Acid-Activated Clay Removal of Volatile Phosphates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods fail to effectively remove volatile phosphorus from hydrocarbon oils contaminated with phosphate derivatives during fracturing operations, leading to equipment fouling and efficiency issues in oil refineries, despite existing technologies like non-phosphorus gellants, low-volatility systems, and water-based fracturing, which have limitations or higher costs.
Innovation Solution
A process involving the use of acid-activated clay to create a slurry with hydrocarbon oil, allowing for the separation and removal of phosphorus compounds, with parameters such as reaction time, particle size, and clay concentration optimizing greater than 99% decontamination, effectively reducing volatile phosphorus levels below refinery limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If phosphate esters are used as gelling agents in frac fluids, then the viscosity of the frac fluid is increased to facilitate proppant transport, but volatile phosphorus compounds are formed that cause equipment fouling and flow restrictions in refinery towers
Solution Approach 1:
The patent removes phosphorus compounds from crude oil through multiple washing steps using caustic solutions and activated clay, extracting the harmful volatile phosphorus that was introduced during fracturing operations
Solution Approach 2:
The patent changes the chemical state of phosphorus compounds by treating them with caustic solutions to form water-soluble phosphates, then using activated clay to adsorb and remove these compounds from the oil phase
2Quantity of substance
If conventional washing methods are used to remove phosphorus from crude oil, then some phosphorus removal is achieved, but greater than 99% decontamination required by refinery specifications is not attained
Solution Approach 1:
The patent divides the phosphorus removal process into multiple sequential washing steps (first wash with caustic solution, second wash with fresh caustic solution, third wash with activated clay), where each step removes a portion of the phosphorus to achieve cumulative greater than 99% removal
Solution Approach 2:
The patent introduces activated clay as an intermediary substance that selectively adsorbs phosphorus compounds from the crude oil, enabling removal levels that conventional washing alone cannot achieve
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process significantly reduces total and volatile phosphorus content in hydrocarbon oils, achieving near-complete removal and meeting industry standards, while also removing associated metal ions, thereby preventing equipment fouling and enhancing oil clarity.
Implementation Method 1
a process for treating a hydrocarbon oil contaminated with phosphorus contaminants, comprising the steps of: a) adding acid activated clay to the hydrocarbon oil to create a hydrocarbon oil and clay slurry; b) mixing the hydrocarbon oil and clay slurry; and c) separating the hydrocarbon oil and clay slurry to form a separated clay containing phosphorus compounds contaminants
Implementation Method 2
This application relates to processes for selectively removing anionic phosphate molecules from contaminated hydrocarbon oil using the ion exchange activity of acid activated clay
Data Source
AI summary
This application relates to processes for selectively removing anionic phosphate molecules from contaminated hydrocarbon oil using the ion exchange activity of acid activated clay. The methods are particularly applicable to the removal of volatile phosphates from hydrocarbons contaminated during fracturing operations.