EA043893B1 - METHOD FOR PARTIAL UPGRADING OF HEAVY OIL - Google Patents

Description

Cross reference to related application

This application claims priority to U.S. Provisional Patent Application No. 62/660718, entitled PROCESS FOR PARTIAL UPGRADING OF HEAVY OIL, filed April 20, 2018, and incorporated herein by reference in its entirety.

Field of technology

The present method generally relates to a process for cracking heavy oil and other heavy liquid hydrocarbon materials using a spark discharge.

State of the art

Heavy oil (including extra-heavy oil and bitumen) accounts for half of the world's oil reserves, but only a small portion has been produced to date (USGS Fact Sheet 70-03). Currently, in heavy oil fields, the heavy oil produced must be immediately upgraded or diluted with lighter hydrocarbons (naphtha, natural gas condensate or other lower molecular weight saturated hydrocarbons). This necessary dilution helps separate oil from produced water and reduce the density and viscosity of the product during transportation (pipeline, railway, ship, etc.). Dilution may require 20-40% of the total volume of marketable crude oil, and the diluent must be purchased and delivered to production facilities.

North America has large reserves of heavy oil and recognizes the value that partial upgrading will bring to extract heavy oil. Several competing technologies are being developed to meet the demand for more economical extraction of heavy oil. Almost all modern processes involve modifications to existing refining technology and thus involve the same harsh operating conditions and high capital/operating costs.

There is a need for methods and devices to optimize the transportation and processing of heavy oil while simultaneously producing high-value, upgraded oil and hydrocarbon products.

Disclosure of the Invention

In one aspect, a device is provided for continuous upgrading of heavy oil. The apparatus may include a heavy oil supply line connected to a heat exchanger for transporting the heavy oil through the heat exchanger. The heavy oil supply line may be continuous with the first line connecting the heat exchanger to the first control heat exchanger. The device may also include a reactor with a second line configured to supply heavy oil. The second line may pass through the first control heat exchanger and may be a continuation of the first line. In addition, the device may contain a separator connected to the reactor by a third line. The separator can be connected to a fourth line, which is branched into a recirculation line and a fifth line. The recirculation line can merge with the second line. The fifth line can be connected to a heat exchanger. The sixth line can be connected to the separator and can be branched into a light liquid line and a seventh line. The seventh line can be connected to a mixer. The device may further comprise a second control heat exchanger connected to the heat exchanger by an eighth line. The eighth line can be continuous with the fifth line. The device may further comprise a ninth line connecting the mixer and the second control heat exchanger. In addition, the device may include a line of upgraded oil connected to a mixer for removing upgraded oil from the device. The device may also include a compressor. The tenth line may be connected to the separator and may be branched into a gas recirculation line and an eleventh line. The gas recirculation line may be connected to the compressor, and the eleventh line may be connected to the power generator. In addition, the device may include a light hydrocarbon gas supply line for supplying fresh light hydrocarbon gas to the reactor. The device may further comprise a twelfth line connecting the compressor to the light hydrocarbon gas supply line. The device may further comprise a power supply line connecting the power generator to the reactor.

In another aspect, a device is provided for continuously upgrading heavy oil to produce upgraded oil. The apparatus may include a heavy oil supply line connected to a heat exchanger for transporting the heavy oil through the heat exchanger. The heavy oil supply line may be continuous with the first line connecting the heat exchanger to the first control heat exchanger. The device may also include a separator connected to the first control heat exchanger by a second line, which may be a continuation of the first line. In addition, the device may include a third line connected to the separator. The third line can branch into a heavy oil line and a fourth line. The heavy oil line may pass through the heat exchanger and may be extended by a fifth line connected to a second control heat exchanger. The fourth line can connect to the reactor. The sixth line can connect the reactor to the separator. The device may further comprise a mixer connected to the second control heat exchanger via a seventh line. An upgraded oil line for removing upgraded oil from the device can be connected to a mixer. The device may further comprise an eighth line connected to the separator. The eighth line may branch into a light hydrocarbon liquid line and a produced light liquid line. The liquid light hydrocarbon line can be connected to a mixer. In addition, the device may include a ninth line connected to the separator. The ninth line can branch into a tenth line and a gas recirculation line. The tenth line can be connected to a power generator. The gas recirculation line may be connected to a compressor, which may be connected to the eleventh line. The eleventh line may merge with a light hydrocarbon gas supply line, which may be configured to transport fresh light hydrocarbon gas to the reactor. The device may further comprise a power supply line connecting the power generator to the reactor.

In another aspect, a method is provided for continuously upgrading heavy oil to produce upgraded oil using a pulsed plasma reactor. The method may include injecting heavy oil through the heavy oil supply line at a first pressure of 0.1 to 10 barg. or alternatively 0.9 to 2 barg. In the interelectrode gap inside the reactor. The heavy oil supply line may first pass the heavy oil through a heat exchanger to adjust the temperature of the heavy oil, and it enters the first control heat exchanger through which the heavy oil passes and enters the reactor. The interelectrode gap may be formed by a distance between the first end of the negative electrode and the first end of the positive electrode. The second end of the positive electrode and the second end of the negative electrode may be connected to the power generator via a power line. The method may also include injection at a second pressure of 0.2 to 20 barg. or alternatively 1 to 3 barg. light hydrocarbon gas, through the light hydrocarbon gas supply line, and into the reactor for mixing therein with heavy oil to form a hydrocarbon liquid-gas mixture in the interelectrode gap. In addition, the method may include creating a spark discharge in the interelectrode gap to react the hydrocarbon liquid-gas mixture. The method may further include introducing the reacted hydrocarbon liquid-gas mixture into a separator and separating the light hydrocarbon liquid and the light hydrocarbon gas from the heavy oil. The method may further include supplying the separated light hydrocarbon gas from the separator to a compressor and compressing the light hydrocarbon gas. Fresh hydrogen and fresh hydrocarbon gas may be added to the light hydrocarbon gas to produce a gas mixture of hydrogen and light hydrocarbon, and recycle the gas mixture of hydrogen and light hydrocarbon to the reactor. Additionally, the method may include feeding heavy oil from the separator to a heat exchanger. The heavy oil from the separator may be combined with the heavy oil from the heavy oil supply line to produce a combined heavy oil. The method may also include removing the combined heavy oil or mixing the combined heavy oil with liquid light hydrocarbons to produce an upgraded oil.

In one or more embodiments, from 1 to 50% by volume of the heavy oil may be converted to light hydrocarbon liquid and/or light hydrocarbon gas, with a preferred range of 3 to 30%.

In one or more embodiments, the heavy oil from the separator and the heavy oil from the heavy oil supply line may be combined in a ratio of 1:10 to 20:1, with a preferred ratio of 1:1 to 10:1.

In one or more embodiments, the combined heavy oil from the separator and the heavy oil from the heavy oil feed line may be adjusted to a temperature of 25 to 200° C. and a viscosity of 1 to 1000 cP upon entering the reactor, with a preferred viscosity of 10 to 200 cP.

In one or more embodiments, the reactor may include a plurality of interelectrode spaces. The preferred number of gaps can increase linearly with the required throughput of the method application. Ancillary equipment associated with reactions can be sized accordingly, and larger applications can provide economies of scale for this equipment.

In one or more embodiments, the separator may comprise a fractional distillation device or absorber, which may be a pressure swing absorber.

In one or more embodiments, the light hydrocarbon liquid may have an upper boiling point of from 100 to 300°C.

In one or more embodiments, a portion of the light hydrocarbon liquid may be removed before mixing the light hydrocarbon liquid with the combined heavy oil.

In one or more embodiments, fresh hydrogen and/or fresh hydrocarbon gas may be added to the separated light hydrocarbon gas before and/or after it is compressed.

In one or more embodiments, the composition of the light hydrocarbon gases may be analyzed before entering the reactor.

In one or more embodiments, the compressed light hydrocarbon gas may be purified. The purified light hydrocarbon gas may provide power to the reactor and/or may provide heat used in the process. Hydrogen can be separated from purified light hydrocarbon gas.

In one or more embodiments, the energy for the spark discharge may be provided by a microturbine. The amount of fresh hydrogen added to the light hydrocarbon gas may be an amount sufficient to produce a gas mixture of hydrogen and light hydrocarbon containing a hydrogen concentration of 1 to 65% by volume, with a preferred concentration of 10 to 50% hydrogen. A gas mixture of hydrogen and light hydrocarbon can be fed into the reactor at a rate of 0.01 to 1 l/min.

In one or more embodiments, the upgraded oil may have an improved boiling curve, as indicated by the conversion. The amount of conversion can be defined as the amount of new material boiling below 400°C that is formed during the reactions divided by the total original mass. In some embodiments, the transformation may be defined as creating a new material that boils below 300°C or some other temperature. The upgraded oil may also have an improved API gravity of 0.1 to 20. The upgraded oil may have an improved asphaltene content of 0 to 10%. Preferred ranges for conversion, API gravity improvement, and asphaltene reduction may depend on the specific application and the relative values of the raw materials and products. In one or more embodiments, the heavy oil bypasses the heat exchanger. In one or more embodiments, the heavy oil may bypass the first control heat exchanger and/or the second control heat exchanger.

In one or more embodiments, the heavy oil pumped through the heavy oil supply line may be cooled by a heat exchanger and/or a first control heat exchanger.

