Asphaltene conversion, separation, removal and transport preparation for heavy hydrocarbons

Abstract

A process to convert asphaltenes found in heavy hydrocarbon sources, remove the converted solid asphaltene portion from the hydrocarbon source at operating conditions and to prepare the separated solid asphaltenes for easier handling, storage or bulk transport, with a minimal amount of heavy hydrocarbon remaining with the asphaltenes to serve as an inherent binder for larger and robust formed solid asphaltene pieces.

What is claimed is: 
     
         1 .- 16 . (canceled) 
     
     
         17 . An agglomerated solid asphaltene product comprising:
 a solid asphaltene particulate obtained from a hydrocarbon feedstock, the solid asphaltene particulate comprising:
 asphaltene particles; and 
 residual resin in an amount ranging between 2 wt % and 10 wt % of the solid asphaltene particulate, 
   wherein the residual resin acts as an indigenous binder to enable agglomeration of the solid asphaltene particulate to form the agglomerated solid asphaltene product, and   wherein the solid asphaltene particulate has a softening point above pyrolysis temperatures at atmospheric pressure.   
     
     
         18 . The agglomerated solid asphaltene product of  claim 17 , wherein the solid asphaltene particulate has a melting point above pyrolysis temperatures at atmospheric pressure. 
     
     
         19 . The agglomerated solid asphaltene product of  claim 17 , wherein the amount of residual resin ranges between 2 wt % and 6 wt % of the solid asphaltene particulate. 
     
     
         20 . The agglomerated solid asphaltene product of  claim 17 , wherein no extraneous binder is used to obtain the agglomerated solid asphaltene product, and the amount of residual resin is sufficient to agglomerate the solid asphaltene particulate. 
     
     
         21 . The agglomerated solid asphaltene product of  claim 17 , wherein an extraneous binder is added to the solid asphaltene particulate in an amount of less than 10 wt % of the solid asphaltene particulate. 
     
     
         22 . The agglomerated solid asphaltene product of  claim 17 , comprising less than 2 wt % of un-agglomerated asphaltene particles. 
     
     
         23 . The agglomerated solid asphaltene product of  claim 17 , wherein between the 10th and 90th percentile of the asphaltene particles have a diameter ranging from 40 μm to 200 μm. 
     
     
         24 . The agglomerated solid asphaltene product of  claim 17 , wherein the solid asphaltene particulate is a bottom fraction-derived material of a solvent deasphalting unit used to separate asphaltene precipitates from deasphalted oil. 
     
     
         25 . The agglomerated solid asphaltene product of  claim 17 , wherein the agglomerated solid asphaltene product comprises at least one of pellets or briquettes. 
     
     
         26 . The agglomerated solid asphaltene product of  claim 17 , wherein the agglomerated solid asphaltene product comprises extrudates having a diameter ranging from 3 inches to 3 feet. 
     
     
         27 . A process for producing an agglomerated solid asphaltene product, the process comprising:
 agglomerating a solid asphaltene particulate having a softening point above pyrolysis temperatures at atmospheric pressure, the solid asphaltene particulate comprising:
 asphaltene particles; and 
 residual resin in an amount ranging between 2 wt % and 10 wt % of the solid asphaltene particulate, the residual resin acting as an indigenous binder to enable agglomeration of the solid asphaltene particulate to form the agglomerated solid asphaltene product, 
   wherein the agglomerating is performed at a pressure of between 100 psig and 2200 psig.   
     
     
         28 . The process of  claim 27 , wherein the agglomerating the solid asphaltene particulate further comprises heating the solid asphaltene particulate. 
     
     
         29 . The process of  claim 28 , wherein heating the solid asphaltene particulate is performed at a temperature ranging between 100° F. and 400° F. 
     
     
         30 . The process of  claim 27 , wherein the agglomerating the solid asphaltene particulate to obtain the agglomerated solid asphaltene product comprises extruding the solid asphaltene particulate. 
     
     
         31 . The process of  claim 27 , wherein the agglomerating the solid asphaltene particulate to obtain the agglomerated solid asphaltene product comprises briquetting the solid asphaltene particulate. 
     
     
         32 . The process of  claim 27 , wherein the agglomerating the solid asphaltene particulate to obtain the agglomerated solid asphaltene product comprises pelletizing the solid asphaltene particulate. 
     
     
         33 . The process of  claim 27 , wherein the agglomerating the solid asphaltene particulate comprises adding an extraneous binder to the solid asphaltene particulate in an amount of less than 10 wt % of the solid asphaltene particulate. 
     
     
         34 . The process of  claim 27 , wherein the solid asphaltene particulate is a bottom fraction-derived material of a solvent deasphalting unit used to separate asphaltene precipitates from deasphalted oil. 
     
     
         35 . The process of  claim 34 , wherein the asphaltene precipitates are thermally affected asphaltene precipitates. 
     
     
         36 . The process of  claim 34 , further comprising subjecting the asphaltene precipitates to a vapour-solids separation to remove residual solvent from the asphaltene precipitates and produce the solid asphaltene particulate subjected to the agglomerating.