U.S. patent application number 12/606896 was filed with the patent office on 2011-04-28 for residuum oil supercritical extraction process.
This patent application is currently assigned to KELLOGG BROWN & ROOT LLC. Invention is credited to Raymond Floyd, Anand Subramanian.
Application Number | 20110094937 12/606896 |
Document ID | / |
Family ID | 43897487 |
Filed Date | 2011-04-28 |
United States Patent
Application |
20110094937 |
Kind Code |
A1 |
Subramanian; Anand ; et
al. |
April 28, 2011 |
Residuum Oil Supercritical Extraction Process
Abstract
Systems and methods for processing one or more hydrocarbons are
provided. A hydrocarbon can be selectively separated to provide one
or more finished products and an asphaltenic hydrocarbon using a
pretreatment process. The asphaltenic hydrocarbon can be
selectively separated to provide a deasphalted oil and one or more
asphaltenes. At least a portion of the deasphalted oil can be
converted to one or more first products using a first
post-treatment process. At least a portion of the one or more
asphaltenes can be converted to one or more second products using a
second post-treatment process.
Inventors: |
Subramanian; Anand; (Sugar
Land, TX) ; Floyd; Raymond; (Katy, TX) |
Assignee: |
KELLOGG BROWN & ROOT
LLC
Houston
TX
|
Family ID: |
43897487 |
Appl. No.: |
12/606896 |
Filed: |
October 27, 2009 |
Current U.S.
Class: |
208/40 ; 196/46;
208/39; 208/41 |
Current CPC
Class: |
C10G 21/003
20130101 |
Class at
Publication: |
208/40 ; 208/39;
208/41; 196/46 |
International
Class: |
C10C 3/00 20060101
C10C003/00; C10C 3/02 20060101 C10C003/02; C10C 3/06 20060101
C10C003/06 |
Claims
1) A method for processing one or more hydrocarbons comprising,
selectively separating a hydrocarbon to provide one or more
finished products and an asphaltenic hydrocarbon using a
pretreatment process, selectively separating the asphaltenic
hydrocarbons to provide a deasphalted oil and one or more
asphaltenes, converting at least a portion of the deasphalted oil
to one or more first products using a first post-treatment process,
and converting at least a portion of the one or more asphaltenes to
one or more second products using a second post-treatment
process.
2) The method of claim 1 wherein the pretreatment process is
selected from the group consisting of petroleum residue
desulfurization units, vacuum distillation units, residuum
conversion units, hydrocarbon sludge removal units, atmospheric
distillation units, gravimetric hydrocarbon/water separation units,
thermal cracking units, tar sand treatment units,
hydrocarbon/solids separation units, hydrocarbon demetallizing
units, bitumen froth separation units, hydrocarbon emissions
reduction treatment units, vacuum distillation units, fractional
distillation units, asphaltenic dispersion units, gas plant
dilution units, visbreaking units, hydrocracking units, vaporizer
units, solvent dewatering units, and flash separation units.
3) The method of claim 1 wherein the first post-treatment process
is selected from the group consisting of steam generation units,
gasification units, fractionation units, hydrotreatment units,
thermal cracking units, visbreaking units, desulfurization units,
hydrodesulfurization units, catalytic cracking units, and fluidized
catalytic cracking units.
4) The method of claim 1 wherein the second post-treatment process
is selected from the group consisting of steam generation units,
pelletization units, hydrocarbon-based catalyst production units,
asphalt building product production units, gasification units,
olefinic hydrocarbon production units, catalytic cracking units,
and fluidized catalytic cracking units.
5) The method of claim 1 wherein the first post-treatment process
comprises a steam generation unit providing steam, and wherein at
least a portion of the steam is used to stimulate extraction of
additional hydrocarbons via steam assisted gravity drainage.
6) The method of claim 1 wherein the second post-treatment process
comprises a steam generation unit providing steam, and wherein at
least a portion of the steam is used to stimulate extraction of
additional hydrocarbons via steam assisted gravity drainage.
7) The method of claim 1 wherein the pretreatment process comprises
a solvent dewatering unit and wherein the addition of solvent in
the solvent dewatering unit satisfies at least a portion of the
solvent requirements within the solvent deasphalting process.
8) The method of claim 1 wherein the selective separation of the
asphaltenic hydrocarbons to provide the deasphalted oil and the one
or more asphaltenes comprises a solvent deasphalting system
operated at or above supercritical temperature or pressure
conditions based upon the solvent.
9) The method of claim 1 wherein the selective separation of the
asphaltenic hydrocarbons to provide the deasphalted oil and the one
or more asphaltenes comprises a solvent deasphalting system
operated below supercritical temperature and pressure conditions
based upon the solvent.
10) A method for processing one or more hydrocarbons comprising:
selectively separating a hydrocarbon to provide one or more
finished products and an asphaltenic hydrocarbon using a
pretreatment process, selectively separating the asphaltenic
hydrocarbons to provide a light deasphalted oil, a heavy
deasphalted oil and one or more asphaltenes, converting at least a
portion of the light deasphalted oil to one or more products using
a first post-treatment process, converting at least a portion of
the heavy deasphalted oil to one or more products using a second
post-treatment process, and converting at least a portion of the
one or more asphaltenes to one or more products using a third
post-treatment process.
11) The method of claim 10 wherein the pretreatment process is
selected from the group consisting of petroleum residue
desulfurization units, vacuum distillation units, residuum
conversion units, hydrocarbon sludge removal units, atmospheric
distillation units, gravimetric hydrocarbon/water separation units,
thermal cracking units, tar sand treatment units,
hydrocarbon/solids separation units, hydrocarbon demetallizing
units, bitumen froth separation units, hydrocarbon emissions
reduction treatment units, vacuum distillation units, fractional
distillation units, asphaltenic dispersion units, gas plant
dilution units, visbreaking units, hydrocracking units, vaporizer
units, solvent dewatering units, and flash separation units.
12) The method of claim 10 wherein the first post-treatment process
is selected from the group consisting of steam generation units,
gasification units, fractionation units, hydrotreatment units,
thermal cracking units, visbreaking units, desulfurization units,
hydrodesulfurization units, catalytic cracking units, and fluidized
catalytic cracking units.
13) The method of claim 10 wherein the second post-treatment
process is selected from the group consisting of steam generation
units, pelletization units, hydrocarbon-based catalyst production
units, asphalt building product production units, gasification
units, olefinic hydrocarbon production units, catalytic cracking
units, and fluidized catalytic cracking units.
14) The method of claim 10 wherein the first post-treatment process
comprises a steam generation unit providing steam, and wherein at
least a portion of the steam is used to stimulate extraction of
additional hydrocarbons via steam assisted gravity drainage.
15) The method of claim 10 wherein the second post-treatment
process comprises a steam generation unit providing steam, and
wherein at least a portion of the steam is used to stimulate
extraction of additional hydrocarbons via steam assisted gravity
drainage.
16) The method of claim 10 wherein the pretreatment process
comprises a solvent dewatering unit and wherein the addition of
solvent in the solvent dewatering unit satisfies at least a portion
of the solvent requirements within the solvent deasphalting
process.
17) The method of claim 10 wherein the pretreatment process
comprises a solvent dewatering unit and wherein the addition of
solvent in the solvent dewatering unit satisfies at least a portion
of the solvent requirements within the solvent deasphalting
process.
18) The method of claim 10 wherein the selective separation of the
asphaltenic hydrocarbons to provide the deasphalted oil and the one
or more asphaltenes comprises a solvent deasphalting system
operated at or above supercritical temperature or pressure
conditions based upon the solvent.
19) The method of claim 10 wherein the selective separation of the
asphaltenic hydrocarbons to provide the deasphalted oil and the one
or more asphaltenes comprises a solvent deasphalting system
operated below supercritical temperature and pressure conditions
based upon the solvent.
20) A system for processing one or more hydrocarbons comprising:
means for selectively separating a hydrocarbon to provide one or
more finished products and an asphaltenic hydrocarbon using a
pretreatment process, means for selectively separating the
asphaltenic hydrocarbons to provide a deasphalted oil and one or
more asphaltenes, means for converting at least a portion of the
deasphalted oil to one or more first products using a first
post-treatment process, and means for converting at least a portion
of the one or more asphaltenes to one or more second products using
a second post-treatment process.
Description
BACKGROUND
[0001] 1. Field
[0002] Embodiments of the present invention generally relate to
extraction processes for processing hydrocarbons. More
particularly, embodiments of the present invention relate to
processes for upgrading one or more hydrocarbons using a solvent
de-asphalting unit.
[0003] 2. Description of the Related Art
[0004] Solvent de-asphalting ("SDA") processes have been used to
treat residuum ("residual") oil. Traditional refinery distillation
processes separate light hydrocarbon compounds from feedstocks,
leaving a large volume of residual oil that is primarily heavy
hydrocarbons. SDA processes have been used to treat the heavy
hydrocarbons with a solvent to generate asphaltenic and
de-asphalted oil ("DAO") products. The asphaltenic and DAO products
are typically treated and/or processed into useful products.
[0005] DAO can be economically attractive when downstream treatment
facilities such as hydrotreating or fluid catalytic cracking
("FCC") are adequately sized to process the large volume of DAO
generated when treating residuum. However, hydrocracking the DAO
requires a capital intensive, high-pressure, system to fractionate
the large quantity of DAO, especially when intermediate products
such as diesel, gas oil, and/or kerosene are preferred.
[0006] A need, therefore, exists for an improved process for
upgrading residuum hydrocarbons while minimizing capital
investment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] So that the manner in which the above recited features of
the present invention can be understood in detail, a more
particular description of the invention, briefly summarized above,
may be had by reference to embodiments, some of which are
illustrated in the appended drawings. It is to be noted, however,
that the appended drawings illustrate only typical embodiments of
this invention and are therefore not to be considered limiting of
its scope, for the invention may admit to other equally effective
embodiments.
[0008] FIG. 1 depicts an illustrative two-stage solvent extraction
system according to one or more embodiments described.
[0009] FIG. 2 depicts an illustrative three-stage separator/solvent
extraction system according to one or more embodiments
described.
[0010] FIG. 3 depicts an illustrative solvent dewatering system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0011] FIG. 4 depicts an illustrative flash evaporation system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0012] FIG. 5 depicts an illustrative distillation system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0013] FIG. 6 depicts an illustrative hydrotreating system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0014] FIG. 7 depicts an illustrative integrated vacuum separation
and hydrogenation system integrated with one or more
separator/solvent extraction systems, according to one or more
embodiments described.
[0015] FIG. 8 depicts an illustrative integrated gasification and
separation system integrated with one or more separator/solvent
extraction systems, according to one or more embodiments
described.
[0016] FIG. 9 depicts an illustrative tank cleaning and separation
system integrated with one or more separator/solvent extraction
systems, according to one or more embodiments described.
[0017] FIG. 10 depicts an illustrative distillation based
fractionation system integrated with one or more separator/solvent
extraction systems, according to one or more embodiments
described.
[0018] FIG. 11 depicts an illustrative hydrogenation system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0019] FIG. 12 depicts an illustrative thermal treatment system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0020] FIG. 13 depicts an illustrative extraction system integrated
with one or more separator/solvent extraction systems, according to
one or more embodiments described.
[0021] FIG. 14 depicts an illustrative solids removal system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0022] FIG. 15 depicts an illustrative demetallization system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0023] FIG. 16 depicts an illustrative solids separation and
hydrocarbon recovery system integrated with one or more
separator/solvent extraction systems, according to one or more
embodiments described.
[0024] FIG. 17 depicts an illustrative emissions reduction system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0025] FIG. 18 depicts another illustrative distillation system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0026] FIG. 19 depicts an illustrative asphaltene blending system
integrated with one or more separator/solvent extraction systems,
according to one or more embodiments described.
[0027] FIG. 20 depicts an illustrative fractionating and
hydrorefining system integrated with one or more separator/solvent
extraction systems, according to one or more embodiments
described.
DETAILED DESCRIPTION
[0028] A detailed description will now be provided. Each of the
appended claims defines a separate invention, which for
infringement purposes is recognized as including equivalents to the
various elements or limitations specified in the claims. Depending
on the context, all references below to the "invention" may in some
cases refer to certain specific embodiments only. In other cases it
will be recognized that references to the "invention" will refer to
subject matter recited in one or more, but not necessarily all, of
the claims. Each of the inventions will now be described in greater
detail below, including specific embodiments, versions and
examples, but the inventions are not limited to these embodiments,
versions or examples, which are included to enable a person having
ordinary skill in the art to make and use the inventions, when the
information in this patent is combined with available information
and technology.
[0029] Systems and methods for processing one or more hydrocarbons
are provided. A hydrocarbon can be selectively separated to provide
one or more finished products and an asphaltenic hydrocarbon using
a pretreatment process. The asphaltenic hydrocarbon can be
selectively separated to provide a deasphalted oil and one or more
asphaltenes. At least a portion of the deasphalted oil can be
converted to one or more first products using a first
post-treatment process. At least a portion of the one or more
asphaltenes can be converted to one or more second products using a
second post-treatment process.
[0030] As used herein, the terms "solvent" and "solvents" can refer
to one or more alkane or alkene hydrocarbons having three to seven
carbon atoms (C.sub.3 to C.sub.7), mixtures thereof, derivatives
thereof and combinations thereof. In one or more embodiments, the
solvent can have a normal boiling point (for pure solvents) or bulk
normal boiling point (for solvent mixtures) of less than
538.degree. C.
[0031] As used herein, the terms "asphaltene," "asphaltenes,"
"asphaltenic hydrocarbon," and "asphaltenic hydrocarbons" can refer
to one or more hydrocarbons that are insoluble in n-alkanes but are
totally or partially soluble in aromatics such as benzene and/or
toluene. Asphaltenes can consist primarily of carbon, hydrogen,
nitrogen, oxygen, and sulfur, as well as trace amounts of vanadium
and nickel. Asphaltenes can have a carbon-to-hydrogen ("C:H") ratio
of about 1:2, about 1:1.5, about 1:1.2, or about 1:1. In one or
more embodiments, asphaltenes can be an n-heptane (C.sub.7H.sub.16)
insoluble and toluene (C.sub.6H.sub.5CH.sub.3) soluble component of
a carbonaceous material such as crude oil, bitumen or coal. In one
or more embodiments, asphaltenes can have a molecular mass
distribution in the range of from about 400 u to about 1500 u.
[0032] The terms "light deasphalted oil" and "L-DAO" as used herein
can refer to a solution or mixture containing one or more
hydrocarbons sharing similar physical properties and containing
less than about 5% wt, less than about 4% wt, less than about 3%
wt, less than about 2% wt, or less than about 1% asphaltenic
hydrocarbons. In one or more embodiments, the L-DAO can have a
boiling point ranging from a low of about 250.degree. C., about
275.degree. C., or about 315.degree. C. to a high of about
600.degree. C., about 675.degree. C., about 750.degree. C., or
more. In one or more embodiments, the L-DAO can have a viscosity
(at 50.degree. C.) of about 30 cSt to about 75 cSt, about 35 cSt to
about 70 cSt, or about 40 cSt to about 65 cSt. In one or more
embodiments, the L-DAO can have a flash point greater than about
110.degree. C., greater than about 115.degree. C., greater than
about 120.degree. C., greater than about 130.degree. C., or
more.
[0033] The terms "heavy deasphalted oil" and "H-DAO" as used herein
can refer to a solution or mixture containing one or more
hydrocarbons sharing similar physical properties and containing
less than about 5% wt, less than about 4% wt, less than about 3%
wt, less than about 2% wt, or less than about 1% asphaltenic
hydrocarbons. In one or more embodiments, the H-DAO can have a
boiling point of about 300.degree. C. to about 900.degree. C.,
about 350.degree. C. to about 850.degree. C., or about 400.degree.
C. to about 800.degree. C. In one or more embodiments, the H-DAO
can have a viscosity (at 50.degree. C.) of about 40 cSt to about
190 cSt, about 45 cSt to about 180 cSt, or about 50 cSt to about
170 cSt. In one or more embodiments, the H-DAO can have a flash
point greater than about 135.degree. C., greater than about
140.degree. C., greater than about 145.degree. C., greater than
about 150.degree. C., or more.
[0034] The terms "deasphalted oil" and "DAO" as used herein refer
to a mixture of light deasphalted and heavy deasphalted oils.
[0035] FIG. 1 depicts an illustrative two-stage solvent extraction
system 100 according to one or more embodiments. The two-stage
solvent extraction system 100 can include one or more mixers 110,
separators 120, 150, and strippers 130, 160. Any number of mixers,
separators, and strippers can be used depending on the amount of
the hydrocarbon to be processed. In one or more embodiments, a
hydrocarbon via line 105 and a solvent via line 177 can be mixed or
otherwise combined within the one or more mixers 110 to provide a
hydrocarbon mixture via line 112. The solvent-to-hydrocarbon weight
ratio can vary depending upon the physical properties and/or
composition of the hydrocarbon. For example, a high boiling point
hydrocarbon can require greater dilution with low boiling point
solvent to obtain the desired bulk boiling point for the resultant
mixture. The hydrocarbon mixture in line 112 can have a
solvent-to-hydrocarbon dilution ratio of about 1:1 to about 100:1,
about 2:1 to about 10:1, or about 3:1 to about 6:1.
[0036] In one or more embodiments, the hydrocarbon in line 105 can
include, but is not limited to, one or more carbon-containing
materials whether solid, liquid, gas, or any combination thereof.
