U.S. patent application number 13/726038 was filed with the patent office on 2013-06-27 for methods and systems for removing material from bitumen-containing solvent.
This patent application is currently assigned to Marathon Oil Canada Corporation. The applicant listed for this patent is Marathon Oil Canada Corporation. Invention is credited to Mahendra Joshi, Jose Armando Salazar, Dominic J. Zelnik.
Application Number | 20130161238 13/726038 |
Document ID | / |
Family ID | 48653505 |
Filed Date | 2013-06-27 |
United States Patent
Application |
20130161238 |
Kind Code |
A1 |
Salazar; Jose Armando ; et
al. |
June 27, 2013 |
Methods and Systems for Removing Material from Bitumen-Containing
Solvent
Abstract
Methods and systems for preparing bitumen-laden solvent for
downstream processing are described. The bitumen-laden solvent can
be treated with various materials, such as water and emulsion
breakers, followed by treating the bitumen-laden solvent in a
desalter. The desalted bitumen-laden solvent can then be subjected
to downstream processing, such as upgrading in a nozzle
reactor.
Inventors: |
Salazar; Jose Armando;
(Ashland, KY) ; Joshi; Mahendra; (Katy, TX)
; Zelnik; Dominic J.; (Sparks, NV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Marathon Oil Canada Corporation; |
Calgary |
|
CA |
|
|
Assignee: |
Marathon Oil Canada
Corporation
Calgary
CA
|
Family ID: |
48653505 |
Appl. No.: |
13/726038 |
Filed: |
December 22, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61579948 |
Dec 23, 2011 |
|
|
|
Current U.S.
Class: |
208/391 ;
196/14.52; 208/390 |
Current CPC
Class: |
C10G 1/045 20130101;
C10G 53/02 20130101; C10G 1/002 20130101; C10G 31/08 20130101; C10G
55/04 20130101; C10G 33/04 20130101 |
Class at
Publication: |
208/391 ;
208/390; 196/14.52 |
International
Class: |
C10G 1/04 20060101
C10G001/04; C10G 1/00 20060101 C10G001/00 |
Claims
1. A method of removing material from bitumen-containing solvent,
the material removing method comprising the steps of: (i) providing
a bitumen-containing solvent stream; (ii) mixing the
bitumen-containing solvent stream and a water stream; (iii)
introducing the mixture of the bitumen-containing solvent stream
and the water stream in a desalter to remove solid particles from
the mixture; (iv) removing a desalted bitumen-containing solvent
stream from the desalter; and (iv) subjecting the desalted
bitumen-containing solvent stream to downstream processing.
2. The material removing method as recited in claim 1, wherein the
bitumen-containing solvent stream provided in step i) comprises
from 0 to 35% solvent and from 100 to 65% bitumen.
3. The material removing method as recited in claim 2, wherein the
solvent component of the bitumen-containing solvent stream
comprises an aromatic solvent, a paraffinic solvent, or a polar
solvent.
4. The material removing method as recited in claim 1, wherein the
bitumen-containing solvent stream comprises inorganic salts.
5. The material removing method as recited in claim 1, wherein
prior to processing the mixture in the desalter, the mixture is
heated to a temperature in the range of from 80 to 120 .degree.
C.
6. The material removing method as recited in claim 1, wherein
prior to mixing the bitumen-containing solvent stream and the water
stream, the bitumen-containing solvent stream is heated to a
temperature in the range of from 100 to 140.degree. C.
7. The material removing method as recited in claim 1, wherein the
mixture includes from 0 to 35% bitumen-containing solvent and from
1 to 25% water.
8. The material removing method as recited in claim 1, further
comprising adding an emulsion breaker to the mixture.
9. The material removing method as recited in claim 8, wherein the
emulsion breaker comprises amines, amyl resins, butyl resins, and
mixtures thereof.
10. The material removing method as recited in claim 1, wherein the
bitumen-containing solvent is obtained from a SAGD process.
11. The material removing method as recited in claim 1, wherein the
bitumen-containing solvent is obtained from a double solvent
extraction process.
12. The material removing method as recited in claim 1, wherein the
bitumen-containing solvent is obtained from an in-situ extraction
process.
13. The material removing method as recited in claim 1, wherein the
bitumen-containing solvent is obtained from a single solvent
extraction process.
14. The material removing method as recited in claim 1, wherein the
downstream processing comprises distillation of the desalted
bitumen-containing solvent stream.
15. The material removing method as recited in claim 1, wherein the
downstream processing comprises cracking of the bitumen content of
the desalted bitumen-containing solvent stream in a nozzle
reactor.
16. A method of removing material from bitumen-containing solvent,
the material removing method comprising the steps of: (i) providing
a bitumen-containing solvent stream; (ii) mixing the
bitumen-containing solvent stream and a water stream; (iii)
introducing the mixture of the bitumen-containing solvent stream
and the water stream in a desalter to remove solid particles from
the mixture; (iv) removing a desalted bitumen-containing solvent
stream from the desalter; and (iv) upgrading the desalted
bitumen-containing solvent stream in a nozzle reactor.
