Gravitational collision enhanced upgrading of heavy oils

Abstract

The present invention relates to gravitational collision enhanced upgrading of heavy oils, It thus describes a thermodynamic cracking process for heavy oil, extra heavy oil and bituem as well as a thermodynamic cracking unit for carrying out the process.

1 . A thermodynamic cracking process of heavy oil, extra heavy oil and bitumen, characterized in that cracking is carried out in an reactor (oil cracker) having re-circulation rings under the influence two or more gravitational and accelerated jets of hot mineral heat carrier and combustion gasses, colliding jets injected at a positive angle into the lower part of the oil cracker whereby the stream will be diverted upwards introducing mechanical shear forces and hotspots which together with an operating temperature between 450 C and 600 C cracks the oil injected and atomized at the bottom of the oil cracker. 
     
     
         2 . The thermodynamic process in accordance with  claim 1 , characterized in that the energy carrier is selected from fine grained minerals, such as silica, magnesium oxide, aluminum oxide, copper oxide, anorthisite, olivine or similar materials. 
     
     
         3 . The thermodynamic process in accordance with  claim 1 , characterized in that hydrogen is produced in the oil cracker by the gas/water shift CO+H 2 0 ═H   2 +C0 2  where the hydrogen hydrogenates the cracked oil gas in the oil cracker under the influence of cavitations due to internal remixing rings. 
     
     
         4 . The thermodynamic process in accordance with  claim 1 , characterized in that the energy carrier is regenerated in a fluidized regeneration chamber having fluidizing fluidization nozzles above a plenum receiving air and where the energy carrier is regenerated by oxidizing co-accumulated coke contained therein and that the regenerator have internal recirculation rings for optimizing combustion conditions. 
     
     
         5 . The thermodynamic process in accordance with  claim 4 , characterized in that the regenerator comprises a heat exchanger and a recirculation pipe for flue gas to control the temperature of the energy carrier in the reactor by steam generation in the heat exchanger. 
     
     
         6 . The thermodynamic process in accordance with  claim 1 , characterized in that regenerated energy carrier is transported pneumatically and by gravitational fall down  2  pipes termed collision pipes which at their lower ends are diverted to connect with an oil cracker and that the internal diameter is reduced in order to accelerate the stream of heat carrier and combustion gasses entering the oil cracker. 
     
     
         7 . The thermodynamic process in accordance with  claim 1 , characterized in that the coke which is oxidized on the energy carrier delivers the energy for the operation of the process and surplus energy for steam production. 
     
     
         8 . The thermodynamic process in accordance with  claim 1 , characterized in that the product gases are passed to a suitable condensing system consisting of an oil- or steam condenser or a distillation column. 
     
     
         9 . The thermodynamic process in accordance with  claim 1 , characterized in that the feed oil is preheated by the heat of condensation of the gases and that the oil is atomized in a an atomization nozzle by steam or gas. 
     
     
         10 . A thermodynamic cracking unit, characterized in that it comprises a cyclone and a down comer connected to a loop seal with two exits whereby the heat carrier can be re-circulated either to the oil cracker or the regenerator thus optimizing the control of the process as regard temperature and heat carrier load. 
     
     
         11 . The thermodynamic cracking unit in accordance with  claim 10 , characterized in that the colliding particles in the oil cracker lead to sonoluminiscense caused by the fact that gas trapped in cavities on the particles and between these are exposed to adiabatic compression whereby temperature and pressure of the gas bubbles are increased and sonoluminescense is created by splitting of the molecules in the gas, which can be oil gas or steam, and emits light and by the fact that part of the oxygen radicals binds to the cracked oil molecules and thereby results in hydrogenation of the oil and that the collisions generates hot spots.