Systems and methods for separating hydrocarbons with substantially reduced emissions

A reactor for separating a crude oil feedstock into heavy and light fractions, the reactor having a reactor body including:

• a first atomizing system and first atomizing nozzles for introducing and atomizing a feedstock in the reactor body under conditions to effect rapid surface-area generation of the feedstock and separation of the feedstock into heavy and light fractions;
• a heavy-fraction collection and recirculation system (HFCRS) connected to the reactor body, the HFCRS having:
• a heavy fraction product system for selectively removing a heavy fraction product from the reactor;
• and,
• a heavy fraction recirculation system for selectively recirculating and atomizing a portion of the heavy fraction to the reactor through a second atomizing system independent of the introduction of feedstock into the reactor;
• wherein the first and second atomizing systems are separate loops;
• and,
• a light fraction removal system adjacent to the top of the reactor body.

A crude oil refining system comprising one or more production units, each production unit having:

• a reactor for separating the feedstock into heavy and light fractions, the reactor having a reactor body including:
• a first atomizing system for introducing and atomizing feedstock in the reactor body under conditions to effect rapid surface-area generation of the feedstock and separation of the feedstock into heavy and light fractions;
• a heavy fraction removal system connected to a bottom of the reactor body;
• and
• a light fraction removal system adjacent a top of the reactor body;
• a condenser connected to the at least one reactor to receive the light fraction, the condenser having:
• a condenser body;
• a sectioned cooling system configured to the condenser body to condense the light fraction into one or more light hydrocarbon products;
• a light hydrocarbon collection system for selectively removing the one or more light hydrocarbon products;
• a light fraction return system configured between the condenser and the reactor to return un-condensed light fraction gases to the reactor;
• a heavy-fraction collection and recirculation system (HFCRS) connected to the heavy fraction removal system, the HFCRS having:
• a heavy fraction product system for selectively removing a heavy fraction product from the HFCRS;
• and
• a heavy fraction recirculation system for selectively recirculating and atomizing a portion of the heavy fraction to the reactor through a second atomizing system independent of the first atomizing system, and wherein the second atomizing system introduces a portion of the heavy fraction into the reactor independent of the introduction of feedstock into the reactor;
• a control system configured to enable independent and selective control of a feedstock flow rate into the reactor via the first atomizing system and a heavy fraction recirculation rate into the reactor via the second atomizing system.