The carbon-containing materials can include but are not limited to,
whole crude oil, crude oil, vacuum gas oil, heavy gas oil,
residuum, atmospheric tower bottoms, vacuum tower bottoms,
distillates, paraffins, aromatic rich material from solvent
deasphalting units, aromatic hydrocarbons, naphthenes, oil shales,
oil sands, tars, bitumens, kerogen, waste oils, derivatives
thereof, or mixtures thereof. In one or more embodiments, the
hydrocarbon in line 105 can have an API Gravity at 15.6.degree. C.
ranging from a low of about -12, about 0, about 5, or about 10 to a
high of about 20, about 25, about 30, or about 35. In one or more
embodiments, the hydrocarbon in line 105 can have an API Gravity at
15.6.degree. C. of from about -12 to about 20, or from about 5 to
about 23, or from about 10 to about 30. In one or more embodiments,
the paraffin content of the hydrocarbon in line 105 can range from
a low of about 30% vol, about 35% vol, or about 40% vol to a high
of about 55% vol, about 60% vol, or about 65% vol. In one or more
embodiments, the aromatic hydrocarbon content of the hydrocarbon in
line 105 can range from a low of about 2% vol, about 7% vol, or
about 12% vol to a high of about 20% vol, about 50% vol, or about
80% vol. In one or more embodiments, the naphthene content of the
hydrocarbon in line 105 can range from a low of about 0% vol, about
10% vol, or about 20% vol to a high of about 25% vol, about 30%
vol, or about 35% vol. In one or more embodiments, the hydrocarbon
in line 105 can have a C:H ratio of from about 0.8:1, about 1:1,
about 1:1.1, about 1:1.2, about 1:1.3, or about 1:1.4.
[0037] The one or more mixers 110 can be one or more system,
device, or combination of systems and/or devices suitable for
batch, intermittent, and/or continuous mixing of the hydrocarbon
and the solvent. The mixer 110 can be capable of homogenizing
immiscible fluids. Illustrative mixers can include but are not
limited to ejectors, inline static mixers, inline mechanical/power
mixers, homogenizers, or combinations thereof. The mixer 110 can
operate at temperatures of about 25.degree. C. to about 600.degree.
C., about 25.degree. C. to about 500.degree. C., or about
25.degree. C. to about 300.degree. C. The mixer 110 can operate at
a pressure slightly higher than the pressure of the separator 120.
In one or more embodiments, the mixer can operate at a pressure of
about 101 kPa to about 2,100 kPa above the critical pressure of the
solvent ("P.sub.C,S"), about P.sub.C,S-700 kPa to about
P.sub.C,S+2,100 kPa, about P.sub.C,S-500 kPa to about
P.sub.C,S+1,500 kPa, about P.sub.C,S-300 kPa to about P.sub.C,S+700
kPa.
[0038] The hydrocarbon mixture in line 112 can be introduced to the
one or more separators ("asphaltene separators") 120 to provide a
deasphalted oil ("DAO") mixture via line 122 and an asphaltenic
mixture via line 128. The DAO mixture in line 122 can contain
deasphalted oil and a first portion of the solvent. The asphaltenic
mixture in line 128 can contain insoluble asphaltenes and the
balance of the solvent. In one or more embodiments, the DAO
concentration in line 122 can range from about 1% wt to about 50%
wt, about 5% wt to about 40% wt, or about 14% wt to about 34% wt.
In one or more embodiments, the solvent concentration in line 122
can range from about 50% wt to about 99% wt, about 60% wt to about
95% wt, or about 66% wt to about 86% wt. In one or more
embodiments, the specific gravity (API density@15.6.degree. C.) of
the DAO mixture in line 122 can range from about 10.degree. API to
about 100.degree. API, about 30.degree. API to about 100.degree.
API, or about 50.degree. API to about 100.degree. API.
[0039] In one or more embodiments, the asphaltenic mixture in line
128 can have an asphaltene concentration of from about 10% wt to
about 99% wt, about 30% wt to about 95% wt, or about 50% wt to
about 90% wt. In one or more embodiments, the asphaltenic mixture
in line 128 can have a solvent concentration of from about 1% wt to
about 90% wt, about 5% wt to about 70% wt, or about 10% wt to about
50% wt.
[0040] The one or more separators 120 can include one or more
systems, devices, or combination of systems and/or devices suitable
for separating one or more asphaltenes from the hydrocarbon and
solvent mixture to provide deasphalted oil via line 122 and
asphaltenes via line 128. In one or more embodiments, the one or
more separators 120 can contain one or more internal structures
including, but not limited to bubble trays, packing elements such
as rings or saddles, structured packing, or combinations thereof.
In one or more embodiments, the one or more separators 120 can be
an open column without internals. In one or more embodiments, the
one or more separators 120 can be one or more partially empty
columns containing one or more internal structures. In one or more
embodiments, the separators 120 can operate at a temperature of
about 15.degree. C. to about 150.degree. C. above the critical
temperature of the one or more solvent ("T.sub.C,S"), about
15.degree. C. to about T.sub.C,S+100.degree. C., or about
15.degree. C. to about T.sub.C,S+50.degree. C. In one or more
embodiments, the separators 120 can operate at a pressure of about
101 kPa to about 2,100 kPa above the critical pressure of the
solvent ("P.sub.C,S"), about P.sub.C,S-700 kPa to about
P.sub.C,S+2,100 kPa, about P.sub.C,S-500 kPa to about
P.sub.C,S+1,500 kPa, about P.sub.C,S-300 kPa to about P.sub.C,S+700
kPa.
[0041] In one or more embodiments, the asphaltenes in line 128 can
be heated using one or more heat exchangers 115, prior to
introduction to the one or more strippers 130. In one or more
embodiments, the asphaltenes in line 128 can be heated to a
temperature of about 100.degree. C. to about T.sub.C,S+150.degree.
C., about 150.degree. C. to about T.sub.C,S+100.degree. C., or
about 300.degree. C. to about T.sub.C,S+50.degree. C. using one or
more heat exchangers 115.
[0042] The one or more heat exchangers 115 can include one or more
systems, devices, or combination of systems and/or devices suitable
for increasing the temperature of the asphaltenes in line 128.
Illustrative heat exchanger systems or devices can include, but are
not limited to shell-and-tube exchangers, plate and frame
exchangers, spiral wound exchangers, or any combination thereof. In
one or more embodiments, a heat transfer medium such as steam, hot
oil, hot process fluids, electric resistance heat, hot waste
fluids, or combinations thereof can be used to transfer heat to the
asphaltenes in line 128. In one or more embodiments, the one or
more heat exchangers 115 can be a direct fired heater or the
equivalent. In one or more embodiments, the one or more heat
exchangers 115 can operate at a temperature of about 25.degree. C.
to about T.sub.C,S+150.degree. C., about 25.degree. C. to about
T.sub.C,S+100.degree. C., or about 25.degree. C. to about
T.sub.C,S+50.degree. C. In one or more embodiments, the one or more
heat exchangers 115 can operate at a pressure of about 101 kPa to
about P.sub.C,S+2,100 kPa, about 101 kPa to about P.sub.C,S+1,500
kPa, or about 101 kPa to about P.sub.C,S+700 kPa.
[0043] Within the stripper 130, the solvent in the asphaltenes in
line 128 can be selectively separated to provide a recovered
solvent via line 132 and asphaltenes ("asphaltene product") via
line 133. In one or more embodiments, the recovered solvent in line
132 can contain a first portion of the solvent and small quantities
of residual DAO, and the asphaltenes in line 133 can contain a
mixture of insoluble asphaltenes and the balance of the solvent. In
one or more embodiments, the recovered solvent in line 132 can have
a solvent concentration ranging from a low of about 50% wt, about
70% wt, or about 80% wt to a high of about 90% wt, about 95% wt,
about 99% wt, or more. In one or more embodiments, the recovered
solvent in line 132 can contain less about 5% wt, less than about
3% wt, less than about 1% wt, or less than about 0.5% wt DAO. In
one or more embodiments, the asphaltene product in line 133 can
have an asphaltene concentration ranging from a low of about 20%
wt, about 40% wt, or about 50% wt to a high of about 75% wt, about
80% wt, about 95% wt, or more.
[0044] In one or more embodiments, steam, for example saturated or
superheated, can be injected into the one or more strippers 130 via
line 134 to further enhance the separation of the asphaltenes from
the solvent. In one or more embodiments, the steam in introduced to
the one or more strippers 130 via line 134 can be at a pressure
ranging from about 200 kPa to about 2,160 kPa, from about 300 kPa
to about 1,475 kPa, or from about 400 kPa to about 1,130 kPa.
[0045] In one or more embodiments, the asphaltene product in line
133 can have a solvent concentration ranging from a low of about 1%
wt, about 5% wt, about 10% wt, or about 20% wt to a high of about
50% wt, about 60% wt, about 70% wt, or about 80% wt. In one or more
embodiments, the specific gravity (at 15.6.degree. C.) of the
asphaltene product in line 133 can range from a low of about
-15.degree. API, about -10.degree., or about -5.degree. to a high
of about 5.degree., about 10.degree., or about 15.degree. or more.
In one or more embodiments, at least a portion of the asphaltene
product in line 133 can be dried and pelletized. In one or more
embodiments, at least a portion of the asphaltene product in line
133 can be gasified to provide one or more gas products for power
generation, process heating, or combinations thereof. In one or
more embodiments, at least a portion of the asphaltene product in
line 133 can be combusted or otherwise converted to provide steam,
mechanical power, electrical power, or any combination thereof.
[0046] The one or more strippers 130 can include one or more
systems, devices, or combination of systems and/or devices suitable
for selectively separating the asphaltenes in line 128 to provide
the recovered solvent via line 132 and the asphaltene product via
line 133. In one or more embodiments, the one or more strippers 130
can contain one or more internal structures including, but not
limited to bubble trays, packing elements such as rings or saddles,
structured packing, or combinations thereof. In one or more
embodiments, the one or more strippers 130 can be an open column
without internals. In one or more embodiments, the one or more
strippers 130 can be one or more partially empty columns containing
one or more internal structures. In one or more embodiments, the
one or more strippers 130 can operate at a temperature of about
30.degree. C. to about 600.degree. C., about 100.degree. C. to
about 550.degree. C., or about 300.degree. C. to about 550.degree.
C. In one or more embodiments, the one or more strippers 130 can
operate close to zero pressure, for example at about 0.1 kPa. In
one or more embodiments, the one or more strippers 130 can operate
at a pressure ranging from a low of about 30 kPa, about 100 kPa,
about 500 kPa, or about 1,000 kPa to a high of about 2,500 kPa,
about 3,300 kPa, about 4,000 kPa, or about 4,500 kPa.
[0047] Referring again to the one or more asphaltene strippers 120,
the DAO mixture in line 122 can be heated using one or more heat
exchangers 145, 148 to provide a heated DAO mixture via line 124.
In one or more embodiments, the temperature of the heated DAO
mixture in line 124 can be increased above the critical temperature
of the solvent T.sub.C,S. In one or more embodiments, the heated
DAO mixture in line 124 can have a temperature of from about
25.degree. C. to about T.sub.C,S+150.degree. C., about
T.sub.C,S-100.degree. C. to about T.sub.C,S+100.degree. C., or
about T.sub.C,S-50.degree. C. to about T.sub.C,S+50.degree. C.
[0048] The one or more heat exchangers 145, 148 can include one or
more systems, devices, or combination of systems and/or devices
suitable for increasing the temperature of the DAO mixture in line
122. In one or more embodiments, the heat exchanger 145 can be a
regenerative type heat exchanger using a high temperature process
stream to heat the DAO mixture in line 122 prior to introduction to
the separator 150. In one or more embodiments, a recovered solvent
via line 152 can be introduced to the heat exchanger 145 to heat
the DAO mixture introduced via line 122. In one or more
embodiments, the one or more heat exchangers 145, 148 can operate
at a pressure of about 101 kPa to about P.sub.C,S+2,100 kPa, about
101 kPa to about P.sub.C,S+1,500 kPa, or about 101 kPa to about
P.sub.C,S+700 kPa.
[0049] The heated DAO mixture via line 124 can be introduced to the
one or more separators 150 and selectively separated therein to
provide a recovered solvent via line 152 and DAO via line 158. In
one or more embodiments, the recovered solvent in line 152 can
contain a first portion of the solvent, and the deasphalted oil in
line 158 can contain DAO and the balance of the solvent. In one or
more embodiments, the recovered solvent in line 152 can have a
solvent concentration ranging from a low of about 50% wt, about 70%
wt, or about 85% wt to a high of about 95% wt, about 98%, about
99%, or more, with the balance being DAO. In one or more
embodiments, in the deasphalted oil in line 158 can have a DAO
concentration ranging from a low of about 20% wt, 40% wt, or about
50% wt to a high of about 80% wt, 90% wt, about 95% wt, or more,
with the balance being the solvent. In one or more embodiments, the
deasphalted oil in line 158 can have a specific gravity (API
density at 15.6.degree. C.) ranging from a low of about 5.degree.,
about 10.degree., or about 12.degree. to a high of about
20.degree., about 25.degree., about 30.degree., or more.
[0050] The one or more separators 150 can include one or more
systems, devices, or combination of systems and/or devices suitable
for separating the DAO mixture introduced via line 122 to provide a
the recovered solvent in line 152 and the DAO in line 158. In one
or more embodiments, the one or more separators 150 can contain one
or more internal structures including, but not limited to bubble
trays, packing elements such as rings or saddles, structured
packing, or combinations thereof. In one or more embodiments, the
one or more separators 150 can be an open column without internals.
In one or more embodiments, the one or more separators 150 can be
one or more partially empty columns containing one or more internal
structures. In one or more embodiments, the one or more separators
150 can operate at a temperature of about 15.degree. C. to about
600.degree. C., about 15.degree. C. to about 500.degree. C., or
about 15.degree. C. to about 400.degree. C. In one or more
embodiments, the one or more separators 150 can operate at a
pressure of about P.sub.C,S-700 kPa to about P.sub.C,S+2,100 kPa,
about P.sub.C,S-500 kPa to about P.sub.C,S+1,500 kPa, or about
P.sub.C,S-300 kPa to about P.sub.C,S+700 kPa.
[0051] In one or more embodiments, at least a portion of the DAO in
line 158 can be directed to the one or more strippers 160 and
selectively separated therein to provide a recovered solvent via
line 162 and DAO ("DAO product") via line 163. In one or more
embodiments, the recovered solvent in line 162 can contain a first
portion of the solvent, and the DAO product in line 163 can contain
DAO and the balance of the solvent. In one or more embodiments, the
recovered solvent in line 162 can have a solvent concentration of
from about 70% wt to about 100% wt, about 85% wt to about 99.9% wt,
or about 90% wt to about 99.9% wt or more, with the DAO providing
the balance. In one or more embodiments, the DAO product in line
163 can have a DAO concentration of from about 20% wt to about 100%
wt, about 40% wt to about 97% wt, or about 50% wt to about 95% wt,
with the solvent providing the balance. In one or more embodiments,
the specific gravity (API density at 15.6.degree. C.) of the DAO
product in line 163 can range from about 5.degree. API to about
30.degree. API, about 5.degree. API to about 20.degree. API, or
about 5.degree. API to about 15.degree. API.
[0052] In one or more embodiments, steam, for example saturated or
superheated, can be introduced via line 164 to the stripper 160 to
further enhance the separation of the DAO from the solvent. In one
or more embodiments, the steam in line 164 can be at a pressure
ranging from about 200 kPa to about 2,160 kPa, from about 300 kPa
to about 1,475 kPa, or from about 400 kPa to about 1,130 kPa.
[0053] The one or more strippers 160 can include one or more
systems, devices, or combination of systems and/or devices suitable
for separating DAO mixture in line 158 to provide the recovered
solvent via line 162 and the DAO product via line 163. In one or
more embodiments, the one or more strippers 160 can contain one or
more internal structures including, but not limited to bubble
trays, packing elements such as rings or saddles, structured
packing, or combinations thereof. In one or more embodiments, the
one or more strippers 160 can be an open column without internals.
In one or more embodiments, the one or more strippers 160 can be
one or more partially empty columns containing one or more internal
structures. In one or more embodiments, the one or more strippers
160 can operate at a temperature of about 15.degree. C. to about
600.degree. C., about 15.degree. C. to about 500.degree. C., or
about 15.degree. C. to about 400.degree. C. In one or more
embodiments, the pressure in the one or more strippers 160 can
operate close to zero pressure, for example at about 0.1 kPa. In
one or more embodiments, the one or more strippers 160 can operate
at a pressure ranging from a low of about 30 kPa, about 100 kPa,
about 500 kPa, or about 1,000 kPa to a high of about 2,500 kPa,
about 3,300 kPa, about 4,000 kPa, or about 4,500 kPa.
[0054] In one or more embodiments, at least a portion of the
recovered solvent in lines 132 and 162 can be combined to provide a
recycled solvent via line 138. Although not shown, at least a
portion of the recovered solvent in line 152 can be combined with
at least a portion of the recovered solvent in line 132 and/or at
least a portion of the recovered solvent in line 162 to provide the
recycled solvent in line 138. In one or more embodiments, the
recycled solvent in line 138 can be a two phase mixture containing
both liquid and vapor. In one or more embodiments, the temperature
of the recycled solvent in line 138 can range from about 30.degree.
C. to about 600.degree. C., about 100.degree. C. to about
550.degree. C., or about 300.degree. C. to about 500.degree. C.
