The present invention consists of an improved method and apparatus to
upgrade bitumen in various forms which comprises four main components;
namely, a fractionator equipped with a condenser, a heavy gas oil
catalytic treater, a catalyst regenerator/gasifier and a gas cleanup
assembly. In operation, the bitumen in liquid form is fed to the
fractionator for initial separation of fractions with the bulk of the
bitumen leaving the bottom of the fractionator in the form of a heavy gas
oil which is pumped to the catalytic treater and sprayed on a hot
catalyst to crack the heavy gas oil (an endothermic reaction) to release
lighter hydrocarbons in the form of H.sub.2 rich volatile matter while
depositing carbon on the catalyst. The volatile matter from the treater
is directed to the fractionator where the condensable fractions are
separated from the non-condensable H.sub.2 rich gas, a valuable primary
gas. The carbon containing catalyst from the treater is recycled to the
regenerator/gasifier, and the catalyst after being regenerated (an
exothermic reaction) is fed hot to the treater. Various fractions are
removed from the fractionator as intermediates in the form of light
napthas and light oils. The off-gas from the regenerator/gasifier is
directed to a gas cleanup system to produce a valuable secondary gas.
Both the primary gas and the secondary gas may be further utilized in the
processing of the intermediates produced by the method, the primary gas
being a source of H.sub.2 and the secondary gas being a source of thermal
energy.