EA022662B1 - Device for reforming heavy oil and method of reforming heavy oil - Google Patents

Abstract

A device and method for reforming a heavy oil are provided with which it is possible to control the degree of progress of the thermal cracking of the heavy oil when the heavy oil is reformed using supercritical water. A reactor (1) is kept at a temperature and a pressure which are equal to or higher than the critical points of water. A heavy oil is brought into contact with supercritical water in the reactor (1), and while thermal cracking of the heavy oil is allowed to proceed, the heavy oil is separated into a first phase comprising heavy-oil residual matter obtained by the thermal cracking and supercritical water dissolved in the heavy-oil residual matter, and a second phase comprising supercritical water and light-oil matter extracted in the supercritical water. An interface detector (75) detects the level of the interface between the first phase and the second phase in the reactor. A control unit controls, on the basis of the volume of the first phase determined from the level of the interface, the discharge rate of the mixed fluid composed of the heavy-oil residual matter and the supercritical water dissolved therein, so that the residence time of the heavy-oil matter/supercritical water mixed fluid is a first residence time preset.

Description

The present invention relates to a technique used to improve the characteristics of heavy oil using supercritical water.

Background of the invention

Since they forecast an increase in the consumption of crude oil, especially in developing countries such as China and India, and the extraction of traditionally used light natural oil has reached its maximum, the need to use heavy crude oil or super-heavy crude oil, which has almost never been used, is increasing. Even in the field of super heavy oil, cost-effective technologies have been developed for the extraction and processing of tar sands in Canada and the Orinoco basin in Venezuela, and production volumes continue to increase.

These types of super heavy crude oils have extremely high density and viscosity. Therefore, pipelines cannot be directly used to transport these types of oil from wells in production areas to refineries and consumers. For this reason, two treatment methods are usually chosen for use at the oil production site: dilution, in which a diluent is mixed to reduce viscosity, and a method for improving crude oil characteristics, where an enterprise called an anadworker plant is built near the production site, and through thermal cracking and hydrogenation light synthetic crude oil.

However, the following complications are associated with the dilution method. In particular, it is necessary to provide a sufficient amount of a diluent, such as condensate; in addition, transport costs increase due to the fact that dilution leads to an increase in the amount transported. Some of the difficulties associated with the method of upgrading. So, since a large plant-upgrade is needed at the well site, comparable in size to an oil refinery, such a design will be cost-effective only in the vicinity of large oil fields. In addition, it is necessary to process by-products, such as coke and sulfur, and to ensure the supply of hydrogen required for upgrading.

Thermal cracking methods (such as those using a delayed coking and coking unit in a fluidized bed) and hydrocracking methods (such as the Η-Θίΐ and LС-Ршдк) processes are currently available as methods for improving the performance (upgrading) of heavy oil. In the process of thermal cracking, heavy oil is split and cracking fuel oil, gas and coke are formed. A complication of this method is that for storing waste products of by-products, such as coke and sulfur, produced in large quantities, it is often necessary to occupy free territories.

The hydrocracking process is a technology for the decomposition of heavy oil using a catalyst under conditions of high temperature and high hydrogen pressure. In this case, a large amount of hydrogen is required and therefore carburized or natural gas is required. As a result, there is a problem of its delivery. In addition, the need for catalyst supply and disposal of spent catalyst should be taken into account.

As described earlier in this document, modern technology has complications associated with the processing of by-products, the production of hydrogen, the supply of catalyst and the processing of used catalysts.

To overcome the above complications, the authors of this application have focused their attention on the method of improving the characteristics of heavy crude oil or super heavy crude oil (hereinafter referred to as heavy oil) using supercritical water and on the method of producing synthetic crude oil that can be transported in pipelines without using thinner, through a simple upgrade scheme. According to this technique, synthetic crude oil, which can be transported through pipelines, can be obtained by parallelly carrying out a thermal cracking reaction of heavy oil, induced by contact of heavy oil with supercritical water, and extraction of the light oil fraction formed by thermal cracking, into supercritical water, carried out in a reactor , and the separation and extraction of extracted light oil fraction. A heavy residual oil fraction that has not been extracted into supercritical water can be used as a residual oil product, used, for example, as boiler fuel.

For example, as a method for improving the characteristics of heavy oil through the use of supercritical water, patent document 1 describes a method in which heavy oil is introduced vertically in the lower direction from the top of a reactor, into which supercritical (or subcritical) water is introduced from the bottom, leading them to contact for upgrading, thereby dividing heavy oil into a light oil fraction dissolved in supercritical water, and into a heavy residual oil fraction that would not la dissolved in it.

In addition, Patent Document 2 proposes a machine for upgrading, having a primary thermal cracking unit, in which heavy oil is heated and mixed with supercritical water in the lower part inside a vertical reactor and a part of the source material is split into a light component and gasified, and installation secondary cracking, suspended vertically inside the reactor above its central part and serving to further splitting part of the gasified light component to the component subjected to high temperature. In a primary thermal cracking unit inside the reactor, a thermal cracking tank is provided, and the heavy oil reacts inside it. The liquid that flows from this thermal cracking tank is discharged as an oil residue from the bottom of the reactor. In addition, Patent Document 3 discloses a method for reacting heavy oil with supercritical water inside a reactor to form an emulsion oil that has been upgraded and coke while continuously withdrawing an oil emulsion that has been upgraded and periodically removing coke.

List of cited documents

Patent documents

Patent document 1. Japanese Patent No. 4171062: Clause 1, Paragraphs [0030] - [0033], FIG. one.

Patent document 2. 1Р-Л-2008-208170: paragraph 1, paragraphs [0012] - [0017], FIG. one.

Patent document 3. 1P-L-2007-51224: paragraph 1, paragraphs [0024] - [0030], FIG. 3

Summary of Invention

Problems solved by the present invention

Using the method described in patent document 1 cited among the above priority materials, heavy oil is brought into contact with supercritical water and the light oil fraction is dissolved in this supercritical water, thereby removing heavy metals such as vanadium contained in heavy oil and obtaining gas turbine fuel that does not cause high temperature corrosion. In this case, the heavy metals contained in the heavy oil are concentrated in the heavy residual oil fraction, which has not been dissolved in supercritical water, and this heavy residual oil fraction is used as boiler fuel, etc.

In addition, the description of patent document 1 (paragraph [0012]) indicates that although upgrading occurs when heavy oil is brought into contact with supercritical water, this technique focuses on dissolving the light oil fraction in supercritical water, while heavy oil that is not was dissolved in it, precipitated and separated without further upgrade. Therefore, Patent Document 1 does not disclose a technique for improving the characteristics of a heavy residual oil fraction that has not been dissolved in supercritical water, a decrease in density or viscosity and the production of synthetic crude oil.

In addition, in the method described in patent document 2, the primary thermal cracking unit is heated to a temperature of 380-450 ° C, and the secondary thermal cracking unit placed above the primary thermal cracking unit is heated to a temperature of 450-550 ° C, which is more higher than the temperature in the primary thermal cracking unit; as a result, the cracking is carried out in two stages: the heavy oil brought into contact with supercritical water is split into a light oil fraction, and then into a component, door upgrade. However, where the cracking of the light component is actively continued, as is the case when applying the method described above, the amount of gas generated due to excessively deep cracking (with a decrease in the yield of the liquid product) increases, or the concentration of olefins in the light component increases. Therefore, this technique is not suitable for the production of synthetic crude oil.

In addition, Patent Document 2 (paragraph [0018]) indicates that the reaction time of heavy oil inside a thermal cracking vessel attributable to a primary thermal cracking unit is controlled by changing the amount of heavy oil introduced or the volume of a thermal cracking vessel, and The secondary thermal cracking unit is adjusted by changing the flow rate of the heavy oil or by placing the filler in the secondary thermal cracking unit and changing its internal volume.

The description of patent document 2 does not disclose, for example, the distance between the primary thermal cracking unit and the secondary thermal cracking unit or the gap between the thermal cracking tank placed inside the reactor of the primary thermal cracking unit and the reactor itself, or temperature conditions in the lower part of the reactor, where keep the liquid flowing from the thermal cracking vessel. However, by the above methods it is difficult to exercise sufficient control over the cracking reaction, the polymerization reaction of the light component, the liquid in contact with the medium having a temperature reaching, for example, 380-550 ° C, and its flow, which can proceed in this medium, and the reaction inside the reactor .

Using the method described in patent document 3, technological operations are carried out under conditions where coke is actively formed, the processing of which creates certain complications. In addition, the increase in gas formation (decrease in the yield of the liquid product) due to excessively deep cracking of light oil, and an increase in the concentration of olefins in the upgraded oil, requires special attention, especially under severe conditions (such as conditions causing coke formation).

