A review of in situ upgrading technology for heavy crude oil

With the growing demand of oil worldwide, heavy oil has increasingly become vital in the world energy market. However, further development of heavy oil reservoirs are limited by regular enhanced oil recovery (EOR) methods. In situ upgrading technology provides potential for the development of heavy oil and bitumen reservoirs. This study reviews three categories of in situ upgrading methods: solvent-based, in situ combustion (ISC), and catalytic. Solvent-based methods, including cyclic solvent injection, vapor extraction, and hybrid processes, have recently received attention and have been progressed in both laboratory and field applications. However, high solvent costs in relation to the low price of heavy oil have continued to limit the field applications of these techniques. ISC, which may have the potential to develop particularly harsh reservoirs with extremely viscous crude oil, involves complex reaction mechanisms and consists of three main steps: oxidation, combustion, and gas flooding. Yet, complex operating conditions and a low success rate have restricted its application. Catalytic methods, which have demonstrated the potential to refine and upgrade crude oil in a more economic and environmentally friendly way, are often accompanied by conventional thermal EOR methods, such as steam flooding and ISC, and involve a series of hydroprocessing or hydrotreating reactions, such as hydrocracking, hydrodesulfurization, hydrodenitrogenation, hydrodeoxygenation, and hydrodemetallization. However, the high cost and complexity of the reaction mechanisms have limited their applications.