Catalytic down-hole upgrading of heavy oil and oil sand bitumens

Abstract

The invention relates to systems and methods for catalytic down-hole upgrading of heavy oil and oil sand bitumens. The method enables upgrading heavy oil in a production well within a hydroprocessing zone including the steps of: introducing a controlled amount of heat to the hydroprocessing zone; introducing a selected quantity of hydrogen to the hydroprocessing zone to promote a desired hydrocarbon upgrading reaction; and, recovering upgraded hydrocarbons at the surface. The invention further includes the hardware capable of performing the method.

1 . A method of upgrading heavy oil in a production well within a hydroprocessing zone comprising the steps of:
 a. introducing a controlled amount of heat to the hydroprocessing zone;   b. introducing a selected quantity of hydrogen to the hydroprocessing zone to promote a desired hydrocarbon upgrading reaction; and,   c. recovering upgraded hydrocarbons at the surface.   
   
   
       2 . A method as in  claim 1  further comprising the step of introducing a catalyst to the hydroprocessing zone. 
   
   
       3 . A method as in  claim 2  wherein the catalyst is a nano-particle catalyst. 
   
   
       4 . A method as in  claim 3  wherein the catalyst is circulated within the hydroprocessing zone. 
   
   
       5 . A method as in  claim 1  wherein the hydroprocessing zone is a vertical section of a wellbore. 
   
   
       6 . A method as in  claim 1  wherein the method includes separating heavy oil from water prior to introducing heavy oil into the hydroprocessing zone. 
   
   
       7 . A method as in  claim 1  wherein the heavy hydrocarbon is bitumen and the upgraded hydrocarbons are characterized by an API gravity increase. 
   
   
       8 . A method as in  claim 3  wherein the catalyst is a bi-metallic catalyst of the general formula: BxMyS [(1.1 to 4.6)y+(0.5 to 4)x]  where B is a group VIIIB non-noble metal and M is a group VI B metal and 0.05≦y/x≦15. 
   
   
       9 . A method as in  claim 3  wherein 0.2≦y/x≦6. 
   
   
       10 . A method as in  claim 9  wherein y/x=3. 
   
   
       11 . A method as in  claim 3  wherein the catalyst is a tri-metallic catalyst of the general formula: B x M1 y M2 z O (2 to 3)z S [(0.3 to 2)y+(0.5 to 4)x]  where B is a group VIIIB non-noble metal and M1 and M2 are group VI B metals and 0.05≦y/x≦15 and 1≦z/x≦14. 
   
   
       12 . A method as in  claim 11  wherein the y/x ratio is in the range of 0.2<y/x<6. 
   
   
       13 . A method as in  claim 11  wherein 10<z/x<14. 
   
   
       14 . A method as in  claim 11  wherein z/x=12. 
   
   
       15 . A method as in  claim 11  wherein 1<z/x<5 and the upgrading process is mild hydrocracking. 
   
   
       16 . A method as in  claim 11  wherein z/x=3 and the upgrading process is mild hydrocracking. 
   
   
       17 . A method as in  claim 1  wherein the controlled amount of heat is introduced using any one of or a combination of electrical, hot fluid, or an in-well combustion device. 
   
   
       18 . A method as in  claim 1  wherein the production well includes at least two hydroprocessing zones and a different hydroprocessing reaction is controlled in each hydroprocessing zone. 
   
   
       19 . A method as in  claim 1  wherein the upgrading process is part of a steam flooding process including any one of steam assisted gravity drainage (SAGD), vapor extraction (VAPEX), cyclic steam stimulation (CSS) and CAPRI. 
   
   
       20 . A method as in  claim 1  wherein the upgrading reaction is hydrodenitrogenation. 
   
   
       21 . A method as in  claim 1  wherein the upgrading reaction is hydrodesulfurization. 
   
   
       22 . A system for upgrading heavy oil in a production well within a hydroprocessing zone comprising:
 a downhole heater for introducing a controlled amount of heat to the hydroprocessing zone;   a hydrogen delivery system for introducing a selected quantity of hydrogen to the hydroprocessing zone to promote a desired hydrocarbon upgrading reaction; and,   a surface recovery system for recovering upgraded hydrocarbons at the surface.   
   
   
       23 . A system as in  claim 22  further comprising a downhole water separator for separating water from heavy hydrocarbon, the downhole water separator operatively located upstream of the hydroprocessing zone.