PT2336274E - Rapid thermal processing of heavy oil feedstocks - Google Patents

Abstract

The present invention is directed to the use of an upgraded liquid feedstock as a product for pipeline transport to permit further processing of the upgraded liquid feedstock elsewhere. The upgraded liquid feedstock is produced from a heavy hydrocarbon feedstock, which is not transportable by pipeline to an offsite location without addition of diluents, by a method for upgrading a heavy hydrocarbon feedstock comprises introducing a particulate heat carrier into an upflow reactor, introducing the heavy hydrocarbon feedstock into the upflow reactor at a location above that of the particulate heat carrier so that a loading ratio of the particulate heat carrier to feedstock is from about 15:1 to about 200:1, allowing the heavy hydrocarbon feedstock to interact with the heat carrier with a residence time of less than about 1 second, to produce a product stream, separating the product stream from the particulate heat carrier, regenerating the particulate heat carrier, and collecting a gaseous and liquid product from the product stream. The upgraded feedstock exhibiting reduced viscosity and increased API gravity.

Description

1

DESCRIPTION

" QUICK THERMAL RAW MATERIAL PROCESSING OF HEAVY OILS " heat treatment of viscous oil. The present invention relates to the fasting of raw materials of this invention, the use of pyrolysis in order to viscosity of these oils.

Background of the invention

The bitumen and heavy oil resources are supplementing the decline in conventional light and medium crude oil production and production of these resources is expected to increase significantly. Expansion of pipelines is also expected to cope with increased production of heavy oils, however, heavy oil must be treated to allow transport by pipelines. At present, crude heavy oil and bitumen are transportable through the addition of diluents or are beneficiated through synthetic crude oil. However, diluted crudes or beneficiated synthetic crudes are significantly different from conventional crude oils. As a result, bitumen blends or synthetic crudes are not easily transformed into conventional fluid catalytic cracking refineries. Therefore, in both cases the refiner has to be configured to handle either diluted or beneficiated raw materials.

Many heavy hydrocarbons are also characterized as comprising significant amounts of BS & W (background and water sediments). Such raw materials are not suitable for transportation in pipelines or improvement because of the sand, water and corrosive properties of the feedstock. Typically, raw materials characterized as having less than 0.5% by weight of BS & W are transportable by pipeline, and those which include higher amount of BS & W require some degree of processing and treatment to reduce BS & W before transport. Such treatment may include storage to allow water and particles to settle, followed by heat treatment to conduct water and other components. However, these manipulations are expensive and time-consuming. There is therefore a need in the art for an efficient method for the modernization of the feedstock, comprising a significant BS & W content prior to the transportation or subsequent processing of the feedstock.

Heavy oils and bitumen may be improved using a range of rapid processes, including thermal procedure (for example, US 4,490,234; US 4,294,686; US 4,161,442), hydrocracking (US 4,252,634), visco-retraction (US 4,427,539, US 4,569,753, US 5,413,702) or catalytic cracking (US 5,723,040, US 5,662,868, US 5,296,131, US 4,985,136, US 4,772,378, US 4,668,378; 4,578,183). Several of these processes, such as catalytic cracking or cracking, utilize inert or catalytic particulate contacting materials within upstream or downstream reactors. Catalytic contact materials are mostly based on zeolite (see, for example, US 5,723,040, US 5,662,858, US 5,296,131, US 4,985,136, US 4,772,378, US 4,668,378, US 4,578 (US Pat. No. 4,427,539, US Pat. No. 4,569,753), the carbonaceous solids (for example, US Pat. No. 5,413,702) , or inert kaolin (e.g., US Pat. No. 4,569,753). The use of fluid catalytic cracking (FCC) or other units for the direct processing of bitumen raw materials is known in the art. However, many compounds present in raw raw materials interfere with these processes by deposition on the contact material itself. These contaminants of the feedstock include metals such as nickel and vanadium, coke precursors such as Conradson carbon and asphaltenes, and sulfur, and the deposition of these materials results in the need for extensive regeneration of the contact material. This is especially true for the contact material employed with FCC processes such as efficient cracking and proper temperature control of the process requires contact materials comprising few or no combustible deposit material or metals that interfere with the catalytic process.

To reduce contamination of the catalytic material within the catalytic cracking units, pretreatment of the feedstock by visbreaking (US 5,413,702; US 4,569,753; US 4,427,539), thermal (US 4,252,634; US No. 4,161,442) or other processes, typically using reactors such as FCC, operating at temperatures below that required for cracking of feedstock (e.g., US 4,980,045, US 4,818,373 and US 4,263,128) have been suggested. These systems operate in series with FCC units and function as pre-treated for FCC. These pre-treatment processes are designed to remove contaminant materials from the feedstock and operate under conditions that attenuate any cracking. This ensures that any controlled and improved cracking of the feedstock occurs within the FCC reactor under ideal conditions. Various of these processes (e.g., US 4,818,373, US 4,427,539, US 4,311,580, US 4,232,514, US 4,263,128) have been specifically adapted to process " resids " (ie raw materials produced from the fractional distillation of a total crude oil) and the bottom fractions in order to optimize the recovery from the initial feedstock. The processes described for the recovery of residues or bottom fractions are physical and involve the selective vaporization or fractional distillation of the feedstock with minimal or no chemical change of the feedstock. These processes are also combined with the removal of metals and provide raw materials suitable for FCC processing. Selective resid vaporization occurs under non-cracking conditions without any reduction in the viscosity of the raw material components and ensures cracking occurs within an FCC reactor under controlled conditions. None of these approaches describes the improvement of the feedstock within this pretreatment process (ie metals and coke removal). Other processes for the thermal treatment of raw materials involve the addition of hydrogen (hydrotreatment), which results in some chemical alteration of the raw material. US 4,294,686 discloses a steam distillation process in the presence of hydrogen for the pretreatment of raw materials for the FCC processing. This document also indicates that this process may also be used to reduce the viscosity of the feedstock, such that the feedstock may be suitable for transport within an oil pipeline. However, the use of short residence time reactors for the production of a transportable raw material is not disclosed. US 4,080,285 discloses a process for the non-catalytic increase of the cracking of shale oil to produce ethylene in the presence of inert solids entrained in hot.

There is a need in the technical area for a rapid and effective improvement process of bitumen or heavy oil feedstock which involves a partial chemical improvement or a gentle cracking of the feedstock, in order to obtain a product characterized by having a reduced viscosity on the starting material. Ideally, this process would be able to accommodate raw materials comprising significant amounts of BS & W. This product must be transportable for further processing and improvement. Such a process should not involve any catalytic cracking activity due to the known contamination of catalyst contact materials with the components present in the bitumen or heavy oil feedstocks. The rapid and effective breeding process should yield a product characterized by having reduced viscosity, reduced metal content, increased API and optimum yield of the product. The present invention is directed to the improvement of heavy oil feedstocks using a short residence time pyrolytic reactor operating under conditions which crack and chemically improve the feedstock. The feedstock used in this process may comprise significant levels of BS & W and still be processed efficiently, thereby increasing the handling efficiency of the feedstock. The process of the present invention provides the preparation of a partially improved feedstock having reduced viscosity and higher API density. The process described herein selectively removes metals, salts, water and nitrogen from the feedstock, while at the same time maximizing the yield of the liquid and minimizing the production of coke and gas. In addition, this process reduces the viscosity of the feedstock to an extent which may allow transportation of the feedstock into the pipeline without addition of diluents. The partially improved product optionally allows off-site transportation of raw material to better equipped locations for refining handling. These facilities are usually located at a distance from the point where raw raw material is obtained.

SUMMARY OF THE INVENTION The present invention relates to the rapid thermal processing of heavy oil feedstocks. More specifically, this invention relates to the use of pyrolysis in order to improve and reduce the viscosity of these oils.

