Oil flow cleaning device and method

Abstract

The invention relates to a device and a method for treating a first stream (S1) of a colloidal suspension of water and ultrafine particles and a second stream (S2) of heavy oil, both from a stream of treated heavy crude oil or bitumen, to convert them into separate clean water, clean oil, decanted solids and usable gases. The first stream (S1) is treated in a series of electrodynamic reactors (20) operated by electrolysis / electroflocculation and water tank clarifiers (30) in parallel. The second stream (S2) is treated in an ultrasonic cyclone chamber (40). The released gas is collected from the top of the electrokinetic reactor (20) and the ultrasonic cyclone chamber (40). The decanted solids are collected from the bottoms of the electric reactor (20) and the ultrasonic cyclone chamber (40). Clean water is collected from the water tank clarifier (30). Cleaning oil is collected from the water tank clarifier (40).

Description

Technical Field

[0001] The present invention relates to the treatment of heavy crude oil and bitumen, and more particularly to an apparatus and method for treating a first stream of a colloidal suspension of water and ultrafine particles and a second stream of heavy oil, both streams resulting from the treatment of heavy crude oil or bitumen. Background Art

[0002] Heavy crude oil and bitumen are highly polluting and expensive to produce and refine. Now, as the world faces a climate crisis, the oil industry is trying to find solutions to decarbonize its production matrix. The present invention helps meet this need.

[0003] The present invention involves the partial upgrading of natural bitumen and heavy crude oil by separating ultrafine particles from colloidal dispersions, with the goal of maximizing water and energy efficiency and replacing polluting fuels and processes.

[0004] The technology of electrolyzing water to release hydrogen and oxygen (H2, O2) in the presence of an electrolyte such as sodium hydroxide (NaOH) or potassium hydroxide (KOH) is well known. The process involves applying a DC potential difference between two or more anode / cathode electrode pairs and providing the minimum energy required to break the H--O bond (i.e., 68.3 kcal per mole at STP). Gas O2:H2 is released from the anode (+) and cathode (-) in a stoichiometric ratio of 1:2, respectively.

[0005] Reference may be made to the following texts: Modern Electrochemistry (Volume 2), by John O'M. Bockris and Amulya K. N. Reddy, (Plenum Press); Electrochemical Science, by J. O'M. Bockris and D. M. Drazic, (Taylor & Francis Ltd.); and Fuel Cells and Their Electrochemistry, by J. O'M. Bockris and S. Srinivasan, (McGraw-Hill Book Company).

[0006] Electroflocculation is a technique for removing pollutants from wastewater. In electroflocculation, metal ions (acting as coagulants or flocculants) are released into solution from the anode under the action of an electric current. Electroflocculation also results in the production of hydrogen gas at the cathode due to the chemical reduction of water molecules. The coagulant (metal ions) binds to the pollutants, and the condensed pollutants may then be captured by rising bubbles, causing most of the pollutants to float to the surface. In addition, pollutants that do not rise to the surface with the bubbles usually settle out, thereby facilitating their removal.

[0007] Electroflocculation has also been shown to remove many common wastewater impurities, including, for example, large dissolved molecules, bacteria, algae, and other substances. As specific examples, electroflocculation has been shown to be effective in removing the following substances from wastewater: textile and printing dyes, humic substances; dissolved heavy metal cations; emulsified fats, oils, and greases; and phosphates. In an electroflocculation system, it is ultimately necessary to separate the treated water from the foam generated in the process. In existing electroflocculation processes, separation of foam from treated water is typically achieved by sedimentation or filtration. However, sedimentation systems are generally only suitable for situations where the treated liquid can be settled with little or no disturbance. In addition, filtration-based systems typically require another system to prevent foam from clogging the filter, which (in addition to the additional filter itself) increases the complexity, cost, and size of the equipment.

[0008] Ultrasonic enhanced oil recovery technology has been applied in many aspects of the petroleum industry, including ultrasonic demulsification, ultrasonic oil pollution treatment, ultrasonic wax prevention, ultrasonic plugging removal, ultrasonic heavy oil viscosity reduction, etc.

[0009] The main principle of ultrasonic demulsification technology is that oil and water particles, under the action of cavitation effect, thermal effect and displacement effect generated by vibration, continuously move to the wave nodes and then coalesce to produce water droplets and oil droplets with larger diameters, and finally separate oil and water by gravity. The application of ultrasonic technology has greatly promoted the demulsification and dehydration effect of emulsions.

[0010] Through ultrasonic cavitation, large molecular hydrocarbons in heavy oil can be reduced to small molecular hydrocarbons, thereby achieving the separation of crude oil and sludge.

[0011] Ultrasonic plugging removal technology has been widely used in Chinese oil fields. The main principle of this technology is to remove water plugging, organic dirt, inorganic scale plugging and polymer gel plugging through ultrasonic cavitation and vibration; therefore, the permeability near the well area can be restored and the effect of water injection and oil recovery can be improved.

