Homogeneous Phase Catalyst for Heavy Crude Viscosity Reduction
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Solution Overview
Problem
Current enhanced oil recovery technologies face limitations in extracting heavy oils due to high viscosity and density, with existing methods like Steam Assisted Gravity Drainage and air injection posing risks such as explosion and combustion front deviation, and failing to effectively improve the physical and chemical properties of heavy and extra-heavy crude oils.
Innovation Solution
A homogeneous phase catalyst using inorganic salts of metals like Fe, Co, Ni, Cu, Mo, and W is applied to heavy and extra-heavy crude oils, promoting hydro-disintegration and hydrogenation reactions, which reduces viscosity, increases API gravity, and enhances the yield of distillates by altering the hydrocarbon composition and reducing sulfur and nitrogen content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If Steam Assisted Gravity Drainage or Cyclic Steam Injection is used to extract heavy oils, then the viscosity of heavy crude oil is reduced and flow is improved, but these methods can only be applied at medium depths around 1,000 m and require high energy input
Solution Approach 1:
The patent changes the chemical parameters of heavy crude oil by introducing homogeneous phase catalysts that alter the molecular structure through hydro-disintegration and hydrogenation reactions. This transforms long-chain hydrocarbons into shorter chains, fundamentally changing the fluid's physical properties including viscosity and flow characteristics without requiring thermal energy input
Solution Approach 2:
The patent replaces the thermal-mechanical system (steam injection requiring high temperature and pressure) with a chemical system using homogeneous phase catalysts. The catalyst system operates under milder conditions and achieves viscosity reduction through chemical transformation rather than thermal heating, eliminating the 1,000m depth limitation
2Speed
If air injection technologies are used to improve heavy oil recovery, then the viscosity of heavy crude oil is reduced through combustion heat, but there is a high risk of explosion and combustion front deviation
Solution Approach 1:
The patent converts the harmful effect of thermal methods (explosion risk, uncontrolled combustion) into a beneficial chemical transformation process. By using homogeneous phase catalysts, the system achieves viscosity reduction through controlled chemical reactions rather than uncontrolled combustion, eliminating safety hazards while maintaining effectiveness
Solution Approach 2:
The patent introduces homogeneous phase catalysts as intermediaries that facilitate the transformation of heavy crude oil properties without requiring direct thermal energy input. The catalyst system mediates the chemical changes in the oil, enabling viscosity reduction and flow improvement without the harmful side effects of air injection and combustion
3Speed
If THAI or CAPRI technologies are used with vertical and horizontal wells, then high temperatures are generated to reduce viscosity and improve flow, but the device complexity and operational difficulty increase
Solution Approach 1:
The patent creates a universal solution that can be applied to existing well configurations without requiring complex vertical-horizontal well patterns. The homogeneous phase catalyst system works with standard well architectures and can be integrated into existing production infrastructure, eliminating the need for specialized well configurations while achieving the same flow improvement goals
4Productivity
If conventional extraction techniques are used for heavy crude oils with densities between 10 and 15° API, then production can be maintained at current levels, but the recovery factor is significantly limited and quality requirements cannot be met
Solution Approach 1:
The patent applies preliminary chemical treatment to heavy crude oils by introducing homogeneous phase catalysts that transform the oil properties before extraction and processing. This preliminary hydro-disintegration and hydrogenation reduces viscosity and improves flow characteristics, enabling higher recovery factors and meeting quality requirements that would otherwise be unachievable with conventional techniques
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst significantly improves the fluidity and quality of heavy crude oils, achieving higher yields of lighter products with reduced sulfur and nitrogen content, and minimizing carbon formation, thereby enhancing the extraction efficiency and quality of heavy and extra-heavy crude oils.
Implementation Method 1
promoting hydro-disintegration and hydrogenation reactions, which reduces viscosity, increases API gravity
Implementation Method 2
promoting hydro-disintegration and hydrogenation reactions, which reduces viscosity, increases API gravity, and enhances the yield of distillates by altering the hydrocarbon composition and reducing sulfur and nitrogen content
Data Source
AI summary
This disclosure relates to a procedure, which through the application of a catalyst in homogeneous phase, allows the transformation of heavy hydrocarbons (vacuum residue, atmospheric residue, heavy and extra-heavy crudes) into hydrocarbons of lower molecular weight, characterized because after its application, the hydrocarbons obtain greater API gravity, lower kinematic viscosity and different composition by hydrocarbon families (SARA) that increases the proportion of saturated and aromatic resins and asphalts. The sulphur and nitrogen content is also reduced, resulting in higher yields to high commercial value distillates and a lighter product as compared to the original crude.