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Feed Delivery System and Internals for a Froth Settling Unit

IP.com Disclosure Number: IPCOM000244429D
Publication Date: 2015-Dec-10

Publishing Venue

The IP.com Prior Art Database

Abstract

Froth Settling Unit (FSU) design concepts are proposed to improve hydrodynamics within the FSU to achieve higher upward flux (thus throughput) without increasing solids carryover with the bitumen product. Many of the concepts are directed to encourage smaller solid particles to be incorporated into or trapped within or dragged down by larger solid particles and to be carried to an underflow, or reduce re-entrainment of small solid particles and transport to the overflow by hydrodynamic flow patterns within the vessel.

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          Feed Delivery System and Internals for a Froth Settling Unit Summary

Froth Settling Unit (FSU) design concepts are proposed to improve hydrodynamics within the FSU to achieve higher upward flux (thus throughput) without increasing solids carryover with the bitumen product. Many of the concepts are directed to encourage smaller solid particles to be incorporated into or trapped within or dragged down by larger solid particles and to be carried to an underflow, or reduce re-entrainment of small solid particles and transport to the overflow by hydrodynamic flow patterns within the vessel.

Description

The design modifications include feed barrel & FSU inlet modifications and FSU internals - intended to enhance fines scavenging (e.g. reduce momentum of the FSU inlet stream), prevent re-entrainment of solids and transport to the FSU overflow by hydrodynamic flow patterns (e.g. internals) and improve solids separation (e.g. hydrocyclone or cyclonic inlet, inclined plates) - potentially to increase FSU throughput without increased solids carryover with the bitumen product.

The design modifications may be grouped based their impact to FSU performance:

 Feed barrel & FSU Inlet Modifications - 8 concepts o Cyclonic Inlets (2)
o Baffled Inlets (2)
o Enhanced Solids Separation (3)
o Inlet Redesign (1)

 FSU Internals - 14 concepts
o Inlet - Cyclonic Action (2) o Inlet - Liners & Ducts (2) o Inlet - Manifolds (3)
o Overhead - Polishing (2) o Underflow - Internals (5)

Many of the concepts are directed to increase the separation of coarse and fine solid agglomerates, reduce momentum of the FSU inlet stream, and prevent re-entrainment of solids and transport to the FSU overflow by hydrodynamic flow patterns. Two dimensionless group numbers are also mentioned frequently in the proposed designs. The Reynolds number (Re) relates inertial to viscous forces and indicates the degree of turbulence and mixing within the vessel. The Richardson number (Ri) relates the buoyant velocity to the convective velocity, indicating density-driven flow and plume behavior.

Each design concept sketch along with some process considerations are summarized herein.


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Table 1. Summary of Feed barrel and FSU Inlet Concepts

Title

Option #

Modification

Category

                                       FBI.01.01 Feedbarrel Internals Cyclonic Separation Figure A.2 Centrifugal Solids Separation + Vortex Finder FBI.01.02 Feedbarrel Internals Cyclonic Separation Figure A.3 Inlet Turning Vanes + Flared Inlet

FBI.02.01 Feedbarrel Internals Internals

Figure A.1 Centrifugal Solids Separation

Figure A.4 Slit Sparger + Perforated Plate

FBI.02.02 Feedbarrel Internals Internals

Figure A.5 Inclined Angle Inlet

FR.01.01 FSU Inlet

Inlet Redesign

Figure A.6 External Hydrocyclone Separator

FR.02.01 FSU Inlet

Enhanced Solids Separation

Figure A.7 External Solids Chute Manifold + Perforated Plates FR.02.02 FSU Inlet

Enhanced Solids Separation

Figure A.8 External Graded Inline IPSes

FR.02.03 FSU Inlet

Enhanced Solids Separ...