Heavy Oil Fraction Separation with Automated Solvent Flow Switching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for separating four fractions of heavy oil are labor-intensive, time-consuming, and require large amounts of solvents, leading to potential health and environmental hazards, while existing automated systems still rely on manual steps and suffer from weighing errors and inefficient solvent use.
Innovation Solution
An automatic separation apparatus and method using a solvent reservoir, filter disc, chromatographic column, and flow path switching valves to achieve online separation and collection of heavy oil fractions, reducing manual steps and solvent consumption, and incorporating a receiving apparatus to minimize weighing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual preparation and packing of alumina chromatography column is performed, then the separation process can be carried out, but the properties of alumina packing materials have large differences and short valid time, affecting separation effect
Solution Approach 1:
The patent replaces manual mechanical packing operations with an automated column packing device that uses vibration and pressure control to pack alumina uniformly. This substitution eliminates human variability in packing density and ensures consistent column properties, directly resolving the contradiction between ease of manual operation and reliability of separation effect.
2Device complexity
If gravity and duplex ball are used to pressurize the column separation process, then the separation can be performed, but the elution speed is slow and uncontrollable, affecting repeatability
Solution Approach 1:
The patent replaces the gravity-based mechanical pressurization system with a computer-controlled pump system that can precisely control solvent flow rate and pressure. This allows the elution speed to be adjusted and maintained at optimal levels, improving both productivity and repeatability while reducing the complexity of manual pressure control.
Solution Approach 2:
The patent incorporates a pressure sensor and computer control system that monitors and adjusts the pressurization in real-time based on feedback from the system state. This closed-loop control ensures stable and repeatable elution conditions, resolving the issue of uncontrollable elution speed.
3Quantity of substance
If glass conical flasks of 150 mL-250 mL are used for refluxing and receiving fractions, then the separation process can be completed, but the mass of the container exceeds 100 g causing large weighing errors for fractions less than 1 g
Solution Approach 1:
The patent employs disposable micro-balloon containers with mass less than 10 mg for receiving and weighing the separated fractions. These lightweight, single-use containers eliminate the weighing error problem associated with heavy glass flasks, as the container mass is negligible compared to the fraction mass. The disposable nature ensures no cross-contamination between samples.
4Quantity of substance
If about 500 mL n-heptane, toluene and other volatile organic solvents are used to process each sample, then the separation can be achieved, but this brings potential dangers to health, safety and environmental protection
Solution Approach 1:
The patent changes the operational parameters of the separation process by using a computer-controlled system that optimizes solvent flow rates and volumes. This reduces the total solvent consumption from 500 mL to much lower amounts while maintaining separation effectiveness. The reduced solvent volume directly decreases health and safety hazards for operators.
Solution Approach 2:
The patent replaces manual refluxing and solvent handling operations with an automated system that precisely controls solvent delivery and collection. This automation reduces the need for large volumes of volatile solvents and minimizes operator exposure to harmful fumes, thereby improving health and safety conditions.
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 apparatus enables rapid, precise, and automated separation of heavy oil fractions, reducing manual errors and solvent use, while allowing parallel processing of multiple samples, enhancing safety and efficiency.
Implementation Method 1
NB/SH/T 0509-2010 'TEST METHOD FOR SEPARATION OF ASPHALT INTO FOUR FRACTIONS' is applied in petrochemical field in China for measuring the four fractions of heavy oil. Major steps of this standard method includes: (1) Preparation of packing materials of alumina chromatography column.
Implementation Method 2
the filter disc and a chromatographic column sequentially, and using the first solvent to flush the separation unit for four fractions of heavy oil, to obtain a saturates eluent
Data Source
AI summary
The present disclosure provides an automatic separation apparatus for four fractions of heavy oil and a separation method thereof, wherein the apparatus includes a solvent reservoir tank (1), a separation unit for four fractions of heavy oil (100) and a receiving apparatus (9). The separation unit for four fractions of heavy oil (100) includes: a filter disc (4) having one end in communication with the solvent reservoir tank (1), and the other end in communication with an inlet of a pre-column flow path switching valve (5); a chromatographic column (6) having an inlet in communication with an outlet of the pre-column flow path switching valve (5), and an outlet in communication with an inlet of a post-column flow path switching valve (8). The receiving apparatus is in communication with an outlet of the post-column flow path switching valve (8).