[0012] The main principle of this technology is to instantly generate local high temperature, high pressure and strong physical disturbance in the fluid through ultrasonic cavitation, heating, physical oscillation and thixotropy, thereby reducing the viscosity of heavy oil and improving its fluidity. This technology has the advantages of high efficiency, low cost and low pollution.

[0013] Ultrasonic waves affect the oxidative desulfurization of hydrocarbons and asphaltene separation in heavy oil through physical oscillation and thixotropy, and the extent to which chemical cavitation reduces crude oil viscosity, as well as the microscopic mechanism of chemical action, are also reflected.

[0014] When the crude oil viscosity is reduced by ultrasound, the water is clarified. The mechanism of ultrasonic cavitation to reduce chemical viscosity is a combination of the breaking of heteroatom bonds in heavy oil and the ionization of hydrogen radicals in water.

[0015] Prior art

[0016] US Patent Application 2015 / 0076073 discloses a method for treating wastewater, including oil and gas industrial wastewater, by sequentially passing through different units using a single system of electrocoagulation, magnetic cavitation, and flocculation.

[0017] A crude oil and bitumen treatment process called the M-CRACK process and its MCT subsystem is www.alfaluz.net and www.alfalug.ca It is described on the website.

[0018] The M-CRACK process processes a crude oil stream and produces two streams to be processed in the MCT separator. The two streams are (i) water containing suspended ultrafine negatively charged particles as colloidal dispersions, heavy metals and dissolved salts, and (ii) oil containing water and a small amount of ultrafine particles. In the known M-CRACK process, the above two streams are obtained and further processed in the MCT subsystem. The output of the M-CRACK process is clean water, clean decanted solids and clean oil. Summary of the invention

[0019] The present invention relates to a method for improving the quality of oil in terms of density, viscosity, water content, solid content, sulfur content and acidity using centrifugal force, ultrasound, electrodynamic force, magnetic force and gravity, while removing ultrafine matter in colloidal dispersion in water and dissolved salts in water. As a by-product of the process, an electrolytic process produces hydrogen, oxygen and chloride gases from the water, and other gases generated by ultrasound are collected for further applications using the released gases. Embodiments of the present invention particularly relate to a series of equipment for efficient partial upgrading of crude oil, separation of ultrafine solids and generation of gas for use in replacing natural gas use in boilers and / or power generation.

[0020] Thus, the present invention provides an apparatus and method for removing contaminants from water, upgrading heavy oil, and providing a valuable output.

[0021] The invention particularly relates to an apparatus for treating a first stream of a colloidal suspension of water and ultrafine particles and a second stream of heavy oil, both streams resulting from the processing of heavy crude oil or bitumen, to convert the first and second streams into separate clean water, clean oil, decanted solids and released gases.

[0022] The apparatus of the present invention comprises a plurality of electrokinetic reactors and water tank clarifiers connected in parallel to receive and process the first stream; and at least one ultrasonic cyclone chamber connected to receive and process the second stream.

[0023] Each electrokinetic reactor of the device of the present invention comprises:

[0024] - an involute inlet connected to receive a first flow,

[0025] - an innovative set of spaced-anodes and cathodes arranged in a reactor to electrolyze a first stream,

[0026] - a top outlet arranged to release the generated gases,

[0027] - a lower lamellar outlet arranged to extract part of the clarified water containing ultrafine particles and ferrous material, and

[0028] - a bottom funnel with a bottom outlet arranged to extract the decanted solids;

[0029] Each water tank clarifier of the apparatus of the present invention comprises:

[0030] - an inlet connected to the lower outlet of the electro-reactor for receiving partly clarified water,

[0031] - an innovative electromagnetic belt surrounding the tank clarifier and arranged to magnetically push the ultrafine ferrous material in the partially clarified water towards the bottom of the tank clarifier,

[0032] - an outlet at the bottom of the tank clarifier arranged to remove solids, and

[0033] -Clean water outlet.

[0034] The ultrasonic cyclone chamber or each ultrasonic cyclone chamber of the device of the present invention comprises:

[0035] -Innovative tangential inlet, which is connected to receive the second flow,

[0036] - a cyclone chamber configured to convey the inlet second flow in a cyclonic manner,

[0037] - an ultrasonic generator comprising an innovative transducer array arranged to ultrasonically treat the oil, salts and heavy metals contained in the second stream as it is conveyed through the cyclone chamber and to accelerate the dripping of solids to a bottom outlet in the cyclone chamber,

[0038] - a top outlet arranged to release the generated gases, and

[0039] - a further outlet in the cyclone chamber, the further outlet being arranged to deliver clean oil,

[0040] The plurality of electrodynamic reactors and the water tank clarifier and the or each ultrasonic cyclone chamber of the apparatus of the present invention are interconnected as follows.

[0041] The inlets of all electrokinetic reactors are connected to a common supply conduit of the first stream to receive the first stream.

[0042] The top outlets of all electrokinetic reactors and the or each supersonic cyclone chamber are connected to a common gas extraction conduit.

