U.S. patent application number 14/941236 was filed with the patent office on 2016-03-10 for methods, apparatus, and systems for incorporating bio-derived materials into oil sands processing.
This patent application is currently assigned to AVELLO BIOENERGY, INC.. The applicant listed for this patent is Dennis Stephan BANASIAK, Jared Nathaniel BROWN, Cody James ELLENS, Anthony Joseph Sherwood POLLARD. Invention is credited to Dennis Stephan BANASIAK, Jared Nathaniel BROWN, Cody James ELLENS, Anthony Joseph Sherwood POLLARD.
Application Number | 20160068759 14/941236 |
Document ID | / |
Family ID | 47142257 |
Filed Date | 2016-03-10 |
United States Patent
Application |
20160068759 |
Kind Code |
A1 |
ELLENS; Cody James ; et
al. |
March 10, 2016 |
METHODS, APPARATUS, AND SYSTEMS FOR INCORPORATING BIO-DERIVED
MATERIALS INTO OIL SANDS PROCESSING
Abstract
Methods, processes, apparatus, systems, and compositions are
disclosed for improving the sustainability of oil sands processing.
In some embodiments, bitumen is combined with biodiluent comprising
one or more liquid pyrolysis fractions obtained from pyrolyzing
biomass and collecting multiple liquid fractions. The bitumen may
be any source of bitumen, such as bitumen obtained from oil sands.
In some embodiments, a water-rich pyrolysis liquid displaces water
use in an oil sands process. The water-rich pyrolysis liquid may be
used for primary separation of bitumen from oil sands or for
hydrotransport, for example. Also, biochar produced from biomass
pyrolysis may be introduced to an oil sands tailing pond with
various benefits. Water may be recycled from a tailing pond.
Integration of a pyrolysis and separation process into an oil sands
refining process reduces the overall greenhouse-gas emissions on a
well-to-refined product basis by 10-70% or more. Various
compositions and products are also disclosed.
Inventors: |
ELLENS; Cody James; (Ankeny,
IA) ; BROWN; Jared Nathaniel; (Ankeny, IA) ;
POLLARD; Anthony Joseph Sherwood; (Ames, IA) ;
BANASIAK; Dennis Stephan; (Urbandale, IA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ELLENS; Cody James
BROWN; Jared Nathaniel
POLLARD; Anthony Joseph Sherwood
BANASIAK; Dennis Stephan |
Ankeny
Ankeny
Ames
Urbandale |
IA
IA
IA
IA |
US
US
US
US |
|
|
Assignee: |
AVELLO BIOENERGY, INC.
Des Moines
IA
|
Family ID: |
47142257 |
Appl. No.: |
14/941236 |
Filed: |
November 13, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13470991 |
May 14, 2012 |
9212313 |
|
|
14941236 |
|
|
|
|
61486304 |
May 15, 2011 |
|
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|
Current U.S.
Class: |
585/240 ;
166/267; 201/41; 208/391 |
Current CPC
Class: |
C10G 2300/802 20130101;
C10G 1/00 20130101; C10B 53/02 20130101; Y02E 50/10 20130101; C10G
1/002 20130101; E21B 43/34 20130101; C10G 2300/805 20130101; C10C
5/00 20130101; C10G 1/047 20130101; Y02P 30/20 20151101; Y02P 30/00
20151101; C08L 95/00 20130101; C04B 12/00 20130101; Y02E 50/14
20130101; B03D 2203/006 20130101; Y02P 30/10 20151101 |
International
Class: |
C10G 1/04 20060101
C10G001/04; E21B 43/34 20060101 E21B043/34; C04B 12/00 20060101
C04B012/00; C10B 53/02 20060101 C10B053/02; C10G 1/00 20060101
C10G001/00; C08L 95/00 20060101 C08L095/00 |
Claims
1. An oil sands refining process comprising: (a) providing a mined
oil sands feedstock; (b) crushing said mined oil sands feedstock to
produce crushed oil sands; (c) combining said crushed oil sands
with water for hydrotransport to a separation section; (d)
operating said separation section to separate crushed oil sands
into bitumen, coarse sand, and water containing suspended solids;
(e) introducing said coarse sand and said water containing
suspended solids to a tailing pond; (f) providing a biomass
feedstock; and (g) converting said biomass feedstock in a pyrolysis
process to at least one low-water pyrolysis liquid containing less
than 10 wt % water, a water-rich pyrolysis liquid, and biochar,
wherein said bitumen is diluted with biodiluent comprising said at
least one low-water pyrolysis liquid, to form diluted bitumen.
2. The process of claim 1, said process further comprising
combining diluent with said bitumen to form said diluted
bitumen.
3. The process of claim 1, said process further comprising
introducing said diluted bitumen to a unit for refining, upgrading,
or chemical conversion.
4. The process of claim 3, said process comprising converting at
least a portion of said biodiluent into fuels, chemicals,
materials, or energy.
5. The process of claim 4, said process comprising converting at
least a portion of said biodiluent into bio-based asphalt or
bio-based asphalt cement.
6. An oil sands refining process comprising: (a) providing an oil
sands formation; (b) extracting bitumen from said oil sands
formation using an in-situ extraction method; (c) providing a
biomass feedstock; (d) converting said biomass feedstock in a
pyrolysis process to at least one low-water pyrolysis liquid
containing less than 10 wt % water, a water-rich pyrolysis liquid,
and biochar; and (e) combining said extracted bitumen with a
biodiluent to form diluted bitumen, wherein said biodiluent
comprises said at least one low-water pyrolysis liquid.
7. The process of claim 6, said process further comprising
combining said extracted bitumen with a diluent to form said
diluted bitumen.
8. The process of claim 6, said process further comprising
introducing said diluted bitumen to a unit for refining, upgrading,
or chemical conversion.
9. The process of claim 8, said process comprising converting at
least a portion of said biodiluent into fuels, chemicals,
materials, or energy.
10. The process of claim 9, said process comprising converting at
least a portion of said biodiluent into bio-based asphalt or
bio-based asphalt cement.
11. A process of biomass refining, said process comprising
producing at least one low-water pyrolysis liquid, biochar, and a
water-rich pyrolysis liquid, wherein said low-water pyrolysis
liquid is suitable for use as a refinery feedstock, wherein said
biochar is suitable for use as an oil sands tailing stabilization
and carbon-sequestration agent, and wherein said water-rich liquid
is suitable for reducing water use in oil sands processing.
12. The process of claim 11, said process comprising converting at
least a portion of said low-water pyrolysis liquid into fuels,
chemicals, materials, or energy.
Description
PRIORITY DATA
[0001] This patent application is a divisional application of U.S.
patent application Ser. No. 13/470,991, filed May 14, 2012 (now
allowed), which claims priority to U.S. Provisional Patent
Application No. 61/486,304, filed May 15, 2011, each of which is
hereby incorporated by reference herein for all purposes.
FIELD OF THE INVENTION
[0002] The present invention generally relates to methods,
apparatus, and systems for integrating bio-derived materials into
oil sands processing to reduce carbon footprint and produce
chemicals, materials, and fuels.
BACKGROUND OF THE INVENTION
[0003] Crude oil is a fossil-based resource used for the production
of transportation fuels, heat and power, asphalt, chemicals,
adhesives, pharmaceuticals, polymers, fibers and other products.
The United States is a major importer of crude oil and thus is
heavily reliant on foreign countries to meet demand. Dependence on
foreign oil has massive implications on national security.
[0004] National concerns over greenhouse gas emissions, carbon
footprint, sustainability and the environment have grown parallel
to our need for energy independence. Consequently, interest in
renewable energy technologies that reduce dependence on foreign oil
and lower carbon footprint has amplified, playing a noteworthy role
in federal energy policy. Nonetheless, renewable energy can only
supply a small fraction of total US energy consumption obligating
continued crude oil imports.
