Bitumen Recovery Research Articles

Evaluation of heavy hydrocarbon liquid in the Eastern Dahomey Basin, Southwestern Nigeria (case study of Agbabu Bitumen in Ondo State)

Solvent-aided dilution processes are often employed to recover bitumen by reducing its viscosity. In this study, methanol, toluene, and xylene were investigated as potential hydrocarbon solvents for solvent-aided hydrocarbon recovery of Agbabu bitumen. To achieve this, the solubility of the sample in the solvents was determined with a solubility test, its viscosity was measured with the Saybolt Furol Viscometer using the ASTM D88 method, and its SARA analysis was conducted using high-performance liquid chromatography. Agbabu bitumen was found to have a high content of saturates and aromatics. Viscosity decreases as pressure increases, while solubility reduces as temperature increases. The sample was most soluble in toluene, and its viscosity was reduced most in it, followed by xylene. Methanol reduced the saturates content and significantly raised the asphaltene content, keeping the mixture viscosity high. In terms of asphaltene stability of the mixtures, the bitumen-methanol system with the lowest colloidal instability index of 0.874 will give a mild asphaltene deposit issues compared with others that are unstable. This approach of combining multiple tests with the CII can accurately predict the behavior of Agbabu bitumen in solvents and enhance decision on the choice of bitumen recovery technology.

Novel THAI well arrangements for improving heavy oil recovery rate in comparison to that achievable in the conventional THAI in situ combustion technology

The toe-to-heel air injection (THAI) method is an environmentally friendly process for in situ upgrading of heavy oils and bitumen via in situ combustion (ISC). Unlike the conventional ISC that uses a vertical producer, the THAI process uses a horizontal producer (HP) well to produce the upgraded oil to the surface. Recent field data has shown that the THAI process is a relatively low-oil-production-rate technology. These considerations call for innovative solutions so that the oil production rate is improved, whilst propagating a stable, efficient, and safe combustion front. Consequently, this work has provided those solutions. Through numerical reservoir simulations, using CMG STARS, five completely new THAI well configurations, which have been labeled A01, A02, A03, A04, and A05, have been developed and studied, and their performances are compared against that of the conventional THAI process which has wells arranged in a classic SLD pattern (i.e. the best-performing conventional THAI process) and against each other. The THAI arrangements A02-A04, however, assume a horizontal air injection well, which currently is not used in field practice but may be developed in the future. In field practice, THAI is applied in a line drive configuration starting up-dip and going down on the structure whilst taking advantage of the contribution provided by the drainage due to gravity; the expansion is made one way only (by drilling new patterns in one direction only). For this reason, the classic SLD pattern refers to the case where the dip of the reservoir is significant (>2–3°). However, when the dip of the reservoir is not significant (“flat” reservoirs) there is a possibility to expand the process in both opposing directions. This is the case dealt with in this work. All configurations A01-A05 assume expansion of the THAI commercial operation in both directions. Selection criteria have been developed and used to determine the two best performing processes. For example, in terms of long-term stability, safety, and efficiency of the combustion process, a process named model A01 is the best, as it achieved 99.8% oxygen utilisation when compared with any other model. It also achieves oil recovery, due to two years of combustion only, of 30.78% OOIP, which is greater than that in the base case model. Overall, based on the weighted selection criteria, which are developed from the deepest analyses of the quantitative 1-dimensional time-dependent parameters and from thorough analyses of the qualitative 2-dimensional profiles of temperature, the combustion zone in the form of oxygen mole fraction, and the oil-flow dynamics inside the reservoir in the form of oil saturation, then model A01 is the best and is followed by model A03. The overall performance of each of these two novel methods outweighs that of the conventional THAI process. However, model A03 uses a horizontal well for injection, which is not current field practice. Therefore, future developmental work should concentrate on the novel method A01 for upgrading and recovery of heavy oils and bitumen, especially since this is low-carbon, efficient, wastewater-free, and provides upgrading inside the reservoir and hence it has a low surface footprint.

Investigation of Unresolved Interface "Rag Layer" in Athabasca Oil Sand Bitumen In Situ Recovery.

