Methods for carbon abatement and upscaling of petroleum products and uses thereof

Abstract

There is provided a method for upscaling a petroleum product. There is also provided a method for zero-emissions refining and zero-emissions power generation, and a use of a petroleum product as a medium for sequestering carbon from a carbon containing gas by way of abatement of carbon from the carbon containing gas and sequestration of the carbon into the petroleum product.

Description

METHODS FOR CARBON ABATEMENT AND UPSCALING OF PETROLEUM PRODUCTS AND USES THEREOFCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and benefit from United States Patent Application Serial No. 63 / 604,021 filed on November 29, 2023, which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure generally relates to methods for upscaling petroleum products and uses thereof, and more particularly, to methods for forming an upscaled petroleum product by abatement of carbon from a carbon containing gas into a petroleum product.BACKGROUND

[0003] The generation of electricity, in particular from the use of fossil fuels is important for economic development. However, there is a perception that renewables-based technologies to produce electricity are “good” while fossil fuels-based technologies are “bad”. This perception extends to several aspects of fossil fuels-based technologies including electricity generation, crude oil refining, petrochemical processing, and transportation of energy and petroleum products.

[0004] Solutions to produce clean energy often focus on a shift away from fossil fuels towards alternative renewable energy sources that, on the surface, may appear more environmentally friendly. However, it is early days for large scale energy generation from alternative sources, and already some are not proving to be as “green” as expected. For example, while electric cars reduce fossil fuel emissions while they are on the road, it has been reported that the production of the lithium-ion batteries that power them causes more displacement and CO2 emissions than the production of regular gas-powered cars, not to mention the environmental concern relating to battery disposal. Moreover, focusing solely on a shift to alternative energy sources will come at a loss to economic development. Furthermore, fossil fuels are the only source for the hydrocarbon building blocks that arerequired to produce all of the consumer and industrial goods, including the clothes that we wear.

[0005] A need therefore exists for improved methods for sustainable energy.SUMMARY

[0006] The present disclosure provides methods for carbon abatement of environmentally harmful carbon containing gases, upscaling of petroleum products, methods for zero-emissions refining and zero-emissions power generation, and uses of petroleum products as a medium for abatement of carbon from a carbon containing gas. The present disclosure recognizes that there are problems in the current methodologies for providing sustainable and / or renewable energy, and provides improved methods.

[0007] In an embodiment, the present disclosure relates to a method for upscaling a petroleum product, the method comprising: providing the petroleum product to a vessel; and providing a carbon containing gas to the vessel to abate carbon from the carbon containing gas and sequester the carbon into the petroleum product, to form an upscaled petroleum product.

[0008] In an embodiment, the present disclosure relates to a method for zero-emissions refining and zero-emissions power generation, the method comprising: i) producing from a fossil fuel powered generator heat, electricity and an exhaust gas; ii) providing a petroleum product to a distillation apparatus; iii) delivering the heat, electricity and exhaust gas to the distillation apparatus, wherein the heat is used as a heat source for a distillation procedure, the electricity is used as a power source for the distillation procedure, and the exhaust gas is used as a carbon source for sequestration of carbon into the petroleum product to form an upscaled petroleum product; and iv) distilling the petroleum product and / or the upscaled petroleum product to vaporize one or more refined products, for zero-emissions refining and zero-emissions power generation. In an embodiment, the method further comprises v) delivering at least one of the one or more refined products to the fossil fuel powered generator as a power source. In an embodiment, the method further comprises vi) repeating steps (i) to (v) any number of times.

[0009] In an embodiment, the present disclosure relates to use of a petroleum product in a vessel as a medium for sequestering carbon from a carbon containing gas, with concurrent abatement of carbon from the carbon containing gas.

[0010] Other aspects and embodiments of the disclosure are evident in view of the detailed description provided herein.BRIEF DESCRIPTON OF THE DRAWINGS

[0011] Further advantages, permutations and combinations of the invention will now appear from the above and from the following detailed description of the various particular embodiments of the invention taken together with the accompanying drawings, each of which are intended to be non limiting, in which:

[0012] FIG. 1 is a flowchart showing the steps of a method for upscaling a petroleum product, according to one embodiment of the present disclosure.

[0013] FIG. 2 is a cross-sectional elevation view of an exemplary distillation apparatus for the abatement and upscaling methods disclosed herein, according to one embodiment of the present disclosure.

[0014] FIG. 3 is a flowchart showing the steps of a method for zero-emissions refining and zero-emissions power generation, according to one embodiment of the present disclosure.

[0015] FIG. 4 is a schematic of an exemplary zero-emissions refining and zero-emissions power generation, according to one embodiment of the present disclosure.DETAILED DESCRIPTION

[0016] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure belongs. Although any methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present disclosure, the suitable methods and materials are described below.

[0017] The generation of energy, in particular from the development of fossil fuels is important for economic development. Petroleum product upscaling technologies, in particularthose incorporating carbon sequestration steps, can help meet ambitious carbon dioxide emission reduction targets while keeping fossil fuels part of the energy system. A method of upscaling petroleum products that eliminates harmful emissions from fossil fuel development is desired to improve the sustainability, transportability, and efficiency of generating power from fossil fuels.

[0018] The embodiments of the present disclosure pertain to methods having improved functionality in emissions reduction and sustainability. Methods of the present disclosure advantageously provide for abatement of carbon from a carbon containing gas and sequestration of the carbon into a petroleum product to form an upscaled petroleum product.