The present invention was created to solve the above problems, and its purpose is to provide an apparatus for improving the performance (upgrading) of heavy oil and the method of upgrading, which makes it possible to adjust the degree of thermal cracking of heavy oil when heavy oil is subjected to upgrading through the use of supercritical water .

Means for Solving the Problem

A heavy oil retrofit apparatus according to one aspect of the present invention includes a reactor that is maintained at a temperature and pressure corresponding to or above critical water points, at which heavy oil and supercritical water are brought into mutual contact, and the heavy oil is divided into the first phase consisting of heavy residual oil fraction obtained by thermal cracking and supercritical water dissolved in a heavy residual oil fraction, and in the second phase consisting of supercritical water and light oil fraction, extracted into supercritical water during the process of thermal cracking of heavy oil;

a heavy oil supply unit that supplies heavy oil to the reactor;

a supercritical water supply unit that supplies supercritical water to the reactor;

the first block of discharge, which removes from the first phase the liquid mixed from the heavy residual oil fraction and supercritical water;

the second block of discharge, which removes from the second phase a liquid mixed from supercritical water and light oil fraction;

interphase detector that detects the height of the position of the boundary between the first phase and the second phase in the reactor, and the control unit that finds the volume of the first phase along the height of the position of the interphase boundary detected by the interphase detector and regulates the amount of liquid mixed from the heavy residual oil fraction and the supercritical water, the largest volume of the first phase, so that the residence time of the liquid mixed from the heavy residual oil fraction and supercritical water dissolved in the heavy residual phyto fraction becomes the first residence time, which is set in advance.

An apparatus for upgrading heavy oil according to another aspect of the present invention includes a reactor that is maintained at a temperature and pressure equal to or above critical water points, at which heavy oil and supercritical water are brought into mutual contact, and the heavy oil is divided into the first phase consisting of heavy residual oil fraction obtained by thermal cracking and supercritical water dissolved in a heavy residual oil fraction, and in the second phase consisting of supercrit garlic water and light oil fraction extracted into supercritical water during the thermal cracking of heavy oil;

a heavy oil supply unit that supplies heavy oil to the reactor;

a supercritical water supply unit that supplies supercritical water to the reactor;

a first diversion unit, which drains liquid mixed from heavy residual oil fraction and supercritical water, from the first phase;

the second discharge unit, which discharges liquid mixed from supercritical water and light oil fraction, from the second phase, and a control unit that regulates the discharge amount of liquid mixed from heavy residual oil fraction and supercritical water, according to the input amount of heavy oil, so time the residence of the liquid mixed from the heavy residual oil fraction and the supercritical water dissolved in the heavy residual oil fraction becomes the first residence time that is set in advance.

The above described devices improving the characteristics of heavy oil may have the following features:

(a) to inhibit coke formation in a heavy residual oil fraction, the control unit adjusts the discharge amount of the liquid mixed from the heavy residual oil fraction and supercritical water so that the first residence time is at least 3 minutes and not more than 95 minutes;

(b) the first residence time is the residence time during which the thermal cracking of heavy oil proceeds in a range in which the amount of coke formed is equal to or greater than 0 wt.% and equal to or less than 20 wt.% of the heavy residual oil fraction;

(c) the first residence time is the residence time during which the thermal cracking of heavy oil proceeds until the kinematic viscosity of the heavy residual oil fraction at a temperature of 350 ° C becomes equal to or less than 3.0 χ 10 ^-5 m ² / with;

(ά) the control unit finds the volume of the second phase according to the height of the position of the interphase boundary detected by the interphase detector, and adjusts the input amount of supercritical water based on the volume of the second phase, so that the residence time of the liquid mixed from supercritical water and light oil fraction extracted into the supercritical water becomes the second residence time, which is set in advance;

- 3,022,662 (e) the control unit adjusts the amount of supercritical water injected based on the amount of heavy oil injected, so that the residence time of the liquid mixed from the supercritical water and light oil fraction extracted into the supercritical water becomes the second residence time, which is set in advance;

(ί) in order to inhibit the excessively deep cracking of the light oil fraction, the control unit regulates the amount of supercritical water injected so that the second residence time is equal to or greater than 1 minute and less than or equal to 25 minutes;

(e) the second residence time is the residence time during which the thermal cracking of heavy oil proceeds in a range in which the amount of gas formed by excessively deep cracking is equal to or greater than 0% by weight and equal to or less than 5% by weight heavy residual oil fraction;

(B) the second residence time is the residence time during which the thermal cracking of heavy oil proceeds until the kinematic viscosity of the light oil fraction at 10 ° C is equal to or less than 5.0 x 10 ^-3 m ² / s , and (ί) heavy oil is selected from the group of heavy oils, including oil sand bitumen, the Orinoco Basin bitumen, the atmospheric residual fraction and the vacuum residual fraction.

A method for improving the performance of heavy oil in accordance with yet another aspect of the present invention includes the following steps:

the introduction of heavy oil into the reactor; the introduction of supercritical water into the reactor;

maintaining the internal space of the reactor at a temperature and pressure equal to or higher than the critical points of water, bringing heavy oil and supercritical water into mutual contact and separation of heavy oil into the first phase, consisting of heavy residual oil fraction obtained by thermal cracking, and supercritical water, dissolved in a heavy residual oil fraction, and in the second phase, consisting of supercritical water and light oil fraction, extracted into supercritical water during the process nical cracking heavy oil;

removal of the liquid mixed from the heavy residual oil fraction and supercritical water from the first phase;

removal of liquid mixed from supercritical water and light oil fraction from the second phase;

detecting the height of the position of the interphase boundary between the first phase and the second phase in the reactor and finding the volume of the first phase along the height of the position of the interphase boundary detected by the interphase detector, and adjusting the amount of liquid mixed from the heavy residual oil fraction and supercritical water, calculated on the volume of the first phase so that the residence time of the liquid mixed from the heavy residual oil fraction and the supercritical water dissolved in the heavy residual oil fraction becomes first m the residence time, which is set in advance.

A method for improving the performance of heavy oil in accordance with yet another aspect of the present invention includes the following steps:

the introduction of heavy oil into the reactor; the introduction of supercritical water into the reactor;

maintaining the internal space of the reactor at a temperature and pressure equal to or higher than the critical points of water, bringing heavy oil and supercritical water into mutual contact and separation of heavy oil into the first phase, consisting of heavy residual oil fraction obtained by thermal cracking, and supercritical water, dissolved in a heavy residual oil fraction, and in the second phase, consisting of supercritical water and light oil fraction, extracted into supercritical water during the process nical cracking heavy oil;

removal of the liquid mixed from the heavy residual oil fraction and supercritical water from the first phase;

removing the liquid mixed from supercritical water and light oil fraction from the second phase and regulating the discharge amount of liquid mixed from heavy residual oil fraction and supercritical water, based on the input amount of heavy oil, so that the residence time of the liquid mixed from heavy residual oil fractions and supercritical water dissolved in heavy residual oil fraction becomes the first residence time, which is set in advance.

The above methods that improve the characteristics of heavy oil may have the following features:

(ί) the first residence time is set in the range of at least 3 minutes to not more than 95 minutes to inhibit the formation of coke in the heavy residual oil fraction;

- 4 022662 (k) the first residence time is the residence time during which the thermal cracking of heavy oil proceeds in a range in which the amount of coke formed is equal to or greater than 0% by weight and equal to or less than 20% by weight of the heavy residual oil fraction ;

(l) The first residence time is the residence time during which the thermal cracking of heavy oil proceeds until the kinematic viscosity of the heavy residual oil fraction at 350 ° C becomes equal to or less than 3.0 x 10 ^-5 m ² / with;

(t) the stage of finding the volume of the second phase along the height of the position of the interphase boundary detected at the stage of detecting the height of the position of the interphase boundary between the first phase and the second phase in the reactor, and controlling the amount of supercritical water injected, so that the residence time of the liquid mixed from supercritical water and the light oil fraction, extracted into supercritical water in the second phase, becomes the second residence time, which is set in advance;

(p) the stage of controlling the input amount of supercritical water based on the input amount of heavy oil is included, so that the residence time of the liquid mixed from the supercritical water and the light oil fraction extracted into the supercritical water becomes the second residence time, which is set in advance;

(o) regulating the second residence time, it is set in the range of at least 1 minute to at most 25 minutes to inhibit excessively deep cracking of the light oil fraction;

(p) the second residence time is the residence time during which the thermal cracking of heavy oil proceeds in a range in which the amount of gas formed by excessively deep cracking is equal to or greater than 0% by weight and equal to or less than 5% by weight heavy residual oil fraction;

