WO2015142330A1 - Appareil et procédé mettant en oeuvre un chauffage par micro-ondes d'un fluide hydrocarboné dans une cavité de résonance - Google Patents

Appareil et procédé mettant en oeuvre un chauffage par micro-ondes d'un fluide hydrocarboné dans une cavité de résonance Download PDF

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Publication number
WO2015142330A1
WO2015142330A1 PCT/US2014/031251 US2014031251W WO2015142330A1 WO 2015142330 A1 WO2015142330 A1 WO 2015142330A1 US 2014031251 W US2014031251 W US 2014031251W WO 2015142330 A1 WO2015142330 A1 WO 2015142330A1
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WIPO (PCT)
Prior art keywords
resonant cavity
microwave radiation
resonant
pipe
hydrocarbon fluid
Prior art date
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PCT/US2014/031251
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English (en)
Inventor
Wai-Ming Tam
Original Assignee
Schlumberger Canada Limited
Services Petroliers Schlumberger
Schlumberger Holdings Limited
Schlumberger Technology B.V.
Prad Research And Development Limited
Schlumberger Technology Corporation
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Publication date
Application filed by Schlumberger Canada Limited, Services Petroliers Schlumberger, Schlumberger Holdings Limited, Schlumberger Technology B.V., Prad Research And Development Limited, Schlumberger Technology Corporation filed Critical Schlumberger Canada Limited
Priority to PCT/US2014/031251 priority Critical patent/WO2015142330A1/fr
Publication of WO2015142330A1 publication Critical patent/WO2015142330A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G15/00—Cracking of hydrocarbon oils by electric means, electromagnetic or mechanical vibrations, by particle radiation or with gases superheated in electric arcs
    • C10G15/08—Cracking of hydrocarbon oils by electric means, electromagnetic or mechanical vibrations, by particle radiation or with gases superheated in electric arcs by electric means or by electromagnetic or mechanical vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J19/12—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
    • B01J19/122—Incoherent waves
    • B01J19/126—Microwaves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2415—Tubular reactors
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G32/00—Refining of hydrocarbon oils by electric or magnetic means, by irradiation, or by using microorganisms
    • C10G32/02—Refining of hydrocarbon oils by electric or magnetic means, by irradiation, or by using microorganisms by electric or magnetic means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00054—Controlling or regulating the heat exchange system
    • B01J2219/00056—Controlling or regulating the heat exchange system involving measured parameters
    • B01J2219/00058—Temperature measurement
    • B01J2219/00063—Temperature measurement of the reactants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/0015—Controlling the temperature by thermal insulation means
    • B01J2219/00155—Controlling the temperature by thermal insulation means using insulating materials or refractories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00193—Sensing a parameter
    • B01J2219/00195—Sensing a parameter of the reaction system
    • B01J2219/002—Sensing a parameter of the reaction system inside the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00222—Control algorithm taking actions
    • B01J2219/00227—Control algorithm taking actions modifying the operating conditions
    • B01J2219/00238—Control algorithm taking actions modifying the operating conditions of the heat exchange system
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1209—Features relating to the reactor or vessel
    • B01J2219/1212—Arrangements of the reactor or the reactors
    • B01J2219/1215—Single reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1209—Features relating to the reactor or vessel
    • B01J2219/1221—Features relating to the reactor or vessel the reactor per se
    • B01J2219/1224—Form of the reactor
    • B01J2219/1227—Reactors comprising tubes with open ends
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1209—Features relating to the reactor or vessel
    • B01J2219/1221—Features relating to the reactor or vessel the reactor per se
    • B01J2219/1242—Materials of construction
    • B01J2219/1245—Parts of the reactor being microwave absorbing, dielectric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1248—Features relating to the microwave cavity
    • B01J2219/1266—Microwave deflecting parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1248—Features relating to the microwave cavity
    • B01J2219/1269—Microwave guides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1248—Features relating to the microwave cavity
    • B01J2219/1272—Materials of construction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1275—Controlling the microwave irradiation variables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/12—Processes employing electromagnetic waves
    • B01J2219/1203—Incoherent waves
    • B01J2219/1206—Microwaves
    • B01J2219/1287—Features relating to the microwave source
    • B01J2219/129—Arrangements thereof
    • B01J2219/1293—Single source

Definitions

  • the present application relates generally to thermal processing of materials. More particularly, the present application relates to the use of electromagnetic energy (specifically microwave energy) to promote a chemical process or reaction, such as visbreaking of a hydrocarbon fluid where the molecular bonds in hydrocarbon molecules are broken so that smaller or lighter hydrocarbons are created in order to irreversibly reduce the viscosity of the hydrocarbon fluid.
  • electromagnetic energy specifically microwave energy
  • the most common method of transport is blending heavy oils with diluents to reduce the viscosity to a lower value that makes pipeline transport of the heavy oil technically and economically feasible.
  • the diluents may be solvents, condensate liquids, naphtha, or light conventional oils that are compatible with the heavy oils.
  • Such methods require large and readily available volumes of diluents as well as infrastructure to blend, transport, and recover the diluents at the other end of the pipeline. Since the costs of diluents and pumping additional volumes of liquid are significant, alternative viscosity reduction methods that can be deployed at a wellsite location prior to pipeline transport are attractive.
  • Heavy oil has a high molecular weight fraction (typically referred to as a residual fraction) that distills at temperatures above 524°C.
  • Visbreaking involves heating the heavy oil to a reaction temperature (typically in the range of 350°C to 500°C) where thermal cracking of the heavy oil will take place with relatively low conversion of the residual fraction.
  • a reaction temperature typically in the range of 350°C to 500°C
  • no more than 30 percent of the residual fraction of the heavy oil is converted, with the result being that just enough material is converted to reduce the viscosity but not significantly alter the quality of the heavy oil.
  • visbreaking is a different process than conventional upgrading (e.g., delayed cokers and fluidized bed cokers) where the composition of the feedstock is significantly altered to produce a higher quality oil for refining.
  • visbreaking is typically carried out by a gas-fired heated tubular reactor that provides directional heating from outside to inside (i.e. heat flow from the tube wall to the oil contained inside the tube). While effective and relatively efficient, this mechanism introduces the risk of thermally-driven fouling on the inside of the reactor tube walls. The fouling, or buildup of insoluble coke particles on the tube walls, must be cleaned at regular maintenance intervals leading to scheduled shutdowns to replace and clean the reactor tubes.
  • an apparatus and method is provided to heat hydrocarbon feedstock (such as heavy crude oil) by microwave radiation confined inside a resonant cavity.
  • Microwave radiation is generated by an EM source (at radio frequency (RF) or microwave (MW) frequencies) and delivered to the resonant cavity by a power coupler, which may be an iris coupler.
  • the resonant cavity is a sealed vessel that confines microwave radiation supplied thereto and supports resonance of the supplied microwave radiation at one or more resonant frequencies.
  • the coupling strength of the power coupler that operably couples the EM source to the resonant cavity can be tuned such that the effective load impedance matches the output impedance of the EM source in order to maximize power transfer.
  • the hydrocarbon feedstock is loaded into a pipe made from a material primarily transparent to the microwave radiation, such as sapphire.
  • a length of the pipe extends through the resonant cavity between an inlet and outlet of the resonant cavity.
  • the hydrocarbon feedstock is contained within the interior space of the resonant cavity and physically isolated from the interior space of the resonant cavity by the pipe wall.
  • the pipe has a central point that is centrally located between the inlet and the outlet.
  • the resonant cavity is configured to focus microwave radiation to a localized area occupied by the pipe within the internal space of the resonant cavity such that power density distribution of the microwave radiation along the length of the pipe has a peak (i.e., maximum magnitude) located at a point offset from the central point between the central point and the outlet of the resonant cavity.
  • the peak can be located a point at or near the outlet of the resonant cavity.
  • the resonant cavity is defined by at least one surface contour that controls the power density distribution of the microwave radiation along the length of the pipe such that it has the peak located at the point offset from the central point between the central point and the outlet of the resonant cavity.
  • the at least one surface contour can be provided by an object or feature located within the resonant cavity.
  • the at least one surface contour can be realized by a tapered surface (such as the inside surface of a conical section selected from the group consisting of a circular cone section, a parabolic cone section, and an elliptical cone section) at the inlet of the resonant cavity.
  • the microwave radiation supplied to the resonant cavity, the resonant cavity itself, and the pipe can be configured to heat the hydrocarbon feedstock loaded into the pipe to a reaction temperature suitable for visbreaking of the hydrocarbon feedstock.
  • the resonant frequency(ies) supported by the resonant cavity can lie in a frequency band between 0.1 GHz and 100 GHz.
  • the EM source includes an EM signal generator and an EM amplifier, wherein output of the EM signal generator is subject to amplification by the EM amplifier.
