Adiabatic Expansion for Heavy Residue Separation
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Solution Overview
Problem
Current methods for treating bituminous residues with high asphaltene content from hydrocarbon conversion processes face challenges in managing and disposing of these residues due to their viscous nature and high coke and inorganic content, leading to difficulties in re-use and environmental impact.
Innovation Solution
A process involving adiabatic expansion and high vacuum separation of bituminous residues to separate a less volatile fraction enriched in asphaltenes and a more volatile fraction rich in maltenes, allowing for the conversion of residues into more manageable and reusable products, such as granular solids and gaseous fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal cracking is used to convert bituminous residue, then conversion to combustible products is achieved, but coke formation occurs during preheating phase
Solution Approach 1:
The invention applies preliminary action by pre-mixing the bituminous residue with a diluent (such as light oil or solvent) before heating. This preliminary mixing action prevents coke formation during the preheating phase by ensuring proper fluidization and heat distribution, eliminating the need for separate coke prevention measures while maintaining conversion efficiency.
Solution Approach 2:
The diluent acts as an intermediary substance between the bituminous residue and the heating process. It facilitates uniform heat transfer and prevents direct contact between the residue and heating surfaces that would cause coke formation, while still allowing the conversion reaction to proceed effectively.
2Productivity
If bituminous residue is heated to high temperature, then conversion reaction proceeds, but viscous paste becomes difficult to manage for transportation and disposal
Solution Approach 1:
The invention changes the physical parameters of the bituminous residue by mixing it with a diluent, which alters its viscosity and flow characteristics. This parameter change makes the residue easier to pump, transport, and handle throughout the conversion process, while the conversion reaction still proceeds at the required high temperatures.
Solution Approach 2:
The invention segments the bituminous residue into a mixture with the diluent, creating a more manageable composite material. This segmentation approach divides the problematic viscous paste into a fluidizable mixture that can be easily transported and processed, while maintaining the integrity of the conversion reaction.
3Manufacturing precision
If solvent deasphalting process is used, then asphaltene component can be separated, but requires multiple columns and supercritical conditions
Solution Approach 1:
The invention merges the heating, conversion, and separation operations into a single integrated process. By combining these functions in one reactor system with controlled atmosphere, it achieves effective separation of asphaltene components without requiring multiple separate columns or complex supercritical extraction equipment.
Solution Approach 2:
The conversion reactor in the invention serves multiple functions simultaneously: it performs the thermal conversion reaction, prevents coke formation through controlled atmosphere, and enables separation of the converted products. This multi-functionality eliminates the need for separate dedicated equipment for each operation.
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
Effectively separates high-asphaltene residues into usable products, reducing environmental harm and improving management and disposal capabilities by achieving high separation efficiency and preventing coke formation, while maintaining the integrity of volatile components.
Implementation Method 1
a process involving adiabatic expansion and high vacuum separation of bituminous residues to separate a less volatile fraction enriched in asphaltenes and a more volatile fraction rich in maltenes
Implementation Method 2
a process involving adiabatic expansion and high vacuum separation of bituminous residues to separate a less volatile fraction enriched in asphaltenes and a more volatile fraction rich in maltenes
Data Source
Figure 1
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AI summary
The process for treating a hydrocarbon-based heavy residue (1), in particular bituminous residues with a high asphaltene content, comprises the following operations : A) bringing the heavy residue to be treated to a temperature within the range of 325-500°C; B) subjecting the heavy residue to be treated to a substantially adiabatic expansion in an environment at a pressure equal to or lower than about 0.1 bara, and at a temperature equal to or lower than 450°C, so as to separate, from the heavy residue to be treated, a first less volatile fraction (17) having a boiling point at atmospheric pressure equal to or higher than 540°C and whose solid and/or anhydrous residue prevalently contains asphaltenes insoluble in pentane and/or other residues insoluble in tetrahydrofuran. It allows a more effective flushing, and also to actuate the process in an extremely simple plant and without centrifugations.