Treatment and refining mechanism for oil and gas systems

Abstract

Treatment and Refining Mechanism for Oil and Gas Systems The invention relates to A treatment and refining mechanism for oil and gas systems to implement ultra-high reliability as a hydrodynamical coa

Description

[0001] Treatment and Refining Mechanism for Oil and Gas Systems

[0002] Technical Field

[0003] The invention relates to a treatment and refining mechanism for oil and gas systems.

[0004] The invention particularly relates to a treatment and refining mechanism for oil and gas systems which has been designed with a shearing rotor-stator to implement ultra-high reliability as a hydrodynamical coaxial turbo machine type.

[0005] Present State of the Art

[0006] The global market has an industrial demand for energy resources due to the high availability of heavy crude oil with the fact that its usage is low with no advantage taken from it. These facts made it important to search for new technologies that treat and convert heavy hydrocarbon into value-light products. The crude oil's main parameters such as viscosity increase capital requirements and handling issues for equipment necessary to handle these materials. System reliability due to the severity of the handling conditions became a problem, also heating requirements and costs become important factors.

[0007] In the patent document numbered UA79617C2 a method for cavitation hydrogenation and hydrolysis of hydrocarbons and mechanism for realizing the same is disclosed. The application relates to petroleum refining, chemical, petroleum, and coal-chemical industry, and can be used for fluidization of black and brown coal, complete reprocessing petroleum and petroleum products and products of coking products in traditional processes. A method consists in that on the flow of original raw material mixed with water act by cavitation field, and hydrogenation and hydrolysis are carried out in rotor-pulsation apparatus by hydrodynamic cavitation treatment in acid-alkaline medium, formed due dissociation of water into ions of H+ and OH-, at a ratio of hydrogen-carbon of H / C>2.5. A mechanism for realizing the process contains four- stage rotor-pulsation apparatus, working in closed cycle, which rotors and stators are disposed with a gap of 30-100 nm, made in the form of perforated coaxial cylinders with amounts of perforations, which are increased from internal couple of cylinders to external, with respective reducing width of perforation. As a result, a complete reprocessing hydrocarbon is carried out and power inputs are reduced. However, there is no solution to increase the hardness and to promote a uniformly hardened microstructure across the full cross section. In this application, rotor and stator with several transport teeth uniformly distributed over the circumference of both are not mentioned.

[0008] In the prior art, technical difficulties and deficiencies of present treatment and refining applications in the same sector worldwide are below: limited types of hydrocarbon feeds that can be treated in the industry; hydrocarbon loss and spill; emissions; energy generation and energy loss; environmental risks such as nature, human, animals, health and safety; nonflexible systems to changes of operations and feed; economical loss related to technical problems such as low-quality production, hydrocarbon loss / spill and energy loss.

[0009] As a result, due to inadequacy of the solutions to meet above mentioned needs, it was necessary to make a development in the relevant technical field.

[0010] The Object of the invention

[0011] The invention is inspired by present situations and aims to solve above mentioned disadvantages.

[0012] The main object of the invention is to reveal a treatment and refining mechanism for oil and gas systems which has been designed with a shearing rotor-stator to implement ultra-high reliability as an experimentally hydrodynamical coaxial turbo machine type.

[0013] Another objective of the present invention is to increase the ratio of light petroleum cuts produced, specially from 22% to 38%.

[0014] Another objective of the present invention is to increase circulation time specially between 5 - 10 min with higher rotor speed (3000 rpm).

[0015] Another objective of the present invention is to decrease the flash point, pour point, density, and viscosity of the used crude oil.

[0016] Another objective of the present invention is to realize dispersion and heavy crude oil improvement with and without (SLS) additives.