17. The material removing method as recited in claim 16, wherein
the nozzle reactor comprises: a reactor body having a reactor body
passage with an injection end and an ejection end; a first material
injector having a first material injection passage and being
mounted in the nozzle reactor in material injecting communication
with the injection end of the reactor body passage, the first
material injection passage having (a) an enlarged volume injection
section, an enlarged volume ejection section, and a reduced volume
mid-section intermediate the enlarged volume injection section and
enlarged volume ejection section, (b) a material injection end in
material injecting communication with the combustion chamber, and
(c) a material ejection end in material injecting communication
with the reactor body passage; and a second material feed port
penetrating the reactor body and being (a) adjacent to the material
ejection end of the first material injection passage and (b)
transverse to a first material injection passage axis extending
from the material injection end to the material ejection end in the
first material injection passage in the first material
injector;
18. A system for removing material from bitumen-containing solvent,
the material removing system comprising: a desalter having a
bitumen-containing solvent stream inlet and a desalted
bitumen-containing solvent stream outlet; and a nozzle reactor
having a feed material inlet, wherein the feed material inlet is in
fluid communication with the desalted bitumen-containing solvent
stream outlet of the desalter.
19. The material removing system as recited in claim 18, wherein
the structure of the nozzle reactor comprises: a reactor body
having a reactor body passage with an injection end and an ejection
end; a first material injector having a first material injection
passage and being mounted in the nozzle reactor in material
injecting communication with the injection end of the reactor body
passage, the first material injection passage having (a) an
enlarged volume injection section, an enlarged volume ejection
section, and a reduced volume mid-section intermediate the enlarged
volume injection section and enlarged volume ejection section, (b)
a material injection end in material injecting communication with
the combustion chamber, and (c) a material ejection end in material
injecting communication with the reactor body passage; and a second
material feed port penetrating the reactor body and being (a)
adjacent to the material ejection end of the first material
injection passage and (b) transverse to a first material injection
passage axis extending from the material injection end to the
material ejection end in the first material injection passage in
the first material injector;
20. The material removing system as recited in claim 18, further
comprising: a mixing vessel having a water inlet, a
bitumen-containing solvent stream inlet, and a bitumen-containing
solvent stream outlet, wherein the bitumen-containing solvent
stream outlet of the mixing vessel is in fluid communication with
the bitumen-containing solvent stream inlet of the desalter.
Description
[0001] This application claims priority to U.S. Provisional
Application No. 61/579,948, filed Dec. 23, 2011, the entirety of
which is hereby incorporated by reference.
BACKGROUND
[0002] Extraction of bitumen from bituminous material such as oil
sands can be carried out using a variety of different processes.
Many extraction processes use solvent capable of dissolving bitumen
as a means for extracting bitumen from bituminous material. As a
result, an initial product of many extraction processes is a
bitumen-containing solvent stream. Bitumen-containing solvent
streams generally include solvent having a content of bitumen
dissolved therein.
[0003] Many bitumen-containing solvent streams also include other
components in the solvent stream. For example, many
bitumen-containing solvent streams will include non-bitumen solid
particles. The non-bitumen solid particles can include a variety of
different materials, including inorganic salts, silica, and coal
particles. These solid particles are often present in the
bitumen-containing solvent streams because they are present in the
material from which the bitumen-containing solvent was obtained.
For example, when the bituminous material is oil sands, the oil
sands material will generally include inorganic salts and silica.
In that event, the solvent used to extract bitumen from the oil
sands will also usually pick up a portion of these solid
particles.
[0004] Generally speaking, the presence of this solid material in
the bitumen-containing solvent is undesirable. A primary reason why
the solid material is undesirable is that the solid material can
cause a variety of issues in downstream processing of the
bitumen-containing solvent material. For example, when the
bitumen-containing solvent material is run through heat exchangers
prior to being separated in a distillation column, the solid
material can leave deposits on and foul the heat exchangers. Also,
when bitumen-containing solvent is heated prior to distillation,
some solid materials can be converted to corrosive material.
[0005] For example, inorganic salts present in bitumen-containing
solvent, such as magnesium chloride, can convert to hydrochloric
acid when exposed to elevated temperatures. The hydrochloric acid
can subsequently damage downstream processing equipment, such as
overhead condensers used after distillation. In another example,
solid materials in bitumen-containing solvent upgraded in a nozzle
reactor can act as coke precursors that can eventually plug the
nozzle reactor.
[0006] Various attempts have been made to remove solid material
from bitumen-containing solvent streams prior to downstream
processing. For example, both filtration systems and centrifuges
have been used to treat bitumen-containing solvent with the aim of
removing non-bitumen solid material. One of the biggest problems
faced with both filtration systems and centrifuges is the
difficulties with scaling up this equipment when large volumes of
bitumen-containing solvent need to be treated. In both instances,
scale up of this equipment can be commercially unfeasible.
Additionally, with respect to centrifuges, the separation of solids
usually provides less than desirable results, and the separation
typically has to occur on a batch basis rather than on a more
desirable continuous basis.
SUMMARY
[0007] The applicants have invented an improved method and system
for removing material, such as solid particles, from a stream of
bitumen-containing solvent. In some embodiments, the method can
include the steps of: i) providing a bitumen-containing solvent
stream; ii) mixing the bitumen-containing solvent stream and a
water stream; iii) introducing the mixture of the
bitumen-containing solvent stream and the water stream in to a
desalter, such as to remove, for example, solid particles from the
mixture; iv) removing a desalted bitumen-containing solvent stream
from the desalter; and iv) subjecting the desalted
bitumen-containing solvent stream to downstream processing. In some
embodiments, the downstream processing includes injecting the
desalted bitumen-containing solvent stream into a nozzle reactor in
order to upgrade the bitumen component of the desalted
bitumen-containing solvent stream.