According to the present invention there is provided a method of upgrading and transporting in oil to an external site for refining, said heavy oil method comprises: i) supplying silica sand as a particulate thermal conveyor in an upflow reactor; ii) introducing said preheated heavy oil into said upflow reactor in at least one location above said particulate thermal conveyor, so that a particulate thermal conveyor loading ratio for said heavy oil is from 10: 1 to 200: 1, wherein said upflow reactor is operated at a temperature of from 480 ° C to 620 ° C; iii) allowing said heavy oil to interact with said particulate thermal conveyor, with a residence time of less than about 5 seconds, to produce a product stream; iv) separating said product stream from said particulate thermal conveyor; v) regenerating said particulate thermal conveyor, and vi) collecting a gaseous product and improved feed liquid from said product stream, wherein the improved feed liquid has an increase in API density, a reduced pour point, a reduced viscosity and a reduced level of contaminants over that of said heavy oil, wherein said liquid feedstock has a yield of greater than 70 vol.%. With a minimum production of bioproducts, such as coke and gas; vii) transporting said improved feed liquid product through a pipeline from said location for the improvement of the heavy oil to said exterior location for refining said improved liquid feedstock.

Preferably, the loading ratio of the method as outlined above is from 20: 1 to 30: 1. The present invention also relates to the method, as defined above, wherein the residence time is 0.5 to 2 seconds.

This invention is also directed to the above method in which the contaminants, including carbon Conradson (coke), BS & W, nickel and vanadium are removed from the feedstock or deposited on the thermal conveyor. The present invention also includes the method, as defined above, wherein said product stream of a first pyrolysis is separated into a lighter fraction and a heavier fraction, collecting the lighter fraction from the product stream, and recycling of the heavier fraction back into the upflow reactor, for further processing into a second pyrolysis to produce a second product stream. Preferably, further processing includes mixing the heavier fraction with particulate heat carrier, wherein the temperature of the particulate thermal conveyor of the second pyrolysis is about, or above, that used in the processing of the feedstock within the first pyrolysis . The residence time of the second pyrolysis is the same as, or greater than, the residence time of the first pyrolysis. In addition, the heavier fraction may be added to the raw material, before being introduced into the upflow reactor, for the second pyrolysis.

An improved heavy oil is characterized by the following properties: i) an API density of 13 to 23; ii) a density of 0.92-0.98; iii) a viscosity at 40 ° C (cSt) of 15 to 300, and iv) a reduced vanadium content of 60 to 100 ppm, and v) a reduced nickel content of 10 to 50 ppm. The liquid product is characterized as having at least one of the following properties: i) less than 50% of the components evolving temperatures above 538 ° C during the simulated distillation; ii) from 60% to 95% of the product evolving below 538 ° C during the simulated distillation; iii) from 1.0% to 10% of the liquid product below 193 ° C during the simulated distillation; iv) from 2% to 6% of the liquid product evolving between 193-232 ° C during the simulated distillation; v) from 10% to 25% of the liquid product evolving between 232-327 ° C during the simulated distillation; vi) from 6% to 15% of the liquid product evolving between 327-360 ° C during the simulated distillation, and vii) from 34.5% to 60% of the liquid product evolving between 360-538 ° C during distillation.

An upflow pyrolysis reactor for the improvement of the heavy hydrocarbon feedstock comprises: i) means for preheating the heavy hydrocarbon feedstock; ii) at least one injection medium in at least one of a plurality of locations along the upflow reactor, at least one injection medium for introducing the heavy hydrocarbon feedstock into the upflow reactor; iii) an inlet for the introduction of a particulate thermal conveyor, the inlet located below at least one injection means, the particulate thermal conveyor present in a charge ratio of at least 10: 1; iv) a conversion section into the upflow reactor; V) separating means to an output of the upflow reactor for the separation of the gaseous and liquid products from the particulate thermal conveyor; vi) regenerating means of the particulate thermal conveyor; vii) a recirculating line of the particulate thermal conveyor, from means for the regeneration of the inlet to the supply of particulate thermal conveyor to said mixing section; viii) condensing means for cooling and condensing the liquid products;

In the upflow reactor, as defined above, the plurality of locations includes locations distributed along the length of said reactor. In addition, the upflow reactor may comprise means for a hot condenser prior to condensing means. Preferably, the particulate thermal carrier is silica sand and the loading ratio is from 20: 1 to 30: 1. The upflow reactor as defined above may also comprise means for recirculating a fraction of the heavy product from means for the hot condensation to injection means of the upflow reactor. The present invention addresses the need in the technical area for a rapid improvement process of the bitumen feedstock involving partial chemical improvement or light cracking of the feedstock. This product may, if desired, be transportable for further processing and breeding. The process as described herein also reduces the levels of contaminants in the raw materials, thus there is a mitigation of the contamination of catalytic contacting materials with the components present in heavy oil raw materials. 11

In addition, a variety of heavy hydrocarbon feedstocks may be processed by methods such as those described herein, including feedstocks comprising a significant amount of BS & W. Raw materials comprising a significant BS & W content are non-transportable because of their corrosive properties. Current practices for the treatment of raw materials to lower their BS & W content is time consuming and costly, and still requires further processing or partial improvement prior to transportation. The methods described herein enable the use of raw materials having a substantial BS & W component and produce a liquid product which is partially improved and suitable for pipelines or other transport methods. Thus, the present invention provides an initial transformation of the heavy oil and reduces associated costs and processing time.

Brief description of the drawings

These and other features of the invention will become more apparent from the following description in which reference is made to the accompanying drawings in which: Figure 1 is a schematic drawing of an embodiment of the present invention relating to a system for processing of raw materials. Figure 2 is a schematic drawing of one embodiment of the present invention relating to the system for introducing the feedstock into the system for the pyrolytic processing of the feedstocks. Figure 3 is a schematic drawing of one embodiment of the present invention relating to the feed system for introducing feedstock into the second stage of a two-stage process using the system for the pyrolytic processing of feedstocks, as described herein. Figure 4 is a schematic drawing of one embodiment of the present invention relating to the raw material recovery system to be collected from the primary or recycled condenser for the second step of a two-step process using the system for the pyrolytic processing of raw materials, as described herein. Figure 5 is a schematic drawing of one embodiment of the present invention relating to a multi-step system for the pyrolytic processing of the starting materials.

Description of the Preferred Embodiment The present invention relates to the rapid thermal processing of heavy oil. More specifically, this invention relates to the use of pyrolysis in order to improve and reduce the viscosity of these oils. The following description is of one preferred embodiment by way of example only and without limitation to the combination of features necessary for the execution of the invention. The feedstock may contain significant amounts of BS & W (bottom and water sediments), for example, but not limited to, more than 0.5% (wt%) of BS & W. 13

These heavy oil feedstocks are typically viscous and difficult to transport. The liquid product resulting from the process as described herein may be suitable for transport within a conduit to allow further processing of the feedstock elsewhere. Typically, further processing occurs at a location far from where the feedstock is obtained. However, it is contemplated within the scope of the present invention that the liquid product produced using the present method may also be directly introduced into a unit capable of further improving the feedstock, such as but not limited to FCC, carbonization , viscorreduction, hydrocracking or pyrolysis, etc. In this capacity, the pyrolysis reactor of the present invention partially improves the feedstock, while at the same time acting as a feedstock pretreator for further processing, as described in, for example, but not limited to, US 5,662. 868, US 4,980,045, US 4,818,373, US 4,569,753, US 4,435,272, US 4,427,538, US 4,427,539, US 4,328,091, 4,311,580, 4,243,514, US 4,294,686.

