GB2514934B - Offshore heavy oil production - Google Patents
Offshore heavy oil production Download PDFInfo
- Publication number
- GB2514934B GB2514934B GB1412825.0A GB201412825A GB2514934B GB 2514934 B GB2514934 B GB 2514934B GB 201412825 A GB201412825 A GB 201412825A GB 2514934 B GB2514934 B GB 2514934B
- Authority
- GB
- United Kingdom
- Prior art keywords
- steam
- oil
- station
- heavy oil
- hydrocarbon cracking
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000000295 fuel oil Substances 0.000 title claims description 24
- 238000004519 manufacturing process Methods 0.000 title description 5
- 229930195733 hydrocarbon Natural products 0.000 claims description 47
- 150000002430 hydrocarbons Chemical class 0.000 claims description 47
- 239000003921 oil Substances 0.000 claims description 42
- 238000005336 cracking Methods 0.000 claims description 36
- 239000004215 Carbon black (E152) Substances 0.000 claims description 25
- 239000010779 crude oil Substances 0.000 claims description 24
- 238000000034 method Methods 0.000 claims description 17
- 230000005611 electricity Effects 0.000 claims description 12
- 238000000926 separation method Methods 0.000 claims description 12
- 239000012530 fluid Substances 0.000 claims description 10
- 239000013535 sea water Substances 0.000 claims description 7
- 238000003860 storage Methods 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 4
- 239000013505 freshwater Substances 0.000 claims description 3
- 239000002826 coolant Substances 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 11
- 239000004576 sand Substances 0.000 description 6
- 125000004432 carbon atom Chemical group C* 0.000 description 4
- 239000007788 liquid Substances 0.000 description 3
- 230000005484 gravity Effects 0.000 description 2
- 238000007670 refining Methods 0.000 description 2
- 241000191291 Abies alba Species 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000004230 steam cracking Methods 0.000 description 1
- 238000004227 thermal cracking Methods 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/01—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells specially adapted for obtaining from underwater installations
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/35—Arrangements for separating materials produced by the well specially adapted for separating solids
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
- B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING
- B63B35/00—Vessels or similar floating structures specially adapted for specific purposes and not otherwise provided for
- B63B35/44—Floating buildings, stores, drilling platforms, or workshops, e.g. carrying water-oil separating devices
- B63B35/4413—Floating drilling platforms, e.g. carrying water-oil separating devices
Landscapes
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
Description
BACKGROUND OF THE INVENTION
Some undersea hydrocarbon reservoirs contain a high proportion of heavy crude oil (hydrocarbons), so output from the reservoir (over a period of a plurality of days) comprises over 50% hydrocarbons of a density above that of water and with a high viscosity. Such heavy crude oil generally contains at least 60 carbon atoms per molecule and/or has a viscosity on the order of magnitude of over 0.05 Pa.s (0.5 poise). Other liquid hydrocarbons (light oil or light liquid hydrocarbons) generally have about 5 to 10 carbon atoms per molecule (light oil). Hydrocarbons with less than 4 or 5 carbon atoms per molecule are generally gas. Heavy oil hydrocarbons are difficult to treat and are difficult to pump into and out of storage tanks. The heavy crude can be cracked in refineries to produce light oil (generally oil having a specific gravity less than water and with a low viscosity) which is usually the most desirable hydrocarbons, but considerable effort is required to handle and transport the heavy crude to the refinery. A system that could be used at an offshore heavy crude oil production facility to crack heavy crude oil so as to facilitate its transport and transfer through pipes to a further refining and treatment facility, would be of value.
SUMMARY OF THE INVENTION
In accordance with the present invention, a floating hydrocarbon production facility is provided that is anchored to the sea floor to lie near an offshore heavy hydrocarbon reservoir, which treats the heavy hydrocarbons to facilitate their transport, transfer through pipes, and further treatment. The facility includes a separation station that separates the well effluent into light liquid oil, heavy crude oil, gaseous hydrocarbons, water, and solid materials (e.g sand). The heavy oil (oil with a specific gravity greater than water and generally with an API of less than 20) passes to a cracking station on the floating facility that cracks, or breaks down, the heavy crude oil into light crude oil. Such cracking can be accomplished in a number of ways. One approach is to use thermal cracking, such as “steam cracking” in which steam at about 800° C (650 to 1000° C) is applied to the crude oil. Another approach is to spray preheated heavy oil at a hot fluidized catalyst to break down the oils into various light oils (referred to as a FCC process, or process that uses fluidized carbon cracking). The cracking methods require large amounts of hot pressured steam and produce more hot steam. The processes also require considerable amounts of electricity. Much of the pressured steam produced in the cracking process is used to drive a steam engine (piston or turbine) that, in turn, drives an electric generator.