Steam-assisted gravity drainage (SAGD), the leading commercial in situ bitumen recovery process, involves the underground injection of steam and produces at the well head a hot fluid containing water, hydrocarbons, and sand. This fluid is subjected to separation by diluent addition and gravity in several parallel treaters. Occasionally, the separation may be disrupted in one or few treaters by the occurrence of an unresolved interface or "rag layer" while continuing without disruption in the rest of the treaters. In the current study, we investigate "rag layer" occurrence based on the quantification of laboratory-scale and SAGD field tests and imaging of the "rag layer" morphology. The quantification results show that the formation and volume of the "rag layer" are affected by solids, mixing speed, and solvent addition. The microscopic images demonstrate the presence of both water-in-oil or oil-in water emulsions with a distinct transition between the continuous phases. The visual detection boundaries of the "rag layer" are defined as the threshold between the agglomerated and individual droplet layers. The extent of agglomeration increases in the proximity to the oil-water interface. The contribution of hydrophobic fine inorganic solids (less than 10 μm) to forming a "rag layer" is supported by their accumulation observed at the treaters' oil-water interface, compared to the feed. In well-controlled field operations, the perceived randomness of "rag layer" occurrence could be associated with the fluctuation of fine solid contents in the feed.

Measurements and PR EoS Modeling of Thermophysical Properties at Vapor-Liquid Equilibrium Conditions for Natural Gas Condensate/Live Bitumen Mixtures.

In response to the need for less energy-intensive and greener bitumen recovery techniques, the use of multicomponent diluents through the expanding solvent steam-assisted gravity drainage (ES-SAGD) technique has garnered significant interest in recent years. In this work, we report new comprehensive measurements and Peng-Robinson equation of state (PR EoS) modeling of thermophysical properties (saturation pressure, density, viscosity, and K-values) of multicomponent mixtures of methane-bitumen-solvent. The multicomponent solvent is a natural gas condensate comprised of C3, i-C4, n-C4, i-C5, n-C5, C6, and C7+. Density, viscosity, solubility, and K-values of live bitumen (bitumen with dissolved methane) and various multicomponent mixtures are measured in the pressure range of 1-4 MPa and the temperature range of 313.41-459.10 K. A systematic approach is utilized to model the measured data. The experimental data show that the saturation pressure of the live bitumen can be controlled by selecting an appropriate solvent (condensate) composition. Condensate also has a significant effect on reducing the density and viscosity of the system. The results also show that the K-values of the components are almost independent of the composition of the solvent. The new comprehensive data set and the EoS model parameters reported in this work find applications in reservoir simulation as well as the design and optimization of the ES-SAGD process.

Small modular nuclear reactors: A pathway to cost savings and environmental progress in SAGD operations

Small Modular Nuclear Reactors (SMRs) offer a promising option for environmentally friendly bitumen recovery operations. The extraction of oil sands in Western Canada is vital for the economy, but traditional methods like Steam-Assisted Gravity Drainage (SAGD) contribute significantly to greenhouse gas (GHG) emissions. In SAGD, steam generation, primarily fueled by natural gas combustion, is the main source of emissions. Given the imperative to reduce carbon intensity, less emissive recovery methods are needed to sustain production and economic viability in Canadian oil sands. Currently, there are limited non-carbon alternatives for steam generation in oil sands applications. The utilization of SMRs for steam generation presents a clean alternative. In this study, we examine the feasibility of employing SMRs in in-situ oil sands recovery operations. Through standardized economic metrics and sensitivity analysis, we demonstrate that integrating SMRs into SAGD operations eliminates GHG emissions significantly and can potentially outperform conventional natural gas-based steam generation in terms of net present value, under certain operational scenarios. Hence, our findings indicate that SMRs hold promise for decarbonizing oil sands recovery processes.