[0043] The clean water outlets of all tank clarifiers are connected to a common clean water delivery conduit.

[0044] The outlets of the bottom hoppers of all electrokinetic reactors, the outlets of the bottoms of all tank clarifiers and the bottom outlet of the or each ultrasonic cyclone chamber are connected to a common solids separation conduit.

[0045] Thus, the apparatus of the present invention converts an input first stream and an input second stream into outputs of gas, decanted solids, clean water, and clean oil.

[0046] In a preferred embodiment of the apparatus of the present invention, the top outlet of each of the electrokinetic reactors and the ultrasonic cyclone chamber or the top outlet of each of the ultrasonic cyclone chambers is connected to a common gas extraction conduit via a pressure relief valve and a flame arrester.

[0047] In another preferred embodiment of the apparatus of the invention, each inlet and each outlet of the electrokinetic reactor, each inlet and each outlet of the water tank clarifier and each inlet and each outlet of the or each ultrasonic cyclone chamber comprises a solenoid valve.

[0048] Preferably, each water tank clarifier is a cyclone separator having an upper tangential inlet and a lower clean water outlet, wherein the upper tangential inlet is connected to the lower outlet of the electro-reactor to receive partially clarified water.

[0049] Advantageously, the spaced apart anodes and cathodes of each electrokinetic reactor comprise an array of staggered partial cylindrical anodes and cathodes, the anodes and cathodes being concentrically disposed and equally spaced apart. For example, each electrokinetic reactor comprises two sets of face-to-face equal semi-cylindrical anodes and cathodes, each anode and cathode being concentrically disposed and equally spaced apart, the two sets of face-to-face equal semi-cylindrical anodes and cathodes forming a generally cylindrical array, the face-to-face semi-cylindrical anodes and cathodes being separated by a radially extending gap, the ends of the anodes and cathodes of the two sets of semi-cylindrical anodes and cathodes facing each other opposite the gap, and wherein the face-to-face anodes and cathodes of the generally cylindrical array define a circular circulation path for the first flow.

[0050] Another aspect of the invention is a method of operating the above-described apparatus to treat a first stream of a colloidal suspension of water and ultrafine particles and a second stream of heavy oil, both streams being derived from processing heavy crude oil or asphalt, to convert the first stream and the second stream into separate clean water, clean oil, decanted solids and released gases.

[0051] The method of the present invention comprises:

[0052] - delivering the first stream to the inlet of the electrokinetic reactor via a common supply conduit,

[0053] - delivering said second flow to said tangential inlet of the or each said supersonic cyclone chamber,

[0054] - removing gases through said common gas extraction conduit connected to the top outlets of all electrokinetic reactors and to the top outlet of the or each supersonic cyclone chamber,

[0055] - removing clean water through said common clean water delivery conduit connected to the clean water outlet of said tank clarifier,

[0056] - removing separated solids through the common solids separation conduit connected to the outlet of the bottom hopper of the electrokinetic reactor, the outlet of the bottom of the water tank clarifier, and the bottom outlet in the or each ultrasonic cyclone chamber, and

[0057] - removing cleaning oil from another outlet in the or each ultrasonic cyclone chamber.

[0058] In an electrokinetic reactor, the method of the invention preferably comprises:

[0059] - electrolyzing said first stream between an anode and a cathode facing each other in each of said electrokinetic reactors,

[0060] - releasing the produced gas through the top outlet of each of the electrokinetic reactors,

[0061] - extracting part of the clarified water containing ultrafine and iron-containing materials through the lower outlet of each said electro-reactor, and

[0062] - The decanted solids are extracted through an outlet of the bottom hopper of each electrokinetic reactor. By appropriate choice of anode and cathode materials, the first stream can be electrolyzed in each electrokinetic reactor, producing an electroflocculation effect, with the resulting flocculated material being discharged from the electrokinetic reactor through a side outlet.

[0063] Advantageously, the first stream circulates in each electrokinetic reactor around a circular circulation path between the anode and cathode facing each other.

[0064] The method of the present invention preferably further comprises:

[0065] - conveying partially clarified water from said lower outlet of each said electro-reactor to said upper inlet of its water tank clarifier,

[0066] - magnetically push the ultrafine and ferrous materials in the partially clarified water contained in each of said tank clarifiers towards an outlet at the bottom thereof, and

[0067] - Discharging clean water from each of said tank clarifiers.

[0068] The method of the present invention preferably further comprises:

[0069] - conveying the second flow cyclonically through the or each ultrasonic cyclone chamber,

[0070] - generating ultrasonic waves in a transducer array in the or each ultrasonic cyclone chamber to ultrasonically treat the oil, salts and heavy metals contained in the second stream as it is conveyed through the cyclone chamber to accelerate the dripping of solids into the bottom outlet in the or each ultrasonic cyclone chamber,

[0071] - exhausting the generated gas through the top outlet of the or each ultrasonic cyclone chamber, and

[0072] - delivering cleaning oil from another outlet in the or each ultrasonic cyclone chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] The present invention will be further described by way of example with reference to the accompanying drawings, in which:

[0074] Figure 1 is a schematic diagram showing an overall installation for crude oil / bitumen processing, into which the device according to the present invention can be integrated.