[0055] In one or more embodiments, the recycled solvent in line 138
can be condensed using the one or more condensers 135, to provide a
condensed solvent in line 139. In one or more embodiments, the
cooled solvent in line 139 can have a temperature ranging from a
low of about 10.degree. C., about 20.degree. C., or about
30.degree. C. to a high of about 100.degree. C., about 200.degree.
C., about 400.degree. C., or more. The solvent concentration in
line 139 can range from a low of about 80% wt, about 85% wt, or
about 90% wt to a high of about 95% wt, about 98% wt, about 99% wt,
or more.
[0056] The one or more condensers 135 can include one or more
systems, devices, or combination of systems and/or devices suitable
for decreasing the temperature of the recycled solvent in line 138
to provide a condensed solvent via line 139. In one or more
embodiments, the condenser 135 can include, but is not limited to
liquid or air cooled shell-and-tube, plate and frame, fin-fan,
and/or spiral wound cooler designs. In one or more embodiments, a
cooling medium such as water, refrigerant, air, or combinations
thereof can be used to remove the necessary heat from the recycled
solvent in line 138. In one or more embodiments, the one or more
condensers 135 can operate at a temperature of about -20.degree. C.
to about T.sub.C,S.degree. C., about -10.degree. C. to about
300.degree. C., or about 0.degree. C. to about 300.degree. C. In
one or more embodiments, the one or more condensers 135 can operate
close to zero pressure, for example at about 0.1 kPa. In one or
more embodiments, the one or more condensers 135 can operate at a
pressure of about 30 kPa to about P.sub.C,S+700 kPa, or about 100
kPa to about P.sub.C,S+500 kPa, or about 100 kPa to about
P.sub.C,S+300 kPa.
[0057] In one or more embodiments, at least a portion of the
condensed solvent in line 139 can be stored in the one or more
reservoirs 140. At least a portion of the solvent in the one or
more reservoirs 140 can be recycled via line 186 using one or more
pumps 192. The recycled solvent in line 186 can be combined with at
least a portion of the recovered solvent in line 152 to provide a
solvent recycle via line 177. A first portion of the solvent
recycle in line 177 can be recycled to the mixer 110 in the
two-stage solvent extraction system 100.
[0058] A second portion of the solvent in line 177 can be recycled
via line 178 to one or more external systems, for example one or
more solvent dewatering systems described in detail with reference
to FIG. 3. The temperature of the recycled solvent in line 178 can
be adjusted by passing an appropriate amount of a heating or
cooling medium through one or more heat exchangers 175. In one or
more embodiments, the solvent in line 178 or 179, depending upon
whether the heat exchanger 175 is used, can have a temperature
ranging from a low of about 10.degree. C., about 20.degree. C., or
about 30.degree. C. to a high of about 100.degree. C., about
200.degree. C., about 400.degree. C., or more.
[0059] The one or more heat exchangers 175 can include, but is not
limited to liquid or air cooled shell-and-tube, plate and frame,
fin-fan, or spiral wound cooler designs. In one or more
embodiments, the one or more heat exchangers 175 can operate at a
temperature of about -20.degree. C. to about T.sub.C,S.degree. C.,
about -10.degree. C. to about 300.degree. C., or about 0.degree. C.
to about 300.degree. C. In one or more embodiments, the one or more
condensers 175 can operate can operate close to zero pressure, for
example at about 0.1 kPa. In one or more embodiments, the one or
more condensers 175 can operate at a pressure of about 30 kPa to
about P.sub.C,S+700 kPa, or about 100 kPa to about P.sub.C,S+500
kPa, or about 100 kPa to about P.sub.C,S+300 kPa.
[0060] In one or more embodiments, the DAO product in line 163 can
be introduced to one or more post treatment processes 180 to
provide one or more products via line 185. In one or more
embodiments, all or a portion of the DAO product in line 163 can be
combusted in one or more combustion and/or heat recovery systems
180 to provide heat and/or steam via line 185. In one or more
embodiments, the steam produced by combusting the deasphalted oil
can be used to provide at least a portion of the thermal energy
required in the two-stage separator/solvent extraction system 100,
to provide at least a portion of the steam required for stimulation
of additional crude hydrocarbons, for example through
steam-assisted gravity drainage ("SAGD") as disclosed in U.S. Pat.
Nos. 6,257,334; 5,626,193; 5,318,124; and/or U.S. Patent
Publication No.: 2008/0000644, to provide at least a portion of the
electrical energy required, for example through the use of one or
more steam turbine generators, or any combination thereof.
[0061] In one or more embodiments, one or more thermal and/or
catalytic post-treatment processes 180 can be used to crack, react,
or otherwise convert the DAO product in line 163 to provide one or
more finished products via line 185. In one or more embodiments,
all or a portion of the DAO product in line 163 can be thermally
cracked to provide one or more finished products via line 185.
Typical, non-limiting, thermal cracking processes are disclosed in
U.S. Pat. Nos. 6,547,956; 6,514,403; 6,303,842 and 6,183,627. In
one or more embodiments, all or a portion of the DAO product in
line 163 can be reacted with hydrogen using one or more
hydrotreaters to provide one or more finished products via line
185. Typical, non-limiting, hydrotreatment and/or hydrocracking
processes are disclosed in U.S. Pat. Nos. 7,169,291; 7,094,332;
7,048,845; 6,689,273; 6,315,889; 6,312,586; 6,294,080; 6,294,079;
6,235,190; 6,217,746; 6,113,775; 5,985,132; 5,980,732; 5,904,835;
5,888,377; 5,885,440; 5,565,088; 5,385,663; 5,393,409; 5,244,565;
5,171,727; 5,164,070; 5,120,427; 5,114,562; and 5,098,994;
5,026,472 and U.S. Publication Nos.: 2006/0175229; 2006/0118466;
2004/0168956; and 2004/0031725.
[0062] In one or more embodiments, all or a portion of the DAO
product in line 163 can be mixed or otherwise combined with one or
more catalysts, for example one or more zeolite catalysts, and
cracked using one or more fluidized catalytic cracking ("FCC")
systems 180 to provide one or more light hydrocarbon products via
line 185. Typical, non-limiting, FCC treatment processes are
disclosed in U.S. Pat. Nos. 6,001,162; 5,601,697; 5,135,640;
4,940,529; 4,359,379 and U.S. Publication Nos.: 2007/0034550 and
2006/0042999.
[0063] In one or more embodiments, all or a portion of the DAO
product in line 163 can be gasified using one or more hydrocarbon
gasification systems 180 to provide one or more products,
including, but not limited to hydrogen, carbon monoxide, carbon
dioxide, mixtures thereof, or any combination thereof via line 185.
In one or more embodiments, all or a portion of the DAO product in
line 163 can be fractionated using one or more fractionation
systems 180 to provide one or more fractionated hydrocarbon
products via line 185. In one or more embodiments, all or a portion
of the DAO product in line 163 can be selectively separated using
one or more visbreaking units 180 to provide one or more products
via line 185. In one or more embodiments, all or a portion of the
DAO product in line 163 can be desulfurized using one or more
desulfurization units 180 to provide one or more low-sulfur and/or
ultra low-sulfur products via line 185. In one or more embodiments,
all or a portion of the DAO product in line 185 can be
hydro-desulfurized using one or more hydro-desulfurization units
180 to provide one or more low-sulfur and/or ultra low-sulfur
products via line 185.
[0064] In one or more embodiments, the asphaltene product in line
133 can be introduced to one or more post treatment processes 190
to provide one or more finished products via line 195. In one or
more embodiments, all or a portion of the asphaltene product in
line 133 can be combusted in one or more combustion and/or heat
recovery systems 190 to provide heat and/or steam via line 195. In
one or more embodiments, the steam can be used to provide at least
a portion of the thermal energy required in the two-stage
separator/solvent extraction system 100, to provide at least a
portion of the steam required for stimulation of additional crude
hydrocarbons, for example through SAGD, to provide at least a
portion of the electrical energy required, for example through the
use of one or more steam turbine generators, or any combination
thereof.
[0065] In one or more embodiments, all or a portion of the
asphaltene product in line 133 can be introduced to one or more
treatment processes 190 to provide one or more finished products
via line 195. In one or more embodiments, the treatment process 190
can include pelletizing all or a portion of the asphaltenes present
in the asphaltene product in line 133. Various pelletization
processes are described in U.S. Pat. Nos. 7,101,499; 6,499,979;
6,361,682; 6,331,245; 4,931,231 and 3,847,751. In one or more
embodiments, at least a portion of the asphaltene product
introduced via line 133 to the treatment process 190 can be used to
produce one or more hydrocarbon based catalysts via line 195.
Various processes for the production of one or more hydrocarbon
catalysts are disclosed in U.S. Pat. Nos. 5,288,681 and 5,171,727.
In one or more embodiments, at least a portion of the asphaltene
product introduced via line 133 to the treatment process 190 can be
used to produce one or more asphalt based building products. A
process for the production of asphalt building products is
disclosed in U.S. Pat. No. 6,899,839. In one or more embodiments,
at least a portion of the asphaltene product introduced to the
treatment process 190 can be gasified to produce hydrogen, carbon
monoxide, carbon dioxide, or any combination thereof via line 195.
A process for the gasification of an asphaltenic hydrocarbon is
disclosed in U.S. Pat. No. 6,773,630. In one or more embodiments,
at least a portion of the asphaltene product introduced via line
133 to the treatment process 190 can be converted to provide one or
more olefinic hydrocarbons via line 195. A process for the
conversion of an asphaltenic hydrocarbon to olefinic hydrocarbons
is disclosed in U.S. Pat. No. 6,303,842. In one or more
embodiments, at least a portion of the asphaltene product
introduced via line 133 to the treatment process 190 can be
catalytically converted to provide one or more lighter hydrocarbons
via line 195 using an FCC. A process for the catalytic conversion
of an asphaltenic hydrocarbon to lighter hydrocarbons in an FCC is
disclosed in U.S. Pat. No. 5,328,591.
[0066] FIG. 2 depicts an illustrative three-stage separator/solvent
extraction system 200 according to one or more embodiments. In
addition to the system 200 shown and described above with reference
to FIG. 1, the extraction system 200 can further include one or
more separators 270 and strippers 280 for the selective separation
of the DAO mixture in line 122 into a heavy deasphalted oil
("H-DAO") product via line 205 and a light deasphalted oil
("L-DAO") product via line 288. In one or more embodiments, the
extraction system 200 can include one or more heat exchangers (two
are shown 215, 225). The hydrocarbon in line 105 can be as
discussed and described above with reference to FIG. 1.
[0067] In one or more embodiments, the temperature of the DAO
mixture in line 122 can be increased using one or more heat
exchangers 145 to provide a heated DAO mixture via line 124. In one
or more embodiments, the temperature of the heated DAO mixture in
line 124 can be less than the critical temperature ("T.sub.C,S") of
the solvent introduced via line 177 to the hydrocarbon. In one or
more embodiments, the temperature of the heated DAO mixture in line
124 can be at or above the critical temperature of the solvent
introduced via line 177 to the hydrocarbon.
[0068] In one or more embodiments, the temperature of the heated
DAO mixture in line 124 can be at or above the critical temperature
of the solvent using the one or more heaters 145. Increasing the
temperature of the heated DAO mixture in line 124 above the
critical temperature of the solvent can promote the separation of
the DAO mixture into two distinct phases, a L-DAO phase containing
essentially L-DAO and a H-DAO phase containing essentially H-DAO.
In one or more embodiments, the temperature of the heated DAO in
line 124 can range from about 15.degree. C. to about
T.sub.C,S+150.degree. C., about 15.degree. C. to about
T.sub.C,S+100.degree. C., or about 15.degree. C. to about
T.sub.C,S+50.degree. C.
[0069] The heated DAO mixture in line 124 can be and introduced to
the one or more separators 150 wherein the L-DAO and H-DAO phases
can separate to provide a L-DAO phase containing L-DAO and at least
a portion of the solvent, and a H-DAO phase containing H-DAO and
the balance of the solvent. In one or more embodiments, the L-DAO
phase can be recovered from the separator 150 via line 210. In one
or more embodiments, the H-DAO phase can be recovered from the
separator 150 via line 158.
[0070] The L-DAO phase in line 210 can have an L-DAO concentration
ranging from a low of about 1% wt, about 5% wt, or about 10% wt to
a high of about 30% wt, about 40% wt, about 50% wt, or more. In one
or more embodiments, the L-DAO phase in line 210 can have a solvent
concentration ranging from a low of about 50% wt, about 60% wt, or
about 70% wt to a high of about 90% wt, about 95% wt, or about 99%
wt. In one or more embodiments, the L-DAO phase in line 210 can
have an H-DAO concentration of about 20% wt or less, about 15% wt
or less, about 10% wt or less, about 5% wt or less, about 1% wt or
less.
[0071] The H-DAO phase in line 158 can have an H-DAO concentration
ranging from a low of about 10% wt, about 25% wt, or about 40% wt
to a high of about 70% wt, about 80% wt, about 90% wt, or more. The
H-DAO phase in line 158 can have a solvent concentration ranging
from a low of about 10% wt, about 20% wt, or about 30% wt to a high
of about 60% wt, about 75% wt, or about 90% wt. In one or more
embodiments, the H-DAO phase in line 158 can have a L-DAO
concentration of about 20% wt or less, about 15% wt or less, about
10% wt or less, about 5% wt or less, about 1% wt or less.
[0072] The one or more separators 150 can include one or more
systems, devices, or combination of systems and/or devices suitable
for separating the heated DAO in line 124 to provide a L-DAO phase
in line 210 and a H-DAO phase in line 158. In one or more
embodiments, the one or more separators 150 can contain one or more
internal structures including, but not limited to bubble trays,
packing elements such as rings or saddles, structured packing, or
combinations thereof. In one or more embodiments, the one or more
separators 150 can be an open column without internals. In one or
more embodiments, the one or more separators 150 can be one or more
partially empty columns containing one or more internal structures.
In one or more embodiments, the one or more separators 150 can be a
partially or completely open column without internals. In one or
more embodiments, the one or more separators 150 can have an
operating temperature of from about 15.degree. C. to about
T.sub.C,S+150.degree. C., about 15.degree. C. to about
T.sub.C,S+100.degree. C., or about 15.degree. C. to about
T.sub.C,S+50.degree. C. In one or more embodiments, the one or more
separators 150 can have an operating pressure of from about 100 kPa
to about P.sub.C,S+2,100 kPa, about P.sub.C,S-700 kPa to about
P.sub.C,S+1,500 kPa, or about P.sub.C,S-300 kPa to about
P.sub.C,S+700 kPa.
[0073] The H-DAO phase via line 158 can be introduced into the one
or more strippers 160 and selectively separated therein to provide
a recovered solvent via line 162 and H-DAO ("H-DAO product") via
line 205. In one or more embodiments, steam, for example saturated
or superheated, can be introduced via line 164 to the stripper 160
to further enhance the separation of the H-DAO from the solvent. In
one or more embodiments, the recovered solvent in line 162 can have
a solvent concentration ranging from a low of about 50% wt, about
70% wt, or about 80% wt to a high of about 90% wt, about 95% wt,
about 99% wt, or more, with the balance being H-DAO. In one or more
embodiments, the H-DAO in line 205 can have an H-DAO concentration
ranging from a low of about 20% wt, about 40% wt, or about 50% wt
to a high of about 80% wt, about 90% wt, about 95% wt, or more,
with the balance being the solvent and/or L-DAO. In one or more
embodiments, the H-DAO in line 205 can have a specific gravity (API
density@15.6.degree. C.) ranging from a low of about 5.degree.,
about 7.degree., or about 10.degree. to a high of about 20.degree.,
about 25.degree., about 30.degree., or more.
[0074] The one or more strippers 160 can include one or more
systems, devices, or combination of systems and/or devices suitable
for separating the H-DAO phase in line 158 to provide the recovered
solvent via line 162 and the H-DAO via line 205. In one or more
embodiments, the one or more strippers 160 can contain one or more
internal structures including, but not limited to bubble trays,
packing elements such as rings or saddles, structured packing, or
combinations thereof. In one or more embodiments, the one or more
strippers 160 can be an open column without internals. In one or
more embodiments, the one or more strippers 160 can be one or more
partially empty columns containing one or more internal structures.
In one or more embodiments, the one or more strippers 160 can be a
partially or completely open column without internals. In one or
more embodiments, the one or more strippers 160 can have an
operating temperature of from about 15.degree. C. to about
600.degree. C., about 15.degree. C. to about 500.degree. C., or
about 15.degree. C. to about 400.degree. C. In one or more
embodiments, the one or more strippers 160 can operate can operate
close to zero pressure, for example at about 0.1 kPa. In one or
more embodiments, the one or more strippers 160 can have an
operating pressure of from about 100 kPa to about 4,000 kPa, about
500 kPa to about 3,300 kPa, or about 1,000 kPa to about 2,500
kPa.
[0075] Referring again to the one or more separators 150, in one or
more embodiments, the L-DAO phase via line 210 can be heated using
one or more heat exchangers (two are shown 215, 225) to provide a
heated L-DAO in line 230. In one or more embodiments, the heated
L-DAO in line 230 can be at a temperature of from about 15.degree.
C. to about T.sub.C,S+150.degree. C., about 15.degree. C. to about
T.sub.C,S+100.degree. C., or about 15.degree. C. to about
T.sub.C,S+50.degree. C. In one or more embodiments, a recovered
solvent in line 272 can be introduced in series or in parallel to
the one or more heat exchangers 215, 225 to provide the heated
L-DAO in line 230 and a cooled recovered solvent via line 274.
