Note: Descriptions are shown in the official language in which they were submitted.
METHOD AND SYSTEM FOR TRANSPORTING BITUMEN IN FLEXITANK
ABSTRACT
The invention provides an innovative process encompass flexitank and sea
containers for crude
bitumen shipment without special equipment or facilities, extra energy input,
additional chemicals
and diluents.
FIELD OF TECHNOLOGY
The present invention relates to method and system for transporting crude
bitumen.
BACKGROUND
Bitumen is often produced in remote locations away from where it will be
consumed. While
moving bitumen is extremely challenging because of their inability to flow
freely. Bitumen
transportation network involves all modes of transportation that includes
truck, rail, pipeline and
marine vessel.
Bitumen can be transported in undiluted form by truck. Truck transportation is
easily accessible
and the least impactful option environmentally because each load is relatively
small amount, on
land and less chance to be detrimental to a body of water. But truck is
restricted by the weather
and large distance. Moreover, truck carry comparatively small load compared to
rail.
For long distance bitumen transportation, rail is a rapidly growing industry.
Furthermore, no
diluent is required during bitumen transportation in the railcar. A
significant amount of diluent can
be saved by railway. A rail tank car can accommodate roughly 30,000 gallons of
bitumen with 100
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cars, which is a significant amount of crude. However, the railway
transportation has a high carbon
footprint and reputation for spilling of millions of gallons of crude.
Pipeline transportation is most convenient option and it can bring the bitumen
from oil wells to
processing facilities, tanks, terminal facilities, refineries. However,
diluent has to be added to thin
the bitumen because of the huge energy (i.e. high pumping power) required to
overcome the high
pressure drop in the pipeline due to the high viscosity. Moreover, pipeline is
not everywhere and
there is no enough capacity available for producers in some cases. And diluent
recovery system is
required at the destination to remove the diluent from the bitumen.
Bitumen can also be delivered by tanker oversea, it can travel all around the
world. As the large
quantity the tanker can carry, the transportation per barrel of bitumen is
cheap compare to other
methods. However, the Western Canada Government proposed a moratorium would
prohibit oil
tankers from stopping, loading or unloading crude or persistent oil products
in northern British
Columbia. It applies to tankers carrying more than 12,500 metric tons of crude
or persistent oil
products. The moratorium covers the area from the Canada/United States border
in the north, down
to the point on British Columbia's mainland across from the northern tip of
Vancouver Island. It
also includes Haida Gwaii.
Besides, novel inventions related to crude bitumen transportation including
diluent additives,
blending, emulsification, bitumen containers, special capsules, or converted
into solid form, etc.
Each invention faces economic, technical or environmental challenges of its
own.
In terms of diluent additives, researchers have proposed additives to thin the
bitumen, the bitumen
transport comprising bitumen and a diluent present in an amount of 24 weight
percent or less and
an additive wherein the additive is a mono-alcohol, a mono-nitrile, an amine
or mixtures thereof,
which is designed for reduction of the amount of diluent needed to transport
the bitumen through
pipelines. However, it is similar to diluent option, an extra cost will be
associated with diluent and
chemical additives, and diluent recovery system is required.
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In terms of blending, methods for transporting bitumen extraction product
include providing
bitumen-laden aromatic solvent, providing bitumen-laden paraffinic solvent,
and blending the two
materials. The mixture can share the existing infrastructure and avoid
undesirable asphaltene
precipitation. However, the solvent is not cheap.
In terms of emulsification, a process involving oil-in-water emulsion
transportation wherein
impurities from the bituminous phase are transferred to the continuous water
phase, the impurities
including solid mineral materials. The emulsification process contains large
amount of water to be
transported and cost per barrel of bitumen transportation is increased as
well. Additionally, a large
quantity of water is contaminated and a portion of the emulsion stabilizer is
required.
In terms of bitumen containers, the invention provides a heatable container
for bitumen comprising
a body member defining a base zone, side wall zones, end wall zones and a roof
zone. Extra energy
input needed for the device and there is no large quantity available in the
market.
In terms of special capsules, the invention provide a special package or
container equipment
required for shipping bitumen. The special capsule has a very unique design
while retaining some
of the characteristics of the common variety of intermodal containers.
Furthermore, a unique
device which clamps on the top of a capsule immerse in the rehabilitation unit
to reheat the bitumen.
Unfortunately the capsule own a unique design and there is no large quantity
available in the open
market, and the cleaning of the capsules after the bitumen discharge also
accounts huge work and
cost.
