EA031927B1 - Reactor apparatus - Google Patents

Abstract

The apparatus for processing bitumen or oil products contains a flow path through which the bitumen or oil product flows and one or more reagents and / or catalysts. The apparatus may contain a gas separation unit for removing gas from the flow path. The pressure reducer can be located in front of the gas separation unit. The separation unit may contain a separation volume that is elongated or flat in the horizontal plane in order to maintain a large surface area relative to the volume of the bitumen or oil product in the separation volume. The separation unit may comprise a spray structure configured to spray a product of bitumen or oil mixed with gas into the separation volume. Two or more shut-off valves may be arranged to block the flow path section, thereby restricting or preventing air and / or oxygen from entering the blocked flow path section when the unit is turned off. Two or more mixing stages can be arranged in order to work sequentially or independently.

Description

Field of Invention

The invention relates to an apparatus and methods for modifying, processing or producing bitumen and / or other oil products.

BACKGROUND OF THE INVENTION

References to any prior art in this specification do not constitute recognition that such prior art is part of well-known knowledge.

Bitumen is a viscoelastic mixture of hydrocarbons used to hold skeletal materials together in the road surface. At ambient temperature, it is a very viscous, water-resistant adhesive. In general, the source of bitumen is the fraction from the distillation of crude oil, but it can also be found in natural sediments. One way to use bitumen in road surfaces is to spray bitumen at elevated temperatures on the surface of the road surface and then apply fine gravel (usually skeletal material of the same size) to the surface of the bitumen. Under various names, this is known as spraying with bitumen, applying an insulating layer of bitumen, isolating with gravel, or surface improvement of the roadbed. This can differ significantly from the use of hot mix or asphalt, where bitumen and skeletal material are mixed together at elevated temperatures and then applied to the substrate. When using a cold mixture (or a factory mixture), highly liquefied bitumen and skeletal material are mixed together at ambient temperature and then applied to the substrate.

A modification of bitumen is known, and more specifically, a modification of the properties of bitumen through the oxidation of bitumen. Oxidized or so-called blown bitumen is obtained by blowing or passing air through the bitumen when the bitumen is at a very high temperature, for example 200-350 ° C, typically from 240 to 280 ° C. The resulting modified bitumen is harder, i.e. It has an increased softening temperature and viscosity at comparable temperatures.

Using suitable reagents, the properties of bitumen can be further modified so that the viscosity of bitumen is less susceptible to temperature.

The process of modifying bitumen by blowing is relatively slow. It can also be substantially hazardous due to the presence of volatile hydrocarbons in any airspace inside the bitumen modification apparatus. The process can also lead to significant carbon deposition. The process is often not effective. There may also be a real risk of fire or explosion and subsequent damage to equipment and potential damage to personnel.

Applicant has proposed improvements to an apparatus and methods for modifying bitumen in its US Pat. No. 7,871,509, the entire contents of which are hereby incorporated by reference. Further improvements are the subject of this patent specification.

The objective of the invention is to provide an improved reactor apparatus for the modification, processing or production of bitumen and / or other oil products.

Another object of the invention is to provide an improved modification method for modifying bitumen and / or other oil products.

Each task should be considered without regard to the task of at least providing the public with a useful choice.

SUMMARY OF THE INVENTION

In a first aspect, the invention relates to an apparatus for processing bitumen or oil products, which comprises: a flow path through which a bitumen or oil product and gas flow at a pressure above atmospheric pressure; a pressure reducer configured to reduce the pressure of the product of bitumen or oil and gas; and a gas separation unit, which comprises: an inlet configured to receive a bitumen or oil product under reduced pressure, mixed with gas, from a pressure reducer; separation volume into which bitumen and gas pass from the inlet; a gas outlet for removing gas, which is separated from the bitumen in a separation volume; and an outlet for the bitumen or oil product to recover the bitumen or oil product from the separation volume.

Preferably, the pressure reducer is a variable flow controller. Preferably, the pressure reducer is a valve. Preferably, the pressure reducer is a ball valve.

Preferably, the pressure reducer reduces the pressure substantially to atmospheric pressure.

Preferably, the separation volume is elongated or flat in the horizontal plane to maintain a large surface area relative to the volume of the bitumen or oil product in the separation volume.

Preferably, the apparatus comprises a spray structure configured to spray a bitumen or oil product mixed with gas into a separation volume.

Preferably, the spray structure comprises one or more rotating substantially conical or truncated-conical elements arranged to receive the bitumen or oil product from the inlet. Preferably, the one or more rotating elements comprise two or more substantially conical or truncated-conical elements mounted concentrically.

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Preferably, the spray structure is configured to spray the bitumen or oil product mixed with the gas in a separation volume above the level of the bitumen or oil product in the separation volume.

In a second aspect, the invention relates to an apparatus for processing bitumen or oil products, which has a gas separation unit, which comprises: a separation volume; a spray structure configured to spray a bitumen or oil product mixed with gas into a separation volume; a gas outlet for removing gas that is separated from the bitumen or oil product in a separation volume; and an outlet for the bitumen or oil product to recover the bitumen or oil product from the separation volume.