In one or more embodiments, the heavy oil supply line includes heavy oil that does not require upgrading. The heavy oil supply line may bypass the reactor and enter the separator after passing through the heat exchanger and the first control heat exchanger. The method may include separating light hydrocarbon liquid and light hydrocarbon gas from heavy oil. The separated heavy oil can be fed into the reactor. In another aspect, a method is provided for continuously upgrading heavy oil to produce upgraded oil using a pulsed plasma reactor. The method may include injecting heavy oil through the heavy oil supply line at a first pressure of 0.1 to 10 barg. or alternatively with a range of 0.9 to 2 barg. through a heat exchanger and a first control heat exchanger into a separator and separating liquid light hydrocarbons and light hydrocarbon gas from heavy oil. The separated heavy oil may be supplied to a heat exchanger to be combined with heavy oil from the heavy oil supply line, and/or the separated heavy oil may be supplied to an interelectrode gap provided in the reactor. The interelectrode gap may be formed by a distance between the first end of the negative electrode and the first end of the positive electrode. The second end of the positive electrode and the second end of the negative electrode may be connected to the power generator via a power line. The light hydrocarbon gas may be supplied to a compressor and/or power generator. The light hydrocarbon gas in the compressor can be compressed and/or sent to the reactor. The light hydrocarbon liquid may be directed to a mixer and/or collected. The method may also include injection at a second pressure of 0.2 to 20 barg. or alternatively 1 to 3 barg. light hydrocarbon gas through the light hydrocarbon gas supply line and into the reactor for mixing therein with heavy oil to form a hydrocarbon liquid-gas mixture in the interelectrode gap. In addition, the method may include creating a spark discharge in the interelectrode gap to react the hydrocarbon liquid-gas mixture. The method may further include passing the reacted hydrocarbon liquid-gas mixture to a separator and separating the light hydrocarbon liquid and the light hydrocarbon gas from the heavy oil. The method may further include combining the separated heavy oil and the heavy oil from the heavy oil supply line, and passing the combined heavy oil through a second control heat exchanger into a mixer, and mixing the combined heavy oil with the light hydrocarbon liquid to produce an upgraded oil.

In one or more embodiments, from 1 to 50% by volume of the heavy oil may be converted to light hydrocarbon liquid and/or light hydrocarbon gas, with a preferred range of 3 to 30%.

In one or more embodiments, the heavy oil from the separator and the heavy oil from the heavy oil supply line may be combined in a ratio of 1:10 to 20:1, with a preferred range of 1:1 to 1:10. The combined heavy oil can be brought to temperatures from 25 to 200°C and can have a viscosity from 1 to 1000 cP after combining, with a preferred range of 10 to 200 cP.

In one or more embodiments, the reactor may comprise a plurality of interelectrode

- 3 043893 spaces. The preferred number of gaps can increase linearly with the required throughput of the method application. Ancillary equipment associated with reactions can be sized accordingly, and larger applications can provide economies of scale for this equipment.

In one or more embodiments, the separator may comprise a fractional distillation device and/or an absorber. The absorber may be a pressure swing absorber.

In one or more embodiments, the light hydrocarbon liquid may have an upper boiling point of from 100 to 300°C.

In one or more embodiments, a portion of the light hydrocarbon liquid may be removed before it is mixed with the combined heavy oil.

In one or more embodiments, fresh hydrogen and/or fresh hydrocarbon gas may be added to the separated light hydrocarbon gas before and/or after it is compressed.

In one or more embodiments, the composition of the light hydrocarbon gas may be analyzed before it is introduced into the reactor.

In one or more embodiments, the compressed light hydrocarbon gas may be purified. The purified light hydrocarbon gas can power the reactor and/or provide heat used in the process. Hydrogen can be separated from purified light hydrocarbon gas. In one or more embodiments, the energy for the spark discharge may be provided by a microturbine. The amount of fresh hydrogen added to the light hydrocarbon gas may be an amount sufficient to produce a gas mixture of hydrogen and light hydrocarbon containing a hydrogen concentration of 1 to 65% by volume, with a preferred concentration of 10 to 50% hydrogen. A gas mixture of hydrogen and light hydrocarbon can be fed into the reactor at a rate of 0.01 to 1 l/min. In one or more embodiments, the upgraded oil may have an improved boiling curve, as indicated by the conversion. The amount of conversion can be defined as the amount of new material boiling below 400°C that is formed during the reactions divided by the total original mass. In some embodiments, the transformation may be defined as creating a new material that boils below 300°C or some other temperature. Upgraded oils may also have improved API gravity, from 0.1 to 20. Upgraded oils can have improved asphaltene contents, from 0 to 10%. Preferred ranges for conversion, API gravity improvement, and asphaltene reduction may depend on the specific application and the relative values of the raw materials and products.

In one or more embodiments, the heavy oil from the heavy oil supply line and/or the heavy oil from the separator may bypass the heat exchanger.

In one or more embodiments, the heavy oil may bypass the first control heat exchanger and/or the second control heat exchanger.

In one or more embodiments, the heavy oil pumped through the heavy oil supply line may be cooled by a heat exchanger and/or a first control heat exchanger.

Brief description of drawings

Fig. 1 illustrates a continuous heavy oil upgrading apparatus in which the heavy oil is first cracked, then the products (light hydrocarbon gas and light hydrocarbon liquid) are separated from the remaining heavy oil, and the products and remaining heavy oil are subsequently collected or reused in the plant for use in further upgrading of heavy oil.

Fig. 2 illustrates a continuous heavy oil upgrading apparatus in which the heavy oil is first separated into light hydrocarbon gas, light hydrocarbon liquid and heavy oil. The heavy oil is then cracked in a reactor and the components are then separated again. The light hydrocarbon gas and light hydrocarbon liquid are collected after separation or further reused in the device for use in further upgrading of heavy oil.

Disclosure of the Invention

This method relates to the field of processing liquids containing heavy hydrocarbon molecules into lighter liquid and/or gaseous fractions. The present method can be used to crack liquid heavy oil into lighter hydrocarbon fractions using a stream of carrier gas introduced into the liquid heavy oil to form a mixture, followed by ionization of the mixture by electrical discharge. This method can be successfully applied to achieve efficient continuous conversion of heavy oil into more valuable marketable upgraded oil.

The heavy oil upgrading method and apparatus described herein involves cracking liquid hydrocarbon materials into light hydrocarbon fractions using a spark discharge. The method includes supplying liquid hydrocarbon material through a discharge

- 4 043893 chamber into the interelectrode gap inside the discharge chamber, in which the interelectrode gap is formed between a pair of electrodes located at a distance from each other. The method further includes injecting a carrier gas into the liquid hydrocarbon material as it enters the interelectrode gap, resulting in the formation of a gas-liquid hydrocarbon mixture. The electrode pair comprises a positive electrode and a negative electrode, the negative electrode being connected to a capacitor. The capacitor is charged to a voltage equal to or greater than the breakdown voltage of the carrier gas in the interelectrode gap. As the gas-liquid hydrocarbon mixture is formed, it is exposed to current between the electrodes at a voltage sufficient to cause a spark discharge. The method also includes the extraction of light hydrocarbon gases and liquids formed as a result of the action of a pulsed spark discharge on a gas-liquid hydrocarbon mixture.

As used herein, the term heavy oil refers to those hydrocarbon compounds and mixtures thereof that are liquid under atmospheric conditions. Heavy oil may not necessarily contain suspended solids. Heavy oils may contain other conventional additives including, but not limited to, flow improvers, antistatic agents, antioxidants, anti-wax agents, corrosion inhibitors, ashless detergents, anti-knock agents, flame improvers, degassers, flavorings, pipeline reducers, lubricants substances, cetane number improvers, spark enhancers, valve seat protectors, synthetic or mineral oil carrier fluids and antifoam additives. Illustrative heavy oils include, but are not limited to, mineral oil; petroleum products including, but not limited to, crude oil, gasoline, kerosene and fuel oil; straight and branched chain paraffinic hydrocarbons; cycloparaffin hydrocarbons; monoolefin hydrocarbons; diolefin hydrocarbons; alkene hydrocarbons; and aromatic hydrocarbons including, but not limited to, benzene, toluene and xylene. In the context of this document, the term bypass refers to the complete or partial bypass of the flow of fluid through which it passes. The heavy oil pipeline or line may bypass the heat exchanger or control heat exchanger without passing the heavy oil through it, or with a certain percentage of the flow diverted from passing through the heat exchanger or control heat exchanger.

As used herein, the term heat exchanger refers to a device used to transfer heat between a monolithic object and a fluid or between two or more fluids. The fluids may be separated by a monolithic wall to prevent mixing or may be in direct contact. As used herein, the term control heat exchanger refers to a heat exchanger that uses external auxiliaries, such as cooling water, air, steam, heat transfer oil, or some other cooling or heating medium, to provide more precise temperature control of the process fluid.

As used herein, the term separator refers to a housing containing means for separating or purifying the components of a mixture. Such means include stills, chromatography columns, absorbers, crystallization units, sublimators, filters, centrifuges, liquid-liquid extractors and activated carbon.

As used herein, the term mixer refers to a container for stirring, mixing, emulsifying or homogenizing multi-component liquids.

If heavy oil contains crude oil, the crude oil may contain hydrocarbons with a wide range of molecular weights and forms. For example, hydrocarbons may include, but are not limited to, paraffins, aromatic hydrocarbons, naphthenes, cycloalkanes, alkenes, dienes and alkynes. Hydrocarbons can be characterized by the total number of carbon atoms (C) and/or the number of single (C-C), double (C=C) or triple (C=C) bonds between the carbon atoms. Due to the variety of compounds present in crude oil, this feedstock is well suited for the described process. It can be used to conveniently produce light hydrocarbons, including, but not limited to, gasoline and kerosene, or heavier hydrocarbons, including, but not limited to, diesel fuel and heating oil. Using the methods of this technology, hundreds of different hydrocarbon molecules in crude oil are converted into components that can be used as fuels, lubricants and as feedstocks in other petrochemical processes.

