U.S. patent application number 13/589927 was filed with the patent office on 2013-02-21 for upgrading hydrocarbon material on offshore platforms.
This patent application is currently assigned to MARATHON OIL CANADA CORPORATION. The applicant listed for this patent is Thomas Edward Carter, Mahendra Joshi, Jose Armando Salazar. Invention is credited to Thomas Edward Carter, Mahendra Joshi, Jose Armando Salazar.
Application Number | 20130043033 13/589927 |
Document ID | / |
Family ID | 50150858 |
Filed Date | 2013-02-21 |
United States Patent
Application |
20130043033 |
Kind Code |
A1 |
Salazar; Jose Armando ; et
al. |
February 21, 2013 |
UPGRADING HYDROCARBON MATERIAL ON OFFSHORE PLATFORMS
Abstract
Methods and systems for upgrading hydrocarbon on offshore
platforms are described. Hydrocarbon material can be extracted from
deposits under bodies of water and upgraded on offshore platforms,
such as through the use of one or more nozzle reactors. The
upgraded hydrocarbon material produced by the nozzle reactor, can
than be transported back to shore through pipelines, in part due to
the improved viscosity of the upgraded material.
Inventors: |
Salazar; Jose Armando;
(Reno, NV) ; Joshi; Mahendra; (Katy, TX) ;
Carter; Thomas Edward; (Magnolia, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Salazar; Jose Armando
Joshi; Mahendra
Carter; Thomas Edward |
Reno
Katy
Magnolia |
NV
TX
TX |
US
US
US |
|
|
Assignee: |
MARATHON OIL CANADA
CORPORATION
Calgary
CA
|
Family ID: |
50150858 |
Appl. No.: |
13/589927 |
Filed: |
August 20, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61525515 |
Aug 19, 2011 |
|
|
|
Current U.S.
Class: |
166/335 |
Current CPC
Class: |
C10G 2300/302 20130101;
C10G 1/002 20130101; C10G 1/02 20130101; C10G 1/04 20130101; E21B
43/01 20130101 |
Class at
Publication: |
166/335 |
International
Class: |
E21B 43/013 20060101
E21B043/013 |
Claims
1. An offshore hydrocarbon material recovery and transportation
method comprising: providing an offshore platform adapted for
extracting hydrocarbon material from hydrocarbon deposits located
below the floor of a body of water; extracting hydrocarbon material
from a hydrocarbon deposit located below the floor of a body of
water; collecting the extracted hydrocarbon material on the
offshore platform; upgrading the collected hydrocarbon material on
the offshore platform; and transporting the upgraded hydrocarbon
material through pipelines.
2. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 1, wherein the collected hydrocarbon
material has a viscosity greater than 25000 cSt @ 20 deg C.
3. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 1, wherein upgrading the collected
hydrocarbon material comprises: injecting a stream of cracking
material through a converging then diverging passage of a cracking
material injector into a reaction chamber, wherein passing the
cracking material through the converging then diverging passage
accelerates the cracking material to supersonic speed; and
injecting the collected hydrocarbon material into the reaction
chamber adjacent to the cracking material injector and transverse
to the stream of cracking material entering the reaction chamber
from the cracking material injector and cracking the collected
hydrocarbon material with the injection of the cracking
material.
4. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 3, wherein the collected hydrocarbon
material injecting step includes injecting the collected
hydrocarbon material into the reaction chamber annularly around the
stream of cracking material.
5. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 3, wherein the cracking material is a
cracking gas.
6. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 5, wherein the cracking gas comprises
steam.
7. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 3, wherein the collected hydrocarbon
material comprises bitumen.
8. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 6, wherein the steam is generated by a
method comprising: injecting an air stream and a fuel stream into a
combustor and producing a combustion flame in a combustion chamber;
and injecting atomized water into the combustion chamber and
forming steam.
9. The offshore hydrocarbon material recovery and transportation
method as claimed in claim 1, wherein the upgraded hydrocarbon
material has a viscosity lower than 380 cSt @ 15.5 deg C.
10. A offshore hydrocarbon material recovery and transportation
system comprising: an offshore platform established over a body of
water; and a nozzle reactor established on the offshore
platform.
11. The offshore hydrocarbon material recovery and transportation
system as claimed in claim 10, further comprising: upgraded
hydrocarbon material transportation piping extending from the
offshore platform to land surrounding the body of water.
12. The offshore hydrocarbon material recovery and transportation
system as claimed in claim 10, further comprising: a combustor
adaptable for generating steam to be used in the nozzle
reactor.
13. The offshore hydrocarbon material recovery and transportation
system as claimed in claim 10, wherein the nozzle reactor
comprises: a reactor body having a reactor body passage with an
injection end and an ejection end; a first material injector having
a first material injection passage and being mounted in the nozzle
reactor in material injecting communication with the injection end
of the reactor body passage, the first material injection passage
having (a) an enlarged volume injection section, an enlarged volume
ejection section, and a reduced volume mid-section intermediate the
enlarged volume injection section and enlarged volume ejection
section, (b) a material injection end in material injecting
communication with the combustion chamber, and (c) a material
ejection end in material injecting communication with the reactor
body passage; and a second material feed port penetrating the
reactor body and being (a) adjacent to the material ejection end of
the first material injection passage and (b) transverse to a first
material injection passage axis extending from the material
injection end to the material ejection end in the first material
injection passage in the first material injector.
Description
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/525,515, filed Aug. 19, 2011, the entirety of
which is hereby incorporated by reference.
BACKGROUND
[0002] Offshore oil recovery typically entails recovering heavy oil
from deposits located in the earth below bodies of water such as
oceans, seas, and lakes. Typically, offshore platforms are
established on or above the surface of a body of water and over the
area where drilling and extraction are to take place. The offshore
platforms serves as the base of operations for drilling wells,
running and monitoring the oil extraction process, storing the
successfully extracted material, and initiating the process of
transporting the recovered material back to shore.
[0003] One main issue faced by many offshore platforms relates to
the transportation of the recovered oil back to shore, where the
oil can be subjected to various refinery processes in order to
provide a commercially useful product. In many instances, the oil
recovered from the deposits located below the sea floor is highly
viscous and therefore difficult and expensive to transport back to
shore via pipelines. Additionally, a market penalty is
traditionally applied to oil transported ashore from offshore
platforms that is still in a highly viscous state.
SUMMARY
[0004] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary, and the foregoing
Background, is not intended to identify key aspects or essential
aspects of the claimed subject matter. Moreover, this Summary is
not intended for use as an aid in determining the scope of the
claimed subject matter.
[0005] In some embodiments, an offshore hydrocarbon material
recovery and transportation method is disclosed. The method
includes providing an offshore platform adapted for extracting
hydrocarbon material from hydrocarbon deposits located below the
floor of a body of water;
[0006] extracting hydrocarbon material from a hydrocarbon deposit
located below the floor of a body of water; collecting the
extracted hydrocarbon material on the offshore platform; upgrading
the collected hydrocarbon material on the offshore platform; and
transporting the upgraded hydrocarbon material through pipelines.