There are many other known methods for cracking heavy oil.
The novel features of the invention are set forth with particularity in the appended claims. The invention will be best understood from the following description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a diagrammatic view of an offshore hydrocarbon production facility of the present invention, with a tanker shown in a reduced size.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Fig. 1 illustrates a production facility 10 of the invention, which includes a floating structure 12 which carries treatment equipment that produces and treats heavy crude oil, or heavy hydrocarbons, from an undersea reservoir or well 14. Heavy crude oil can be considered to be oil having an API (American Petroleum Institute) rating of less than 20, so the oil floats on water. Such oil generally has a high viscosity such as on the order of magnitude of at least 0.05 Pa.s (0.5 poise), and/or has hydrocarbons with at least 60 carbon atoms per molecule. Fluid from the seafloor reservoir passes through an electrically-energized pump 20 that lies within tubing extending down to the well or that lies in the downhole casing. The pump pumps the fluid through a riser 22 up to the vessel or other floating structure 12 at the sea surface. Part of the oil is light oil that passes through a conduit 30 from a cracking station 32, towards a “Christmas tree” 33 on the seabed, and helps in lifting heavy crude oil from the well. Heavy oil and gas from the reservoir pass through a conduit 34 to a separation station 36. The separation station 36 separates out gas, which optionally flows through conduit 40 to a gas turbine power generator set 75. The set 75 is an engine-generator set that uses steam (which may be produced by gas) to drive a generator 74 that generates electricity. Produced water flows through a pipe 42 to a settling tank 44. Other non-hydrocarbon material such as sand and stones, are released into the sea after treatment.
In Fig. 1, heavy crude oil entering the separation station 36 is delivered through outlets 51, 53 of conduits 50, 52 to the station 32, which is a cracking station that converts heavy crude oil to light crude oil. The cracking station uses hot (e.g.800° C) sand to break down heavy crude and uses a small amount of hydrocarbon gas and diluent to initially generate heat and steam. The process reuses the sand and creates additional heat which creates additional steam. Applicant uses the additional steam, as described below.
Applicant provides a heavy oil storage tank, or buffer 60 that receives heavy crude oil from the separation station 36 and that can deliver heavy crude oil to the cracking station 32. Optimum operation of the cracking station 32 requires a steady flow of heavy crude oil into the station. When the flow through the conduit 34 deceases, this shortfall is made up by the flow of oil from the buffer tank 60 to the cracking station. The buffer tank preferably has a capacity to store more oil than the average flow of oil into the cracking station in one minute (more than 3.8 m3 (1,000 gallons) and preferably more than 19.0 m3 (5,000 gallons)). Heavy crude that has been cracked at the cracking station into light oil, is delivered through conduit 61 to a light oil storage tank 62, and from the light oil storage tank the oil flows through a transfer system 64 to a tanker 66, or to an export pipeline on the sea bed (not shown). The tanker 66 carries the oil to a distant refining facility where appropriate amounts of oil of selected densities are combined. The fact that oil in the storage tank 62 is light oil, means that it can be readily loaded into the tanker 66, as by passing through a pipeline, and later unloaded and further processed. Such further processing can be used to obtain the desired mix of light oils and additives, etc.
The cracking station 32 uses Hot sand and/or steam to heat incoming heavy crude oil at 52 to crack it, with the process creating additional heat which is carried away by additional steam, Applicant uses the steam to produce electricity. The steam produced by the cracking station is delivered through a conduit 70 to a steam powered engine 72, which can be a sleam engine that has pistons or which can include a steam turbine The vessel can have boilers (78) that use hydrocarbons to create steam during startup of the process. The steam powered generator is connected to an electrical generator 74 that generates electricity Alternatively, a closed loop heat transfer system can be used to deliver the steam to apparatus that heats if and delivers the heated steam to the engine 72.
Steam Is produced by the cracking station only after a period of operation (e.g. quarter hour). During this time, applicant uses hydrocarbon gas that flows through conduit 40 to drive an engine-generator set such as 75 wherein electricity Is obtained from the generator 74.. The gas can be Ignited and used to energize the same engine 72 or an auxiliary one. In the present embodiment a steam generator Is used, but as an alternative, steam from vessel steam boilers 78 can be used to start up the process.
