WO2016008024A1 - Agencement de transition de sauvegarde à étage unique pour unité de sédimentation de mousse à étages multiples partiellement hors ligne - Google Patents

Agencement de transition de sauvegarde à étage unique pour unité de sédimentation de mousse à étages multiples partiellement hors ligne Download PDF

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Publication number
WO2016008024A1
WO2016008024A1 PCT/CA2014/050666 CA2014050666W WO2016008024A1 WO 2016008024 A1 WO2016008024 A1 WO 2016008024A1 CA 2014050666 W CA2014050666 W CA 2014050666W WO 2016008024 A1 WO2016008024 A1 WO 2016008024A1
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Prior art keywords
fsu
stream
stage
solvent
bypass
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PCT/CA2014/050666
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English (en)
Inventor
Saba Moetamed-Shariati
William Nicholas Garner
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TotalEnergies E&P Canada Ltd
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Total E&P Canada Ltd
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Priority to PCT/CA2014/050666 priority Critical patent/WO2016008024A1/fr
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Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03D—FLOTATION; DIFFERENTIAL SEDIMENTATION
    • B03D1/00—Flotation
    • B03D1/02—Froth-flotation processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03D—FLOTATION; DIFFERENTIAL SEDIMENTATION
    • B03D1/00—Flotation
    • B03D1/14—Flotation machines
    • B03D1/1406—Flotation machines with special arrangement of a plurality of flotation cells, e.g. positioning a flotation cell inside another
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03D—FLOTATION; DIFFERENTIAL SEDIMENTATION
    • B03D2203/00—Specified materials treated by the flotation agents; Specified applications
    • B03D2203/006—Oil well fluids, oil sands, bitumen

Definitions

  • Embodiments disclosed herein relate to vessels for separation of components of slurries, and more particularly, to multi-stage vessel and method of use for separation of components of a bitumen froth therein.
  • a slurry stream comprising liquid and solid particles is delivered to a vessel where the solid particles settle by gravity and are removed from the bottom of the vessel, while the clarified liquid is removed from the top of the vessel.
  • mined oilsand is typically mixed with warm water.
  • the resulting slurry is piped to a primary gravity separation cell or separation vessel (PSV) where the coarse solids fall to the bottom, a middlings stream containing some bitumen, fine solids and water is removed from the middle of the vessel, and a froth containing bitumen, water and some fine mineral solids is removed from the top of the PSV.
  • PSV primary gravity separation cell or separation vessel
  • the froth comprises about 60% bitumen, 30% water and 10% fine solids.
  • the froth is further processed for removal of water and solids from the bitumen to permit further processing of the bitumen. It is known to use centrifuges, gravity separation vessels and inclined plate settlers to separate the bitumen from the water and the solids.
  • the froth is typically diluted with a hydrocarbon solvent to reduce the viscosity and density of the oil phase prior to this further processing.
  • Bitumen froth is diluted with solvent and added to the first froth separation vessel.
  • the underflow is removed, mixed with additional solvent and is pumped to the second froth separation vessel.
  • the overflow from the second vessel is returned to the first vessel and the underflow is mixed with additional solvent and is pumped to the third froth separation vessel.
  • the overflow from the third vessel is pumped to the second vessel and the underflow is removed for tailings handling.
  • the overflow from the first vessel is removed to a separation vessel for removal of solvent therefrom and the bitumen recovered is pumped to a facility for upgrading.
  • bitumen predominately comprises maltenes, the marketable component, and some asphaltenes.
  • paraffinic solvents when sufficient solvent is added, much of the asphaltenes aggregate upon contact between the solvent and the heavy hydrocarbon fraction. Large aggregates typically form between the water droplets, mineral solids and the rejected asphaltenes. Formation of aggregates aids in separation of the bitumen and solvent from the solids, including both aggregates and mineral solids, and water.
  • conventional methods of separation are typically costly, require multiple pumps and other auxiliary equipment and require large volumes of solvent commensurate with the number of separation units employed.
  • oilsands operations are subject to and sensitive to periodic interruptions in materials handling.
