Settler Vessel Design for Bitumen Froth Separation
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Solution Overview
Problem
Current settler vessel design techniques result in oversized vessels due to design factors based on settling rates and detention times, leading to increased costs and operational inefficiencies in separating bitumen froth with high water and mineral content, particularly in counter-current flow configurations.
Innovation Solution
A novel settling vessel design with a vertically downward feed inlet and a conical base, allowing the feed to dissipate momentum in the lighter phase zone, reducing the vessel diameter and height while maintaining separation performance, and incorporating a degassing pipe to manage gases and regulate pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional settler vessel design techniques are used with design factors based on settling rates and detention times, then separation performance is maintained, but vessel size becomes oversized leading to increased costs
Solution Approach 1:
The invention changes the operational parameters by operating at elevated temperatures (above the pour point of bitumen) which fundamentally alters the fluid properties and settling behavior. This temperature parameter change allows for reduced detention times and smaller vessel volumes while maintaining separation performance, directly resolving the contradiction between reliable separation and oversized vessel volume
Solution Approach 2:
The invention applies preliminary heating of the bitumen froth feed before it enters the settler vessel. This preliminary thermal action ensures the feed is already at the optimal temperature for separation, preventing asphaltene precipitation and emulsion formation that would otherwise require larger vessels and longer detention times, thus reducing vessel size while maintaining separation effectiveness
2Reliability
If conventional settler vessel design is used, then separation performance is maintained, but material and fabrication costs increase due to oversized vessels
Solution Approach 1:
By changing the temperature parameter to operate above bitumen pour point, the invention achieves more efficient separation kinetics that require smaller vessel dimensions. This directly reduces material costs (less steel required) and fabrication costs (smaller vessels are cheaper to manufacture and install), while maintaining the required separation performance through optimized thermal conditions
Solution Approach 2:
The invention effectively replaces the need for large, expensive conventional settler vessels with smaller, more economical vessels that operate under optimized thermal conditions. The smaller vessel size translates to reduced material consumption and lower fabrication costs, achieving the same separation performance through a more cost-effective means
3Productivity
If feed is discharged at high velocity into the vessel interior, then separation efficiency is improved, but momentum dissipation requirements increase vessel size
Solution Approach 1:
The invention changes the temperature parameter of the feed to above pour point conditions, which maintains bitumen in a more fluid state. This parameter change reduces the momentum dissipation distance required because the heated feed flows more readily and integrates faster with the vessel contents, allowing high separation efficiency to be achieved in a smaller vessel volume
4Reliability
If counter-current flow configuration is used, then separation performance is improved, but gas evolution and pressure management become problematic
Solution Approach 1:
By operating at temperatures above the pour point but controlled to prevent excessive gas evolution, the invention optimizes the counter-current flow configuration. The temperature parameter is set to maintain bitumen fluidity for effective separation while avoiding the gas pressure management problems that would otherwise complicate the device operation
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 design results in a smaller, cost-effective settler vessel capable of handling bitumen froth feeds with reduced material and fabrication costs while maintaining separation performance objectives, effectively managing gas evolution and ensuring stable separation processes.
Implementation Method 1
settling of the feed establishes a heavier phase zone in the vicinity of the base and a lighter phase zone above an interface with the heavier phase zone
Implementation Method 2
the feed velocity of the feed dissipates in the lighter phase zone as the discharged feed entrains lighter phase material above the interface and spreads across the vessel interior
Data Source
AI summary
A solvent diluted bitumen is produced by a method that includes adding paraffinic solvent to bitumen froth to form a solvent diluted bitumen froth, and discharging the solvent diluted bitumen froth into a vessel, such that settlement of the solvent diluted bitumen froth in the interior of the vessel establishes a heavier phase zone, a lighter phase zone, and an interface. A discharge point is located above the interface and within the lighter phase zone. Lighter phases separate up toward an overflow outlet of the vessel while heavier phases separate down toward an underflow outlet of the vessel. The solvent diluted bitumen is collected from the overflow outlet, and a solvent diluted underflow stream is collected from the underflow outlet.