Preferably, the spray structure comprises one or more rotating substantially conical or truncated-conical elements arranged to receive bitumen from the inlet.

Preferably, one or more rotating elements comprise two or more substantially conical or truncated-conical elements mounted concentrically.

Preferably, the spray structure is configured to spray the bitumen or oil product mixed with the gas in a separation volume above the level of the bitumen or oil product in the separation volume.

Preferably, the separation volume is elongated or flat in the horizontal plane to maintain a large surface area relative to the volume of the bitumen or oil product in the separation volume.

In an additional aspect, the invention relates to an apparatus for processing bitumen or oil products, which has a gas separation unit, which comprises: an inlet configured to receive a bitumen or oil product mixed with gas; the separation volume into which the bitumen or oil product and gas pass from the inlet, the separation volume is elongated or flat in a horizontal plane so as to maintain a large surface area relative to the volume of the bitumen or oil product in the separation volume; a gas outlet for removing gas that is separated from the bitumen or oil product in a separation volume; and an outlet for the bitumen or oil product to recover the bitumen or oil product from the separation volume.

Preferably, the apparatus comprises a spray structure configured to spray a bitumen or oil product mixed with gas into a separation volume above the level of a bitumen or oil product in the separation volume.

In another aspect, the invention relates to an apparatus for processing bitumen or oil products, which comprises: a flow path; the inlet of the bitumen or oil product to introduce the bitumen or oil product into the flow path; an outlet for a bitumen or oil product to recover a processed bitumen or oil product from a flow path; many static mixers located in the flow path section; a pump arranged to pump a bitumen or oil product through a plurality of static mixers; two or more shut-off valves arranged to shut off a section of the flow path, thereby restricting or preventing the flow of air and / or oxygen into the shut-off section of the flow path when the apparatus is turned off.

Preferably, the apparatus comprises one or more inlets for introducing air and / or reagents and / or catalysts into the flow path.

In a further aspect, the invention relates to an apparatus for processing bitumen or oil products, which comprises a flow path; the inlet of the bitumen or oil product to introduce the bitumen or oil product into the flow path; an outlet for a bitumen or oil product to recover a processed bitumen or oil product from a flow path; one or more first inlets for introducing air and / or reagents and / or catalysts into the flow path; the first set of static mixers located in the first section of the flow path downstream of the inlet of the bitumen or oil product and one or more first inlets; a first pump arranged to pump bitumen or oil product and air, and / or reagents and / or catalysts through a first section of the flow path; a first gas separation unit located downstream of the first section of the flow path, configured to separate gas from a bitumen or oil product; one or more second inlets for introducing air and / or reagents and / or catalysts into the flow path downstream of the first degasser unit; a second set of static mixers located in the second section of the flow path downstream relative to the second reagent inlets; a second pump arranged to pump bitumen or oil product and air and / or reagents and / or catalysts through a second section of the flow path; and a second gas separation unit located downstream of the second section of the flow path, configured to separate the gas from the bitumen or oil product.

Preferably, the apparatus comprises a pressure reducer located in front of each gas separation unit.

Preferably, the flow path forms a closed loop such that the product of bitumen or oil circulates inside the apparatus.

This aspect also extends to a bitumen processing or production system that holds two or more such apparatuses connected in series.

In another aspect, the invention relates to an apparatus for processing bitumen or oil products, which comprises one or more inlets of a bitumen or oil product for introducing a bitumen or oil product; one or more releases for a bitumen or oil product to recover a processed bitumen or oil product; a plurality of reactor stages, each comprising: one or more inlets for introducing air and / or reagents and / or catalysts; many static mixers; a pump arranged to pump bitumen or oil product and air, and / or reagents and / or catalysts through a plurality of static mixers; and a gas separation unit located downstream of the plurality of static mixers, configured to separate gas from a bitumen or oil product; an apparatus configured to operate two or more of a plurality of reactor stages in series or to operate each of a plurality of reactor stages independently.

Brief Description of the Drawings

The invention will now be described, by way of example only, with reference to the accompanying drawings, in which in FIG. 1 is a schematic illustration of an apparatus in accordance with one embodiment;

in FIG. 2 is a more detailed view of the spray structure of FIG. 1;

in FIG. 2A is a sectional view of a spray structure;

in FIG. 2B is a sectional view of an additional embodiment of a spray structure;

in FIG. 3 shows one embodiment of a control structure for the apparatus of FIG. 1;

in FIG. 4 shows an apparatus according to a further embodiment;

in FIG. 5 illustrates an embodiment of an apparatus in accordance with a further embodiment;

in FIG. 6 illustrates a second embodiment of the apparatus of FIG. 5;

in FIG. 7 illustrates a third embodiment of the apparatus of FIG. 5 and in FIG. 8 illustrates an apparatus in accordance with a further embodiment.

