Novel energy efficient in-situ bitumen upgrading technology to facilitate pipeline transportation using natural gas: Sustainability evaluation using a new hybrid approach based on fuzzy multi-criteria decision-making tool and techno-economic and life cycle assessment

An assessment of the techno-economics and life cycle impacts of a new in-situ bitumen upgrading technology using natural gas has been conducted in this study. A comparison was also made between the two other commercial technologies such as hydrogen-assisted upgrading (HAU) and dilbit production with the novel proposed methane-assisted upgrading (MAU). To determine the total capital investment (TCI), the total operating cost (TOC), and the energy consumption, a process simulation was undertaken. HAU process has the highest TCI among all the processes and the lowest TCI belongs to dilbit production. In terms of TOC, MAU has the lowest operating costs compared to other technologies. The Internal Rate of Return (IRR) and Payback Period were calculated in three scenarios over the project's lifetime. As a result of the techno-economic analysis, the MAU process has the highest IRR and the shortest payback period for all scenarios. A comparison was also made between the proposed MAU process and other research studies. Results indicate that MAU with the total operating cost of (34.1 $/bbl. bitumen) and transportation cost of (1.1 $/bbl. Bitumen for 500 km pipeline transportation) has the best results. Based on the life cycle assessment results, it was determined that the MAU process has a lower impact on climate change, human toxicity, ecotoxicity, eutrophication potential, and resource usage than the HAU process. Finally, the sustainability index for processes was calculated using a hybrid approach based on fuzzy decision modeling, TEA, and LCA results. As compared to other commercial technologies like dilution, heating, and dilbit production, the MAU process has the highest level of sustainability.