[0019] The present disclosure provides a number of advantages over existing technologies in the refining, transport, and production of unrefined or refined petroleum products. For example, components used in the methods herein can be of a modular design and may be mass-fabricated, such as modular natural gas turbine generators and / or zero-emission refineries (e.g. in shipping containers). An advantageous aspect of the embodiments of the methods herein is integration between power generation and refining to provide a zero-emissions system for the production of refined petroleum products. Moreover, the generation of the upscaled petroleum products disclosed not only provides for sequestration of carbon-containing gases that otherwise would have been emitted into the atmosphere, but also creates a valuable petroleum product having elevated amounts of carbon.

[0020] In an embodiment, there is provided a method for upscaling a petroleum product, the method comprising: providing the petroleum product to a vessel; and providing a carbon containing gas to the vessel to abate carbon from the carbon containing gas and sequester the carbon into the petroleum product, to form an upscaled petroleum product.

[0021] As used herein, the term “petroleum product” refers to any form of petroleum-containing substance that is no longer present underground. In an embodiment, the petroleum product may be an extracted petroleum product. In an embodiment, the petroleum product may be a refined petroleum product. In an embodiment, the petroleum product may be a by-product petroleum product. The petroleum product may be in any form, including a liquid, a gas, a semi-solid (e.g. tar-like consistency), solid, or any combinationthereof. In an embodiment, the petroleum product is a semi-solid. In an embodiment, the petroleum product is a solid. In an embodiment, the petroleum product is a liquid.

[0022] As used herein, the term “extracted petroleum product” refers to petroleum that has been extricated to the surface from underground reservoirs, whether or not it has been further refined and / or processed. The term extracted petroleum product, as used herein, encompasses both crude oil and certain refined petroleum products. The extracted petroleum product may be in any form, including a liquid, a gas, a semi-solid, solid, or any combination thereof. Any form of petroleum may be extricated to the surface from underground reservoirs to comprise the extracted petroleum product. The skilled person will appreciate that extracted petroleum products may exist in a form that also comprises diluent. Non-limiting examples of petroleum products with diluent include Western Canadian Select, West Texas Intermediate, Brent Blend, Dubai Crude, and Edmonton Par.

[0023] As used herein, the term “refined petroleum product” refers to any petroleum product that is derived from crude oil through one or more refinery processes (e.g. catalytic cracking, fractional distillation, etc.). Without limitation, refined petroleum products include motor gasoline, kerosene, diesel fuel, marine gas oil, light fuel oil, aviation fuel, heavy fuel oil, asphalt, or liquefied petroleum products. The term “refined petroleum product” may be used interchangeably with “processed petroleum product”.

[0024] As used herein the term “by-product petroleum product” refers to any petroleum product that is formed as a by-product in refinery processes for preparing a refined petroleum product. Without limitation, by-product petroleum products include bitumen, petroleum coke, or waste oil. As the skilled person will appreciate, bitumen is not only a by-product of refinery processes, but is also naturally occurring such as in oil sands deposits.

[0025] In an embodiment, an extracted petroleum product is used in the methods herein. The extracted petroleum product may be a crude or refined product. In an embodiment, the extracted petroleum product is a crude oil. In an embodiment, the extracted petroleum product is bitumen.

[0026] In an embodiment, the petroleum product used in the methods herein comprises or is waste oil, petroleum coke, high-asphaltene oil, bunker oil, gasification bunker oil, heavy oil, extra-heavy oil, bitumen, or any combination thereof. In an embodiment, the petroleum product is a light oil. In an embodiment, the petroleum product is heavy oil, extra-heavy oil, bitumen, or any combination thereof. In a particular embodiment, the petroleum product is bitumen. As used herein, embodiments of a light oil are crude oils having an American Petroleum Institute (API) gravity of greater than 30. As used herein, embodiments of a heavy oil are crude oils having an API gravity of between about 14 and about 22. As used herein, embodiments of an extra-heavy oil are crude oils having an API gravity of between about 10 and about 14. As used herein, embodiments of a bitumen are crude oils having an API gravity of less than 10.

[0027] In embodiments of the methods herein, any of the petroleum products may be used in a distillation refining process to abate carbon from the carbon containing gas and sequester carbon into the remaining petroleum product. As used herein, the term “remaining petroleum product” is intended to refer to any petroleum product that is not distilled off during the refining process (e.g. it remains in the distillation vessel during).

[0028] As used herein, the term “carbon containing gas” refers to a chemical substance in gaseous form that contains at least the element carbon. Carbon containing gases may also comprise elements other than carbon. For example, and without limitation, carbon-containing gases may comprise or be carbon dioxide, carbon monoxide, methane, chlorofluorocarbon-12, hydrofluorocarbon, and hydrogen sulphide. In an embodiment, the carbon containing gas comprises at least one or more carbon atoms and one or more oxygen atoms. In an embodiment, the carbon containing gas comprises at least carbon dioxide, carbon monoxide, or a combination thereof. In a particular embodiment, the carbon containing gas comprises at least carbon dioxide. In an embodiment, the carbon containing gas is an exhaust gas.

[0029] In an embodiment, the exhaust gas is from an industrial high-emission CO2 facility. As used herein, the “industrial high-emission CO2 facility” may be any device, apparatus, structure, complex, building or facility that emits a substantial or non-negligible quantity of CO2 or a gas containing CO2 in an industrial process. In an embodiment, the industrial high-emission CO2 facility a (conventional) refinery (e.g. oil and gas refinery), an upgrader, a cement factory, a power plant (e.g. a natural gas or coal-fired power plant), a logging facility or operation, or an agricultural facility. In an embodiment, the methods of the present disclosure are performed within the industrial high-emission CO2 facility, such as for example within the same building in which the CO2 or a gas containing CO2 is being formed. In an embodiment, the methods of the present disclosure are performed in a facility(e.g. building or structure) onsite with industrial high-emission CO2 facility. In such embodiment, the exhaust gas may for example be transferred to the facility onsite by piping between the buildings or structures. In an embodiment, the methods of the present disclosure are performed in a facility (e.g. building or structure) near to the industrial high- emission CO2 facility, such as on adjacent lands or lands close to the industrial high-emission CO2 facility. In an embodiment, “near to” is within 1 , 2, 5, 10, 15, 20, 25, 50, 75 or 100 kilometers. In such embodiment, the exhaust gas may for example be transferred to the nearby facility by piping or any other means of transportation (e.g. container truck).