Detailed description

In FIG. 1 shows a modification of an apparatus or reactor 1 in accordance with one embodiment. The apparatus is described, only as an example, with reference to the modification of bitumen. However, the apparatus of the applicant can be used to modify other oil products. For example, in one of the embodiments discussed below, the apparatus can be used to process other oil products in order to produce bitumen.

In preferred embodiments, apparatus 1 is a continuous loop reactor apparatus as shown. Bitumen circulates through the apparatus 1 in the direction indicated by arrows 2. As discussed below, inlets and outlets allow the introduction of bitumen and other reagents and / or catalysts and retrieve the modified bitumen from apparatus 1. In other embodiments, the apparatus may be a linear reactor apparatus, which bitumen passes from the end of the inlet to the end of the release of the apparatus.

The apparatus contains an inlet 3 for bitumen, through which bitumen can be added to the pipe path of the reactor apparatus 1 with a continuous circuit. Near and preferably downstream of the bitumen inlet 3, one or more reactant and / or catalyst inlets 4, 5 are provided for introducing the reactants and / or catalysts into the pipe path of the continuous reactor apparatus 1.

The apparatus contains the first stage 6 of the reactor. In this first stage 6 of the reactor, the pump 7 causes the bitumen and any reagents (including air) and / or catalysts to flow along the flow path 8 in the direction and through the first mixing stage 9.

The first mixing stage 9 comprises a pipe path which comprises a first plurality of static mixers 10. As shown in FIG. 1, the first plurality of static mixers 10 may be located in a certain number of vertical columns 11, 12. However, other pipe structure designs may be used in the first mixing stage. In general, a certain number of mixing steps may be provided, and each mixing step comprises a pipe section that contains a certain number of static mixers.

Static mixers are fixed fixed components that mix bitumen and the reactants and / or catalysts flowing through them. Various types of static mixers are known. Preferably, the mixers are formed from a strong inert material that is resistant to bitumen or other petroleum products to be modified and to any other reagents, catalysts or reaction products. Mixers can be formed of stainless steel.

Pump 7 ensures that the flow rate of the fluid inside the apparatus coincides with the functioning of static mixers. Static mixers create rapid changes in the direction of flow of a fluid, and the resulting turbulent flow ensures thorough mixing of all components in the flow of a fluid.

Due to the many static mixers in the first mixing stage 9, bitumen and other reagents and / or catalysts are thoroughly mixed, which leads to excellent reaction rates in the first mixing stage 9. After exiting the first mixing stage 9, bitumen flows through a pressure reducer 14. The pump 7 can be actuated in order to maintain the pressure in the first mixing stage from about 6 to 7 bar. The pressure reducer 14 reduces the pressure to about 1 bar or, typically, about 1-2 bar downstream of the pressure reducer.

The output column 15 may be provided in the first stage 6 of the reactor, which leads to the first gas separation unit or degasser 16. The first degasser unit separates the gases from the bitumen stream. The first degasser unit comprises a separation volume 17, which may be a tank, as shown. Bitumen is introduced into the separation volume through the inlet structure 18, which is shown in detail in FIG. 2. The inlet structure 18 comprises an inlet 19 through which bitumen flows from the pressure reducer 14. Bitumen is sent from the inlet 19 to the spray structure 20. The spray structure 20 is configured to spray mixed bitumen and air into the separation volume. When mixed material is sprayed, the gases tend to separate from the sprayed film or droplets of bitumen. Then droplets of bitumen fall down or a film of bitumen falls down. The approximate bitumen level in the separation volume 17 is marked 22 in FIG. 1. The level can be maintained within the desired range, as discussed below.

In one embodiment, the spray (spray) structure 20 may include a spray (spray) head 23, shown in more detail in FIG. 2 and 2A. The spray head 23 may contain a certain number of elements 24, 25, 26 installed to create a certain number of flow paths 27, 28 through the spray head 23. Any number of elements of the spray heads can be used to create any desired number of paths flow. Bitumen flows from the inlet 19 through the flow paths 27, 28 and is sprayed (sprayed) into the separation volume 17. In the illustrated embodiment, the elements 24, 25 are generally truncated conical or truncated-conical elements extending from the lower pipe sections 29, 30. The central element 23 may be conical.

In preferred embodiments, the spray head 23 is a rotating spray head. The rotating spray head can be mounted on a barrel 32 driven by a suitable engine 33. The rotation can be in the range of 300 to 1000 rpm. The cones may have a maximum diameter in the range of 200-400 mm, preferably about 300 mm. Cones can be formed from stainless steel 2 mm thick. In one embodiment, the conical walls can be formed at an angle of approximately 45 degrees to the vertical.

In another embodiment, the upper parts 24 ', 25', 26 'of the cones 24, 25, 26 may be curved in the horizontal direction, as shown in FIG. 2B. This changes the angle at which bitumen is sprayed into the separation volume.

This rotation effectively throws the bitumen outward, contributing to the dispersal of the bitumen from the spray head into the separation volume and forming a three-dimensional curtain of droplets of bitumen or a three-dimensional film of bitumen. A significant proportion of the gas is separated from bitumen when sprayed.

