WO2023178410A1

WO2023178410A1 - Cavitation apparatus and related systems and methods

Info

Publication number: WO2023178410A1
Application number: PCT/CA2023/000006
Authority: WO
Inventors: Michael Turner; Kord YOUNG
Original assignee: Base Element Energy Inc.
Priority date: 2022-03-25
Filing date: 2023-03-22
Publication date: 2023-09-28

Abstract

Cavitation apparatuses are provided. The cavitation apparatus is configured to cavitate a feedstream of crude oil in the presence of an activated hydrogen-donor gas. Also provided are related systems and methods for upgrading crude oil. Embodiments of the system comprise the cavitation apparatus and a gas activating unit for generating the activated hydrogen-donor gas. The apparatuses, systems, and methods may partially upgrade heavy and extra-heavy crude oils to facilitate transportation and downstream processing.

Description

CAVITATION APPARATUS AND RELATED SYSTEMS AND METHODS

TECHNICAL FIELD:

[0001] The present disclosure relates to processes for treating hydrocarbons. More particularly, the present disclosure relates to apparatuses and related systems and methods for upgrading crude oil.

BACKGROUND:

[0002] Conventional oil is extracted from “normal" reservoirs using standard methods and technologies. Utilization of non-conventional oil, including heavy and extraheavy oils, together with conventional oil has also become more common. Heavy and extra-heavy oils are found mainly in Canada and Venezuela, with reserves in the United States and Russia. Sources of heavy and extra-heavy oil in Western Canada include bituminous oil from oil sands and SAGD (Steam Assisted Gravity Drainage) operations. Other sources include shale oil, bottoms from crude oil atmospheric and vacuum distillation, cycle oil, and coal- and tar-derived liquids.

[0003] Crude oil comprises light and heavy compounds, including straight and branched chain hydrocarbons, cyclic saturated and unsaturated hydrocarbons, polycyclic aromatics, polar compounds, asphaltenes, and heavy metals. Compared to conventional oils, heavy and extra-heavy crude oils have higher molecular weight hydrocarbon compositions with elevated asphaltene content. Heavy crude oil is also distinguished from conventional and light oil by its higher density and viscosity. All grades of oil, depending on where they are extracted from, typically also contain heteroatoms such as sulfur, nitrogen, and oxygen compounds.

[0004] Heavy oils undergo upgrading (or bitumen refining) to be converted into usable products. Prior to upgrading, the heavy crude oil or bitumen must first be transported from the oilfields to an upgrader or refinery facility, typically via pipelines. To ensure the crude oil flows through the pipeline at low temperatures, the oil must meet certain pipeline specifications for total water content and maximum viscosity and density. However, heavy oil and bitumen typically do not meet these specifications, particularly for viscosity.

[0005] One option to increase flowability of heavy oil or bitumen is the addition of diluent In this technique, lower-density hydrocarbon (e.g. light oil or natural gas condensate) is admixed with the heavy oil or bitumen to reduce the mixture viscosity. However, the diluent that is used for heavy oil transport can be expensive, scarce (at times), and can take up to 30% of pipeline capacity.

[0006] Alternatively, full or partial upgrading technologies can be used to reduce density and viscosity of heavy and extra-heavy oils to facilitate transportation and processing. However, upgrading technologies are typically expensive and require large- scale, capital-intensive facilities.

SUMMARY:

[0007] In one aspect, there is provided a cavitation apparatus comprising: an inlet member comprising a plurality of ports and a plurality of pressure reduction nozzles, each pressure reduction nozzle received in a respective port; a cavitation housing comprising a cavitation chamber, the cavitation housing coupled to the inlet member such that the plurality of pressure reduction nozzles extends into the cavitation chamber; a gas feed member comprising a gas outlet, the gas feed member coupled to the cavitation housing such that the gas outlet extends into the cavitation chamber; and wherein a feedstream is introduced into the cavitation chamber via the pressure reduction nozzles to induce cavitation thereof while an activated hydrogen-donor gas is fed into the cavitation chamber via the gas outlet.

[0008] In some embodiments, the cavitation chamber comprises a main portion proximate the Inlet member and a throat portion proximate the gas feed member, the throat portion narrower than the main portion.

[0009] In some embodiments, the pluraity of ports and the plurality of pressure reduction nozzles comprise six port and six pressure reduction nozzles. [0010] In some embodiments, the gas outlet comprises a dispersion nozzle.

[0011] In some embodiments, the apparatus further comprises a mixing valve assembly downstream of the cavitation housing.

[0012] In some embodiments, the mixi ng valve assembly comprises a first conduit defining a first mixing passage and a second conduit defining a second mixing passage.

[0013] In some embodiments, each of the first conduit and the second conduit comprises a respective rough inner surface.

[0014] In another aspect, there is provided a gas activating unit for generating an activated hydrogen-donor gas from a supply gas; and a cavitation apparatus for inducing cavitation of the crude oil, the cavitation apparatus in fluid communication with the gas activating unit to receive the activated hydrogen- donor gas therefrom.

[0015] In some embodiments, the cavitation apparatus is an embodiment of the cavitation apparatus disclosed herein.

[0016] In some embodiments, the primary catalyst reactor further comprises a pair of electrical probes operatively connectable to a power source, the pair of electrical probes in contact with the primary catalyst.

[0017] In some embodiments, at least one of the primary catalyst and the secondary catalyst comprises tourmaline.

[0018] In some embodiments, the primary catalyst comprises black tourmaline, magnesium tourmaline, and spinel.

