Apparatus for Upgrading Crude Oil and System Incorporating Same

Abstract

A scalable system for producing upgraded crude oil includes one or more production lines. Bach of the one or more production lines comprises an oil well, an upgrader using microwave radiation operably associated with the oil well, and a pump operably associated with the upgrader. The upgrader is constructed to reduce the viscosity of and increase the API gravity of crude oil. A method for scalably upgrading crude oil includes providing an upgrader using a microwave radiation proximate an oil well, producing crude oil from the oil well, and transporting the crude oil to the upgrader. The method further includes upgrading the crude oil in the upgrader and transporting the upgraded crude oil away from the upgrader.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an apparatus for upgrading crude oil and a system incorporating the apparatus.

2. Description of Related Art

Crude oil must be transported from where it is extracted from an underground reservoir to a refinery where it is refined into marketable products. As the specific gravity and viscosity of oil varies from reservoir to reservoir, the methods of transportation vary. For example, certain heavier oils embedded in oil sands may be shoveled out of the ground and transported by truck. Other heavier oils, produced from wells, are heated after exiting the wellhead and pumped to a local storage tank. Periodically, oil is extracted from the tank and transported by truck or other means to a central processing facility. In some situations where heavier oil is produced from wells, a diluent is mixed with the oil to reduce its viscosity prior to injection into a transportation pipeline which transports the combined oil and diluent to a central processing facility. By contrast, lighter oils may be directly injected into a pipeline which transports the oil to a central processing facility. The processing facility may be, for example, an input stage of a refinery, or the processing facility may be an upgrading facility, the output of which is then transported to the refinery.

Conventional upgrading facilities are designed to handle large volumes, e.g., 100,000 barrels, of crude oil per day and are typically located proximate refineries. Such large scale facilities require significant financing to complete, often in the billions of dollars. Projects of this magnitude require complex design, approval, and procurement rules that significantly increase the time required to bring crude oil to market. Furthermore, it is virtually impossible to match the capacity of such large facilities to the capacity of the oil-producing infrastructure. Crude oil is produced from individual wells, which are drilled one at a time. Production capacity, therefore, increases in small increments, while large upgrading facilities typically have gross amounts of excess capacity as production capacity is being increased. This mismatch in synchronization of production and processing capacity leads to an underutilization of capital as, at any one time, the production capacity will exceed the processing capacity or vice versa.

There are many designs for upgrading crude oil well known in the art, however, considerable shortcomings remain.

BRIEF SUMMARY OF THE INVENTION

In one aspect, the present invention provides a scalable system for producing upgraded crude oil comprising one or more production lines. Each of the one or more production lines comprises an oil well, an upgrader operably associated with the oil well, and a pump operably associated with the upgrader. The upgrader is constructed to reduce the viscosity of and increase the API gravity of the crude oil.

In another aspect of the present invention, a method for scalably upgrading crude oil is provided. The method includes providing an upgrader proximate an oil well, producing crude oil from the oil well, and transporting the crude oil to the upgrader. The method further includes upgrading the crude oil in the upgrader and transporting the upgraded crude oil away from the upgrader.

The present invention provides significant advantages, including: (1) providing a way to upgrade crude oil that is scalable with respect to the production capacity of wells within the system; (2) providing a way to allow heavy crude oil to be transported without the use of a diluent; (3) providing a way to upgrade crude oil that is less expensive than conventional means; and (4) providing a way to upgrade crude oil that can be more quickly implemented than conventional means.

Additional objectives, features, and advantages will be apparent in the written description which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings in which the leftmost significant digit(s) in the reference numerals denote(s) the first figure in which the respective reference numerals appear, wherein:

FIG. 1 is a graphical representation of an upgraded crude oil production line;

FIG. 2 is a graphical representation of a system for producing upgraded crude oil;

FIG. 3 is a stylized depiction of a first illustrative embodiment of a crude oil upgrader of FIG. 1;

FIG. 4 is a stylized depiction of a second illustrative embodiment of a crude oil upgrader of FIG. 1;

FIG. 5 is a stylized depiction of a third illustrative embodiment of a crude oil upgrader of FIG. 1;

FIG. 6 is a stylized depiction of a fourth illustrative embodiment of a crude oil upgrader of FIG. 1;

FIG. 7 is a graphical representation of an embodiment wherein upgraded, light hydrocarbons are routed to ancillary equipment;