[0076] In one or more embodiments, the one or more heat exchangers
215 and 225 can have an operating temperature of from about
15.degree. C. to about T.sub.C,S+150.degree. C., about 15.degree.
C. to about T.sub.C,S+100.degree. C., or about 15.degree. C. to
about T.sub.C,S+50.degree. C. In one or more embodiments, the one
or more heat exchangers 215 and 225 can have an operating pressure
of from about 100 kPa to about P.sub.C,S+2,100 kPa, about 100 kPa
to about P.sub.C,S+1,500 kPa, or about 100 kPa to about
P.sub.C,S+700 kPa.
[0077] In one or more embodiments, the heated L-DAO in line 230 can
be introduced to the one or more separators 270 and selectively
separated therein to provide the recovered solvent via line 272 and
L-DAO via line 278. The recovered solvent in line 272 can have a
solvent concentration ranging from a low of about 50% wt, about 70%
wt, or about 85% wt to a high of about 90% wt, about 95% wt, about
99% wt, or more, with the balance being L-DAO. In one or more
embodiments, the L-DAO in line 278 can have an L-DAO concentration
ranging from a low of about 20% wt, about 20% wt, or about 40% wt
to a high of about 70% wt, about 80% wt, about 90% wt, or more,
with the balance being the solvent.
[0078] The one or more separators 270 can include one or more
systems, devices, or combination of systems and/or devices suitable
for separating the heated L-DAO phase in line 230 to provide the
recovered solvent via line 272 and the L-DAO via line 278. In one
or more embodiments, the separator 270 can include one or more
multi-staged extractors having alternate segmental baffle trays,
packing, structured packing, perforated trays, and combinations
thereof. In one or more embodiments, the separator 270 can be a
partially or completely open column without internals. In one or
more embodiments, the one or more separators 270 can have an
operating temperature of from about 15.degree. C. to about
T.sub.C,S+150.degree. C., about 15.degree. C. to about
T.sub.C,S+150.degree. C., or about 15.degree. C. to about
T.sub.C,S+50.degree. C. In one or more embodiments, the one or more
separators 270 can have an operating pressure of from about 100 kPa
to about P.sub.C,S+700 kPa, about P.sub.C,S-700 kPa to about
P.sub.C,S+700 kPa, or about P.sub.C,S-300 kPa to about
P.sub.C,S+300 kPa.
[0079] In one or more embodiments, the L-DAO in line 278 can be
introduced to the one or more strippers 280 and selectively
separated therein to provide a recovered solvent via line 282 and
an L-DAO product via line 288. In one or more embodiments, steam,
for example saturated or superheated, can be introduced via line
284 to the stripper 280 to further enhance the separation of the
L-DAO from the solvent. In one or more embodiments, the recovered
solvent in line 282 can have a solvent concentration ranging from a
low of about 50% wt, about 70% wt, or about 85% wt to a high of
about 90% wt, about 95% wt, about 99% wt or more, with the balance
being L-DAO. In one or more embodiments, the L-DAO product in line
288 can have an L-DAO concentration ranging from a low of about 30%
wt, about 40% wt, or about 50% wt to a high of about 85% wt, about
90% wt, about 95% wt, or more, with the balance being the solvent
and/or H-DAO. In one or more embodiments, the light deasphalted
product in line 288 can have an L-DAO concentration of about 97% wt
or more, about 95% wt or more, about 99% wt or more. In one or more
embodiments, the L-DAO product in line 288 can have a specific
gravity (API density@15.6.degree. C.) ranging from a low of about
10.degree., about 20.degree., or about 25.degree. to a high of
about 35.degree., about 45.degree., about 60.degree., or more.
[0080] The one or more strippers 280 can include one or more
systems, devices, or combination of systems and/or devices suitable
for separating L-DAO in line 278 to provide the recovered solvent
via line 282 and the L-DAO product via line 288. In one or more
embodiments, the one or more strippers 280 can contain one or more
internal structures including, but not limited to bubble trays,
packing elements such as rings or saddles, structured packing, or
combinations thereof. In one or more embodiments, the one or more
strippers 280 can be an open column without internals. In one or
more embodiments, the one or more strippers 280 can be one or more
partially empty columns containing one or more internal structures.
In one or more embodiments, the one or more strippers 280 can
operate at a temperature of about 15.degree. C. to about
600.degree. C., about 15.degree. C. to about 500.degree. C., or
about 15.degree. C. to about 400.degree. C. In one or more
embodiments, the one or more strippers 280 can operate can operate
close to zero pressure, for example at about 0.1 kPa. In one or
more embodiments, the one or more strippers 280 can have an
operating pressure of from about 30 kPa to about 4,000 kPa, about
500 kPa to about 3,300 kPa, or about 1,000 kPa to about 2,500
kPa.
[0081] In one or more embodiments, at least a portion of the
solvent in line 132, 162, and/or 282 can be combined to provide a
combined solvent in line 138. Although not shown, in or more
embodiments at least a portion of the recovered solvent in line 272
can be combined with at least a portion of the recovered solvent in
line 132, 162, and/or 282 to provide the combined solvent in line
138. In one or more embodiments, the solvent in line 138 can be
present as a two phase liquid/vapor mixture. In one or more
embodiments, the combined solvent overhead in line 138 can have a
temperature ranging from a low of about 30.degree. C., about
100.degree. C., or about 200.degree. C. to a high of about
400.degree. C., about 500.degree. C., about 600.degree. C., or
more.
[0082] In one or more embodiments, the combined solvent in line 138
can be partially or completely condensed using one or more
condensers 135 to provide a condensed solvent via line 139. In one
or more embodiments, the condensed solvent in line 139 can have a
temperature ranging from a low of about 10.degree. C., about
20.degree. C., or about 30.degree. C. to a high of about
100.degree. C., about 200.degree. C., about 400.degree. C., or
more. In one or more embodiments, the condensed solvent in line 139
can have a solvent concentration ranging from a low of about 80%
wt, about 85% wt, or about 90% wt to a high of about 95% wt, about
97% wt, about 99% wt, or more.
[0083] The one or more condensers 135 can include one or more
systems, devices, or combination of systems and/or devices suitable
for decreasing the temperature of the solvent in line 138. In one
or more embodiments, condenser 135 can include, but is not limited
to liquid or air cooled shell-and-tube, plate and frame, fin-fan,
or spiral wound cooler designs. In one or more embodiments, a
cooling medium such as water, refrigerant, air, or combinations
thereof can be used to remove the necessary heat from the solvent
in line 138. In one or more embodiments, the one or more condensers
135 can have an operating temperature of from about -20.degree. C.
to about T.sub.C,S.degree. C., about -10.degree. C. to about
300.degree. C., or about 0.degree. C. to about 300.degree. C. In
one or more embodiments, the one or more condensers 135 can operate
can operate close to zero pressure, for example at about 0.1 kPa.
In one or more embodiments, the one or more condensers 135 can have
an operating pressure of from about 100 kPa to about P.sub.C,S+700
kPa, about 100 kPa to about P.sub.C,S+500 kPa, or about 100 kPa to
about P.sub.C,S+300 kPa.
[0084] In one or more embodiments the condensed solvent in line 139
can be stored or accumulated in one or more reservoirs 140. In one
or more embodiments, the solvent in the reservoir 140 can be
transferred using one or more solvent pumps 192 and recycle lines
186. Recycling at least a portion of the solvent to either the
solvent deasphalting process 200 can decrease the quantity of fresh
solvent make-up required. In one or more embodiments, all or a
portion of the solvent in the one or more reservoirs can be
transferred via line 135 to one or more systems, for example a
solvent dewatering system as discussed in greater detail with
respect to FIG. 3.
[0085] Referring again to the one or more separators 270, in one or
more embodiments, at least a portion of the recovered solvent in
line 272 can be cooled using one or more heat exchangers 145 and
215 to provide a cooled solvent in line 274. In one or more
embodiments, about 1% wt to about 95% wt, about 5% wt to about 55%
wt, or about 1% wt to about 25% wt of the solvent in line 272 can
be cooled using one or more heat exchangers 215 and 145. In one or
more embodiments, the solvent in line 274 can be at a temperature
of from about 25.degree. C. to about 400.degree. C., about
50.degree. C. to about 300.degree. C., or about 100.degree. C. to
about 250.degree. C. In one or more embodiments, at least a portion
of the cooled solvent in line 274 can be combined with at least a
portion of the recycled solvent in line 186 for recycle to the one
or more mixers 110 via line 177. In one or more embodiments, all or
a portion of the solvent in line 177 can be introduced to one or
more external systems via line 279.
[0086] In one or more embodiments, the L-DAO product in line 288
can be introduced to one or more post treatment processes 270 to
provide one or more products via line 275. In one or more
embodiments, the H-DAO product in line 205 can be introduced to one
or more post treatment processes 250 to provide one or more
products via line 255. For clarity, conciseness, and ease of
description, the treatment processes 270 will be described below
with reference to the L-DAO product in line 288 as the hydrocarbon.
It should be understood that any one or more of the post-treatment
processes 270 described below can provide an equally effective
process for post treatment processing of the H-DAO product in line
205 via post-treatment system 250.
[0087] In one or more embodiments, all or a portion of the L-DAO
product can be combusted using one or more combustion and/or heat
recovery systems 270 to provide heat and/or steam via line 275. In
one or more embodiments, the steam produced by combusting the L-DAO
product can be used to provide at least a portion of the thermal
energy required in the three-stage separator/solvent extraction
system 200, to provide at least a portion of the steam required for
stimulation of additional crude hydrocarbons, for example through
SAGD, to provide at least a portion of the electrical energy
required, for example through the use of one or more steam turbine
generators, or any combination thereof.
[0088] In one or more embodiments, one or more thermal and/or
catalytic post-treatment processes 270 can be used to crack, react,
or otherwise convert the L-DAO product in line 288 to one or more
finished products via line 275. In one or more embodiments, all or
a portion of the L-DAO product in line 288 can be thermally cracked
to provide one or more finished products via line 275. In one or
more embodiments, all or a portion of the L-DAO product in line 288
can be reacted with hydrogen using one or more hydrotreaters to
provide one or more finished products via line 275.
[0089] In one or more embodiments, all or a portion of the L-DAO
product in line 288 can be mixed or otherwise combined with one or
more catalysts, for example one or more zeolite catalysts, and
cracked using one or more fluidized catalytic cracking systems 270
to provide one or more light hydrocarbon products via line 275. In
one or more embodiments, all or a portion of the L-DAO product in
line 288 can be gasified using one or more hydrocarbon gasification
systems 270 to provide one or more products, including, but not
limited to hydrogen, carbon monoxide, carbon dioxide, mixtures
thereof, or any combination thereof via line 275. In one or more
embodiments, all or a portion of the L-DAO product in line 288 can
be fractionated using one or more fractionation systems 270 to
provide one or more fractionated hydrocarbon products via line 275.
In one or more embodiments, all or a portion of the L-DAO product
in line 288 can be selectively separated using one or more
visbreaking units 270 to provide one or more products via line 275.
In one or more embodiments, all or a portion of the L-DAO product
in line 288 can be desulfurized using one or more desulfurization
units 270 to provide one or more low-sulfur and/or ultra low-sulfur
products via line 275. In one or more embodiments, all or a portion
of the L-DAO product in line 288 can be hydro-desulfurized using
one or more hydro-desulfurization units 270 to provide one or more
low-sulfur and/or ultra low-sulfur products via line 275.
[0090] In one or more embodiments, the asphaltene product in line
233 can be introduced to one or more post treatment processes 290
to provide one or more finished products via line 295. In one or
more embodiments, all or a portion of the asphaltene product in
line 233 can be combusted to provide heat and/or steam. In one or
more embodiments, the steam can be used to provide at least a
portion of the thermal energy required in the three-stage
separator/solvent extraction system 200, to provide at least a
portion of the steam required for stimulation of additional crude
hydrocarbons, for example through SAGD, to provide at least a
portion of the electrical energy required, for example through the
use of one or more steam turbine generators, or any combination
thereof.
[0091] In one or more embodiments, all or a portion of the
asphaltene product in line 233 can be introduced to one or more
treatment processes 290 to provide one or more finished products
via line 295. In one or more embodiments, the treatment process 290
can include pelletizing all or a portion of the asphaltenes present
in the asphaltene product in line 233. In one or more embodiments,
at least a portion of the asphaltene product introduced via line
233 to the treatment process 290 can be used to produce one or more
hydrocarbon based catalysts via line 295. In one or more
embodiments, at least a portion of the asphaltene product
introduced via line 233 to the treatment process 290 can be used to
produce one or more asphalt based building products via line 295.
In one or more embodiments, at least a portion of the asphaltene
product introduced via line 233 to the treatment process 290 can be
gasified to produce hydrogen, carbon monoxide, carbon dioxide, or
any combination thereof via line 295. In one or more embodiments,
at least a portion of the asphaltene product introduced via line
233 to the treatment process 290 can be converted into one or more
olefinic hydrocarbons via line 295. In one or more embodiments, at
least a portion of the asphaltene product introduced via line 233
to the treatment process 290 can be catalytically converted into
one or more lighter hydrocarbons via line 295 using a fluidized
catalytic cracker.
[0092] FIG. 3 depicts an illustrative solvent dewatering system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 300 can include one or more contactors 310, one or
more separators 320, and one or more solvent extraction systems
100, 200. A hydrocarbon that can contain water can be introduced
via line 305 to the one or more contactors 310. In one or more
embodiments, solvent via line 179 from the separator/solvent
extraction system 100 and/or solvent via line 279 from the
separator/solvent extraction system 200 can be introduced via line
303 to the contactor 310 to provide a solvent/hydrocarbon mixture.
In one or more embodiments solvent via line 301 can be introduced
in place of or in addition to solvent from either line 279 and/or
179.
[0093] The hydrocarbon in line 305 can be or include, but are not
limited to whole crude oil, crude oil, oil shales, oil sands, tars,
bitumens, combinations thereof, derivatives thereof, or mixtures
thereof. In one or more embodiments, the hydrocarbon in line 305
can include one or more particulate components, such as carbon or
coke, ash, clays, inorganic compounds, metals, metal oxides, such
as SiO.sub.2, Al.sub.2O.sub.3, and the oxides and oxysulfides of
metals such as Fe and Ca. These particulate components may
originate from the producing formation as sand or clays or may have
been picked up by the high viscosity oil during transportation and
processing. Residual oils or oils having prior treatment may also
contain residual catalyst fines. Such catalysts typically comprise
metals of the group VIA or the group VIII of the Periodic Table
supported on a supporter comprising an iron-containing
aluminosilicate and inorganic oxides.
[0094] The hydrocarbon in line 305 can include one or more inert
materials, water, gases, and the like. In one or more embodiments,
the hydrocarbon in line 305 can be a mixture containing one or more
hydrocarbons having an API specific gravity (API@15.6.degree.
C.--ASTM D4052) of about 35.degree. or less, about 30.degree. or
less, about 25.degree. or less, or about 20.degree. or less. In one
or more embodiments, the hydrocarbon in line 305 can have an API
specific gravity (API@15.6.degree. C.--ASTM D4052) of from about
6.degree. to about 25.degree., about 7.degree. to about 23.degree.,
about 8.degree. to about 19.degree., or about 8.degree. to about
15.degree.. In one or more embodiments, the hydrocarbon in line 305
can be or include one or more hydrocarbons having a normal,
atmospheric, boiling point of less than about 1,090.degree. C.,
less than about 1,000.degree. C., less than about 900.degree. C.,
less than about 800.degree. C., less than about 700.degree. C., or
less.
[0095] In one or more embodiments, the hydrocarbon in line 305 can
have an asphaltene concentration of about 5% wt or more, about 10%
wt or more, about 15% wt or more, about 20% wt or more, about 25%
wt or more, or about 30% wt or more. In one or more embodiments,
the hydrocarbon in line 305 can include a mixture of inert material
and hydrocarbons, for example a tar sand containing bitumen
combined with one or more inert materials. In one or more
embodiments, the hydrocarbon in line 305 can include about 5% vol
to about 25% vol naphthenes, or from about 10% vol to about 20% vol
naphthenes, or from about 13% vol to about 18% vol naphthenes. The
hydrocarbon in line 305 can include about 5% vol to about 25% vol
aromatic hydrocarbons, or from about 10% vol to about 20% vol
aromatic hydrocarbons, or from about 13% vol to about 18% vol
aromatic hydrocarbons. The hydrocarbon in line 305 can include
about 50% vol to about 85% vol paraffins, or from about 60% vol to
about 75% vol paraffins, or from about 63% vol to about 70% vol
paraffins. The hydrocarbon in line 305 can include from about 25
ppmw to about 400 ppmw or more nickel and from about 200 ppmw to
about 1,000 ppmw or more vanadium.
[0096] In one or more embodiments, the one or more inert materials
can include, but are not limited to sands, clays, silt, mud, or any
combination thereof. In one or more embodiments, the concentration
of inert materials can range from a low of about 1% wt, about 2%
wt, about 5% wt, or about 10% wt to a high of about 35% wt, about
40% wt, about 50% wt, or about 70% wt. In one or more embodiments,
the hydrocarbon in line 305 can include one or more tar sands
saturated with a relatively heavy, viscous bitumen in quantities
ranging from a low of about 1% wt, about 5% wt, or about 10% wt to
a high of about 20% wt, about 25% wt, or about 30% wt. The bitumen
can have a sulfur content of about 2% wt, about 3% wt, about 4% wt,
about 5% wt, or about 6% wt. In one or more embodiments, the
bitumen can have an aromatics content of about 20% wt, about 25%
wt, about 30% wt, about 35% wt, or about 40% wt.
