CA3016084A1

CA3016084A1 - Partial upgrading of bitumen or heavy oil using microwave assisted aquathermolysis

Info

Publication number: CA3016084A1
Application number: CA3016084A
Authority: CA
Inventors: Syed K. Rizvi
Original assignee: Suncor Energy Inc
Current assignee: Suncor Energy Inc
Priority date: 2018-08-31
Filing date: 2018-08-31
Publication date: 2020-02-29
Anticipated expiration: 2038-08-31
Also published as: CA3016084C

Abstract

Techniques are described for above surface partial upgrading of bitumen or heavy oil recovered from subsurface recovery operations. The techniques include treating, in continuous mode, a bitumen or heavy oil-containing produced fluid stream including bitumen or heavy oil, water and solids generated in a subsurface recovery operation, by addition of a metal catalyst to the bitumen or heavy oil-containing produced fluid stream, followed by an aquathermolysis reaction in which the bitumen or heavy oil- containing produced fluid stream including the metal catalyst is irradiated with microwaves, resulting in the generation of a partially upgraded bitumen or heavy oil- containing fluid stream. The subsurface recovery operation can be an in situ steam assisted recovery operation, such as CSS or SAGD.

Description

PARTIAL UPGRADING OF BITUMEN OR HEAVY OIL USING MICROWAVE
ASSISTED AQUATHERMOLYSIS
TECHNICAL FIELD
[01] The technical field generally relates to the treatment of bitumen or heavy oil-containing material produced from subsurface reservoirs for partial upgrading of the bitumen or heavy oil therein. More particularly, the technical field relates to an ex situ process for partially upgrading bitumen or heavy oil produced from subsurface reservoirs, involving a microwave assisted aquathermolysis treatment.
BACKGROUND

[02] Extraction of petroleum products from subsurface reservoirs can involve many different techniques, generally resulting in the recovery of highly viscous fluids containing crude oil or bitumen, water and solids. Depending on the extraction technique, the water content in the produced fluids can be up to 50% by weight of the total produced material. For example, steam assisted technologies are thermal in situ extraction methods used for recovering heavy oil and/or bitumen from subsurface reservoirs (e.g., oil sands), which result in the production of fluids with high water content. There exist two common thermal in situ techniques, the so-called "Cyclic Steam Stimulation" (CSS) and "Steam Assisted Gravity Drainage" (SAGD). Both CSS and SAGD can have similar central processing facilities. The main difference between these two techniques lies in the positioning and number of wellheads. In CSS, a single well is drilled into the underground reservoir and high-pressure steam is injected into the reservoir to heat the bitumen and reduce its viscosity. The steam is continuously injected for several weeks in order to fully saturate the reservoir. The bitumen is then allowed to soak for several days or weeks in the hot pressurized reservoir. As the reservoir cools, the flow is then reversed so that the bitumen/water emulsion can be pumped back to the surface. In SAGD, two horizontal wells are drilled a few meters apart, one above the other at a well depth which can vary for example anywhere from 150 to 450 meters. High pressure steam is injected into the top well (injection well). The hot steam heats the surrounding bitumen and as the bitumen warms up, it liquifies and begins to flow by gravity towards the lower well (production well). The bitumen and condensed steam emulsion contained in the production well is then pumped to the surface.

[03] In both CSS and SAGD, the produced bitumen/water emulsion is then sent to a processing plant, where the bitumen and water are separated. The separated water is then treated and recycled back into the process. The bitumen is also treated to reduce the bitumen viscosity and facilitate transportation.

[04] One method to reduce bitumen viscosity is to dilute the bitumen, for example with naphtha or natural gas condensate as a diluent. Diluted bitumen is often referred to as "dilbit" and includes a significant volume of diluent (e.g., one third diluent and two thirds bitumen per barrel of diluted bitumen). Significant pipeline capacity is therefore taken up by the diluent for pipelining of the dilbit as well as the return pipelining of separated diluent to be reused in bitumen dilution. Thus, since diluent travels to and from the bitumen recovery operation, approximately a third of the pipeline capacity can be required for diluent transport and approximately a third of the hydrocarbon inventory can be diluent, which can be costly.

[05] Other bitumen upgrading methods involve high severity operating conditions and/or significant coking and/or hydrocracking, which can also involve technical challenges as well as high capital and operating costs.
SUMMARY

[06] According to an aspect, there is provided an above surface process for continuous treatment of a bitumen or heavy oil-containing produced fluid stream generated in a subsurface recovery operation, wherein the bitumen or heavy oil-containing produced fluid stream comprises bitumen or heavy oil, and water, the process comprising: adding a metal catalyst to the bitumen or heavy oil-containing produced fluid stream; subjecting the bitumen or heavy oil to an aquathermolysis reaction comprising irradiating the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst with microwaves; and generating a partially upgraded bitumen or heavy oil-containing fluid stream.

[07] In some implementations, adding the metal catalyst comprises adding the metal catalyst in solid form to the bitumen or heavy oil-containing produced fluid stream.

[08] In some implementations, adding the metal catalyst comprises adding the metal catalyst in a liquid. The liquid can include water, an organic liquid, or an inorganic liquid.

The organic liquid can include a hydrocarbon solvent or a light hydrocarbon.
The liquid can comprise a strong hydrogen donor solvent. The liquid can be referred to as a carrier liquid in which the metal catalyst is dispersed, and then injected or otherwise introduced into the produced fluid stream using an injector of various types or a pipe intersection (tee, Aye, etc.), for example.

[09] In some implementations, the metal catalyst is added to the bitumen or heavy oil-containing produced fluid stream to reach a content of the metal catalyst in the range of ppnn to 2 % per volume of bitumen or heavy oil content in the produced fluid stream.
The metal catalyst can comprise iron, nickel, copper or molybdenum or a combination of two or more of those metals.

[010] In some implementations, the metal catalyst comprises nano-sized metal catalyst particles. The nano-sized metal catalyst particles can comprise nanoparticles having a size ranging from 1 to 500 nm.

[011] In some implementations, the bitumen or heavy oil-containing produced fluid stream comprises from 1 % to 50 % water by weight. In some implementations, the bitumen or heavy oil-containing produced fluid stream comprises from 30 % to 50 %
water by weight.

[012] In some implementations, the aquathermolysis reaction is conducted to generate the partially upgraded bitumen or heavy oil-containing fluid stream with a viscosity reduced bitumen or heavy oil, a reduced asphaltene content, a reduced resin content, a reduced content of long chain cyclic molecules, and/or a partially sweetened bitumen or heavy oil.

[013] In some implementations, the aquathermolysis reaction is conducted with microwaves having a frequency ranging from 900 MHz to 2.8 GHz, or from 965 MHz to 2.45 GHz. In some implementations, the frequency is adjusted based on measured and/or determined dielectric properties of the bitumen or heavy oil-containing produced fluid stream. In some implementations, the frequency is adjusted to maximize energy absorbed by the bitumen or heavy oil-containing produced fluid stream.

[014] In some implementations, the aquathermolysis reaction is conducted in an aquathermolysis reactor comprising a chamber wherein the bitumen or heavy oil-containing produced fluid stream containing the metal catalyst is irradiated with microwaves. In some implementations, the aquathermolysis reactor comprises a plurality of tubes extending throughout the chamber in which the bitumen or heavy oil-containing produced fluid stream flows while being irradiated. The tubes can comprise a material that transmit microwave energy, e.g., quarts or ceramic. The tubes can also comprise a material that partially absorbs microwave energy and is capable of transferring the absorbed energy as heat to the bitumen or heavy oil-containing produced fluid stream (e.g., ceramic with an embedded microwave absorbent material, such as iron or graphite).

[015] In some implementations, the aquathermolysis reactor comprises a microwave generating device configured to generate microwaves of a frequency ranging from 900 MHz to 2.8 GHz.

[016] In some implementations, the aquathermolysis reactor further comprises a waveguide assembly configured to guide the microwaves from the microwave generating device into the chamber.

[017] In some implementations, the process further includes separating the metal catalyst from the partially upgraded bitumen or heavy oil-containing fluid stream and recycling at least part of the separated metal catalyst for addition to the bitumen or heavy oil-containing produced fluid stream generated in the subsurface recovery operation. In some implementations, the process further includes supplying the partially upgraded bitumen or heavy oil-containing fluid stream to a bitumen or heavy oil/water separator to recover a produced water stream and a partially upgraded bitumen or heavy oil stream. In some implementations, the partially upgraded bitumen or heavy oil-containing stream has a lower viscosity and a lower asphaltene and resin content than the bitumen or heavy oil in the bitumen or heavy oil-containing produced fluid stream before the aquathermolysis reaction. In some implementations, the process further includes treating the produced water stream to recover treated water and separated solids. In some implementations, the subsurface recovery operation is an in situ steam assisted recovery operation, and the treated water is recycled to be injected as steam in the in situ steam assisted recovery operation.

