CA2999577A1 - Method and system for transporting bitumen in flexitank - Google Patents

Abstract

THE INVENTION provides an innovative process encompass flexitank and sea containers for crude bitumen shipment without special equipment or facilities, extra energy input, additional chemicals and diluents.

Description

METHOD AND SYSTEM FOR TRANSPORTING BITUMEN IN FLEXITANK
ABSTRACT
The invention provides an innovative process encompass flexitank and sea containers for crude bitumen shipment without special equipment or facilities, extra energy input, additional chemicals and diluents.
FIELD OF TECHNOLOGY
The present invention relates to method and system for transporting crude bitumen.
BACKGROUND
Bitumen is often produced in remote locations away from where it will be consumed. While moving bitumen is extremely challenging because of their inability to flow freely. Bitumen transportation network involves all modes of transportation that includes truck, rail, pipeline and marine vessel.
Bitumen can be transported in undiluted form by truck. Truck transportation is easily accessible and the least impactful option environmentally because each load is relatively small amount, on land and less chance to be detrimental to a body of water. But truck is restricted by the weather and large distance. Moreover, truck carry comparatively small load compared to rail.
For long distance bitumen transportation, rail is a rapidly growing industry.
Furthermore, no diluent is required during bitumen transportation in the railcar. A
significant amount of diluent can be saved by railway. A rail tank car can accommodate roughly 30,000 gallons of bitumen with 100 cars, which is a significant amount of crude. However, the railway transportation has a high carbon footprint and reputation for spilling of millions of gallons of crude.
Pipeline transportation is most convenient option and it can bring the bitumen from oil wells to processing facilities, tanks, terminal facilities, refineries. However, diluent has to be added to thin the bitumen because of the huge energy (i.e. high pumping power) required to overcome the high pressure drop in the pipeline due to the high viscosity. Moreover, pipeline is not everywhere and there is no enough capacity available for producers in some cases. And diluent recovery system is required at the destination to remove the diluent from the bitumen.
Bitumen can also be delivered by tanker oversea, it can travel all around the world. As the large quantity the tanker can carry, the transportation per barrel of bitumen is cheap compare to other methods. However, the Western Canada Government proposed a moratorium would prohibit oil tankers from stopping, loading or unloading crude or persistent oil products in northern British Columbia. It applies to tankers carrying more than 12,500 metric tons of crude or persistent oil products. The moratorium covers the area from the Canada/United States border in the north, down to the point on British Columbia's mainland across from the northern tip of Vancouver Island. It also includes Haida Gwaii.
Besides, novel inventions related to crude bitumen transportation including diluent additives, blending, emulsification, bitumen containers, special capsules, or converted into solid form, etc.
Each invention faces economic, technical or environmental challenges of its own.
In terms of diluent additives, researchers have proposed additives to thin the bitumen, the bitumen transport comprising bitumen and a diluent present in an amount of 24 weight percent or less and an additive wherein the additive is a mono-alcohol, a mono-nitrile, an amine or mixtures thereof, which is designed for reduction of the amount of diluent needed to transport the bitumen through pipelines. However, it is similar to diluent option, an extra cost will be associated with diluent and chemical additives, and diluent recovery system is required.

In terms of blending, methods for transporting bitumen extraction product include providing bitumen-laden aromatic solvent, providing bitumen-laden paraffinic solvent, and blending the two materials. The mixture can share the existing infrastructure and avoid undesirable asphaltene precipitation. However, the solvent is not cheap.
In terms of emulsification, a process involving oil-in-water emulsion transportation wherein impurities from the bituminous phase are transferred to the continuous water phase, the impurities including solid mineral materials. The emulsification process contains large amount of water to be transported and cost per barrel of bitumen transportation is increased as well. Additionally, a large quantity of water is contaminated and a portion of the emulsion stabilizer is required.
In terms of bitumen containers, the invention provides a heatable container for bitumen comprising a body member defining a base zone, side wall zones, end wall zones and a roof zone. Extra energy input needed for the device and there is no large quantity available in the market.
In terms of special capsules, the invention provide a special package or container equipment required for shipping bitumen. The special capsule has a very unique design while retaining some of the characteristics of the common variety of intermodal containers.
Furthermore, a unique device which clamps on the top of a capsule immerse in the rehabilitation unit to reheat the bitumen.
Unfortunately the capsule own a unique design and there is no large quantity available in the open market, and the cleaning of the capsules after the bitumen discharge also accounts huge work and cost.
In terms of bitumen converted into solid form, this invention including a mixture of bitumen and an additives to increase the viscosity of bitumen to form a solid bitumen pellet. Optionally, the pellet includes a protective shell. The process involves extra input energy with elevated temperature and chemical additives such as hydrocarbonaceous polymer. It is easier to transport the bitumen as a solid phase while the chemical additives are very expensive, and the requirement for the pellets crush resistance is high when subjected to a load of pellets having a certain heights.
Additionally, the chemical additives added is not easy to separate without extra energy input and the bitumen recovery system is required at the destination.