  • interruptions domino wherein a backup of, or failure of, a single-stage can quickly and negatively affect additional stages.
  • even a short interruption can lead to vessel operation failure with vessels and piping blocked with solids.
  • the settling units known as froth separation units (FSUs) produce a bitumen and solvent overflow and a solids and water underflow.
  • the overflow is directed to a solvent recovery unit (SRU) to separate bitumen and solvent, and the underflow is directed to a tailing solids recovery unit (TSRU).
  • SRU solvent recovery unit
  • TSRU tailing solids recovery unit
  • Embodiments disclosed herein enable a multi-stage FSU system to be reorganized for operation on one FSU.
  • Reorganization or restructuring of the process streams includes bypassing one or more other stages in the event of at least one FSU being compromised.
  • a single-stage backup transitional arrangement is provided for instances when multi-stage FSU's go partially offline. Continued operation with a single stage FSU maintains operability and maximizes separation at performance approximating that of the multi-stage operations. Accordingly, despite localized disruption due to one stage of a multi-stage FSU system going offline for one reason or another, propagation of the disturbance to other connected systems is minimized, both upstream and downstream of the FSU system.
  • a reliable method for a transitional bypass circuit around the offline FSU is provided at low cost and with convenience.
  • recovery of the maltene portion of the bitumen froth feedstream can reach 98%.
  • maltene recovery can be maintained in the order of about or greater than 95% while repair operations facilitate a return to two-stage operation.
  • FSU failure such as due to plugging, pump failure and the like, can take a considerable time to resolve, impacting production and the operability of upstream and downstream facilities. More than a mere bypass, the remaining FSU or FSU's are capable of sustained operation at a substantially full process flow capacity until such time as the problem FSU is back online.
  • two-stages of FSU are protected by a process arrangement permitting single-stage operation.
  • One area of frequent failure is in downstream handling of tailings, typically coupled downstream of the second-stage of a two-stage system or the last stage of a multi-stage FSU system.
  • the second or last stage can be bypassed. While early stages are less vulnerable, such operational units are still subject to various mechanical or process failures. Therefore, as contemplated herein, arrangements include instances in which the first-stage FSU can go offline, and transitional bypass arrangements are herein provided to enable continued backup operations on the second or latter stage FSU alone, bypassing the first-stage FSU.
  • Applicant favors two-stages of FSU, a greater number of stages requiring proportionally greater capital costs. Accordingly, while first, intermediate or latter stages of multi-stage systems can be bypassed for operation on other stages of the system, embodiments are described herein in the context of two-stage FSU systems.
  • two or more redundant underflow pumps or a series of pumps are provided in parallel for at least the vulnerable stage of the multi-stage system.
  • One or more of the pumps are made available in standby mode in the event of a failure of the other on-stream pump, including for normal operations in two-stage mode.
  • the underflow pump or pumps of the remaining operational stage are required to handle a higher recirculatory flow, including recirculation of a portion of the underflow tailings stream.
  • the two or more redundant underflow pumps are sized so that each of series of pumps independently can manage the increased recirculatory stream flow in the event of the loss of one stage.
  • the capacity of each pump stream is maintained as conventionally designed for normal backup, parallel operation, however both are simultaneously pressed into service together for use in tandem for enabling increased recirculatory capacity when required.
  • first and second redundant underflow pumps at the first and second underflow streams respectively.
  • first FSU operation of the first FSU
  • one operates at least one of the first redundant pumps for normal delivery of the first underflow stream to the second FSU in normal multi-stage FSU operations. If the second FSU goes offline, one operates both of the first redundant pumps for delivery of an increased recirculating flow of the first underflow stream to first and second bypass streams for single-stage FSU operations.
  • the remaining operational stage or stages of the FSU system has its ultimate underflow stream split between a reject tailing stream directing solids and water to a downstream TSRU and to a recycle stream, including solvent enrichment, directed back to the inlet of the operational FSU.
  • the usual stream of the solvent addition is re-routed to bypass the reject tailings stream for exclusively joining and solvent-enriching the recycle stream, aiding in FSU operation for separation of maltenes and solvent from solids and water.
