Solvent de-asphalting with cyclonic separation

Abstract

The present invention relates to a method of improving a heavy hydrocarbon, such as bitumen, to a lighter more fluid product and, more specifically, to a final hydrocarbon product that is refinery-ready and meets pipeline transport criteria without the addition of diluent. A solid asphaltene by-product is created for easy handling and further processing. The invention is targeted to enhance Canadian bitumen, but has general application in improving any heavy hydrocarbon.

1 .- 23 . (canceled) 
     
     
         24 . Process apparatus for processing heavy hydrocarbons to produce pipeline-ready or refinery-ready feedstock and dry thermally-affected asphaltene solids, comprising:
 a) a process fluid preparation component for mixing heavy hydrocarbon with other substances as required to prepare a process fluid;   b) transport means to move the process fluid to a pre-heater;   c) The pre-heater capable of heating the process fluid to a temperature close to or at a desired operating temperature of a reactor;   d) transport means to move the heated process fluid to the reactor;   e) the reactor having heat exchange means to provide a desired heat flux to the process fluid and maintain the process fluid in-reactor at a substantially uniform desired temperature for a desired residence time;   f) means to provide sweep gas to the process fluid in the reactor;   g) means to remove various produced fluids from the reactor at the end of the residence time, those fluids comprising at least:
 1. -non-condensable vapours 
 2. -light liquid hydrocarbons 
 3. -thermally-affected asphaltene-rich fractions; 
   h) means to separate non-condensable vapours from light liquid hydrocarbons;   i) transport means to move the thermally affected asphaltene-rich fractions to a solvent extraction processor;   j) the solvent extraction processor, with means to remove extracted products from the thermally affected asphaltene-rich fractions, those products being:
 a. -deasphalted oils 
 b. -resins 
 c. -concentrated asphaltene; 
   k) means to collect the deasphalted oils, resins and the light liquid hydrocarbons in appropriate quantities and blend them together to provide the pipeline-ready or refinery-ready feedstock;   l) means to dry the concentrated asphaltenes to provide dry thermally-affected asphaltene solids.   
     
     
         25 . The apparatus of  claim 24  where the reactor is a single thermal conversion reactor with an overhead partial condenser. 
     
     
         26 . The apparatus of  claim 25  operating with uniform heat flux introduced to process fluid in the reactor between 7,000 and 12,000 BTU/hr.sq.ft. 
     
     
         27 . The apparatus of  claim 25  operating with sweep gas introduced within the reactor. 
     
     
         28 . The apparatus of  claim 25  where the ratio of sweep gas to process fluid is between 20 and 80 scf/bbl. 
     
     
         29 . The apparatus of  claim 25  where the sweep gas is at least one of:
 nitrogen, steam hydrogen or light hydrocarbon such as: methane, ethane, or propane. 
 
     
     
         30 . The apparatus of  claim 25  with a heater to heat the sweep gas prior to introduction to the reactor. 
     
     
         31 . The apparatus of  claim 25  operating with residence times for process fluid in reactor between 40 and 180 minutes in duration. 
     
     
         32 . The apparatus of  claim 25  providing substantially uniform temperatures for the process fluid in the reactor between 675 and 775 degrees Fahrenheit. 
     
     
         33 . The apparatus of  claim 25  with the process fluid in the reactor being at or near atmospheric pressure. 
     
     
         34 . The apparatus of  claim 25  operating at pressures below 50 psig. 
     
     
         35 . The apparatus of  claim 25  with pneumatic transport means to handle the dry thermally-affected asphaltenese. 
     
     
         36 .- 41 . (canceled)