NIR Spectroscopy for Residual Metal Monitoring in Paraffinic Froth Treatment

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Solution Overview

Problem

In bitumen production, high clay contents in oil sands ore lead to reduced recovery rates and lower efficiency in primary separation processes, and there are challenges in monitoring and controlling paraffinic froth treatment (PFT) operations to ensure bitumen quality and reduce off-specification streams.

Innovation Solution

The method involves using near-infrared (NIR) spectral measurements to monitor residual metal concentrations in PFT process streams, adjusting alkaline agent dosage in the primary separation vessel, and controlling operating parameters such as solvent addition and asphaltene rejection based on these measurements to maintain bitumen quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If alkaline agent dosage is increased to improve bitumen recovery and froth quality, then bitumen recovery rate is improved, but residual metal concentration in PFT streams increases

Engineering Contradiction:

Improvebitumen recovery rateVSAvoidresidual metal concentration

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system implements real-time feedback control by continuously monitoring residual metal concentrations in PFT streams using NIR spectroscopy and automatically adjusting alkaline agent dosage in the primary separation vessel based on the monitored levels, maintaining metal concentrations within specifications while optimizing bitumen recovery

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes the dosage parameter of alkaline agents based on real-time metal concentration measurements, adjusting the chemical dosing rate to maintain optimal bitumen recovery while preventing excessive metal accumulation in downstream streams

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If traditional monitoring methods are used for PFT streams, then measurement cost is reduced, but measurement precision and real-time control capability deteriorate

Engineering Contradiction:

Improveresidual metal concentration measurement accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system replaces traditional mechanical/chemical sampling and laboratory analysis methods with optical-based NIR spectroscopy for residual metal measurement, achieving real-time continuous monitoring with high precision while reducing manual intervention and laboratory dependency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses NIR spectral measurements as an intermediary to indirectly determine residual metal concentrations in PFT streams, avoiding direct complex chemical analysis while achieving accurate real-time monitoring through spectral fingerprinting of metal-containing compounds

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If real-time monitoring and control is implemented to maintain bitumen quality, then product quality is improved, but operational complexity increases

Engineering Contradiction:

Improvebitumen product quality consistencyVSAvoidprocess control complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system implements self-regulating control where the monitoring and adjustment mechanisms operate automatically without continuous operator intervention, with the control system self-correcting metal concentrations by adjusting alkaline agent dosage based on real-time NIR measurements

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system establishes closed-loop feedback control for bitumen quality maintenance, where residual metal measurements continuously inform dosage adjustments, ensuring consistent product quality while automating the control process to reduce operational burden

Inventive Principle:

Principle #23Feedback

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 monitoring and control of bitumen quality, improving recovery rates and reducing off-specification streams by adjusting alkaline agent dosage and operating parameters in response to residual metal concentrations, thereby enhancing the efficiency of bitumen production.

Implementation Method 1

acquiring near infrared (NIR) spectral measurements from an NIR probe located online in at least one of the PFT process streams

Methodology Applied

Scientific EffectNear-infrared spectroscopy: Absorption Spectroscopy

Data Source

PatentUS11198821B2Monitoring of residual metals in paraffinic froth treatment operations and process control

Publication Date: 2021.12.14 TRUENORTH ENERGY CORP

AI summary

Techniques provided herein relate to regulating at least one operating parameter of a paraffinic froth treatment (PFT) operation and controlling the quality of the produced bitumen in response to a determined concentration of at least one residual metal in a PFT process stream. Determination of the residual metal concentration is based on acquired NIR spectral measurements of the PFT process stream. An alkaline agent dosage in primary extraction operation can be for example regulated in response to a difference between a determined calcium concentration and a calcium concentration specification.