Process analysis of a low emissions hydrogen and steam generation technology for oil sands operations

Nduagu, Experience; Gates, Ian D.

doi:10.1016/j.apenergy.2015.01.118

Cited by 18 publications

(6 citation statements)

References 18 publications

(37 reference statements)

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“…5 Despite the commercial success of thermal in situ processes such as SAGD and CSS, they present multiple challenges including considerable supply cost, high-energy intensity, high GHG emissions, and substantial water consumption. 6…”

Section: Introductionmentioning

confidence: 99%

“…Hence, SAGD presents the most economically viable option and is considered the most widely used in situ recovery method in Canada . Despite the commercial success of thermal in situ processes such as SAGD and CSS, they present multiple challenges including considerable supply cost, high-energy intensity, high GHG emissions, and substantial water consumption …”

Section: Introductionmentioning

confidence: 99%

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Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C₁–C₅)/Bitumen Systems Using Genetic Programming

2019

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Accurate modeling of thermophysical properties of solvent/bitumen mixtures is critical for proper design and implementation of thermal- and solvent-based bitumen recovery processes. In this study, three generalized correlations were developed for prediction of solubility, density, and viscosity of light hydrocarbon/bitumen mixtures. The generalized correlations were developed using symbolic regression based on genetic programming and employing a 10-year set of comprehensive phase behavior experimental studies conducted under the SHARP research program on solvent-aided thermal recovery of bitumen. The data set comprised Surmont, JACOS, Mackay River, and Cold Lake bitumen samples and five light hydrocarbon solvents including methane, ethane, propane, n -butane, and n -pentane. The developed correlations are valid for gaseous solvents. Finally, the developed correlations for solubility, density, and viscosity were validated against a large data set of experimental measurements collected from the literature. The validation demonstrates that the developed correlations are able to accurately predict the available experimental data of solubility, density, and viscosity reported in the literature.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C₁–C₅)/Bitumen Systems Using Genetic Programming

2019

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“…SAGD being a thermal recovery process is extremely energy intensive as it requires handling of hot fluids across different stages of operation, e.g., ground transportation of steam from boilers to the wellhead, steam injection through the vertical well bore, maintaining the temperature of the steam chamber, and transportation of viscous heavy oil to refineries. , All of these steps are critical and direct determiners of the overall productivity and cost of production. Therefore, minimizing energy losses at every step is pivotal to the efficiency and cost-effectiveness of the SAGD process. , Operational modifications aimed at reducing energy losses include the injection of a solvent intermittently with steam (solvent-assisted SAGD), , injecting noncondensable gases with steam (NCG-SAGD), , coinjecting surfactant solutions, performing foam-assisted SAGD (FA-SAGD), , and drilling injection and production wells perpendicular to each other (cross SAGD) . Alternative strategies have focused on increasing energy efficiency through improved materials selection and design without altering the basic SAGD operational process.…”

Section: Coatings and Cement Sheaths For Thermal Insulationmentioning

confidence: 99%

A Materials Science Perspective of Midstream Challenges in the Utilization of Heavy Crude Oil