[0075] Figure 2 is a schematic diagram of an apparatus according to the present invention.

[0076] Figure 3 It is a front view of the electrokinetic reactor of the device of the present invention.

[0077] Figure 4 is a top view showing the electrode configuration located on top of the electrokinetic reactor inlet.

[0078] Figure 5 The decanter settler of the apparatus of the present invention is shown.

[0079] Figure 6 is a general view of the cyclone chamber, showing its tangential inlet in detail. DETAILED DESCRIPTION

[0080] Figure 1 is a schematic flow diagram of an integrated plant for processing crude oil and bitumen, which corresponds to a version of the prior art M-CRACK system with MCT units.

[0081] like Figure 1 As shown, the crude oil and bitumen to be processed are received in a receiving tank 10 where large solids are removed. The crude oil and bitumen containing the positively charged particles then pass through two injection chambers 12 where liquid reagents are injected to reverse the charge of the particles in the crude oil and eliminate H2S.

[0082] For this purpose, the liquid agent to be hydraulically injected into the injection chamber IC is available from ALFALUZ S.A. of Montevideo, Uruguay under the trade name PETROMAX TM get.

[0083] This results in an emulsion of negatively charged solid particles in the water / crude oil mixture which readily separate and are conveyed to a dual dissolved air flotation cell (DAF) 14 for separation.

[0084] In the injection chamber 12, the liquid reagents injected into bitumen, heavy oil, oil sands ore, oil processing tailings and contaminated soil have the following effects:

[0085] High pressure penetration:

[0086] The resin covering the solid is forcibly penetrated and the strong bond with the solid is broken (clay, sand, quartz, asphaltene, etc.).

[0087] High pressure mixing:

[0088] Solids are excited to produce flows in which the most complex compounds are suspended and evenly dispersed (colloidal dispersion).

[0089] Weaker bonds are broken so that solids such as heavy molecular weight asphaltenes, some paraffins, and heavy metals do not reattach to the heavy oil.

[0090] After passing through the injection chamber 12, the main results of the bitumen are:

[0091] The emulsion has been broken. There are no hydrocarbons in the solids. Fine particles, some resins, some paraffin and black powder are suspended in the fluid (colloidal suspension). About 50% of the asphaltenes will be encapsulated, so they will be separated in the MCT together with the sand and other fine and ultrafine particles instead of reducing H2S. In the bitumen, more than 80% of the sulfur will be bound to the asphaltenes, and the asphaltenes will be separated from the oil. Therefore, the final sulfur content will also be reduced.

[0092] The lower DAF 14 unit separates the emulsion into: clean fine particles and the heaviest asphaltenes removed therefrom; water that is recycled to the injection chamber 12; and partially purified oil that is sent to the MCT unit. The lower DAF unit 14 sends the solids separated from the emulsion and water to the upper DAF unit 14. The upper DAF unit 14 sends a water stream containing charged microparticles in a colloidal dispersion to the MCT unit.

[0093] The MCT unit then receives two streams: (S1) a water stream containing fine negatively charged particles, and (S2) a partially purified oil stream.

[0094] In the MCT unit shown:

[0095] - Stream (S1) is divided into two parts, namely the water stream that is circulated to the injection chamber, and the residue that is cleaned of fine particles and the heaviest ash. This includes resins, asphaltenes, sulfur, crystalline paraffins, heavy metals and crystalline salts.

[0096] - Stream (S2) is sent to an oil upgrading unit which delivers on the one hand clean commercial oil and on the other hand clean fine particles and residues of the heaviest ashes which can be collected together with the particles in the first stream.

[0097] The two main outputs of the M-CRACK system are known to be:

[0098] -1. Clean water, which is separated and recycled in the M-CRACK system and can be delivered to the central processing facility of the oil company.

[0099] -2. Commercial grade cleaning oil.

[0100] The device according to the present invention receives Figure 1 The same two flows (S1) and (S2), but the device according to the invention advantageously replaces Figure 1 The MCT unit shown is an alternative.

[0101] As mentioned above, the MCT receives two streams from the previous process. These are the same two streams that are processed in the device according to the invention.

[0102] Stream S1: Contaminated water. Suspended ultrafine clay, dissolved salts, other ultrafine materials, etc.

[0103] Stream S2: Partially purified non-commercial petroleum, still containing some sulfur, asphaltenes, water, fines and salts.

[0104] Figure 2is a schematic diagram of a preferred embodiment of the device according to the invention, comprising six electrokinetic reactors 20 and six water tank clarifiers 30 connected in parallel cascade to receive a first stream S1 of contaminated water, and two ultrasonic cyclone chambers 40 connected to receive and treat a second stream S2 of partially purified oil.