[018] In some implementations, the process further includes the subsurface recovery operation is an in situ steam assisted recovery operation. The subsurface recovery operation can comprise Cyclic Steam Stimulation (CSS) or Steam Assisted Gravity Drainage (SAGD).

[019] In some implementations, the bitumen or heavy oil-containing produced fluid stream further comprises mineral solids. The process can further include removing at least some of the mineral solids after aquathermolysis.

[020] In some implementations, the process further includes the bitumen or heavy oil-containing produced fluid stream is recovered from a wellhead and is directly subjected to addition of the metal catalyst followed by the aquathermolysis.

[021] In some implementations, the process further includes the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst is subjected to in-line mixing prior to the aquathermolysis.

[022] In another aspect, there is provided an above surface process for continuous treatment of a bitumen-containing produced fluid stream generated in an in situ steam assisted recovery operation, wherein the bitumen-containing produced fluid stream comprises bitumen, and water, the process comprising: adding a metal catalyst to the bitumen-containing produced fluid stream, subjecting the bitumen in the bitumen-containing produced fluid stream to an aquathermolysis reaction comprising irradiating the bitumen-containing produced fluid stream comprising the metal catalyst with microwaves, and generating a partially upgraded bitumen-containing fluid stream.

[023] In another aspect, there is provided a process for improving bitumen/water separation of a bitumen-containing produced fluid stream generated in an in situ steam assisted recovery operation, the process comprising, prior to the bitumen/water separation, in-line addition of a metal catalyst to the bitumen-containing produced fluid stream and then subjecting in continuous mode the bitumen in the bitumen-containing produced fluid stream to a microwave assisted aquathermolysis reaction and generating a partially upgraded bitumen-containing fluid stream.

[024] In some implementations, the metal catalyst is added to the bitumen-containing produced fluid stream in solid form.

[025] In some implementations, adding the metal catalyst comprises adding the metal catalyst in a liquid. The liquid can comprise water, an organic liquid and/or an inorganic liquid. The organic liquid can comprise a hydrocarbon solvent or a light hydrocarbon.
The liquid can comprise a strong hydrogen donor solvent.

[026] In some implementations, the metal catalyst is added to the bitumen-containing produced fluid stream to reach a content of the catalyst in the range of 5 ppm to 2 % per volume of bitumen or heavy oil content in the produced fluid stream.

[027] In some implementations, the metal catalyst comprises iron, nickel, copper or molybdenum or a combination of two or more of those metals.

[028] In some implementations, the metal catalyst comprises nano-sized metal catalyst particles. The nano-sized metal catalyst particles can comprise nanoparticles having a size ranging from 1 to 500 nm.

[029] In some implementations, the aquathermolysis reaction is conducted to generate a partially upgraded bitumen-containing produced fluid stream with a viscosity reduced bitumen, a reduced asphaltene content, a reduced resin content, a reduced content of long chain cyclic molecules, and/or a partially sweetened bitumen or heavy oil.

[030] In some implementations, the aquathermolysis reaction is conducted with microwaves having a frequency ranging from 900 MHz to 2.8 GHz, or from 965 MHz to 2.45 GHz. The frequency can be adjusted based on measured and/or determined dielectric properties of the bitumen or heavy oil-containing produced fluid stream. The frequency can be adjusted to maximize energy absorbed by the bitumen or heavy oil-containing produced fluid stream.

[031] In some implementations, the aquathermolysis reaction is conducted in an aquathermolysis reactor comprising a chamber wherein the bitumen or heavy oil-containing produced fluid stream containing the metal catalyst is irradiated with microwaves. The aquathermolysis reactor can include a plurality of tubes extending throughout the chamber in which the bitumen or heavy oil-containing produced fluid stream flows while being irradiated. The tubes can comprise a material that transmit microwave energy (e.g., quartz or ceramic). The tubes can also comprise a material that partially absorbs microwave energy and is capable of transferring the absorbed energy as heat to the bitumen or heavy oil-containing produced fluid stream (e.g., ceramic with an embedded microwave absorbent material, such as iron or graphite).

[032] In some implementations, the aquathermolysis reactor comprises a microwave generating device configured to generate microwaves of a frequency ranging from 900 MHz to 2.8 GHz.

[033] In some implementations, the aquathermolysis reactor further comprises a waveguide assembly configured to guide the microwaves from the microwave generating device into the chamber.

[034] In some implementations, the process also includes separating the metal catalyst from the partially upgraded bitumen or heavy oil-containing fluid stream and recycling at least part of the separated metal catalyst for addition to the bitumen or heavy oil-containing produced fluid stream generated in the subsurface recovery operation. The process can also include supplying the partially upgraded bitumen or heavy oil-containing fluid stream to a bitumen or heavy oil/water separator to recover a produced water stream and a partially upgraded bitumen or heavy oil stream. In some implementations, the partially upgraded bitumen or heavy oil-containing stream has a lower viscosity and a lower asphaltene and resin content than the bitumen or heavy oil in the bitumen or heavy oil-containing produced fluid stream before the aquathermolysis reaction. The process can also include treating the produced water stream to recover treated water and separated solids. In some implementations, the subsurface recovery operation is an in situ steam assisted recovery operation, and the treated water is recycled to be injected as steam in the in situ steam assisted recovery operation.

[035] In some implementations, the subsurface recovery operation is an in situ steam assisted recovery operation. The subsurface recovery operation can include Cyclic Steam Stimulation (CSS) and/or Steam Assisted Gravity Drainage (SAGD).

[036] In some implementations, the bitumen or heavy oil-containing produced fluid stream further comprises mineral solids. The process can include removing at least some of the mineral solids after aquathermolysis.

[037] In some implementations, the bitumen or heavy oil-containing produced fluid stream is recovered from a wellhead and is directly subjected to addition of the metal catalyst followed by the aquathermolysis.

[038] In some implementations, the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst is subjected to in-line mixing prior to the aquathermolysis.

[039] In another aspect, there is provided a system for ex-situ continuous treatment of a bitumen or heavy oil-containing produced fluid stream comprising bitumen or heavy oil, and water, the system comprising: a catalyst addition assembly for adding a metal catalyst to the bitumen or heavy oil-containing produced fluid stream; and an aquathermolysis reactor comprising an inlet for receiving the bitumen or heavy oil-containing produced fluid stream comprising the added metal catalyst, and a microwave generating device configured for irradiating the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst with microwaves to produce a partially upgraded bitumen-containing fluid stream.

[040] In some implementations of the system, the catalyst addition assembly comprises a pump and an addition line, and is configured to add the metal catalyst within a liquid into the bitumen or heavy oil-containing produced fluid stream. The liquid can include water, an organic liquid, and/or an inorganic liquid. The catalyst and the liquid can form a suspension.

[041] In some implementations, the pump is configured to enable injection of the suspension of the metal catalyst into the bitumen or heavy oil-containing produced fluid stream at a flow rate allowing a content of the metal catalyst in the bitumen or heavy oil-containing produced fluid stream to reach 5 ppm to 2 % per volume of bitumen or heavy oil content in the produced fluid stream.

[042] In some implementations, the aquathermolysis reactor comprises a chamber in which the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst is irradiated with microwaves.

[043] In some implementations, the aquathermolysis reactor comprises a plurality of tubes extending through the chamber and in which the bitumen or heavy oil-containing produced fluid stream flows while being irradiated. The tubes can comprise or consist of a material that transmits microwave energy, such as quartz and/or ceramic. The tubes can also comprise a material which partially absorbs microwave energy and is capable of transferring the absorbed energy as heat to the bitumen or heavy oil-containing produced fluid stream. The material which partially absorbs microwave energy can comprise a ceramic that is impregnated with an absorbent metal. The absorbent metal can be iron and can be present in an amount of 1 to 5 % by weight. The material which partially absorbs microwave energy can comprise a ceramic that is impregnated with graphite, which can be present in an amount of 1 to 5 % by weight.

[044] In some implementations, each tube comprises multiple tube sections coupled to each other end to end. Each tube can also include flexible connectors for coupling adjacent tube sections together. Flexible connectors can be particularly advantageous when the tube sections are composed of a relatively rigid and inelastic material, such as ceramic.

[045] In some implementations, the microwave generating device comprises at least one magnetron. In some implementations, the microwave generating device comprises a plurality of magnetrons arranged in series to generate microwaves. The microwave generating device can be configured to generate microwaves of a frequency ranging from 900 MHz to 2.8 GHz. The device can be controlled to adapt frequency depending on measurements and determinations or calculations regarding the produced stream feed.