Applicant passes excess steam at the engine 72 through a conduit 82 to the buffer tank 60 to heat heavy crude therein so It flows more easily. Excess heat also can be used to beat light oil In the light oil tank 62. If is well known that steam exiting a steam engine Is usually cooled In order to decrease Its pressure so there is a large pressure dtffemnttel between incoming and outgoing steam. Applicant uses a seawater lift pump system 80 to deliver sea water to a fresh water generator 84 that uses beat to produce clean water (most salt removed). The clean water Is passed io the steam engine to cool the exiting steam and to produce clean water for the steam engine. Electricity from the generator 74 Is used to power pumps that pump fluids into various stations. These include the pomp 20 that pumps heavy crude up through a riser, an offloading pump that pumps light oil to the tanker 66 that carries oil away from the floating structure 12. and a seawater lift pomp 80 that provides water to the steam engine,
Thus, the invention provides a method and system for handling oil that Is produced from an offshore reservoir or seabed pipeline that produces primarily (at least 50%) heavy crude oil. The crude oil is produced from the reservoir by a floating structure, or vessel, that includes a cracking station that cracks the crude oil after it has been initially processed to remove water, sand, gas and light oil. The cracking station preferably uses high temperature (e.g. 800°C) steam to crack the heavy oil to produce light oil or lighter oil (less viscous oil) that can be more easily pumped or otherwise flowed through pipes for processing and transport. Steam created by cracking heavy oil into light oil, is used to energize a steam engine that powers an electrical generator, with sea water used as a coolant for the steam engine.
Electricity from the electrical generator powers the cracking station and other facilities, and electricity can be exported to consumers on shore or to another offshore system through a cable.
Claims (10)
1. A method for obtaining light oil from an undersea reservoir (14) which produces a produced fluid that contains heavy crude oil, comprising: passing said produced fluid from the undersea reservoir up from said undersea reservoir through a riser (22) to a floating structure (12) that floats at a sea surface; passing said produced fluid to a separation station (36) on the floating structure, and, in said separation station separating said heavy crude oil of said produced fluid into hydrocarbons and non-hydrocarbon material, and separating the hydrocarbons into gaseous hydrocarbons, light oil, and heavy oil, including disposing of said non-hydrocarbon material into sea; flowing said heavy oil to a hydrocarbon cracking station (32) on said floating structure wherein said hydrocarbon cracking station is energizeable in part by electricity, and energizing said hydrocarbon cracking station to crack said heavy oil to produce light oil, gaseous hydrocarbons, and heat; using said heat produced by said hydrocarbon cracking station to produce pressured steam, using said pressured steam to drive a steam engine (72), using said steam engine to drive an electrical generator (74), and using a portion of electricity from said electrical generator to energize said hydrocarbon cracking station.
2. The method described in claim 1 including: using said gaseous hydrocarbons to initially generate steam to drive said electrical generator, before steam is available.
3. The method described in claim 1 including: storing a quantity of heavy oil in a heavy oil buffer tank (60) that is connected to said hydrocarbon cracking station, to enable the constant flow of heavy oil to said hydrocarbon cracking station (32), and using excess steam at the steam engine to heat oil in said heavy oil buffer tank.
4. The method described in claim 1 including: using electricity from said electrical generator to energize a sea floor pump (20) that lies no higher than the sea floor to pump fluid from said undersea reservoir to said floating structure.
5. The method described in claim 1 including: flowing seawater from said sea and using said seawater as a cooling medium for said steam engine.
6. The method described in claim 1 including: using heat from said hydrocarbon cracking station to generate freshwater from seawater, and using said generated freshwater to produce steam.
7. Apparatus for producing hydrocarbons from an undersea reservoir which produces a produced fluid that contains heavy oil, comprising: a floating structure (12) that floats at a sea surface, and a riser (22) that connects said undersea reservoir to said floating structure; a separation station (36) on said floating structure which is coupled to said riser and which separates the heavy crude oil of said produced fluid into hydrocarbons and non-hydrocarbon material, and separates the hydrocarbons into gaseous hydrocarbons, light oil, and heavy oil, said separation station having a heavy oil outlet (51, 53) and said separation station uses electrical power; a hydrocarbon cracking station (32) on said floating structure which is connected to the heavy oil outlet (53) of said separation station, said hydrocarbon cracking station having a light oil outlet (61) and a steam outlet (70) and which is arranged to crack said heavy oil to produce light oil, gaseous hydrocarbons, and heat; an engine-generator set that receives heat from said hydrocarbon cracking station to produce pressured steam to drive a steam engine and which uses the steam engine to drive an electrical generator (74), said electrical generator having an electrical outlet connected to said hydrocarbon cracking station; wherein the hydrocarbon cracking station is energized by using a portion of electricity from said electrical generator.
8. The apparatus described in claim 7 including: a buffer tank (60) which stores heavy oil and which has an inlet connected to said separation station to receive and store heavy oil therefrom and an outlet connected to said hydrocarbon cracking station.
