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US 8,105,480B2 34 as the liquid comprising the heavy oil passes through the cavitationzone suchasacapillaryornozzle,theliquidcom prising the heavy oil is subjected to a pressure drop of from about150psigtoabout5,000psig.Inthecavitationzone,the heavy oil is subjected to cavitation. As knoWn in the art, cavitation is produced by microbubbles of gas dispersed in theheavyoil.Suchmicrobubblesexpandandthenimplodeor collapse. The implosion or collapse of the microbubbles raisesthetemperatureattheinterfaceofthemicrobubblesand heavyoiltoveryhighlevels,forexample,fromaboutl,000° C. to about 2,000° C., for a period of microseconds, Which facilitates free radical formation and chemical reactions. In a non-limiting embodiment, the liquid comprising the heavyoilispassedthroughthecavitationzoneatavelocityof fromabout 150m/sectoabout300m/sec.Inanotherembodi ment,theliquidcomprisingtheheavyoilispassedthrough the cavitation zone at a velocity of from about 200 m/sec to about 300 m/sec. In a non-limiting embodiment, the liquid comprising the heavyoilissubjectedtoapressuredropinthecavitationzone 20 of from about 400 psig to about 4,000 psig. In another non limitingembodiment,theliquidcomprisingtheheavyoilis subjected to a pressure drop in the cavitation zone of from about 400 psig to about 2,000 psig. In another embodiment, theliquidcomprisingtheheavyoilissubjectedtoapressure25 drop in the cavitation zone of from about 400 psig to about 1,500psig.Inyetanotherembodiment,theliquidcomprising the heavy oil is subjected to a pressure drop in the cavitation zone of from about 1,000 psig to about 1,500 psig. Inanon-limitingembodiment,theratioofthelengthofthe 30 cavitation zone to the Width of the cavitation zone is from about 10 to about 125. In another non-limiting embodiment, theratioofthelengthofthecavitationzonetotheWidthofthe cavitation zone is from about 50 to about 125. Inanon-limitingembodiment,theheavyoilisheatedand 35 then the heavy oil is subjected to conditions Which produce cavitation as hereinabove described. In a non-limiting embodiment, the heavy oil is heated to a temperature of from about 75° C. to about 450° C. In another embodiment,theheavyoilisheatedtoatemperatureoffrom 40 about 150° C. to about 450° C. In another embodiment, the heavy oil is heated to a temperature of from about 200° C. to about 450° C. In yet another embodiment, the heavy oil is heated to a temperature of from about 200° C. to about 400° C.Instilanotherembodiment,theheavyoilisheatedtoa 45 temperature of from about 300° C. to about 400° C. Inanon-limitingembodiment,theliquidfurthercomprises an organic material, that is not a heavy oil and is a liquid at standard temperature and pressure. Thus, in a non-limiting embodiment, there is provided a process for treating a heavy oil Which comprises subjecting a heavy oil in combination With an organic material to cavitation in order to reduce the viscosityoftheheavyoil. Themixtureoftheheavyoilandorganicmaterialmay be subjected to cavitation as hereinabove described. For example, the mixture of the heavy oil and organic material may bepassedthroughthecavitationzoneunderthevelocity and pressure drop conditions mentioned hereinabove. In addition, When the mixture of heavy oil and organic materialissubjectedtohydrodynamiccavitation,aportionof themixtureofheavyoilandorganicmaterialisintheformof a gas dispersed in the liquid. The gaseous portion may be (i) aportionoralloftheorganicmaterial,or(i)bothaportionor all of the organic material and a portion of the heavy oil, or (i)onlyaportionoftheheavyoil.Preferably,thegas includestheorganicmaterialandmay ormay notincludea portionoftheheavyoil. In a non-limiting embodiment, each of the heavy oil and organic material is heated, the heavy oil and the organic materialaremixed,andthenthemixtureofheavyoiland organic material is subjected to conditions Which produce cavitation as hereinabove described. Inanon-limitingembodiment,subsequenttotheheatingof theheavyoilandorganicmaterial,theheavyoilandorganic materialaremixedinamixingzone,andthensubjectedto cavitation in the cavitation zone. In another non-limiting embodiment, a portion of the heavyoilWhenheated,priortobeingmixedWiththeorganic materialinthemixingzone,may ormay notbevaporized.If aportionoftheheavyoilisvaporized,suchportion,ina non-limiting embodiment, does not exceed the amounts here inabove described. Inanothernon-limitingembodiment,Whenheated(priorto being mixed With the heavy oil in the mixing zone), all or a portionoftheorganicmaterialisvaporized. Inanothernon-limitingembodiment,theorganicmaterial, When heated (prior to being mixed With the heavy oil in the mixing zone), remains a liquid. In yet another non-limiting embodiment, When such liquid organic material is passed throughthecavitationzone,alloraportionofsuchliquid organicmaterialisvaporized. Althoughthescopeofthepresentinventionisnotintended Inanothernon-limitingembodiment,theorganicmaterial to be limited thereby, in general the heavy oil to be treated may be those oils referred to by the American Petroleum Institute(API)asheavyoilsandextraheavyoils.Asnoted 50 hereinabove,aheavyoilhasanAPI gravityofbetWeen223° (densityof920kg/m3or0.920g/cm3)and100°(densityof 1,000kg/m3or1g/cm3).AnextraheavyoilhasanAPIgravity oflessthan 100° (densitygreaterthan 1,000kg/m3 orgreater than1g/cm3).Examplesofsuchheavyoilsinclude,butare55 not limited to, bitumen, heavy oils extracted from beloW the groundsurfacebysteamassistedgravitydrainage,orSAGD, and other methods, bottoms products from atmospheric or vacuum distillation of bitumen or heavy oil, shale oils, coal derivedliquids,crudeoilresidues,andtoppedcrudeoils. 60 In another non-limiting embodiment, a portion of the heavy oil When heated may or may not be vaporized. Inanon-limitingembodiment,theportionoftheheavyoil Whichisvaporizeddoesnotexceed35vol.% ofthevolume oftheheavyoil.Inanothernon-limitingembodiment,the65 portionoftheheavyoilWhichisvaporizeddoesnotexceed15 vol.% ofthevolumeoftheheavyoil. has been subjected to a temperature above the critical tem perature and a pressure above the critical pressure and thus becomesasupercritical?uid,Whichhaspropertiesofaliquid andagas.Theresultisthattheorganicmaterialhastheability tointeractorassociateWithcomponentsoftheheavyoil Which are similar to those as When the organic material exists asaliquid,butithasahigherdiffusivity,loWerviscosity,and loWersurfacetensionthansuchmaterialintheliquidphase.It is to be understood that the scope of the present invention is not to be limited to such an embodiment. Thus, in a non-limiting embodiment, at least a portion of the mixture of heavy oil and organic material is a liquid. In oneembodiment,theamountofthemixtureWhichisaliquid is an amount su?icient to form a continuous liquid phase Which is subjected to cavitation as hereinabove described. In a non-limiting embodiment, liquid is present in an amount of atleast40vol.% ofthetotalvolumeofthemixtureofheavy oilandorganicmaterial.Inanotherembodiment,liquidis presentinanamountofatleast60vol.% ofthetotalvolume ofheavyoilandorganicmaterial.PDF Image | PROCESS FOR TREATING HEAVY OILS
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