The raw materials of the present invention are processed through a rapid pyrolysis reactor, such as that described in US 5,792,340 (WO 91/11499; EP 513.051), involving times of contact between the thermal conveyor and the feedstock of 0.01 to 2 sec. Other known vertical tubular reactors with short residence times may also be employed, for example, but not limited to, US 4,427,539, 4,569,753, 4,818,373, 4,243,514. It is preferred that the thermal conveyor used within the pyrolysis reactor exhibits a low catalytic activity. Such a thermal conveyor consists of silica sand. By silica sand is meant that it is a sand which comprises more than 30% silica, preferably greater than 95% silica and more preferably greater than 99% silica. Other components of the silica sand may include, but are not limited to, from 0.01% (about 100 ppm) to 0.04% (400 ppm) of iron oxide, preferably about 0.035% (358 ppm), about 0.00037% (3.78 ppm) of potassium oxide, about 0.00688% (68.88 ppm) of aluminum oxide, about 0.0027 (27.25) of magnesium and about 0.0051% (51.14 ppm) of calcium oxide. It is understood that the above composition is an example of a silica sand which may be used as a heat carrier as described herein, however, variations may exist within the proportions of such ingredients within other silica sands and may still be suitable for use as a thermal conveyor. Processing of raw materials using rapid pyrolysis results in the production of product vapors and solid by-products associated with the thermal conveyor. After removal of the thermal conveyor from the product stream, product vapors are condensed to obtain a liquid product and gaseous by-products. For example, which is not to be construed as limiting, the liquid product obtained from the processing of the heavy oil feedstock as described herein is characterized as having the following properties: a boiling point of less than about 600 ° C , preferably less than 525 ° C, and more preferably less than 500 ° C; An API density of at least 12 °, and preferably greater than 17 ° (where the API density = [141.5 / specific density] -131.5; the higher the API density, the lighter the compound); • very low metal content, including V and Ni; • a very low viscosity, more than 25 times lower than the starting material (for example, as determined at 40 ° C), and • liquid product yields of at least 70% by volume, preferably the yields are greater than about 80% by volume.

The high yields and low viscosity of the liquid product produced in accordance with the present invention may allow liquid product to be transported by pipeline to refineries for further processing with the addition of little or no diluent. On the other hand, liquid products exhibit reduced levels of contaminants (eg metals and water), with slightly reduced sulfur and nitrogen content. Therefore, the liquid product may also be used as feedstock either directly or after transportation for further processing using, for example, FCC, hydrocracking, etc.

Additionally, liquid products of the present invention may be characterized using simulated distillation analysis (SimDist), as is commonly known in the art, for example, but not limited to ASTM D 5307-97 or HT 750 (NCUT). The SimDist analysis indicates that liquid products obtained after heavy oil processing can be characterized by any or a combination of the following properties (see Examples 1, 2 and 5): having less than 50% of their components at increasing temperatures above 538 ° C (residual fraction in vacuo); Comprising from 60% to 95% of the product below 538 ° C.

Preferably, from 62% to 85% of the product evolves during SimDist below 538 ° C (i.e., before residual fraction in vacuo); Having from 1.0% to 10% of the liquid product evolves below 193 ° C. Preferably from 1.2% to 6.5% evolves below 193 ° C (i.e., before the naphtha / kerosene fraction); Having from 2% to 6% of the liquid product evolves between 193-232 ° C. Preferably from 2.5% to 5% evolves between 193-232 ° C (kerosene fraction); Having from 10% to 25% of the liquid product evolves between 232-327 ° C. Preferably, from 13 to 24% evolves between 232-327 ° C (diesel fraction); • having from 6% to 15% of the liquid product evolves between 327-360 ° C. Preferably, from 6.5 to 11% evolves between 327-360 ° C (VGO light fraction); • having between 34.5% and 60% of the liquid product evolves between 360-538 ° C. Preferably, from 35 to 55% evolves between 360-538 ° C (VGO heavy fraction);

A first method for improving the raw material for obtaining liquid products with desired properties involves a one step process. Referring to Figure 1, in brief form, the rapid pyrolysis system includes a feed system, generally indicated as (10; see also Figures 2 and 3), which injects the feedstock to a reactor (20), a system (100, 180) and recycles the thermal conveyor to the reheat / regeneration system (30), a reheat system of the inorganic particulate thermal conveyor (30), wherein the thermal conveyor separates the thermal conveyor from the steam (i.e., 100 and 180) ), which reheats and regenerates the thermal conveyor and primary (40) and secondary capacitors (50) collecting the product. The preheated feedstock enters the reactor immediately below the mixing zone (170) and is brought into contact with the stream flowing up the hot inert conveyor into a transport fluid, typically a recycle gas provided by a recycling gas line (210). Conductive thermal transfer through rapid mixing from the thermal conveyor to the feedstock takes place in the short residence time conversion section of the reactor. The feedstock may enter the reactor through at least one of several locations along the length of the reactor. The different entry points indicated in Figures 1 and 2 are non-limiting examples of such entry sites. By providing multiple points of entry along the length of the reactor, the residence time duration within the reactor can be varied. For example, for longer residence times, the feedstock enters the reactor at a lower location in the reactor, whereas for shorter residence times, the feedstock enters the reactor at a location higher than the reactor. In all these cases, the introduced feedstock is mixed with the upflowing thermal conveyor within a mixing zone (170) of the reactor. The vapors of the product produced during the pyrolysis are cooled and collected, using a suitable condenser medium (40, 50), so as to obtain a liquid product. It is understood that other rapid pyrolysis systems, comprising differences in reactor design using separators on the thermal transposer, different numbers or sizes of different capacitors, or different condensing means, may be used for the preparation of the improved product of the present invention . For example, which should not be considered as limiting, the reactors disclosed in US 4,427,539, 4,569,753, 4,818,373, 18 4,243,514 may be modified to operate under the conditions as described herein, for the production of a product improved chemically with increased API and reduced viscosity.

After the pyrolysis of the feedstock in the presence of the inert thermal conveyor, some contaminants present within the feedstock are deposited on the inert thermal conveyor. These contaminants include metals (especially nickel and vanadium), coke and to some extent nitrogen and sulfur. Thus, the inert thermal conveyor requires regeneration (30) prior to re-introduction into the reaction stream. The thermal conveyor can be regenerated by combustion within a fluidized bed at a temperature of 600 to 900 ° C.

Additionally, if necessary, the tanks may also be removed from the heat carrier by an acid treatment, for example, as disclosed in US 4,818,373 (which is incorporated by reference). The heated, regenerated thermal conveyor is then reintroduced into the reactor (20) and acts as a thermal conveyor for rapid pyrolysis. The feed system 10 supplies a preheated feedstock to the reactor 20. An example of a feed system, which should not be considered limiting in any way, is shown in Figure 2, however, other embodiments of the feed system are within the scope of the present invention, for example, but not limited to a feed preheater unit as shown in Figure 5 (discussed below) and may optionally be used in conjunction with a feed system (10; Figure 5). The feed system (generally shown as 10, Figures 1 and 2) is designed to provide a regulated flow of the preheated raw materials 19 to the reactor unit (20). The feed system shown in Figure 2 includes an equilibrium tank for preheating the feedstock 110, heated using outer belt heaters 130 at 80 ° C and is associated with a recirculation / transfer pump 120 ). The raw material is constantly heated and mixed in this tank at 80 ° C. The hot raw material is pumped from the balance tank into a primary feed tank 140, also heated using outer belt heaters 130, as required. However, it is understood that variations in the feed system may also be employed in order to provide a heated raw material to the reactor. The main feed tank 140 may also be provided with a recirculation / delivery pump 150. The heat transfer lines 160 are maintained at about 150Â ° C and the feedstock is preheated prior to entry into the reactor through an injector 170. The atomization in the injector 70 positioned near the mixing zone 170 within the reactor 20 can be achieved by any suitable means. The injector arrangement should provide for a homogeneous dispersed material flow in the reactor. For example, which is not considered limiting in any mode, the mechanical pressure using single phase flow atomization, or atomization of a two phase flow can be used. With a two-phase flow of the atomization nozzle, preheated air, recycled nitrogen or by-product gas, can be used as a conveyor. Instrumentation is also dispersed throughout the system for precise control (eg pressure transducers, temperature sensors, DC controllers, 3-way gas flow measuring valves, etc.) of the system. The conversion of the feedstock is initiated in the mixing zone (170, for example, Figure 1), under moderate temperatures and continues through the conversion section within the reactor unit (20) and connections (e.g., pipes, conduits to the primary separation system (e.g., 100), where most of the thermal conveyor is removed from the steam stream of the product. The solid heat carrier and the solid coke by-product are removed from the primary product vapor stream in a separation unit. Preferably, the product vapor stream is separated from the thermal conveyor as quickly as possible after its exit from the reactor (20), so that the residence time of the product vapor flow in the presence of the thermal conveyor is as short as possible. The primary separation unit may be any suitable solids separation device, for example, but not limited to a cyclone separator, a U-Beam separator or Rams Horn separator, as are known in the prior art. A cyclone separator is shown schematically in Figures 1, 3 and 4. The solids separator, for example, a primary cyclone (100), is preferably equipped with a high abrasion resistant coating. Any solids that avoid the collection in the primary collection system are collected downstream and recovered in a secondary collection system (180). The secondary separation unit may be the same as the primary separation unit, or may comprise an alternative solids separation device, for example, but not limited to a cyclone separator, a 1/4 turn separator, for example a Rams Horn separator, or an impact separator, as are known in the art. A secondary cyclone separator 180 is shown graphically in Figures 1 and 4, however, further separators may be used as a secondary separator unit. 21