[0030] In an embodiment, the exhaust gas is from a fossil fuel combustion device. As an example, and without limitation, the exhaust gas may be from a fossil fuel powered generator, such as a turbine generator.

[0031] As used herein, the term “abatement of carbon” or “abate carbon” means to remove carbon atoms or carbon containing molecules from a carbon containing source. In an embodiment, the carbon-containing source is a carbon containing gas, such as an exhaust gas. As used herein, the term “sequester carbon” or “sequestration of carbon” mean to capture carbon atoms or carbon containing molecules from one medium and store those carbon atoms or carbon containing molecules in another medium.

[0032] As used herein, the term “upscaled petroleum product” refers to a petroleum product that has been modified to contain an additional quantity or amount of carbon and optionally other elements (e.g. sulphur, nitrogen, etc.), whereby that carbon and optionally the other elements has been sequestered therein. Thus, in an embodiment, the upscaled petroleum product has a higher concentration of carbon than the source petroleum product. Indeed, another term to describe an upscaled petroleum product, as referenced herein, may therefore be a carbon loaded petroleum product. In an embodiment, the upscaled petroleum product is derived from waste oil, petroleum coke, high-asphaltene oil, bunker oil, gasification bunker oil, heavy oil, extra-heavy oil, bitumen, or any combination thereof. In an embodiment, the upscaled petroleum product is derived from heavy oil, extra-heavy oil, bitumen, or any combination thereof. In a particular embodiment, the upscaled petroleum product is derived from bitumen. In a more particular embodiment, the upscaled petroleum product is derived from hardened bitumen. As used herein, the term “hardened bitumen” refers to a form of bitumen that substantially maintains its shape at 20°C. As used herein, by “derived from” itis intended to refer to a source product that is converted to an upscaled petroleum product in accordance with the methods herein.

[0033] Reference will now be made in detail to exemplary embodiments of the disclosure, wherein numerals refer to like components, examples of which are illustrated in the accompanying drawings that further show exemplary embodiments, without limitation.

[0034] FIG. 1 illustrates the steps of an exemplary method of the present disclosure for upscaling a petroleum product to form an upscaled petroleum product.

[0035] As used herein, the term “vessel” refers to any form of container that can be used to hold a liquid, a fluid (e.g. gas), a solid, or any combination thereof. In an embodiment, the vessel is a distillation vessel.

[0036] In an embodiment, the methods herein comprise a step of providing a petroleum product to a vessel. The vessel may be any vessel. In an embodiment, the vessel is a storage tank. In an embodiment, the storage tank is a bitumen storage tank.

[0037] In an embodiment, the storage tank is a shipping container. As used herein, the term “shipping container” refers to a container with the requisite durability, dimensions, and composition to withstand shipment, storage, and handling. In some non-limiting embodiments, the storage tank comprises a 10 foot shipping container, a 20 foot shipping container, a 40 foot shipping container, a 40 foot high cube shipping container, a 45 foot high cube shipping container, or 53 foot shipping container. In a particular embodiment, the storage tank comprises a 40 foot shipping container. In some further embodiments, the storage tank is a shipping container and the petroleum product is bitumen. In a further and more particular embodiment, the bitumen is hardened bitumen suitable for transport in a shipping container. In some embodiments, the storage tank is a custom shipping container designed with no doors, a hatch on top for loading, and valves on the bottom for unloading. In an embodiment, it is an all steel construction.

[0038] In an embodiment, the vessel is a crude oil upgrader and the petroleum product is a heavy crude oil. As used herein, the term “crude oil upgrader” refers to a facility that produces a form of crude oil from another form of crude oil. For example, and without limitation, the crude oil upgrader may produce synthetic crude oil from bitumen.

[0039] The petroleum product may be provided to the vessel in any suitable fashion. In an embodiment, the petroleum product is liquid enough to be delivered to the vessel by one or more pipes or conduits. In an embodiment, the petroleum product is delivered to the vessel by a transport vehicle.

[0040] In an embodiment herein, the methods comprise a step of providing a carbon containing gas to the vessel. The carbon containing gas may be delivered to the vessel by any suitable means. In an embodiment, the carbon containing gas is delivered to the vessel by one or more pipes or conduits. The pipes or conduits may, for example, be in direct interconnection to the source of the carbon containing gas. In other embodiments, the pipes or conduits may be in interconnection with a storage apparatus in which the carbon containing gas is stored. In an embodiment, the carbon containing gas is delivered to the vessel by a transport vehicle. In an embodiment,

[0041] In an embodiment, the carbon containing gas may be delivered to the vessel without further processing. In other embodiments, the carbon containing gas may be processed into separate gases to separate and deliver a CO2 enriched exhaust gas to the vessel. The processing to separate the gases may, for example, be by way of sorbents, solvents, membranes (e.g. filters), or any combination thereof.

[0042] Providing both the petroleum product and the carbon containing gas to the vessel is to abate carbon from the carbon containing gas and sequester the carbon into the petroleum product to form an upscaled petroleum product. In an embodiment, the carbon containing gas and petroleum product are heated within the vessel to abate carbon from the carbon containing gas and sequester it into the petroleum product.

