Systems and methods for integrating bitumen extraction with bitumen upg...

Abstract

Methods and systems for integrating bitumen extraction processes with bitumen upgrading processes are disclosed. The methods and systems can include recovering an emulsion of hydrocarbon and water from a Steam Assisted Gravity Drainage extraction process, breaking the emulsion, using the water from the emulsion to make steam, upgrading the hydrocarbon from the emulsion using the steam, separating diluent from the upgraded hydrocarbon, and using the diluent to break SAGD-produced emulsion.

1 . A method comprising:
 recovering a first quantity of an emulsion of hydrocarbon material and water from a Steam Assisted Gravity Drainage system;   adding an emulsion breaker to the first quantity of emulsion and providing a water stream and a dilbit stream;   converting the water stream to steam;   upgrading the dilbit stream using the steam and providing an upgraded hydrocarbon stream;   separating a diluent stream from the upgraded hydrocarbon stream; and   adding the diulent stream to a second quantity of the emulsion recovered from the Steam Assisted Gravity Drainage system.   
     
     
         2 . The method of  claim 1 , wherein the emulsion breaker comprises a hydrocarbon solvent having a boiling point in the range of from −44 to 800° F. 
     
     
         3 . The method of  claim 1 , wherein the emulsion breaker comprises paraffinic solvent. 
     
     
         4 . The method of  claim 1 , wherein the emulsion breaker is obtained from an upgraded stream of SAGD-derived hydrocarbon material. 
     
     
         5 . The method of  claim 1 , wherein the emulsion breaker is added to the emulsion at a ratio of from 5 to 30 on a volume basis. 
     
     
         6 . The method of  claim 1 , wherein adding an emulsion breaker to the emulsion and providing a water stream and a dilbit stream comprises separating the water stream from the dilbit stream by settling or hydrocycloning the dilbit stream. 
     
     
         7 . The method of  claim 1 , wherein the water stream is subjected to water treatment prior to being converted to steam. 
     
     
         8 . The method of  claim 1 , wherein the steam is converted to superheated steam. 
     
     
         9 . The method of  claim 1 , wherein upgrading the dilbit stream using the steam and providing an upgraded hydrocarbon stream comprises:
 injecting the steam through a converging then diverging passage of a cracking material injector into a reaction chamber, wherein passing the steam through the converging then diverging passage accelerates the steam to supersonic speed; and   injecting the dilbit into the reaction chamber adjacent to the steam entering the reaction chamber from the cracking material injector and cracking the dilbit at least proximate the intersection of the steam and the dilbit.   
     
     
         10 . The method of  claim 1 , wherein the diluent comprises a hydrocarbon solvent having a boiling point in the range of from −44 to 800° F. 
     
     
         11 . The method of  claim 1 , wherein hydrocarbon residue is separated from the upgraded hydrocarbon stream prior to separating a diluent stream from the upgraded hydrocarbon stream. 
     
     
         12 . A system comprising:
 a Steam Assisted Gravity Drainage system comprising an injection well and a production well;   an emulsion breaking unit comprising a production well inlet, an emulsion breaker inlet, a water stream outlet, and a dilbit stream outlet, wherein the production well of the SAGD system is in fluid communication with the production well inlet of emulsion breaking unit;   a steam generation unit comprising a water stream inlet and a steam outlet, wherein the water stream outlet of the emulsion breaking unit is in fluid communication with the water stream inlet of the steam generation unit;   a nozzle reactor comprising a steam inlet, a dilbit inlet, and an upgraded hydrocarbon outlet, wherein the steam outlet of the steam generation unit is in fluid communication with the steam inlet of the nozzle reactor and the dilbit stream outlet of the emulsion breaking unit is in fluid communication with the dilbit inlet of the nozzle reactor; and   a separation unit comprising an upgraded hydrocarbon inlet and a diluent outlet, wherein the upgraded hydrocarbon outlet of the nozzle reactor is in fluid communication with the upgraded hydrocarbon inlet of the separation unit, and wherein diluents outlet of the separation unit is in fluid communication with the diluent inlet of the emulsion breaking unit.