[046] In some implementations, the aquathermolysis reactor further comprises a waveguide assembly to guide the microwaves from the microwave generators to the chamber.

[047] In some implementations, the system also includes a catalyst separator for separating the metal catalyst from the partially upgraded bitumen or heavy oil-containing fluid stream.

[048] In some implementations, the system also includes a recycling line for recycling at least a portion of the separated metal catalyst to the bitumen or heavy oil-containing produced fluid stream. The recycling line can be coupled to the catalyst addition assembly for supplying the portion of the separated metal catalyst thereto.

[049] In some implementations, the system also includes a bitumen or heavy oil/water separator to separate the partially upgraded bitumen or heavy oil-containing fluid stream into a produced water stream and a partially upgraded bitumen or heavy oil stream. The bitumen or heavy oil-containing produced fluid stream comprises mineral solids and the system further can comprise a produced water treatment unit to recover treated water and separated mineral solids.

[050] In some implementations, the bitumen or heavy oil-containing produced fluid stream is obtained from a wellhead of a subsurface hydrocarbon recovery operation.
The catalyst addition assembly can be configured and positioned to add the metal catalyst directly into the bitumen or heavy oil-containing produced fluid stream after withdrawal from the wellhead. The subsurface hydrocarbon recovery operation can comprise an in situ steam assisted recovery operation and the system may further comprise a steam generator for receiving the treated water for recycling to the in situ steam assisted recovery operation. The subsurface hydrocarbon recovery operation can comprise CSS or SAGD.

[051] In some implementations, the system also includes a mixer that is provided in between the catalyst addition assembly and the aquathermolysis reactor for ensuring dispersion of the metal catalyst in the bitumen or heavy oil-containing produced fluid stream. The mixer can comprise at least one in-line mixer, which cab be a static mixer.

[052] In some implementations, the system also includes a monitoring device for monitoring properties of the bitumen or heavy oil-containing produced fluid stream. The monitored properties can comprise temperature, flow rate, water content, and/or dielectric properties.

[053] In some implementations, the system also includes a control unit for controlling the aquathermolysis reactor, wherein the control unit is configured to shut down the aquathermolysis reactor in response to a detected over-temperature or over-pressure therein.

[054] In some implementations, the aquathermolysis reactor has a modular design wherein each module comprises a chamber section, multiple tube sections within the chamber section, and at least one microwave generating device for generating microwaves for irradiating the bitumen or heavy oil-containing produced fluid stream to flow through the corresponding multiple tube sections.

[055] It should also be noted that various aspects, implementations, features or steps described or illustrated herein can be combined with other aspects, implementations, features or steps.
BRIEF DESCRIPTION OF THE DRAWINGS

[056] Figure 1 is a flowchart of a process for recovering a partially upgraded bitumen from a bitumen-containing produced fluid, in accordance with an example implementation.

[057] Figure 2 is a schematic representation of a general flow diagram for treating a bitumen-containing fluid produced in a SAGD operation, including a microwave assisted aquathermolysis treatment for partially upgrading the bitumen followed by various separation and/or purification steps, including the separation of the partially upgraded bitumen from the produced water containing the catalyst and disposal of the catalyst with sediment waste from the produced water, in accordance with an example implementation.

[058] Figure 3 is a schematic representation of a general flow diagram for treating a bitumen-containing fluid produced in a SAGD operation, including a microwave assisted aquathermolysis treatment for partially upgrading the bitumen followed by various separation and/or purification steps, including the separation of the catalyst from the partially upgraded bitumen/water stream, the catalyst being recycled to the aquathermolysis step, in accordance with an example implementation.

[059] Figure 4 is a perspective view of part of an example of an aquathermolysis reactor that can be used for conducting a microwave assisted aquathermolysis treatment of a bitumen-containing produced fluid, in accordance with an example implementation.

[060] Figure 5 is a top view of an example aquathermolysis reactor.

[061] Figure 6 is a schematic of a system including an aquathermolysis reactor.

[062] Figure 7 is a cross-section view of an example aquathermolysis reactor.
DETAILED DESCRIPTION

[063] The process described herein relates to the ex situ treatment of bitumen or heavy oil-containing fluids, which can also be referred to as "microwave Assisted Aquathermolytic partial upgrading". The partial upgrading of the bitumen or heavy oil-containing fluids includes a microwave assisted aquathermolysis treatment performed in the presence of a metal catalyst.

[064] The partial upgrading technique described herein facilitates viscosity and/or density reduction of the bitumen or heavy oil in the produced fluids. The viscosity and/or density reduction can, in turn, help reduce or eliminate diluent requirements for the bitumen or heavy oil product to be pipelinable.

[065] In some implementations, the bitumen or heavy oil-containing fluids submitted to the ex situ partial upgrading can be an emulsion containing bitumen or heavy oil and water, produced from an in situ recovery operation such as steam-assisted in situ hydrocarbon recovery operation, for example Cyclic Steam Stimulation (CSS) or Steam Assisted Gravity Drainage (SAGD). In some implementations, the ex situ partial upgrading process can be applied to bitumen or heavy oil-containing material produced from variations of SAGD or CSS processes that use solvents or other light hydrocarbons for enhanced recovery (e.g., operations involving steam-solvent co-injection).
In some implementations, the bitumen-containing fluids subjected to partial upgrading are fluids produced from a SAGD operation.
Definitions

[066] Throughout this description, numerous terms and expressions are used in accordance with their ordinary meanings. Below are definitions of some terms and expressions that are used in the description that follows.

[067] "Ex situ" as used herein in reference to a treatment, process and/or partial upgrading, refers to the above surface treatment, process and/or partial upgrading to which the bitumen or heavy oil, extracted from the subsurface reservoir, is subjected.
The partial upgrading treatment is performed above the surface, and therefore takes place ex situ (as opposed to any in situ operations which take place under the surface within the formation).

[068] "Aquathermolysis" as used herein refers to a series of chemical reactions wherein, under heating and in the presence of a proper catalyst and water as hydrogen donor, the bitumen or heavy oil undergoes partial upgrading resulting in a viscosity reduction of the bitumen or heavy oil, making it suitable to flow in pipelines without the addition of diluent. The aquathermolysis reaction involves a hydrous pyrolysis (or thermal cracking) of the bitumen or heavy oil in the presence of water and the catalyst.
The partial upgrading and viscosity reduction can be attributed to a reduction of the asphaltene content in the bitumen. It also involves bond cleavage reaction whereby sulfur from the molecules in the bitumen/heavy oil can be removed and reacted with the hydrogen produced during the reaction to form H2S. In some implementations, aquathermolysis can be performed using microwaves as the heating source. The catalyst used for the aquathermolysis reaction can be a metal catalyst, such as a nano-sized metal catalyst, i.e., a metal catalyst in the form of nanoparticles. The catalyst can be provided in solid form (e.g., as a powder) or as a suspension of nanoparticles in a liquid, i.e. in the form of a nanofluid.

[069] "Bitumen" as used herein can refer to hydrocarbon material extracted from bituminous formations, such as oil sands formations, the density of which is typically around 1000 kg/m3 and the American Petroleum Industry's (API) gravity is around 8 .
Bitumen can be recovered from a bitumen-containing reservoir using in situ recovery processes. The bitumen can include various non-hydrocarbon compounds (e.g., sulfur, metals, etc.) that are often found in bitumen and can be associated with certain hydrocarbon components (e.g., asphaltenes). Examples of bitumen include bitumen extracted from the Athabasca and Cold Lake regions, in Alberta, Canada.

[070] "Heavy oil", which can also be referred to as "heavy crude oil", can refer to any liquid petroleum with an American Petroleum Industry's (API) gravity of less than 22.3 and a density of about 920 to about 1000 kg/m3, although the density could be higher.
Heavy oil usually contains asphaltenes and resins.

[071] "Bitumen-containing produced fluid", "bitumen-containing produced fluid stream", "bitumen or heavy oil-containing produced fluid" or "bitumen or heavy oil-containing produced fluid stream" refer to the material/stream containing the bitumen or heavy oil that is subjected to the aquathermolytic partial upgrading. The bitumen or heavy oil-containing material includes bitumen or heavy oil, and also contains water.
The water content of the bitumen or heavy oil-containing material that is subjected to the aquathermolytic treatment can be from 1 to 50 % by weight of the material. In some implementations, the bitumen or heavy oil-containing material subjected to aquathermolytic treatment can include from 30 to 50 % water by weight. The water content of the produced fluid stream can be at least 5, 10, 15, 20, 25, 30 or 35 % by weight, for example, and the water can be inherent to the produced fluid and the steam based process used to recover the fluid from the reservoir where no water is added to the produced fluid at surface. The bitumen or heavy oil-containing material subjected to the aquathermolytic treatment can also include mineral solids. In some implementations, the bitumen or heavy oil-containing material to be treated can be obtained from steam-assisted hydrocarbon in situ operations, for example Cyclic Steam Stimulation (CSS) or Steam Assisted Gravity Drainage (SAGD). In some implementations, the bitumen or heavy oil-containing material to be treated can be obtained from variations of the SAGD
or CSS processes, involving the use of solvents and/or light hydrocarbons along with steam for enhanced oil recovery. The bitumen or heavy oil-containing produced fluid stream refers to the bitumen or heavy oil-containing stream that is produced to the surface from a well or derived from a production stream withdrawn from a well and can be in the form of a bitumen or heavy oil/water emulsion that may contain some solids.

