Modular Bitumen Processing System for Solvent Extraction
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Solution Overview
Problem
Conventional hydrocarbon resource recovery methods, such as Steam-Assisted Gravity Drainage (SAGD), face challenges with high water addition and the need for expensive diluents due to emulsified bitumen and water having similar gravity, requiring additional processing steps and safety concerns during transportation.
Innovation Solution
A portable modular treatment system for solvent extraction bitumen wells, comprising an initial separation module, free water removal module, skimming tank module, and condenser module, which liberates non-condensable gases, separates bitumen and solvent from produced water, and recovers solvent for reuse, eliminating the need for surface diluent addition and reducing water content in bitumen for transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Steam-Assisted Gravity Drainage (SAGD) is used to extract bitumen, then bitumen recovery is achieved, but significant amounts of water are added to the emulsion output
Solution Approach 1:
The treatment system is divided into multiple modular units including a free water removal module, a diluent removal module, and a heating module. Each module performs a specific separation function, allowing systematic removal of water and diluent while maintaining bitumen recovery efficiency.
Solution Approach 2:
The system changes temperature parameters by heating the emulsion to specific ranges (e.g., 25°C to 100°C or higher) to alter the physical properties of water and diluent, enabling their separation from bitumen through phase changes and density differences.
2Ease of operation
If diluents are added to lower bitumen gravity for free water knock out, then water separation is improved, but expensive diluents are required and additional processing is needed
Solution Approach 1:
The diluent removal module specifically extracts and removes diluent from the emulsion through separation processes, eliminating the need to add expensive diluents in the first place and recovering any diluent that was previously added.
Solution Approach 2:
The system recovers diluent from the emulsion stream and returns it to the process, reducing diluent consumption and eliminating the need for continuous diluent addition while maintaining effective water separation.
3Ease of operation
If diluents are added to meet pipeline requirements, then bitumen can be transported, but 30% diluent by volume is required which increases cost and complexity
Solution Approach 1:
The treatment system extracts and removes diluent from the bitumen stream, producing undiluted or reduced-diluent bitumen that meets pipeline specifications without requiring the addition of 30% diluent by volume.
Solution Approach 2:
The system changes the composition parameters of the bitumen stream by removing water and diluent, producing a concentrated bitumen product that meets transportation requirements without excessive diluent content.
4Device complexity
If emulsified bitumen and water are separated by gravity, then separation is simple, but they have nearly the same gravity which prevents effective separation
Solution Approach 1:
The system changes temperature parameters to heat the emulsion, which alters the density and viscosity of water and bitumen differently, creating sufficient gravity difference for effective separation without complex equipment.
Solution Approach 2:
The separation process is segmented into multiple stages: initial heating, free water removal, and diluent removal, with each stage addressing specific separation challenges through progressively refined temperature and pressure conditions.
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 processes bitumen without adding diluents, reducing water content, and enables safe transportation of undiluted bitumen, enhancing efficiency and safety by maintaining bitumen at high temperatures and utilizing non-condensable gases as fuel, thus avoiding the need for steam generation and diluent addition.
Implementation Method 1
heating the emulsion to a temperature between 25°C and 100°C or higher to reduce the viscosity
Implementation Method 2
the heated emulsion is then transferred to a free water removal module where the water is separated from the heated emulsion
Implementation Method 3
the bitumen and solvent mixture is then transferred to a diluent removal module where the diluent is separated from the bitumen and solvent mixture
Implementation Method 4
a condenser module configured to receive the bitumen and solvent from the portable free water removal module and separate the bitumen and solvent
Data Source
AI summary
A portable modular treatment system to be remotely deployed adjacent a solvent extraction bitumen well may include a portable initial separation module configured to receive a liquid emulsion from the solvent extraction bitumen well including bitumen, produced water, solvent, and at least one non-condensable gas, and liberate the at least one non-condensable gas while the solvent remains with the liquid emulsion. The system may further include a portable free water removal module configured to receive the liquid emulsion from the portable initial separation module and separate the bitumen and solvent from the produced water, a portable skimming tank module configured to receive the produced water from the portable free water removal module and remove free oil from the produced water through gravity separation, and a portable condenser module configured to receive the bitumen and solvent from the portable free water removal module and separate the bitumen and solvent.