Solid products that have been removed in the primary and secondary collection systems are transferred to a vessel for the regeneration of the thermal conveyor, for example, but not limited to, a direct contact reheating system (30). In a direct contact reheating system (30), the coke and by-products gases are oxidized to provide thermal energy processes, which is transported directly to the solid thermal conveyor, as well as regeneration of the thermal conveyor. The direct contact reheat temperature is maintained independently of the feedstock of the raw material conversion system (reactor). However, as indicated above, other methods for the regeneration of the heat carrier may be employed, for example, but not limited to, acid treatment. The hot product stream from the secondary separation unit is extinguished in a primary collection column (or primary condenser, 40; Figure 1). The vapor stream is rapidly cooled from the conversion temperature to below 400 ° C. Preferably, the vapor stream is cooled to about 300 ° C. The product is withdrawn from the main column and pumped (220) into product storage tanks. A secondary condenser (50) may be used to collect any material escaping from the primary condenser (40). The product obtained from the secondary condenser (50) is also being pumped (230) into the product storage tanks. The remaining noncondensible gas is compressed in a blower 190 and a part is returned to the regeneration system of the thermal conveyor 30 through the line 200 and the remaining gas is returned to the reactor 20 via the line 210, and acts as a thermal and medium conveyor. It is preferred that the reactor used with the process of the present invention be capable of producing high yields of liquid product, for example at least greater than 60% by volume, preferably the yield is greater than 70% by volume, and more preferably, the yield is greater than 80%, with a minimum production of by-product, such as coke and gas. Without wishing to limit the scope of the invention in any way, for example, to conditions suitable for a pyrolysis treatment of the feedstock and the production of a liquid product is disclosed in US 5,792,340. This process uses sand (silica sand) as the thermal conveyor, and a reactor temperature ranging from 480 ° to 620 ° C, thermal conveyor load ratios for the feedstock from 10: 1 to 200: 1 and times of residence of 0.35-0.7s. Preferably, the reactor temperature ranges from 500 ° to 550 ° C. The preferred loading ratio is from 15: 1 to 50: 1, with a more preferred ratio of 20: 1 to 30: 1. Furthermore, it should be understood that the longer residence times within the reactor, for example up to 5 seconds, can be obtained, if desired, by introducing the feedstock into the reactor into a position towards the base of the reactor by increasing the length of the reactor itself by reducing the speed of the thermal conveyor through the reactor (provided there is sufficient velocity for the product vapor and thermal conveyor to exit the reactor) or a combination thereof. The preferred residence time is 0.5 to 2 s.

Without wishing to be bound by theory, it is believed that the chemical improvement of the feedstock which takes place within the reactor system, as described above, is in part due to the high loading rates of raw materials for the conveyor which are used in the method of the present invention. The prior art loading rates 23 typically range from 5: 1 to 12.5: 1. However, the loading rates as described herein, from 15: 1 to 200: 1, result in a very rapid, ablative and consistent heat transfer from the thermal conveyor to the feedstock. The high volume and density of the thermal conveyor within the mixing and conversion zones ensures that a fast and uniform processing temperature is achieved and maintained. Thus, the temperatures required for the cracking process described herein are easily controlled. This also allows the use of relatively low temperatures to minimize over-cracking, while ensuring a smooth cracking of the feed load. In addition, with increasing density of the thermal conveyor inside the reactor, the undesirable contaminants and components present in the raw materials and by-products of the reaction, including metals (eg nickel and vanadium), coke and at some point nitrogen and sulfur , are easily absorbed due to the large surface area of the thermal conveyor present. This ensures an efficient and optimized removal of contaminants from the raw material during pyrolysis processing of the raw material. As a larger surface area of the thermal conveyor is used, the thermal conveyor itself is not unduly contaminated and any metal or coke adsorbed is readily withdrawn during regeneration of the thermal conveyor. With this system the residence times can be carefully regulated in order to optimize the treatment of the raw material and the yields of the liquid products. The liquid product which is formed from the heavy oil processing as described herein has a significant conversion of the residual fraction as compared to the heavy oil feedstock. Thus, the liquid product of the present invention obtained from the processing of heavy oil feedstock is characterized, for example, but is not to be considered as limiting, an increase in API density of at least 13Â ° and more preferably, of at least 17 °. However, as indicated above, higher API densities can be achieved by a reduction in volume. For example, a liquid product obtained from heavy oil processing using the method of the present invention is characterized as having 10 to 15% by volume background, 10 to 15% by final light volume, with the remainder in the form of distillates. The viscosity of the liquid product produced from heavy oil is substantially reduced from the initial starting material levels, from 250 cSt to 80 ° C, for the product levels of 4.5 to 10 ° C at 80 ° C, or from 6343cSt at 40 ° C, in the raw material, from 15 to 35 cSt at 40 ° C in the liquid product. Following a single-phase process, liquid yields of greater than 80% by volume and API densities of about 17 are obtained with viscosity reductions of at least 25-fold relative to the raw material (at 40 ° C). These viscosity levels are suitable for transporting the liquid product through conduits. The results of the simulated distillation (SimDist, for example ASTM D 5307-97, HT 750, (Ncut)) further shows substantially different properties between the feedstock and the liquid product as produced herein. For the heavy oil feedstock, approx. 1% (wt.%) Of the feedstock is distilled below 232 ° C (kerosene fraction), approx. 8.7% from 232Â ° to 327Â ° C (Diesel fraction) and 51.5% evolved at temperatures above 538Â ° C (residual fraction vacuum, see Example 1 for complete analysis). The SimDist analysis of the liquid product produced as described above may be characterized as having, but not limited to having, the following properties: approx. 4% 25 (% by weight) evolving below 232 ° C (kerosene fraction), approx. 14.2% from 232Â ° to 327Â ° C (Diesel fraction) and 37.9% in the residual fraction in vacuo (above 538Â ° C). It is to be understood that modifications of these values may occur depending on the composition of the raw material used. These results demonstrate that there is no significant change in many of the components within the liquid product as compared to the heavy oil feedstock, with a general tendency to decrease the molecular weight of the components that evolve earlier during the SimDist analysis after processing.

Therefore, the liquid product obtained from the processing of heavy oil with a single phase can be characterized as having at least one of the following properties: having less than 50% of its components at increasing temperatures above 538 ° C (residual fraction of vacuum); • comprising from 60% to 95% of the evolving product below 538 ° C. Preferably, from 60% to 80% during Simulated Distillation below 538 ° C (i.e., before residual vacuum fraction); • have from 1.0% to 6% of the liquid product evolving below 193 ° C. Preferably from 1.2% to 5% below 193 ° C (i.e., before the naphtha / kerosene fraction); • having from 2% to 6% of the liquid product between 193-232 ° C. Preferably 2.0% to 5% between 193-232 ° C (diesel fraction); • having from 12% to 25% of the liquid product between 232-327 ° C. Preferably, from 13 to 18% between 232-327 ° C (diesel fraction); • have from 5% to 10% of the liquid product between 327-360 ° C. Preferably, from 6.0 to 8.0% at 327-360øC (VGO light fraction); • having from 40% to 60% of the liquid product between 360-538 ° C. Preferably, from 30 to 50% between 360-538 ° C (VGO heavy fraction). The liquid product produced as described herein also exhibits a high degree of stability. Analysis of the liquid product over a period of 30 days indicates a negligible change in the SimDist profile, viscosity and API density for liquid products produced from heavy oil or heavy oil feedstocks (see Example 1 and 2).

Because cracking is not so severe and because residence times are short, undesirable reactions can generate excessive amounts of undesirable aromatic and olefin compounds. In addition, contaminants such as metals and water have been found to be significantly reduced. There is no concentration of contaminants in the liquid product.