[0019] In some embodiments, the secondary catalyst comprises black tourmaline, magnesium tourmaline, and sodium silicate.

[0020] In some embodiments, at least one of the primary catalyst and the secondary catalyst is formed into a ball. [0021] In some embodiments, the system further comprises a scrubber for scrubbing the supply gas, the scrubber upstream of the heater.

[0022] In another aspect, there is provided a method for upgrading crude oil, comprising: generating an activated hydrogen-donor gas; and cavitating the crude oil in the presence of the activated hydrogen-donor gas.

[0023] In some embodiments, the method further comprises mixing the cavitated crude oil with the activated hydrogen-donor gas.

[0024] In some embodiments, the activated hydrogen-donor gas is generated from propane.

[0025] In some embodiments, the crude oil comprises heavy crude oil or extraheavy crude oil.

[0026] Other aspects and features of the present disclosure will become apparent, to those ordinarily skilled in the art, upon review of the following description of specific embodiments of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS:

[0027] Some aspects of the disclosure will now be described in greater detail with reference to the accompanying drawings. In the drawings:

[0028] Figure 1 is a perspective view of an example cavitation apparatus, according to some embodiments;

[0029] Figure 2 is a partial side view of the cavitation apparatus of Figure 1 ;

[0030] Figure 3 is a top view of an inlet flange of the cavitation apparatus of Figure

1;

[0031] Figure 4 is a flow diagram of an example system for upgrading crude oil according to some embodiments; [D032] Figure 4A is a further detailed flow diagram of an upstream end of the system of Figure 4;

[0033] Figure 4B is a further detailed flew diagram of a downstream end of the system of Figure 4;

[0034] Figure 5 is a flowchart of an example method for upgrading crude oil, according to some embodiments;

[0035] Figure 6 and Figures 7A and 7B are photos of an example gas activating unit and cavitation apparatus, respectively, used in the experiments described herein;

[0036] Figure 8 and Figures 9A and 9B are photos of another example gas activating unit and cavitation apparatus;

[0037] Figure 10 is a side view schematic of another example cavitation apparatus, indicating measurement points used in the experiments described herein;

[0038] Figure 11 is a graph showing standard density (kg/m³) of untreated oil (sample S1) compared to treated oil (samples S2-S5);

[0039] Figure 12 is a graph showing oil viscosity (Cst) vs. temperature (°C) for samples S1-S5;

[0040] Figure 13 is a graph showing total sulfur content (wt%) for samples S1-S5;

[0041] Figure 14 is a graph showing total add number (TAN; mg/gr.) for samples

S1-S5;

[0042] Figure 15 is a graph showing basic water and sediment (BS&W; wt%) for samples S1-S5;

[0043] Figure 16 is a graph showing boiling temperature (°C) vs. distillate recovery (vol%), according to ASTM D86, for samples S1-S5;

[0044] Figure 17 is a graph showing the trend lines of the data points of Figure 16; [0045] Figure 18 is a graph showing naphtha yield (vol%) for samples S1-S5, where the data is corrected to 1 atmosphere;

[0046] Figure 19 is a graph showing the residue yield (vol%) for samples S1-S5, where the data is corrected to 1 atmosphere;

[0047] Figure 20 is a graph showing oil fraction yield (vol%) of residue, gas oil, kerosene, and naphtha for samples S1 -S5;

[0048] Figure 21 is a graph comparing the oil fraction yields (vol%) of Figure 20 for samples S1 and S5; and

[0049] Figures 22 to 24 show the mass balance for samples S3, S4, and S5, respectively, before and after cavitation.

DETAILED DESCRIPTION:

[0050] Generally, the present disdosure provides a cavitation apparatus. The cavitation apparatus is configured to cavitate a feedstream of crude oil in the presence of an adivated hydrogen-donor gas. Also provided herein are related systems and methods for upgrading crude oil. Embodiments of the system comprise the cavitation apparatus and a gas activating unit for generating the adivated hydrogen-donor gas. The apparatuses, systems, and methods disdosed herein may partially upgrade heavy and extra-heavy crude oils to facilitate transportation and downstream processing.

[0051] As used herein the terms "a," "an," and "the" may indude plural referents unless the context clearly dictates otherwise.

[0052] As used herein, “coupled" or “engaged" means diredly or indiredly, permanently or temporarily joined, attached, adhered, affixed, or bonded.

[0053] As used herein, “upstream" and “downstream" refer to the diredion of the flow of fluids through embodiments of the apparatuses and systems described herein. Under normal operating conditions, fluids flow from an upstream position to a downstream position. [0054] It is is to be understood that directional or relative terms such as “vertical", “horizontal", “upper", “lower", “side", “top", “bottom" and the like are used for ease of description and illustrative purposes, and embodiments are not limited to a particular orientation of the apparatuses and systems described herein during use or normal operation.

[0055] As used herein, “feedstream" or “raw oil" are both used to refer to a liquid to be upgraded by the apparatuses and systems disclosed herein. The feedstream may comprise crude oil. As used herein, “crude oil" refers to petroleum extracted from an earth formation and in a substantially unrefined form. The crude oil may be heavy or extraheavy crude oil. Heavy crude oil is defined as crude oil with standard density of greater than about 930 kg/m³ (gravity of less than 20° API). Extra-heavy erode oil is defined as crude oil with standard density greater than 1000 kg/m³ (or gravity of less than 10° API). Bitumen is categorized as extra-heavy oil due to its density of less than 10° API.