[0008] In certain embodiments, a system for removing solids from a
stream of bitumen-containing solvent and upgrading the bitumen
component of the resulting stream can include a) a desalter having
a bitumen-containing solvent stream inlet and a desalted
bitumen-containing solvent stream outlet, and b) a nozzle reactor
having a feed material inlet that is in fluid communication with
the desalted bitumen-containing solvent stream outlet of the
desalter. In some embodiments, the system can also include a mixing
vessel upstream of the desalter for mixing water and a
bitumen-containing solvent stream.
[0009] Various advantages can be achieved from the methods and
systems described herein. For example, in some embodiments, the
methods and systems can provide for improved separation of solid
particles, including inorganic salts and other undesirable solid
material such as silica and coal particles, from bitumen-containing
solvent streams. In certain embodiments, the methods and systems
can be performed/operated continuously, and it can be commercially
feasible to scale up the desalter used in the methods and systems
so that the methods and systems can continuously process large
volumes of bitumen-containing solvent.
[0010] It is to be understood that this Summary is provided to
introduce a selection of concepts in a simplified form that are
further described below in the Detailed Description. As a result,
this Summary, and the foregoing Background, are not intended to
identify key aspects or essential aspects of the claimed subject
matter.
[0011] In addition, these and other aspects of the presently
described methods and systems will be apparent after consideration
of the Detailed Description and accompanying Figures. It is to be
understood, however, that the scope of the systems and methods
described herein shall be determined by the claims as issued and
not by whether given subject matter addresses any or all issues
noted in the Background or includes any features or aspects recited
in this Summary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Non-limiting and non-exhaustive embodiments of the presently
described systems and methods, including the preferred embodiments,
are described with reference to the following figures, wherein like
reference numerals refer to like parts throughout the various views
unless otherwise specified.
[0013] FIG. 1 is a flow chart detailing steps of a method of
separating non-bitumen solid particles from a bitumen-containing
solvent stream according to various embodiments described
herein;
[0014] FIG. 2 is a cross-sectional view of a desalter suitable for
use in various embodiments described herein;
[0015] FIG. 3 is a block diagram illustrating a system suitable for
use in carrying out some of the methods disclosed in this
specification;
[0016] FIG. 4 shows a cross-sectional view of some embodiments of a
nozzle reactor suitable for use in various embodiments of the
systems and methods described herein;
[0017] FIG. 5 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 4;
[0018] FIG. 6 shows a cross-sectional perspective view of the
mixing chamber in the nozzle reactor shown in FIG. 4;
[0019] FIG. 7 shows a cross-sectional perspective view of the
distributor from the nozzle reactor shown in FIG. 4;
[0020] FIG. 8 shows a cross-sectional view of some embodiments of a
nozzle reactor suitable for use in various embodiments of the
systems and methods described herein; and
[0021] FIG. 9 shows a cross-sectional view of the top portion of
the nozzle reactor shown in FIG. 7.
DETAILED DESCRIPTION
[0022] With reference to FIG. 1, a method 1000 for removing solid
particles from a bitumen-containing solvent stream includes a step
1100 of mixing a bitumen-containing solvent stream with a water
stream, a step 1200 of introducing the mixture of
bitumen-containing solvent and water into a desalter, a step 1300
of removing a desalted bitumen-containing solvent stream from the
desalter, and a step 1400 of subjecting the desalted
bitumen-containing solvent stream to downstream processing. The
removal of the solid particles in the desalter reduces or
eliminates several issues that can arise when downstream processing
is carried out on bitumen-containing solvent streams including
solid material such as inorganic salts and silica.
[0023] In step 1100, a bitumen-containing solvent stream is mixed
with a water stream. One objective of mixing the water stream and
the bitumen-containing solvent stream is to provide water in which
the solid particles can become immersed and/or dissolve. In this
manner, the solid particles leave the bitumen-containing solvent
stream and become a part of the water in the mixture. Due to the
immiscible nature of the bitumen-containing solvent and the water,
this then provides a mechanism for separating the solids from the
bitumen-containing solvent stream by removing the water from the
mixture of bitumen-containing solvent and the water.
[0024] The bitumen-containing solvent can include a solvent in
which bitumen content is dissolved. In some embodiments, the
bitumen-containing solvent includes from 0 to 35% solvent and from
100 to 65% bitumen. In some embodiments, the bitumen-containing
solvent also includes from 0.001 to 1% non-bitumen solid
material.
[0025] Many different types of non-bitumen solid material can be
present in the bitumen-containing solvent. Examples include, but
are not limited to, inorganic salts (such as magnesium chloride,
calcium chloride, and sodium chloride), silica, catalyst fines,
quartz, rust, silt, metals, metal oxides, and coal particles. In
some embodiments, the amount of non-bitumen solid material in the
bitumen-containing solvent stream can range from 0.01 to 1%. The
bitumen-containing solvent may also include water, such as from
0.01 to 2% water.
[0026] The solvent component of the bitumen-containing solvent can
be any solvent capable of dissolving bitumen. The solvent component
typically includes the type of solvent traditionally used in
solvent bitumen extraction techniques.
[0027] In some embodiments, the solvent is an aromatic solvent,
such as Solvesso 100 or Solvesso 150 (commercially available
solvents manufactured by ExxonMobil Chemical). In some embodiments,
the solvent is a paraffinic solvent, such as propane, butane,
pentane, hexane, heptanes, or mixtures thereof. In some
embodiments, the solvent is a polar solvent, such as methanol. The
solvent can also include two or more different solvents, such as
any combination of the solvents listed above.