[0017] In order to achieve above mentioned purposes, the invention comprises A motor which drives force to lead the cavitation of the liquid due to high viscosity,

[0018] • At least one rotor and at least two separate stators with several transport teeth uniformly distributed over the circumference of both, wherein rotor and stators are analogous in the coaxial construction and connected to the motor,

[0019] • A tank which is used for dosing additives to the feed liquid as a part of performing treatment for the feed,

[0020] • A feed pump which is used to input the feeding liquid from the tank to the rotor and stator combination,

[0021] • A platform which is used to provide holding, protection, stability, and / or isolation from ground for the motor, rotor and stator.

[0022] The structural and characteristic features of the invention and all its advantages will be understood more clearly thanks to the figures given below and the detailed description written with reference to these figures and therefore the evaluation should be made considering these figures and detailed description.

[0023] Brief Description of the Figures

[0024] Figure 1 shows the inventive treatment and refining mechanism for oil and gas systems.

[0025] Figure 2 shows stator top view.

[0026] Figure 3 shows stator real view.

[0027] Figure 4 shows API gravity of crude oil sample (A) with different treatment and refining mechanisms and selected rotation speed.

[0028] Figure 5 shows the viscosity of crude oil sample (A) with different viscometer rotation speed at selected treatment and refining mechanism rotation speed without (SLS) additives. Figure 6 shows viscosity of crude oil sample (A) with different viscometer rotation speed at selected treatment and refining mechanism rotation speed with (SLS) additives.

[0029] Figure 7 shows effect of the inventive treatment and refining mechanism rotation speed and time on flash point for crude oil sample (A) treated with and without (SLS) additives.

[0030] Figure 8 shows effect of the inventive treatment and refining mechanism rotation speed and time on pour point for crude oil sample (A) treated with and without (SLS) additives.

[0031] Figure 9 shows API gravity of another crude oil sample (B) with different treatment and refining mechanism with / without (SLS) additives.

[0032] Figure 10 shows viscosity of another crude oil sample (B) with different treatment and refining mechanism with / without (SLS) additives.

[0033] Figure 11 shows pour point for another crude oil sample (B) with different treatment and refining mechanism treated with / without (SLS) additives.

[0034] Figure 12 shows Flash Point for another crude oil sample (B) with different treatment and refining mechanism treated with / without (SLS) additives.

[0035] Brief Description of the Tables

[0036] Table 1 shows the components and parameters as per the components of the inventive treatment and refining mechanism.

[0037] Table 2 shows the parameters of the crude oil sample (A).

[0038] Table 3 shows the percentage of yield fractions cuts for the sample (A) treated in the inventive treatment and refining mechanism at selected rotation time and speed without (SLS) additives.

[0039] Table 4 shows the percentage of yield fractions cuts for the sample (A) treated in the inventive treatment and refining mechanism at selected rotation time and speed with (SLS) additives. Table 5 shows the summary of the parameters of the crude oil sample (A) as per the test results of the improved parameters with / without (SLS) additives.

[0040] Table 6 shows initial parameters of another crude oil sample (B).

[0041] Table 7 shows the summary of the parameters of another crude oil sample (B) as per the test results of the improved parameters with / without (SLS) additives.

[0042] Description of the Part References

[0043] 1. Motor

[0044] 2. Rotor

[0045] 3. Stators

[0046] 4. Feed pump

[0047] 5. Control panel

[0048] 6. Platform

[0049] 7. Feed tank

[0050] Detailed Description of the Invention

[0051] The invention relates to a treatment and refining mechanism (Rotary - Pulsation- Apparatus / RPA) for oil and gas systems which has been designed with a shearing rotor (2)-stator (3) to implement ultra-high reliability as a hydrodynamical coaxial turbo machine type.

[0052] As shown in Figure 1 , the inventive treatment and refining mechanism comprises a motor (1), one disc of the rotor (2), two separate stators (3), a feed pump (4), a control panel (5), a platform (6) and a feed tank (7).