In some embodiments, upgrading hydrocarbon material is carried out
using methods and systems described in U.S. Pat. Nos. 7,618,569,
7,927,565, or 7,988,847, or U.S. patent application Ser. No.
13/227,470.
[0007] In some embodiments, an offshore hydrocarbon material
recovery and transportation system is disclosed. The offshore
hydrocarbon material recovery and transportation system includes an
offshore platform established over a body of water and a nozzle
reactor established on the offshore platform. In some embodiments,
the nozzle reactor is similar or identical to the nozzle reactor
described in U.S. Pat. Nos. 7,618,569, 7,927,565, or 7,988,847, or
U.S. patent application Ser. No. 13/227,470. The system can also
include transportation piping for transporting upgraded hydrocarbon
material back to land and a combustor adapted for generating steam
and integrated with the nozzle reactor for providing steam to the
nozzle reactor.
[0008] The above summarized methods and systems can advantageously
provide a mechanism for upgrading collected hydrocarbon material on
the offshore platform, which thereby makes transportation of the
recovered material back to shore easier and more economical. While
previous upgrading technologies could not be carried out on
offshore platforms due to space and material constraints, the use
of the nozzle reactor described herein makes upgrading on the
offshore platform logistically and commercially feasible.
[0009] These and other aspects of the present system will be
apparent after consideration of the Detailed Description and
Figures herein. It is to be understood, however, that the scope of
the invention shall be determined by the claims as issued and not
by whether given subject matter addresses any or all issues noted
in the Background or includes any features or aspects recited in
this Summary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Non-limiting and non-exhaustive embodiments of the present
invention, including the preferred embodiment, are described with
reference to the following figures, wherein like reference numerals
refer to like parts throughout the various views unless otherwise
specified.
[0011] FIG. 1 is flow chart of embodiments of an offshore
hydrocarbon recovery and transportation method described
herein;
[0012] FIG. 2 is a cross-sectional view of a nozzle reactor
suitable for use in embodiments described herein;
[0013] FIG. 3 is a cross-sectional view of a nozzle reactor
suitable for use in embodiments described herein;
[0014] FIG. 4 is a cross-sectional view of a combustor suitable for
use in embodiments described herein;
[0015] FIG. 5 is a block diagram illustrating embodiments of a
hydrocarbon recovery and upgrading system described herein;
[0016] FIG. 6 shows a cross-sectional view of some embodiments of a
nozzle reactor described herein;
[0017] FIG. 7 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 6;
[0018] FIG. 8 shows a cross-sectional perspective view of the
mixing chamber in the nozzle reactor shown in FIG. 6; and
[0019] FIG. 9 shows a cross-sectional perspective view of the
distributor from the nozzle reactor shown in FIG. 6.
DETAILED DESCRIPTION
[0020] With reference to FIG. 1, some embodiments of a method for
offshore hydrocarbon material recovery and transportation method
include a step 1000 of providing an offshore platform adapted for
extracting hydrocarbon material from hydrocarbon deposits located
below the floor of a body of water; a step 1100 of extracting
hydrocarbon material from a hydrocarbon deposit located below the
floor of the body of water; a step 1200 of collecting the extracted
hydrocarbon material on the offshore platform; a step 1300 of
upgrading the collected hydrocarbon material on the offshore
platform; and a step 1400 of transporting the upgraded hydrocarbon
material through pipelines. The method provides a mechanism for
upgrading hydrocarbon material on the offshore platform in order to
make transportation of recovered hydrocarbon back to shore easier
and more economical.
[0021] Step 100 of providing an offshore platform adapted for
extracting hydrocarbon material from hydrocarbon deposits located
below the floor of a body of water can include providing any type
of offshore platform known to those of ordinary skill in the art
for extracting hydrocarbon from deposits located under bodies of
water. Exemplary types of offshore platform platforms that can be
used in embodiments described herein include, but are not limited
to, fixed platforms, compliant towers, sea star platforms, floating
production systems, tension leg platforms, subsea systems, and SPAR
platforms. The offshore platform will generally include all of the
standard equipment necessary for drilling production wells and
extracting bitumen from deposits below the floor of the body of
water. Exemplary equipment that will be included on the offshore
platform includes oil rig, crane, derricks, flame boom, drilling
mud module, process module, etc. In some embodiments, the offshore
platform also includes a nozzle reactor for upgrading extracted
hydrocarbon material on the offshore platform. While space on
offshore platforms is limited, the relatively small size of the
nozzle reactor allows for its inclusion on the offshore platform
with only minor adjustments to the general layout of equipment on
the offshore platform.
[0022] The offshore platform provided in step 100 is positioned
over an area of the floor of the body of water in which deposits of
bituminous material exist. Deposits of bituminous material can be
identified by any techniques known to those of ordinary skill in
the art, including remote sensing, seismic exploration,
magnetotellurics and some other geological and geophysiscs
techniques.
[0023] Step 1100 of extracting hydrocarbon material from a
hydrocarbon deposit located below the floor of the body of water
can be carried out using any hydrocarbon extraction method known to
those of ordinary skill in the art and which can be carried out on
an offshore platform. Generally, the extraction process entails
drilling a well in the deposit below the body of water and then
injecting various materials to aid in the recovery of the
hydrocarbon material. The materials injected into the well help to
lower the viscosity of the hydrocarbon material and cause it to
flow towards the well, where it can then be pumped up to the
offshore platform. Various materials can be used to aid in the
recovery process, including steam and various solvents known to
reduce the viscosity of the hydrocarbon and/or dissolve the
hydrocarbon material.
[0024] The hydrocarbon material extracted from the deposit under
the body of water can include various hydrocarbon components,
including bitumen and asphaltenes. In some embodiments, the
extracted hydrocarbon material will include predominantly heavy
hydrocarbon molecules, including hydrocarbon molecules having a
boiling point temperature above 1,050 F. In some embodiments, the
viscosity of the extracted hydrocarbon material will be greater
than 25000 cSt @ 20 deg C.
[0025] In step 1200, the extracted hydrocarbon material is
collected on the offshore platform. As mentioned above, the
hydrocarbon material that is made to flow towards the drilled wells
can be pumped up to the offshore platform, where it can then be
collected and stored in storage vessels included on the offshore
platforms. Alternatively or in conjunction with storing the
collected hydrocarbon material on offshore platform, the collected
hydrocarbon material can be fed directly into processing equipment
included on the offshore platforms, such as nozzle reactors. In
some embodiments, the processing equipment included on the offshore
platform is designed to have a capacity that matches or exceeds
that rate at which bitumen is extracted and collected on the
offshore platform in order to minimize or eliminate the need for
storage vessels on the offshore platforms.
