Energy efficient process for separating hydrocarbonaceous materials into various fractions

Claim 2

A process comprising: introducing a hydrocarbonaceous material feed and a solvent into a first separation zone maintained at an elevated temperature level and pressure level to effect a separation of the mixture into a first light phase comprising solvent and at least a portion of the hydrocarbonaceous material and a first heavy phase comprising the remainder of the hydrocarbonaceous material feed and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure level to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising at least a portion of the hydrocarbonaceous material feed; withdrawing said second light phase from the second separation zone for recycle without substantial pressure reduction to said first separation zone to provide at least a portion of the solvent introduced therein; and recovering said first light phase and second heavy phase.

Claim 3

The process of claim 1 wherein the first separation zone is maintained at a temperature level of from about 150 degrees F. to above the critical temperature of the solvent and a pressure level at least equal to the vapor pressure of the solvent when at a temperature below the critical temperature of the solvent and at least equal to the critical pressure of the solvent when at a temperature equal to or above the critical temperature of the solvent.

Claim 4

The process of claim 1 wherein the solvent comprises at least one member selected from the group consisting of paraffinic hydrocarbons containing from 3 through 9 carbon atoms, mono-olefin hydrocarbons containing from 4 through 8 carbon atoms,aromatic hydrocarbons having a normal boiling point temperature below about 350 degrees F. and alcohols containing from 3 through 9 carbon atoms.

Claim 5

The process of claim 1 wherein the pressure level in the second separation zone is substantially the same pressure level as in the first separation zone.

Claim 6

A process comprising: introducing a hydrocarbonaceous material feed comprising asphaltenes, resins and oils and a solvent into a first separation zone maintained at an elevated temperature level and pressure level to effect a separation of the mixture into a first light phase and a first heavy phase comprising asphaltenes and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure level to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising asphaltenes; withdrawing said second light phase from the second separation zone for recycle without substantial pressure reduction to said first separation zone to provide at least a portion of the solvent introduced therein; and recovering the first light phase and second heavy phase.

Claim 7

A process comprising: introducing a hydrocarbonaceous material feed comprising asphaltenes, resins and oils and a solvent into a first separation zone maintained at an elevated temperature level and pressure level to effect a separation of the mixture into a first light phase and a first heavy phase comprising asphaltenes and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure level to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising asphaltenes; withdrawing said second light phase from the second separation zone for recycle without substantial pressure reduction to said first separation zone to provide at least a portion of the solvent introduced therein; and recovering the first light phase and second heavy phase.

Claim 8

The process of claim 5 wherein the first separation zone is maintained at a temperature level of from about 150 degrees F. to above the critical temperature of the solvent and a pressure level at least equal to the vapor pressure of the solvent when at a temperature below the critical temperature of the solvent and at least equal to the critical pressure of the solvent when at a temperature equal to or above the critical temperature of the solvent.

Claim 9

The process of claim 5 wherein the solvent comprises at least one member selected from the group consisting of paraffinic hydrocarbons containing from 3 through 9 carbon atoms, mono-olefin hydrocarbons containing from 4 through 8 carbon atoms, aromatic hydrocarbons having a normal boiling point temperature below about 350 degrees F. and alcohols containing from 3 through 9 carbon atoms.

Claim 10

The process of claim 5 wherein the pressure level in the second separation zone is substantially the same pressure level as in the first separation zone.

Claim 11

A process comprising: introducing a hydrocarbonaceous material feed and a first portion of a solvent into a first separation zone maintained at an elevated temperature and pressure to effect a separation of the mixture into a first light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising at least a portion of the hydrocarbonaceous material feed; introducing said first light phase and a second portion of solvent into a third separation zone maintained at a temperature level above the temperature level in the first separation zone to effect a separation of the mixture into a third light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed in said first light phase and a third heavy phase comprising the remainder of the hydrocarbonaceous material feed in said first light phase and some solvent; introducing said third heavy phase into a fourth separation zone maintained at a temperature level above the temperature level in the third separation zone and at an elevated pressure level to effect a separation of said third heavy phase into a fourth light phase comprising solvent and a fourth heavy phase comprising at least a portion of the hydrocarbonaceous material feed in said third heavy phase; recycling at least a portion of at least one member selected from the group consisting of the second light phase and the fourth light phase without substantial pressure reduction to provide at least a portion of at least one member selected from the group consisting of the first portion of solvent and the second portion of solvent; and recovering said second heavy phase and fourth heavy phase.

