Hydrocarbon Recovery from Wet Sludge via Multi-Stage Separation
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Solution Overview
Problem
Traditional hydrocarbon refining processes generate sludge and blowdown feeds that are typically considered waste and are often flared or burned, despite containing valuable hydrocarbon components, leading to inefficiencies and environmental concerns.
Innovation Solution
A system comprising multiple liquid/gas separation vessels, a surge drum, and a stripper system is used to process wet hydrocarbon sludge streams, separating and recovering usable hydrocarbons from what would otherwise be considered waste, thereby reducing waste volume and capturing valuable hydrocarbon components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If sludge and blowdown feeds are flared or burned for disposal, then waste volume is reduced, but valuable hydrocarbon components are lost and environmental impact increases
Solution Approach 1:
The patent applies discarding and recovering by capturing valuable hydrocarbon components from sludge and blowdown feeds that would otherwise be discarded through flaring or burning. The system recovers these components and incorporates them into usable crude product streams, transforming waste disposal into a resource recovery process that reduces both substance loss and environmental harm
Solution Approach 2:
The patent converts the harmful aspect of sludge and blowdown feeds (being waste products requiring disposal) into a benefit by extracting and recovering valuable hydrocarbon components. The system transforms what was previously a harmful disposal operation into a beneficial recovery operation that produces usable crude products
2Loss of substance
If traditional separation processes are used for sludge and blowdown feeds, then processing is simple, but recovery of usable hydrocarbons is insufficient
Solution Approach 1:
The patent applies segmentation by dividing the recovery process into multiple sequential separation stages: initial separation of blowdown and sludge feeds, followed by fractionation into light ends, crude product, and residue streams. This segmented approach enables progressive recovery of hydrocarbons at different volatility levels, improving overall recovery efficiency while maintaining manageable system complexity through modular processing steps
Solution Approach 2:
The patent applies parameter changes by utilizing differences in volatility and boiling points of hydrocarbon components to enable selective separation. The separation system exploits these physical property variations to partition hydrocarbons into different product streams based on their vapor-liquid equilibrium characteristics, achieving effective recovery without requiring overly complex separation mechanisms
3Productivity
If sludge and blowdown feeds are disposed of through flaring or burning, then operational simplicity is maintained, but refining efficiency is reduced
Solution Approach 1:
The patent applies universality by designing a separation system that handles multiple feed streams (blowdown and sludge) through a unified processing architecture. The system simultaneously performs separation, fractionation, and product generation functions, enabling the recovery of usable hydrocarbons from diverse waste streams through a single integrated process rather than multiple separate operations
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 system effectively reduces waste and carbon footprint by recovering valuable hydrocarbon components from sludge and blowdown feeds, enhancing refining efficiency and increasing production of useful hydrocarbon products.
Implementation Method 1
separating the wet hydrocarbon sludge stream into a gaseous separation stream, a first crude product stream, and a liquid separation stream using a separation vessel
Implementation Method 2
separating the liquid separation stream into a surge drum gas stream, a first surge drum liquid stream, and a second surge drum liquid stream using a surge drum
Implementation Method 3
separating the second surge drum liquid stream into a stripper gaseous stream and a stripper liquid stream using a stripper system
Implementation Method 4
separating the stripper liquid stream into an aqueous process stream and a primary crude product stream using a wet hydrocarbon separation vessel
Data Source
AI summary
Methods for treating a wet hydrocarbon sludge stream comprising separating the wet hydrocarbon sludge stream into a gaseous separation stream, a first crude product stream, and a liquid separation stream using a separation vessel. Then separating the liquid separation stream into a surge drum gas stream, a first surge drum liquid stream, and a second surge drum liquid stream using a surge drum. Then separating the second surge drum liquid stream into a stripper gaseous stream and a stripper liquid stream using a stripper system, and then separating the stripper liquid stream into an aqueous process stream and a primary crude product stream using a wet hydrocarbon separation vessel. Methods further comprising separating a blowdown stream into a blowdown gaseous stream and a blowdown liquid stream using a blowdown separation vessel and sending the blowdown liquid stream to the separation vessel.