[0097] The contactor 310 can include any system, device, or
combination of systems and/or devices suitable for mixing or
otherwise combining the solvent introduced via line 303 with the
hydrocarbon introduced via line 305. In one or more embodiments,
the one or more contactors 310 can contain internals such as rings,
saddles, structured packing, balls, irregular sheets, tubes,
spirals, trays, baffles, or any combinations thereof. In one or
more embodiments, the contactor 310 can be a partially or
completely open column without internals. In one or more
embodiments, the one or more contactors 310 can include but are not
limited to ejectors, inline static mixers, inline mechanical/power
mixers, homogenizers, or combinations thereof. In one or more
embodiments, the one or more contactors 310 can have an operating
temperature of from about 0.degree. C. to about 95.degree. C.,
about 5.degree. C. to about 80.degree. C., or about 10.degree. C.
to about 70.degree. C. In one or more embodiments, the one or more
contactors 310 can have an operating pressure of from about 100 kPa
to about 1,150 kPa, about 200 kPa to about 1,000 kPa, or about 500
kPa to about 800 kPa.
[0098] The mixing or combining of the solvent in line 303 and the
hydrocarbon in line 305 permits the separation of water contained
in the hydrocarbon to separate, forming a plurality of discrete
hydrocarbon and aqueous phases. Any solvent that can differentiate
the density of the oil and water to facilitate a phase separation
therebetween can be used. Suitable solvents can include, but are
not limited to aliphatic hydrocarbons, cycloaliphatic hydrocarbons,
and aromatic hydrocarbons, and mixtures thereof. In one or more
embodiments, the solvent can include propane, butane, pentane,
benzene, or mixtures thereof. In one or more embodiments, the
solvent can include at least 90% wt, at least 95% wt, or at least
99% wt of one or more hydrocarbons having a normal boiling point
below 538.degree. C. In one or more embodiments, the solvent can
include one or more gas condensates having a boiling range of about
27.degree. C. to about 121.degree. C., one or more light naphthas
having a boiling range of about 32.degree. C. to about 82.degree.
C., one or more heavy naphthas having a boiling range of about
82.degree. C. to about 221.degree. C., or mixtures thereof. In one
or more embodiments, the solvent can have a critical temperature of
about 90.degree. C. to about 538.degree. C., about 90.degree. C. to
about 400.degree. C., or about 90.degree. C. to about 300.degree.
C. In one or more embodiments, the solvent can have a critical
pressure of about 2,000 kPa to about 6,000 kPa, about 2,300 kPa to
about 5,800 kPa, or about 2,600 kPa to about 5,600 kPa.
[0099] The solvent and hydrocarbon mixture can be recovered via
line 315 from the one or more contactors 310 and can be introduced
to the one or more separators 320. The separator 320 can be one or
more systems, devices, or combination of systems and/or devices
suitable for selectively separating the aqueous and hydrocarbon
phases formed by combining the solvent with the hydrocarbon in the
contactor 310. For example, the separator 320 can be or include any
one or more gravity separators and coalescer-assisted separators.
In one or more embodiments, chemical-assisted and/or plate assisted
separators can be used. In one or more embodiments, the solvent and
hydrocarbon mixture in line 315 can be heated and/or cooled to
further differentiate the specific gravity of the hydrocarbon and
aqueous phases to improve the overall separation efficiency within
the separator 320.
[0100] Within the one or more separators 320, the density
difference between the hydrocarbon and aqueous phases can permit a
phase separation to occur. In one or more embodiments, the phase
separation can be gravity based. In one or more embodiments, the
phase separation can be mechanically assisted, for example through
centrifugal and/or cyclonic separation. Although not shown, the
aqueous phase recovered from the separator 320 via line 327 can be
further processed and/or treated to remove entrained hydrocarbons
and other contaminants prior to recycle, reuse, and/or disposal.
The hydrocarbon can be recovered via line 105 from the one or more
separators 320. The hydrocarbon in line 105 can be as discussed and
described above with reference to FIGS. 1 and 2.
[0101] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163 as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288. In one or more embodiments, all or
a portion of the solvent recovered from the extraction unit 100,
200 can be recycled to the contactor 310 via lines 179, 279,
respectively. In one or more embodiments, the one or more two-stage
and/or three-stage solvent extraction systems 100, 200 can operate
at sub-critical, critical, or supercritical temperatures and/or
pressures with respect to the solvent to permit separation of the
asphaltenes from the hydrocarbon phase in line 105. In one or more
embodiments, the asphaltene product provided via line 133 and or
233, the DAO product via line 163, the H-DAO product via line 205,
and/or the L-DAO product via line 288 can be further processed as
discussed and described above with reference to FIGS. 1 and 2.
[0102] FIG. 4 depicts an illustrative flash evaporation system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. In one or more
embodiments, the hydrocarbon treatment system 400 can include one
or more heaters 410, one or more pressure control devices 430, one
or more evaporators 450, and one or more separator/solvent
extraction systems 100, 200. In one or more embodiments, a
hydrocarbon mixture containing one or more hydrocarbons and
asphaltenes, can be introduced via line 405 to the one or more
heaters 410. The hydrocarbon in line 405 can be as similar to the
hydrocarbon in line 105 and/or 305 discussed and described above
with reference to FIGS. 1-3.
[0103] In one or more embodiments, the temperature of the
hydrocarbon in line 405 can range from a low of about 0.degree. C.,
about 10.degree. C., about 30.degree. C., about 50.degree. C., or
about 75.degree. C. to a high of about 80.degree. C., about
100.degree. C., about 120.degree. C., or about 150.degree. C. In
one or more embodiments the pressure of the hydrocarbon in line 305
can range from a low of about 150 kPa, about 300 kPa, about 450
kPa, or about 600 kPa to a high of about 750 kPa, about 900 kPa,
about 1,050 kPa, or about 1,200 kPa.
[0104] Passage of the hydrocarbon through the one or more heaters
410 can increase the temperature of the hydrocarbon by about
50.degree. C., about 100.degree. C., about 200.degree. C., about
300.degree. C., or more. The heated hydrocarbon can exit the one or
more heaters 410 via line 415. In one or more embodiments, the
temperature of the heated hydrocarbon in line 415 can range from a
low of about 50.degree. C., about 60.degree. C., about 80.degree.
C., about 100.degree. C., or about 125.degree. C. to a high of
about 380.degree. C., about 400.degree. C., about 420.degree. C.,
or about 450.degree. C. In one or more embodiments, the heating of
the hydrocarbon in the one or more heaters 410 can vaporize at
least a portion of one or more light hydrocarbons contained in the
hydrocarbon. The vaporization of at least a portion of the one or
more light hydrocarbons can increase the pressure of the heated
hydrocarbon in line 415. In one or more embodiments, the pressure
of the one or more heated hydrocarbon in line 415 can range from a
low of about 350 kPa, about 500 kPa, about 650 kPa, or about 800
kPa to a high of about 1,150 kPa, about 1,300 kPa, about 1,450 kPa,
or about 1,600 kPa.
[0105] The one or more heaters 410 can include any system, device
or combination of systems and/or devices suitable for heating a
high viscosity, hydrocarbon containing asphaltenes. In one or more
embodiments, the one or more heaters 410 can include one or more
direct fired heaters. In one or more embodiments, the one or more
heaters 410 can include one or more non-contact heaters including,
but not limited to one or more plate and frame heat exchangers, one
or more spiral wound heat exchangers, one or more shell and tube
heat exchangers, or any combination thereof. In one or more
embodiments, a hot fluid can be passed through the non-contact
heater to warm the crude hydrocarbon therein. Suitable hot fluids
can include, but are not limited to heat transfer fluids, such as
Radtherm.RTM. and Dowtherm.RTM. heat transfer fluids, hot process
fluids, hot waste fluids, such as furnace effluents or combustion
exhausts. In one or more embodiments, the one or more heaters 410
can include one or more contact heaters in which one or more high
temperature fluids are mixed or otherwise combined with the
hydrocarbon to increase the bulk temperature of the mixture. In one
or more embodiments, the one or more heaters 410 can include one or
more direct fired heaters, one or more contact heat exchangers,
and/or one or more non-contact heat exchangers in any combination
and/or frequency.
[0106] The heated hydrocarbon in line 415 can flow through the one
or more pressure control devices 430 to provide a hydrocarbon in
line 435 having a reduced and/or increased pressure. In one or more
embodiments, the hydrocarbon in line 435 can be introduced to the
one or more separators 450. The one or more separators 450 can be
maintained at a pressure less than the pressure of the crude
hydrocarbons within line 415. In one or more embodiments, the
pressure differential between the pressure within the separators
450 and the pressure within line 415 can be about 150 kPa, about
200 kPa, about 400 kPa, about 800 kPa, or more. In one or more
embodiments, the operating pressure of the one or more separators
450 can range from a low of about 50 kPa, about 250 kPa, about 400
kPa, or about 600 kPa to a high of about 750 kPa, about 900 kPa,
about 1,050 kPa, or about 1,200 kPa. Introducing the heated
hydrocarbon to the reduced pressure environment of the one or more
separators 450 the vaporized light hydrocarbon can volatilize and
"flash" from the heated hydrocarbon within the separator 450. In
one or more embodiments, the flashed light hydrocarbon can be
recovered via line 460 from the one or more separators 450. The
residual hydrocarbons can be recovered from the one or more
separators 450 via line 105.
[0107] In one or more embodiments, the vaporized light hydrocarbon
recovered via line 460 from the one or more separators 450 can
include C.sub.1-C.sub.20 hydrocarbons. For example, the vaporized
light hydrocarbons recovered via line 460 from the one or more
separators 450 can include, but are not limited to one or more
C.sub.1 to C.sub.8 alkanes, one or more C.sub.1 to C.sub.8 alkenes,
C.sub.1 to C.sub.8 alkynes, one or more naphthas, one or more
aromatics, mixtures thereof, derivatives thereof, or any
combination thereof. The pressure of the vaporized light
hydrocarbon in line 460 can range from a low of about 50 kPa, about
100 kPa, about 400 kPa, or about 600 kPa to a high of about 750
kPa, about 900 kPa, about 1,050 kPa, or about 1,200 kPa. In one or
more embodiments, the temperature of the vaporized light
hydrocarbon in line 460 can range from a low of about 25.degree.
C., about 40.degree. C., about 50.degree. C., about 70.degree. C.,
or about 90.degree. C. to a high of about 200.degree. C., about
250.degree. C., about 300.degree. C., or about 350.degree. C. In
one or more embodiments, the vaporized light hydrocarbon in line
460 can be further reacted, converted, fractionated and/or
separated into one or more finished products.
[0108] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0109] The pressure of the residual hydrocarbons in line 105 can
range from a low of about 150 kPa, about 250 kPa, about 400 kPa, or
about 600 kPa to a high of about 750 kPa, about 900 kPa, about
1,050 kPa, or about 1,200 kPa. The temperature of the residual
hydrocarbons in line 105 can be lower than the temperature of the
hydrocarbon in line 415 due to the evaporative cooling which occurs
within the one or more separators 450. In one or more embodiments,
the temperature of the residual hydrocarbon in line 105 can range
from a low of about 25.degree. C., about 40.degree. C., about
50.degree. C., about 70.degree. C., or about 90.degree. C. to a
high of about 200.degree. C., about 250.degree. C., about
300.degree. C., or about 350.degree. C.
[0110] FIG. 5 depicts an illustrative distillation system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 500 can include one or more topping towers 510,
one or more distillation units 530, and one or more
separator/solvent extraction systems 100, 200. In one or more
embodiments the one or more distillation units 530 can include one
or more atmospheric distillation units, one or more vacuum
distillation units, or any combination thereof. In one or more
embodiments, a hydrocarbon, which can be as discussed and described
above with reference to FIG. 3 can be introduced via line 305 to
the one or more topping towers 510.
[0111] The topping tower 510 can separate the hydrocarbon into a
naphtha product via line 520 and a residue via line 515. In one or
more embodiments, the naphtha product via line 520 can be
introduced to a hydrotreater (not shown) to provide a hydrotreated
naphtha product. The hydrotreated naphtha product can be introduced
to one or more reformers to provide a reformed naphtha product. The
reformed naphtha product can be introduced to the one or more
Benzene, Toluene, Xylene ("BTX") units (not shown) to provide a BTX
product.
[0112] In one or more embodiments, the residue via line 515 can be
introduced to the one or more distillation units 530 to provide a
distillate or light distillate via line 535, a gas oil or heavy
distillate via line 540, and a hydrocarbon via line 105. The
hydrocarbon in line 105 can be as discussed and described above
with reference to FIGS. 1 and 2. In one or more embodiments, the
light distillate in line 535 can have a boiling point of about
296.degree. C. or less, about 285.degree. C. or less, or about
274.degree. C. or less. In one or more embodiments, the gas oil in
line 540 can have a boiling point of about 274.degree. C. or more,
about 285.degree. C. or more, or about 296.degree. C. or more. In
one or more embodiments, the residue in line 105 can have a boiling
point of about 343.degree. C. or more, about 358.degree. C. or
more, or about 374.degree. C. or more.
[0113] In one or more embodiments, the one or more distillation
units 530 can be designed to process about 100,000 BPSD or more,
about 120,000 BPSD or more, about 150,000 BPSD or more, about
175,000 BPSD or more, or about 200,000 BPSD or more or more topped
crude. In one or more embodiments, the one or more distillation
units 530 can include one or more systems, devices, or combination
of systems and/or devices suitable for distilling or separating two
or more hydrocarbons or groups of hydrocarbons. In one or more
embodiments, the one or more distillation units 530 can include one
or more crude preheat exchangers, a furnace, a crude fractionator,
and/or a gas oil stripper.
[0114] In one or more embodiments, all or a portion of the gas oil
or heavy distillate in line 540 can be combined with the DAO
provided via line 163 from the one or more two-stage
separator/solvent extraction systems 100. In one or more
embodiments, all or a portion of the gas oil or heavy distillate in
line 540 can be combined with the H-DAO provided via line 205 from
the one or more three-stage separator/solvent extraction systems
200. In one or more embodiments, all or a portion of the light
distillate in line 535 can be combined with the L-DAO provided via
line 288 from the one or more three-stage separator/solvent
extraction systems 200.
[0115] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0116] FIG. 6 depicts an illustrative hydrotreating system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 600 can include one or more hydrotreaters (four
are shown: a first-stage, 610, a second-stage, 630, a third-stage,
650, and a fourth-stage, 670), and one or more separator/solvent
extraction systems 100, 200. In one or more embodiments, the
hydrocarbon treatment system 600 can include one or more systems as
disclosed in U.S. Pat. No. 5,980,732. In one or more embodiments, a
hydrocarbon via line 305, which can be as discussed and described
above with reference to FIG. 3 and hydrogen via line 605 can be
introduced to the one or more first-stage hydrotreaters 610. In one
or more embodiments, the hydrogen in line 605 can be introduced
directly into the hydrocarbon in line 305 prior to introducing the
mixture to the one or more hydrotreaters 610.
[0117] In one or more embodiments, the hydrogen in line 605 can
contain a mixture of hydrogen, carbon monoxide, carbon dioxide, or
any combination thereof, for example a synthesis gas (syngas')
provided from one or more gasifiers. In one or more embodiments,
the hydrogen in line 605 can have a hydrogen concentration of about
5% mol or more, about 10% mol or more, about 25% mol or more, about
50% mol or more, about 75% mol or more, about 90% mol or more,
about 95% mol or more. In one or more embodiments, the hydrogen in
line 605 can have a carbon monoxide concentration of about 5% mol
or more, about 10% mol or more, about 25% mol or more, about 50%
mol or more, about 75% mol or more, about 90% mol or more, about
95% mol or more. In one or more embodiments, the hydrogen in line
605 can have a carbon dioxide concentration of about 5% mol or
more, about 10% mol or more, about 25% mol or more, about 50% mol
or more, about 75% mol or more, about 90% mol or more, about 95%
mol or more. In one or more embodiments, the hydrogen in line 605
can contain purified hydrogen, having a hydrogen concentration of
about 90% mol or more, about 95% mol or more, about 99% mol or
more, or about 99.9% mol or more.
[0118] In one or more embodiments, the one or more hydrotreaters
610, 630, 650, and 670 can be any suitable hydrotreating system,
device, or combination of systems and/or devices. For example, the
one or more hydrotreaters 610, 630, 650, and 670 can include, but
are not limited to hydrodesulfurization, hydrotreating,
hydrocracking, hydrogenation of aromatics, hydroisomerization,
hydrodewaxing, metal removal, ammonia removal, and the like. In one
or more embodiments, the one or more hydrotreaters 610, 630, 650,
and can reduce the sulfur content of the hydrocarbon to provide a
de-sulfurized and/or hydrogenated hydrocarbon.
[0119] In one or more embodiments, the one or more hydrotreaters
610, 630, 650 and 670 can have an operating temperature of from
about 300.degree. C. to about 600.degree. C., about 325.degree. C.
to about 535.degree. C., or about 330.degree. C. to about
460.degree. C. In one or more embodiments, the one or more
hydrotreaters 610, 630, 650 and 670 can have an operating pressure
of from about 1,000 kPa to about 30,000 kPa, about 4,500 kPa to
about 27,500 kPa, about 5,000 kPa to about 25,000 kPa, or about
5,520 kPa to about 24,100 kPa. In one or more embodiments, the one
or more hydrotreaters 610, 630, 650, and 670 can have a hydrogen
circulation rate of from about 1,000 standard cubic feet per barrel
("SCF/B") to about 18,000 SCF/B, about 1,000 SCF/B to about 15,500
SCF/B, or from about 1,000 SCF/B to about 10,000 SCF/B. In one or
more embodiments, the one or more hydrotreaters 610, 630, 650, 670
can have a space velocity of from about 0.05/hr.sup.-1 to about
4.00/hr.sup.-1, about 0.75/hr.sup.-1 to about 3.00/hr.sup.-1, or
about 0.10/hr.sup.-1 to about 2.00/hr.sup.-1.