[0056] As used herein, “upgrading" refers to changing the structure of the hydrocarbons of crude oil in such a way as to improve one or more properties of the oil including, but not limited to, reducing viscosity and/or density, increasing API gravity, decreasing the amount of impurities (e.g. sulfur, nitrogen, metals, etc.), decreasing the amount of asphaltenes, increasing the light hydrocarbon fractions, etc. “Full" upgrading transforms the erode oil into high quality light oil (e.g. synthetic erode oil “SCO") while “partial" upgrading improves the quality of the oil enough to facilitate transportation and downstream processing.

[0057] An example cavitation apparatus 100 will be discussed with reference to Figures 1 to 3.

[0058] Referring to Figures 1 and 2, the apparatus 100 has a first (inlet) end 103, a second (outlet) end 105, and extends approximately along a longitudinal axis 101. In this embodiment, the apparatus 100 comprises an inlet member 102, a cavitation housing 104, a gas feed member 106, and a mixing valve assembly 108. In Figure 2, the cavitation housing 104, the gas feed member 106, and the mixing valve assembly 108 are shown as transparent for illustrative purposes only. [0059] The inlet member 102 defines the first end 103 of the apparatus 100. The inlet member 102 is configured to receive a feedstream and introduce the feedstream into the cavitation housing 104. The inlet member 102 may comprise an inlet flange 110 and an annular flange 112. The inlet flange 110 is approximately circular or disc-shaped. The annular flange 112 is approximately ring-shaped with a central hole therethrough (not shown). The inlet flange 110 may be attached to the annular flange 112 by bolts 114 or any other suitable attachment elements.

[0060] In this embodiment, the inlet flange 110 and the annular flange 112 each have an outer diameter of about 12 inches (-30.5 cm). In other embodiments, the inlet flange 110 and the annular flange 112 may be any other suitable size. It will be understood that the dimensions disclosed herein are provided as examples only and embodiments are not limited to specific dimensions. It will also be understood that the apparatus 100 can be scaled up or down in size while maintaining the same overall function.

[0061] The inlet member 102 comprises a plurality of inlet ports therethrough. In this embodiment, the inlet flange 110 comprises six inlet ports 116 (visible in Figure 3) machined therethrough. The inlet ports 116 are radially spaced from the center 115 of the inlet flange 110 and are spaced circumferentially evenly from one another (e.g. about 60° apart). In some embodiments, the inlet ports 116 are approximately 1/2 inch (-1.3 cm) in diameter. In other embodiments, the inlet ports 116 are any other suitable size. The inlet ports 116 axially align with the central bore of the annular flange 112.

[0062] The inlet member 102 further comprises a plurality of pressure reduction nozzles to reduce the pressure of the feedstream entering the cavitation housing 104 and induce cavitation. As used herein, “pressure reduction nozzle" is intended to refer to any device having an orifice through which fluid passes, causing a drop in pressure. In this embodiment, the inlet member comprises six pressure reduction nozzles 118 (three of the nozzles 118 are visible in Figure 2). Each pressure reduction nozzle 118 is received within a respective inlet port 116 in the inlet flange 110. In some embodiments, each pressure reduction nozzle 118 has a diameter of about 1/4-inch (-0.6 cm). The nozzles 118 extend from the inlet member 102 into the cavitation housing 104. [0063] In other embodiments, the pressure of the feedstream may be reduced by at least one venturi, control valve, or any other suitable pressure reducing means.

[0064] Referring to Figure 2, the cavitation housing 104 has a first (inlet) end 107 and a second (outlet) end 109. The first end 107 is coupled to the annular flange 112 of the inlet member 102 and the second end 109 is coupled to the gas feed member 106. The cavitation housing 104 defines a cavitation chamber 120 therein in which cavitation of the feedstream occurs. The housing 104 in this embodiment is approximately conical or tapered in shape such that the diameter at the second end 109 is narrower than the diameter at the first end 107.

[0065] The housing 104 may comprise a first concentric reducer 122 and a second concentric reducer 124. The first concentric reducer 122 is at the first end 107 and defines a first (main) portion 126 of the chamber 120. In this embodiment, the first concentric reducer 122 has a maximum diameter at the first end 107 of about 12 inches (-30.5 cm) and narrows to a minimum diameter of about 6 inches (-15.2 cm). The second concentric reducer 124 extends from the first concentric reducer 122 to the second end 109 of the housing 104 and defines a second (throat) portion 128 of the chamber 120. The second concentric reducer 124 has a maximum diameter of about 6 inches (-15.2 cm) where it connects to the first concentric reducer 122 and narrows to a minimum diameter of about 2 inches (-5.1 cm) at the second end 109 of the housing 104.

[0066] The pressure reduction nozzles 118 of the inlet member 102 extend into the first concentric reducer 122 and thus the main chamber portion 126. In some embodiments, the first concentric reducer 122 comprises an upper port 130. The upper port 130 may be configured to receive a sensor therein (not shown), such as a temperature and/or pressure sensor. The sensor may be used to monitor the conditions within the cavitation chamber 120. The first concentric reducer 122 may also comprise a lower port (not shown) opposite to the upper port 130. The lower port may be used as a drain to empty the cavitation chamber 120 if needed.

[0067] The gas feed member 106 is coupled to the cavitation housing 104. In this embodiment, the gas feed member 106 is coupled to the second concentric reducer 124. The gas feed member 106 is configured to feed an activated hydrogen-donor gas into the throat portion 128 of the cavitation chamber 120. The gas feed member 106 may comprise a pipe tee 132 or any other suitable structure. The pipe tee 132 comprises a fluid passage 133 therethrough and a lateral branch 135. The fluid passage 133 fluidly connects the cavitation chamber 120 to the mixing valve assembly 108 described below. The lateral branch 135 is coupled to a flange 137.

