U.S. patent application number 13/527146 was filed with the patent office on 2012-10-18 for methods and compositions for removing residues and substances from substrates using environmentally friendly solvents.
Invention is credited to Ruben G. Carbonell, Peter Kilpatrick, Nael Zaki.
Application Number | 20120264671 13/527146 |
Document ID | / |
Family ID | 27767927 |
Filed Date | 2012-10-18 |
United States Patent
Application |
20120264671 |
Kind Code |
A1 |
Carbonell; Ruben G. ; et
al. |
October 18, 2012 |
METHODS AND COMPOSITIONS FOR REMOVING RESIDUES AND SUBSTANCES FROM
SUBSTRATES USING ENVIRONMENTALLY FRIENDLY SOLVENTS
Abstract
Environmentally friendly solvents used to dissolve or remove
residues and/or substances from substrates wherein the residue
and/or substance is contacted with a Generally Recognized As Safe
solvent to dissolve the residue and/or substance in the solvent
followed by the extraction of the residue and/or substance from the
solvent such as by contact with carbon dioxide.
Inventors: |
Carbonell; Ruben G.;
(Raleigh, NC) ; Kilpatrick; Peter; (Cary, NC)
; Zaki; Nael; (Raleigh, NC) |
Family ID: |
27767927 |
Appl. No.: |
13/527146 |
Filed: |
June 19, 2012 |
Related U.S. Patent Documents
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Application
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Patent Number |
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13221059 |
Aug 30, 2011 |
8201445 |
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13527146 |
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12844080 |
Jul 27, 2010 |
8006551 |
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13221059 |
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12336045 |
Dec 16, 2008 |
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12844080 |
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11634754 |
Dec 6, 2006 |
7465395 |
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12336045 |
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10374119 |
Feb 25, 2003 |
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11634754 |
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60359935 |
Feb 27, 2002 |
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60359826 |
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60359976 |
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60359975 |
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Current U.S.
Class: |
510/405 |
Current CPC
Class: |
C10G 29/22 20130101;
C10G 21/08 20130101; C11D 11/0076 20130101; C10G 21/003 20130101;
C11D 7/266 20130101; C11D 7/5022 20130101; C10G 2300/206 20130101;
C10G 2300/44 20130101; C10G 1/04 20130101; C10G 21/16 20130101;
B01D 11/0288 20130101; C10G 2300/301 20130101 |
Class at
Publication: |
510/405 |
International
Class: |
C11D 3/20 20060101
C11D003/20 |
Claims
1. A composition comprising: a. between 70 and 95 percent by weight
of an aromatic ester; b. between 5 and 30 percent by weight of a
co-solvent; and c. between 0 and 10 percent by weight of a
surfactant.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 13/221,059 now U.S. Pat. No. 8,201,445 issued Jun. 19, 2012,
which is a continuation of U.S. application Ser. No. 12/844,080,
filed on Jul. 27, 2010 now U.S. Pat. No. 8,006,551 issued Aug. 30,
2011, which is a continuation of patent application Ser. No.
12/336,045, filed Dec. 16, 2008 (now abandoned), which is a
continuation of U.S. patent application Ser. No. 11/634,754, filed
Dec. 6, 2006 now U.S. Pat. No. 7,465,395, which is a continuation
of U.S. patent application Ser. No. 10/374,119, filed Feb. 25, 2003
(now abandoned), which claims the benefit of, and incorporates
herein by reference in their entireties, the following U.S.
Provisional Applications: U.S. Provisional Application No.
60/359,935, filed Feb. 27, 2002 (now abandoned); U.S. Provisional
Application No. 60/359,826 (now abandoned), filed Feb. 27, 2002;
U.S. Provisional Application No. 60/359,976 (now abandoned), filed
Feb. 27, 2002; and U.S. Provisional Application No. 60/359,975 (now
abandoned), filed Feb. 27, 2002.
FIELD OF THE INVENTION
[0002] This invention relates to methods and compositions for
removing residues and substances from substrates and/or
compounds.
BACKGROUND OF THE INVENTION
[0003] Various wanted and unwanted substances or residues may be
removed from objects or substrates using various methods. For
instance, chemical solvents may be used to remove unwanted residues
from machinery, unwanted particles from products, or otherwise.
Solvents may also be used to extract residues or substances from
chemical compositions, products, or materials. For instance, a
solvent may be used to separate a particular chemical compound from
a mixture of chemical compounds. However, many of the solvents
typically used by industry are not environmentally friendly. In
fact, many of the solvents are hazardous materials and are
expensive to use, maintain, control, and dispose of.
[0004] As one example, solvents are used to remove the build-up of
solid and liquid petroleum residues and substances from substrates
such as processing equipment. The build-up of oil residues such as
asphalt and asphalt-related liquids (e.g., tar, pitch, and tack) on
processing equipment utilized in petroleum and chemical processing,
storage, and transport industries, as well as equipment used in
highway and road construction, has long been problematic. After a
certain level of build-up occurs, the equipment is often no longer
capable of being used for its intended purpose. Accordingly, it is
typically necessary to clean such equipment. Diesel fuel or a
similar type of fuel has been used in the past for cleaning
construction equipment. However, the use of these solvents has
largely fallen into disfavor due to heightened environmental
concerns. See e.g., Federal Water Pollution Control Act Amendments
of 1972 (PL 92-500) Section 311(b)(1).
[0005] Another alternative is to employ organic solvents. Such
solvents also pose potential environmental concerns. For instance,
chlorinated solvents such as 1,1,1-trichloroethane or methylene
chloride may be used to remove petroleum residues or substances
from substrates. Moreover, notwithstanding any potential benefits
associated therewith, these solvents are typically less than fully
effective in removing petroleum residue. More specifically, these
solvents are often not able to remove hard-to-dissolve petroleum
residue fractions such as asphaltenes. Accordingly, these fractions
are typically removed by employing labor-intensive efforts that are
often time-consuming and expensive.
[0006] As another example, there is a current increasing interest
in extracting wanted tar sand oil from its naturally occurring
ores. Such ores are substantial underutilized sources of fossil
fuels, particularly, for example, in Venezuela, Canada, and the
United States. As crude oil reserves become relatively heavier, the
need and consequent demand for recovering bitumen fractions from
inorganic substrates (e.g., tar sands) increases.
[0007] Examples of methods currently employed in the extraction of
tar sands involve the use of hot water, organic solvents, or
petroleum distillates. During hot water extraction, emulsions are
formed that are often difficult to break and to efficiently
separate bitumen from water. These processes usually result in the
generation of relatively high quantities of wastewater, termed
"extraction tailings". Methods of wastewater treatment are often
needed to allow a production site to attempt to comply with
environmental regulations. Extractions with organic solvents or
petroleum distillates often utilize materials of relatively high
capital value to obtain bitumen of a lower capital value. Moreover,
solvent extraction typically requires significant expenditures of
equipment and energy to separate extracted bitumen from the organic
solvent. As a result, it is extremely difficult on a commercial
scale to employ extraction methods employing organic solvents.
[0008] The treatment and remediation of asphaltenic deposits
occurring in different places in the production, refining, and
transportation of crude oil is also desirous. Many crude oils are
prone to form asphaltenic deposits. These deposits are detrimental
to the productivity of the reservoir (as they clog the porosity of
the pay zone), throughput of the pipeline, efficiency of the
desalter and gas-liquid separator, and the storage capacity of a
storage tank. Currently these asphaltenic deposits are either
removed mechanically, or by employing expensive and environmentally
irresponsible solvents.
[0009] Therefore, it is desirous to develop and use compositions
and methods for removing residues or substances from substrates
without the employment of expensive manual processes or expensive,
and often environmentally hazardous, organic solvent extraction
processes.