  • the EM source also includes a control system that controls frequency and power level of the microwave radiation that is supplied to the resonant cavity.
  • the control system includes a temperature sensor that measures temperature of the hydrocarbon fluid contained within the tubular member.
  • the control system can be configured to interface to the EM signal generator to control frequency of the microwave radiation that is supplied to the resonant cavity, and the control system can be configured to interface to the EM amplifier to control power level of the microwave radiation that is supplied to the resonant cavity.
  • the resonant cavity has a variable volume that resonates microwave radiation at different resonant frequencies according to the volume of the resonant cavity.
  • the microwave radiation at the different resonant frequencies is focused to a localized area occupied by the tubular member within the internal space of the resonant cavity.
  • the resonant cavity is defined by a body with a plunger that moves linearly into and out of the body, wherein the movement of the plunger causes the plunger to occupy a variable volume within the resonant cavity and thus vary the volume of the resonant cavity and corresponding resonant frequency of the cavity.
  • the apparatus can further include a control system that controls variable volume of the resonant cavity in order to control resonant frequency of the resonant cavity.
  • the control system can include circuitry that measures resonant frequency of the resonant cavity, and the control system can be configured to control the variable volume of the resonant cavity in response to the measured resonant frequency of the resonant cavity.
  • the apparatus and systems as described herein can be configured to heat the hydrocarbon feedstock loaded into the pipe to a reaction temperature suitable for visbreaking of the hydrocarbon feedstock.
  • the reaction temperature is in the range of 350°C to 500°C, which is suitable for visbreaking of heavy crude oil feedstock (i.e., the thermal cracking of the heavy crude oil feedstock with relatively low conversion of the residual fraction such that viscosity of the oil is reduced without significantly altering the quality of the oil).
  • Pumps and valves can be fluidly coupled to the opposed ends of the pipe outside the resonant cavity and configured to provide a pressurized flow of the hydrocarbon feedstock through the pipe during the heating process such that it remains in a liquid phase so as to suppress the gas phase and avoid two-phase flow.
  • the resonant cavity can be configured to focus microwave radiation at the resonant frequency to a localized area within the internal space of the resonant cavity. This localized area can be occupied by the length of pipe disposed within the internal space of the resonant cavity for efficient heating.
  • the resonant cavity can be configured to resonate microwave radiation at a desired transverse magnetic (TM) or transverse (TE) mode, such as TMoio mode.
  • TM transverse magnetic
  • TE transverse
  • the pipe can extend along an axis of the resonant cavity defined by the TMoio mode.
  • At least one soaker section can be disposed downstream of the resonant cavity.
  • the soaker section is configured to contain hydrocarbon fluid and limit heat loss from the contained hydrocarbon fluid.
  • the soaker section can include a tube or pipe or any pressure-containing vessel that contains the hydrocarbon fluid with thermally-insulative material that surrounds the tube or pipe or pressure vessel.
  • the soaker section can also include an active heater element (such as heat tape or a heating coil) that is disposed between the thermally-insulative material and the tube or pipe or pressure vessel.
  • An inlet port and an outlet port can be sealably coupled to opposed ends of the pipe outside the resonant cavity.
  • a thermally-insulative material that is primarily transparent to the microwave radiation can surround the pipe within the resonant cavity, and/or may be placed against the cavity wall.
  • the hydrocarbon fluid can flow at a controlled flow rate through the pipe within the resonant cavity while being heated by the microwave radiation confined within the interior space of the resonant cavity.
  • the hydrocarbon fluid can remain stationary inside the pipe within the resonant cavity while being heated by the microwave radiation confined within the interior space of the resonant cavity.
  • the hydrocarbon fluid heated by the apparatus can be crude oil, heavy oil, or bitumen.
  • a mathematical model can be used to determine the size of the tubular member, the resonant frequency of the microwave radiation, the geometry of the resonant cavity that supports such resonant frequency, and the required residence time in order to carry out desired
  • an apparatus for heating a hydrocarbon fluid with microwave radiation includes a plurality of microwave resonant cavity heaters (or resonator heater sections) as described above.
  • the plurality of resonator heaters sections are configured such that the pipes that extend within the resonant cavities of the resonator heater sections contain hydrocarbon fluid that is subject to heating by microwave radiation confined within the interior spaces of such resonant cavities.
  • the resonant frequency (ies) supported by such resonant cavities can lie in a frequency band between 0.1 GHz and 100 GHz.
  • Multiple EM sources can supply microwave radiation to corresponding resonant cavities of the resonator heater sections.
  • An EM source can cooperate with a power splitter to split microwave radiation into multiple legs for supply to a number of the resonant cavities of the resonator heater sections.
  • a flow splitter and associated tubing can distribute an inflow of hydrocarbon fluid to the pipes that extend within the resonant cavities of the resonator heater sections.
  • At least one soaker section can be disposed downstream of the plurality of microwave resonator heater sections.
  • the soaker section is configured to contain hydrocarbon fluid and limit heat loss from the contained hydrocarbon fluid.
  • the soaker section can include a tube or pipe or any pressure-containing vessel that contains the hydrocarbon fluid with thermally- insulative material that surrounds the tube or pipe or pressure vessel.
  • the soaker section can also include an active heater element (such as heat tape or a heating coil) that is disposed between the thermally-insulative material and the tube or pipe or pressure vessel.
  • a plurality of soaker sections can be disposed downstream of the plurality of microwave resonant cavity heaters.
  • FIG. 1 is a schematic cross-sectional view of an exemplary embodiment of an apparatus for heating hydrocarbon fluid employing microwave radiation confined in a resonant cavity.
  • FIG. 2 is a color diagram illustrating the amplitude of the electric field distribution in the resonant cavity of FIG. 1 during an exemplary visbreaking process.
  • FIG. 3 is a color diagram illustrating the power loss density distribution in the resonant cavity of FIG. 1 during the exemplary visbreaking process.
  • FIG. 4 is a curve that shows the required inner diameter of the resonant cavity body of FIG. 1 operating at 2.45 GHz as a function of inner diameter of the hydrocarbon-containing pipe (with the pipe made of alumina and with a fluid pressure of 1000 psi (70.3 kg/square cm)).
  • Such a curve can be created for any frequency, fluid pressure, and pipe material, which results in dimensional change of the apparatus shown in FIG. 1.
  • FIG. 5 is a plot of the reflection coefficient (Sn of the S-parameters) in the resonant cavity of FIG. 1 over a frequency range, which shows the TM 0 io mode as well as its neighboring, undesired modes.
  • FIG. 6 is a schematic cross-sectional view of a second exemplary embodiment of an apparatus for heating hydrocarbon fluid employing microwave radiation confined in a resonant cavity.
  • FIG. 7 is a color diagram illustrating the amplitude of the electric field distribution in the resonant cavity of FIG. 6 during an exemplary visbreaking process.
  • FIG. 8 is a color diagram illustrating the power loss density distribution in the resonant cavity of FIG. 6 during the exemplary visbreaking process.
  • FIG. 9 is a schematic cross-sectional view of a third exemplary embodiment of an apparatus for heating hydrocarbon fluid employing microwave radiation confined in a resonant cavity.
  • FIG. 10 is a color diagram illustrating the amplitude of the electric field distribution in the resonant cavity of FIG. 9 during an exemplary visbreaking process.
  • FIG. 11 is a color diagram illustrating the power loss density distribution in the resonant cavity of FIG. 9 during the exemplary visbreaking process.
  • FIG. 12A is a curve that illustrates the required inner diameter of the resonant cavity body of FIG. 9 for a TMoio mode operating at a resonant frequency 2.46 GHz as a function of the inner diameter of the hydrocarbon-containing pipe.
  • FIG. 12B is a curve that illustrates the required inner diameter of the resonant cavity body of FIG. 9 for a TM 0 io mode operating at a resonant frequency of 0.3 GHz as a function of the inner diameter of the hydrocarbon-containing pipe.
  • FIG. 13 is a curve that illustrates the reflection coefficient (Sn of the S-parameters) in the resonant cavity of FIG. 9 as a function of frequency, which shows a single TM 0 io mode at a frequency at or near 2.45 GHz.
  • FIGS. 14A and 14B are schematic cross-sectional views of an apparatus for heating hydrocarbon fluid employing microwave radiation confined in a resonant cavity adapted from the embodiment of FIG. 9.
  • FIG. 15 is a color diagram illustrating the amplitude of the electric field distribution in the resonant cavity of FIGS. 14A/14B during an exemplary visbreaking process.
  • FIG. 16 is a color diagram illustrating the power loss density distribution in the resonant cavity of FIGS. 14A/14B during the exemplary visbreaking process.
  • FIG. 17 is a diagram illustrating the profile of power loss density distribution along the axis of the resonant cavity of FIGS. 14A/14B for different lengths L of the heating profile modifier as noted in the cross-section of FIG. 14B.
