Systems and processes for upgrading hydrocarbons

Abstract

A process for upgrading a hydrocarbon-based composition, comprising: combining a supercritical water stream with a pressurized and heated hydrocarbon-based composition in a mixer to produce a mixed feed stream, which is introduced into a supercritical upgrading reactor to at least partially convert the mixed feed stream to an upgraded product; separating the upgraded product to produce a light fraction and a heavy fraction, and separating the light fraction in a gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; combining the heavy fraction with at least a portion of either the liquid oil fraction or the first water fraction to form a diluted heavy fraction; and passing the diluted heavy fraction from the flash drum through a demulsifying mixer to form a demulsified heavy fraction.

Description

Description of Related Applications

[0001] This application claims priority to U.S. Patent Application No. 17 / 142,746, filed January 6, 2021, the entire disclosure of which is incorporated herein by reference. [Technical field]

[0002] FIELD OF THE DISCLOSURE Embodiments of the present disclosure relate generally to upgrading petroleum-based compositions, and more particularly to supercritical reactor systems, processes, and uses for upgrading petroleum-based compositions. [Background technology]

[0003] Petroleum is an essential energy source; however, most petroleum is heavy or sour, meaning that it contains a large amount of impurities, including sulfur and coke, a high-carbon petroleum residue. Heavy petroleum must be upgraded before it can be made into commercially valuable products, such as fuel. Supercritical water is known to be an effective reaction medium for upgrading heavy oils without excessive hydrogen supply. Although supercritical water processes have superior performance over conventional refining processes, it is important to achieve maximum efficiency in upgrading by separating as much water as possible from the upgraded hydrocarbons to increase recovery yields. However, conventional oil and water separation processes typically have more than 3 mass percent of the original feedstock lost to water separation, meaning that the separated water product contains more than 3 mass % upgraded hydrocarbons based on the mass of the hydrocarbons in the original feedstock. In addition, there are inherent difficulties in separating water from hydrocarbons in conventional processes due to dense water / oil emulsions. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a need for a process to more efficiently separate water from the upgraded hydrocarbon product in a supercritical water hydrocarbon upgrading process. [Means for solving the problem]

[0005] The present disclosure addresses this need by introducing the upgraded hydrocarbons into a flash drum to produce a light fraction and a heavy fraction, and then introducing the heavy fraction into a demulsifying mixer. The process of the present invention differs from conventional processes in which the upgraded hydrocarbons are introduced into a demulsifying mixer without passing through a flash drum. Additionally, the present disclosure addresses the need for more efficient water separation by introducing a cutterstock fraction, which includes at least a portion of the light fraction, into the heavy fraction either before or after the heavy fraction is introduced into the demulsifying mixer.

[0006] According to one embodiment of the present disclosure, there is provided a process for upgrading a hydrocarbonaceous composition, the process comprising the steps of: combining a supercritical water stream with a pressurized and heated hydrocarbonaceous composition in a mixing device to produce a mixed feed stream; introducing the mixed feed stream into a supercritical upgrading reactor operating at a temperature above the critical temperature of water and a pressure above the critical pressure of water; at least partially converting the mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrading reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing the light fraction to a gas / oil / water separator; separating the light fraction in the gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; combining the heavy fraction with at least a portion of either the liquid oil fraction or the first water fraction to form a diluted heavy fraction; and passing the diluted heavy fraction from the flash drum to a demulsifying mixer to form a demulsified heavy fraction.

[0007] In another embodiment of the present disclosure, another process for upgrading a hydrocarbonaceous composition is provided, the process comprising the steps of: combining a supercritical water stream with a pressurized and heated hydrocarbonaceous composition in a mixer to form a mixed feed stream; introducing the mixed feed stream into a supercritical upgrading reactor operating at a temperature above the critical temperature of water and at a pressure above the critical pressure of water; at least partially converting the mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrading reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing the light fraction to a gas / oil / water separator; separating the light fraction in the gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; passing the heavy fraction from the flash drum to a demulsifying mixer to form a demulsified heavy fraction; and separating the heavy fraction from the flash drum to produce a demulsified heavy fraction. liquid oil fraction to form a diluted demulsified heavy fraction.

[0008] Although the concepts of the present invention are expressed primarily with reference to boilers, gas turbines, compression units, incineration units, and the like, it is believed that the concepts are applicable to systems having any configuration or means. [Brief description of the drawings]

[0009] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings. [Figure 1] 1 is a schematic diagram of a process for upgrading a hydrocarbon-based composition according to an embodiment of the present disclosure. [Diagram 2] 1 is a schematic diagram of a process for upgrading a hydrocarbon-based composition according to an embodiment of the present disclosure. [Diagram 3] 1 is a schematic diagram of a process for upgrading a hydrocarbon-based composition according to an embodiment of the present disclosure. [Figure 4] 1 is a schematic diagram of a process for upgrading a hydrocarbon-based composition according to an embodiment of the present disclosure. [Diagram 5] 1 is a schematic diagram of a process for upgrading a hydrocarbon-based composition according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] SUMMARY OF THE DISCLOSURE Embodiments of the present disclosure relate to a process for separating an upgraded hydrocarbonaceous product from a water product in a supercritical water process.

[0011] As used throughout this disclosure, "supercritical" refers to a substance at or above its critical pressure and temperature, such that no distinct phases exist and the substance may exhibit rapid diffusion of gases while dissolving liquid-like materials. Thus, supercritical water is water with a temperature and pressure above the critical temperature and pressure of water. At temperatures and pressures above the critical temperature and pressure, the boundary between the liquid and gas phases of water disappears and the fluid has characteristics of both liquid and gaseous substances. Supercritical water can dissolve organic compounds such as organic solvents and has excellent gas-like diffusivity. By adjusting the temperature and pressure, continuous "tuning" of the properties of supercritical water to be more liquid-like or more gaseous is possible. Supercritical water has reduced density and less polarity compared to liquid-phase subcritical water, which greatly expands the range of possible chemical reactions that can take place in water.

[0012] As used throughout this disclosure, "upgrading" means increasing the American Petroleum Institute (API) gravity, decreasing the amount of impurities such as sulfur, nitrogen, and metals, decreasing the amount of asphaltenes, and increasing the amount of light ends.

[0013] Supercritical water has a variety of unexpected properties when it reaches the supercritical boundary. Supercritical water has very high solubility for organic compounds and infinite miscibility with gases. Additionally, radical species can be stabilized by supercritical water due to the cage effect (i.e., a condition in which one or more water molecules surround a radical species, thereby preventing the radical species from interacting). Without being limited by theory, stabilizing the radical species helps prevent inter-radical condensation, thereby reducing overall coke formation in the current embodiment. For example, coke formation can be a result of inter-radical condensation. In certain embodiments, supercritical water produces hydrogen gas through steam reforming and water-gas shift reactions, which can then be utilized in the upgrading reaction.

[0014] Furthermore, the high temperature and pressure of supercritical water would give water a density of 0.123 grams per milliliter (g / mL) at 27 MPa and 450°C. In contrast, if the pressure were reduced to produce superheated steam, for example at 20 MPa and 450°C, the steam would have a density of only 0.079 g / mL. At that density, the hydrocarbons would interact with the superheated steam, vaporize, and mix with the vapor phase, leaving behind heavy fractions that can form coke upon heating. If coke or coke precursors form, they can clog lines and must be removed. Thus, supercritical water is superior to steam in some applications.

[0015] Specific embodiments will now be described with reference to the drawings, in which, wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0016] 1-5 generally illustrate various processes 100 for upgrading a hydrocarbonaceous composition 105 that is upgraded in a supercritical upgrading reactor 140 according to described embodiments.

[0017] The hydrocarbon-based composition 105 may refer to any hydrocarbon source derived from petroleum, coal liquids, or biomaterials. Potential sources of the hydrocarbon-based composition 105 may include crude oil, distillate crude oil, atmospheric resid, residual oil, tops crude oil, product streams from petroleum refineries, product streams from steam cracking processes, liquefied coal, liquid products recovered from oil or tar sands, bitumen, oil shale, asphaltenes, biomass hydrocarbons, and the like. Many compositions are suitable for the hydrocarbon-based composition 105. In some embodiments, the hydrocarbon-based composition 105 may include heavy crude oil or a portion of heavy crude oil. In other embodiments, the hydrocarbon-based composition 105 may include atmospheric resid (AR), atmospheric distillate, vacuum gas oil (VGO), vacuum distillate, or vacuum resid (VR), or cracked products (light cycle oil (LCO), coker gas oil). In some embodiments, the hydrocarbon-based composition 105 may be a combined stream from a refinery, a product oil, or other hydrocarbon stream from upstream operations, etc. The hydrocarbon-based composition 105 may be a decanted oil, an oil containing 10 carbons or more (C10+ oil), or a hydrocarbon stream from an ethylene plant. The hydrocarbon-based composition 105 may be, in some embodiments, a biomaterial derivative, such as liquefied coal or biofuel oil. In some embodiments, used lube oil or brake fluid may be used.

[0018] The hydrocarbonaceous composition 105 may be a naphtha or kerosene or diesel fraction in some embodiments. Such fractions may be used, but would not be significantly upgraded with supercritical water and therefore would be undesirable. Contaminated hydrocarbonaceous fractions may also be used. In some embodiments, fractions contaminated with brine may be used as the hydrocarbonaceous composition 105. For example, commercial crude oils typically have a salt content of less than about 10 PTB (pounds of salt per thousand barrels of oil). The salts in the brine may be precipitated with supercritical water to produce a desalted product, which may be desirable in certain embodiments.

[0019] As shown in Figures 1-5, the hydrocarbon-based composition 105 can be pressurized in a hydrocarbon pump 112 to create a pressurized hydrocarbon-based composition 116. The pressure of the pressurized hydrocarbon-based composition 116 can be at least 22.1 megapascals (MPa), which is about the critical pressure of water. Alternatively, the pressure of the pressurized hydrocarbon-based composition 116 can be between 23 MPa and 35 MPa, or between 24 MPa and 30 MPa. For example, the pressure of the pressurized hydrocarbon-based composition 116 can be between 25 MPa and 29 MPa, between 26 MPa and 28 MPa, between 25 MPa and 30 MPa, between 26 MPa and 29 MPa, or between 24 MPa and 28 MPa.

[0020] Still referring to any of Figures 1-5, the pressurized hydrocarbonaceous composition 116 can then be heated in one or more hydrocarbon preheaters 120 to form a pressurized heated hydrocarbonaceous composition 124. In one embodiment, the pressurized heated hydrocarbonaceous composition 124 has a pressure greater than the critical pressure of water and a temperature greater than 75°C. Alternatively, the temperature of the pressurized heated hydrocarbonaceous composition 124 is between 10°C and 300°C, or between 50°C and 250°C, or between 75°C and 225°C, or between 100°C and 200°C, or between 125°C and 175°C, or between 140°C and 160°C. The pressurized heated hydrocarbonaceous composition 124 should not be heated above about 350°C, and in some embodiments, should not be heated above 300°C to avoid the formation of coke products. See U.S. Patent No. 4,243,633 to Hozuma, all of which are incorporated by reference. Although some coke or coke precursor products may be allowed to pass through the process line without slowing down or stopping the process 100, the formation of these potentially problematic compounds should be avoided, if possible.