SUMMARY OF THE INVENTION
[0010] Embodiments of the present invention include compositions
and methods for extracting or removing residues and/or substances
from substrates. In certain embodiments, the residues and/or
substances are removed from a substrate using an environmentally
responsible solvent, for example, a Generally Recognized As Safe
(also known as "GRAS") solvent. Preferably the GRAS solvent is
miscible with carbon dioxide. Once removed, the residues or
substances may be removed from a GRAS solvent, such as by
contacting the GRAS solvent with carbon dioxide to separate any
residue and/or substance from the GRAS solvent. For example, a
petroleum residue may be removed from a substrate in the form of a
tool by contacting the tool with a GRAS solvent composition, and
the GRAS solvent composition could be separated from the dissolved
or collected petroleum residue by contacting the GRAS solvent with
carbon dioxide and precipitating the petroleum residue.
[0011] The methods and compositions of various embodiments of the
present invention may be used to remove or dissolve petroleum-based
residues or substances from substrates. In various embodiments, the
invention comprises a method of removing petroleum residue from a
substrate. The method comprises contacting the substrate with a
solvent such that the petroleum residue separates from the
substrate and is dissolved in the solvent. The solvent may include
a GRAS solvent such as an ester-containing solvent. For example, a
residue on a substrate may be separated from the substrate (e.g., a
tool, tar sand, aqueous stream, etc.) by contacting the substrate
with a benzoic acid ester-containing solvent such that the
petroleum residue separates from the substrate and is dissolved in
the benzoic acid ester-containing solvent. The solvent may be used
to remove residues and/or substances from organic or inorganic
substrates.
[0012] In other embodiments of the invention, the quantity of
bitumen present in a petroleum residue sample may be determined
using the compositions and methods of the present invention. A
petroleum sample may be contacted with a GRAS solvent to remove
bitumen from the sample. The weight of the bitumen extracted from
the petroleum sample may be determined from weight measurements of
the sample before and after being contacted with the GRAS solvent.
Alternatively, the bitumen extracted by the GRAS solvent from the
sample may be extracted from the GRAS solvent by contact with
carbon dioxide and weighed or otherwise measured.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0013] The invention can be more readily ascertained from the
following description of the invention when read in conjunction
with the accompanying drawings in which:
[0014] FIG. 1 compares precipitated bitumen (weight percent) versus
pressure at different temperatures, and corresponds to Example
8.
[0015] FIG. 2 compares precipitated bitumen (weight percent) versus
preserve at different bitumen concentration, and corresponds to
Example 9.
[0016] FIG. 3 compares precipitated bitumen (weight percent) versus
carbon dioxide density, and corresponds to Example 10.
[0017] FIG. 4 compares precipitated bitumen (weight percent) versus
pressure at different solvent to carbon dioxide ratios, and
corresponds to Example 11.
[0018] FIG. 5 compares precipitated bitumen (weight percent) versus
pressure using single batch extraction and multiple batch
extraction at 25.degree. C., and corresponds to Example 12.
[0019] FIG. 6 compares precipitated bitumen (weight percent) versus
pressure using single batch extraction and multiple batch
extraction at 35.degree. C., and corresponds to Example 13.
[0020] FIG. 7 compares precipitated bitumen (weight percent) versus
pressure using single batch extraction and multiple batch
extraction at 50.degree. C., and corresponds to Example 14.
[0021] FIG. 8 compares precipitated bitumen (weight percent) versus
pressure using single batch extraction and multiple batch
extraction at 80.degree. C., and corresponds to Example 15.
[0022] FIG. 9 compares precipitated bitumen (weight percent) versus
pressure using single batch extraction and multiple batch
extraction at 100.degree. C., and corresponds to Example 16.
[0023] FIG. 10 compares the amount of extracted bitumen as a
function of both temperature and pressure, and corresponds to
Example 18.
[0024] FIG. 11 compares the amount of extracted bitumen as a
function of both temperature and pressure, and corresponds to
Example 19.
DETAILED DESCRIPTION OF THE INVENTION
[0025] This invention may, however, be embodied in many different
forms and should not be construed as limited to the embodiments set
forth herein; rather, these embodiments are provided so that this
disclosure will be thorough and complete, and will fully convey the
scope of the invention to those skilled in the art and optionally
collected or removed.
[0026] In general, the present invention provides a method of
dissolving a petroleum-based substance. The petroleum-based
substance is contacted with a carbon dioxide miscible solvent and a
portion of the petroleum-based substance is dissolved. The
dissolved petroleum-based substance is separated and contacted with
carbon dioxide such that the petroleum-based substance is
precipitated.
[0027] For example, a substrate is contacted with a carbon dioxide
miscible solvent to extract or remove a residue or desired
substance from the substrate. A substrate may be fed to a first
reaction chamber to which a solvent is also fed. The solvent
contacts the substrate within the reaction chamber and dissolves or
otherwise separates a residue or desired substance from the
substrate. A product stream of the solvent with dissolved and/or
suspended residue or substances removed from the substrate in the
first reaction chamber may then be fed to a second reaction chamber
where the solvent is contacted with carbon dioxide to remove any
residue dissolved or otherwise suspended in the solvent from the
solvent.
[0028] In various embodiments, the invention provides a method of
removing petroleum residue from a substrate. A substrate may be an
organic substrate, an inorganic substrate, or a combination
thereof. The method comprises contacting the substrate with a
solvent such that the petroleum residue separates from the
substrate and is dissolved in the solvent. The solvent, in addition
to being carbon dioxide miscible, is preferably an environmentally
friendly solvent such as a solvent that is Generally Recognized As
Safe. Such solvents are also known as "GRAS solvents" and such term
is used throughout the description to represent such solvents. For
instance, ester-containing solvents such as benzoic acid
ester-containing solvents are representative GRAS solvents that may
be used as compositions of various embodiments of the present
invention or with the methods of various embodiments of the present
invention.
[0029] The term "substrate" is to be construed broadly and refers
to various liquid materials, solid materials, combinations thereof,
including, without limitation, semi-liquid and/or semi-solid
materials, which contain a substance or residue to be removed,
dissolved or extracted. In various embodiments, the residue may be
"on" the surface of the substrate, may be embedded, entrained or
contained within the substrate, or may be partially embedded,
entrained or contained within the substrate. Inorganic (e.g., metal
and ceramic) and organic substrates, as well as alloys and
composites thereof, are well within the scope of the invention. In
various embodiments, for example petroleum substance recovery
processes, exemplary substrates may be present in and/or on
articles of manufacture employed in the petroleum refining,
storage, and transportation fields, including, without limitation,
cleaning storage tanks, electrostatic desalters, API separators,
slop oil tanks, electrostatic precipitators, crude oil storage
tanks, gas separators, pipelines, reservoirs, and the like.
[0030] The term "inorganic substrate" is to be construed broadly
and refers to various materials that contain a petroleum residue.
In particular, the petroleum residue may be "on" the surface of the
substrate, may be embedded, entrained or contained within the
substrate, or may be partially embedded, entrained or contained
within the substrate. Inorganic substrates include those formed
from or containing inorganic compounds such as, without limitation,
mineral ores, mineral oxides, rock, clay, silica, as well as
combinations thereof Preferred inorganic substrates are those that
are tar or oil sands and oil shales.
[0031] The term "dissolved in the solvent" is to be broadly
construed to refer to residue being solubilized or entrained in a
solvent. The term may refer to a one-phase solution or a
multi-phasic, or biphasic, dispersion or suspension in the solvent.
Accordingly, the term is intended to encompass all embodiments in
which a residue could be fully soluble, partially soluble, or
insoluble in a solvent according to embodiments of the present
invention.
[0032] The term "tar or oil sands" is defined broadly as porous
sandstone structures occurring on the surface and depths well below
the surface that are impregnated with heavy, viscous black crude
oil that typically cannot be retrieved well by conventional
production techniques. For the purposes of the invention, the terms
"bituminous sands" or "oil sands" may be used as an alternative to
tar sands. Tar sands typically contain a sizeable proportion of
bitumen, containing primarily asphaltenes and heavy low volatility
fractions of maltha, typically together with a substantial
percentage of sulfur and heavy metals.