[0068] The gas feed member 106 further comprises a gas injection device 134. The gas injection device 134 comprises a conduit 136 and a gas outlet 138 at the end of the conduit 136. The conduit 136 is mounted through the flange 137 and extends into the fluid passage 133 of the pipe tee 132 via the lateral branch 135. The conduit 136 in this embodiment is approximately L-shaped such that the gas outlet 138 extends into the throat portion 128 of the cavitation chamber 120. The gas outlet 138 may comprise a nozzle, such as a dispersion nozzle.

[0069] The gas feed member 106 is coupled to the mixing valve assembly 108. In this embedment, the gas feed member 106 is coupled to the mixing valve assembly 108 via a connection member 140. The connection member 140 may comprise a flange 145. In other embodiments, the gas feed member 106 may be coupled to the mixing valve assembly 108 by any other suitable coupling means.

[0070] The mixing valve assembly 108 has a first (inlet) end 111 and a second (outlet) end 113. The mixing valve assembly 108 is configured to mix the fluid flowing from the cavitation chamber 120 to form a stabilized solution, as described in more detail below. The mixing valve assembly 108 may comprise a branched conduit comprising two mixing passages. The assembly 108 in this embodiment comprises a first mixing conduit 142 comprising a first mixing passage 150 and a second mixing conduit 144 comprising a second mixing passage 152. The first and second mixing conduits 142 and 144 are fluidly connected at the first end 111 by a first pipe tee 146 and fluidly connected at the second end 113 by a second pipe tee 148.

[0071] The first mixing conduit 142 has an outer surface 141 and an inner surface 143. The inner surface 143 defines the first mixing passage 150. The first mixing passage 150 extends through the first mixing conduit 142 from the first pipe tee 146 to the second pipe tee 148. The inner surface 143 has a rough finish that creates friction for fluids flowing therethrough to increase homogenization. The first mixing conduit 142 may be made of stainless steel and the rough finish may be provided on the stainless steel itself. The first mixing conduit 142 in this embodiment has a diameter of about 1 inch and a longitudinal length of about 24 inches. The second mixing conduit 144 is similar in structure and dimension to the first mixing conduit 142 and may also have a rough inner surface.

[0072] The second end 113 of the mixing valve assembly 108 is coupled to an outlet member 154. In this embodiment, the outlet member 154 comprises an outlet flange 156. The outlet flange 156 is configured to release the treated fluid from the apparatus 100 to a suitable downstream fluid conduit or container (not showi).

[0073] All of the components of the apparatus 100 may be comprised of a non- conductive material so as not to lose energy from the cavitation fluids to the material of the apparatus. The non-conductive material may comprise stainless steel or another suitable material.

[0074] In operation, a liquid feedstream is pumped to the apparatus 100 at an elevated pressure by an upstream feed pump (discussed in more detail below) and enters the apparatus 100 via the Inlet member 102. The feedstream flews through the pressure reduction nozzles 118, causing the static pressure of the liquid to decline below the vapor pressure, thereby inducing cavitation in the main portion 126 of the cavitation chamber 120. Cavitation bubbles (cavities) are formed and then implode as pressure rises. The implosion of the bubbles releases an enormous amount of energy, which is liberated into the surrounding liquid. The released energy forms shock waves with localized high pressures and temperatures that reduce large hydrocarbon molecules into smaller hydrocarbon molecules.

[0075] As cavitation is occurring, an activated hydrogen-donor gas is introduced into the throat portion 128 of the cavitation chamber 120 via the gas outlet (e.g. dispersion nozzle) 138. The smaller hydrocarbon molecules will bond with hydrogen atoms of the activated hydrogen donor gas. This bonding causes the cavitation pressure to recover to above the vapor pressure, thereby forming liquid droplets.

[0076] The liquid droplets flow through the throat portion 128 of the cavitation chamber 120 and into the mixing valve assembly 108 via the fluid passage 133 of the pipe tee 132. As the liquid droplets flow through the first and second mixing passages 150 and 152 of the first and second mixing conduits 142 and 144, respectively, vertical force is transformed into centrifugal force such that the droplets follow an approximately helical (i.e., “corkscrew") flow path. The centrifugal force continuously disrupts the formation of large particles, thereby homogenizing the liquid droplets and the activated hydrogen-donor gas to form a stabilized solution. The rough finish of the interior of the mixing conduits 142, 144 increases friction in order to increase homogenization. The stabilized solution leaves the mixing valve assembly and flows out of the apparatus 100 via the outlet member 154.

[0077] Thus, the apparatus 100 uses cavitation in the presence of an activated hydrogen-donor gas to convert heavy and extra-heavy oils and bitumen to lighter hydrocarbons. Cavitation is a more environmentally friendly alternative to solvent dilution or thermal treatments that are conventionally used to treat heavy oils to reduce viscosity and enhance flowability. Compared to conventional treatments, cavitation can be performed under near-ambient conditions without the addition of external energy.

[0078] Figures 4, 4A and 4B are flow diagrams of an example system 200 for upgrading crude oil, according to some embodiments. The system 200 in this embodiment comprises the cavitation apparatus 100 of Figures 1 and 2 and a gas activating unit 202.