[0021] Embodiments of the hydrocarbon preheater 120 may include a natural gas furnace, a heat exchanger, or an electric heater or any type of heater known in the art. In some embodiments, not shown, the pressurized and heated hydrocarbonaceous composition 124 may be heated in a double-pipe heat exchanger. For example, and without limitation, the double-pipe heat exchanger may heat the pressurized and heated hydrocarbonaceous composition 124 after it is combined with the supercritical water stream 126 to form the combined feed stream 132.

[0022] As shown in FIGS. 1-5, the water stream 110 can be any water source, such as a water stream having a conductivity of less than 1 microsiemens (μS) / centimeter (cm), e.g., less than 0.1 μS / cm. The water stream 110 can also include demineralized water, distilled water, boiler water (BFW), and deionized water. In at least one embodiment, the water stream 110 is a boiler water stream. The water stream 110 is pressurized by a water pump 114 to form a pressurized water stream 118. The pressure of the pressurized water stream 118 is at least 22.1 MPa, which is about the critical pressure of water. Alternatively, the pressure of the pressurized water stream 118 can be between 23 MPa and 35 MPa, or between 24 MPa and 30 MPa. For example, the pressure of the pressurized water stream 118 may be between 25 MPa and 29 MPa, between 26 MPa and 28 MPa, between 25 MPa and 30 MPa, between 26 MPa and 29 MPa, or between 24 MPa and 28 MPa.

[0023] The pressurized water stream 118 can then be heated in a water preheater 122 to create a supercritical water stream 126. The temperature of the supercritical water stream 126 is greater than 374° C., which is approximately the critical temperature of water. Alternatively, the temperature of the supercritical water stream 126 can be greater than 380° C., for example, between 380° C. and 600° C., or between 400° C. and 550° C., or between 400° C. and 500° C., or between 400° C. and 450° C., or between 450° C. and 500° C. In some embodiments, the maximum temperature of the supercritical water stream 126 can be 600° C., since mechanical components of the water preheater and supercritical reactor system will be affected at temperatures greater than 600° C. In embodiments, the supercritical water stream 126 has a low metal content and a low electrical conductivity, such as less than 1 microSiemens.

[0024] Suitable water preheaters 122 may include natural gas furnaces, heat exchangers, or electric heaters, similar to the hydrocarbon preheater 120. The water preheater 122 may be a separate and independent unit from the hydrocarbon preheater 120.

[0025] The supercritical water stream 126 and the pressurized and heated hydrocarbonaceous composition 124 may then be mixed in a feed mixer 130 to produce a mixed feed stream 132. The feed mixer 130 can be any type of mixing device capable of mixing the supercritical water stream 126 and the pressurized and heated hydrocarbonaceous composition 124. In one embodiment, the feed mixer 130 can be a mixing tee. The feed mixer 130 can be an ultrasonic device, a miniature continuous stirred tank reactor (CSTR), or any suitable mixer. The volumetric flow ratio of supercritical water to hydrocarbons fed to the feed mixer 130 can vary. In one embodiment, the volumetric flow ratio can be 10:1 to 1:10, or 5:1 to 1:5, or 1:1 to 4:1 at standard ambient temperature and pressure (SATP).

[0026] The mixed feed stream 132 can then be introduced into a supercritical upgrade reactor 140 designed to upgrade the mixed feed stream 132. The supercritical upgrade reactor 140 can be an upflow, downflow, or horizontal flow reactor. Upflow, downflow, or horizontal flow reactor refers to the direction in which the supercritical water and the hydrocarbonaceous composition flow through the supercritical upgrade reactor 140. An upflow, downflow, or horizontal flow reactor can be selected based on the desired application and system configuration. Without intending to be bound by any theory, in a downflow supercritical reactor, the heavy hydrocarbon fraction can flow very fast due to its greater density, which can result in a short residence time (also known as channeling). This can hinder upgrading as there is less time for reactions to occur. Upflow supercritical reactors have an increased and uniform distribution of residence time (no channeling), but can experience difficulties due to large particles, such as the undissolved portion of the heavy fraction and carbon-containing compounds in the heavy fraction, accumulating at the bottom of the reactor. This accumulation can impede the upgrading process and plug the reactor. Upflow reactors typically utilize a catalyst to increase contact with the reactants; however, the catalyst can break down and form insoluble agglomerates due to the harsh conditions of the supercritical water, which can result in the production of coke. Horizontal reactors can be useful for applications that require phase separation or seek to reduce pressure drop; however, it is difficult to control the hydrodynamics of the internal fluids. Each type of reactor flow has significantly different positive and negative attributes based on the applicable process; however, in some embodiments, upflow or downflow reactors can be preferred.

[0027] The mixed feed stream 132 can be introduced through an inlet port of the supercritical upgrade reactor 140. The supercritical upgrade reactor 140 can operate at a temperature above the critical temperature of water and a pressure above the critical pressure of water. In one or more embodiments, the supercritical upgrade reactor 140 can have a temperature of 380° C. to 480° C., or 390° C. to 450° C. The supercritical upgrade reactor 140 can be an isothermal or non-isothermal reactor. The reactor can be a tubular vertical reactor, a tubular horizontal reactor, a tank reactor, a tank reactor with an internal mixing device such as an agitator, or any combination of these reactors. Additionally, additional components such as a stirrer or agitation devices can also be included in the supercritical upgrade reactor 140.

[0028] The supercritical upgrade reactor 140 may have dimensions defined by the formula L / D, where L is the length of the supercritical upgrade reactor 140 and D is the diameter of the supercritical upgrade reactor 140. In one or more embodiments, the L / D value of the supercritical upgrade reactor 140 may be sufficient to achieve a superficial velocity of the fluid of greater than 0.5 meters (m) / min, or sufficient to achieve a superficial velocity of the fluid of between 1 m / min and 5 m / min. Such relatively high fluid velocities are desirable to obtain fully turbulent flow of the internal fluid. The desired Reynolds number (a measure of flow rate) is greater than 5000.

[0029] In some embodiments, the residence time of the internal fluid in the supercritical upgrade reactor 140 can be greater than 5 seconds, e.g., greater than 1 minute. In some embodiments, the residence time of the internal fluid in the supercritical upgrade reactor 140 can be between 2 and 30 minutes, e.g., between 2 and 20 minutes, or between 5 and 15 minutes, or between 5 and 10 minutes.

[0030] The pressure of the upgraded product 142 of the supercritical upgrade reactor 140 may be reduced upon exiting the reactor to produce a cooled upgraded product 146, which may be at a pressure of 0.05 MPa to 2.2 MPa. The reduction in pressure may be accomplished by a number of devices, for example, valve 144, as shown in Figures 1-5. If desired, the upgraded product 142 may be cooled in a chiller (not shown) upstream of the valve 144 to a temperature below the critical point of water (374°C), for example, to 200°C to 300°C, 200°C to 250°C, or 250°C to 300°C. Various cooling devices, such as a heat exchanger, are contemplated for the chiller.

[0031] Still referring to any of Figures 1-5, the cooled upgraded product 146 may then be fed to a flash drum 150 to separate the cooled upgraded product 146 into a heavy fraction 152 and a light fraction 154. In some embodiments, the light fraction 154 and the heavy fraction 152 may be liquid-containing fractions, where the hydrocarbons in the light fraction 154 have a greater API gravity value than those in the heavy fraction 152. API gravity is a measure of how heavy or light an oil is compared to water based on its density relative to water (also known as specific gravity). API gravity can be calculated according to Equation 1, as follows:

[0032]

number

[0033] API gravity is a dimensionless quantity expressed in degrees, with most petroleum oils falling between 10° and 70°. In some embodiments, the hydrocarbons in the light fraction 154 will have an API gravity value of 30° or greater. The hydrocarbons in the light fraction 154 may have an API gravity value of 30° to 40°, 30° to 45°, or 30° to 50°, or 30° to 70°. In some embodiments, the hydrocarbons in the light fraction 154 may have an API gravity value of 31° or greater, for example, 31.1°. In some embodiments, the hydrocarbons in the light fraction 154 may have an API gravity value of 40° to 45°, which may be highly commercially desirable. In some embodiments, it may be desirable for the hydrocarbons in the light fraction 154 to have an API gravity value of less than 45°.

[0034] The hydrocarbons in the heavy fraction 152 may have an API gravity value of 30° or less. For example, the hydrocarbons in the heavy fraction 152 may have an API gravity value of less than 30° and greater than or equal to 1°. In some embodiments, the hydrocarbons in the heavy fraction 152 may have API gravity values ​​of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°. The hydrocarbons in the heavy fraction 152 may have API gravity values ​​of 20° or less, 15° or less, or 10° or less.

[0035] The heavy fraction 152 may have a temperature of 40°C to 300°C, 40°C to 200°C, 40°C to 150°C, 40°C to 120°C, 40°C to 80°C, 40°C to 50°C, 50°C to 300°C, 50°C to 200°C, 50°C to 150°C, 50°C to 120°C, 50°C to 80°C, 80°C to 300°C, 80°C to 200°C, 80°C to 150°C, 80°C to 120°C, 120°C to 300°C, 120°C to 200°C, 120°C to 150°C, 150°C to 300°C, 150°C to 200°C, or 200°C to 300°C.

[0036] In some embodiments, the hydrocarbons in the light fraction 154 may have a T5 true boiling point (TBP), referred to when at least 5% of the fraction has evaporated, of 350° C. or less. In embodiments, vapor phase products having a boiling point below 5° C. at ambient pressure are removed from the light fraction 154 before measuring the TBP. This ensures that the TBP is free of such light gases (at least in amounts). These gases include CO, CO2, H2S, C1, C2, C3, and C4. For example, the hydrocarbons in the light fraction 154 may have a T5TBP of 340° C. or less, 330° C. or less, 300° C. or less, 250° C. or less, 200° C. or less, 150° C. or less, 100° C. or less, 75° C. or less, 60° C. or less, 50° C. or less, 40° C. or less, 35° C. or less, 30° C. or less, or 25° C. or less. In some embodiments, the hydrocarbons in the light fraction 154 may have a T5TBP of 150° C. or less, e.g., 125° C. or less, 75° C. or less, or 50° C. or less. The hydrocarbons in the light fraction 154 may have a T5TBP of 450° C. or less, or 440° C. or less, or 435° C. or less, or 430° C. or less, or 425° C. or less, which is referred to when at least 90% of the fraction has evaporated. 90 May have TBP.

[0037] In some embodiments, the light ends fraction 154 may contain 50 to 100%, 70 to 100%, 80 to 100%, 85 to 100%, 90 to 100%, 95 to 100%, 99 to 100%, 50 to 99%, 70 to 99%, 80 to 99%, 85 to 99%, 90 to 99%, 95 to 99%, 50 to 95%, 70 to 95%, 80 to 95%, 85 to 95%, 90 to 95%, 50 to 90%, 70 to 90%, 80 to 90%, 85 to 90%, 50 to 85%, 70 to 85%, or 80 to 85% water by weight.