[0026] In step 1300, the collected hydrocarbon material on the
offshore platform is upgraded on the offshore platform. Any
technique known to those or ordinary skill in the art can be used
to carry out the upgrading of the collected hydrocarbon material.
In some embodiments, the techniques suitable for upgrading will be
limited by space and material constraints on the offshore platform.
Thus, in a preferred embodiment, upgrading is carried out in a
nozzle reactor. Nozzle reactors can be suitable for use on offshore
platforms due to their relatively small size and the ability to
provide materials needed to carry out nozzle reactor upgrading from
process integration and/or through the use of water from the body
of water on which the offshore platform is established.
[0027] In some embodiments, the nozzle reactor provided on the
offshore platform and used to carry out step 1300 is similar or
identical to embodiments of the nozzle reactor described in U.S.
Pat. Nos. 7,618,569, 7,927,565, or 7,988,847, or U.S. patent
application Ser. No. 13/227,470. The nozzle reactor described in
the '597 patent generally receives a cracking material and
accelerates it to a supersonic speed via a converging and diverging
injection passage. Collected hydrocarbon material is injected into
the nozzle reactor adjacent the location the cracking material
exits the injection passage and at a direction transverse to the
direction of the cracking material. The interaction between the
cracking material and the hydrocarbon material results in the
cracking of the hydrocarbon material into a lighter hydrocarbon
material.
[0028] With reference to FIG. 2, a nozzle reactor suitable for use
in embodiments described herein, indicated generally at 10, has an
injection end 12, a tubular reactor body 14 extending from the
injection end 12, and an ejection port 13 in the reactor body 14
opposite its injection end 12. The injection end 12 includes an
injection passage 15 extending into the interior reactor chamber 16
of the reactor body 14. The central axis A of the injection passage
15 is coaxial with the central axis B of the reactor chamber.
[0029] With continuing reference to FIG. 2, the injection passage
15 has a circular diametric cross-section and, as shown in the
axially-extending cross-sectional view of FIG. 2, opposing inwardly
curved side wall portions 17, 19 (i.e., curved inwardly toward the
central axis A of the injection passage 15) extending along the
axial length of the injection passage 15. In certain embodiments,
the axially inwardly curved side wall portions 17, 19 of the
injection passage 15 allow for a higher speed of injection when
passing through the injection passage 15 into the reactor chamber
16.
[0030] In certain embodiments, the side wall of the injection
passage 15 can provide one or more among: (i) uniform axial
acceleration of material passing through the injection nozzle
passage; (ii) minimal radial acceleration of such material; (iii) a
smooth finish; (iv) absence of sharp edges; and (v) absence of
sudden or sharp changes in direction. The side wall configuration
can render the injection passage 15 substantially isentropic. These
latter types of side wall and injection passage 15 features can be,
among other things, particularly useful for pilot plant nozzle
reactors of minimal size.
[0031] A material feed passage or channel 18 extends from the
exterior of the junction of the injection end 12 and the tubular
reactor body 14 toward the reaction chamber 16 transversely to the
axis B of the interior reactor chamber 16. The material feed
passage 18 penetrates an annular material feed port 20 adjacent the
interior reactor chamber wall 22 at the end 24 of the interior
reactor chamber 16 abutting the injection end 12. The material feed
port 20 includes an annular, radially extending chamber feed slot
26 in material-injecting communication with the interior reactor
chamber 16. The material feed port 20 is thus configured to inject
feed material: (i) at about a 90.degree. angle to the axis of
travel of cracking material injected from the injection nozzle
passage 15; (ii) around the entire circumference of a cracking
material injected through the injection passage 15; and (iii) to
impact the entire circumference of the free cracking material
stream virtually immediately upon its emission from the injection
passage 15 into the reactor chamber 16.
[0032] The annular material feed port 20 may have a U-shaped or
C-shaped cross-section among others. In certain embodiments, the
material feed port may be open to the interior reactor chamber 16,
with no arms or barrier in the path of fluid flow from the material
feed passage 18 toward the interior reactor chamber 16. The
junction of the material feed port 20 and material feed passage 18
can have a radiused cross-section.
[0033] In alternative embodiments, the material feed passage 18,
associated feed port 20, and/or injection passage 15 may have
differing orientations and configurations, and there can be more
than one material feed port and associated structure. Similarly, in
certain embodiments the injection passage 15 may be located on or
in the side 23 of the reactor chamber 16 (and if desired may
include an annular cracking material port) rather than at the
injection end 12 of the reactor chamber 16; and the material feed
port 20 may be non-annular and located at the injection end 12 of
the reactor chamber 16.
[0034] In the embodiment of FIG. 2, the interior reactor chamber 16
can be bounded by stepped, telescoping tubular side walls 28, 30,
32 extending along the axial length of the reactor body 14. In
certain embodiments, the stepped side walls 28, 30, 32 are
configured to: (i) allow a free jet of injected cracking material,
such as superheated steam, natural gas, carbon dioxide, or other
material, to travel generally along and within the conical jet path
C generated by the ejection nozzle passage 15 along the axis 13 of
the reactor chamber 16, while (ii) reducing the size or involvement
of back flow areas, e.g., 34, 36, outside the conical or expanding
jet path C, thereby forcing increased contact between the high
speed cracking material stream within the conical path C and feed
material, such as heavy hydrocarbons, injected through the feed
port 20.
[0035] As indicated by the drawing gaps 38, 40 in the embodiment of
FIG. 2, the tubular reactor body 14 has an axial length (along axis
B) that is much greater than its width. In the FIG. 2 embodiment,
exemplary length-to-width ratios are typically in the range of 2 to
4 or more.
[0036] With reference now to FIG. 3 and the particular embodiment
shown therein, the reactor body 44 includes a generally tubular
central section 46 and a frustoconical ejection end 48 extending
from the central section 46 opposite an insert end 50 of the
central section 46, with the insert end 50 in turn abutting the
injection nozzle 52. The insert end 50 of the central section 46
consists of a generally tubular central body 51. The central body
51 has a tubular material feed passage 54 extending from the
external periphery 56 of the insert end 50 radially inwardly to
injectingly communicate with the annular circumferential feed port
depression or channel 58 in the otherwise planar, radially inwardly
extending portion 59 of the axially stepped face 61 of the insert,
end 50. The inwardly extending portion 59 abuts the planar radially
internally extending portion 53 of a matingly stepped face 55 of
the injection nozzle 52. The feed port channel 58 and axially
opposed radially internally extending portion 53 of the injection
nozzle 52 cooperatively provide an annular feed port 57 disposed
transversely laterally, or radially outwardly, from the axis A of a
preferably non-linear injection passage 60 in the injection nozzle
52.