[0028] The bitumen-containing solvent can be obtained from any
suitable source. In some embodiments, the bitumen-containing
solvent is obtained from a bitumen extraction process that results
in the production of a bitumen-containing solvent. In some
embodiments, this generally includes solvent bitumen extraction
processes that use a solvent as part of the bitumen extraction
mechanism.
[0029] In some embodiments, the bitumen extraction process from
which the bitumen-containing solvent is obtained is a single
solvent bitumen extraction process, such as those described in U.S.
patent application Ser. Nos. 13/558,041; 13/557,503; 13/557,842;
13/559,124; and 13/584,432 each of which is hereby incorporated by
reference in its entirety.
[0030] In some embodiments, the bitumen extraction process from
which the bitumen-containing solvent stream is obtained is a double
solvent bitumen extraction process, such as those processes
described in U.S. Pat. Nos. 7,909,989; 7,985,333; 8,101,067;
8,257,580; U.S. Published Application Nos. 2011/0062057;
2011/0155648; 2011/0180458; 2011/0180459; 2012/0152809; and
2012/0228196, each of which such Patent and Application as
applicable is hereby incorporated by reference in its entirety.
[0031] In some embodiments, the bitumen extraction process from
which the bitumen-containing solvent stream is obtained is an
in-situ solvent extraction process, such as those processes
described in U.S. patent application Ser. Nos. 13/584,333 and
13/557,842, each of which such Application is hereby incorporated
by reference in its entirety.
[0032] In some embodiments, the bitumen extraction process from
which the bitumen-containing solvent stream is obtained is a Steam
Assisted Gravity Drainage (SAGD) process, in which steam is
injected into deposits of bituminous material to decrease the
viscosity of the bitumen and allow it to flow out of the deposit
via production wells. The product of the SAGD process may be a
mixture of water and bitumen material. In some embodiments,
solvents are used in conjunction with the steam to help extract the
bitumen from the bituminous deposits and/or are added to the
recovered SAGD product. In such embodiments, SAGD processes provide
a bitumen-containing solvent stream.
[0033] The water stream used in step 1100 for mixing with
bitumen-containing solvent stream can be any suitable water stream
available. In some embodiments, the water is of a water wash
quality. A suitable water source includes, but is not limited to,
stripped sour water provided that ammonia and hardness levels are
kept low and the pH is kept high to keep salts from partitioning
the oil phase.
[0034] The mixing of the bitumen-containing solvent and water can
be carried out in any suitable fashion. In some embodiments, the
mixing of the bitumen-containing solvent and water occurs in a
mixing vessel.
[0035] Any vessel capable of receiving a water stream and a
bitumen-containing solvent stream and mixing the two can be used.
In some embodiments, the mixing vessel is piping through which the
bitumen-containing solvent stream and/or water is transported. For
example, the mixing can take place at a mixing valve where water
travelling through pipelines joins the bitumen-containing solvent
travelling through pipelines.
[0036] When a mixing vessel is used, the mixing vessel can include
a water inlet, a bitumen-containing solvent inlet, and a
bitumen-containing solvent outlet through which the mixture of
water and bitumen-containing solvent can leave the mixing vessel.
In some embodiments, the bitumen-containing solvent outlet of the
mixing vessel is in fluid communication with a bitumen-containing
solvent inlet of a downstream desalter so that the mixture of water
and bitumen-containing solvent leaving the mixing vessel can be
introduced into the desalter for removal of solid material from the
mixture.
[0037] The mixing of the two streams is preferably vigorous mixing
such that the mixing promotes the movement of solid particles in
the bitumen-containing solvent into the water. Any suitable
equipment and/or technique can be used to promote vigorous mixing
between the two streams. In some embodiments, the amount of water
mixed with bitumen-containing solvent stream is from 4 to 25% by
volume of the bitumen-containing solvent stream.
[0038] Additional steps can be performed before, after, or as part
of the mixing step 1100. For example, in some embodiments, the
bitumen-containing solvent can be heated prior to being mixed with
the water in step 1100. Any manner of heating the
bitumen-containing solvent can be used, and in some embodiments,
the bitumen-containing solvent is heated to a temperature of from
70 to 120.degree. C. In some embodiments, the resulting mixture of
water and bitumen-containing solvent is heated to a temperature of
from 80 to 110.degree. C.
[0039] In some embodiments, an emulsion breaker is added to the
bitumen-containing solvent phase prior to mixing or after the
mixing of bitumen-containing solvent and water. Any suitable
emulsion breaker can be used, including but not limited to water
soluble or oil soluble demulsifying agents such as amines, amyl
resins, butyl resins or nonyl resins. The emulsion breaker can help
to promote the separation of the bitumen-containing solvent and the
water in the desalter.
[0040] In step 1200, the mixture of water and bitumen-containing
solvent is introduced into a desalter. The desalter works to remove
non-bitumen solid particles from the bitumen-containing solvent,
including both inorganic salts and other materials such as silica
and coal particles. Any suitable desalter can be used for carrying
out the separation of solid particles from the bitumen-containing
solvent.