[0038] In some embodiments, the hydrocarbons in the heavy fraction 152 may have a T5TBP of 80° C. or more, e.g., from 80° C. to 120° C. The hydrocarbons in the heavy fraction 152 may have a T5TBP of 130° C. or more, or 140° C. or more, or 560° C. or less. The hydrocarbons in the heavy fraction 152 may have a T5TBP of 900° C. or less, e.g., 890° C. or less, or 885° C. or less, or 875° C. or less. 90 May have TBP.

[0039] In some embodiments, heavy fraction 152 may contain 0 to 50%, 0 to 30%, 0 to 20%, 0 to 15%, 0 to 10%, 0 to 5%, 0 to 1%, 1 to 50%, 1 to 30%, 1 to 20%, 1 to 15%, 1 to 10%, 1 to 5%, 5 to 50%, 5 to 30%, 5 to 20%, 5 to 15%, 5 to 10%, 10 to 50%, 10 to 30%, 10 to 20%, 10 to 15%, 15 to 50%, 15 to 30%, or 15 to 20% water by weight.

[0040] Still referring to any of Figures 1-5, the light fraction 154 may be passed to a gas / oil / water separator 160. The gas / oil / water separator 160 may separate the light fraction 154 into a gas fraction 164, a liquid oil fraction 162, and a first water fraction 166. The gas / oil / water separator 160 may be any separator known in the industry. The gas / oil / water separator 160 may separate the light fraction into at least a gas fraction 164, a liquid oil fraction 162, and a first water fraction 166, although it should be appreciated that additional fractions may be produced.

[0041] The hydrocarbons in the liquid oil fraction 162 may have a T5TBP of 340° C. or less, 330° C. or less, 300° C. or less, 250° C. or less, 200° C. or less, 150° C. or less, 100° C. or less, 75° C. or less, 60° C. or less, 50° C. or less, 40° C. or less, 35° C. or less, 30° C. or less, or 25° C. or less. In some embodiments, the hydrocarbons in the liquid oil fraction 162 may have a T5TBP of 150° C. or less, e.g., 125° C. or less, 75° C. or less, or 50° C. or less. The hydrocarbons in the liquid oil fraction 162 may have a T5TBP of 450° C. or less, or 440° C. or less, or 435° C. or less, or 430° C. or less, or 425° C. or less, referred to when at least 90% of the fraction has evaporated. 90 May have TBP.

[0042] In embodiments, the liquid oil fraction 162 may contain 0 to 0.3 wt. % water, 0 to 0.1 wt. % water, or 0 wt. % water.

[0043] In embodiments, the first water fraction 166 may contain 99 to 100% by weight, 99 to 99.9% by weight, 99 to 99.7% by weight, 99.7 to 100% by weight, 99.7 to 99.9% by weight, 99.9 to 100% by weight, or 100% by weight water.

[0044] 1-2, in an embodiment, the liquid oil fraction 162 may be sent to an oil storage tank 168 and the first water fraction 166 may be diverted via a water stream diverter 170 into a water product 172 and a water cutter stock 174. The first water fraction 166 may be diverted such that the water product 172 comprises 5 vol.% to 95 vol.%, 10 vol.% to 95 vol.%, 20 vol.% to 95 vol.%, 30 vol.% to 95 vol.%, 40 vol.% to 95 vol.%, 50 vol.% to 90 vol.%, 50 vol.% to 80 vol.%, 50 vol.% to 75 vol.%, 50 vol.% to 70 vol.%, 50 vol.% to 60 vol.%, 60 vol.% to 90 vol.%, 60 vol.% to 80 vol.%, 60 vol.% to 75 vol.%, 60 vol.% to 70 vol.%, 70 vol.% to 90 vol.%, 70 vol.% to 80 vol.%, 70 vol.% to 75 vol.%, 75 vol.% to 90 vol.%, 75 vol.% to 80 vol.%, or 80 vol.% to 90 vol.% of the first water fraction 166. In each of the examples described above, the water cutter stock 174 comprises the remainder of the volume of the first water fraction 166 that was diverted through the water stream diverter 170 . For example, the water cutter stock 174 may comprise 5% to 95% by volume, 5% to 90% by volume, 5% to 80% by volume, 5% to 70% by volume, 5% to 60% by volume, 5% to 50% by volume, 10% to 50% by volume, 10% to 40% by volume, 10% to 30% by volume, 10% to 25% by volume, 10% to 20% by volume, 20% to 50% by volume, 20% to 40% by volume, 20% to 30% by volume, 20% to 25% by volume, 25% to 50% by volume, 25% to 40% by volume, 25% to 30% by volume, 30% to 50% by volume, 30% to 40% by volume, or 40% to 50% by volume of the first water fraction 166. In an embodiment, the flow rate of the water cutter stock 174 is less than the flow rate of the water product 172. The water stream splitter 170 may be any known splitting device capable of separating the first water fraction 166 into at least two streams as shown. As shown in Figures 1-2, in an embodiment, the water product 172 may be sent to a water storage tank 210.The water cutter stock 174 may be sent to a water heater 176 to form heated water cutter stock 178. The water heater 176 may include a natural gas furnace, a heat exchanger, an electric heater, or any type of heater known in the art.

[0045] 2, in embodiments, the heated water cutter stock 178 may then be combined with the heavy fraction 152. Specifically, the heated water cutter stock 178 is combined with the heavy fraction 152 to form a first combined stream 153. In embodiments, the heated water cutter stock 178 may be combined with the heavy fraction 152 by a mixer (not shown), which may be any suitable mixer known in the art, such as a simple mixing tee, an ultrasonic device, a small continuous stirred tank reactor (CSTR), or another known mixer.

[0046] In embodiments, first mixed stream 153 may include 0 to 50%, 0 to 30%, 0 to 20%, 0 to 15%, 0 to 10%, 0 to 5%, 0 to 1%, 1 to 50%, 1 to 30%, 1 to 20%, 1 to 15%, 1 to 10%, 1 to 5%, 5 to 50%, 5 to 30%, 5 to 20%, 5 to 15%, 5 to 10%, 10 to 50%, 10 to 30%, 10 to 20%, 10 to 15%, 15 to 50%, 15 to 30%, or 15 to 20% water by weight. Increasing the water content is believed to reduce the viscosity of the stream, thereby improving mobility of first mixed stream 153 relative to heavy fraction 152.

[0047] The first mixed stream 153 is then reduced in pressure by the heavy ends valve 180 to form a first reduced-pressure mixed stream 184. The pressure of the first reduced-pressure mixed stream 184 is controlled by the demulsifier mixer valve 194. The pressure of the first reduced-pressure mixed stream 184 may be greater than the saturation pressure of water at the temperature of the first reduced-pressure mixed stream 184 and the first demulsified heavy ends 192.

[0048] In embodiments, first depressurized mixed stream 184 may include 0 to 50%, 0 to 30%, 0 to 20%, 0 to 15%, 0 to 10%, 0 to 5%, 0 to 1%, 1 to 50%, 1 to 30%, 1 to 20%, 1 to 15%, 1 to 10%, 1 to 5%, 5 to 50%, 5 to 30%, 5 to 20%, 5 to 15%, 5 to 10%, 10 to 50%, 10 to 30%, 10 to 20%, 10 to 15%, 15 to 50%, 15 to 30%, or 15 to 20% water by weight.

[0049] Alternatively, returning to Figure 1, in embodiments, the heavy end fraction 152 may first be depressurized via a heavy end valve 180 to form a depressurized heavy end fraction 182 prior to being combined with the heated water cutter stock 178. In such embodiments, the heated water cutter stock 178 may be combined with the depressurized heavy end fraction 182 to form a first depressurized combined stream 184, as shown in Figure 1. In embodiments, the heated water cutter stock 178 may be combined with the depressurized heavy end fraction 182 via a mixer (not shown), as previously described.

[0050] 1-2, the first depressurized mixed stream 184 may then be sent to a demulsifier mixer 190 to form a first demulsified heavy fraction 192. The first depressurized mixed stream 184 may have a flow rate of 0.2 to 0.35 liters per hour (L / hr), 0.2 to 0.3 L / hr, 0.2 to 0.25 L / hr, 0.25 to 0.35 L / hr, 0.25 to 0.3 L / hr, or 0.3 to 0.35 L / hr. In embodiments, the demulsifier mixer 190 may include a CSTR having an internal agitator. In embodiments, the temperature of the demulsifier mixer 190 may be 50° C. to 300° C., 90° C. to 250° C., 110° C. to 200° C., or 150° C. to 175° C. Without intending to be bound by theory, a temperature of 190° C. may provide enough energy for the water droplets in the fluid emulsion to form larger droplets. The size of the water droplets dispersed in the oil medium affects the speed at which the water droplets move and attach to each other through the oil medium. Larger water droplets tend to coalesce more easily and faster due to similar density, polarity, hydrogen bonding, and van der Waals interactions, thereby making it easier to separate the emulsion phases. The pressure of the demulsifying mixer 190 may be higher than the saturation pressure of water at the temperature of the demulsifying mixer 190 to maintain the water in the liquid phase. In an embodiment, a demulsifier may be injected into the demulsifying mixer 190 at 0.001% to 1.5%, 0.01% to 0.5%, or about 0.1% by volume of the volumetric flow rate of the first reduced pressure mixed stream 184. Without intending to be bound by theory, a relatively low injection rate of the demulsifier may be beneficial at least because the demulsifier will introduce additional impurities into the first demulsified heavy fraction 192. In embodiments, the demulsifier may include an amine compound, a polyhydric alcohol, a polyethylene oxide, a glycol, or a combination thereof.

[0051] In an embodiment, the first demulsified heavy fraction 192 may be depressurized through the demulsifier mixer valve 194 to form a first depressurized demulsified heavy fraction 196. The first emulsified heavy fraction 192 may have a pressure of 0.01 MPa to 0.05 MPa, 0.01 MPa to 0.04 MPa, 0.01 MPa to 0.03 MPa, 0.01 MPa to 0.02 MPa, 0.02 MPa to 0.05 MPa, 0.02 MPa to 0.04 MPa, 0.02 MPa to 0.03 MPa, 0.03 MPa to 0.05 MPa, 0.03 MPa to 0.04 MPa, or 0.04 MPa to 0.05 MPa. The first depressurized demulsified heavy fraction 196 may have a pressure of 0.01 MPa to 0.05 MPa, 0.01 MPa to 0.04 MPa, 0.01 MPa to 0.03 MPa, 0.01 MPa to 0.02 MPa, 0.02 MPa to 0.05 MPa, 0.02 MPa to 0.04 MPa, 0.02 MPa to 0.03 MPa, 0.03 MPa to 0.05 MPa, 0.03 MPa to 0.04 MPa, or 0.04 MPa to 0.05 MPa. The first demulsified heavy fraction 192 and the first depressurized demulsified heavy fraction 196 have similar pressure ranges, but the pressure of the first demulsified heavy fraction 196 is lower than the pressure of the first demulsified heavy fraction 192 due to the depressurization by the demulsifier mixer valve 194. This ensures a pressure drop between the first demulsified heavy fraction 192 and the first depressurized demulsified heavy fraction 196, thereby ensuring flow. The first depressurized demulsified heavy fraction 196 may then be sent to an oil / water separator 200 to separate the first depressurized demulsified heavy fraction 196 into a first heavy oil fraction 202 and a second water fraction 204. The oil / water separator 200 may be any separator known in the industry. The first heavy oil fraction 202 may be sent to the oil storage tank 168. The second water fraction 204 may then be sent to a water storage tank 210. In embodiments, the second water fraction 204 may contain 99 to 100%, 99 to 99.9%, 99 to 99.7%, 99.7 to 100%, 99.7 to 99.9%, 99.9 to 100%, or 100% water by weight.

