Heavy Hydrocarbon Removal via Two-Stage Extractive Solvent System
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Solution Overview
Problem
Heavy hydrocarbons, such as bitumen and tars, pose challenges in refinery processing due to their high viscosity and tendency to build up in systems, leading to fouling and inefficient separation, which hampers refinery operations and requires costly downtime.
Innovation Solution
The implementation of a two-stage extractive unit system with light hydrocarbon and water inputs to selectively remove heavy hydrocarbons from solvent streams, utilizing a closed-loop system with minimal water and organic waste generation, and integrating a solvent regeneration process to recycle and regenerate solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heavy hydrocarbons are present in solvent streams, then extraction efficiency improves, but system fouling increases and operational continuity deteriorates
Solution Approach 1:
The system divides the extraction process into multiple sequential stages (first extractive unit, second extractive unit) with different solvent compositions. The first stage uses a first solvent to extract heavy hydrocarbons, while the second stage uses a second solvent to further remove remaining heavy hydrocarbons. This segmentation allows each stage to be optimized for specific extraction objectives while preventing fouling accumulation in any single unit.
Solution Approach 2:
The system changes solvent parameters (composition, concentration) between different extraction stages. The first solvent and second solvent have different properties tailored to their respective stages, enabling progressive extraction while maintaining system cleanliness. This parameter variation allows efficient heavy hydrocarbon removal without causing fouling in any single extraction unit.
2Reliability
If heavy hydrocarbons are removed from solvent streams, then operational continuity improves, but separation efficiency decreases
Solution Approach 1:
By segmenting the removal process into multiple stages with different solvent systems, the patent achieves both continuous operation and high separation efficiency. Each stage handles a specific portion of the separation task, allowing the system to maintain continuous flow while achieving complete heavy hydrocarbon removal through cumulative effect of multiple stages.
Solution Approach 2:
The system maintains continuous operation by designing extractive units that process solvent streams continuously through multiple stages. The first and second extractive units operate in sequence to continuously remove heavy hydrocarbons from the solvent stream, ensuring uninterrupted production while achieving complete separation.
3Productivity
If multiple extraction stages are implemented, then heavy hydrocarbon removal completeness improves, but device complexity increases
Solution Approach 1:
The patent segments the extraction function into distinct units (first extractive unit, second extractive unit) that can be independently designed and operated. Each unit has specific input and output streams clearly defined, making the complex multi-stage process manageable and easier to implement than a single complex unit would be.
Solution Approach 2:
Both extractive units follow the same basic operational pattern and can be designed with similar configurations, allowing for standardized manufacturing and simplified maintenance. The repeated modular design reduces overall system complexity compared to custom complex units, while achieving complete removal through the series configuration.
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 enables efficient and continuous removal of heavy hydrocarbons, maintaining system performance, reducing waste, and allowing for further processing of heavy hydrocarbons into lighter products, thereby improving refinery operations and reducing operational costs.
Implementation Method 1
extracting the first batch of the mixture with a light hydrocarbon wash
Implementation Method 2
washing the first batch of the mixture with a first water wash to produce a solvent stream depleted in heavy hydrocarbons
Implementation Method 3
The first water input line is supplied by condensed stripping steam
Data Source
AI summary
Apparatuses and systems for removing heavy hydrocarbons from a solvent stream are disclosed herein. The apparatuses extract heavy hydrocarbons into light hydrocarbons and provide a solvent stream having the heavy hydrocarbons removed. Two water washing steps are used to remove residual solvent from the heavy hydrocarbon solution in light hydrocarbons. In some embodiments, the second water wash is used for processing subsequent batches of the solvent stream. The heavy hydrocarbons and solvent can be recovered and processed further. Methods for removing heavy hydrocarbons from a solvent stream are also disclosed herein.