[072] "Nano-sized" or simply "nano" means smaller than microscopic in size.
The term "nano-sized" used herein to qualify the catalyst refer to a particulate catalyst having a particle size that is smaller than 1000 nm. In some implementations, the size of particles can range from 1 to 500 nm.

[073] "Pipelinable bitumen" or "pipelinable heavy oil" as used herein refers to a bitumen or heavy oil stream that meets a predetermined pipeline specification. For instance, a non-limiting example of a pipeline specification can require a viscosity of 350 cSt or less at the reference temperature of the pipeline and a density of 940 kg/m3 or less.

[074] "Upgrading" and "partial upgrading", which are used interchangeably herein, refers to a process where the bitumen or heavy oil is processed to improve its characteristics, for instance, by decreasing its viscosity and/or density or increasing its hydrogen-to-carbon ratio. Upon upgrading, the macromolecular components of the bitumen or heavy oil (e.g., asphaltenes, resins and long chain cyclic molecules) can be broken down resulting in a viscosity reduction. In addition, bond cleavage in sulfur and nitrogen-containing compounds results in partial bitumen or heavy oil sweetening.
Aquathermolytic partial upgrading process

[075] As mentioned above, techniques are described here to partially upgrade bitumen or heavy oil contained in fluids produced from subsurface reservoirs. These techniques allow a reduction in viscosity and/or density of the bitumen or heavy oil component contained in produced fluids, which can, in turn, render the bitumen product or the heavy oil to be pipelinable. In some implementations, the bitumen or heavy oil product is made to be pipelineable with or without the addition of diluent or light hydrocarbon component.

[076] For clarity reasons, the following detailed description will refer to the aquathermolytic treatment and partial upgrading of bitumen in bitumen-containing produced fluid stream or bitumen/water emulsion. However, the process and system described below are not limited to partial upgrading of bitumen and also encompasses the aquathermolytic treatment and partial upgrading of heavy oil in heavy oil-containing produced fluid streams (and heavy oil/water emulsions). The present process and system can be used to treat any hydrocarbon-containing streams with heavy hydrocarbon components such as asphaltenes and resins, also containing water.
In some implementations, the water content of the bitumen or heavy oil-containing material that is subjected to the aquathermolytic treatment can be from 1 to 50 % by weight of the material, or from 10 to 50 % by weight of the material, or from 20 to 50 % by weight of the material, or from 30 to 50 % by weight of the material. In some implementations, the bitumen or heavy oil-containing material subjected to aquathermolytic treatment can include from 30 to 50 % water by weight.

[077] Referring to Figure 1, one implementation of the partial upgrading process 10 includes the initial step of producing the bitumen produced fluid 12, through a subsurface recovery operation, such as in situ steam assisted recovery operation for instance.
Steam assisted hydrocarbon recovery operations are well known in the field and can include Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity Drainage (SAGD).
In CSS, a single well is drilled into the underground reservoir and high-pressure steam is injected into the reservoir to heat the bitumen and reduce its viscosity. The steam can be injected continuously for several weeks in order to fully saturate the reservoir. The bitumen can then be allowed to soak for several days or weeks in the hot pressurized reservoir. As the reservoir cools, the flow can then be reversed so that the bitumen/water emulsion can be pumped back to the surface. In SAGD, pairs of horizontal wells positioned a few meters apart, one above the other, are drilled in the formation. High pressure steam can be injected into the injection wells (top wells). The hot steam can heat the bitumen in the reservoir and as the bitumen warms up, it can liquify and begin to flow by gravity towards the production wells (lower wells). The bitumen and condensed steam emulsion contained in the production wells can then be pumped as a bitumen/water emulsion to the surface. The bitumen/water emulsion recovered in the production wells contains some solids initially present in the formation.

[078] The next step of the process includes the in-line addition of a metal catalyst to the bitumen/water emulsion 14, which is followed by an aquathermolysis reaction 16 in which the bitumen/water emulsion containing the metal catalyst is subjected to microwave irradiation, resulting in the partial upgrading of the bitumen in the bitumen/water emulsion. These steps are performed in continuous mode, meaning that the produced fluid stream that is being processed is flowing when the catalyst is added thereto and when undergoing aquathermolysis reaction. The catalyst can be added to the bitumen/water emulsion in-line, meaning that it can be added directly into the produced fluid stream as it flows out of the production well towards the next aquathermolysis step. While "bitumen" is generally referred to in this and other paragraphs, it should be noted that the features also apply to heavy oil throughout the present disclosure.

[079] Continuous operation can facilitate various advantages, such as efficiently treating production fluids at high throughputs, facilitating mass transfer to and from the catalyst by leveraging the dispersion occurring within the continuous flow of the fluid during aquathermolysis, and facilitating integration of the aquathermolysis operation within a continuous in situ hydrocarbon recovery operation. By continuously treating the produced fluid removed from the well, the heat and composition of the produced fluid can be leveraged in the aquathermolysis process.

[080] Suitable catalysts can be those containing strong, active sites that can actively break the C-C, C-S, C-0 and related bonds in resins and asphaltenes contained in the extracted bitumen, resulting in an increase in the concentration of saturates and lighter aromatic hydrocarbons and thereby a reduction of the viscosity of the bitumen.
In some implementations, the metal catalyst can be a nano-sized metal, i.e., a metal-based catalyst in the form of nanoparticles having a size ranging from 1 to 500 nm.
Examples of catalysts can include catalysts based on iron (Fe), nickel (Ni), copper (Cu) or molybdenum (Mo) or a combination of two or more of those metals. In some implementations, the catalyst can include natural zeolites, zirconium oxides, metal alloys such as alloys of Mo, W, C and Ni, nano oxides of Cu and Fe, Ni-chelates, supported nano-Fe particles, etc.

[081] In some implementations, the metal catalyst can be added to the bitumen/water emulsion in the form of a solution or suspension (e.g., colloidal suspension) prepared by addition of the catalyst nanoparticles in water and/or in an organic or inorganic liquid. In some implementations, the organic or inorganic liquid can be a hydrocarbon solvent, a light hydrocarbon or a strong hydrogen donor solvent or material such as formic acid, or any other organic liquid known to allow the formation of a suspension of metal nanoparticles therein (e.g., a nanofluid). In some implementations, the catalyst suspension can also contain stabilizing agents and/or dispersing agents.

[082] The quantity of catalyst added to the bitumen/water emulsion can be determined and adjusted depending on the characteristics of the bitumen/water emulsion.
For instance, the quantity of catalyst can be calculated based on the bitumen to water ratio in the produced fluids. In some implementations, the catalyst can be added to the bitumen/water emulsion in order to reach a content of the catalyst in the range of 5 ppm to 2 % per volume of bitumen or heavy oil content in the produced fluid stream. A
hydrocarbon measurement device can be provided to determine or estimate the bitumen or heavy oil content of the produced fluid stream, and the catalyst dosage can be adjusted accordingly in response to the measured hydrocarbon content and/or other various regarding the composition and/or physicochemical properties of the produced fluid.

[083] Optionally, the bitumen/water emulsion produced in the CSS or SAGD
operation can be characterized in a characterizing step (not shown in the figures) to determine various properties including density, viscosity, composition, and so on. The properties that can be determined can include, for example, the bitumen to water ratio in the produced fluids stream, the quantities of solids, the flow rate of the produced fluids stream, and can be used to adjust the operating conditions of the next treatment steps 14 and 16. If required, operating conditions including modifying the temperature, pressure, and/or flow rate of the produced fluids stream can be adjusted for allowing an optimal aquathermolysis treatment.