Accordingly, there is a need for a novel bitumen transportation which takes advantage of the options and infrastructure available, contributes to alleviate at least some of the deficiencies addressed above.
SUMMARY
Above present the pros and cons of each transportation option, also a variety of inventions have been proposed to overcome the challenge of bitumen transportation. As embodied and broadly described herein, the invention proposed here encompass flexitank and general purpose sea container for crude bitumen shipment without special equipment, unique facilities, extra energy input, additional chemicals and diluents.
The method and system for transporting bitumen in the flexitank, which allows the warm bitumen pumped into the flexitank at a temperature ranges from 40 to 82 t. The flexitank is fitted with corrugated papers in the general purpose sea container, and make the shipment by road, rail or sea when the bitumen temperature drops below 60 C. The crude bitumen shipped in the flexitank has a flash point above 60 C. In this case, the crude bitumen shipped as non-dangerous goods. This process maintains the integrity of flexitank and sea container and is able to withstand the demands of shipment by road, rail or sea. Furthermore, it is easily handle without special design or equipment, unique facilities, the general purpose sea containers are in large quantities in the open market. The flexitank for shipping crude bitumen is flexible with different fleets, different numbers of containers can be booked and shipped through marine vessels instead of oil tankers through Western Canada coast, which is not part of the moratorium if the quantity below 12,500 metric tons at one time. Moreover, there is no need for extra energy input during loading and discharge the crude bitumen, less energy input means less carbon footprint and savings in cost. And there is no additional chemicals, solvent and diluents required, which is a huge saving and environmental friendly. Also there is no need for bitumen recovery system at the destination, the discharge process is easy to handle and economically feasible. Additionally, the process is beneficial to customers without extra cleaning work for the containers, the corrugated papers are help to make sure the cleaning of the containers, and the flexitank can be disposed directly after the bitumen unloaded. The flexitank can withstand the temperature ranges from 82t to -57 C and fitted inside sea containers, the process will not be limited by the weather when the sea containers travelling all around the world. The process offers a global solution to the transportation of crude bitumen that is safe, economical and environmentally friendly.
DETAILED DESCRIPTION OF THE PROCESS
The method and system for transporting the bitumen in flexitank comprising the following steps:
The drawings which illustrate embodiments of the invention. As shown in Fig.
1, at the wellsite or tank farm 1, crude bitumen is produced from underground and stored in the sales tank at an elevated temperature around 80 C. At such condition, the bitumen can be pumped into the truck and loaded to the flexitank in the container 2 or load the flexitank directly from the bitumen tank 1. Afterwards, the sea container 2 can be shipped to customers 4 by road, rail and sea 3. The bitumen should have a flash point over 60 C and a API lower than 15 to match with the invention.
Additionally, the target crude bitumen has a Basic Sediment and Water (BS&W) content lower than 1 wt% to meet the regulations of transportation.
Turing now to Fig. 2, bitumen producer 5 can be far away from the open market and the tank farm 6 can store the bitumen at an elevated temperature around 80 C. A truck 7, usually the Super B
truck is used to transport the crude bitumen in a short distance. When it arrives at the flexitank plant, which can be fitted in the sea container 8, load with bitumen in a temperature ranges from 40 to 82 C, the flexitank can withstand the temperature ranges from 82 `C to -57 C. Once the flexitank is fully loaded and the container is sealed, the sea container 8 is ready to be delivered to railway intermodal and travel on rail 9. The sea container has to be delivered when bitumen in the flexitank has a temperature lower than 60 C. Because the bitumen has a flash point over 60 C. In this case, the bitumen is delivered as the non-dangerous goods. Furthermore, the flexitank bulk liquid can travel around the world by marine vessel 10.

