Refinery Purge Stream Asphaltene Separation via Static Sedimentation
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Solution Overview
Problem
Current methods fail to effectively separate asphaltenes with a conversion degree higher than or equal to 90% and solids from refinery purge streams, leading to low stability and inefficient use of these streams in hydroconversion processes, resulting in yield losses and limited economic viability for metal recovery.
Innovation Solution
A method involving heating the refinery purge stream to 185-220°C and then progressively lowering the temperature to 100-150°C to induce static sedimentation, separating the stream into a dense 'cake' phase and a lighter 'clarified product' phase, allowing for the concentration of metals and solids in the cake and recycling the clarified product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current separation methods are used for refinery purge streams, then the separation process is simpler, but the conversion degree of asphaltenes remains below 90% and stability is low
Solution Approach 1:
The separation process is divided into multiple distinct stages: initial heating to 185-220°C for homogenization, followed by controlled cooling to 100-150°C for sedimentation. This segmentation allows each stage to optimize for its specific function, achieving 90%+ asphaltene conversion while maintaining operational simplicity through standardized temperature zones.
Solution Approach 2:
The method employs systematic parameter changes by controlling temperature transitions between specific ranges (185-220°C heating zone, 100-150°C sedimentation zone). These parameter changes trigger phase separation and asphaltene precipitation, achieving high conversion degrees without requiring complex equipment modifications.
2Manufacturing precision
If temperature is increased to improve asphaltene dispersion, then conversion degree increases, but energy consumption increases
Solution Approach 1:
The system performs preliminary heating to 185-220°C to fully disperse and convert asphaltenes before the separation stage. This preliminary action ensures maximum conversion is achieved in advance, allowing the subsequent cooling stage to simply precipitate already-converted asphaltenes rather than requiring continuous high-energy heating throughout the entire process.
Solution Approach 2:
The temperature profile uses periodic action with distinct heating and cooling phases. The system heats to conversion temperature, maintains it briefly for complete conversion, then cools to precipitation temperature. This periodic temperature cycling achieves high conversion degrees while minimizing energy consumption by limiting high-temperature exposure to only when necessary.
3Loss of substance
If physical separation method is applied, then yield losses are reduced and clarified product can be recycled, but the process requires precise temperature control
Solution Approach 1:
The temperature control system uses self-service principles by leveraging the natural thermodynamics of asphaltene precipitation. Once heated to the conversion zone, the system simply needs to cool to the precipitation zone, allowing the asphaltene molecules to self-organize and precipitate automatically. This reduces the need for active control mechanisms while maintaining precise separation and minimizing yield losses.
Data Source
AI summary
The present invention relates to a method for the physical separation of solids and asphaltenes with a conversion degree higher than or equal to 90%, present in refinery purge streams. Said method provides for heating a refinery purge stream to a temperature higher than or equal to 185° C. and not exceeding 220° C. and, subsequently, subjecting said heated purge to sedimentation by progressively lowering the temperature in a controlled manner to a minimum temperature of 100° C., without stirring the purge, so as to form a light phase and a heavy phase defined in relation to the density.