[0033] The term "oil shale" is to be broadly construed and
typically refers to extensive sedimentary rock deposits typically
containing a relatively high percentage of kerogen.
[0034] For the purposes of the invention the term "petroleum
residue" is to be broadly construed and includes, without
limitation, material that is typically present in various
applications that are related to petroleum products (e.g., crude
oils, asphaltic residues, coal tar, waxes, resins, petroleum
sludges, and tank bottoms), and any number of by-products. For the
purposes of the invention, "petroleum residue" encompasses heavy
petroleum fractions preferably having a boiling point of at least
150.degree. C. or 200.degree. C., more preferably at least
340.degree. C., which includes a mixture of paraffinic and aromatic
hydrocarbons along with heterocyclic compounds containing sulfur,
nitrogen, and oxygen. Asphalt, as well as residues and related
materials thereof, also are construed as being encompassed by the
term "petroleum residue" for the purposes of the invention. The
asphalt content varies considerably as known by one skilled in the
art. For example, in one embodiment, the asphalt content may vary
from 3 to 8 percent. In another embodiment, the asphalt content may
vary from 4 to 6 percent. The asphalt content may be higher or
lower. For example, in a roofing application, the asphalt content
may be higher.
[0035] As understood by one skilled in the art, asphalt is a
product of crude oil refining. In an exemplary asphalt production
process, crude oil is distilled in a primary flash distillation
column, the residue of this process is introduced to an atmospheric
distillation column. The residue of the atmospheric distillation
process is typically distilled under reduced pressure (e.g., vacuum
distillation), and the residue is termed asphalt. The asphalt
produced from the vacuum distillation of crude oil typically has
softening points ranging from 25.degree. C. to 55.degree. C.
Asphalts of intermediate softening points may be made, for example,
by blending with higher and lower softening point asphalts. If the
asphalt has a low softening point, it can be hardened by further
distillation with steam or by oxidation (e.g., air blowing).
Furthermore, asphalt can be also produced by propane deasphalting
in the production of lubricating oils from crude oil residual. The
asphalt produced by propane deasphalting may have a softening point
of about 90.degree. C. Softer grades may be made by blending the
hard asphalt with the extract obtained in the solvent treatment of
lubricating oils.
[0036] In general, "asphalt" may be defined as the residue of
mixed-base and asphalt-base crude oils. For the most part, it is
difficult to distill even under the highest vacuum, because such
temperatures which are often employed tend to promote formation of
coke. For the most part, asphalts have complex chemical and
physical compositions that usually vary with the source of the
crude oil and are considered dispersions or solutions of particles
or aggregates, called asphaltenes, in a high-boiling fluid composed
of oil and resins. Asphaltene content in petroleum residues vary
widely as known. As appreciated in the art, the nature of the
asphalt is often determined by such factors as the nature of the
medium (e.g., paraffinic or aromatic), as well as the nature and
proportion of the asphaltenes and of the resins. The polar and
fused ring portions of the asphaltenes have been suggested to be
lyophobic; the resins are considered to be lyophilic, and the
"interaction" of the resins with the asphaltenes is believed to be
responsible for asphaltene solvation or dispersion, which seems to
exercise marked control on the quality of the asphalt. The
asphaltenes vary in character, but typically are either of
sufficiently high molecular weight or aggregate size to require
solvation or dispersion by the resins. Various asphaltic materials
may be removed from substrates by the various embodiments of the
present invention. As an example, cutbacks and emulsions compose
liquid asphalts. A cutback may be defined as a cement that has been
liquefied with solvents such as, for example, naptha or gasoline or
kerosene. Emulsified asphalts are mixtures of asphalt cement, water
and an emulsifying agent.
[0037] An important class of petroleum residue is bitumen. As known
in the art, "bitumen" is defined as a mixture of hydrocarbons
occurring in the petroleum. Other components such as, for example,
oils, waxes, resins, pitch and tack are typically present in the
petroleum residue. Bitumen is also well understood to be the liquid
fuel product obtained by extraction of petroleum from tar or oil
sands. Another component of the petroleum residue is the asphaltene
fraction, which is present as part of the bitumen. For the purposes
of this invention, the term "asphaltenes" is defined to be
components of the high boiling point fraction of the crude oil
which are composed of polynuclear aromatic hydrocarbons of
molecular weights ranging from 500 to 2000 or greater and aggregate
molecular weights of up to 20,000 joined by alkyl chains. See,
e.g., Hawley's Condensed Chemical Dictionary, 12.sup.th Ed.,
Richard J. Lewis, Sr., Editor, (1993), p. 101.
[0038] As discussed above, a solvent according to an embodiment of
the present invention may include an ester contained GRAS solvent,
and for example a benzoic acid ester-containing solvent. The
benzoic acid ester containing solvent comprises one or more benzoic
acid esters. Exemplary benzoic acid esters include, without
limitation, methyl benzoic acid ester, ethyl benzoic acid ester,
n-propylbenzoic acid ester, isobutylbenzoic acid ester, n-butyl
benzoic acid ester, tert-butyl benzoic acid ester, isomers of
pentylbenzoic acid ester, isopropylbenzoic acid ester, and mixtures
thereof.
[0039] An exemplary benzoic acid ester is isopropylbenzoic acid
ester ("IPB"). Preferably, in various embodiments, the benzoic acid
ester-containing solvent contains at least about 70, 80, 85, 90,
95, or 99 percent by weight of the one or more benzoic acid esters.
In one preferred embodiment, the benzoic acid ester-containing
solvent contains from about 90 to about 95 percent by weight of the
one or more benzoic acid esters. The benzoic acid ester may contain
other components, processing aids, and the like as deemed
appropriate by one skilled in the art.
[0040] The benzoic acid ester-containing solvent is potentially
environmentally-advantageous in that, in a preferred embodiment, it
has a flash point (open cup) greater than about 98.degree. C.
(e.g., 98.9.degree. C.). The benzoic acid ester-containing solvent
is potentially nontoxic, readily biodegradable, and has a UK OCNS
rating category E which is the least toxic category of this method
of evaluating toxic chemicals, meanwhile category A being the most
toxic. Any compound rated from C-E typically signifies that the
material may be readily biodegradable and may be nonbioaccumulative
(Offshore Chemical Notification Scheme).
[0041] In one preferred embodiment, the benzoic acid
ester-containing solvent is substantially devoid of surfactant; in
any event, as an example, the benzoic acid ester-containing solvent
may, in certain preferred embodiments, contain no more than about
0.01 weight percent of surfactant. Accordingly, in embodiments
which employ little if any surfactant, the benzoic acid
ester-containing solvent is non-foaming. In other preferred
embodiments, the benzoic acid ester-containing solvent is
non-ionic. In other embodiments, the benzoic acid ester-containing
solvents may be free or essentially free of phosphate-acids,
halogen-containing compounds (e.g., chlorine-containing solvents
such as methylene chloride and 1,1,1-trichloroethane), and/or
petroleum distillates, as well as combinations thereof, e.g.,
preferably 1, 0.5, or 0.1 percent by weight of such solvents.
Advantageously, after extraction in one embodiment, the
concentration of petroleum residue in the benzoic acid
ester-containing solvent may range from about 5 to about 30
weight/volume (wt/vol) percent.
[0042] Other components may be used in the benzoic acid
ester-containing solvent, the selection of which is known to one
skilled in the art. For example, limonene, terpeneoids, alkyl
phthalate esters, alkyl esters of cyclohexanoic acid, glycerol
fatty acid esters (diglycerides and triglycerides), glycerol,
ethylene glycol, polyethylene glycol, propylene glycol,
alkanolamines, such as: ethanolamine, diethanolamine,
triethanolamine, propanolamine, and butanolamine may be used.
[0043] Other GRAS solvents may include other ester-containing
solvents. In a preferred embodiment, the ester is an "aromatic
ester compound" which may be defined as an ester-containing
substituent attached to a substituted or an unsubstituted aromatic
ring. Exemplary ester compounds include, without limitation,
salicylic acid esters, cinnamic acid esters, propionic acid esters,
butyric acid esters, pentanoic acid esters, and hexanoic acid
esters.