[0043] In an embodiment, the method further comprises a step of refining, by distillation, the petroleum product. Thus, in an embodiment, the vessel may be a distillation apparatus. In an embodiment, the step of refining comprises treating the extracted petroleum product with electromagnetic (EM) energy, such as described in international patent publication no. WO2016134476, which is hereby incorporated by reference in its entirety.

[0044] As used herein, the term “distillation apparatus” refers to a vessel or system wherein distillation may take place. In an embodiment, the distillation procedure comprises atmospheric distillation. In an embodiment, the distillation procedure comprises vacuum distillation. In an embodiment, the distillation procedure comprises pressure distillation. In anembodiment, the distillation apparatus comprises a petroleum refinery. As used herein, the term “petroleum refinery” refers to a facility or industrial plant where petroleum product is upgraded or processed.

[0045] As used herein, the term “distillation” refers to the separation of components or substances from a liquid mixture through the selective vaporization and condensation of the liquid mixture and / or components thereof. The skilled person will appreciate that various forms of distillation exist. Non-limiting examples of distillation include simple distillation, fractional distillation, steam distillation, vacuum distillation, molecular distillation, zone distillation, reactive distillation, catalytic distillation, atmospheric distillation, and extractive distillation. Any distillation involving petroleum or petroleum products may be used in the context of the present disclosure. In an embodiment, the distillation is an atmospheric distillation. In an embodiment, the distillation is a vacuum distillation. In an embodiment, the distillation is a pressure distillation.

[0046] In an embodiment, the distillation is performed prior to providing the carbon containing gas to the vessel to distill off one or more refined products from the vessel, and subsequently abate carbon from the carbon containing gas and sequester the carbon into one or more remaining petroleum products within the vessel. As used herein, the term “refined product” is intended to refer to any petroleum product derived through the refining of crude oil or any other petroleum product, including other refined products. The term is used interchangeably herein with “refined petroleum product” in respect of the products the terms encompass. However, “refined products” refers specifically to those products produced during and by the methods herein. In an embodiment, the refined products are one or more light oils having an API gravity of greater than 30. In a further embodiment, the one or more refined products are butane, gasoline, naphtha, kerosene, jet fuel, diesel fuel, marine gas oil, or any combination thereof.

[0047] In an embodiment, the distillation is performed in the presence of the carbon containing gas to abate carbon from the carbon containing gas and sequester the carbon into one or more remaining petroleum products within the vessel. In a further embodiment, the one or more remaining petroleum products comprise bitumen.

[0048] FIG. 2 illustrates an exemplary vessel 10 of the present disclosure being used to provide a heat source 42 to the received carbon containing gas (COG) 21 and the receivedpetroleum product (PP) 40. The heat source 42 may be any form of energy. The heat source 42 may be delivered or provided to the vessel in any suitable manner to provide heat to the exposure zone 16. In an embodiment, the heat source 42 is provided through a heat delivery passage 20. The heat delivery passage 20 may comprise a vapour shield 22 that permits the transfer of heat, but prevents the transfer of refined products in vapour phase 44. In an embodiment, the heat source 42 is from electricity. The vessel 10 as shown in FIG. 2 comprises a body 12 having contained therein an exposure zone 16, a heat delivery passage 20, a recovery zone 18, and a shield 14. The shield 14 is configured to permit the transfer of vapour. In an embodiment, the shield 14 may be a plate having holes through which vapour can pass. In an embodiment, the vessel 10 may comprise one shield, two shields, three shields, four shields, or five shields.

[0049] Referring still to FIG. 2, in an embodiment, the vessel 10 comprises one or more conduits 43 for providing the carbon containing gas 21 to the vessel 10. In an embodiment, the one or more conduits (41, 43) comprise steel, black iron, polyvinyl chloride, high-density polyethylene, copper, or a combination thereof. In an embodiment, the vessel 10 comprises one or more conduits 41 for providing the petroleum product 40 to the vessel 10. In a particular embodiment, the vessel 10 comprises both the one or more conduits 41 for providing the carbon containing gas 21 and the one or more conduits 43 for providing the petroleum product 40 to the vessel 10.

[0050] In an embodiment, distillation to produce the one or more refined products as a vapour 44 comprises condensation of the one or more refined products into a liquid 46. In an embodiment, the vessel 10 comprises a plurality of cooling coils (27, 29) for facilitating the condensation of the one or more refined products in gas phase 44 into one or more refined products in liquid phase 46. In an embodiment, the plurality of cooling coils (27, 29) is two cooling coils, three cooling coils, four cooling coils, or five cooling coils. In an embodiment, the plurality of cooling coils (27, 29) is two cooling coils. In an embodiment, the two cooling coils comprises a lower cooling coil 27 and an upper cooling coil 29.

[0051] In an embodiment, the vessel 10 comprises a plurality of outlets (26, 28) for releasing, expelling or removing the one or more refined products in liquid phase 46 from the vessel 10. In an embodiment, the plurality of outlets (26, 28) are embedded within and pass through the body 12. In other embodiments, the plurality of outlets (26, 28) may be interconnected to the body 12 in a manner that allows the one or more refined products inliquid phase 46 to be released, expelled or removed from the vessel 10. In an embodiment, the one or more refined products in liquid phase 46 are two or more refined products. In an embodiment, the plurality of outlets are two or more outlets (26, 28) for differentially receiving and expelling respective refined products in liquid phase 46 from the vessel 10. In an embodiment, the two or more outlets (26, 28) differentially receive a respective refined product in liquid phase 46 based on their location along the body 12 and the cooling temperature at that location provided by the cooling coils (27, 29). The refined product in liquid phase 46 released at each respective outlet (27, 29) may, for example, be based on its condensation point. The location of the two or more outlets (26, 28) may facilitate the condensation of a specific refined product in liquid phase 46 based on the expected or known reaction conditions and the petroleum product 40 which is delivered to the vessel 10.