et al. 2022

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An increasing global population and a sharply upward trajectory of per capita energy consumption continue to drive the demand for fossil fuels, which remain integral to energy grids and the global transportation infrastructure. The oil and gas industry is increasingly reliant on unconventional deposits such as heavy crude oil and bitumen for reasons of accessibility, scale, and geopolitics. Unconventional deposits such as the Canadian Oil Sands in Northern Alberta contain more than one-third of the world’s viscous oil reserves and are vital linchpins to meet the energy needs of rapidly industrializing populations. Heavy oil is typically recovered from subsurface deposits using thermal recovery approaches such as steam-assisted gravity drainage (SAGD). In this perspective article, we discuss several aspects of materials science challenges in the utilization of heavy crude oil with an emphasis on the needs of the Canadian Oil Sands. In particular, we discuss surface modification and materials’ design approaches essential to operations under extreme environments of high temperatures and pressures and the presence of corrosive species. The demanding conditions for materials and surfaces are directly traceable to the high viscosity, low surface tension, and substantial sulfur content of heavy crude oil, which necessitates extensive energy-intensive thermal processes, warrants dilution/emulsification to ease the flow of rheologically challenging fluids, and engenders the need to protect corrodible components. Geopolitical reasons have further led to a considerable geographic separation between extraction sites and advanced refineries capable of processing heavy oils to a diverse slate of products, thus necessitating a massive midstream infrastructure for transportation of these rheologically challenging fluids. Innovations in fluid handling, bitumen processing, and midstream transportation are critical to the economic viability of heavy oil. Here, we discuss foundational principles, recent technological advancements, and unmet needs emphasizing candidate solutions for thermal insulation, membrane-assisted separations, corrosion protection, and midstream bitumen transportation. This perspective seeks to highlight illustrative materials’ technology developments spanning the range from nanocomposite coatings and cement sheaths for thermal insulation to the utilization of orthogonal wettability to engender separation of water–oil emulsions stabilized by endogenous surfactants extracted during SAGD, size-exclusion membranes for fractionation of bitumen, omniphobic coatings for drag reduction in pipelines and to ease oil handling in containers, solid prills obtained from partial bitumen solidification to enable solid-state transport with reduced risk of damage from spills, and nanocomposite coatings incorporating multiple modes of corrosion inhibition. Future outlooks for onsite partial upgradation are also described, which could potentially bypass the use of refineries for some fractions, enable access to a broader cross-se...

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“…Once‐through steam generators (OTSGs) are used to generate steam for bitumen production in steam‐assisted gravity drainage (SAGD) oil recovery operations. [ 1,2 ] OTSGs involve complex multiphase flows with heat, mass, and species transfer in a high temperature and pressure environment (≈318°C, 11 MPa). A schematic of a typical OTSG system used in the SAGD oil recovery operations is shown in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

Investigation of solid particle erosion‐related failures in once‐through steam generators (OTSGs) in oil sands in‐situ production: The limitations of the API RP 14E guideline in OTSG design or operational decision‐making

et al. 2023

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The required steam for steam‐assisted gravity drainage (SAGD) oil sands operations is generated using a once‐through steam generator (OTSG) that is fed with relatively poor quality process water. Industries have reported possible solid particle erosion‐related failure in the OTSG boiler tubes because of the transport of precipitated dense inorganic particles. However, the presence of other damage mechanisms, e.g. corrosion, flow accelerated corrosion (FAC), often masks the evidence of erosive wear. Also, industries set an upper limit operating velocity for the OTSG using the API RP 14E guideline, which provides no quantitative erosion rates to determine an operating envelope. This study presents a computational fluid dynamics (CFD) analysis of erosion damage in a SAGD OTSG boiler tube. The results revealed that API RP 14E may not be an effective decision‐making tool for operating the OTSG system. For example, a 10% increase in velocity, even at conditions below the API RP 14E threshold, showed a decrease in the failure time of the boiler tubes by 40%–50%.

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Process analysis of a low emissions hydrogen and steam generation technology for oil sands operations

Cited by 18 publications

References 18 publications

Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C₁–C₅)/Bitumen Systems Using Genetic Programming

Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C₁–C₅)/Bitumen Systems Using Genetic Programming

A Materials Science Perspective of Midstream Challenges in the Utilization of Heavy Crude Oil

Investigation of solid particle erosion‐related failures in once‐through steam generators (OTSGs) in oil sands in‐situ production: The limitations of the API RP 14E guideline in OTSG design or operational decision‐making

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Process analysis of a low emissions hydrogen and steam generation technology for oil sands operations

Cited by 18 publications

References 18 publications

Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C1–C5)/Bitumen Systems Using Genetic Programming

Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C1–C5)/Bitumen Systems Using Genetic Programming

A Materials Science Perspective of Midstream Challenges in the Utilization of Heavy Crude Oil

Investigation of solid particle erosion‐related failures in once‐through steam generators (OTSGs) in oil sands in‐situ production: The limitations of the API RP 14E guideline in OTSG design or operational decision‐making

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Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C₁–C₅)/Bitumen Systems Using Genetic Programming

Development of Generalized Correlations for Thermophysical Properties of Light Hydrocarbon Solvents (C₁–C₅)/Bitumen Systems Using Genetic Programming