[0105] Electric reactor EKR 20 Figure 2 and Figure 3 Each electrokinetic reactor EKR 1 to EKR 6 comprises: an involute inlet 22 connected through a solenoid valve 74 to receive a first flow S1 from a main supply conduit 50; a set of spaced-apart anodes and cathodes 24 (see Figure 4 ), which is arranged in the reactor 20 to electrolyze the first stream S1; a top outlet 26, which is arranged to release the generated gas to the common gas extraction conduit 60 via a pressure relief valve 70 and a flashback flame arrester 72; a lower lamellar outlet 27, which has a solenoid valve 74, which is arranged to extract partially clarified water with ultrafine iron-containing material; and a bottom funnel with a bottom outlet 28, which is arranged to extract decanted solids through the solenoid valve 74.

[0106] Figure 4 24 is a schematic top view of a configuration showing how electrodes 24 are located inside an EKR reactor 20. The arrangement includes a plurality of anode-forming electrodes in a convex relationship, each anode electrode including a convex plate through which one or more first common conductive interconnecting elements pass. There are a plurality of cathode-forming electrodes in a convex opposite relationship to the first anode, each cathode electrode including a convex plate through which one or more second common conductive interconnecting elements pass. The anode electrodes and cathode electrodes are staggered to form a series of circular circulation paths between them for the first flow through the reactor. The opposing semi-cylindrical units of the anode and cathode 24 are separated by radially extending gaps 25.

[0107] By having at least the anode made of, for example, iron which releases Fe+ ions, the arrangement produces electro-flocculation of water to release hydrogen, oxygen and chlorate gas.

[0108] Directly below each EKR 20 there is a tank clarifier WT 30. The tank clarifier provides residence time for flocculants and other solid matter to settle at the bottom. Figure 5 This is a decanting jug designed for these purposes and has enhanced magnetic forces which will force the ultra-fine ferrous material to fall easily onto the cone of the jug for further removal.

[0109] Figure 2 and Figure 3Shown are tank clarifiers WT 3030. Each tank clarifier WT 30 includes an inlet 32 ​​connected to the lower outlet 27 of the electro-reactor 20 to receive partially clarified water, an electromagnetic belt 34 surrounding the tank clarifier 30 and arranged to magnetically push ultrafine ferrous material in the partially clarified water to the bottom of the tank clarifier without causing clogging, an outlet 38 at the bottom of the tank clarifier 30 arranged to remove solids via a solenoid valve 74, and a clean water outlet 36 connected to a common clean water delivery conduit 62.

[0110] Figure 2 and Figure 6 Ultrasonic cyclone chambers UCR 40 are shown. Each ultrasonic cyclone chamber UCR 40 includes a lower tangential inlet 42 connected to receive the second stream S2; a cyclone chamber configured to deliver the inlet second stream S2 in a cyclonic manner; an ultrasonic generator (not shown) including a transducer array arranged to ultrasonically treat the oil, salts and heavy metals contained therein as the second stream S2 is delivered through the cyclone chamber and accelerate the solids to drop to the bottom outlet 49 in the cyclone chamber; a top outlet 44 associated with a pressure relief valve 70 and a flashback flame arrester 72 to release the generated gas; and another outlet 48 associated with a solenoid valve 74 for delivering clean oil.

[0111] Figure 6 is a schematic diagram of an ultrasonic cyclone chamber UCR 40 showing in detail a cross-sectional view of its lower tangential inlet 42 through which the second stream S2 is introduced and ultrasonically treated, generating a counter-cyclonic circulation in the cylindrical chamber.

[0112] like Figure 2 As shown, six electro-dynamic reactors EKR 20 and water tank clarifiers WT 30 and two ultrasonic cyclone chambers UCR 40 are interconnected as follows. The involute inlet 22 of all electro-dynamic reactors EKR 20 is connected to a common supply conduit 50 of the first stream to receive the first stream S1. The top outlet 26 of all electro-dynamic reactors EKR 20 and the top outlet 44 of the cyclone chamber UCR 40 are connected to a common gas extraction conduit 60 for releasing HHO gas. The clean water outlet 36 of all water tank clarifiers WT 30 is connected to a common clean water delivery conduit 62. The outlet 28 of the bottom hopper of all electro-dynamic reactors EKR 20, the outlet 36 at the bottom of all water tank clarifiers WT 30, and the bottom outlet 28 in each ultrasonic cyclone chamber UCR 20 are connected to a common solid separation conduit 64.

[0113] The apparatus of the present invention may be controlled by a programmable logic controller PLC which is designed and programmed not only to automatically control its operation but also to improve exposure time and provide operation and maintenance alerts to the operator.

[0114] All solenoid valves 74 are automatically controlled by a specially designed and programmed PLC which, in addition to operating controls, is designed to maximize exposure time and provide operating and maintenance alarms.

[0115] All electric actuators, valves, devices, connections, panels and programmable logic computers PLCs are designed to comply with ATEX hazardous materials regulations.