  • FIGS. 18A and 18B are front and top views, respectively, of an exemplary embodiment of an apparatus for heating hydrocarbon fluid employing microwave radiation; the apparatus employs four microwave resonator heater sections and one soaker section similar to the components of the design of FIGS. 9 or 14A/14B.
  • FIGS. 19A and 19B are front and top views, respectively, of an exemplary embodiment of an apparatus for heating hydrocarbon fluid employing microwave radiation; the apparatus employs four microwave resonator heater sections and two soaker sections similar to the components of the design of FIGS. 9 or 14A/14B.
  • FIGS. 20A and 20B are schematic cross-sectional views of an apparatus for heating hydrocarbon fluid employing microwave radiation confined in a tunable variable volume resonant cavity adapted from the embodiment of FIGS. 14A/14B.
  • FIG. 21 is a plot illustrating resonant frequency of the resonant cavity of FIGS. 20A/20B as a function of plunger volume ratio and plunger length.
  • FIG. 22 is a schematic block diagram of a control system that controls the resonant frequency of the resonant cavity heater of FIGS. 20A/20B as well as supplies microwave radiation to such resonant cavity heater.
  • microwaves microwave radiation or energy
  • RF radio frequency
  • EM electromagnetic
  • the term “dBm” is a power value in decibels (dB) referenced to one milliwatt of power.
  • incident power refers to the microwave power (preferably in dB or dBm or watts) being supplied to the resonant cavity heater, which may or may not include both amplitude and phase information.
  • reflected power refers to the microwave power (preferably in dB or dBm or watts) that is reflected from the resonant cavity heater, which may or may not include both amplitude and phase data.
  • absorbed power refers to the microwave power (preferably in dB or dBm or watts) that is absorbed by the resonant cavity heater and fluids contained therein, which may or may not include both amplitude and phase data.
  • transmitted power refers to the microwave power (preferably in dB or dBm or watts) that is transmitted through the resonant cavity heater, which may or may not include both amplitude and phase data.
  • power loss density distribution refers to the spatial distribution of the power of microwave radiation transmitted within the resonant cavity heater.
  • the embodiments of the present application disclose apparatus and methods for microwave heating of a hydrocarbon feedstock (such as heavy crude oil) inside a resonant cavity defined by a body made from an electromagnetic conductive material.
  • Microwave radiation is generated by an EM source and delivery system and supplied to the resonant cavity by a power coupler, which can be an iris coupler.
  • the resonant cavity is a sealed vessel that confines microwave radiation supplied thereto and supports resonance of the supplied microwave radiation at one or more resonant frequencies.
  • the impedance of the power coupler that operably couples the EM delivery system to the resonant cavity can be tuned such that the effective load impedance matches the output impedance of the EM delivery system in order to maximize power transfer.
  • the hydrocarbon feedstock is loaded into a pipe made from a material primarily transparent to the microwave radiation, such as sapphire, quartz, or alumina.
  • the pipe is configured to extend through the resonant cavity and to enter and exit the resonant cavity.
  • the hydrocarbon feedstock is contained within the interior space of the resonant cavity and physically isolated from the interior space of the resonant cavity by the pipe wall.
  • the microwave radiation supplied to the resonant cavity, the resonant cavity itself, and the pipe can be configured to heat the hydrocarbon feedstock loaded into the pipe to a reaction temperature suitable for visbreaking of the hydrocarbon feedstock.
  • the reaction temperature is in the range of 350°C to 500°C, which is suitable for visbreaking of heavy crude oil feedstock (i.e., the thermal cracking of the heavy crude oil feedstock with relatively low conversion of the residual fraction such that viscosity of the oil is reduced without significantly altering the quality of the oil).
  • Pumps and valves can be fluidly coupled to the opposed ends of the pipe outside the resonant cavity and configured to provide a pressurized flow of the hydrocarbon feedstock through the pipe during the heating process such that it remains in a liquid phase so as to suppress the gas phase and avoid two-phase flow.
  • the resonant cavity supports or facilitates at least one mode of electromagnetic radiation within the microwave radio frequency band - the frequency band between 0.1 GHz and 100 GHz.
  • mode refers to a particular pattern of a standing
  • the mode can be any one of the various possible patterns of standing electromagnetic waves. Each mode is characterized by its frequency and standing wave pattern.
  • the electromagnetic wave pattern of a mode depends on the frequency, refractive indices, or dielectric constants of the materials of the cavity, the pipe and the hydrocarbon fluid, and the cavity geometry.
  • a transverse electric (TE) mode is one whose electric field vector is normal to a particular plane of reference.
  • a transverse magnetic (TM) mode is one whose magnetic field vector is normal to a particular plane of reference.
  • the actual field distribution inside the resonant cavity is a superposition of the modes therein.
  • Each of the modes can be identified with one or more subscripts (e.g., TE 010 ).
  • Each subscript attributes to the boundary condition in a particular dimension in the three geometric dimensional Maxwell's equations.
  • For a resonant cavity each of the three geometric dimensions has one boundary condition, resulting in three subscripts.
  • the modes are discreet and the subscripts are integers. In general, the larger a particular subscript the more modes are present in the standing wave in that particular geometric dimension.
  • the resonant frequencies of different modes have different sensitivity to the geometric dimensions, so the density and distribution of the mode frequencies in the frequency spectrum of a particular resonant cavity depends on the ratio of its geometric dimensions. It is possible to manipulate the ratio of the geometric dimensions of a resonant cavity to locate the mode of interest, e.g. TM 0 io, to a region in the frequency spectrum where the mode density is relatively low, which reinforces single mode resonation. In case the frequency of the mode of interest is near or overlaps with the frequencies of one or more other modes, simultaneous resonation of more than one mode can occur.
  • the resulting electromagnetic field pattern will be the superposition of the fields of individual modes, which in general does not show the same types of strong maxima and minima field values within the cavity.
  • FIG. 1 illustrates an embodiment of an apparatus 11 for visbreaking of a hydrocarbon feedstock (such as heavy crude oil) through focused heating by microwave radiation inside a resonant cavity.
  • the resonant cavity 12 is defined by an elongate cylindrical body 13 of circular cross-section and opposed end caps 15.
  • the body 13 and end caps 15 are made from a metallic material (such as aluminum, stainless steel, copper, bronze, or any electrically conductive metal) that is primarily reflective of microwave radiation with minimal absorption.
  • Each end cap 15 includes an outward extending neck 17 that defines a central passageway through the respective end cap 15.
  • the end caps 15 are configured to receive and support a pipe 19 that extends through the end caps 15 and through the center of the body 13 along the central longitudinal axis of the elongate body 13.
  • the pipe 19 is made from a nonconductive material (such as sapphire, quartz, ceramic, alumina, or other suitable material) that is primarily transparent to microwave radiation.
  • a power coupler 35 interfaces to the body 13 and supplies microwave radiation to the resonant cavity 12.
  • the end cap 15 closest to the power coupler 35 provides an inlet 20A that sealably receives the pipe 19 and provides for inflow of hydrocarbon feedstock into the portion of pipe 19 disposed within the resonant cavity 12.
  • the end cap 15 furthest from the power coupler 35 provides an outlet 20B that sealably receives the pipe 19 and provides for outflow of hydrocarbon feedstock from the portion of pipe 19 disposed within the resonant cavity 12.
  • the opposed ends of the pipe 19 that extend beyond the respective necks 17 of the end caps 15 interface to corresponding ported tube receptacles 21.
  • Each ported tube receptacle 21 is shouldered on a support flange 23 and retained to the support flange 23 by a retainer 25.
  • the support flanges 23 are fastened to tie rods 27 that are fastened to the respective end cap 15 as shown.
  • a high pressure seal 29 is provided for each ported tube receptacle 21 adjacent the interface of the ported tube receptacle 21 and the respective support flange 23 in order to prevent fluid leakage at this joint.
  • the hydrocarbon feedstock 31 to be treated is loaded inside the pipe 19 and is physically isolated from the body 13 of the resonant cavity 12.
  • a temperature sensor 33 that is made from a material that is primarily transparent to microwave radiation, such as a single-crystal sapphire optical fiber temperature sensor, can be inserted inside the pipe 19 and placed in direct contact with the hydrocarbon feedstock 31.
  • the temperature sensor 33 can extend through the pipe 19 outside the resonant cavity 12 through neck 17 and corresponding ported tube receptacle 21 such that it is coupled to associated light processing equipment for deriving temperature of the hydrocarbon feedstock 31 at one more positions inside the pipe 19 during the visbreaking process.
  • Pumps and valves can be fluidly coupled to the opposed ported tube receptacles 21 and configured to supply a pressurized flow of the hydrocarbon feedstock 31 inside the pipe 19 during the visbreaking process such that it remains in a liquid phase so as to suppress the gas phase and avoid two phase flow in the pipe 19.