[0041] With reference to FIG. 2, a cross-section view of an
exemplary desalter suitable for use in the method described herein
is illustrated. As shown in FIG. 2, a mixture of water and
bitumen-containing solvent enters the desalter as an immiscible
mixture of water droplets suspended in the bitumen-containing
solvent. The vigorous mixing of the water and bitumen-containing
solvent prior to introduction of the mixture into the desalter
results in solid particles from the bitumen-containing solvent now
being immersed and/or dissolved in the water droplets. A positive
and negative electrode are provided proximate the entry of the
mixture into the fluid tank of the desalter in order to create an
electrostatic field that induces dipole attractive forces between
neighboring droplets of water. In other words, the electrostatic
field results in each droplet having a positive charge on one side
and a negative charge on the other. The attractive force generated
by the opposite charges on neighboring water droplets causes the
water droplets to coalesce. The resulting larger water globules,
along with solids, then settle to the bottom of the fluid tank. The
settled water is continuously withdrawn from the desalter from a
point somewhat above the desalter bottom.
[0042] In step 1300, a desalted bitumen-containing solvent stream
is removed from the desalter. As shown in FIG. 2, the desalted
bitumen-containing solvent is removed from an outlet at the top of
the desalter. The outlet at the top of the desalter takes advantage
of the desalted bitumen-containing solvent resting on top of the
settled water phase and helps to ensure that predominantly or only
desalted bitumen-containing solvent exits the outlet at the top of
the desalter. As shown in FIG. 2, a baffle can also be positioned
inside of the desalter to further ensure that no water droplets or
globules end up exiting the desalter via the outlet of the desalted
bitumen-containing solvent phase.
[0043] Once the desalted bitumen-containing solvent stream is
removed from the desalter, step 1400 of performing downstream
processing on the bitumen-containing solvent stream can be
performed with little or no concern over the downstream processing
being negatively impacted by solid particles contained within the
bitumen-containing solvent stream.
[0044] Downstream processing of the desalted bitumen-containing
solvent stream is not limited and may include any processing steps
known and used by those of ordinary skill in the art. In some
embodiments for example, downstream processing can include passing
the desalted bitumen-containing solvent stream through a heat
exchanger in order to warm the stream. The removal of solid
particles from the stream allows for the use of a heat exchanger
with reduced or eliminated concerns pertaining to fouling the heat
exchanger due to solid deposits forming on the walls of the heat
exchanger.
[0045] In some embodiments, the downstream processing includes use
of a distillation tower to separate solvent from bitumen and/or
separate fractions of the bitumen component. Atmospheric and/or
vacuum distillation towers can be used. The removal of the solid
particles from the bitumen-containing solvent stream can be
performed prior to the distillation so that material capable of
converting to corrosive material (i.e., magnesium chloride capable
of converting to HCl due to water hydrolysis) is not present in the
distillation towers and associated condensers.
[0046] In some embodiments, the downstream processing includes the
cracking and upgrading of the bitumen component of
bitumen-containing solvent. Cracking and upgrading can be carried
out in, for example, a nozzle reactor. In some embodiments, the
desalted bitumen-containing solvent provided by the desalter is
injected into a nozzle reactor similar or identical to the nozzle
reactor described in U.S. Pat. No. 7,618,597; U.S. Pat. No.
7,927,565; U.S. Published Application No. 2011/0084000; and U.S.
Published Application No. 2011/0308995, each of which is hereby
incorporated by reference in its entirety.
[0047] FIGS. 4 and 5 show cross-sectional views of one embodiment
of a nozzle reactor 100 suitable for use in the methods described
herein. The nozzle reactor 100 includes a head portion 102 coupled
to a body portion 104. A main passage 106 extends through both the
head portion 102 and the body portion 104. The head and body
portions 102, 104 are coupled together so that the central axes of
the main passage 106 in each portion 102, 104 are coaxial so that
the main passage 106 extends straight through the nozzle reactor
100.
[0048] It should be noted that for purposes of this disclosure, the
term "coupled" means the joining of two members directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
members or the two members and any additional intermediate members
being integrally formed as a single unitary body with one another
or with the two members or the two members and any additional
intermediate member being attached to one another. Such joining may
be permanent in nature or alternatively may be removable or
releasable in nature.
[0049] The nozzle reactor 100 includes a feed passage 108 that is
in fluid communication with the main passage 106. The feed passage
108 intersects the main passage 106 at a location between the
portions 102, 104. The main passage 106 includes an entry opening
110 at the top of the head portion 102 and an exit opening 112 at
the bottom of the body portion 104. The feed passage 108 also
includes an entry opening 114 on the side of the body portion 104
and an exit opening 116 that is located where the feed passage 108
meets the main passage 106.
[0050] During operation, the nozzle reactor 100 includes a reacting
fluid that flows through the main passage 106. The reacting fluid
enters through the entry opening 110, travels the length of the
main passage 106, and exits the nozzle reactor 100 out of the exit
opening 112. A feed material flows through the feed passage 108.
The feed material enters through the entry opening 114, travels
through the feed passage 106, and exits into the main passage 108
at exit opening 116.
[0051] The main passage 106 is shaped to accelerate the reacting
fluid. The main passage 106 may have any suitable geometry that is
capable of doing this. As shown in FIGS. 4 and 5, the main passage
106 includes a first region having a convergent section 120 (also
referred to herein as a contraction section), a throat 122, and a
divergent section 124 (also referred to herein as an expansion
section). The first region is in the head portion 102 of the nozzle
reactor 100.
[0052] The convergent section 120 is where the main passage 106
narrows from a wide diameter to a smaller diameter, and the
divergent section 124 is where the main passage 106 expands from a
smaller diameter to a larger diameter. The throat 122 is the
narrowest point of the main passage 106 between the convergent
section 120 and the divergent section 124. When viewed from the
side, the main passage 106 appears to be pinched in the middle,
making a carefully balanced, asymmetric hourglass-like shape. This
configuration is commonly referred to as a convergent-divergent
nozzle or "con-di nozzle".
