Heavy Hydrocarbon Stabilization via Solvent Flocculation

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Solution Overview

Problem

Heavy hydrocarbons in storage tanks and transportation lines face sludge formation due to asphaltene precipitation, leading to equipment blockages, reduced storage capacity, and environmental concerns, with conventional treatments causing yield losses and adverse effects.

Innovation Solution

A process involving mixing a high carbon number paraffinic or heavy naphtha solvent with heavy hydrocarbon feedstocks to solvent-flocculate asphaltenes, followed by separation and flashing to produce sediment-free hydrocarbon fractions, minimizing sludge formation while maintaining yield and quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional treatments are used to remove sludge, then sludge formation is reduced, but yield loss increases and environmental impact worsens

Engineering Contradiction:

Improvesludge formation preventionVSAvoidyield loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent changes the chemical parameters of the treatment process by using specific solvent systems (aromatic hydrocarbons, cyclic hydrocarbons, or esters) with controlled molecular structures and ratios. This allows selective interaction with asphaltenes to prevent sludge formation while minimizing yield loss and environmental impact, resolving the contradiction between effective sludge prevention and maintaining product yield.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces intermediary solvent substances that mediate between the heavy hydrocarbon feedstock and the harmful asphaltene precipitation. These solvents (aromatic hydrocarbons, cyclic hydrocarbons, esters) act as intermediaries to stabilize asphaltenes in solution, preventing sludge formation without causing significant yield loss or environmental harm, thus resolving the technical contradiction.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If asphaltenes are removed to prevent sludge, then sludge formation is reduced, but quality of treated oil deteriorates

Engineering Contradiction:

Improvesludge formation preventionVSAvoidquality of treated oil

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by selectively targeting only the problematic asphaltene fraction while leaving the bulk of the oil product unchanged. The solvent system is designed to interact specifically with asphaltenes at localized concentrations, preventing sludge formation without adversely affecting the overall quality characteristics of the treated oil, thus resolving the contradiction between sludge prevention and quality maintenance.

Inventive Principle:

Principle #3Local quality

3Quantity of substance

If high carbon number solvents are used to extract asphaltenes, then asphaltenes are effectively removed, but sediment formation increases

Engineering Contradiction:

Improveasphaltene removal efficiencyVSAvoidsediment formation

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent changes the molecular parameters of the solvent by selecting aromatic hydrocarbons, cyclic hydrocarbons, or esters with specific carbon numbers and chemical structures. These parameter changes allow the solvent to effectively solubilize asphaltenes without causing excessive sediment formation, resolving the contradiction between asphaltene removal efficiency and sediment formation control.

Inventive Principle:

Principle #35Parameter changes

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 process effectively stabilizes heavy hydrocarbons by reducing sludge formation, minimizing yield loss, and allowing for low-cost, efficient operation with broad applicability to whole crude oil and its fractions, while reducing environmental impact.

Implementation Method 1

mixing a solvent with a heavy hydrocarbon feedstock containing asphaltenes to solvent-flocculate a portion of the asphaltenes

Methodology Applied

Scientific EffectSolvent-flocculation: Flocculation

Implementation Method 2

separating the feedstock containing solvent-flocculated asphaltenes in a contact vessel into a solvent/hydrocarbon phase and a sediment phase

Methodology Applied

Scientific EffectPhase separation:

Implementation Method 3

flashing the solvent/hydrocarbon phase to produce a sediment-free hydrocarbon fraction and a solvent fraction

Methodology Applied

Scientific EffectFlashing:

Data Source

PatentUS9493710B2Process for stabilization of heavy hydrocarbons

Publication Date: 2016.11.15 SAUDI ARABIAN OIL CO

AI summary

A process for stabilization of heavy hydrocarbons to reduce sludge formation in storage tanks and/or transportation lines and to enhance the hydrocarbon yield includes mixing a paraffinic or heavy naphtha solvent having carbon numbers in the range 10 to 20 with the feedstock to solvent-flocculate a relatively small, predetermined portion of asphaltenes present in the feedstock, separating and flashing the sediment to recover a light hydrocarbon fraction, flashing the heavy hydrocarbon/solvent phase and recycling the solvent to stabilize the heavy hydrocarbons without significantly affecting the yield of valuable products.