Asphalt Residue Granulation for Heavy Oil Separation
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Solution Overview
Problem
Existing solvent deasphalting processes for heavy oil face challenges in achieving high yield and quality of deasphalted oil (DAO) due to the need for high-temperature heating, which leads to asphalt decomposition and difficulties in solvent recovery, especially when processing heavier feedstocks with high softening points.
Innovation Solution
A deep separation method using coupled post-extraction asphalt residue granulation, where the asphalt phase is dispersed into solid particles at low temperatures through a gas-solid separation process, eliminating the need for high-temperature heating and allowing for adjustable particle size and improved solvent recovery, utilizing alkanes as solvents and a three-stage process for enhanced separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy oil is processed using traditional solvent deasphalting with heating to remove solvent, then solvent recovery is achieved, but asphalt decomposition occurs and DAO yield is limited
Solution Approach 1:
The patent utilizes phase transition of the solvent from liquid to gas state by controlling temperature and pressure conditions. The solvent is heated to a temperature above its boiling point but below the softening point of asphalt, allowing it to vaporize and separate from the asphalt residue without causing asphalt decomposition. This phase transition enables efficient solvent recovery while preserving asphalt integrity.
Solution Approach 2:
The patent changes the temperature parameter to a specific range (above solvent boiling point but below asphalt softening point) and controls pressure conditions to achieve selective vaporization of the solvent. By adjusting these parameters, the process achieves complete solvent recovery through vaporization while preventing asphalt thermal decomposition, thereby resolving the contradiction between solvent recovery and asphalt stability.
2Productivity
If heavier solvents are used to increase DAO yield, then DAO yield improves, but asphalt softening point increases and requires higher heating temperature
Solution Approach 1:
The patent employs phase transition of the solvent through controlled vaporization at temperatures above the solvent's boiling point but below the asphalt's softening point. This allows the use of heavier solvents (pentane, hexane) that would normally require high-temperature heating, while the controlled phase transition prevents asphalt decomposition. The solvent vaporizes selectively, enabling high DAO yield without excessive temperature damage to the asphalt.
Solution Approach 2:
The patent introduces a controlled vaporization process as an intermediary mechanism between the solvent removal and asphalt protection. By using controlled vaporization as the separation mechanism, the process can utilize heavier solvents with higher boiling points without directly heating the asphalt to high temperatures, thus achieving high DAO yield while protecting asphalt from thermal decomposition.
3Reliability
If high temperature heating is applied to remove solvent from asphalt, then solvent recovery is achieved, but asphalt viscosity increases and discharge becomes difficult
Solution Approach 1:
The patent uses phase transition of the solvent through controlled vaporization to achieve complete solvent recovery without subjecting the asphalt to high-temperature heating that would increase its viscosity. By vaporizing the solvent at controlled temperatures (above boiling point but below softening point), the process maintains asphalt流动性 and ease of discharge while achieving complete solvent recovery through the vapor phase.
Solution Approach 2:
The patent replaces the traditional mechanical heating and pumping system with a vaporization-based separation system. Instead of heating asphalt to high temperatures and using mechanical pumps to handle viscous material, the process uses controlled vaporization of the solvent to create a gas phase that can be easily separated and condensed, eliminating the need for high-temperature mechanical handling and improving operational ease.
4Productivity
If traditional three-stage separation process is used, then separation efficiency is improved, but process complexity and heat exchange system requirements increase
Solution Approach 1:
The patent uses phase transition (vaporization and condensation) of the solvent as the core separation mechanism, eliminating the need for complex multi-stage heat exchange systems. By controlling the vaporization process to achieve complete solvent separation from asphalt, and then condensing the vapor phase, the process achieves high separation efficiency through a simpler single-stage or two-stage configuration, reducing equipment complexity while maintaining productivity.
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 method achieves higher yields and improved quality of DAO, simplifies the process, reduces investment, and allows for the use of heavier feedstocks, while avoiding asphalt decomposition and solvent recovery issues, making it suitable for catalytic cracking and hydroprocessing.
Implementation Method 1
The asphalt phase and the dispersing solvent are mixed and introduced into a gas-solid separator for rapid phase change separation
Implementation Method 2
The solvent becomes gaseous after expansion and thus separates from the asphalt particles in a low temperature gas-solid separation process
Implementation Method 3
The solvent becomes gaseous after expansion and thus separates from the asphalt particles in a low temperature gas-solid separation process
Data Source
AI summary
The present invention is a separation method and system in which granulation of coupled post-extraction asphalt residue is used to achieve deep separation of heavy oil. A dispersion solvent is introduced into the asphalt phase after separation by solvent extraction and the asphalt phase undergoes rapid phase change in a gas-solid separator and is dispersed into solid particles while the solvent vaporizes, resulting in low temperature separation of asphalt and solvent with adjustable size of the asphalt particles. The separation method of this invention also includes a three-stage separation of heavy oil feedstock, in which the deasphalted oil phase separated from heavy oil is treated with supercritical solvent and results in the further separation of the resin portion of the deasphalted oil, maximizing the yield and quality of the deasphalted oil. The processes and systems in this invention use atmospheric pressure and a low temperature gas-solid separator instead of a high temperature and high pressure furnace and do not require the feed pre-heating or heat exchange equipment at the inlet of resin separator column, resulting in a simplified process flow and reduced investment.