[0044] Exemplary salicylic acid esters include, without limitation,
methyl salicylate, ethyl salicylate, n-propyl salicylate, isobutyl
salicylate, n-butyl salicylate, tert-butyl salicylate, isomers of
pentyl salicylate, isomers of hexyl salicylate, isomers of heptyl
salicylate, isopropyl salicylate, and mixtures thereof.
[0045] Exemplary cinnamic acid esters include, without limitation,
methyl cinnamate, ethyl cinnamate, n-propyl cinnamate, isobutyl
cinnamate, n-butyl cinnamate, tert-butyl cinnamate, isomers of
pentyl cinnamate, isomers of hexyl cinnamate, isomers of heptyl
cinnamate, isopropyl cinnamate, benzyl cinnamate, and mixtures
thereof.
[0046] Exemplary propionic acid esters include, without limitation,
phenyl propionate, benzyl propionate, hydroxyphenyl propionate,
methyl phenyl propionate, isobutyl phenyl propionate, n-butyl
phenyl propionate, tert-butyl phenyl propionate, isomers of pentyl
phenyl propionate, isomers of hexyl phenyl propionate, isomers of
heptyl phenyl propionate, isopropyl phenyl propionate, and mixtures
thereof.
[0047] Exemplary butyric acid esters include, without limitation,
phenyl butyrate, benzyl butyrate, hydroxyphenyl butyrate, methyl
phenyl butyrate, isobutyl phenyl butyrate, n-butyl phenyl butyrate,
tert-butyl phenyl butyrate, isomers of pentyl phenyl butyrate,
isomers of hexyl phenyl butyrate, isomers of heptyl phenyl
butyrate, isopropyl phenyl butyrate, and mixtures thereof.
[0048] Exemplary pentanoic acid esters include, without limitation,
phenyl pentanoate, benzyl pentanoate, hydroxyphenyl pentanoate,
methyl phenyl pentanoate, isobutyl phenyl pentanoate, n-butyl
phenyl pentanoate, tert-butyl phenyl pentanoate, isomers of pentyl
phenyl pentanoate, isomers of hexyl phenyl pentanoate, isomers of
heptyl phenyl pentanoate, isopropyl phenyl pentanoate, and mixtures
thereof.
[0049] Exemplary hexanoic acid esters include, without limitation,
phenyl hexanoate, benzyl hexanoate, hydroxyphenyl hexanoate, methyl
phenyl hexanoate, isobutyl phenyl hexanoate, n-butyl phenyl
hexanoate, tert-butyl phenyl hexanoate, isomers of pentyl phenyl
hexanoate, isomers of hexyl phenyl hexanoate, isomers of heptyl
phenyl hexanoate, isopropyl phenyl hexanoate, and mixtures
thereof.
[0050] Preferably, the ester-containing solvent contains at least
about 70, 85, 90, 95, or 99 percent by weight of the one or more of
the esters. In one preferred embodiment, the ester-containing
solvent contains from about 70 to about 95 percent by weight of the
ester. The ester-containing solvent may contain other components,
processing aids, and the like as deemed appropriate by one skilled
in the art.
[0051] The method of removing petroleum residue from a substrate
may encompass numerous steps. In one embodiment, for example, the
method further comprises the step of contacting the carbon dioxide
miscible or GRAS solvent with a fluid comprising carbon dioxide,
wherein the petroleum residue is recovered in the fluid such that
the carbon dioxide miscible or GRAS solvent is separated from the
petroleum residue, e.g., at least 95 weight percent of the carbon
dioxide miscible or GRAS solvent is separated from the petroleum
residue. Furthermore, the method of the invention may further
comprise the step of recycling the carbon dioxide miscible or GRAS
solvent for further use. Moreover, in another embodiment, the
invention may encompass the step of subjecting the substrate to a
fluid or gas comprising carbon dioxide ("CO.sub.2") or hydrocarbon
gas to remove a portion of the petroleum residue from the
substrate, with the subjecting step occurring prior to the step of
contacting the substrate with the carbon dioxide miscible or GRAS
solvent.
[0052] In one embodiment, bitumen can be removed and recovered from
a petroleum residue. The substance containing bitumen is contacted,
preferably in a reaction vessel, with a GRAS solvent. At least a
portion of the bitumen is dissolved in the solvent. The dissolved
bitumen and solvent is contacted with CO.sub.2 to precipitate the
bitumen from the solvent. The precipitated bitumen is then
recovered. The weight of bitumen extracted may be determined from
weight measurements of the sample before and after contacting with
the GRAS solvent. The solvent may remove from about 5, 10, 20, 30,
or 40 to about 60, 70, 80, 90, or 100 percent by weight of bitumen
from a petroleum residue based on the weight of bitumen that is
present in the residue. In one embodiment, a petroleum residue
comprises asphaltene. In a preferred embodiment, the contacting
step comprises removing from about 60 or 70 to about 80, 90, or 100
percent by weight of asphaltene based on the asphaltene present in
the petroleum residue, although it should be appreciated that other
amounts may be removed in accordance with the present invention.
The asphaltene content of the petroleum residue ranges from about 1
to 30 percent by weight, although it should be appreciated that
other amounts may be removed in accordance with the present
invention.
[0053] For the purposes of the invention, carbon dioxide may be
employed in the fluid in a liquid, gaseous, or supercritical phase.
Preferably, the fluid comprises carbon dioxide in a continuous
phase, and typically has a concentration ranging from about 10, 20,
30, or 40 to about 60, 70, 80, 90 or up to 100 percent by weight of
carbon dioxide. If liquid CO.sub.2 is used, the temperature
employed during the process is preferably below 31.degree. C. If
gaseous CO.sub.2 is used, it is preferred that the phase be
employed at high pressure. As used herein, the term "high pressure"
generally refers to CO.sub.2 having a pressure from about 500 to
about 5,000 psi. In a preferred embodiment, the CO.sub.2 is
utilized in a "supercritical" phase. As used herein,
"supercritical" means that a fluid medium is above its critical
temperature and pressure, i.e., above about 31.degree. C. and above
about 71 bar (1,073 psi) for CO.sub.2. The thermodynamic properties
of CO.sub.2 are reported in Hyatt, J. Org. Chem. 49: 5097-5101
(1984); therein, it is stated that the critical temperature of
CO.sub.2 is about 31.degree. C.; thus the method of the present
invention may be carried out at a temperature above 31.degree. C. A
preferred pressure of the carbon dioxide containing fluid ranges
from about 1000 psi to 3000 psi.
[0054] Other optional components may be used in the fluid
containing carbon dioxide, the selection of which is known to one
skilled in the art. Examples of other components include, without
limitation, co-solvents, surfactants, co-surfactants, buffers,
rheology modifiers, biological agents, and viscosity reduction
modifiers. Other components may be used in the carbon dioxide
containing fluid, the selection of which may be determined by the
skilled artisan. The components that may be added to CO.sub.2
include but are not limited to gases such as, nitrogen, oxygen,
argon, helium, nitrogen dioxide, methane, ethane, propane, butane,
and hydrogen sulfide, alcohols such as, methanol, ethanol,
isopropanol, n-propanol, and the like, ethers, such as, dimethyl
ether, methyl-ethyl ether, methyl-isopropyl ether and the like,
polymers, specially those that are soluble in CO.sub.2 such as
polysiloxanes, fluorinated polymers such as,
poly(hexafluoropropylene oxide) poly(vinyledenefluoride),
sugar-containing diblock fluorocopolymers,
Bis(perfluoro-2-N-propoxypropionyl) peroxide and fluorosurfactants
such as, poly(1,1-dihydroperfluorooctyl acrylate) ,
PS-b-poly(dimethylsiloxane) and 1,1-dihydroperfluorooctyl
acrylate-hexamethylcyclotrisiloxane diblock copolymer. It is also
contemplated that gases other than CO.sub.2 could be employed. For
example, hydrocarbon gases such as methane, ethane or argon or
mixtures thereof can be used.
