JetShear, Fractal's first commercial-ready suite of technologies, dramatically reduces the viscosity of heavy oil and bitumen allowing processed fluids to move more freely in transport pipelines and thereby reduce costly diluent.
The positive field demonstration of JetShear led Fractal Systems and its partner to expand the JetShear Technology Platform to demonstrate increases in diluent displacement and reductions in acidity. The Commercial demonstration met or exceeded all of its key objectives, which included:
Meeting processing objectives using the Enhanced JetShear™ and ARP configurations while maintaining 100% volumetric yield and reaching pipeline transportation specifications for viscosity and density;
Achieving ambitious product quality targets (olefin content, acidity, diluent displacement, product stability and Greenhouse Gas Lifecycle benefits); and
Ensuring facility operability and throughput expectations with zero safety or environmental incidents.
The Facility processed over 113,000 barrels of partially-diluted bitumen achieving up to 55% diluent displacement with the acid content (Total Acid Number or “TAN”) of the diluted bitumen (“Dilbit”) reduced by at least 60% to well below a TAN level equal to 1 mgKOH/g (one milligram of potassium hydroxide (KOH) per gram of oil sample).
The 1,000 barrel per day facility operated for approximately one-year demonstrating long-term reliability with commercial scale nozzles. During this period, the facility processed over 100,000 barrels of partially diluted bitumen.
All key targets were met or exceeded and the demonstration was deemed a success by the partnership.
Fractal Systems successfully completed the commercial demonstration phase of JetShear in April 2015. The 1,000 barrel per day facility commenced processing in April 2014 and operated for approximately one year. Partially diluted bitumen was trucked to the site near Provost, Alberta from SAGD projects in the Athabasca region that are operated by Fractal’s partner. The goal of the project was to (1) meet processing objectives with commercial size nozzles, (2) achieve desired nozzle life performance, (3) meet facility operability and throughput expectations with no safety or environmental incidents, and to (4) achieve certain product quality targets (product stability, H2S content, acidity, and liquid yield).
Fractal validated the bench scale studies by processing diluted heavy oil in the field at a 300 barrel per day “Pilot Facility”. The field performance effectively demonstrated that the bench scale results could be “scaled up” (e.g. 300:1) in a field facility.