  • This provides better control by minimizing the variability in the residence time and temperature profiles experienced by the hydrocarbon feedstock 31 during the visbreaking process, which in turn provides improved control of the targeted visbreaking reactions.
  • the hydrocarbon feedstock flow is pressurized up to 5000 psi (351.5 kg/square cm) inside the pipe 19 during the visbreaking process such that it remains in a liquid phase so as to suppress the gas phase and avoid two phase flow in the pipe 19.
  • An EM source is configured to generate and supply microwave radiation via a waveguide or coaxial cable or transmission line to the power coupler 35, which guides the supplied microwave radiation into the body 13 and can provide for impedance matching of the power transmission system to the impedance of the body 13.
  • the power coupler 35 There are many designs available for the power coupler 35, including but not limited to iris couplers and loop couplers.
  • FIG. 1 shows an iris coupler design which includes a waveguide 37 and plate 39 with a tuned iris geometry attached to the outside of the body 13.
  • the waveguide 37 and plate 39 are made from a metallic material (such as aluminum, stainless steel, copper, bronze, or any electrically conductive metal) that is primarily reflective of microwave radiation with minimal absorption.
  • the resonant cavity 12 defined by the body 13 and end caps 15 can be elongate in nature with the power coupler 35 disposed nearer one end of the resonant cavity 12 (and thus further away from the other end of the resonant cavity 12) as evident from FIGS. 2 and 3.
  • the microwave energy generated and supplied by the EM source is centered at a predefined frequency, which can range between 0.1 and 10 GHz depending on the specific flow rate requirements of the system as described below in more detail.
  • the geometry of the resonant cavity 12 is configured to resonate at the predefined frequency of the microwave energy generated and supplied by the EM source and delivery system via the power coupler 35.
  • the microwave energy and the resonant cavity 12 and the pipe 19 are configured to heat the hydrocarbon feedstock loaded into the pipe 19 to a reaction temperature suitable for visbreaking of the hydrocarbon feedstock.
  • the reaction temperature is in the range of 350°C to 500°C, which is suitable for visbreaking of heavy crude oil feedstock (i.e., the thermal cracking of the heavy crude oil feedstock with relatively low conversion of the residual fraction such that viscosity of the oil is reduced without significantly altering the quality of the oil).
  • the geometry of the resonant cavity 12 can be configured to ensure that the vast majority of the microwave energy in the cavity is concentrated along the central axis of the pipe 19.
  • the material of the body 13, the end caps 15, and the power coupler 35 is optimized to minimize microwave energy reflection and enabling a high-Q resonant cavity, and thereby allowing the maximum amount of microwave energy to heat the hydrocarbon feedstock fluid to the desired reaction temperature, while avoiding coke buildup on the inside walls of the pipe 19. If allowed to form on the pipe walls, coke will ultimately lead to the loss of cavity resonance - an undesired outcome.
  • This can be achieved by operating the resonant cavity in an optimal TMoio mode with the option of operating at additional single TM and TE modes.
  • TE modes can also be excited, for example, simply by rotating the coupler 35 and the corresponding iris by 90 degrees.
  • the design of the resonant cavity 12 is configured to provide the maximum and most efficient energy transfer into the hydrocarbon fluid flowing in the pipe 19.
  • the resonant cavity 12 can be tuned in order to minimize the reflected power from, or equivalently, to maximize the transmitted power into the resonant cavity for the desired transverse magnetic (TM) or transverse electric (TE) mode.
  • TM transverse magnetic
  • TE transverse electric
  • the minimized reflected power, or equivalently the maximized transmitted power results in the maximum energy transfer into the resonant cavity and thus the most efficient operation.
  • the heating process requires the microwave energy to be focused on the center of the resonant cavity 12 along the length of the pipe 19 and hence achieves a desired heating profile in the hydrocarbon feedstock and avoids "hot spots.”
  • the resonant cavity 12 can be designed to operate at a single TMoio mode with the ability to operate at additional single TM and TE modes if desired.
  • FIG. 2 shows the amplitude of the electric field distribution in the resonant cavity 12 of FIG. 1 during the visbreaking process.
  • FIG. 3 shows the power loss density distribution in the resonant cavity 12 of FIG. 1 during the visbreaking process.
  • the microwave energy has a TMoio mode at a resonant frequency of 2.45 GHz. The results are desirable since the majority of the microwave energy is focused on the hydrocarbon feedstock contained inside the pipe 19 and thus provides efficient and controlled heating of the
  • the thermal reactions (i.e. upgrading reactions) of the visbreaking process are controlled by flowing the hydrocarbon feedstock in a liquid phase through the resonant cavity 12 defined by the body 13 and end caps 15.
  • the hydrocarbon feedstock enters the resonant cavity 12 from the end of the pipe 19 closest to the coupler 35 via the inlet 20A.
  • the hydrocarbon feedstock then flows through the pipe 19 past the coupler 35 and exits the pipe 19 at the end furthest from the coupler 35 via the outlet 20B.
  • the fluid flow of the hydrocarbon feedstock within the pipe 19 is from right to left.
  • FIGS. 2 and 3 the fluid flow of the hydrocarbon feedstock within the pipe 19 is from left to right. As indicated by FIG.
  • the amount of conversion (i.e., visbreaking) of the hydrocarbon feedstock is dictated by the amount of time that the hydrocarbon feedstock remains at the desired reaction temperature, also known as the residence time.
  • the desired flow rate, the length of the pipe 19 inside the resonant cavity 12 (i.e., which corresponds to the resonant cavity length between the inlet 20A and the outlet 20B), and the inner diameter of the pipe 19 of the apparatus of FIG. 1 can be used to determine the residence time. Therefore, the apparatus of FIG. 1 may accommodate larger flow rates by increasing the diameter of the pipe 19.
  • the microwave energy is focused on the center of the pipe 19.
  • the inside diameter of the resonant cavity body 13 must increase to accommodate a decrease in the operating resonant frequency.
  • FIG. 4 is a curve based on mathematical analysis using a perturbation technique that shows the required inner diameter of the resonant cavity body 13 operating at 2.45 GHz as a function of the inner diameter of the pipe 19 with the pipe made of alumina and with a fluid pressure of 1000 psi (70.3 kg/square cm).
  • a curve can be created for any frequency, fluid pressure, and pipe material, which results in dimensional change of the apparatus shown in FIG. 1.
  • the only dimension affecting the cavity design operating at the TMoio mode is the inner diameter of the resonant cavity body 13 and not its length (i.e., the dimension along the length of the pipe 19).
  • the apparatus of FIG. 1 can also be configured to accommodate larger flow rates by other mechanisms, such as by adding one or more additional resonant cavity heater sections (similar to the resonant cavity heater section of FIG. 1) configured in a parallel arrangement (similar to FIGS. 18A/18B and 19A/19B) or in a series arrangement, if desired.
  • the apparatus of FIG. 1 can employ well-known monitoring and control mechanisms to maintain the desired resonance mode (e.g., TM 0 io mode) and the desired heating efficiency, as well as the desired fluid temperature during the visbreaking process.
  • FIG. 5 is a plot of the reflection coefficient (Sn of the S-parameters) over a frequency range showing the TM 0 io mode as well as its neighboring, undesired modes.
  • Resonance control may be achieved by i) frequency tracking, where the power source frequency is frequently updated to maintain the desired resonance mode and/or ii) by the use of tuning mechanisms to control the volume of the resonant cavity, including, but not limited to, mechanical, thermal, and electromagnetic measures.
  • Resonance control can involve monitoring and assurance of the minimization of the reflection coefficient (Sn of the S-parameters) or of the maximization of the transmission coefficient (S 21 of the S-parameters) during the visbreaking process.
  • Temperature control can utilize the temperature sensor 33 to detect the temperature of the hydrocarbon feedstock and control the level of microwave power in order to achieve the desired reaction temperature of the visbreaking process.
  • the location of the power coupler 35 can be dictated by the desired location for rapid heating of the hydrocarbon feedstock.
  • the power coupler 35 can be located anywhere along the length of the resonant cavity 12. In the exemplary design of FIG. 1 , the power coupler 35 is located closer to the inlet end of the resonant cavity, where the hydrocarbon feedstock flowing in the pipe 19 enters into the resonant cavity 12. This can provide rapid heating of the hydrocarbon feedstock to the desired reaction temperature immediately upon entry to the resonant cavity 12, and the remaining length of the resonant cavity 12 is then left to maintain the reaction temperature of the hydrocarbon fluid to the outlet 20B.
  • the apparatus of FIG. 1 produces rapid heating of the hydrocarbon feedstock while maintaining relatively cool temperatures on the walls of the resonant cavity body 13 and end caps 15.