The flexitank fitting process is illustrated in Fig. 3. Select a general purpose sea container 8 which has different fleets in the open market with a large quantity. The container 8 should be inspected inside and outside before it is fitted with the flexitank 11, if there is evidence that the container 8 is weakened, it should not be used. Walls, floor and roof should be in good condition and not significantly distorted. Doors should work properly and be capable of being securely locked and sealed. The container 8 shall be weatherproof, previous patches and repairs should be carefully checked. The container 8 should be free from major damage, with no broken flooring or protrusions such as nail, bolts, glass, sharp edges, etc, which can cause injury to persons or damage the flexitank 11. Furthermore, the container 8 should be clean, dry and free of residues and persistent odors from previous cargo. Carefully sweep the floor and check by eyes and hand for any rough edges, projections, splinters, screw heads or weld patches. Take off the nail and sharp items on the floor, make sure the container wall is good enough and the container number is clear for tracking; Heavy duty tape and extra cardboards should be used to cover and protect potential trouble spots.
The corrugated papers 13 are placed afterwards, such that the contact area of fully loaded flexitank and container 8 can be covered by corrugated papers 13. The corrugated papers 13 should be fixed by tape at interval. The corrugated papers 13 have a dimension at least 48 inch in height.
The fitting includes unfolding the flexitank 11, laying the flexitank 11 and opening the flexitank 11 forwards or backwards, and tying the strips to secure rings inside the container 8, place the bulkhead 14 and steel safety bars 15 in the front, make the flange and valve in the right position, close the container 8 and move on the trailer by forklift or crane lift if needed. Ensure that flexitank 11 unfolds properly and does not trap itself in corners, the room 16 is spared for the ball valve 19 at the bottom of flexitank 11 in case of bottom loading or discharge.
The flexitank 11 can be manufactured with two inner layers co-extruded linear low density polyethylene film 12, the flexitank 11 can withstand the temperature in a range of 82 C to -57 C.
Three inch ball valve 18 or 19 associated with the flexitank 11 has a good resistance to pressure.
There is no block when valve 18 or 19 is opened, which make the bitumen flow through freely.
Flange on the valve 18 or 19 of the flexitank 11 is used to reduce the pressure against the flexitank surface thus reduce the risk of failures. Additionally, safety pin is added on the ball valve 18 or 19 to help to source thefting activities if happened during transportation. The special design of pressure release valve 17 on the top can help to release vapor pressure. It would keep the flexitank 11 safe during loading and transportation. And the loading and discharge ball valve 18 or 19 can be either at the top or at the bottom.
Once the fitting is ready, remove all old labels and stickers, and keep the right door of container open and the left door closed with warning placard. In the embodiment shown in Fig. 4 and Fig. 5, attach the hose 20 with female camlock connection to the male adapter of flexitank valve 18 or 19.
Be sure that the ball valve 18 or 19 is on open position. Start loading the flexitank 11 slowly. Once approximately three cubes bitumen have been filled, loading rate of plum can be increased. The hose 20 can be three or four inches in dimension. And the loading rate is close to one cubic meter per minute. Check constantly for leaks in hoses and connections, In the process of loading the wings of flexitank 11 will slowly open out against container sides and bulkhead. Warm bitumen is loaded at an elevated temperature 40 C to 82 C. After loading is completed, close the valve 18 or 19, drain feeding hose 20, disconnect hose 20 from the flexitank 11 and replace valve cap.
Visually check the exterior of the standard container to ensure no damage has occurred during loading process. Little bulging of container walls may happen. Once the loading is completed, make sure the surrounding of value 18 or 19 on the flexitank 11 is clean.
Packing list and material safety data sheet are prepared and attached with the flexitank 11.
Referring to Fig. 6, once the bitumen cools down below 60 C, each container 8 is sealed and labeled with bulk liquid non-dangerous goods placard on the left door and sides of the container 8. Afterwards, the flexitank 11 in the sea container 8 is delivered to the intermodal yard, and processed by rail-sea intermodal transport. The containers have to meet the rail, road and sea weight guideline.
Once the sea container 8 is arrived at the destination. The flexitank 11 discharge process can be three different ways.