[0055] The removal of petroleum residue from the substrate may be
carried out by using known equipment. The solvent, for example, may
be applied to the substrate by using known and accepted systems. In
a preferred embodiment, the application of the benzoic acid
ester-containing solvent typically takes place from about 1 to
about 20 min, at a temperature ranging from about 10.degree. C. to
about 50.degree. C. With respect to asphalt cleaning for example,
the solvent is typically sprayed under pressure on the
residue-containing tools that are placed on a perforated grid
capable of filtering the solvent from the inorganic
solvent-insoluble contaminants. The filtered solvent is stored in
containers for further treatment with CO.sub.2.
[0056] Embodiments encompassing the use of the fluid containing
carbon dioxide may take place in a number of vessels, cells, or
other delivery systems, the selection of which is known to one
skilled in the art. For example, the extraction of the petroleum
residue may be carried out either batchwise, continuously, or
semi-continuously, in appropriately designed reaction vessels or
cells. Additional features may be employed such as, for example,
agitation devices (e.g., a paddle stirrer or impeller stirrer) and
heaters (e.g., a heating furnace or heating rods). These vessels or
cells may be modified in accordance with the scope of the present
invention, particularly in view of the specific substrate.
[0057] In general, the methods of the present invention may employ
solvents for removing petroleum residue in a number of varied
applications. Examples of such applications include, without
limitation:
[0058] Agricultural applications, such as: cattle sprays,
dampproofing and waterproofing buildings and structures,
disinfectants, fence post coating, mulches, mulching paper, paved
barn floors, barnyards, feed platforms, and the like, protecting
tanks, vats, and the like, protection for concrete structures, tree
paints, water and moisture barriers (above & below ground),
wind and water erosion control, and weather modification areas.
Buildings and building applications, such as: floors, e.g.,
damp-proofing and water-proofing building and structures, floor
compositions, tiles and coverings, insulating fabrics, papers, step
treads; roofing, e.g., building papers, built-up roof adhesives,
felts, primes, caulking compounds, cement waterproofing compounds,
cleats for roofing, glass wool compositions, insulating fabrics,
felts, papers, joint filler compounds, laminated roofing, shingles,
liquid roof coatings, plastic cements, and shingles; walls, siding,
ceilings, e.g., acoustical blocks, compositions, felts,
architectural decoration, bricks, brick siding, building blocks,
papers, damp-proofing coatings, compositions, insulating board,
fabrics, felts, paper, joint filler compounds, masonry coatings,
plaster boards, putty, asphalt, siding compositions, soundproofing,
stucco base, and wallboard; hydraulics and erosion control
applications, e.g., canal linings, sealants, catchment areas,
basins, dam groutings, dam linings, protection, dike protection,
ditch linings drainage gutters, structures, embankment protection,
groins, jetties, levee protection, mattresses for levee and bank
protection, membrane linings, waterproofing, ore leaching pads,
reservoir linings, revetments, sand dune stabilization, sewage
lagoons, oxidation ponds, swimming pools, waste ponds, and water
barriers; industrial applications, e.g., aluminum oil compositions
using asphalt backed felts, conduit insulation, lamination,
insulating boards, paint compositions, papers, pipe wrapping,
roofing, shingles, automotive, acoustical compositions, felts,
brake linings, clutch facings, floor sound deadeners, friction
elements, insulating felts, panel boards, shim strips, tacking
strips, underseal, electrical, armature carbons, windings, battery
boxes, carbons, electrical insulating compounds, papers, tapes,
wire coatings, junction box compound, molded conduits,
compositions, black grease, buffing compounds, cable splicing
compound, embalming, etching compositions, extenders, rubber,
other, explosives, fire extinguisher compounds, joint fillers, lap
cement, lubricating grease, pipe coatings, dips, joint seals,
plastic cements, plasticizers, preservatives, printing inks, well
drilling fluid, wooden cask liners, impregnated, treated materials,
armored bituminized fabrics, burlap impregnation, canvas treating,
carpeting medium, deck cloth impregnation, fabrics, felts, mildew
prevention, packing papers, pipes and pipe wrapping, planks, rugs,
asphalt base, saw dust, cork, asphalt composition, textiles,
waterproofing, tiles, treated leather, wrapping papers, paints,
varnishes, etc, acid-proof enamels, mastics, varnishes,
acid-resistant coatings, air-drying paints, varnishes,
anti-corrosive & anti-fouling paints, anti-oxidants and
solvents, base for solvent compositions, baking and heat resistant
enamels, boat deck sealing compound, lacquers, japans, marine
enamels, belting, blasting fuses, briquette binders, burial vaults,
casting molds, clay articles, clay pigeons, depilatory, expansion
joints, flower pots, foundry cores, friction tape, gaskets,
imitation leather, mirror backing, phonograph records, rubber,
molded compounds, shoe fillers, soles, table tops, airport runways,
taxiways, aprons, etc., asphalt blocks, brick fillers, bridge deck
surfacing, crack fillers, curbs, gutters, drainage ditches, floors
for buildings, warehouses, garages, etc., highways, roads, streets,
shoulders, parking lots, driveways, pcc underseal, roof-deck
parking, sidewalk, footpaths, soil stabilization,
ballast-treatment, curve lubricant, dust laying, paved ballast,
sub-ballast, paved crossings, freight yards, station platforms,
rail fillers, railroad ties, tie impregnating, stabilization, paved
surfaces for: dance pavilions, drive-in movies, gymnasiums, sports
arenas, playgrounds, school yards, race tracks, running tracks,
skating rinks, swimming & wading pools, tennis courts, handball
courts, crude oil spills, wildlife cleanup, and tar sand
separation.
[0059] In another embodiment, the invention relates to a method for
determining the quantity of bitumen present in a petroleum residue
sample comprising bitumen. The method comprises contacting the
petroleum residue sample with a GRAS solvent to remove the bitumen
therefrom. The weight of the bitumen in the sample is determined by
comparing the initial weight of the petroleum residue and the
weight of the remaining portion of the petroleum residue. In a
preferred embodiment, a remaining portion of the petroleum residue
is present in the form of inorganic material.
[0060] The method of determining the quantity of bitumen present in
a petroleum residue sample may include other optional embodiments.
As an example, the petroleum residue comprises bitumen and
inorganic material, and wherein the inorganic material remains
subsequent to the step of contacting the petroleum residue sample
with a GRAS solvent, the method further comprising contacting the
inorganic material at least once with an organic solvent to remove
GRAS solvent from the petroleum residue sample. Preferably, the
inorganic material is contacted several times with the organic
solvent.
[0061] A number of organic solvents may be employed in the above
method. Exemplary organic solvents include, without limitation,
C.sub.1-C.sub.4 alcohols. A preferred organic solvent is
ethanol.
[0062] Optionally, the method of determining the quantity of
bitumen present in a petroleum residue sample may also include
various other steps set forth herein, including without limitation,
those involving carbon dioxide. As an example, in one embodiment,
the method further comprising the step of contacting the benzoic
acid ester-containing solvent comprising petroleum residue with a
fluid comprising carbon dioxide, wherein the petroleum residue is
recovered in the fluid such that the benzoic acid ester-containing
solvent is separated from the petroleum residue.
[0063] The invention will now be described in greater detail with
respect to the examples that follow. It should be understood that
these examples are set forth merely for illustrating the invention,
and do not limit the scope of the invention as defined by the
claims.