[0053] As a turbo-centrifugal machine, rotor (2) and stator (3) are analogous in the coaxial construction and connected to the motor (1 ) as a driving force that has 37 kw power and (3000) rpm speed as per in Figure (5) and Table (1). The motor (1) is selected specially for the invention with the described high power to force the rotor (2)- stator (3) to rotate at high speed of (3000 rpm) to lead to the Cavitation of the Liquid due to its high viscosity according to the invention. To provide reliable operation of the invention while implementation, the rotor (2) both directions are designed to have several transport teeth uniformly distributed over the circumference of both the rotor disc and the stator disc. It is also an advantage to provide an irregular or non-uniform arrangement of the transport teeth, to avoid the design noises caused by the machine. The influence of acoustic-mechanical effect suspected an effective operation on flowing of liquid passing exposed to hydro- dynamical power, shearing and fractional forces, acceleration power and high frequency ultrasonic waves. In order to meet the rotor (2) and stators (3) property requirements for the invention, an extra high toughness steel of the type (30CrNiMo8) is selected, its main role is to increase the hardness and to promote a uniformly hardened microstructure across the full cross section. Also, alloy dynamic structural steel is selected for instruction of the rotor (2) and stators (3). In steel carbon is partly replaced by alloys-up to 0.8% Mo to retain a good weld ability or extra high toughness. The invention comprises a tank (7) used for dosing additives to the feed liquid as a part of performing treatment for the feed and a feed pump (4) used to input the feeding liquid from the tank (7) to the rotor (2) and stator (3) combination. A horizontal shape platform (6) is used to provide holding, protection, stability, and isolation from ground for the motor (1), rotor (2) and stator (3). A control panel (5) provides essential power required for the operating and calibrates measurements, controls, and readings of the operation.

[0054] In one embodiment of the invention, the rotor (2) - stator (3) fundamentals dispersion occurs along them in two stages. The first stage is the action of the mechanical agitation, which occurs in the clearance between the rotor (2) and stator (3). The directions of flowing liquid represent two types of flow in the channels between the rotor (2) and stator (3). The channel between the stator teeth is closed with the rotor teeth. Then the flow in this case occurs directly in the clearance between the coaxial cylinders of the rotor (2) and stator (3). Between the teeth of stator (3), the channel is opened, and then the liquid flows on it to the similar next stages as per the workflow. The combination of teeth position and channels on the rotor (2) and stator (3) creates effective mechanical agitation dispersion on the medium liquid. The shear forces are affected by vital factors, which depends on rotor (2) and stator (3) the construction details, which are circumferential speed, outer diameter of the rotor (2), and the number of teeth, and the gap between rotor (2) and stator (3). The rotor (2) and a stationary stator (3) typically operate at considerably high rotational speeds and as result, differential speed between rotor (2) and stator (3) imparts extremely high shear and turbulent energy which produces an intense friction on the material being processed in the gap between the rotor (2) and stator (3). The dynamics forces between rotor (2) and stator (3) carries out highly efficient mechanical breakdown of the initial fluid velocity and of the internal fluid velocity profile. Such as impact and shock wave and stress caused by turbulent flow and surrounding fluid. The non uniform, accelerated flow of the liquid in the stator channels brings about developed turbulence, intensive cavitations and liquid pressure, and viscosity pulses. If gap between rotor (2) and stator (3) is narrow (0.1 -0.5 mm), the main effect exerted on the heterogeneous liquid system will be a hydro- acoustic nature. After effective mechanical preparation on flowing liquid, the second stage takes place by action of dynamic radial pressure pulsations, which plays a main role from elements side of the flowing area in the invention to the liquid system by cavitations and ultrasonic emission. The circumferential of the rotation of the rotor (2) and the vibration of the stator (3) ensures a deeper and effective treatment of the medium in the apparatus. This stage occurs the final dispersion and size reduction of the dispersed particles. The liquid chemical and physical changes are improved through the ultrasonic power generated in the liquid medium through the generation and subsequent destruction of cavitations bubbles. Like any sound wave ultrasound is propagated via a series of compression and rarefaction waves induced in the molecules of the medium through which it passes. Cavitations bubbles will form due to the rarefaction cycle that may exceed the attractive forces of the molecules of the liquid at sufficiently high power. Such bubbles grow by a process known as rectified diffusion for example small amounts of vapor or gas from the medium enters the bubble during its expansion phase and is not fully expelled during compression. The bubbles grow over the period of a few cycles to an equilibrium size for the particular frequency applied. It is the fate of these bubbles when they collapse in succeeding compression cycles which generates the energy for chemical and mechanical effects. Cavitations bubble collapse is a remarkable phenomenon induced throughout the liquid by the power of sound. The liquid medium is affected with verities by cavitations bubble depending upon the type of system in which it is generated. These systems can be broadly divided into homogeneous liquid, heterogeneous solid / liquid and heterogeneous liquid / liquid. Within chemical systems these three groups represent most processing situations.