Referring to Fig. 4 and Fig. 5, in case of the flexitank 11 has a temperature below 60 `C and above body temperature at the destination, attach the discharge hose 20 with female camlock connection to the male adapter of flexitank valve 18 or 19. Be sure that the valve 18 or 19 is on the open position. Start discharging the flexitank 11 slowly at the beginning and end of the process, the average discharge rate is close to one cubic meter per minute. Discharge hose 20 inspected to ensure excessive strain is not applied to the hose. Check constantly for potential leaks in hoses 20 and connections. Drained all residual product from flexitank 11 and dispose the flexitank 11 on the basis of local environmental regulations. Do not open left hand door until discharge completed.
In case of the bitumen has a temperature below body temperature, the discharge of congeal bitumen will be challenge. Referring to Fig. 7, one way to discharge the bitumen can be tilt the container 8 upward or downward, take off the bulkhead 14 and safety bars 15. Turning now to Fig. 8, cut the edges of the flexitank, as the flexitank has inner layer films 12, the inner layer 12 contacts with all the bitumen inside the flexitank and it can be pull out directly to the holder 22, which spare only one direction to release the bitumen. The holder 22 can squeeze the flexitank inner layer films 12 to crystal and discharge the bitumen to the bitumen pool 21. In this way, the bitumen inside the flexitank can be released, and the flexitank is used one time only.
There is another way to discharge the bitumen when the flexitank temperature drops much lower than the body temperature. Referring to Fig. 9 and Fig. 10, immerse a heater 22 and a straw 23 into the valve 18 or 19. The heater 22 helps to increases the temperature of nearby bitumen to body temperature. The congeal bitumen from the valve 18 or 19 can be mobilized. And the straw 23 suck the heated bitumen back simultaneously as the heater 22 works. The heater 22 can be driven by electricity or hot water and has a maximum temperature of 60 'C. Once the discharge process is over, the flexitank 11 is disposed based on local environmental regulations.
The above describes the thought process of crude bitumen shipment by flexitank and sea container.
The method and system of designing bitumen shipment can offer solutions to global transport of water, wine, edible oils, food and beverages, industrial and petroleum products, pharmaceuticals, and agricultural commodities.

DESCRIPTION OF DRAWINGS
Fig. 1 Flow Chart of Method and System for Transporting Bitumen in Flexitank;
Fig. 2 Illustration of Method and System for Transporting Bitumen in Flexitank;
Fig. 3 Fitting of Flexitank in Sea Container;
Fig. 4 Top View of Fitted Flexitank in the Sea Container;
Fig. 5 Flexitank Bottom Loading or Discharge;
Fig. 6 Flexitank Top Loading or Discharge;
Fig. 7 Flexitank Tilt Upward or Downward;
Fig. 8 Squeeze Flexitank to Crystal;
Fig. 9 Flexitank Bottom Discharge with Heater and Straw;
Fig. 10 Flexitank Top Discharge with Heater and Straw.

Claims (43)

What is claimed is

1. Method and system for transporting bitumen in flexitank comprises of:
a) Inspect and clean the sea container carefully;
b) Place the corrugated papers at the sides and bottom of internal container;
c) Unfold the flexitank and fit it inside the container;
d) Install the bulkhead and steel swept bars at the front;
e) Leave the right door open and left door close for sake of loading;
f) Hose connect the flexitank to the crude bitumen tank or truck;
g) Once loading is done, close the right door for the container with seal;
h) Put on placards and wait for delivery;
i) At the destination, tilt upward or downward to remove the steel swept bars and the bulkhead, discharge the crude bitumen by cutting edges of the flexitank and pull the inner layer of flexitank into a holder, the bitumen can be released by squeezing the inner layer of the flexitank to crystal;
j) Discharge the crude bitumen by heater and suck it with straw;
k) Dispose the flexitank based on local environmental regulations;
l) Send the container back to rail intermodal.

2. The process defined in Claim 1, wherein the flexitank can be manufactured with one layer of film.

3. The process defined in Claim 1, wherein the flexitank can be manufactured with two layers of film.

4. The process defined in Claim 1, wherein the flexitank can be manufactured with three layers of film.

5. The process defined in Claim 1, wherein the flexitank can be manufactured with four layers of film.

6. The process defined in Claim 1, wherein the flexitank can be manufactured with five layers of film.

7. The process defined in Claim 1, wherein the flexitank can be manufactured with loading and discharge from the top.

8. The process defined in Claim 1, wherein the flexitank can be manufactured with loading and discharge from the bottom.

9. The process defined in Claim 1, wherein the flexitank can be manufactured with loading from the top and discharge from the bottom.

