Reactor and process for upgrading heavy hydrocarbon oils

Abstract

A reactor for conducting a process using supercritical water to upgrade a heavy hydrocarbon feedstock into an upgraded hydrocarbon product or syncrude with highly desirable properties (low sulfur content, low metals content, lower density (higher API), lower viscosity, lower residuum content, etc.) is described. The reactor is operable under continuous) semi-continuous or batch mode and is equipped with means to enable momentum, heat and mass transfer in and out of and within the reactor.

1 . An apparatus for upgrading a hydrocarbon by reaction with a fluid comprising water under supercritical water conditions comprising:
 a. means for dispersing and mixing the fluid comprising water and the hydrocarbon under conditions which disfavor thermal cracking and formation of coke.   b. means for injecting a dispersed water-hydrocarbon mixture into is a reaction zone under supercritical water conditions;   c. a reaction zone having means for maintaining a uniform temperature within said reaction zone; means for controlling the residence time in the reaction zone within determined limits and means for avoiding the settling of inorganic solids within the reaction zone; and   d. means for recovering an upgraded hydrocarbon.   
     
     
         2 . An apparatus according to  claim 1 , wherein the means for dispersing the fluid comprising water and the hydrocarbon comprise at least one static mixer, spray nozzle, sonic or ultrasonic agitator, thermal siphon or combinations thereof 
     
     
         3 . An apparatus according to  claim 1 , wherein the reaction zone comprises a reactor having means for collecting reaction products and means for accumulating metals or solids. 
     
     
         4 . An apparatus according to  claim 1  wherein the means for recovering an upgraded hydrocarbon comprises a vessel having a dip tube a cyclone, a filter, a membrane or a packed bed. 
     
     
         5 . An apparatus according to  claim 1 , wherein the reaction zone comprises a tubular reactor having a length to diameter ratio from 50 to 10,000 and a length selected to provide adequate residence time in the reaction zone. 
     
     
         6 . An apparatus according to  claim 1 , wherein the reaction zone comprises a tubular reactor having a length to diameter ratio from 100 to 4,000 and a length selected to provide adequate residence time in the reaction zone. 
     
     
         7 . An apparatus according to  claim 1  wherein the reaction zone compresses a tubular reactor having a diameter selected to sustain a turbulent flow of reactants to avoid precipitation of solids and a length selected to provide adequate residence time in the reaction zone. 
     
     
         8 . An apparatus according to  claim 1 , wherein the reaction zone comprises at least two reactors. 
     
     
         9 . An apparatus according to  claim 8  further comprising quenching means between said at least two reactors. 
     
     
         10 . An apparatus according to  claim 3 , wherein a mixer precedes the reactor.