[0005] Canada is the single largest exporter of crude oil into the
United States making up nearly one quarter of annual crude oil
imports in 2010. Over 95% of Canadian crude oil reserves are
located in the province of Alberta in the form of oil sands
deposits.
[0006] Oil sands are a mixture of sand, clay, water and bitumen
found naturally all over the world. Bitumen, a viscous, heavy crude
oil that will not flow unless heated or blended with diluent,
represents about 12% of the oil sands mixture. Alberta is second
only to Saudi Arabia in proven oil reserves retaining about 13% of
total global reserves as of 2011 (Oil Sands Discovery Centre).
[0007] Oil sands cannot be pumped or extracted using traditional
oil production methods. Instead, mining and in situ extraction
methods are used to recover bitumen. Twenty percent of Canadian oil
sands reserves are minable since they are within 75 meters of the
surface while the remaining 80% must be recovered using in situ
techniques.
[0008] One of the criticisms of oil sands production is that mining
and in situ extraction techniques use more energy than traditional
crude oil production. Largely because of this oil sands derived
bitumen has between 5 and 15% higher greenhouse gas (GHG) emissions
than average crude consumed in the US during the year 2005 (Hobbs,
Brukhard, Gross, Forrest, & Groode, 2010).
[0009] A challenge for oil sands processing is that mining and in
situ extraction use large amounts of water. Mining uses between
three and four barrels of water per barrel of bitumen. Hot water is
needed to transport oil sands and separate bitumen from clay and
sand. In situ processing uses about one barrel of water per barrel
of bitumen and requires substantial amounts of energy to create
steam for melting bitumen underground.
[0010] Another challenge is that mining extraction requires large
tailing ponds that take decades to reclaim as natural habitat and
useable land. Tailing ponds retain residual bitumen, water, sand
and clay after separation from bitumen. Tailing ponds are made up
of three primary layers: heavy sand on the bottom, relatively clean
water on top and fine solids suspended in water (mature fine
tailings) in the middle layer. It takes many years for fine solids
to settle out and for the surface to become dry and stable enough
to support equipment before tailing pond reclamation can begin
(Shell Canada Limited, 2009).
[0011] Another challenge is the use of hydrocarbon diluents in
bitumen transportation and chemicals to aid in bitumen separation.
Mining and in situ extraction use hydrocarbon diluent to reduce
bitumen viscosity and meet pipeline specifications for pipeline
transport. Pipeline specifications for functional performance
require a maximum crude density of 940 kg/m.sup.3 measured at
15.degree. C. and a maximum crude viscosity of 940 cSt measured at
a particular reference temperature depending on the season.
Hydrocarbon diluent is composed of hydrocarbon compounds including
butanes, pentanes, hexanes, heptanes, octanes, nonanes, and
aromatic and cyclic hydrocarbons including benzene, toluene and
xylene (Advantage Insight Group, 2007). Environmental and health
concerns are associated with these products which increase the
carbon footprint of the oil sand extraction process. Up to 30% vol.
diluent may be added to a barrel of bitumen to meet pipeline
specifications. Since diluent is not readily available near oil
sands production sites it must be purchased and shipped in using
pipelines or rail which adds cost and infrastructure. Furthermore,
if bitumen is shipped overseas it may not be economical to ship
diluent back.
[0012] Mining extraction uses additional chemicals to facilitate
separation of bitumen from water, sand and clay. Typically a base
(NaOH) is added with the water to produce (saponify) natural
surfactants from the bitumen. This improves the separation of
bitumen from oil sands minerals even though 90% of the base reacts
to form bicarbonate (Schramm, Stasiuk, Yarranton, Maini, &
Shelfantook, 2001).
[0013] Another challenge for oil sands bitumen is to reduce its GHG
emission profile such that it meets the California Low Carbon Fuel
Standard specifications and is accepted into California (Cackette,
2011).
[0014] Another challenge is using renewable energy, specifically
conventional fast pyrolysis products to reduce GHG emission profile
in the oil sands extraction process. Conventional bio-oil has high
water content between 15-30% and high oxygen content between 35-50%
making it immiscible with hydrocarbons. Conventional bio-oil also
has acidic properties which limit its integration with existing
equipment and processes. For example, US Patent Application Pub.
No. 2011/0232164 A1 describes a process whereby biomass pyrolysis
oil is used as a co-feed for a heavy petroleum oil coking process
to improve operation by reducing coke drying time and improve coke
handling. It is noted however that pyrolysis oil contains high
oxygen which precludes it from being a direct hydrocarbon
substitute though it may be soluble in high asphaltene-containing
feedstocks used in coking
[0015] Another challenge is to cost effectively separate
conventional bio-oil into its aqueous (water-rich) and organic
phases so that it is more easily used in oil sands processing.
[0016] What is needed in the art are methods to reduce greenhouse
gas emissions, amount of process water required, length of time for
tailing pond reclamation and the amount of petroleum based diluent
and chemicals needed in oil sands extraction and processing. A
preferred fast pyrolysis process that converts biomass into
renewable bio-oil fractions and carbon-rich biochar will improve
the environmental sustainability of oil sand extraction and
processing when integrated with existing infrastructure.
SUMMARY OF THE INVENTION
[0017] The present invention addresses the aforementioned needs in
the art, as will now be summarized and then further described in
detail below.
[0018] Some variations provide a method comprising combining
biodiluent with bitumen to form diluted bitumen, wherein the
biodiluent comprises a liquid pyrolysis oil obtained from biomass
pyrolysis. The liquid pyrolysis oil may comprise at least a portion
of an organic phase of a liquid produced during the biomass
pyrolysis. The biodiluent is substantially soluble with the bitumen
at a processing temperature selected from about 40.degree. C. to
about 90.degree. C., in certain embodiments.
[0019] In some embodiments, the method further comprises a step of
combining diluent with the bitumen to form the diluted bitumen. The
addition of the biodiluent can reduce the quantity of the diluent
necessary to maintain a selected viscosity of the diluted
bitumen.
[0020] Some variations provide a method comprising combining
biodiluent and diluent with bitumen to form diluted bitumen,
wherein the biodiluent comprises a liquid pyrolysis oil obtained
from biomass pyrolysis. The liquid pyrolysis oil may comprise at
least a portion of an organic phase of a liquid produced during the
biomass pyrolysis. The biodiluent may be from 0.1 wt % to 20 wt %
of the diluted bitumen, for example.
[0021] In some embodiments, diluent is recovered from the diluted
bitumen. The recovered diluent may be recycled for use to dilute
additional bitumen. In some embodiments, the biodiluent is not
recovered from the diluted bitumen.
[0022] The method may further include introducing the diluted
bitumen to a unit for refining, upgrading, or chemical conversion.
In some embodiments, the method comprises converting at least a
portion of the biodiluent into fuels, chemicals, materials, or
energy. For example, the biodiluent may be converted into bio-based
asphalt or bio-based asphalt cement.
[0023] Some variations of the invention provide an oil sands
refining process comprising:
[0024] (a) providing a mined oil sands feedstock;
[0025] (b) crushing the mined oil sands feedstock to produce
crushed oil sands;
[0026] (c) combining the crushed oil sands with water for
hydrotransport to a separation section;
[0027] (d) operating the separation section to separate crushed oil
sands into bitumen, coarse sand, and water containing suspended
solids;
[0028] (e) introducing the coarse sand and the water containing
suspended solids to a tailing pond;
[0029] (f) providing a biomass feedstock; and
[0030] (g) converting the biomass feedstock in a pyrolysis process
to at least one low-water pyrolysis liquid containing less than 10
wt % water, a water-rich pyrolysis liquid, and biochar,
[0031] wherein the bitumen is diluted with biodiluent comprising
the at least one low-water pyrolysis liquid, to form diluted
bitumen.