In some embodiments, other spray structures may be suitable, including: simple conical spray heads (i.e., contain only one conical element), rotating and stationary spray heads, spray nozzles, etc. A plurality of spray heads may be used in each degasser unit.

In some embodiments, the spray structure can be replaced with a simple inlet in which bitumen is poured from the inlet into the separation volume. Such a mechanism is disclosed in US7871509.

A pressure reducer also contributes to the separation of gas and bitumen. With a decrease in pressure, the gas in the bitumen stream tends to coalesce in order to form bubbles. With a decrease in pressure, the solubility of air and some other gases in bitumen also decreases.

Optionally, all of the gas mixed with bitumen is separated from the bitumen during spraying by the spray structure 20. In order to provide additional gas separation, the bitumen is held in the separation volume at the level noted 22 in FIG. 1. Bitumen has a residence time or delay in the separation volume, and during this period more gases are released from the bitumen in a volume of 35 above the level of 22 bitumen. Here, the geometric shape of the separation volume 17 helps. The separation volume is preferably elongated or flat in the horizontal plane. This gives a large surface area per unit volume of bitumen in the separation volume 17.

Gas leaves the degasser through gas outlet 36. Gases may contain low oxygen air and volatile substances, but the gas content will depend on the particular application.

- 4 031927 devices. Although not shown, an explosive valve can be connected to the gas outlet 36. One or more separators can be used to separate liquid and solid substances from the gas stream (for example, water with small amounts of carbon and liquid hydrocarbons). Gases passing through the gas outlet may pass into a waste incinerator (not shown).

In one embodiment, the exhaust gases may pass into a waste incinerator with a heat exchanger so that the burnt air / steam mixture can be used as an energy source to be used, for example, when heating an oil heat carrier passing through a heat exchanger coil. Then, the heated oil coolant can be used for other technological operations, such as preheating bitumen and / or air. Alternatively, air and volatiles can be fed into a simple incinerator for incineration.

In order to maintain the bitumen at a suitable level, a level sensor may be provided. A certain number of pipes 37 is installed in the separation volume 17. A level sensor 38 is mounted on the upper part of the pipe 39, which contains bitumen at the same level as the separation volume 17. The level sensor in one embodiment may be a radar unit configured to perceive the surface of bitumen (and therefore the level of bitumen) inside the pipe 39.

Therefore, the first reactor stage comprises a first pump 7, inlets 3, 4, 5, a first mixing stage 9 and a first degasser unit 16. Bitumen leaves the first block 16 of the degasser through outlet 46 and passes into the second stage 47 of the reactor. The second stage of the reactor comprises a second pump 48, inlets 49, 50, a second mixing stage 51 and a second degasser unit 52, which functions in a similar manner to the corresponding elements of the first stage of the reactor.

In general, any number of reactor stages can be connected in series in this way. Therefore, the apparatus 1 may contain a first reactor stage and a certain number of additional reactor stages connected in series. Each step modifies the bitumen passing through it.

The effect of two or more steps is as follows. Bitumen introduced into the apparatus through inlet 3 is mixed with reagents and / or catalysts introduced through inlets 4, 5 in the first mixing stage 9. Partially modified bitumen passes through a first degasser 16, where gases are removed. When the modification is mediated by air or oxygen, the degasser must remove unwanted exhaust gases and gaseous reaction products. Partially modified bitumen is pumped by pump 48 from the first degasser to the second stage of the reactor. Then additional reactants and / or catalysts are introduced through inlets 49, 50 in the second stage of the reactor. Bitumen and additional reagents and / or catalysts are then mixed in the second mixing stage 51, further modifying the bitumen. An additionally modified bitumen passes through a second degasser 52, in which the gases are again removed. If desired, this process can be repeated in a certain number of additional reactor stages. This significantly improves the processing efficiency of bitumen compared to a single-stage apparatus. In a two-stage apparatus, an increase in efficiency is more than a twofold improvement, which could be expected by doubling the number of stages.

Modified bitumen is removed from the apparatus through the outlet port 55. This extraction is carried out using an extraction pump 56. When the apparatus is in the form of a reactor with a continuous loop, only part of the bitumen can be removed through the outlet port, while the rest of the bitumen is recycled for further modification.

The apparatus of FIG. 1 can be turned off as needed, without removing bitumen from the apparatus. When the bitumen cools, it contracts and its viscosity increases. In order to turn off the apparatus, the gas level in the system is preferably reduced by running the apparatus for several minutes without introducing additional bitumen, reagents or catalysts. The degasser units 16, 52 continue to operate during this period. At the end of this period, bitumen in the pipe path has a reduced gas content. Then turn off the pumps 7, 48, which causes the flow of bitumen through the apparatus to stop. The shut-off valves are then closed in order to isolate the mixing stages. In the present embodiment, four shut-off valves take place. In one embodiment, the first and second pressure reducers 14, 14 ′ may be in the form of valves. These valves also act as shut-off valves. However, in other embodiments, separate shut-off valves and pressure reducers may be provided. Returning to the embodiment of FIG. 1, two additional shut-off valves 58, 58 ′ are also provided. They can be knife valves or some other valve suitable to block the pipe path. In the off phase, the first knife gate valve 58 and the first pressure reducer valve 14 are closed to isolate the first mixing stage 9. The second knife gate valve 58 'and the second valve of the pressure reducer 14' are closed to isolate the second mixing stage 51.

