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.
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).
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.
The Enhanced JetShear and ARP demonstration project is expected to be commissioned in Q3 2016 and yield results over the remainder of the year.
The positive field demonstration of JetShear has led Fractal Systems and its partner to an expansion of the current technology platform to demonstrate increases is diluent displacement and reductions in acidity. The new platform is called Enhanced JetShear with Acid Reduction Process (ARP) and targets diluent displacement up to 60%, olefin content less than 0.5 wt% and TAN levels less than 1 mgKOH/g while maintaining almost 100% yield and pipeline transportation specifications.