Tar Sands Vacuum Sealing via Magnetic Coupling
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Solution Overview
Problem
Existing systems for recovering hydrocarbons from tar sands lack effective vacuum monitoring and leak detection, leading to inefficiencies and potential gas releases.
Innovation Solution
A system with a heated enclosure, internal baffles, rotary drum, and vacuum pump maintains a selective vacuum, using input and discharge control valves with axially spaced closure gates and leak detector sensors to ensure efficient vapor collection and minimize leaks, while a processor controls auger rotation based on flow and leak data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packing is used on the end of auger tube shafts to maintain vacuum, then the system structure is simple, but the vacuum sealing reliability is insufficient leading to potential leaks
Solution Approach 1:
The patent replaces conventional mechanical packing with magnetic coupling technology. The magnetic drive system uses magnetic fields to transmit rotational force from the motor to the auger shaft without physical contact, eliminating the need for mechanical seals and packing materials. This substitution of mechanical contact with magnetic field interaction achieves reliable vacuum sealing while maintaining system functionality.
Solution Approach 2:
The patent introduces a magnetic coupling mechanism as an intermediary between the motor and the auger shaft. This magnetic coupling acts as a non-contact intermediary that transmits torque through the vacuum barrier without compromising the vacuum seal. The magnetic field serves as the mediating element that enables power transmission while maintaining vacuum integrity.
2Measurement precision
If vacuum pumps are used to maintain selected vacuum, then hydrocarbon vapors are drawn to the condenser, but there is no effective way of monitoring the vacuum within the system at potential leak sites
Solution Approach 1:
The patent incorporates vacuum gauges at multiple strategic locations throughout the system, including at potential leak sites and along the vapor flow path. These gauges provide continuous feedback on vacuum pressure levels, enabling real-time monitoring of system integrity. The feedback from these measurement points allows operators to detect vacuum breakdowns and locate leaks promptly, ensuring reliable 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 system effectively recovers hydrocarbons by maintaining a controlled vacuum, reducing leaks, and optimizing vapor flow, resulting in cleaner emissions and more efficient hydrocarbon extraction with minimal environmental impact.
Implementation Method 1
a heated enclosure having an interior chamber and a plurality of internal baffles within the heated chamber
Implementation Method 2
A heated conveyor within the flow line mechanically moves the tar sands and the residual solids along the flow line. A heated rotary drum is provided in fluid communication with the flow line for receiving the tar sands and the residual solids
Implementation Method 3
Vacuum pumps have been used in some experimental units to maintain a selected vacuum within the heated enclosure, such that hydrocarbon vapors are drawn from the heated enclosure to the condenser
Implementation Method 4
A vacuum pump maintains a selective vacuum of less than 5 inches of water between the two or more input valves and the two or more discharge valves, such that hydrocarbon vapors are drawn from the flow line and the rotary drum into the condenser
Implementation Method 5
A condenser received vapors from the heated enclosure and output liquid hydrocarbons and gas hydrocarbons
Implementation Method 6
a flow line within the heated enclosure in fluid communication with the one or more input conveyors for receiving tar sands and positioned with respect to the plurality of baffles to provide a temperature gradient along the flow line of at least 150° F., thereby producing hydrocarbon vapors and residual solids
Data Source
AI summary
A system for recovering hydrocarbons from tar sands includes a heated enclosure 66, one or more input conveyors 60, 67 move tar sands through the heated enclosure, provide a flow line with a temperature gradient of at least 150° F., and mechanically move the tar sands along the flow line. A heated rotary drum 74 is in fluid communication with the flow line, and condenser unit 94, 98 receive vapors from the flow line and the rotary drum and output hydrocarbons. One or more discharge conveyors 76 discharge stripped sands from the rotary drum. Control valves 80, 82 seal a vacuum downstream from the discharge conveyors, and control valves 34, 46 seal vacuum upstream from the one or more input conveyors. Various types of vacuum pumps may be used to maintain a selected vacuum between the control valves.