FIG. 8 is a graphical representation of an embodiment, alternative to the embodiment of FIG. 7, wherein upgraded, light hydrocarbons are routed to ancillary equipment;

FIG. 9 is a graphical representation of an embodiment wherein upgraded, light hydrocarbons are routed to an electrical power generator;

FIG. 10 is a graphical representation of an embodiment wherein upgraded, light hydrocarbons are routed to a steam generator;

FIG. 11 is a graphical representation of an upgraded crude oil production line including an oil/water separator;

FIG. 12 is a graphical representation of an illustrative embodiment of one particular crude oil upgrader;

FIG. 13 is a graphical representation of an illustrative embodiment of another particular crude oil upgrader

FIG. 14 is a graphical representation of an illustrative embodiment of a production line alternative to that of FIG. 1; and

FIG. 15 is a graphical representation of an illustrative embodiment of a system of controlled upgraders.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

The present invention relates to the scalable upgrading of crude oil. In one embodiment, a scalable system for producing upgraded crude oil includes one or more production lines. Each of the one or more production lines comprises an oil well, an upgrader operably associated with the oil well, and a pump operably associated with the upgrader. The upgrader is constructed to reduce the viscosity of and increase the American Petroleum Institute (API) gravity of crude oil using various techniques including, but not limited to, microwave radiation.

In another embodiment, a method for scalably upgrading crude oil includes providing an upgrader proximate an oil well, producing crude oil from the oil well, and transporting the crude oil to the upgrader. The method further includes upgrading the crude oil, such as, for example, by irradiating the crude oil in the upgrader with microwave radiation to upgrade the crude oil, and transporting the upgraded crude oil away from the upgrader.

FIG. 1 depicts a graphical representation of an upgraded production line 101 for producing crude oil. Production line 101 comprises a well 103 from which crude oil is produced, an apparatus 105 for upgrading the crude oil from well 103, also referred to herein as an “upgrader” 105, and a pump 107 for transporting upgraded crude oil from upgrader 105 to another desired location, such as to a pipeline, a refinery, or the like. Upgrader 105 is particularly useful in decreasing the viscosity and/or increasing the API gravity of heavy crude oil produced from well 103, known as “upgrading” the crude oil, so that the upgraded crude oil, sometimes referred to as “synthetic crude,” can be efficiently transported to a desired location. For purposes of this disclosure, the term “heavy crude oil” means crude oil that has an API gravity of less than about 22.3° . However, upgrader 105 can be used with crude oils other than heavy crude oils. In one embodiment, upgrader 105 has a capacity for upgrading crude oil that corresponds to the output of crude oil from well 103. In some embodiments, a heater 109 is provided to heat crude oil produced from well 103, so that the crude oil is more easily transported to upgrader 105. The inclusion of heater 109, however, is not required. In one embodiment, heater 109 is a resistive heater operatively associated with the pipe or line used to transport the crude oil from well 103 to upgrader 105. The resistive heater heats the crude oil through the transport pipe or line.

FIG. 2 depicts a graphical representation of a system 201 for producing upgraded crude oil. System 201 comprises one or more production lines 101 (shown in FIG. 1), which are referred to in FIG. 2 as production lines 101a, 101b, . . . , 101n. Thus, system 201 may comprise one production line 101 or a plurality of production lines 101, up to a desired number (n) of production lines 101. Each of production lines 101, i.e., production lines 101a, 101b, . . . , 101n, comprises an oil well 103, referred to in FIG. 2 as oil wells 103a, 103b, . . . , 103n, and an upgrader 105, referred to in FIG. 2 as upgraders 105a, 105b, . . . , 105n. Each of production lines 101 further comprises a pump 107, referred to in FIG. 2 as pumps 107a, 107b, . . . , 107n, which urge upgraded crude oil into a transportation line or pipeline 203. As more wells 103 are brought on-line, each well 103 is operably associated with an upgrader 105. Thus, as the overall production capacity of a field comprising oil wells 103a, 103b, . . . , 103n increases, the overall upgrading capacity of system 201 is correspondingly increased.

