Infrared Spectrometer for Bitumen Stream Composition Control

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Solution Overview

Problem

Current bitumen extraction processes from oil sands face inefficiencies due to variations in the composition of oil sand slurry and bitumen-containing wellhead product streams, leading to delayed composition measurement and suboptimal process adjustments.

Innovation Solution

An online infrared spectrometer system is used to direct a beam of infrared light towards the bitumen-containing process stream, capture and analyze the light spectrum to estimate composition, and automatically adjust control setpoints of upstream or downstream process components based on the analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional composition measurement methods are used, then measurement accuracy is maintained, but real-time monitoring capability deteriorates

Engineering Contradiction:

Improvecomposition measurement accuracyVSAvoidmeasurement response time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces traditional mechanical/chemical measurement systems with an optical measurement system. An infrared spectrometer is used to direct infrared light through the process stream and detect absorption spectra, which are then analyzed to determine composition. This optical substitution enables real-time measurement without the time delays inherent in traditional laboratory analysis methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary optical path through which infrared light travels the length of the process stream. This optical intermediary allows measurement of the entire stream volume rather than discrete samples, providing both real-time response and accurate representation of overall composition while enabling automated control adjustments.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If manual process adjustment is used, then process stability is maintained, but productivity deteriorates

Engineering Contradiction:

Improveprocess stabilityVSAvoidbitumen recovery rate

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements a closed-loop feedback system where the infrared spectrometer continuously monitors process stream composition, and the controller automatically adjusts process parameters based on real-time composition data. This automated feedback loop maintains process stability while optimizing bitumen recovery rates, eliminating the trade-off between manual stability and automated productivity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system enables self-adjusting process control where the measurement and control system automatically responds to composition changes without human intervention. The controller modifies process parameters based on real-time spectral analysis, allowing the process to self-optimize for maximum bitumen recovery while maintaining stability.

Inventive Principle:

Principle #25Self-service

3Productivity

If increased process water is used, then bitumen separation efficiency is improved, but environmental emissions deteriorate

Engineering Contradiction:

Improvebitumen separation efficiencyVSAvoidenvironmental emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent uses real-time composition measurement to dynamically adjust process parameters including water addition rates. By precisely controlling the amount of process water added based on actual bitumen content measurements, the system optimizes separation efficiency while minimizing excess water usage and associated environmental emissions from tailings management.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables real-time composition estimation and adjustment, improving bitumen recovery performance by reducing process water usage, lowering environmental emissions, increasing throughput, and minimizing downtime.

Implementation Method 1

directing a beam of infrared light toward an opaque bitumen-containing process stream as it passes between stages in the process; capturing light corresponding to the beam of infrared light after interaction with the bitumen-containing process stream

Methodology Applied

Scientific EffectInfrared absorption spectroscopy: Absorption Spectroscopy

Implementation Method 2

directing a beam of infrared light toward an opaque bitumen-containing process stream

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Data Source

PatentUS10668408B2Measurement and control of bitumen-containing process streams

Publication Date: 2020.06.02 SUNCOR ENERGY INC

AI summary

A method and apparatus for analyzing a bitumen-containing process stream and controlling a process. The method including directing a beam of infrared light at the bitumen-containing process stream, capturing light corresponding to the infrared light after interaction with the bitumen-containing process stream, and analyzing the captured light to obtain a spectrum. A composition estimate can be generated based on the spectrum and a calibrated model. A controller is operative to adjust a setpoint of the process in response to the composition estimate.