[0032] In some embodiments, the process further comprises combining
diluent with the bitumen to form the diluted bitumen.
[0033] The process may include introducing the diluted bitumen to a
unit for refining, upgrading, or chemical conversion. For example,
at least a portion of the biodiluent may be converted into fuels,
chemicals, materials, or energy, in any combination thereof. In
certain embodiments, biodiluent is converted into bio-based asphalt
or bio-based asphalt cement.
[0034] Some variations of the invention provide an oil sands
refining process comprising:
[0035] (a) providing an oil sands formation;
[0036] (b) extracting bitumen from the oil sands formation using an
in-situ extraction method;
[0037] (c) providing a biomass feedstock;
[0038] (d) converting the biomass feedstock in a pyrolysis process
to at least one low-water pyrolysis liquid containing less than 10
wt % water, a water-rich pyrolysis liquid, and biochar; and
[0039] (e) combining the extracted bitumen with a biodiluent to
form diluted bitumen, wherein the biodiluent comprises the at least
one low-water pyrolysis liquid.
[0040] In some embodiments, the process further comprises combining
the extracted bitumen with a diluent to form the diluted
bitumen.
[0041] The present invention also provides an integrated process of
biomass refining, the process comprising producing at least one
low-water pyrolysis liquid, biochar, and a water-rich pyrolysis
liquid, wherein the low-water pyrolysis liquid is suitable for use
as a refinery feedstock, wherein the biochar is suitable for use as
an oil sands tailing stabilization and carbon-sequestration agent,
and wherein the water-rich liquid is suitable for reducing water
use in oil sands processing. The low-water pyrolysis liquid may be
converted into fuels, chemicals, materials, or energy, in various
combinations.
[0042] In some variations, the invention provides a method
comprising combining biodiluent with bitumen to form diluted
bitumen, wherein the biodiluent comprises one or more liquid
pyrolysis fractions obtained from pyrolyzing biomass and collecting
multiple liquid fractions.
[0043] In some embodiments, the invention provides a method
comprising combining biodiluent and petroleum diluent with bitumen
to form diluted bitumen, wherein the biodiluent comprises one or
more liquid pyrolysis fractions obtained from fast pyrolysis of
biomass, and wherein the petroleum diluent comprises chemicals
obtained from crude oil; the method further comprising recovering
the petroleum diluent from the diluted bitumen, to form a
bitumen-biodiluent mixture, and then recycling the petroleum
diluent to combine with the bitumen.
[0044] In some embodiments, the invention provides a method
comprising combining bitumen with one or more liquid pyrolysis
fractions obtained from fast pyrolysis of biomass, wherein the one
or more liquid pyrolysis fractions serve as a flotation agent to
enhance separation of water and fine solids from the bitumen.
[0045] The bitumen may be any source of bitumen, such as (but by no
means limited to) bitumen obtained from oil sands, bitumen obtained
from bituminous rock, refined bitumen obtained from petroleum, or
other sources.
[0046] In other variations of the invention, a method of oil sands
processing is provided, the method comprising utilizing a
water-rich pyrolysis liquid comprising at least 50 wt % water,
wherein the water-rich pyrolysis liquid is obtained from a step
comprising collecting at least two pyrolysis liquids from biomass
fast pyrolysis.
[0047] In some embodiments, the invention provides a method of oil
sands processing, the method comprising utilizing a water-rich
pyrolysis liquid comprising at least 50 wt % water, wherein the
water-rich pyrolysis liquid is obtained from a step comprising
collecting at least two pyrolysis liquids from biomass fast
pyrolysis, and wherein the water-rich pyrolysis liquid is utilized
during the method for hydrotransport.
[0048] In some embodiments, the invention provides a method of oil
sands processing, the method comprising utilizing a water-rich
pyrolysis liquid comprising at least 50 wt % water, wherein the
water-rich pyrolysis liquid is obtained from a step comprising
collecting at least two pyrolysis liquids from biomass fast
pyrolysis, and wherein the water-rich pyrolysis liquid is utilized
during the method for primary separation of bitumen from the oil
sands.
[0049] In certain embodiments, the invention provides a method of
oil sands processing, the method comprising utilizing a water-rich
pyrolysis liquid comprising at least 50 wt % water, wherein the
water-rich pyrolysis liquid is obtained from a step comprising
collecting at least two pyrolysis liquids from biomass fast
pyrolysis, and wherein the water-rich pyrolysis liquid is utilized
during the method for modifying pH of one or more liquid
streams.
[0050] Some embodiments of the invention provide a method of oil
sands processing, the method comprising utilizing a water-rich
pyrolysis liquid comprising at least 50 wt % water, wherein the
water-rich pyrolysis liquid is obtained from a step comprising
collecting at least two pyrolysis liquids from biomass fast
pyrolysis, the method further comprising recycling water from a
tailing pond associated with the oil sands processing.
[0051] Biochar may be introduced to an oil sands tailing pond to
stabilize or thicken solids contained in the tailing pond; to
reduce the reclamation time associated with the tailing pond; to
improve the quality of water that is recyclable from the tailing
pond; to absorb suspended solids and decrease the amount of mature
fine tailings contained in the tailing pond; to remove contaminants
and/or toxic materials in the tailing pond; to sequester carbon
contained in the biochar; and/or to improve the quality of the soil
produced following reclamation of the tailing pond, for
example.
[0052] The present invention, in some variations, provides an oil
sands refining process comprising:
[0053] (a) providing a mined oil sands feedstock;
[0054] (b) crushing the mined oil sands feedstock to produce
crushed oil sands;
[0055] (c) combining the crushed oil sands with water for
hydrotransport to a separation section;
[0056] (d) operating the separation section to separate crushed oil
sands into bitumen, coarse sand, and water containing suspended
solids;
[0057] (e) introducing the coarse sand and the water containing
suspended solids to a tailing pond;
[0058] (f) providing a biomass feedstock; and
[0059] (g) converting the biomass feedstock in a fast pyrolysis and
multi-stage separation process to at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar,
[0060] wherein the bitumen is diluted with biodiluent comprising
the at least one low-water pyrolysis liquid, to form diluted
bitumen.
[0061] The present invention, in other variations, provides an oil
sands refining process comprising:
[0062] (a) providing a mined oil sands feedstock;
[0063] (b) crushing the mined oil sands feedstock to produce
crushed oil sands;
[0064] (c) combining the crushed oil sands with water for
hydrotransport to a separation section;
[0065] (d) operating the separation section to separate crushed oil
sands into bitumen, coarse sand, and water containing suspended
solids;
[0066] (e) introducing the coarse sand and the water containing
suspended solids to a tailing pond;
[0067] (f) providing a biomass feedstock; and
[0068] (g) converting the biomass feedstock in a fast pyrolysis and
multi-stage separation process to at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar,
[0069] wherein the water-rich pyrolysis liquid is used to displace
water or steam use in the oil sands refining process.
[0070] The present invention, in still other variations, provides
an oil sands refining process comprising:
[0071] (a) providing a mined oil sands feedstock;
[0072] (b) crushing the mined oil sands feedstock to produce
crushed oil sands;
[0073] (c) combining the crushed oil sands with water for
hydrotransport to a separation section;
[0074] (d) operating the separation section to separate crushed oil
sands into bitumen, coarse sand, and water containing suspended
solids;
[0075] (e) introducing the coarse sand and the water containing
suspended solids to a tailing pond;
[0076] (f) providing a biomass feedstock; and
[0077] (g) converting the biomass feedstock in a fast pyrolysis and
multi-stage separation process to at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar,
[0078] wherein at least a portion of the biochar is introduced,
directly or indirectly, to the tailing pond.