FIG. 3 depicts a first illustrative embodiment of an upgrader 301, which corresponds to upgrader 105 of FIG. 1 and upgraders 105a, 105b, . .. , 105n of

FIG. 2. In the illustrated embodiment, upgrader 301 comprises an inlet chute 303, a conveyor 305, a solids output chute 307, an upgraded oil receiving tray 309, a gas outlet 311, and a microwave irradiation system 312. Microwave irradiation system 312 comprises a microwave generator 313 and one or more microwave antennas 314 operably associated with microwave generator 313. Heavy oil 315 is introduced into upgrader 301 via inlet chute 303, as indicated by arrow 317, which leads heavy oil 315 onto a perforated belt 319 of conveyor 305. As conveyor 305 rotates, as indicated by arrow 321, heavy oil 315 is moved along beneath microwave antennas 314, which are used to propagate microwave radiation into heavy oil 315. Microwave radiation at least partially upgrades heavy oil into upgraded oil 323, such as medium-gravity oil and/or light-gravity oil. For the purposes of this disclosure, the term “medium-gravity oil” means oil that exhibits an API gravity within a range of about 22.3° to 31.1°. The term “light-gravity oil,” for the purposes of this disclosure, means oil that exhibits an API gravity greater than about 31.1°.

Still referring to FIG. 3, upgraded oil 323 passes through the perforations of perforated belt 319 of conveyor 305 into upgraded oil receiving tray 309. Tray 309 receives and funnels upgraded oil 323 into an upgraded oil output line 325 which leads, as indicated by arrow 327, to pump 107 (shown in FIG. 1). Remaining solids are fed by conveyor 305 into solids output chute 307, which directs the solids to a suitable container, such as a barrel 329. Gases produced during the microwave irradiation of heavy oil 315 are channeled, as indicated by arrow 331, through gas outlet 311 to a suitable storage facility, for burn-off, or for other uses, as discussed in greater detail herein with reference to FIGS. 7-10. Upgrader 301 further includes a container 333 that houses microwave antennas 314 and heavy oil 315 as heavy oil 315 is being irradiated and, thus, upgraded. In one embodiment, a vacuum pump 335 is operatively associated with container 333 to provide a sub-atmospheric pressure environment within container 333. In another embodiment, an inert gas 337 is provided within container 333 to provide an environment including the inert gas within container 333. In one embodiment, inert gas 337 is nitrogen.

FIG. 4 depicts a second illustrative embodiment of an upgrader 401, corresponding to upgrader 105 of FIG. 1. In the illustrated embodiment, upgrader 401 comprises a microwave reactor 403, a microwave irradiation system 405, one or more vacuum pumps 407, and one or more vacuum lines 409 extending between and in fluid communication with microwave reactor 403 and the one or more vacuum pumps 407. Microwave reactor 403 comprises an atomizer 411 disposed in a vessel 413. Microwave irradiation system 405 comprises one or more microwave generators 415, one or more microwave antennas 417, and one or more microwave waveguides 419 operably coupling the one or more microwave generators 415 and the one or more microwave antennas 417. An upgraded oil outlet 421 and a gas outlet 423 extend from and are in fluid communication with vessel 413. An input pump 425 is in fluid communication with vessel 413 via an input line 427.

Heavy oil is pumped from a well 429, by input pump 425, via input line 427, into vessel 413 of microwave reactor 403. The heavy oil is atomized by atomizer 411. Atomized, heavy oil 431 is irradiated by microwave radiation generated by the one or more microwave generators 415 and emitted by the one or more microwave antennas 417 to at least partially upgrade atomized, heavy oil 431 into upgraded oil and solids. Vacuum pump 407 maintains a pressure of less than one standard atmosphere within vessel 413. In one embodiment, vacuum pump 407 maintains a pressure within vessel 413 of less than about 100 millimeters of mercury (mm Hg), less than about 40 mm Hg, or less than about 20 mm Hg. Upgraded oil is retrieved from microwave reactor 403 via upgraded oil outlet 421, and hydrocarbon-containing gases are removed from microwave reactor 403 via gas outlet 423.

FIG. 5 is a stylized depiction of a third illustrative embodiment of an upgrader 501, corresponding to upgrader 105 of FIG. 1. The illustrated embodiment incorporates the elements of upgrader 401 (shown in FIG. 4) and further includes a crude oil heating means 503, such as a reboiler, a convection heating means, a conduction heating means, an irradiation heating means, or the like, disposed inline with input line 427. Crude oil produced from well 429 is heated by heating means 503, then pumped to microwave reactor 403. Heating means 503 heats crude oil to a temperature of at least about 250° C., or at least about 300° C., or at least about 350° C., or at least about 400° C., or at least about 450° C., or at least about 500° C. It should be noted that the present invention contemplates incorporating heating means 503 into upgrader 301 (shown in FIG. 3), such that heating means 503 heats crude oil 315 prior to the crude oil being disposed on conveyor 305.