  • a thermally-insulative material that is primarily transparent to microwave radiation can be used to cover the pipe 19 containing the hydrocarbon feedstock inside the resonant cavity body 13 of FIG. 1 in order to limit heat loss (and thus reduce the energy input requirements of the EM source) and maintain the desired reaction temperature.
  • FIG. 6 illustrates an embodiment of an apparatus 111 for visbreaking of a hydrocarbon feedstock (such as heavy crude oil) through focused heating by microwave radiation inside a resonant cavity.
  • the apparatus 111 of FIG. 6 is fundamentally the same as the apparatus 11 of FIG. 1 except for the addition of metallic thin discs 41 that are disposed inside the elongate body 13 and extend transverse to the longitudinal axis of the elongate body 13 and the pipe 19.
  • the discs 41 are spaced from one another along the length of the elongate body 13 to define a number of shorter-length resonant cavities 12-2 that are disposed adjacent one another within the body 13.
  • the sequence of shorter-length resonant cavities 12-2 is disposed adjacent a main resonant cavity 12-1 (the resonant cavity adjacent the inlet 20A and the power coupler 35).
  • the adjacent shorter- length resonant cavities 12-2 are coupled to the main resonant cavity 12-1 and to one another together through apertures in the discs 41.
  • the shorter-length resonant cavities 12-2 each behave like single mode cavities by suppressing other modes.
  • the apertures of the discs 41 allow for signal attenuation as microwave energy propagates from the main resonant cavity 12-1 through the sequence of shorter-length resonant cavities 12-2.
  • the metallic surfaces of the discs 41 also function to mirror the microwave signal in each respective resonant cavity, which lessens the attenuation of the signal and increases the overall heating length of the hydrocarbon feedstock inside the pipe 19.
  • the focus of electric field intensity can be changed so that a designated part of the hydrocarbon feedstock receives more microwave energy.
  • the number of employed discs 41 , their spacing, and the aperture size on each disc 41 can be optimized for performance enhancement.
  • the main resonant cavity 12-1 and the adjacent sequence of shorter- length resonant cavities 12-2 mimic the operation of a multi-mode resonator cavity.
  • the main resonant cavity 12-1 can operate with a TMoio mode, if desired.
  • a frequency tracking system can be used to ensure the main resonant cavity 12-1 is operating at the frequency of the desired resonance mode (e.g., TM 0 io mode).
  • FIG. 7 shows the amplitude of the electric field distribution in the main resonant cavity 12-1 and the shorter-length resonant cavities 12-2 of FIG. 6 during the visbreaking process.
  • FIG. 8 shows the power loss density distribution in the main resonant cavity 12-1 and the shorter- length resonant cavities 12-2 of FIG. 6 during the visbreaking process.
  • the microwave energy has a TMoio mode at a resonant frequency of 2.45 GHz. The results are desirable since the majority of the microwave energy is focused on the hydrocarbon feedstock contained inside the pipe 19 and thus provides efficient and controlled heating of the
  • the thermal reactions (i.e., upgrading reactions) of the visbreaking process are controlled by flowing the hydrocarbon feedstock in a liquid phase through the main resonant cavity 12-1 and the shorter-length resonant cavities 12-2, where such resonant cavities are defined by the body 13 and end caps 15 and the discs 41.
  • the hydrocarbon feedstock enters into the end of the pipe 19 closest to the coupler 35 and flows through the pipe 19 within the main resonant cavity 12-1 supplied with microwave radiation via the power coupler 35.
  • the hydrocarbon feedstock then flows through the pipe 19 into the shorter-length resonant cavities 12-2 and exits the pipe 19 at the end furthest from the power coupler 35.
  • the end cap 15 closest to the power coupler 35 provides an inlet 20A that sealably receives the pipe 19 and provides for inflow of hydrocarbon feedstock into the portion of pipe 19 disposed within the main resonant cavity 12-1.
  • the end cap 15 furthest from the power coupler 35 provides an outlet 20B that sealably receives the pipe 19 and provides for outflow of hydrocarbon feedstock from the portion of pipe 19 disposed within the last shorter-length resonant cavity 12-2.
  • the fluid flow of the hydrocarbon feedstock is from right to left.
  • the fluid flow of the hydrocarbon feedstock is from left to right. As indicated by FIG.
  • the desired flow rate, the length of the pipe 19 extending through the main resonant cavity 12-1 and the smaller-size resonant cavities 12-2 (i.e., the total resonant cavity length between the inlet 20A and the outlet 20B), and the inner diameter of the pipe 19 can be used to determine the residence time of the hydrocarbon feedstock flowing within the pipe 19. Similar to the apparatus of FIG. 1 , the apparatus of FIG. 6 may accommodate larger flow rates by increasing the diameter of the pipe 19. For the case where a TMoio mode is desired, the microwave energy is focused on the center of the pipe 19.
  • the inner diameter of the resonant cavity body 13 must increase to accommodate a decrease in the operating resonant frequency.
  • the apparatus of FIG. 6 can also be configured to accommodate larger flow rates by other mechanisms, such as by adding one or more additional resonant cavity heater sections (similar to the resonant cavity heater section of FIG. 6) configured in a parallel arrangement (similar to FIGS. 18A/18B and 19A/19B) or in a series arrangement, if desired.
  • a thermally-insulative material that is primarily transparent to microwave radiation can be used to cover the tube 19 containing the hydrocarbon feedstock inside the resonant cavity body 13 of FIG. 6 in order to limit heat loss (and thus reduce the energy input requirements of the EM source) and maintain the desired reaction temperature.
  • FIG. 9 illustrates an embodiment of an apparatus 1 1 1 1 for visbreaking of a hydrocarbon feedstock (such as heavy crude oil) through focused heating by microwave radiation inside a resonant cavity 12.
  • the apparatus 1 1 1 1 1 of FIG. 9 is fundamentally similar to the apparatus 1 1 of FIG. 1 except for the power coupler 35 interfacing to the body 13 centrally along its length midway between the inlet end and the outlet end of the body 13 as well as the addition of a soaker section 43 disposed outside the resonant cavity 12 defined by the body 13 and end caps 15.
  • the soaker section 43 covers a length of the pipe 19 downstream of the resonant cavity 12.
  • the soaker section 43 provides insulation and/or heating to such length of pipe 19 and to the hydrocarbon feedstock disposed therein in order to ensure the desired reaction temperature of the hydrocarbon feedstock is maintained over such length of pipe 19.
  • the soaker section 43 can include one or more layers of thermally-insulative material (such as mineral fiber, glass fiber, silica, aerogel, or other suitable insulating material) that surrounds the length of pipe 19. Such thermally-insulative material insulates the length of pipe to minimize conductive heat loss from the hydrocarbon feedstock disposed in the length of pipe.
  • the soaker section 43 can also include resistive heat tape or a heater coil wrapped around the length of pipe 19 under the thermally- insulative material.
  • the resistive heat tape or heater coil can be configured to apply heat to the length of pipe 19 and to the hydrocarbon feedstock disposed therein as desired.
  • the soaker section 43 can be a pressure-containing vessel that contains the hydrocarbon fluid with thermally-insulative material that surrounds the pressure vessel.
  • the soaker section 43 can also include an active heater element (such as a heating coil) that is disposed between the thermally-insulative material and the pressure vessel.
  • the resonant cavity 12 can operate with a TMoio mode, if desired.
  • a frequency tracking system can be used to ensure the resonant cavity is operating at the optimal frequency of the desired resonance mode (e.g., TM 0 io mode).
  • the end cap 15 opposite the soaker section 43 provides an inlet 20A that sealably receives the pipe 19 and provides for inflow of hydrocarbon feedstock into the portion of pipe 19 disposed within the resonant cavity 12, and the end cap 15 adjacent the soaker section 43 provides an outlet 20B that sealably receives the pipe 19 and provides for outflow of hydrocarbon feedstock from the portion of pipe 19 disposed within the resonant cavity 12.
  • FIG. 10 shows the amplitude of the electric field distribution in the resonant cavity 12 of FIG. 9 during the visbreaking process.
  • FIG. 1 1 shows the power loss density distribution in the resonant cavity 12 of FIG. 9 during the visbreaking process.
  • the microwave energy has a TMoio mode operating at a resonant frequency of 2.45 GHz. The results are desirable since the majority of the microwave energy is focused on the hydrocarbon feedstock contained inside the pipe 19 and thus provides efficient and controlled heating of the hydrocarbon feedstock.
  • the thermal reactions (i.e. upgrading reactions) of the visbreaking process are controlled by flowing the hydrocarbon feedstock in a liquid phase through the resonant cavity 12 defined by the body 13 and end caps 15.
  • the hydrocarbon feedstock enters the resonant cavity 12 from the end of the pipe 19 closest to the coupler 35 via the inlet 20 A.