[084] In the aquathermolysis treatment step 16, the bitumen/water emulsion produced in the steam assisted recovery operation with added metal catalyst, is subjected to microwave irradiation. Upon microwave irradiation, the bitumen/water emulsion is heated, and the bitumen therein can undergo an aquathermolysis reaction that includes hydrous pyrolysis (or thermal cracking) occurring in the presence of water and the catalyst. The hydrous pyrolysis reaction can result in the breaking of some C-C, C-S, C-O and related bonds in resins, asphaltenes and long chain cyclic molecules contained in the bitumen, resulting in an increase in the concentration of lighter hydrocarbons and thereby a reduction of the viscosity of the bitumen. The frequency of the microwaves for performing the aquathermolylsis reaction can be determined and adjusted depending on the characteristics of the bitumen/water emulsion. In some implementations, the microwave irradiation can be performed at a frequency ranging from 900 MHz to 2.8 GHz. An example of a system that can be used for performing the aquathermolysis reaction will be described in more detail below.

[085] Once the aquathermolysis reaction is completed, the bitumen/water emulsion containing partially upgraded bitumen can be treated in a separating step 18, wherein the water is separated from the partially upgraded bitumen. The separation techniques are well known in the field. For example, the partially upgraded bitumen/water separation can be performed in a separator such as a Free Water Knock Out (FWKO) vessel.
Thanks to the partial upgrading of the bitumen in the aquathermolysis step, the bitumen/water separation can be improved, which in turn can limit or avoid the addition of a diluent before the separation step as is the case in prior art designs.
More specifically, the density difference between the partially upgraded bitumen and water after aquathermolysis is increased compared to the density difference between bitumen and water before the aquathermolysis treatment, and such density difference can allow a better bitumen/water separation. The separated partially upgraded bitumen can then be supplied to a pipeline for transportation or stored as a bitumen product in a further step 20.

[086] The water phase separated from the partially upgraded bitumen can undergo further treatment/purification steps 22. Then, in a further step 24, the purified water can be recycled for re-use in the in situ steam assisted hydrocarbon extraction process.
These steps are well known in the field. In some implementations, the produced water can be sent to de-oiling treatment, then the de-oiled water can undergo a thermal water treatment before being further decontaminated to obtain purified water suitable for steam generation. In these steps, various sludges and/or slurries are eliminated as waste material containing some residual solids. As will be explained in more detail below, the catalyst used for the aquathermolysis reaction can be eliminated with the solids eliminated during the produced water treatment. However, in another implementation, the catalyst can be separated upstream, after the aquathermolysis reaction and before the partially upgraded bitumen/water separation as will be explained below.

[087] In some implementations, the bitumen partial upgrading treatment is performed on produced fluids obtained from a SAGD operation as shown in Figures 2 and 3.
Hot steam 26 is injected into a bitumen-containing reservoir, such as an oils sands reservoir, through at least one horizontal injection well 28. Once the steam reaches the bitumen in the reservoir, it can heat the bitumen which warms up and becomes liquified.
The hot liquified bitumen then begins to flow by gravity towards the production well 30. The bitumen and condensed steam emulsion contained in the production wells can then be pumped as produced fluids 32 to the surface. The produced fluids 32 comprise a bitumen/water emulsion which also contains some solids that were present in the reservoir and are recovered in the extraction process. A dispersion of the metal catalyst as described above, such as an aqueous dispersion or a dispersion in an organic liquid, can be prepared in a preparation step 34 by mixing the catalyst in solid form (e.g., as a powder) with the water or organic liquid. The mixing can be performed in any appropriate mixing vessel. Then, the catalyst dispersion is injected into the flowing bitumen-containing produced fluids 32, for example through a pump system, for instance a metering pump. In some implementations, the catalyst dispersion is injected into the bitumen-containing produced fluids such that the content of active catalyst can be in the range of 5 ppm to 2 % per volume of bitumen or heavy oil content in the produced fluid stream. In some implementations, a mixer can be provided downstream of the catalyst addition point to ensure dispersion of the metal catalyst in the produced fluid stream prior to aquathermolysis. The mixer can be an in-line mixer, such as a static mixer.

[088] In a continuous flow process, the bitumen-containing produced fluids, which also contains the metal catalyst, can be subjected to a microwave assisted aquathermolysis treatment step 36 to reduce the bitumen viscosity in the fluids stream and recover a partially upgraded bitumen-containing fluid stream 38. The partially upgraded bitumen-containing fluid stream 38 includes a bitumen/water emulsion presenting a reduced asphaltene and/or resin content, resulting in the viscosity reduction. After the aquathermolysis treatment, the flowing stream which contains the partially upgraded bitumen can be further processed for separating the partially upgraded bitumen product from the water phase. The bitumen/water separation step 40 and the water phase treatment step 46 can be performed using methods known in the field, as described above.

[089] In some implementations, as shown in Figure 2, the partially upgraded bitumen-containing fluid stream 38, which also contains the catalyst, can be sent to the step of bitumen/water separation 40. In the bitumen/water separator (e.g., FWKO), the bitumen phase is separated from the water phase to recover a partially upgraded bitumen product 42, which can be pipelined or stored for future use, and recover a catalyst-containing produced water stream 44, which can be sent to further downstream purification treatments 46, as described previously. A purified water stream 48 can then be sent to a steam generation step 50 for generating steam 26 to be injected in the injection well 28 of the SAGD operation. Sludges and/or slurries 52 eliminated during the produced water treatments 46, which mainly contain solids and also contain the catalyst can be disposed of in a solids disposal step 54.

[090] In another implementation, as represented in Figure 3, the catalyst which flows with the partially upgraded bitumen/water emulsion stream can be removed before the bitumen/water separation. More particularly, the partially upgraded bitumen-containing fluid stream 38, which also contains the catalyst is subjected to a catalyst separation step 56 before the step of bitumen/water separation. In some implementations, the catalyst can be separated from the bitumen-containing fluid stream 38 by settling of the catalyst in a settler and removal of the catalyst from the bottom of the settler vessel.
Then, the recovered catalyst 58 can be recycled to step 34 for being mixed with water or the organic liquid and then can be reinjected in the produced fluid stream 32.

[091] When the catalyst is separated from the partially upgraded bitumen-containing fluid stream 38 in the catalyst separation step 56, a catalyst depleted partially upgraded bitumen/water emulsion 60 is sent to the bitumen/water separation step 40. In the bitumen/water separator, the bitumen phase is separated from the water phase to recover an upgraded bitumen product 42, which can be pipelined or stored for future use, and recover a produced water stream 62, depleted of catalyst, which can be sent to further downstream purification treatments 46. The purified water stream 48 can then be sent to a steam generation step 50 for generating steam 26 to be injected in the injection well 28 of the SAGD operation. Sludges and/or slurries 64 eliminated during the produced water treatments 46, which mainly contain solids, can be disposed of in a solids disposal step 66.
Aquathermolysis treatment system

[092] As described above, the bitumen partial upgrading process involves a microwave assisted aquathermolysis treatment of a bitumen-containing produced fluid stream, such as bitumen-containing fluid produced in an in situ steam assisted recovery operation, e.g., a SAGD operation. In some implementations, the aquathermolysis treatment can be carried out in an aquathermolysis reactor 70, some features of which can be seen in Figures 4 to 7. The aquathermolysis reactor 70 is designed to enable microwave irradiation of the bitumen-containing produced fluid stream, which also contain the metal catalyst, in a continuous flow.

[093] In some implementations, referring to Figures 4 to 7, the aquathermolysis reactor 70 includes a microwave generating device, such as a magnetron, to generate the microwaves at the desired frequency and a waveguide assembly to guide the microwaves from the microwave generators to a chamber 78 wherein the bitumen-containing produced fluid stream containing the metal catalyst can be irradiated with the microwaves. The microwave generating device can include a plurality of microwave generators 72 including magnetrons, and the waveguide assembly can include a plurality of waveguides 74. Each microwave generator 72 can be connected to a corresponding waveguide 74 of the waveguide assembly and each waveguide 74 is in turn connected to the chamber 78. The waveguides can be constructed using several tubular components that are fitted together to provide the waveguide with the desired trajectory depending on the arrangement of the magnetrons, the chamber and the tubes. The waveguides 74 can be provided with waveguide tuners 76 used for impedance matching of microwave energy between the load impedance and the source impedance. In some implementations, the microwave generators can generate microwaves at a frequency ranging from 900 MHz to 2.8 GHz. The microwaves are generally generated at a constant energy but can be pulsed to control the amount of energy delivered to the fluid.

[094] In some implementations, the chamber 78 can be provided with a plurality of tubes 80 extending throughout the chamber in a longitudinal section thereof, in which the bitumen-containing produced fluid stream can flow while being irradiated with the microwaves generated in the microwave generators. In the implementations represented in Figures 4 to 7, the chamber 78 has a rectangular cross-section and the microwave generators and waveguides are positioned regularly along the length of the chamber.
However, the system is not limited to these example arrangements and other layouts could be contemplated. For instance, the chamber 78 could have a round or polygonal cross-section instead of a rectangular one. The number of microwave generators and waveguides could be adapted depending on the power of the generators and/or the size of the tubes 80, i.e., the volume of fluid traversing the chamber and being irradiated.