[0120] In one or more embodiments, the partially hydrotreated
hydrocarbons can be recovered via line 615 from the one or more
first-stage hydrotreaters 610. In one or more embodiments, the
partially hydrotreated hydrocarbon in line 615 can be introduced to
one or more second-stage hydrotreaters 630. The partially
hydrotreated hydrocarbons can be recovered via line 635 from the
one or more second-stage hydrotreaters 630. In one or more
embodiments, the partially treated hydrocarbon in line 635 can be
introduced to the one or more third-stage hydrotreaters 650. In one
or more embodiments, the partially hydrotreated hydrocarbon can be
recovered via line 105 from the one or more third-stage
hydrotreaters.
[0121] In one or more embodiments, the first-stage hydrotreater
610, second-stage hydrotreater 630, and third-stage hydrotreater
650 can be operated at the same or different conditions. In one or
more embodiments, all or a portion of the partially hydrotreated
hydrocarbon provided via line 105 from the one or more third-stage
hydrotreaters 650 can be introduced to one or more the two-stage
separator/solvent extraction systems 100. In one or more
embodiments, all or a portion of the partially hydrotreated
hydrocarbon provided via line 105 from the one or more third-stage
hydrotreaters 650 can be introduced to the one or more three-stage
separator/solvent extraction systems 200. The separator/solvent
extraction systems 100 and 200 can be as discussed and described
above with reference to FIGS. 1 and 2.
[0122] In one or more embodiments, all or a portion of the DAO
provided via line 163 from the two-stage separator/solvent
extraction system 100 can be introduced via line 655 to the
fourth-stage hydrotreater 670. In one or more embodiments, all or a
portion of the H-DAO provided via line 205 from the three-stage
separator/solvent extraction system 200 can be introduced via line
665 to the fourth-stage hydrotreater 670. The hydrotreated
hydrocarbons can exit the fourth-stage hydrotreater 670 via line
675.
[0123] FIG. 7 depicts an illustrative integrated vacuum separation
and hydrogenation system integrated with one or more
separator/solvent extraction systems 100, 200, according to one or
more embodiments. The hydrocarbon treatment system 700 can include
one or more vacuum separation units 710, one or more flash
separation units 770, and one or more separator/solvent extraction
systems 100, 200. In one or more embodiments, the hydrocarbon
treatment system 600 can include one or more systems as disclosed
in U.S. Pat. No. 5,244,565. In one or more embodiments, a
hydrocarbon via line 305, which can be as discussed and described
above with reference to FIG. 3 can be introduced to the one or more
vacuum separation units 710 to provide one or more vaporized
hydrocarbons via line 715 and one or more residual hydrocarbons via
line 720.
[0124] In one or more embodiments, all or a portion of the residual
hydrocarbons in line 720 can provide, via line 730, at least a
portion of the hydrocarbons in line 105. In one or more
embodiments, all or a portion of the residual hydrocarbons in line
720 can be introduced, via line 725 to one or more flash separation
units 770. In one or more embodiments, one or more waste oils via
line 735 can be introduced to the one or more flash separation
units 770. In one or more embodiments, a high-temperature
hydrogen-rich gas via line 740 can be introduced to the one or more
flash-separation units 770. In one or more embodiments, the
high-temperature hydrogen-rich gas in line 740 can have a
temperature of from about 93.degree. C. to about 815.degree. C.,
about 93.degree. C. to about 760.degree. C., or about 93.degree. C.
to about 649.degree. C.
[0125] In one or more embodiments, the waste oil can include, but
is not limited to hydraulic fluids, heat transfer fluids, used
lubricating oil, used cutting oils, used motor oils, used solvents,
or any combination thereof. In one or more embodiments, the waste
oil in line 735 can contain non-distillable components which
include, for example, organometallic compounds, inorganic metallic
compounds, finely divided particulate matter and non-distillable
carbonaceous compounds.
[0126] In one or more embodiments, the residual hydrocarbons in
line 720 can have a temperature of from about 93.degree. C. to
about 593.degree. C., about 121.degree. C. to about 538.degree. C.,
or about 149.degree. C. to about 482.degree. C. In one or more
embodiments, the volumetric feed ratio of waste oil-to-residual can
range from a low of about 1:1, about 2:3 or about 1:3 to a high of
about 400:1, about 300:1, or about 200:1.
[0127] In one or more embodiments, the flash separation unit 770
can have an operating temperature of from about 50.degree. C. to
about 600.degree. C., about 55.degree. C. to about 500.degree. C.,
or about 65.degree. C. to about 460.degree. C. In one or more
embodiments, the flash separation unit 770 can have an operating
pressure of from about 101 kPa to about 17,000 kPa, about 101 kPa
to about 15,500 kPa, or about 101 kPa to about 13,800 kPa. In one
or more embodiments, the flash separation unit 770 can have a
hydrogen circulation rate of from about 100 standard cubic meters
per cubic meter of waste oil feed ("SCM/m.sup.3") to about 15,000
SCM/m.sup.3, about 130 SCM/m.sup.3 to about 13,000 SCM/m.sup.3,
about 170 SCM/m.sup.3 to about 10,100 SCM/m.sup.3. In one or more
embodiments the residence time of the high-temperature
hydrogen-rich gas in line 740, the residual hydrocarbons in line
720, and the waste oils in line 735 within the flash separation
unit 770 can range from a low of about 0.1 sec, about 1 sec., or
about 5 sec., to a high of about 10 sec., about 30 sec., about 50
sec., or more.
[0128] The simultaneous introduction of the high-temperature
hydrogen-rich gas in line 740, the residual hydrocarbons in line
720, and/or the waste oil in line 735 to the flash separation unit
770 can vaporize at least a portion of the hydrocarbon. In one or
more embodiments, all or a portion of the vaporized hydrocarbon via
line 775 can be recovered from the flash separation unit 770. In
one or more embodiments, all or a portion of the residual
hydrocarbon in the flash separation unit 770 can be recovered via
line 780. In one or more embodiments, all or a portion of the
residual hydrocarbons recovered from the flash separation unit 770
via line 780 can provide at least a portion of the hydrocarbons in
line 105.
[0129] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0130] FIG. 8 depicts an illustrative integrated gasification and
separation system integrated with one or more separator/solvent
extraction systems 100, 200, according to one or more embodiments.
The hydrocarbon treatment system 800 can include one or more
gasifiers 810, one or more separators 830, one or more
fractionators 850, one or more regenerators 870, and one or more
separator/solvent extraction systems 100, 200. In one or more
embodiments, the hydrocarbon treatment system 800 can include one
or more systems as disclosed in U.S. Pat. No. 7,033,486. In one or
more embodiments, a hydrocarbon via line 305, which can be as
discussed and described above with reference to FIG. 3, can be
introduced to the one or more gasifiers 810 to provide a suspension
of coke-covered solids and one or more gasified hydrocarbons via
line 815.
[0131] In one or more embodiments, one or more solids introduced to
the gasifier 810 via line 875 can include, but are not limited to
refractory particulates, such as alumina, alpha alumina, zirconia,
titania, hafnia, silica, rare earth modified refractory metal
oxides, where the rare earth may be any rare earth metal (e.g.
lanthanum or yttrium), alkali earth metal modified refractory
oxides, magnesia, a mullite; synthetically prepared or naturally
occurring material such as pumice, ash, clay, kieselguhr,
diatomaceous earth, bauxite, derivatives thereof, or mixtures
thereof.
[0132] In one or more embodiments, all or a portion of the one or
more solids can be inert. The solids can have a substantially
stable surface area at reaction conditions, for example, a surface
area that is not substantially reactive at the operating
conditions, e.g. temperature and pressure. In one or more
embodiments, all or a portion of the one or more solids can be
catalytic. In one or more embodiments, the one or more solids in
line 875 can have an average particle size of about 40 microns to
about 2,000 microns, about 45 microns to about 1,500 microns, or
about 50 microns to about 800 microns. In one or more embodiments,
the one or more solids can be heated prior to being introduced to
the gasifier 810. In one or more embodiments, the one or more
solids in line 875 can have a temperature of from about 450.degree.
C. to about 700.degree. C., about 500.degree. C. to about
675.degree. C., or about 550.degree. C. to about 650.degree. C.
[0133] In one or more embodiments, the hydrocarbon in line 305 can
have a residence time in the gasifier 810 of from about 0.1 sec. to
about 15 sec., about 0.25 sec. to about 10 sec., or about 0.5 sec.
to about 5 sec. In one or more embodiments, the solids in line 875
can have a residence time in the gasifier 810 of from about 5 sec.
to about 60 sec., about 7 sec. to about 45 sec., or about 10 sec.
to about 30 sec. In one or more embodiments, the residence time of
the hydrocarbon within the gasifier 810 and the residence time of
the one or more solids in the gasifier 810 can be independently
controlled. In one or more embodiments, the solids-to-hydrocarbon
weight ratio can range from about 1:1 to about 20:1, about 3:1 to
about 15:1, or about 5:1 to about 10:1.
[0134] The temperature of the suspension of coke-covered solids and
one or more gasified hydrocarbons recovered via line 815 from the
gasifier 810 can be reduced to minimize or stop thermal cracking of
the hydrocarbons contained therein. In one or more embodiments, the
temperature of the suspension in line 815 can be reduced to below
about 500.degree. C., about 450.degree. C., or about 350.degree. C.
In one or more embodiments the suspension in line 815 can be
introduced to the one or more separators 830 to provide a
solids-lean vaporized hydrocarbon via line 835 and coke covered
solids via line 840. In one or more embodiments, the solids-lean
vaporized hydrocarbons in line 835 can have a solids concentration
of about 5% wt or less, about 3% wt or less, about 2% wt or less,
about 1% wt or less, about 0.75% wt or less, or about 0.5% wt or
less.
[0135] In one or more embodiments, the solids-lean vaporized
hydrocarbons in line 835 can be introduced to one or more
fractionators 850 to provide a vaporized overhead fraction via line
855 and a condensed bottom fraction via line 105. In one or more
embodiments, the overhead fraction in line 855 can have a normal
boiling point of about 460.degree. C. or less, about 480.degree. C.
or less, or about 510.degree. C. or less. In one or more
embodiments, the bottom fraction in line 105 can have a normal
boiling point of about 460.degree. C. or more, about 480.degree. C.
or more, or about 510.degree. C. or more. The hydrocarbon in line
105 can be as discussed and described above with reference to FIGS.
1 and 2.
[0136] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0137] FIG. 9 depicts an illustrative tank cleaning and separation
system integrated with one or more separator/solvent extraction
systems 100, 200, according to one or more embodiments. The
hydrocarbon treatment system 900 can include one or more
hydrocarbon storage units 910, one or more separators 950, and one
or more separator/solvent extraction systems 100, 200. In one or
more embodiments, the hydrocarbon treatment system 900 can include
one or more systems as disclosed in U.S. Pat. No. 6,673,231. In one
or more embodiments, one or more heated hydrocarbons via line 305
can be introduced to the one or more hydrocarbon storage units 910
to melt any thickened and/or solidified hydrocarbons 907 within the
one or more hydrocarbon storage unit 910 to provide a flowable
hydrocarbon via line 915. In one or more embodiments, the thickened
and/or solidified hydrocarbons can include asphaltenes, waxes,
bitumens, and insoluble inorganic components and/or particulates
such as rust, clays, metals, and other inorganic compounds.
[0138] In one or more embodiments, the hydrocarbon in line 305 can
be as discussed and described above with reference to FIG. 3. In
one or more embodiments, the heated hydrocarbons in line 305 can
have a temperature of about 100.degree. C., about 150.degree. C.,
about 200.degree. C., about 300.degree. C., or about 400.degree. C.
In one or more embodiments, the heated hydrocarbons in line 305 can
include one or more atmospheric residues, vacuum residues, vacuum
gas oils, light cycle oils, light gas oils, kerosene, mixtures
thereof, derivatives thereof, or any combination thereof. In one or
more embodiments, the weight ratio of the heated
hydrocarbons-to-hydrocarbon solids can range from about 1:1 to
about 30:1, about 2:1 to about 25:1, or about 3:1 to about 20:1. In
one or more embodiments, the heated hydrocarbons in line 305 can
have a high boiling point, high flash point and low vapor pressure.
In one or more embodiments, the heated hydrocarbons in line 305 can
contain a small quantity of paraffinic hydrocarbons.
[0139] In one or more embodiments, after fluidizing, dissolving,
and/or solubilizing all or a portion of the hydrocarbons in the
hydrocarbon storage unit 910, the hydrocarbon mixture can be
withdrawn from the hydrocarbon storage unit 910 via line 915. The
hydrocarbon mixture in line 915 can include, but is not limited to
all or a portion of the elevated temperature hydrocarbons
introduced via line 905, all or a portion of the fluidized,
dissolved, and/or solubilized hydrocarbons from the hydrocarbon
storage unit 910, one or more insoluble particulates the
hydrocarbon storage unit 910, or any combination thereof. In one or
more embodiments, the hydrocarbon mixture in line 915 can have a
temperature of from about 30.degree. C. to about 250.degree. C.,
about 40.degree. C. to about 200.degree. C., or about 50.degree. C.
to about 150.degree. C.
[0140] In one or more embodiments, the hydrocarbon mixture in line
915 can be introduced to the one or more separators 950 to provide
a hydrocarbon mixture via line 105 and a solids slurry via line
955. In one or more embodiments, the solids slurry in line 955 can
have a minimum solids concentration of about 5% wt, about 10% wt,
about 25% wt, or about 50% wt. The one or more separators 950 can
be maintained at or above a minimum temperature to promote the
separation of the hydrocarbon mixture into two or more phases. In
one or more embodiments, the one or more separators can be
maintained at a minimum temperature of about 50.degree. C., about
60.degree. C., about 70.degree. C., or about 75.degree. C. In one
or more embodiments, the separation of the hydrocarbon mixture
within the one or more separators can be a batch process where the
hydrocarbon mixture in line 915 is introduced to the one or more
separators 950 and allowed to settle for an extended period of
time. In one or more embodiments, the settling time within the one
or more separators can be a minimum of about 6 hours, about 8
hours, about 10 hours or about 12 hours.
[0141] In one or more embodiments, the inorganic components and
other insoluble components can be recovered via line 955 and
treated, disposed of, or further processed. In one or more
embodiments, the hydrocarbon in line 105 can be as discussed and
described above with reference to FIGS. 1 and 2. In one or more
embodiments, the hydrocarbon in line 105 can be selectively
separated within the two-stage separator/solvent extraction system
100 to provide the asphaltene product via line 133 and the DAO
product via line 163, as discussed and described above with
reference to FIG. 1. In one or more embodiments, the hydrocarbon in
line 105 can be selectively separated within the three-stage
separator/solvent extraction system 200 to provide the asphaltene
product via line 233, the H-DAO product via line 205 and the L-DAO
product via line 288, as discussed and described above with
reference to FIG. 2.
[0142] FIG. 10 depicts an illustrative distillation based
fractionation system integrated with one or more separator/solvent
extraction systems 100, 200, according to one or more embodiments.
The hydrocarbon treatment system 1000 can include one or more
distillation units 1010 and one or more separator/solvent
extraction systems 100, 200. In one or more embodiments, the
hydrocarbon treatment system 1000 can include one or more systems
as disclosed in U.S. Pat. No. 6,702,936. In one or more
embodiments, a hydrocarbon via line 305, which can be as discussed
and described above with reference to FIG. 3, can be introduced to
the one or more distillation units 1010 to vaporize all or a
portion of the light hydrocarbons present in the hydrocarbon in
line 305.
[0143] The one or more distillation units 1010 can include one or
more distillation units operating at atmospheric and/or
sub-atmospheric pressures. In one or more embodiments, the one or
more distillation unit 1010 can provide an overhead vapor
containing one or more light hydrocarbons via line 1015. In one or
more embodiments, the distillation unit 1010 can provide one or
more fractionated products, for example one or more heavy gas oils
via line 1040, one or more light gas oils via line 1035, one or
more naphthas via line 1030 and one or more light ends via line
1015. In one or more embodiments, the residual, high boiling point
hydrocarbons can exit the distillation unit 1010 via line 105,
which can be as discussed and described above with reference to
FIGS. 1 and 2.
[0144] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0145] In one or more embodiments, all or a portion of the
asphaltenes exiting the one or more separator/solvent extraction
systems 100 and/or 200 via lines 133 and/or 233, respectively, can
be combined to provide an asphaltene feed via line 1050. In one or
more embodiments, the asphaltenes in line 1050 can be introduced to
one or more gasifiers and gasified therein to provide one or more
products including, but not limited to hydrogen, carbon monoxide,
carbon dioxide, or any combination thereof.
[0146] In one or more embodiments, all or a portion of the DAO
recovered via line 163 from the separator/solvent extraction system
100, and/or all or a portion of the H-DAO recovered via line 205
from the separator/solvent extraction system 200 can be combined to
provide a combined DAO in line 1060. In one or more embodiments,
all or a portion of the combined DAO in line 1060 can be introduced
to one or more upgraders, for example one or more cracking units
(not shown).