FIG. 6 is a stylized depiction of a fourth illustrative embodiment of an upgrader 601, corresponding to upgrader 105 of FIG. 1. The illustrated embodiment incorporates the elements of upgrader 401 (shown in FIG. 4) and further includes an electron activator pump 603, disposed inline with input line 427, for introducing an electron activator, represented by arrow 605, into the crude oil prior to the crude oil being introduced into microwave reactor 403. It should be noted that the present invention contemplates incorporating electron activator pump 603 into upgrader 301 (shown in FIG. 3), such that electron activator pump 603 introduces electron activator 605 into the crude oil prior to the crude oil 315 being disposed on conveyor 305.

The addition of an electron activator to the crude oil, for example about two percent by weight of crude oil, gives rise to a much faster, more efficient absorption of microwaves to yield more efficient cracking of the crude oil. The electron activator made using microwave processing of tire chips described in U.S. Patent Application Publication US 2007/0131591, is one suitable electron activator for the present process. A suitable electron activator is preferably provided as a fine powder, for example of about 100 mesh or finer. However, the electron activator may be coarser than 100 mesh, depending on the precise application and handling requirements. Without being limited by any particular theory of operation, the electron activator enhances the absorption of microwaves by the crude oil, which gives rise to faster and more efficient processing of the crude oil. The electron activator, which comprises carbon powder particulates, is capable of absorbing microwave radiation. Solid particles containing residual hydrocarbons, such as electron activator, result in popping (as in popcorn) when irradiated. Without being bound by any particular theory of operation, it is believed that the popping action of the electron activator particles within the crude oil enhances the microwave processing of the crude oil. In certain embodiments, the electron activator functions as a catalyst for effectuating the microwave cracking process.

In upgrader 105 (shown in FIG. 1), including upgrader embodiments 301, 401, 501, and 601 (shown in FIGS. 3, 4, 5, and 6, respectively), suitable microwave radiation frequencies range between about 4 gigahertz (GHz) and about 18 GHz. In some embodiments, microwave frequencies are generated within a range between about 8.0 GHz and about 8.8 GHz, within a range between about 8.1 GHz and about 8.7 GHz, within a range between about 8.2 GHz and about 8.6 GHz, or within a range between about 8.3 GHz and about 8.5 GHz. Moreover, the microwave frequency may be, in certain embodiments, about 8.4 GHz. Microwaves may exhibit a single frequency or different microwave antennas, such as microwave antennas 314 (shown in FIGS. 3) and 417 (shown in FIGS. 4-6), may emit microwaves of different frequencies. When the microwave frequencies differ, the frequencies are separated in increments of about 0.2 GHz in some embodiments. The microwave radiation may be applied in a “sweeping” or “pulsing” regimen. “Sweeping,” as the term is used herein, is defined as the application of a plurality of radiation frequencies over a period of time. “Pulsing,” as used herein, means the application of microwave radiation for a period of time, followed by a period of time wherein microwave radiation is not applied. The scope of the present invention, however, is not so limited. Rather, the particular frequency or application regimen is implementation specific and, thus, the present invention contemplates any suitable microwave radiation frequency and application regimen.

As discussed herein, light hydrocarbons, such as hydrocarbon gases, can be channeled away from the upgrader, such as upgraders 105, 301, 401, 501, or the like to a suitable storage facility or for burn-off. Alternatively, the present invention contemplates using at least a portion of such light hydrocarbons produced from the upgrading process for operating equipment that is ancillary to the crude oil production and/or crude oil upgrading processes. For example, FIG. 7 depicts an embodiment, wherein ancillary equipment 701 is coupled with one or more gas outlets 311 (shown in FIG. 3) or 423 (shown in FIGS. 4-6). Light hydrocarbons, such as hydrocarbon gases, that are channeled via gas outlets 311 or 423 to ancillary equipment 701 are utilized by ancillary equipment 701 in the operation of ancillary equipment 701. In another embodiment, shown in FIG. 8, a feed line 801 extends between and is in fluid communication with ancillary equipment 701 and gas outlet 311 and/or 423. Thus, only a portion of the light hydrocarbons that are channeled via gas outlets 311 or 423 are routed to ancillary equipment 701, while the remaining light hydrocarbons are channeled for storage or burn-off.

