Multi-level optimization of naphtha hydrotreating catalysts

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The oilsands are an enormous resource for Canada, with over 1.7 trillion barrels of oil in place. With available technology for open-pit mining and in-situ production, the recoverable oil is estimated to be 315 billion barrels, larger than the total reserves of Saudi Arabia. The production of bitumen and synthetic crude reached 1 million barrels per day in 2003, and is expected to increase to between 1.8 and 2.4 million barrels per day by 2015. While current production and upgrading methods are profitable, they are not sustainable if this resource is to be developed to its full potential. During the production of synthetic crude from the oilsands bitumen, catalysts used for the removal of sulfur and nitrogen inevitably deactivate with time due to arsenic deposition and coke accumulation.  In turn, this deactivation reduces the catalyst efficiency and increases the frequency in which the catalyst must be replaced, placing increasing demands on the reactors and production scheduling.  The present research seeks to combine two research foundations in catalysis, namely molecular simulation and experimental validation of predictions, to develop a comprehensive understanding of naphtha catalyst deactivation to support the development of a control and optimization strategy for naphtha hydrotreating reactors. The successful development of naphtha hydrotreating catalysts and process optimization strategy to maximize catalyst life can be rapidly commercialized and implemented into bitumen upgrading processes to increase the productivity and energy efficiency of the hydrotreating operation. The potential impact as a result of this research would be recognized by Canadian economy and industry through the increased utilization of the oilsands bitumen, while decreasing the environmental impact associated with the increased consumption of petroleum-based natural resources.