Additionally, as disclosed herein, further treatment of the liquid product obtained from the heavy oil feedstock process may take place following the method of the present invention. Such further processing may utilize conditions that are very similar to the initial rapid pyrolysis treatment of the feedstock, or the conditions can be modified to increase the removal of lighter products (a single phase process with a medium cracking) followed by further cracking of the recycled fraction (i.e., a two-stage process). 27

In the first case, the additional processing under similar conditions, the liquid product from a first pyrolytic treatment is recycled back to the pyrolysis reactor in order to further improve the properties of the final product to produce a lighter product. In this arrangement, the liquid product from the first pyrolysis cycle is used as the feedstock for a second pyrolysis cycle, after the lighter fraction of the product has been removed from the product stream. In addition, a recycle compound may also be made where the heavy fraction of the product stream from the first process is fed back into the reactor along with the addition of fresh raw material (for example, Figure 3, below) in more detail). The second method of improving the raw material to obtain liquid products with desired properties involves a two stage pyrolysis process (see Figures 2 and 3). These two-stage processes comprise a first stage in which the feedstock is exposed to moderate cracking conditions of the hydrocarbon components in order to avoid over-cracking and production of excess gas and coke. An example of such conditions include, but is not limited to, injection of the feedstock at about 150 ° C into a hot gas stream comprising the thermal conveyor at the inlet of the reactor. The feedstock is processed with a residence time of less than about one second in the reactor, at less than 500 ° C, for example 300 ° C. The product, comprising lighter materials (low boiling point) is separated (100 and 180, Figure 3), and removed after the first phase of the condensation system (40). The heavier materials 240, spaced outwardly at the bottom of the condenser 40 are collected, subjected to a more severe cracking within the reactor 20, so as to process a liquid product of reduced viscosity and high yield . Conditions used in the second step include, but are not limited to, a processing temperature of 530 ° to 590 ° C. The product of the second step is processed and collected as shown in Figure 1, using a primary and secondary cyclone (100, 180, respectively) and primary and secondary capacitors (40 and 50, respectively).

After the two step process, an example of the product, which should not be considered limiting, of the first step (light boilers) is characterized in a yield of about 30% by volume, an API of about 19 and a reduction of relative to the starting material. The boiler heavy fraction product produced after the processing of the recycle fraction in the second stage is typically characterized by a yield of greater than 75% by volume and an API density of about 12 and a reduced viscosity over the fraction of materials recycled raw materials. The SimDist analysis for the liquid product produced from heavy oil feedstock is characterized by approx. 7.4% (wt.%) Of the feedstock, which was distilled below 232 ° C (kerosene fraction of 1.1% by volume, for the feedstock), approx. 18.9% from 232 ° to 327 ° C (diesel fraction 8.7% by volume, for the raw material) and 21.7% evolved above 538 ° C (residual fraction in vacuum 51.5% in volume, for the raw material, see Example 1 for complete analysis).

Alternative conditions of a two stage process may include a first stage of operation where the feedstock is preheated to 150øC and injected into the reactor and processed at 530øC to 620øC, and with a time of residence time of less than one second inside the reactor (see Figure 2). The product is collected using primary and secondary cyclones (100 and 180, respectively, Figures 2 and 4) and the remainder is transferred to a hot condenser (250). The condensation system (Figure 4) is designed to selectively recover heavy asphaltenes components using a hot condenser (250) placed prior to the primary condenser (40). The heavy asphaltenes are collected and returned to the reactor (20) for further processing (i.e., the second stage). The second phase uses reactor conditions that operate at higher temperatures or longer residence times, or at higher temperatures and longer residence times (eg, injection at a lower point in the reactor), than that used in first step to optimize the liquid product. In addition, a portion of the product stream may be recycled to extinction following this method.

However, another modification of the compounds and two-stage processing systems, referred to as " multi-stage " processing, comprises introducing the primary feedstock (untreated feedstock) into the main condenser (see Figure 5) through line 280 and using the main feedstock to quickly cool product vapors into the primary condenser. The product obtained from the condenser of the primary product is then recycled to the reactor via line 270 to be combined with that of the " first phase " and " second phase " (i.e., recycled processing). The recycled feedstock is exposed to conditions that crack the hydrocarbon components on average so as to avoid over-cracking and production of coke and excess gas. An example of such conditions include, but is not limited to, injection of the feedstock at about 150 ° C into a stream of hot gas comprising the thermal conveyor at the inlet of the reactor. The stock 30 is processed with a residence time of less than about two seconds inside the reactor at a temperature between 500 ° C to 600 ° C. Preferably, the residence time is from 0.8 to 1.3 s. And the reactor temperature is 52 ° to 580 ° C. The product, comprising lighter materials (low boiling point) is separated (100 and 180, Figure 5) and removed in the condensation system (40). The heavier materials 240 are separated outwardly at the bottom of the condenser 40, collected and reintroduced into the reactor 20 via line 270. The gases from the product leaving the primary condenser 40 enter the secondary condenser (50), where a liquid product of reduced viscosity and high yield (300) is collected (see Example% for run analysis using this method). With multi-stage processing, the feedstock is recycled through the reactor so as to produce a product that can be collected from the second condenser, improving and optimizing the properties of the liquid product.

Alternative feed systems can also be used as needed for one, two, or multi-step processing. For example, in the system described in Figure 5, the feedstock (raw or raw feedstock) is obtained from the feed system (10) and is transported within the line 280 which can be heated , as described above) to a primary condenser (40). The primary product obtained from the primary condenser can also be recycled back into the reactor 20 within a primary product recycling line 270. The primary product recycling line may be heated if necessary and may also comprise a preheater unit 290, as shown in Figure 5, to reheat the recycled feedstock to the desired temperature, inside the reactor (20). 31

Subsequently to the recycling process, as described above and shown graphically in Figure 5, the product having a yield greater than 60, and preferably above 75% (wt%), and having the following characteristics, which are not to be considered as limiting in some way, can be produced from any heavy oil feedstock: API 14-19; viscosity of 20 to 100 (cSt at 40 ° C); and a low metal content (see Example 5). From the SimDist analysis the liquid product obtained from multi-stage heavy oil processing can be characterized as having at least one of the following properties: having less than 50% of its components at increasing temperatures above 538 ° C ( residual fraction in vacuum); Comprising from 60% to 95% of the product below 538 ° C. Preferably, from 70% to 90% and more preferably from 75 to 87% of the product evolves during the simulated distillation below 538 ° C (i.e., residual fraction in vacuo); • have 1.0% to 6% of the liquid product below 193 ° C. Preferably from 1.2% to 5%, and more preferably from 1.3% to 4.8%, it is below 193 ° (i.e., before the naphtha / kerosene fraction); Having from 2% to 6% of the liquid product between 193-232 ° C. Preferably from 2.8% to 5% between 193-232 ° C (diesel fraction); • having 15% to 25% of the liquid product evolves between 232-327 ° C. Preferably, from 18.9 to 23.1% evolves between 232-327 ° C (diesel fraction); • 8% to 15% of the liquid product evolves between 327-360 ° C. Preferably, from 8.8 to 10.8% at 327-360øC (VGO light fraction); • having from 40% to 60% of the liquid product evolves between 360-538 ° C. Preferably, from 42 to 55% evolves between 360-538 ° C (VGO heavy fraction);

Collectively these results show that a substantial proportion of the low volatility components in any of the feedstocks were converted into higher volatility components (light naphtha, kerosene and diesel) in the liquid product. These results demonstrate that the liquid product is substantially improved and exhibits properties suitable for transport. The present invention will be further illustrated in the following examples. However, it is to be understood that these examples are for illustrative purposes only and should not be used to limit the scope of the present invention in any way.

Examples of bitumen are not in accordance with the invention.

