Methods of preparing solid formations of non-volatile bituminous materials suitable for reducing carbon dioxide emissions during transport
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Solution Overview
Problem
The transportation of heavy crude oil and bitumen poses challenges due to their high viscosity and density, requiring diluents for pipeline transport, which leads to environmental risks, increased costs, and a significant carbon footprint, as well as difficulties in processing and spill cleanup.
Innovation Solution
Converting bituminous materials into irregular solid formations with customizable polymer skeletons and buoyant features, allowing for transport without diluents and enhancing buoyancy, thus reducing environmental impact and reliance on fossil fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bitumen is diluted with conventional light crude or natural gas liquids to enable pipeline transport, then transportability through pipelines is improved, but environmental risks increase due to pipeline ruptures and oil spills
Solution Approach 1:
The patent changes the physical state of bitumen from liquid to solid by cooling it below its melting point. This parameter change enables transport without diluents, eliminating the environmental risks associated with dilbit pipeline ruptures while maintaining transportability through specialized infrastructure
Solution Approach 2:
The patent uses readily available natural gas as a heating source during extraction and transport operations. This cheap, accessible energy source replaces the need for complex diluent systems and their associated environmental management requirements
2Ease of operation
If bitumen is diluted to reduce viscosity for pipeline transport, then flow characteristics are improved, but carbon footprint increases due to diluent production and processing
Solution Approach 1:
The patent changes the temperature parameter to solidify bitumen for transport, eliminating the need for diluents and their associated carbon-intensive production and processing. The solid form maintains stability without requiring carbon-emitting diluent management
Solution Approach 2:
The patent extracts and removes the diluent component entirely from the bitumen transport system. By transporting neat bitumen in solid form, the carbon footprint associated with diluent production, blending, and processing is completely eliminated
3Ease of operation
If bitumen is transported as dilbit, then pumpability is improved, but spill cleanup difficulty increases due to separation of components
Solution Approach 1:
The patent changes bitumen to solid form for transport, which maintains structural integrity during spills. Unlike dilbit where components separate and evaporate, solid bitumen bricks remain contained and predictable, dramatically improving cleanup ease through mechanical recovery methods
4Productivity
If conventional extraction methods are used to access bitumen, then recovery is achieved, but energy consumption increases due to heating requirements
Solution Approach 1:
The patent utilizes the natural heat from the Earth and the exothermic nature of bitumen extraction processes to maintain bitumen in a transportable state. The system serves itself by using readily available thermal energy sources rather than requiring additional external heating infrastructure
Solution Approach 2:
The patent changes the temperature parameter during extraction to minimize additional heating requirements. By optimizing the thermal parameters of the extraction process, energy consumption is reduced while maintaining effective bitumen recovery
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 enables cost-effective, environmentally friendly transport and storage of bituminous materials, reducing the risk of spills and carbon emissions, while maintaining the materials' integrity and facilitating easier cleanup in case of accidents.
Implementation Method 1
converting bituminous materials into irregular solid formations
Implementation Method 2
customizable polymer skeletons and buoyant features, allowing for transport without diluents and enhancing buoyancy
Data Source
AI summary
A method of preparing non-volatile bituminous material in solid form includes first accessing molds having mold cavities defining an irregularly shaped brick having a plurality of non-planar surfaces and preparing the bituminous material for casting by heating it until it is suitably viscous for casting and optionally blending it with an additive. Then, the molds can be filled with the bituminous materials, preferably using a retractable conduit that progressively fills each mold cavity from its bottom to its top. Next, the bituminous material in the molds is solidified until substantially solid bricks are formed. Optionally, a skeleton with optional additional buoyant features can be placed in each mold cavity prior to casting so that the resulting brick has increased buoyancy throughout, and the skeleton and any buoyant features can be customized according to the needs of the customer. The resulting bricks can be removed for transport.