Effectiveness and mobility of catalysts for gasification of bitumen coke

The compounds K2CO3, KCl, Na2CO3, CaCO3, CaO, and MgO were tested as catalysts for steam gasification of coke from oil sands bitumen at atmospheric pressure and 600–800 °C. Catalysts were added to liquid vacuum residue prior to coke formation and directly to the coke solids. K2CO3 and Na2CO3 were most effective, giving nearly complete conversion at 800 °C in 30 min, regardless of whether they were added before or after coke formation. Ca and Mg compounds did not promote catalytic reactions, nor did they interact physically with the coke based on SEM and EDX analyses. KCl was effective, to a lower extent than K2CO3 and Na2CO3 only at higher temperatures (800 °C). The alkali metal compounds showed high mobility within the coke phase, which was consistent with their catalytic activities.