Kinetic Oil Processing System for Energy-Efficient Shale Extraction
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Solution Overview
Problem
Current processes for extracting useful products from petroleum or oil shale are energy-intensive and time-consuming, limiting the development of oil shale reserves due to high processing costs.
Innovation Solution
A system comprising a pressurized cracking tank, rotary kiln, distillation columns, catalytic reforming units, and thermal insulation, along with a method that involves heating petroleum or oil shale to extract hydrocarbons, followed by processing through a series of units including a conduit system heated by exhaust product streams, enhances efficiency and reduces processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional processing methods are used to extract hydrocarbons from oil shale, then hydrocarbon extraction is achieved, but processing time is excessive and energy consumption is high
Solution Approach 1:
The processing system is divided into multiple independent units operating in sequence: a pressurized cracking tank for initial decomposition, a rotary kiln for further processing, and distillation columns for separation. This segmentation allows each unit to perform its specific function efficiently, reducing overall processing time compared to conventional single-stage methods.
Solution Approach 2:
The pressurized cracking tank performs preliminary decomposition of oil shale before the material enters the rotary kiln and distillation columns. By pre-processing the material under pressure to break down complex structures, the subsequent processing stages can operate more efficiently and faster, reducing total processing time.
2Productivity
If conventional processing methods are used to extract hydrocarbons from oil shale, then hydrocarbon extraction is achieved, but energy consumption is excessive
Solution Approach 1:
Multiple processing functions are combined into an integrated system where the pressurized cracking tank, rotary kiln, and distillation columns operate in sequence. The effluent from one unit becomes the input for the next, eliminating the need for separate energy-intensive processing steps and reducing overall energy consumption while maintaining high extraction efficiency.
Solution Approach 2:
The system maintains continuous operation across all processing units, with material flowing continuously from the pressurized cracking tank through the rotary kiln to the distillation columns. This continuous processing eliminates idle time and repeated heating/cooling cycles, significantly reducing energy consumption compared to batch processing methods.
3Productivity
If processing speed is increased to reduce processing time, then productivity improves, but energy consumption increases
Solution Approach 1:
The system utilizes different operating parameters for each processing unit: high pressure in the cracking tank, controlled rotation and temperature in the rotary kiln, and varying temperatures in the distillation columns. By optimizing parameters for each stage rather than using uniform high-energy conditions throughout, the system achieves fast processing without excessive energy consumption.
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 significantly reduces processing time and energy consumption, making oil shale reserves more appealing by efficiently extracting hydrocarbons, thereby lowering costs and improving the appeal of oil shale as a hydrocarbon source.
Implementation Method 1
heating the petroleum or the oil shale to withdraw oil vapors containing hydrocarbons
Implementation Method 2
feeding the petroleum or the oil shale from the pressurized cracking tank into a rotating kiln
Implementation Method 3
one or more distillation columns having a top portion and a bottom portion, wherein the distillation column is configured to receive product from the rotary kiln at the top portion
Implementation Method 4
the pressurized cracking tank and the rotary kiln are at least partially encased in a thermal insulator
Implementation Method 5
a conduit connects the pressurized cracking tank and the rotary kiln, wherein the conduit is a triangle pipe or a square pipe... the conduit comprises a top and a bottom, and the conduit is heated on the bottom
Data Source
AI summary
A system for purifying petroleum or oil shale is provided. The system includes a pressurized cracking tank configured to receive petroleum or crushed oil shale; and a rotary kiln configured to receive product from the pressurized cracking tank. A method of processing petroleum or oil shale is also provided. The method includes feeding the petroleum or the oil shale into a pressurized cracking tank; heating the petroleum or the oil shale to withdraw oil vapors containing hydrocarbons; and feeding the petroleum or the oil shale from the pressurized cracking tank into a rotating kiln.