(c |) the second residence time is the residence time during which the thermal cracking of heavy oil proceeds until the kinematic viscosity of the light oil fraction at a temperature of 10 ° C becomes equal to or less than 5.0 x 10 ^-3 m ² / c, and (d) included the stage of lowering the temperature and reducing the pressure of the liquid mixed from the heavy residual oil fraction and supercritical water, which was withdrawn from the first phase, and separating the heavy residual oil fraction and water;

(δ) included the stage of reducing the temperature of the liquid mixed from the heavy residual oil fraction and supercritical water, which was withdrawn from the first phase, and obtaining fuel in a state in which the water fraction is included in the heavy residual oil fraction;

(ΐ) the liquid mixed from the heavy residual oil fraction and supercritical water that was withdrawn from the first phase includes an aqueous fraction in the range of at least 3% by weight to not more than 100% by weight of the heavy residual oil fraction;

(i) the stage of lowering the temperature and reducing the pressure of the liquid mixed from supercritical water and light oil fraction, which was withdrawn from the second phase, and separating the light oil fraction and water is included;

(ν) included the stage of extraction of water, separated from the heavy residual oil fraction or light oil fraction, for reuse as supercritical water introduced into the reactor;

(those) include the stages of reducing the temperature and reducing the pressure of the liquid mixed from the heavy residual oil fraction and supercritical water, which was withdrawn from the first phase, and separating the heavy residual oil fraction and water;

lowering the temperature and reducing the pressure of the liquid mixed from supercritical water and light oil fraction, which was removed from the second phase, and separating the light oil fraction and water, and mixing the heavy residual oil fraction and light oil fraction after separation from water, and (x) heavy oil is selected from the heavy oil group, which includes oil sand bitumen, the Orinoco basin bitumen, the atmospheric residual fraction and the vacuum residual fraction.

Advantage of the invention

According to the present invention, heavy oil and supercritical water are brought into mutual contact inside the reactor, thereby separating these two liquids into two phases — the first phase (the phase consisting of a liquid mixed from a heavy residual oil fraction and a supercritical water dissolved in a heavy residual oil fraction ) and the second phase (the phase consisting of a liquid mixed from supercritical water and light oil fraction extracted into supercritical water), and the amount of liquid mixed from the heavy residue internal oil fraction and supercritical water, are adjusted so that the residence time of the mixed liquid constituting the first phase, in the very first phase is the first dwell time which is set in advance. As a result, the degree of thermal cracking depth of the heavy residual oil fraction,

- 5 022662 of what is happening in the first phase, can be adjusted, and the upgrade unit can work in optimal conditions; for example, the maximum thermal limit cracking is carried out in a range in which coke formation from the heavy residual oil fraction is inhibited, or thermal cracking is carried out so that the kinematic viscosity of the heavy residual oil fraction is in the desired range.

Brief Description of the Drawings

FIG. 1 is a flowchart related to the upgrade apparatus of the present invention.

FIG. 2 is an explanatory drawing showing the configuration of the reactor provided in the upgrade apparatus.

FIG. 3 is a flow chart of an example test apparatus.

FIG. 4 is an explanatory drawing showing the interphase boundary between the first phase and the second phase formed inside the reactor.

The method of carrying out the invention

First, an explanation will be given of the overall configuration of the apparatus for improving the performance (upgrading) of heavy oil according to the present invention with reference to the process flow diagram shown in FIG. 1. The upgrading apparatus according to this embodiment of the present invention is located at a well site where crude oil with high density and high viscosity is produced, such as oil sand bitumen or Orinoco basin bitumen; The apparatus serves to improve the performance of heavy oil by converting it into low density, low viscosity synthetic crude oil.

As shown in FIG. 1, the upgrade apparatus is provided with a first reactor in which heavy oil and supercritical water are brought into mutual contact and heavy oil is upgraded and separated into a heavy residual oil fraction and a light oil fraction, with a high pressure separator 2, which separates oil from water in a liquid mixed from the light oil fraction and supercritical water flowing from reactor 1 (for example, under pressure conditions identical to the pressure inside reactor 1), with a low pressure separator 3 that separates oil about t of water in a liquid mixed from light oil and water flowing from a high pressure separator 2 (at a pressure lower than that of high pressure separator 2), with a flash drum 4 that separates oil from water in a liquid mixed from heavy residual oil fraction and supercritical water flowing from reactor 1 (at a pressure lower than reaction pressure 1), and with a reservoir for recycled water 5 reused after its separation from oil.

In reactor 1, heavy oil is subjected to thermal cracking, bringing it into contact (for example, countercurrent) with supercritical water at elevated temperature and elevated pressure. The reactor serves to separate the light oil fraction and the heavy residual oil fraction obtained therein, and to discharge the separated fractions. Reactor 1 is a high pressure vessel with an internal cavity, having, for example, a columnar shape. A heavy oil supply pipeline 110 serving to produce heavy oil from a heavy oil supply source 11 is connected, for example, to the side of the reactor wall in its upper part. The supply source of heavy oil 11 is, for example, a reservoir in which heavy oil is stored.

A heavy oil supply pump 111 is installed on the heavy oil supply pipeline 110, which raises the pressure to a value equal to or greater than 22.1 MPa, which is the critical pressure for water (for example, up to 25-30 MPa) and pumps 1 heavy oil to the reactor received from a heavy oil supply source 11, a valve 112 regulating the flow rate that regulates the supplied quantity of heavy oil, and a heating device 113, consisting, for example, of a heating furnace and serving to heat the heavy oil supplied to reactor 1 (for example, to a temperature of 300-450 ° C). To prevent the polycondensation of heavy oil in the heavy oil supply pipeline 110 or in the heating device 113, heavy oil is supplied at a temperature lower than the temperature (for example, 374-500 ° C) inside the reactor 1. The heavy oil supply pipeline 110, the heavy oil supply pump 111, a flow rate regulating valve 112, and a heating device 113 correspond to the heavy oil supply unit of the present embodiment.

The supply pipe of supercritical water 120, which serves to supply water obtained from a supply source of water 12, consisting of a storage tank or the like, to the reactor 1 in a supercritical state, is connected, for example, with the lateral side of the reactor wall in its lower part. A supercritical water supply pump 121 is installed on the supercritical water supply pipe 120, which increases the pressure to a value equal to or greater than the critical water pressure (22.1 MPa), for example, 25-30 MPa, and pumps 1 water to the reactor water 12, a valve 122 regulating the flow rate that regulates the supplied amount of supercritical water, and a heating device 123 consisting, for example, of a heating furnace and used for heating supercritical water supplied to p Factor 1, for example, to a temperature equal to or greater than its critical temperature (374 ° C), for example, to 450-600 ° C. As described 6 022662, but higher in this document, the heavy oil supplied from supply line 110 is supplied at a temperature lower than the temperature inside reactor 1 to prevent polycondensation. Therefore, where supercritical water is supplied from the supercritical water supply pipeline 120 at a temperature higher than the temperature inside the reactor 1, the heat necessary for the reaction of thermal cracking of heavy oil is supplied to the reactor. The supercritical water supply line 120, the supercritical water supply pump 121, the flow rate regulating valve 122, and the heating device 123 correspond to the supercritical water supply unit of this embodiment of the present invention.

The light oil fraction 130 discharge pipe, which serves to drain the mixed liquid formed by extracting the light oil fraction obtained by cracking heavy oil inside reactor 1, into supercritical water, is connected, for example, to the upper part of the reactor column 1. On the light oil discharge pipe 130, a cooling device 132 is installed, consisting of a heat exchanger or the like. and serving to cool the mixed liquid flowing in the light oil discharge pipe 130 to a temperature lower than the critical water temperature (for example, up to 200-374 ° C), and a valve 131 regulating the pressure inside the reactor 1 (for example, 25 -30 MPa). The light oil discharge pipe 130, the pressure regulating valve 131, and the cooling device 132 correspond to the second discharge block of this embodiment of the present invention.

A high pressure separator 2 used to separate the mixed liquid cooled in a cooling device 132 into a light oil fraction (this light oil fraction also contains an aqueous fraction) and water under pressure almost equal to the pressure inside reactor 1 is provided after the light oil fraction 130. The pipeline of light oil fraction 210, through which the light oil fraction is withdrawn and pumped to the low pressure separator 3, is connected to the upper part of the high pressure separator 2. On the pipeline cooling oil 210 is installed cooling device 212, consisting of a heat exchanger or the like. and serving to cool the light oil fraction to a temperature of about 40-100 ° C, and a valve 211 that lowers the pressure of the light oil fraction flowing in line 210, for example, to a pressure of about 0.2 to 1.0 MPa, which is higher than normal pressure.