As used herein, the terms light hydrocarbon gas or resulting light liquids refer to hydrocarbons produced by cracking higher carbon hydrocarbons into lower carbon compounds. The light hydrocarbon gas may include C1-C5 alkanes. Light hydrocarbon gas may also be introduced into the process or device from a fresh source external to the device or method described herein.

As used herein, the term line may refer to a pipe, conduit, or path for transporting fluid. In the context of the present description, the power supply line

- 5 043893 transmits energy.

As used herein, the term compressor refers to a mechanical device that increases the pressure of a gas by decreasing its volume. Non-limiting examples include reciprocating compressors, ionic liquid reciprocating compressors, rotary screw compressors, rotary vane compressors, rotary pistons, scroll compressors, diaphragm compressors, dynamic compressors, air bubble compressors, centrifugal compressors, centrifugal axial compressors, or diagonal compressors. compressors, gas jet compressors, or axial flow compressors. As used herein, the term power generator or energy source refers to standard energy generation processes, including fired heaters, gas turbines, fuel cells, or methods for converting the chemical energy of hydrocarbon gas into electrical or thermal energy. Without being limited by theory, in any of the above methods or embodiments, heavy oils with a high carbon content are broken down into molecules with a lower carbon content to produce lighter hydrocarbon fractions (in terms of both molecular weight and boiling point) on average than more heavy oils in raw materials. In addition, without being limited by theory, it is believed that the splitting of heavy molecules occurs due to the cleavage of C-C bonds. For these molecules, the energy required to break a C-C bond is approximately 261.9 kJ/mol. This amount of energy is significantly less than the energy required to break a C-H bond (364.5 kJ/mol).

This application provides methods and devices for optimizing the transportation and processing of heavy oil simultaneously to produce high-value, upgraded oil and hydrocarbon products with continuous processing of products obtained from the refining of heavy oil. This method uses a spark discharge between electrodes to crack hydrocarbons in heavy oil. Cracked hydrocarbons are mixed with cracked products to produce upgraded oil with the desired viscosity. Before cracking, the heavy oil may be mixed with light hydrocarbon liquids and/or light hydrocarbon gases that are produced from the continuously cracked heavy oil and products that are recycled. Light hydrocarbon liquids and gases are also collected as valuable products. Light hydrocarbon gases can be reused from the cracking process or introduced fresh to mix with heavy oil to form gas-liquid hydrocarbon mixtures that react via spark discharge.

The light hydrocarbon gases used in the spark cracking process contain hydrogen atoms. When heavy oil is exposed to a spark discharge, free radicals are formed. Hydrocarbon free radicals attract hydrogen atoms. The carrier gas or light hydrocarbon gas used in the process can thus be used as a source of hydrogen atoms in the process. Light hydrocarbon gas is separated from heavy oil in the process or device or supplied fresh to the process or device from an external source. Suitable carrier gases may include, but are not limited to, gases containing hydrogen atoms. Exemplary carrier gases may include, but are not limited to, hydrogen, methane, natural gas and other hydrocarbon gases. In any of the above embodiments, a mixture of such illustrative carrier gases may be used.

Since the process must be carried out continuously, the various steps or stages of the process may occur simultaneously or sequentially, such that heavy oil is continuously fed into the discharge chamber or reactor as hydrocarbon product fractions exit the chamber.

As stated above, the method involves creating a spark discharge plasma in a gas stream in the interelectrode gap. The breakdown voltage of the carrier gas will be less than the breakdown voltage of the liquid; therefore, a gas jet can be used at the same voltage level to create a longer interelectrode gap. Increasing the interelectrode gap while simultaneously reducing the corrosive effect of the method on the electrodes increases the area of direct contact between the plasma discharge and the treated heavy oil. Without wishing to be bound by any particular theory, it is believed that when the discharge plasma comes into contact with heavy oil in the interelectrode gap, the heavy oil quickly heats up and evaporates to form steam. Thus, heavy oil molecules are mixed with carrier gas molecules and plasma particles formed in them. Plasma electrons collide with hydrocarbon molecules, thereby breaking them into smaller molecules that have one unsaturated bond and are essentially free radicals, i.e. fragments of molecules that have a free bond. Free radicals also arise from the direct interaction of fast-moving electrons with liquid walls formed around a plasma channel installed between the electrodes.

As noted above, various carrier gases known in the art can be used in the methods and devices of the present technology. Examples of carrier gases include, but are not limited to, helium, neon, argon, xenon, methane, C1- _C5 hydrocarbons, and hydrogen ( _H2 ). In some embodiments, the carrier gas is a hydrogen-containing gas, including, but not limited to, water, steam, pure hydrogen, methane, natural gas, or other hydrocarbon gases.

- 6 043893 dy. Mixtures of any two or more such hydrogen-containing gases may be used in any of the described embodiments. In addition, non-hydrogen gases, including but not limited to helium, neon, argon and xenon, can be used either as diluent gases for any of the hydrogen-containing gases, or they can be used with heavy oils, thereby allowing free radicals to tear off each other, rather than the hydrogen atom from the carrier gas. From the point of view of energy expenditure for the formation of one free hydrogen atom, in order to select a suitable carrier gas, it is advisable to compare the dissociation energy of various carrier gases or hydrogen-containing gases. For example, to break the bond between hydrogen atoms in an H2 molecule, approximately 432 kJ/mol will be required. For water vapor, the energy required to release a hydrogen atom is approximately 495 kJ/mol, while the energy required to remove a hydrogen atom from a hydrocarbon molecule, including but not limited to methane, requires approximately 364.5 kJ/mol.

In some embodiments, the carrier gas is methane. Using methane or natural gas is advantageous not only in terms of the energy required to break the bonds, but also because of its relatively low cost. The use of methane ensures that C-H bonds are broken to form a hydrogen radical and a methyl radical, each of which can combine with larger hydrocarbon radicals in the scission step. In some embodiments, the carrier gas is methane or a mixture of methane and an inert gas, including, but not limited to, helium, argon, neon, or xenon. In some embodiments, the carrier gas is a mixture of methane, hydrogen (fresh and/or produced by the process or apparatus), and optionally light hydrocarbon gas produced by the disclosed process or apparatus.

To create plasma in a gas stream, various types of electrical discharges can be used. These discharges can exist in both continuous and pulsed modes. For example, in some embodiments it is effective to use continuous discharges, including, but not limited to, arc discharge or glow discharge. However, the use of this type of discharge for cracking heavy hydrocarbons may be limited by the fact that heating the gaseous medium with direct current can lead to an undesirable increase in temperature inside the discharge chamber. This increase in temperature can lead to increased coking and soot formation. In addition, when using a continuous discharge, the products of the hydrocarbon fraction are constantly exposed to the discharge until they leave the plasma. In contrast, the use of a pulsed discharge, especially a pulsed spark discharge, may be desirable for the purpose of producing light hydrocarbon fractions from heavy oil fractions, since the interval between pulses allows the formation of free radicals to cease and allows time for the light hydrocarbon products to escape from the plasma. In another aspect, a device is provided for converting a liquid hydrocarbon medium into a hydrocarbon fraction product. The device may include a discharge chamber extending into the reactor to accommodate elements that provide the spark discharge that causes the conversion. The discharge chamber, and, consequently, the device, contains an inlet configured to transport heavy oil into the discharge chamber, an outlet configured to transport the hydrocarbon fraction product from the discharge chamber, a negative electrode having a first end and a second end, and a positive electrode, having a first end and a second end. In the discharge chamber, the first end of the negative electrode is spaced from the first end of the positive electrode by a distance that determines the interelectrode gap. To provide a method of mixing heavy oil with a carrier gas as described above, the discharge chamber may also include a gas jet configured to introduce the carrier gas near the interelectrode gap. The carrier gas is introduced into the heavy oil during injection into the interelectrode gap or immediately before it. The second end of the negative electrode and the second end of the positive electrode are connected to a, which may include a capacitor, and a power generator configured to create a spark discharge in the interelectrode gap is provided.

In a reactor, a spark discharge is formed in the interelectrode gap when the voltage (V) applied to the electrodes is equal to or greater than the breakdown voltage ( _Vb ) in the interelectrode gap. A spark discharge is initiated by free electrons, which usually appear at the positive electrode as a result of field emission or other electron emission processes. Free electrons are accelerated in an electric field spanning the gap, and when the gas in the gap is ionized, a spark plasma channel is created. After the spark discharge channel is formed, a discharge current flows through the plasma. The voltage inside the plasma channel (Vd) is lower than the breakdown voltage (Vb). An arc discharge occurs if the generator power is sufficient to allow current to flow in the discharge channel in continuous mode. In a spark discharge, the plasma is also heated. However, you can regulate the temperature not only by adjusting the discharge current, but also by controlling the duration of the discharge. In some embodiments, by creating a plasma channel in the gas, the temperature of the gas can reach several thousand degrees Celsius.

Alternatively, a different power circuit can be used to create the spark discharge. In some embodiments, a large number of different pulse generators are used to ignite the spark discharges. For example, a circuit can be used that discharges the precharge storage capacitor under load. The parameters of the pulse voltage at the load are determined by the storage capacity, as well as the parameters of the entire discharge circuit. Energy losses will depend on the characteristics of the discharge circuit, in particular, on losses in the switch.

In some embodiments, a spark switch is directly used as the load, i.e. plasma reactor, which reduces energy losses in the discharge circuit. In addition, the storage capacitor can be connected in parallel with the spark gap in a circuit with minimal inductance. Gap breakdown occurs when the voltage across the storage capacitor reaches the breakdown voltage, and energy is supplied to the plasma spark during the discharge of the capacitor. Consequently, energy losses in the circuit are low.

