Processing unconventional and opportunity crude oils using zeolites

Abstract

The disclosed process removes or reduces impurities such as asphaltenes, solids (especially solid fines), sulfur, metals, chlorides, water, salts, and acids from bitumen, oil sands, and crude oils with a wide range of gravities. A crude source composition is contacted with one or more zeolite materials to remove asphaltenes, solids, sulfur, NSO, metals, chlorides, water, salts, and/or acids from the composition. The crude source is typically diluted with a hydrocarbon solvent such as naphtha before contacting the zeolite(s). The disclosed processes represent an improvement over prior and presently available processes because the disclosed processes are capable of processing emulsions.

1 . A process for removing an impurity from a petroleum composition, comprising: contacting the composition with one or more zeolite materials.  
   
   
       2 . The process of  claim 1 , wherein the petroleum composition comprises acidic crude oil, extra heavy oil, heavy oil, high salinity crudes, acidic residuum, gas oil, oil sand, diluted bitumen, undiluted bitumen, or a mixture thereof.  
   
   
       3 . The process of  claim 1 , wherein the impurity comprises asphaltenes, solids, sulfur, NSO, metals, chlorides, water, salts, surfactants or a combination thereof.  
   
   
       4 . The process of  claim 1 , wherein the zeolite is a type Z zeolite.  
   
   
       5 . The process of  claim 1 , wherein the zeolite is a chabazite zeolite.  
   
   
       6 . The process of  claim 1 , wherein the zeolite material is surface-modified to have a positive surface potential.  
   
   
       7 . The process of  claim 1 , wherein the composition is co-currently contacted with the zeolite material.  
   
   
       8 . The process of  claim 1 , wherein the composition is counter-currently contacted with the zeolite material.  
   
   
       9 . The process of  claim 1 , wherein the zeolite material is contained in a static bed, a fluidized bed, or an expandable bed.  
   
   
       10 . The process of  claim 1 , further comprising adding one or more reagents to the composition, wherein the reagent is selected from the group consisting of acids, demulsifiers, caustic agent, and coagulants.  
   
   
       11 . The process of  claim 1 , further comprising recovering zeolite material from the composition.  
   
   
       12 . The process of  claim 1 , further comprising the steps of: 
 adding a hydrocarbon solvent to the composition to provide a density-modified composition;    removing a portion of water and/or solids from the composition;    adding to the density-modified composition one or more reagents selected from the group consisting of acids, caustics, demulsifiers, coagulants, and viscosity modifiers;    contacting the density-modified composition with a first zeolite material and substantially removing the first zeolite material from the density-modified composition;    contacting the composition with a second zeolite material and substantially removing the second zeolite material from the density-modified composition; and    evaporating the density-modified composition mixture in one or more evaporation stages to provide a solvent stream and a product stream.    
   
   
       13 . A process for removing an impurity from a petroleum composition, comprising: 
 contacting the petroleum composition with a first zeolite material;    contacting the petroleum composition with a second zeolite material;    wherein one of the zeolite materials has a positive surface potential and the other zeolite material has a negative surface potential.    
   
   
       14 . The process of  claim 13 , wherein the petroleum composition comprises acidic crude oil, extra heavy oil, heavy oil, high salinity crudes, acidic residuum, gas oil, oil sand, diluted bitumen, undiluted bitumen, or a mixture thereof.  
   
   
       15 . The process of  claim 13 , wherein the impurity comprises asphaltenes, solids, sulfur, NSO, metals, chlorides, water, salts, surfactants, or a combination thereof.  
   
   
       16 . The process of  claim 13 , wherein the petroleum composition comprises an emulsion.  
   
   
       17 . A process for removing an impurity from a petroleum composition, comprising: 
 adding a hydrocarbon solvent to the petroleum composition;    removing a portion of water and/or solids from the petroleum composition;    contacting the petroleum composition with a first zeolite material and substantially removing the first zeolite material from the petroleum composition; and    contacting the petroleum composition with a second zeolite material and substantially removing the second zeolite material from the petroleum composition;    wherein one of the zeolite materials has a positive surface potential and the other zeolite material has a negative surface potential.