Process modelling and simulation of bitumen partial upgrading: Analysis of solvent deasphalting‐thermal cracking configuration

In this study, we investigate a process for partial upgrading of Canadian oil sands bitumen by means of modelling and simulation. In continuation of our previous study focused on a different process configuration for partial upgrading, the process scheme analyzed in this work consists of a solvent deasphalting step to reject asphaltenes from bitumen, a thermal cracking of the deasphalted product step, and a hydrotreating step to saturate the olefins generated by thermal cracking. The model was built using commercial simulation software, incorporating customized models for the solvent deasphalting and thermal cracking units. Trends in partial upgrader product yields and quality are examined under two operating scenarios: one where the thermal cracker operates in once‐through mode and the other where the heavy portion of the thermal cracker product is recycled. Both scenarios were observed to have difficulties in achieving the product quality targets set for partial upgrading (density <0.9400 g/cm 3 at 15.6°C and viscosity <350 cSt at 7°C) without any diluent addition. A key factor that significantly impacts final product yield and quality in this partial upgrading process is the formation of new asphaltenes during thermal cracking.