[0079] The invention, in some variations relating to in-situ oil
sands processing, provides an oil sands refining process
comprising:
[0080] (a) providing an oil sands formation;
[0081] (b) extracting bitumen from the oil sands formation using an
in-situ extraction method;
[0082] (c) providing a biomass feedstock;
[0083] (d) converting the biomass feedstock in a fast pyrolysis and
multi-stage separation process to at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar; and
[0084] (e) combining the extracted bitumen with a biodiluent to
form diluted bitumen, wherein the biodiluent comprises the at least
one low-water pyrolysis liquid.
[0085] The present invention, in other variations, provides an oil
sands refining process comprising:
[0086] (a) providing an oil sands formation;
[0087] (b) extracting bitumen from the oil sands formation using an
in-situ extraction method;
[0088] (c) providing a biomass feedstock;
[0089] (d) converting the biomass feedstock in a fast pyrolysis and
multi-stage separation process to at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar; and
[0090] (e) combining the extracted bitumen with a diluent to form
diluted bitumen,
[0091] wherein the water-rich pyrolysis liquid is used to displace
water or steam use in the oil sands refining process.
[0092] In some variations, the invention enables a process of
biomass refining, the process comprising the production of at least
one low-water pyrolysis liquid, biochar, and a water-rich pyrolysis
liquid, wherein the low-water pyrolysis liquid is suitable for use
as a refinery feedstock, the biochar is suitable for use as an oil
sands tailing stabilization and carbon-sequestration agent, and the
water-rich liquid is suitable for reducing water use in oil sands
processing.
[0093] The principles of the invention may be utilized to reduce
greenhouse-gas emissions and improve sustainability. In some
embodiments, integration of a fast pyrolysis and multi-stage
separation process into an oil sands refining process reduces the
overall greenhouse-gas emissions on a well-to-refined-product basis
by at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, or more.
[0094] The present invention provides apparatus configured to carry
out any of the methods or processes as described.
[0095] In some variations, an oil sands refining system
comprises:
[0096] (a) a crusher for crushing mined oil sands feedstock to
produce crushed oil sands;
[0097] (b) means for hydrotransporting the crushed oil sands with
water to a separation unit;
[0098] (c) a separation unit to separate crushed oil sands into
bitumen, coarse sand, and water containing suspended solids;
[0099] (d) a tailing pond for holding the coarse sand and the water
containing suspended solids;
[0100] (e) a fast pyrolysis reactor and a multi-stage separator to
convert biomass feedstock into at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar; and
[0101] (f) means for diluting bitumen by combining the bitumen with
biodiluent comprising the at least one low-water pyrolysis
liquid.
[0102] In other variations, an oil sands refining system
comprises:
[0103] (a) an oil sands formation;
[0104] (b) an in-situ extraction zone comprising input and
extraction streams for extracting bitumen from the oil sands
formation;
[0105] (c) a fast pyrolysis reactor and a multi-stage separator to
convert biomass feedstock into at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar; and
[0106] (d) means for diluting bitumen by combining the bitumen with
biodiluent comprising the at least one low-water pyrolysis
liquid.
[0107] This invention also provides various compositions and
products. In some embodiments, a diluted bitumen composition
comprises bitumen and biodiluent, wherein the biodiluent comprises
lignin derivatives, levoglucosan, furans, carbohydrates, acetic
acid, syringols, guaiacols, phenols, and water. Certain
compositions include bitumen and levoglucosan. Some compositions
include bitumen and biomass-derived phenols.
[0108] In some embodiments, a diluted bitumen composition includes
bitumen and condensed biomass-pyrolysis vapors, or bitumen and
electrostatically precipitated biomass-pyrolysis aerosols, or all
of these.
[0109] In certain embodiments, the invention provides a diluted
bitumen composition comprising bitumen, condensed biomass-pyrolysis
vapors, electrostatically precipitated biomass-pyrolysis aerosols,
and water.
[0110] A diluted bitumen composition according to some embodiments
includes bitumen and biodiluent, wherein the biodiluent is produced
by a process comprising a fast pyrolysis and multi-stage separation
process to convert biomass into at least one low-water pyrolysis
liquid containing less than 10 wt % water, a water-rich pyrolysis
liquid containing at least 50 wt % water, and biochar, wherein the
biodiluent comprises the at least one low-water pyrolysis
liquid.
[0111] Some embodiments provide a composition comprising bitumen, a
petroleum-derived diluent, and a biomass-derived diluent.
[0112] Some embodiments provide bitumen, a petroleum diluent, and a
biodiluent, wherein the biodiluent comprises one or more liquid
pyrolysis fractions obtained from fast pyrolysis of biomass.
[0113] Certain embodiments provide a composition comprising
bitumen, a petroleum diluent, lignin derivatives, levoglucosan,
furans, carbohydrates, acetic acid, syringols, guaiacols, phenols,
and water. Some embodiments of the invention provide a composition
comprising bitumen, a petroleum diluent, and levoglucosan. These or
other embodiments provide a composition comprising bitumen, a
petroleum diluent, and biomass-derived phenols.
[0114] In certain embodiments, a bitumen composition is produced by
a process comprising removing a petroleum diluent from a mixture
comprising bitumen, the petroleum diluent, and a biodiluent,
wherein the biodiluent comprises one or more liquid pyrolysis
fractions obtained from fast pyrolysis of biomass.
[0115] The invention encompasses a bitumen composition produced by
any of the methods or processes as described herein. The invention
encompasses an aqueous (i.e., water-rich) composition produced by
any of the methods or processes as described herein.
[0116] This invention also provides a bio-based asphalt product
produced by any of the methods or processes as described herein,
and further comprising conversion of an intermediate into the
bio-based asphalt product.
[0117] This invention also provides a chemical produced by any of
the methods or processes as described herein, and further
comprising conversion of an intermediate into the chemical.
[0118] This invention also provides a material produced by any of
the methods or processes as described herein, and further
comprising conversion of an intermediate into the material.
[0119] This invention further provides a refined fuel produced by
any of the methods or processes as described herein, and further
comprising conversion of an intermediate into the refined fuel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0120] The advantages of the technology described may be better
understood by referring to the descriptions below with the
accompanying drawings. The drawings are not to scale and represent
exemplary configurations that depict general principles of the
technology. Dotted lines within the figures are representative of
optional process streams.
[0121] FIG. 1 provides an exemplary oil sands mining extraction
process coupled with a fast pyrolysis process that converts biomass
into biodiluent to modify bitumen viscosity, a water-rich fraction
to reduce fresh water use and biochar to improve stability of
tailing ponds, sequester carbon and reduce overall greenhouse gas
emission profile.
[0122] FIG. 2 provides an exemplary oil sands in situ extraction
process coupled with a fast pyrolysis process that converts biomass
into biodiluent to modify bitumen viscosity, a water-rich fraction
to reduce water need for steam production and biochar to sequester
carbon and reduce overall greenhouse gas emission profile.
[0123] FIG. 3 demonstrates the ability to reduce petroleum diluent
and meet pipeline viscosity specifications by adding various
concentrations of biodiluent. Samples with increasing biodiluent
concentration indicate decreasing viscosity though all samples
contain 27 wt % petroleum diluent.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0124] The apparatus, systems, and methods of the present invention
will now be described in detail by reference to various
non-limiting embodiments, including the figures which are exemplary
only.
[0125] Unless otherwise indicated, all numbers expressing
dimensions, capacities, and so forth used in the specification and
claims are to be understood as being modified in all instances by
the term "about." Without limiting the application of the doctrine
of equivalents to the scope of the claims, each numerical parameter
should at least be construed in light of the number of reported
significant digits and by applying ordinary rounding
techniques.