[0037] The tubular body 51 of the insert end SD is secured within
and adjacent the interior periphery 64 of the reactor body 44. The
mechanism for securing the insert end 50 in this position may
consist of an axially-extending nut-and-bolt arrangement (not
shown) penetrating co-linearly mating passages (not shown) in: (i)
an upper radially extending lip 66 on the reactor body 44; (ii) an
abutting, radially outwardly extending thickened neck section 68 on
the insert end 50; and (iii) in turn, the abutting injector nozzle
52. Other mechanisms for securing the insert end 50 within the
reactor body 44 may include a press fit (not shown) or mating
threads (not shown) on the outer periphery 62 of the tubular body
51 and on the inner periphery 64 of the reactor body 44. Seals,
e.g., 70, may be mounted as desired between, for example, the
radially extending lip 66 and the abutting the neck section 68 and
the neck section 68 and the abutting injector nozzle 52.
[0038] The non-linear injection passage 60 has, from an
axially-extending cross-sectional perspective, mating, radially
inwardly curved opposing side wall sections 72, 74 extending along
the axial length of the non-linear injection passage 60. The entry
end 76 of injection passage 60 provides a rounded circumferential
face abutting an injection feed tube 78, which can be bolted (not
shown) to the mating planar, radially outwardly extending distal
face 80 on the injection nozzle 52.
[0039] In the embodiment of FIG. 2, the nozzle passage 60 is a
DeLaval type of nozzle and has an axially convergent section 82
abutting an intermediate relatively narrower throat section 84,
which in turn abuts an axially divergent section 86. The nozzle
passage 60 also has a circular diametric cross-section (i.e., in
cross-sectional view perpendicular to the axis of the nozzle
passage) all along its axial length. In certain embodiments, the
nozzle passage 60 may also present a somewhat roundly curved thick
82, less curved thicker 84, and relatively even less curved and
more gently sloped relatively thin 86 axially extending
cross-sectional configuration from the entry end 76 to the
injection end 88 of the injection passage 60 in the injection
nozzle 52.
[0040] The nozzle passage 60 can thus be configured to present a
substantially isentropic or frictionless configuration for the
injection nozzle 52. This configuration may vary, however,
depending on the application involved in order to yield a
substantially isentropic configuration for the application.
[0041] The injection passage 60 is formed in a replaceable
injection nozzle insert 90 press-fit or threaded into a mating
injection nozzle mounting passage 92 extending axially through an
injection nozzle body 94 of the injection nozzle 52. The injection
nozzle insert 90 is preferably made of hardened steel alloy, and
the balance of the nozzle reactor 100 components other than seals,
if any, are preferably made of steel or stainless steel.
[0042] In the particular embodiment shown in FIG. 2, the narrowest
diameter D within the injection passage is 140 mm. The diameter E
of the ejection passage opening 96 in the ejection end 48 of the
reactor body 44 is 2.2 meters. The axial length of the reactor body
44, from the injection end 88 of the injector passage 60 to the
ejection passage opening 96, is 10 meters.
[0043] The interior peripheries 89, 91 of the insert end 50 and the
tubular central section 46, respectively, cooperatively provide a
stepped or telescoped structure expanding radially outwardly from
the injection end 88 of the injection or injector passage 60 toward
the frustoconical end 48 of the reactor body 44. The particular
dimensions of the various components, however, will vary based on
the particular application for the nozzle reactor, generally 100.
Factors taken into account in determining the particular dimensions
include the physical properties of the cracking gas (density,
enthalpy, entropy, heat capacity, etc.) and the pressure ratio from
the entry end 76 to the injection end 88 of the injector passage
60.
[0044] In certain embodiments having one or more non-linear
cracking gas injection passages, e.g., 60, such as the
convergent/divergent configuration of FIG. 2, the pressure
differential can yield a steady increase in the kinetic energy of
the cracking material as it moves along the axial length of the
cracking gas injection passage(s) 60. The cracking material may
thereby eject from the ejection end 88 of the injection passage 60
into the interior of the reactor body 44 at supersonic speed with a
commensurately relatively high level of kinetic energy. In these
embodiments, the level of kinetic energy of the supersonic
discharge cracking material is therefore greater than can be
achieved by certain prior art straight-through.
[0045] Feed stock is injected into the material feed passage 54 and
then through the mating annular feed port 57. The feed stock
thereby travels radially inwardly to impact a transversely (i.e.,
axially) traveling high speed cracking mateiral (for example,
steam, natural gas, carbon dioxide or other gas not shown)
virtually immediately upon its ejection from the ejection end 88 of
the injection passage 60. The collision of the radially injected
feed stock with the axially traveling high speed steam jet delivers
kinetic and thermal energy to the feed stock. The applicants
believe that this process may continue, but with diminished
intensity and productivity, through the length of the reactor body
44 as injected feed stock is forced along the axis of the reactor
body 44 and yet constrained from avoiding contact with the jet
stream by the telescoping interior walls, e.g., 89, 91 101, of the
reactor body 44. Depending on the nature of the feed stock and its
pre-feed treatment, differing results can be procured, such as
cracking of heavy hydrocarbons, including bitumen, into lighter
hydrocarbons.
[0046] FIGS. 6 and 7 show cross-sectional views of another
embodiment of a nozzle reactor 100 suitable for use in the methods
described herein. The nozzle reactor 100 includes a head portion
102 coupled to a body portion 104. A main passage 106 extends
through both the head portion 102 and the body portion 104. The
head and body portions 102, 104 are coupled together so that the
central axes of the main passage 106 in each portion 102, 104 are
coaxial so that the main passage 106 extends straight through the
nozzle reactor 100.
[0047] It should be noted that for purposes of this disclosure, the
term "coupled" means the joining of two members directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
members or the two members and any additional intermediate members
being integrally formed as a single unitary body with one another
or with the two members or the two members and any additional
intermediate member being attached to one another. Such joining may
be permanent in nature or alternatively may be removable or
releasable in nature.
[0048] The nozzle reactor 100 includes a feed passage 108 that is
in fluid communication with the main passage 106. The feed passage
108 intersects the main passage 106 at a location between the
portions 102, 104. The main passage 106 includes an entry opening
110 at the top of the head portion 102 and an exit opening 112 at
the bottom of the body portion 104. The feed passage 108 also
includes an entry opening 114 on the side of the body portion 104
and an exit opening 116 that is located where the feed passage 108
meets the main passage 106.
[0049] During operation, the nozzle reactor 100 includes a reacting
fluid that flows through the main passage 106. The reacting fluid
enters through the entry opening 110, travels the length of the
main passage 106, and exits the nozzle reactor 100 out of the exit
opening 112. A feed material flows through the feed passage 108.
The feed material enters through the entry opening 114, travels
through the feed passage 106, and exits into the main passage 108
at exit opening 116.