Microstructural characterization and corrosion behaviour of heat treated standard stainless steels in tar sand

This paper aims to investigate the corrosion behaviour of heat-treated standard duplex stainless steel (UNS S32205) in the recovery of bitumen from Nigerian-rich tar sand, using sodium hydroxide (NaOH) as the process solution. Appropriate material family needs to be identified for the exploitation of tar sand resources to ensure sustainable extraction of bitumen. UNS S32205 offers exceptional mechanical properties and excellent corrosion resistance which makes it a great material choice for demanding applications, including offshore platforms and construction projects. Samples of UNS 32205 were heat-treated and immersed in the digested tar sand, maintaining a process temperature of 90°C. The microstructure of the corrosion coupons was studied using SEM/EDS (Scanning Electron Microscope/Energy Dispersive Spectroscope), and the corrosion rate of the samples was derived using gravimetric technique following ASTM G31 standard. The SEM micrographs indicated varying degrees of pits associated with the passivity of UNS 32205 and an imbalance between its ferrite and austenite phases due to the presence of secondary precipitates formed during heat treatment.The normalized sample, having a corrosion rate of 0.053 mm/year, exhibited the best corrosion resistance, followed by oil quenching (0.054 mm/year), then annealing (0.076 mm/year), and water quenching (0.077 mm/year), where they all showed improved corrosion resistance over the as-received sample having a corrosion rate of 0.078 mm/year.

Molecular insights into oil detachment from hydrophobic quartz surfaces in clay-hosted nanopores during steam–surfactant co-injection

Thermal recovery techniques for producing oil sands have substantial environmental impacts. Surfactants can efficiently improve thermal bitumen recovery and reduce the required amount of steam. Such a technique requires solid knowledge about the interaction mechanism between surfactants, bitumen, water, and rock at the nanoscale level. In particular, oil sands ores have extremely complex mineralogy as they contain many clay minerals (montmorillonite, illite, kaolinite). In this study, molecular dynamics simulation is carried out to elucidate the unclear mechanisms of clay minerals contributing to the bitumen recovery under a steam–anionic surfactant co-injection process. We found that the clay content significantly influenced an oil detachment process from hydrophobic quartz surfaces. Results reveal that the presence of montmorillonite, illite, and the siloxane surface of kaolinite in nanopores can enhance the oil detachment process from the hydrophobic surfaces because surfactant molecules have a stronger tendency to interact with bitumen and quartz. Conversely, the gibbsite surfaces of kaolinite curb the oil detachment process. Through interaction energy analysis, the siloxane surfaces of kaolinite result in the most straightforward oil detachment process. In addition, we found that the clay type presented in nanopores affected the wettability of the quartz surfaces. The quartz surfaces associated with the gibbsite surfaces of kaolinite show the strongest hydrophilicity. By comparing previous experimental findings with the results of molecular dynamics (MD) simulations, we observed consistent wetting characteristics. This alignment serves to validate the reliability of the simulation outcomes. The outcome of this paper makes up for the lack of knowledge of a surfactant-assisted bitumen recovery process and provides insights for further in-situ bitumen production engineering designs.

Digital twin and control of an industrial-scale bitumen extraction process

This article presents a digital twin solution for bitumen extraction process required to study process dynamics, control, and optimization of this critical oil sands process. It captures the actual process interconnectivity and scale, enabling the bidirectional data connection between the virtual and physical entities. The proposed model was validated using data from an oil sands extraction facility. Results demonstrate the model well mimics real process behavior in both steady-state and dynamic conditions, with tunable parameters tailored for any further adaption. The model was used to study extraction performance under various production scenarios. It enables analyzing process behavior and testing strategies to optimize bitumen recovery.