Example 1
Experimental Protocol for Single-Batch Extraction Experiments of
Tar Sand Samples Using CO.sub.2
[0064] A tar sand sample is placed in a high-pressure 20 mL
capacity reactor. The reactor is heated to the desired temperature,
the system is pressurized with CO.sub.2 at 10 mL/min flow rate
until the desired pressure is reached by means of a high-precision
syringe pump. The system is left for 1 hr at the desired
temperature and pressure after which CO.sub.2 and the extracted
bitumen is conveyed under pressure to another reactor supplied with
sapphire windows (view-cell) at a rate of 10 mL/min. After cooling
the extract to ambient temperature, CO.sub.2 is slowly discharged
from the system at a rate of 1 mL/min. The system is thereafter
opened, the extracted bitumen is collected quantitatively by
dissolving in MeCl.sub.2, and the solvent is evaporated in a vacuum
oven at 50.degree. C. for 24 hrs.
[0065] The mass of the extracted bitumen is calculated and the
percentage extraction is obtained. The total bitumen content of the
sample is determined by MeCl.sub.2 extraction.
Example 2
Experimental Protocol for Single-Batch Extraction Experiments of
Asphalt Samples Using CO.sub.2
[0066] The procedure according to Example 1 is repeated except that
an asphalt sample is employed instead of a tar sand sample.
Example 3
Experimental Protocol for Single-Batch Extraction Experiments of
Bitumen Samples Using CO.sub.2
[0067] The procedure according to Example 1 is repeated except that
a bitumen sample is employed instead of a tar sand sample.
Example 4
Extraction of Bitumen from Tar Sands Using Esters
[0068] A bitumen sample, either subjected to extraction with
CO.sub.2, or without being subjected to CO.sub.2 extraction, is
placed in a Buchner funnel. The ester solvent or solvent mixture is
added continuously until the color of the liquid did not changed,
indicating complete bitumen extraction. The solution of bitumen in
the aromatic ester solvent, or solvent mixture, is then charged in
a high-pressure view cell. CO.sub.2 is pressurized at a specified
flow rate until the desired pressure is reached using a precision
syringe pump. The temperature is maintained and controlled at the
set temperature by means of a thermostated heating tape. The system
is stirred by means of a magnetic stirrer. The system is left to
equilibrate until there was no more bitumen precipitation observed
through the sapphire windows of the view cell. When apparent
complete precipitation of bitumen occurred, the compressed gas is
allowed to discharge into a series of cooled traps, where CO.sub.2
is separated from the ester solvent. When the system was completely
depressurized from CO.sub.2, the precipitated bitumen is retrieved
and quantified.
Example 5
Isopropyl Salicylate Miscibility in Carbon Dioxide
[0069] The miscibility of isopropyl salicylate is evaluated in
liquid, gaseous, or supercritical carbon dioxide under a number of
conditions using high pressure equipment. Carbon dioxide is
determined to be completely miscible with isopropyl salicylate at
the following conditions: 1:1, 1:2, 1:3, 1:4, 1:5, 2:1, 3:1, 4:1,
and 5:1, CO.sub.2:isopropyl salicylate vol.:vol. ratios, at the
following temperatures: 25, 35, 45, and 60.degree. C., and at the
following pressures: 500, 1000, 1500, 2000, 2500, 3000, 3500, 4000,
4500, and 5000 psi.
Example 6
Experimental Protocol for Multiple-Batch Extraction Experiments
Using CO.sub.2
[0070] An asphalt sample is placed in a high-pressure 20 mL
capacity reactor. The reactor is heated to the desired temperature
and then pressurized with CO.sub.2 to the desired pressure at 10
mL/min flow rate by means of a high-precision syringe pump. The
system is left for 1 hr at the desired temperature and pressure
after which CO.sub.2 and the extracted bitumen is conveyed under
pressure to another reactor supplied with sapphire windows
(view-cell) at a rate of 10 mL/min followed by another transfer to
a second view cell in the same manner. After cooling the extract to
ambient temperature, CO.sub.2 is slowly discharged from the system
at a rate of 1 mL/min, the system is repressurized as described in
the above steps. The process is repeated six times and the
residence time for each step is fixed at 15 min. At the end of the
sixth extraction, the system is opened, and the extracted bitumen
is collected from both of the two view cells quantitatively by
dissolving in MeCl.sub.2. The solvent is then evaporated in a
vacuum oven at 50.degree. C. for 24 hrs. The mass of the extracted
bitumen is then calculated and the percentage extraction is
obtained.
[0071] The total bitumen content of asphalt is obtained by
MeCl.sub.2 extraction.
Example 7
Extraction of Bitumen from Tar Sands Using a Benzoic Acid Ester
[0072] A bitumen sample, either subjected to extraction with
CO.sub.2, or without being subjected to CO.sub.2 extraction, is
placed in a Buchner funnel. The benzoic acid ester solvent or
solvent mixture is added continuously until the color of the liquid
did not change, indicating complete bitumen extraction. The
solution of bitumen in the solvent is then charged in a
high-pressure view cell. CO.sub.2 is pressurized at a specified
flow rate until the desired pressure is reached using a precision
syringe pump. The temperature is maintained and controlled at the
set temperature by means of a thermostated heating tape. The system
is stirred by means of a magnetic stirrer. The system is left to
equilibrate until there is no more bitumen precipitation observed
through the sapphire windows of the view cell. When apparent
complete precipitation of bitumen occurred, the compressed gas is
allowed to discharge into a series of cooled traps, where CO.sub.2
is separated from the aromatic ester solvent. When the system is
completely depressurized from CO.sub.2, the precipitated bitumen is
retrieved and quantified.
Example 8
Effect of Temperature on Bitumen Precipitation
[0073] The effect of temperature on the removal of bitumen from a
benzoic acid ester-containing solvent by employing a carbon dioxide
fluid is measured. The bitumen is present in the solvent in an
amount of 4 wt./vol/percent. The bitumen is present in the solvent
in a 1:3 ratio. As can be seen from FIG. 1, the amount of
precipitated bitumen decreased with temperature for a given
pressure value.
Example 9
Effect of Concentration on Bitumen Precipitation
[0074] The effect of bitumen concentration in a benzoic acid
ester-containing solvent on subsequent precipitation in a carbon
dioxide fluid is evaluated. The precipitation runs are carried out
at 35.degree. C. for a 2 hr residence time within a reactor that is
mixed with a magnetic stirrer.
[0075] As seen from FIG. 2, bitumen precipitation in the carbon
dioxide fluid increased as a function of solvent concentration.
Example 10
Bitumen Precipitation from Benzoic Acid Ester-Containing Solvent as
a Function of Carbon Dioxide Density
[0076] The precipitation of bitumen is evaluated as a function of
carbon dioxide density at various temperatures ranging from
35.degree. C. to 55.degree. C. and pressures ranging from 2000 psi
to 4000 psi. The residence time is 2 hr.
[0077] As illustrated by FIG. 3, the amount of bitumen that is
precipitated increases as a function of carbon dioxide density.
Example 11
Effect of Benzoic Acid Ester-Containing Solvent-to-Carbon Dioxide
Fluid Ratio on Bitumen Precipitation
[0078] The effect of benzoic acid ester-containing
solvent-to-carbon dioxide fluid ratio on bitumen precipitation is
evaluated at 35.degree. C. As seen from FIG. 4, the amount of
precipitated bitumen increased as the ratio of solvent to carbon
dioxide fluid decreased.
Example 12
Comparison between Single and Multiple Extraction of Bitumen in
Carbon Dioxide
[0079] A comparison between a single batch extraction and a
multiple batch extraction of bitumen in carbon dioxide is
illustrated in FIG. 5. The study is carried out at 25.degree. C. As
seen, the multiple batch extractions provided for higher yields of
extracted bitumen.
Example 13
Comparison between Single and Multiple Extraction of Bitumen in
Carbon Dioxide
[0080] The procedure according to Example 12 is repeated except
that the temperature is set at 35.degree. C. The results are shown
in FIG. 6. In general, the yields are higher in comparison to
Example 10.
Example 14
Comparison between Single and Multiple Extraction of Bitumen in
Carbon Dioxide
[0081] The procedure according to Example 12 is repeated except
that the temperature is set at 50.degree. C. The results are shown
in FIG. 7. In general, the yields are higher in comparison to those
set forth in Examples 12-13.
