FlexUp Technology for Heavy-Sour Crude Oil Upgrading
FlexUp is a catalytic process that upgrades heavy-sour crude oil, bitumen, and coal liquefaction products. It improves the value of crude oil by enhancing API gravity, lowering sulfur content, reducing total acid number (TAN), and removing metals and nitrogen. FlexUp requires less operating cost than conventional methods and fits into small field sites for on-site use.
Improving API Gravity
Raising API gravity increases the market value of crude oil. For example, upgrading oil sands bitumen from an API of 10 to 20 removes the need for diluent. Many heavy crudes see a 5% to 20% increase in value from this enhancement.
Reducing Sulfur Content
High sulfur levels (above 1%) often lead to financial penalties between 2% and 5%. FlexUp adjusts sulfur content to meet quality targets, improving the crude’s market value.
Lowering TAN Levels
Feeds with 3% to 4% naphthenic acid face price discounts. Reducing TAN expands the range of compatible refineries, beyond only those designed for high-TAN crude.
Removing Metals and Nitrogen
Crude oil with high metals and nitrogen affects refining performance and downstream catalysts. FlexUp removes these contaminants without reducing its own catalyst life. This reduction helps refiners extend catalyst life and use less process intensity, increasing the crude’s value.
FlexULS for Sulfur and Nitrogen Polishing
FlexULS, developed from FlexUp, focuses on sulfur and nitrogen removal. It reduces sulfur in crude oil or transmix from up to 2,000 parts per million (PPM) to below 10 PPM. This process uses adsorption instead of hydrogen, eliminating the need for hydrogen infrastructure.