Smectite-bitumen interactions in non-aqueous bitumen extraction process

The non-aqueous extraction (NAE) is an alternative to the commercial water-based extraction technology used to liberate bitumen from oil sands. Although the impact of kaolinite, illite, chlorite, illite-smectite and montmorillonite on NAE process has been previously studied, the effect of different types of smectites has not been fully understood yet. In this work, mixtures of bitumen with bentonites dominated by saponite, hectorite, nontronite, beidellite and montmorillonite were reacted for several days and then washed with solvent (cyclohexane) to remove bitumen from the bentonites. The main goal was to better understand the impact of different smectites properties (specific surface area, pore structure characteristics, particle size, crystallite thickness, swelling ability, cation exchange capacity, layer charge and crystal-chemistry of smectites) on NAE process. The results showed that the porosity, particle size and swelling ability were the key parameters affecting the solvent-based bitumen recovery under the studied conditions. Samples with larger initial total pore volume and smaller particle size displayed reduced solvent bitumen extractability. The particle size of studied samples was affected primarily by swelling of smectites during the solvent bitumen extraction experiments. Smectites were swelling in water but not in cyclohexane. Swelling of smectite caused splitting of larger clay particles into many smaller particles. As a consequence, the efficiency of solvent bitumen extraction was significantly lower for fine grained samples, consisting of thin delaminated smectite particles, in which the bitumen was distributed among small-sized clay particles.

What is next for SAGD? Evaluation of low GHG and high-efficiency tertiary recovery

Steam injection has been widely applied in different forms to recover heavy-oil and bitumen for decades. Even though this method is a proven and effective technology, the steam generation process itself may lead to environmental issues and low economic viability. Also, many worldwide steam projects, including SAGD projects in Canada, have already reached their maturity with a severe decline in production despite continuous steam injection. Escalating greenhouse gas (GHG) emissions is another crucial downside of steam injection application, contributing to an emission growth rate of about 1.1% worldwide and 0.8% annually in Canada. This requires us to search for different techniques to deplete the remaining (conditioned) oil efficiently and in an eco-friendly manner. This paper focuses on the testing of a new technique to minimize GHG emissions resulting from steam generation while enhancing the ultimate recovery post-SAGD.∼50,000 cP heavy crude and processed oil (for visual models) samples were used as an oleic phase in this experimental research. Condensable gases as single and multiple (mixed with methane) components were included as potential solvents to be applied to the already steamed models. Visual Hele-Shaw and glass-bead-pack models were employed to investigate the displacement mechanism, displacement efficiency, and phase distribution in porous media. All experiments were performed at currently existing temperatures in matured SAGD reservoirs to further evaluate the sensitivity of phase behavior of condensable solvents in a heavy-oil/steam system, as well as existing condensed water which is not compatible with hydrocarbon solvents.We observed that condensable solvents could improve the displacement efficiency/incremental heavy-oil recovery by over 30% by mobilizing residual oil and providing favorable conformance to the steam chamber. More importantly, the steam usage was able to be entirely cut off, and the energy efficiency could be ramped up to almost 100%. Additionally, the type (and composition) for applying condensable solvents were determined at a given post-SAGD temperature. Also, the retrieval potential of the condensable solvent with oil was investigated for an efficient process.Condensable gases with different compositions were introduced as potential solvents to recuperate heavy-oil and bitumen recovery and reduce or even completely cut off the steam injection at late-stage SAGD, diminishing its GHG emission and improving energy efficiency. Valuable findings present beneficial recommendations for low-emission and high-efficiency late-stage heavy-oil recovery as post-SAGD applications, as well as other types of steam injection processes.

Effect of ore quality on non‐aqueous oil sand extraction performance

AbstractCurrent commercial aqueous based extraction processes are energy and greenhouse gas (GHG) intensive and require large tailings ponds. Non‐aqueous extraction (NAE) of bitumen from mineable oil sands is an alternative that eliminates tailings ponds with potentially lower energy requirements and GHG emissions. The economics of the NAE process depend partly on the impact of ore quality on bitumen recovery and product quality (low water and solids content). It has been claimed that NAE performance is insensitive to the quality (bitumen content) of the oil sand ores. However, the available data are ambiguous because different extraction methods and solvents were used in different studies and, in many cases, a limited range of ore qualities was examined. In this study, bitumen was extracted from eight ores of different quality with cyclohexane using a multistage method equivalent to a countercurrent process with a solvent/ore ratio of 0.67 w/w. The bitumen recovery and the water and solids content of the product bitumen were determined for each ore. It was found that bitumen recovery correlated negatively to clay content of the ore. The loss of recovery was attributed to bitumen adsorption on clays. The product quality was insensitive to the ore quality and instead depended on the density of the fluid medium, as expected with a centrifuge‐based separation method. The recovery and product quality from the NAE method were similar to those from aqueous extractions.

