Optimizing in-situ upgrading of heavy crude oil via catalytic aquathermolysis using a novel graphene oxide-copper zinc ferrite nanocomposite as a catalyst

Abstract

Abstract Unconventional resources, such as heavy oil, are increasingly being explored and exploited due to the declining availability of conventional petroleum resources. Heavy crude oil poses challenges in production, transportation, and refining, due to its high viscosity, low API gravity, and elevated sulfur and metal content. Improving the quality of heavy oil can be achieved through the application of steam injection, which lowers the oil’s viscosity and enhances its flow. However, steam injection alone falls short of meeting the growing demand for higher-quality petroleum products. Catalytic upgrading is therefore being investigated as a viable solution to improve heavy oil quality. This study experimentally investigates the application of two novel catalysts, namely copper-substituted zinc ferrite (ZCFO) synthesized via the sol–gel combustion method and a graphene oxide-based nanocomposite (GO-ZCFO) with different ratios, for catalyzing aquathermolysis reactions in the steam injection process, with the aim of enhancing the in-situ upgrading of heavy oil. These catalysts underwent characterization using X-ray powder diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR), and Transmission Electron Microscopy (TEM). Their catalytic performance was assessed utilizing a high-pressure/high-temperature reactor (300 ml), with a comprehensive analysis of the changes in the physical and chemical properties of the heavy oil before and after upgrading. This analysis included measurements of sulfur content, SARA fractions, viscosity, API gravity, and Gas Chromatography (GC) of saturated hydrocarbons and evolved gases. All upgrading experiments, including both catalytic and non-catalytic aquathermolysis processes, were conducted under a reaction time of 6 h, a reaction temperature of 320 °C, and high pressure (86–112 bar). The results indicated that the introduction of the proposed catalysts as additives into the upgrading system resulted in a significant reduction in sulfur content. This, in turn, led to a decrease in resin and asphaltene content, an increase in the content of saturated hydrocarbon, particularly low-molecular-weight alkanes, and ultimately, a reduction in viscosity along with higher API gravity of the crude oil. GO-ZCFO with a weight ratio (50:50) exhibited the best catalytic performance. The heavy crude oil, upgraded with this 50:50 ratio, exhibited significant enhancements, including a 29.26% reduction in sulfur content, a 21.27% decrease in resin content, a 37.60% decrease in asphaltene content, a 46.92% increase in saturated hydrocarbon content, a 66.48% reduction in viscosity, and a 25.49% increase in API gravity. In comparison, the oil upgraded through non-catalytic aquathermolysis showed only marginal improvements, with slight reductions in sulfur content by 5.41%, resin content by 3.60%, asphaltene content by 11.36%, viscosity by 17.89%, and inconsiderable increases in saturated hydrocarbon content by 9.9% and API gravity by 3.02%. The GO-ZCFO, with its high catalytic activity, stands as a promising catalyst that contributes to improving the in-situ upgrading and thermal conversion of heavy crude oil.

Keywords

• Heavy crude oil
• In-situ upgrading
• Catalytic aquathermolysis
• Graphene oxide-based nanocomposite
• Enhanced heavy oil recovery