  • the hydrocarbon fluid then flows through the pipe 19 past the coupler 35, and exits the resonant cavity 12 at the end furthest from the coupler 35 via the outlet 20B into the soaker section 43.
  • the fluid flow of the hydrocarbon feedstock is from right to left. As indicated by FIG.
  • the hydrocarbon feedstock flows through the pipe 19 and into the resonant cavity 12 via the inlet 20A, it is exposed to a rapidly increasing power intensity which leads to rapid heating.
  • the peak rate of heating occurs as the hydrocarbon feedstock passes by the coupler 35, after which the rate of heating decreases.
  • the hydrocarbon feedstock is at or close to the desired (upgrading) reaction temperature, which can be in the range of 350°C to 500°C.
  • the soaker section 43 is a length of the pipe 19 that is provided with insulation or/and heating as described above.
  • the soaker section 43 operates to minimize heat loss in order to ensure the desired reaction temperature of the hydrocarbon feedstock is maintained over the length of the soaker section 43.
  • the soaker section 43 provides a relatively accurate control over the level and the uniformity of the temperature profile of the hydrocarbon feedstock necessary for the visbreaking to occur.
  • the desired flow rate, the length of the pipe 19 extending through the resonant cavity 12 (i.e., which corresponds to the resonant cavity length between the inlet 20 A and the outlet 20B) together with the length of pipe 19 of the soaker section 43, and the inner diameter of the pipe 19 can be used to determine the residence time of the hydrocarbon feedstock flowing within the pipe 19.
  • the apparatus of FIG. 9 can be configured to
  • the microwave energy is focused on the center of the pipe 19.
  • FIG. 12A is a curve that illustrates the required inner diameter of the resonant cavity body for a TMoio mode operating at a resonant frequency of 2.46 GHz as a function of inner diameter of the pipe 19.
  • FIG. 12B is a curve that illustrates the required inner diameter of the resonant cavity body for a TMoio mode operating at a resonant frequency of 0.3 GHz as a function of inner diameter of the pipe 19.
  • FIG. 13 illustrates the reflection coefficient (Sn of the S-parameters in dB) in an exemplary embodiment of the resonant cavity of FIG. 9 as a function of frequency, which shows a single TM 0 io mode at a frequency at or near 2.45 GHz.
  • the microwave coupler 35 of the apparatus of FIG. 9 is located at the center of the resonant cavity body 13, which enhances the stability of the desired longitudinal temperature profile along the length of the pipe 19 inside the resonant cavity 12. The enhanced stability results in higher energy efficiency and significantly simplifies resonance control, such as field profile monitoring.
  • the apparatus of FIG. 9 employs a pipe 19 (of material primarily transparent to microwave radiation) that extends along the entire length of the central axis of the resonant cavity 12 as well as the entire length of the soaker section 43. Note that transparency to microwave radiation is only required in the resonant cavity 12.
  • the hydrocarbon fluid that flows through the soaker section 43 can be contained inside a pipe, cylindrical vessel, or vessel of any shape made of a metallic material that is non-transparent to microwave radiation, such as stainless steel, nickel alloy, or other material strong enough for the pressure conditions of the visbreaking process.
  • Thermally-insulative material can surround the pipe or vessel of the soaker section 43 to limit heat loss.
  • An active heater element such as heat tape or a heater coil, can be used to heat the fluid in the soaker section, if desired.
  • a thermally-insulative material that is primarily transparent to microwave radiation can be used to cover the tube 19 containing the hydrocarbon feedstock inside the resonant cavity body 13 of FIG. 9 in order to limit heat loss (and thus reduce the energy input requirements of the EM source) and maintain the desired reaction temperature.
  • the temperature profile of the hydrocarbon fluid along the length of the pipe 19 within the resonant cavity 12 during the visbreaking process is similar to the power loss density profile (which is equivalent to the heating profile) within the resonant cavity 12 as shown in FIG. 11, which has a peak (i.e., maximum magnitude) near the center of the resonant cavity 12 (which corresponds to the center point along the length of pipe 19 that extends between the inlet 20A and the outlet 20B).
  • the hydrocarbon fluid is heated during the visbreaking process while flowing through the resonant cavity 12 of FIG.
  • the peak of the temperature profile of the hydrocarbon fluid during the visbreaking process departs from the center of the resonant cavity 12 depending on factors such as the fluid flow rate and the rate of heat loss.
  • the fluid flow rate, or residence time which is determined by other factors such as the required amount of reaction, is generally not to be used to optimize the temperature profile of the hydrocarbon fluid during the visbreaking process.
  • a heating profile modifier 51 is positioned inside the resonant cavity 12 of the apparatus of FIG. 9.
  • the heating profile modifier 51 is an object or feature whose surface contour(s) alters the geometry of the hollow space inside the resonant cavity 12, and thus alters the electric field distribution within the resonant cavity and the corresponding heating profile provided by the microwave energy.
  • the heating profile modifier 51 provides a tapered surface with a small diameter cross-section disposed adjacent the inlet 20 A of the resonant cavity 12. The cross-sectional diameter of the tapered surface increases linearly as the surface extends in the axial direction of pipe 19 away from the inlet 20A.
  • the tapered surface extends at an angle a relative to the central axis of the pipe 19 as shown in the cross-section of FIG. 14B and this defines the inside surface of a circular conical section.
  • the tapered surface terminates at a point along the top wall of the resonant cavity 12 that is spaced from the opening 40 of the power coupler 35 toward the inlet side of the resonant cavity 12.
  • FIG. 15 shows the predicted amplitude of the z-component of the electric field distribution with the heating profile modifier 51 positioned in the resonant cavity 12 as shown in FIGS. 14A and 14B.
  • FIG. 16 shows the power loss density distribution in the resonant cavity 12 for the optimal TMoio mode operating at a resonant frequency of near 2.45 GHz with the heating profile modifier positioned in the resonant cavity 12 as shown in FIGS. 14A and 14B.
  • the predicted results are desirable in the sense that the majority of the microwave energy is focused on the hydrocarbon fluid contained inside the pipe 19.
  • the peak (i.e., maximum magnitude) of the profile of the power loss density distribution along the axis of the pipe 19 is shifted from the center of resonant cavity 12 (which corresponds to the central point of the length of pipe 19 that extends between the inlet 20A and the outlet 20B) toward the outlet 20B of the resonant cavity 12.
  • the amount of shift is determined by the length L of the heating profile modifier 51 as shown in FIG. 14B.
  • FIG. 17 shows the one-dimensional power loss density profile along the axis of the pipe 19 within the resonant cavity 12 for various lengths L of the heating profile modifier 51.
  • the peak of the power loss density profile (which is equivalent to the heating profile) shifts more toward the outlet 20B of the resonant cavity 12.
  • the heating profile modifier 51 provides a heating profile along the axis of the pipe 19 with a peak that is offset from the center of resonant cavity 12 (which corresponds to the central point of the length of pipe 19 that extends between the inlet 20A and the outlet 20B) toward the outlet 20B of the resonant cavity 12.
  • the desired temperature profile of the hydrocarbon fluid during the visbreaking process along the pipe 19 from the inlet 20 A to the outlet 20B of the resonant cavity 12 is generally a monotonically increasing profile whose peak is at the desired reaction temperature and is located at the outlet 20B of the resonant cavity 12.
  • the length L of the heating profile modifier 51 can be used to optimize the heating profile such that the peak of the temperature profile of the hydrocarbon fluid is at or near the outlet 20B of the resonant cavity 12 and is at the desired reaction temperature as maintained by the soaker section 43.
  • a temperature profile whose peak is located prior to the outlet 20B is undesirable because it implies energy inefficiency due to heat loss.
  • peak temperatures higher than the desired reaction temperature are undesirable because they can induce unwanted reactions in the hydrocarbon fluid as it flows through the pipe 19 within the resonant cavity 12.
  • the heating profile modifier 51 can be an object or feature of any shape, such as, but not limited to, objects that define the tapered surface as the inside surface of a conical section (such as a circular cone section, parabolic cone section or elliptical cone section).
  • the heating profile modifier 51 can be made with the same material as the resonant cavity, with the goal of optimizing the temperature profile.
  • the heating profile modifier 51 can be mechanically fixed in its desired position within the resonant cavity.
  • the heating profile modifier 51 can be formed as an integral part of the inside walls of the resonant cavity 12.
  • the power coupler 35 when implemented by a variable position power coupler can also be used as a heating profile modifier. If desired, the heating profile modifier can be incorporated into the control system to perform real time temperature profile control.
  • a non-centrally positioned power coupler has a disadvantage of possible TM 0 io dipole mode degeneracy due to fabrication tolerances, which could lead to resonance control instability.
