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A More Sustainable Way to Win Oil from Oil Sands

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A More Sustainable Way to Win Oil from Oil Sands A More Sustainable Way to Win Oil from Oil Sands Richard Schlosberg Schlosberg Consulting LLC, Highland Park, Illinois USA Received June 04, 2013; Accepted December 09, 2013 Abstract: Along with Saudi Arabia and Venezuela, Canada has one of the world’s major hydrocarbon resource. The Canadian resource, estimated to contain as much as 1.7 trillion barrels of heavy oil or bitumen is largely found in the province of Alberta in the form of oil sands. Oil sands are a mixture of sands and other rock materials and contain crude bitumen. Currently about 1.5 million barrels of oil per day are generated from Canadian oil sands and after primary upgrading, much of that is transported to the United States for additional upgrading to fi nal products. The majority of the oil sands processing is a combination of strip mining and a water-based extraction. Hugh quantities of water (2–4 barrels per barrel of oil) are required to win a single barrel of oil from the oil sands. Oil sands companies are currently held to a zero-discharge policy by the Alberta Environmental Protection and Enhancement Act (1993). Thus, all oil sands produced water (OSPW) must be held on site. This requirement has resulted in over a billion cubic meters of tailings water held in containment systems. Ultimately, the companies are responsible for reclaiming this water and fi nding a way to release it back into the local environment. Despite extensive programs that have led to signifi cant improvements including up to 90+% use of recycled water, the tailings ponds and build up of contaminants in the recycled water and in tailings ponds represent what is fundamentally a non-sustainable process. Waterless approaches using hydrocarbon solvent extraction technology are being developed. These approaches offer a pathway to winning oil from oil sands that is potentially low energy, water free, and environmentally superior to the current technology. Keywords: Oil sands, low impact, water free, solvent extraction 1 Introduction - Oil Sands As A Hydrocarbon Resource Oil Sands are defi ned as: “sand, clay or other minerals saturated with bitumen. Defi ned in the Mines and Minerals Act as “(i) sands and other rock materials *Corresponding author: [email protected] DOI: 10.7569/JSEE.2013.629520 286 J. Sustainable Energy Eng., Vol. 1, No. 4, January 2014 Richard Schlosberg: A More Sustainable Way to Win Oil from Oil Sands containing crude bitumen, (ii) the crude bitumen contained in those sands and other rock materials, and (iii) any other mineral substance (except natural gas) associated with the above-mentioned crude bitumen, sands or rock materials and includes a hydrocarbon substance declared to be oil sands under section 7(2) of the Oil Sands Conservation Act” [1]. Among the useful hydrocarbon sources in the world one lists natural gas, petroleum both conventional and extra heavy oil, coal and oil sands. The world supply of oil sands is estimated 5.5 trillion barrels of oil equivalent by the U.S. Geological Survey [2]. A vast amount of oil sands is found in Alberta, Canada. A comparable amount of extra heavy oil (EHO) is found in Venezuela. According to a Government of Alberta, Canada document, “As world demand for crude oil continues to grow, the oil sands deposits of northern Alberta represent one of the few reliable, long-term sources of supply. The oil sands reserves are larger than the reserves of Iran, Iraq or Russia, and are second only in size to those of Saudi Arabia.” The Alberta oil sands resource is estimated to contain as much as 1.7 trillion barrels of bitumen. The reserves - the amount that can be recovered economically with existing technology - are estimated to hold 170 billion barrels of recoverable bitumen, which would be enough to produce three million barrels per day for over 150 years. The oil sands are contained in three major areas of northern Alberta beneath approximately 142,200 km2 - an area similar in size as the state of New York, or twice the size of New Brunswick. Surface mining can only be used in a 4,800 km2 area within the Athabasca oil sands - an area similar in size to the state of Rhode Island or smaller than the size of the Greater Toronto Area” [3]. Today approximately 1.5 million barrels per day of oil from Canadian oil sands are being produced. We will discuss the technologies involved and sustainability efforts therein in section 3 below. A smaller, but signifi cant amount of oil sands are located in the continental United States. It is estimated that there are 12–19 billion barrels of recoverable oil from oil sands in Eastern Utah (Uinta). There is no current commercial production of oil from American oil sands. 