[0052] In an embodiment, the vessel 10 comprises a drain feature, such as a drain pipe 30, to remove the upscaled petroleum product 48 from the vessel. The drain feature may be of any suitable design and / or configuration that is capable of removing the upscaled petroleum product 48 from the vessel 10. In an embodiment, the drain feature is a drain pipe 30 oriented downwards from the bottom of the vessel 10, such that the upscaled petroleum product can be removed from the vessel 10 largely by gravity flow. The drain feature may remain in a closed configuration until it is desirable to remove the upscaled petroleum product 48 from the vessel 10. Thus, in an embodiment, the drain feature (e.g. drain pipe 30) has an open / close mechanism 32. The open / close mechanism 32 can be operated in any suitable fashion, such as manually or by way of control mechanisms, optionally automated.

[0053] In operation, the vessel 10 receives the carbon containing gas 21 and the petroleum product 40 in the exposure zone 16 through the one or more conduits (41, 43). In the exposure zone 16, the carbon containing gas 21 and the petroleum 40 are exposed to heat from the heat source 42, resulting in the distillation of the petroleum product 40 to produce one or more refined products in vapour phase 44. The distilled one or more refined products in vapour phase 44 is then received in the recovery zone 18 through the shield 14. During the distillation, carbon from the carbon containing gas 21 is concurrently abated from the carbon containing gas and sequestered into one or more remaining petroleum products within the exposure zone 16 that have not been distilled, to form an upscaled petroleum product 48.

[0054] FIGs. 3 and 4 illustrates an exemplary method (FIG. 3) and system (FIG. 4) of the present disclosure for advantageously employing the carbon abatement and sequestration technologies herein in the context of zero-emissions refining and zero-emissions power generation.

[0055] As shown in the exemplary schematic of FIG. 4, a turbine generator powered by a fossil fuel source (and optionally other sources of fuel) is used to produce heat, electricity and exhaust gas. All of these products are then used in a refining process (e.g. distillation) in a unique manner, particularly in respect of the exhaust gas. The heat may be supplied to the distillation apparatus as a heat source. The electricity may be supplied to the distillation apparatus as a source of power, for example to additionally provide heat. The exhaust gas may be supplied to the distillation apparatus to provide an upscaled petroleum product in accordance with the methods herein. In some embodiments, the exhaust gas may further or alternatively be supplied to a vessel (e.g. storage vessel) containing a petroleum product for upscaling of the petroleum product in accordance with the methods herein that do not involved a refining process (e.g. distillation). Thus, all of the products of the fossil fuel powered generator, including waste streams (e.g. exhaust gas) are utilized.

[0056] From the distillation refining process, typical refined products may be provided. Exemplary refined products are described elsewhere herein, and include without limitation gasoline, naphtha (light and heavy), jet fuel kerosene, diesel fuel, and marine gas oil. These refined products may be used in conventional downstream treatment processes (e.g. merox treater, hydrotreater, isomerization, catalytic reformer, etc.) and / or may be added to pools / stores or supply chains for gasoline and other fuel products. For example, the refined products may be added to gas pools, gasoline blending pools, jet fuel and / or kerosene pools, etc. Alternatively, the refined products may directly enter into fuel supply chains.

[0057] Advantageously, one or more of the refined products (e.g. gasoline) may be used as fuel source for the fossil fuel powered generator. As a whole, this contributes to the zero-emissions refining and zero-emissions power generation of the present disclosure. Electricity from the fossil fuel powered generator is capable of being zero-emissions since the exhaust gas is used in the refining of petroleum products to abate carbon from the exhaust gas and capture it into an upscaled petroleum product that may be subsequently used (e.g. asphalt) or retain as a storage of what would have been an environmentally harmful carbon emission. Also, a refined product produced by the refining (e.g. distillation) can beused to power the fossil fuel powered generator, thus reducing the amount of fuel that needs to be obtained from other sources and acting as a clean energy source. Further, electricity generated from the fossil fuel powered generator can be delivered to the grid. The advantageous methods and systems herein integrate power generation and refining in a manner capable of resulting in zero-emissions.

[0058] In an embodiment, the present disclosure relates to a method for zero-emissions refining and zero-emissions power generation, the method comprising: i) producing from a fossil fuel powered generator heat, electricity and an exhaust gas; ii) providing a petroleum product to a distillation apparatus; iii) delivering the heat, electricity and exhaust gas to the distillation apparatus, wherein the heat is used as a heat source for a distillation procedure, the electricity is used as a power source for the distillation procedure, and the exhaust gas is used as a carbon source for sequestration of carbon into the petroleum product to form an upscaled petroleum product; and iv) distilling the petroleum product and / or the upscaled petroleum product to vaporize one or more refined products, for zero-emissions refining and zero-emissions power generation. In an embodiment, the method further comprising v) delivering at least one of the one or more refined products to the fossil fuel powered generator as a power source. In an embodiment, the method further comprises vi) repeating steps (i) to (v) any number of times.

[0059] FIG. 3 illustrates the steps of an exemplary method of the present disclosure for zero-emissions refining and zero-emissions power generation using a fossil fuel powered generator, heat, electricity and exhaust gas therefrom, a petroleum product, and a distillation apparatus.