According to any of the above embodiments, the positive electrode may be in the form of a planar electrode, either in the form of a sheet, blade or flat terminal, while the negative electrode is in the form of a tube, i.e. cannulated The negative cannulated electrode is a hollow electrode through which a carrier gas can be introduced into the heavy oil in the interelectrode space. Thus, the negative cannulated electrode can serve as a channel for carrier gas. When the negative electrode is cannulated, the cannula passage will have a radius of curvature at the tube opening. The height or length of the discharge electrode is usually measured from the base, which is the attachment point, to the top. In some embodiments, the ratio of the radius of curvature to the height or length of the cathode may be greater than about 10.

As noted above, the interelectrode gap, i.e. the distance between the two electrodes affects the effectiveness of the method. The interelectrode gap is a characteristic that can be optimized, for example, based on the particular hydrocarbon material supplied to the discharge chamber, the carrier gas introduced, and the applied voltage and/or current. However, certain interelectrode gap ranges can be set. For example, in any of the above embodiments, the interelectrode gap may range from about 1-3 mm to about 100 mm. This may include an interelectrode gap of about 3 mm to about 20 mm, when using an operating voltage of 30-50 kV, the optimal gap length will be from 8 to 12 mm. The negative electrode and the positive electrode may both protrude into the discharge chamber.

As stated, the storage capacitor can be charged to a voltage equal to or greater than the breakdown voltage of the carrier gas such that a spark discharge occurs. In some embodiments, a discharge occurs between the positive electrode and a carrier gas near the first end of the positive electrode. In some embodiments, the discharge is continuous. In some embodiments, the discharge is pulsed. In some embodiments, the intensity of the electrical discharge is controlled by the resistance value in the charging circuit of the storage capacitor.

A power generator is connected to the entire system to provide the energy needed to start the discharge. In some embodiments, the apparatus described herein may utilize a DC generator with an operating voltage of 15-25 kV. The power generator depends on the number of intervals for processing the hydrocarbon liquid, their length, pulse repetition rate, liquid flow through the reactor, and gas flow through each interval. An example of a device in which 12 spaces are used is described herein. For example, the device may contain a reactor that uses 3.5 mm long interelectrode gaps, 100 pF capacitors, an operating voltage of 18 kV and a pulse repetition rate of 5 Hz. The power consumption of the generator can be from 1 to 2 W, and the plasma can consume approximately 0.97 W of power directly in the discharge. The remaining power can be dissipated in the charging system capacitors. Other components may also be included in the device. For example, a reservoir or piping system may connect a heavy oil supply line to a source of heavy oil, and the reservoir or piping system may be connected to outlets for collecting upgraded oil, light hydrocarbon gas, or light hydrocarbon liquids. The products can be further processed by separating the lower molecular weight components by distillation, with the higher molecular weight components returning to the reactor for possible further processing. A gas recovery system may be connected to an outlet on the device, allowing the capture of low molecular weight hydrocarbon gases, liquid hydrocarbon gas and/or carrier gases, the latter of which is reused for reinjection as carrier gas, and the first two collected for another use. The device can be adapted to any specific heavy oil processing regime. This adaptive flexibility allows for convenient control of crude oil processing, which can vary over a wide range of compositions and impurities. Control of heavy oil cracking process conditions is possible by changing only a few operating parameters. For example, such parameters may include changes in the length of the interelectrode gap and/or the applied voltage (V). An increase in voltage can lead to an increase in the square proportion of the energy W=CV2/2 stored in the capacitor. Changing the Capacitance of a Capacitor

- 8 043893 is directly proportional to the change in power consumption in the W discharge. Control of the pulse repetition rate can be achieved by changing the capacitance and resistance of the circuit. In some embodiments, the pulse rate is from about 1 pulse per second to about 1000 pulses per second. In other embodiments, the pulse rate is from about 2 pulses per second to about 7 pulses per second. In any of these embodiments, the pulse rate is from about 3 pulses per second to about 5 pulses per second.

Changes in the electrical characteristics of the power circuit are not the only reason for changes in the cracking process using the device. Regulation of the spark discharge can be accomplished by changing the flow rate of carrier gas and heavy oil, as well as by adjusting the processing time of liquid hydrocarbons and hydrocarbon fraction products in the chamber. All other things being equal, the flow of carrier gas into heavy oil has a significant impact on upgraded oil, light hydrocarbon liquids and light hydrocarbon gas products. Streams or jets of carrier gas of various diameters can be formed in the interelectrode gap depending on the gas flow rate and the viscosity of the fluid. The spark discharge plasma is not in direct contact with the liquid due to the large diameter gas jet if it is generated at a high gas flow rate. At low gas flow, the diameter of the gas jet is comparable to the diameter of the spark in the channel. In such cases, intense interaction of the discharge plasma with the surrounding liquid occurs. Intense interaction indicates that the contact area between the plasma channel and the liquid is maximum.

In one aspect, with reference to FIG. 1, a device for continuous upgrading of heavy oil is proposed, the device comprising a heavy oil supply line (31) connected to a heat exchanger (11) for transporting heavy oil through the heat exchanger (11), wherein the heavy oil supply line (31) is continuous with the line (33 ), connecting the heat exchanger (11) with the first control heat exchanger (12). The device contains a reactor (13) with a line (34) configured to supply heavy oil into it, while the line (34) passes through the first control heat exchanger (12) and is continuous with the line (33). The device contains a separator (14) connected to the reactor (13) by a line (36), while the separator (14) is connected to a line (44), which is branched into a recirculation line (45) and a line (46), while the line (45 ) recirculation merges with line (34), and line (46) is connected to the heat exchanger (11), and line (37) is connected to the separator and is branched into a line (38) of the resulting light liquids and a second line (39), while the second line (39) is connected to the mixer (18). The device contains a second control heat exchanger (16) connected to the heat exchanger (11) by line (30), wherein line (30) is a continuation of line (46). The device contains a line (32) connecting the mixer (18) and the second control heat exchanger (16). The device contains a line (35) of upgraded oil connected to a mixer (18). The device contains a compressor (15), with line (40) connected to the separator (14) and branched into a gas recirculation line (42) and a third line (41), with gas recirculation line (42) connected to the compressor (15), and the third line (41) is connected to the power generator (17). The device contains a light hydrocarbon gas supply line (66) for transporting fresh light hydrocarbon gas to the reactor (13). The device contains a line (43) connecting the compressor (15) with the light hydrocarbon gas supply line (66). The device contains a power supply line (47) connecting the power generator (17) to the reactor (13).

In another aspect, with reference to FIG. 2, a device is proposed for continuous upgrading of heavy oil to obtain upgraded oil, the device comprising a heavy oil supply line (48) connected to a heat exchanger (21) for transporting heavy oil through the heat exchanger (21), while the heavy oil supply line (48) is continuous with a line (49) connecting the heat exchanger (21) to the first control heat exchanger (22). The device contains a separator (24) connected to the first control heat exchanger (22) by line (50), wherein line (50) is continuous with line (49). The device contains a line (57) connected to the separator (24), wherein the line (57) is branched into a heavy oil line (59) and a line (58), and the heavy oil line (59) passes through the heat exchanger (21) and is continuous with line (56) connected to the second control heat exchanger (26), and wherein line (58) is connected to the reactor (23), and line (60) connects the reactor (23) to the separator (24). The device contains a mixer (28) connected to the second control heat exchanger (26) by a line (54), while the upgraded oil line (55) is connected to the mixer (28), line (51) is connected to the separator (24), and line ( 51) is branched into a line (53) for liquid light hydrocarbons and a line (52) for the resulting light liquid, while line (53) for liquid light hydrocarbons is connected to the mixer (28). The device contains a line (61) connected to a separator (24), while line (61) is branched into a gas recirculation line (63) and a gas recirculation line (62), while line (63) is connected to a power generator (27), and when in this case, the gas recirculation line (62) is connected to the compressor (25), while the compressor (25) is connected to line (64), and line (64) merges with the light hydrocarbon gas supply line (67), while the light hydrocarbon gas supply line configured to transport fresh light hydrocarbon gas into the reactor (23). Container device

- 9 043893 live power supply line (65) connecting the power generator (27) to the reactor (23).