[0055] Experimental Works In order to demonstrate the operating logic and the principle of the invention; Experimental Works are summarized as following, as these Experimental Works were done on an experimental treatment and refining mechanism on the following samples with / without (SLS) additives. Experiments are done with Crude Oil Sample (A) of (29) API and Crude Oil Sample (B) of (17,5-18,5) API.

[0056] Table 1

[0057] Table 1 shows the components and parameters as per the components of the inventive treatment and refining mechanism. The same testing criteria and conditions in table (1) were applied on Both samples (A and B) with (SLS) Additives and without (SLS) additives. With the following parameters charts and demonstrations shows the detailed improvements on the parameters of the crude oil Sample (A), and the final test results of the Crude Oil Sample (B). The aim of this work is to investigate the effects of inventive mechanism time and rotation speed for both scenarios with (SLS) additives or without additives on percentage yield of light and intermediate fractions; namely gasoline, naphtha, erosene, and gasoil; using ASTM standard distillation curve method (ASTM D86), NDJ-4 rotational viscometer, API gravity, Cleveland open-cup flash point analyzer (ASTM D93) and pour point (ASTM D97). The quality of the product usually improves with the number of loops and with increasing residence time in the mixing head. Therefore, in tank recycling in batch process, in order to obtain the desired product, the number of loops needed as a vital parameter. Laboratory works and experiment criteria as per table (1) were performed with maximum rotor speed approximately (3000 rpm), with 32 channels of rotor (2) and stator (3), and high frequency of acoustic emission, about 60 KHz created in a rotor- stator unit in order to study the effect of acoustic -mechanical on physicochemical properties of heavy crude oil, the implementation of these working criteria were with (SLS) Additives and without (SLS) additives.

[0058] Laboratory analyses that were performed have following test results: For sample (A)

[0059] Table 2

[0060] Table 3

[0061] Table 4

[0062] Table 5

[0063] Table 2 shows the parameters of the crude oil sample (A). Table 3 shows the percentage of yield fractions cuts for the sample (A) treated in the inventive treatment and refining mechanism at selected rotation time and speed without (SLS) additives.

[0064] Table 4 shows the percentage of yield fractions cuts for the sample (A) treated in the inventive treatment and refining mechanism at selected rotation time and speed with (SLS) additives. Table 5 shows the summary of the parameters of the crude oil sample (A) as per the test results of the improved parameters with / without (SLS) additives. For sample (B)

[0065] Table 6

[0066] Table 7

[0067] Table 6 shows initial parameters of another crude oil sample (B). Table 7 shows the summary of the parameters of another crude oil sample (B) as per the test results of the improved parameters with / without (SLS) additives.