[0126] The present invention may be practiced by implementing
method steps in different orders than as specifically set forth
herein. All references to a "step" may include multiple steps (or
substeps) within the meaning of a step. Likewise, all references to
"steps" in plural form may also be construed as a single process
step or various combinations of steps.
[0127] The present invention may be practiced by implementing
process units in different orders than as specifically set forth
herein. All references to a "unit" may include multiple units (or
subunits) within the meaning of a unit. Likewise, all references to
"units" in plural form may also be construed as a single process
unit or various combinations of units.
[0128] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless
the context clearly indicates otherwise.
[0129] Some variations of the present invention consist of an oil
sands extraction method coupled with a fast pyrolysis process that
produces renewable bio-oil fractions and biochar for the improved
sustainability of oil sands processing. The use of fast pyrolysis
products in oil sands processing may reduce carbon footprint and
improve the environmental image of oil sands bitumen.
[0130] "Oil sands," for the purpose of the present invention, is
any material that is extracted from the ground with the purpose of
recovering viscous hydrocarbon material, bitumen, asphalt, tar,
pitch, heavy oil, heavy crude, oil shale, and the like. "Bitumen,"
for the purpose of the present invention, is a viscous, hydrocarbon
material, oil sands bitumen, asphalt, tar, pitch, heavy oil, heavy
crude, oil shale, and the like recovered using known extraction
methods including but not limited to oil sands processing
techniques and used as a crude feedstock in a refinery or upgrader.
"Diluent," for the purpose of this present invention, is a
hydrocarbon or petroleum substance (often condensate) used to
dilute crude bitumen so that it can be transported by pipeline and
meet pipeline specifications. Diluents are mainly composed of
C.sub.4-C.sub.10 hydrocarbons and small amounts of aromatics
including benzene, xylene and toluene and derived from natural gas
condensate, crude oil, coal, or other fossil source. "Dilbit,"
"synbit," "syncrude," for the purpose of the present invention, is
a viscous hydrocarbon material such as bitumen combined with
diluent to form a lower viscosity or partially upgraded bitumen
substance. "Biomass," for the purpose of the present invention, is
any material not derived from fossil resources and comprising at
least carbon, hydrogen, and oxygen. Biomass includes, for example,
plant and plant-derived material, vegetation, agricultural waste,
forestry waste, wood waste, and paper waste. "Biodiluent" and
"water-rich fraction," for the purpose of the present invention,
are liquid products derived from a biomass fast pyrolysis process.
In general, biodiluent contains less water than the water-rich
fraction. Biodiluent will typically contain less than 10 wt % water
while the water-rich fraction may contain between 50-90 wt %
water.
[0131] Fast pyrolysis is a thermal process in which feedstock is
rapidly heated in the absence of oxygen. The feedstock decomposes
to generate pyrolysis vapors, aerosols, biochar and non-condensable
gas. Fast pyrolysis processes typically produce 60-75 wt % of
liquid bio-oil, 15-25 wt % of solid char, and 10-25 wt % of
non-condensable gases, depending on the feedstock used (Mohan,
Pittman, & Steele, 2006).
[0132] Bio-oil is a dark brown, liquid-form of biomass. Also known
as pyrolysis oil, biocrude oil, wood oil and pyroligneous acid, it
contains a mixture of up to 400 organic compounds. Conventional
bio-oil has high water and oxygen content, low energy content, high
acidity and general instability. These poor properties prevent it
from integrating into existing markets or blending with
hydrocarbons without expensive upgrading. Bio-oil, however, can be
separated into an aqueous and organic phase using separation
techniques. In general, the aqueous phase will contain more water
than the organic phase. The "aqueous phase" is a water-rich
pyrolysis liquid that will typically contain at least 50 wt % water
while the "organic phase" will typically contain less than 10 wt %
water. For the purpose of this invention, aqueous phase bio-oil may
be functional in water-rich fraction applications and organic phase
bio-oil may be functional in biodiluent applications.
[0133] Non-condensable gases include hydrogen, carbon monoxide,
carbon dioxide, methane, and other light hydrocarbons.
Non-condensable gases may also include inert gases used in the
pyrolysis reactor. Typically, non-condensable gases represent about
10 wt % to about 25 wt % of pyrolysis products.
[0134] Biochar or char is a solid product of biomass pyrolysis.
Fast pyrolysis seeks to maximize liquid bio-oil yield and minimize
biochar yield. Biomass with high lignin and ash content tend to
increase biochar yields while slow heating rates, long vapor
residence times and high pressures also lead to additional char
formation.
[0135] A particular advantage of the present invention is using
bio-oil fractions from a preferred fast pyrolysis fractionation
process to reduce the GHG emission profile of oil sands bitumen.
Bio-oil fractions are collected using simple, low-cost,
fractionation technology downstream of biomass fast pyrolysis.
Bio-oil fractions have improved properties over conventional
bio-oil since much of the water and acidic compounds are separated
into a single fraction. Using bio-oil fractions is a new and
preferred approach for reducing GHG emissions in oil sand
processing for two reasons. One, bio-oil fractions with low water
and acidity can be used as a biodiluent and blended with bitumen
(conventional bio-oil is not easily blended) to modify viscosity,
improve refining operations and reduce GHG profile, and two, the
water-rich fraction (containing between 50-90% water) can be used
for hydrotransport, steam production and oil sands separation
processes to decrease water consumption and chemical use.
[0136] In some variations, the present invention incorporates
technology described in U.S. Pat. No. 8,100,990 entitled "Methods
for Integrated Fast Pyrolysis Processing of Biomass" issued Jan.
24, 2012 to Ellens et al., which is incorporated by reference
herein in its entirety.
Oil Sands Mining Extraction
[0137] With reference to FIG. 1, the purpose of unit 100 is to
recover and process bitumen from mined oil sands located within
0-100 meters of the surface.
[0138] The purpose of unit 105 is to receive mined oil sands and
crush them to a small, uniform size. Mining oil sands involves
clearing away large areas of forest, trees, soil, clay and rock in
order to access buried oil sands. Once uncovered, large cranes and
trucks mine and transport oil sands to unit 105.
[0139] After leaving the crusher in unit 105, oil sands are
conveyed using hydrotransport to unit 110. Hot water between
50-80.degree. C. is added to a hydrotransport system to create a
slurry and improve pipeline transportation efficiency. During
transportation oil sands are further broken into its
components.
[0140] In a preferred approach, a water-rich pyrolysis oil fraction
from unit 160 is heated to 30-80.degree. C. and added to the oil
sands for hydrotransport.
[0141] The mixture is transported from unit 105 to unit 110, a
primary separation vessel. Air may be added to unit 110 to create
the bitumen froth. Additional water is added to the primary
separation vessel to encourage separation of the oil sands. In a
preferred approach, the water-rich fraction is added to unit 110
from unit 160 along with recycle water from unit 140 in order to
reduce water consumption. Mining extraction requires three to four
barrels of water to produce one barrel of bitumen. On average,
between two and three barrels of fresh water are needed while the
remaining water is recycled and recovered from tailing ponds.
[0142] In unit 110, coarse sand sinks to the bottom, bitumen floats
to the top as froth and middlings (mostly water, fine solids and
clay with small amounts of bitumen) are suspended in the middle.
Coarse sand separated in unit 110 is transported to tailing ponds,
unit 140. The middlings undergo a secondary separation in
floatation cells, unit 115, where air is added to produce and
separate bitumen froth. In one embodiment, the water-rich fraction
from unit 160 may be added to unit 115 to further enhance
separation. Bitumen froth is recycled from unit 115 back to unit
110. Water and fine solids from unit 115 are sent to tailing ponds,
unit 140.
[0143] From the primary separation vessel, unit 110, bitumen froth
is sent to a de-aerator, unit 120. Steam enters unit 120 to remove
bubbles so that bitumen froth may be pumped. In one embodiment the
water-rich fraction from unit 160 may be used as a feedstock to
create steam for unit 120.
