Bitumen Froth Treatment via Agglomeration-Based Solvent Separation
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Solution Overview
Problem
Current bitumen froth treatment processes, such as NFT and PFT, face challenges with residual water and solids in the bitumen product, leading to pipeline transport issues and increased downstream processing costs, and there is a need for a method that combines the advantages of both while minimizing environmental impact.
Innovation Solution
An agglomeration-based oil-water separation process using a solvent blend with a ratio of 1.0-1.6 by mass, comprising 60-90 wt% paraffinic solvent and 2.0-4.7 wt% aromatic components, which inhibits coalescence and initiates spontaneous agglomeration, allowing for gravity separation of bitumen without bulk asphaltene precipitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If naphtha-based solvents with high aromatic and naphthenic contents are used in NFT process, then asphaltenes are retained in the bitumen product increasing hydrocarbon recovery, but residual water and solids remain in the product requiring further treatment
Solution Approach 1:
The patent changes the solvent composition parameters by using a paraffinic solvent with controlled aromatic content (0-5 wt%) instead of high aromatic naphtha, and adjusts the solvent-to-bitumen ratio to 1.6:1 to achieve optimal separation while preventing asphaltene precipitation
Solution Approach 2:
The patent utilizes the phase transition behavior of asphaltenes by controlling solvent composition to prevent asphaltene precipitation, maintaining them in solution while allowing water and solids to separate through gravitational settling
2Manufacturing precision
If paraffinic solvents with high S/B ratio are used in PFT process, then water and solids are effectively removed through agglomeration, but substantial product loss occurs due to asphaltene precipitation
Solution Approach 1:
The patent changes the solvent parameters by using paraffinic solvents with controlled aromatic content (0-5 wt%) and optimizing the S/B ratio to 1.6:1, which enables effective water and solids removal through agglomeration while preventing bulk asphaltene precipitation
Solution Approach 2:
The patent uses a composite solvent system combining paraffinic hydrocarbons with controlled aromatic components, creating a solvent blend that provides both the agglomeration capability of paraffinic solvents and the asphaltene-stabilizing properties of aromatic solvents
3Device complexity
If gravitational settling alone is used for separation, then the process is simple and low-cost, but residual water and solids contents remain high at 2-5 wt%
Solution Approach 1:
The patent applies preliminary action by adding a specific paraffinic solvent with controlled aromatic content before gravitational settling to induce agglomeration of water and solids, preparing the mixture for more effective separation without requiring additional complex equipment
Solution Approach 2:
The patent introduces a paraffinic solvent with controlled aromatic content as an intermediary substance that facilitates the separation process by promoting agglomeration of water and solids, enabling gravitational settling to achieve lower residual contents without additional equipment
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 achieves a bitumen product virtually free from residual water and solids (<0.1 wt%) while retaining asphaltenes, reducing product loss and environmental impact, and operates within a transition region between NFT and PFT conditions.
Implementation Method 1
The PFT process is based primarily on the gravitational settling of those agglomerates
Implementation Method 2
spontaneous agglomeration (FIG. 1 top)
Implementation Method 3
the oil-water separation occurs by the coalescence of water droplets (FIG. 1 bottom)
Implementation Method 4
Separation by gravity settling alone at an S/B ratio near yields
Data Source
AI summary
The present application provides a method for bitumen froth treatment in the transition region between coalescence and agglomeration. The method involves separating diluted bitumen product from a bitumen froth mixture, comprising the bitumen, water and mineral solids, the method comprising: (a) combining the mixture with a solvent blend to obtain a combination having a ratio of said solvent blend to the bitumen of about 1.0-1.6 by mass, wherein said solvent blend comprises from 2.2-4.5 (±0.2) wt % aromatic solvent or from 70-80 (±10) wt % paraffinic solvent; (b) mixing the combination; and (c) separating the diluted bitumen product from the water and mineral solids.