For water separated at high pressure, a pipeline 220 is provided at the bottom of the high-pressure separator 2, which discharges water separated from the light oil fraction under pressure of about 25-30 MPa and under conditions of temperature 200-374 ° C. The pipeline 220 of water separated at high pressure is connected to the circulating water pipeline 510 described below, and the separated water from the high pressure separator 2 can again be fed to the reactor 1. A recirculation pump 221 of water separated at high pressure installed on the water pipeline 220, separated at high pressure, serves to pump the separated water from the high pressure separator 2.

The following is an explanation of the low pressure separator 3 provided after the light oil fraction 210 pipeline. The low pressure separator 3 serves to re-separate the light oil fraction and water under pressure of about 0.2-1.0 MPa and under the conditions of temperature approximately 40-100 ° C, carried out in relation to the light oil fraction, including the water fraction and flowing from the high-pressure separator 2. Positional designation 320 refers to a pipeline of synthetic crude oil, which divert t light oil fraction, separated from water, as synthetic crude oil in a reservoir for synthetic crude oil 62.

Pipeline 330 circulating water, separated at low pressure, connect, for example, with the lower part of the low pressure separator 3. Pipeline 330 circulating water, separated at low pressure, serves to drain water, separated from the light oil fraction, and pumps the water withdrawn in the form of supercritical water in the circulating water tank 5 for reuse. In addition, from the pipeline of recycled water 330, separated at low pressure, a branch pipe of wastewater 340 is branched, through which part of the water to be reused is diverted to wastewater treatment equipment 63, and the concentration of oil fraction or salt concentration in circulating water, which circulates inside the upgrade unit, it can be brought to a value not exceeding a predetermined value by increasing or decreasing the amount of fluid pumped to wastewater treatment equipment 63. Positional signs Report 310, shown in the figure, refers to a pipeline of discharged gas, which serves to pump gas that has evaporated from the light oil fraction to the equipment for treatment of discharged gas 61.

Regarding the technological scheme in the upper part of the column of the above described reactor 1, it can be indicated that the pipeline 140 diverts the heavy residual oil fraction, which serves to drain liquid mixed from the heavy residual oil fraction (which was not extracted into supercritical water) was dissolved in a heavy residual oil fraction), from the heavy oil cracked inside reactor 1, is

- 7 022662 connected, for example, to the column of the lower part of the reactor 1. A cooling device 141 consisting of a heat exchanger or the like is installed on the pipeline 140 which discharges the heavy residual oil fraction. and serving to cool the mixed liquid flowing in conduit 140 to a temperature of about 200-350 ° C, and a valve 142 regulating the flow rate and serving to control the amount of the mixed liquid withdrawn from the column of the lower part of the reactor 1 and to reduce the pressure a mixed fluid flowing inside the pipeline 140 which discharges a heavy residual oil fraction (for example, to a pressure of about 0.2-1.0 MPa, which is higher than the normal pressure). A conduit 140 for withdrawing a heavy residual oil fraction, a cooling device 140 and a valve 142 regulating the flow rate correspond to the first withdrawal unit of this embodiment of the present invention.

The valve 142 regulating the flow rate is connected to the evaporation drum 4, and the evaporation drum 4 plays the role of a separator separating the heavy residual oil fraction and water dissolved in the heavy residual oil fraction under conditions of pressure of 0.21 MPa and temperature conditions of approximately 200-350 ° C. The pipe 410 for the water separated in the drum, provided in the evaporation drum 4, serves to drain the water separated inside the evaporation drum 4 to the circulating water pipeline 330 separated at low pressure and to reuse the water. The residual oil pipeline 420 serves to drain heavy residual oil fraction separated from water (for example, as residual oil boiler fuel) to the residual oil reservoir 64.

Pipeline 430 branches off the residual oil pipeline 420, mixing synthetic crude oil used to mix the total amount of heavy residual oil fraction withdrawn from the evaporator drum 4 (or its part) with the light oil fraction withdrawn from the low-pressure separator 3 and for pumping this mixture into a reservoir of synthetic crude oil 62. By mixing heavy residual oil fraction with a light oil fraction, it is possible to increase the yield of synthetic crude oil with added value, revoskhodyaschey boiler fuel costs. The amount of heavy residual oil fraction mixed with the light oil fraction is adjusted so that the mixed amount is in the range in which, after mixing, the compatibility of synthetic crude oil is ensured; in other words, so that the mixed quantity is in the range in which the synthetic crude oil after mixing would not be separated again into heavy and light oil fractions.

For example, as an indicator to determine the compatibility of synthetic crude oil, you can use C11 (Co11o1ba1 PMaBPU 1beh - the instability index of colloids), represented by equation (1) below. C11 is found using equation (1), for example, by analyzing GALKL (G1G1E8, Lgosha! 1C8, KE8SH8 apb LcrAypek - saturated and aromatic hydrocarbons, resins and asphaltenes) for synthetic crude oil after mixing heavy and light oil fractions and measuring quantities of saturated hydrocarbons, aromatic hydrocarbons, resins and asphaltenes contained in synthetic crude oil. The mixed amount of heavy residual oil fraction is adjusted so that the value of C11 becomes equal to or less than 0.5.

C11 = {(saturated hydrocarbons + asphaltenes) / (aromatic hydrocarbons + resins)} <0.5 (1)

Below is an explanation of the water recycling system.

The circulating water reservoir 5 provided after the circulating water pipeline 330, separated at low pressure, plays the role of receiving water separated from the light oil fraction in the low pressure separator 3, and water separated from the heavy residual oil fraction in the evaporation drum 4 re-supplying water collected in the reservoir of circulating water 5, into the supply pipe of supercritical water 120. In the figures, reference numeral 510 refers to the pipeline of recycled water that connects the reservoir of circulating water 5 with it is supercritical water pipeline 120, and reference numeral 511 refers to a circulating water pump used to increase the pressure of water discharged from the circulating water reservoir 5 (for example, to a pressure of 22.1-40 MPa, which is equal to the critical pressure MPa) or exceeds it), and for pumping water to the supercritical water supply pipeline 120. In addition, as described earlier in this document, water pipe 220 separated at high pressure is used to reuse water separated in The high pressure steam generator 2 is connected to the circulating water pipeline 510. By reusing water intended for use as supercritical water, it is possible to reduce the amount of new water required for the application, and it is easy to provide the amount of water that is needed to improve the performance of heavy oil, as well as reduce the burden on the environment.

As shown in FIG. 2, the upgrade apparatus includes a control unit 7. The control unit 7 consists, for example, of a computer provided with a CPU and a storage device. The storage device has a program recorded therein that includes a group of stages (regulatory commands) related to the operation of the upgrade apparatus, i.e. to the operations of reduction in mutual

- 8 022662 contact of heavy oil and supercritical water inside reactor 1 and carrying out thermal cracking, separation into heavy residual oil fraction and light oil fraction, removing the water fraction contained in each oil fraction, and obtaining residual oil consisting of one light oil fraction, or synthetic crude oil, in which the light oil fraction is mixed with the heavy residual oil fraction, and the heavy residual oil fraction. This program is stored in a storage device (for example, on a hard disk, compact disk, a magneto-optical disk and a memory card) and is installed on the computer from it.

The upgrading apparatus according to this embodiment of the present invention, for which the entire process flow has been schematically described above, has a configuration that allows adjustment by applying mutually independent operator variables: (1) a regulator that reduces the kinematic viscosity of a heavy residual oil fraction, simultaneously inhibiting the formation of coke in the heavy residual oil fraction, and (2) a regulator that reduces the kinematic viscosity l soft petroleum fraction, simultaneously inhibiting the formation of gas accompanying the overcracking of light fraction oil. This configuration will be described in more detail below.

FIG. 2 schematically shows the internal structure of the above reactor 1 and the configuration of the control system provided in reactor 1. The heavy oil that is heated during its passage through the heavy oil supply pipeline 111 is supplied from the upper side of the reactor 1, and the supercritical water that is heated during it passing through the feed pipe of supercritical water 120, is supplied from the bottom of reactor 1. When these two liquids come into contact, the heat brought by supercritical water stimulates the flow of heat heavy oil cracking, which is converted to lighter oil. The reference numeral 101 shown in FIG. 2 refers to the heavy oil inlet nozzle, and reference numeral 102 refers to the supercritical water inlet nozzle.