  • scaling of the apparatus of FIG. 9 or FIGS. 14A/14B to achieve higher flow rates can be performed by using different combinations of the resonant cavity heater sections and soaker sections (vessels).
  • the hydrocarbon feedstock flows into the microwave resonant cavity heater sections followed by the soaker section(s).
  • the number of microwave resonant cavity heater sections is dictated by the flow rate of the inflow of hydrocarbon feedstock that is to be processed (upgraded) and the flow rate capacity of each resonant cavity heater section or the given pipe volume and required residence time.
  • the number of soaker sections (or vessels) will depend on the volume requirement, required residence time, and operational restrictions, such as physical space, pressure handling capabilities, and flow restrictions.
  • FIGS. 18A/18B and 19A/19B two possible examples of apparatus for larger flow rates are shown in FIGS. 18A/18B and 19A/19B.
  • the inflow of the hydrocarbon feedstock 10 is divided by a flow splitter and associated tubing to a parallel arrangement of four microwave resonant cavity heaters 13 similar to the design of FIG. 9 or FIGS. 14A/14B that bring the hydrocarbon fluid to the desired reaction temperature using the microwave energy supplied at 9.
  • the output flow of the four microwave resonant cavity heaters is combined and fed into a single soaker vessel, where the hydrocarbon fluid is allowed to remain for the desired residence time before exiting the apparatus at 14.
  • FIGS. 18A/18B the inflow of the hydrocarbon feedstock 10 is divided by a flow splitter and associated tubing to a parallel arrangement of four microwave resonant cavity heaters 13 similar to the design of FIG. 9 or FIGS. 14A/14B that bring the hydrocarbon fluid to the desired reaction temperature using the microwave energy supplied at 9.
  • the inflow of the hydrocarbon feedstock is divided by a flow splitter and associated tubing to a parallel arrangement of four microwave resonant cavity heaters similar to the apparatus of FIG. 9 or FIGS. 14A/14B that bring hydrocarbon fluid to the desired reaction temperature using the microwave energy supplied at 9.
  • the output flow of the four microwave resonant cavity heaters is combined and fed into a parallel arrangement of two soaker vessels, where the hydrocarbon fluid is allowed to remain for the desired residence time before exiting at 14.
  • the four microwave resonant cavity heaters and the soaker vessels are similar to the respective parts of FIG. 9 or FIGS. 14A/14B as described above.
  • the apparatus of FIGS. 18A/18B and 19A/19B can employ multiple EM sources and delivery systems for supplying the microwave radiation to corresponding resonant cavity heaters of the apparatus.
  • a single EM source and delivery system can employ a power splitter to split the microwave radiation into multiple legs for supply to the resonant cavity heaters of the apparatus.
  • multiple EM source and delivery systems and one or more power splitters can be used to supply the microwave radiation to the resonant cavity heaters of the apparatus.
  • the apparatus of FIGS. 18A/18B and 19A/19B can also employ well-known monitoring and control mechanisms to maintain the desired resonance mode (e.g., TMoio mode) and heating efficiency, as well as the desired fluid temperature during the visbreaking process.
  • Resonance control may be achieved by i) frequency tracking, where the power source frequency is frequently updated to maintain the desired resonance mode and/or ii) by the use of tuning mechanisms to control the volume of the resonant cavity, including, but not limited to, mechanical, thermal, and electromagnetic measures.
  • Resonance control can involve monitoring and assurance of the minimization of the reflection coefficient (Sn of the S-parameters) or of the maximization of the transmission coefficient (S 21 of the S-parameters) during the visbreaking process.
  • Temperature control can utilize the temperature sensor 33 to detect the temperature of the hydrocarbon feedstock and control the level of microwave power in order to achieve the desired reaction temperature of the visbreaking process.
  • Table I as provided below is a summary of exemplary calculations illustrating scaling of the resonant cavity 12 of the apparatus of FIG. 9 or FIGS. 14A/14B.
  • Resonant Residence Time is the total time (in seconds) that the hydrocarbon feedstock is heated inside the microwave resonant cavity to provide the
  • Tempoture Increase is the temperature increase (in °C) from the temperature of the hydrocarbon feedstock at the inlet to the desired reaction temperature in the resonant cavity;
  • Resonant Frequency is the resonant frequency (in GHz) of the microwave resonant cavity
  • Opening IDpipe is the inner diameter (in cm) of the pipe 19;
  • Flow Rate is the flow rate (in barrels per day or BPD) of the hydrocarbon feedstock that flows through the pipe 19;
  • “Cavity Diameter” is the inner diameter (in cm) of the resonant cavity body 13; it is dictated by Resonant Frequency; and
  • “Cavity Length” is the length (in cm) of the resonant cavity body 13 between the inlet 20A and the outlet 20B; it is dictated by the Flow Rate and the inner diameter of the pipe 19 to satisfy the desired Resonant Residence Time. [0097] In the exemplary Table I, it is assumed that a Resonant Residence Time of 30 seconds is required for the case where the microwave radiation in the resonant cavity 12 heats the hydrocarbon feedstock from an initial temperature below the 350-500°C range of the reaction temperature to a desired reaction temperature within the 350-500°C for the visbreaking process. In this manner, the microwave radiation heats the hydrocarbon feedstock to raise its temperature by 100°C.
  • the hydrocarbon feedstock can be preheated.
  • Such preheating reduces the amount of microwave energy that is required to heat the hydrocarbon feedstock to the desired reaction temperature for thermal visbreaking.
  • Such preheating can be carried out through conventional means, such as electric, gas fired, coal burning, or other suitable fluid heating schemes.
  • Table I can be derived from practical maximum diameters determined from plots like FIGS. 12A and 12B. Then, for each operating resonant frequency, it is possible to determine the dimensions of the resonant cavity 12 and the flow rate that can be achieved.
  • the resonant cavity 12 of the apparatus of FIG. 9 or FIGS. 14A/14B can be configured to operate at a resonant frequency of 2.45 GHz with the resonant cavity body 13 having an inner diameter of 7.37 cm and the pipe 19 having an inner diameter of 1.00 cm.
  • the length of the resonant cavity is 18.4 cm as dictated by the hydrocarbon feedstock flow rate of 0.26 BPD and the 1.00 cm inner diameter of the pipe 19 to satisfy the desired Resonant Residence Time of 30 seconds.
  • a flow of hydrocarbon feedstock i.e., heavy crude oil
  • a required Resonant Residence Time of 30 seconds to heat the hydrocarbon feedstock from a temperature of 340°C (after preheating) to a reaction temperature of 440°C (a temperature increase of 100°C
  • the 14A/14B can be configured to operate at a resonant frequency of 0.3 GHz with the resonant cavity body 13 having an inner diameter of 58.32 cm and the pipe 19 having an inner diameter of 8.50 cm.
  • the length of the resonant cavity 12 is 146.0 cm as dictated by the hydrocarbon feedstock flow rate of 150.00 BPD and the 8.50 cm inner diameter of the pipe 19 to satisfy the desired Resonant Residence Time of 30 seconds.
  • the residence time of the hydrocarbon feedstock flowing through the system necessary for the visbreaking process is a function of the reaction temperature.
  • a reaction temperature of 410°C requires a residence time of 32 minutes.
  • the heavy crude oil feedstock is preheated to a temperature at or near 310°C and the resonant cavity 12 operates to heat the heavy crude oil feedstock at or near the reaction temperature of 410°C.
  • the soaker section 43 is configured to maintain the heated hydrocarbon feedstock at the reaction temperature for 31.5 minutes (with the resonant cavity providing the necessary heating for the remaining 0.5 minutes of the requisite 32 minute residence time).
  • the soaker section 43 can be one vessel (similar to the apparatus of FIGS. 18A/18B), a parallel arrangement of vessels (similar to the apparatus of FIGS. 19A/19B), or a series arrangement of vessels, if desired.
  • a reaction temperature of 440°C requires a residence time of 8 minutes.
  • the heavy crude oil feedstock is preheated to a temperature at or near 340°C and the resonant cavity 12 operates to heat the heavy crude oil feedstock at or near the reaction temperature of 440°C.
  • the soaker section 43 is configured to maintain the heated hydrocarbon feedstock at the reaction temperature for 7.5 minutes (with the resonant cavity providing the necessary heating for the remaining 0.5 minutes of the requisite 8 minute residence time).
  • the soaker section 43 can be one vessel (similar to the apparatus of FIGS. 18A/18B), a parallel arrangement of vessels (similar to the apparatus of FIGS. 19A/19B), or a series arrangement of vessels, if desired.
  • multiple microwave resonant cavities can be fluidly coupled to the downstream soaker section or vessel(s).
  • the multiple microwave resonant cavities can be arranged in a parallel arrangement (similar to the apparatus of FIGS. 18A/18B and 19A/19B) or a series arrangement, if desired.
