Hydrocarbon Purification via Countercurrent Liquid-Liquid Extraction
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Solution Overview
Problem
Current hydrocarbon purification methods, such as the Colgate-Emery process, are costly and inefficient, producing undesirable byproducts like glycerin and free fatty acids, and require large equipment and long residence times, making them unsuitable for economically viable alternative fuel production.
Innovation Solution
A countercurrent liquid-liquid extraction method where an aqueous phase and an organic phase with contaminants are mixed in a reactor, with the organic phase flowing opposite to the aqueous phase, allowing for efficient separation and purification of hydrocarbons, reducing waste and byproduct formation, and utilizing a temperature profile to enhance contaminant removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the Colgate-Emery process is used for hydrocarbon purification, then waste disposal and product loss are reduced, but the process requires large equipment and long residence times, making it cost prohibitive
Solution Approach 1:
The patent changes the temperature parameter by operating at elevated temperatures (200-400°C) compared to conventional processes. This temperature increase accelerates the purification reaction kinetics, allowing the process to achieve the same purification effect in shorter residence times (minutes rather than hours), thereby resolving the contradiction between reducing product loss and maintaining productivity
Solution Approach 2:
The patent replaces the mechanical gravity separation system (requiring large settling tanks and long residence times) with a chemical reaction-based purification system. By using reactive extraction or in-situ purification mechanisms, the process achieves separation without relying on slow gravitational settling, thus reducing equipment size and residence time while maintaining effective contaminant removal
2Manufacturing precision
If multiple purification steps are implemented to remove contaminants, then purification effectiveness is improved, but capital and operating expenses increase
Solution Approach 1:
The patent combines multiple purification functions (extraction, separation, and purification) into a single integrated reactor system. By merging these previously separate unit operations into one continuous process, the patent achieves high purification effectiveness while reducing the number of equipment items, capital investment, and operating complexity
Solution Approach 2:
The reactor system is designed to perform multiple functions simultaneously: contaminant extraction, phase separation, and product purification all occur within the same equipment. This multi-functionality eliminates the need for separate dedicated equipment for each purification step, thereby reducing device complexity and capital expenses while maintaining high purification effectiveness
3Manufacturing precision
If conventional water washing and adsorbent filtration are used, then contaminants are removed, but each subsequent process increases capital and operating expenses
Solution Approach 1:
The patent extracts contaminants directly from the hydrocarbon phase using a reactive extraction mechanism in a single step. By taking out the contaminant removal function from the multi-step conventional process (water washing → acid refining → caustic refining → adsorbent filtration) and consolidating it into one extraction operation, the patent achieves equivalent contaminant removal at lower cost and complexity
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
This method significantly reduces capital and operating expenses by minimizing waste and byproduct formation, achieving high purity hydrocarbons with shorter residence times and lower equipment requirements, making it more economically viable for alternative fuel production.
Implementation Method 1
A countercurrent liquid-liquid extraction method where an aqueous phase and an organic phase with contaminants are mixed in a reactor
Implementation Method 2
The mixing region is heated
Data Source
AI summary
The present disclosure provides methods of purifying hydrocarbons. The methods include flowing an aqueous phase comprising water into a first end of a mixing region of a reactor along a first direction. An organic phase is mixed, via a countercurrent flow, with the aqueous phase by flowing the organic phase into a second end opposite to the first end of the mixing region. The organic phase comprises an oil, fat, grease, or combinations thereof, such as from vegetable and/or animal sources. The flow of the organic phase is along a second direction opposite to the first direction, and the organic phase comprises at least a contaminant comprising halides, phosphorous, sulfur, alkali metals, metalloids, heavy metals, or any combination thereof. The mixing region is heated. A purified organic phase is extracted from a purification region of the reactor. A waste is extracted from a waste region of the reactor.