In another aspect, with reference to FIG. 1 proposes a method for continuous upgrading of heavy oil to obtain upgraded oil using a pulsed plasma reactor (13), including: injection of heavy oil through the heavy oil supply line (31) under a first pressure of 0.1 to 10 barg. (preferably 0.9 to 2 barg) into the interelectrode gap inside the reactor (13), wherein the heavy oil supply line (31) first passes the heavy oil through the heat exchanger (11) to adjust the temperature of the heavy oil, and delivers it to a first control heat exchanger (12) through which heavy oil passes to enter the reactor (13), and wherein the interelectrode gap is determined by the distance between the first end of the negative electrode and the first end of the positive electrode, and the second end of the positive electrode and the second end of the negative electrode are connected to the power generator (17) via the power supply line (47). The method further includes injection at a second pressure of 0.2 to 20 barg. (preferably 1 to 3 barg) of light hydrocarbon gas through line (66) supplying light hydrocarbon gas to reactor (13) for mixing therein with heavy oil to form a hydrocarbon liquid-gas mixture in the interelectrode gap. The method further includes creating a spark discharge in the interelectrode gap to react the hydrocarbon liquid-gas mixture. The method further includes supplying the reacted hydrocarbon liquid-gas mixture to a separator (14) and separating the light hydrocarbon liquid and light hydrocarbon gas from the heavy oil. The method further includes supplying the separated light hydrocarbon gas from the separator (14) to the compressor (15) and compressing the light hydrocarbon gas, wherein fresh hydrogen and/or fresh hydrocarbon gas is added to the light hydrocarbon gas to obtain a gas mixture of hydrogen and light hydrocarbons and recycling a gas mixture of hydrogen and light hydrocarbons into the reactor (13). In addition, the method includes supplying heavy oil from the separator (14) to a heat exchanger (11), in which the heavy oil from the separator (14) is combined with the heavy oil from the heavy oil supply line to produce a combined heavy oil. The method further includes removing the combined heavy oil or mixing the combined heavy oil with a light hydrocarbon liquid to produce an upgraded oil. In some embodiments, from 1 to 50% by volume of the heavy oil is converted to light hydrocarbon liquid and/or light hydrocarbon gas. In some embodiments, from 1 to 10% by volume of the heavy oil is converted to light hydrocarbon liquid and/or light hydrocarbon gas. In some embodiments, 10 to 20% by volume of the heavy oil is converted to light hydrocarbon liquid and/or light hydrocarbon gas. In some embodiments, 20 to 30% of the heavy oil volume is converted to light hydrocarbon liquid and/or light hydrocarbon gas. In some embodiments, 30 to 50% of the heavy oil volume is converted to light hydrocarbon liquid and/or light hydrocarbon gas. In some embodiments, 50 to 75% of the heavy oil volume is converted to light hydrocarbon liquid and/or light hydrocarbon gas. In some embodiments, from 75 to 100% by volume of the heavy oil is converted to light hydrocarbon liquid and/or light hydrocarbon gas. Depending on the application, the preferred range may be as low as 3% to be economical, while other embodiments may require higher conversion per reaction cycle to be competitive. Each application will have an optimal conversion range, since increasing the cost of the product due to higher conversion will require additional energy. The preferred conversion for partial upgrading of heavy crude oil for pipeline transport is 3 to 10%, while the preferred conversion of refinery heavy gas oil may be 5 to 30%.

In some embodiments, the heavy oil from the separator (14) and the heavy oil from the heavy oil supply line are combined in a ratio of 1:10 to 20:1. In some embodiments, the heavy oil from the separator (14) and the heavy oil from the heavy oil supply line are combined in a ratio of 1:10 to 1:5. In some embodiments, the heavy oil from the separator (14) and the heavy oil from the heavy oil supply line are combined in a ratio of 1:5 to 1:2. In some embodiments, the heavy oil from the separator (14) and the heavy oil from the heavy oil supply line are combined in a ratio of 1:2 to 1:1. In some embodiments, the heavy oil from the separator (14) and the heavy oil from the heavy oil supply line are combined in a ratio of 1:1 to 2:1. In some embodiments, the heavy oil from the separator (14) and the heavy oil from the heavy oil supply line are combined in a ratio of 2:1 to 5:1. In some embodiments, the heavy oil from the separator (14) and the heavy oil from the heavy oil supply line are combined in a ratio of 5:1 to 10:1. The preferred oil feed/recycle ratio is from 1 to 10.

In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line is controlled to a temperature of from 25 to 200°C. In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line is controlled to a temperature of from 15 to 50°C. In some embodiments, the combi

- 10 043893 unified heavy oil from the separator (14) and heavy oil from the heavy oil supply line are controlled to a temperature of 50 to 100°C. In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line is controlled to a temperature of from 100 to 150°C. In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line is controlled to a temperature of between 150 and 200°C, with a preferred temperature between 120 and 150°C.

In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line has a viscosity of 1 to 1000 cP at the inlet to the reactor (13). In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line has a viscosity of 1 to 50 cP at the inlet to the reactor (13). In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line has a viscosity of 50 to 300 cP at the inlet to the reactor (13). In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line has a viscosity of 300 to 600 cP at the inlet to the reactor (13). In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line has a viscosity of 600 to 900 cP at the inlet to the reactor (13). In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line has a viscosity of 900 to 1250 cP at the inlet to the reactor (13). In some embodiments, the combined heavy oil from the separator (14) and the heavy oil from the heavy oil supply line has a viscosity greater than 1000 cP at the inlet to the reactor (13). The preferred viscosity range is from 10 to 200 cP.

In some embodiments, the reactor (13) includes a plurality of interelectrode spaces. In some embodiments, the reactor (13) contains two interelectrode spaces. In some embodiments, the reactor (13) contains three interelectrode spaces. In some embodiments, the reactor (13) contains four interelectrode spaces. In some embodiments, the reactor (13) contains five interelectrode spaces. In some embodiments, the reactor (13) contains 5-10 interelectrode spaces. In some embodiments, the reactor (13) contains 20-50 interelectrode spaces. In some embodiments, the reactor (13) contains 50-100 interelectrode spaces. In some embodiments, the reactor (13) contains more than 100 interelectrode spaces. The preferred number of gaps will increase linearly with the desired process throughput according to the application. Ancillary equipment involved in reactions will be sized accordingly, and larger applications will provide economies of scale for that equipment.

In some embodiments, the separator (14) includes a fractional distillation device or absorber. In some embodiments, the absorber is a pressure variable absorber.

In some embodiments, the light hydrocarbon liquid has an upper boiling point of from 100 to 300°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 90 to 110°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 110 to 130°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 130 to 150°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 150 to 170°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 170 to 190°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 190 to 210°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 210 to 230°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 230 to 250°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 250 to 270°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 270 to 290°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 270 to 310°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of less than 90°C. In some embodiments, the method further includes removing a portion of the light hydrocarbon liquid before mixing with the combined heavy oil. In some embodiments, fresh hydrogen and/or fresh hydrocarbon gas is added to the separated light hydrocarbon gas before and/or after compression.

In some embodiments, the method includes analyzing the composition of the light hydrocarbon gas before it is supplied to the reactor (13). In some embodiments, the analysis is performed by a colorimetric assay. In some embodiments, the analysis is performed by gas chromatography (GC). In some embodiments, the analysis is performed by gas chromatography mass spectrometry (GCMS). In some embodiments, the analysis is performed by measuring gas density, gas molecular weight, or other measurement methods to determine the composition of the gas, directly or indirectly.

- 11 043893

In some embodiments, the method further includes treating the compressed light hydrocarbon gas to regulate pressure. In some embodiments, the purified light hydrocarbon gas powers the reactor (13) and/or provides heat used in the process. In some embodiments, hydrogen is recovered from the purified light hydrocarbon gas. In some embodiments, the energy for the spark discharge is provided by a microturbine.

In some embodiments, the amount of fresh hydrogen added to the light hydrocarbon gas is an amount sufficient to produce a gas mixture of hydrogen and light hydrocarbon gas having a hydrogen concentration of from 1 to 50% by volume. In some embodiments, the hydrogen concentration is from 1 to 10% by volume. In some embodiments, the hydrogen concentration is from 10 to 20% by volume. In some embodiments, the hydrogen concentration is 20 to 30% by volume. In some embodiments, the hydrogen concentration is 30 to 40% by volume. In some embodiments, the hydrogen concentration is 40 to 50% by volume. In some embodiments, the hydrogen concentration is 50 to 60% by volume. In some embodiments, the hydrogen concentration is from 60 to 80% by volume. In some embodiments, the hydrogen concentration is greater than 80% by volume. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.01 to 1 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.01 to 0.2 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.2 to 0.4 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.4 to 0.6 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.6 to 0.8 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.8 to 1 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate greater than 1 L/min.

In some embodiments, the upgraded oil has an improved boiling curve, as indicated by conversion. The amount of conversion is defined as the amount of new material boiling below 400°C that is created during the reactions divided by the total initial mass. In some embodiments, the transformation may be defined as creating a new material that boils below 300°C or some other temperature. The upgraded oil will also have an improved API gravity, from 0.1 to 20. The upgraded oil will have an improved asphaltene content, from 0 to 10%. Preferred ranges for conversion, API gravity improvement, and asphaltene reduction will depend on the specific application and the relative values of the raw materials and products.

In some embodiments, the heavy oil is bypassed through the heat exchanger (11). In some embodiments, heavy oil is bypassed by the first control heat exchanger (12) and/or the second control heat exchanger (16). In some embodiments, the heavy oil pumped through the heavy oil supply line (31) is cooled by a heat exchanger (11) and a first control heat exchanger (12). In some embodiments, the heat exchanger (11) cools the heavy oil. In some embodiments, the heat exchanger (11) heats the heavy oil. In some embodiments, the heat exchanger (11) may be bypassed by a passing line.

In some embodiments, the first control heat exchanger (12) heats the heavy oil passing through it. In some embodiments, the first control heat exchanger (12) cools the heavy oil passing through it. In some embodiments, the second control heat exchanger (16) heats the heavy oil passing through it. In some embodiments, the second control heat exchanger (16) cools the heavy oil passing through it. In some embodiments, the heavy oil feed line contains heavy oil that does not require upgrading, and wherein the heavy oil feed line bypasses the reactor (13) to enter the separator (14) after passing through the heat exchanger (11) and the first control heat exchanger (12), the method comprising separating light hydrocarbon liquid and light hydrocarbon gas from heavy oil, wherein the separated heavy oil is transported to a reactor (13).

