Solids Removal from Heavy Hydrocarbon Fractions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heavy hydrocarbon fractions with high particle content pose challenges in processing due to fouling and equipment degradation, leading to yield loss and reduced value of products during slurry hydrocracking, as existing methods struggle to effectively separate solids and asphaltenes from these fractions.
Innovation Solution
A method involving fractionation of heavy hydrocarbon feeds to form a bottoms fraction with high solids content, followed by mixing with a C5-C10 hydrocarbon solvent to facilitate phase separation, allowing for the recovery of hydrocarbons in a centrifugal separator, resulting in an extract phase with reduced solids content and increased hydrocarbon recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If slurry hydroprocessing is used to treat heavy feed, then coke formation on catalyst is reduced, but particle content in effluent increases
Solution Approach 1:
The patent extracts and removes particles from the slurry hydroprocessing effluent using a combination of gravity separation and filtration systems. The heavy ends fraction containing concentrated particles is separated from the lighter hydrocarbon products, effectively removing the harmful particle content while preserving the valuable liquid products.
Solution Approach 2:
The effluent is segmented into different fractions based on density and boiling point. The process divides the mixture into a light ends fraction (low particle content), a middle fraction, and a heavy ends fraction (high particle content), allowing selective handling and processing of each segment to maximize product recovery while removing particles.
2Manufacturing precision
If high severity slurry hydroprocessing is used to minimize liquid products entrained with solids, then solids separation is improved, but light ends production increases
Solution Approach 1:
The patent performs preliminary fractionation of the effluent into light ends, middle fraction, and heavy ends before the solids separation step. This preliminary action ensures that light ends are already separated and can be recovered without loss, while the subsequent solids separation focuses only on the heavy ends fraction where particles are concentrated.
Solution Approach 2:
The patent introduces an intermediary filtration system with specific mesh sizes that acts as a mediator between the high severity hydroprocessing and final product recovery. This intermediary step allows fine particle removal while permitting liquid hydrocarbons to pass through, preventing loss of light ends during solids separation.
3Quantity of substance
If conventional separation methods are used for heavy hydrocarbon fractions, then solids removal is achieved, but hydrocarbon yield is lost
Solution Approach 1:
The patent changes the physical parameters of the separation process by using controlled temperature conditions and pressure differentials during fractionation. By maintaining temperatures below the cracking point and using pressure-driven separation, the process removes particles while preventing thermal degradation and maximizing hydrocarbon recovery in the liquid phase.
Solution Approach 2:
The patent replaces conventional thermal cracking-based separation with a mechanical separation system using gravity settlers and filters. This substitution allows particle removal through physical means rather than thermal degradation, preserving hydrocarbon yield while achieving solids removal.
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 enables the recovery of 75 vol % or more of hydrocarbons from the heavy hydrocarbon fraction while achieving a solids content of 300 wppm or less, minimizing yield loss and reducing fouling, thereby enhancing the processing efficiency and product value.
Implementation Method 1
separating the extract phase from the rejected phase in a centrifugal separator
Implementation Method 2
mixing a separation solvent comprising a C5-C10 hydrocarbon with at least a portion of the bottoms fraction at a temperature of 50° C. to 150° C. to form a mixture comprising an extract phase and a rejected phase
Data Source
AI summary
Systems and methods are provided for separation of particles and/or asphaltenes from heavy hydrocarbon fractions. The heavy hydrocarbon fraction can correspond to a feed including particles or a processing effluent that includes particles. If the heavy hydrocarbon fraction is mixed with lower boiling fractions, a separation can be performed to reduce or minimize the amount of hydrocarbons that are present in the heavy hydrocarbon fraction. The heavy hydrocarbon fraction can then be mixed with a sufficient amount of a separation solvent to cause a phase separation. One phase can correspond to the separation solvent plus a portion of the hydrocarbons. The other phase can correspond to hydrocarbons rejected by the separation solvent plus the particles from the heavy hydrocarbon fraction. The phases can then be separated from each other using a solids-liquid centrifugal separator.