Use of syngas for the upgrading of heavy crude at the wellhead

Abstract

The present system may be used to hydroprocess heavy crude oil at the wellhead, effectively lowering the viscosity and removing contaminants such as sulfur, nitrogen and metal contents. The hydrogen source for hydroprocessing is the separated hydrogen product from the methane produced from a syngas plant.

What is claimed is:  
     
         1 . A method for upgrading heavy crude oils at the wellhead comprising: 
 producing syngas in a syngas-producing process;    separating the syngas into H 2  and CO streams; and    injecting the H 2  stream into a hydroprocessing operation located at the wellhead.    
     
     
         2 . The method according to  claim 1  wherein the syngas-producing operation is of a type selected from the group consisting of CPOX (catalytic partial oxidation), ATR (autothermal reforming), and steam reforming processes.  
     
     
         3 . The method according to  claim 2  wherein the syngas-producing process is CPOX.  
     
     
         4 . The method according to  claim 3  wherein a methane-containing gas and oxygen-containing gas feed is supplied to the CPOX process.  
     
     
         5 . The method according to  claim 4  wherein the methane-containing gas is associated gas co-produced from the oil well.  
     
     
         6 . The method according to  claim 4  wherein the methane-containing gas is supplied via pipeline from other sources.  
     
     
         7 . The method according to  claim 1  wherein a hydrogen separation process separates the syngas into H 2  and CO streams and optionally co-existing nitrogen streams.  
     
     
         8 . The method according to  claim 7  wherein the hydrogen separation process employs membrane separation technology.  
     
     
         9 . The method according to  claim 1  wherein the hydroprocessing operation is of a type selected from the group consisting of hydrogenation, hydrocracking, hydrodenitrogenation, hydrodemetalization, and hydrodesulfurization processes.  
     
     
         10 . The method according to  claim 9  wherein the hydroprocessing operation is hydrodesulfurization.  
     
     
         11 . A method for upgrading heavy crude oils at the wellhead comprising: 
 producing syngas in a syngas-producing process;    separating the syngas into H 2  and CO streams;    running the CO stream in the presence of a water feed through a water gas shift process to produce a water gas shift product comprising CO 2  and additional H 2 ;    separating the water gas shift product into H 2  and CO 2  streams; and    injecting the H 2  streams into a hydroprocessing process located at the wellhead.    
     
     
         12 . The method according to  claim 11  wherein the syngas-producing process is of a type selected from the group consisting of CPOX (catalytic partial oxidation), ATR (autothermal reforming), and steam reforming processes.  
     
     
         13 . The method according to  claim 12  wherein the syngas-producing process is CPOX.  
     
     
         14 . The method according to  claim 13  wherein a methane-containing gas and oxygen-containing gas feed is supplied to the CPOX process.  
     
     
         15 . The process according to  claim 14  wherein the methane-containing gas is associated gas co-produced from the oil well.  
     
     
         16 . The process according to  claim 14  wherein the methane-containing gas is supplied via pipeline from other sources.  
     
     
         17 . The method according to  claim 11  wherein a hydrogen separation process separates the syngas into H 2  and CO streams and optionally co-existing nitrogen streams.  
     
     
         18 . The method according to  claim 17  wherein the hydrogen separation process employs membrane separation technology.  
     
     
         19 . The method according to  claim 11  wherein the hydroprocessing process is of a type selected from the group consisting of hydrogenation, hydrocracking, hydrodenitrogenation, hydrodemetalization, and hydrodesulfurization processes.  
     
     
         20 . The method according to  claim 19  wherein the hydroprocessing process comprises a hydrodesulfurization process.  
     
     
         21 . The method according to  claim 11  further comprising feeding the product CO 2  into a carbon dioxide compressor.  
     
     
         22 . The method according to  claim 21  wherein the compressed CO 2  is injected into the formation via injection wells to facilitate movement of the crude oil to the producing wellhead.  
     
     
         23 . A method for upgrading heavy crude oils at the wellhead comprising: 
 producing syngas in a syngas-producing process running at CPOX favorable conditions with a methane-containing gas and oxygen-containing gas feed;    separating the syngas into H 2  and CO streams; and    injecting the H 2  stream into a hydroprocessing process located at the wellhead.    
     
     
         24 . A method for upgrading heavy crude oils at the wellhead comprising: 
 producing syngas in a syngas-producing process running at CPOX favorable conditions with a methane-containing gas and oxygen-containing gas feed;    separating the syngas into H 2  and CO streams;    running the CO stream in the presence of a water feed through a water gas shift process to produce a water gas shift product comprising CO 2  and additional H 2 ;    separating the water gas shift product into H 2  and CO 2  streams; and    injecting the H 2  streams into a hydroprocessing process located at the wellhead.    
     
     
         25 . A system for upgrading heavy crude oils at the wellhead comprising: 
 providing a syngas-producing process running at CPOX favorable conditions with a methane-containing gas and oxygen-containing gas feed to produce syngas;    providing a hydrogen separation process, wherein the syngas is separated into H 2  and CO streams; and    providing a hydroprocessing process located at the wellhead, wherein the H 2  stream is injected.    
     
     
         26 . A system for upgrading heavy crude oils at the wellhead comprising: 
 providing a syngas-producing process running at CPOX favorable conditions with a methane-containing gas and oxygen-containing gas feed to produce syngas;    providing a first hydrogen separation process, wherein the syngas is separated into H 2  and CO streams;    providing a water gas shift process with a water feed and a recycle means for running the CO stream to the water gas shift process, wherein the water gas shift process produces a water gas shift product comprising additional H 2  and CO 2 ;    providing a second hydrogen separation process, wherein the water gas shift product is separated into additional H 2  and CO 2  streams; and    providing a hydroprocessing process located at the wellhead, wherein the H 2  streams are injected.