Thus, the insulation of the mixing steps prevents or at least restricts the entry of gases containing air or oxygen into the mixing steps when the unit is turned off. This is desirable because bitumen continues to oxidize when the unit is turned off and when it is started. During these periods of shutdown and start-up, bitumen in the apparatus passes between a high operating temperature and a low ambient temperature. At temperatures above approximately 140 °, significant oxidation will occur. If uncontrolled oxidation is allowed in the mixing stages after the apparatus is turned off, sintering will slowly occur on the mixers, which limits their effectiveness or even blocks the flow path.

An apparatus containing pumps and a pipe path may be jacketed. The oil coolant can be passed through the jacket to preheat the apparatus and the contained bitumen, as well as the bitumen of the pumps, before starting or restarting the modification process. A certain number of heating jackets 40 are shown in FIG. 1. Extra shirts can be used, but they are not shown due to clarity.

At the initial start-up, the apparatus or reactor must be filled with bitumen before introducing air, other reagents and / or catalysts. If the pump is restarted, the shut-off valves should be closed and re-opened. The first and second pumps 7, 48 should be slowly brought to operating conditions. Reagents and catalysts can then be added in order to create stable operating conditions.

The bitumen can be preheated before introduction through the inlet port 3. In one embodiment, where the bitumen is to be modified by blowing, the bitumen can be fed into the bitumen inlet 3 at a temperature of about 220-230 ° C., resulting in processed bitumen exiting the reactor at a temperature of approximately 230-240 ° C.

Bitumen, air, other reagents and catalysts can also be supplied at a pressure close to the working pressure used in the mixing stages, preferably from about 6 to 7 bar.

In the embodiment of FIG. 1, the first pump 7 acts to cause bitumen to flow through the first stage of the reactor. However, it also acts as a circulation pump, causing bitumen to flow from the outlet 46 ′ of the second degasser back to the first mixing stage 9. In other embodiments, a separate circulation pump can be used.

Pressure reducers 14, 14 'may be of any suitable design for reducing pressure. Preferably, the pressure drop is sudden, i.e. close to stepwise decrease. In one embodiment, each pressure reducer may be a ball valve. In other embodiments, any suitable pressure-reducing valve or other pressure-reducing structure (e.g., a diaphragm with a bore) may be used. In preferred embodiments, the pressure reducers may be adjusted.

The apparatus can be controlled as described below with reference to FIG. 1 and 3.

The movement of bitumen through static mixers is controlled mainly by the first and second pumps 7, 48. The amount of bitumen in the apparatus is controlled by the combined action of the inlet pump 60 and the extraction pump 56. The inlet pump adds bitumen to the recycled bitumen inside the apparatus. When the bitumen level inside the apparatus is sufficiently high, bitumen will be collected in the pipe path in the degassers 16, 47 and in sections of the pipe path 61, 62 immediately downstream of the degassers 16, 47.

Perceiving the level of bitumen in this area, preferably in degassers, the second pump 48 and the extraction pump 56 can be controlled as follows. When the level in the first degasser 16 exceeds a threshold, the speed of the second pump 48 increases in order to pump bitumen through the second mixing stage 51. When the level in the second degasser 52 exceeds a threshold, the speed of the extraction pump 56 is increased in order to extract the modified bitumen from the apparatus. By controlling the movement and extraction of bitumen in this way, the bitumen level can be kept within the desired range for optimal operation of the apparatus.

In addition, the operation of the inlet pump can be used to control the number of circulation through the apparatus through which bitumen must pass, which provides a certain control over the level of modification of bitumen. For example, if the inlet pump operates at a low speed, bitumen will, on average, pass through the apparatus many times before removal, since bitumen will be collected in separation volumes at a lower speed. If the inlet pump operates at high speed, the bitumen will collect at a higher speed and will, on average, pass through the machine fewer times before being removed. Therefore, level sensors and associated control provide an excellent and convenient mechanism for automatically controlling the bitumen level in the apparatus and extracting bitumen from the apparatus for many different modification levels.

Therefore, controlling the inlet and extraction pumps provides a mechanism for controlling the bitumen delay time inside the reactor and therefore (along with other parameters, such as the reagents and / or catalysts used, temperature and pressure) the level of modification that will occur.

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In FIG. 3 illustrates a central controller 65 that receives information from sensors and provides control signals to at least some of the many pumps and valves discussed above.

The controller provides control signals to the inlet pump 60, the catalyst pumps 66, 67, the reagent pumps 68, 69, the first pump 7, the second pump 48, and the extraction pump 56. In some embodiments, some of these pumps may be fixed speed pumps, which do not need to be managed. However, it is preferable that at least the second pump 48 and the extraction pump 56 can be controlled. In more preferred embodiments, all of the above pumps can be controlled. The pumps can be controlled by changing their speed or by turning the pumps on or off. The discharge rate can be changed by directly controlling the speed or by turning the pump on and off in order to change its utilization rate. In addition, pumps can provide feedback to the controller about their current status, discharge rate, etc.