[095] In some implementations, the chamber 78 can have walls made of a metal, such as steel, which does not allow passage of microwaves. As shown in Figure 4, doors 88 can be provided along the chamber 78 to provide an access to the interior of the chamber 78 and to the tubes 80 inside the chamber, for control and/or maintenance of the system.

[096] In some implementations, as shown in Figure 6, several tube sections of predetermined lengths can be consecutively connected one to another at their respective ends inside the chamber 78 to form a corresponding tube 80. The so-connected tube sections can then form a longer tube 80 that extends throughout the chamber in a longitudinal section thereof. More particularly, each tube section can be provided with pipe flanges at each of its ends to allow a flexible coupling between consecutive tube sections. This layout using several interconnected tube sections inside the chamber can be advantageous in terms of maintenance and to limit maintenance costs. Indeed, if one tube section would need to be repaired or replaced, one would simply need to intervene on that one tube section.

[097] In some implementations, as shown in Figure 7 for example, tube supports can be provided to support the tubes 80 inside the chamber 78. The tube support 86 can provide support for several tubes 80. However, one could have one support for each tube, for instance, and the support could take a variety of forms. One could also contemplate alternative systems for holding the tubes in the chamber, such as a suspension mechanism.

[098] In some implementations, the tubes 80 can be made of a material which can transmit microwaves (i.e., the microwaves can pass through the material) such that the microwaves reaching the chamber can be directed to the fluid flowing in the tubes and directly heat the fluid components. For instance, the material transmitting the microwaves used for the tubes 80 can be quartz or ceramic. In some implementations, the tubes 80 can be made of a composite material combining the properties of a material that does not absorb microwave energy (to a major extent) with the properties of a material which can absorb microwave energy (to a minor extent) so as to heat the tubes to a certain temperature. For instance, the tubes 80 can be made of ceramic impregnated with a material (e.g., 1-5 % by weight) which can strongly absorb microwave energy. Such microwave absorbent materials can include metals (e.g., iron) or graphite, to allow heating of the tubes to a certain extent.

[099] In some implementations, referring to Figure 6, the aquathermolysis reactor 70 has a modular design that includes multiple modules 90 that can be coupled to each other depending on the process design parameters for a given flow of produced fluid.
When greater microwave energy is desired, additional modules 90 can be added to the overall aquathermolysis reactor 78. Each module can be designed in various ways, and may include a chamber portion, a bundle of tube sections, and at least one microwave generating device (including a magnetron and a waveguide).

[0100] It is also noted that the waveguide 74 can take various forms and can be constructed with subcomponents to provide the desired geometry depending on the arrangement of the other components of the reactor 70. Figures 4 to 7 provide a few example illustrations of such arrangements.

[0101] Referring now to Figure 6, the system can also include a mixer 92 that is provided upstream of the aquathermolysis reactor 70 and ensures good dispersion of the catalyst particles in the produced fluid. For some implementations, a mixer 92 may not be used when the addition of the catalyst particles is done to fully disperse the catalyst particles in the fluid and/or when the fluid flow is sufficiently turbulent to provide dispersion of the catalyst particles. When catalyst particles are introduced along with a carrier liquid, they can be more easily dispersed throughout the produced fluid. The catalyst particles can be kept in a catalyst tank 94 prior to being injected into the produced fluid. The catalyst tank 94 can also receive recycled catalyst 58 and a carrier liquid 96. A pump 98 may also be provided in order to pump the catalyst containing liquid into the produced fluid 32.

[0102] In some implementations, the aquathermolysis reactor 70 can be provided with means for monitoring and controlling the operating conditions, such as the flow rate, the temperature and/or the pressure inside the chamber/tubes. For instance, means can be provided to control the flow rate, the temperature and/or the pressure of the SAGD fluid for optimizing the reaction kinetics of aquathermolysis reaction. Systems can also be implemented for protecting the aquathermolysis arrangement against over-temperature and over-pressure, and a control system can be provided to shut-down the aquathermolysis reactor in case of emergencies.

[0103] Example features of aquathermolysis reactor configurations, which can be used in the present microwave assisted aquathermolysis treatment, have been described herein. However, reactors with other configurations could also be used to perform the treatment as long as the produced fluid to be treated can be irradiated with microwaves to result in aquathermolysis and partial upgrading.

Claims

1- An above surface process for continuous treatment of a bitumen or heavy oil-containing produced fluid stream generated in a subsurface recovery operation, wherein the bitumen or heavy oil-containing produced fluid stream comprises bitumen or heavy oil, and water, the process comprising:
adding a metal catalyst to the bitumen or heavy oil-containing produced fluid stream;
subjecting the bitumen or heavy oil to an aquathermolysis reaction comprising irradiating the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst with microwaves; and generating a partially upgraded bitumen or heavy oil-containing fluid stream.

2- The process of claim 1, wherein adding the metal catalyst comprises adding the metal catalyst in solid form to the bitumen or heavy oil-containing produced fluid stream.

3- The process of claim 1, wherein adding the metal catalyst comprises adding the metal catalyst in a liquid.

4- The process of claim 3, wherein the liquid comprises water.

5- The process of claim 3 or 4, wherein the liquid comprises an organic liquid.

6- The process of any one of claims 3 to 5, wherein the liquid comprises an inorganic liquid.

7- The process of claim 5, wherein the organic liquid comprises a hydrocarbon solvent.

8- The process of claim 5, wherein the organic liquid comprises a light hydrocarbon.

9- The process of claim 3, wherein the liquid comprises a strong hydrogen donor solvent.

10- The process of any one of claims 1 to 9, wherein the metal catalyst is added to the bitumen or heavy oil-containing produced fluid stream to reach a content of the metal catalyst in the range of 5 ppm to 2 % per volume of bitumen or heavy oil content in the produced fluid stream.

11- The process of any one of claims 1 to 10, wherein the metal catalyst comprises iron.

12- The process of any one of claims 1 to 11, wherein the metal catalyst comprises nickel.

13- The process of any one of claims 1 to 12, wherein the metal catalyst comprises copper.

14- The process of any one of claims 1 to 13, wherein the metal catalyst comprises molybdenum.

15- The process of any one of claims 1 to 10, wherein the metal catalyst comprises two or more of iron, nickel, copper and molybdenum.

16- The process of any one of claims 1 to 15, wherein the metal catalyst comprises nano-sized metal catalyst particles.

17- The process of claim 16, wherein the nano-sized metal catalyst particles comprise nanoparticles having a size ranging from 1 to 500 nm.

18- The process of any one of claims 1 to 17, wherein the bitumen or heavy oil-containing produced fluid stream comprises from 1 % to 50 % water by weight.

19- The process of any one of claims 1 to 18, wherein the bitumen or heavy oil-containing produced fluid stream comprises from 30 % to 50 % water by weight.

20- The process of any one of claims 1 to 19, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen or heavy oil-containing fluid stream with a viscosity reduced bitumen or heavy oil.

21- The process of any one of claims 1 to 20, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen or heavy oil-containing fluid stream with a reduced asphaltene content.

22- The process of any one of claims 1 to 21, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen or heavy oil-containing fluid stream with a reduced resin content.

23- The process of any one of claims 1 to 22, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen or heavy oil-containing fluid stream with a reduced content of long chain cyclic molecules.

24- The process of any one of claims 1 to 23, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen-containing fluid stream with a partially sweetened bitumen or heavy oil.

25- The process of any one of claims 1 to 24, wherein the aquathermolysis reaction is conducted with microwaves having a frequency ranging from 900 MHz to 2.8 GHz.

26- The process of any one of claims 1 to 24, wherein the aquathermolysis reaction is conducted with microwaves having a frequency ranging from 965 MHz to 2.45 GHz.

27- The process of claim 25 or 26, wherein the frequency is adjusted based on measured and/or determined dielectric properties of the bitumen or heavy oil-containing produced fluid stream.

28- The process of claim 27, wherein the frequency is adjusted to maximize energy absorbed by the bitumen or heavy oil-containing produced fluid stream.

29- The process of any one of claims 1 to 28, wherein the aquathermolysis reaction is conducted in an aquathermolysis reactor comprising a chamber wherein the bitumen or heavy oil-containing produced fluid stream containing the metal catalyst is irradiated with microwaves.

30- The process of claim 29, wherein the aquathermolysis reactor comprises a plurality of tubes extending throughout the chamber in which the bitumen or heavy oil-containing produced fluid stream flows while being irradiated.

