Shockwave Hydrocarbon Separation from Particulates
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Solution Overview
Problem
Current methods for separating hydrocarbons from solid particles, such as bitumen from sand or rock, are inefficient and often require high energy or result in hazardous by-products, particularly in SAGD operations, where viscous oils and abrasive materials complicate the process, leading to incomplete recovery and safety concerns.
Innovation Solution
An apparatus utilizing a shockwave generator with electrical terminal pairs and a pulsed power supply to create shockwaves in a hydrocarbon-particulate-aqueous mixture, promoting separation through various physical and chemical effects, including acoustic waves, thermal changes, and chemical reactions, without the need for external heating or hazardous additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal desorption technology is used to separate oil from solid particles, then hydrocarbons can be vaporized and recovered, but high energy consumption and formation of hazardous hydrogen sulfide gas occur
Solution Approach 1:
The patent replaces the thermal field (heat-based vaporization) with a shockwave field generated by electrical discharge. The shockwaves mechanically disrupt the adhesive bonds between viscous hydrocarbons and particulates, enabling separation without thermal energy input. This substitution eliminates the energy-intensive heating process while avoiding hydrogen sulfide formation, directly resolving the contradiction between recovery effectiveness and energy consumption.
Solution Approach 2:
The patent utilizes the phase transition of water to ice during freezing, combined with shockwave application. By freezing the aqueous phase while maintaining hydrocarbon mobility, the system creates a matrix that facilitates shockwave propagation and hydrocarbon release from particulates. This phase transition approach enables effective separation at low temperatures, avoiding the high energy consumption associated with thermal desorption.
2Productivity
If high temperatures and long residence times are used in thermal treatment, then hydrocarbon vaporization is improved, but hydrogen sulfide gas is formed which is dangerous for operators
Solution Approach 1:
The patent replaces thermal vaporization with shockwave-induced mechanical separation. The shockwaves generated by electrical discharge in the frozen matrix physically detach hydrocarbons from particulate surfaces without requiring temperature elevation. This mechanical approach eliminates the chemical reactions that produce hydrogen sulfide gas, simultaneously achieving effective hydrocarbon recovery while eliminating hazardous by-product formation.
Solution Approach 2:
The patent fundamentally changes the operational parameters from high temperature/long residence time to low temperature/short duration shockwave treatment. By operating in the frozen state at ambient or sub-ambient temperatures, the system prevents the thermal conditions necessary for hydrogen sulfide generation while maintaining effective hydrocarbon separation through shockwave application, directly resolving the safety contradiction.
3Productivity
If mechanical shear heating elements are used, then hydrocarbon separation can be achieved, but abrasive sand damages the devices
Solution Approach 1:
The patent replaces mechanical shear heating elements with electrical discharge shockwave generation. The shockwaves are generated by electrical fields in the frozen matrix, eliminating direct mechanical contact between moving parts and abrasive sand. This substitution maintains effective hydrocarbon separation through shockwave propagation while eliminating the mechanical wear and damage caused by abrasive particulates, resolving the contradiction between separation capability and device durability.
4Productivity
If intensive energy addition is used for high molecular weight hydrocarbon recovery, then separation can be achieved, but the process becomes more expensive than other crude sources
Solution Approach 1:
The patent utilizes the phase transition of water to ice to create a frozen matrix that enables effective shockwave propagation. This phase transition approach allows low-energy shockwave treatment to successfully separate viscous, high molecular weight hydrocarbons from particulates. By leveraging the physical properties of frozen water rather than applying intensive thermal energy, the system achieves heavy hydrocarbon recovery at lower energy input, directly addressing the cost contradiction.
Solution Approach 2:
The patent replaces energy-intensive thermal desorption with low-energy shockwave generation through electrical discharge. The shockwaves efficiently separate heavy hydrocarbons from particulates in the frozen matrix without requiring sustained high energy input. This substitution dramatically reduces the energy consumption and associated costs of heavy hydrocarbon recovery, making the process economically competitive with conventional crude sources.
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
Effectively separates hydrocarbons from solid particles with reduced energy consumption and safer by-products, achieving high recovery rates and safe disposal of waste, as demonstrated by experiments showing over 99% removal of hydrocarbons from particulates.
Implementation Method 1
a shockwave generator configured to generate one or more shockwaves within the mixture in the container; the apparatus being configured such that the generated shockwaves promote separation of the components of the mixture
Implementation Method 2
promote separation through various physical and chemical effects, including acoustic waves
Implementation Method 3
promote separation through various physical and chemical effects, including acoustic waves, thermal changes, and chemical reactions
Data Source
AI summary
The invention relates to an apparatus and method for separating hydrocarbons from solid particles in a hydrocarbon-particulate-aqueous mixture. The apparatus comprises: a container for the mixture; a shockwave generator comprising two electrical terminals; and a pulsed power supply. The pulsed power supply is configured to apply a series of one or more voltage pulses to the terminals, such that, when each voltage pulse is applied to the terminals, a shockwave is applied to the mixture to promote separation of the components of the mixture. This may mitigate the need to heat the mixture and/or add chemicals to facilitate separation of hydrocarbons from solid particles such as sand or soil, mineral or carbonate particles.