Claim 12

A process comprising: introducing a hydrocarbonaceous material feed and a first portion of a solvent into a first separation zone maintained at an elevated temperature and pressure to effect a separation of the mixture into a first light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising at least a portion of the hydrocarbonaceous material feed; introducing said first light phase and a second portion of solvent into a third separation zone maintained at a temperature level above the temperature level in the first separation zone to effect a separation of the mixture into a third light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed in said first light phase and a third heavy phase comprising the remainder of the hydrocarbonaceous material feed in said first light phase and some solvent; introducing said third heavy phase into a fourth separation zone maintained at a temperature level above the temperature level in the third separation zone and at an elevated pressure level to effect a separation of said third heavy phase into a fourth light phase comprising solvent and a fourth heavy phase comprising at least a portion of the hydrocarbonaceous material feed in said third heavy phase; recycling at least a portion of at least one member selected from the group consisting of the second light phase and the fourth light phase without substantial pressure reduction to provide at least a portion of at least one member selected from the group consisting of the first portion of solvent and the second portion of solvent; and recovering said second heavy phase and fourth heavy phase.

Claim 13

The process of claim 9 wherein the first separation zone is maintained at a temperature level of from about 150 degrees F. to above the critical temperature of the solvent and a pressure level at least equal to the vapor pressure of the solvent when at a temperature below the critical temperature of the solvent and at least equal to the critical pressure of the solvent when at a temperature equal to or above the critical temperature of the solvent.

Claim 14

The process of claim 9 wherein the solvent comprises at least one member selected from the group consisting of paraffinic hydrocarbons containing from 3 through 9 carbon atoms, mono-olefin hydrocarbons containing from 4 through 8 carbon atoms, aromatic hydrocarbons having a normal boiling point temperature below about 350 degrees F. and alcohols containing from 3 through 9 carbon atoms.

Claim 15

A process comprising: introducing a hydrocarbonaceous material feed and a first portion of a solvent into a first separation zone maintained at an elevated temperature and pressure to effect a separation of the mixture into a first light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising at least a portion of the hydrocarbonaceous material feed; introducing said first light phase into a third separation zone maintained at a temperature level above the temperature level in the first separation zone to effect a separation of said first light phase into a third light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed in said first light phase and a third heavy phase comprising the remainder of the hydrocarbonaceous material feed in said first light phase and some solvent; introducing said third heavy phase into a fourth separation zone maintained at a temperature level above the temperature level in the third separation zone and at an elevated pressure level to effect a separation of said third heavy phase into a fourth light phase comprising solvent and a fourth heavy phase comprising at least a portion of the hydrocarbonaceous material feed in said third heavy phase; introducing said third light phase and a second portion of solvent into a fifth separation zone maintained at a temperature level above the temperature level in the third separation zone to effect a separation of said third light phase into a fifth light phase comprising solvent and a fifth heavy phase comprising at least a portion of the hydrocarbonaceous feed material in said third light phase; recycling at least a portion of at least one member selected from the group consisting of the second light phase and the fourth light phase without substantial pressure reduction to provide at least a portion of at least one member selected from the group consisting of the first portion of solvent and the second portion of solvent; and recovering said second heavy phase, fourth heavy phase and fifth heavy phase.