[0116] In operation, a first flow S1 of a colloidal suspension of water and ultrafine charged particles is delivered and controlled via a common supply conduit 50 to the inlet of the electrokinetic reactor EKR 20 by means of a flow indicator and a transducer, and a second flow S2 of heavy oil is delivered to the tangential inlet 42 of each ultrasonic cyclone chamber 40, both of which are derived from processing heavy crude oil or bitumen, for example, as in the case of a reference Figure 1 described.

[0117] In general, the following valuable outputs were produced during the operation:

[0118] - Gas is removed via a common gas extraction conduit 60 connected to the top outlet 26 of all electrokinetic reactors EKR 20 and to the top outlet 44 of each ultrasonic cyclone chamber UCR 40. The removed gas constitutes a valuable by-product that can be delivered to customers for further use to replace or minimize the use of natural gas and to produce electricity, thereby offsetting the cost of electricity and reducing the carbon footprint.

[0119] - Clean water is removed through a common clean water delivery / separation conduit 62 connected to the clean water outlet of the tank clarifier WT. The clean water can be recycled to Figure 1 in the device.

[0120] - The separated solids are removed through a common solid separation conduit 64 which is connected to the outlet 28 of the bottom hopper of the electrokinetic reactor EKR 20, the outlet 36 at the bottom of the water tank clarifier WT 30 and the bottom outlet 49 in the ultrasonic cyclone chamber UCR 40. The separated solids are a useful by-product which can be sold to asphalt production companies or the generated gas can be used for gasification to generate electricity.

[0121] From another outlet 48 in each ultrasonic cyclone chamber UCR 40, clean and more valuable commercial quality oil is removed.

[0122] Furthermore, in operation: In each electric reactor EKR 20, the first stream S1 is electrolyzed between the facing anode and cathode 24. The produced HHO gas is released through the pressure release valve 70 and the flame arrester 72 via the top outlet 26 of each electric reactor EKR 20. Part of the clarified water containing ultrafine iron-containing materials is removed via the lower outlet 27 of each electric reactor EKR 20 through its solenoid valve 74, and the decanted solids are extracted via the outlet 28 in the bottom hopper of each electric reactor EKR 20 and its solenoid valve 74.

[0123] The first stream S1 is usually electrolyzed in each electrokinetic reactor EKR 20 , an electro-flocculation effect is produced due to the release of metal anions such as Fe + from the anode, and the produced flocculated material is removed from the electrokinetic reactor AKR 20 via the lower outlet 28 thereof.

[0124] The first stream S1 may, for example, circulate in each electrokinetic reactor 20 around a circular circulation path defined between the facing anode and cathode 24. The involute inlet 22 of the reactor facilitates the circulation of the first stream S1 in the EKR 20 around the circular path.

[0125] The first stream S1 of contaminated water and ultrafine solids in colloidal dispersion enters the involute inlet of the EKR 20 using a distribution manifold that increases the residence time within each electrokinetic reactor EKR and minimizes the use of direct current.

[0126] The EKR 20 involves a combination of hydrocyclones, electro-flocculation and magnetic forces arranged to maximise exposure of the water to electrodes arranged to exploit the fact that the water has a large negative surface charge.

[0127] This arrangement also disrupts the double electrical layer on the particles that keeps the ultrafine particles in suspension. The unit also uses the heat generated by the electrodes (clay expansion) and the bubbles produced by the HHO to flocculate lightweight solids. Solids that are larger in weight and diameter are thus decanted. The energy efficiency of the system is also maximized.

[0128] The partially clarified water is conveyed from the lower outlet 28 of each electro-reactor EKR 20 to the upper inlet 32 ​​of its water tank clarifier WT 30 .

[0129] The ultrafine ferrous materials in the partially clarified water contained in each tank clarifier WT 30 are magnetically pushed toward the outlet 36 at the bottom thereof, and the clean water is discharged from the outlet 36 of each tank clarifier WT 30 through its solenoid valve.

[0130] The second stream S2 40 passes through the ultrasonic cyclone chamber UCR in a cyclonic manner by virtue of being introduced through its tangential inlet 42 and via a manifold, controlled by a flow indicator and a flow sensor.

[0131] The UCR 40 incorporates a special cyclonic involute inlet 42 with transducers placed in an array to maximize the ultrasonic treatment of oils, salts and heavy metals. The treated oil follows the path of the cyclone separator, maximizing exposure of the material to the ultrasonic treatment effects as described below.

[0132] Ultrasonic waves are generated in the transducer array in the ultrasonic cyclone chamber UCR 40 to ultrasonically treat the oil, salts and heavy metals contained therein as the second stream is conveyed through the cyclone chamber to accelerate the solid droplets to the bottom outlet 49 in the cyclone chamber UCR 40. The ultrasonic energy is applied in the form of ultra-high frequency ultrasound of 32 KHz, high frequency ultrasound of 28 KHz or low frequency ultrasound of 18 KHz, depending on the nature of the main characteristics of the medium containing the colloid.

