U.S. patent application number 14/208895 was filed with the patent office on 2014-09-18 for emulsion fuel from sonication-generated asphaltenes.
This patent application is currently assigned to PetroSonic Energy Inc.. The applicant listed for this patent is PetroSonic Energy Inc.. Invention is credited to Art AGOLLI, Patrick Brunelle, Alfred Fischer.
Application Number | 20140259883 14/208895 |
Document ID | / |
Family ID | 51520811 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140259883 |
Kind Code |
A1 |
AGOLLI; Art ; et
al. |
September 18, 2014 |
EMULSION FUEL FROM SONICATION-GENERATED ASPHALTENES
Abstract
An emulsification method for converting deasphalted oil and/or
asphaltenes into more suitable products for market demands and
utilization in self sufficient energy production treatments plants
is disclosed. Asphaltenes and residues from sonication of heavy oil
feedstocks, as well as de-asphalted oil, may be used in combination
with water and other chemical additives for conversion into a
suitable fuel which may be stored, handled, and transported.
Inventors: |
AGOLLI; Art; (Calgary,
CA) ; Brunelle; Patrick; (Langdon, CA) ;
Fischer; Alfred; (Calgary, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PetroSonic Energy Inc. |
Calgary |
|
CA |
|
|
Assignee: |
PetroSonic Energy Inc.
Calgary
CA
|
Family ID: |
51520811 |
Appl. No.: |
14/208895 |
Filed: |
March 13, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61798955 |
Mar 15, 2013 |
|
|
|
Current U.S.
Class: |
44/282 ; 44/280;
44/301; 44/639 |
Current CPC
Class: |
C10L 1/324 20130101;
C10L 1/326 20130101; F23K 5/12 20130101; C10L 1/328 20130101 |
Class at
Publication: |
44/282 ; 44/280;
44/301; 44/639 |
International
Class: |
C10L 1/32 20060101
C10L001/32 |
Claims
1. A method of converting asphaltenes into emulsion fuel
comprising: combining a first batch of heavy oil feedstock with a
solvent to form a mixture; performing sonication on the mixture
using a sonic reactor to separate deasphalted oil from asphaltenes;
determining a number of mixing cycles or a mixing time for the
emulsion based on a predetermined stability of emulsion, wherein
the stability of the emulsion increases with additional mixing
cycles or longer mixing time; and forming emulsion by mixing a
fluid and a chemical additive with the asphaltenes for the
determined number of mixing cycles or the determined mixing time to
enhance designated characteristics of the emulsion.
2. The method of claim 1, wherein sonication applies a low
frequency, high-amplitude, high-vibrational energy to the
mixture
3. The method of claim 1, further comprising: recovering solvent
from the deasphalted oil and the asphaltenes by separating the
solvent from the deasphalted oil and the asphaltenes; and combining
a second batch of heavy oil feedstock with the recovered
solvent.
4. The method of claim 1, wherein the fluid is water.
5. The method of claim 1, wherein the designated characteristics
may be one or more from the group consisting of viscosity,
oiliness, sulfur levels, flash point, and heavy metal
concentrations.
6. The method of claim 1, wherein the chemical additive has a
concentration in the range of 0.1% to 2% in emulsion.
7. The method of claim 1, further comprising: applying heat while
mixing the asphaltenes with the fluid and the chemical
additive.
8. The method of claim 1, wherein the emulsion further comprises
deasphalted oil.
9. The method of claim 1, wherein mixing the fluid and the chemical
additive to the asphaltenes is performed by static mixing,
recirculation mixing, mixing by convection, or mixing by
sparkling.
10. A method of converting deasphalted oil into emulsion fuel
comprising: combining a first batch of heavy oil feedstock with a
solvent to form a mixture; performing sonication on the mixture
using a sonic reactor to separate deasphalted oil from asphaltenes;
determining a number of mixing cycles or a mixing time for the
emulsion based on a predetermined stability of emulsion, wherein a
stability of the emulsion increases with additional mixing cycles
or longer mixing time; and forming emulsion by mixing a fluid and a
chemical additive with the deasphalted oil for the determined
number of mixing cycles or the determined mixing time to enhance
designated characteristics of the emulsion.