  • a method of operating a system of two- stages of froth separation units (FSU) as a single-stage FSU system is provided.
  • Froth comprising bitumen, mineral solids and water and separation of the froth normally occurs in the two-stage froth separation system for producing a dilbit product stream of bitumen and solvent, a solvent-enriched recycle stream for comingling with the bitumen froth to form a diluted bitumen froth as a feedstream to the system, and a reject tailings stream of predominately mineral solids and water.
  • the two-stage FSU system is operated by receiving the feedstream at a first inlet to a first-stage FSU for producing the dilbit product stream at a first product outlet and a first underflow stream directed to a second inlet of a second-stage FSU, adding solvent to the first underflow stream before the second inlet, and producing a second product stream at a second product outlet of the second-stage FSU for forming the recycle stream and a second underflow stream at a second underflow outlet forming the reject tailings stream.
  • the two-stage FSU system can be operated as a single-stage FSU system for bypassing an offline FSU of the two-stage FSU, comprising: isolating the offline FSU at the offline product outlet, at the offline inlet, and at the offline underflow outlet; directing the froth to the inlet of the online FSU; splitting the underflow stream of the online FSU into first and second bypass streams; and re- directing the solvent addition to the first bypass stream, wherein the first bypass stream forms the solvent-enriched recycle stream to the online inlet, and the second bypass stream forms the reject tailings stream.
  • the offline FSU is the second-stage FSU and accordingly, the one isolates the second-stage FSU at the second product outlet, at the second inlet, and at the second underflow outlet; splits the first underflow stream into the first and second bypass streams; and re-directs the solvent addition to the first bypass stream, wherein the first bypass stream forms the solvent-enriched recycle stream to the first inlet and the second bypass stream forms the tailings stream.
  • the froth remains directed to the first inlet.
  • the flow rate of the first and second bypass streams can be split about 50:50 by volume. Further, one can provide redundant underflow pumps at the underflow stream of the operating FSU for management of the higher recirculatory flow rates of the first bypass stream during single-stage FSU operations.
  • Figure 1 is a flow diagram of a two-stage froth separation system, for separation of at least bitumen, solids and water from a bitumen froth using utilizing two froth settling or separation units (FSU);
  • FSU froth settling or separation units
  • Figure 2A is a flow diagram of the two FSU's according to Fig. 1 wherein a second FSU is offline and the system is re-configured for sole operation of a first-stage FSU;
  • Figure 2B is a flow diagram of the two FSU's according to Fig. 1 wherein the first-stage FSU is offline and the system is re-configured for sole operation of the second FSU; and
  • Figure 3 is a graph illustrating an example of the effect of production rates on maltene recovery using a backup bypass arrangement implementing single-stage operations for a system normally operated as a multi-stage FSU system.
  • Applicant normally implements an embodiment of a multi-stage froth separation system, for separation of at least bitumen, solids and water from a bitumen froth utilizing several, typically two, froth settling or separation units (FSU).
  • the solids can include mineral solids and asphaltene aggregates.
  • a bitumen froth F results from conventional production/extraction of bitumen from oilsand processes.
  • the bitumen froth F typically comprises about 60% bitumen, 30% water and 10% fine solids, the bitumen being, in one example, about 16 to about 22% asphaltene and the balance being maltene.
  • the froth F and solvents S or solvent-rich stream are comingled for dilution of the froth F, for at least reducing the viscosity and density of the oil phase therein, and forming a solvent-diluted bitumen froth feedstream 8.
  • a first- stage FSU 10 receives the feedstream 8.
  • the solvent S can be a single solvent, a mixture of solvents or solvent mixed with other components recycled from the froth separation system as described below, including water and solids, as is understood by those of skill in the art.
  • the paraffinic solvent encourages asphaltene precipitation as agglomerates for recovery with mineral solids.
  • the first FSU 10 is a settling or separation vessel having a first inlet 1 1 and first product outlet 12. Separation occurs in the first FSU 10.