[0133] Exposure of the oil to ultrasonic treatment is maximized to minimize impedance and optimize the acoustic field intensity to break up emulsions, reduce sulfur content, and unbalance asphaltene, which then falls along with the same salts like calcium carbonate, heavy metals and solids. It also accelerates the fall of solids to the tank bottom and maximizes the energy efficiency of the system.

[0134] Gases are produced in the UCR 40. These gases are a combination of hydrogen produced by ultrasound, oil vapor produced during the breaking of hydrocarbon molecules, and volatile organic compounds (VOCs). The ultrasound creates a pressure zone that creates high pressure and high temperature bubbles that, when they explode, increase in temperature and break apart some, but not all, of the oil and water molecules. Hydrogen is produced from the water and other gases in the oil.

[0135] The overall effect is to upgrade the oil, producing gas in small, easily manageable volumes.

[0136] The generated gas is discharged through the top outlet 26 of each cyclone chamber UCR 20, through the pressure relief valve 70 and the flashback flame arrester 72. Finally, the cleaned oil is delivered through the other outlet 48 in the ultrasonic cyclone chamber UCR 40 through the solenoid valve 74 thereof.

[0137] Revise

[0138] Figure 2 The installation shown with six electrodynamic reactors EKR 20 and two ultrasonic cyclones UCR 40 is intended to treat a flow line with an original volume of 300 BB / h (barrels / hour), but can be adjusted to treat smaller or larger volumes. As a minimum requirement, the installation should include two to four electrodynamic reactors EKR 20 and one ultrasonic cyclone UCR 40. For example, a smaller installation can include four electrodynamic reactors EKR 20 and two ultrasonic cyclones UCR 40

[0139] The apparatus of the invention can also be operated using an input second stream S2 of partially clarified oil and partially clarified water. In this case, the ultrasonic cyclone chamber (s) UCR 40 for separating oil and solids can supplement the cyclone separator for separating water, which can be delivered to the common clean water outlet conduit 62 of the water tank clarifier WT 30.

Claims

1. A device for treating a first flow (S1) of a colloidal suspension of water and ultrafine particles and a second flow (S2) of heavy oil, characterized in that Both streams are derived from processing a heavy crude oil or bitumen stream to convert the first and second streams into separate clean water and clean oil streams, decanting solids and releasing gases, the apparatus comprising: - a plurality of electro-dynamic reactors (20) and water tank clarifiers (30) connected in parallel for receiving and treating said first stream (S1), and - at least one ultrasonic cyclone chamber (40) connected to receive and process said second flow (S2), in: Each of the electrokinetic reactors (20) comprises: - an involute inlet (22) connected to receive said first flow (S1), - a set of spaced-apart anodes and cathodes (24) arranged in the reactor to electrolyze the first stream (S1), - a top outlet (26) arranged to release the generated gases, - a lower outlet (27) arranged to extract partly clarified water containing ultrafine ferrous material, and - a bottom funnel with a bottom outlet (29) arranged to extract the decanted solids; Each of the water tank clarifiers (30) comprises: - an inlet (32) connected to the lower outlet (27) of the electro-reactor (20) for receiving the partially clarified water, - an electromagnetic belt (34) surrounding the tank clarifier and arranged to magnetically push the ultrafine ferrous material in the partially clarified water towards the bottom of the tank clarifier (30). - an outlet (38) at the bottom of the tank clarifier (30) arranged to remove solids, and - a clean water outlet (36); and The ultrasonic cyclone chamber or each ultrasonic cyclone chamber (40) comprises: - a tangential inlet (42) connected to receive the second flow (S2), - a cyclone chamber configured to convey the inlet second flow (S2) in a cyclonic manner, - an ultrasonic generator comprising a transducer array arranged to ultrasonically treat the oil, salts and heavy metals contained in the second flow (S2) as it is conveyed through the cyclone chamber and to accelerate the solids to drip into a bottom outlet (49) in the cyclone chamber, - a top outlet (44) arranged to release the generated gases, and - a further outlet (48) in the cyclone chamber, the further outlet (48) being arranged to deliver clean oil, wherein a plurality of the electrokinetic reactors (20) and the water tank clarifier (30) and the ultrasonic cyclone chamber (40) or each of the ultrasonic cyclone chambers (40) are interconnected as follows: - said involute inlets (22) of all electrokinetic reactors (20) are connected to a common supply conduit (50) of said first stream (S1) to receive said first stream (S1), - the top outlets (26) of all electrokinetic reactors (20) and the top outlets (44) of the or each ultrasonic cyclone chamber (40) are connected to a common gas extraction duct (60); - said clean water outlets (36) of all tank clarifiers (30) are connected to a common clean water delivery conduit (62); and - The outlets (28) of the bottom hoppers of all electrokinetic reactors (20), the outlets (36) of the bottoms of all tank clarifiers (30) and the bottom outlet (49) of the or each ultrasonic cyclone chamber (40) are connected to a common solid separation conduit (64).

