Catalytic pyrolysis method and apparatus
AssigneeRacional Energy & Environment Company
InventorRamon Perez-Cordova
Life of this patent
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Abstract
Method includes heating mixture of heavy oil (API<22.3), water, and catalyst in a reactor to form pyrolyzate vapor condensable to form an oil phase lighter than the heavy oil. The feed mixture can include 100 parts by weight heavy oil, 5 to 100 parts by weight water, and 1 to 20 parts by weight solid catalyst particulates, which can include an oxide or acid addition salt of a Group 3-16 metal on a mineral support. Also, an apparatus for treating the heavy oil includes a mixing zone to prepare the emulsion, a transfer line to a pyrolysis zone; and a control system for the pyrolysis zone. Also, a process includes injecting the pyrolyzate in a treatment fluid into an injection well.
Claims31
A process comprising:
- passing to a feed mixture through a line reactor, the mixture comprising 100 parts by weight heavy oil (API<22.3), from about 5 to 100 parts by weight water, and from about 1 to 20 parts by weight solid catalyst particulates comprising a mineral support and an oxide or acid addition salt of a Group 3-16 metal;
- heating the feed mixture in the reactor at a temperature, pressure, and for a period of time sufficient to produce a pyrolyzate vapor phase at an exit from the reactor condensable to form an oil phase lighter than the heavy oil, wherein the mixture comprises an emulsion of the oil, water, and catalyst particulates.
A process comprising:
- contacting an oil contaminated substrate comprising a Group 3-16 metal and a peptizable matrix component selected from acid-reactive clays and minerals, with an acidic reagent to form a peptizate;
- mixing the peptizate with a combustion effluent gas comprising less than about 1 volume percent oxygen, under turbulent conditions at a temperature above 200° C., to form a light phase comprising desorbed oil and a dense phase;
- recovering solid particulates from the light phase, the dense phase, or a combination thereof;
- feeding to a reactor a feed mixture comprising 100 parts by weight heavy oil (API<22.3), from about 5 to 100 parts by weight water, and from about 1 to 20 parts by weight of the recovered solid particulates;
- and
- heating the feed mixture in the reactor at a temperature, pressure, and for a period of time sufficient to produce a pyrolyzate vapor phase at an exit from the reactor condensable to form an oil phase lighter than the heavy oil.
A process comprising:
- preparing an emulsion of 100 parts by weight heavy oil (API<22.3), from about 5 to 100 parts by weight water, and from about 1 to 20 parts by weight solid catalyst particulates comprising a mineral support and an oxide or acid addition salt of a Group 8-10 metal;
- spraying the emulsion into a vapor phase of a pyrolysis reactor;
- heating the emulsion in the reactor to a temperature above 300° C., at a pressure of about 1-1.5 atmospheres, and for a period of time sufficient to produce a pyrolyzate vapor phase at an exit from the reactor;
- removing entrained fines from the vapor phase;
- and
- condensing the pyrolyzate to form an oil phase lighter than the heavy oil.
Dependencies are inferred from the claim text.