Processing and Recovery of Heavy Crude Oil Using an HPA-Ni Catalyst and Natural Gas

Abstract

To maintain economic profitability and stabilize fuel prices, refineries actively explore alternatives for efficiently processing (extra) heavy crude oils. These oils are challenging to process due to their complex composition, which includes significant quantities of asphaltenes, resins, and sulfur and nitrogen heteroatoms. A critical initial step in upgrading these oils is the hydrogenation of polyaromatic compounds, requiring substantial hydrogen sources. Methane from natural gas streams is known to act as an effective hydrogen donor. This study investigates the use of a heteropolyacid (HPA) catalyst modified with nickel and methane to enhance the quality of heavy crude oil with an initial 8.0°API (at 15.5 °C) and 2200 cSt viscosity (at 37.5 °C). After treatment in a batch reactor at 380 °C and 4.4 MPa for 2 h, the oil properties markedly improved: API gravity increased from 8.0 to 16.0 (at 15.5 °C), and kinematic viscosity reduced from 2200 to 125 cSt (at 37.5 °C). Additionally, there was a significant decrease in asphaltenes (from 38.7 to 16.4% by weight), sulfur (from 5.9 to 4.0% by weight), and nitrogen (from 971 to 695 ppm). This was accompanied by an increase in the volume of light distillates from 1.3 to 4.9%, and middle distillates from 8.8 to 21.0%. These results suggest that nickel-modified HPA catalysts, combined with methane as a hydrogen donor, are a promising option for upgrading heavy crude oils.