  • a first product stream of predominately clarified bitumen B and solvent S, substantially free of solids and water, is recovered at the first product outlet 12 as a diluted bitumen or dilbit 14.
  • the dilbit 14 can be routed through a first surge vessel 16 before delivery to a solvent recovery unit (SRU) 18 for recovery of a majority of the solvent S from the bitumen B.
  • SRU solvent recovery unit
  • Recovered solvent from the SRU (not detailed) is recyclable to various stages of the system processes including back to froth treatment.
  • the bitumen B portion recovered from the FSU is directed to product or upgrading.
  • the first FSU 10 has a first underflow outlet 20 at a bottom thereof for removal of a first underflow stream 22.
  • the first underflow stream 22 contains predominately water W, solids T and can still contain some bitumen B and solvent S.
  • the presented embodiment illustrates a conical bottom vessel however other vessel configurations are contemplated.
  • the first underflow stream 22 is directed to a second inlet 24 of a second-stage FSU 30 for further separation of solvent S and residual bitumen from water W and solids T. While not detailed herein, additional stages can be provided in a like manner.
  • a second product stream of predominately solvent, and some water, is recovered at second product outlet 32 as a solvent-enriched recycle stream 34.
  • the second product stream from second product outlet 32 can be routed through a second surge vessel 36 for forming the recycle stream 34.
  • Recycle stream 34 is directed back towards the first inlet 1 1 for comingling with the bitumen froth F and forming feedstream 8, in particular for introducing solvent S to the first FSU 10.
  • a majority of the solids T and water W are recovered at a second underflow outlet 41 and a second underflow stream 42 as a reject tailings stream 44.
  • the reject tailings stream 44, containing tailings solids T, water W and some solvent S is directed to a tailings solvent recovery unit (TSRU) 48.
  • Solvent S received from the TSRU is typically combined with the solvent recovered from the SRU.
  • solvent S in the recycle stream 34 to the first FSU 10 aids in the precipitation of at least a portion of asphaltenes for subsequent collection with the mineral portion of the tailings solids T. Removal of at least a portion, of the asphaltenes from the bitumen leaves a maltene-enriched product stream in the dilbit 14.
  • a further solvent addition inlet 40 is provided for the addition of additional solvent S that reports, via solvent-enriched recycle stream 34, to the first FSU 10.
  • Solvent is added interstage, or intermediate the first underflow stream 22 and the second inlet 24, the solvent being provided through the solvent addition inlet 40, normally in fluid communication with the first underflow stream 22, for mixing therewith and delivery to the second FSU 30.
  • a majority of the added solvent S is readily separated in the second FSU 30 and reports at the second product outlet 32.
  • the recycle stream 34 from second product outlet 32 can be routed through a second surge vessel 36 before recycle to the first FSU 10.
  • a bypass flow arrangement is implemented to provide for orderly transition from multi-stage to a single-stage FSU operation, the restructuring occurring for use of a remaining operating FSU while the offline FSU is repaired. It is anticipated that the bypass of an offline FSU would be temporary for timely return to multi-stage FSU operations.
  • a combination of proper direction of the feedstream of the operating FSU, rerouting of the addition of solvent S and an apportionment of the operating underflow stream is provided for achieving acceptable bitumen and solvent recoveries from the remaining, operational FSU.
  • FSU systems are likely limited to two-stages.
  • first or second FSU whether it is the first or second FSU that goes offline, one isolates the inlets and outlets of the offline FSU, isolating whichever of the first or second product stream, and whichever of the first or second underflow stream that is associated with or related to the offline FSU. If the second FSU goes offline, one isolates the second product stream, the second inlet and the second underflow outlet stream. Further, one ensures that the feedstream is directed to either of the second or first inlet of the online FSU. One also splits, at the operating FSU, the other of the second or first underflow stream associated with the operating and online FSU into first and second bypass streams. Finally, one re-directs the addition of solvent, before making the usual addition to the online underflow stream, instead to comingle with the first bypass stream, wherein the first bypass stream forms the solvent-enriched recycle stream and the second bypass stream forms the reject tailings stream.
