High Pressure Hydrocarbon Separation System
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Solution Overview
Problem
High-pressure continuous processing systems produce hydrocarbons with high water and inorganic content, making conventional separation methods ineffective for producing high-quality transportation fuels and specialty chemicals.
Innovation Solution
A method involving cooling and depressurizing the product mixture from high-pressure processes, followed by phase separation into gas, oil, and water phases, with subsequent purification using washing agents to reduce water and inorganic content, including the use of acidifying agents and viscosity-reducing agents to enhance separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional separation methods are used on hydrocarbons produced from carbonaceous material, then the separation process is simple and familiar, but the hydrocarbon product contains too much water and inorganics for many applications
Solution Approach 1:
The separation system is divided into multiple sequential stages: a first separator for initial phase separation, followed by a washing section with wash separators, and optionally a second separator for further purification. Each stage targets specific contaminants, progressively improving hydrocarbon purity from crude separation to final product specification.
Solution Approach 2:
A washing agent is introduced as an intermediary substance to facilitate the removal of water and inorganics from the hydrocarbon phase. The washing agent mixes with the hydrocarbon stream, allows contaminants to transfer to the washing agent phase, and is then separated away, effectively mediating the purification process.
2Manufacturing precision
If multiple separation stages are implemented to reduce water and inorganics, then the purity of hydrocarbon product improves, but the equipment complexity and operational complexity increase
Solution Approach 1:
The washing agent system is designed to be self-regulating where the washing agent naturally absorbs water and inorganics from the hydrocarbon phase through contact, and the separated washing agent can be recycled back into the system. This reduces the need for complex external control mechanisms while maintaining high purification effectiveness.
3Manufacturing precision
If washing agents are used to purify the oil phase, then water and inorganic content is reduced, but additional separation steps and equipment are required
Solution Approach 1:
The washing agent is continuously circulated through the system, being reused across multiple hydrocarbon streams rather than being discarded after single use. This continuous circulation maintains constant purification action without requiring proportionally increased equipment capacity, preserving system throughput while achieving high purity products.
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
Significantly reduces water and inorganic contaminants in the hydrocarbon product, improving its quality for further use in catalytic upgrading processes and reducing the overall energy and economic costs of the separation process.
Implementation Method 1
the converted feed stream is cooled to a temperature in the range 50 to 250° C.
Implementation Method 2
the converted feed stream is cooled to a temperature in the range 50 to 250° C., and depressurized to a pressure in the range 1 to 150 bar
Implementation Method 3
purifying the oil phase from the first phase separator by mixing it with one or more washing agents, and separating the oil phase from the one or more washing agents
Data Source
AI summary
The invention relates to a method of separating and purifying products from a high pressure processing system adapted for processing a feed stream comprising carbonaceous material at a pressure of at least 150 bar and a temperature of at least 300° C., where the converted feed stream (product mixture) is cooled to a temperature in the range 50 to 250° C., and depressurized to a pressure in the range 1 to 150 bar, the method comprising separating the depressurized product mixture in gas phase, an oil phase (liquid hydrocarbon), and a water phase comprising water soluble organics, dissolved salts and optionally suspended particles in a first phase separator and purifying the oil phase from the first phase separator by mixing it with one or more washing agents, at least one of which comprises water, and separating the oil phase from the one or more washing agents in a further separation step.