Asphalt Conditioning via Dynamic Temperature Control
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Solution Overview
Problem
The operability of heavy hydrocarbon fractions, particularly asphalts, leads to fouling and clogging in processing units, limiting efficient upgrading due to high viscosity and softening points above 160°C, which current technologies cannot address effectively.
Innovation Solution
A novel de-asphalting process integrates a dynamic conditioning system that heats and cools asphalt in solid form, eliminating intermediate viscosity constraints and clogging risks, allowing for the production of asphalt with high softening points in a transportable and upgradable form by incorporating steps of solvent extraction, separation, and optional flux injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stripping equipment is used to handle asphalt, then the process can operate at standard temperatures, but the equipment becomes fouled and clogged due to high viscosity and softening point above 160°C
Solution Approach 1:
The patent applies parameter changes by cooling the asphalt below its softening point to transform it into a solid or semi-solid state with reduced viscosity. This temperature parameter change allows the asphalt to be handled without causing fouling and clogging in equipment, while still maintaining its chemical properties for subsequent upgrading processes
Solution Approach 2:
The patent introduces an intermediary cooling step between the stripping unit and the asphalt handling system. By cooling the asphalt in this intermediate stage, the system avoids direct handling of high-temperature, high-viscosity asphalt that causes fouling, while still enabling effective asphalt removal and upgrading
2Ease of operation
If asphalt is cooled to reduce viscosity for pumping, then pumpability improves, but the asphalt may solidify and cause clogging
Solution Approach 1:
The patent applies dynamics by implementing a controlled cooling process that dynamically adjusts temperature to achieve the optimal state for pumping. The asphalt is cooled sufficiently to reduce viscosity and improve pumpability, but not so much that it solidifies completely, maintaining a dynamic balance between flowability and solidification prevention
Solution Approach 2:
The patent changes the temperature parameter of asphalt to a specific range below the softening point but above complete solidification. This parameter change transforms the asphalt into a handleable state that is pumpable without causing clogging, resolving the contradiction between ease of operation and harmful effects
3Loss of substance
If individual asphalt stripping step is used, then solvent removal is achieved, but equipment fouling occurs and frequent stopping for cleaning is required
Solution Approach 1:
The patent merges the asphalt stripping step with the cooling and solidification process into an integrated operation. By combining solvent removal with temperature reduction and phase change, the system achieves effective solvent elimination while preventing equipment fouling, thereby maintaining continuous operation and improving productivity
Solution Approach 2:
The patent utilizes phase transitions by cooling asphalt from liquid to solid or semi-solid state during the stripping process. This phase change facilitates solvent removal while the solidified asphalt does not adhere to equipment surfaces, preventing fouling and enabling continuous operation without frequent cleaning stops
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
This process enables the production of asphalt in solid form with high softening points, facilitating easy withdrawal and upgrading, while reducing impurity content in de-asphalted oil and recovering solvents, thus enhancing process efficiency and eliminating the need for conventional stripping equipment prone to fouling.
Implementation Method 1
a step of extracting the feedstock using a solvent or a solvent mixture making it possible to obtain, on the one hand, at least one fraction comprising asphalt and solvent or solvent mixture
Implementation Method 2
a substep f) during which the asphalt fraction is heated to a temperature of between 120 and 340° C. and above the softening point of the asphalt
Implementation Method 3
a substep g) during which the asphalt separated from the solvent, from the solvent mixture and/or from the flux is cooled to a temperature below the softening point of the asphalt
Data Source
AI summary
The invention relates to a process for treating a hydrocarbon-based feedstock, comprising a) a step of extracting the feedstock, b) a step of separating the fraction comprising de-asphalted oil, c) an optional step of injecting a withdrawal flux into the fraction comprising asphalt, d) an optional step of separating the fraction comprising asphalt and solvent or solvent mixture obtained from the extraction step a), e) an optional step of injecting a withdrawal flux into the asphalt fraction alone or as a mixture with a withdrawal flux obtained from step d) and an integrated step of conditioning the asphalt fraction obtained from steps a) and/or c) and/or d) and/or e), in solid form, performed in successive or simultaneous substeps.