The controller 65 receives information from a certain number of sensors. It includes first and second level sensors 38, 38 ', temperature sensors and any other sensors that may be desirable for a particular application.

The controller 65 can also control and receive feedback from valves 14, 14 ', 58, 58'. This allows the controller to control the shutdown process described above, as well as the pressure drop across the ball valves 14, 14 '. Alternatively, these valves may be manually actuated.

The flow path may have a diameter of from about 25 to 300 mm, with large sizes being preferred for industrial applications.

Any reagents suitable for the desired modification process may be used. For example, various forms of phosphoric acid can be used in blowing bitumen.

Any catalysts suitable for the desired modification process may be used. For example, metal halides, such as iron (III) chloride, can be used as a catalyst for blowing bitumen.

The apparatus is described above with respect to the modification of bitumen, in particular, but not exclusively, to blowing bitumen. However, the apparatus can also be used to process other substances, in particular oil products, including distillation products obtained from crude oil, as well as non-standard sources of oil, such as heavy oil yield, tar sands, tar sands and oil sands.

For example, the apparatus can be used to obtain bitumen from other fractions of crude oil. Vacuum residues (also known as tars) can be processed in order to form bitumen, through an oxidation process over a relatively long residence time, using phosphoric acid as a reagent. The products of the release of heavy oil, tar sands, tar sands and oil sands can be processed using the apparatus in order to provide bitumen.

Bitumen products that are not suitable for many applications can be processed to a more usable form for a specific application. For example, solvent precipitated bitumen (also known as deasphalted bitumen) is generally too viscous for road applications. However, it can be processed using tar and distillation at atmospheric pressure using the apparatus of the applicant in order to form a less viscous bitumen suitable for roads. Tar and / or other additives can be added if necessary for a specific application, either before or after other reactions that must pass.

The apparatus can also process mixtures of any of the above substances or mixtures of the above substances with bitumen.

The apparatus can be used for various processes, including but not limited to: rectification of bitumen or oil products at atmospheric pressure; dehydrogenation and / or oxidation; polymerization and / or crosslinking; mixing thermoplastics into bitumen with high shear.

Suitable reagents include oxygen, various forms of phosphoric acid. Catalysts include iron (III) chloride. Tar oils include suitable vegetable oils, mineral oils, recycled oils, etc. Polymers include styrene-butadiene-styrene (SBS) polymers, styrene-butadiene rubber (SBR), latex rubber, ground tire rubber, etc. You can use waxes.

Oxygen is generally obtained simply by using air, as purified oxygen increases the cost. However, in some applications, purified oxygen may be used.

In General, the apparatus of the applicant creates excellent reaction conditions for the modification or processing of bitumen products or oil products or for the production of bitumen from other products, in particular oil products.

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Compared with the apparatus of the applicant described in US7871509, the system of FIG. 1 provides a longer time for bitumen to perform one circulation through the apparatus. However, the total residence time of bitumen in the apparatus in order to achieve a certain level of modification is reduced.

In FIG. 4 shows an apparatus in accordance with a further embodiment. In this apparatus, the two apparatuses discussed above are connected in series. Thus, the first apparatus 1 contains the first and second stages 6, 47 of the reactor, and the second apparatus 1 'contains the first and second stages 6', 47 'of the reactor. Port 55 for removing the first apparatus 1 is connected to the inlet 3 'for the bitumen of the second apparatus 1'. Any number of devices can be connected in series in this way.

The chemical processes in each apparatus 1, 1 'can be one and the same. Alternatively, various reagents and / or catalysts may be used in various apparatuses 1, 1 ′.

In FIG. 5-7, an additional embodiment of an apparatus or reactor 101 for modification with two mixing stages is illustrated, in which three different flow conditions can be implemented. Preferably, it allows you to turn off or operate each stage independently of the others. Therefore, one stage can be serviced, for example, while the other stage continues production.

In this embodiment, apparatus 101 is also in the form of a continuous loop reactor apparatus. However, several contour paths are possible. In each mode, some valves are closed and some pumps are not used. For transparency, closed valves and unused pumps are marked with a black fill for each mode.

In FIG. 5 illustrates a first mode in which two stages are connected in series with the left inlet. Bitumen circulates through the apparatus 101 in the direction indicated by arrows 102.

The apparatus contains an inlet 103 for bitumen, through which bitumen can be added to the pipe path of the reactor apparatus 101 with a continuous circuit. Bitumen flows along the paths 104, 105, 106 of the flow to the right stage 107 of the reactor. One or more inlets 108, 108a are provided for introducing air and / or reagents and / or catalysts into the pipe path of the continuous loop reactor apparatus 101.

In this right-hand stage 107 of the reactor, pump 109 causes bitumen and any air, reagents and catalysts to flow along the flow path in the direction and through the first mixing stage 110.