[0052] The hydrocarbons in the first reduced pressure demulsified heavy fraction 196 may have an API gravity value of 30° or less. For example, the hydrocarbons in the first reduced pressure demulsified heavy fraction 196 may have an API gravity value of less than 30° and greater than or equal to 1°. In some embodiments, the hydrocarbons in the first reduced pressure demulsified heavy fraction 196 may have an API gravity value of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°. The hydrocarbons in the first depressurized demulsified heavy fraction 196 may have an API gravity value of 20° or less, 15° or less, or 10° or less.

[0053] In some embodiments, the hydrocarbons in the first reduced pressure demulsified heavy fraction 196 may have a T5TBP of 80° C. or more, e.g., 80° C. to 120° C. The hydrocarbons in the first reduced pressure demulsified heavy fraction 196 may have a T5TBP of 130° C. or more, or 140° C. or more, or 560° C. or less. The hydrocarbons in the first reduced pressure demulsified heavy fraction 196 may have a T5TBP of 900° C. or less, e.g., 890° C. or less, or 885° C. or less, or 875° C. or less. 90 May have TBP.

[0054] The hydrocarbons in the first heavy oil fraction 202 may have an API gravity value of 30° or less. For example, the hydrocarbons in the first heavy oil fraction 202 may have an API gravity value of less than 30° and greater than or equal to 1°. In some embodiments, the hydrocarbons in the first heavy oil fraction 202 may have an API gravity value of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°. The hydrocarbons in the first heavy oil fraction 202 may have an API gravity value of 20° or less, 15° or less, or 10° or less.

[0055] In some embodiments, the hydrocarbons in the first heavy oil fraction 202 may have a T5TBP of 80° C. or more, e.g., 80° C. to 120° C. The hydrocarbons in the first heavy oil fraction 202 may have a T5TBP of 130° C. or more, or 140° C. or more, or 560° C. or less. The hydrocarbons in the first heavy oil fraction 202 may have a T5TBP of 900° C. or less, e.g., 890° C. or less, or 885° C. or less, or 875° C. or less. 90 May have TBP.

[0056] Additionally or alternatively, and now referring to Figures 3-5, in an embodiment, the first water fraction 166 may be sent to a water storage tank 210 and the liquid oil fraction 162 may be diverted via a flow diverter 220 into a liquid oil product 222 and a liquid oil cutter stock 224. The liquid oil fraction 162 may be diverted such that the liquid oil product 222 comprises 50% to 90% by volume, 50% to 80% by volume, 50% to 75% by volume, 50% to 70% by volume, 50% to 60% by volume, 60% to 90% by volume, 60% to 80% by volume, 60% to 75% by volume, 60% to 70% by volume, 70% to 90% by volume, 70% to 80% by volume, 70% to 75% by volume, 75% to 90% by volume, 75% to 80% by volume, or 80% to 90% by volume of the liquid oil fraction 162. In each of the examples described above, the liquid oil cutter stock 224 comprises the remainder of the volume of the liquid oil fraction 162 diverted via the flow diverter 220. For example, the liquid oil cutter stock 224 may comprise 10% to 50% by volume, 10% to 40% by volume, 10% to 30% by volume, 10% to 25% by volume, 10% to 20% by volume, 20% to 50% by volume, 20% to 40% by volume, 20% to 30% by volume, 20% to 25% by volume, 25% to 50% by volume, 25% to 40% by volume, 25% to 30% by volume, 30% to 50% by volume, 30% to 40% by volume, or 40% to 50% by volume of the liquid oil fraction 162. The flow splitter 220 may be any known flow splitting device capable of separating the liquid oil fraction 162 into at least two streams as shown. In an embodiment, the liquid oil product 222 may be sent to the oil storage tank 168. The liquid oil cutter stock 224 may be delivered to an oil heater 226 to form heated liquid oil cutter stock 228 .The heated liquid oil cutter stock 228 may have a temperature of 40° C. to 300° C., 40° C. to 200° C., 40° C. to 150° C., 40° C. to 120° C., 40° C. to 80° C., 40° C. to 50° C., 50° C. to 300° C., 50° C. to 200° C., 50° C. to 150° C., 50° C. to 120° C., 50° C. to 80° C., 80° C. to 300° C., 80° C. to 200° C., 80° C. to 150° C., 80° C. to 120° C., 120° C. to 300° C., 120° C. to 200° C., 120° C. to 150° C., 150° C. to 300° C., 150° C. to 200° C., or 200° C. to 300° C. The oil heater 226 may include a natural gas furnace, a heat exchanger, an electric heater, or any type of heater known in the art.

[0057] The heated liquid oil cutter stock 228 may be combined with the heavy fraction 152 at various points in the downstream process, as shown in each of Figures 3-5. Referring now to Figure 3, in an embodiment, the heated liquid oil cutter stock 228 may then be sent to be combined with the heavy fraction 152. Specifically, the heated liquid oil cutter stock 228 is combined with the heavy fraction 152 to form the second mixed stream 156. In an embodiment, the heated liquid oil cutter stock 228 may be combined with the heavy fraction 152 by a mixer (not shown), which may be any suitable mixer known in the art, such as a simple mixing tee, an ultrasonic device, a small CSTR, or another known mixer. The second mixed stream 156 is then depressurized by the heavy fraction valve 180 to form the second depressurized mixed stream 230. The pressure of the second reduced pressure mixed stream 230 may be greater than the saturation pressure of water at the temperature of the second reduced pressure mixed stream 230 .

[0058] Alternatively, referring to Figure 4, in an embodiment, the heavy distillate 152 may first be depressurized by the heavy distillate valve 180 to form a depressurized heavy distillate 182 prior to being combined with the heated liquid oil cutter stock 228. In such an embodiment, the heated liquid oil cutter stock 228 may be combined with the depressurized heavy distillate 182 to form a second depressurized combined stream 230, as shown in Figure 4. In an embodiment, the heated liquid oil cutter stock 228 may be combined with the depressurized heavy distillate 182 by a mixer (not shown), as previously described.

[0059] 3-4, the second depressurized mixed stream 230 may then be sent to a demulsifying mixer 190 to form a second demulsified heavy fraction 232. The demulsifying mixer 190 may be as previously described.

[0060] Alternatively, with reference to Figure 5, in embodiments, the depressurized heavy fraction 182 may be sent first to a demulsifier mixer 190 before being combined with the heated liquid oil cutter stock 228 to form a third demulsified heavy fraction 198. In such embodiments, the heated liquid oil cutter stock 228 may be combined with the third demulsified heavy fraction 198 to form a second demulsified heavy fraction 232, as shown in Figure 5. In embodiments, the heated liquid oil cutter stock 228 may be combined with the demulsified heavy fraction 232 by a mixer (not shown), as previously described.

[0061] 3-5, in an embodiment, the second demulsified heavy fraction 232 may be depressurized through the demulsifier mixer valve 194 to form a second depressurized demulsified heavy fraction 234. The second depressurized demulsified heavy fraction 234 may have a pressure of 0.01 MPa to 0.05 MPa, 0.01 MPa to 0.04 MPa, 0.01 MPa to 0.03 MPa, 0.01 MPa to 0.02 MPa, 0.02 MPa to 0.05 MPa, 0.02 MPa to 0.04 MPa, 0.02 MPa to 0.03 MPa, 0.03 MPa to 0.05 MPa, 0.03 MPa to 0.04 MPa, or 0.04 MPa to 0.05 MPa. The second depressurized demulsified heavy fraction 234 may then be sent to an oil / water separator 200 to separate the second depressurized demulsified heavy fraction 234 into a second heavy oil fraction 236 and a third water fraction 238. The oil / water separator 200 may be any separator known in the industry. The second heavy oil fraction 236 may be sent to the oil storage tank 168. The third water fraction 238 may then be sent to the water storage tank 210.

[0062] The hydrocarbons in the second heavy oil fraction 236 may have an API gravity value of 30° or less. For example, the hydrocarbons in the second heavy oil fraction 236 may have an API gravity value of less than 30° and greater than or equal to 1°. In some embodiments, the hydrocarbons in the second heavy oil fraction 236 may have an API gravity value of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°. The hydrocarbons in the second heavy oil fraction 236 may have an API gravity value of 20° or less, 15° or less, or 10° or less.

[0063] In some embodiments, the hydrocarbons in the second heavy oil fraction 236 may have a T5TBP of 80° C. or more, e.g., 80° C. to 120° C. The hydrocarbons in the second heavy oil fraction 236 may have a T5TBP of 130° C. or more, or 140° C. or more, or 560° C. or less. The hydrocarbons in the second heavy oil fraction 236 may have a T5TBP of 900° C. or less, e.g., 890° C. or less, or 885° C. or less, or 875° C. or less. 90 May have TBP.

[0064] In an embodiment, the oil product stored in the oil storage tank 168 may include the liquid oil fraction 162 and the first heavy oil fraction 202, or the liquid oil product 222 and the second heavy oil fraction 236. In an embodiment, the oil product stored in the oil storage tank 168 may include the liquid oil fraction 162 and the first heavy oil fraction 202, or the liquid oil product 222 and the second heavy oil fraction 236. In an embodiment, the oil product stored in the oil storage tank 168 may include the liquid oil fraction 162 and the first heavy oil fraction 202, or the liquid oil product 222 and the second heavy oil fraction 236. to 200°C, 120°C to 195°C, 120°C to 190°C, 120°C to 185°C, 150°C to 250°C, 150°C to 215°C, 150°C to 214°C, 150°C to 210°C, 150°C to 200°C, 150°C to 195°C, 150°C to 190°C, 150°C to 185°C, 160°C to 250°C, 160°C to 215°C, 160°C to 214°C, 160°C to 2 10℃, 160℃ to 200℃, 160℃ to 195℃, 160℃ to 190℃, 160℃ to 185℃, 165℃ to 250℃, 165℃ to 215℃, 165℃ to 214℃, 165℃ to 210℃, 165℃ to 200℃, 165℃ to 195℃, 165℃ to 190℃, 165℃ to 185℃, 170℃ to 250℃, 170℃ to 215℃, 170℃ to 214℃ , 170°C to 210°C, 170°C to 200°C, 170°C to 195°C, 170°C to 190°C, 170°C to 185°C, 175°C to 250°C, 175°C to 215°C, 175°C to 214°C, 175°C to 210°C, 175°C to 200°C, 175°C to 195°C, 175°C to 190°C, 175°C to 185°C, or about 180°C.