In addition, where the two liquids come into contact, first the light oil fraction contained in the heavy oil is extracted into supercritical water, and the heavy residual oil fraction that remains non-extracted into the supercritical water is subjected to thermal cracking, and the light oil fraction produced thermally cracked, extracted into supercritical water, resulting in the formation of two phases: a continuous phase (hereinafter referred to as the second phase), consisting of supercritical water and light oil fraction, and a continuous phase (hereinafter referred to as the term first phase), formed by a light oil fraction that has not been extracted into supercritical water. Since the heavy residual oil fraction has a specific gravity higher than the specific gravity of the liquid mixed from supercritical water and light oil fraction, the first phase is formed in the lower part of the reactor 1, and the second phase is formed in the upper part of the reactor 1.

In reality, supercritical water in an amount of from about 3 to 100 wt.% Heavy residual oil fraction (calculated on dry weight in a state in which it does not contain any water fraction) is dissolved in the heavy residual oil fraction making up the first phase, and the real The amount of dissolved supercritical water depends on the type of heavy oil and temperature conditions and pressure in the reactor 1. From this point of view, it can be argued that the first phase is formed by a liquid mixed from a heavy residual oil th fraction and supercritical water. As a result of this dissolution of supercritical water in a heavy residual oil fraction, water molecules penetrate, for example, between polycyclic hydrocarbon molecules that make up the heavy residual oil fraction subjected to thermal cracking, and a cell effect can be demonstrated that inhibits the formation of asphaltenes by polycondensation of polycyclic aromatic hydrocarbons , and coke formation occurring through the asphaltenes polycondensation.

In the reactor 1 according to this embodiment of the present invention, supercritical water is supplied from the inlet nozzle of supercritical water 102 to the first phase in the lower part of the reactor, and heavy oil is fed from the inlet nozzle of heavy oil 101 to the second phase in the upper part. In this case, the extraction of the light oil fraction into supercritical water and the dissolution of the supercritical water in the heavy residual oil fraction occurs at the interphase boundary with supercritical water (dispersed phase), which rises in the first phase, at the interphase boundary with heavy oil (dispersed phase), which descends in the second phase, and at the contact interphase boundary between the first phase and the second phase.

The authors of the present invention found that the rate of rise of supercritical water, which rises in the first phase, and the rate of sedimentation of heavy oil, which descends in the second phase, are extremely high and that supercritical water and heavy oil pass inside the first and second phases, for example, during from several seconds to several tens of seconds. Therefore, the thermal cracking of heavy oil and the thermal cracking of heavy residual oil fraction actually occur in the first phase, and the light oil fraction formed as a result of such thermal cracking is extracted into the second phase and the thermal cracking of the light oil fraction and

- 9 022662 light oil fraction coming from the first phase, then proceeds in the second phase.

The mixed liquid constituting the first phase is withdrawn from the pipeline of heavy residual oil fraction 140 and cooled in a cooling device 141, thereby stopping the thermal cracking of the heavy residual oil fraction. The mixed liquid constituting the second phase is withdrawn from the pipeline leading to the light oil fraction 130 and cooled in a cooling device 132, thereby stopping the thermal cracking of the light oil fraction.

According to the thermal cracking mechanism described above, the degree of thermal cracking depth of the heavy residual oil fraction can be controlled by the residence time in the first phase of the liquid mixed from the heavy residual oil fraction and supercritical water dissolved in this heavy residual oil fraction (hereafter, this mixed liquid is called the term effluent from the first phase). The yield of light oil fraction increases as the thermal cracking of heavy oil proceeds. In addition, by dissolving the supercritical water in the heavy residual oil fraction and adequately cracking the heavy residual oil fraction under conditions where the cell effect is manifested, the viscosity of the heavy residual oil fraction is reduced, and the synthetic crude oil becomes easy to handle when used as a boiler fuel or after mixing with a light oil fraction. Where the cracking reaches the depth at which the above effect of the cell disappears, coke is formed in the heavy residual oil fraction.

Accordingly, in the upgrade apparatus according to this embodiment of the present invention, a mechanism is provided that controls the residence time in the first phase of effluent from the first phase, so that the kinematic viscosity (for example, at 350 ° C) of the heavy residual oil fraction, which becomes the residual oil, was not more than 3.0 x 10 ^-5 m ² / s (not more than 30 cSt) and that the thermal cracking of the heavy residual oil fraction continued to the extent that coke formation is inhibited.

Regarding the degree of thermal cracking depth of the light oil fraction, it can be stated that the residence time in the second phase of the mixed fluid (hereinafter referred to as effluent from the second phase) consisting of supercritical water and light oil fraction extracted into supercritical water can be regulated. The kinematic viscosity of the light oil fraction decreases as the thermal cracking deepens and, for example, in regions with a cold climate, synthetic crude oil can be transported without providing special heating equipment. However, with excessively deep cracking, the amount of gas produced from the light oil fraction increases and the yield of synthetic crude oil decreases.

Accordingly, the upgrade apparatus of the present invention is provided with a mechanism that controls the residence time of the second phase effluent from the second phase, so as to obtain the kinematic viscosity (for example, at 10 ° C) of one light oil fraction or synthetic crude oil after mixing with heavy residual oil fraction of not more than 5.0 x 10 ^-3 m ² / s (not more than 5000 cSt), and that the thermal cracking of the light oil fraction continued to the extent that coke formation is inhibited . In this case, to obtain the kinematic viscosity of synthetic crude oil after mixing with a heavy residual oil fraction of not more than 5.0 x 10 ^-3 m ² / s (no more than 5000 cSt), the second residence time is adjusted so that the kinematic viscosity of one light oil fraction, which will be mixed with heavy residual oil fraction, having a relatively high kinematic viscosity, took an even lower value.

For example, if the residence time of the effluent from the first phase to the first phase, denoted 0rn _in g, the residence time of the effluent from the second phase in the second phase denoted 0ts, the amount of heavy oil supplied per unit time from the supply of heavy oil conduit 110 designate Τοίη, the amount of supercritical water supplied per unit of time from the supply pipeline of supercritical water 120, designate Τ ^; _η , mark the amount of effluent from the first phase withdrawn per unit of time from the heavy residual oil fraction 140, take out the number of effluent from the second phase, withdrawn per unit time from the light oil discharge section 130, set to P ^ ₂ + and, then the balance of supply and discharge of liquids in the reactor 1 can be represented by the following equation (2):

The degree of extraction of the light oil fraction into the second phase varies depending on the state of the heavy oil, as well as on the temperature conditions and pressure in the reactor 1 and the degree of thermal cracking depth of the heavy residual oil fraction. In the present example, a case will be considered in which a heavy oil is used so that a fraction lighter than a DOE (Wheyitey Oaz Οΐί, vacuum gas oil) with a boiling point, for example, not higher than 540 ° C, is extracted as a light oil fraction into supercritical water, and the fraction corresponding to the Criminal Code (Wieiitiei Quasi, vacuum residue) with a boiling point above 540 ° C, is discharged as a heavy residual oil fraction, which is not extracted into supercritical water. In this embodiment of the present invention, the output of the OCR (i.e., the output of the MC) is supposed to be maintained almost constant by adjusting 0 _P ; _1c q, for example, in the range of deviations that are approximately ± 1 min from the desired value, and adjusting the degree of thermal cracking depth in a constant range.

If for heavy oil supplied to reactor 1, the flow rate of the heavy residual oil fraction withdrawn from it is marked Г _{Р | 1сН} and the flow rate of the light oil fraction withdrawn from it is marked Hz, and for supercritical water fed to reactor 1, supercritical water flow rate was dissolved in a heavy residual oil fraction and withdrawn from the first phase, denoted T ^ ₁ and the flow rate of the supercritical water, extracting a light oil fraction and discharged from the second phase, denoted R ^ _2, the bleed quant CTBA first liquid and the second liquid may be represented by the following equations (3) and (4):

Ldo1 + pd_ £ cb ^- (3)

P "2 + I; = Pu2 ⁺ P'y: (4)

If the volume of the first phase in reactor 1 is designated Y ₁ , and the volume of the second phase is designated Y ₂ , then the residence time of the effluent from the first phase in the first phase is 0 _P c _s 1, and the residence time of the effluent from the second phase in the second phase 0ts can be represented by the following equations (5) and (6):

θρίτσϊι ^- 3 / ι / Ενίΐ + ρίτοΗ ^- Uz. / (ΡΜΙ + ΡρίΤοΙι) (5) θ ^ = ν ₂ / Ρ „ _{1 + βϋ} = ν ₂ / (Ρμ2 + Ριχ) (6)

According to equation (5), when the volume of the first phase Y ₁ is constant, the residence time of the effluent from the first phase in the first phase 0 _P c _s 1 can be adjusted by increasing or decreasing the amount of effluent from the first phase Γ ^ | _{P | 1CN} through the pipeline for the discharge of heavy residual oil fraction 140. The results of the examples described below confirmed that in the upgrading apparatus according to this embodiment of the present invention it is possible to inhibit the formation of coke in the heavy residual oil fraction, and the kinematic viscosity of residual oil at 350 ° C can be adjusted to a value equal to or less than 3.0 χ 10 ^-5 m ² / s (equal to or less than 30 cSt) by setting the residence time 0 _{Р | 1с} н in the range of 3 min <0 _{Р | 1с} н <95 min.