9. The apparatus described in claim 8 wherein: said buffer tank has a storage capacity of more than 1,000 gallons.
10. The apparatus described in claim 8 including: a conduit that carries from said steam outlet of said hydrocarbon cracking station to said buffer tank to heat heavy oil therein.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/355,242 US9062525B2 (en) | 2011-07-07 | 2012-01-20 | Offshore heavy oil production |
PCT/US2012/062846 WO2013109331A1 (en) | 2012-01-20 | 2012-10-31 | Offshore heavy oil production |
Publications (3)
Publication Number | Publication Date |
---|---|
GB201412825D0 GB201412825D0 (en) | 2014-09-03 |
GB2514934A GB2514934A (en) | 2014-12-10 |
GB2514934B true GB2514934B (en) | 2019-06-05 |
Family
ID=48799571
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB1412825.0A Expired - Fee Related GB2514934B (en) | 2012-01-20 | 2012-10-31 | Offshore heavy oil production |
Country Status (8)
Country | Link |
---|---|
KR (1) | KR20140128339A (en) |
CN (1) | CN104246121A (en) |
BR (1) | BR112014017820A8 (en) |
CA (1) | CA2862123A1 (en) |
GB (1) | GB2514934B (en) |
MX (1) | MX353097B (en) |
SG (1) | SG11201404250VA (en) |
WO (1) | WO2013109331A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9803511B2 (en) * | 2015-08-24 | 2017-10-31 | Saudi Arabian Oil Company | Power generation using independent dual organic rankine cycles from waste heat systems in diesel hydrotreating-hydrocracking and atmospheric distillation-naphtha hydrotreating-aromatics facilities |
US9803505B2 (en) | 2015-08-24 | 2017-10-31 | Saudi Arabian Oil Company | Power generation from waste heat in integrated aromatics and naphtha block facilities |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20030124034A1 (en) * | 2001-11-29 | 2003-07-03 | China Petroleum & Chemical Corporation | Catalytic cracking reaction-regeneration system |
US20060116543A1 (en) * | 1999-07-07 | 2006-06-01 | Naphtachimie S.A. & Bp Chemicals Limited | Method and apparatus for steam cracking hydrocarbons |
US20060283590A1 (en) * | 2005-06-20 | 2006-12-21 | Leendert Poldervaart | Enhanced floating power generation system |
US20110130474A1 (en) * | 2009-11-27 | 2011-06-02 | Korea Institute Of Science And Technology | Gtl-fpso system for conversion of associated gas in oil fields and stranded gas in stranded gas fields, and process for production of synthetic fuel using the same |
US20110251728A1 (en) * | 2010-04-08 | 2011-10-13 | Framo Engineering As | System and method for subsea production system control |
-
2012
- 2012-10-31 GB GB1412825.0A patent/GB2514934B/en not_active Expired - Fee Related
- 2012-10-31 MX MX2014008753A patent/MX353097B/en active IP Right Grant
- 2012-10-31 BR BR112014017820A patent/BR112014017820A8/en not_active IP Right Cessation
- 2012-10-31 WO PCT/US2012/062846 patent/WO2013109331A1/en active Application Filing
- 2012-10-31 CN CN201280067645.6A patent/CN104246121A/en active Pending
- 2012-10-31 CA CA2862123A patent/CA2862123A1/en not_active Abandoned
- 2012-10-31 KR KR1020147023083A patent/KR20140128339A/en active Search and Examination
- 2012-10-31 SG SG11201404250VA patent/SG11201404250VA/en unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20060116543A1 (en) * | 1999-07-07 | 2006-06-01 | Naphtachimie S.A. & Bp Chemicals Limited | Method and apparatus for steam cracking hydrocarbons |
US20030124034A1 (en) * | 2001-11-29 | 2003-07-03 | China Petroleum & Chemical Corporation | Catalytic cracking reaction-regeneration system |
US20060283590A1 (en) * | 2005-06-20 | 2006-12-21 | Leendert Poldervaart | Enhanced floating power generation system |
US20110130474A1 (en) * | 2009-11-27 | 2011-06-02 | Korea Institute Of Science And Technology | Gtl-fpso system for conversion of associated gas in oil fields and stranded gas in stranded gas fields, and process for production of synthetic fuel using the same |
US20110251728A1 (en) * | 2010-04-08 | 2011-10-13 | Framo Engineering As | System and method for subsea production system control |
Also Published As
Publication number | Publication date |
---|---|
WO2013109331A1 (en) | 2013-07-25 |
MX353097B (en) | 2017-12-19 |
BR112014017820A2 (en) | 2017-06-20 |
KR20140128339A (en) | 2014-11-05 |
GB201412825D0 (en) | 2014-09-03 |
CA2862123A1 (en) | 2013-07-25 |
BR112014017820A8 (en) | 2017-07-11 |
MX2014008753A (en) | 2014-08-27 |
SG11201404250VA (en) | 2014-08-28 |
GB2514934A (en) | 2014-12-10 |
CN104246121A (en) | 2014-12-24 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20211031 |