[0065] In an embodiment, the oil product stored in the oil storage tank 168 may be at a temperature between 150°C to 250°C, 150°C to 230°C, 150°C to 229°C, 150°C to 225°C, 150°C to 220°C, 150°C to 215°C, 150°C to 210°C, 170°C to 250°C, 170°C to 230°C, 170°C to 229°C, 170°C to 225°C, 170°C to 220°C, 170°C to 215°C, 170°C to 210°C, 185°C to 250°C, 185°C to 230°C, 185°C to 229°C, 185°C to 225°C, 185°C to 220°C, 185°C to 215°C, T of 185°C to 210°C, 190°C to 250°C, 190°C to 230°C, 190°C to 229°C, 190°C to 225°C, 190°C to 220°C, 190°C to 215°C, 190°C to 210°C, 200°C to 250°C, 200°C to 230°C, 200°C to 229°C, 200°C to 225°C, 200°C to 220°C, 200°C to 215°C, 200°C to 210°C, 205°C to 250°C, 205°C to 230°C, 205°C to 229°C, 205°C to 225°C, 205°C to 220°C, 205°C to 215°C, 205°C to 210°C, or about 208°C 10 May have TBP.

[0066] In an embodiment, the oil product stored in the oil storage tank 168 may be at a temperature between 210°C to 350°C, 210°C to 320°C, 210°C to 301°C, 210°C to 300°C, 210°C to 295°C, 210°C to 290°C, 230°C to 350°C, 230°C to 320°C, 230°C to 301°C, 230°C to 300°C, 230°C to 295°C, 230°C to 290°C, 260°C to 350°C, 260°C to 320°C, 260°C to 301°C, 260°C to 300°C, 260°C to 295°C, 260°C to 290°C, 270°C to 350°C, 270°C to 320°C, 270°C to 301°C, 270°C to 300°C, 270°C to 295°C, 270°C to 290°C, 275°C to 350°C, 275°C to 320°C, 275°C to 301°C, 275°C to 300°C, 275°C to 295°C, 275°C to 290°C, 280°C to 350°C, 280°C to 320°C, 280°C to 301°C, 280°C to 300°C, 280°C to 295°C, 280°C to 290°C, 285°C to 350°C, 285°C to 320°C, 285°C to 301°C, 285°C to 300°C, 285°C to 295°C, 285°C to 290°C, or a T of about 287°C 30 May have TBP.

[0067] In an embodiment, the oil product stored in the oil storage tank 168 may be at a temperature between 300°C to 550°C, 300°C to 520°C, 300°C to 513°C, 300°C to 512°C, 300°C to 510°C, 300°C to 505°C, 300°C to 500°C, 300°C to 495°C, 350°C to 550°C, 350°C to 520°C, 350°C to 513°C, 350°C to 512°C, 350°C to 510°C, 350°C to 505°C, 350°C to 500°C, 350°C to 495°C, 400°C to 550°C, 400°C to 520°C, 400℃ to 513℃, 400℃ to 512℃, 400℃ to 510℃, 400℃ to 505℃, 400℃ to 500℃, 400℃ to 495℃, 425℃ to 550℃, 425℃ to 520℃, 425℃ to 513℃, 425℃ to 512℃, 425℃ to 510℃, 425℃ to 505℃, 425℃ to 500℃, 425℃ to 495℃, 450℃ to 550℃, 450℃ to 520℃, 450℃ to 513℃, 450℃ to 512℃, 450℃ to 510℃, 450℃ to 505℃, 450℃ to 500℃, 450℃ to 495℃, 470℃ to 550℃, 470℃ to 520℃, 470℃ to 513℃, 470℃ to 512℃, 470℃ to 510℃, 470℃ to 505℃, 470℃ to 500℃, 470℃ to 495℃, 475℃ to 550℃, 475℃ to 520℃, 475℃ to 513℃, 475℃ to 512℃, 475℃ to 510℃, 475℃ to 505℃, 475℃ to 500℃, 475℃ to 495℃, 480℃ to 550℃, 480℃ to 520℃, 480℃ to 513℃, 480℃ to 512℃ , 480°C to 510°C, 480°C to 505°C, 480°C to 500°C, 480°C to 495°C, 485°C to 550°C, 485°C to 520°C, 485°C to 513°C, 485°C to 512°C, 485°C to 510°C, 485°C to 505°C, 485°C to 500°C, 485°C to 495°C, 490°C to 550°C, 490°C to 520°C, 490°C to 513°C, 490°C to 512°C, 490°C to 510°C, 490°C to 505°C, 490°C to 500°C, 490°C to 495°C, or about 494°C 50 May have TBP.

[0068] In an embodiment, the oil product stored in the oil storage tank 168 may be at a temperature between 495°C to 650°C, 495°C to 620°C, 495°C to 609°C, 495°C to 608°C, 495°C to 605°C, 500°C to 650°C, 500°C to 620°C, 500°C to 609°C, 500°C to 608°C, 500°C to 605°C, 525°C to 608 ... 650℃, 525℃ to 620℃, 525℃ to 609℃, 525℃ to 608℃, 525℃ to 605℃, 550℃ to 650℃, 550℃ to 620℃, 550℃ to 609℃, 550℃ to 608℃, 550℃ to 605℃, 575℃ to 650℃, 575℃ to 620℃, 575℃ to 609℃, 575℃ to 608℃, 575℃ to 605℃, 580℃ to 650℃, 580℃ to 620℃, 580℃ to 609℃, 580℃ to 608℃, 580℃ to 605℃, 585℃ to 650℃, 585℃ to 620℃, 585℃ to 609℃, 585℃ to 608℃, 585℃ to 605℃, 590℃ to 650℃, 590℃ to 620℃, 590℃ to to 609°C, 590°C to 608°C, 590°C to 605°C, 595°C to 650°C, 595°C to 620°C, 595°C to 609°C, 595°C to 608°C, 595°C to 605°C, 600°C to 650°C, 600°C to 620°C, 600°C to 609°C, 600°C to 608°C, 600°C to 605°C, or a T of about 601°C 70 May have TBP. EXAMPLES

[0069] The following simulation examples are illustrative of one or more embodiments of the present disclosure as set forth above. In particular, simulations were performed according to the embodiments described above, particularly with respect to the process embodiment depicted in Figures 1-5. Additionally, comparative examples were simulated. In the tables below, the term "depressurized" has been shortened to "depressurized" for convenience.

[0070] The following examples include simulations of the process as described in this application. In the following examples, the feed water was demineralized and had a conductivity of 0.056 microsiemens per centimeter (μS / cm). The feed oil had a volumetric flow rate at standard ambient temperature and pressure (SATP) of 0.5 L / h. The feed water had a volumetric flow rate at SATP of 1.0 L / h. The feed oil and feed water were preheated to 150° C. and 480° C., respectively, using separate electric heaters. The feed mixer was a T-connector with an internal diameter of 1.6 mm. The reactor consisted of two tubular reactors in series, the first reactor was of upflow type and the second reactor was of downflow type. The volume of each reactor was about 160 mL (20.2 mm internal diameter and 500 mm length). The reactors were surrounded by electric heaters. The temperature of both reactors was set at 430° C. (temperature of the internal fluid at the outlet). The upgraded product from the reactor was cooled by a double-tube heat exchanger with cooling water flowing inside the outer shell to form a cooled upgraded product 146. The following scheme and conditions were then applied to the cooled upgraded product 146:

[0071] Example 1 The simulation was performed according to Figure 1. The separation conditions for the process are listed in Table 1, both by name and by the reference number used in Figure 1.

[0072] [Table 1]

[0073] Example 2 The simulation was performed according to Figure 2. The separation conditions for the process are listed in Table 2, both by name and by the reference number used in Figure 2.

[0074] [Table 2]

[0075] Example 3 The simulation was performed according to Figure 3. The separation conditions for the process are listed in Table 3, both by name and by the reference number used in Figure 3.

[0076] [Table 3]

[0077] Example 4 The simulation was performed according to Figure 4. The separation conditions for the process are listed in Table 4, both by name and by the reference number used in Figure 4.

[0078] [Table 4]

[0079] Example 5 The simulation was performed according to Figure 5. The separation conditions for the process are listed in Table 5, both by name and by the reference number used in Figure 5.

[0080] [Table 5]

[0081] In Example 5, the upgraded product 142 was cooled to 250°C and then depressurized to 0.1 MPa to form a cooled upgraded product 146 having a temperature of 180°C. The cooled upgraded product 146 was then sent to a flash drum 150, which was equipped with an external heater such that the cooled upgraded product 146 maintained a fluid temperature of 180°C and had an internal volume of 0.75 liters. The heavy fraction 152 and the light fraction 154 were then depressurized to 0.05 MPa. The depressurized light fraction 154 was then cooled to about 30°C and sent to a gas / oil / water separator 160 (having a diameter of 0.14 meters, a length of 0.75 meters, and an internal volume of about 10 liters) for separation into a liquid oil fraction 162, a gas fraction 164, and a first water fraction 166. The depressurized heavy fraction 182 was then sent to a demulsifier mixer 190, which was then depressurized to 100°C. Third Demulsified heavy fraction 198 The demulsification mixer was a cascade continuous stirred tank reactor (CSTR) with internal agitation, the temperature of which was maintained at 70°C. Demulsifier (Petrolite RP2241 available from Baker Hughes) was injected into the CSTR at a flow rate of 2 mL / hr. liquid oil fraction at a flow rate of 100 mL / hour The third demulsification The mixed stream was then depressurized to 0.15 MPa and sent to an oil / water separator 200 having a diameter of 0.14 meters, a length of 0.75 meters, an internal volume of about 10 liters, and an internal temperature of 70° C. The mixed stream was then separated in the oil / water separator 200 to form an oil product and a water product.

[0082] The oil product was analyzed to determine the water content according to ASTM D1769. The oil product contained 0.2% water by weight, which met the acceptable downstream operational requirements of hydroprocessing, which require a water content of less than 0.3% by weight. The oil recovered through the oil stream was about 95% by weight of the feedstock. The gas stream contained about 4% by weight of the feedstock. Thus, in Example 1, about 1% by weight of the feedstock was lost to the water stream, which represents about 10% by weight of the feedstock. 5 The performance was superior to that of Comparative Example 1, in which 100% by mass was lost to the water flow.

[0083] Comparative Example 1 In Comparative Example 1, a simulation was performed in which the process was similar to the process described herein up to the cooled upgraded product 146. In other words, the process was similar to the process described herein and shown in the drawings up to the cooled upgraded product 146, but after that the process was different. However, in Comparative Example 1, a feed stream similar to the cooled upgraded product 146 as disclosed herein was sent to a demulsifier mixer (instead of the flash drum 150 shown in Figures 1-5) to form a demulsified stream, and then sent to a gas / oil / water separator where the demulsified stream was separated into at least a gas product, an oil product, and a water product.