[0147] FIG. 11 depicts an illustrative hydrogenation system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 1100 can include one or more hydrogenation units
1110 and one or more separator/solvent extraction systems 100, 200.
In one or more embodiments, the hydrocarbon treatment system 1100
can include one or more systems as disclosed in U.S. Pat. No.
6,645,369. In one or more embodiments, a hydrocarbon via line 305
and hydrogen via line 1105 can be introduced to the one or more
hydrogenation units 1110. In one or more embodiments, the
hydrocarbon in line 305 can be as discussed and described above
with reference to FIG. 3.
[0148] In one or more embodiments, the hydrogen in line 1105 can
contain a mixture of hydrogen, carbon monoxide, carbon dioxide, or
any combination thereof, for example a syngas provided from one or
more gasifiers. In one or more embodiments, the hydrogen in line
1105 can have a hydrogen concentration of about 5% mol or more,
about 10% mol or more, about 25% mol or more, about 50% mol or
more, about 75% mol or more, about 90% mol or more, about 95% mol
or more. In one or more embodiments, the hydrogen in line 1105 can
have a carbon monoxide concentration of about 5% mol or more, about
10% mol or more, about 25% mol or more, about 50% mol or more,
about 75% mol or more, about 90% mol or more, about 95% mol or
more. In one or more embodiments, the hydrogen in line 1105 can
have a carbon dioxide concentration of about 5% mol or more, about
10% mol or more, about 25% mol or more, about 50% mol or more,
about 75% mol or more, about 90% mol or more, about 95% mol or
more. In one or more embodiments, the hydrogen in line 1105 can
contain purified hydrogen, having a hydrogen concentration of about
90% mol or more, about 95% mol or more, about 99% mol or more, or
about 99.9% mol or more.
[0149] Within the hydrogenation unit 1110, the hydrogen introduced
via line 1105 can contact the liquid hydrocarbons introduced via
line 305 to provide one or more vaporized hydrocarbons via line
1120 and one or more residual hydrocarbons via line 105. The
residence time within the hydrogenation unit can range from a low
of about 30 seconds, about 60 seconds, about 90 seconds, or about
120 seconds, to a high of about 2 minutes, about 3 minutes, about 5
minutes, or about 10 minutes. In one or more embodiments, the
weight ratio of the hydrogen gas flow to the hydrocarbon flow can
range from a low of about 0.1:1, about 0.5:1, or about 1:1 to a
high of about 2:1, about 3:1, about 5:1, or about 10:1.
[0150] In one or more embodiments, the hydrocarbon in line 305 can
be introduced to the hydrogenation system at an elevated
temperature. In one or more embodiments, the temperature of the
hydrocarbon in line 305 can range from a low of about 20.degree.
C., about 75.degree. C., about 150.degree. C., or about 200.degree.
C. to a high of about 450.degree. C., about 500.degree. C., about
550.degree. C., or about 600.degree. C.
[0151] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0152] FIG. 12 depicts an illustrative thermal treatment system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 1200 can include one or more visbreakers 1210, one
or more heat exchangers 1230, one or more separators 1250, and one
or more solvent extraction systems 100, 200. In one or more
embodiments, the hydrocarbon treatment system 1200 can include one
or more systems as disclosed in U.S. Pat. No. 6,524,469.
[0153] In one or more embodiments, a hydrocarbon via line 305 and
hydrogen via line 1205 can be introduced to the one or more
visbreakers 1210. In one or more embodiments, the hydrocarbon in
line 305 can be as discussed and described above with reference to
FIG. 3. In one or more embodiments, the hydrocarbon can be
preheated prior to introduction to the one or more visbreakers
1210. In one or more embodiments, the hydrocarbon in line 305 can
have a temperature of about 300.degree. C. or more, about
350.degree. C. or more, about 400.degree. C. or more, about
450.degree. C. or more, or about 500.degree. C. or more.
[0154] In one or more embodiments, the hydrogen in line 1205 can
contain a mixture of hydrogen, carbon monoxide, carbon dioxide, or
any combination thereof, for example a syngas provided from one or
more gasifiers. In one or more embodiments, the hydrogen in line
1205 can have a hydrogen concentration of about 5% mol or more,
about 10% mol or more, about 25% mol or more, about 50% mol or
more, about 75% mol or more, about 90% mol or more, about 95% mol
or more. In one or more embodiments, the hydrogen in line 605 can
have a carbon monoxide concentration of about 5% mol or more, about
10% mol or more, about 25% mol or more, about 50% mol or more,
about 75% mol or more, about 90% mol or more, about 95% mol or
more. In one or more embodiments, the hydrogen in line 1205 can
have a carbon dioxide concentration of about 5% mol or more, about
10% mol or more, about 25% mol or more, about 50% mol or more,
about 75% mol or more, about 90% mol or more, about 95% mol or
more. In one or more embodiments, the hydrogen in line 1205 can
contain purified hydrogen, having a hydrogen concentration of about
90% mol or more, about 95% mol or more, about 99% mol or more, or
about 99.9% mol or more.
[0155] In one or more embodiments, the hydrogen in line 1205 can
have a pressure of from about 650 kPa, to about 10,000 kPa, about
1,000 kPa to about 7,000 kPa, or about 1,400 kPa to about 5,500
kPa. The severity in visbreakers can be measured in "equivalent
seconds" at some reference temperature, for example 90 seconds at
469.degree. C. In one or more embodiments, the cracking severity
within the one or more visbreakers 1210 (at about 469.degree. C.)
can be about 30 equivalent seconds to about 120 equivalent seconds,
about 40 equivalent seconds to about 105 equivalent seconds, or
about 60 equivalent seconds to about 90 equivalent seconds.
[0156] The cracked hydrocarbons recovered via line 1215 from the
one or more visbreakers 1210 can be introduced to the one or more
heat exchangers 1230. Within the one or more heat exchangers 1230,
the temperature of the cracked hydrocarbons can be reduced to
provide a cooled hydrocarbon via line 1235. In one or more
embodiments, the cooled hydrocarbon in line 1235 can have a
temperature of from about 170.degree. C. to about 250.degree. C.,
about 180.degree. C. to about 240.degree. C., or about 190.degree.
C. to about 230.degree. C.
[0157] In one or more embodiments, at least a portion of the cooled
hydrocarbons in line 1235 can be introduced to one or more
separators 1250 wherein at least a portion of the lighter
hydrocarbons can vaporize or flash, to provide one or more
vaporized hydrocarbons via line 1255 and one or more non-vaporized
hydrocarbons via line 105. In one or more embodiments, the
hydrocarbon in line 105 can be similar to the hydrocarbon in line
105 discussed and described above with reference to FIGS. 1 and
2.
[0158] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0159] FIG. 13 depicts an illustrative extraction system integrated
with one or more separator/solvent extraction systems 100, 200,
according to one or more embodiments. The hydrocarbon treatment
system 1300 can include one or more mixers 1310, one or more heat
exchangers 1330, one or more separators 1350, and one or more
separator/solvent extraction systems 100, 200. In one or more
embodiments, the hydrocarbon treatment system 1300 can include one
or more butoxy-ethanol extraction systems as disclosed in U.S. Pat.
No. 6,464,856.
[0160] In one or more embodiments, the hydrocarbon in line 305 and
solvent in line 1305 can be mixed or otherwise combined using the
mixer 1310 to provide a mixture. In one or more embodiments, the
hydrocarbon in line 305 can be as discussed and described above
with reference to FIG. 3. In one or more embodiments, the solvent
in line 1305 can be a mixture of butoxy-ethanol and water. The
butoxy-ethanol concentration in the solvent in line 1305 can be
about 5% wt or more, about 10% wt or more, about 20% wt or more,
about 25% wt or more, or about 30% wt or more, with the balance
water. In one or more embodiments, the hydrocarbon to solvent
weight ratio can be about 0.5:1 or more, about 1:1 or more, about
2:1 or more, about 3:1 or more, or about 5:1 or more. The
hydrocarbon and solvent mixture can exit the one or more mixers
1310 via line 1315.
[0161] The mixture in line 1315 can be introduced to one or more
heaters 1330 to provide a heated mixture via line 1335. The
temperature of the heated mixture in line 1335 can range from a low
of about 35.degree. C., about 40.degree. C., about 45.degree. C.,
or about 50.degree. C. to a high of about 80.degree. C., about
85.degree. C., about 90.degree. C., or about 95.degree. C. Heating
the mixture above about 40.degree. C. can promote the separation of
the mixture into two or more phases.
[0162] The heated mixture in line 1335 can be introduced to the one
or more separators 1350. Within the one or more separators 1350,
the mixture can separate into two or more phases, with hydrocarbons
collecting on the top of an upper phase and within the interface
region between the upper phase and a lower phase. In one or more
embodiments, the upper phase can have a butoxy-ethanol
concentration of about 50% wt or more, about 55% wt or more, about
60% wt or more, about 65% wt or more, about 70% wt or more with the
balance water. In one or more embodiments, the lower phase can have
a butoxy-ethanol concentration of less than about 20% wt, about 15%
wt, about 10% wt, about 5% wt with the balance water.
[0163] The surface and interface hydrocarbons can be withdrawn from
the separator via line 105. The butoxy-ethanol rich upper layer can
be withdrawn via line 1355. In one or more embodiments, all or a
portion of the butoxy-ethanol rich upper layer in line 1355 can be
withdrawn from the separator 1350 and recycled for reuse or
recovery. The water-rich lower layer can be withdrawn from the
separator 1350 via line 1360. In one or more embodiments, the
water-rich lower layer can be treated prior to disposal or
recycle.
[0164] In one or more embodiments, the hydrocarbon via line 105,
which can be as discussed and described above with reference to
FIGS. 1 and 2. In one or more embodiments, the hydrocarbon in line
105 can be selectively separated within the two-stage
separator/solvent extraction system 100 to provide the asphaltene
product via line 133 and the DAO product via line 163, as discussed
and described above with reference to FIG. 1. In one or more
embodiments, the hydrocarbon in line 105 can be selectively
separated within the three-stage separator/solvent extraction
system 200 to provide the asphaltene product via line 233, the
H-DAO product via line 205 and the L-DAO product via line 288, as
discussed and described above with reference to FIG. 2.
[0165] FIG. 14 depicts an illustrative solids removal system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 1400 can include one or more mixers 1410, one or
more separation units 1430, and one or more separator/solvent
extraction systems 100, 200. In one or more embodiments, the
hydrocarbon treatment system 1400 can include one or more solids
removal systems as disclosed in U.S. Pat. No. 6,274,030.
[0166] In one or more embodiments a hydrocarbon via line 305 and
solvent via line 1405 can be mixed or otherwise combined using the
one or more mixers 1410. The hydrocarbon in line 305 can be as
discussed and described above with reference to FIG. 3. In one or
more embodiments, the solvent can be an alkane solvent having an
alkane concentration of about 70% wt or more, about 75% wt or more,
about 80% wt or more, about 85% wt or more, about 90% wt or more.
In one or more embodiments, the solvent can include, but is not
limited to propane, butane, pentane, hexane, heptane, mixtures
thereof, or any combination thereof. In one or more specific
embodiments, the solvent can include propane and butane. In one or
more embodiments, the solvent can have a propane concentration of
about 5% wt or more, about 25% wt or more, about 50% wt or more,
about 75% wt or more, about 95% wt or more with the balance
butane.
[0167] In one or more embodiments, mixing of the solvent with the
hydrocarbon within the one or more mixers 1410 can sufficiently
reduce the viscosity of the hydrocarbon to permit the selective
separation of the solids present in the hydrocarbon. The mixture
can exit the one or more mixers 1410 via line 1420. In one or more
embodiments, the solvent/hydrocarbon mixture in line 1420 can have
a temperature of from about 50.degree. C. to about 370.degree. C.,
about 55.degree. C. to about 300.degree. C., or about 60.degree. C.
to about 200.degree. C.
[0168] In one or more embodiments, the mixture in line 1420 can be
introduced to one or more separation units 1430. Within the one or
more separation units 1430, all or a portion of the solids present
in the mixture can be selectively separated. A slurry containing
the recovered solids can be withdrawn from the separation unit 1430
via line 1435, while the mixture can be withdrawn via line 105. In
one or more embodiments, the solids recovered from the hydrocarbon
can include, but are not limited to silica, alumina, iron, clays,
suspended catalyst fines, entrained catalyst fines, or any
combination thereof. In one or more embodiments, the filter can
remove solids of about 25 microns and larger, about 50 microns and
larger, about 100 microns and larger, about 200 microns and larger,
about 400 microns and larger, about 800 microns and larger, or
about 1,000 microns and larger.
[0169] In one or more embodiments, the mixture can contain less
than about 50% wt solids, less than about 30% wt solids, less than
about 20% wt solids, less than about 10% wt solids, less than about
5% wt solids, less than about 3% wt solids, or less than about 1%
wt solids.
[0170] In one or more embodiments, the one or more separation units
1430 can be any system, device, or any combination of systems
and/or devices suitable for separating at least a portion of the
solids from the mixture. In one or more embodiments, the one or
more separation units 1430 can include a filter, a gravity
separator, a centrifuge, a cyclone, or combinations thereof. In one
or more embodiments, the one or more separation units 1430 can
include a ceramic filter that can be similar to the filter
described in U.S. Pat. No. 5,785,860. In one or more embodiments,
the solids can be separated by other suitable methods in lieu of
the filter 1430 or in addition to the filter 1430. Another method
may be an electrodynamic method in which a strong electric field is
imposed to collect solids, as described in U.S. Pat. No. 5,843,301.
Another method can include a magnetic method in which a strong
magnetic field is imposed to collect solids, as described in U.S.
Pat. No. 5,607,575.
[0171] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2. In one or more embodiments, the recovered
solvent in line 279 and/or the recovered solvent in line 179 can be
recycled or otherwise introduced via line 1405 to the one or more
mixers 1410 to provide at least a portion of the solvent introduced
to the one or more mixers 1410.
[0172] FIG. 15 depicts an illustrative demetallization system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more. The hydrocarbon treatment
system 1500 can include one or more mixers 1510 and one or more
separator/solvent extraction systems 100, 200. In one or more
embodiments, the hydrocarbon treatment system 1500 can include one
or more demetallization systems as disclosed in U.S. Pat. No.
6,245,222.
[0173] In one or more embodiments, the hydrocarbon in line 305 and
an additive via line 1515 can be introduced to one or more mixers
1510. In one or more embodiments, the hydrocarbon in line 305 can
be as discussed and described above with reference to FIG. 3. In
one or more embodiments, the additive can be a metal-complexing
additive. In one or more embodiments, the additive in line 1515 can
include one or more alkane-insoluble polyoxy-alkylene group
containing additives, for example an alky (polyoxyalkylene) moiety.
In one or more embodiments, the additive can be selected from a
group of compounds insoluble in the solvent used in the one or more
separator/solvent extraction systems 100, 200. The additive can be
introduced to the one or more mixers 1510 ranging from a low of
about 0.25% wt, about 0.5% wt, about 1.0% wt, or about 1.5% wt, or
about 2.0% wt to a high of about 5.0% wt, about 10.0% wt, or about
20.0% wt based upon the weight of the hydrocarbon in line 305. In
one or more embodiments, the mixer 1510 can operate at a
temperature of from about 20.degree. C. to about 200.degree. C.,
about 50.degree. C. to about 150.degree. C., or about 75.degree. C.
to about 125.degree. C.
[0174] When mixed or otherwise combined with the hydrocarbon in the
mixer 1510, the additive can combine with the metals present in the
hydrocarbon in line 305, including, but not limited to
organo-metallic compounds, such as organo-nickel, organo-vanadium,
organo-iron, heteroatoms, derivatives thereof, or any combination
thereof. The metal-complexing additive can combine with all or a
portion of the metals present in the hydrocarbon in line 305,
forming one or more insoluble organo-metallic complexes.
[0175] In one or more embodiments, a hydrocarbon mixture that can
include the insoluble organo-metallic complexes can be recovered
via line 105 from the mixer 1510. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
two-stage separator/solvent extraction system 100 to provide the
asphaltene product via line 133 and the DAO product via line 163,
as discussed and described above with reference to FIG. 1. In one
or more embodiments, the hydrocarbon in line 105 can be selectively
separated within the three-stage separator/solvent extraction
system 200 to provide the asphaltene product via line 233, the
H-DAO product via line 205 and the L-DAO product via line 288, as
discussed and described above with reference to FIG. 2.
[0176] FIG. 16 depicts an illustrative solids separation and
hydrocarbon recovery system integrated with one or more
separator/solvent extraction systems 100, 200, according to one or
more embodiments. The hydrocarbon treatment system 1600 can include
one or more primary separators 1610, one or more secondary
separators 1650, and one or more separator/solvent extraction
systems 100, 200. In one or more embodiments, the hydrocarbon
treatment system 1600 can include one or more solids separation and
hydrocarbon recovery systems as disclosed in U.S. Publication No.:
2006/0249439. In one or more embodiments, the hydrocarbon in line
305, which can be as discussed and described above with reference
to FIG. 3, can be mixed or otherwise contacted with a diluent
introduced via line 1605 and optionally one or more recycled
hydrocarbons introduced via line 1655.