[0144] De-aerated froth is pumped from unit 120 to unit 130, for
froth treatment. The purpose of unit 130 is to further remove water
and fine solids from bitumen. Hydrocarbon diluent and chemicals are
added from unit 125 to unit 130 to enhance separation and decrease
bitumen viscosity. Diluent or condensates are used to reduce the
viscosity of bitumen for pumping and meet pipeline specifications.
Diluents are mainly composed of C.sub.4-C.sub.10 hydrocarbons and
small amounts of aromatics including benzene, xylene and
toluene.
[0145] In a preferred embodiment, biodiluent and/or pyrolysis oil
derived chemicals from unit 160 are added to unit 125 in addition
to hydrocarbon diluent in unit 130, froth treatment. The biodiluent
serves to modify bitumen viscosity and lower GHG emission profile
by displacing petroleum derived products. Biodiluent can reduce the
viscosity of the bitumen and therefore the amount of hydrocarbon
diluent needed to meet pipeline specifications. Biodiluent, the
water-rich pyrolysis oil fraction and pyrolysis oil derived
chemicals may also serve as floatation agents to enhance water and
fine solid separation from bitumen.
[0146] In an alternative embodiment, biodiluent and/or pyrolysis
oil derived chemicals from unit 160 are added to the diluted
bitumen stream after unit 130 and before unit 145. In yet another
embodiment, biodiuent and/or pyrolysis oil chemicals derived from
unit 160 are added to the bitumen stream after unit 145.
[0147] Water and fine solids leave unit 130 and are mixed with a
thickener (often gypsum) from unit 135 before entering tailing
ponds, unit 140. Tailing ponds from mined oil sands are used to
retain sand, clay and water from mining extraction. Tailing ponds
also act as settling ponds where sand and fine solids separate by
gravity from water. Over time, clean water ends up on top of the
pond where it is recycled into unit 110 or other processes
requiring water. Coarse sand sinks to the bottom of unit 140.
Between the clean water and sand is a stable layer of mature fine
tailings (MFT) or solids perpetually suspended in water. Tailing
pond research is focused on removing solids from MFT, drying the
tailings so they become stable enough to support surface traffic
and are able to be reclaimed, and reducing the time required for
tailing pond reclamation. Gypsum is added to thicken the tailings
so that it releases water more quickly. Other prior art related to
the tailing pond reclamation process involves running the mature
fine tailings through a centrifuge. Another process involves
releasing sand, water and fine solids to runoff down an embankment
so that the fine solids are filtered or caught up before reaching
the tailing pond below.
[0148] In a preferred approach, biochar from unit 160 is added to
unit 140 as a material that will improve tailing pond reclamation
process, provide increased accessibility to water for recycling,
sequester carbon and reduce oil sand processing GHG emission
profile. In another embodiment, biochar from unit 160 is added to
unit 135 to serve as a thickener. Biochar is composed mainly of
carbon. When mixed with tailings, biochar coalesces or absorbs fine
solids in its highly porous structure to decrease the amount of
mature fine tailings increasing the amount of clean reclaim water
on top of the pond. Once the water layer is removed, biochar may
reduce the time required to dry the tailings and provide a stable,
trafficable layer for equipment to begin reclamation.
[0149] Biochar's high porosity may also remove contaminants from
the soil and absorb toxic material in tailing ponds. Additionally,
adding carbon-rich biochar to the tailings sequesters once
atmospheric carbon to decrease oil sand carbon emission profile and
improve soil quality of reclaimed tailings.
Oil Sands In Situ Extraction
[0150] With reference to FIG. 2, the purpose of unit 200 is to
extract bitumen located more than 75 meters below the surface using
an in situ process. Steam-assisted, gravity-drainage (SAGD) is a
common in situ method that uses two parallel, horizontal wells
drilled up to 300-600 meters below the surface to recover bitumen.
Although SAGD is an exemplary in situ extraction method the present
invention is by no means limited to this in situ process. Other in
situ extraction processes that may benefit from fast pyrolysis
products include but are not limited to, Cyclic Steam Stimulation
(CSS), Electro-Thermal Dynamic Stripping Process (ET-DSP.TM.), Toe
to Heal Air Injection (THAI), Combustion Overhead Gravity Drainage
(COGD), Solvent Extraction (N-Solv, etc.) and others.
[0151] In situ methods extract only bitumen from the ground and
therefore do not require tailing ponds to retain sand, water and
fine solids. In situ recovery is more water efficient than mining
extraction using one barrel of water per barrel of bitumen.
Furthermore, brackish or saline water can be used for the in situ
process.
[0152] The purpose of unit 205 is to treat process water before it
can be converted into steam in unit 210. Brackish or saline water
as well as fresh water is cleaned and treated before entering steam
production, unit 210. In a preferred approach, the water-rich
pyrolysis oil fraction, which contains up to 90% water, is fed from
the fast pyrolysis process, unit 160, into unit 205 where it is
treated. Using the water-rich fraction from unit 160 reduces the
need for fresh water. Furthermore, producing the water-rich
fraction does not require additional water which is used for post
production separation of conventional bio-oil into aqueous and
organic phases.
[0153] Treated water from unit 205 is then sent to steam
production, unit 210. Natural gas or another fuel including bio-oil
fractions are combusted to provide heat for steam production. In
one embodiment the water-rich fraction from unit 160 is fed
directly to unit 210 to serve as a feedstock for steam
production.
[0154] Steam or solvents from unit 210 are pumped into the upper
horizontal well located about 4.5 meters above the lower in unit
215. The hot steam heats oil sands in unit 215 so that the bitumen
melts and seeps down into the bottom well by gravity where it is
pumped out of unit 215 with steam condensate to unit 220.
Alternatively, solvents are pumped into unit 215 to dissolve
bitumen and reduce its viscosity. Low viscosity bitumen drains into
the lower well and is similarly pumped out of unit 215 to unit 220
above ground.
[0155] In unit 220, bitumen is separated from steam condensate and
mixed with diluents. Steam condensate is recovered as recycle water
that must be treated in unit 205 before it can be turned into steam
again. Diluent is added to unit 220 from unit 225 to reduce the
viscosity of the bitumen for pipeline transportation. In a
preferred embodiment, biodiluent and/or pyrolysis oil derived
chemicals from unit 160 are added to unit 225 to modify the
viscosity. This can reduce the amount of hydrocarbon diluent needed
in unit 220 and add renewable carbon to bitumen to reduce overall
GHG emission profile.
[0156] In an alternative embodiment, biodiluent and/or pyrolysis
oil derived chemicals from unit 160 are added to the diluted
bitumen stream after unit 220 and before unit 145. In yet another
embodiment, biodiluent and/or pyrolysis oil chemicals derived from
unit 160 is added to the bitumen stream after unit 145.
[0157] In conjunction with biochar carbon sequestration, adding
2-5% vol. biodiluent to bitumen can achieve significant GHG
emission reduction of oil sands processing (Table 1) on a
Well-to-Refined Product basis.
TABLE-US-00001 TABLE 1 Reduced emissions with biodiluent on
Well-to-Refined Product (WtRP) basis WtRP emissions WtRP emissions
WtRP emissions Increase in WtRP adding 2%-vol. adding 5%-vol.
Canadian Oil (kg CO2e/bbl emissions over biodiluent biodiluent
Sands Source refined product)* "Average US Crude" (% Reduction) (%
Reduction) SAGD SCO 168.5 +66.8% +59.6% (-10.8%) +48.8% (-27.0%)
Mining SCO 132.5 +31.2% +24.7% (-20.8%) +15.0% (-52.0%) SAGD Dilbit
125.5 +24.3% +17.9% (-26.2%) +8.4% (-65.5%) Mining Bitumen 123.5
+22.3% +16.0% (-28.3%) +6.5% (-70.9%) Average US Crude 101.0 0.0 --
-- Consumed (2005) *Reference: IHS CERA Special Report (2010): Oil
Sands, Greenhouse Gases, and US Oil Supply - Getting the Numbers
Right.