Ancillary equipment 701 may include a single device, apparatus, or system, or a plurality of devices, apparatuses, or systems. Examples of ancillary equipment 701 contemplated by the present invention include any device, apparatus, or system that can operate or benefit from using at least a portion of the light hydrocarbons produced from the crude oil upgrading process. It should be noted that light hydrocarbons may be in the form of liquids or gases. For example, as shown in FIG. 9, feed line 801 is coupled with an electrical power generator 901. Thus, at least a portion of the light hydrocarbons produced by upgrader 105, 301, 401, 501, or the like and channeled via gas outlet 311 or 423 is used to operate electrical power generator 901. Electrical power produced by electrical power generator 901 is routed to an upgrader 903, such as upgrader 105, 301, 401, 501, or the like, to operate upgrader 903. Alternatively or additionally, electrical power produced by electrical power generator 901 is routed to other equipment 905 to operate other equipment 905, such as other equipment related to the production, upgrading, and/or distribution of crude oil. It should be noted that the embodiment of FIG. 9 may also be configured such that all of the light hydrocarbons channeled by gas outlet 311 or 423 is used by electrical power generator 901, as shown in FIG. 7.

In another example, shown in FIG. 10, at least a portion of the light hydrocarbons produced from the crude oil upgrading process is used to operate a steam generator 1001. Feed line 801 is coupled with steam generator 1001 to deliver at least a portion of the light hydrocarbons channeled via gas outlet 311 or 423 to steam generator 1001. In one embodiment, steam generated by steam generator 1001 is routed to well 429 for use in stimulating the reservoir. It should be noted that steam generator 1001 may be disposed at the surface or inside well 429 proximate the production zone. Moreover, a single steam generator may be coupled to a plurality of wells 429 or the like. Steam generated by steam generator 1001 may alternatively or additionally be routed to other equipment 1003, such as other equipment related to the production, upgrading, and/or distribution of crude oil. It should be noted that the embodiment of FIG. 10 may also be configured such that all of the light hydrocarbons channeled by gas outlet 311 or 423 is used by steam generator 1001, as shown in FIG. 7.

Referring now to FIG. 11, many crude oil upgrading technologies require that the crude oil to be upgraded include little water. Accordingly, it is particularly useful in situations wherein the crude oil to be upgraded includes significant amounts of water for an upgraded production line 1101 to include an oil/water separator 1103 in-line before upgrader 105. In other words, production line 1101 includes oil well 103 that is operatively associated with oil/water separator 1103. In turn, oil/water separator 1103 is operatively associated with upgrader 105, such that water is separated from the crude oil and oil is provided to upgrader 105. Upgrader 105 is operatively associated with pump 107.

While FIGS. 3-6 depict upgraders 301, 401, 501, and 601 as utilizing microwave energy to upgrade the crude oil, the scope of the present invention is not so limited. Rather, the present invention contemplates many different techniques for upgrading crude oil, such as, but not limited to, removal of water, sand, physical waste and lighter products; catalytic purification by hydrodemetallization, hydrodesulfurization, and hydrodenitrogenation; hydrogenation through carbon rejection or catalytic hydrocracking; desalting; distillation; deasphalting; thermal cracking; coking; hydroconversion; and/or the like. In each embodiment, however, the upgrader services one or a few oil wells, rather than being a centralized upgrader that services many wells. Upgrader 105, shown in FIG. 1, referred to in FIG. 2 as upgraders 105a, 105b, . . . , 105n, may utilize one or more technologies for upgrading crude oil. In one embodiment, upgrader 105 is an upgrader employing a hydroretorting process, such as the “Chattanooga Process” offered by Chattanooga Corporation of Bradenton, Florida, USA; the hydroretorting process disclosed in U.S. Pat. No. 4,075,081, or the like. In another embodiment, upgrader 105 is an alternate activation upgrader, in which energy is added to the crude oil to facilitate upgrading. In yet another embodiment, upgrader 105 is a demetallizing upgrader, in which selective separations are applied to remove hydrocarbon structures trapping metals. In another embodiment, upgrader 105 is a direct froth upgrader, in which water and/or solids are substantially removed from the crude oil.