The pyrolytic processing of Saskatchewan heavy oil and Athabasca bitumen (see Table 1) were performed at more than one temperature range using a pyrolysis reactor as described in US 5,772,340 . 33

Table 1: Characteristics of raw materials of bitumen and heavy oil

Compound Heavy Oil11 Bitumen * 1 Carbon (wt%) 84.27 83.31 Hydrogen (wt%) 10.51 10.31 Nitrogen (wt%) <0.5 <0.5 Sulfur (wt%) 3 , 6 4.8 Ash (wt%) 0.02 0.02 Vanadium (ppm) 127 204 Nickel (ppm) NA 82 Water content (wt%) 0.8 0.19 API gravity 11.0 8.6 Viscosity at 40 ° C (cSt) 633 30380 Viscosity at 60 ° C (cSt) 892.8 1.268.0 Viscosity at 80 ° C (cSt) 243.4953.0 Aromaticity (C13 NMR) 0.31 0.35 1 ) heavy oil Saskatchewan 2) Athabasca bitumen (pure)

Briefly the processing conditions include a reactor temperature of 500 ° to 620 ° C. The charge rates for the particulate thermal conveyor (silica sand) for the feedstock are between 20: 1 to 30: 1 and residence times of 0.35-0.7s. These conditions are described in more detail below (Table 2). 34

Table 2: Saskatchewan single-stage heavy-oil processing

Temperature. . . , Viscosity at 40 C cracking. (cSt) Yield% weight Density at 15 ° C g / ml API Yield% Vol. 620 4, δ1 '71.5 0.977 13.3 72.7 592 15.21 '74.5 0.970 14, 4 76, 2 590 20.2 70.8 0, 975 13, 6 72.1 590 31.66, 80.0, 977 13.3 77.1 560 10, o '79, 92) 0, 963 15, 4 82.32) 560 10, 1 '83, 03) 0, 963 86, 33) 16, 23) 550 20.8 78.5 0, 973 14.0 80.3 5504) 15.7 59.82) 0, 956 16.5, 61.52), 550 (15.7, 62.03), 0.956 18.32 (65.13) 530 32.2 80.92) 0.9622 15.72.82) 530 32.2 83.83) 0, 962 16, 63) 87.13) D 2) Viscosity at 80 ° C Yields do not include top condensation 3) The estimated yields and API with top condensation 4) Not all liquids were captured in this assay. The liquid products of the cycles at 620øC, 592øC and 560øC were analyzed for the metal, water and sulfur content. These results are presented in Table 3. Nickel, vanadium and water levels were reduced by 72, 69 and 87%, respectively, while the sulfur and nitrogen remained the same or were slightly reduced. The metals were not concentrated in the liquid product. 35

Table 3: Analysis of Metals of liquid products (ppm) 1}

Component Heavy oil Saskatchewan Cycle at 620 ° C Cycle at 592 ° C Cycle at 560 ° C Aluminum <1 <1 11 <1 Iron <1 2 4 <1 Nickel 44 10 12 9 Zinc 2 <1 2 1 Calcium 4 2 3 1 Magnesium 3 1 2 <1 Boron 21 42 27 <1 Sodium 6 5 5 4 Silicon 1 10 140 4 Vanadium 127 39 43 39 Potassium 7 7 <1 4 Water (% by weight) 0, 78 Copper, tin, chromium, lead, cadmium, titanium, molybdenum, barium and manganese all showed less than 0.6% than 1 ppm in raw materials and liquid products. The gas yields for the two cycles are given in Table 4

Table 4: Pyrolysis cycle gas analysis. Gas (% weight) Cycle at 620 ° C Cycle at 560 ° C Gas yield 30 V [-1 [-1 7.2 total Ethylene 27.0 16.6 Ethane 8.2 16.4 Propylene 30.0 15.4 Methane 24.0 21.0 36 The flow point of the improved feedstock was reduced from 32 ° F to about -54 ° F. The Conradson carbon was reduced from 12 wt% to about 6.6 wt%.

Based on the analysis of these cycles, the highest API values and yields of the product were obtained at cracking temperatures of 530-560øC. At these temperatures, API densities of 14 to 18.3, product yields of 80-87% by volume and viscosities of 15 to 35cSt (at 40øC) or about 10øC (at 80øC) were obtained (the cycle yields from 550 ° C are not included in this range, as the net yield capture was not optimized during this cycle). These liquid products reflect a significant degree of improvement and show the qualities suitable for pipeline transport. The simulated distillation analysis of the feedstock and the liquid product obtained from several separate cycles is presented in Table 5. The SimDist analysis followed the protocol described in ASTM D 5307-97, which reports the residue as something with boiling point greater than 538 ° C. Other methods for SimDist, for example HT 750 (NCUT, which includes boiling point distribution up to 750 ° C) may also be used. These results indicate that more than 50% of the components within the feedstock evolve at temperatures above 538 ° C. These are the components of high molecular weight and with low volatility. On the other hand, in the liquid product, the majority of the components, to about 62.1% of the product are the most volatile and evolve below 538 ° C. 37

Table 5: SimDist analysis of raw material and liquid product after single-phase processing (reactor temperature 538 ° C)

Fraction Temperature (° C) Raw material R245 Light naphtha &lt; 71 0.0 0.5 Light naphtha / med 71-100 0.0 0.3 Naphtha med 100-166 0.0 1.4 Naphtha / kerosene 166- 193 0.1 1, Kerosene 193-232 1.0 2, 8 Diesel 232-327 8.7 14.2 Light VGO 327-360 5.2 6, 5 VGO heavy 360-538 33.5 35.2 Residual vacuum &gt; 538 51.5 37.9 The feedstock may further be characterized with approx. 0.1% of its components evolving below 193 ° C (naphtha / kerosene fraction), v. approx. 6% for the liquid product. The diesel fraction also shows significant differences between the raw material and the liquid product with 8.7% and 14.2%, evolving at this temperature range (232-327 ° C), respectively. Collectively, these results show that a substantial proportion of components with low volatility in the feedstock were converted into components of higher volatility (light naphtha, kerosene and diesel) in the liquid product. The stability of the liquid product was also determined over a period of 30 days (Table 6). No significant change in viscosity, API or density of the liquid product was observed over a period of 30 days. 38

Table 6: Stability of liquid products after processing with a single stage.

Fraction time = 0 7 days 14 days 30 days Density at 15.6øC (g / cm 3) 0.9592 0.9590 0.9597 0.9597 API (API degrees) Viscosity 15.9 9.9 15.8 , 8,000 79.7 81.2 81.2 83.2 (cSt) Example 2: Bitumen (single phase) Several tests using Athabaska bitumen were conducted using the pyrolysis reactor described in US 5,792,340. Processing conditions include a reactor temperature of 520 ° to 590 ° C. Charge ratios of the particulate thermal conveyor for the feed are from 20: 1 to 30: 1, and the residence times 0.35-1.2 sec. Such conditions and the resulting liquid products are described in more detail below (Table 7).

Table 7: Single-stage processing with undiluted Athabasca bitumen

Viscosity Metals

Temp. At 40 ° C Yield Density Metals Ni

(Ppm) ** 519 ° C 205 81.0 na na 13.0 525 ° C 9 201 74.4 0.997 88 24 12.9 39 528 ° C 278 82.7 na na 12.5 645 ° C 151 77.4 0, 987 74 27 11.8 590 ° C 25.677, 60.0, 983 na na 12.4 * Raw material V 209 ppm ** Raw material Ni 86 ppm

These results indicate that the undiluted bitumen may be processed according to the method of the present invention to produce a liquid product having a reduced viscosity of greater than 1300cSt (at 40 ° C) at 25.6-200 cSt (at 40 ° C depending on the cycle conditions, see also Tables 8 and 9) in yields of greater than 75% to 85% and an improvement in the API product from 8.6 to about 12-13. Again, as in Example 1, the The SimDist analysis and other properties of the liquid product are presented in Table 8 and the stability studies in Table 9. Table 8: Properties and SimDist analysis of raw material and liquid product after (° C) Raw material R239 14 days 30 days Density at 15.5 ° C - 0.9871 0.9876 API - 11.7 11.6 Viscosity at 40 ° C - 162.3 169.4 Light naphtha &lt; 71 0.0 0.2 0.1 Naft a Light / med 71-100 0.0 0.2 0.2 Naphtha Med 100-166 0.0 1.5 1.4 Naphtha / Kerosene 166-193 0.1 1.0 1.0 Kerosene 193-232 0 , 9 3.13, 0.040

