Carbon Disulfide Bitumen Extraction Process
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Solution Overview
Problem
Current bitumen extraction processes from oil sands are inefficient, causing water pollution and requiring significant energy and investment, with existing methods failing to meet environmental and cost-effectiveness standards.
Innovation Solution
The process involves mixing oil sands with carbon disulfide to dissolve and extract bitumen, followed by thermal viscosity reduction and fractionation, conducted under anhydrous conditions to minimize water pollution, with recycled carbon disulfide to reduce consumption, and hydrotreating to enhance oil recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hot water and caustic are used to extract bitumen from oil sands, then bitumen recovery is achieved, but water pollution is caused and energy efficiency is poor
Solution Approach 1:
The patent changes the fundamental parameter of the extraction medium from water-based to carbon disulfide-based. This parameter change eliminates water pollution while maintaining bitumen recovery efficiency, as carbon disulfide is an effective solvent for bitumen that can be processed under anhydrous conditions
Solution Approach 2:
The patent extracts and removes water from the extraction process entirely. By using carbon disulfide as the solvent, the harmful water-based emulsion formation is eliminated, and bitumen is extracted in an anhydrous system that avoids water pollution in tailings
2Productivity
If hot water and caustic are used to extract bitumen from oil sands, then bitumen recovery is achieved, but investment in plant and equipment is considerable
Solution Approach 1:
The patent changes the operational parameters to anhydrous conditions with carbon disulfide solvent, which simplifies the required equipment compared to water-based systems. The absence of water eliminates the need for complex water handling, evaporation, and caustic management systems
Solution Approach 2:
The patent introduces carbon disulfide as an intermediary solvent that facilitates bitumen extraction without requiring the complex infrastructure needed for water-based processes. This intermediary substance enables simpler equipment design and operation
3Object-affected harmful factors
If carbon disulfide is used as solvent for extraction, then water pollution is avoided and oil recovery is enhanced, but solvent consumption increases
Solution Approach 1:
The patent implements a recovery system for carbon disulfide solvent. The solvent is recovered from the extraction process and recycled back to the extraction unit, minimizing solvent consumption and loss while maintaining effective bitumen extraction
Solution Approach 2:
The patent establishes a feedback loop where the carbon disulfide solvent is recovered and reused in the extraction process. This feedback mechanism ensures continuous solvent utilization with minimal loss, balancing extraction effectiveness with solvent conservation
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 approach reduces water pollution, enhances oil recovery, and minimizes solvent consumption, resulting in a cost-effective and environmentally friendly method for producing high-quality synthetic crude oil.
Implementation Method 1
oil sands are contacted with carbon disulfide to dissolve the hydrocarbon contained in the sands
Implementation Method 2
the resulting solution of hydrocarbon is treated to reduce viscosity, and then fractionated to recover the bitumen. The treatment to reduce viscosity is preferably carried out by way of a thermal reaction
Implementation Method 3
the resulting solution of hydrocarbon is treated to reduce viscosity, and then fractionated to recover the bitumen
Data Source
AI summary
Carbon disulfide is used as a solvent to extract bitumen from oil sands in an anhydrous countercurrent flow process that is compatible with existing procedures for upgrading bitumen. The solution is then treated in a thermal reaction to reduce viscosity and then fractionated to recover the bitumen.