In yet another embodiment, upgrader 105 is an upgrader that utilizes oxygen and steam to partially oxidize the crude oil, producing hydrogen for immediate pick up and resulting in integrated recovery and significant upgrading. In another embodiment, upgrader 105 is a selective separation upgrader, in which the crude oil is physically and/or chemically separated into fractions, leading to segregated and more targeted process steps, including more efficiently targeted hydrogen addition. In yet another embodiment, upgrader 105 is an upgrader in which a thin-film coking process is utilized, such as fluid coking; the “Ensyn Process” offered by Ensyn Technologies, Inc. of Ottawa, Ontario, Canada; or the like. In another embodiment, upgrader 105 is an upgrader in which thermal processes are used to upgrade the crude oil. In yet another embodiment, upgrader 105 includes a slurry reactor, in which fine catalyst particles are carried by the crude oil and hydrogen in a high pressure reactor.

In another embodiment, upgrader 105 is an upgrader that utilizes a bulk thermal process, such as “visbreaking;” visbreaking variants; the “ORMAT Process,” offered by ORMAT Technologies, Inc. of Reno, Nev., USA; or the like. In yet another embodiment, upgrader 105 is an ebullated bed hydroconversion upgrader. Such an upgrader uses a fluidized bed of hydroprocessing catalyst with continuous addition and removal of catalyst to maintain system activity. In another embodiment, upgrader 105 is an upgrader that utilizes light solvents to selectively remove high molecular weight asphaltenes, i.e., “deasphalting,” and the associated heavy metals. In yet another embodiment, upgrader 105 utilizes fixed bed hydroprocessing to upgrade the crude oil. In another embodiment, upgrader 105 utilizes delayed coking or fluid coking to upgrade the crude oil. In yet another embodiment, upgrader 105 utilizes catalysis to upgrade the crude oil.

In another embodiment, upgrader 105 includes a ceramic membrane to separate asphaltenes from the crude oil, such as described in U.S. Pat. No. 5,785,860. In yet another embodiment, upgrader 105 hydrotreats the crude oil by processing the crude oil with hydrogen in the presence of a catalyst composition comprising an activated carbon component, a molybdenum component, and a cobalt or nickel component, such as described in U.S. Pat. No. 5,374,350. In another embodiment, upgrader 105 utilizes a process in which the crude oil is contacted with hydrogen in a reactor containing an activated carbon catalyst, such as described in U.S. Pat. No. 5,358,634. In yet another embodiment, upgrader 105 utilizes a process in which an oxygen source and a hydrogen source are ignited and the resulting synthetic gas is used to initiate a predominately gas phase heavy oil upgrade reaction that is subsequently quenched with an additional source of un-upgraded hydrocarbon, such as described in U.S. Pat. No. 6,852,215. In another embodiment, upgrader 105 includes a solvent desaphalting unit, such as described in U.S. Pat. No. 5,976,361.

Referring now to FIG. 12, one particular embodiment of upgrader 105 comprises a hydrocracker 1201, and a hydrotreater 1203. In this embodiment, hydrocracker 1201 is a processing unit for reducing heavy hydrocarbons into lighter fractions, using hydrogen and a catalyst. Hydrotreater 1203 is a unit that removes sulfur, nitrogen, and the like from the components of crude oil by the catalytic addition of hydrogen. In some embodiments, hydrotreater 1203 is omitted.

Referring now to FIG. 13, one particular embodiment of upgrader 105 upgrades crude oil into upgraded crude oil using a continuous, short contact time thermal conversion process, such as “Rapid Thermal Processing” offered by Ivanhoe Energy of Vancouver, British Columbia, Canada. In the illustrated embodiment, crude oil is fed into a rapid thermal processing reactor 1301, wherein the crude oil is atomized and mixed with hot circulating silica sand. The mixture is transported up and through a reaction zone of reactor 1301 by a transport or carrier gas, such as recycle product gas or by-product gas. Rapid mixing of the oil and sand promotes heat transfer and thermal cracking of the crude oil. Carbon is rejected as the long hydrocarbon chains are cracked and coke is deposited on the sand during thermal conversion. When the long chain hydrocarbons are cracked, the boiling point is reduced and the cracked product is vaporized. The coke covered sand, vapor, i.e., cracked crude oil, transport gas, and feed that survive the first pass in reactor 1301 are routed to a high temperature cyclone system 1303, as indicated by arrow 1305, and separated in high temperature cyclone system 1303. The fluids are quenched rapidly and vapors condensed with light oil to maximize liquid yield and minimize undesirable secondary thermal cracking reactions. A very short residence time is required between the feed injection point at reactor 1301 and the quench point. Typically, residence times less than a few seconds are targeted. Following quenching, the upgraded crude oil is routed to a transportation pipeline or storage facility. It should be noted that the upgraded crude oil may be further processed by various methods after exiting upgrader 105.

