Upgrading Oil Sands and Heavy Oil | Residue Formation Mitigation
Upstream residue formation in refineries during petroleum processing occurs when fuels are subjected to temperatures typically around 300°C. It is estimated that the cost of residue formation to the Canadian refining industry is in the order of $2.8 billion per year — these costs ultimately lead to higher prices at the pump (according to the Dr. Paul Watkinson of the University of British Columbia).
Deposition of organic/inorganic solids during petroleum processing in a refinery results in the plugging of pipes and vessels, which then restricts the flow of petroleum liquids. The flow restriction reduces throughput and solids formation reduces process efficiency resulting in higher energy cost and overall greenhouse gas emissions inefficiencies.
Most common causes of residue formation have been identified as inorganic solids, oil incompatibility on mixing, coke from over thermal treating, polymerization of olefins and di-olefins, and insoluble asphaltenes on cooling after conversion. Once the cause of residue formation is identified the mitigation practices can be develop to reduce or eliminate solids formation. Different chemistries have been developed to reduce process residue formation by using anti-residuants. Different laboratory methods and techniques, such as Hot Liquid Process Simulator (HLPS) the Portable Residue formation Research Unit, the Laboratory Residue formation Test Apparatus, and the High-Temperature Residue Formation Unit have been developed for measuring residue formation rates of petroleum streams.
In order to reduce the negative impacts of residue formation on our environment and to keep petroleum costs lower for Canadian consumers, our scientists are focusing their research efforts following areas:
- investigation of residue formation propensities of synthetic crude oils using a residue formation rig, HLPS
- studies of the residue formation onset of different petroleum feedstocks
- correlation of residue formation propensities of different feedstocks with their chemical and physical properties
- development of methods and techniques for early detection of residue formation in bitumen processing
- development of methods and techniques for residue formation mitigation
- stability and compatibility of feedstocks and processing streams
Plugging of pipes and vessels
Upstream residue formation can be compared with cholesterol deposits in the human body that results in blood flow restriction, and ultimately heart (analogous to upgrader equipment) failure.