Patent 7820034 was granted and assigned to Kellogg Brown & Root Limited on October, 2010 by the United States Patent and Trademark Office.
An apparatus and process for partially upgraded heavy oil diluent production. A crude heavy oil and/or bitumen feed is supplied to an FCC unit having a low activity catalyst and low conversion number. A distillate fraction is supplied for use as diluent to end users. The distillate fraction and FCC unit gas oil products can be supplied to a hydrotreater for upgrading and collected as a synthetic crude product stream. An asphaltene fraction can be supplied to a gasifier for the recovery of power, steam and hydrogen, which can be supplied to the hydrotreater or otherwise within the process or exported.