Project Overview
Axonai Energy Services was selected by a leading Canadian oil sands operator to design and implement an upgrade to their existing sand separation and de-oiling facilities. The project aimed to address declining separation efficiency due to changing feed characteristics and to reduce the high operational costs associated with downstream equipment wear and frequent maintenance. The total investment for the upgrade project was approximately $4.2 million CAD.
The existing facilities struggled with high solids carryover in the bitumen froth and significant oil content in the separated tailings, leading to both production losses and environmental concerns. Axonai's task was to deliver a robust, cost-effective solution to enhance overall separation performance.
Challenges Faced
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Highly abrasive nature of oil sands causing rapid wear on separation equipment.
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Varying feed composition (bitumen, water, solids content) impacting separation consistency.
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Need to minimize bitumen losses in tailings to maximize recovery.
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Reducing oil content in tailings to meet stricter environmental discharge limits.
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Integrating new technology within the existing plant footprint and minimizing shutdown time for the upgrade.
Axonai's Solution & Services
Axonai delivered a tailored separation enhancement solution:
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Advanced Process Audit & Modeling: Conducted a detailed analysis of the existing separation process and used advanced modeling to identify key bottlenecks and areas for improvement.
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Technology Retrofit & Upgrade: Designed and managed the installation of high-efficiency cyclonic separators and enhanced de-oiling units, incorporating wear-resistant materials.
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Process Control Optimization: Implemented an improved process control strategy with real-time monitoring to adapt to varying feed conditions and optimize chemical dosage for de-oiling.
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Commissioning & Performance Testing: Oversaw the commissioning of the upgraded facilities and conducted rigorous performance testing to verify operational targets were met.
Results & Benefits
Bitumen Recovery Increased by 3%
Resulting in substantial additional revenue for the client.
Solids in Bitumen Froth Reduced by 40%
Improving downstream processing efficiency and product quality.
25% Reduction in Downstream Maintenance Costs
Due to lower solids carryover and equipment wear.
Compliance with Tailing Oil Content Limits
Ensuring environmental regulations were consistently met.
The $4.2 million CAD investment in the upgrade is projected to yield a full payback within 2.5 years through increased recovery and reduced operational costs.
Client Testimonial
"Axonai's separation technology expertise was crucial in upgrading our oil sands processing facility. The project was managed professionally, delivered on time, and the performance improvements have exceeded our expectations, leading to significant operational cost savings and better bitumen recovery. The $4.2M CAD investment is already showing a strong ROI."