[0079] The gas activating unit 202 is in fluid communication with the cavitation apparatus 100 and Is configured to generate an activated hydrogen-donor gas from a supply gas. The supply gas may comprise propane or any other suitable gas. Other potential supply gases may include methane, ethane, butane, natural gas and/or any other suitable gas. In some embodiments, the supply gas is supplied to the gas activating unit 202 at a pressure of about 50 psi (about 345 kPa), a flow rate of about 24 kg/hr (about 13 Sm³/hr) and a temperature of about 25°C (about 77°F).

[0080] The gas activating unit 202 in this embodiment comprises a scrubber 206, a heater 208, a primary catalyst reactor 210 (also referred to as a reformer reactor 210), and a secondary catalyst reactor 212 (also referred to as a catalyst bed 212).

[0081] The scrubber 206 is configured to receive the supply gas and scrub (i.e. remove) liquid and/or other contaminants therefrom. The scrubber 206 may be in fluid communication with a gas source via a feed pimp (not shown). In this embodiment, the scrubber 206 fluidly connected to the feed pump via a fluid line 205. As used herein, “fluid line" will be understood to include one or more pipes, hoses, ducts, tubes, conduits, channels, or the like, in any suitable size, shape, or configuration. An emergency shut down valve (ESDV) 214 and a pressure regulator 216 may optionally be installed on the fluid line 205. The ESDV 214 is configured to dose and automatically cut off the flow of gas to the gas activating unit 202 in an emergency situation if needed. The liquid or other contaminants scrubbed from the supply gas may be dispensed through a fluid line 207 to a drain 209.

[0082] The heater 208 is in fluid communication with the scrubber 206 to receive scrubbed gas therefrom. The heater 208 may be fluidly connected to the scrubber 206 via a fluid line 211. The heater 208 is configured to pre-heat the scrubbed gas. For example, the heater 208 may heat the scrubbed gas to about 80°C (about 176°F). In this embodiment, the heater 208 comprises an inline electric heater operatively connected to a power source 218. In other embodiments, the heater 208 comprises any other suitable type of heater.

[0083] The primary catalyst reactor 210 is in fluid communication with the heater 208 to receive pre-heated gas therefrom. The primary reactor 210 may be fluidly connected to the heater 208 via a fluid line 213. The primary reactor 210 is configured to contain a first (primary) catalyst The primary reactor 210 may comprise a suitable canister to contain the primary catalyst. In some embodiments, the canister is fitted with devices (not shown) to continuously monitor pressure, differential pressure and/or internal canister temperature.

[0084] The primary catalyst may comprise a first infrared (IR)-emitting material to radiate the molecules of the pre-heated gas. The first IR-emitting material may comprise tourmaline. Tourmaline crystal is nearly a triangle columnar and its crystallization ends have nature positive and negative polarities, piezoelectric, and pyroelectric properties. In this embodiment, the first IR-emitting material comprises a mixture of black tourmaline, magnesium tourmaline, and spinel. Each of the black tourmaline, magnesium tourmaline, and spinel may be present in approximately equal amounts and the mixture may be ground into a fine powder. The fine powder may be formed into an approximately spherical ball, for example, by mixing the fine powder with day and ceramic powder. In some embodiments, about 65% fine powder is mixed with approximately equal amounts of day and ceramic powder.

[0085] The primary catalyst reactor 210 may further comprise a pair of electrical probes 220 received within the canister in contact with the first catalyst. The pair of probes 220 comprises a positive probe and a negative probe. The positive and negative probes may be axially spaced from one another and extend inwards from opposite sides of the canister. In some embodiments, each of the probes 220 is an approximately 6-inch stainless steel probe and the probes are spaced about 2 inches apart. The probes 220 are operatively connected to a power supply (not shown). In this embodiment, the power supply is a 24V DC power supply. The probes 220 may apply an electric field to the first catalyst to increase infrared radiation emitted therefrom.

[0086] The secondary catalyst reactor 212 is in fluid communication with the primary catalyst reactor 210 to received radiated gas therefrom. The secondary catalyst reactor 212 may be fluidly connected to the primary catalyst reactor 210 via a fluid line 215. The secondary reactor 212 is configured to contain a second (secondary) catalyst (not shown). The secondary reactor 212 may comprise a suitable canister to contain the secondary catalyst. Similar to the primary reactor 210, the canister may optionally be fitted with devices (not shown) to continuously monitor pressure, differential pressure and/or internal canister temperature.

[0087] The secondary catalyst may comprise a second IR-emitting material to further radiate the radiated gas from the primary reactor 210. The second IR-emitting material may comprise tourmaline. In this embodiment, the second IR-emitting material comprises a mixture of black tourmaline, magnesium tourmaline, and sodium silicate. Each of the black tourmaline, magnesium tourmaline, and sodium silicate may be present in approximately equal amounts and the mixture may be ground into a fine powder. The fine powder may be formed into an approximately spherical ball, for example, by mixing the fine powder with day and ceramic powder. In some embodiments, about 75% fine powder is mixed with approximately equal amounts of day and ceramic powder.

[0088] The cavitation apparatus 100 is in fluid communication with the secondary reactor 212 and receives radiated gas (i.e. the activated hydrogen-donor gas) therefrom. The cavitation apparatus 100 may be fluidly connected to the secondary reactor 212 via a fluid line 217. A control valve on the fluid line 217 may be used to control the flow of gas into the cavitation apparatus 100. Optionally, an ESDV 222 is installed on the fluid line 217 to cut off the flow of radiated gas to the apparatus 100 if needed.

