Integrated process for deasphalting heavy oils using a gaseous antisolvent

Claim 2

A process for separating a liquid feedstream comprising a solvent selected from the group consisting of propane, butane, isobutane, pentane, isopentane, neopentane, hexane, 2-methyl pentane, 3-methyl pentane, 2-ethyl butane, heptane, 2-, 3-methyl hexane, or 3-ethyl pentane and a deasphalted oil containing aromatics and saturates comprising the steps of: introducing a sufficient amount of a gaseous expansion gas into said liquid feedstream to cause it to form an upper liquid phase and a lower phase comprising aromatics, separating the upper liquid phase from the lower liquid phase, and flashing said separated upper liquid phase to produce an expansion gas phase, a second upper liquid phase comprising solvent, and a second lower liquid phase comprising saturates.

Claim 3

The process of claim 1 wherein said solvent is selected from the group consisting of propane, butane, pentane or hexane.

Claim 4

The process of claim 1 wherein the expansion gas is selected from the group consisting of methane, ammonia and CO 2 .

Claim 5

The process of claim 3 wherein the expansion gas is CO 2 .

Claim 6

The process of claim 1 additionally comprising the step of extracting a heavy oil stream with said solvent to produce the solvent and deasphalted oil liquid stream.

Claim 7

The process of claim 5 wherein the heavy oil feedstock is selected from the group consisting of raw tar sand extracts, shale oils, atmospheric residual oils, and vacuum distilled residual oils.

Claim 8

The process of claim 6 wherein the heavy oil feedstock is vacuum distilled residual oil.

Claim 9

The process of claim 5 wherein a stream comprising asphaltene is recovered.

Claim 10

The process of solvent deasphalting a heavy oil feedstock and recycling the solvent comprising the steps of: contacting the heavy oil feedstock with at least one solvent-containing stream to produce an extract stream containing solvent and deasphalted oil and a heavy stream containing heavy polar material, introducing a sufficient amount of a gaseous expansion gas into said extract stream to cause it to form a first upper liquid phase and a first lower liquid phase comprising solvents and aromatics, separating the first upper liquid phase from the first lower liquid phase and flashing it to produce an expansion gas phase, a second upper liquid phase comprising solvent, and a second lower liquid phase comprising saturates, separating the first lower liquid phase into a stream comprising aromatics and a stream comprising solvent for recycle to the extraction step, separating the second lower liquid phase into a stream comprising saturates and a stream comprising solvent for recycle to the extraction step, compressing the expansion gas phase for recycle to said extract stream.

Claim 11

The process of solvent deasphalting a heavy oil feedstock and recycling the solvent comprising the steps of: contacting the heavy oil feedstock with at least one solvent-containing stream to produce an extract stream containing solvent and deasphalted oil and a heavy stream containing heavy polar material, introducing a sufficient amount of a gaseous expansion gas into said extract stream to cause it to form a first upper liquid phase and a first lower liquid phase comprising solvents and aromatics, separating the first upper liquid phase from the first lower liquid phase and flashing it to produce an expansion gas phase, a second upper liquid phase comprising solvent, and a second lower liquid phase comprising saturates, separating the first lower liquid phase into a stream comprising aromatics and a stream comprising solvent for recycle to the extraction step, separating the second lower liquid phase into a stream comprising saturates and a stream comprising solvent for recycle to the extraction step, compressing the expansion gas phase for recycle to said extract stream.

Claim 12

The process of claim 9 wherein a portion of the extract stream is blended with the feedstock heavy oil to reduce its viscosity.

Claim 13

The process of claim 9 wherein the lower first liquid phase comprising aromatics is separated by a simple still to produce the recycle solvent stream and the aromatic stream.

Claim 14

The process of claim 9 wherein the second lower liquid phase comprising saturates is separated in a simple still to produce a recycle solvent stream and a stream comprising saturates.

Claim 15

The process of claim 9 wherein the compressed expansion gas phase leaving the compressor is first mixed with a bottoms stream comprising asphaltenes leaving the extraction step prior to recycling the expansion gas to the extract stream.

Claim 16

The process of claim 13 wherein the expansion gas asphaltene mixture is separated to produce a stream comprising polars and a stream comprising solvent and oil for contacting with the extract stream.

Claim 17

The process of claim 9 wherein the solvent is selected from the group consisting of propane, butane, isobutane, pentane, isopentane, neopentane, hexane, 2-methyl pentane, 3-methyl pentane, 2-ethyl butane, heptane, 2-, 3-methyl hexane, 3-ethyl pentane.

Claim 18

The process of claim 15 wherein the solvent is selected from the group consisting of propane, butane, pentane, hexane, or heptane.

Claim 19

The process of claim 9 wherein the expansion gas is selected from the group consisting of methane, ammonia and CO 2 .

Claim 20

The process of claim 17 wherein the expansion gas is CO 2 .

Claim 21

The process of claim 9 wherein the heavy oil feedstock is selected from the group consisting of raw tar sand extracts, shale oils, atmospheric residual oils, and vacuum distilled residual oils.

Claim 22

The process of claim 19 wherein the heavy oil feedstock is vacuum residual oil.