In another aspect, with reference to FIG. 2, a method for continuous upgrading of heavy oil is proposed to obtain upgraded oil using a pulsed plasma reactor (23), including injecting heavy oil through a heavy oil supply line (48) at a first pressure of 0.1 to 10 barg. (preferred range 0.9 to 2 barg) through the heat exchanger (21) and the first control heat exchanger (22) to the separator (24), and separating the light hydrocarbon liquid and light hydrocarbon gas from the heavy oil, wherein the separated heavy oil enters heat exchanger (21) for combining with heavy oil from the heavy oil supply line (48), and/or from

- 12 043893 the divided heavy oil enters the interelectrode gap included in the reactor (23), and the interelectrode gap is determined by the distance between the first end of the negative electrode and the first end of the positive electrode, while the second end of the positive electrode and the second end of the negative electrode are connected to the generator (27 ) power through the power supply line (65), and wherein the light hydrocarbon gas is supplied to the compressor (25) or power generator (27), wherein the light hydrocarbon gas in the compressor (25) is compressed and sent to the reactor (23), and wherein the light hydrocarbon liquid is fed into the mixer (28) or collected. The method further includes injection at a second pressure of 0.2 to 20 barg. (preferably in the range of 1 to 3 barg) of light hydrocarbon gas through line (67) supplying light hydrocarbon gas to reactor (23) for mixing therein with heavy oil to form a hydrocarbon liquid-gas mixture in the interelectrode gap. The method further includes creating a spark discharge in the interelectrode gap to react the hydrocarbon liquid-gas mixture. The method further includes supplying the reacted hydrocarbon liquid-gas mixture to a separator (24) and separating the light hydrocarbon liquid and light hydrocarbon gas from the heavy oil. The method further includes combining the separated heavy oil and the heavy oil from the heavy oil supply line and passing the combined heavy oil through the second control heat exchanger (26) into the mixer (28), and mixing the combined heavy oil with the light hydrocarbon liquid to obtain an upgraded oil.

In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line is controlled to a temperature of from 25 to 200°C. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line is controlled to a temperature of from 15 to 50°C. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line is controlled to a temperature of from 50 to 100°C. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line is controlled to a temperature of from 100 to 150°C. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line is controlled to a temperature of between 150 and 200°C, with a preferred temperature between 120 and 150°C.

In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line has a viscosity of 1 to 1000 cP after combining. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line has a viscosity of 1 to 50 cP after combining. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line has a viscosity of 50 to 300 cP after combining. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line has a viscosity of 300 to 600 cP after combining. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line has a viscosity of 600 to 900 cP after combining. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line has a viscosity of 900 to 1250 cP after combining. In some embodiments, the combined heavy oil from the separator (24) and the heavy oil from the heavy oil supply line has a viscosity greater than 1000 cP after combining. The preferred viscosity range is from 10 to 200 cP.

In some embodiments, the reactor (23) includes a plurality of interelectrode spaces. In some embodiments, the reactor (23) includes two interelectrode spaces. In some embodiments, the reactor (23) includes three interelectrode spaces. In some embodiments, the reactor (23) includes four interelectrode spaces. In some embodiments, the reactor (23) contains five interelectrode spaces. In some embodiments, the reactor (23) contains 5-10 interelectrode spaces. In some embodiments, the reactor (23) contains 20-50 interelectrode spaces. In some embodiments, the reactor (23) contains 50-100 interelectrode spaces. In some embodiments, the reactor (23) contains more than 100 interelectrode spaces. The preferred number of gaps will increase linearly with the desired process throughput according to the application. Ancillary equipment involved in reactions will be appropriately sized, and larger applications will provide economies of scale for that equipment.

In some embodiments, the separator (24) includes a fractional distillation device or absorber. In some embodiments, the absorber is a pressure variable absorber.

In some embodiments, the light hydrocarbon liquid has an upper boiling point of 100 to 300°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 90 to 110°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 110 to 130°C. In some embodiments, light carbon

- 13 043893 hydrogen liquid has an upper boiling point of 130 to 150°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 150 to 170°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 170 to 190°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 190 to 210°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 210 to 230°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 230 to 250°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 250 to 270°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 270 to 290°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of 270 to 310°C. In some embodiments, the light hydrocarbon liquid has an upper boiling point of less than 90°C. In some embodiments, the method further includes removing a portion of the light hydrocarbon liquid before mixing it with the combined heavy oil. In some embodiments, fresh hydrogen and/or fresh hydrocarbon gas is added to the separated light hydrocarbon gas before and/or after compression.

In some embodiments, the method includes analyzing the composition of the light hydrocarbon gas before it is supplied to the reactor (23). In some embodiments, the analysis is performed by a colorimetric assay. In some embodiments, the analysis is performed by gas chromatography (GC). In some embodiments, the analysis is performed by gas chromatography mass spectrometry (GCMS). In some embodiments, the analysis is performed by measuring gas density, gas molecular weight, or other measurement methods to determine the composition of the gas, directly or indirectly.

In some embodiments, the method further includes treating the compressed light hydrocarbon gas to regulate pressure. In some embodiments, the purified light hydrocarbon gas powers the reactor (23) and/or provides heat used in the process. In some embodiments, hydrogen is recovered from the purified light hydrocarbon gas. In some embodiments, the energy for the spark discharge is provided by a microturbine.

In some embodiments, the amount of fresh hydrogen added to the light hydrocarbon gas is an amount sufficient to produce a gas mixture of hydrogen and light hydrocarbon gas containing a hydrogen concentration of from 1 to 50% by volume. In some embodiments, the hydrogen concentration is from 1 to 10% by volume. In some embodiments, the hydrogen concentration is from 10 to 20% by volume. In some embodiments, the hydrogen concentration is 20 to 30% by volume. In some embodiments, the hydrogen concentration is 30 to 40% by volume. In some embodiments, the hydrogen concentration is 40 to 50% by volume. In some embodiments, the hydrogen concentration is 50 to 60% by volume. In some embodiments, the hydrogen concentration is from 60 to 80% by volume. In some embodiments, the hydrogen concentration is greater than 80% by volume. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.01 to 1 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.01 to 0.2 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.2 to 0.4 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.4 to 0.6 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.6 to 0.8 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate of 0.8 to 1 L/min. In some embodiments, a gas mixture of hydrogen and light hydrocarbon is supplied to the reactor at a flow rate greater than 1 L/min.

In some embodiments, the upgraded oil has an improved boiling curve, as indicated by conversion. The amount of conversion is defined as the amount of new material boiling below 400°C that is created during the reactions divided by the total initial mass. In some embodiments, the transformation may be defined as creating a new material that boils below 300°C or some other temperature. The upgraded oil will also have an improved API gravity, from 0.1 to 20. The upgraded oil will have an improved asphaltene content, from 0 to 10%. Preferred ranges for conversion, API gravity improvement, and asphaltene reduction will depend on the specific application and the relative values of the raw materials and products.

In some embodiments, the heavy oil from the heavy oil supply line (48) and/or the heavy oil from the separator (24) bypasses the heat exchanger (21). In some embodiments, the first control heat exchanger (22) and/or the second control heat exchanger (26) is bypassed by bypassing the heavy oil from the heavy oil supply line (48) and/or the heavy oil from the separator (24). .

In some embodiments, the heavy oil pumped through the heavy oil supply line (31) is cooled by a heat exchanger (21) and a first control heat exchanger (22). In some embodiments, the heat exchanger (21) cools the heavy oil. In some embodiments, the heat exchanger (21) heats the heavy oil. In some embodiments, the heat exchanger (21) may be bypassed by a passing line.

In some embodiments, the first control heat exchanger (22) heats the heavy oil passing through it. In some embodiments, the first control heat exchanger (22) cools the heavy oil passing through it. In some embodiments, the second control heat exchanger (26) heats the heavy oil passing through it. In some embodiments, the second control heat exchanger (26) cools the heavy oil passing through it. The apparatus and methods generally described above will be better understood with reference to the following examples, which are in no way intended to limit the apparatus or methods described above.

Examples

In the first example with reference to FIG. 1 A heavy process oil stream, such as sludge, unreacted hydrocracking oil and/or other heavy gas oil, is introduced into the process, and a heat exchanger and control heat exchanger maintain the appropriate reactor feed temperature from 100 to 200°C. This temperature can be varied depending on the composition of the liquid to obtain a viscosity low enough to maintain small bubble sizes. Any light refinery gas that does not contain oxygen and sulfur can be used as the source gas. As a result of the reactions in the spark discharge, lighter fuel products will be formed, which can be removed in the separator and sent to other plants for further processing and mixing. Some of the heavy liquid product from the separator can also be returned back to the reactor to increase overall feed conversion. Some of the recycle gas from the separator can be removed to be used as fuel for an energy source that provides electricity to spark discharges and other process equipment.

In a second example with reference to FIG. 2, the dilute heavy crude oil stream is supplied to the process through a heat exchanger and a control heat exchanger to maintain the appropriate temperature at the bottom of the separator. The existing light material (diluent) is removed in the separator and the heavy material is sent to the reactor at a temperature that produces a low viscosity liquid that maintains small bubble sizes. The feed gas may be natural gas or associated produced gas that does not contain oxygen. The spark discharge reactions will produce lighter hydrocarbon products which can be blended to improve crude oil transport characteristics and/or disposed of as a light product. Some of the heavy liquid product from the separator can also be removed and mixed to improve the quality of the crude oil. Some of the recycle gas from the separator can be removed to be used as fuel for an energy source that provides electricity to spark discharges and other process equipment.

The invention is further defined by the following embodiments.