Gravity drainage of bitumen under controlled thermodynamic conditions in DME-steam co-injection

Dimethyl ether (DME), a water-soluble solvent, has been studied as a potential additive to steam for improving the efficiency of steam-assisted gravity drainage (SAGD) for bitumen recovery. This paper presents an experimental study of bitumen gravity drainage in DME-SAGD in comparison to SAGD and butane-SAGD (C4-SAGD).Small-scale experiments were conducted using a sand pack with a diameter of 1.5 inches and a length of 15 inches, which was housed inside a 25-L cylindrical steel vessel. A DME-SAGD experiment with 10 mol% DME was conducted at 3500 kPa with a total in-situ injection rate of 3897 cm3/min. Temperature distributions inside and outside the sand pack, as well as injection and production histories, were recorded during the experiment. Results were compared with previous studies of SAGD and C4-SAGD (20 mol% C4) that used the same experimental program. Then, numerical simulations were performed to history-match the experimental data and investigate the bitumen recovery mechanisms.The peak bitumen rate was 16.8 cm3/min for 10 mol% DME-SAGD, 9.8 cm3/min for SAGD, and 14.6 cm3/min for 20 mol% C4-SAGD. That is, DME was more effective than C4 as a steam additive even at the concentration reduced by half. The observed enhancement in bitumen drainage was attributed partly to the combined thermal and dilution effects on bitumen viscosity reduction, in which DME-SAGD exhibited a higher chamber-edge temperature than C4-SAGD. Furthermore, the oleic (L) and aqueous (W) phases were more evenly distributed with less gravity segregation in the sand pack in DME-SAGD than in SAGD and C4-SAGD, which facilitated the overall bitumen flow in the sand pack. Results collectively show that the slight polarity of DME as a solvent additive to steam enhanced the bitumen flow not only by L-phase viscosity reduction, but also by more uniformly enhanced bitumen flow in the sand pack.

Vapor-liquid-liquid equilibrium (VLLE), density, and viscosity of the ternary mixtures of normal hexane, water and bitumen at T=185–210°C and at P= 2.5 MPa

This paper presents a study on the vapor-liquid-liquid equilibrium (VLLE) of a ternary system consisting of normal-hexane (n-C6) as a solvent, water (H2O), and Mackay River bitumen. The study was conducted at temperatures ranging from 185 to 210 °C and a pressure of 2.5 MPa. The solvent/steam and solvent/bitumen ratios were varied to understand the effect of solvent (n-C6) on the phase behavior and the thermophysical properties of the associated phases. The co-injected solvent with steam is often reported as the concentration of solvent in the solvent/steam mixture. Two concentrations of n-C6 in n-C6/water mixture, including mole fractions of 0.01 and 0.05 (i.e., 6.85 and 27.70 vol.%), were considered to examine the effect of the co-injected solvent with steam. Also, two different mole fractions of n-C6 in the mixture of bitumen/n-C6 at 0.7 and 0.4 (37.45 and 14.61 vol.%), respectively, were considered to examine the effect of solvent solubility in bitumen. In addition to the VLLE study, the viscosity and density of the two distinct liquid phases, hydrocarbon-rich oleic and water-rich aqueous phases, were measured and reported. The results from the experiment infer that the concentration of n-C6 co-injected with steam does not significantly affect the equilibrium phase concentrations and thermophysical properties. However, the mixture showed liquid-liquid equilibria (LLE) instead of the vapor-liquid-liquid equilibria (VLLE) when the concentration of n-C6 in bitumen/solvent mixture was less than the equilibrium solubility of n-C6 in the hydrocarbon-rich phase at that operating condition. Furthermore, the results suggest that the presence of bitumen in equilibrium with n-C6 and H2O has no significant effect on the concentration of n-C6 in the vapor phase when compared with the n-C6/H2O binary mixture. Thermodynamic modelling of the VLLE data was performed using the cubic plus association equation of state (CPA EoS). The matching parameters were obtained by tuning the two-phase data, and those parameters were used in predicting the VLLE data. The model was also used to construct the phase regions of the solvent/bitumen/water system on the ternary diagram at different temperatures and pressures. Different phase regions were determined by phase stability analysis. The findings provide insight into steam/solvent condensation behavior with applications to the solvent-aided thermal recovery of bitumen from oil sands.

