Naphthenic Acid Removal and Conversion via Sorbent Filtration
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Solution Overview
Problem
Current methods for removing naphthenic acids from wastewater streams are not cost-effective and often produce additional byproducts that pose disposal challenges, due to stringent environmental regulations and increasing naphthenic acid levels in produced water from heavy oil operations.
Innovation Solution
A system comprising a naphthenic acid filtering unit using a sorbent to remove naphthenic acids from water, followed by a conversion unit with a catalyst to convert the acids into hydrocarbons, where the sorbent is regenerated and reused, and the acids are extracted into diesel for hydrotreating to produce additional fuel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior approaches are used to remove naphthenic acids from wastewater streams, then naphthenic acids are removed from water, but additional byproducts are produced that still present disposal problems and cost-effectiveness deteriorates
Solution Approach 1:
The patent converts harmful naphthenic acids into beneficial hydrocarbons through catalytic conversion. The naphthenic acids that were previously problematic contaminants are transformed into useful fuel components, eliminating disposal issues while creating a valuable product. This resolves the contradiction by turning the harmful substance into a benefit rather than producing separate byproducts that require disposal.
Solution Approach 2:
The patent changes the chemical parameters of naphthenic acids through catalytic conversion, transforming them from oxygen-containing contaminants into hydrocarbons. By altering the chemical composition and structure through controlled reactions, the substance transitions from a harmful contaminant requiring disposal to a beneficial fuel component, thereby eliminating the byproduct waste problem.
2Reliability
If sorbent is used to filter naphthenic acids from water, then naphthenic acids are removed from water, but sorbent requires regeneration or disposal
Solution Approach 1:
The sorbent performs dual functions: first filtering naphthenic acids from water, then serving as a catalyst support for converting the captured acids into hydrocarbons. The sorbent essentially serves itself by transitioning from a filtration medium to a conversion catalyst, eliminating the need for separate regeneration systems and reducing overall device complexity.
Solution Approach 2:
The sorbent is designed to perform multiple functions within the same system. It initially acts as an adsorption medium to remove naphthenic acids from wastewater, then serves as a catalyst or catalyst support for converting the captured acids into hydrocarbons. This multi-functionality eliminates the need for separate regeneration equipment, resolving the contradiction between removal effectiveness and system complexity.
3Ease of manufacture
If conventional treatment methods are applied to wastewater containing naphthenic acids, then treatment is provided, but environmental compliance deteriorates due to stringent regulations and increasing acid levels
Solution Approach 1:
The patent transforms the harmful naphthenic acids that cause environmental compliance issues into beneficial hydrocarbons. By converting the contaminant into a useful fuel product, the process simultaneously treats the wastewater and eliminates the environmental concern, making compliance with stringent regulations achievable while maintaining ease of manufacture.
Solution Approach 2:
The patent changes the chemical parameters of naphthenic acids through catalytic conversion, transforming them from environmental contaminants into acceptable fuel components. This parameter transformation converts substances that would fail environmental regulations into products that meet or exceed fuel specifications, thereby resolving the environmental compliance issue while keeping the treatment process simple.
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 approach effectively treats wastewater by converting naphthenic acids into hydrocarbons, reducing environmental concerns and generating additional fuel without byproduct waste, thus enhancing cost-effectiveness and environmental compliance.
Implementation Method 1
filtering organic oxygen-containing molecules from water by contacting the water with a sorbent for the molecules
Implementation Method 2
extracting the molecules from the sorbent by contacting the sorbent with a liquid hydrocarbon
Implementation Method 3
converting of the molecules generates hydrocarbons
Implementation Method 4
hydrotreating the diesel containing the naphthenic acids converts the naphthenic acids into hydrocarbons that add to constituents of the diesel
Data Source
AI summary
Methods and apparatus relate to handling of organic contaminants in aqueous streams. The methods and apparatus enable removing the contaminants, such as naphthenic acids, from the aqueous streams and then converting the contaminants into hydrocarbons. The removing and converting of the organic contaminates results in treated discharge and generation of the hydrocarbons, which add to amount of hydrocarbon recovery.