[0084] In Comparative Example 1, the feed stream was cooled to below 100°C and depressurized to 0.15 MPa. The feed stream, which closely resembled the cooled upgraded product 146, was then sent to a demulsifier mixer to form a demulsified stream. The demulsifier mixer was a cascade continuous stirred tank reactor (CSTR) with an internal agitator, and its temperature was maintained at 70°C. Demulsifierwas injected into the CSTR at a flow rate of 3 mL / hr. The demulsified stream was then sent at a flow rate of approximately 1.5 L / hr to a gas / oil / water separator having a diameter of 0.14 meters, a length of 0.75 meters, and an internal volume of approximately 10 liters. The top and bottom ports of the flash drum were located approximately 0.7 meters from the edge. The demulsified stream was then separated in the flash drum to form a gas product, an oil product, and a water product.

[0085] The compositional properties of the feed stream and oil product are listed in Table 6. The properties were measured using ASTM D1796.

[0086] [Table 6]

[0087] The oil stream was analyzed to determine the water content according to ASTM D179. The oil stream contained 1.6 wt% water. This is greater than the acceptable downstream operational requirements of hydroprocessing, which require a water content of less than 0.3 wt%. The oil recovered through the oil stream was about 91 wt% feedstock. The gas stream contained about 4 wt% feedstock. Thus, in Comparative Example 1, about 5 wt% feedstock was lost to the water stream. Table 6 shows that the oil products in Examples 1-5 contain more lighter hydrocarbons, at least because the T5TBP is 180°C, compared to the Comparative Example, which has a T5TBP of 215°C. This means that the oil products in Examples 1-5 contain more lighter hydrocarbons than the Comparative Example, and therefore the process of Examples 1-5 results in less naphtha loss.

[0088] In addition, when a demulsifier is used upstream of a flash column (as in Comparative Example 1) as opposed to when a flash column is used upstream of a demulsifier (as in the embodiments of the present disclosure), liquid A portion of the oil fraction will adhere to the water and separate in the gas / oil / water separator 160 with the water-rich phase. liquidThe oil fraction is attached to the water by emulsification caused by the presence of alkali metals, vanadium, iron, nickel, etc., in the feed stream, which act as emulsifiers. liquid Since some of the oil fraction will be in the water fraction, the recovery rate of the hydrocarbons will be smaller, which means that the oil products in Examples 1-5 contain more lighter hydrocarbons than Comparative Example 1, and therefore the process of Examples 1-5 results in less loss of hydrocarbons than Comparative Example 1.

[0089] Please note that in one or more of the following claims, the transitional phrase "where" or "in which" is utilized. Please note that for purposes of defining the present technology, this term is introduced into the claims as an open-ended transitional phrase used to introduce a recitation of a series of features of a structure, and should be interpreted similarly to the more commonly used open-ended postscript "comprising." For purposes of defining the present technology, the transitional phrase "consisting of" may be introduced into the claims as a closed preamble term that limits the scope of the claim to the recited components or steps and naturally occurring impurities. For purposes of defining the present technology, the transitional phrase "consisting essentially of" may be introduced into the claims to limit the scope of one or more claims to the recited elements, components, materials, or method steps, as well as unrecited elements, components, materials, or method steps that do not materially affect the novel characteristics of the subject matter of the claim. The transitional phrases "consisting of" and "consisting essentially of" can be interpreted as part of open-ended transitional phrases such as "comprising" and "including," such that the use of an open-ended phrase to introduce a recitation of a series of elements, components, materials, or steps should be interpreted as also disclosing the recitation of the series of elements, components, materials, or steps using the closed terms "consisting of" and "substantially consisting of." For example, a description of a composition "comprising" components A, B, and C should be interpreted as also disclosing compositions "consisting of" components A, B, and C, as well as compositions "consisting essentially of" components A, B, and C. Any quantitative values ​​expressed in this application are considered to include open-ended embodiments consistent with the transitional phrases "comprising" and "including," as well as closed or partially closed embodiments consistent with the transitional phrases "consisting of" and "substantially consisting of."

[0090] As used in this specification and the accompanying claims, nouns include plural referents unless the context clearly dictates otherwise. The verb "comprises" and its conjugations should be construed as referring to elements, components, or steps in a non-exclusive manner. A referenced element, component, or step may be present, utilized, or combined with other elements, components, or steps not expressly mentioned.

[0091] It should be understood that any two quantitative values ​​given for a property may constitute a range for that property, and all combinations of ranges formed from all listed quantitative values ​​for a given property are contemplated in this disclosure. The subject matter of this disclosure has been described in detail with reference to specific embodiments. It should be understood that any detailed description of a certain component or feature of an embodiment does not necessarily imply that the component or feature is essential to that particular embodiment or any other embodiment.

[0092] It should be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Therefore, this specification is intended to cover modifications and variations of the various embodiments described herein, provided that such modifications and variations come within the scope of the appended claims and their equivalents. Unless otherwise specified herein, all testing, characterization, and experiments were performed at room temperature and atmospheric pressure.

[0093] The presently described subject matter may include one or more embodiments, which should not be construed as limitations of the teachings of the present disclosure. A first embodiment may include a process for upgrading a hydrocarbonaceous composition, the process including the steps of: combining a supercritical water stream with a pressurized and heated hydrocarbonaceous composition in a mixing device to produce a mixed feed stream; introducing the mixed feed stream into a supercritical upgrading reactor operating at a temperature above the critical temperature of water and at a pressure above the critical pressure of water; at least partially converting the mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrading reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing the light fraction to a gas / oil / water separator; separating the light fraction in the gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; combining the heavy fraction with at least a portion of either the liquid oil fraction or the first water fraction to form a diluted heavy fraction; and passing the diluted heavy fraction from the flash drum to a demulsifying mixer to form a demulsified heavy fraction.

[0094] A second embodiment is a process for upgrading a hydrocarbonaceous composition comprising the steps of: combining a supercritical water stream with a pressurized and heated hydrocarbonaceous composition in a mixer to form a mixed feed stream; introducing the mixed feed stream into a supercritical upgrading reactor operating at a temperature above the critical temperature of water and at a pressure above the critical pressure of water; at least partially converting the mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrading reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing the light fraction to a gas / oil / water separator; separating the light fraction in the gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; passing the heavy fraction from the flash drum to a demulsifying mixer to form a demulsified heavy fraction; and separating the heavy fraction from the flash drum to produce a demulsified heavy fraction. liquid oil fraction to form a diluted demulsified heavy fraction.

[0095] Another embodiment may include any of the previous embodiments, wherein combining the heavy fraction with at least a portion of one of the liquid oil fraction or the first water fraction comprises combining the heavy fraction with at least a portion of the first water fraction.

[0096] Another embodiment may include any of the previous embodiments, wherein combining the heavy fraction with at least a portion of one of the liquid oil fraction or the first water fraction comprises combining the heavy fraction with at least a portion of the liquid oil fraction.

[0097] Another embodiment may include any of the previous embodiments, further comprising passing the upgraded product after it leaves the supercritical upgrade reactor through a cooling device to form a cooled upgraded product.

[0098] Another embodiment may include any of the preceding embodiments, further comprising passing the cooled upgraded product through a pressure reduction device.

[0099] Another embodiment may include any of the previous embodiments, further comprising the step of reducing the pressure of the light ends fraction prior to passing the light ends fraction through the gas / oil / water separator.

[0100] Another embodiment may include any of the previous embodiments, wherein the step of reducing the pressure of the light fraction comprises reducing the pressure of the light fraction to less than 1 MPa.

[0101] Another embodiment may include any of the previous embodiments, further comprising passing the demulsified heavy fraction through an oil / water separator.

[0102] Another embodiment may include any of the previous embodiments, further comprising separating the demulsified heavy fraction in an oil / water separator to produce a heavy oil fraction and a second water fraction.

[0103] Another embodiment may include any of the preceding embodiments, further including depressurizing the heavy fraction prior to forming the diluted heavy fraction.

[0104] Another embodiment may include any of the preceding embodiments, wherein the step of depressurizing the heavy fraction comprises depressurizing the heavy fraction to less than 1 MPa.

[0105] Another embodiment may include any of the preceding embodiments, further comprising the step of depressurizing the diluted heavy fraction prior to passing the diluted heavy fraction through the demulsifying mixer, wherein depressurizing the heavy fraction comprises depressurizing the heavy fraction to less than 1 MPa.

[0106] Another embodiment may include any of the previous embodiments, further comprising sending at least a portion of the liquid oil fraction to an oil storage tank.

[0107] Another embodiment may include any of the preceding embodiments, further comprising sending the demulsified heavy fraction to an oil storage tank.

[0108] Another embodiment may include any of the previous embodiments, further comprising passing the diluted demulsified heavy fraction through an oil / water separator.

[0109] Another embodiment may include any of the previous embodiments, further comprising separating the diluted demulsified heavy fraction in an oil / water separator to produce a heavy oil fraction and a second water fraction.

[0110] Another embodiment may include any of the previous embodiments, further comprising the step of reducing the pressure of the light ends fraction prior to passing the light ends fraction through the gas / oil / water separator.

[0111] Another embodiment may include any of the previous embodiments, wherein the step of reducing the pressure of the light fraction comprises reducing the pressure of the light fraction to less than 1 MPa.

[0112] Another embodiment may include any of the previous embodiments, further comprising the steps of conveying at least a portion of the liquid oil fraction to an oil storage tank and conveying the demulsified heavy fraction to an oil storage tank.

[0113] Another embodiment may include any of the preceding embodiments, where the temperature of the supercritical water stream may be greater than 380°C, e.g., between 380°C and 600°C, or between 400°C and 550°C, or between 400°C and 500°C, or between 400°C and 450°C, or between 450°C and 500°C.

[0114] Another embodiment may include any of the preceding embodiments, wherein the hydrocarbons in the light fraction may have an API gravity value of from 30° to 40°, from 30° to 45°, or from 30° to 50°, or from 30° to 70°.

[0115] Another embodiment may include any of the preceding embodiments, where the hydrocarbons in the heavy fraction may have an API gravity value of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°.

[0116] Another embodiment may include any of the previous embodiments, where the hydrocarbons in the light fraction may have a T5TBP of 340° C. or less, 330° C. or less, 300° C. or less, 250° C. or less, 200° C. or less, 150° C. or less, 100° C. or less, 75° C. or less, 60° C. or less, 50° C. or less, 40° C. or less, 35° C. or less, 30° C. or less, or 25° C. or less.

[0117] Another embodiment is when the hydrocarbons in the light fraction have a T of 450° C. or less, or 440° C. or less, or 435° C. or less, or 430° C. or less, or 425° C. or less, which is referred to as when at least 90% of the fraction has vaporized. 90It may include any of the above aspects, which may have TBP.

