Demonstrating an Innovative Bitumen Upgrading System
This project was a follow-on to the Molten Sodium Upgrading Pilot Plant project and was funded through ERA’s Oil Sands Innovation call in 2018. Enlighten Innovations proposed a demonstration pilot of its proprietary DSU® technology to confirm its commercial applications; however, it was ultimately terminated prior to completion.
Enlighten Innovation’s DSU® technology selectively targets the components of bitumen and other heavy petroleum feedstocks that reduce the value of an upgraded product, without reducing the volume. These components include sulphur, heavy metals and the total acidic number (TAN). While the technology initially focused on upgrading transportation fuels, marine fuel was determined as the best initial market. This technology results in a near pipeline-ready product, with no sulphur oxide emissions and lower greenhouse gas (GHG) lifecycle emissions.
The DSU® process can be separated into three main process sections: (1) the reactor, (2) the oil-solids separator and (3) sodium recovery. First, sodium, hydrogen and heavy oil are mixed in a reactor. The sodium eliminates sulphur and metal atoms from the heavy oil molecules, and the hydrogen helps make the product oil ‘lighter’. Next, the oil-solids separator separates the solid metals and sodium sulphide from the oil through a process called electrolysis. Finally, in the sodium recovery section, sodium is separated from the sodium sulphide through a process called electrolysis, where a direct current is passed through the sodium sulphide, causing the reaction. This sodium is then recycled back to the reactor, making the DSU® process unique and cost-effective.
Repurposing DSU®for Sodium Batteries
During the project, Enlighten aimed to show that the scale-up risk was eliminated, validate the commercial assumptions, confirm utility demands and produce a DSU® marine fuel product that meets market specifications. This work on the main technology was paused in September 2022 to pursue a spin-off technology for sodium-sulphur flow batteries. Enlighten successfully repurposed the electrolysis section of the plant into a working sodium-based flow battery. This system operates by storing electrical energy in liquid electrolytes, which can be charged and discharged to the grid in cycles. It offers a promising solution for storing surplus renewable energy, such as from wind or solar, when generation exceeds grid demand and releasing it when demand is higher. Enlighten ran the flow battery for over 1,000 hours in 2023 and continues to refine the design, highlighting a new commercial pathway for the core technology.
In 2024, the funding relationship with the project was terminated partway through the construction of the demonstration. Despite the cancellation, Enlighten learned key lessons for future technology demonstrations. These takeaways included the importance of early and complete mechanical specifications, especially when working with exotic materials, and maintaining up-to-date engineering documents to avoid complications. Additionally, the team emphasized starting quality control and procurement processes early and keeping close communication with suppliers to avoid delays. Strong on-site collaboration and consistent survey work were also important for staying on schedule.
What’s next?
Since the funding relationship with the project terminated in early 2024, Enlighten has stated that they are working to secure additional investment in the company, but do not have a timeline to complete this fundraising. Enlighten says they hope to run the plant partially constructed during this project and further develop the DSU® technology and the sodium flow battery.