[0060] As used herein, the term “fossil fuel combustion device” is intended to refer to any device, apparatus, structure or facility that combusts a fossil fuel (e.g. gasoline, diesel, etc.) and from that combustion produces an exhaust gas (e.g. a gas containing CO2). In an embodiment, and without limitation, the fossil fuel combustion device is a fossil fuel powered generator.

[0061] As used herein, the term “fossil fuel generator” or “fossil fuel powered generator” is used to refer to any apparatus that is capable of using (e.g. burning) a fossil fuel to produce electricity. In an embodiment, the fossil fuel generator is a power station. In an embodiment, the fossil fuel generator is or comprises a turbine generator. As used herein,the term “turbine generator”, refers to a machine or facility that converts energy (including, but not limited to, mechanical, thermal, nuclear, wind, hydro, etc.) to electricity through the use of a turbine. In some embodiments, the turbine generator comprises a natural gas power plant, a coal-fired power plant, a diesel-fired power plant, or a biofuel-fired power plant. In a particular embodiment, the turbine generator comprises a natural gas power plant. In an embodiment, the turbine generator is a natural gas turbine generator. In an embodiment, the fossil fuel powered generator is a diesel-fueled generator.

[0062] In an embodiment, the exhaust gas is a carbon containing gas. In an embodiment, the carbon containing gas comprises at least one or more carbon atoms and one or more oxygen atoms. In a further embodiment, the carbon containing gas comprises at least carbon dioxide, carbon monoxide, or a combination thereof. In a particular embodiment, the carbon containing gas comprises at least carbon dioxide. In an embodiment, the carbon containing gas further comprises other elements (e.g. sulphur, nitrogen, or any combination thereof).

[0063] In an embodiment, the exhaust gas may be delivered to the distillation apparatus without further processing. For example, in embodiments where the exhaust gas is highly concentrated in carbon dioxide (CO2) and contains minimal oxygen (O2), the exhaust gas may be delivered directly to the distillation apparatus in the same composition as emitted from the fossil fuel powered generator (e.g. turbine generator). In an embodiment, the exhaust gas is processed into separate gases contained therein and deliver a CO2 enriched exhaust gas to the distillation apparatus. The processing to separate the gases may, for example, be by way of sorbents, solvents, membranes (e.g. filters), or any combination thereof. In an embodiment, the exhaust gas is passed through a filter before it is provided to the distillation apparatus, and the filter separates the exhaust gas into an oxygen (O2) enriched containing component and a carbon dioxide (CO2) enriched containing component. After separation, the carbon dioxide enriched component is provided to the distillation apparatus as the exhaust gas, and optionally the oxygen-enriched component is delivered back to the turbine generator as a source of air to drive the turbines. Thus, as used herein, the term “exhaust gas” is intended to include both exhaust gases in the same form or composition as emitted from a source (e.g. turbine generator) and exhaust gases that have been processed prior to delivery to the distillation apparatus.

[0064] In an embodiment, the step of delivering the heat, electricity and exhaust gas to the distillation apparatus comprises using a plurality of conduits. In an embodiment, the plurality of conduits comprises two or more conduits. In an embodiment, the step of delivering the heat, electricity and exhaust gas to the distillation apparatus comprises delivery to a petroleum refinery.

[0065] In an embodiment, the petroleum product comprises waste oil, petroleum coke, high asphaltene oil, bunker oil, gasification bunker oil, heavy oil, extra-heavy oil, bitumen, or any combination thereof. In an embodiment, the petroleum product is heavy oil, extra-heavy oil, bitumen, or any combination thereof. In a particular embodiment, the petroleum product is bitumen.

[0066] In an embodiment, the one or more refined products are butane, gasoline, naphtha, kerosene, jet fuel, diesel fuel, marine gas oil, or any combination thereof. In an embodiment, the vaporization of the one or more refined products results in one or more remaining petroleum products being left within a vessel of the distillation apparatus. In an embodiment, the method comprises the abatement of carbon from the exhaust gas and sequestration of the carbon into one or more remaining petroleum products remaining within the vessel. In an embodiment, the remaining petroleum product comprises bitumen. In an embodiment, the bitumen is hardened bitumen suitable for transport in a shipping container.

[0067] In an embodiment, delivery of the at least one of the one or more refined products to the fossil fuel powered generator is sufficient to provide at least a portion of the power source required by the fossil fuel powered generator for operation. In an embodiment, delivery of the at least one of the one or more refined products to the fossil fuel powered generator is sufficient to provide at least 25%, at least 35%, at least 45%, at least 50%, at least 55%, at least 65%, at least 75%, at least 85%, at least 90%, at least 95%, or 100% of the power source required by the fossil fuel powered generator for operation. In an embodiment, the method produces an excess quantity of one or more of the refined products that is not required by the fossil fuel powered generator, and which can be used for other purposes. In an embodiment, the fossil fuel powered generator produces excess electricity that is delivered to a power grid.

[0068] In some embodiments, the method of zero emission refining comprises modular assembly of the distillation apparatus, the fossil fuel powered generator (e.g. turbinegenerator), and any other components used in steps (i) to (vi). In some embodiments, the modular assembly comprises configuration for mass fabrication. In an embodiment, the modular assembly comprises having standardized dimensions for the distillation apparatus, the fossil fuel powered, and the any other components used in steps (i) to (vi). In a further embodiment, the standardized dimensions comprise dimensions for storage, shipping, handling, and operation in a shipping container.

[0069] In some embodiments of the method disclosed herein, the method of zero emission refining comprises a single location for the distillation apparatus, the fossil fuel powered generator, and the any other components used in steps (i) to (vi). In some embodiments, the single location comprises a shipping port, a storage facility, or a combination thereof.