Example 15
Comparison between Single and Multiple Extraction of Bitumen in
Carbon Dioxide
[0082] The procedure according to Example 12 is repeated except
that the temperature is set at 80.degree. C. The results are shown
in FIG. 8. In general, the yields are higher in comparison to those
set forth in Examples 12-14.
Example 16
Comparison between Single and Multiple Extraction of Bitumen in
Carbon Dioxide
[0083] The procedure according to Example 12 is repeated except
that the temperature is set at 100.degree. C. The results are shown
in FIG. 9. In general, the yields were higher in comparison to
those set forth in Examples 12-14.
Example 17
Benzoic Acid Ester Solvent Cleaning Measurement
[0084] 1 g bitumen was weighed in a 20 mL capacity transparent
glass vial caped with PTFE caps. 5 mL of the solvent to be tested
was transferred to the vial, caped, and shaken by hand, with the
amount of dissolved bitumen was visually inspected every minute.
The time at which the last traces of bitumen disappeared was
recorded as the time taken for complete bitumen dissolution. If the
entire bitumen sample dissolved, the concentration of the bitumen
in the solution may reach 20 wt/vol percent which is a relatively
high concentration. The results obtained from these experiments are
summarized in Table 1:
TABLE-US-00001 TABLE 1 Solubility No Sample Name in Minutes Remarks
1 Pave Pro (Edgecombe 15 Complete Solubility County) Generated
Appreciable Amount of Foam 2 HTF-959-B (Wilson 22 Incomplete
Solubility County) 3 Orange asphalt Remover 17 Complete Solubility
(Nash County) 4 Big Orange E (Edgecombe 22 Incomplete Solubility
County) 5 Pure and Natural Orange 22 Incomplete Solubility Bean
(Specially Formulated) 6 Invention 12 Completely Soluble No (IPB)
Foam Was Generated
The solution employed in the method of the invention (No. 6) is the
most efficient solvent for bitumen as it was the fastest to
dissolve the 1 g sample in 12 minutes. The Pave Pro solvent (No. 1)
dissolved the 1 g of bitumen in 15 minutes. Nonetheless, No. 6 is
distinguished from No. 1 by the fact that it doesn't foam when it
was shaken. Conversely, No. 1 produced a high foam column when it
was shaken. According to the Department of Transportation (DOT)
guidelines, it is highly recommended that the solvent does not
produce foam as this will potentially decrease its efficiency when
it is applied by sprayers. Such a decrease is often experienced
when these solvents are used in cleaning asphalt-paving
equipment.
Example 18
Bitumen Extraction from Asphalt
[0085] An asphalt sample obtained from Texaco Petroleum Company of
Houston, Texas was contacted with a solution of IPB for
approximately 15 min. at a temperature of about 25.degree. C. A
maximum concentration of 23.71 wt./vol. percent of bitumen in the
IPB was achieved. Such a result compared favorably with a 26.40
wt./vol. percent concentration of bitumen in a conventional
solution of methylene chloride.
Example 19
Extraction of Bitumen in Carbon Dioxide as a Function of
Temperature and Pressure (Single-Batch)
[0086] Bitumen was extracted using a carbon dioxide containing
fluid, and the effect on fluid temperature and pressure was
evaluated. An asphalt sample (5 g) was loaded into a high-pressure
20 mL capacity reactor. The reactor was heated to the desired
temperature. The system was pressurized with carbon dioxide at a
rate of 10 mL/min until the desired pressure was reached by means
of a high-pressure syringe pump. The system was left for 1 hr at
the desired temperature and pressure after which carbon dioxide and
the extracted bitumen was conveyed under pressure to another
reactor supplied with sapphire windows (view-cell) at a rate of 10
mL/min. After the extract was cooled to ambient temperature, the
carbon dioxide was slowly discharged from the system at a rate of 1
mL. The system was thereafter opened, the extracted bitumen was
collected quantitatively by dissolution in methylene chloride, and
subsequently the solvent was evaporated in a vacuum oven at
50.degree. C. for 24 hrs. The mass of extracted bitumen was
calculated and the percent extracted was thus obtained. The total
bitumen content of asphalt was determined by methylene chloride
extraction.
[0087] The extractions were each carried out for a one hour
residence time. The results of the extraction are set forth in FIG.
10. As exhibited, the amount of extracted bitumen increased as a
function of both temperature and pressure.
Example 20
Extraction of Bitumen in Carbon Dioxide as a Function of
Temperature and Pressure (Multiple Extractions)
[0088] Various asphalt samples were placed in a high-pressure 20 mL
capacity reactor. The reactor was heated to the desired temperature
and then pressurized with carbon dioxide to the desired pressure at
a flow rate of 10 mL/min by means of a high-precision syringe pump.
The system was left at 1 hr at the desired temperature and pressure
after which CO.sub.2 and the extracted bitumen was conveyed under
pressure to another reactor supplied with sapphire windows
(view-cell) at a rate of 10 mL/min followed by another transfer to
a second view cell in the same manner. After cooling the extract to
ambient temperature, CO.sub.2 was slowly discharged from the system
at a rate of 1 mL/min. The system was repressurized in the manner
described above, and the process was repeated six times. The
residence time for each step was held constant at 15 min. At the
end of the sixth extraction, the system was opened and the
extracted bitumen was collected from both view cells quantitatively
by dissolution in methylene chloride. The solvent was thereafter
evaporated in a vacuum oven at 50.degree. C. for 24 hours. The mass
of the extracted bitumen was then calculated and the percentage
extraction was obtained. The total bitumen content of asphalt was
obtained by methylene chloride extraction.
[0089] The results of the multiple extraction runs are illustrated
in FIG. 11. In general, extraction quantity increased as a function
of temperature and pressure. A maximum of 94.96 weight percent of
bitumen was extracted at a pressure of 5000 psi and a temperature
of 100.degree. C.
Example 21
Extraction with Supercritical Carbon Dioxide
[0090] An asphalt paving sample (to the nearest 0.1 mg) is placed
in a high-pressure reactor. The reactor is pressurized with
CO.sub.2 at a pressure ranging from 1000 to 5000 psi and the
temperature is adjusted and maintained at the set temperature
ranging from 25 to 120.degree. C. The system is left to equilibrate
for the appropriate residence time after which the pressurized gas
is allowed to pass onto a collecting cooled trap. CO.sub.2 is
slowly vented from the trap at a flow rate of 1 mL/min leaving the
extracted bitumen in the trap which is quantified by weighing the
trap before and after extraction. The process may be repeated for 6
times to extract the maximum amount of bitumen.
Example 22
Extraction with the Benzoic Acid Ester Containing Solvent
[0091] The residue which is left in the high-pressure reactor after
extraction with CO.sub.2 according to Example 21 is mixed with the
benzoic acid ester containing solvent using a mechanical stirrer
mounted over the reactor. The solvent-to-sample ratio ranges from
2:1 to 5:1 volume-to-mass ratio. Although not intending to be bound
by theory, it is believed that such a ratio depends on the amount
of bitumen present in the sample.
[0092] The solvent is added in 4 to 6 aliquots until the solvent
venting the system becomes colorless. In a preferred embodiment,
the solvent venting the cell is filtered from the inorganic
insoluble particles constituting part of the asphalt paving mixture
using online filters with 0.2.mu. pore size. The refractive index
of the filtrate is measured by a refractometer until the refractive
index of the solvent is exactly the same as that of the pure
solvent to insure that bitumen is fully extracted from the
sample.
