Bitumen Upgrading Apparatus with Spherical Catalyst Discharge
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Solution Overview
Problem
Current methods for processing bitumen are inefficient, requiring high capital investment, are difficult to operate and maintain, and produce low-value by-products with high sulfur content, leading to environmental concerns and production challenges.
Innovation Solution
A modified process and apparatus that includes a fractionator, catalytic treater, and regenerator/gasifier with specific structural features to enhance heat transfer, catalyst movement, and desulfurization, using a fixed-level/moving bed design to prevent bridging and promote uniform catalyst flow, and a gas cleanup system to produce high-quality, low-sulfur products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bitumen is heated to crack hydrocarbons and form carbon layer against the wall, then volatile matter is generated, but heat transfer efficiency decreases due to insulating carbon barrier
Solution Approach 1:
The patent extracts the carbon layer from the heating surface by periodically scraping it off, preventing it from forming an insulating barrier that would reduce heat transfer efficiency. This allows continuous efficient heat transfer while maintaining volatile matter generation.
Solution Approach 2:
The patent performs preliminary carbon removal through scraping before the carbon layer can significantly insulate the heating surface. This preliminary action maintains optimal heat transfer conditions throughout the heating process.
2Ease of operation
If conical bottom is used for catalyst discharge, then catalyst can be discharged, but catalyst flow is interrupted due to bridging
Solution Approach 1:
The patent replaces the conical bottom with a spherical bottom design. The spherical curvature prevents catalyst particles from bridging and blocking the discharge opening, ensuring continuous reliable catalyst flow while maintaining ease of discharge operation.
3Quantity of substance
If heavy petroleum crude is processed, then bitumen is produced, but sulfur content increases requiring removal
Solution Approach 1:
The patent uses oxygen as a strong oxidant in the combustion chamber to burn off sulfur-containing compounds from the bitumen processing stream. This oxidation process effectively removes harmful sulfur while allowing continued production of bitumen from heavy petroleum crude.
4Productivity
If indirect wall heating is used, then hydrocarbons are cracked, but apparatus complexity and capital investment increase
Solution Approach 1:
The patent combines multiple functions into integrated components: the heating chamber serves as both the cracking reactor and the volatile matter generation zone, while the spherical bottom simultaneously enables catalyst discharge and prevents bridging. This merging reduces overall apparatus complexity and capital investment compared to separate specialized components.
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 solution enables efficient production of high-quality, low-sulfur products with reduced capital costs, improved environmental impact, and efficient catalyst handling, producing valuable hydrogen-rich gas for further upgrading and providing economical thermal energy.
Implementation Method 1
contacting the bitumen with a catalyst at a temperature of from 300°C to 450°C for a period of from 0.001 to 5.0 hours
Implementation Method 2
burning the carbon-containing catalyst in a regenerator/gasifier to regenerate the catalyst and produce a hydrogen-rich gas
Implementation Method 3
separating the volatiles in a fractionator
Implementation Method 4
heating the bitumen to a temperature of from 300°C to 450°C
Data Source
AI summary
The present invention consists of an improved method and apparatus to upgrade bitumen in various forms which comprises four main components; namely, a fractionator equipped with a condenser, a heavy gas oil catalytic treater, a catalyst regenerator/gasifier and a gas cleanup assembly. In operation, the bitumen in liquid form is fed to the fractionator for initial separation of fractions with the bulk of the bitumen leaving the bottom of the fractionator in the form of a heavy gas oil which is pumped to the catalytic treater and sprayed on a hot catalyst to crack the heavy gas oil (an endothermic reaction) to release lighter hydrocarbons in the form of H2 rich volatile matter while depositing carbon on the catalyst. The volatile matter from the treater is directed to the fractionator where the condensable fractions are separated from the non-condensable H2 rich gas, a valuable primary gas. The carbon containing catalyst from the treater is recycled to the regenerator/gasifier, and the catalyst after being regenerated (an exothermic reaction) is fed hot to the treater. Various fractions are removed from the fractionator as intermediates in the form of light napthas and light oils. The off-gas from the regenerator/gasifier is directed to a gas cleanup system to produce a valuable secondary gas. Both the primary gas and the secondary gas may be further utilized in the processing of the intermediates produced by the method, the primary gas being a source of H2 and the secondary gas being a source of thermal energy.