2 Some Characterization Details of Oil Sands A great deal of work has been performed to characterize various oil sands. The bitumen (oil) content of oil sands varies widely, but for commercially important oil sands, the bitumen content typically is ~seven or eight to ~15% or higher. From a hydrocarbon recovery perspective, the higher the bitumen content the better. Some of the general features of oil from oil sands are: The fact that Athabasca (Canadian) oil sands are water-wet while US oil sands are oil-wet has enormous impact on processability. The majority of oil currently produced from Canadian oil sands is achieved using a hot water/caustic treat to DOI: 10.7569/JSEE.2013.629520 J. Sustainable Energy Eng., Vol. 1, No. 4, January 2014 287 Richard Schlosberg: A More Sustainable Way to Win Oil from Oil Sands create a froth from which the bitumen can be separated from the clays and sand. The so-called Clark process, named after Dr. Karl Clark, established the basis for the oil sands industry in Canada. Canadian Patent # 289058 (April, 1929) discloses Clark’s technology. The fi rst claim in this patent is illustrative: “A process of sepa- rating bitumen from sand, silt or clay which consists in mixing the compound with a reagent, introducing the mixture to a large body of hot water to effect separation, introducing an electrolyte to the water to prevent coalescence in the wash of the separated bitumen with the sand, silt or clay, and recovering the bitumen from the surface of the wash water” [5]. American oil sands which are oil-wet rather than water-wet do not respond favorably to the Clark process approach. The API gravity of both Canadian and US oil from oil sands is quite low, in fact too low to enable facile transportation without dilution. Thus, to bring the API gravity to >20 or so, a diluent such as a naphtha cut is added to the bitumen. This blend is then able to be pipelined or otherwise transported to a facility for upgrading. The atomic ratio of hydrogen to carbon atoms (Hydrogen/Carbon ratio or H/C) is indicative of the kind of molecules present in the stream. In general, the higher the H/C, the more paraffi nic and waxlike. While compositions vary (light vs. heavy crudes, etc.), a fairly typical H/C for a petroleum crude might be ~1.75 +/– 0.1. Comparing that value with what is shown in Table 1 where H/C varies from 1.44 (Canadian) to 1.56 (US), it is clear that the oil in oil sands is hydrogen poor. In terms of generating the hydrogen rich products of value such as Table 1 Chemical Properties of Some Oil Sands Bitumens [4]. Oil Sands Source Athabasca US - Utah US - Kentucky Wettability Water-wet Oil-wet Oil-wet Gravity, oAPI ~7–10 ~10 ~8–9 Viscosity, cp 640 1000 520 Hydrogen/Carbon ratio 1.44 1.56 1.56 % Sulfur ~4.9 ~0.5 ~1.6 % Nitrogen ~0.4 ~0.9 ~0.6 Ni + V, ppm ~350 ~150 N.D. Total Acid Number, TAN, ~2-3 ~4 ~4 mgKOH/g DOI: 10.7569/JSEE.2013.629520 288 J. Sustainable Energy Eng., Vol. 1, No. 4, January 2014 Richard Schlosberg: A More Sustainable Way to Win Oil from Oil Sands mogas, diesel and jet, one must therefore add hydrogen or reject carbon from the oil found in oil sands. The sulfur content of Athabasca bitumen is in excess of 4 wt. % and thus causes this material to be labelled as a sour crude, requiring the use of substantial amounts of hydrogen to remove the sulfur as H2S. The American bitumens are much lower in sulfur. The amounts of metals (nickel and vanadium) are not remarkably different from what is seen in many crude oils. The acidity of oil from oil sands is >1, thus making these high TAN streams. The acids are largely naphthenic acids of varying molecular weights. 3 Sustainability Initiatives - Commercial Oil Sands Activities There are multiple sustainability challenges in the processes used to separate bitumen from sand, clay, water and minerals in the oil sands. In this paper we will concentrate on the challenges associated with the use of water in the process beginning with strip mining, followed by hot water froth fl otation, etc.. A 2010 paper states: “Oil is extracted from surface-mined oil sands by use of the Clark hot (79–93 °C) water process that uses caustic soda to separate bitumen from other con- stituents such as clay, sand, dissolved metals, and organic compounds, including PAHs and naphthenic acids (NAs). The resultant oil sands process water (OSPW) is stored in on-site tailings ponds [6]. Currently, two to four barrels of water are required to extract one barrel of oil, and four cubic meters of OSPW are produced for each cubic meter of oil sands processed [7].
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