[0177] In one or more embodiments, the diluent introduced via line
1605 can include a solvent, including, but not limited to light
naphthas, heavy naphthas, whole naphthas, paraffinic hydrocarbons,
alkane hydrocarbons, mixtures thereof, derivatives thereof, or any
combination thereof. In one or more embodiments, the hydrocarbon in
line 305 can be mixed or otherwise combined with the solvent in
line 1605 and, optionally, one or more recycled hydrocarbons via
line 1655 to provide a diluted hydrocarbon in line 1607. The
addition of the solvent to the hydrocarbon can reduce the viscosity
of the hydrocarbon, permitting the settling of any solids present
in the hydrocarbon.
[0178] The diluted hydrocarbon in line 1607 can be introduced to
one or more primary separators 1610 where at least a portion of any
solids present in the hydrocarbon can settle. The settled solids
can be recovered via line 1615 from the primary separator 1610. The
hydrocarbons can be recovered via line 105 from the primary
separator 1610. In one or more embodiments, the settled solids in
line 1615 can have a solids concentration of about 10% wt or more,
about 20% wt or more, about 30% wt or more, about 40% wt or more,
about 50% wt or more.
[0179] In one or more embodiments, the solids in line 1615 can be
introduced to the one or more secondary separators 1650 to provide
further separate additional hydrocarbons from the solids. In one or
more embodiments, the one or more secondary separators 1650 can
include one or more centrifugal separators, for example one or more
cyclones. The solids can be recovered via line 1660 from the
secondary separator 1650. The separated hydrocarbons can be
recovered via line 1655 from the secondary separator 1650. In one
or more embodiments, the solids in line 1660 can have a solids
concentration of about 10% wt or more, about 20% wt or more, about
30% wt or more, about 40% wt or more, about 50% wt or more. In one
or more embodiments, the recovered hydrocarbons in line 1655 can
have a solids concentration of about 20% wt or less, about 15% wt
or less, about 10% wt or less, about 5% wt or less, about 3% wt or
less, about 1% wt or less, about 0.5% wt or less.
[0180] In one or more embodiments, at least a portion of the
recovered hydrocarbons can be recycled via line 1655 to the
hydrocarbon in line 305. In one or more embodiments, at least a
portion of the recovered hydrocarbons via line 1655 can be
introduced to the separated hydrocarbons in line 105.
[0181] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0182] FIG. 17 depicts an illustrative emissions reduction system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 1700 can include one or more mixers 1710, and one
or more separator/solvent extraction systems 100, 200. In one or
more embodiments, the hydrocarbon treatment system 1700 can include
one or more emissions reduction systems as disclosed in U.S.
Publication No.: 2006/0116450. In one or more embodiments, a
hydrocarbon in line 305, which can be as discussed and described
above with reference to FIG. 3, can be mixed or otherwise combined
with an emissions reducing additive ("ERA") introduced via line
1705.
[0183] The ERA can include one or more metal oxides suspended in a
hydrocarbon carrier. In one or more embodiments, the one or more
metal oxides can include one or more transition metal oxides,
including but not limited to zinc oxide, copper oxide, iron oxide,
aluminum oxide, or any combination thereof. In one or more
embodiments, the ERA can be in the form of a powder, flake or
granule. In one or more embodiments, the ERA can be dispersed,
suspended, emulsified, or otherwise mixed in a diluent hydrocarbon
having a flash point less than the flash point of the hydrocarbon
in line 305, for example mineral oil, Sunpave 125, Hydrolene, light
flux oils or the like. Where the diluent hydrocarbon has a flash
point less than the hydrocarbon in line 305, the ERA concentration
in the diluent hydrocarbon can be about 5% wt or more, about 10% wt
or more, about 15% wt or more, about 20% wt or more, about 25% wt
or more, about 30% wt or more, 50% wt or more, or about 60% wt or
more.
[0184] In one or more embodiments, one or more additives, in
addition to the ERA, such as sulfonating agents and/or crosslinking
agents can be introduced via line 1705. The cross-linking agents
can be activators, e.g., zinc oxide, accelerators, such as sulfur
compounds, e.g., mercaptobenzothizole (MBT) or both accelerators
and activators, such as a zinc salt of MBT, for example. In one
embodiment, the cross-linking agent can be a metal oxide. Although
the metal oxide can be the same or a different metal oxide than the
ERA, such cross-linking metal oxide can be added in addition to the
metal oxide ERA, when used. In another embodiment, the
cross-linking agent can be a sulfur containing compound. The
additives can further include unsaturated functional monomers,
unsaturated carboxylic acids, unsaturated dicarboxylic acids,
unsaturated anhydrides, unsaturated esters and/or unsaturated
amides, for example.
[0185] The ERA/diluent hydrocarbon solution and/or one or more
additional additives in line 1750 and the hydrocarbon in line 305
can be mixed or otherwise combined to provide one or more reduced
emissions hydrocarbons via line 105. In one or more embodiments,
the reduced emissions hydrocarbons in line 105 can have an ERA
concentration of from about 0.05% wt to about 2% wt, about 0.07% wt
to about 1% wt, or about 0.05% wt to about 0.09% wt, or about 0.1%
wt to about 0.2% wt. In one or more embodiments, the one or more
mixers 1710 can have an operating temperature of from about
100.degree. C. to about 300.degree. C., about 150.degree. C. to
about 250.degree. C., or about 175.degree. C. to about 225.degree.
C.
[0186] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0187] FIG. 18 depicts another illustrative distillation system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 1800 can include one or more heat exchangers (two
are shown, 1810 and 1850), one or more atmospheric distillation
units ("ADUs") 1830, one or more vacuum distillation units ("VDUs")
1870, and one or more separator/solvent extraction systems 100,
200. In one or more embodiments, the distillation system can
include one or more distillation systems as disclosed in U.S.
Publication No.: 2006/0032789.
[0188] In one or more embodiments, a hydrocarbon in line 305, which
can be as discussed and described above with reference to FIG. 3,
can be heated using the one or more heat exchangers 1810 to provide
a heated hydrocarbon via line 1815. In one or more embodiments, the
temperature of the heated hydrocarbon in line 1815 can be about
100.degree. C. or more, about 150.degree. C. or more, about
200.degree. C. or more, about 300.degree. C. or more, or about
400.degree. C. or more.
[0189] The heated hydrocarbon in line 1815 can be introduced to one
or more atmospheric distillation units 1830, where at least a
portion of the hydrocarbons can vaporize to provide a vaporized
hydrocarbon mixture via line 1840. In one or more embodiments, the
vaporized hydrocarbon mixture in line 1840 can be selectively
separated or otherwise fractionated to provide one or more finished
hydrocarbon products including, but not limited to light naphthas,
full-range naphthas, C.sub.6 and lighter alkanes, or any
combination thereof. In one or more embodiments, non-vaporized,
residual hydrocarbons can be recovered via line 1835 from the one
or more ADUs 1830. In one or more embodiments the operating
pressure of the one or more ADUs 1830 can range from a low of about
100 kPa, about 150 kPa, about 200 kPa, or about 250 kPa, to a high
of about 300 kPa, about 350 kPa, about 400 kPa, or about 450
kPa.
[0190] In one or more embodiments the temperature of the residual
hydrocarbons in line 1835 can be increased using the one or more
heat exchangers 1850 to provide heated residual hydrocarbons via
line 1855. In one or more embodiments, the temperature of the
heated residual hydrocarbons in line 1855 can be about 100.degree.
C. or more, about 150.degree. C. or more, about 200.degree. C. or
more, about 300.degree. C. or more, or about 400.degree. C. or
more.
[0191] In one or more embodiments, the heated residual hydrocarbons
via line 1855 can be introduced to one or more VDUs 1870 where at
least a portion of the hydrocarbons can vaporize to provide a
vaporized hydrocarbon mixture via line 1880. In one or more
embodiments, non-vaporized, residual hydrocarbons ("resid") can be
recovered via line 105 from the one or more VDUs 1870. In one or
more embodiments the operating pressure of the one or more VDU 1870
can range from a low of about 0 kPa, about 10 kPa, about 20 kPa, or
about 25 kPa, to a high of about 80 kPa, about 85 kPa, about 90
kPa, or about 95 kPa.
[0192] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0193] FIG. 19 depicts an illustrative asphaltene blending system
integrated with one or more separator/solvent extraction systems
100, 200, according to one or more embodiments. The hydrocarbon
treatment system 1900 can include one or more mixers 1910 and one
or more separator/solvent extraction systems 100, 200. In one or
more embodiments, the hydrocarbon treatment system 1900 can include
an asphaltene blending system as disclosed in U.S. Publication No.:
2006/0000749.
[0194] In one or more embodiments, a hydrocarbon in line 305, which
can be as discussed and described above with reference to FIG. 3
can be introduced to the one or more mixers 1910. In one or more
embodiments, the hydrocarbon in line 305 can contain one or more
hydrophilic asphaltenic hydrocarbons. To reduce the wetting
tendency of the hydrophilic asphaltenes in the hydrocarbon in line
305, a solution containing one or more hydrophobic asphaltenic
hydrocarbons in line 1905 can be mixed or otherwise combined with
the hydrocarbon in line 305 to provide an asphaltenic hydrocarbon
mixture having reduced wetting tendencies via line 105.
[0195] In one or more embodiments, the hydrocarbon feed in line 305
can contain one or more hydrophobic asphaltenic hydrocarbons. To
reduce the wetting tendency of the hydrophobic asphaltenes in the
hydrocarbon in line 305, a solution containing one or more
hydrophilic asphaltenic hydrocarbons in line 1905 can be mixed or
otherwise combined with the hydrocarbon in line 305 to provide an
asphaltenic hydrocarbon mixture having reduced wetting tendencies
via line 105.
[0196] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0197] FIG. 20 depicts an illustrative fractionating and
hydrorefining system integrated with one or more separator/solvent
extraction systems 100, 200, according to one or more embodiments.
The hydrocarbon treatment system 2000 can include one or more heat
exchangers (two are shown 2010 and 2050), one or more fractionators
2030, one or more hydrorefiners 2070, and one or more
separator/solvent extraction systems 100, 200. In one or more
embodiments, the hydrocarbon treatment system 2000 can include one
or more fractionation and hydrorefining systems as disclosed in
U.S. Publication No.: 2004/0069685.
[0198] In one or more embodiments, a hydrocarbon in line 305, which
can be as discussed and described above with reference to FIG. 3,
can be heated using the one or more heat exchangers 2010 to provide
a heated hydrocarbon via line 2015. In one or more embodiments, the
temperature of the heated hydrocarbon in line 2015 can be about
100.degree. C. or more, about 150.degree. C. or more, about
200.degree. C. or more, about 300.degree. C. or more, or about
400.degree. C. or more. The heated hydrocarbon in line 2015 can be
introduced to one or more fractionators 2030 where at least a
portion of the hydrocarbons present can be vaporized to provide a
vaporized hydrocarbon mixture via line 2035. One or more
non-vaporized residual hydrocarbons can be recovered via line 105
from the fractionator 2030.
[0199] In one or more embodiments, all or a portion of the
vaporized hydrocarbons in line 2035 can be heated using the one or
more heat exchangers 2050 to provide a heated vaporized hydrocarbon
in line 2055. In one or more embodiments, the temperature of the
vaporized hydrocarbons in line 2055 can be about 100.degree. C. or
more, about 150.degree. C. or more, about 200.degree. C. or more,
about 300.degree. C. or more, or about 400.degree. C. or more.
[0200] In one or more embodiments, all or a portion of the heated
hydrocarbon in line 2055 and hydrogen via line 2065 can be
introduced to the one or more hydrorefiners 2070. The hydrogen
introduced via line 2065 to the one or more hydrorefiners 2070 can
have a hydrogen concentration of about 40% wt or more, about 50% wt
or more, about 60% wt or more, about 70% wt or more, about 80% wt
or more, about 90% wt or more, about 95% wt or more, about 99% wt
or more.
[0201] In one or more embodiments, the hydrogen in line 2065 can
contain a mixture of hydrogen, carbon monoxide, carbon dioxide, or
any combination thereof, for example a syngas provided from one or
more gasifiers. In one or more embodiments, the hydrogen in line
2065 can have a hydrogen concentration of about 5% mol or more,
about 10% mol or more, about 25% mol or more, about 50% mol or
more, about 75% mol or more, about 90% mol or more, about 95% mol
or more. In one or more embodiments, the hydrogen in line 2065 can
have a carbon monoxide concentration of about 5% mol or more, about
10% mol or more, about 25% mol or more, about 50% mol or more,
about 75% mol or more, about 90% mol or more, about 95% mol or
more. In one or more embodiments, the hydrogen in line 605 can have
a carbon dioxide concentration of about 5% mol or more, about 10%
mol or more, about 25% mol or more, about 50% mol or more, about
75% mol or more, about 90% mol or more, about 95% mol or more. In
one or more embodiments, the hydrogen in line 2065 can contain
purified hydrogen, having a hydrogen concentration of about 90% mol
or more, about 95% mol or more, about 99% mol or more, or about
99.9% mol or more.
[0202] The one or more hydrorefiners 2070 can include one or more
catalysts suitable for hydrogenating unsaturated hydrocarbons. In
one or more embodiments, the one or more hydrorefiners 2070 can use
one or more fixed catalyst beds, one or more moving catalyst beds,
or any combination thereof. In one or more embodiments, a
hydrotreated hydrocarbon via line 2075 can be recovered from the
one or more hydrorefiners 2070.
[0203] In one or more embodiments, the hydrocarbon in line 105 can
be selectively separated within the two-stage separator/solvent
extraction system 100 to provide the asphaltene product via line
133 and the DAO product via line 163, as discussed and described
above with reference to FIG. 1. In one or more embodiments, the
hydrocarbon in line 105 can be selectively separated within the
three-stage separator/solvent extraction system 200 to provide the
asphaltene product via line 233, the H-DAO product via line 205 and
the L-DAO product via line 288, as discussed and described above
with reference to FIG. 2.
[0204] Referring to FIGS. 1-20, in one or more embodiments at least
a portion of at least one of the DAO product via line 163 and the
asphaltene product via line 133 from the two-stage
separator/solvent extraction system, the H-DAO product via line
205, the L-DAO product via line 288, and the asphaltene product via
line 233 from the three-stage separator/solvent extraction system
200, or any combination thereof can be introduced to one or more
delayed cokers. The hydrocarbon introduced to the delayed coker can
be heated and subjected to destructive thermal cracking to provide
lower-boiling point petroleum distillate products and solid
carbonaceous residue, also referred to as coke.
[0205] In one or more embodiments, the coke provided from the one
or more cokers can be fuel grade coke and/or anode grade coke. As
used herein, the term "anode grade coke" is petroleum coke which
has a sulfur content of less than 3% wt, a total metals content of
less than 500 ppm, a nickel content of less than 200 ppm, a
vanadium content less than 350 ppm, a bulk density of at least
800.9 kg/m.sup.3, a Hardgrove grindability index ("HGI") greater
than 70, and a volatile carbonaceous matter ("VCM") content of less
than 10-12% wt. Fuel grade coke is coke which does not meet one or
more of the specifications required for anode grade coke.
[0206] In one or more embodiments, a portion of the hydrocarbon in
line 105, the H-DAO product in line 205, and/or the DAO product in
line 163 can be hydrotreated in a hydrotreater to provide a
hydrotreated hydrocarbon and lighter hydrocarbon products. In one
or more embodiments, at least a portion of the hydrotreated
hydrocarbon can be introduced to the coker. In one or more
embodiments, at least a portion of the hydrocarbon in line 105 can
be hydrotreated in a hydrotreater before introducing the
hydrocarbon to the two-state separator/solvent extraction system
100 and/or the three-stage separator/solvent extraction system 200.
In one or more embodiments, at least a portion of the hydrocarbon
in line 105 can be hydrotreated in a hydrotreater to provide a
hydrotreated hydrocarbon which can then be introduced directly to
the one or more delayed cokers.
[0207] In one or more embodiments, the one or more delayed cokers
can include one or more systems, devices, or combination of systems
and/or devices suitable for providing anode coke, fuel coke, or
both. The one or more delayed cokers can be heated to a temperature
ranging from about 425.degree. C. to about 485.degree. C. and can
operate at a pressure ranging from about 100 kPa to about 225 kPa.
In one or more embodiments, the hydrotreater can be operated at a
temperature ranging from about 310.degree. C. to about 375.degree.
C. and a pressure ranging from about 4,000 kPa to about 5,600 kPa.
Typical, non-limiting, processes integrating solvent deasphalting,
hydrotreating, and coking are disclosed in U.S. Pat. Nos.
4,940,529; 5,013,427; 5,124,027; 5,228,978; 5,242,578; 5,258,117;
5,312,543; and 6,332,975.
[0208] Certain embodiments and features have been described using a
set of numerical upper limits and a set of numerical lower limits.
It should be appreciated that ranges from any lower limit to any
upper limit are contemplated unless otherwise indicated. Certain
lower limits, upper limits and ranges appear in one or more claims
below. All numerical values are "about" or "approximately" the
indicated value, and take into account experimental error and
variations that would be expected by a person having ordinary skill
in the art.
[0209] Various terms have been defined above. To the extent a term
used in a claim is not defined above, it should be given the
broadest definition persons in the pertinent art have given that
term as reflected in at least one printed publication or issued
patent. Furthermore, all patents, test procedures, and other
documents cited in this application are fully incorporated by
reference to the extent such disclosure is not inconsistent with
this application and for all jurisdictions in which such
incorporation is permitted.
[0210] While the foregoing is directed to embodiments of the
present invention, other and further embodiments of the invention
may be devised without departing from the basic scope thereof, and
the scope thereof is determined by the claims that follow.
* * * * *