Mechanically resilient bitumen microcapsules for midstream transport

Patent metadata

Field	Value
Publication number	US-12319876-B2
Application number	US-202318380561-A
Country	US
Kind code	B2
Filing date	Oct 16, 2023
Priority date	Nov 3, 2020
Publication date	Jun 3, 2025
Grant date	Jun 3, 2025

Abstract

Disclosed herein are methods of preparing bitumen for transport, apparatus for preparing bitumen for transport, methods of transporting bitumen, and transportation-ready forms of bitumen. Instead of relying on exogenous components to induce bitumen solidification, the methods and apparatus of the present disclosure reorganize bituminous materials derived from the same origin into core-shell bitumen microcapsules, such that relatively low solubility components (e.g. asphaltenes) encapsulate relatively high solubility components (e.g. maltenes). Importantly, the bitumen microcapsules of the present disclosure are sufficiently mechanically resilient to meet one or more thresholds for midstream transportation, and they are readily fluidized for downstream processing with conventional technologies. Taken together, these aspects may ameliorate one or more challenges in achieving commercially viable bitumen solidification technologies.

First claim

What is claimed is:

1. A method for transporting bitumen, comprising:
generating a plurality of asphaltene-coated bitumen microcapsules comprising a plurality of microcapsule cores and a plurality of microcapsule shells, wherein: (i) the microcapsule cores comprise bitumen, deasphalted oil, or a combination thereof, (ii) the microcapsule shells comprise asphaltenes, and (iii) the microcapsule cores and the microcapsule shells are substantially derived from the same origin;
curing the asphaltenes, the bitumen, the deasphalted oil, or the combination thereof by aging under a set of conditions such that the asphaltene-coated bitumen microcapsules are, on average, sufficiently mechanically resilient to surpass a threshold for transportation, wherein the threshold for transportation is defined as a velocity-impact resiliency of at least about 10 m/s and/or a compression-stress resiliency of at least about 50 KN/m 2 ; and
transporting the plurality of asphaltene-coated bitumen microcapsules in a transportation vessel and under conditions that specify the threshold for transportation.

2. The method of claim 1 , further comprising fluidizing the plurality of asphaltene-coated bitumen microcapsules for further processing.

3. A method for generating a plurality of asphaltene-coated bitumen microcapsules, comprising:
(i) generating a plurality of concentric streams comprising a distal stream and a proximal stream, wherein the distal stream comprises asphaltenes, and wherein the proximal stream comprises bitumen, deasphalted oil, or a combination thereof;
(ii) modulating the proximal stream to form a plurality of microcapsule cores comprising the bitumen, the deasphalted oil, or the combination thereof;
(iii) modulating the distal stream to form a plurality of microcapsule shells comprising the asphaltenes, wherein the plurality of microcapsule shells substantially encapsulate the plurality of microcapsule cores to form a plurality of nascent asphaltene-coated bitumen microcapsules; and
(iv) curing the asphaltenes, the bitumen, the deasphalted oil, or the combination thereof by aging under a set of conditions, such that the plurality of nascent asphaltene-coated bitumen microcapsules harden into a plurality of asphaltene-coated bitumen microcapsules that are, on average, sufficiently mechanically resilient to surpass a threshold for transportation, wherein the threshold for transportation is defined as a velocity-impact resiliency of at least about 10 m/s and/or a compression-stress resiliency of at least about 50 kN/m 2 .

4. The method of claim 3 , wherein the proximal stream:
comprises deasphalted oil that is deasphalted with a C 5 -C 7 hydrocarbon solvent;
has a temperature of between about 60° C. and about 120° C.; and/or
has a flow rate of between about 0.2 mL/min and about 10.0 mL/min.

5. The method of claim 3 , wherein the distal stream:
comprises xylene, chloroform, tetrahydrofuran, toluene, carbon tetrachloride, or a combination thereof;
has an asphaltene content of between about 0.2 mg/ml and about 2.0 mg/ml;
has a temperature of between 10° C. and about 80° C.; and/or
has a flow rate of between about 0.2 mL/min and about 10.0 mL/min.

6. The method of claim 3 , wherein the modulating of the distal stream, the modulating of the proximal stream, or a combination thereof comprises operating a pulsation unit at a vibration frequency to interrupt the proximal stream, the distal stream, or the combination thereof.

7. The method of claim 3 , wherein the curing of the asphaltenes, the bitumen, the deasphalted oil, or the combination thereof comprises:
cooling in the presence of water, alcohol, a surfactant, or a combination thereof; and/or
aging the asphaltene-coated bitumen microcapsules in the presence of air, an inert gas or a combination thereof.

8. The method of claim 3 , wherein after or during the curing of the asphaltenes, the bitumen, the deasphalted oil, or the combination thereof, the method further comprises dispersing the nascent asphaltene-coated bitumen microcapsules in a plurality of particles comprising asphaltenes.

9. A method for generating a plurality of asphaltene-coated bitumen microcapsules, comprising:
dispersing a plurality of droplets comprising bitumen, deasphalted oil, or a combination thereof into a plurality of particles comprising asphaltenes such that: (i) the bitumen, the deasphalted oil, or the combination thereof form a plurality of microcapsule cores, (ii) the asphaltenes form a plurality of microcapsule shells, and (iii) the plurality of microcapsule shells substantially encapsulate the plurality of microcapsule cores to form a plurality of nascent asphaltene-coated bitumen microcapsules; and
curing the asphaltenes, the bitumen, the deasphalted oil, or the combination thereof by aging under a set of conditions such that the plurality of nascent asphaltene-coated bitumen microcapsules harden into a plurality of asphaltene-coated bitumen microcapsules that are, on average, sufficiently mechanically resilient to surpass a threshold for transportation, wherein the threshold for transportation is defined as a velocity-impact resiliency of at least about 10 m/s and/or a compression-stress resiliency of at least about 50 kN/m 2 .

10. The method of claim 9 , wherein the deasphalted oil is deasphalted with a C 5 -C 7 hydrocarbon solvent.

11. The method of claim 9 , wherein the bitumen, the deasphalted oil, or the combination thereof has:
a temperature of between about 60° C. and about 120° C.; and/or
a flow rate of between about 0.2 mL/min and about 60.0 mL/min; and/or
a viscosity of between about 200 cP and about 700 cP.

12. The method of claim 9 , wherein the asphaltenes:
have an average particle size of: (i) between about 20 μm and about 1,000 μm; and/or
are preheated to between about 50° C. and about 100° C.

13. The method of 9 , wherein the dispersing of the bitumen, the deasphalted oil, or the combination thereof further comprises operating a pulsation unit to interrupt flow.

14. The method of claim 13 , wherein the operating of the pulsation unit comprises vibrating at a frequency of between about 10 Hz and about 1 MHz.

Assignees

• Cenovus Energy Inc

Inventors

• Gupta Subodh
• Anita
• Banerjee Sarbajit
• Zaheer Wasif

Classifications

• C08L95/00

  Compositions of bituminous materials, e.g. asphalt, tar, pitch · CPC title

• C10G1/00

  Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal (mechanical winning of oil from oil-shales, oil-sand, or the like B03B) · CPC title

• C10G2300/4075

  Limiting deterioration of equipment · CPC title

• B01J13/206

  Hardening; drying · CPC title

• B01J13/04

  by physical processes, e.g. drying, spraying · CPC title