[0053] The convergent section of the main passage 106 accelerates
subsonic fluids since the mass flow rate is constant and the
material must accelerate to pass through the smaller opening. The
flow will reach sonic velocity or Mach 1 at the throat 122 provided
that the pressure ratio is high enough. In this situation, the main
passage 106 is said to be in a choked flow condition.
[0054] Increasing the pressure ratio further does not increase the
Mach number at the throat 122 beyond unity. However, the flow
downstream from the throat 122 is free to expand and can reach
supersonic velocities. It should be noted that Mach 1 can be a very
high speed for a hot fluid since the speed of sound varies as the
square root of absolute temperature. Thus the speed reached at the
throat 122 can be far higher than the speed of sound at sea
level.
[0055] The divergent section 124 of the main passage 106 slows
subsonic fluids, but accelerates sonic or supersonic fluids. A
convergent-divergent geometry can therefore accelerate fluids in a
choked flow condition to supersonic speeds. The
convergent-divergent geometry can be used to accelerate the hot,
pressurized reacting fluid to supersonic speeds, and upon
expansion, to shape the exhaust flow so that the heat energy
propelling the flow is maximally converted into kinetic energy.
[0056] The flow rate of the reacting fluid through the
convergent-divergent nozzle is isentropic (fluid entropy is nearly
constant). At subsonic flow the fluid is compressible so that
sound, a small pressure wave, can propagate through it. At the
throat 122, where the cross sectional area is a minimum, the fluid
velocity locally becomes sonic (Mach number=1.0). As the cross
sectional area increases the gas begins to expand and the gas flow
increases to supersonic velocities where a sound wave cannot
propagate backwards through the fluid as viewed in the frame of
reference of the nozzle (Mach number>1.0).
[0057] The main passage 106 only reaches a choked flow condition at
the throat 122 if the pressure and mass flow rate is sufficient to
reach sonic speeds, otherwise supersonic flow is not achieved and
the main passage will act as a venturi tube. In order to achieve
supersonic flow, the entry pressure to the nozzle reactor 100
should be significantly above ambient pressure.
[0058] The pressure of the fluid at the exit of the divergent
section 124 of the main passage 106 can be low, but should not be
too low. The exit pressure can be significantly below ambient
pressure since pressure cannot travel upstream through the
supersonic flow. However, if the pressure is too far below ambient,
then the flow will cease to be supersonic or the flow will separate
within the divergent section 124 of the main passage 106 forming an
unstable jet that "flops" around and damages the main passage 106.
In one embodiment, the ambient pressure is no higher than
approximately 2-3 times the pressure in the supersonic gas at the
exit.
[0059] The supersonic reacting fluid collides and mixes with the
feed material in the nozzle reactor 100 to produce the desired
reaction. The high speeds involved and the resulting collision
produces a significant amount of kinetic energy that helps
facilitate the desired reaction. The reacting fluid and/or the feed
material may also be pre-heated to provide additional thermal
energy to react the materials.
[0060] The nozzle reactor 100 may be configured to accelerate the
reacting fluid to at least approximately Mach 1, at least
approximately Mach 1.5, or, desirably, at least approximately Mach
2. The nozzle reactor may also be configured to accelerate the
reacting fluid to approximately Mach 1 to approximately Mach 7,
approximately Mach 1.5 to approximately Mach 6, or, desirably,
approximately Mach 2 to approximately Mach 5.
[0061] As shown in FIG. 5, the main passage 106 has a circular
cross-section and opposing converging side walls 126, 128. The side
walls 126, 128 curve inwardly toward the central axis of the main
passage 106. The side walls 126, 128 form the convergent section
120 of the main passage 106 and accelerate the reacting fluid as
described above.
[0062] The main passage 106 also includes opposing diverging side
walls 130, 132. The side walls 130, 132 curve outwardly (when
viewed in the direction of flow) away from the central axis of the
main passage 106. The side walls 130, 132 form the divergent
section 124 of the main passage 106 that allows the sonic fluid to
expand and reach supersonic velocities.
[0063] The side walls 126, 128, 130, 132 of the main passage 106
provide uniform axial acceleration of the reacting fluid with
minimal radial acceleration. The side walls 126, 128, 130, 132 may
also have a smooth surface or finish with an absence of sharp edges
that may disrupt the flow. The configuration of the side walls 126,
128, 130, 132 renders the main passage 106 substantially
isentropic.
[0064] The feed passage 108 extends from the exterior of the body
portion 104 to an annular chamber 134 formed by head and body
portions 102, 104. The portions 102, 104 each have an opposing
cavity so that when they are coupled together the cavities combine
to form the annular chamber 134. A seal 136 is positioned along the
outer circumference of the annular chamber 134 to prevent the feed
material from leaking through the space between the head and body
portions 102, 104.
[0065] It should be appreciated that the head and body portions
102, 104 may be coupled together in any suitable manner. Regardless
of the method or devices used, the head and body portions 102, 104
should be coupled together in a way that prevents the feed material
from leaking and withstands the forces generated in the interior.
In one embodiment, the portions 102, 104 are coupled together using
bolts that extend through holes in the outer flanges of the
portions 102, 104.
[0066] The nozzle reactor 100 includes a distributor 140 positioned
between the head and body portions 102, 104. The distributor 140
prevents the feed material from flowing directly from the opening
141 of the feed passage 108 to the main passage 106. Instead, the
distributor 140 annularly and uniformly distributes the feed
material into contact with the reacting fluid flowing in the main
passage 106.
