Improving the in-situ upgrading of extra heavy oil using metal-based oil-soluble catalysts through oxidation process for enhanced oil recovery

The demand for fuel from unconventional sources is increasing all over the world, however, there are still special and strict regulations regarding the methods of enhanced oil recovery as well as the content of the oil produced, including the amount of sulfur. In-situ combustion (ISC) is an attractive thermal method to enhance oil recovery and in-situ upgrading process. In this work, copper (II) oleate and copper (II) stearate were used for the oxidation of extra heavy oil with high sulfur content in the ISC process using a self-designed porous medium thermo-effect cell (PMTEC) and visual combustion tube. Using PMTEC the catalytic performances of the synthesized oil-soluble copper (II) oleate and copper (II) stearate and kinetic parameters such as activation energy using Ozawa-Flynn-Wall method were studied. The X-ray diffraction (XRD) and high-resolution field emission scanning electron microscopy were used to examine the characteristics of in-situ synthesized CuO nanoparticles during oxidation. As shown, the presence of oil-soluble copper (II) stearate and copper (II) oleate reduced oil viscosity from 9964 to 8000 and 6090 mPa˙s, respectively. Following ISC process in porous media in the presence of copper (II) oleate, the high sulfur extra heavy oil upgraded, and its sulfur content decreased from 10.33 to 6.79%. Additionally, SARA analysis revealed that asphaltene and resin content decreased in the presence of oil-soluble catalysts. During the oxidation reaction, homogeneous catalyst decomposed into nanoparticles, and heterogeneous catalyst is distributed uniformly in porous media and played an active role in the catalytic process. It should be noticed that, these kind of oil-soluble catalysts can be novel and highly potential candidates for initiation and oxidation of extra heavy oil in order to decrease the viscosity, enhanced oil recovery and production of the upgraded oil. Graphical abstract: (Figure presented.) © The Author(s) 2024.