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  • Oil & Natural Gas Technology

    DOE Award No.: DE-FE0000408

    Quarterly Report

    July 2011 September 2011

    Post Retort, Pre Hydro-treat Upgrading of

    Shale Oil

    Submitted by:

    Ceramatec Inc

    2425 S. 900 W.

    Salt Lake City, UT 84119

    Prepared by: John H. Gordon, PI

    Prepared for:

    United States Department of Energy

    National Energy Technology Laboratory

    October 31, 2011

    Office of Fossil Energy

  • Quarterly Report: January - March 2011 Ceramatec Inc, 1

    Table of Contents

    1. EXECUTIVE SUMMARY ................................................................................................................................ 4

    2. PROGRESS, RESULTS AND DISCUSSION ................................................................................................. 5

    2.1 TASK 1.0 -- PROJECT MANAGEMENT PLAN ...................................................................................................... 5 2.2 TASK 2.0 -- UPGRADING DEVELOPMENT .......................................................................................................... 5 2.3 TASK 3.0 -- ELECTROLYSIS DEVELOPMENT ..................................................................................................... 5 2.4 TASK 4.0 -- ANALYSIS ...................................................................................................................................... 5 2.5 TASK 5.0 UPGRADING DEVELOPMENT .......................................................................................................... 5

    2.5.1 Subtask 5.1 - Analysis lab upgrade ........................................................................................................ 9 2.6 TASK 6.0 POST REACTOR / PRE ELECTROLYSIS SEPARATION STEPS ............................................................... 10

    2.6.1 Subtask 6.1-Separations Experimental set up ...................................................................................... 10 2.6.2 Subtask 6.2-Separation of metal Salts ................................................................................................. 10 2.6.3 Subtask 6.3-Separation of metal mercaptides ...................................................................................... 10 2.6.4 Sub-task 6.4 - Design ........................................................................................................................... 10

    2.7 TASK 7.0 - ELECTROLYSIS DEVELOPMENT ..................................................................................................... 10 2.7.1 Subtask 7.1 Membrane fabrication ................................................................................................... 11 2.7.2 Subtask 7.2 Seal testing .................................................................................................................... 11 2.7.3 Subtask 7.3 Cell design and set up .................................................................................................... 11 2.7.4 Subtask 7.4 Cell operation ................................................................................................................ 11

    2.8 TASK 8.0 MODELING AND ECONOMIC ANALYSIS ........................................................................................ 23 2.8.1 Subtask 8.1 Model Upgrading process ............................................................................................. 23 2.8.2 Subtask 8.2 Model Electrolysis process ............................................................................................ 23 2.8.3 Subtask 8.3 Preliminary cost analysis .............................................................................................. 25 2.8.4 Subtask 8.4 Pilot plant cost estimate ................................................................................................ 28

    3. CONCLUSION................................................................................................................................................. 28

    4. COST STATUS ................................................................................................................................................ 29

    5. MILESTONE STATUS ................................................................................................................................... 31

    6. ACCOMPLISHMENTS .................................................................................................................................. 32

    7. PROBLEMS OR DELAYS ............................................................................................................................. 32

    8. PRODUCTS ...................................................................................................................................................... 32

    9. LIST OF APPENDICES.................................................................................................................................. 32

  • Quarterly Report: January - March 2011 Ceramatec Inc, 2

    List of Tables

    Table 1: List of Experiments Performed with Bitumen samples .................................................... 6 Table 2: C, H, N, and S Composition of Raw Materials ................................................................ 6 Table 3: Metals contents in bitumen ............................................................................................... 7 Table 4: Summary of sodium recovery test cells tested in long-term mode during the reporting

    period ............................................................................................................................................ 12 Table 5: Summary of performance of sodium recovery test cells run in long-term testing mode

    during reporting period ................................................................................................................. 13 Table 6: Summary of processed oil run conditions and properties of separated solids ................ 17

    Table 7: Sodium recovery test cells, using dissolved solids from processed oil samples,

    assembled and tested during the reporting period......................................................................... 18

    Table 8: Mass balance for the electrolytic sodium make-up production process ......................... 25 Table 9: Operating costs (in dollars per kg of sodium) for an electrolytic sodium production

    process, where the cells are operated at the optimum current density and temperature conditions

    ....................................................................................................................................................... 26 Table 10: Total capital costs for an electrolytic sodium production facility sized to produce 5%

    of the total sodium metal requirements of a 25,000 barel per day oil upgrading plant ................ 27

    Table 11: Project revised costing profile for the 7th

    Quarter ....................................................... 29

    Table 12: Project costing profile for the 8th

    Quarter ..................................................................... 29 Table 13: Milestone log for the 6

    th Quarter .................................................................................. 31

  • Quarterly Report: January - March 2011 Ceramatec Inc, 3

    List of Figures

    Figure 1: Sulfur removal from bitumen using Na treatment .......................................................... 7 Figure 2: API improvement in bitumen .......................................................................................... 8 Figure 3: Changes in viscosity of Bitumen ..................................................................................... 8

    Figure 4: Metals removal from Bitumen. ....................................................................................... 9 Figure 5: Cell voltage at 60 mA/cm

    2 and Open Circuit Voltage (OCV) versus run time for

    sodium recovery cell Na_molten_2011100504. Run time includes time periods for OCV

    measurements (no current). ........................................................................................................... 13 Figure 6: Comparison between total sulfur added and measured for Anolyte #4 during long term

    test for cell Na Recovery Cell 20110504 ...................................................................................... 14

    Figure 7: Cell voltage and current density versus test elapsed time for sodium recovery Test Cell

    Molten Na_SJ_DL07166_20110630 ............................................................................................ 19 Figure 8 Platinized Ti electrode [A] and anode side surface of NaSICON-GY membrane [B] of

    Test Cell Molten Na SJ DL07174 20110721 after the test .19

    Figure 9: Cell voltage and current denstiy versus total elapsed time for sodium recovery Test

    Cell Molten Na_Bitumen_DL07_180-189-183+JK03004_20110808 ......................................... 20 Figure 10: Total sodium recovered during operation of Test Cell Molten Na_Bitumen_DL07-

    180-189-183+JK03004_20110808 ............................................................................................... 20

    Figure 11: Platinized Ti electrode [A] and anode side surface of NaSICON-GY membrane [B] of

    Test Cell Molten Na_Bitumen_DL07_180-189-183+JK03004_20110808 after the test ............ 21

    Figure 12: Cell Voltage and current density versus total elapsed time for sodium recovery Test

    Cell Molten Na_Bitumen_JK03028_20110908 ........................................................................... 21

    Figure 13: Total sodium recov

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