[0067] As shown in FIG. 7, the distributor 140 includes an outer
circular wall 148 that extends between the head and body portions
102, 104 and forms the inner boundary of the annular chamber 134. A
seal or gasket may be provided at the interface between the
distributor 140 and the head and body portions 102, 104 to prevent
feed material from leaking around the edges.
[0068] The distributor 140 includes a plurality of holes 144 that
extend through the outer wall 148 and into an interior chamber 146.
The holes 144 are evenly spaced around the outside of the
distributor 140 to provide even flow into the interior chamber 146.
The interior chamber 146 is where the main passage 106 and the feed
passage 108 meet and the feed material comes into contact with the
supersonic reacting fluid.
[0069] The distributor 140 is thus configured to inject the feed
material at about a 90.degree. angle to the axis of travel of the
reacting fluid in the main passage 106 around the entire
circumference of the reacting fluid. The feed material thus forms
an annulus of flow that extends toward the main passage 106. The
number and size of the holes 144 are selected to provide a pressure
drop across the distributor 140 that ensures that the flow through
each hole 144 is approximately the same. In one embodiment, the
pressure drop across the distributor is at least approximately 2000
pascals, at least approximately 3000 pascals, or at least
approximately 5000 pascals.
[0070] The distributor 140 includes a wear ring 150 positioned
immediately adjacent to and downstream of the location where the
feed passage 108 meets the main passage 106. The collision of the
reacting fluid and the feed material causes a lot of wear in this
area. The wear ring is a physically separate component that is
capable of being periodically removed and replaced.
[0071] As shown in FIG. 7, the distributor 140 includes an annular
recess 152 that is sized to receive and support the wear ring 150.
The wear ring 150 is coupled to the distributor 140 to prevent it
from moving during operation. The wear ring 150 may be coupled to
the distributor in any suitable manner. For example, the wear ring
150 may be welded or bolted to the distributor 140. If the wear
ring 150 is welded to the distributor 140, as shown in FIG. 6, the
wear ring 150 can be removed by grinding the weld off. In some
embodiments, the weld or bolt need not protrude upward into the
interior chamber 146 to a significant degree.
[0072] The wear ring 150 can be removed by separating the head
portion 102 from the body portion 104. With the head portion 102
removed, the distributor 140 and/or the wear ring 150 are readily
accessible. The user can remove and/or replace the wear ring 150 or
the entire distributor 140, if necessary.
[0073] As shown in FIGS. 4 and 5, the main passage 106 expands
after passing through the wear ring 150. This can be referred to as
expansion area 160 (also referred to herein as an expansion
chamber). The expansion area 160 is formed largely by the
distributor 140, but can also be formed by the body portion
104.
[0074] Following the expansion area 160, the main passage 106
includes a second region having a converging-diverging shape. The
second region is in the body portion 104 of the nozzle reactor 100.
In this region, the main passage includes a convergent section 170
(also referred to herein as a contraction section), a throat 172,
and a divergent section 174 (also referred to herein as an
expansion section). The converging-diverging shape of the second
region differs from that of the first region in that it is much
larger. In one embodiment, the throat 172 is at least 2-5 times as
large as the throat 122.
[0075] The second region provides additional mixing and residence
time to react the reacting fluid and the feed material. The main
passage 106 is configured to allow a portion of the reaction
mixture to flow backward from the exit opening 112 along the outer
wall 176 to the expansion area 160. The backflow then mixes with
the stream of material exiting the distributor 140. This mixing
action also helps drive the reaction to completion.
[0076] The dimensions of the nozzle reactor 100 can vary based on
the amount of material that is fed through it. For example, at a
flow rate of approximately 590 kg/hr, the distributor 140 can
include sixteen holes 144 that are 3 mm in diameter. The dimensions
of the various components of the nozzle reactor shown in FIGS. 4
and 5 are not limited, and may generally be adjusted based on the
amount of feed flow rate if desired. Table 1 provides exemplary
dimensions for the various components of the nozzle reactor 100
based on a hydrocarbon feed input measured in barrels per day
(BPD).
TABLE-US-00001 TABLE 1 Exemplary nozzle reactor specifications Feed
Input (BPD) Nozzle Reactor Component (mm) 5,000 10,000 20,000 Main
passage, first region, entry opening 254 359 508 diameter Main
passage, first region, throat diameter 75 106 150 Main passage,
first region, exit opening 101 143 202 diameter Main passage, first
region, length 1129 1290 1612 Wear ring internal diameter 414 585
828 Main passage, second region, entry opening 308 436 616 diameter
Main passage, second region, throat diameter 475 672 950 Main
passage, second region, exit opening 949 1336 1898 diameter Nozzle
reactor, body portion, outside diameter 1300 1830 2600 Nozzle
reactor, overall length 7000 8000 10000
[0077] It should be appreciated that the nozzle reactor 100 can be
configured in a variety of ways that are different than the
specific design shown in the Figures. For example, the location of
the openings 110, 112, 114, 116 may be placed in any of a number of
different locations. Also, the nozzle reactor 100 may be made as an
integral unit instead of comprising two or more portions 102, 104.
Numerous other changes may be made to the nozzle reactor 100.
[0078] Turning to FIGS. 8 and 9, another embodiment of a nozzle
reactor 200 is shown. This embodiment is similar in many ways to
the nozzle reactor 100. Similar components are designated using the
same reference number used to illustrate the nozzle reactor 100.