31- The process of claim 30, wherein the tubes comprise a material that transmit microwave energy.

32- The process of claim 30 or 31, wherein the tubes comprise a material that partially absorbs microwave energy and is capable of transferring the absorbed energy as heat to the bitumen or heavy oil-containing produced fluid stream.

33- The process of any one of claims 30 to 32, wherein the aquathermolysis reactor comprises a microwave generating device configured to generate microwaves of a frequency ranging from 900 MHz to 2.8 GHz.

34- The process of claim 33, wherein the aquathermolysis reactor further comprises a waveguide assembly configured to guide the microwaves from the microwave generating device into the chamber.

35- The process of any one of claims 1 to 34, further comprising separating the metal catalyst from the partially upgraded bitumen or heavy oil-containing fluid stream and recycling at least part of the separated metal catalyst for addition to the bitumen or heavy oil-containing produced fluid stream generated in the subsurface recovery operation.

36- The process of any one of claims 1 to 35, further comprising supplying the partially upgraded bitumen or heavy oil-containing fluid stream to a bitumen or heavy oil/water separator to recover a produced water stream and a partially upgraded bitumen or heavy oil stream.

37- The process of claim 36, wherein the partially upgraded bitumen or heavy oil-containing stream has a lower viscosity and a lower asphaltene and resin content than the bitumen or heavy oil in the bitumen or heavy oil-containing produced fluid stream before the aquathermolysis reaction.

38- The process of claim 36 or 37, further comprising treating the produced water stream to recover treated water and separated solids.

39- The process of claim 38, wherein the subsurface recovery operation is an in situ steam assisted recovery operation, and the treated water is recycled to be injected as steam in the in situ steam assisted recovery operation.

40- The process of any one of claims 1 to 39, wherein the subsurface recovery operation is an in situ steam assisted recovery operation.

41- The process of any one of claims 1 to 40, wherein the subsurface recovery operation comprises Cyclic Steam Stimulation (CSS).

42- The process of any one of claims 1 to 40, wherein the subsurface recovery operation comprises Steam Assisted Gravity Drainage (SAGD).

43- The process of any one of claims 1 to 42, wherein the bitumen or heavy oil-containing produced fluid stream further comprises mineral solids.

44- The process of claim 43, further comprising removing at least some of the mineral solids after aquathermolysis.

45- The process of any one of claims 1 to 44, wherein the bitumen or heavy oil-containing produced fluid stream is recovered from a wellhead and is directly subjected to addition of the metal catalyst followed by the aquathermolysis.

46- The process of any one of claims 1 to 44, wherein the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst is subjected to in-line mixing prior to the aquathermolysis.

47- An above surface process for continuous treatment of a bitumen-containing produced fluid stream generated in an in situ steam assisted recovery operation, wherein the bitumen-containing produced fluid stream comprises bitumen, and water, the process comprising:
adding a metal catalyst to the bitumen-containing produced fluid stream, subjecting the bitumen in the bitumen-containing produced fluid stream to an aquathermolysis reaction comprising irradiating the bitumen-containing produced fluid stream comprising the metal catalyst with microwaves, and generating a partially upgraded bitumen-containing fluid stream.

48- A process for improving bitumen/water separation of a bitumen-containing produced fluid stream generated in an in situ steam assisted recovery operation, the process comprising, prior to the bitumen/water separation, in-line addition of a metal catalyst to the bitumen-containing produced fluid stream and then subjecting in continuous mode the bitumen in the bitumen-containing produced fluid stream to a microwave assisted aquathermolysis reaction and generating a partially upgraded bitumen-containing fluid stream.

49- The process of claim 47 or 48, wherein the metal catalyst is added to the bitumen-containing produced fluid stream in solid form.

50- The process of claim 47 or 48, wherein adding the metal catalyst comprises adding the metal catalyst in a liquid.

51- The process of claim 50, wherein the liquid comprises water.

52- The process of claim 50 or 51, wherein the liquid comprises an organic liquid.

53- The process of any one of claims 50 to 52, wherein the liquid comprises an inorganic liquid.

54- The process of claim 52, wherein the organic liquid comprises a hydrocarbon solvent.

55- The process of claim 52, wherein the organic liquid comprises a light hydrocarbon.

56- The process of claim 50, wherein the liquid comprises a strong hydrogen donor solvent.

57- The process of any one of claims 47 to 56, wherein the metal catalyst is added to the bitumen-containing produced fluid stream to reach a content of the catalyst in the range of 5 ppm to 2 % per volume of bitumen or heavy oil content in the produced fluid stream.

58- The process of any one of claims 47 to 57, wherein the metal catalyst comprises iron.

59- The process of any one of claims 47 to 58, wherein the metal catalyst comprises nickel.

60- The process of any one of claims 47 to 59, wherein the metal catalyst comprises copper.

61- The process of any one of claims 47 to 60, wherein the metal catalyst comprises molybdenum.

62- The process of any one of claims 47 to 57, wherein the metal catalyst comprises two or more of iron, nickel, copper and molybdenum.

63- The process of any one of claims 47 to 62, wherein the metal catalyst comprises nano-sized metal catalyst particles.

64- The process of claim 63, wherein the nano-sized metal catalyst particles comprise nanoparticles having a size ranging from 1 to 500 nm.

65- The process of any one of claims 47 to 64, wherein the aquathermolysis reaction is conducted to generate a partially upgraded bitumen-containing produced fluid stream with a viscosity reduced bitumen.

66- The process of any one of claims 47 to 65, wherein the aquathermolysis reaction is conducted to generate a partially upgraded bitumen-containing fluid stream with a reduced asphaltene content.

67- The process of any one of claims 47 to 66, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen-containing fluid stream with a reduced resin content.

68- The process of any one of claims 47 to 67, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen-containing fluid stream with a reduced content of long chain cyclic molecules.

69- The process of any one of claims 47 to 68, wherein the aquathermolysis reaction is conducted to generate the partially upgraded bitumen-containing fluid stream with a partially sweetened bitumen or heavy oil.

70- The process of any one of claims 47 to 69, wherein the aquathermolysis reaction is conducted with microwaves having a frequency ranging from 900 MHz to 2.8 GHz.

71- The process of claim 70, wherein the aquathermolysis reaction is conducted with microwaves having a frequency ranging from 965 MHz to 2.45 GHz.

72- The process of claim 70 or 71, wherein the frequency is adjusted based on measured and/or determined dielectric properties of the bitumen or heavy oil-containing produced fluid stream.

73- The process of claim 72, wherein the frequency is adjusted to maximize energy absorbed by the bitumen or heavy oil-containing produced fluid stream.

74- The process of any one of claims 47 to 73, wherein the aquathermolysis reaction is conducted in an aquathermolysis reactor comprising a chamber wherein the bitumen or heavy oil-containing produced fluid stream containing the metal catalyst is irradiated with microwaves.

75- The process of claim 74, wherein the aquathermolysis reactor comprises a plurality of tubes extending throughout the chamber in which the bitumen or heavy oil-containing produced fluid stream flows while being irradiated.

76- The process of claim 75, wherein the tubes comprise a material that transmit microwave energy.

77- The process of claim 75 or 76, wherein the tubes comprise a material that partially absorbs microwave energy and is capable of transferring the absorbed energy as heat to the bitumen or heavy oil-containing produced fluid stream.

78- The process of claim 76, wherein the tubes comprise ceramic or quartz.

79- The process of claim 77, wherein the tubes comprise ceramic with an embedded microwave absorbent material.

80- The process of claim 79, wherein the microwave absorbent material comprises graphite.

81- The process of claim 79 or 80, wherein the microwave absorbent material comprises a metal.

82- The process of any one of claims 74 to 81, wherein the aquathermolysis reactor comprises a microwave generating device configured to generate microwaves of a frequency ranging from 900 MHz to 2.8 GHz.

83- The process of claim 82, wherein the aquathermolysis reactor further comprises a waveguide assembly configured to guide the microwaves from the microwave generating device into the chamber.

84- The process of any one of claims 47 to 83, further comprising separating the metal catalyst from the partially upgraded bitumen or heavy oil-containing fluid stream and recycling at least part of the separated metal catalyst for addition to the bitumen or heavy oil-containing produced fluid stream generated in the subsurface recovery operation.

85- The process of any one of claims 47 to 84, further comprising supplying the partially upgraded bitumen or heavy oil-containing fluid stream to a bitumen or heavy oil/water separator to recover a produced water stream and a partially upgraded bitumen or heavy oil stream.

86- The process of claim 85, wherein the partially upgraded bitumen or heavy oil-containing stream has a lower viscosity and a lower asphaltene and resin content than the bitumen or heavy oil in the bitumen or heavy oil-containing produced fluid stream before the aquathermolysis reaction.

