in Coking Processes	335
9.8 Liquid-Phase Mass Transfer in Coking Processes	339
9.9 Additives to Control Coke Yield	342
9.10 Development of New Coking Processes	343
9.11 Control of Sulfur Emissions from Coking Processes	349
9.12 Kinetic Modelling of Thermal Cracking and Coking Processes	349
9.13 Heat of Reaction of Visbreaking and Coking	357
Notation	358
References	359
10 Residue Hydroconversion Processes	364
10.1 Fixed-Bed Catalytic Processes	366
10.2 Catalytic Ebullated-Bed Processes: LC-Fining and H-Oil	369
10.3 Additive-Based Processes: Slurries, Suspensions and Solutions	380
10.4 Roles of Hydrogen and Catalysts in Suppressing Coke Formation	387
10.5 Limits to the Performance of HydroconversionProcesses	390
10.6 Hydrogenation Reactions During Hydroconversion	392
10.7 Heat of Reaction for Hydroconversion	397
10.8 Catalyst Deactivation in Hydroconversion	398
10.9 Kinetic Models of Hydroconversion	410
Notation	414
References	415
11 Hydrotreating Processes	418
11.1 Hydrotreating of Distillate Fractions	419
11.2 Conversion of Diolefins	424
11.3 Hydrotreating for Aromatics Saturation	425
11.4 Hydrocracking of Gas Oils	429
11.5 Hydrogenation Reactions During Hydrotreating	430
11.6 Stoichiometry of Catalytic Hydrogenation	437
11.7 Heats of Reaction of Hydrotreating Reactions	438
11.8 Catalyst Properties	438
11.9 Catalyst Deactivation	443
Notation	450
References	451
12 Hydrogen Production and Gas Purification Processes	454
12.1 Hydrogen Production Processes	455
12.2 Cost of Hydrogen Production	460
12.3 Purification of Hydrogen-Rich Process Streams	461
12.4 Gas Recovery	462
12.5 Amine Treating	463
12.6 Sulfur Removal	465
References	470
Appendix A Glossary and List of Acronyms	472
A.1 Glossary of Selected Terms Commonly Used in theOilsands Industry	472
A.2 Common Acronyms in the Oilsands Industry	483
References	483
Appendix B Assay Data for Bitumen and Upgraded Products	484
Index	492
About the Author	513

Upgrading Oilsands Bitumen and Heavy Oil

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