Apparatus for Upgrading Crude Oil and System Incorporating Same

Abstract

A scalable system for producing upgraded crude oil includes one or more production lines. Bach of the one or more production lines comprises an oil well, an upgrader using microwave radiation operably associated with the oil well, and a pump operably associated with the upgrader. The upgrader is constructed to reduce the viscosity of and increase the API gravity of crude oil. A method for scalably upgrading crude oil includes providing an upgrader using a microwave radiation proximate an oil well, producing crude oil from the oil well, and transporting the crude oil to the upgrader. The method further includes upgrading the crude oil in the upgrader and transporting the upgraded crude oil away from the upgrader.

1 . A scalable system for producing upgraded crude oil, comprising:
 one or more production lines, each of the one or more production lines comprising:
 an oil well; 
 an upgrader operably associated with the oil well, the upgrader constructed to reduce the viscosity of and increase the API gravity of crude oil; and 
 a pump operably associated with the upgrader. 
   
     
     
         2 . The system of  claim 1 , wherein the upgrader uses microwave radiation to reduce the viscosity of and increase the API gravity of the crude oil. 
     
     
         3 . The system of  claim 1 , wherein the upgrader comprises:
 a microwave irradiation system comprising one or more microwave antennas, the microwave irradiation system for at least partially upgrading crude oil using microwave energy to form upgraded crude oil;   a conveyor comprising a perforated belt, the one or more microwave antennas directed toward a portion of the perforated belt, the perforated belt configured to allow the upgraded crude oil to pass through openings defined thereby;   an inlet chute disposed to direct the crude oil onto the perforated belt;   a solids output chute disposed to receive solids from the perforated belt; and   an upgraded oil receiving tray disposed below the perforated belt.   
     
     
         4 . The system of  claim 3 , wherein the microwave irradiation system is configured to generate microwave energy having at least one frequency within a range between about 4 gigahertz and about 18 gigahertz, within a range between about 8.0 gigahertz and about 8.8 gigahertz, within a range between about 8.1 gigahertz and about 8.7 gigahertz, within a range between about 8.2 gigahertz and about 8.6 gigahertz, within a range between about 8.3 gigahertz and about 8.5 gigahertz, or about 8.4 gigahertz. 
     
     
         5 . The system of  claim 3 , wherein the upgrader further comprises a gas outlet extending from the solids output chute. 
     
     
         6 . The system of  claim 3 , further comprising ancillary equipment fluidly coupled with the gas outlet. 
     
     
         7 . The system of  claim 3 , wherein the upgrader further comprises a heating means for heating the crude oil prior to the crude oil being disposed on the conveyor. 
     
     
         8 . The system of  claim 3 , wherein the upgrader further comprises an electron activator pump for introducing an electron activator into the crude oil prior to the crude oil being disposed on the conveyor. 
     
     
         9 . The system of  claim 1 , wherein the upgrader comprises:
 a microwave reactor comprising a vessel and an atomizer disposed in the vessel;   a microwave irradiation system comprising one or more microwave generators and one or more microwave antennas disposed in the vessel;   a vacuum pump in fluid communication with the vessel;   a crude oil inlet extending into the vessel and in fluid communication with the atomizer;   an upgraded oil outlet extending from the vessel; and   a gas outlet extending from the vessel.   
     
     
         10 . The system of  claim 9 , further comprising ancillary equipment fluidly coupled with the gas outlet. 
     
     
         11 . The system of  claim 9 , wherein the upgrader further comprises an input pump in fluid communication with the crude oil inlet. 
     
     
         12 . The system of  claim 9 , wherein the microwave irradiation system is configured to generate microwave energy having at least one frequency within a range between about 4 gigahertz and about 18 gigahertz, within a range between about 8.0 gigahertz and about 8.8 gigahertz, within a range between about 8.1 gigahertz and about 8.7 gigahertz, within a range between about 8.2 gigahertz and about 8.6 gigahertz, within a range between about 8.3 gigahertz and about 8.5 gigahertz, or about 8.4 gigahertz. 
     
     
         13 . The system of  claim 9 , wherein the upgrader further comprises a heating means for heating the crude oil prior to the crude oil being introduced to the microwave reactor. 
     
     
         14 . The system of  claim 9 , wherein the upgrader further comprises an electron activator pump for introducing an electron activator into the crude oil prior to the crude oil being introduced to the microwave reactor. 
     
     
         15 . The system of  claim 1 , at least one of the one or more production lines comprising an oil/water separator operably associated with the oil well and the upgrader, such that crude oil produced from the oil well is processed by the oil/water separator before being routed to the upgrader. 
     
     
         16 . The system of  claim 1 , further comprising a second oil well operatively associated with the upgrader. 
     
     
         17 . The system of  claim 1 , further comprising a control system operatively associated with the upgrader for operating the upgrader. 
     
     
         18 . The system of  claim 1 , wherein a capacity of the upgrader generally corresponds to a crude oil production rate of the one or more oil wells. 
     
     
         19 . A method for scalably upgrading crude oil, comprising:
 providing an upgrader proximate an oil well;   producing crude oil from the oil well;   transporting the crude oil to the upgrader;   upgrading the crude oil in the upgrader; and   transporting the upgraded crude oil away from the upgrader.   
     
     
         20 . The method of  claim 19 , wherein upgrading the crude oil in the upgrader is accomplished by irradiating the crude oil in the upgrader with microwave radiation. 
     
     
         21 . The method of  claim 20 , further comprising transporting the crude oil on a conveyor as the crude oil is irradiated with microwave radiation. 
     
     
         22 . The method of  claim 20 , further comprising atomizing the crude oil prior to the crude oil being irradiated with microwave radiation. 
     
     
         23 . The method of  claim 20 , further comprising heating the crude oil prior to irradiating the crude oil with microwave radiation. 
     
     
         24 . The method of  claim 20 , further comprising introducing an electron activator into the crude oil prior to irradiating the crude oil with microwave radiation. 
     
     
         25 . The method of  claim 20 , wherein irradiating the crude oil with microwave radiation is accomplished by irradiating the crude oil with microwave radiation exhibiting at least one frequency within a range between about 4 gigahertz and about 18 gigahertz, within a range between about 8.0 gigahertz and about 8.8 gigahertz, within a range between about 8.1 gigahertz and about 8.7 gigahertz, within a range between about 8.2 gigahertz and about 8.6 gigahertz, within a range between about 8.3 gigahertz and about 8.5 gigahertz, or about 8.4 gigahertz. 
     
     
         26 . The method of  claim 20 , further comprising using light hydrocarbons produced from irradiating the crude oil in the upgrader to operate an ancillary equipment. 
     
     
         27 . The method of  claim 19 , further comprising removing at least some water from the crude oil before upgrading the crude oil in the upgrader. 
     
     
         28 . The method of  claim 19 , further comprising:
 producing crude oil from a second oil well;   transporting the crude oil produced from the second oil well to the upgrader; and   upgrading the crude oil from the second oil well in the upgrader.   
     
     
         29 . The method of  claim 19 , further comprising;
 remotely sensing conditions of the upgrader; and   remotely controlling operation of the upgrader.   
     
     
         30 . The method of  claim 19 , wherein providing the upgrader is accomplished by providing an upgrader having a capacity that generally corresponds to a crude oil production rate of the oil well.