[0050] The main passage 106 is shaped to accelerate the reacting
fluid. The main passage 106 may have any suitable geometry that is
capable of doing this. As shown in FIGS. 6 and 7, the main passage
106 includes a first region having a convergent section 120 (also
referred to herein as a contraction section), a throat 122, and a
divergent section 124 (also referred to herein as an expansion
section). The first region is in the head portion 102 of the nozzle
reactor 100.
[0051] The convergent section 120 is where the main passage 106
narrows from a wide diameter to a smaller diameter, and the
divergent section 124 is where the main passage 106 expands from a
smaller diameter to a larger diameter. The throat 122 is the
narrowest point of the main passage 106 between the convergent
section 120 and the divergent section 124. When viewed from the
side, the main passage 106 appears to be pinched in the middle,
making a carefully balanced, asymmetric hourglass-like shape. This
configuration is commonly referred to as a convergent-divergent
nozzle or "con-di nozzle".
[0052] The convergent section of the main passage 106 accelerates
subsonic fluids since the mass flow rate is constant and the
material must accelerate to pass through the smaller opening. The
flow will reach sonic velocity or Mach 1 at the throat 122 provided
that the pressure ratio is high enough. In this situation, the main
passage 106 is said to be in a choked flow condition.
[0053] Increasing the pressure ratio further does not increase the
Mach number at the throat 122 beyond unity. However, the flow
downstream from the throat 122 is free to expand and can reach
supersonic velocities. It should be noted that Mach 1 can be a very
high speed for a hot fluid since the speed of sound varies as the
square root of absolute temperature. Thus the speed reached at the
throat 122 can be far higher than the speed of sound at sea
level.
[0054] The divergent section 124 of the main passage 106 slows
subsonic fluids, but accelerates sonic or supersonic fluids. A
convergent-divergent geometry can therefore accelerate fluids in a
choked flow condition to supersonic speeds. The
convergent-divergent geometry can be used to accelerate the hot,
pressurized reacting fluid to supersonic speeds, and upon
expansion, to shape the exhaust flow so that the heat energy
propelling the flow is maximally converted into kinetic energy.
[0055] The flow rate of the reacting fluid through the
convergent-divergent nozzle is isentropic (fluid entropy is nearly
constant). At subsonic flow the fluid is compressible so that
sound, a small pressure wave, can propagate through it. At the
throat 122, where the cross sectional area is a minimum, the fluid
velocity locally becomes sonic (Mach number=1.0). As the cross
sectional area increases the gas begins to expand and the gas flow
increases to supersonic velocities where a sound wave cannot
propagate backwards through the fluid as viewed in the frame of
reference of the nozzle (Mach number>1.0).
[0056] The main passage 106 only reaches a choked flow condition at
the throat 122 if the pressure and mass flow rate is sufficient to
reach sonic speeds, otherwise supersonic flow is not achieved and
the main passage will act as a venturi tube. In order to achieve
supersonic flow, the entry pressure to the nozzle reactor 100
should be significantly above ambient pressure.
[0057] The pressure of the fluid at the exit of the divergent
section 124 of the main passage 106 can be low, but should not be
too low. The exit pressure can be significantly below ambient
pressure since pressure cannot travel upstream through the
supersonic flow. However, if the pressure is too far below ambient,
then the flow will cease to be supersonic or the flow will separate
within the divergent section 124 of the main passage 106 forming an
unstable jet that "flops" around and damages the main passage 106.
In one embodiment, the ambient pressure is no higher than
approximately 2-3 times the pressure in the supersonic gas at the
exit.
[0058] The supersonic reacting fluid collides and mixes with the
feed material in the nozzle reactor 100 to produce the desired
reaction. The high speeds involved and the resulting collision
produces a significant amount of kinetic energy that helps
facilitate the desired reaction. The reacting fluid and/or the feed
material may also be pre-heated to provide additional thermal
energy to react the materials.
[0059] The nozzle reactor 100 may be configured to accelerate the
reacting fluid to at least approximately Mach 1, at least
approximately Mach 1.5, or, desirably, at least approximately Mach
2. The nozzle reactor may also be configured to accelerate the
reacting fluid to approximately Mach 1 to approximately Mach 7,
approximately Mach 1.5 to approximately Mach 6, or, desirably,
approximately Mach 2 to approximately Mach 5.
[0060] As shown in FIG. 7, the main passage 106 has a circular
cross-section and opposing converging side walls 126, 128. The side
walls 126, 128 curve inwardly toward the central axis of the main
passage 106. The side walls 126, 128 form the convergent section
120 of the main passage 106 and accelerate the reacting fluid as
described above.
[0061] The main passage 106 also includes opposing diverging side
walls 130, 132. The side walls 130, 132 curve outwardly (when
viewed in the direction of flow) away from the central axis of the
main passage 106. The side walls 130, 132 form the divergent
section 124 of the main passage 106 that allows the sonic fluid to
expand and reach supersonic velocities.
[0062] The side walls 126, 128, 130, 132 of the main passage 106
provide uniform axial acceleration of the reacting fluid with
minimal radial acceleration. The side walls 126, 128, 130, 132 may
also have a smooth surface or finish with an absence of sharp edges
that may disrupt the flow. The configuration of the side walls 126,
128, 130, 132 renders the main passage 106 substantially
isentropic.
[0063] The feed passage 108 extends from the exterior of the body
portion 104 to an annular chamber 134 formed by head and body
portions 102, 104. The portions 102, 104 each have an opposing
cavity so that when they are coupled together the cavities combine
to form the annular chamber 134. A seal 136 is positioned along the
outer circumference of the annular chamber 134 to prevent the feed
material from leaking through the space between the head and body
portions 102, 104.
[0064] It should be appreciated that the head and body portions
102, 104 may be coupled together in any suitable manner. Regardless
of the method or devices used, the head and body portions 102, 104
should be coupled together in a way that prevents the feed material
from leaking and withstands the forces generated in the interior.
In one embodiment, the portions 102, 104 are coupled together using
bolts that extend through holes in the outer flanges of the
portions 102, 104.
[0065] The nozzle reactor 100 includes a distributor 140 positioned
between the head and body portions 102, 104. The distributor 140
prevents the feed material from flowing directly from the opening
141 of the feed passage 108 to the main passage 106. Instead, the
distributor 140 annularly and uniformly distributes the feed
material into contact with the reacting fluid flowing in the main
passage 106.
[0066] As shown in FIG. 9, the distributor 140 includes an outer
circular wall 148 that extends between the head and body portions
102, 104 and forms the inner boundary of the annular chamber 134. A
seal or gasket may be provided at the interface between the
distributor 140 and the head and body portions 102, 104 to prevent
feed material from leaking around the edges.
[0067] The distributor 140 includes a plurality of holes 144 that
extend through the outer wall 148 and into an interior chamber 146.
The holes 144 are evenly spaced around the outside of the
distributor 140 to provide even flow into the interior chamber 146.
The interior chamber 146 is where the main passage 106 and the feed
passage 108 meet and the feed material comes into contact with the
supersonic reacting fluid.
