Laminar-Flow Solvent Extraction for Hydrocarbon Purification
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Solution Overview
Problem
Existing methods for purifying hydrocarbons, such as oils, fats, and greases, are costly and inefficient, leading to high capital and operating expenses, waste disposal issues, and significant product loss.
Innovation Solution
A method and system utilizing a laminar flow reactor with controlled solvent mixing and separation processes to reduce contaminants in hydrocarbons, including heating, solvent combination, and laminar flow to produce a purified hydrocarbon stream with reduced contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water washing and centrifuging are used to solubilize contaminants, then contaminant removal is improved, but capital and operating expenses increase
Solution Approach 1:
The invention changes the physical-chemical parameters of the hydrocarbon stream by adjusting temperature, pressure, and solvent composition to optimize contaminant removal. By controlling these parameters throughout the process, effective purification is achieved without requiring multiple complex unit operations.
Solution Approach 2:
The continuous extraction system performs multiple functions within a single integrated process: heating, solvent mixing, contaminant extraction, and separation all occur in one continuous flow system. This multi-functional approach replaces the need for separate water washing, centrifuging, and filtration units.
2Manufacturing precision
If adsorbent filtration is used to remove remaining contaminants, then purification is improved, but product loss and waste disposal costs increase
Solution Approach 1:
The invention replaces mechanical filtration systems (adsorbent filters, centrifuges) with a continuous liquid-liquid extraction system. This substitution allows for more selective contaminant removal based on solubility differences, minimizing product loss while achieving high purification levels.
Solution Approach 2:
A solvent is introduced as an intermediary substance to facilitate contaminant removal. The solvent selectively dissolves contaminants from the hydrocarbon stream, allowing for efficient separation without direct contact between the hydrocarbon and filtration media that would cause product loss.
3Productivity
If high shear mixing and cavitation are implemented to reduce waste, then efficiency is improved, but capital and operating expenses remain high
Solution Approach 1:
The system uses dynamic control of flow rates, temperature, and solvent composition to optimize the extraction process. By continuously adjusting these parameters, the system achieves high processing efficiency without requiring complex high-shear mixing or cavitation equipment.
Solution Approach 2:
The continuous extraction system maintains constant useful action through uninterrupted flow of hydrocarbon and solvent through the extraction column. This continuous operation achieves high productivity without the intermittent high-energy input required by batch processing with high-shear mixing.
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 method achieves a contaminant reduction of up to 100 times in the purified hydrocarbon product, minimizing waste and reducing operational costs while maintaining high efficiency.
Implementation Method 1
flowing a feedstock hydrocarbon stream through a heating unit to produce a heated hydrocarbon stream
Implementation Method 2
flowing the hydrocarbon-solvent stream through a cooling unit to produce a cooled hydrocarbon-solvent stream
Implementation Method 3
introducing the cooled hydrocarbon-solvent stream into a separation unit to produce a scrubbed hydrocarbon stream and a solvent stream
Data Source
AI summary
Embodiments of the present disclosure generally relate to methods and systems for purifying hydrocarbons, such as feedstock hydrocarbons containing one or more contaminants. In one or more embodiments, a method of purifying a hydrocarbon is provided and includes flowing a feedstock hydrocarbon stream through a heating unit, then combining the hydrocarbon stream and a primary solvent in a laminar flow reactor to produce a hydrocarbon-solvent stream, flowing the hydrocarbon-solvent stream through a cooling unit, and introducing the hydrocarbon-solvent stream into a separation unit to produce a scrubbed hydrocarbon stream and a solvent stream. The scrubbed hydrocarbon stream has a final contaminant concentration which is less than the initial contaminant concentration. The methods and systems for purifying hydrocarbons may be used to prepare a purified hydrocarbon product having the contaminant reduced by 10 times, about 40 times, about 100 times, or greater compared to the feedstock hydrocarbons.