Nanopore Membrane Hydrocarbon Separation
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Solution Overview
Problem
Conventional hydrocarbon separation processes are energy-intensive and inefficient, struggling to effectively remove organic and inorganic impurities, such as asphaltenes, metals, and Conradson Carbon Residue, from hydrocarbon feedstock.
Innovation Solution
A process using nanopore membranes to separate hydrocarbon feedstock into lighter and heavier molecular streams based on refractive indices, with or without separation enhancing additives, allowing for the efficient removal of impurities through differential permeation and recycling of the retentate for further purification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional distillation columns and solvent extraction processes are used to separate hydrocarbon fractions and remove impurities, then separation effectiveness is improved, but energy consumption increases significantly
Solution Approach 1:
The patent employs nanopore membranes with precisely controlled pore sizes (1-100 nm) to achieve molecular separation of hydrocarbon fractions and impurity removal. The porous structure enables size-based filtration where lighter hydrocarbon molecules pass through while heavier impurities like asphaltenes and metals are retained, eliminating the need for energy-intensive thermal distillation and solvent extraction processes
Solution Approach 2:
The invention replaces the mechanical/thermal separation systems (distillation columns, centrifugal separators) with a membrane-based separation system that operates at ambient or near-ambient conditions. The nanopore membrane acts as a selective barrier that separates components based on molecular size and shape without requiring high temperatures, pressures, or complex mechanical separation equipment
2Manufacturing precision
If conventional solvent extraction and dewaxing processes are applied to remove organic impurities, then purity of hydrocarbon stream is improved, but process complexity increases
Solution Approach 1:
The nanopore membrane provides a single-step separation mechanism that simultaneously removes multiple types of impurities (asphaltenes, metals, sulfur compounds, waxes) based on their molecular characteristics. This eliminates the need for multiple sequential processing units including solvent extraction columns, dewaxing units, and filtration systems required in conventional processes
Solution Approach 2:
The membrane selectively extracts and retains impurity molecules from the hydrocarbon feed stream based on their size and shape. The nanopores act as selective gates that allow desired hydrocarbon molecules to pass while blocking larger impurity molecules, achieving purification in a single pass through the membrane
3Manufacturing precision
If ultrafiltration with ceramic membranes is used to remove metals from heavy oil, then metal content is reduced, but inability to separate lighter hydrocarbon fractions limits effectiveness
Solution Approach 1:
The nanopore membrane features a hierarchical pore structure with sizes (1-100 nm) that can be tuned to separate molecules across a wide range of sizes. This enables simultaneous removal of metal particles, asphaltene aggregates, and wax crystals while also fractionating lighter hydrocarbons, providing both the metal removal capability of ultrafiltration and the fractionation capability of distillation in a single unit
Solution Approach 2:
The membrane system performs multiple separation functions simultaneously: it acts as a mechanical filter for solids, a molecular sieve for size-based separation, and a fractionation medium for hydrocarbon splitting. This multi-functionality replaces multiple dedicated units (metal filters, distillation columns, dewaxing units) with a single nanopore membrane system
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 process achieves significant reduction of impurities in the permeate stream while recycling enriched impurities, offering an energy-efficient and eco-friendly alternative to conventional methods by leveraging the physical and chemical properties of nanopore membranes for molecular separation.
Implementation Method 1
passing the hydrocarbon feedstock with or without separation enhancing additive/additives to produce permeate stream of lighter molecular hydrocarbon and a retentate stream of heavier molecular hydrocarbon
Implementation Method 2
process for molecular separation of hydrocarbon using nanopore membrane
Implementation Method 3
differentiated with their respective refractive indices
Data Source
AI summary
The present invention relates to the process for molecular separation of hydrocarbons using nanopore membrane comprising passing the hydrocarbon feedstock with or without separation enhancing additive/additives to produce permeate streams having different refractive indices which resonate with that of naphtha, kerosene and heavier molecules.