[0068] The distributor 140 is thus configured to inject the feed
material at about a 90.degree. angle to the axis of travel of the
reacting fluid in the main passage 106 around the entire
circumference of the reacting fluid. The feed material thus forms
an annulus of flow that extends toward the main passage 106. The
number and size of the holes 144 are selected to provide a pressure
drop across the distributor 140 that ensures that the flow through
each hole 144 is approximately the same. In one embodiment, the
pressure drop across the distributor is at least approximately 2000
pascals, at least approximately 3000 pascals, or at least
approximately 5000 pascals.
[0069] Referring to FIG. 8, holes 144 are shown having a circular
cross-section. Circular holes 144 are suitable for effective nozzle
reactor operation when the nozzle reactor is relatively small and
handling production capacities less than, e.g., 1,000 bbl/day. At
such production capacities, the feed material passing through the
circular holes will break up into the smaller droplet size
necessary for efficient mixing or shearing with the reacting
fluid.
[0070] The distributor 140 includes a wear ring 150 positioned
immediately adjacent to and downstream of the location where the
feed passage 108 meets the main passage 106. The collision of the
reacting fluid and the feed material causes a lot of wear in this
area. The wear ring is a physically separate component that is
capable of being periodically removed and replaced.
[0071] As shown in FIG. 9, the distributor 140 includes an annular
recess 152 that is sized to receive and support the wear ring 150.
The wear ring 150 is coupled to the distributor 140 to prevent it
from moving during operation. The wear ring 150 may be coupled to
the distributor in any suitable manner. For example, the wear ring
150 may be welded or bolted to the distributor 140. If the wear
ring 150 is welded to the distributor 140, as shown in FIG. 8, the
wear ring 150 can be removed by grinding the weld off. In some
embodiments, the weld or bolt need not protrude upward into the
interior chamber 146 to a significant degree.
[0072] The wear ring 150 can be removed by separating the head
portion 102 from the body portion 104. With the head portion 102
removed, the distributor 140 and/or the wear ring 150 are readily
accessible. The user can remove and/or replace the wear ring 150 or
the entire distributor 140, if necessary.
[0073] As shown in FIGS. 6 and 7, the main passage 106 expands
after passing through the wear ring 150. This can be referred to as
expansion area 160 (also referred to herein as an expansion
chamber). The expansion area 160 is formed largely by the
distributor 140, but can also be formed by the body portion
104.
[0074] Following the expansion area 160, the main passage 106
includes a second region having a converging-diverging shape. The
second region is in the body portion 104 of the nozzle reactor 100.
In this region, the main passage includes a convergent section 170
(also referred to herein as a contraction section), a throat 172,
and a divergent section 174 (also referred to herein as an
expansion section). The converging-diverging shape of the second
region differs from that of the first region in that it is much
larger. In one embodiment, the throat 172 is at least 2-5 times as
large as the throat 122.
[0075] The second region provides additional mixing and residence
time to react the reacting fluid and the feed material. The main
passage 106 is configured to allow a portion of the reaction
mixture to flow backward from the exit opening 112 along the outer
wall 176 to the expansion area 160. The backflow then mixes with
the stream of material exiting the distributor 140. This mixing
action also helps drive the reaction to completion.
[0076] As noted above, the cracking material used to upgrade the
collected hydrocarbon material in the nozzle reactor can be steam.
In some embodiments where steam is used as a cracking material,
steam for use in the nozzle reactor can be generated using a
combustor. Generally speaking, steam is generated from a combustor
by injecting an air stream and a fuel stream into a combustor and
producing a combustion flame in a combustion chamber and injecting
atomized water into the combustion chamber and forming steam. This
method of steam generation beneficially provides an alternative to
boilers for steam generation. In addition to being less
cost-intensive than boilers, the method also allows for the use of
treated water in steam generation, which further makes the method
more cost effective than steam generated by boilers. Other benefits
of the method over the use of boilers for steam generation include
the elimination of a flue gas by-product and ability to take
advantage of produced streams from other processes for better
process integration.
[0077] In the first step of generating steam from a combustor, an
air stream and a fuel stream are injected into a combustor. The
reaction of the fuel stream and the air stream creates a combustion
flame in the combustion chamber of the combustor. An objective of
this step is to provide a heat from the reaction between the fuel
stream and the air stream to convert water injected into the
combustion chamber into steam. The reaction between the air stream
and the fuel stream can also produce additional materials that can
be used as motive fluids in upgrading processes such as cracking of
hydrocarbon material in a nozzle reactor.
[0078] Any air stream capable of being reacted with a fuel stream
in a combustor to produce an exothermic reaction can be used. In
some embodiments, the air stream is standard air from the
surrounding environment. The air stream will typically include a
content of O.sub.2 of N.sub.2. In some embodiments, the air stream
includes an O.sub.2 content in the range of from 18 to 21%. In some
embodiments, the air is turbine air, which can include a depleted
amount of oxygen (such as less than 14 vol % oxygen). In some
embodiments, the air is enriched air, such as air having from 22 to
28 vol % oxygen). In some embodiments, the air is industrial
oxygen, such as from 90 to 99 vol % oxygen). Industrial oxygen can
be beneficial in that the removal of nitrogen can results in the
creation of cracking material free of nitrogen. This, in turn, can
result in cleaner and combustible fuel gas being produced by the
nozzle reactor.
[0079] The air stream injected into the combustor can be at a
raised temperature and pressure to facilitate the reaction in the
combustor. In some embodiments, the air stream has a temperature in
the range of from 1,350 to 1,500.degree. F. and the air stream can
have a pressure of from 400 to 550 psig. When the source of the air
stream does not provide air at the desired temperature and/or
pressure, steps can be taken to adjust the temperature and/or
pressure to within the desired ranges. Any suitable techniques for
heating and/or pressurizing the air stream can be used. For
example, the air stream can be run through a compressor to raise
the pressure to within a suitable range.
[0080] In instances where a turbine, such as a gas turbine, is
present on the offshore platform, the exhaust from the turbine can
be used as the air stream. Use of the turbine exhaust as the air
stream can be useful because turbine exhaust typically has a raised
temperature and pressure and has the desired O.sub.2 content.
Accordingly, use of turbine exhaust can eliminate or reduce the
need to heat and pressurize the air stream prior to injecting the
air stream into the combustor. In one example, turbine exhaust
having an O.sub.2 content of 14% is provided at a temperature of
1,400.degree. F. and a pressure of 450 psig, meaning that the
exhaust from the turbine can be directly injected into the
combustor with the need for any pre-treatment. Such process
integration lowers the overall cost of generating steam.