The first mixing stage 110 comprises a pipe path that contains a first plurality of static mixers 111 and which is similar to the mixing steps discussed above.

After exiting the first mixing stage 110, bitumen flows through a pressure reducer 112 and a degasser unit 113, which also work as discussed above.

Bitumen leaves the right degasser unit 113 via flow paths 115, 116, 117, and is pumped using pumps 118 and / or 139 to the left stage 119 of the reactor. In this configuration, one of these two pumps (for example, pump 118) can operate in a fixed speed mode, while the other (for example, pump 139) has a variable speed in order to control the bitumen level in the degasser 113.

The left reactor stage contains inlets 120, 121, the second mixing stage 122 and the second degasser unit 123, which function similarly to the corresponding elements of the right reactor stage.

Bitumen exits the left stage 119 of the reactor through a flow path 125. Pump 126 operates as a circulation pump in order to pass bitumen back to the right stage 107 of the reactor through flow paths 127 and 106. Pump 129 functions as a recovery pump in order to recover processed bitumen through a discharge 130.

In this mode, valves 131, 132, 133, 134, 135, 136, and 137 are closed and pump 138 is inactive. Pump 139 maintains a circulating flow through flow paths 140, 141, 142. However, in some embodiments, this flow path may be closed by valves 143, 144.

In FIG. 6 illustrates a second mode of operation for the apparatus of FIG. 5. Two stages are connected in series using the right inlet. Bitumen circulates through the apparatus 101 in the direction indicated by arrows 102.

In this mode, the inlet for bitumen is designated 202. Bitumen flows along the flow paths 104, 203, 204 to the left stage 119 of the reactor. After exiting the left stage 119 of the reactor, bitumen is pumped by pump 126 through the flow paths 125, 127, 106 to the right stage 107 of the reactor. In this mode, the pump 139 functions as an extraction pump in order to extract bitumen from the outlet 205. The pump 118 performs the function of a circulation pump in order to cause the bitumen to return to the left stage of the reactor 119 through the flow paths 117, 204.

In this mode, valves 206, 207, 208, 209, 132, 137, and 144 are closed and pump 109 is inactive.

Consequently, operation in this mode occurs essentially according to the same principle as in FIG. 5, but change the position of the inlet and outlet and the direction of flow in some flow paths.

In FIG. 7 illustrates a third mode of operation of the apparatus of FIG. 5 and 6. In this mode, each stage operates independently of the other. Valves 210, 211, 212 are closed, preventing any flow between the two stages 107, 119 of the reactor. This allows each stage to work separately while the other is off. Valves 131, 144 are also closed.

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In the left reactor, bitumen flows from inlet 103 through pump 138 and flow paths 203, 204 to the left stage

119 reactors. Pump 126 acts as a circulation pump, receiving bitumen from a degasser

123 and returning it to the left step of the reactor 119. The pump 129 acts as an extraction pump for recovering treated bitumen through an outlet 130. The extraction pump also controls the level of bitumen in the degasser 123.

Similarly, in the right reactor, bitumen flows from the inlet 202 through the pump 109 and flow paths 105, 106 to the right stage 107 of the reactor. The pump 118 performs the function of a circulation pump, receiving bitumen from the degasser 113 and returning it to the right stage 107 of the reactor. The pump 139 functions as an extraction pump for recovering treated bitumen through a discharge 205. The extraction pump also controls the level of bitumen in the degasser 113.

In general, any number of reactor stages can be connected, thus making it possible for all or some of the reactor stages to operate sequentially or independently for each stage of the reactor.

The various elements of this apparatus can be controlled by a central controller similar to what is discussed above.

An apparatus enabling independent or sequential operation of two or more reactor stages can be implemented using other configurations of flow paths, valves and pumps, and other such configurations fall within the scope of the invention.

In FIG. 8 illustrates an apparatus in accordance with a further embodiment. In this apparatus, two apparatuses of FIG. 5-7 are connected in series. Thus, the first apparatus 101 and the second apparatus 101 'are connected. The port 205 for removing the first apparatus 101 is connected to the bitumen inlet 103 of the second apparatus 101 '. Any number of devices can be connected in series in this way.

In one embodiment, the apparatus is suitable for blowing bitumen. The blown bitumen is oxidized by reaction with air or another gas containing oxygen.

It should be noted that some aspects of the invention may find application in single-stage reactor apparatuses and should not be limited by a configuration with two or more reactor stages until they are explicitly limited by the appended claims.

The process and apparatus of the present invention provide a very stable and controllable means for modifying bitumen. It also makes it possible to produce bitumen with a wide range of specifications, including universal bitumen. Universal bitumens are less susceptible to temperature bitumen.

The process can be carried out using catalysts and reagents that may be required in order to produce bitumen with the desired final specification.

The use of a multi-stage apparatus further enhances the efficiency of the reaction. Spent reagents and undesirable gaseous reaction products are removed from the system after each mixing stage by adding fresh reagents and / or catalysts. Pumps in each stage of the reactor provide mixing at the desired pressure. Any number of mixing stages may be provided, with a gas separation unit after each mixing stage and a pump in front of each mixing stage.