10. The process defined in Claim 1 to 9, wherein the sea container fleet is composed of 20 ft.

11. The process defined in Claim 1 to 9, wherein the sea container fleet is composed of 40 ft.

12. The process defined in Claim 1 to 9, wherein the sea container fleet is composed of 48 ft.

13. The process defined in Claim 1 to 9, wherein the sea container fleet is composed of 53 ft.

14. The process defined in Claim 1 to 13, wherein the crude bitumen has a flash point above 60 C.

15. The process defined in Claim 1 to 14, wherein the crude bitumen has an API
lower than 15.

16. The process defined in Claim 1 to 15, wherein the crude bitumen has a Basic Sediment and Water (BS&W) content lower than 1 wt%.

17. The process defined in Claim 1 to 16, wherein the hose used for loading and discharge can be three inch hose.

18. The process defined in Claim 1 to 16, wherein the hose used for loading and discharge can be four inch hose.

19. The process defined in Claim 1 to 18, wherein the crude bitumen has no additional diluent and chemicals included.

20. The process defined in Claim 1 to 19, wherein the crude bitumen has a temperature ranges from 40 to 82 °C for loading crude bitumen to the flexitank.

21. The process defined in Claim 1 to 20, wherein the crude bitumen has a temperature below 60 °C for discharging crude bitumen from the flexitank.

22. The process defined in Claim 1 to 21, wherein the flexitank fully loaded with bitumen has a weight limits by rail, road and sea.

23. The process defined in Claim 1 to 22, wherein the flexitank is associated with seal number, rail intermodal RV number and marine vessel booking number for online tracking.

24. The process defined in Claim 1 to 23, wherein the container has to be delivered when bitumen in the flexitank has a temperature lower than 60 °C.

25. The process defined in Claim 1 to 24, wherein the containers movement during loading and discharging may need forklift or crane lift.

26. The process defined in Claim 1 to 25, wherein the bitumen has a loading and discharging rate around one cubic meter per minute.

27. The process defined in Claim 1, wherein the flexitank in the sea container can be general purpose for global transport of water, wine, edible oils, food and beverages, industrial and petroleum products, pharmaceuticals, agricultural commodities and many others.

28. The process defined in Claim 1 to 27, wherein the flexitank can withstand the temperature ranges from 82 °C to -57°C.

29. The process defined in Claim 1 to 28, wherein there to fifteen steel swept bars are installed at the front of flexitank.

30. The process defined in Claim 1 to 29, wherein the flexitank has a pressure release valve on the top.

31. The process defined in Claim 1 to 30, wherein the fully loaded flexitank can withstand the force of multiple impacts routinely endured during the handling and transportation via rail, road and sea.

32. The process defined in Claim 1 to 31, wherein crude bitumen is transport as bulk liquid non-dangerous good in the flexitank via rail, road and sea.

33. The process defined in Claim 1 to 32, wherein the flexitank has a safety pin and cap on the ball valve.

34. The process defined in Claim 1 to 33, wherein the flexitank can be used only one time to avoid cross contaminations.

35. The process defined in Claim 1 to 34, wherein the flexitank has to be disposed after discharge on the basis of local environmental regulations.

36. The process defined in Claim 1 to 35, wherein the hose used for loading the bitumen to flexitank can withstand the temperature ranges from 82 °C to -57°C.

37. The process defined in Claim 1 to 36, wherein the hose used for loading the bitumen to flexitank are made with rubber.

38. The process defined in Claim 1 to 37, wherein the hose used for loading the bitumen to flexitank has a strong seal inside.

39. The process defined in Claim 1 to 38, wherein the seal inside the hose has to be clean and checked daily for reuse.

40. The process defined in Claim 1, wherein the heater for discharge can be driven by electricity.

41. The process defined in Claim 1, wherein the heater for discharge can be driven by hot water.

42. The process defined in Claim 1, wherein the holder for discharge has only one direction to release bitumen.

43. The process defined in Claim 1 to 42, wherein the personnel are well trained.