Catalytic upgrading of heavy oil with supercritical water
AssigneeSaudi Arabian Oil Company
InventorsKi-Hyouk CHOI, Faisal M. ALMULLA
Life of this patent
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Abstract
Embodiments of the disclosure provide a method and system for upgrading heavy hydrocarbons. A heavy hydrocarbon feed and a non-saline water feed are introduced to a first stage reactor. The first stage reactor is operated under supercritical water conditions to produce an effluent stream. The effluent stream and a saline water feed are combined to produce a mixed stream, where the saline water feed includes an alkali or alkaline earth metal compound. The mixed stream is introduced to a second stage reactor. The second stage reactor is operated under supercritical water conditions to produce a product stream including upgrading hydrocarbons. The second stage reactor is operated at a temperature less than that of the first stage reactor.
Claims21
A method for upgrading heavy hydrocarbons, the method comprising the steps of:
- introducing a heavy hydrocarbon feed and a non-saline water feed to a first stage reactor, wherein the heavy hydrocarbon feed comprises the heavy hydrocarbons, wherein the first stage reactor is operated at a pressure equal to or greater than 22.06 MPa and a temperature equal to or greater than 373.9 deg. C. to produce an effluent stream, wherein the effluent stream comprises a product from the first stage reactor;
- combining the effluent stream and a saline water feed to produce a feed stream, wherein the saline water feed comprises an alkali or alkaline earth metal compound, wherein the volume ratio of the saline water feed to the non-saline water feed is between 0.05 and 1, wherein the first stage reactor increases miscibility of the heavy hydrocarbons in the non-saline water, such that the heavy hydrocarbons have increased miscibility in the effluent stream;
- and
- introducing the feed stream to a second stage reactor, wherein the second stage reactor is operated at a pressure equal to or greater than 22.06 MPa and a temperature less than that of the first stage reactor but equal to or greater than 373.9 deg. C. to produce a product stream, wherein conversion reactions and desulfurization reactions take place in the second stage reactor, wherein the increased miscibility of the heavy hydrocarbons increases interaction between the alkali or alkaline earth metal compound in the saline water feed in the second stage reactor, wherein the product stream comprises upgraded hydrocarbons.
A supercritical water system for upgrading heavy hydrocarbons, the supercritical water system comprising:
- a first pump, the first pump configured to pressurize a heavy hydrocarbon feed to a pressure ranging between 27 MPa and 30 MPa, wherein the heavy hydrocarbon feed comprises the heavy hydrocarbons;
- a first heat exchanger, the first heat exchanger configured to heat the heavy hydrocarbon feed to a temperature ranging between 90 deg. C. and 150 deg. C.;
- a second pump, the second pump configured to pressurize a non-saline water feed to a pressure ranging between 27 MPa and 30 MPa;
- a second heat exchanger, the second heat exchanger configured to heat the non-saline water feed to a temperature ranging between 400 deg. C. and 550 deg. C.;
- a first stage reactor, the first stage reactor fluidly connected downstream of the first pump and the first heat exchanger and fluidly connected downstream of the second pump and the second heat exchanger, the first stage reactor operated at a pressure ranging between 27 MPa and 30 MPa and a temperature ranging between 425 deg. C. and 500 deg. C. to produce an effluent stream;
- a third pump, the third pump configured to pressurize a saline water feed to a pressure ranging between 27 MPa and 30 MPa, wherein the saline water feed comprises an alkali or alkaline earth metal compound;
- a third heat exchanger, the third heat exchanger configured to heat the saline water feed to a temperature ranging between 380 deg. C. and 420 deg. C.;
- a mixer, the mixer fluidly connected downstream of the first stage reactor and fluidly connected downstream of the third pump and the third heat exchanger, the mixer configured to combine the effluent stream and the saline water feed to produce a mixed stream;
- and
- a second stage reactor, the second stage reactor fluidly connected downstream of the first separator, the second stage reactor operated at a pressure ranging between 27 MPa and 30 MPa and a temperature ranging between 380 deg. C. and 420 deg. C. to produce a product stream, wherein the product stream comprises upgraded hydrocarbons.
Dependencies are inferred from the claim text.