[0081] The turbine integrated into process can include the turbine
used to generate power for the entire offshore platform, such as
the power needed for all rotating machines, powered electrical
units, and accommodations (lights, air conditioning, etc.). Such
turbines can be natural gas or fuel gas powered turbines. The steam
generation capacity can be calculated based on the exhaust gas
temperature and flow rate from the turbine designed to power the
off-shore platform, which in turn can be used to calculate the
capacity of the nozzle reactor. An example of a commercially
available gas turbine that can be used on the off-shore platform
and integrated into the process is the Centaur 50 manufactured by
Solar Turbines of California, USA. The Centaur 50 is a natural gas
fired turbine that generates roughly 5 MW of electrical power.
[0082] In some embodiments, the exhaust from a custom engine can be
used as the air stream. The custom engine can include only an air
compressor and a combustor section. The exhaust from such a custom
engine can be used in the combustor to generate steam in the same
manner as described above when exhaust from a turbine is used in
the combustor.
[0083] Any low molecular weight fuel stream capable of being
reacted with an air stream in a combustor to produce an exothermic
reaction without coke formation can be used. Exemplary fuels
streams include natural gas, methane, and ethane.
[0084] The source of the fuel stream is generally not limited, and
can include both fuel provided independently of any other processes
being performed on the offshore platform and fuel produced by other
processes being performed on the offshore platform.
[0085] The air stream and the fuel stream are injected into a
combustor to react and provide an exothermic reaction. Any
combustor suitable for reacting the air stream and fuel stream to
provide an exothermic reaction can be used. With reference to FIG.
4, a typical combustor 200 suitable for use in the methods
described herein will include a fuel injector 210, an air stream
injector 220, an igniter 230, a combustion chamber 240 where the
exothermic reaction takes place and where the combustion flame is
produced, and a casing 250 housing all of the components of the
combustor. The air and fuel stream are injected into the combustor,
where the two materials react, give off heat, and with the aid of
the igniter, provide a combustion flame. A basic example of the
reaction that can take place inside the combustion zone when the
fuel stream is methane is shown below:
CH.sub.4+0.5O.sub.2.fwdarw.CO+2H.sub.2, h=-36 kJ/mol
[0086] In addition to CO and H.sub.2, other reaction products that
can be formed by the reaction of the fuel stream and the air stream
in the combustor include CO.sub.2, N.sub.2 and H.sub.2O.
[0087] The amount of the fuel stream and air stream injected into
the combustor can include any rates suitable for reacting the two
streams and that can be handled by the combustor used. In some
embodiments, the stoichiometric ratio of fuel to air is greater
than 1 (i.e., fuel rich). Typical combustion products for the
reaction of air and natural gas (no additional steam added) at
various stoichiometric ratios of fuel to air (.PHI.) are provided
in Table 1.
TABLE-US-00001 TABLE 1 .PHI. = 1.1 .PHI. = 1.3 .PHI. = 1.5 Wet (%)
Wet (%) Wet (%) N2 69 N2 66 N2 63 CO2 8 CO2 5.5 CO2 3.9 CO 2.5 CO
2.5 CO 9.0 H2 1.0 H2 4.0 H2 7.5 H2O 18.5 H2O 18.0 H2O 17.0 O2 0.0
O2 0.0 O2 0.0
[0088] Combustion of the fuel stream and air stream and
sub-stoichiometric ratios lowers the adiabatic temperature of the
combustion flame. Table 2 provides the adiabatic flame temperature
at various .PHI. when the air stream is not pre-heated and then the
air stream is pre-heated to 1,400.degree. F.
TABLE-US-00002 TABLE 2 Without Air With Air .PHI. Preheating
(.degree. F.) Preheating (.degree. F.) 1.0 3500 4100 1.3 3400 4000
1.5 2800 3400 2.0 2400 3000
[0089] Heat energy provided by the combustion flame is generally
sufficient to produce steam at a desired temperature and quench the
products of combustion. For example, some cracking processes using
nozzle reactors (discussed in greater detail below) require steam
at 1,200.degree. F. At many of the temperatures provided in Table 2
above, sufficient heat energy will be available to both produce
steam at 1,200.degree. F. and quench the combustion products.
[0090] After injection of the air stream and the fuel stream,
atomized water is injected into the combustion chamber and steam is
formed. When the atomized water enters the combustion chamber, the
heat energy provided by the combustion reaction between the air
stream and the fuel stream converts the atomized water into steam.
Thus produced, the steam can be used for various recovery and
upgrading processing being carried out on the offshore
platform.
[0091] The water injected into the combustion chamber can be
obtained from any suitable source available at the offshore
platform. The water may not require pretreatment, and therefore the
source of the water is greatly expanded as compared to water
sources that can be used when a boiler is used for steam
generation. In some embodiments, seawater can be used as the source
of water. In some embodiments where seawater is used, some
pretreatment may be carried out, such as filtration to remove
solids or desalination.
[0092] The water injected into the combustion chamber is atomized.
Atomized water refers to small droplets of water that are part of
fine spray injected into the combustion chamber. Any technique
capable of atomizing water can be used. In some embodiments,
atomization of the water and injection of the atomized water is
performed by the same equipment. For example, high pressure
atomizer nozzles can be used to both create an atomized water spray
and inject the atomized water spray into the combustion chamber.
With continued reference to FIG. 4, the combustor 200 can be
equipped with such a high pressure atomizer nozzle 260. The
atomizer nozzle 260 is in fluid communication with the combustion
chamber 240 such that the atomized water can be injected into the
combustion chamber where heat energy is available to create steam
from the atomized water droplets. As shown in FIG. 4, in some
embodiments the atomizer nozzle 260 is located near the periphery
of the combustion chamber 240. In this manner, the atomized water
can enter the combustion chamber 240 around the entire diameter of
the combustion flame.
[0093] In some embodiments, the amount of atomized water injected
into the combustion chamber is generally dependent on the amount of
heat energy being produced inside the combustion chamber and
available to convert the atomized water to steam. As noted above,
some of the produced heat energy will be used to quench the other
combustion products. In some embodiments, the atomized water is
injected into the combustion chamber at a rate of from 0.5 to 1.5
times the fuel stream flow rate to be processed.
[0094] Other reactions occur in the combustion chamber as a result
of injecting the atomized water into the combustion chamber and
creating steam. For example, produced steam can react with
unreacted fuel (e.g., methane) to produce H.sub.2 and CO, which is
an endothermic reaction. An exemplary reaction between steam and
methane fuel is provided below:
CH4+H2O.fwdarw.CO+3H2, h=+206 kJ/mol
[0095] Carbon monoxide produced from this reaction with react with
steam to undergo an exothermic water gas shift reaction. For
example:
CO+H2O=CO+H2, h=-41 kJ/mol
[0096] Taking into consideration all of these possible reactions,
the final products that can be produced in the combustion chamber
as a result of the introduction of the air stream, the fuel stream,
and atomized water into the combustion chamber include steam,
H.sub.2, CO, CO.sub.2, and N.sub.2. Each of these products can be
used as motive fluids in the nozzle reactor cracking processes
described in greater detail below.
