A system and method is provided for upgrading a continuously flowing process stream including heavy crude oil (HCO). A reactor receives the process stream in combination with water, at an inlet temperature within a range of about 60 C. to about 200 C. The reactor includes one or more process flow tubes having a combined length of about 30 times their aggregated transverse cross-sectional dimension, and progressively heats the process stream to an outlet temperature T(max)1 within a range of between about 260 C. to about 400 C. The reactor maintains the process stream at a pressure sufficient to ensure that it remains a single phase at T(max)1. A controller selectively adjusts the rate of flow of the process stream through the reactor to maintain a total residence time of greater than about 1 minute and less than about 25 minutes.

A method of separating solids and hydrocarbons from oil sands material has the steps of: mixing the oil sands material with water to create an oil sands slurry, the oil sands slurry comprising hydrocarbons, sand, water and a bubbling agent, the oil sands slurry being free from added surfactants, the bubbling agent comprising metal compounds present in the oil sands material that act as a catalyst; and conditioning the oil sands slurry such that: the bubbling agent produces bubbles within the oil sands slurry; at least a portion of the sand settles out from the oil sands slurry; and the bubbles interact with the hydrocarbons to produce a hydrocarbon froth at a top of the oil sands slurry. Metal compounds may be extracted from the oil sands slurry to be reused as a catalyst or as a source of revenue.

A method of extraction of a liquid hydrocarbon fraction from carbonaceous waste feedstock. Waste material is slurried, by grinding or comminution of same into a substantially uniform stream of around waste material. Fluid would be added as required to supplement the ground waste to yield a slurry of desirable parametersthe fluid used would be primarily liquid effluent fraction recovered from previous operation of the method. Feedstock slurry is placed into a pressurized heat transfer reactor where it is maintained at temperature and pressure for a predetermined period of time. On discharge from the heat transfer reactor the processed emulsion is separated into liquid hydrocarbon fraction, liquid effluent fraction and solid waste fraction. A novel heat transfer reactor design is also disclosed.

A steam assisted gravity drainage (SAGD) processing facility comprising: an oil/water separation process block operable for bulk separation of produced water from a produced fluid comprising produced water and hydrocarbons; a de-oiling process block operable to remove residual oil from the produced water separated from the produced fluid in the oil/water separation process block and provide a de-oiled water; a water treatment block operable to remove contaminants from the de-oiled water and provide a treated water; and a steam generation process block operable to produce steam from the treated water. In embodiments, each of the oil/water separation process block, the de-oiling process block, the water treatment process block, and the steam generation process block is modularized and comprises a plurality of modules. Methods for operating and assembling a SAGD processing facility are also provided.

A process for in situ thermal recovery of hydrocarbons from a reservoir is provided. The process includes: providing an oxygen-enriched mixture, fuel, feedwater and an additive including at least one of ammonia, urea and a volatile amine to a Direct-Contact Steam Generator (DCSG); operating the DCSG, including contacting the feedwater and the additive with hot combustion gas to obtain a steam-based mixture including steam, CO.sub.2 and the additive; injecting the steam-based mixture or a stream derived from the steam-based mixture into the reservoir to mobilize the hydrocarbons therein; and producing a produced fluid including the hydrocarbons.

Direct steam injection (DSI) heating techniques can use a heater to heat a process stream in bitumen froth treatment. The DSI heater can include a diffuser with multiple side-by-side rows of outlets perpendicular to a longitudinal axis of the diffuser, and a piston plug that moves axially within the diffuser to selectively cover rows of outlets to vary steam injection. The piston plug has first and second annular seals and is moved between different axial positions in a stepwise fashion such that when one or more rows of outlets are completely covered, the first annular seal is located in between adjacent rows and the second annular seal abuts against the diffuser to inhibit passage of steam so as to prevent cavitation. The DSI heater can include various other features, such as particular seal unit constructions and diffuser outlet configurations.

Techniques provided herein relate to regulating at least one operating parameter of a paraffinic froth treatment (PFT) operation and controlling the quality of the produced bitumen in response to a determined concentration of at least one residual metal in a PFT process stream. Determination of the residual metal concentration is based on acquired NIR spectral measurements of the PFT process stream. An alkaline agent dosage in primary extraction operation can be for example regulated in response to a difference between a determined calcium concentration and a calcium concentration specification.

An apparatus for washing solid particles removed from a hydrocarbon-containing fluid produced from an oil and gas production facility using a company automated unit. The apparatus comprises an inlet that carries a mixture of solids particles and water flushed from a de-sander.

Method for cleaning a material contaminated with an organic pollutant by heat treatment, where energy for heating the material is provided by direct heat treatment of the material in a hammermill. An organic polar additive with a boiling temperature above 100 C. is added to and mixed with the material prior to the direct heat treatment. A use of the organic polar additive is described as well.

A steam assisted gravity drainage (SAGD) processing facility comprising: an oil/water separation process block operable for bulk separation of produced water from a produced fluid comprising produced water and hydrocarbons; a de-oiling process block operable to remove residual oil from the produced water separated from the produced fluid in the oil/water separation process block and provide a de-oiled water; a water treatment block operable to remove contaminants from the de-oiled water and provide a treated water; and a steam generation process block operable to produce steam from the treated water. In embodiments, each of the oil/water separation process block, the de-oiling process block, the water treatment process block, and the steam generation process block is modularized and comprises a plurality of modules. Methods for operating and assembling a SAGD processing facility are also provided.