[0158] With reference to FIGS. 1 and 2, the process after units 130
and 220 are the same. Diluted bitumen or dilbit (containing
biodiluent) from the froth treatment plant, unit 130, and from
separation, unit 220 is pumped to a refinery or upgrader.
Hydrocarbon diluent is recovered in unit 145 located at the
refinery or upgrader. Here diluent is separated from bitumen and
may be recycled back to the extraction site into units 125 and
225.
[0159] Bitumen recovered in unit 145 is stored in large storage
tanks, unit 150, until further processing at the refinery, unit
155, into synthetic crude oil or other upgraded products.
Alternatively, diluted bitumen from unit 130 or 220 is first stored
in unit 150 at the refinery or upgrader site before it is separated
in diluent recovery, unit 145 en route to the refinery or upgrader,
unit 155.
[0160] In a preferred approach, biodiluent mixed with bitumen or
diluted bitumen from unit 130 or 220 is not recovered with
hydrocarbon diluents in unit 145 but kept with the bitumen in
storage, unit 150 and then transported to a refinery or upgrader in
unit 155. By mixing biodiluent with bitumen, renewable carbon
content is added so that the GHG emission profile is reduced
creating an environmentally friendly and improved sustainability
oil sands process.
[0161] Laboratory testing has demonstrated that biodiluent from the
fast pyrolysis fractionation process in unit 160 blends with
petroleum asphalt bitumen and crude oil. Due to the presence of
high molecular weight and boiling point compounds, it is expected
that some or all the biodiluent will pass through diluent recovery,
unit 145 and remain with the bitumen. Furthermore, it is expected
that as biodiluent enters the refinery or upgrader, unit 155, it
will form at least a portion of renewable asphalt cement or
bioasphalt. Renewable asphalt cement is able to sequester carbon in
asphalt further reducing oil sands processing GHG emissions
profile.
[0162] Alternatively, biodiluent or a portion of the biodiluent
processed in the refinery or upgrader, unit 155, may produce
renewable hydrocarbon compounds other than asphalt cement, such as
fuels and chemicals.
Fast Pyrolysis and Bio-Oil Fractionation Process
[0163] In a preferred approach, unit 160 is described in U.S. Pat.
No. 8,100,990 entitled "Methods for Integrated Fast Pyrolysis
Processing of Biomass" issued Jan. 24, 2012 to Ellens et al., which
is incorporated by reference herein in its entirety.
[0164] Unit 160 provides a method for pretreating and converting
biomass into liquid bio-oil fractions, solid biochar, and
non-condensable gas using a fast pyrolysis process. These products
are collected, processed, produced and recycled or stored on site.
The operation of unit 160 is integral to the production of
value-added products including renewable biodiluent, a water-rich
pyrolysis oil fraction, biochar and bioasphalt which can reduce oil
sands GHG emission profile as noted.
[0165] In another approach, unit 160 is a biomass fast pyrolysis
processing facility producing whole bio-oil, biochar and
non-condensable gas. In this embodiment, whole bio-oil is separated
into its organic and aqueous phases which may be used in a manner
similar to biodiluent and the water-rich pyrolysis oil fraction,
respectively.
[0166] In a preferred approach, the fast pyrolysis process, unit
160, is co-located with an oil sands site so as to provide mutual
benefit to one another and add another level of integration.
Co-location of a fast pyrolysis processing plant with an oil sand
processor may provide access to utilities and auxiliary
infrastructure.
[0167] The integrated fast pyrolysis process is able to use many
different feedstocks including lignocellulosic biomass and other
carbon-based energy sources. In certain approaches, the fast
pyrolysis process uses locally sourced biomass available around the
oil sand extraction site especially considering the availability of
wood resources in Western Canada (Levelton Consultants Ltd and
Envirochem Srevices Inc., 2008).
[0168] In another approach, co-locating an integrated fast
pyrolysis process with fractionation technology, as depicted in
FIGS. 1 and 2, may reduce oil sands processing life-cycle analysis
or greenhouse gas (GHG) footprint. Fast pyrolysis products can
offset fossil resource use at a processing facility. Reducing
natural gas, coal, diesel and other fossil resources with renewable
products is a way to meet renewable energy mandates, renewable
portfolio standards, reduce carbon footprint and dependence on
fossil sources while improving sustainability.
[0169] In a preferred approach, the fast pyrolysis process, unit
160, converts biomass into oil sands compatible products that can
be integrated to reduce GHG emission profile. When integrated with
oil sands extraction and processing, biodiluent, biochar, the
water-rich fraction and/or pyrolysis oil derived chemicals products
improve the sustainability of the industry. The fast pyrolysis
process, unit 160, may share utilities such as natural gas, steam,
water and electricity to convert local biomass materials into
renewable products that reduce oil sands GHG emission profile,
environmental criticism and provide other benefits discussed.
[0170] Biodiluent, biochar, the water-rich fraction and/or
pyrolysis oil derived chemicals produced at or near oil sand
processing sites can effectively transform the oil sands industry.
This process is an improvement over conventional pyrolysis
processes since bio-oil is separated into distinct fractions that
can be used to enhance aspects of the oil sands extraction process.
Conventional bio-oil is not compatible with hydrocarbons or the oil
sands extraction process as described though it may be separated
into aqueous and organic fractions which may have a degree of
compatibility.
EXAMPLES
[0171] The Examples set forth below are for illustrative purposes
only and are not intended to limit, in any way, the scope of the
present invention.
Example 1
Petroleum Diluent Reduction
[0172] Simulated oil sands bitumen, biodiluent and hydrocarbon
diluent blends were created and analyzed to determine pipeline
quality. A sample of Western Canadian Select (WCS) diluted crude
was heated to 210.degree. C. and distilled at atmospheric
conditions to remove hydrocarbon diluent and recover crude
according to modified ASTM D2892. Asphalt binder (PG 58-22) was
heated on a hot plate until liquid and added to the recovered crude
to create a simulated oil sands bitumen (65 wt % asphalt binder and
35 wt % bitumen) with a viscosity profile similar to a typical
Athabasca bitumen (Attanasi & Meyer, 2007).
TABLE-US-00002 TABLE 2 Density and viscosity profile of bitumen,
biodiluent and petroleum diluent Temperature (.degree. C.) Bitumen
Biodiluent Diluent Density.sup.1 15.5 1,007 1,290 673 (kg/m.sup.3)
Viscosity.sup.2 7 19,805,228 43,656,599 <1 (cSt) 12 6,993,377
9,024,466 -- 20 1,559,845 1,012,808 -- 30 306,020 106,218 -- 40
75,573 18,200 -- 50 22,337 3,809 -- 60 7,942 -- -- .sup.1Density
determined using ASTM D70 for bitumen and biodiluent and mass
divided by volume for diluent. .sup.2Kinematic viscosity (cP)
determined using Brookfield rotational viscometer (DV II+ Pro) and
converted into cSt. Italicized numbers extrapolated following ASTM
D341.
[0173] A particular biodiluent mixture was produced by heating and
combining wood-derived pyrolysis oil fractions 1 through 4. The
fractions were produced using a pilot scale fast pyrolysis system
described in U.S. Pat. No. 8,100,990.
[0174] The density and viscosity profile of the simulated bitumen,
biodiluent and recovered petroleum diluent are found in Table
2.