Removing exhaust gases or gaseous wastes, including reaction by-products, from the system and introducing fresh gases increases efficiency.

Shut-off valves isolate mixing stages during shutdown. Therefore, the flow of oxygen or other undesirable gases into the mixing stages after shutdown is limited. This reduces the possibility of unwanted sintering of oxidized bitumen or other materials on the surfaces of the mixers, which keeps the static mixers in good working condition.

The degasser unit operates at reduced pressure, preferably near atmospheric pressure, which contributes to improved gas separation and also increased safety in some applications (since uncontrolled combustion is less likely at reduced pressure). The degasser unit comprises a spray structure that sprays mixed bitumen into a separation volume, which contributes to improved gas and bitumen separation. In addition, the geometrical shape of the separation volume provides a large surface area of bitumen for the bitumen in the tank, which also contributes to an improved separation of gas and bitumen.

Safety is also enhanced by improved reaction conditions, since less excess oxygen mixed with volatile substances is present in the degassing units. For example, in some bitumen purge applications, the gaseous waste can be only about 5% oxygen. Therefore, burning is less likely.

Although the present invention has been illustrated by describing its embodiments, and although the embodiments are described in detail, it is not the intention of the applicant to define the limits or in any way limit the scope of the attached claims to such details. Additional benefits and modifications will be readily apparent to those skilled in the art. Therefore, the invention in its broadest aspects is not limited to specific details, representative apparatus and methods, as well as illustrative examples cited and described. Accordingly, it is possible to create derogations from such details without departing from the essence and scope of the main patentable idea of the applicant.

Claims (12)

CLAIM 1. Apparatus for processing products of bitumen or oil, which contains: (i) The first pipe reactor stage through which bitumen or oil and gas can flow at pressures above atmospheric pressure; ii) an inlet for a bitumen or oil product for introducing a bitumen or oil product into said first reactor stage; iii) a release for a bitumen or oil product to recover a processed bitumen or oil product from said first reactor stage; iv) one or more first inlets for introducing air and / or reagents and / or catalysts into said first reactor stage; v) a first plurality of static mixers located in a first mixing section of a first pipe reactor stage downstream of an inlet for a bitumen or oil product and one or more first inlets; vi) a first pump configured to pump a bitumen or oil and air product and / or reagents and / or catalysts through a first mixing section; vii) a first gas separation unit located downstream of the first mixing section, which is configured to separate gas from a bitumen or oil product; viii) a second pipe reactor stage connected to the first gas separation unit through which bitumen or oil and gas from the first gas separation unit can pass; ix) one or more second inlets for introducing air and / or reagents and / or catalysts into said second tube reactor stage; x) a second set of static mixers located in the second mixing section of the second pipe reactor stage downstream of the second inlets; xi) a second pump configured to pump a bitumen or oil and air product and / or reagents and / or catalysts through said second reactor stage; xii) a second gas separation unit located downstream of the second mixing section and configured to separate gas from bitumen or oil product; and xiii) a pressure reducer located in front of each gas separation unit, wherein each pressure reducer is configured to reduce the pressure of the bitumen product or oil and gas supplied to the corresponding gas separation unit. 2. The apparatus according to claim 1, in which each pressure reducer reduces the pressure to about atmospheric pressure. 3. The apparatus according to claim 2, in which each pressure reducer is a variable flow regulator. 4. The apparatus according to claim 3, in which each pressure reducer is a valve. 5. The apparatus according to any one of claims 2 to 4, in which each pressure reducer is a ball valve. 6. The apparatus according to any one of the preceding paragraphs, in which each gas separation unit includes a separation volume that is elongated or flat in the horizontal plane to maintain a large surface area relative to the volume for the bitumen or oil product in the separation volume. 7. The apparatus according to any one of the preceding paragraphs, in which each gas separation unit includes a separation volume and a spray structure configured to spray a bitumen or oil product mixed with gas in the separation volume. 8. The apparatus according to claim 7, in which the spray structure includes two or more conical or truncated-conical elements mounted concentrically. 9. The apparatus according to claim 7 or 8, in which the spray structure is configured to spray a bitumen or oil product mixed with gas into a separation volume above the level of the bitumen or oil product in the separation volume. 10. The apparatus according to any one of the preceding paragraphs, comprising two or more shut-off valves configured to shut off the first mixing section and / or the second mixing section, thereby restricting or preventing air and / or oxygen from entering the blocked section of the apparatus when the apparatus switched off. 11. The apparatus according to any one of the preceding paragraphs, in which the first and second reactor stages form a closed loop, so that the product of bitumen or oil circulates inside the apparatus. 12. A bitumen processing or production system comprising two or more apparatuses according to any one of the preceding paragraphs, which are connected in series through an outlet for extraction, located downstream of the second gas separation unit of one apparatus and connected through an extractor - 10 031927 forging pump with the first reactor stage of the next apparatus in sequence.