[0068] As can be seen in above tables, as an efficient solution, the inventive treatment and refining mechanism has been re-deployed to solve issues of heavy oil such as handling as well as many other applications such as food, pharmaceutical, and microbiological industries for improving processes of dispersion, homogenization, pasteurization, sterilization and the sonochemical reaction using controlled ultrasonic vibration of the rotor and stator. The inventive treatment and refining mechanism’s design, construction, and implementation are highly reliable and extremely simple in both operations and economies and require a minimum time of maintenance and services and can be handled within equipment without the need for heating, transportation vessels, and containers. The preferred specialty design of the inventive treatment and refining mechanism is made to handle and withstand the most requiring applications and provide the most flexible implementation. The inventive treatment and refining mechanism can deliver flow and ultra-high shear throughput, improved process control, and superior end-product consistency.

[0069] In the preferred application of the invention, the implementation was demonstrated with sodium lauryl sulfate (SLS - sodium lauryl sulfate) additive, which is an organic compound and anionic surfactant. (SLS) functions as a surfactant, wetting surfaces, emulsifying, or solubilizing oils. The additive (SLS) is safe for use as a surfactant and considered as non-hazardous as per international standards. On the processing side, the addition of (SLS) as a surfactant to reduce the interfacial tension of the crude oil prolongs the life of the equipment and material and improves its processing efficiency. For the crude oil parameters improvement, treatment, and conversion effects, the addition of (SLS) surfactant improves the percentage yield of light fractions, improves API gravity, reduces flash point, reduces pour point, and other primary parameters such as density and sulfur content. The experimental results of two crude oil samples (A and B) are shown in the figures and tables.

[0070] The advantages of the invention against the present applications are below:

[0071] • Limited types of hydrocarbon feeds that can be treated in the industry problem can be solved by the invention. The treatment and refining mechanism can perform treatment to various types of feed hydrocarbons such as Heavy Crude Oil, HFO, FO, VGO, Used Oils and various types of Sludge, Residues, Slop Oils, Pit Oils, Oil Spill, and Waste Oils.

[0072] • The treatment and refining mechanism works on ZDL (Zero Discharge Liquid) Systems, so Hydrocarbon loss and spill can be prevented.

[0073] • The treatment and refining mechanism works on ZES (Zero Emissions Systems).

[0074] • The treatment and refining mechanism works on recycling of off material (gas, liquids) to re-produce energy.

[0075] • The treatment and refining mechanism adheres to the Local and Worldwide Environment Agencies, Unions, regulations, and goals.

[0076] • The treatment and refining mechanism is designed to be calibrated and adjusted to the project needs and changes.

[0077] • The treatment and refining mechanism can be applied as a solution for multiple applications such as recycling, treatment, upgrading and results in high ratios of value products, supported by the ZDL and ZES systems.

[0078] The inventive treatment and refining mechanism is demonstrated in the type of metal, the design, and the working method of the rotor-stator at the speed of (3000) rpm, this unique design of the invention leads to the Cavitation status of the Liquid with additives.

Claims

CLAIMS1. A treatment and refining mechanism for oil and gas systems to implement ultra- high reliability as a hydrodynamical coaxial turbo machine type, and characterized by comprising• A motor (1) which drives force to lead the cavitation of the liquid due to high viscosity,• At least one rotor (2) and at least two separate stators (3) with several transport teeth uniformly distributed over the circumference of both, wherein rotor (2) and stators (3) are analogous in the coaxial construction and connected to the motor (1),• A tank (7) which is used for dosing additives to the feed liquid as a part of performing treatment for the feed,• A feed pump (4) which is used to input the feeding liquid from the tank (7) to the rotor (2) and stator (3) combination,• A platform (6) which is used to provide holding, protection, stability, and / or isolation from ground for the motor (1 ), rotor (2) and stator (3).

2. The treatment and refining mechanism according to claim 1 and characterized by comprising a control panel (5) which calibrates measurements and controls the operation.

3. The treatment and refining mechanism according to claim 1 and characterized by comprising the rotor (2) and the stator (3) are produced by extra high toughness steel of the type (30CrNiMo8) to increase the hardness and to promote a uniformly hardened microstructure across the full cross section.

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