87- The process of claim 85 or 86, further comprising treating the produced water stream to recover treated water and separated solids.

88- The process of claim 87, wherein the subsurface recovery operation is an in situ steam assisted recovery operation, and the treated water is recycled to be injected as steam in the in situ steam assisted recovery operation.

89- The process of any one of claims 47 to 88, wherein the subsurface recovery operation is an in situ steam assisted recovery operation.

90- The process of any one of claims 47 to 89, wherein the subsurface recovery operation comprises Cyclic Steam Stimulation (CSS).

91- The process of any one of claims 47 to 90, wherein the subsurface recovery operation comprises Steam Assisted Gravity Drainage (SAGD).

92- The process of any one of claims 47 to 91, wherein the bitumen or heavy oil-containing produced fluid stream further comprises mineral solids.

93- The process of claim 92, further comprising removing at least some of the mineral solids after aquathermolysis.

94- The process of any one of claims 47 to 93, wherein the bitumen or heavy oil-containing produced fluid stream is recovered from a wellhead and is directly subjected to addition of the metal catalyst followed by the aquathermolysis.

95- The process of any one of claims 47 to 94, wherein the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst is subjected to in-line mixing prior to the aquathermolysis.

96- A system for ex-situ continuous treatment of a bitumen or heavy oil-containing produced fluid stream comprising bitumen or heavy oil, and water, the system comprising:
a catalyst addition assembly for adding a metal catalyst to the bitumen or heavy oil-containing produced fluid stream; and an aquathermolysis reactor comprising an inlet for receiving the bitumen or heavy oil-containing produced fluid stream comprising the added metal catalyst, and a microwave generating device configured for irradiating the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst with microwaves to produce a partially upgraded bitumen-containing fluid stream.

97- The system of claim 96, wherein the catalyst addition assembly comprises a pump and an addition line, and is configured to add the metal catalyst within a liquid into the bitumen or heavy oil-containing produced fluid stream.

98- The system of claim 97, wherein the liquid comprises water.

99- The system of claim 97, wherein the liquid comprises an organic liquid.

100- The system of claim 97, wherein the liquid comprises an inorganic liquid.

101- The system of any one of claims 97 to 100, wherein the catalyst and the liquid form a suspension.

102- The system of claim 101, wherein the pump is configured to enable injection of the suspension of the metal catalyst into the bitumen or heavy oil-containing produced fluid stream at a flow rate allowing a content of the metal catalyst in the bitumen or heavy oil-containing produced fluid stream to reach 5 ppm to 2 % per volume of bitumen or heavy oil content in the produced fluid stream.

103- The system of any one of claims 96 to 102, wherein the aquathermolysis reactor comprises a chamber in which the bitumen or heavy oil-containing produced fluid stream comprising the metal catalyst is irradiated with microwaves.

104- The system of claim 103, wherein the aquathermolysis reactor comprises a plurality of tubes extending through the chamber and in which the bitumen or heavy oil-containing produced fluid stream flows while being irradiated.

105- The system of claim 104, wherein the tubes comprise a material that transmits microwave energy.

106- The system of claim 104, wherein the tubes consist of a material that transmits microwave energy.

107- The system of claim 104 or 105, wherein the tubes comprise quartz.

108- The system of claim 104 or 105, wherein the tubes comprise ceramic.

109- The system of claim 102, wherein the tubes comprise a material which partially absorbs microwave energy and is capable of transferring the absorbed energy as heat to the bitumen or heavy oil-containing produced fluid stream.

110- The system of claim 109, wherein the material which partially absorbs microwave energy comprises a ceramic that is impregnated with a microwave absorbent metal.

111- The system of claim 110, wherein the microwave absorbent metal comprises iron.

112- The system of claim 110 or 111, wherein the microwave absorbent metal is present in the form of particles dispersed within the ceramic.

113- The system of any one of claims 110 to 112, wherein the microwave absorbent material is present in an amount of 1 to 5 % by weight.

114- The system of claim 109, wherein the material which partially absorbs microwave energy comprises a ceramic that is impregnated with graphite.

115- The system of claim 114, wherein the graphite is present in an amount of 1 to 5 % by weight.

116- The system of any one of claims 96 to 115, wherein the microwave generating device comprises at least one magnetron.

117- The system of claim 116, wherein the microwave generating device comprises a plurality of magnetrons arranged in series to generate microwaves.

118- The system of any one of claims 96 to 117, wherein the microwave generating device is configured to generate microwaves of a frequency ranging from 900 MHz to 2.8 GHz.

119- The system of any one of claims 96 to 118, wherein the aquathermolysis reactor further comprises a waveguide assembly to guide the microwaves from the microwave generators to the chamber.

120- The system of any one of claims 96 to 119, further comprising a catalyst separator for separating the metal catalyst from the partially upgraded bitumen or heavy oil-containing fluid stream.

121- The system of claim 120, further comprising a recycling line for recycling at least a portion of the separated metal catalyst to the bitumen or heavy oil-containing produced fluid stream.

122- The system of claim 121, wherein the recycling line is coupled to the catalyst addition assembly for supplying the portion of the separated metal catalyst thereto.

123- The system of any one of claims 96 to 122, further comprising a bitumen or heavy oil/water separator to separate the partially upgraded bitumen or heavy oil-containing fluid stream into a produced water stream and a partially upgraded bitumen or heavy oil stream.

124- The system of claim 123, wherein the bitumen or heavy oil-containing produced fluid stream comprises mineral solids and the system further comprises a produced water treatment unit to recover treated water and separated mineral solids.

125- The system of any one of claims 96 to 124, wherein the bitumen or heavy oil-containing produced fluid stream is obtained from a wellhead of a subsurface hydrocarbon recovery operation.

126- The system of claim 125, wherein the catalyst addition assembly is configured and positioned to add the metal catalyst into the bitumen or heavy oil-containing produced fluid stream directly after withdrawal from the wellhead.

127- The system of claim 125 or 126, wherein the subsurface hydrocarbon recovery operation comprises an in situ steam assisted recovery operation and the system further comprises a steam generator for receiving the treated water for recycling to the in situ steam assisted recovery operation.

128- The system of any one of claims 125 to 127, wherein the subsurface hydrocarbon recovery operation comprises Cyclic Steam Stimulation (CSS).

129- The system of any one of claims 125 to 128, wherein the subsurface hydrocarbon recovery operation comprises Steam Assisted Gravity Drainage (SAGD).

130- The system of any one of claims 104 to 115, wherein each tube comprises multiple tube sections coupled to each other end to end.

131- The system of claim 130, wherein each tube comprises flexible connectors for coupling adjacent tube sections together.

132- The system of claim 130 or 131, wherein the tubes are arranged in multiple rows that are vertically spaced apart from each other.

133- The system of any one of claims 96 to 132, further comprising a mixer that is provided in between the catalyst addition assembly and the aquathermolysis reactor for ensuring dispersion of the metal catalyst in the bitumen or heavy oil-containing produced fluid stream.

134- The system of claim 133, wherein the mixer comprises at least one in-line mixer.

135- The system of claim 134, wherein the in-line mixer comprises a static mixer.

136- The system of any one of claims 96 to 135, further comprising a fluid monitoring device for monitoring properties of the bitumen or heavy oil-containing produced fluid stream.

137- The system of claim 136, wherein the monitored properties comprise temperature, flow rate, water content, bitumen content, heavy oil content and/or dielectric properties.

138- The system of claim 136 or 137, further comprising a control unit for controlling the aquathermolysis reactor.

139- The system of claim 138, wherein the control unit is configured to receive at least one of the monitored properties and to adjust dosage of the metal catalyst, flow rate of the bitumen or heavy oil-containing produced fluid stream, and/or the frequency of the microwaves, in response thereto.

140- The system of claim 138 or 139, wherein the control unit is further configured to shut down the aquathermolysis reactor in response to a detected over-temperature or over-pressure therein.

141- The system of any one of claims 96 to 140, wherein the aquathermolysis reactor has a modular design wherein each module comprises a chamber section, multiple tube sections mountable within the chamber section, and at least one microwave generating device for generating microwaves for irradiating the bitumen or heavy oil-containing produced fluid stream to flow through the corresponding multiple tube sections.

142- The system of any one of claims 96 to 141, wherein the metal catalyst comprises iron.

143- The system of any one of claims 96 to 142, wherein the metal catalyst comprises nickel.

144- The system of any one of claims 96 to 143, wherein the metal catalyst comprises copper.

145- The system of any one of claims 96 to 144, wherein the metal catalyst comprises molybdenum.

146- The system of any one of claims 96 to 141, wherein the metal catalyst comprises two or more of iron, nickel, copper and molybdenum.