The previous discussion of these components applies equally to the
similar or same components includes as part of the nozzle reactor
200.
[0079] The nozzle reactor 200 differs a few ways from the nozzle
reactor 100. The nozzle reactor 200 includes a distributor 240 that
is formed as an integral part of the body portion 204. However, the
wear ring 150 is still a physically separate component that can be
removed and replaced. Also, the wear ring 150 depicted in FIG. 9 is
coupled to the distributor 240 using bolts instead of by welding.
It should be noted that the bolts are recessed in the top surface
of the wear ring 150 to prevent them from interfering with the flow
of the feed material.
[0080] In FIGS. 8 and 9, the head portion 102 and the body portion
104 are coupled together with a clamp 280. The seal, which can be
metal or plastic, resembles a "T" shaped cross-section. The leg 282
of the "T" forms a rib that is held by the opposing faces of the
head and body portions 102, 104. The two arms or lips 284 form
seals that create an area of sealing surface with the inner
surfaces 276 of the portions 102, 104. Internal pressure works to
reinforce the seal.
[0081] The clamp 280 fits over outer flanges 286 of the head and
body portions 102, 104. As the portions 102, 104 are drawn together
by the clamp, the seal lips deflect against the inner surfaces 276
of the portions 102, 104. This deflection elastically loads the
lips 284 against the inner surfaces 276 forming a self-energized
seal. In one embodiment, the clamp is made by Grayloc Products,
located in Houston, Tex.
[0082] When a nozzle reactor as described above and/or in one of
the aforementioned documents is used, the desalted
bitumen-containing solvent stream leaving the outlet of the
desalter can be injected into the nozzle reactor via a feed
material inlet included in the nozzle reactor. The outlet of the
desalter can be in fluid communication with the feed material inlet
of the nozzle reactor in order to allow for transportation of the
desalted bitumen-containing solvent stream from the desalter to the
nozzle reactor. Once injected into the nozzle reactor via the feed
material inlet, the desalted bitumen-containing solvent stream
interacts with the cracking material also injected into the nozzle
reactor in order to crack and upgrade the bitumen component of the
bitumen-containing solvent stream. Additional details of the nozzle
reactor upgrading process are set forth in the above-mentioned
nozzle reactor Patents and Applications.
[0083] FIG. 3 illustrates a system 300 that can be used in order to
carry out the methods described above. The system 300 includes a
mixing vessel 310, a desalter 320, and a nozzle reactor 330. In
operation, a bitumen-containing solvent stream 311 is passed into
the mixing vessel 310. Water stream 312 is also passed into the
mixing vessel 310 so that the water stream 312 and the
bitumen-containing solvent stream mix. A mixture 313 of water and
bitumen-containing solvent leaves the mixing vessel 310 and is
passed into the desalter. The desalter works to remove solid
particles from the mixture 313 as described in greater detail
above, and ultimately produces a desalted bitumen-containing
solvent stream 321. The desalted bitumen-containing solvent stream
321 is then injected into a nozzle reactor 330. A cracking material
331 is injected into the nozzle reactor at a direction
perpendicular to the desalted bitumen-containing solvent stream 321
and can be accelerated to supersonic speed. The cracking material
331 and the desalted bitumen-containing solvent stream 321 interact
inside of the nozzle reactor 330 in order to crack and upgrade the
bitumen component of the desalted bitumen-containing solvent stream
321. Cracked bitumen (i.e., hydrocarbons that are lighter than the
original bitumen) 332 exits the nozzle reactor 330.
[0084] The above described processes and methods can be carried out
one or more times in order to remove a sufficient amount of
non-bitumen solid particles from the bitumen-containing solvent.
For example, a series of desalters can be provided wherein the
bitumen-containing solvent is moved through each desalter in a
series in order to remove sufficient amounts of non-bitumen solid
particles. The bitumen-containing solvent can also be run through
the same desalter numerous times for achieve a similar result. In
some embodiments, a 90% desalting efficiency is desirable and can
be achieved by using multiple desalting stages.
[0085] In some embodiments, the above described processes and
systems are utilized in order to provide a bitumen-containing
solvent that has less than 0.5% BS&W (basic sediments and
water). Bitumen-containing solvent having a BS&W level below
0.5% can be suitable for pipelining and other downstream
processing. Another measure of solid particles in
bitumen-containing solvent is PTB or pounds per 1000 bbls of oil or
equivalent sodium chloride in pounds per 1000 bbls oil. In some
embodiments, obtaining a PTB below 20 is important for providing
bitumen-containing solvent suitable for pipelining and downstream
processing.
[0086] Unless otherwise indicated, all numbers or expressions, such
as those expressing dimensions, physical characteristics, etc. used
in the specification are understood as modified in all instances by
the term "approximately." At the very least, and not as an attempt
to limit the application of the doctrine of equivalents to the
claims, each numerical parameter recited in the specification or
claims that is modified by the term "approximately" should at least
be construed in light of the number of recited significant digits
and by applying ordinary rounding techniques. Moreover, all ranges
disclosed herein are to be understood to encompass and provide
support for claims that recite any and all subranges or any and all
individual values subsumed therein. For example, a stated range of
1 to 10 should be considered to include and provide support for
claims that recite any and all subranges or individual values that
are between and/or inclusive of the minimum value of 1 and the
maximum value of 10; that is, all subranges beginning with a
minimum value of 1 or more and ending with a maximum value of 10 or
less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values
from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).
* * * * *