11. The method of claim 10, wherein sonication applies a low
frequency, high-amplitude, high-vibrational energy to the
mixture
12. The method of claim 10, further comprising: recovering solvent
from the deasphalted oil and the asphaltenes by separating the
solvent from the deasphalted oil and the asphaltenes; and combining
a second batch of heavy oil feedstock with the recovered
solvent.
13. The method of claim 10, wherein the fluid is water.
14. The method of claim 10, wherein the designated characteristics
may be one or more from the group consisting of viscosity,
oiliness, sulfur levels, flash point, and heavy metal
concentrations.
15. The method of claim 10, wherein the chemical additive has a
concentration in the range of 0.1% to 2% in emulsion.
16. The method of claim 10, further comprising: applying heat while
mixing the asphaltenes with the fluid and the chemical
additive.
17. The method of claim 10, wherein the emulsion further comprises
asphaltenes.
18. The method of claim 10, wherein mixing the fluid and the
chemical additive to the deasphalted oil is performed by static
mixing, recirculation mixing, mixing by convection, or mixing by
sparkling.
19. An emulsion generating system comprising: an in-line mixer
configured to receive heavy oil feedstock and solvent and mix the
heavy oil feedstock and solvent to form a mixture; a sonicator
configured to receive the mixture from the in-line mixer and apply
a low-frequency, high-amplitude, high-vibrational energy to the
mixture to separate deasphalted oil from asphaltenes comprising the
mixture; a first reservoir configured to store the asphaltenes
received from the sonicator and output the asphaltenes when a first
control valve is activated; a second reservoir configured to store
water and output the water when a second control valve is
activated; a third reservoir configured to store a chemical
additive and output the chemical additive when a third control
valve is activated; a mixer configured to mix the asphaltenes, the
water, and the chemical additive to form emulsion; and a
recirculation valve configured to control a mixing time or a number
of mixing cycles for the emulsion, wherein a stability of the
emulsion increases with additional mixing cycles or longer mixing
time.
20. The emulsion generation system of claim 19, wherein the first
reservoir also stores deasphalted oil.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn.119
to U.S. Provisional Patent Application Ser. No. 61/798,955,
entitled "Emulsion Fuel from Sonication-generated Asphaltenes,"
filed Mar. 15, 2013, the entire contents of which are hereby
incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Disclosure
[0003] The present disclosure relates generally to sonic treatment
of heavy oil feedstocks, and more particularly, to a method for
converting asphaltenes from sonication into an emulsion fuel.
[0004] 2. Background Information
[0005] Refineries, power plants among others may not always be
suited for processing and burning different types of heavy
hydrocarbons. Viscosity, density, asphaltenes, heavy metals, sulfur
and other impurities in those fuels demand processing to modify
and/or upgrade their chemical properties. Low viscosity is required
to make them suitable for transportation, storage and utilization.
For those reasons, demand of lighter fuels has increased, but such
demand entails higher prices and operational costs.
[0006] In order to use heavy hydrocarbons, such as asphaltenes,
power plants, refineries and the like, use a variety of methods to
make heavy hydrocarbons suitable for power, heat and steam
generation. Current methods include heating, chemical addition of
solvent and reducers, and blending with other type of fuels like
diesel and kerosene amongst others. Such methods are expensive
because they require high level of energy consumption and large
volume of chemical additives. Furthermore, blending may reduce
volume of other suitable fuels, decreasing sale revenues.
[0007] The increasing demand for petroleum products has moved the
oil industry towards using heavy oil feedstock byproducts, as well
as other type of heavy hydrocarbons, for powering their operations,
but power plants and refineries continue to face processing
problems and higher costs. In order to improve operational results
from processing of heavy oil feedstocks, a method for recovery and
economical utilization of asphaltenes may be necessary to address a
plurality of problems encountered in current art.
SUMMARY
[0008] Present disclosure may provide an emulsification procedure
to recover and convert asphaltenes and de-asphalted oil from heavy
oil feedstocks into an emulsified fuel which may be more suitable
for transportation, storage and utilization in a plurality of
applications.
