Process for partial upgrading of heavy oil
AssigneesThe Texas A&M University System, Lteoil LLC
InventorsHoward Jemison, David Staack, Kunpeng Wang
Life of this patent
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Abstract
A process for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the process as a carrier gas used in spark-discharge hydrocarbon cracking within the process. The process also produces light hydrocarbon liquids which are used to upgrade the heavy oil. An apparatus for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the as a carrier gas used in spark-discharge hydrocarbon cracking within the apparatus. The apparatus also produces light hydrocarbon liquids which are used to upgrade the heavy oil.
Claims20
A process for continuously upgrading heavy oil through plasma processing, using spark discharges in a plasma reactor, the process comprising:
- passing, through a heavy oil feed, a heavy oil into a heat exchanger to bring the temperature of the heavy oil to first temperature;
- forcing the heavy oil from the heat exchanger to an inter-electrode gap inside of the plasma reactor, wherein the inter-electrode gap is defined by a distance between a negative electrode and a positive electrode;
- forcing a light hydrocarbon gas into the plasma reactor to mix with the heavy oil therein to form a first mixture in the inter-electrode gap, the first the first mixture comprising the heavy oil and the light hydrocarbon gas;
- generating a spark-discharge in the inter-electrode gap to react the first mixture to generate a reacted first mixture;
- flowing the reacted first mixture into a separator to separate a light hydrocarbon liquid and light hydrocarbon gas from the reacted first mixture;
- adding fresh hydrogen and fresh hydrocarbon gas to the separated light hydrocarbon gas to produce a second mixture and recycling the second mixture to the plasma reactor to increase overall conversion of the heavy oil;
- flowing heavy oil from the separator to the heat exchanger to combine with heavy oil from the heavy oil feed to produce combined heavy oil;
- and
- obtaining upgraded oil by performing at least one of (1) removing the combined heavy oil, or (2) blending the combined heavy oil with the light hydrocarbon liquid.
An apparatus for continuously upgrading heavy oil through plasma processing, the apparatus comprising:
- a heavy oil feed connected to a heat exchanger for conveying heavy oil through the heat exchanger, wherein the heavy oil feed is continuous with a first line connecting the heat exchanger with a first trim exchanger;
- a plasma reactor with a second line configured to deliver heavy oil to the plasma reactor, wherein the second line runs through the first trim exchanger and is continuous with the first line;
- a light hydrocarbon gas feed for conveying fresh light hydrocarbon gas to the plasma reactor to form a mixture in the inter-electrode gap, the mixture including the heavy oil and the light hydrocarbon gas;
- a separator connected to the plasma reactor by a third line, wherein the separator is connected to a fourth line that splits into a recycling line and a fifth line, wherein the recycling line merges with the second line, and the fifth line connects to the heat exchanger, and wherein a sixth line is connected to the separator and splits into a produced light liquids line and a seventh line;
- one or more additional modules, at least one of the one or more additional modules connected to an upgraded oil line for removing upgraded oil from the apparatus;
- wherein the apparatus is configured to recycle at least a portion of heavy liquid product from the separator back to the plasma reactor to increase overall conversion of the heavy oil.
An apparatus for continuously upgrading heavy oil through plasma processing, the apparatus comprising:
- a heavy oil feed connected to a heat exchanger for conveying heavy oil through the heat exchanger, wherein the heavy oil feed is continuous with a first line connecting the heat exchanger with a first trim exchanger;
- a separator connected to the first trim exchanger by a second line, wherein the second line is continuous with the first line;
- a third line connected to the separator, wherein the third line branches into a heavy oil line and a fourth line, wherein the heavy oil line runs through the heat exchanger, and wherein the fourth line connects to a plasma reactor, wherein a fifth line connects the reactor with the separator;
- a sixth line connected to the separator, wherein the sixth line branches into a light hydrocarbon liquid line and a produced light liquid line;
- a seventh line connected to the separator, wherein the seventh line branches into an eight line and a recycle gas line;
- a light hydrocarbon gas feed configured to convey fresh light hydrocarbon gas to the plasma reactor;
- and
- an upgraded oil line for removing upgraded oil from the apparatus.
Dependencies are inferred from the claim text.