  • the product stream of the online FSU forms the dilbit.
  • Whether a stage or stages of the multistage FSU system is compromised or not is monitored and can be evidenced be a variety of factors such as change in flow rate, pressure, and stream quality or characteristics. In the case that the monitoring determines one or more of the stages are compromised then single stage operations are implemented.
  • this multistage FSU system one might classify at least two stages of FSU as a first-stage FSU and an ultimate-stage FSU.
  • the ultimate FSU is the second stage FSU.
  • the feedstream of bitumen, mineral solids, water and feed solvent is directed to the first- stage FSU.
  • the feed solvent is the solvent-enriched recycle stream from the ultimate-stage FSU.
  • the first-stage FSU is normally the stage at which the ditbit product is recovered.
  • the final, last or ultimate-stage FSU is normally the stage at which the reject tailings is produced.
  • the added solvent is introduced intermediate the stages, or interstage, prior to the inlet of the ultimate-stage and after the outlet of the underflow from the first-stage FSU. Therefore, where the monitoring determines one or more of the stages are compromised, one isolates the one or more compromised stages, termed collectively as an offline FSU. The remaining one or more stages remain operational and are termed collectively as an online FSU.
  • To manage the system one isolates the offline FSU and directing the feedstream to the online FSU.
  • the method includes recovering the dilbit product stream from the online FSU and splitting the tailings reject stream from the online FSU into first and second bypass streams. Regarding the bypass streams, the added solvent is directed to the first bypass stream, wherein the first bypass stream forms the solvent-enriched recycle stream; and second bypass stream is directed as the reject tailings stream.
  • the reject tailings stream 44 often containing in the order of up to about 20% solids T, is difficult to handle and can periodically block or plug the flow streams. Such a disruption can occur at second underflow outlet 41 . Accordingly, the second FSU 30 can be compromised and go offline, having no useable outlet for the reject tailings stream 44.
  • Such FSU vessels are large and the processes have some inertia even during the duration of an orderly shutdown of the system. Solids accumulation and resulting blockage causing, or indeed continuing while going offline, can be significant and cause longer term outage.
  • a bypass flow arrangement is implemented for orderly transition from a two-stage operation to a single-stage FSU operation, the restructuring occurring for sole use of the first FSU 10 in the event the operation of the second FSU 30 is compromised and goes offline. It is anticipated that the bypass of an offline FSU would be temporary.
  • a combination of rerouting of addition of solvent S and an apportionment of first underflow stream 22 is provided for acceptable bitumen and solvent recoveries from the remaining, operational, first FSU 10.
  • the recovery of the water W and solids S at a second underflow outlet 41 or reject tailings stream 44 is compromised and is involuntarily or voluntarily placed offline.
  • the first underflow stream 22 from the first FSU 10 is now directed, at least in part, to the TSRU 48.
  • the first underflow stream 22 is split to form, in part, the recycle stream 34 back to the first inlet 1 1 and to form, in part, the reject tailings stream 44. Accordingly, the first underflow stream 22, now the sole outlet for tailings solids T and water W, is now connected to both of a recycle bypass 50 and a tailings bypass 52.
  • the recycle and tailings bypasses 50,52 are fluidly connected at a location between the first underflow outlet 20 and the second FSU 30.
  • first underflow stream 22 is fluidly driven from the first FSU 10 to the second FSU 30 by a suitable solids-capable, first-stage pump or first- stage pumps 54.
  • the bypasses 50,52 are located downstream of first-stage pumps 54, so as to receive the first underflow stream 22, and before or upstream of the second inlet 24 so as to divert flow from the offline FSU.
  • a portion of the recycle bypass 50 recirculates through the operating FSU, despite there being no significant increase in the dilbit 14.
  • the pumps 54 are now managing a recirculatory load as well as the flow-through mass rates of the reject tailings stream 44. Accordingly, if the pumps 54 are not already suitably sized for the increased throughout, one or more redundant and parallel sets of the pumps 54 are placed online.