Still referring to FIG. 13, the coke covered sand from reactor 1301 is routed to a reheater 1307, as indicated by arrow 1309, for carbon removal. Air is used to fluidize the sand and facilitate combustion in reheater 1307. Sand that has been processed to remove carbon is routed back to reactor 1301, as indicated by an arrow 1311, for reuse in reactor 1311.

It should be noted that, while one upgrader may be coupled with each well, the scope of the present invention is not so limited. Rather, as shown in FIG. 14, a production line 1401 includes several wells 103, represented in FIG. 14 as 103a, 103b, . . . , 103n, coupled with one upgrader 105. A group of several wells 103a, 103b, . . . , 103n may originate from a single pad in the oilfield. One or more heaters 109 (shown only in FIG. 1) may be included to heat crude oil produced from wells 103a, 103b, . . . , 103n so that the crude oil is more easily transported to upgrader 105. As in the embodiment of FIG. 1, pump 107 transports upgraded crude oil from upgrader 105 to another desired location, such as to a pipeline, a refinery, or the like. In the illustrated embodiment, crude oil produced from wells 103a, 103b, . . . , 103n is collected in a tank 1405 before being upgraded by upgrader 105. In one embodiment, a capacity of upgrader 105 generally corresponds to a crude oil production rate of wells 103a, 103b, . . . , 103n.

FIG. 15 depicts an illustrative embodiment of a system 1501 of managed upgraders 105, represented in FIG. 15 as 105a, 105b, . . . , 105n. Each upgrader 105a, 105b, . . . , 105n is outfitted with one or more sensors to monitor its operating conditions, such as, but not limited to, temperatures of products inputted to and outputted from upgraders 105a, 105b, . . . , 105n; operating pressures of upgraders 105a, 105b, . . . , 105n; power used by upgraders 105a, 105b, . . . , 105n; conditions of products inputted to and outputted from upgraders 105a, 105b, . . . , 105n; and the like. The conditions of products inputted to and outputted from upgraders 105a, 105b, . . . , 105n include, but are not limited to, API gravity, viscosity, water content, metal content, and the like. The one or more sensors operatively associated with upgraders 105a, 105b, . . . , 105n are read by corresponding remote terminal units (“RTU”) 1503a, 1503b, . . . , 1503n or the like and transmitted over corresponding links 1505a, 1505b, . . . , 1505n to a controller 1507, such as a supervisory control and data acquisition (SCADA) controller. Links 1505a, 1505b, . . . , 1505n may be hard-wired links or wireless links, depending upon the implementation. Controller 1507 controls the operations of upgraders 105a, 105b, . . . , 105n based upon at least the sensed operating conditions at upgraders 105a, 105b, . . . , 105n.

The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope of the invention. Accordingly, the protection sought herein is as set forth in the claims below. Although the present invention is shown in a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications.

Claims

1. A scalable system for producing upgraded crude oil, comprising:

one or more production lines, each of the one or more production lines comprising: an oil well; an upgrader operably associated with the oil well, the upgrader constructed to reduce the viscosity of and increase the API gravity of crude oil; and a pump operably associated with the upgrader.

2. The system of claim 1, wherein the upgrader uses microwave radiation to reduce the viscosity of and increase the API gravity of the crude oil.

3. The system of claim 1, wherein the upgrader comprises:

a microwave irradiation system comprising one or more microwave antennas, the microwave irradiation system for at least partially upgrading crude oil using microwave energy to form upgraded crude oil;

a conveyor comprising a perforated belt, the one or more microwave antennas directed toward a portion of the perforated belt, the perforated belt configured to allow the upgraded crude oil to pass through openings defined thereby;

an inlet chute disposed to direct the crude oil onto the perforated belt;

a solids output chute disposed to receive solids from the perforated belt; and

an upgraded oil receiving tray disposed below the perforated belt.

4. The system of claim 3, wherein the microwave irradiation system is configured to generate microwave energy having at least one frequency within a range between about 4 gigahertz and about 18 gigahertz, within a range between about 8.0 gigahertz and about 8.8 gigahertz, within a range between about 8.1 gigahertz and about 8.7 gigahertz, within a range between about 8.2 gigahertz and about 8.6 gigahertz, within a range between about 8.3 gigahertz and about 8.5 gigahertz, or about 8.4 gigahertz.