Density and viscosity of multicomponent diluent/bitumen mixtures with application to in-situ bitumen recovery and diluted bitumen transportation

The extraction of bitumen relies on energy-intensive methods, and its transportation necessitates dilution due to its high viscosity. Hence, there is a growing demand to explore alternative approaches that are cost-effective and energy-efficient to enhance the extraction and transportation processes. While there is ample thermophysical data available in the literature regarding the individual performance of pure solvents and bitumen systems, there is a significant gap in data concerning density and viscosity measurements for multicomponent solvents and their interaction with bitumen. This study presents new measurements by investigating the effect of varying multicomponent diluent concentrations (7 to 70 wt%) on the density and viscosity of multicomponent diluent/Mackay River bitumen system in a pressure range of 1.291–8.769 MPa and a temperature range of 295–389 K. These thermophysical data are essential in the design, optimization, and reservoir simulation of solvent-based and solvent-aided recovery processes, as well as the surface processing and transportation of diluted bitumen. The findings demonstrated that the addition of the diluent, even at a lower mole fraction, has a notable impact on reducing both the density and viscosity of the bitumen. As part of this study, we have also obtained empirical correlations based on well-established relationships that can be employed as predictive tools for estimating the density and viscosity of a multicomponent diluent/bitumen system. The obtained correlations estimate the density and viscosity of mixtures of bitumen and diluent with average absolute relative deviations (AARD) of 0.4 % and 16.29 %, respectively. The new experimental data are then used to perform zeroth-order energy, greenhouse gas emission, and carbon tax recovery analyses of solvent-aided viscosity reduction. The results reveal that the utilization of natural gas condensate as a diluent leads to significant energy reductions and greenhouse gas emissions. The results find applications in solvent-based and solvent-aided bitumen recovery processes, surface processing, and the transportation of diluted bitumen.

Long-Term Aging Behavior of Plastic/Styrene Butadiene Rubber (SBR) Composite Modified Bitumen.

The reuse of recycled waste plastics has long been attempted in pavement engineering as bitumen modifier. It was revealed that waste plastics can significantly enhance the high-temperature performance of bitumen and bitumen mixtures. Even so, the application of waste plastics as a bitumen modifier is still not widespread. This is attributable to the generally poor low-temperature performance of plastic-modified bitumen, which often fails to meet specification requirements. For this purpose, styrene butadiene rubber (SBR) was selected to improve the low-temperature performance of plastic-modified bitumen. However, due to the long-term aging process, the composite and structure of the modified bitumen will change, which negatively impacts its performance. The objective of this study is to investigate the long-term aging behavior of plastic/SBR composite-modified bitumen. For this purpose, waste polyethylene was used as a plastic modifier and was mixed with base bitumen and 3% SBR at ratios 4.5%, 6% and 7.5%. The rheological properties and molecular weight distribution of base bitumen, plastic and plastic/SBR-modified bitumen before and after long-term aging were measured. Results show that the incorporation of plastic can improve the complex modulus, rutting factor and percent recovery of bitumen and reduce the non-recoverable creep compliance of the bitumen, indicating the modification process enhances the high-temperature performance of bitumen. The enhancement effect is more pronounced with the increase of plastic content. For modified bitumen with 7.5% plastic modifier, the complex modulus of modified bitumen is increased by 1127.55% compared to base bitumen. The addition of 3% SBR modifier can further improve the high-temperature performance of the modified bitumen. In addition, the modification process also increases the large molecule size percentage (LMSP) and weight average molecular weight of bitumen. Compared with weight average molecular weight, the LMSP correlates well with the rheological properties of modified bitumen. In accordance with the complex modulus, using the LMSP and weight average molecular weight of bitumen before and after aging, the corresponding aging index was calculated. The quantitative results showed that the addition of plastic modifier can improve the aging resistance of bitumen, but the enhancement effect is not as obvious as that of SBR modifier.

