Supercritical CO2 Extraction for Hydrocarbon Emulsion Breaking
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Solution Overview
Problem
Conventional methods for processing hydrocarbon feedstocks are inefficient in removing impurities like asphaltenes and producing hydrogen from heavy residue, due to low hydrogen to carbon ratio and limited miscibility of steam with heavy residue, leading to high energy and catalyst consumption in refining operations.
Innovation Solution
The method involves a two-step process using supercritical carbon dioxide extraction followed by supercritical water gasification, where the heavy fraction is separated and recycled to break emulsions, reducing the need for downstream equipment and allowing for hydrogen production, and recycling water to minimize make-up water usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional methods are used to remove impurities and asphaltenes from hydrocarbon fractions, then the refining process can proceed, but energy, hydrogen, and catalyst consumption increases
Solution Approach 1:
The patent applies parameter changes by using supercritical carbon dioxide extraction instead of conventional thermal treatment. This changes the physical state and properties of the extraction medium, enabling selective removal of asphaltenes and impurities at lower temperatures, thereby reducing energy consumption while maintaining or improving removal efficiency
Solution Approach 2:
The patent utilizes phase transitions of carbon dioxide between supercritical and gaseous states to achieve impurity removal. By controlling pressure and temperature, CO2 transitions to a supercritical state for extraction, then returns to gaseous state for separation, enabling efficient impurity removal with reduced energy input compared to conventional high-temperature methods
2Quantity of substance
If heavy residue is used for hydrogen production by conventional processes, then hydrogen can be produced, but the hydrogen to carbon ratio is low and miscibility of steam and heavy residue is limited
Solution Approach 1:
The patent introduces an intermediary substance (supercritical water) to facilitate the reaction between heavy residue and water for hydrogen production. This intermediary enables better miscibility and contact between the reactants, improving the efficiency of hydrogen generation from heavy residue compared to conventional steam-based processes
Solution Approach 2:
The patent changes the physical parameters of water to a supercritical state, which fundamentally alters its properties to achieve complete miscibility with heavy residue. This parameter change enables effective hydrogen production from low-hydrogen-to-carbon ratio feedstocks that are difficult to process with conventional steam reforming
3Quantity of substance
If supercritical water gasification is used to produce hydrogen from heavy fraction, then hydrogen production is enhanced, but an emulsion comprising hydrocarbons and water is formed requiring additional downstream equipment
Solution Approach 1:
The patent merges the emulsion breaking function with the existing supercritical carbon dioxide extraction unit. The CO2 extraction system performs dual functions: extracting light hydrocarbons from the feedstock and simultaneously breaking the emulsion formed in the gasification step, thereby eliminating the need for separate emulsion breaking equipment
Solution Approach 2:
The supercritical carbon dioxide extraction unit is designed to perform multiple functions: initial light hydrocarbon extraction from the feedstock, and subsequent emulsion breaking from the gasification product. This multi-functionality reduces overall process complexity and equipment requirements while maintaining hydrogen production efficiency
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 separates light and heavy hydrocarbon fractions, reduces energy and catalyst consumption, and enhances hydrogen production efficiency by utilizing supercritical carbon dioxide to break emulsions and recycle water, thereby improving overall refining operations.
Implementation Method 1
Heavy fractions of hydrocarbon feedstocks that include impurities such as asphaltenes may be separated from light hydrocarbon fractions using supercritical carbon dioxide extraction
Implementation Method 2
The heavy fraction may then be used to produce hydrogen by a supercritical water gasification process
Implementation Method 3
Supercritical carbon dioxide may be used to break such emulsions
Data Source
AI summary
According to one or more embodiments described herein, a method for processing a hydrocarbon feedstock may include contacting the hydrocarbon feedstock and a product emulsion with supercritical carbon dioxide in a supercritical carbon dioxide extraction unit to form at least an extract emulsion and a pitch emulsion; contacting at least a portion of the pitch emulsion with supercritical water in a supercritical water gasification unit to form a gasified product; separating the gasified product into at least a product gas and the product emulsion, the product emulsion comprising water and one or more hydrocarbons; and recycling at least a portion of the product emulsion to the supercritical carbon dioxide extraction unit. Contacting the product emulsion with the supercritical carbon dioxide may break at least a portion of the product emulsion.