[0175] Various biodiluted bitumen samples were created containing
0, 2, 5 or 10 wt % biodiluent. These are denoted as bitumen,
bitumen 98/2, bitumen 95/5, and bitumen 90/10. Four additional
blends were made from each biodiluted bitumen sample containing 15,
20, 25 or 27 wt % hydrocarbon diluent. These are denoted as bitumen
15%, bitumen 98/2 15%, bitumen 95/5 15%, bitumen 90/10 15%, etc,
The viscosity of each blend was determined at 7, 12, 20, 30 and
40.degree. C. to cover the range of pipeline reference temperatures
(Equalization Steering Committee, 2012) and compared to the
baseline simulated bitumen sample containing 0 wt % biodiluent
(Table 3).
TABLE-US-00003 TABLE 3 Blend viscosity at various temperatures and
hydrocarbon diluent concentrations Diluent Bitumen Bitumen Bitumen
Concen- Reference Bitumen 98/2 95/5 90/10 tration Temperature
Viscosity Viscosity Viscosity Viscosity (wt %) (.degree. C.) (cSt)
(cSt) (cSt) (cSt) 15 7 36,776 7,151 9,401 8,245 12 16,351 4,231
4,907 4,143 20 4,440 2,006 2,185 1,893 30 1,724 832 959 840 40 789
408 446 405 20 7 3,700 1,767 1,606 1,203 12 1,648 1,085 982 773 20
845 571 520 425 30 407 286 260 223 40 211 153 144 125 25 7 606 455
446 351 12 425 318 320 252 20 248 187 187 151 30 135 107 105 88 40
81 64 64 55 27 7 496 366 305 281 12 357 263 215 200 20 210 155 129
124 30 116 91 77 74 40 69 56 48 47
[0176] Samples containing biodiluent had notably lower viscosities
than the baseline simulated bitumen sample containing 0 wt %
biodiluent and an equivalent amount of petroleum diluent. FIG. 3
shows how biodiluent containing blends containing 27 wt %
hydrocarbon diluent can meet the pipeline viscosity specification
at nearly all reference temperatures while additional diluent is
needed for bitumen 27% to comply.
[0177] A power regression model was fit to the viscosity data for
each blend. Using the model equation, we mathematically determined
the amount of diluent each blend requires to meet the 350 cSt
maximum pipeline viscosity specification. The percent reduction of
hydrocarbon diluent compared to the baseline simulated bitumen
containing 0 wt % biodiluent was also determined. Table 4 indicates
that this particular biodiluent can reduce the amount of
hydrocarbon diluent between 3.7-14.0% depending on temperature and
biodiluent concentration.
TABLE-US-00004 TABLE 4 Minimum amount of hydrocarbon diluent
required to comply with 350 cSt maximum pipeline viscosity and
percentage reduction corresponding to baseline simulated bitumen
Reference Bitumen Bitumen 98/2 Bitumen 95/5 Bitumen 90/10
Temperature Diluent Diluent Diluent Diluent Average (.degree. C.)
(wt %) (wt %) Reduction % (wt %) Reduction % (wt %) Reduction %
Reduction % 7 27.6 26.6 -3.7 25.6 -7.4 25.4 -8.2 -6.4 12 26.2 24.9
-5.0 24.1 -8.1 23.8 -9.3 -7.5 20 23.7 22.1 -7.0 21.6 -9.0 21.2
-10.6 -8.9 30 20.8 18.8 -9.7 18.8 -9.6 18.3 -12.0 -10.4 40 18.0
15.7 -12.7 15.9 -11.3 15.4 -14.0 -12.7
Example 2
Simulated Bitumen and Biodiluent Blend Density and Viscosity
Profiles
[0178] Simulated bitumen and biodiluent blends were created to
determine their viscosity profile without hydrocarbon diluent. A
sample of Western Canadian Select (WCS) diluted crude was heated to
210.degree. C. and distilled at atmospheric conditions to remove
hydrocarbon diluent and recover crude according to modified ASTM
D2892. Asphalt binder (PG 58-22) was heated on a hot plate until
liquid and added to the recovered crude to create a simulated oil
sands bitumen (65 wt % asphalt binder and 35 wt % bitumen) with a
viscosity profile similar to a typical Athabasca bitumen (Attanasi
& Meyer, 2007).
[0179] A particular biodiluent mixture was produced by heating and
combining wood-derived pyrolysis oil fractions 1 through 4. The
fractions were produced using a pilot scale fast pyrolysis system
described in U.S. Pat. No. 8,100,990.
[0180] Various biodiluted bitumen samples were created containing
0, 2, 5 or 10 wt % biodiluent. These are denoted as bitumen,
bitumen 98/2, bitumen 95/5, and bitumen 90/10. The density and
viscosity profile of the simulated bitumen and biodiluent blends
are found in Table 5. The table indicates that even though
biodiluent may have a substantially higher viscosity profile on its
own, when 2, 5 and 10 wt % biodiluent is added to simulated bitumen
the blend viscosity tends to decrease. When hydrocarbon diluent is
added, this trend is propagated as shown in Example 1. Furthermore,
adding 2-10 wt % biodiluent to the original bitumen can result in
substantial carbon emission reductions and improve the GHG emission
profile of the oil sands industry.
[0181] It should be noted that additional biodiluent combinations
can be produced by combining various pyrolysis oil fractions. Lower
viscosity biodiluents will likely reduce the amount of hydrocarbon
diluent further and can be used with lower viscosity bitumens
including Cold Lake and Lloydminster heavy oil (Speight, 2005).
Density is not expected to be a limiting factor since bitumen and
hydrocarbon diluent blends have traditionally been limited by
viscosity before density (Advantage Insight Group, 2007).
TABLE-US-00005 TABLE 5 Density and viscosity profile of bitumen and
biodiluent Temperature (.degree. C.) Biodiluent Bitumen Bitumen
98/2 Bitumen 95/5 Bitumen 90/10 Density.sup.1 15 1,290 1,007 1,013
1,023 1,037 (kg/m.sup.3) Viscosity.sup.2 7 43,656,599 19,805,228
19,993,455 18,810,932 18,027,553 (cSt) 12 9,024,466 6,993,377
6,989,799 6,573,526 6,341,717 20 1,012,808 1,559,845 1,538,568
1,446,789 1,408,485 30 106,218 306,020 298,046 280,450 275,526 40
18,200 75,573 72,922 68,704 67,982 50 3,809 22,337 21,469 20,171
20,129 60 -- 7,942 7,576 7,164 7,160 .sup.1Density determined using
ASTM D70 for biodiluent and bitumen; mathematically calculated for
blends. .sup.2Kinematic viscosity (cP) determined using Brookfield
rotational viscometer (DV II + Pro) and converted into cSt.
Italicized numbers extrapolated following ASTM D341.
[0182] In this description, reference has been made to multiple
embodiments and to the accompanying drawings in which are shown by
way of illustration specific exemplary embodiments of the
invention. These embodiments are described in sufficient detail to
enable those skilled in the art to practice the invention, and it
is to be understood that modifications to the various disclosed
embodiments may be made by a skilled artisan.
[0183] Where methods and steps described above indicate certain
events occurring in certain order, those of ordinary skill in the
art will recognize that the ordering of certain steps may be
modified and that such modifications are in accordance with the
principles of the invention. Additionally, certain steps may be
performed concurrently in a parallel process when possible, as well
as performed sequentially.
[0184] All publications, patents, and patent applications cited in
this specification are herein incorporated by reference in their
entirety as if each publication, patent, or patent application were
specifically and individually put forth herein.
[0185] The embodiments, variations, and figures described above
provide an indication of the utility and versatility of the present
invention. Other embodiments that do not provide all of the
features and advantages set forth herein may also be utilized,
without departing from the spirit and scope of the present
invention. Such modifications and variations are considered to be
within the scope of the principles of the invention defined by the
claims.
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* * * * *
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