Hydrocarbon Refining Process with Atmosphere Separation
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Solution Overview
Problem
The economic recovery of hydrocarbons from low-quality oil or tar sands and oil shale is hindered by high water consumption and emissions of waste waters containing residual oil, with existing processes being energy-intensive and inefficient due to the risk of coking and lack of control over temperature and hydrogen generation.
Innovation Solution
A process involving the supply of water to an expulsion stage and a downstream gasification stage to produce hydrogen and expel hydrocarbon vapors, which are then processed through cracking, coking, or hydrotreating, with a separate combustion stage to recycle heat and separate atmospheres to prevent oxidation, allowing for controlled hydrogen production and improved energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional in situ steam injection or pyrolysis is used to recover hydrocarbons from oil sands or oil shale, then hydrocarbon recovery is achieved, but water consumption is extremely high and waste water containing residual oil is emitted
Solution Approach 1:
The patent changes the fundamental parameters of the recovery process by operating at atmospheric pressure instead of high pressure, and by using a fluidized bed reactor with controlled temperature zones. This allows efficient hydrocarbon extraction without the need for large amounts of water injection, thereby reducing both water consumption and waste water emission while maintaining productivity
Solution Approach 2:
The patent uses an inert or reducing atmosphere in the reaction zone to prevent unwanted oxidation reactions and to facilitate controlled hydrocarbon extraction. This approach eliminates the need for water-based extraction methods, significantly reducing water consumption and waste water generation while maintaining effective hydrocarbon recovery
2Productivity
If high temperature pyrolysis is applied to extract hydrocarbons from oil shale, then hydrocarbon yield increases, but energy consumption and risk of coking increase
Solution Approach 1:
The patent divides the reaction system into distinct zones: a heating zone for controlled temperature increase, a reaction zone for hydrocarbon extraction, and a cooling zone for vapor condensation. This segmentation allows efficient energy utilization and prevents excessive energy consumption while maintaining high hydrocarbon yield and reducing coking risk through controlled thermal gradients
Solution Approach 2:
The patent implements continuous operation with recirculation of heat and materials throughout the system. The fluidized bed maintains continuous contact between reactants and catalyst, and heat from product condensation is continuously fed back to the reaction zone, eliminating energy waste and maintaining sustained high hydrocarbon yield without excessive energy input
3Productivity
If thermal cracking is used to process hydrocarbon vapors, then oil product is obtained, but the process consumes a great deal of energy and is expensive
Solution Approach 1:
The patent employs catalytic cracking instead of thermal cracking, where a catalyst enables the cracking reaction to proceed at lower temperatures. The system is self-sufficient by using the heat generated from product condensation and catalyst regeneration to maintain reaction temperatures, eliminating the need for additional high-energy thermal input while maintaining high oil product production efficiency
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 approach reduces water consumption, minimizes waste emissions, and enhances energy efficiency by controlling hydrogen production and optimizing oil vapor yield, making the process more economically viable for low-quality hydrocarbon sources.
Implementation Method 1
Water is supplied to the combustion zone in order to react with carbon residues present in the raw material and/or in the solids and thereby generate hydrogen
Implementation Method 2
expel hydrocarbonaceous vapour at a temperature of from about 300 to about 1000° C.
Implementation Method 3
expel hydrocarbonaceous vapour
Implementation Method 4
The hot solids are recirculated from the combustion zone into the expulsion zone and/or the gasification stage
Implementation Method 5
The hot solids are recirculated from the combustion zone
Implementation Method 6
An oxidizing atmosphere of the combustion zone is separated from an atmosphere of the expulsion zone and/or the gasification stage using a blocking device
Data Source
AI summary
A process for refining raw materials containing oil and/or bitumen includes supplying water and the raw materials to an expulsion stage and/or an expulsion stage and a downstream gasification stage to obtain solids containing non-evaporated fractions of heavy hydrocarbons and to expel hydrocarbonaceous vapor. The expelled hydrocarbonaceous vapor is supplied to a processing stage and is further processed to expel hydrocarbonaceous vapor to obtain processing stage products which are separated and withdrawn. The solids from the expulsion stage and/or the expulsion stage and the downstream gasification stage are introduced into a combustion stage. The non-evaporated fractions of heavy hydrocarbons are burned in the combustion stage to obtain hot solids which are recirculated from the combustion stage into the expulsion stage and/or the downstream gasification stage. An oxidizing atmosphere of the combustion stage is separated from an atmosphere of the expulsion stage and/or the downstream gasification stage using a blocking device.