[0009] The emulsification procedure may be integrated with
de-asphalting process for providing main component of emulsion,
such component may be asphaltenes, de-asphalted oil (DAO), or a
combination of both. Furthermore, de-asphalting process may include
sonication to improve separation of asphaltenes and DAO from heavy
oil feedstocks. Combining sonication in de-asphalting process with
the emulsification procedure may provide suitable fuel that may be
fed to generators and other plant equipment for producing power,
steam and heat, thus making de-asphalting plant using sonic
treatment self sufficient in regards to energy requirements.
Additionally, the emulsion fuel that may be converted from
asphaltene, DAO, or a combination of both may be made available for
a plurality of industry applications.
[0010] Mixing asphaltenes, DAO, or both with other emulsion
elements, such as water and chemical additives, may produce an
emulsion fuel. A variety of emulsions may be produced by a
plurality of emulsification methods. Such methods may include
static or dynamic mixers, and recirculation layouts amongst others
to convert asphaltenes, DAO, or a combination of both into an
emulsion fuel.
[0011] The stability of the emulsion may depend on the efficiency
of the emulsion method. If a higher stability may be desirable,
then it may be necessary to employ a more efficient method, and
mixing may require a specific mixer design to address the level of
efficiency. In addition, by increasing mixing time, emulsion
stability may be improved. Lower stability of emulsion may be
related to a sooner utilization of emulsion, while higher stability
may be related to a later use of the emulsion, such as exportation,
long storage time, as well as other factors which are determined by
the operators.
[0012] Emulsion may reduce viscosity and the level of sulfur and
heavy metals in the asphaltenes, as well as other properties such
as flash point and oiliness amongst others. Transportation and
storage costs may be reduced because of resultant low viscosity of
the emulsion. This may enable a less expensive operation with
conventional equipment. In addition, emulsion may be used as light
fuel by conventional generators, which may include turbines,
boilers, furnaces, internal combustion engines and other plant
equipment. Therefore, a self sufficient energy loop may be
established for plant operations, including production of heat and
steam.
[0013] In one embodiment, a method of converting asphaltenes into
emulsion fuel comprises: combining a first batch of heavy oil
feedstock with a solvent to form a mixture; performing sonication
on the mixture using a sonic reactor to separate deasphalted oil
from asphaltenes; determining a number of mixing cycles or a mixing
time for the emulsion based on a predetermined stability of
emulsion, wherein the stability of the emulsion increases with
additional mixing cycles or longer mixing time; and forming
emulsion by mixing a fluid and a chemical additive with the
asphaltenes for the determined number of mixing cycles or the
determined mixing time to enhance designated characteristics of the
emulsion.
[0014] In another embodiment, a method of converting deasphalted
oil into emulsion fuel comprises: combining a first batch of heavy
oil feedstock with a solvent to form a mixture; performing
sonication on the mixture using a sonic reactor to separate
deasphalted oil from asphaltenes; determining a number of mixing
cycles or a mixing time for the emulsion based on a predetermined
stability of emulsion, wherein a stability of the emulsion
increases with additional mixing cycles or longer mixing time; and
forming emulsion by mixing a fluid and a chemical additive with the
deasphalted oil for the determined number of mixing cycles or the
determined mixing time to enhance designated characteristics of the
emulsion.
[0015] In another embodiment, an emulsion generating system
comprises: an in-line mixer configured to receive heavy oil
feedstock and solvent and mix the heavy oil feedstock and solvent
to form a mixture; a sonicator configured to receive the mixture
from the in-line mixer and apply a low-frequency, high-amplitude,
high-vibrational energy to the mixture to separate deasphalted oil
from asphaltenes comprising the mixture; a first reservoir
configured to store the asphaltenes received from the sonicator and
output the asphaltenes when a first control valve is activated; a
second reservoir configured to store water and output the water
when a second control valve is activated; a third reservoir
configured to store a chemical additive and output the chemical
additive when a third control valve is activated; a mixer
configured to mix the asphaltenes, the water, and the chemical
additive to form emulsion; and a recirculation valve configured to
control a mixing time or a number of mixing cycles for the
emulsion, wherein a stability of the emulsion increases with
additional mixing cycles or longer mixing time.