  • One or more parallel sets of redundant underflow pumps are located at each of the first and second underflow streams. Allowing for proper design considerations contemplating pressure drop, fluid velocity and solids carrying capacities, the piping for the underflow stream line is designed for flow rates within a specified range of rates. For example, in normal multi-stage FSU operations, the underflow piping 22 from first underflow outlet 20 for the first-stage FSU is designed for flow rates for carrying steady-state streams of water, solids and added solvent.
  • first and second redundant underflow pumps 54,74 are located at the first and second underflow streams 22,44 respectively.
  • first FSU 10 one operates at least one of the first redundant pumps 54 for delivery of the first underflow stream 22 to the second FSU 30 in normal multi-stage FSU operations. If the second FSU 30 goes offline, one operates both of the first redundant pumps 54,54 for delivery of the first underflow stream 22 to first and second bypass streams 50,52 for single-stage FSU operations.
  • a third set of redundant pumps can be provided.
  • the integrity and performance of the increased recirculatory stream flow of the recycle bypass 50 can be aided using a pre-existing product pump 136 situated at the second surge vessel 36, if appropriately designed for this service. Accordingly, as shown in Fig. 2A, the recycle bypass 50 can be routed to the second surge vessel 36 via line 51 , pump 136 acting to boost the recycle stream 34 to join the bitumen froth F.
  • Solvent addition is still provided, however, so as to minimize loss of solvent S with the reject tailing stream 44, the solvent addition is diverted to be fluidly connected ultimately with the froth for comingling therewith.
  • the recycle bypass 50 can fluidly connect with one of a variety of arrangements to connect solvent S with the feedstream 8. As shown, the solvent addition is connected downstream of the intersection of the recycle bypass 50 and tailings bypass 52, avoiding involvement and loss associated with the tailings bypass 52.
  • the solvent addition inlet 40 is diverted from the first underflow stream 22 with a solvent bypass 56.
  • the recycle stream in bypass 50 is a comingled solvent and underflow stream 22.
  • the solvent bypass 56 is directed to carrying solvent S to the recycle bypass 50 already carrying the recirculatory underflow stream 22.
  • solvent addition with recirculatory underflow stream aids in asphaltene treatment.
  • the solvent bypass is a pump-bypassing solvent bypass 56, in fluid communication between the solvent addition inlet 40 and the bypass recycle 50, simply bypassing the underflow pumps 54 to join the bypass recycle 50.
  • the solvent bypasses the pumps and piping for stream 22 and the ultimate piping for bypass 50 is designed to handle the recirculatory stream 22 and the added solvent S.
  • Block valves disable/enable the bypass flow paths respectively. As shown in Fig. 2A, for the purposes of illustration, block valves are shown that are related to the disabling or isolation of the offline second FSU 30.
  • An inlet block valve 60 blocks or isolates the usual flow of first underflow stream 22 to the second FSU 30, the bypass recycle 50 departing upstream thereof.
  • a recycle block valve 62 blocks or isolates the usual flow of recycle to the first inlet 1 1 to the first FSU 10, the bypass recycle 50 joining downstream thereof.
  • the inlet block valve 60 isolates the usual flow of first underflow stream 22 to the second FSU 30, the tailings bypass 52 departing upstream thereof.
  • a tailings block valve 64 isolates the discharge of reject tailings stream 44 usually flowing from the second FSU 30, the tailings bypass 52 joining downstream thereof.
  • a solvent addition block valve 66 isolates the usual addition of solvent to the first underflow stream 22, the recycle bypass 50 departing upstream thereof.
  • the two-stage FSU system is operated as a single-stage FSU system for bypassing an offline second-stage FSU by isolating the second-stage FSU 30 at the second product outlet 32, at the second inlet 24, and at the second underflow outlet 41 .
  • the first underflow stream 22 is split into first and second bypass streams 50,52.
  • the solvent addition is re-directed into to the first bypass stream 50.
  • the first bypass stream 50 and added solvent S form the recycle stream 34 and the second bypass stream 52 forming the reject tailings stream 44.