[0070] In an embodiment, the method further comprises a step of upgrading the heavy crude oil into a light oil and petroleum coke. In an embodiment, the step of upgrading is performed prior to providing the carbon containing gas to the vessel, and subsequently abating carbon from the carbon containing gas and sequestering the carbon into the petroleum coke. In an embodiment, the step of upgrading is performed in the presence of the carbon containing gas to abate carbon from the carbon containing gas and sequester the carbon into the petroleum coke. In an embodiment, the step involves injecting the carbon containing gas during the upgrading process.

[0071] In a further embodiment, heat and / or electricity from the fossil fuel powered generator are used in the method to process the petroleum product. In some embodiments, the heat and / or electricity from the fossil fuel powered generator are sufficient to provide 100% of the power source required to process or refine the petroleum product.

[0072] In a further embodiment of the methods disclosed herein, the abatement of carbon from the carbon containing gas and sequestration into the petroleum product occurs with a concurrent or subsequent emission of oxygen. In an embodiment, the oxygen is a component of the carbon containing gas. In an embodiment, the oxygen is a remainder of the carbon containing gas after the sequestration of the carbon into the petroleum product.

[0073] In an embodiment, the method further comprises a step of delivering an excess electricity produced by the fossil fuel powered generator to a power grid. In an embodiment, the one or more refined products comprises at least gasoline. In anembodiment, the one or more refined products is gasoline. In an embodiment, the method further comprises a step of delivering a produced liquid transportation fuel to the fossil fuel powered generator as a fuel source. As used herein, the term “liquid transportation fuel” is intended to refer to any liquid substance containing combustible molecules, such as without limitation gasoline, diesel, jet fuel, residential fuel oil, liquified petroleum gas (LPG), and marine fuel. In an embodiment, the produced liquid transportation fuel for delivery to the fossil fuel powered generator is a gasoline.

[0074] In an embodiment, the present disclosure relates to use of a petroleum product as a medium for sequestering carbon from a carbon containing gas.

[0075] In an embodiment of the use disclosed herein, the petroleum product comprises waste oil, petroleum coke, high asphaltene oil, bunker oil, gasification bunker oil, heavy oil, extra-heavy oil, bitumen, or any combination thereof. In an embodiment of the use disclosed herein, the petroleum product is heavy oil, extra-heavy oil, bitumen, or any combination thereof. In a particular embodiment of the use disclosed herein, the petroleum is bitumen.

[0076] In an embodiment of the use disclosed herein, the carbon containing gas is an exhaust gas. In some embodiments of the use disclosed herein, the exhaust gas is from an industrial high-emission CO2 facility or a fossil fuel combustion device, as described elsewhere herein. As an example, and without limitation, the exhaust gas may be from a fossil fuel powered (e.g. a turbine generator).

[0077] In the present disclosure, all terms referred to in singular form are meant to encompass plural forms of the same. Likewise, all terms referred to in plural form are meant to encompass singular forms of the same. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0078] As used herein, the term “about” refers to an approximately + / -10 % variation from a given value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.

[0079] It should be understood that the compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, thecompositions and methods can also "consist essentially of or "consist of the various components and steps. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the element that it introduces.

[0080] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0081] Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, the disclosure covers all combinations of all those embodiments. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be referenced herein, the definitions that are consistent with this specification should be adopted.

[0082] Many obvious variations of the embodiments set out herein will suggest themselves to those skilled in the art in light of the present disclosure. Such obvious variations are within the full intended scope of the appended claims.

Claims

CLAIMS:1 . A method for upscaling a petroleum product, the method comprising:- providing the petroleum product to a vessel; and- providing a carbon containing gas to the vessel to abate carbon from the carbon containing gas and sequester the carbon into the petroleum product, to form an upscaled petroleum product.

2. The method of claim 1 , wherein the vessel is a distillation vessel.

3. The method of claim 2, wherein the method further comprises a step of refining, by distillation, the petroleum product.

4. The method of claim 3, wherein the distillation is performed prior to providing the carbon containing gas to the vessel to distill off one or more refined products from the vessel, and subsequently abate carbon from the carbon containing gas and sequester the carbon into one or more remaining petroleum products within the vessel.

5. The method of claim 4, wherein the one or more refined products are butane, gasoline, naphtha, kerosene, jet fuel, diesel fuel, marine gas oil, or any combination thereof.

6. The method of any one of claims 3 to 5, wherein the distillation is performed in the presence of the carbon containing gas to abate carbon from the carbon containing gas and sequester the carbon into one or more remaining petroleum products within the vessel.

7. The method of any one of claims 4 to 6, wherein the one or more remaining petroleum products comprise heavy oil, extra heavy oil, bitumen, or any combination thereof.

8. The method of any one of claims 3 to 7, wherein the distillation is an atmospheric distillation.

9. The method of any one of claims 3 to 7, wherein the distillation is vacuum distillation.

10. The method of any one of claims 3 to 7, wherein the distillation is pressure distillation.1 1 . The method of any one of claims 1 to 10, wherein the vessel comprises one or more conduits for receiving therefrom the carbon containing gas.

12. The method of claim 1 , wherein the vessel is a storage tank.

13. The method of claim 12, wherein the storage tank is a bitumen storage tank and the petroleum product comprises bitumen.

14. The method of claim 12 or 13, wherein the storage tank is a shipping container.

15. The method of claim 1 , wherein the vessel is a crude oil upgrader and the petroleum product is a heavy crude oil.

16. The method of claim 15, wherein the method further comprises a step of upgrading the heavy crude oil and producing a lighter crude oil and a petroleum coke.