2. The device according to claim 1, characterized in that The top outlet (26) of each of the electrokinetic reactors (20) and the ultrasonic cyclone chamber (40) or the top outlet (44) of each of the ultrasonic cyclone chambers (40) are connected to a common gas extraction conduit (60) via a pressure relief valve (70) and a flame arrester (72).

3. The device according to claim 1 or 2, characterized in that: Each inlet and each outlet of the electro-reactor (20) and each inlet and each outlet of the water tank clarifier (30) are controlled by a solenoid valve (74).

4. The device according to claim 1, 2 or 3, characterized in that Each of the water tank clarifiers (30) is a cyclone separator having an upper tangential inlet (32) and a lower clean water outlet (36), wherein the upper tangential inlet (32) is connected to the lower outlet (27) of the electro-reactor (20) to receive the partially clarified water.

5. A device according to any preceding claim, characterised in that The spaced apart anodes and cathodes (24) of each of the electrokinetic reactors (20) comprise an array of staggered partial cylindrical anodes and cathodes, the anodes and cathodes being concentrically disposed and equally spaced apart.

6. The device according to claim 5, characterized in that Each of the electric reactors (20) comprises two groups of equal semi-cylindrical anodes and cathodes (24) facing each other, each anode and cathode being concentrically arranged and spaced apart at equal intervals, the two groups of equal semi-cylindrical anodes and cathodes facing each other forming a roughly cylindrical array, the semi-cylindrical anodes and cathodes facing each other being separated by a radially extending gap (25), the ends of the anodes and cathodes of the two groups of semi-cylindrical anodes and cathodes (24) facing each other on the opposite side of the gap (25), and wherein the anodes and cathodes facing each other of the roughly cylindrical array define a circular circulation path for the first flow (S1).

7. A method of operating a device according to any of the preceding claims to treat a first flow (S1) of a colloidal suspension of water and ultrafine particles and a second flow (S2) of heavy oil, characterized in that Both streams are derived from processing a heavy crude oil or bitumen stream to convert the first stream and the second stream into separate clean water streams and clean oil streams, decanting solids and releasing gases, the method comprising: - conveying said first stream to said inlet of said electrokinetic reactor (20) through a common supply conduit (50), - conveying the second flow (S2) to the tangential inlet (42) of the or each ultrasonic cyclone chamber (40), - removing gas through said common gas extraction conduit (60) connected to the top outlet (26) of all electrokinetic reactors (20) and the top outlet (44) of said ultrasonic cyclone chamber (40) or of each said ultrasonic cyclone chamber (40), - removing clean water through said common clean water delivery conduit (62) connected to the clean water outlet (36) of said tank clarifier (30), - removing separated solids through the common solids separation conduit (64) connected to the outlet (28) of the bottom hopper of the electrokinetic reactor (20), the outlet (36) at the bottom of the water tank clarifier (30), and the bottom outlet (49) in the or each ultrasonic cyclone chamber (40), and - removing cleaning oil from the further outlet (48) in the or each ultrasonic cyclone chamber (40).

8. The method according to claim 7, characterized in that include: - electrolyzing said first stream in each of said electrokinetic reactors (20) between an anode and a cathode (24) facing each other, - releasing the produced gas through the top outlet (26) of each of the electrokinetic reactors (20), - extracting part of the clarified water containing ultrafine iron-containing material through the lower outlet (27) of each of said electro-reactors (20), and - The decanted solids are extracted through the outlet (28) of the bottom funnel of each electrokinetic reactor.

9. The method according to claim 8, characterized in that The first stream electrolyzed in each of the electrokinetic reactors (20) undergoes electroflocculation and the resulting flocculated material is removed from the electrokinetic reactor via another outlet.

10. A method of operating a device according to claim 6 according to claim 7, 8 or 9, characterized in that The method comprises circulating the first stream (S1) in each of the electrokinetic reactors (20) around a circular circulation path between the anode and cathode (24) facing each other.

11. The method according to any one of claims 7 to 10, characterized in that: The method comprises: - conveying partially clarified water from the lower outlet (27) of each of the electro-reactors (20) to the upper inlet (32) of its tank clarifier (30), - magnetically pushing the ultrafine iron-containing material in the partially clarified water contained in each of said tank clarifiers (30) towards an outlet (36) at the bottom thereof, and - Discharge clean water from each of said tank clarifiers (30).

12. The method according to any one of claims 7 to 11, characterized in that: Also includes: - conveying the second flow (S2) in a cyclonic manner through the ultrasonic cyclone chamber (40), - generating ultrasonic waves in a transducer array in the ultrasonic cyclone chamber (40) to ultrasonically treat oil, salt and heavy metals contained in the second flow (S2) as the second flow (S2) is conveyed through the ultrasonic cyclone chamber, to accelerate the solids to drop to the bottom outlet (49) in the ultrasonic cyclone chamber, and to generate gas, - exhausting the generated gas through the top outlet (44) of the or each ultrasonic cyclone chamber (40), and - delivering clean oil from said further outlet (48) in said ultrasonic cyclone chamber (40).

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