  • a bypass flow arrangement is implemented to provide for orderly transition from a two-stage operation to a single-stage FSU operation, the restructuring occurring for sole use of the second FSU 30 while the first FSU 10 is compromised and is offline.
  • the stream 42 from the second underflow outlet 41 from the second-stage FSU 30 continues to be directed to the TSRU 48, however, only a portion of the stream 42 forms a reject tailing stream 44.
  • a portion of the second underflow stream 42 is re-directed to join the recycle stream 34.
  • addition of solvent S is directed to join the recycle stream 50 while avoiding incorporation and loss with the tailings bypass 52 forming the reject tailings stream 44.
  • the second underflow stream 42 normally the second reject tailings stream 44, is split into recycle bypass 50 and tailings bypass 52 to form, respectively, the recycle stream 34 back to the first inlet 1 1 and, the reject tailings stream 44. While the reject tailings stream 44 remains substantially the same and the sole outlet for tailings solids T and water W, it now forms the tailings bypass 52.
  • the second-stage is the last or ultimate-stage and the existing flow path for the reject tailings stream 44 remains the same.
  • the second underflow stream 42 is fluidly driven from the second FSU 30 to the TSRU 48 by a suitable solids-capable second-stage pump or pumps 74.
  • the recycle bypass 50 is located downstream of the second-stage pumps 74, so as to receive the second underflow stream 42, and yet located before the TSRU 48 so as to divert a portion of the flow to the recycle stream 34.
  • Addition of solvent S for comingling with the recycle stream 34 is maintained.
  • the solvent addition inlet 40 is diverted to join the recycle bypass 50, avoiding involvement and ineffective comingling and loss with the reject tailings stream 44.
  • the solvent addition is diverted from the, now blocked, first underflow stream 22 again using the solvent bypass 56, in fluid communication between the solvent addition inlet 40 and bypass recycle 50.
  • the stream of dilbit 14 is now routed from the second product outlet 32 to flow to the SRU 18, the usual first product outlet 12 blocked at the first FSU 10.
  • a first-stage inlet block valve 80 blocks the usual flow of the diluted feedstream to the first inlet 1 1 of first-stage FSU 10.
  • the dilute feedstream 8 is therefore directed to the second inlet 24 of the second-stage FSU 30 through feedstream bypass 81 departing upstream of valve 80.
  • a second-stage recycle block valve 82 blocks the usual flow of product from the second product outlet 32.
  • a product bypass 83 fluidly connects the second product outlet 32 and dilbit 14.
  • the solvent addition block valve 66 again blocks the usual additional of solvent S to the first underflow stream 22, the recycle bypass 50 departing upstream thereof for directing solvent S to the recycle bypass 56.
  • the rate of underflow from the online FSU can be split about evenly, the recycle bypass stream being about that of the tailings bypass stream, in other words a ratio of about 50:50 by volume.
  • a nominal 200 units of froth F and 160 units of a recycle stream 34 (predominately solvent S) is delivered to comingle with the froth to beget 360 units of feedstream 8 and might result in about 100 units of tailings reject 44 and 260 units of ditbit 14. About 160 units of solvent are recovered from the SRU and TSRU for recycle to the system.
  • the recycle bypass 50 routes 160 units of solvent S to comingle with the 200 units of froth F.
  • the underflow of 100 units is increased to 200 units, 100 units of underflow being recycled through the recycle bypass 34 to join with the 200 units of froth and 160 units of solvent.
  • 100 units of underflow are directed as a tailing bypass to ensure removal of water and solids from the system. This illustrates a 100% redundant recirculation case with a 50%:50% split of the recycle and tailings bypasses.
  • the example rates vary accordingly from the nominal rates provided above for ease of illustration.
  • the ratio of the first and second bypass streams can even increase to those greater than the example 50:50, up to and including ratios in the order of about 90: 10, in other words 90% to the recycle bypass and 10% to the tailings bypass. Higher ratios typically correspond to feedstream rates at less than the nominal design rate, the tailings-reporting fraction being reduced and thus less of the pumping capacity directed to tailings recycle.