17. The method of claim 16, wherein the step of upgrading is performed in the presence of the carbon containing gas to abate carbon from the carbon containing gas and sequester the carbon into the petroleum coke.

18. The method of any one of claims 1 to 17, wherein the carbon containing gas is an exhaust gas.

19. The method of claim 18, wherein the exhaust gas is from an industrial high-emission CO2 facility, such as for example a refinery, an upgrader, a cement factory, a natural gas fired power plant, or a coal-fired power plant.

20. The method of claim 19, which is performed within the industrial high-emission CO2 facility or in a facility onsite or near to the industrial high-emission CO2 facility.

21. The method of claim 18, wherein the exhaust gas is from a fossil fuel combustion device, such as a fossil fuel powered generator, optionally a turbine generator.

22. The method of claim 21 , wherein heat and / or electricity from the fossil fuel powered generator are used in the method to process the petroleum product.

23. The method of claim 21 or 22, wherein the abatement of carbon from the carbon containing gas and sequestration into the petroleum product occurs with a concurrent or subsequent emission of oxygen.

24. The method of claim 23, which further comprises delivering the oxygen to the fossil fuel powered generator in a feedback loop.

25. The method of any one of claims 21 to 24, further comprising a step of delivering an excess electricity produced by the fossil fuel powered generator to a power grid.

26. The method of any one of claims 21 to 25, further comprising a step of delivering a produced liquid transportation fuel, such as gasoline, to the fossil fuel powered generator as a fuel source.

27. The method of any one of claims 1 or 26, wherein the petroleum product comprises waste oil, petroleum coke, high-asphaltene oil, bunker oil, gasification bunker oil, heavy oil, extra-heavy oil, bitumen, or any combination thereof.

28. The method of claim 27, wherein the petroleum product is heavy oil, extra-heavy oil, bitumen, or any combination thereof.

29. A method for zero-emissions refining and zero-emissions power generation, the method comprising: i) producing from a fossil fuel powered generator heat, electricity and an exhaust gas; ii) providing a petroleum product to a distillation apparatus; iii) delivering the heat, electricity and exhaust gas to the distillation apparatus, wherein the heat is used as a heat source for a distillation procedure, the electricity is used as a power source for the distillation procedure, and the exhaust gas is used as a carbon source for sequestration of carbon into the petroleum product to form an upscaled petroleum product; and iv) distilling the petroleum product and / or the upscaled petroleum product to vaporize one or more refined products, for zero-emissions refining and zero-emissions power generation.

30. The method of claim 29, further comprising: v) delivering at least one of the one or more refined products to the fossil fuel powered generator as a power source.

31. The method of claim 30, wherein delivery of the at least one of the one or more refined products and the oxygen to the fossil fuel powered generator is sufficient to provide at least a portion of the power source required by the fossil fuel powered generator for operation.

32. The method of claim 31 , wherein delivery of the at least one of the one or more refined products and the oxygen to the fossil fuel powered generator is sufficient to provide at least 25%, at least 35%, at least 45%, at least 50%, at least 55%, at least 65%, at least 75%, at least 85%, at least 90%, at least 95%, or 100% of the power source required by the fossil fuel powered generator for operation.

33. The method of claim 31 or 32, which produces an excess quantity of one or more of the refined products that is not required by the fossil fuel powered generator, and which can be used for other purposes.

34. The method of any one of claims 30 to 33, further comprising: vi) repeating steps (i) to (v) any number of times.

35. The method of any one of claims 29 to 34, wherein the one or more refined products are butane, gasoline, naphtha, kerosene, jet fuel, diesel fuel, marine gas oil, or any combination thereof.

36. The method of any one of claims 29 to 35, wherein the petroleum product comprises waste oil, petroleum coke, high-asphaltene oil, bunker oil, gasification bunker oil, heavy oil, extra-heavy oil, bitumen, or any combination thereof.

37. The method of claim 36, wherein the petroleum product is heavy oil, extra-heavy oil, bitumen, or any combination thereof.

38. The method of any one of claims 29 to 37, wherein the vaporization of the one or more refined products results in one or more remaining petroleum products being left within a vessel of the distillation apparatus.

39. The method of claim 38, which comprises the abatement of carbon from the exhaust gas and sequestration of the carbon into the one or more remaining petroleum products within the vessel.

40. The method of claim 39, wherein the remaining petroleum product comprises bitumen.

41. The method of claim 40, wherein the bitumen is hardened bitumen suitable for transport in a shipping container.

42. The method of any one of claims 29 to 41 , wherein the fossil fuel powered generator produces excess electricity that is delivered to a power grid.

43. Use of a petroleum product within a vessel as a medium for sequestering carbon from a carbon containing gas.

44. The use of claim 43, wherein the petroleum product comprises waste oil, petroleum coke, high-asphaltene oil, bunker oil, gasification bunker oil, heavy oil, extra-heavy oil, bitumen, or any combination thereof.

45. The use of claim 44, wherein the petroleum product is heavy oil, extra-heavy oil, bitumen, or any combination thereof.

46. The use of claim 45, wherein the petroleum product is bitumen.

47. The use of any one of claims 43 to 46, wherein the carbon containing gas is an exhaust gas.

48. The use of claim 47, wherein the exhaust gas is from an industrial high-emission CO2 facility, such as for example a refinery, an upgrader, a cement factory, a natural gas fired power plant, or a coal-fired power plant.

49. The use of claim 48, which is performed within the industrial high-emission CO2 facility or in a facility onsite or near to the industrial high-emission CO2 facility.

50. The use of claim 47, wherein the exhaust gas is from a fossil fuel combustion device, such as a fossil fuel powered generator, optionally a turbine generator.

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