  • the parallel configuration the hydrocarbon fluid inflow is distributed over the multiple resonant cavities by a flow splitter and associated tubing, which reduces the necessary resonant cavity length.
  • the multiple cavity lengths can be added together to realize the necessary cavity length, which allows for a reduction in length of the respective individual resonant cavities.
  • the hydrocarbon fluid will flow at a controlled flow rate through the apparatus during the visbreaking process as described herein.
  • the valves and pumps can be configured to control the hydrocarbon fluid flow such that it remains stationary within the apparatus during the visbreaking process.
  • the visbreaking of the hydrocarbon feedstock by heating through microwave radiation results in localized heating through the oscillation of molecules in the hydrocarbon feedstock, which results in heating the hydrocarbon feedstock from within.
  • This internal heating prevents thermally driven fouling from occurring on the interior wall of the pipe inside the resonant cavity(ies) of the apparatus.
  • microwave heating also offers the advantage of more rapid heating of a targeted volume of hydrocarbon feedstock and offers the potential for economically visbreaking smaller production volumes.
  • the apparatus and methodology of visbreaking can be used to irreversibly reduce the viscosity of a variety of hydrocarbon fluids, such as heavy crude oil, other viscous crude oil, and bitumen.
  • the apparatus as described herein have a small footprint as compared to the traditional systems for upgrading heavy oil.
  • the apparatus may be located at a wellsite or in a production field so that the heavy oil may be upgraded before it is transported from the wellsite or the production field. It is contemplated that the apparatus can be mounted on skids or trucks and brought to the wellsite or production field for use.
  • the resonant cavity 12 of the apparatus as described herein employs a cylindrical cross- sectional shape.
  • Other cross-sectional shapes such as rectangular cross-sectional shapes, can also be used for the resonant cavity.
  • the apparatus can include a mechanical tuning mechanism to vary the volume of the resonant cavity 12 in order to vary (or tune) the resonant frequency of the resonant cavity 12.
  • resonant frequency tuning is achieved by varying the length, or insertion, of a cylindrical plunger 53, which is usually made with the same material as the tubular body 13 and end caps 15 that define the resonant cavity 12.
  • the plunger 53 can be linearly translated relative to the body 13 such that a variable portion of the plunger 53 resides inside the resonant cavity 12 and thus occupies volumetric space within the resonant cavity 12.
  • FIG. 21 shows the simulation result for this tuning mechanism for different insertion lengths of the plunger 53 into the resonant cavity 12.
  • the resonant cavity 12 can contain more than one plunger 53.
  • the plunger(s) can be of any shape and at any position in the resonant cavity, with the goal of tuning the resonant frequency to the desired value.
  • the mechanical resonant frequency tuning can also be realized by employing diaphragmatic resonant cavity walls, which enables control of the volume of the resonant cavity.
  • thermal measures can be used to control the volume of the resonant cavity.
  • the plunger 53 can include an electrically-controlled actuator that controls the linear movement of the plunger 53 relative to the body 13. Other electrically-controlled actuators can be used for other mechanical resonant frequency tuning.
  • the electrically-controlled actuator can be electrically coupled to a control system for real time resonant frequency control as described below with respect to FIG. 22.
  • FIG. 22 illustrates an exemplary control system 160 that provides for real time resonant frequency control of a resonant cavity heater 1 1.
  • the control system 160 includes an EM signal generator 162 (which can be realized by a voltage-controlled oscillator or other electronic oscillator) and an EM amplifier 164 that cooperate to supply microwave radiation to a waveguide or coaxial cable or transmission line 166 that delivers the microwave radiation to the power coupler 35 of the resonant cavity heater 1 1 (or multiple resonant cavity heater sections) as described above.
  • EM signal generator 162 which can be realized by a voltage-controlled oscillator or other electronic oscillator
  • EM amplifier 164 that cooperate to supply microwave radiation to a waveguide or coaxial cable or transmission line 166 that delivers the microwave radiation to the power coupler 35 of the resonant cavity heater 1 1 (or multiple resonant cavity heater sections) as described above.
  • the control system 160 also includes a resonant frequency control block 168, an EM power control block 170, and a main control block 172, which can all be realized by a software-programmed computer processing system with appropriate interface circuitry or other suitable controller device.
  • the resonant frequency control block 168 can be configured to supply electrical control signals to the electrically-controlled mechanical resonant tuning mechanism 53 (which can include the plunger 53 of FIGS. 20 A and 20B) to vary the resonant frequency of the resonant cavity heater 11 to a desired frequency value.
  • the resonant frequency control block 168 can directly or indirectly monitor the resonant frequency of the resonant cavity heater 11 that causes a desired mode (such as a TMoio mode) to be excited in the resonant cavity heater 11.
  • the monitored resonant frequency can be used as feedback with respect to the electrical control of the mechanical resonant tuning mechanism 53 in order to tune the resonant frequency of the resonant cavity heater 11.
  • the resonant frequency control block 168 can also be configured to supply electrical control signals to the EM signal generator 162 to output an EM signal at the resonant frequency of the resonant cavity heater 11.
  • the monitored resonant frequency can also be used as feedback with respect to the electrical control of the EM signal generator 162 in order to output an EM signal at the resonant frequency of the resonant cavity heater 11.
  • the resonant frequency of the resonant cavity heater 11 can change over time due to factors such as change in the dimensions of the resonant cavity arising from temperature variations of the environment of the resonant cavity heater 11 and variation in the dielectric permittivity of the hydrocarbon feedstock. Such control operations can compensate for these temperature effects.
  • the EM power control block 170 can be configured to monitor the temperature profile of the hydrocarbon fluid in the resonant cavity heater 11 and control the gain of the EM amplifier 164 to control the power level of the microwave energy supplied to the waveguide 166 in order to obtain the desired rate of heating inside the resonant cavity heater 11.
  • the main control block 172 can be configured to interface to both the resonant frequency control block 168 and the EM power control block 170 in order to initiate and carry out a desired control scheme.
  • control schemes include the intermittent frequency track and heat control scheme and the continuous frequency track and heat control scheme as outlined in International Patent Application PCT/US 13/59198, herein incorporated by reference in its entirety.
  • thermocouple fiber optic temperature sensor, infrared, or other appropriate
  • the temperature sensor may be used as part of the control system to monitor the temperature profile of the hydrocarbon fluid contained within the pipe 19 of the resonant cavity heater 11.
  • the temperature sensor is preferably realized from non-metallic material, such as a fiber optic temperature sensor 33 as described above.

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  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Electromagnetism (AREA)
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  • General Health & Medical Sciences (AREA)
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  • Life Sciences & Earth Sciences (AREA)
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Abstract

L'invention concerne un appareil pour le chauffage par des micro-ondes d'un fluide hydrocarboné dans une cavité de résonance, où le fluide hydrocarboné est chargé dans un tuyau qui s'étend au travers de la cavité de résonance entre une entrée et une sortie, un point central étant situé au centre entre celles-ci. La cavité de résonance concentre le rayonnement de micro-ondes sur une zone localisée occupée par le tuyau de telle sorte que la distribution de la densité de puissance le long de la longueur du tuyau présente un pic situé au niveau d'un point décalé du point central, entre le point central et la sortie. Dans un autre aspect, la cavité de résonance peut présenter un volume variable qui fait résonner le rayonnement de micro-ondes à des fréquences de résonance différentes. L'appareil peut être configuré pour chauffer un fluide hydrocarboné à une température de réaction appropriée à la viscoréduction du fluide hydrocarboné. La température de réaction peut se situer dans la plage de 350°C à 500°C, qui est appropriée pour la viscoréduction d'huile lourde.
PCT/US2014/031251 2014-03-19 2014-03-19 Appareil et procédé mettant en oeuvre un chauffage par micro-ondes d'un fluide hydrocarboné dans une cavité de résonance WO2015142330A1 (fr)

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US11187044B2 (en) 2019-12-10 2021-11-30 Saudi Arabian Oil Company Production cavern
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EP3953992A4 (fr) * 2019-04-05 2022-12-14 Pyrowave Inc. Coupleur pour systèmes de pyrolyse à micro-ondes
CN115639222A (zh) * 2022-12-22 2023-01-24 河北科技大学 变频微波和uv协同处理有机污染物评价方法及评价装置
US11619097B2 (en) 2021-05-24 2023-04-04 Saudi Arabian Oil Company System and method for laser downhole extended sensing
US11725504B2 (en) 2021-05-24 2023-08-15 Saudi Arabian Oil Company Contactless real-time 3D mapping of surface equipment

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CN115444954A (zh) * 2022-09-22 2022-12-09 四川大学 一种电磁场分布调节装置、微波加热装置以及加热方法
CN115444954B (zh) * 2022-09-22 2023-10-13 四川大学 一种电磁场分布调节装置、微波加热装置以及加热方法
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