Claim 16

A process comprising: introducing a hydrocarbonaceous material feed and a first portion of a solvent into a first separation zone maintained at an elevated temperature and pressure to effect a separation of the mixture into a first light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising at least a portion of the hydrocarbonaceous material feed; introducing said first light phase into a third separation zone maintained at a temperature level above the temperature level in the first separation zone to effect a separation of said first light phase into a third light phase comprising solvent and at least a portion of the hydrocarbonaceous material feed in said first light phase and a third heavy phase comprising the remainder of the hydrocarbonaceous material feed in said first light phase and some solvent; introducing said third heavy phase into a fourth separation zone maintained at a temperature level above the temperature level in the third separation zone and at an elevated pressure level to effect a separation of said third heavy phase into a fourth light phase comprising solvent and a fourth heavy phase comprising at least a portion of the hydrocarbonaceous material feed in said third heavy phase; introducing said third light phase and a second portion of solvent into a fifth separation zone maintained at a temperature level above the temperature level in the third separation zone to effect a separation of said third light phase into a fifth light phase comprising solvent and a fifth heavy phase comprising at least a portion of the hydrocarbonaceous feed material in said third light phase; recycling at least a portion of at least one member selected from the group consisting of the second light phase and the fourth light phase without substantial pressure reduction to provide at least a portion of at least one member selected from the group consisting of the first portion of solvent and the second portion of solvent; and recovering said second heavy phase, fourth heavy phase and fifth heavy phase.

Claim 17

The process of claim 12 wherein the first separation zone is maintained at a temperature level of from about 150 degrees F. to above the critical temperature of the solvent and a pressure level at least equal to the vapor pressure of the solvent when at a temperature below the critical temperature of the solvent and at least equal to the critical pressure of the solvent when at a temperature equal to or above the critical temperature of the solvent.

Claim 18

The process of claim 12 wherein the solvent comprises at least one member selected from the group consisting of paraffinic hydrocarbons containing from 3 through 9 carbon atoms, mono-olefin hydrocarbons containing from 4 through 8 carbon atoms, aromatic hydrocarbons having a normal boiling point temperature below about 350 degrees F. and alcohols containing from 3 through 9 carbon atoms.

Claim 19

A process comprising: introducing a hydrocarbonaceous material feed comprising asphaltenes, resins and oils and a solvent into a first separation zone maintained at an elevated temperature level and pressure level to effect a separation of the mixture into a first light phase comprising resins, oils and solvent and a first heavy phase comprising asphaltenes and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure level to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising asphaltenes; withdrawing said second light phase from the second separation zone for recycle without substantial pressure reduction to said first separation zone to provide at least a portion of the solvent introduced therein; introducing said first light phase into a third separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure level to effect a separation of said first light phase into a third light phase and a third heavy phase comprising resins and some solvent; introducing said third heavy phase into a fourth separation zone maintained at a temperature level above the temperature level in the third separation zone and at an elevated pressure level to effect a separation of said third heavy phase into a fourth light phase comprising solvent and a fourth heavy phase comprising resins; withdrawing said fourth light phase from the fourth separation zone for recycle without substantial pressure reduction to said first separation zone to provide at least a portion of the solvent introduced therein; and recovering said third light phase and fourth heavy phase.

Claim 20

A process comprising: introducing a hydrocarbonaceous material feed comprising asphaltenes, resins and oils and a solvent into a first separation zone maintained at an elevated temperature level and pressure level to effect a separation of the mixture into a first light phase comprising resins, oils and solvent and a first heavy phase comprising asphaltenes and some solvent; introducing said first heavy phase into a second separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure level to effect a separation of said first heavy phase into a second light phase comprising solvent and a second heavy phase comprising asphaltenes; withdrawing said second light phase from the second separation zone for recycle without substantial pressure reduction to said first separation zone to provide at least a portion of the solvent introduced therein; introducing said first light phase into a third separation zone maintained at a temperature level above the temperature level in the first separation zone and at an elevated pressure level to effect a separation of said first light phase into a third light phase and a third heavy phase comprising resins and some solvent; introducing said third heavy phase into a fourth separation zone maintained at a temperature level above the temperature level in the third separation zone and at an elevated pressure level to effect a separation of said third heavy phase into a fourth light phase comprising solvent and a fourth heavy phase comprising resins; withdrawing said fourth light phase from the fourth separation zone for recycle without substantial pressure reduction to said first separation zone to provide at least a portion of the solvent introduced therein; and recovering said third light phase and fourth heavy phase.

Claim 21

The process of claim 15 wherein the pressure level in the second separation zone and fourth separation zone is above the critical pressure of the solvent.