5. The system of claim 3, wherein the upgrader further comprises a gas outlet extending from the solids output chute.

6. The system of claim 3, further comprising ancillary equipment fluidly coupled with the gas outlet.

7. The system of claim 3, wherein the upgrader further comprises a heating means for heating the crude oil prior to the crude oil being disposed on the conveyor.

8. The system of claim 3, wherein the upgrader further comprises an electron activator pump for introducing an electron activator into the crude oil prior to the crude oil being disposed on the conveyor.

9. The system of claim 1, wherein the upgrader comprises:

a microwave reactor comprising a vessel and an atomizer disposed in the vessel;

a microwave irradiation system comprising one or more microwave generators and one or more microwave antennas disposed in the vessel;

a vacuum pump in fluid communication with the vessel;

a crude oil inlet extending into the vessel and in fluid communication with the atomizer;

an upgraded oil outlet extending from the vessel; and

a gas outlet extending from the vessel.

10. The system of claim 9, further comprising ancillary equipment fluidly coupled with the gas outlet.

11. The system of claim 9, wherein the upgrader further comprises an input pump in fluid communication with the crude oil inlet.

12. The system of claim 9, wherein the microwave irradiation system is configured to generate microwave energy having at least one frequency within a range between about 4 gigahertz and about 18 gigahertz, within a range between about 8.0 gigahertz and about 8.8 gigahertz, within a range between about 8.1 gigahertz and about 8.7 gigahertz, within a range between about 8.2 gigahertz and about 8.6 gigahertz, within a range between about 8.3 gigahertz and about 8.5 gigahertz, or about 8.4 gigahertz.

13. The system of claim 9, wherein the upgrader further comprises a heating means for heating the crude oil prior to the crude oil being introduced to the microwave reactor.

14. The system of claim 9, wherein the upgrader further comprises an electron activator pump for introducing an electron activator into the crude oil prior to the crude oil being introduced to the microwave reactor.

15. The system of claim 1, at least one of the one or more production lines comprising an oil/water separator operably associated with the oil well and the upgrader, such that crude oil produced from the oil well is processed by the oil/water separator before being routed to the upgrader.

16. The system of claim 1, further comprising a second oil well operatively associated with the upgrader.

17. The system of claim 1, further comprising a control system operatively associated with the upgrader for operating the upgrader.

18. The system of claim 1, wherein a capacity of the upgrader generally corresponds to a crude oil production rate of the one or more oil wells.

19. A method for scalably upgrading crude oil, comprising:

providing an upgrader proximate an oil well;

producing crude oil from the oil well;

transporting the crude oil to the upgrader;

upgrading the crude oil in the upgrader; and

transporting the upgraded crude oil away from the upgrader.

20. The method of claim 19, wherein upgrading the crude oil in the upgrader is accomplished by irradiating the crude oil in the upgrader with microwave radiation.

21. The method of claim 20, further comprising transporting the crude oil on a conveyor as the crude oil is irradiated with microwave radiation.

22. The method of claim 20, further comprising atomizing the crude oil prior to the crude oil being irradiated with microwave radiation.

23. The method of claim 20, further comprising heating the crude oil prior to irradiating the crude oil with microwave radiation.

24. The method of claim 20, further comprising introducing an electron activator into the crude oil prior to irradiating the crude oil with microwave radiation.

25. The method of claim 20, wherein irradiating the crude oil with microwave radiation is accomplished by irradiating the crude oil with microwave radiation exhibiting at least one frequency within a range between about 4 gigahertz and about 18 gigahertz, within a range between about 8.0 gigahertz and about 8.8 gigahertz, within a range between about 8.1 gigahertz and about 8.7 gigahertz, within a range between about 8.2 gigahertz and about 8.6 gigahertz, within a range between about 8.3 gigahertz and about 8.5 gigahertz, or about 8.4 gigahertz.

26. The method of claim 20, further comprising using light hydrocarbons produced from irradiating the crude oil in the upgrader to operate an ancillary equipment.

27. The method of claim 19, further comprising removing at least some water from the crude oil before upgrading the crude oil in the upgrader.

28. The method of claim 19, further comprising:

producing crude oil from a second oil well;

transporting the crude oil produced from the second oil well to the upgrader; and

upgrading the crude oil from the second oil well in the upgrader.

29. The method of claim 19, further comprising;

remotely sensing conditions of the upgrader; and

remotely controlling operation of the upgrader.

30. The method of claim 19, wherein providing the upgrader is accomplished by providing an upgrader having a capacity that generally corresponds to a crude oil production rate of the oil well.