Embodiment A: An apparatus for continuous upgrading of heavy oil, comprising a heavy oil supply line connected to a heat exchanger for transporting heavy oil through the heat exchanger, wherein the heavy oil supply line is continuous with a first line connecting the heat exchanger to the first control heat exchanger;

a reactor with a second line configured to supply heavy oil thereto, the second line passing through the first control heat exchanger and being continuous with the first line;

a separator connected to the reactor by a third line, wherein the separator is connected to a fourth line, which is branched into a recirculation line and a fifth line, wherein the recirculation line merges with the second line, and the fifth line is connected to the heat exchanger, while the sixth line is connected to the separator and is branched to the line of light liquids produced and the seventh line, and the seventh line is connected to the mixer;

a second control heat exchanger connected to the heat exchanger by an eighth line, the eighth line being continuous with the fifth line;

a ninth line connecting the mixer and the second control heat exchanger;

an upgraded oil line connected to the mixer for removing upgraded oil from the installation;

a compressor, wherein the tenth line is connected to the separator and is branched into a gas recirculation line and an eleventh line, wherein the gas recirculation line is connected to the compressor, and the eleventh line is connected to the power generator;

light hydrocarbon gas supply line for supplying fresh light hydrocarbon gas to

- 15 043893 reactor;

a twelfth line connecting the compressor to the light hydrocarbon gas supply line; and a power supply line connecting the power generator to the reactor.

Embodiment B: An apparatus for continuously upgrading heavy oil to produce upgraded oil, comprising a heavy oil supply line connected to a heat exchanger for transporting heavy oil through the heat exchanger, the heavy oil supply line being continuous with a first line connecting the heat exchanger to the first control heat exchanger;

a separator connected to the first control heat exchanger by a second line, the second line being continuous with the first line;

a third line connected to the separator, wherein the third line is branched into a heavy oil line and a fourth line, wherein the heavy oil line passes through the heat exchanger and continues with a fifth line connected to the second control heat exchanger, wherein the fourth line is connected to the reactor, and the sixth line connects the reactor to the separator;

a mixer connected to the second control heat exchanger by a seventh line, wherein a line of upgraded oil for removing upgraded oil from the device is connected to the mixer;

an eighth line connected to the separator, wherein the eighth line is branched into a light hydrocarbon liquid line and a produced light liquid line, wherein the light hydrocarbon liquid line is connected to the mixer;

a ninth line connected to the separator, wherein the ninth line is branched into a tenth line and a gas recirculation line, wherein the tenth line is connected to the power generator, and the gas recirculation line is connected to the compressor, and the compressor is connected to the eleventh line, and the eleventh line merges with a light hydrocarbon gas supply line, wherein the light hydrocarbon gas supply line is configured to transport fresh light hydrocarbon gas to the reactor; and a transmission line connecting the power generator to the reactor.

Embodiment C: A method for continuously upgrading heavy oil to produce high quality oil using a pulsed plasma reactor, comprising injecting heavy oil through a heavy oil supply line at a first pressure of 0.1 to 10 barg. (preferred range is 0.9 to 2 barg) into the electrode gap inside the reactor, wherein the heavy oil supply line first passes the heavy oil through a heat exchanger to regulate the temperature of the heavy oil, and enters the first control heat exchanger through which the heavy oil passes before entering the reactor, and the interelectrode gap is determined by the distance between the first end of the negative electrode and the first end of the positive electrode, while the second end of the positive electrode and the second end of the negative electrode are connected to the power generator by a power supply line;

discharge at a second pressure of 0.2 to 20 barg. (preferred range 1 to 3 barg) light hydrocarbon gas through the light hydrocarbon gas supply line into the reactor for mixing therein with heavy oil to form a hydrocarbon liquid-gas mixture in the interelectrode gap;

creating a spark discharge in the interelectrode gap to react the hydrocarbon liquid-gas mixture;

passing the reacted hydrocarbon liquid-gas mixture into a separator and separating the light hydrocarbon liquid and the light hydrocarbon gas from the heavy oil;

passing the separated light hydrocarbon gas from the separator to a compressor and compressing the light hydrocarbon gas, adding fresh hydrogen and fresh hydrocarbon gas to the light hydrocarbon gas to produce a hydrogen-light hydrocarbon gas mixture and recycling the hydrogen-light hydrocarbon gas mixture to the reactor;

supplying the heavy oil from the separator to a heat exchanger in which the heavy oil from the separator is combined with the heavy oil from the heavy oil supply line to produce a combined heavy oil; and removing the combined heavy oil or mixing the combined heavy oil with a light hydrocarbon liquid to produce an upgraded oil.

Embodiment D. The process of Embodiment C, wherein 1 to 50% by volume of the heavy oil is converted to light hydrocarbon liquid and/or light hydrocarbon gas, with a preferred range of 3 to 30%.

Embodiment E. The method of Embodiment C or D, wherein the heavy oil from the separator and the heavy oil from the heavy oil supply line are combined in a ratio of 1:10 to 20:1, with a preferred ratio of 1:1 to 10:1.

Embodiment F. The method according to any one of embodiments C-E, wherein the combined heavy oil from the separator and the heavy oil from the heavy oil supply line may be

- 16 043893 is adjusted to a temperature of 25 to 200°C and a viscosity of 1 to 1000 cP when entering the reactor with a preferred viscosity of 10 to 200 cP.

Embodiment G. The method according to any one of embodiments C-F, wherein the reactor contains a plurality of interelectrode spaces.

Embodiment H. The method according to any of embodiments C to G, wherein the separator comprises a fractional distillation device or an absorber.

Embodiment I. The method according to any one of embodiments C-H, wherein the absorber is a pressure swing absorber.

Embodiment J. The method of any one of Embodiments C-I, wherein the light hydrocarbon liquid has an upper boiling point of 100° C. to 300° C.

Embodiment K. A method according to any one of embodiments C-J, further comprising removing a portion of the light hydrocarbon liquid before mixing it with the combined heavy oil.

Embodiment L. The method according to any one of embodiments C-K, wherein fresh hydrogen and/or fresh hydrocarbon gas is added to the separated light hydrocarbon gas before and/or after compression.

Embodiment M. The method according to any one of embodiments C-L, further comprising analyzing the composition of the light hydrocarbon gas before it is supplied to the reactor.

Embodiment N. The method according to any of embodiments C-M, further comprising purifying the compressed light hydrocarbon gas.

Embodiment O. The method of any one of embodiments C-N, wherein the purified light hydrocarbon gas powers the reactor and/or provides heat used in the process.

Embodiment P. A method according to any one of embodiments C-O, wherein hydrogen is separated from purified light hydrocarbon gas.

Embodiment Q. The method according to any one of embodiments C-P, wherein the energy for the spark discharge is provided by a microturbine.

Embodiment R. The method according to any one of embodiments C-Q, wherein the amount of fresh hydrogen added to the light hydrocarbon gas is an amount sufficient to produce a hydrogen-light hydrocarbon gas mixture containing a hydrogen concentration of from 1 to 65% by volume, preferably hydrogen concentration from 10 to 50%.

Embodiment S. The method according to any one of embodiments C-R, wherein the hydrogen-light hydrocarbon gas mixture is supplied to the reactor at a flow rate of 0.01 to 1 l/min.

Embodiment T. The method according to any one of embodiments C-S, wherein the upgraded oil has an improved boiling curve as indicated by the conversion.

Embodiment U. The method according to any one of embodiments C-T, wherein the heavy oil is bypassed through a heat exchanger.

Embodiment V. The method according to any one of embodiments C-U, wherein the heavy oil is bypassed by the first control heat exchanger and/or the second control heat exchanger.

Embodiment W. The method according to any one of embodiments C-V, wherein the heavy oil pumped through the heavy oil supply line is cooled by the heat exchanger and the first control heat exchanger.

Embodiment X. The method according to any one of embodiments C-W, wherein the heavy oil supply line contains heavy oil that does not require upgrading, wherein the heavy oil supply line bypasses the reactor to enter the separator after passing through the heat exchanger and the first control heat exchanger The method includes separating light hydrocarbon liquid and light hydrocarbon gas from heavy oil, wherein the separated heavy oil is transported to a reactor.

Embodiment Y: A method for continuously upgrading heavy oil to produce upgraded oil using a pulsed plasma reactor, comprising injecting heavy oil through a heavy oil supply line at a first pressure of 0.1 to 10 barg. (preferred range 0.9 to 2 barg) through the heat exchanger and the first control heat exchanger into the separator and separating the light hydrocarbon liquid and light hydrocarbon gas from the heavy oil, with the separated heavy oil entering the heat exchanger to combine with the heavy oil from the heavy oil supply line oil and/or separated heavy oil enters an interelectrode gap provided in the reactor, wherein the interelectrode gap is determined by the distance between the first end of the negative electrode and the first end of the positive electrode, while the second end of the positive electrode and the second end of the negative electrode are connected to the power generator by a power supply line wherein the light hydrocarbon gas is fed to a compressor or power generator, wherein the light hydrocarbon gas in the compressor is compressed and sent to a reactor, wherein the light hydrocarbon liquid is fed to a mixer or collected; discharge, at a second pressure between 0.2 and 20 barg. (preferred range from up to 3 barg) light hydrocarbon gas through the light hydrocarbon gas supply line into the reactor for mixing therein with heavy oil to form a hydrocarbon liquid-gas mixture in the interelectrode gap;

creating a spark discharge in the interelectrode gap to react the hydrocarbon liquid-gas mixture;

passing the reacted hydrocarbon liquid-gas mixture into a separator and separating the light hydrocarbon liquid and the light hydrocarbon gas from the heavy oil;

combining the separated heavy oil and the heavy oil from the heavy oil supply line and passing the combined heavy oil through a second control heat exchanger into a mixer and mixing the combined heavy oil with the light hydrocarbon liquid to obtain an upgraded oil.

Embodiment Z. The method of Embodiment Y, wherein 1 to 50% by volume of the heavy oil is converted to light hydrocarbon liquid and/or light hydrocarbon gas, with a preferred range of 3 to 30%.