Example 23
Precipitating Bitumen from the Benzoic Acid Ester Containing
Solvent
[0093] The solution of bitumen in the benzoic acid ester containing
solvent obtained according to Example 22 is placed in a
high-pressure reactor supplied with a sapphire view cell. The
system is pressurized with a CO.sub.2 specific pressure (1000-5000
psi), temperature (25-120.degree. C.), and residence time (5-120
min) that will efficiently precipitate the bitumen, preferably all
of the bitumen. CO.sub.2, plus the dissolved benzoic acid ester
containing solvent is allowed to vent from the system to a
collecting vessel at a flow rate of 1 mL/min. The system is washed
several times with CO.sub.2 to solubilize the benzoic acid ester
containing solvent and the residue is dried under vacuum and
quantified. CO.sub.2 is separated from the benzoate solvent by
depressurizing and cooling the system. The total extracted bitumen
is quantified as the sum of the bitumen extracted from CO.sub.2 and
that extracted by the benzoic acid ester containing solvent.
Example 24
Analytical Determination of Bitumen in Asphalt Sample
[0094] An asphalt paving mixture sample weighed to the nearest 0.1
mg is placed in the extraction thimble of a soxhlet extractor
apparatus. The benzoic acid ester-containing solvent is heated to
boiling and the condensed liquid extracts the bitumen from the
asphalt paving mixture sample. The process is stopped when the
solvent dripping from the extraction thimble is rendered colorless.
The inorganic material left in the extraction thimble is then
rinsed several times with ethanol, dried until constant mass, and
weighed to the nearest 0.1 mg. The mass of the extracted bitumen is
obtained by subtracting the mass of the residual inorganics from
the mass of the asphalt sample determined before the extraction
step.
Example 25
Analytical Determination of Bitumen in Asphalt Sample
[0095] The procedure according to Example 16 is repeated except
that an asphalt paving mixture is placed in a Buchner funnel,
rinsed with a benzoic acid ester-containing solvent until the
solvent is rendered colorless. The benzoic acid ester-containing
solvent containing the extracted bitumen is subjected to a carbon
dioxide-containing fluid for precipitating the bitumen and
recycling the solvent.
Example 26
Benzoic Acid Ester Miscibility Study
[0096] CO.sub.2 was found to be miscible with isopropyl benzoate at
the following conditions: 1:1, 1:2, 1:3, 1:4, 1:5, 2:1, 3:1, 4:1,
and 5:1, CO.sub.2:isopropyl benzoate vol.:vol. ratios, at the
following temperatures: 25, 35, 45, and 60.degree. C., and at the
following pressures: 500, 1000, 1500, 2000, 2500, 3000, 3500, 4000,
4500, and 5000 psi, as determined using
Example 27
Analytical Determination of Bitumen in Large Asphalt Sample
[0097] An asphalt paving mixture sample weighed to the nearest 0.1
mg is placed in the Ploog Engineering Co. Centrifuge apparatus. The
benzoic acid ester-containing solvent is heated to boiling and the
condensed liquid is run through the centrifuge and extracts the
bitumen from the asphalt paving mixture sample. The process is
stopped when the solvent dripping from the centrifuge is rendered
colorless. The inorganic material left in the centrifuge is then
rinsed several times with ethanol, dried until constant mass, and
weighed to the nearest 0.1 mg. The mass of the extracted bitumen is
obtained by subtracting the mass of the residual inorganics from
the mass of the asphalt sample determined before the extraction
step.
Example 28
Bitumen Extraction from Asphalt
[0098] An asphalt sample was contacted with a solution of isopropyl
salicylate for approximately 15 min. at a temperature of about
25.degree. C. A maximum concentration of 23.71 wt./vol. percent of
bitumen in the isopropyl salicylate was achieved. Such a result
compared favorably with a 26.40 wt./vol. percent concentration of
bitumen in a conventional solution of methylene chloride.
Example 29
Extraction with Supercritical Carbon Dioxide
[0099] An asphalt paving sample (to the nearest 0.1 mg) is placed
in a high-pressure reactor. The reactor is pressurized with
CO.sub.2 at a pressure ranging from 1000 to 5000 psi and the
temperature is adjusted and maintained at the set temperature
ranging from 25 to 120.degree. C. The system is left to equilibrate
for the appropriate residence time after which the pressurized gas
is allowed to pass onto a collecting cooled trap. CO.sub.2 is
slowly vented from the trap at a flow rate of 1 mL/min leaving the
extracted bitumen in the trap which is quantified by weighing the
trap before and after extraction. The process may be repeated for 6
times to extract the maximum amount of bitumen.
Example 30
Extraction with the Ester-Containing Solvent
[0100] The residue which is left in the high-pressure reactor after
extraction with CO.sub.2 according to Example 29 is mixed with the
ester-containing solvent using a mechanical stirrer mounted over
the reactor. The solvent-to-sample ratio ranges from 2:1 to 5:1
volume-to-mass ratio. Although not intending to be bound by theory,
it is believed that such a ratio depends on the amount of bitumen
present in the sample.
[0101] The solvent is added in 4 to 6 aliquots until the solvent
venting the system becomes colorless. The solvent venting the
system is filtered from the inorganic insoluble particles
constituting part of the asphalt paving mixture using online
filters with 0.2 .mu.m pore size. The refractive index of the
filtrate is measured by a refractometer until the refractive index
of the solvent is exactly the same as that of the pure solvent to
insure that bitumen is fully extracted from the sample.
Example 31
Precipitating Bitumen from the Ester-Containing Solvent
[0102] The solution of bitumen in the ester-containing solvent
obtained according to Example 30 is placed in a high-pressure
reactor supplied with a sapphire view cell. The system is
pressurized with a CO.sub.2 specific pressure (1000-5000 psi),
temperature (25-120.degree. C.), and residence time (5-120 min)
that will efficiently precipitate the bitumen, preferably all of
the bitumen. CO.sub.2, plus the dissolved ester-containing solvent
is allowed to vent from the system to a collecting vessel at a flow
rate of 1 mL/min. The system is washed several times with CO.sub.2
to solubilize the ester-containing solvent and the residue is dried
under vacuum and quantified. CO.sub.2 is separated from the solvent
by depressurizing and cooling the system. The total extracted
bitumen is quantified as the sum of the bitumen extracted from
CO.sub.2 and that extracted by the ester-containing solvent.
Example 32
Analytical Determination of Bitumen in Asphalt Sample
[0103] An asphalt paving mixture sample weighed to the nearest 0.1
mg is placed in the extraction thimble of a soxhlet extractor
apparatus. The ester-containing solvent is heated to boiling and
the condensed liquid extracts the bitumen from the asphalt paving
mixture sample. The process is stopped when the solvent dripping
from the extraction thimble is rendered colorless. The inorganic
material left in the extraction thimble is then rinsed several
times with ethanol, dried until constant mass, and weighed to the
nearest 0.1 mg. The mass of the extracted bitumen is obtained by
subtracting the mass of the residual inorganics from the mass of
the asphalt sample determined before the extraction step.
Example 33
Analytical Determination of Bitumen in Asphalt Sample
[0104] The procedure according to Example 32 is repeated except
that an asphalt paving mixture is placed in a Buchner funnel,
rinsed with an ester-containing solvent until the solvent is
rendered colorless. The ester-containing solvent containing the
extracted bitumen is subjected to a carbon dioxide-containing fluid
for precipitating the bitumen and recycling the solvent.
Example 34
Solubility Study of Ester-Containing Solvent in Carbon Dioxide
[0105] The miscibility of CO.sub.2 with isopropyl salicylate was
evaluated. CO.sub.2 was found to be miscible with isopropyl
salicylate at the following conditions: 1:1, 1:2, 1:3, 1:4, 1:5,
2:1, 3:1, 4:1, and 5:1, CO.sub.2:isopropyl salicylate vol.:vol.
ratios, at the following temperatures: 25, 35, 45, and 60.degree.
C., and at the following pressures: 500, 1000, 1500, 2000, 2500,
3000, 3500, 4000, 4500, and 5000 psi.
[0106] Having thus described certain preferred embodiments of the
present invention, it is to be understood that the invention
defined by the appended claims is not to be limited by particular
details set forth in the above description as many apparent
variations thereof are possible without departing from the spirit
or scope thereof as hereinafter claimed.
* * * * *