Rheological, permanent deformation and fatigue analysis for calibration of the recovery process of bitumens in the rotary evaporator

The extraction and recovery of bitumens from bituminous mixtures is an important procedure in the paving industry. This work achieves to evaluate the rheological, permanent deformation and fatigue tests to calibration of the recovery procedure in the rotary evaporator. The protocol was divided in bitumens of known properties with laboratory aging and bitumens of unknown properties subjected to field aging. The materials were subjected to different distillation times and tested chemically, rheologically and for damage by fatigue and permanent deformation. The results indicated that the chemical FTIR test was not sensitive in capturing the presence of residual solvent in the bituminous materials due to low concentrations after recovery. The joint analysis of the |G*|, Jnr at 3.2 kPa of the MSCR and the Nf of the LAS test were consistent for determining the distillation times in the rotary evaporator to result in the absence of residual solvent and additional aging.

Review on Applications of Ionic Liquids (ILs) for Bitumen Recovery: Mechanisms, Challenges, and Perspectives

Water- and solvent-based ex situ extraction processes have been employed to extract bitumen from mineable oil sands. On the other hand, bitumen is recovered in situ from deeper deposits most efficiently by injecting steam to reduce viscosity and increasing production flow to the surface. However, the water-based process with or without solvent (including steam injection) is not sustainable due to various challenges including water requirement and treatment, high energy consumption, and related environmental pollution problems emanating from high volatility of solvents. Ionic liquids (ILs) have become desirable in several industrial applications due to many unique properties including low volatility compared with traditional organic solvents. The potential for application of ILs for bitumen extraction is reviewed in this work, with a focus on the mechanistic aspect. Depending on the properties and/or functionality, the ILs can be used in bitumen extraction (with or without organic solvents) with minimal clay fines contamination and lower water and energy requirements. In the solvent-assisted IL recovery system, the IL–clay interaction is responsible for reducing the adhesive force between bitumen and the sand, which subsequently facilitates separation. Conversely, considering the types of ILs explored in the absence of solvent, the IL–bitumen interaction plays an additional role. Hitherto, applications of ILs in bitumen recovery are at a very preliminary stage. Apart from understanding the mechanisms, the major impediment lies in the high cost and environmental impact due to toxicity. Therefore, to make ILs more attractive for bitumen recovery, concerted efforts should be intensified to reduce the cost of producing ILs, ameliorate environmental impacts, and facilitate field scale applications through technoeconomic analysis of the process.

Effective recovery of bitumen from Jordanian tar sand using several extraction methods

ABSTRACT The study aims to characterize the structural features of Jordanian tar sand using analytical techniques including (FTIR, ultimate and proximate analysis, TGA, XRD, and XRF). The tar sand shows a low content of volatile matter (bitumen) with significant nitrogen content. The bitumen contains a high proportion of aliphatic hydrocarbons of which high content of it attached to oxygen atom. The minerals were mainly quartz and low concentration of carbonate with noticeable content of sulfite and potassium oxide from XRF. The recovery of bitumen was evaluated using three different extraction techniques: solvent extraction methods (ultrasound-assisted extraction, non-aqueous extraction) and thermal pyrolysis using the Fischer assay apparatus. The non-aqueous solvent extraction method gave the highest bitumen recovery using toluene as a solvent; however, the high-temperature Fischer assay method provided a low recovery. The extracted bitumen under the optimum condition was characterized using NMR, elemental analysis, and GC-MS analysis. The oil products from tar sand showed a high concentration of oxygen and noticeable concentration of sulfur atoms. The 1H-NMR revealed a high content of aliphatic hydrocarbons in good agreement with raw tar sand characteristics. The identified compounds in the GC-MS where mainly substituted with oxygen atom in the form of alcohols and ethers.