In addition, under conditions of constant temperature and constant pressure, the solubility of supercritical water in a heavy residual oil fraction is constant. Therefore, at a certain flow rate (Г _Р ц _with ь) of the heavy residual oil fraction withdrawn from the first phase, the amount (Ρ ^ ι) of supercritical water dissolved in the heavy residual oil fraction takes a constant value. By increasing or decreasing the supplied amount of supercritical water (r ^ _n ) in this state, it is possible to increase or decrease the amount of supercritical water not dissolved in the heavy residual oil fraction, i.e. the amount of supercritical water forming the second phase (G ^ ₂ ). The amount of dissolved supercritical water G ^, related to the amount of heavy residual oil fraction flowing out, can be determined, for example, by preliminary tests.

The relationships described above indicate that when the volume of the second phase U ₂ is constant, the value of G \\ ₂ in equation (6) can increase or decrease, and the residence time 0C effluent from the second phase in the second phase can be adjusted by increasing or decreasing the amount of supercritical water G \\ _I1 supplied from the supercritical water supply pipeline 120. The results of the examples described below confirmed that in the upgrade apparatus according to this embodiment of the present invention, it is possible to inhibit the formation of oxa in the heavy residual oil fraction, and the kinematic viscosity at 10 ° C with one light oil fraction or synthetic crude oil after mixing with the heavy residual oil fraction can be adjusted to a value equal to or less than 5.0 χ 10 ^-3 m ² / s (equal to or less than 5000 cSt), setting the residence time 0c in the range of 1 min <0c <25 min.

In accordance with the approach described above, a flow rate controller 74 is provided on the pipeline for discharging a heavy residual oil fraction 140, which serves to regulate the outgoing amount of G ^ |. _{P | 1CN} effluent from the first phase, and the value (b) indicated by the flow rate controller 74 is transmitted to the control unit 7. The control unit 7, using equation (5), calculates the residence time 0 _К1сЬ and increases or decreases the flow rate (e) specified the controller 74, and the opening degree of the valve 142 regulating the flow rate is set so that 0 _{P | 1c} n takes the desired desired value.

On the supply pipe of supercritical water 120, a flow rate controller 72 is provided, which serves to regulate the supply amount G \\ "(i.e. T ^ ₂ ), and the value (a) indicated by the flow rate controller 72 is transmitted to the control unit 7. 7, using equation (6), calculates the residence time 0c and increases or decreases the flow rate (ά) set by the controller 72, and the opening degree of the valve 122 regulating the flow rate is set so that 0c accepts the desired desired value.

In reactor 1, an interface meter 75 (for example, a differential pressure gauge, ultrasonic or X-ray system) is provided, which is an interphase boundary detection unit according to this embodiment of the present invention, and a signal (c) that indicates a high level of interphase border or low level of the interphase boundary (i.e. the level of the interphase boundary between the first and second phases inside the reactor 1 is above or below the specified range), transmitted to the control unit 7. The control unit is configured to keep the volume of the first phase Y ₁ constant (i.e. the volume of the second phase Y ₂ ), increasing or decreasing the flow rate (ί) set by the flow rate controller 71 provided in the heavy oil supply pipeline 110 , and adjust the delivered amount of heavy oil P _Osh so as to return the level of the interphase boundary to a height located in a given range. The pressure inside the reactor controls the pressure controller (not shown in the figure) provided on the pipeline of the light oil fraction 210 of the high pressure separator 2 shown in FIG. 1, by opening and closing the pressure reducing valve 211.

Below will be described the operation of regulating the residence time θρ _1οΡ and the residence time 0 _Ы in the upgrade apparatus, having the configuration described above. If assumed that the residence time θ _Ριίο1ι effluent from the first phase to the first phase exceeds a predetermined value, θ _Ριίώ can be reduced and return to the preset value by increasing the number of allotted effluent from the first stage E _R vivo Recording according to the equation (5). However, as P increases, _P11c decreases the level of the interphase boundary. Therefore, a low signal from the interphase boundary is transmitted from the interphase boundary gauge 75, the valve 112 is actuated to regulate the flow rate, and the supply of heavy oil P _{From the} heavy oil supply pipeline 110 increases.

The increase _from the HLR part AE _r11s supply amount of heavy oil is distributed in the first phase, as part of the _AP's is distributed in a second phase. As a result, as follows from equation (6), θ ^ decreases, but this change can be compensated by reducing the amount of supercritical water Ρ _νιη (ie, P _A2 ), thereby increasing θ ^ and returning it to the specified value.

If it is assumed that the residence time θ ^ effluent from the second phase in the second phase exceeds the specified value, 0c can be reduced and returned to the specified value by increasing the amount of PA given _||| (i.e. Ρ _ν2 ) of supercritical water according to equation (6). Even if Ρ _νιη increases, the amount of P ^ ₂ + and increases from the second phase, respectively, increases Ρ _νιη (Ρ _ν2 ), for example, so as to obtain a constant pressure inside reactor 1, and the phase boundary between the first phase and the second phase maintained at a constant level.

Using the upgrade apparatus according to this embodiment of the present invention, the heavy oil and supercritical water are divided into two phases, namely, the first phase (phase consisting of heavy residual oil fraction and supercritical water dissolved in the heavy residual oil fraction) and the second phase (phase consisting of supercritical water and light oil fraction, which was extracted into supercritical water), bringing the two liquids into contact inside the reactor and adjusting the amount of mixed liquid (eff of the first phase) consisting of a heavy residual oil fraction and supercritical water, so that the residence time of the mixed liquid constituting the first phase in the first phase becomes the first residence time (for example, setting the set value within the range from 3 to 95 minutes), which set in advance. As a result, the degree of thermal cracking depth of the heavy residual oil fraction flowing in the first phase can be controlled, and the upgrade unit can operate under optimal conditions, for example, thermal cracking is carried out in a range in which coke formation from the heavy residual oil fraction is inhibited, or thermal the cracking is carried out so that the kinematic viscosity of the heavy residual oil fraction is in the desired range.

In addition, the amount of effluent withdrawn from the second phase (liquid mixed from light oil fraction and supercritical water) is controlled so that the residence time of the mixed liquid constituting the second phase in the second phase becomes the second residence time (for example, setting a predetermined value within the range of 1 to 25 min), which is set in advance. As a result, the degree of thermal cracking depth of the light oil fraction occurring within the second phase can be controlled, and thermal cracking can be carried out in a range in which, for example, excessively deep cracking of the light oil fraction is inhibited, gas formation is also inhibited and thermal cracking is carried out that the kinematic viscosity of synthetic crude oil obtained from the light oil fraction is in the desired range.

In the example shown in FIG. 2, provide a level meter of the interphase boundary 75, measure the interphase boundary between the first and second phases, and maintain the constants Y ₁ and Y ₂ . However, equipping the upgrade device with a level meter of the interphase boundary 75 is not mandatory. For example, it is also possible to preliminarily determine the yield of the light fraction and the yield of the CC fraction from the DOE, corresponding to the type, temperature conditions and pressure of heavy oil, to assess the level of the interphase boundary inside reactor 1 by the values of P _Ot , Ρ _νιη , Р _Р1РьЬ , _Рц , Р _{№ 1} and Ρ _ν2 .

- 12 022662 maintain constant volumes of _1? ν ₂ on the basis of an estimate of the level of the interphase boundary and regulate the residence times 0 _ris and θ _Εί according to equations (5) and (6).

In the examples shown in FIG. 2, adjusting the residence times Θ _Κ ιλ and θ _Εί , maintain constant volumes ν ₁ , ν ₂ ; however, the residence times θ _ρι ^ and θ _Εί can also be adjusted with variable ν ₁ and ν ₂ . For example, when the residence time of θ _ρίι ^ effluent from the first phase in the first phase exceeds the specified value, a decrease in θρ ^ and its return to the specified value is performed by increasing the withdrawn amount of P _К1сЬ effluent from the first phase and reducing the volume of the first phase ν ₁ according to the equation (5 ). As a result, the volume of the second phase ν2 increases and the residence time of the effluent from the second phase θ _{Ει changes} . However θ _Εί can be returned to a predetermined value, increasing the supply amount F \ y _{| n} supercritical water (that is, P ^ ₂₎ to compensate for the increased volume ν2.

