Cascading Processor Gravity Flow Abrasive Wear

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Solution Overview

Problem

Existing heat extraction processes for oil sands are not well-suited to handle highly abrasive materials, leading to wear and inefficiency in mechanical systems.

Innovation Solution

A cascading processor with a vertically spaced processor body and multiple processing levels allows materials to cascade by gravity, enabling efficient processing of abrasive oil sands through controlled temperature gradients and countercurrent flow of vapors and solids, reducing mechanical wear and enhancing mass transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If mechanical product handling systems are used for heat extraction processes, then material handling capability is improved, but mechanical wear from highly abrasive oil sands worsens

Engineering Contradiction:

Improvematerial handling capabilityVSAvoidmechanical wear

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces mechanical product handling systems with a cascading processor that uses gravity-driven flow and countercurrent vapor-solid contact. Materials cascade by force of gravity through vertically spaced processing levels, eliminating mechanical contact and wear while maintaining effective material handling and processing capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts the material handling function from mechanical systems and implements it through gravity-driven cascading flow. The countercurrent flow of vapors and solids enables mass transfer without mechanical product handling, removing the source of mechanical wear while preserving processing effectiveness

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If conventional heat extraction processes are used, then processing capability is improved, but efficiency with abrasive materials worsens

Engineering Contradiction:

Improveprocessing capabilityVSAvoidprocessing efficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The cascading processor enables continuous countercurrent contact between vapors and cascading materials through multiple processing levels. This continuous action maintains high processing capability while improving efficiency by eliminating interruptions and maximizing heat and mass transfer throughout the entire material flow

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent introduces a vertical dimension with multiple processing levels spaced progressively downwardly. Materials cascade vertically through these levels while vapors move countercurrently, creating three-dimensional contact that enhances processing capability and efficiency simultaneously

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 cascading processor efficiently processes large volumes of solids, reduces mechanical wear, and enhances mass transfer, leading to improved bitumen extraction and upgrading with minimal external fuel and water usage.

Implementation Method 1

materials pass by force of gravity from inlet to the outlet. The processor body has a plurality of processing levels which are sequentially vertically spaced progressively downwardly from the inlet to the outlet, such that materials cascade by force of gravity from one processing level to another processing level

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

enhancing mass transfer through controlled temperature gradients and countercurrent flow of vapors and solids

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

enhancing mass transfer through controlled temperature gradients

Methodology Applied

Scientific EffectTemperature gradient: Temperature Gradient

Data Source

PatentUS9511935B2Cascading processor

Publication Date: 2016.12.06 1304338 ALBERTA LTD

AI summary

A cascading processor is described which includes a processor body having an upper inlet and a lower outlet, such that materials pass by force of gravity from inlet to the outlet. The processor body has a plurality of processing levels which are sequentially vertically spaced progressively downwardly from the inlet to the outlet, such that materials cascade by force of gravity from one processing level to another processing level as the materials pass through the processor body front the inlet to the outlet. This cascading processor was developed for recovery of bitumen front oil sands, but can be used to process oil shales or to process biomasses.