Water Separation Performance in Bitumen Recovery from Athabasca Oil Sands: Implementation of Separation Efficiency Index

The oil (diluted bitumen)–water separation efficiency at steam-assisted gravity drainage (SAGD) process conditions has been evaluated in a laboratory environment by using a custom-built batch gravity setup, using SAGD field fluids and commercial gas condensate as a diluent. The key parameters and conditions investigated are solvent amount, shear conditions, water-to-oil ratio, and the presence and wettability of fine solids. The results demonstrate the complexity of the oil–water separation process, affected by the dependence of the investigated parameters from one another. A new quantification approach is introduced to facilitate the oil–water separation efficiency evaluation, based on the proposed descriptor, referred to as a separation efficiency index (SEI). Defined as the average of the residual water-in-oil and oil-in-water indices, SEI ranges from 0 to 1, where 1 represents a “perfect” (complete) separation and 0 corresponds to a complete emulsification. The SEI allows one to describe the separation efficiency throughout the entire separation vessel volume, using discrete vertical water distribution profiles, and represents the separation efficiency with a single number, regardless of the experimental approach taken. The findings show that in the range of solvent concentrations of 30 vol % or lower, the mixing speed affects the separation performance and becomes predominant at the relatively low solvent concentrations of 10 and 20 vol %. The amount of solvent added becomes predominant in the oil–water separation process and overcomes all other effects in the highest solvent addition (40 and 50 vol %) range. The presence of water-wet solids improves the separation performance, while the presence of oil-wet solids impedes the oil–water separation. The results presented in this study, in particular the proposed SEI, are important for improving the oil–water separation efficiency and can be used to develop operational envelopes and new solvent injection strategies, in terms of location, amount, and stages, further improving the quality of the oil product obtained in SAGD.

Steam allocation for SAGD: Multi-pad multi-criteria short and long-term real-time performance management

Optimizing steam allocation is critical for long-term performance goals in Steam-Assisted Gravity Drainage (SAGD) recovery. The steam supply mainly contributes to the economics, steam chamber conformance, greenhouse gas emissions, and ultimate bitumen recovery. Therefore, SAGD real-time optimization (RTO) must balance steam chamber development and economics to achieve long-term goals. However, in RTO, general-purpose optimization algorithms decide based on short-term responses, unlike long-term optimization processes. Using economic Key Performance Indicators (KPI) such as Net Present Value (NPV) in a single objective, the RTO determines the smallest amount of steam that results in the highest economic returns. Injecting a small amount of steam reduces steam chamber heat loss, growth, and long-term ultimate bitumen recovery. As a result, a suitable selection of critical KPIs is required to balance the development and economics of the steam chamber.This work presents a study of multiple combinations of SAGD KPIs for a multi-pad real-time steam allocation. The KPI combinations used in this study are NPV, cumulative steam-oil-ratio (cSOR), recovery factor (RF), and average pad temperature (aveTemp). A Box-Jenkins-based data-driven model simulates the SAGD recovery process, and a first principle simulator is used as a substitute for an actual reservoir. The Alternating Direction Method of Multipliers (ADMM) is proposed for multi and many-objective optimization for real-time steam allocation across multiple pads. A compromise programming approach guides the decision-makers choice of the optimum control setpoints of the non-dominated solutions on each horizon. At the end of three and half years of RTO, the optimal KPI combination is ranked based on the aggregated performance of NPV, cSOR, and RF of SAGD multi-pad steam allocation. A synthetic Western Canadian reservoir model with four pads and 33 well pairs developed from publicly available data is used for this study.The aggregated performance of this study's results showed that joint optimization of an economic and a steam chamber growth KPIs of two is better than a combination of three or four. The choice of the joint economic and steam chamber growth KPIs depends on the average pad temperature at the start of RTO to achieve optimal fluid balance in the long term. cSOR or NPV with RF joint KPI performs optimally at average pad temperatures above 90 °C, while cSOR or NPV with aveTemp below 90 °C at the start of RTO to achieve injected and produced fluid balance. Optimum economic return, recovery, and greenhouse gas emission of the SAGD process are achieved with cSOR KPI as the primary economic objective.