Embodiment AA. The method according to embodiment Y or Z, wherein the heavy oil from the separator and the heavy oil from the heavy oil supply line are combined in a ratio of 1:10 to 20:1, with a preferred ratio of 1:1 to 1:10.

Embodiment of BB. A method according to any one of the Y-AA embodiments, wherein the combined heavy oil may be brought to a temperature of 25 to 200° C. and has a viscosity of 1 to 1000 cP after combining, with a preferred range of 10 to 200 cP.

SS embodiment. The method according to any one of the Y-BB embodiments, wherein the reactor contains a plurality of interelectrode spaces.

Embodiment DD. The method according to any of the Y-CC embodiments, wherein the separator comprises a fractional distillation device or absorber.

Embodiment EE. The method according to any one of the Y-DD embodiments, wherein the absorber is a pressure swing absorber.

Embodiment FF. The method according to any one of embodiments Y-EE, wherein the light hydrocarbon liquid has an upper boiling point of from 100 to 300°C.

Embodiment GG. The method according to any one of the Y-FF embodiments, further comprising removing a portion of the light hydrocarbon liquid before mixing it with the combined heavy oil.

NN embodiment. The method according to any of the Y-GG embodiments, wherein fresh hydrogen and/or fresh hydrocarbon gas is added to the separated light hydrocarbon gas before and/or after compression.

Embodiment II. The method according to any one of the Y-HH embodiments, further comprising analyzing the composition of the light hydrocarbon gas before it is supplied to the reactor.

Embodiment JJ. The method according to any one of embodiments Y-II, further comprising purifying the compressed light hydrocarbon gas.

Embodiment KK. The method of any one of embodiments Y-JJ, wherein the purified light hydrocarbon gas provides power to the reactor and/or provides heat used in the process.

Embodiment LL. A method according to any one of embodiments Y-KK, wherein hydrogen is separated from purified light hydrocarbon gas.

MM embodiment. The method according to any one of the Y-LL embodiments, wherein the energy for the spark discharge is provided by a microturbine.

Embodiment NN. A method according to any one of Y-MM embodiments, wherein the amount of fresh hydrogen added to the light hydrocarbon gas is an amount sufficient to produce a hydrogen-light hydrocarbon gas mixture containing a hydrogen concentration of from 1 to 65% by volume with a preferred hydrogen concentration from 10 to 50%.

OO embodiment. A method according to any one of the Y-NN embodiments, wherein a hydrogen-light hydrocarbon gas mixture is supplied to the reactor at a flow rate of 0.01 to 1 L/min.

Embodiment PP. The method according to any one of the Y-OO embodiments, wherein the upgraded oil has an improved boiling curve, as indicated by the conversion.

Embodiment QQ. The method according to any one of the Y-PP embodiments, wherein the heavy oil from the heavy oil supply line and/or the heavy oil from the separator bypasses the heat exchanger.

Embodiment RR. The method according to any of the Y-QQ embodiments, wherein the heavy oil is bypassed by the first control heat exchanger and/or the second control heat exchanger.

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Embodiment SS. The method according to any one of the Y-RR embodiments, wherein the heavy oil pumped through the heavy oil supply line is cooled by the heat exchanger and the first control heat exchanger.

For the purposes of this disclosure and unless otherwise indicated, indefinite number means one or more.

As used herein, the term will roughly be understood by those skilled in the art and will vary to some extent depending on the context in which it is used. If there are uses of a term that are not clear to those skilled in the art, given the context in which it is used, it will approximately mean up to plus or minus 10% of the value of a particular quantity.

All publications, patent applications, issued patents and other documents referred to herein are incorporated herein by reference as if each individual publication, patent application, issued patent or other document were specifically and separately identified as being incorporated by reference. in full. Definitions contained in the text incorporated by reference are excluded to the extent that they conflict with the definitions herein.

The embodiments illustratively described herein may be suitably practiced in the absence of any element or elements, limitation or limitations not specifically disclosed herein. Thus, for example, the terms containing, including, contained, etc. should be construed broadly and without limitation. In addition, the terms and expressions used herein are intended to be descriptive and not limiting, and the use of such terms and expressions is not intended to exclude any equivalents of the features shown and described, or portions thereof, but it is recognized that it is possible within the scope of the claimed method various changes. In addition, the expression consisting essentially of should be understood as including those elements that are specifically set forth and those additional elements that do not significantly affect the basic and novel characteristics of the claimed method. The expression consisting of excludes any unspecified element.

The present invention is not limited to the specific embodiments described herein, which are intended only to illustrate various aspects. Many modifications and changes can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent compositions, devices and methods included within the scope of the present invention, in addition to those listed herein, will be apparent to those skilled in the art from the foregoing description. It is intended that such modifications and changes fall within the scope of the appended claims. The present invention shall be limited only by the terms of the appended claims together with the full scope of equivalents to which such claims are entitled. It should be understood that the present invention is not limited to specific methods, reagents, compound compositions or biological systems, which, of course, may vary. It should also be understood that the terminology used herein is intended to describe specific embodiments only and is not intended to be limiting thereof. Moreover, if features or aspects of the invention are described in terms of Markush groups, those skilled in the art will understand that the invention is thus also described in terms of any individual member or subgroup of members of the Markush group. As will be appreciated by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also include any and all possible sub-ranges and combinations thereof. Any range listed may be quite obvious as sufficiently descriptive to allow the same range to be broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range described herein can be easily broken down into a lower third, a middle third, an upper third, and the like. As will also be understood by one skilled in the art, all terms, including, but not limited to, up to at least more than, less than, etc., include the number indicated and refer to ranges that can subsequently be broken down into subbands as described above. Finally, as one skilled in the art will appreciate, the range includes each individual element.

While certain embodiments have been illustrated and described, it should be understood that changes and modifications thereto may be made by those of ordinary skill in the art without departing from the method in its broader aspects as defined in the following claims.

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Claims (16)

CLAIM 1. A method for continuously upgrading heavy oil to produce high quality oil using a pulsed plasma reactor, comprising injecting heavy oil through a heavy oil supply line at a first pressure of 0.1 to 10 barg. (preferably 0.9 to 2 barg) into the electrode gap inside the reactor, wherein the heavy oil supply line first passes the heavy oil through a heat exchanger to regulate the temperature of the heavy oil, and delivers it to the first control heat exchanger through which the heavy oil passes to enter the reactor, and wherein the interelectrode gap is determined by the distance between the first end of the negative electrode and the first end of the positive electrode, the second end of the positive electrode and the second end of the negative electrode being connected to the power generator through a power supply line; discharge at a second pressure of 0.2 to 20 barg. (preferably in the range of 1 to 3 barg) light hydrocarbon gas through a light hydrocarbon gas supply line into a reactor for mixing therein with heavy oil to form a hydrocarbon liquid-gas mixture in the interelectrode gap; creating a spark discharge in the interelectrode gap to react the hydrocarbon liquid-gas mixture; entering the reacted hydrocarbon liquid-gas mixture into the separator and separating the light hydrocarbon liquid and light hydrocarbon gas from the heavy oil; supplying the separated light hydrocarbon gas from the separator to the compressor and compressing the light hydrocarbon gas, adding fresh hydrogen and fresh hydrocarbon gas to the light hydrocarbon gas to produce a gas mixture of hydrogen and light hydrocarbons and recycling the gas mixture of hydrogen and light hydrocarbons to the reactor; supplying heavy oil from the separator to the heat exchanger, wherein the heavy oil from the separator is combined with the heavy oil from the heavy oil supply line to obtain a combined heavy oil; and removing the combined heavy oil or mixing the combined heavy oil with a light hydrocarbon liquid to produce an upgraded oil. 2. The method according to claim 1, characterized in that from 1 to 50% of the heavy oil volume is converted into light hydrocarbon liquid and/or light hydrocarbon gas, with a preferred range from 3 to 30%. 3. The method of claim 1, wherein the heavy oil from the separator and the heavy oil from the heavy oil supply line are combined in a ratio of 1:10 to 20:1, with a preferred ratio of 1:1 to 10:1. 4. The method of claim 1, wherein the combined heavy oil from the separator and the heavy oil from the heavy oil supply line can be adjusted to a temperature of 25 to 200° C. and a viscosity of 1 to 1000 cP upon entering the reactor with a preferred viscosity from 10 to 200 cP. 5. The method according to claim 1, characterized in that the reactor contains a plurality of interelectrode gaps. 6. The method according to claim 1, characterized in that the separator contains a fractional distillation device or absorber. 7. The method according to claim 6, characterized in that the absorber is a pressure-variable absorber. 8. The method according to claim 1, characterized in that the light hydrocarbon liquid has an upper boiling point from 100 to 300°C. 9. The method according to claim 1, characterized in that it further includes removing part of the light hydrocarbon liquid before mixing it with the combined heavy oil. 10. The method according to claim 1, characterized in that fresh hydrogen and/or fresh hydrocarbon gas is added to the separated light hydrocarbon gas before and/or after compression. 11. The method according to claim 1, characterized in that it additionally includes an analysis of the composition of light hydrocarbon gas before it is fed into the reactor. 12. The method according to claim 1, characterized in that it additionally includes purification of compressed light hydrocarbon gas. 13. The method according to claim 12, characterized in that the purified light hydrocarbon gas provides power to the reactor and/or provides heat used in the process. 14. The method according to claim 12, characterized in that hydrogen is isolated from purified light hydrocarbon gas. 15. The method according to claim 1, characterized in that the energy for the spark discharge is provided by a microturbine. 16. The method according to claim 10, characterized in that the amount of fresh hydrogen added to the light -