In the above example, the residence time θ _ΡίίΛ effluent from the first phase to the first phase is adjusted bleed amount P _Rys effluent from the first phase, and the residence time θ _Εί effluent from the second phase in the second phase is controlled supply amount Ι · \ _νιιι supercritical water, but the retention times obviously be adjusted operator and other variables shown in equation (5) in equation (6), such as the supply amount F _O w heavy oil and the amount of bleed Ρ ^ _{2 + ΕΐΟ} πΐ effluent from the second phase.

In the flow chart shown in FIG. 1, an example is illustrated in which water is separated from heavy residual oil fraction in an evaporation drum 4 and pumped as residual oil to a residual oil reservoir 64, but a configuration that does not have an evaporation drum is also possible 4. For example, when residual oil is used as a boiler fuel at the plant, located next door to the unit of upgrading, evaporative drum 4 can not be used. For example, obtaining boiler fuel in a state in which the water fraction is dispersed in the residual oil, and without reducing the pressure of the first liquid, it is possible to further reduce the viscosity of the residual fuel and facilitate handling this residual fuel. At the same time, under the influence of water dispersed in the residual oil, when using boiler fuel, evaporation is enhanced and its flammability in the boiler can be improved.

In the above embodiment of the present invention, an explanation is given for the case in which super heavy crude oil is used, such as oil sand bitumen or the Orinoco basin bitumen, which is refined as heavy oil whose characteristics are improved in the apparatus according to the present invention, but the heavy oils can be processed in the machine upgrade according to the present invention, not limited to crude oil. For example, the technical scope of the present invention includes processing with improved performance, produced with a fraction of the atmospheric residue and with a fraction of a vacuum residue.

Examples

Test 1

The test apparatus shown in FIG. 3, is made as a model of the upgrade apparatus shown in FIG. one; test upgrade was performed with heavy oil.

A. Test Conditions

Reference numeral 200 in FIG. 3 relates to a gas-liquid separation tank, which serves to separate the effluent from the second phase discharged from the upper part of the reactor 1 into a gas and a mixed liquid consisting of a light oil fraction and water. Reference numeral 143 refers to a ball valve, which serves for removing the heavy residual oil fraction (effluent from the second phase) from the bottom of the reactor 1. In the present apparatus the residence time Θ _Κ ιλ effluent from the first stage was controlled bleed P _K1s amount of residual oil, and the residence time θ _Εί effluent from the second phase was regulated by the supplied amount P \ y _{| P of} supercritical water. As a heavy oil used bitumen oil-bearing sand, mined in Canada and having the properties shown in table. one.

Table 1

Example 1

The test was carried out under the following conditions:

reaction temperature in the reactor 1: 430 ° C;

the reaction pressure in the reactor 1: 25 MPa;

Water / oil mass ratio: 1.0;

residence time θ _ΡίΛ effluent from the first phase: 95 min;

sojourn θ _Εί effluent from the second phase: 2.3 min.

Example 2

The test was carried out under the same conditions as in example 1, except for the reaction temperature in the reactor 1: 450 ° C;

- 13 022662 residence time 0 _P11cb effluent from the first phase: 4.9 min;

residence time θ _Εί effluent from the second phase: 11 min.

Example 3

The test was conducted under the same conditions as in Example 1 except the residence time θ _ΡιΐΛ effluent from the first phase for 32 minutes;

residence time θ _Εΐ effluent from the second phase: 25 min.

Example 4

The test was carried out under the same conditions as in example 1, except

The residence time of the θ _ιΛ effluent from the first phase: 67 min;

Residence time θ _Εί effluent from the second phase: 1.8 min.

Comparative Example 1

The test was carried out under the same conditions as in example 1, except for the residence time of the θ _эфф effluent from the first phase: 105 min;

residence time θ _Εί effluent from the second phase: 1.1 min.

The test conditions used in the examples and in the comparative example are given in table. 2

table 2

Example 1 Example 2 Example 3 Example 4 Comparative Example 1 The temperature in the reactor (° C) 430 450 430 430 430 Pressure in the reactor (MPa) 25 25 25 25 25 Water / oil mass ratio 1/0 1/0 0.5 1.0 1.0 Residence time θρϊϋοΗ. first phase effluent (min) 95 4.9 32 67 105 The residence time Vieux effluent from the second phase (min) 2.3 eleven 25 18 1.1

B. Test results

The outputs of gas, synthetic crude oil (light oil fraction) and residual oil (heavy oil fraction) in the examples and in the comparative example are shown in Table. 3. Properties of synthetic crude oil are shown in Table. 4, and the properties of the residual oil are shown in Table. five.

Table 3

Table 4

Example 1 Example 2 Example 3 Example 4 Comparative Example 1 Density (g / cm ³ ) 0.916 0.915 0.911 0.918 - Kinematic viscosity at 10 ° C (m ² / s) 2, Bh10 ^-5 2,0x10 ' ⁵ 1,6x10 ~ ⁵ 2.8x10 ' ⁵ -

- 14 022662

Table 5

In tab. 6 compares the results obtained in examples 1 and 2 with the ratio of the yields of each fraction obtained as a result of visbreaking and delayed coking, carried out with oil sand bitumen, similar to the bitumen used in example 1. The results of examples 1 and 2 are obtained by combining relations yields of synthetic crude oil and residual oil; and conversion to an UOO fraction with a boiling point not higher than 540 ° C and to a UKfraction with a boiling point higher than 540 ° C. Therefore, these results sometimes do not coincide with the ratio of the outputs shown in Table. 3

Table 6

According to the results of Example 1 by first increasing the residence time of 0 _Rys effluent from the first stage in the sequence of Example 2 (θ _ΡίίΛ: 4,9 min) Example 3 (θ _ΡίΛ: 32 min) Example 1 (v 0rd _to 95 min) yield decreases residual oil, but the yield of synthetic crude oil increases. In addition, in comparative example 1, in which θ _ΡίΛ is 105 min, the formation of coke was observed (coking). The reason for the higher yield of residual oil in example 4 (θ _ΡίΛ : 67 min), in which the first residence time θ _Ρί ^ is longer than in example 3, but the yield of synthetic crude oil has the same order as in example 3, remains unclear, but apparently this is a result of the effect produced by the fluctuation error.

With respect to the gas outlet can be noted that, except for Example 1, wherein the gas output was greatest (θ _Εί: 2,3 min), a gas outlet shows a tendency to increase with the second residence time in the range of θ _ρ Example 4 (θ _ρ : 1.8 min) example 2 (θ _ρ : 11 min) example 3 (θ _ρ : 25 min). The reason for achieving the highest gas yield (4 wt.%) In Example 1 with the second-lasting residence time θ _ρ remains unclear, but apparently this is a result of the effect produced by the fluctuation error.

According to the results obtained when measuring the kinematic viscosity of synthetic crude oil, shown in Table. 4, in all the examples, synthetic crude oil with kinematic viscosity was obtained, which did not cause any practical problems, i.e. with a maximum kinematic viscosity of 2.8 χ 10 ^-5 m ² / s (28 cSt) at 10 ° С (standard value is 5.0 χ 10 ^-3 m ² / s (5000 cSt)). In this case, the kinematic viscosity of synthetic crude oil shows a tendency to decrease with increasing second residence time θ _ι in the series example 4 (θ _ρ : 1.8 min) example 1 (θ _ρ : 2.3 min) example 2 (θ _ρ : 11 min) example 3 (θ _ρ : 25 min). This is probably due to the fact that the cracking depth of the light oil fraction increases with increasing second residence time. This can also be confirmed by a decrease in the viscosity of synthetic crude oil, following an increase in the second residence time.

According to the results obtained when measuring the kinematic viscosity of residual oil, shown in Table. 5, in all examples, residual oil with kinematic viscosity was obtained, which did not cause any practical problems, i.e. with a maximum kinematic viscosity of 1.8 χ 10 ^-5 m ² / s (18 cSt) at 310 ° C. The kinematic viscosity was further reduced when the residual oil was heated to 350 ° C. The kinematic viscosity of the residual oil shows a tendency to increase as the first residence time increases θ _ΡίΛ in the series example 2 (θ _Λ : 4.9 min) example 3 (θ _ΡίΛ : 32 min) example 4 (θ _ΡίΛ : 67 min) example 1 θ _ΙΛ : 95 min.) This is probably due to the fact that the polymerization of the heavy residual oil fraction continues against the cellular effect of supercritical water dissolved in the heavy residual oil fraction. This can also be confirmed by an increase in the viscosity of the residual oil, following an increase in the first residence time.

