In situ catalytic upgrading

Abstract

A system and method for in situ upgrading of crude oil is provided. The system includes at least one injection well, at least two first production wells, and at least one second production well. The at least one injection well has a vertical portion and a plurality of non-vertical portions connected to the vertical portion. The at least two first production wells are preferably equi-spaced and each has a horizontal portion with a first axial direction, wherein each said horizontal portion of the first production wells is horizontally spaced apart. The at least one second production well has a horizontal portion with a second axial direction. The catalytic reactor is placed at the horizontal portion of the at least one second production well such that oil coming through the second production well will first go through the catalytic reactor for hydroprocessing.

1 . A system for in situ upgrading crude oil within an oil reservoir prior to production, comprising:
 at least one injection well having a vertical portion and a plurality of non-vertical portions connected to the vertical portion;   at least two first production wells parallel to each other and each having a horizontal portion with a first axial direction, wherein each said horizontal portion of the first production wells being horizontally spaced apart;   at least one second production well having a horizontal portion with a second axial direction; and   a catalytic reactor placed at the horizontal portion of the at least one second production well;   wherein the horizontal portion of the at least one second production well is vertically lower than the horizontal portion of the at least two first production wells; the first axial direction is substantially perpendicular to the second axial direction or are substantially equi-spaced if more than two.   
     
     
         2 . The system of  claim 1 , wherein the catalytic reactor comprises a catalyst bed, a gas inlet and a plurality of slots for taking in crude oil. 
     
     
         3 . The system of  claim 2 , wherein the catalytic bed comprises hydro-processing catalysts. 
     
     
         4 . The system of  claim 3 , wherein the hydro-processing catalysts are selected from the group consisting of metal sulfides, metal carbides, refractory type metal compounds, and combination thereof. 
     
     
         5 . The system of  claim 4 , wherein the metal sulfides are selected from the group consisting of MoS 2 , WS 2 , CoMoS, NiMoS, and combination thereof. 
     
     
         6 . The system of  claim 4 , wherein the metal carbides are selected from the group consisting of MoC, WC, and combinations thereof. 
     
     
         7 . The system of  claim 4 , wherein the refractory type metal compounds are selected from the group consisting of phosphosides, nitrides and borides of transition metals. 
     
     
         8 . The system of  claim 7 , wherein the refractory type metal compounds are selected from the group consisting of Co 2 P, Ni 2 P, MoP, WP, NiMoP, Mo 2 N, Co 4 N, Fe 3 N, W 2 N, MoB, WB, Ni 2 B, Co 2 B, and combinations thereof. 
     
     
         9 . The system of  claim 1 , wherein the injection well extends within the oil reservoir until at least 5 meters above the bottom of the reservoir. 
     
     
         10 . The system of  claim 2 , wherein the catalytic reactor further comprises at least one heater for heating the catalyst bed. 
     
     
         11 . A method of in-situ upgrading crude oil within an oil reservoir prior to production, comprising:
 providing an injection well within the oil reservoir, the injection well having a vertical portion and a plurality of non-vertical portions connected to the vertical portion;   providing at least two first production wells each having a horizontal portion with a first axial direction, wherein each said horizontal portion of the first production wells being horizontally spaced apart;   providing at least one second production well having a horizontal portion with a second axial direction, wherein a catalytic reactor being placed at the horizontal portion of the second production well, the horizontal portion of the at least one second production well being vertically lower than the horizontal portion of the at least two first production wells, and the first axial direction being substantially perpendicular to the second axial direction or are substantially equi-spaced if more than two;   performing steam stimulation to heat the oil deposit with the oil reservoir;   injecting a combustion agent into the injection well; and   producing crude oil from the at least one second production well.   
     
     
         12 . The method of  claim 11 , wherein the catalytic reactor comprises a catalyst bed, a gas inlet, and a plurality of slots for taking in the crude oil. 
     
     
         13 . The method of  claim 12 , wherein the catalytic bed comprises hydro-processing catalysts. 
     
     
         14 . The method of  claim 13 , wherein the hydro-processing catalysts include metal sulfides, metal carbides, refractory type metal compounds, or combinations thereof. 
     
     
         15 . The method of  claim 14 , wherein the metal sulfides are selected from the group consisting of MoS 2 , Ws 2 , CoMoS, NiMoS, and combinations thereof. 
     
     
         16 . The method of  claim 14 , wherein the metal carbides are selected from the group consisting of MoC, WC, and combinations thereof. 
     
     
         17 . The method of  claim 14 , wherein the refractory type metal compounds include phosphosides, nitrides or borides of transition metals. 
     
     
         18 . The method of  claim 17 , wherein the refractory type metal compounds are selected from the group consisting of Co 2 P, Ni 2 P, MoP, WP, NiMoP, Mo 2 N, Co 4 N, Fe 3 N, W 2 N, MoB, WB, Ni 2 B, Co 2 B, and combinations thereof. 
     
     
         19 . The method of  claim 12 , wherein the catalytic reactor further comprises at least one heater for heating the reactor. 
     
     
         20 . The method of  claim 11 , further comprising the following step: introducing hydrogen through the gas inlet to the catalytic reactor. 
     
     
         21 . The system of  claim 11 , wherein the combustion agent is selected from oxygen, oxygen-enriched air, and the combination thereof.