Refinery process for heavy oil and bitumen

摘要

A bitumen and heavy oil upgrading process and system is disclosed for the synthesis of hydrocarbons, an example of which is synthetic crude oil (SCO). The process advantageously avoids the waste attributed to residuum and/or petcoke formation which has a dramatic effect on the yield of hydrocarbon material generated. The process integrates Fischer-Tropsch technology with gasification and hydrogen rich gas stream generation. The hydrogen rich gas generation is conveniently effected using singly or in combination a hydrogen source, a hydrogen rich vapor from hydroprocessing and the Fischer-Tropsch process, a steam methane reformer (SMR) and autothermal reformer (ATR) or a combination of SMR/ATR. The feedstock for upgrading is distilled and the bottoms fraction is gasified and converted in a Fischer-Tropsch reactor. A resultant hydrogen lean syngas is then exposed to the hydrogen rich gas stream to optimize the formation of, for example, the synthetic crude oil.

主权项

1. A process for upgrading crude oil or heavy oil or bitumen to formulate refined hydrocarbon products, wherein said process comprises:
(a) providing a feedstock source of crude oil, heavy oil or bitumen; (b) treating said feedstock to form at least one distilled fraction and a non-distilled bottom fraction; (c) optionally treating said non-distilled bottom fraction to a hydrocarbon treatment operation to form a treated fraction and a treated bottom fraction; (d) processing said at least one distilled fraction and/or said treated fraction in a hydrocarbon cracking operation to form a processed stream; (e) feeding said non-distilled bottom fraction or said treated bottom fraction to a syngas generating operation for formulating a hydrogen lean syngas stream via a partial oxidation reaction and reacting said syngas in a Fischer-Tropsch reactor to formulate synthesized hydrocarbons; (f) adding an external source of hydrogen to said hydrogen lean syngas to formulate said synthesized hydrocarbons; and (g) blending a portion of said synthesized hydrocarbons with a portion of said processed stream to form said fully refined hydrocarbon products comprising naphtha, gasoline, diesel, kerosene, jet fuel or any combination thereof.