Thermal Soaking Apparatus for Heavy Oil Viscosity Reduction
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Solution Overview
Problem
Conventional oil processing techniques struggle to convert extra-heavy oils into pipeline-ready heavy oils without the need for diluents, as these oils are not pumpable due to high densities and viscosities, and existing methods require blending with lighter hydrocarbons to facilitate pumping.
Innovation Solution
The technology involves thermal soaking of liquid hydrocarbons in a multi-stage processing apparatus with controlled thermal environments to reduce viscosity and increase distillate yields, allowing for the direct production of pumpable heavy oils by heating the oil to specific temperatures for defined residence times, eliminating the need for diluents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If extra-heavy oils are processed using conventional techniques, then they can be transported through pipelines, but diluents must be added to reduce viscosity
Solution Approach 1:
The patent applies parameter changes by heating extra-heavy oils to high temperatures (e.g., 500-700°C) for specific residence times (e.g., 0.1-10 seconds) in a thermal processing apparatus. This thermal treatment fundamentally changes the physical and chemical parameters of the oil, reducing its viscosity and transforming heavy constituents into lighter, more pumpable components without requiring diluents.
Solution Approach 2:
The patent utilizes phase transitions through rapid heating that causes thermal cracking and vaporization of heavy oil constituents. The extreme heating causes molecular breakdown and phase changes that convert non-pumpable extra-heavy oil into pumpable heavy oil, eliminating the need for diluent addition.
2Quantity of substance
If thermal soaking is applied to increase distillate yields, then vapor emissions increase, but processing time and energy consumption increase
Solution Approach 1:
The patent employs periodic action through rapid cyclic heating and cooling in the thermal processing apparatus. The oil is quickly heated to high temperatures for a brief residence time to maximize distillate yield, then rapidly cooled to stop the reaction. This periodic thermal action achieves high distillate yields while minimizing total processing time and energy consumption.
Solution Approach 2:
The patent applies the skipping principle by rushing the thermal processing through a very short residence time (e.g., 0.1-10 seconds) at extremely high temperatures. This approach skips the prolonged heating period that would consume excessive energy and time, achieving the same distillate yield through intense, brief thermal exposure.
3Ease of operation
If thermal environments are used to reduce viscosity, then pumpability improves, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by pre-heating the extra-heavy oil to the required processing temperature before it enters the main thermal cracking zone. This preliminary thermal preparation ensures that the oil reaches optimal processing conditions quickly, reducing the total energy required for viscosity reduction compared to heating from ambient temperature in a single stage.
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 method effectively reduces the viscosity of extra-heavy oils to pipeline-ready specifications, increasing vapor yields and enabling direct pumping, thus enhancing the efficiency and economic viability of oil processing by eliminating the need for diluents.
Implementation Method 1
a liquid hydrocarbonaceous material is input to a thermal environment in which the material is heated to a specific temperature for a residence time
Implementation Method 2
heating for a residence time and at a specific temperature... to generate, though chemical reaction, an increased distillate amount
Implementation Method 3
Such may increase the amount of vapors emitted as compared with conventional processing technologies
Implementation Method 4
increase the amount of vapors emitted
Data Source
AI summary
Methods and apparatus are disclosed for possibly producing pipeline-ready heavy oil from substantially non-pumpable oil feeds. The methods and apparatus may be designed to produce such pipeline-ready heavy oils in the production field. Such methods and apparatus may involve thermal soaking of liquid hydrocarbonaceous inputs in thermal environments (2) to generate, though chemical reaction, an increased distillate amount as compared with conventional boiling technologies.