Method to upgrade hydrocarbon mixtures

Abstract

A method of upgrading hydrocarbon mixtures without the need of additives, catalysts or heating using ultrasonic cavitation. Ultrasonic energy is provided at a rate sufficient to induce cavitation in the hydrocarbon mixture. The high temperatures and high pressures resulting from cavitation cause cracking of a portion of the hydrocarbons in the mixture thereby creating lighter hydrocarbons in the diesel range or lighter for recovery via more traditional separation technologies, such as distillation. The resulting upgraded petroleum product exhibits lower distillation curves and decreased pollution causing components. Further, a wide variety of feedstocks can be treated according to the method of this invention.

What is claimed is:  
     
         1 . A method of upgrading a hydrocarbon mixture, comprising the steps of: 
 (a) providing a hydrocarbon mixture to be upgraded; and    (b) treating the hydrocarbon mixture with cavitational energy, wherein the cavitational energy induces cavitation in the hydrocarbon mixture sufficient to cause cracking of a portion of the hydrocarbons within the hydrocarbon mixture to produce a treated hydrocarbon mixture, wherein the treated hydrocarbon mixture comprises at least two hydrocarbon fractions.    
     
     
         2 . The method of  claim 1 , wherein the cavitational energy is provided using a cavitational energy source selected from the group consisting of ultrasonic, electromagnetic, propeller, impeller, venturi and combinations thereof.  
     
     
         3 . The method of  claim 2 , wherein the cavitational energy source is an ultrasonic source.  
     
     
         4 . The method of  claim 3 , wherein the ultrasonic source comprises one or more ultrasonic horns.  
     
     
         5 . The method of  claim 3 , wherein the cavitational energy has a frequency of about 5 kHz to about 500 kHz.  
     
     
         6 . The method of  claim 5 , wherein the cavitational energy has a frequency of about 40 kHz to about 100 kHz.  
     
     
         7 . The method of  claim 3 , wherein the cavitational energy is less than 500 W/cm 2 .  
     
     
         8 . The method of  claim 7 , wherein the cavitational energy is less than about 375 W/cm 2 .  
     
     
         9 . The method of  claim 3 , wherein the hydrocarbon mixture is provided at a pressure of about 150 psi.  
     
     
         10 . The method of  claim 1 , wherein the hydrocarbon mixture is selected from the group consisting of crude oil, atmospheric tower refining bottoms, used motor oil, vacuum gas oils, refining residuums, cat cracker bottoms, fuel oil, vacuum tower bottoms, residual fuel oils and mixtures thereof.  
     
     
         11 . The method of  claim 1 , wherein the hydrocarbon mixture further comprises organic components containing heteroatoms selected from the group consisting of nitrogen, sulfur, oxygen and mixtures thereof.  
     
     
         12 . The method of  claim 1 , wherein the hydrocarbon mixture comprises predominantly hydrocarbons having a boiling point greater than that of diesel.  
     
     
         13 . The method of  claim 1 , wherein the hydrocarbon mixture is treated at a temperature between about 300° F. and less than 500° F.  
     
     
         14 . The method of  claim 1 , wherein the hydrocarbon mixture having a predetermined pour point is treated at a temperature less than about 20° F. over the pour point of the hydrocarbon mixture.  
     
     
         15 . The method of  claim 1 , wherein the hydrocarbon mixture is treated in the absence of substantial amounts of an aqueous phase or additives.  
     
     
         16 . The method of  claim 1 , further comprising the step of separating the at least two hydrocarbon fractions from the treated hydrocarbon mixture into separate fractions.  
     
     
         17 . The method of  claim 16 , wherein the step of separating is accomplished via distillation.  
     
     
         18 . The method of  claim 1 , further comprising subjecting the treated hydrocarbon mixture to step (b) multiple times until the treated hydrocarbon mixture exhibits a predetermined fractionation value.  
     
     
         19 . A treated hydrocarbon mixture produced by the method of  claim 1 , wherein the treated hydrocarbon mixture has a higher distillable hydrocarbon content than the original hydrocarbon mixture.  
     
     
         20 . A method of upgrading a hydrocarbon mixture, comprising the steps of: 
 (a) providing a hydrocarbon mixture in the absence of substantial amounts of an aqueous phase or additives;    (b) treating the hydrocarbon mixture with ultrasonic energy, wherein the ultrasonic energy induces cavitation in the hydrocarbon mixture sufficient to crack a portion of the hydrocarbons within the hydrocarbon mixture to produce a treated hydrocarbon mixture, wherein the treated hydrocarbon mixture comprises at least two hydrocarbon fractions; and    (c) separating the at least two hydrocarbon fractions from the treated hydrocarbon mixture into separate fractions.    
     
     
         21 . A method of upgrading a hydrocarbon mixture, comprising the steps of: 
 (a) providing a hydrocarbon mixture in the absence of substantial amounts of an aqueous phase or additives, wherein the hydrocarbon mixture has a predetermined pour point;    (b) treating the hydrocarbon mixture with ultrasonic energy at a temperature from the pour point of the hydrocarbon mixture to about 20° F. over the pour point, wherein the ultrasonic energy induces cavitation in the hydrocarbon mixture sufficient to crack a portion of the hydrocarbons within the hydrocarbon mixture to produce a treated hydrocarbon mixture, wherein the treated hydrocarbon mixture comprises at least two hydrocarbon fractions; and    (c) separating the at least two hydrocarbon fractions from the treated hydrocarbon mixture into separate fractions.    
     
     
         22 . A method of upgrading a hydrocarbon mixture, comprising the steps of: 
 (a) providing a hydrocarbon mixture;    (b) providing a means for delivering the hydrocarbon mixture to a source of ultrasonic energy using a cup-shaped flow tube;    (c) treating the hydrocarbon mixture with ultrasonic energy, wherein the ultrasonic energy induces cavitation in the hydrocarbon mixture sufficient to crack a portion of the hydrocarbons within the hydrocarbon mixture to produce a treated hydrocarbon mixture, wherein the treated hydrocarbon mixture comprises at least two hydrocarbon fractions.    
     
     
         23 . A continuous self-contained ultrasonic treatment system for upgrading hydrocarbon mixtures comprising: 
 (a) a containment space for containing the hydrocarbon mixture;    (b) an inlet line operatively connected to the containment space;    (c) at least one ultrasonic energy source for emitting ultrasonic energy positioned such that the ultrasonic energy passes through the containment space;    (d) an outlet line operatively connected to the containment space to allow for withdrawal of the hydrocarbon mixture; and    (e) a cup-shaped flow tube operatively connected to the containment space and oriented to direct flow of the hydrocarbon mixture toward the ultrasonic energy source.    
     
     
         24 . A method of upgrading a hydrocarbon mixture, comprising the steps of: 
 (a) providing a hydrocarbon mixture having a predetermined pour point, wherein the hydrocarbon mixture is substantially free of an aqueous phase and additives and is at a temperature less than 20° F. over the pour point;    (c) directing the hydrocarbon mixture toward an ultrasonic energy source using a cup-shaped flow tube;    (b) treating the hydrocarbon mixture with ultrasonic energy emitted from the ultrasonic energy source, wherein the ultrasonic energy has sufficient energy to crack a portion of the hydrocarbons within the hydrocarbon mixture to produce a treated hydrocarbon mixture, wherein the treated hydrocarbon mixture comprises at least two hydrocarbon fractions; and    (c) recovering the at least two hydrocarbon fractions from the treated hydrocarbon mixture.