- 15 022662

Considering together the results of examples 1-4 and comparative example 1, it can be concluded that when bitumen of oil sands is used as the starting material, easy-to-handle residual oil with a kinematic viscosity of not more than 1.8 x 10 ^-5 m ² / s (18 cSt ) at 310 ° С with inhibited formation of coke is obtained under the condition that the first residence time of θ _ΡιΐοΗ is in the range from 3 to 95 minutes. In addition, in cases where the second residence time Od is in the range from 1 to 25 minutes, the formation of gas is inhibited to a value not exceeding about 4 wt.%, And synthetic crude oil is obtained with a kinematic viscosity of not more than 2 , 8 x 10 ⁵ m ² / s (28 cSt) at 10 °.

According to the results shown in the table. 6, coke formation was inhibited, and the yield ratio of the DOE fraction was higher than that obtained with visbreaking, and in Example 1, the output ratio of the DOE fraction was about the same order as was obtained during delayed coking. This result demonstrates that thermal cracking of heavy oil using supercritical water is such a method of thermal cracking, which can result in a high yield ratio of the CCP fraction (light oil fraction) while simultaneously inhibiting the formation of coke and gas, which is achieved by adequate regulation of the first and second time of stay.

Example 2

In the test apparatus reactor, identical to that used in Example 1, a viewing window was provided and it was confirmed that the liquid inside the reactor was divided into the first phase and the second phase and an interphase boundary was formed. The results obtained when photographing the internal space of the reactor 1 through a viewing window are shown in FIG. 4a, and its schematic drawing is shown in FIG. 4b. The results shown in FIG. 4a confirms the presence of a first phase consisting of a heavy residual oil fraction and supercritical water dissolved in a heavy residual oil fraction, and a second phase consisting of supercritical water and a light oil fraction extracted into supercritical water at the bottom of the reactor 1.

Explanation of reference designations

110

112

120

130

140

71,

72, 74 reactor supplying heavy oil pipeline valve regulating the flow rate valve regulating the flow rate in the supply pipeline of supercritical water 122 valve regulating the flow rate in the pipeline leading light oil fraction 131 valve regulating the flow rate in the pipeline leading heavy residual oil fraction 142 separator high pressure low pressure separator evaporating drum circulating water tank control unit flow rate controller pressure controller meter l level interphase boundary

Claims (17)

CLAIM 1. The method of thermal cracking of heavy oil, which includes stages: the introduction of heavy oil into the reactor; the introduction of supercritical water into the reactor; maintaining the internal space of the reactor at a temperature and pressure equal to or above the critical point of water, bringing heavy oil and supercritical water into mutual contact due to said simultaneous introduction of heavy oil and supercritical water into the reactor and separating the products of cracking of heavy oil into the first phase consisting from the heavy residual oil fraction obtained by thermal cracking, and supercritical water dissolved in the heavy residual oil fraction, and in the second phase, consisting from supercritical water and light oil fraction extracted into supercritical water during the thermal cracking of heavy oil; discharge of fluid from the first phase; fluid withdrawal from the second phase; - 16 022662 detecting the height of the position of the interphase boundary between the first phase and the second phase in the reactor, finding the volume of the first phase along the height of the position of the interphase boundary detected by the interphase detector, and adjusting the amount of liquid withdrawn from the first phase so that the current residence time of the liquid in the first phase corresponded to the specified limits of the values of the first residence time, and finding the volume of the second phase along the height of the position of the interphase boundary and controlling the input quantity Coy water so that the actual liquid residence time in the second phase corresponds to a predetermined limit values of the second residence time. 2. The method of thermal cracking of heavy oil, which includes stages: the introduction of heavy oil into the reactor; the introduction of supercritical water into the reactor; maintaining the internal space of the reactor at a temperature and pressure equal to or above the critical point of water, bringing heavy oil and supercritical water into mutual contact due to said simultaneous introduction of heavy oil and supercritical water into the reactor and separating the products of cracking of heavy oil into the first phase consisting from the heavy residual oil fraction obtained by thermal cracking, and supercritical water dissolved in the heavy residual oil fraction, and in the second phase, consisting from supercritical water and light oil fraction extracted into supercritical water during the thermal cracking of heavy oil; discharge of fluid from the first phase; discharging liquid from the second phase, estimating the height of the position of the interphase boundary between the first phase and the second phase in the reactor based on the solubility of supercritical water in the heavy residual oil fraction, the amount of heavy oil introduced per unit time, and the yields of the light oil fraction and the heavy residual oil fraction; finding the volume of the first phase and the second phase based on the estimated height of the position of the interphase boundary; regulation of the withdrawn amount of fluid from the first phase so that the current residence time of the fluid in the first phase corresponds to the specified limits of the values of the first residence time; and adjusting the amount of supercritical water injected so that the current residence time of the liquid in the second phase corresponds to the specified limits of the second residence time values. 3. The method according to claim 1 or 2, wherein the first residence time is set to at least 3 minutes to not more than 95 minutes to inhibit the formation of coke in the heavy residual oil fraction. 4. The method according to claim 1 or 2, wherein the first residence time is the residence time during which the thermal cracking of heavy oil proceeds in a range in which the amount of coke formed is equal to or greater than 0 wt.% And equal to or less than 20 wt. % heavy residual oil fraction. 5. The method according to claim 1 or 2, where the first residence time is the residence time during which the thermal cracking of heavy oil proceeds until the kinematic viscosity of the heavy residual oil fraction at 350 ° C becomes equal to or less than 3, 0x10 ^-5 m ² / s. 6. The method according to claim 1 or 2, where adjusting the second residence time, it is set in the range from at least 1 minute to at most 25 minutes to inhibit excessively deep cracking of the light oil fraction. 7. The method according to claim 1 or 2, wherein the second residence time is a residence time during which the thermal cracking of heavy oil proceeds in a range in which the amount of gas formed by excessively deep cracking is equal to or greater than 0% by weight and equal to or less than 5 wt.% heavy residual oil fraction. 8. The method according to claim 1 or 2, where the second residence time is the residence time during which the thermal cracking of heavy oil proceeds until the kinematic viscosity of the light oil fraction at a temperature of 10 ° C becomes equal to or less than 5.0x 10 ^-3 m ² / s. 9. The method according to claim 1 or 2, comprising a step of lowering the temperature and reducing the pressure of the liquid mixed from the heavy residual oil fraction and supercritical water, which was withdrawn from the first phase, and separating the heavy residual oil fraction and water. 10. The method according to claim 1 or 2, comprising the step of lowering the temperature of the liquid mixed from the heavy residual oil fraction and supercritical water that was withdrawn from the first phase, and producing fuel in a state in which the water fraction is included in the heavy residual oil fraction. - 17 022662 11. A method according to claim 9, where the liquid mixed from the heavy residual oil fraction and supercritical water, which was withdrawn from the first phase, includes an aqueous fraction in the range from at least 3 wt.% To not more than 100 wt.% Heavy residual oil fraction. 12. The method of claim 10, where the liquid mixed from the heavy residual oil fraction and the supercritical water withdrawn from the first phase includes an aqueous fraction in the range from at least 3 wt.% To not more than 100 wt.% Heavy residual oil fractions. 13. The method according to claim 1 or 2, comprising the step of lowering the temperature and reducing the pressure of the liquid mixed from supercritical water and light oil fraction, which was withdrawn from the second phase, and separating the light oil fraction and water. 14. The method according to claim 9, comprising a stage of extracting water separated from the heavy residual oil fraction or light oil fraction, for reuse as supercritical water intended for introduction into the reactor. 15. The method according to item 13, which includes the stage of extraction of water separated from the heavy residual oil fraction or light oil fraction, for reuse as supercritical water, intended for introduction into the reactor. 16. The method according to claim 1 or 2, which includes stages: reducing the temperature and reducing the pressure of the liquid mixed from the heavy residual oil fraction and supercritical water, which was withdrawn from the first phase, and separating the heavy residual oil fraction and water; lowering the temperature and lowering the pressure of the liquid mixed from supercritical water and light oil fraction, which was withdrawn from the second phase, separating the light oil fraction and water, and mixing the heavy residual oil fraction and light oil fraction after separation from water. 17. The method according to claim 1 or 2, wherein the heavy oil is selected from the group of heavy oils, including oil sand bitumen, the Orinoco basin bitumen, the atmospheric residual fraction and the vacuum residual fraction.