Heavy Hydrocarbon Partial Upgrading for Diluent-Reduced Transport
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Solution Overview
Problem
Existing methods for preparing bitumen and heavy hydrocarbons for pipeline transport require substantial amounts of diluent, leading to increased costs and reduced pipeline capacity, and often result in the need for alternative transport methods due to the high volume of diluent and pitch formation.
Innovation Solution
A method involving limited severity hydroconversion of vacuum resid boiling range components, followed by blending with lower boiling portions of the feed, to produce a partially upgraded heavy hydrocarbon product with reduced diluent and pitch content, suitable for pipeline transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If substantial amounts of diluent are added to bitumen for pipeline transport, then the bitumen becomes suitable for pipeline transport, but the pipeline capacity is reduced and transport costs increase
Solution Approach 1:
The patent changes the chemical parameters of the bitumen through hydroconversion processing, transforming heavy hydrocarbon molecules into lighter, lower-viscosity components. This fundamentally alters the physical properties of the bitumen itself, reducing its viscosity and improving flow characteristics without requiring large volumes of external diluent, thereby resolving the contradiction between transportability and diluent volume
2Ease of operation
If substantial amounts of diluent are transported to the extraction site, then the bitumen can be transported via pipeline, but the transport costs increase substantially
Solution Approach 1:
The patent implements a self-service approach where the bitumen is processed at the extraction site through hydroconversion, transforming itself into a transportable form. This eliminates the need to transport large volumes of external diluent to the extraction site, as the bitumen becomes self-sufficient for pipeline transport after processing, thereby reducing transport costs
3Ease of operation
If large volume of diluent is used, then the bitumen can be transported, but the effective capacity of the pipeline is reduced
Solution Approach 1:
The patent changes the molecular structure and physical parameters of the bitumen through hydroconversion, converting heavy high-viscosity hydrocarbons into lighter, lower-viscosity components. This intrinsic modification of the bitumen's flow properties enables pipeline transport without occupying pipeline capacity with external diluent, thereby maintaining full pipeline capacity for productive transport
4Ease of operation
If large volume of diluent is used, then the bitumen can be transported, but the separator capacity at the destination is reduced
Solution Approach 1:
The patent transforms the bitumen's composition through hydroconversion, producing a processed product with reduced viscosity and altered boiling point distribution. This changes the separation characteristics at the destination, requiring less separator capacity since the processed bitumen naturally separates more efficiently without the need to handle large volumes of external diluent
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 method reduces the need for external diluent and minimizes pitch formation, enabling efficient pipeline transport with increased vacuum gas oil content and lower capital costs, while maintaining product quality and avoiding additional processing steps.
Implementation Method 1
exposing at least a portion of the first fraction to hydroconversion conditions in a hydroconversion stage to form a hydroconverted effluent
Implementation Method 2
separating the first feedstock portion to form a first fraction comprising a 566° C.+ portion, a diluent fraction comprising at least a portion of the first diluent
Data Source
AI summary
Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport. In still other aspects, the systems and methods can allow for reduced incorporation of external streams into the final product for transport while still satisfying one or more target properties.