[0016] These and other advantages of the present disclosure may be
evident to those skilled in the art, or may become evident upon
reading the detailed description of this method, as shown in the
accompanying process flow chart.
[0017] Additional features and advantages of an embodiment will be
set forth in the description which follows, and in part will be
apparent from the description. The objectives and other advantages
of the invention will be realized and attained by the structure
particularly pointed out in the exemplary embodiments in the
written description and claims hereof as well as the appended
drawings.
[0018] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are intended to provide further explanation of
the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Non-limiting embodiments of the present disclosure are
described by way of example with reference to the accompanying
figures which are schematic and are not intended to be drawn to
scale. Unless indicated as representing the background art, the
figures represent aspects of the disclosure.
[0020] FIG. 1 depicts a process flowchart for emulsification
procedure, which shows a variety of steps and factors that may be
integrated and analyzed for a correct emulsification procedure.
[0021] FIG. 2 illustrates a process flow diagram of an exemplary
system for emulsification procedure using static mixers.
[0022] FIG. 3 illustrates a process flow diagram of an exemplary
system for emulsification procedure using a mixing vessel and a
mixer.
[0023] FIG. 4A depicts an isometric view of sonic reactor which may
be used for asphaltene separation process.
[0024] FIG. 4B depicts a front view of sonic reactor which may be
used for asphaltene separation process.
[0025] FIG. 4C depicts a cross sectional view of sonic reactor
which may be used for asphaltene separation process.
[0026] FIG. 4D depicts a rear view of sonic reactor which may be
used for asphaltene separation process.
DETAILED DESCRIPTION
[0027] In the following detailed description, reference is made to
the accompanying drawings, which form a part hereof. In the
drawings, which are not to scale or to proportion, similar symbols
typically identify similar components, unless context dictates
otherwise. The illustrative embodiments described in the detailed
description, drawings and claims, are not meant to be limiting.
Other embodiments may be used and/or other changes may be made
without departing from the spirit or scope of present
disclosure.
DEFINITIONS
[0028] As used herein, the following terms may have the following
definitions:
[0029] "Heavy oil feedstocks" may refer to materials that contain
heavy oil with a specific gravity of less than 16 API.
[0030] "Asphaltenes" may refer to materials present in heavy oils
and bitumens, which precipitate in n-alkanes solvent.
[0031] "Emulsion" may refer to a homogenous substance produced from
different substances with different viscosity, specific gravities
and the like.
[0032] "Emulsion components" may refer to substances and materials
concentrated in an emulsion.
[0033] "Emulsification" may refer to the process of mixing emulsion
components in order to obtain an emulsion.
[0034] "Sonication" may refer to any device or system which
produces vibrational energy sufficient to impact one or more
desired end uses.
DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 depicts a process flowchart for emulsification
procedure 100. Emulsification procedure 100 may be implemented for
the optimal production of an emulsion fuel which may be used as
suitable fuel for power generation, heat, and steam production, as
well as an emulsion fuel for existing markets.
[0036] Emulsification procedure 100 may start with de-asphalting
process 102 which may provide main emulsion components.
De-asphalting process 102 may combine solvent addition and
sonication process to achieve asphaltenes and de-asphalted oils
(DAO) separation from heavy oil feedstocks. Separation of
asphaltenes from heavy oil feedstocks may be improved by sonication
applied by a proprietary sonic reactor. Sonication may increase
reaction rate between solvents and heavy oil feedstock in process,
allowing a faster separation of asphaltenes and DAO from heavy oil
feedstocks.
[0037] The mixture of heavy oil feedstock-solvent may be subjected
to sonication at low frequency, high amplitude, high vibrational
energy. Sonication may enable recovery of deasphalted hydrocarbons
containing solvent and asphaltenes, residues and solvents. The
quantities and properties of the separated asphaltenes and residues
may depend on the temperature and nature and quantities of the
solvent selected to produce an optimal efficiency of the recovered
deasphalted hydrocarbon liquids. The sonication process may
significantly reduce processing time from about six hours up to
more than ten hours to about 5 seconds up to two minutes depending
on the solvent-feedstock mixture being processed and enabling
either batch or continuous production modes. Asphaltenes, residue,
solvent and DAO may be separated inside the chamber of at least one
proprietary sonic reactor. The sonication process that may be
applied by proprietary sonic reactor may result in an optimal mass
transfer.