[0097] The steam produced in the combustion chamber can be injected
into a nozzle reactor along with injecting the collected
hydrocarbon material into the nozzle reactor. An objective of
injecting the two materials into the nozzle reactor is to crack the
hydrocarbon material into lighter hydrocarbon compounds.
[0098] The combustion chamber of the combuster can be in fluid
communication with the steam injection passage of the nozzle
reactor such that the produced steam passes directly into the
nozzle reactor. The steam exiting the combustion chamber and
entering the nozzle reactor is passed through the cracking material
injection passage where, as described above, the steam is
accelerated to a supersonic speed. Any amount of steam necessary to
crack hydrocarbon material injected into the nozzle reactor can be
supplied into the nozzle reactor.
[0099] Other manners of providing steam can also be used. In some
embodiments, a normal boiler can be used for steam generation, such
as a stand alone or supplementary fuel fired boiler. In some
embodiments, the exhaust from a turbine (such as the turbine
exhaust described above) can be used in a tube and shell heat
exchanger to heat water and create superheated steam suitable for
use in the methods described herein.
[0100] In some embodiments, some deposits may appear within the
nozzle reactor as a result of the upgrading process. Such scale
build up should be monitored. In some embodiments, chemical
treatment of the water prior to injection into the nozzle reactor
can be provided in order to reduce or avoid scale build up. Any
treatment processes capable of removing salts and other water
impurities that could lead to scale build up from the water can be
used, and include reverse osmosis, distillation, nanotechnolgy, and
ion exchange.
[0101] Product exiting the nozzle reactor will include cracked
hydrocarbons, including lighter hydrocarbon molecules than the
hydrocarbon material injected into the nozzle reactor. The
hydrocarbon material exiting the nozzle reactor will also have a
lower viscosity than the hydrocarbon injected into the nozzle
reactor. Accordingly, the product material leaving the nozzle
reactor will have improved flow characteristics and will be easier
and less costly to transport through pipelines back to shore. In
some embodiments, the upgraded hydrocarbon material has a viscosity
less than 380 cSt @ 15.5 deg C.
[0102] In some embodiments, preliminary separation of the products
leaving the nozzle reactor can be carried out on the offshore
platform. Any manner of separating the hydrocarbon product can be
used. In some embodiments, cyclone separators are used. Cyclone
separators can be useful due to their relatively small foot print.
The hydrocarbon products can be separated into, for example, a
lights, middle distillate, and residue stream. The residue stream
may be recycled back into the nozzle reactor for further
upgrading.
[0103] In step 1400, the upgraded hydrocarbon material will be
transported back to shore through pipelines running from the
offshore platform back to shore. In some embodiments, the ejection
end of the nozzle reactor will be in fluid communication with the
pipeline so that the upgraded hydrocarbon material leaving the
nozzle reactor can be passed directly to the pipelines and be
transported back to shore. Any suitable pipelines can be used to
transport the upgraded material back to shore. In some embodiments,
the piping will run along the floor of the body of water on which
the offshore platform is position and extend from the offshore
platform all the way to the shore. Once ashore, the upgraded
hydrocarbon material can be subjected to further processing at a
refinery. The upgraded hydrocarbon can be transported to the
onshore refinery through a series of pipes that continue from the
shore to the refinery, or the upgraded hydrocarbon material can be
collected once it reaches land from the pipelines and transported
via other means, such as through the use of trucks or trains.
[0104] With reference to FIG. 5, a system for offshore upgrading
and transportation of extracted hydrocarbon material includes an
offshore platform 500 located on a body of water 510 and above a
deposit of hydrocarbon material 520 below the floor of the body of
water. The offshore platform can include a nozzle reactor 501 and a
combustor 502 to be used in the upgrading of the extracted
hydrocarbon material. The system also includes pipelines 530 for
transporting the upgraded hydrocarbon back to shore.
[0105] Offshore platform 500 can be similar or identical to the
offshore platform described above in step 1000. Generally speaking,
the offshore platform 500 is positioned over the deposit of
hydrocarbon material 520 located below a body of water 510. The
offshore platform 500 includes all of the necessary equipment to
drill and establish production wells and extract bitumen from the
deposit 520.
[0106] The nozzle reactor 501 and combustor 502 on the offshore
platform are similar to the nozzle reactor and combustor described
in greater detail above. In some embodiments, the production well
will be in fluid communication with the material feed port of the
nozzle reactor 501 so that extracted hydrocarbon material can be
directly injected into the nozzle reactor for upgrading. The
combustor 502 can also be in fluid communication with the nozzle
reactor 501 so that steam generated in the combustor 502 can be
directly injected into the nozzle reactor 501. In some embodiments
where the combustor uses water from the body of water 510 for the
production of steam, a pipeline can be established for transporting
water from the body of water 510 directly to the combustor 502.
[0107] The pipeline 530 can be any type of pipeline suitable for
transporting upgraded hydrocarbon material back to the shore. The
pipeline 530 can be in fluid communication with the ejection end of
the nozzle reactor 501 so that upgraded hydrocarbon material can be
passed directly into the pipeline for transportation back to the
shore. Pumps can be provided for moving the upgraded hydrocarbon
material through the pipeline. In some embodiments, the pipeline
will be laid along the floor of the body of water 510.
[0108] While the above described systems and methods generally
reference use of a single nozzle reactor, multiple nozzle reactors
can be used in the systems and methods described herein. The
multiple nozzle reactors can be arranged in series, in parallel, or
any combination of the two. Use of multiple nozzle reactors in
series can generally help to increase the conversion of heavy
hydrocarbon material into lighter hydrocarbon material, such as by
separating heavy hydrocarbon exiting a first nozzle reactor and
running it through a second nozzle reactor located downstream and
whose operating conditions are adjusted to improve the conversion
of heavy hydrocarbons. The use of multiple nozzle reactors in
parallel can increase amount of hydrocarbon material that can be
processed and can mitigate issues relating to scaling up nozzle
reactors to handle larger capacities.
[0109] The above described systems and methods also generally refer
to the use of steam as the cracking material. However, it is
possible to use other cracking materials in the systems and methods
described herein. For example, suitable cracking materials include
natural gas, methanol, ethanol, ethane, propane, biodiesel, carbon
monoxide, nitrogen, or combinations thereof. In some embodiments,
these cracking materials can be heated in the combustor described
above (e.g., where the cracking material is injected into the
combustor instead of atomized water).
[0110] While the invention has been particularly shown and
described with reference to a preferred embodiment thereof, it will
be understood by those skilled in the art that various other
changes in the form and details may be made without departing from
the spirit and scope of the invention.
[0111] A presently preferred embodiment of the present invention
and many of its improvements have been described with a degree of
particularity. It should be understood that this description has
been made by way of example, and that the invention is defined by
the scope of the following claims.
* * * * *