Diesel 232-327 8, 6 15, 8 14.8 Light VGO 327-360 5, 2 7.9 7.6 VGO heavy 360-538 34, 0 43, 9 42.0 Resid. vacuum &gt; 538 51.2 26.4 29.9 Table 9: Stability of liquid products after processing &lt; in single phase (reactor temperature 525 ° C) R232 Fraction Temp. (° C) press Day 0 7 days 14 30 days days Density at 15.6 ° C * - 1.0095 0.979 0.980 0, 981 0, 981 API - 8.5 12.9 9 12.7 12, 6 12.6 Viscosity at 40 ° C ** - 30380 201.1 213, 9 214.0 218.5 Light naphtha &lt; 71 0.0 0.1 0.1 0.1 0.1 Light naphtha / med 71 -100 0.0 0.1 0.1 0.1 0.1 Naphtha med 100-166 0.0 1.5 1.5 1.5 1.4 Naphtha / Kerosene 166-193 0.1 1.0 1 , 1.0 1.0 Kerosene 193-232 1.0 2, 6 2, 6 2.6 2.7 Diesel 232-327 8.7 14.1 14.1 14.3 14.3 Light VGO 327- 360 5.2 7.3 7.3 7.4 7.4 VGO heavy 360-538 33.5 41.3 41.3 41.7 42.1 Resid. vacuum &gt; 538 51.5 32.0 32.0 31.2 30.8 * g / cmJ ** cSt

The slight variations in the values presented in the stability studies (Table 9 and other stability studies described herein) are within the error of the test methods used and are acceptable within the technical area. These results demonstrate that liquid products are stable.

These results indicate that more than 50% of the components in the feedstock evolve at temperatures above 538 ° C (residual fraction in vacuo). This fraction is characterized by high molecular weight components with low volatility. On the other hand, in several cycles, the liquid product is characterized as comprising about 68-74% of the product which are more volatile and evolve below 538 ° C. The feedstock can still be characterized with approximately 0.1% of its components evolving below 193 ° C (naphtha / kerosene fraction), v. approx. 2.7-2.9% for the liquid product. The diesel fraction also shows significant differences between the raw material and the liquid product with 8.7% (raw material) and 14.1 to 15.8% (liquid product) evolving in this temperature range (232-327 ° C ). Collectively, these results show that a substantial proportion of components with low volatility in the feedstock were converted into components of higher volatility (light naphtha, kerosene and diesel) in the liquid product. These results demonstrate that the liquid product is substantially improved and exhibits properties suitable for transport.

The pyrolysis reactor as described in US 5,792,340 can be configured so that the recovery capacitors direct the liquid products to the reactor feed line (see Figures 3 and 4) .

The processing conditions include a reactor temperature ranging from 530ø to 590øC. The charge ratio for the particulate thermal conveyor and the feedstock for the starting cycle and recycling cycle is about 30: 1 and residence times of 0.35-0.7s were used. These conditions are described in more detail below (Table 10). After pyrolysis of the feedstock, the lighter fraction was removed and collected using a hot condenser placed before the primary condenser (see Figure 4), while the heavier fraction of the liquid product was recycled back into the reactor for later (see also Figure 3). In this arrangement, the recycle stream 260, comprising heavy fractions, was mixed with the new feedstock (270), resulting in a feedstock composite (240), which was then processed using the same conditions, with an initial cycle inside the pyrolysis reactor.

Table 10: Composite / recycled operation using Saskatchewan heavy crude oil and undiluted Athabasca bitumen

Raw material Temp. Yield Cracking% Vol. C API ° Recycled Yield4% Vol API ° Recycled41 590 77.1 l 13.3 68.6 61.1 Heavy Oil 560 86.32 16.2 78.1 21.1 550 50.11 '14.0 71.6 (17.8 550 65, 12.3) 18.3 56.4229.530 87.12) 16.68.99 21.0 Bitumen 590 75.22) 12.4 67 , 0 16.0 0 1) Yield and API density include (actual) top condensation 2) Yield and API density include top (estimated) condensation 3) Not all of the liquid was recovered in this cycle 4) These values represent the total recovery of product after the recycling cycle and presupposes the removal of about 10% of the heavy fraction, which is recycled to extinction. This is, therefore, a conservative estimate of yield, as some of the heavy fractions will produce lighter components entering the product stream, since not all the heavy fractions will end up as coke. The API density increased from 11.0 in the heavy oil feed to 13-18.5 after the first treatment cycle and subsequent increases from 17 to 23 after a second recycling treatment. A similar increase in API is observed for bitumen having an API of about 8.6 in the feedstock, which increases to about 12.4 after the first cycle and to 16 in the cycle of the recycling cycle. With the API increase, there is an associated increase in yield of 77-87% after the first cycle and 67 to 79% following the recycling cycle. Therefore, related to the production of a lighter product, there is a reduction in the liquid yield. However, a lighter improved product may be desirable for transport and recycling of the liquid product achieves such a product.

Example 4: Treatment of Heavy Oil in Two Phases Heavy oil or bitumen as feedstock can also be processed through a two-stage pyrolytic process, which comprises a first stage, where the feedstock is exposed to conditions of light cracking of the hydrocarbon components in order to avoid over-cracking and excess gas and coke production. Lighter materials are removed after processing in the first cycle and the remaining heavier materials are subjected to a more severe cracking at a higher temperature. Treatment conditions within the first cycle include a reactor temperature varying from 510-530 ° C (data to 515 ° C, given below), while in the second cycle, a temperature of 590 ° C to 800 ° C (data to 590 ° C, shown in table 11). The charge ratios for the particulate thermal conveyor at a range of feedstocks of about 30: 1, and residence times of 0.35s to 0.7s, for both phases. These conditions are described in more detail below (Table 11).

Table 11: Saskatchewan Heavy Oil Two-Phase Cycles

Temp. Cracking ° C Viscosity at 80 ° C (cSt) Yield% wt Density at 15 ° C API ° g / mL Yield% Vol1 * 515 5.3 29.8% 0.943 18.6 31.4 590 52.6 0.990 11.4 78.1 515 &amp; 590 na na na 13.9 86, 6 &quot; nd &quot; means not determined 1) Lightweight condensable materials that were not captured Therefore, these values are conservative estimates.

These results indicate that light initial cracking, which avoids overcoaching of light gas and coke materials, followed by more severe cracking of heavier materials, produces a liquid product characterized by an increase in API while still presenting good yields of products.

Other cycles using a two-stage process involve injecting the feedstock at about 150øC into a hot gas stream maintained at about 515øC and entering the reactor at about 300øC (processing temperature ). The product, which comprises lighter materials (low boiling point) was separated and removed after the first stage of the condensation system. The heavier the materials, separated outwardly in the lower part of the cyclone, were collected under more severe cracking inside the reactor in order to process a liquid product of reduced viscosity and high yield. The conditions used in the second step were a processing temperature comprised between 530 ° to 590 ° C. The product of the second step was processed and collected.

After such a two-stage process, the first stage product (light boilers) is characterized as having a yield of about 30 vol%, an API of about 19 and a reduction in viscosity, relative to the starting material. The high boiling fraction product, produced after the processing of the recycle fraction, in the second step, is typically characterized as having a yield of greater than about 75% by volume, an API density of about 12 and one reduced viscosity relative to the fraction of recycled feedstock.

Example 5: Treatment &quot; Multi-steps &quot; of heavy oil and bitumen using raw material for quenching with a primary condenser. Heavy oil or bitumen as the raw material can also be processed using a &quot; multi-step &quot; pyrolysis process, as described in Figure 5. In this system, the pyrolysis reactor described in US 5,792,340 is configured so that the primary recovery capacitor directs the liquid product into the feed line to the reactor and the feedstock is introduced into the system in the primary condenser where it will cool product vapors produced during pyrolysis. 46

The processing conditions include a reactor temperature ranging from 530ø to 590øC. The charge ratios of the particulate thermal conveyor for the feedstock in the initial cycle and the recycling cycle is about 20: 1 to 30: 1 and residence times of 0.35-1.2 sec. These conditions are described in more detail below (Table 12). Following pyrolysis of the feedstock, the lighter fraction is conveyed to the secondary condenser, while the heavier fraction of the liquid product obtained from the main condenser is recycled back into the reactor for further processing (Figure 5).