  • a second and a third parallel set of pumps is employed wherein the underflow pumping capacity is three-times that normally provided during two-stage operation.
  • Fig. 3 the recovery of maltene for delivery to the SRU 18 is shown for one stage transitional operation for a range of feedstream rates.
  • recovery of the maltene portion of the bitumen froth feedstream can reach 98%.
  • design plant rates of about 200 kbpd of partially deasphalted bitumen (a majority of which is maltene) and using the bypass embodiments described herein, models predict maltene recovery can be maintained in the order of about or greater than about 95% at full feed rates while repair operations facilitate a return to two-stage operation.

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Abstract

L'invention porte sur un procédé pour contourner temporairement une unité de sédimentation de mousse (FSU) de sable bitumineux hors ligne d'un système d'unité de sédimentation de mousse à étages multiples dans le cas d'une défaillance de l'unité de sédimentation de mousse hors ligne tout en maintenant l'aptitude au fonctionnement, en maximisant les performances de sédimentation et en minimisant la propagation de la perturbation à d'autres systèmes. L'unité de sédimentation de mousse hors ligne est isolée et le courant de sous-verse de l'étage fonctionnel restant est divisé en un courant de rejet dirigeant des solides et de l'eau vers une unité de récupération de solvant de produits de queue et un courant de recyclage enrichi en solvant pour se mélanger à une mousse de bitume constituant un courant principal vers l'entrée de l'unité de sédimentation de mousse fonctionnelle. Un courant à addition de solvant est réacheminé à partir de l'addition entre étages de façon à contourner le courant de produits de queue de rejet et à rejoindre le courant de recyclage, aidant à la poursuite du fonctionnement de l'unité de sédimentation de mousse pour la sédimentation de maltènes et d'un solvant à partir de solides rejetés et d'eau. Un produit de dilbit est récupéré à partir de l'unité de sédimentation de mousse en ligne.
PCT/CA2014/050666 2014-07-14 2014-07-14 Agencement de transition de sauvegarde à étage unique pour unité de sédimentation de mousse à étages multiples partiellement hors ligne Ceased WO2016008024A1 (fr)

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PCT/CA2014/050666 WO2016008024A1 (fr) 2014-07-14 2014-07-14 Agencement de transition de sauvegarde à étage unique pour unité de sédimentation de mousse à étages multiples partiellement hors ligne

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10954448B2 (en) 2017-08-18 2021-03-23 Canadian Natural Resources Limited High temperature paraffinic froth treatment process

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2232929A1 (fr) * 1997-03-25 1998-09-25 Shell Canada Limited Methode de traitement d'une mousse de sable bitumineux diluee
CA2502329A1 (fr) * 2005-03-24 2006-09-24 Shell Canada Limited Methode et systeme empechant la deshydratation des flocons d'asphaltenes dans un recipient de separation par moussage du bitume
CA2640914A1 (fr) * 2008-10-10 2009-03-10 Northern Lights Partnership Un procede en plusieurs etapes pour le traitement de la mousse de bitume au moyen d'un diluant paraffinique
US20130075306A1 (en) * 2011-09-22 2013-03-28 Total E&P Canada Ltd. Multi-stage counter-current froth settler and method of use

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2232929A1 (fr) * 1997-03-25 1998-09-25 Shell Canada Limited Methode de traitement d'une mousse de sable bitumineux diluee
CA2502329A1 (fr) * 2005-03-24 2006-09-24 Shell Canada Limited Methode et systeme empechant la deshydratation des flocons d'asphaltenes dans un recipient de separation par moussage du bitume
CA2640914A1 (fr) * 2008-10-10 2009-03-10 Northern Lights Partnership Un procede en plusieurs etapes pour le traitement de la mousse de bitume au moyen d'un diluant paraffinique
US20130075306A1 (en) * 2011-09-22 2013-03-28 Total E&P Canada Ltd. Multi-stage counter-current froth settler and method of use

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10954448B2 (en) 2017-08-18 2021-03-23 Canadian Natural Resources Limited High temperature paraffinic froth treatment process

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