[0089] In this embodiment, the fluid line 217 is fluidly connected to the gas injection device 134 such that the radiated gas Is Introduced Into the cavitation chamber 120 via the gas outlet (e.g. dispersion nozzle) 138. The radiated gas may be injected into the cavitation chamber 120 at a pressure of about 50 psi and the cavitation apparatus 100 may have a maximum operating pressure of about 25 to about 31 psi.

[0090] The cavitation apparatus 100 is also configured to receive a feedstream of crude oil to be upgraded (e.g. heavy oil or extra-heavy oil). In this embodiment, the cavitation apparatus 100 Is In fluid communication with a feed tank 224 via at least one feed charge pump 226.

[0091] The feed tank 224 is configured to contain a suitable volume of feedstream/raw oil. In some embodiments, the feed tank 224 maintains a fluid level 225 above the fluid line 219. The feed tank 224 may be operatively connected to a heating device 228 to pre-heat the feedstream. In this embodiment, the heating device 228 is a gas-powered tank immersion heater. In other embodiments, the heating device 228 may be any other suitable device for heating the raw oil. The feedstream is pre-heated to a suitable temperature to reduce the oil viscosity to ensure flowability to the pump(s) 226. For example, the feedstream may be pre-heated up to about 50°C.

[0092] The feed charge pumps 226 are in fluid communication with the feed tank 224 to receive the feedstream therefrom. For example, the pumps 226 may be fluidly connected to the feed tank 224 by one or more fluid lines 219. At standard operating conditions, the feedstream received by the pumps 226 may have a flow rate of about 220 L/min (about 2000 bpd = 317 m³/d), standard density of between about 900 to about 970 kg/m³, a viscosity of up to about 200 cP, a water content of up to about 3 vol%, a temperature up to about 50°C, and a pressure up to about 100 kpag (15 psig). In some embodiments, these parameters may be altered within a suitable range based on experimental results.

[0093] The feed charge pumps 226 are configured to raise the pressure of the preheated feedstream and deliver the pressurized feedstream to the cavitation apparatus 100. As one example, each feed charge pump 226 may have a design flow of about 14 m³/hr (220 L/min) and about 1400 psi (9660 kPa) differential pressure, with an estimated installed motor of about 100-150 hP. In some embodiments, a pressure safety valve (PSV; not shown) is provided on the immediate discharge of each pump 226. The PSV may be set to a suitable pressure (e.g. 1600 psig, 11 ,000 kPag) to protect the downstream fluid lines.

[0094] The pumps 226 may be fluidly connected to the cavitation apparatus 100 via a common outlet line 221 and individual feed lines (not shown) that connect to the inlet flange 110. The pumps 226 may introduce the feedstream into the cavitation apparatus 100, via the feed lines, at a pressure of about 1200-1250 psi. As the pressurized feedstream passes through the pressure reduction nozzles 118, the pressure is reduced, thereby inducing cavitation as described above. The treated oil exiting the apparatus 100 may have a pressure of about 30 kPa (5 psig) or less and a flow rate of about 220 L/min (2000 bpd = 317 m³/d ).

[0095] An ESDV 230 may be installed on the common outlet line 221 to cut off feedstream flow to the apparatus 100 if needed. The fluid lines 219 and 221 may be comprised of carbon steel up to an intake flange 231 upstream of the cavitation device 100. Downstream of the flange 231 , the fluid lines and the cavitation apparatus 100 itself are comprised of non-conductive material, such as stainless steel, so as not to lose energy to the carbon of the carbon steel. Similarly, the primary and secondary catalyst reactors 210 and 212 of the gas activating unit 202 and their associated fluid lines may also be made of stainless steel for the same reason.

[0096] The cavitation apparatus 100 is also in fluid communication with a downstream upgraded oil storage tank 232. In this embodiment, the cavitation apparatus is fluidly connected to the storage tank 232 via a fluid line 223. The storage tank 232 is configured to receive the treated oil from the cavitation apparatus 100 and store the treated oil for transportation to downstream applications. In some embodiments, a flow meter (not shown), such as a Coriolis flow meter, is provided immediately downstream of the cavitation apparatus 100 to measure volume, mass, flow, and/or density of the treated oil. In some embodiments, the treated oil is degassed by passage through a separator 280 to remove excess hydrogen gas prior to storage.

[0097] The system 200 may operate as follows. A feedstream from the feed tank 224 is pumped to the cavitation device 100 via the feed charge pumps 226. As the feedstream enters the cavitation chamber 120 via the pressure reduction nozzles 118, cavitation occurs as described above to break the bonds of larger hydrocarbon molecules into smaller hydrocarbon molecules.

[0098] Approximately concurrently, supply gas (e.g. propane) Is supplied to the gas activating unit 202. The supply gas is scrubbed by the scrubber 206 to remove liquid and other contaminants and the scrubbed gas is pre-heated via the heater 208. Pre-heating the gas adds thermal energy such that the reactant molecules orient themselves in preparation for the primary catalyst. The pre-heated gas flows to the primary catalyst reactor 210 where it contacts the primary catalyst in the presence of an electric field generated by the probes 220. The infrared wavelengths (e.g. between about 2.5 to about 50 pm) of the energized primary catalyst will enhance the vibration of the gas molecules and strengthen their molecular rotation. Thus, the internal energy of the radiated gas molecules will be substantially increased.

[0099] The radiated gas is then received into the secondary catalyst reactor 212 where it contacts the secondary catalyst. The radiated gas will absorb higher energy wavelengths as it contacts the secondary catalyst, which further excites the hydrogen molecules. The addition of infrared radiation from the secondary catalyst to the gas changes the interfacial tension of the molecules.