[0118] Another embodiment may include any of the preceding embodiments, where the hydrocarbons in the heavy fraction may have a T5TBP of 80° C. or more (such as from 80° C. to 120° C.), 130° C. or more, or 140° C. or more, or 560° C. or less.

[0119] In another embodiment, the hydrocarbons in the heavy fraction have a T of 900° C. or less, e.g., 890° C. or less, or 885° C. or less, or 875° C. or less. 90 It may include any of the above aspects, which may have TBP.

[0120] Another embodiment may include any of the preceding embodiments, wherein the hydrocarbons in the liquid oil fraction may have a T5TBP of 340° C. or less, 330° C. or less, 300° C. or less, 250° C. or less, 200° C. or less, 150° C. or less, 100° C. or less, 75° C. or less, 60° C. or less, 50° C. or less, 40° C. or less, 35° C. or less, 30° C. or less, or 25° C. or less.

[0121] Another embodiment is a process for preparing a liquid oil fraction having a T of 450° C. or less, or 440° C. or less, or 435° C. or less, or 430° C. or less, or 425° C. or less, which is referred to as when at least 90% of the fraction has vaporized. 90 It may include any of the above aspects, which may have TBP.

[0122] Another embodiment may include any of the preceding embodiments, where the hydrocarbons in the first depressurized heavy fraction may have an API gravity value of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°.

[0123] Another embodiment may include any of the preceding embodiments, where the hydrocarbons in the first depressurized heavy fraction may have a T5TBP of 80° C. or more (such as from 80° C. to 120° C.), 130° C. or more, or 140° C. or more, or 560° C. or less.

[0124] In another embodiment, the hydrocarbons in the first depressurized heavy fraction are heated to a T of 900° C. or less, e.g., 890° C. or less, or 885° C. or less, or 875° C. or less. 90 It may include any of the above aspects, which may have TBP.

[0125] Another embodiment may include any of the preceding embodiments, where the hydrocarbons in the first heavy oil fraction may have an API gravity value of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°.

[0126] Another embodiment may include any of the preceding embodiments, wherein the hydrocarbons in the first heavy oil fraction may have a T5TBP of 80° C. or more (such as from 80° C. to 120° C.), 130° C. or more, or 140° C. or more, or 560° C. or less.

[0127] In another embodiment, the hydrocarbons in the first heavy oil fraction have a T of 900° C. or less, e.g., 890° C. or less, or 885° C. or less, or 875° C. or less. 90 It may include any of the above aspects, which may have TBP.

[0128] Another embodiment may include any of the previous embodiments, in which the liquid oil fraction may be divided into a liquid oil product and a liquid oil cutter stock via a flow divider, and the liquid oil fraction may be divided such that the liquid oil product comprises 50% to 90%, 50% to 80%, 50% to 75%, 50% to 70%, 50% to 60%, 60% to 90%, 60% to 80%, 60% to 75%, 60% to 70%, 70% to 90%, 70% to 80%, 70% to 75%, 75% to 90%, 75% to 80%, or 80% to 90% of the liquid oil fraction by volume.

[0129] Another embodiment may include any of the preceding embodiments, where the hydrocarbons in the second heavy oil fraction may have an API gravity value of 1° to 20°, 2° to 20°, 4° to 20°, 6° to 20°, 8° to 20°, 10° to 20°, 15° to 20°, 1° to 15°, 2° to 15°, 4° to 15°, 6° to 15°, 8° to 15°, 10° to 15°, 1° to 10°, 2° to 10°, 4° to 10°, 6° to 10°, 8° to 10°, 1° to 8°, 2° to 8°, 4° to 8°, 6° to 8°, 1° to 6°, 2° to 6°, 4° to 6°, 1° to 4°, or 2° to 4°.

[0130] Another embodiment is where the oil product stored in the oil storage tank is at a temperature between 100°C to 250°C, 100°C to 215°C, 100°C to 214°C, 100°C to 210°C, 100°C to 200°C, 100°C to 195°C, 100°C to 190°C, 100°C to 185°C, 120°C to 250°C, 120°C to 215°C, 120°C to 214°C, 120°C to 210°C, 120°C to 20 ...50°C, 120°C to 215°C, 120°C to 214°C, 120°C to 210°C, 120°C to 200°C, 120°C to 200°C, 120°C to 200°C, 120°C to 200°C, 120°C to 200°C, 120°C to 200°C, 120°C to 200°C, 12 0℃ to 195℃, 120℃ to 190℃, 120℃ to 185℃, 150℃ to 250℃, 150℃ to 215℃, 150℃ to 214℃, 150℃ to 210℃, 150℃ to 200℃, 150℃ to 195℃, 150℃ to 190℃, 150℃ to 185℃, 160℃ to 250℃, 160℃ to 215℃, 160℃ to 214℃, 160℃ to 210℃, 160℃ to 20 0℃, 160℃ to 195℃, 160℃ to 190℃, 160℃ to 185℃, 165℃ to 250℃, 165℃ to 215℃, 165℃ to 214℃, 165℃ to 210℃, 165℃ to 200℃, 165℃ to 195℃, 165℃ to 190℃, 165℃ to 185℃, 170℃ to 250℃, 170℃ to 215℃, 170℃ to 214℃, 170℃ to 210℃, 170 In some embodiments, the T5TBP may include any of the preceding embodiments, which may have a T5TBP of 175°C to 200°C, 170°C to 195°C, 170°C to 190°C, 170°C to 185°C, 175°C to 250°C, 175°C to 215°C, 175°C to 214°C, 175°C to 210°C, 175°C to 200°C, 175°C to 195°C, 175°C to 190°C, 175°C to 185°C, or about 180°C.

[0131] Another embodiment is where the oil product stored in the oil storage tank is at least one of: 150°C to 250°C, 150°C to 230°C, 150°C to 229°C, 150°C to 225°C, 150°C to 220°C, 150°C to 215°C, 150°C to 210°C, 170°C to 250°C, 170°C to 230°C, 170°C to 229°C, 170°C to 225°C, 170°C to 220°C, 170°C to 215°C, 170°C to 210°C, 185°C to 250°C, 185°C to 230°C, 185°C to 229°C, 185°C to 225°C, 185°C to 220°C, 185°C to 215 ...20°C, 1 ℃ to 210℃, 190℃ to 250℃, 190℃ to 230℃, 190℃ to 229℃, 190℃ to 225℃, 190℃ to 220℃, 190℃ to 215℃, 190℃ to 210℃, 200℃ to 250℃, 200℃ to 230℃, 200℃ to 229℃, 200℃ to 225℃, 200℃ to 220℃, 200℃ to 215℃, 200℃ to 210℃, 205℃ to 250℃, 205℃ to 230℃, 205℃ to 229℃, 205℃ to 225℃, 205℃ to 220℃, 205℃ to 215℃, 205℃ to 210℃, or about 208℃ 10 It may include any of the above aspects, which may have TBP.

[0132] Another embodiment is where the oil product stored in the oil storage tank is at least one of: 210°C to 350°C, 210°C to 320°C, 210°C to 301°C, 210°C to 300°C, 210°C to 295°C, 210°C to 290°C, 230°C to 350°C, 230°C to 320°C, 230°C to 301°C, 230°C to 300°C, 230°C to 295°C, 230°C to 290°C, 260°C to 350°C, 260°C to 320°C, 260°C to 301°C, 260°C to 300°C, 260°C to 295°C, 260°C to 290°C, 270°C to 350°C, 270°C to 32 ... ℃ to 301 ℃, 270 ℃ to 300 ℃, 270 ℃ to 295 ℃, 270 ℃ to 290 ℃, 275 ℃ to 350 ℃, 275 ℃ to 320 ℃, 275 ℃ to 301 ℃, 275 ℃ to 300 ℃, 275 ℃ to 295 ℃, 275 ℃ to 290 ℃, 280 ℃ to 350 ℃, 280 ℃ to 320 ℃, 280 ℃ to 301 ℃, 280 ℃ to 300 ℃, 280 ℃ to 295 ℃, 280 ℃ to 290 ℃, 285 ℃ to 350 ℃, 285 ℃ to 320 ℃, 285 ℃ to 301 ℃, 285 ℃ to 300 ℃, 285 ℃ to 295 ℃, 285 ℃ to 290 ℃, or about 287 ℃ T 30 It may include any of the above aspects, which may have TBP.

[0133] Another embodiment is where the oil product stored in the oil storage tank is heated to 300°C to 550°C, 300°C to 520°C, 300°C to 513°C, 300°C to 512°C, 300°C to 510°C, 300°C to 505°C, 300°C to 500°C, 300°C to 495°C, 350°C to 550°C, 350°C to 520°C, 350°C to 513°C, 350°C to 512°C, 350°C to 510°C, 350°C to 505°C, 350°C to 500°C, 350°C to 495°C, 400°C to 550°C, 400°C to 520°C, 400°C to 550°C, 400°C to 520°C, 400°C to 505 ... to 513°C, 400°C to 512°C, 400°C to 510°C, 400°C to 505°C, 400°C to 500°C, 400°C to 495°C, 425°C to 550°C, 425°C to 520°C, 425°C to 513°C, 425°C to 512°C, 425°C to 510°C, 425°C to 505°C, 425°C to 500°C, 425°C to 495°C, 450°C to 550°C, 450°C to 520°C, 450°C to 513°C, 450°C to 512°C, 450°C to 510°C, 450°C to 505°C, 450°C to 50 ... °C to 495 °C, 470 °C to 550 °C, 470 °C to 520 °C, 470 °C to 513 °C, 470 °C to 512 °C, 470 °C to 510 °C, 470 °C to 505 °C, 470 °C to 500 °C, 470 °C to 495 °C, 475 °C to 550 °C, 475 °C to 520 °C, 475 °C to 513 °C, 475 °C to 512 °C, 475 °C to 510 °C, 475 °C to 505 °C, 475 °C to 500 °C, 475 °C to 495 °C, 480 °C to 550 °C, 480 °C to 520 °C, 480 °C to 513 °C, 480 °C to 512 °C, 4 T of 80°C to 510°C, 480°C to 505°C, 480°C to 500°C, 480°C to 495°C, 485°C to 550°C, 485°C to 520°C, 485°C to 513°C, 485°C to 512°C, 485°C to 510°C, 485°C to 505°C, 485°C to 500°C, 485°C to 495°C, 490°C to 550°C, 490°C to 520°C, 490°C to 513°C, 490°C to 512°C, 490°C to 510°C, 490°C to 505°C, 490°C to 500°C, 490°C to 495°C, or about 494°C 50 It may include any of the above aspects, which may have TBP.