Table 12: Characterization of the liquid product obtained after processing in &quot; Multi-steps &quot; of heavy oil and Saskatchewan bitumen

Temp. Viscosity Cracking at 40 ° C (cSt) Yield% by weight Density at 15.6 ° C g / mL API ° Yield1 *% Heavy oil volume 543 80 62, 6 0.9592 15.99 64.9957 24 58, 9 0.9446 18.2 62.1 561 53 70, 9 0.9568 16.8 8 74.0 bitumen 538 40 61.4 0.9718 14.0 71.1 Liquid products produced from multiple stages of the feedstock exhibit transport properties with very low viscosity below 6343cSt (at 40 ° C) for heavy oil and 30380cSt (at 40 ° C) for bitumen. Similarly, the API increased from 11 (heavy oil) to 15.9-18.2, and from 8.6 (bitumen) to 14.7. 47

In addition, the yields for heavy oils under these reaction conditions are 59-68% for heavy oil and 82% for bitumen.

Table 13: Properties and SimDist of liquid products prepared from heavy oil using the multi-step process (for the properties of the raw material see Tables 1 and 5). R241 * R2 4 2 * * R244 *** Fraction Temp. (° C) Day 0 Day 30 Day 30 Density at 15.6 ° C - 0.9592 0.9597 0.9465 0.9591 API - 15, 9 15.8 8 17.8 15.9 Viscosity at 40 ° C - 79.7 83.2 25.0 49.1 Light naphtha &lt; 71 0.0 0.2 0.3 0.3 Light naphtha / med 71-100 0.0 0.1 0.2 0.3 Naphtha med 100-166 0.1 0.4 2.5 1.8 Naphtha / Kerosene 166-193 0.6 0.6 1.8 1.5 Kerosene 193-232 2.8 2.5 5.0 3.0 Diesel 232-327 21.8 21.0 23.1 18.9 VGO light 327-360 10.8 10.2 9.9 8.8 VGO heavy 360-538 51.1 45.0 44.9 9.4 Residual vacuum &gt; 538 12.7 20.0 12.3 21.7

* Temp. 543 ° C ** Temp. 557 ° C *** Temp. 561 ° C

Under these running conditions, the API increased from 11 to about 15.9-17.8. Product yields of 62.6 (wt%, R241), 58.9 (wt%, R242) and 70.9 (wt%, R244) were obtained, with very low viscosity levels. These liquid products have been substantially improved relative to the feedstock and exhibit properties suitable for transport in conduits.

The SimDist results indicate that more than 50% of the components in the feedstock evolved at temperatures above 538 ° C (residual fraction in vacuum), while the liquid product is characterized as comprising about 78-87% of the product, which are more volatile and evolve below 538 ° C. The feedstock can still be characterized with approx. 0.1% of its components evolving below 193 ° C (naphtha / kerosene fraction), v approx. 1.3-4.8% for the liquid product. The kerosene and diesel fractions also demonstrate significant differences between the feedstock and the liquid product with 1% of the feedstock fraction evolving between 193-232 ° C v. 2.8-5% for the liquid product and 8.7% (raw material) and 18.9-23.1% (liquid product), evolving in this temperature range (232-327 ° C, diesel). Collectively these results show that a substantial proportion of components with low volatility in the feedstock were converted into components of higher volatility (light naphtha, kerosene and diesel) in the liquid product. These results demonstrate that the liquid product is substantially improved and exhibits properties suitable for transport.

Table 14: Properties and SimDist of liquid products prepared from bitumen followed by two-stage processing (reactor temperature 538 ° C, for raw material properties see Tables 1, 8 and 9).

Fraction Temp. (° C) R243 Density at 15.6 ° C - 0.9737 API - 13.7 Viscosity at 40 ° C - 45.449

Light naphtha &lt; 71 0.3 Light naphtha / med 71-100 0.4 Naphthal med 100-166 3, 6 Naphtha / Kerosene 166-193 1, 9 Kerosene 193-232 4.4 Diesel 232-327 19.7 VGO light 327-360 9.1 VGO heavy 360-538 41, 1 Residual. vacuum &gt; 538 19.5

Under these performance conditions the API increased from 8.6 to about 14. The product yield of 68.4 (wt%) was obtained along with very low viscosity levels (from 30380cSt at 40øC in the feed, to approx. 45cSt in the liquid product). Simulated distillation analysis demonstrates that more than 50% of the components within the feedstock evolve to temperatures above 538 ° C (residual fraction in vacuum), while 80.5% of the liquid product evolves below 538 ° C. The feedstock can still be characterized with approx. 0.1% of its components evolving 193 ° C (naphtha / kerosene fraction), v. 6.2% for the liquid product. The oil fraction also shows significant differences between the feedstock and liquid product with 8.7% (raw material) and 19.7% (net product) evolving in this temperature range (232-327 ° C). Collectively, these results show that a substantial proportion of components with low volatility in the feedstock were converted into components of higher volatility (light naphtha, kerosene and diesel) in the liquid product. These results demonstrate that the liquid product is substantially improved and exhibits properties suitable for transport. The present invention has been described with respect to preferred embodiments. However, it will be obvious to those skilled in the art that a number of variations and modifications may be made without departing from the scope of protection of the invention as described herein

Lisbon, September 19, 2013

Claims (10)

A method for the upgrading and transport through pipelines to an exterior location for refining of a heavy oil wherein said method comprises: i) delivering silica sand as a particulate thermal conveyor in a flow reactor ascending; ii) introducing said preheated heavy oil into said upflow reactor in at least one location above said particulate thermal conveyor, so that the charge ratio of said particulate thermal conveyor to said heavy oil is from 10: 1 to 200: 1, wherein said upflow reactor operates at a temperature of from 480 ° C to 620 ° C; iii) allowing said heavy oil to interact with said thermal conveyor, with a residence time of less than about 5 seconds and to produce a product stream; iv) separating said product stream from said particulate thermal conveyor; v) regenerating said particulate thermal conveyor; and vi) collecting a gaseous product and said improved liquid product from said product stream, wherein said improved liquid product exhibits an increase in API density, reduced pour point, reduced viscosity and reduction of the level of contaminants relative to said heavy oil, wherein said improved liquid product has a yield greater than 70% by volume with a minimum production of bioproduct, such as coke and gas; vii) transporting said improved liquid product through a pipeline from said location for the improvement of the heavy oil to said external location for the refining of said improved liquid product. The method of claim 1, wherein in said introducing step (step ii) said charge ratio is from 20: 1 to 30: 1. The method of claim 1, wherein said residence time is 0.5 to 2.0 seconds. The method of claim 1, wherein, in said step of allowing (step iii) said product stream of a first pyrolysis cycle to separate into a lighter fraction and a heavier fraction, said lighter fraction is collected from said product stream and said heavier fraction is recycled back to said upflow reactor for further processing in a second pyrolysis cycle to produce a second product stream. The method of claim 4, wherein said further processing comprises mixing said heavier fraction with said particulate thermal conveyor, wherein said particulate thermal conveyor, of said second pyrolysis is performed at a temperature of about , or above, the temperature which has been used in the treatment of said heavy oil, within said first pyrolysis. The method of claim 5, wherein said heavier fraction is added to the unprocessed heavy oil before it is introduced into said upflow reactor for said second pyrolysis operation. The method of claim 6, wherein in said first pyrolysis step, said heavy oil is injected at a temperature of 150øC in the upflow reactor, the temperature of said upflow reactor is less than 500ø C, and the residence time is less than one second, and in said second pyrolysis, the temperature of said upflow reactor is 530 ° C to 590 ° C, and wherein said residence time of said second step of pyrolysis is the same as or above the residence time of said first pyrolysis step. The method of claim 4, wherein said particulate thermal conveyor is separated from said second product stream, and a second product is collected from said second product stream. The method of claim 4, wherein said product stream of said first pyrolysis step is treated within a hot condenser prior to the recovery of said light fraction and said heavy fraction. 4 The method of any one of claims 1 to 9, wherein said improved liquid product is transported without the addition of diluents. Lisbon, September 19, 2013