[0100] The radiated gas (i.e. the activated hydrogen-donor gas) flows out of the secondary reactor 212 of the gas activating unit 202 and is injected into the cavitation chamber 120 of the cavitation apparatus 100 where it releases high amounts of absorbed energy to the surrounding cavitated oil droplets. The high-energy wavelengths carried by the radiated gas can be used to activate and excite molecules to assist in the bonding process. As described above, the oil droplets and gas flow through the mixing valve assembly 108 to provide a stabilized, substantially homogenous product. The final treated product flows out of the cavitation apparatus 100 and is stored in the storage tank 232 for transportation and/or use in downstream applications.

[0101] As described in the Examples below, the treated oil may have a viscosity about 50% or less of the raw oil and the standard density of the treated oil may be about 30 to about 50 kg/m³ less than that of the raw oil. The treated oil may also have lower sulfur content, TAN (total add number), and BS&W (basic sediment and water) as well as improved distillation characteristics (e.g. more light ends/less residue) compared to the raw oil. The treated oil may also have a larger volume due to the reduction in density.

[0102] Therefore, embodiments of the apparatuses and systems disclosed herein enable at least partial upgrading of heavy and extra-heavy crude oils to lighter hydrocarbons. The apparatuses and systems have compact designs with relatively small footprints with electric power as the main utility input. [0103] By reducing the viscosity and density of the raw oil, flowability of the oil can be greatly improved, which facilitates transport and downstream processing. The treated oil may meet pipeline specifications while reducing or eliminating the need for diluent. The treated oil may have also enhanced thermal characteristics and light distillate yields and can produce more light hydrocarbon fractions, such as gasoline, kerosine, and middistillate fuel oils. Therefore, partial upgrading using the apparatuses and systems disclosed herein can produce a product with the characteristics of a higher quality oil at a lower cost per barrel than full upgrading or diluent-based methods.

[0104] Other variations of the system 200 are also possible. It will be understood that, although one specific configuration of the system 200 is shown in Figure 4, other configurations are possible and embodiments are not limited to the specific configuration provided herein, including the specific number and placement of fluid line, valves, sensors, etc.

[0105] Figure 5 is a flowchart of a method 300 for upgrading crude oil, according to some embodiments.

[0106] At block 302, an activated hydrogen-donor gas is generated. In some embodiments, the activated hydrogen-donor gas is generated via the gas activating unit 202 of the system 200 as described above, although other means of generating the activated hydrogen-donor gas are also possible. The activated hydrogen-donor gas is generated from a supply gas. The supply gas may comprise propane, for example. The supply gas may be passed through at least one IR-emitting catalyst to absorb high energy wavelengths in order to generate the activated hydrogen-donor gas. In some embodiments, the supply gas is passed through a primary IR-emitting catalyst and a secondary IR-emitting catalyst. In some embodiments, the supply gas is scrubbed and pre-heated prior to passing through the IR-emitting catalyst(s).

[0107] At block 304, the crude oil is cavitated in the presence of the activated hydrogen-donor gas. In some embodiments, the cavitation is performed using the cavitation apparatus 100 as described above. Cavitation may be induced by flowing the crude oil through a constriction (e.g. the pressure reduction nozzles 118) where there is a pressure decline, followed by a subsequent pressure recovery in a cavitation chamber (e.g. the cavitation chamber 120). The activated hydrogen-donor gas is introduced into the cavitation chamber such that it contacts the cavitated oil droplets.

[0108] Although block 304 is shown after block 302 in Figure 5, it will be understood that the steps may be performed substantially concurrently and continuously such that donor gas is introduced into the cavitation apparatus as it is being generated.

[0109] In some embodiments, the method 300 further comprises mixing the cavitated oil and the activated hydrogen-donor gas. For example, the cavitated oil and donor gas may be centrifugally mixed via the mixing valve assembly 108 of the apparatus 100. The treated oil may be degassed to remove any excess donor gas and then the treated oil may be stored and/or transported.

[0110] Without any limitation to the foregoing, the apparatuses, systems, and methods are further described by way of the following examples.

EXAMPLES

Experimental Systems

[0111] Experimental systems were constructed for conducting trials for upgrading crude oil. Figures 6 and 7A/7B are photos of a gas activating unit 402 and a cavitation apparatus 404, respectively, of a first experimental system. Figures 8 and 9A/9B are photos of a gas activating unit 502 and a cavitation apparatus 504, respectively, of a second experimental system. The first and second experimental systems are similar in structure and function to the system 200 of Figure 4 as described above. A schematic of an experimental cavitation apparatus 604 is shown in Figure 10. During experiments, pressure and temperature were monitored at points M3, M4, M5, and M6 indicated on the apparatus 604.

Experimental Protocol

[0112] The untreated oil used as the feedstream had the following characteristics: • Flow rate = 110 L/min = 29 gpm

• Density at Standard Conditions = 933 kg/m³

• Viscosity at 25°C = 160 cSt = 147 cP

• Total Sulfur = 2.27 wt%

• TAN (total add number) = 0.52 mg/gram

• Temperature = about 50°C

• Pressure ratio (Pu/Pd) = 40

[0113] The following sample points were used:

• S1 (raw oil sample point) located at the suction of the raw oil feed pump; and

• S2 (treated oil sample point) located on the line leaving the cavitation device, en route to the product tank.

[0114] With the exception of the sample labeled S1 (raw oil), samples labeled S2- S5 were all taken at sample point S2.