[0134] Another embodiment is where the oil product stored in the oil storage tank is heated to a temperature between 495°C to 650°C, 495°C to 620°C, 495°C to 609°C, 495°C to 608°C, 495°C to 605°C, 500°C to 650°C, 500°C to 620°C, 500°C to 609°C, 500°C to 608°C, 500°C to 605°C, 525°C to 650°C, 525℃ to 620℃, 525℃ to 609℃, 525℃ to 608℃, 525℃ to 605℃, 550℃ to 650℃, 550℃ to 620℃, 550℃ to 609℃, 550℃ to 608℃, 550℃ to 605℃, 575℃ to 650℃, 575℃ to 620℃, 575℃ to 609℃, 575℃ to 608℃, 575 °C to 605 °C, 580 °C to 650 °C, 580 °C to 620 °C, 580 °C to 609 °C, 580 °C to 608 °C, 580 °C to 605 °C, 585 °C to 650 °C, 585 °C to 620 °C, 585 °C to 609 °C, 585 °C to 608 °C, 585 °C to 605 °C, 590 °C to 650 °C, 590 °C to 620 °C, 590 °C to 609°C, 590°C to 608°C, 590°C to 605°C, 595°C to 650°C, 595°C to 620°C, 595°C to 609°C, 595°C to 608°C, 595°C to 605°C, 600°C to 650°C, 600°C to 620°C, 600°C to 609°C, 600°C to 608°C, 600°C to 605°C, or a T of about 601°C 70 It may include any of the above aspects, which may have TBP.

[0135] Although the subject matter of the present disclosure has been described in detail and with reference to specific embodiments thereof, it should be noted that various details disclosed therein should not be interpreted as implying that these details relate to elements that are essential components of the various embodiments described therein, even if a particular element is illustrated in each of the drawings accompanying this description. Moreover, it should be apparent that modifications and variations are possible without departing from the scope of the present disclosure, including, but not limited to, the embodiments defined in the appended claims. More particularly, while certain aspects of the present disclosure have been identified as particularly advantageous, it is believed that the present disclosure is not necessarily limited to these aspects. Preferred embodiments of the present invention will be described below in detail. EMBODIMENT 1 1. A process for upgrading a hydrocarbon-based composition, comprising: combining the supercritical water stream with a pressurized and heated hydrocarbon-based composition in a mixing device to form a mixed feed stream; introducing said mixed feed stream into a supercritical upgrading reactor operating at a temperature above the water critical temperature and a pressure above the water critical pressure; at least partially converting said mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrade reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing said light fraction through a gas / oil / water separator; separating the light fraction in the gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; combining said heavy fraction with at least a portion of one of said liquid oil fraction or said first water fraction to form a diluted heavy fraction; and passing the diluted heavy fraction from the flash drum through a demulsifying mixer to form a demulsified heavy fraction; A process including. EMBODIMENT 2 2. The process of embodiment 1, wherein combining the heavy fraction with at least a portion of one of the liquid oil fraction or the first water fraction comprises combining the heavy fraction with at least a portion of the first water fraction. EMBODIMENT 3 3. The process of embodiment 1 or 2, wherein combining the heavy fraction with at least a portion of one of the liquid oil fraction or the first water fraction comprises combining the heavy fraction with at least a portion of the liquid oil fraction. EMBODIMENT 4 passing the upgraded product through a cooling device after the upgraded product leaves the supercritical upgrade reactor to form a cooled upgraded product; and passing the cooled upgraded product through a pressure reduction device; 4. The process of any one of embodiments 1 to 3, further comprising: EMBODIMENT 5 5. The process of any one of the preceding claims, further comprising depressurizing the light fraction prior to passing the light fraction through the gas / oil / water separator, wherein depressurizing the light fraction comprises depressurizing the light fraction to less than 1 MPa. EMBODIMENT 6 passing the demulsified heavy fraction through an oil / water separator; and separating the demulsified heavy fraction in an oil / water separator to produce a heavy oil fraction and a second water fraction; 6. The process of any one of embodiments 1 to 5, further comprising: EMBODIMENT 7 7. The process of any one of the preceding embodiments, further comprising depressurizing the heavy fraction prior to forming the diluted heavy fraction, wherein depressurizing the heavy fraction comprises depressurizing the heavy fraction to less than 1 MPa. EMBODIMENT 8 8. The process of any one of the preceding claims, further comprising reducing the pressure of the diluted heavy fraction prior to passing the diluted heavy fraction through the demulsifying mixer, wherein reducing the pressure of the heavy fraction comprises reducing the pressure of the heavy fraction to less than 1 MPa. EMBODIMENT 9 9. The process of any one of the preceding embodiments, further comprising sending at least a portion of the liquid oil fraction to an oil storage tank. EMBODIMENT 10 10. The process of any one of the preceding embodiments, further comprising sending the demulsified heavy fraction to an oil storage tank. EMBODIMENT 11 1. A process for upgrading a hydrocarbon-based composition, comprising: combining the supercritical water stream with a pressurized and heated hydrocarbon-based composition in a mixing device to form a mixed feed stream; introducing said mixed feed stream into a supercritical upgrading reactor operating at a temperature above the water critical temperature and a pressure above the water critical pressure; at least partially converting said mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrade reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing said light fraction through a gas / oil / water separator; separating the light fraction in the gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; passing the heavy fraction from the flash drum through a demulsifying mixer to form a demulsified heavy fraction; and combining said heavy fraction with at least a portion of said liquid oil fraction to form a diluted demulsified heavy fraction; A process including. EMBODIMENT 12 12. The process of embodiment 11, further comprising passing the diluted demulsified heavy fraction through an oil / water separator. EMBODIMENT 13 13. The process of embodiment 12, further comprising separating the diluted demulsified heavy fraction in an oil / water separator to produce a heavy oil fraction and a second water fraction. EMBODIMENT 14 14. The process of any one of embodiments 11 to 13, further comprising reducing the pressure of the light fraction prior to passing the light fraction through the gas / oil / water separator, wherein reducing the pressure of the light fraction comprises reducing the pressure of the light fraction to less than 1 MPa. EMBODIMENT 15 15. The process of any one of embodiments 11 to 14, further comprising the steps of: sending at least a portion of the liquid oil fraction to an oil storage tank; and sending the demulsified heavy fraction to an oil storage tank. [Explanation of symbols]

[0136] 100 Various processes for upgrading hydrocarbon-based compositions 105 Hydrocarbon Compositions 110 Water flow 112 Hydrocarbon Pump 116 Pressurized Hydrocarbon Compositions 118 Pressurized Water Flow 120 Hydrocarbon Preheater 122 Water preheater 124 Pressurized and heated hydrocarbon compositions 126 Supercritical water flow 130 Feed mixer 132 Mixed feed stream 140 Supercritical Upgrade Reactor 142 Upgrade Product 144 Valve 146 Cooled Upgrade Product 150 Flash Drum 152 Heavy fraction 153 First Mixture 154 Light Distillates 166 First Water Fraction 168 Oil Storage Tank 172 Water products 174 Water Cutter Stock 176 Mitsu heater 178 Heated Water Cutter Stock 180 Heavy distillate valve 182 Depressurized Heavy Distillates 184 First depressurized mixed flow 190 Demulsification mixer 192 First demulsified heavy fraction 194 Demulsification mixer valve 196 First depressurized demulsified heavy fraction 200 Oil / Water Separator 202 First heavy oil fraction 204 Second Water Distillate 210 Water Storage Tank 222 Liquid oil products 228 Heated Liquid Oil Cutter Stock 230 Second depressurized mixed flow 232 Second demulsified heavy fraction 234 Second decompressed demulsified heavy fraction 236 Second Heavy Oil Distillate

Claims

1. 1. A process for upgrading a hydrocarbon-based composition, comprising: combining the supercritical water stream with a pressurized and heated hydrocarbon-based composition in a mixing device to form a mixed feed stream; introducing said mixed feed stream into a supercritical upgrading reactor operating at a temperature above the water critical temperature and a pressure above the water critical pressure; at least partially converting said mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrade reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing said light fraction through a gas / oil / water separator; separating said light fraction in said gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; combining said heavy fraction with at least a portion of one of said liquid oil fraction or said first water fraction to form a diluted heavy fraction; and passing the diluted heavy fraction through a demulsifying mixer to form a demulsified heavy fraction; A process including.

2. 2. The process of claim 1, wherein combining the heavy fraction with at least a portion of one of the liquid oil fraction or the first water fraction comprises combining the heavy fraction with at least a portion of the first water fraction.

3. 2. The process of claim 1, wherein combining the heavy fraction with at least a portion of one of the liquid oil fraction or the first water fraction comprises combining the heavy fraction with at least a portion of the liquid oil fraction.

4. passing the upgraded product through a cooling device after the upgraded product leaves the supercritical upgrade reactor to form a cooled upgraded product; and passing the cooled upgraded product through a pressure reduction device; The process of claim 1 , further comprising:

5. 2. The process of claim 1, further comprising the step of reducing pressure on the light fraction prior to passing the light fraction through the gas / oil / water separator, wherein reducing pressure on the light fraction comprises reducing pressure on the light fraction to less than 1 MPa.

6. 2. The process of claim 1, further comprising the step of reducing pressure on the heavy fraction prior to forming the diluted heavy fraction, wherein reducing pressure on the heavy fraction comprises reducing pressure on the heavy fraction to less than 1 MPa.

7. 2. The process of claim 1, further comprising the step of reducing pressure on the diluted heavy fraction prior to passing the diluted heavy fraction through the demulsifying mixer, the step of reducing pressure on the heavy fraction comprising reducing pressure on the heavy fraction to less than 1 MPa.

8. The process of claim 1 further comprising the step of sending at least a portion of said liquid oil fraction to an oil storage tank.

9. Passing the demulsified heavy fraction through an oil / water separator; and separating the demulsified heavy fraction in an oil / water separator to produce a heavy oil fraction and a second water fraction; 9. The process of claim 1 , further comprising:

10. The process of claim 9, further comprising sending the heavy oil fraction to an oil storage tank.

11. 1. A process for upgrading a hydrocarbon-based composition, comprising: combining the supercritical water stream with a pressurized and heated hydrocarbon-based composition in a mixing device to form a mixed feed stream; introducing said mixed feed stream into a supercritical upgrading reactor operating at a temperature above the water critical temperature and a pressure above the water critical pressure; at least partially converting said mixed feed stream to an upgraded product; passing the upgraded product from the supercritical upgrade reactor to a flash drum; separating the upgraded product in the flash drum to produce a light fraction and a heavy fraction; passing said light fraction through a gas / oil / water separator; separating said light fraction in said gas / oil / water separator to produce a gas fraction, a liquid oil fraction, and a first water fraction; passing the heavy fraction from the flash drum through a demulsifying mixer to form a demulsified heavy fraction; and combining said heavy fraction with at least a portion of said liquid oil fraction to form a diluted demulsified heavy fraction; A process including.

12. 12. The process of claim 11, further comprising passing the diluted demulsified heavy fraction through an oil / water separator to separate the diluted demulsified heavy fraction into a heavy oil fraction and a second water fraction.

13. The process of claim 12, further comprising sending the liquid oil fraction and at least a portion of the heavy oil fraction to an oil storage tank.

14. The process of any one of claims 11 to 13, further comprising the step of depressurizing the light fraction prior to passing the light fraction through the gas / oil / water separator, wherein depressurizing the light fraction comprises depressurizing the light fraction to less than 1 MPa.

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