[0038] De-asphalting process 102 may be directed by market demands
and plant requirements for power, heat, steam and the like.
De-asphalting process 102 may also provide the volume of emulsion
demanded by the market, and an economic evaluation may be performed
to determine cost-benefits to assign production according to power
needs and market demands. Combination of sonication in
de-asphalting process 102 with emulsification procedure 100 may
allow the use of asphaltenes as a suitable fuel when converted in
the emulsion.
[0039] Additionally, in de-asphalting process 102, processing of
separated asphaltenes and residues may include the utilization of a
plurality of technologies that may lead to recover solvent from the
solvent-saturated asphaltenes and residues.
[0040] After de-asphalting process 102, emulsification 104 may
start. Emulsification 104 may include a plurality of mixing
technologies which may be used in mixing of emulsion components
106. Such emulsification 104 methods may employ static mixing,
recirculation mixing, mixing by convection, mixing by sparkling
amongst others.
[0041] Emulsion may be produced using one or more proprietary
formulations, which may be related with the desired characteristics
of emulsion. During mixing of emulsion components 106, asphaltenes,
DAO or combination of both may be added to chemicals additives and
other fluids in the mixing technologies of in the processing plant.
Added fluid may be water in a volume concentration capable of
enhancing characteristics of emulsion as per requirements. Enhanced
characteristics for the desired emulsion fuel may be low viscosity,
low oiliness, low sulfur levels and the like.
[0042] Chemical additives may be intended to reduce heavy metals
concentrations, modify flash point, reduce viscosity, reduce sulfur
levels, enable the use of solid heavy hydrocarbons and the like.
Chemical additives may be concentrated in a range from 0.1% to 2%
in emulsion.
[0043] Heat may also be present during mixing of emulsion
components. Heat may increase mixing rate between components.
Furthermore, heat may allow the use of solid heavy hydrocarbons as
emulsion component.
[0044] Emulsion fuel may possess a stability which may be directly
related with the efficiency of the emulsification 104 method that
may be determined according to the components from de-asphalting
process 102. Furthermore, for setting the stability of emulsion,
storage time may be determined by use of emulsion 108. If emulsion
fuel may be utilized in the self sufficient power system in the
plant, then a quick emulsification 104 method may be used to
provide a low stability of the emulsion fuel. Subsequently,
emulsification procedure 100 may end. Otherwise, if the emulsion
fuel may be destined to exportation or may be stored during long
periods of time, then emulsion fuel may require a higher stability
which may be achieved by a more efficient emulsification 104 method
or may require multiple stages of mixing during emulsification 104.
Thus, an additional mixing 110 stage or time may be required.
Subsequently emulsion may be sent to an emulsion storage 112 for
subsequent use and emulsification procedure 100 may end.
[0045] Emulsion may reduce transportation and storage costs because
of its low viscosity. Thus, power generation may be achieved by the
use of any type of generator, including: turbines, internal
combustion engines and the like. Similarly, heat and steam may be
produced by any conventional equipment. This may enable a cheap
operation.
[0046] FIG. 2 depicts emulsification system 200, which may include
two static mixers 202, control valves 204, reservoirs of emulsion
elements, such reservoirs may include reservoir 1206 for water
storage, reservoir II 208 may include asphaltene as main component
of the emulsion (others hydro carbons may be used as described in
FIG. 1) and reservoir III 210 may include chemical additives.
Furthermore, emulsification system 200 may include one pump 212, a
reservoir 214 for power, heat and steam generation as well as a
reservoir 216 for a further use of emulsion; such as exportation,
storage during long periods of time and the like.
[0047] FIG. 3 depicts emulsification system 300, which may include
one mixing vessel 302, more mixer 304, control valves 204,
reservoirs of emulsion elements, such reservoirs may include
reservoir 1206 for water storage, reservoir II 208 may include
asphaltene as main component the emulsion (others hydro carbons may
be used as described in FIG. 1) and reservoir III 210 may include
chemical additives. Furthermore, emulsification system 300 may
include one pump 212, a reservoir 214 for power, heat and steam
generation as well as a reservoir 216 for a further use of
emulsion; such as exportation, storage during long periods of time
and the like.