[0115] The cavitation apparatus was operated as described above and activated hydrogen-donor gas was generated from propane via the gas activating unit. Trial runs were conducted with: cavitation-only, no activated hydrogen-donor gas (S2); 0.5% activated hydrogen-donor gas (S3); 0.75% activated hydrogen-donor gas (S4); and 1.0% activated hydrogen-donor gas (S5).

[0116] The samples S1-S5 were analyzed by Nova Analytics Inc.™ using the methods outlined in Table 1 below.

TABLE 1 - Analytical Methods

[0117] The results of the analysis are shown in Figures 11 to 24 in which the treated samples (S2-S5) are compared to the untreated raw oil sample (S1 ). While the cavitation- only treatment (sample S2) improved some properties of the oil compared to S1, much stronger effects were observed for the combination of cavitation in the presence of the activated hydrogen-donor gas (samples S3-S5; hereafter referred to as the “cavitation + gas" treatment). Compared to raw oil, the cavitation + gas treatment was found to reduce the standard density of the oil by about 6-14% (Figure 11) and reduce viscosity by over 10-fold (Figure 12). Samples S3-S5 also showed more than -50% reduction of total sulfur content (Figure 13), about 1.5-15-fold reduction in total add number (TAN; Figure 14) and about 50-80% reduction in BS&W content (Figure 15) compared to S1. [0118] As shown in Figures 16-17, samples 83-85 also show improvements in distillation characteristics. Untreated oil (81) starts to crack at 340°C, with distillate recovery of about 35 vol%. Cavitation + gas treated oil distillate recovery is about 40-45 vol% at 340°C. Thus, the cavitation + gas treatment converts heavy molecules to lighter molecules, reducing the boiling point for the same distillate recovery.

[0119] The cavitation + gas treated samples also showed an about 40-80% increase in naphtha content (Figure 18) and an about 12-25% reduction in residue content (Figure 19). As shown in Figures 20 and 21, samples S3-S5 showed an increase in light fractions and a decrease in residue fractions out of the total oil fraction yield. Figures 22, 23, and 24 show the mass balance for samples S3, S4, and S5, respectively, in and out of the cavitation apparatus.

[0120] Although particular embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the disclosure. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

Claims

CLAIMS:

1. A cavitation apparatus comprising: an inlet member comprising a plurality of ports and a plurality of pressure reduction nozzles, each pressure reduction nozzle received in a respective port; a cavitation housing comprising a cavitation chamber, the cavitation housing coupled to the inlet member such that the plurality of pressure reduction nozzles extends into the cavitation chamber; a gas feed member comprising a gas outlet, the gas feed member coupled to the cavitation housing such that the gas outlet extends into the cavitation chamber; and wherein a feedstream is introduced into the cavitation chamber via the pressure reduction nozzles to induce cavitation thereof while an activated hydrogen-donor gas is fed into the cavitation chamber via the gas outlet.

2. The apparatus of claim 1, wherein the cavitation chamber comprises a main portion proximate the inlet member and a throat portion proximate the gas feed member, the throat portion narrower than the main portion.

3. The apparatus of claim 1 or 2, wherein the plurality of ports and the plurality of pressure reduction nozzles comprise six port and six pressure reduction nozzles.

4. The apparatus of any one of claims 1 to 3, wherein the gas outlet comprises a dispersion nozzle.

5. The apparatus of any one of claims 1 to 4, further comprising a mixing valve assembly downstream of the cavitation housing.

6. The apparatus of claim 5, wherein the mixing valve assembly comprises a first conduit defining a first mixing passage and a second conduit defining a second mixing passage.

7. The apparatus of daim 6, wherein each of the first conduit and the second conduit comprises a respective rough inner surface.

8. A system tor upgrading erode oil, comprising: a gas activating unit for generating an activated hydrogen-donor gas from a supply gas; and a cavitation apparatus for inducing cavitation of the erode oil, the cavitation apparatus in fluid communication with the gas activating unit to receive the activated hydrogen- donor gas therefrom.

9. The system of daim 8, wherein the cavitation apparatus is the cavitation apparatus of any one of daims 1 to 7.

10. The system of claim 8 or 9, wherein the gas activating unit comprises: a heater for pre-heating the supply gas; a primary catalyst reactor containing a primary catalyst; and a secondary catalyst reactor containing a secondary catalyst

11. The system of daim 10, wherein the primary catalyst reactor further comprises a pair of electrical probes operatively connectable to a power source, the pair of electrical probes in contact with the primary catalyst.

12. The system of daim 10 or 11, wherein at least one of the primary catalyst and the secondary catalyst comprises tourmaline.

13. The system of daim 12, wherein the primary catalyst comprises black tourmaline, magnesium tourmaline, and spinel.

14. The system of daim 12 or 13, wherein the secondary catalyst comprises black tourmaline, magnesium tourmaline, and sodium silicate.

15. The system of any one of claims 10 to 14, wherein at least one of the primary catalyst and the secondary catalyst is formed into a ball.

16. The system of any one of claims 8 to 15, further comprising a scrubber for scrubbing the supply gas, the scrubber upstream of the heater.

17. A method for upgrading crude oil, comprising: generating an activated hydrogen-donor gas; and cavitating the crude oil in the presence of the activated hydrogen-donor gas.

18. The method of claim 17, further comprising mixing the cavitated crude oil wth the activated hydrogen-donor gas.

19. The method of claim 18, wherein the activated hydrogen-donor gas is generated from propane.

20. The method of any one of claims 17 to 19, wherein the crude oil comprises heavy crude oil or extra-heavy crude oil.