[0048] FIG. 4A shows an isometric view 402 of a sonic reactor 400,
which may be used for asphaltene separation. Additionally, FIG. 4B,
FIG. 4C and FIG. 4D show respectively: front view 404, cross
sectional view 406 and rear view 408 of sonic reactor 400. Sonic
reactor 400 is shown having support structure 410, resonant bar
412, and a set of magnet configuration 414, resonant bar supports
416, and reaction chamber 418 on each end of resonant bar 412.
[0049] Sonic reactor 400 may use support structure 410 to hold
resonant bar 412 in place using any suitable support as resonant
bar supports 416. Suitable configurations for resonant bar supports
416 may include configurations including three or more rubber air
cushions. Any suitable magnet configuration 414, activated by a
control module (not shown), may cause resonant bar 412 to vibrate,
sonicating to heavy oil feedstocks in one or more reaction chamber
418. Suitable configurations for magnet configuration 414 include
configurations with at least 3 magnets and power suitable to cause
resonant bar 412 to vibrate.
[0050] Heavy oil feedstocks in reaction chamber 418 may have
previously been chemically altered to allow asphaltenes separation
in reaction chamber 418, methods for preparing it for such
including the addition of one or more solvents.
Examples
[0051] Example #1 is an exemplary case of an emulsification system
200. Emulsification system 200 may utilize two static mixers 202
for obtaining an emulsion from the mixture of asphaltenes, water
and chemical additives. A pump 212 may be set for feeding and
controlling flow of emulsion elements into static mixers 202.
Furthermore, control valves 204 may increase control of flow rate
flowing from each reservoir and every flow rate in different parts
of emulsification system 200. If a higher stability of emulsion is
required, then a recirculation valve 218 may allow the
recirculation of emulsion into the static mixers 202 every
requested time. Once the emulsion is finished, it may be stored in
a reservoir 216 for a further exportation, storage during long
periods of time and the like. However, if there is an immediate
need for power, heat and steam generation, then emulsion may be
stored in a reservoir 214 intended for that purpose or may feed
generators, furnaces, boilers, and the like in a direct connection
without reservoir 214. Emulsion may enable its use in conventional
generators, such as turbines, internal combustion engines and the
like.
[0052] Example #2 is an exemplary case of an emulsification system
300. Emulsification system 300 may utilize mixing vessel 302 and
mixer 304 for obtaining an emulsion from the mixture of
asphaltenes, water and chemical additives. Such mixer 304 may be
integrated by a motor, turbine and any other suitable power source
for impulsing a propeller, helix and the like. A pump 212 may be
set for feeding and controlling flow of emulsion elements into
mixing vessel 302. Furthermore, control valves 204 may increase
control of flow rate flowing from each reservoir and every flow
rate in different parts of emulsification system 300. If a higher
stability of emulsion is required, then a recirculation valve 218
may allow the recirculation of emulsion into the mixing vessel 302
every requested time. In addition, mixer 304 may operate during
more time in order to perform a higher emulsion stability. Once the
emulsion is finished, it may be stored in a reservoir 216 for a
further exportation, long time storage and the like. However, if
there is an immediate need for power, heat and steam generation,
then emulsion may be stored in a reservoir 214 for that purpose or
may feed generators, furnaces, boilers, and the like in a direct
connection without reservoir 214. Emulsion may enable its use in
conventional generators, such as turbines, internal combustion
engines and the like.
[0053] While various aspects of this method may be described in the
present disclosure, other aspects and embodiments may be
contemplated. The various aspects and embodiments disclosed here
are for purpose of illustration, and are not intended to be
limiting with the scope and spirit being indicated by the following
claims.
[0054] The embodiments described above are intended to be
exemplary. One skilled in the art recognizes that numerous
alternative components and embodiments that may be substituted for
the particular examples described herein and still fall within the
scope of the invention.
* * * * *