In terms of bitumen converted into solid form, this invention including a
mixture of bitumen and
an additives to increase the viscosity of bitumen to form a solid bitumen
pellet. Optionally, the
pellet includes a protective shell. The process involves extra input energy
with elevated
temperature and chemical additives such as hydrocarbonaceous polymer. It is
easier to transport
the bitumen as a solid phase while the chemical additives are very expensive,
and the requirement
for the pellets crush resistance is high when subjected to a load of pellets
having a certain heights.
Additionally, the chemical additives added is not easy to separate without
extra energy input and
the bitumen recovery system is required at the destination.
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Accordingly, there is a need for a novel bitumen transportation which takes
advantage of the
options and infrastructure available, contributes to alleviate at least some
of the deficiencies
addressed above.
SUMMARY
Above present the pros and cons of each transportation option, also a variety
of inventions have
been proposed to overcome the challenge of bitumen transportation. As embodied
and broadly
described herein, the invention proposed here encompass flexitank and general
purpose sea
container for crude bitumen shipment without special equipment, unique
facilities, extra energy
input, additional chemicals and diluents.
The method and system for transporting bitumen in the flexitank, which allows
the warm bitumen
pumped into the flexitank at a temperature ranges from 40 to 82 t. The
flexitank is fitted with
corrugated papers in the general purpose sea container, and make the shipment
by road, rail or sea
when the bitumen temperature drops below 60 C. The crude bitumen shipped in
the flexitank has
a flash point above 60 C. In this case, the crude bitumen shipped as non-
dangerous goods. This
process maintains the integrity of flexitank and sea container and is able to
withstand the demands
of shipment by road, rail or sea. Furthermore, it is easily handle without
special design or
equipment, unique facilities, the general purpose sea containers are in large
quantities in the open
market. The flexitank for shipping crude bitumen is flexible with different
fleets, different numbers
of containers can be booked and shipped through marine vessels instead of oil
tankers through
Western Canada coast, which is not part of the moratorium if the quantity
below 12,500 metric
tons at one time. Moreover, there is no need for extra energy input during
loading and discharge
the crude bitumen, less energy input means less carbon footprint and savings
in cost. And there is
no additional chemicals, solvent and diluents required, which is a huge saving
and environmental
friendly. Also there is no need for bitumen recovery system at the
destination, the discharge
process is easy to handle and economically feasible. Additionally, the process
is beneficial to
customers without extra cleaning work for the containers, the corrugated
papers are help to make
sure the cleaning of the containers, and the flexitank can be disposed
directly after the bitumen
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unloaded. The flexitank can withstand the temperature ranges from 82t to -57
C and fitted inside
sea containers, the process will not be limited by the weather when the sea
containers travelling
all around the world. The process offers a global solution to the
transportation of crude bitumen
that is safe, economical and environmentally friendly.
DETAILED DESCRIPTION OF THE PROCESS
The method and system for transporting the bitumen in flexitank comprising the
following steps:
The drawings which illustrate embodiments of the invention. As shown in Fig.
1, at the wellsite or
tank farm 1, crude bitumen is produced from underground and stored in the
sales tank at an
elevated temperature around 80 C. At such condition, the bitumen can be
pumped into the truck
and loaded to the flexitank in the container 2 or load the flexitank directly
from the bitumen tank
1. Afterwards, the sea container 2 can be shipped to customers 4 by road, rail
and sea 3. The
bitumen should have a flash point over 60 C and a API lower than 15 to match
with the invention.
Additionally, the target crude bitumen has a Basic Sediment and Water (BS&W)
content lower
than 1 wt% to meet the regulations of transportation.
Turing now to Fig. 2, bitumen producer 5 can be far away from the open market
and the tank farm
6 can store the bitumen at an elevated temperature around 80 C. A truck 7,
usually the Super B
truck is used to transport the crude bitumen in a short distance. When it
arrives at the flexitank
plant, which can be fitted in the sea container 8, load with bitumen in a
temperature ranges from
40 to 82 C, the flexitank can withstand the temperature ranges from 82 `C to -
57 C. Once the
flexitank is fully loaded and the container is sealed, the sea container 8 is
ready to be delivered to
railway intermodal and travel on rail 9. The sea container has to be delivered
when bitumen in the
flexitank has a temperature lower than 60 C. Because the bitumen has a flash
point over 60 C. In
this case, the bitumen is delivered as the non-dangerous goods. Furthermore,
the flexitank bulk
liquid can travel around the world by marine vessel 10.
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The flexitank fitting process is illustrated in Fig. 3. Select a general
purpose sea container 8 which
has different fleets in the open market with a large quantity. The container 8
should be inspected
inside and outside before it is fitted with the flexitank 11, if there is
evidence that the container 8
is weakened, it should not be used. Walls, floor and roof should be in good
condition and not
significantly distorted. Doors should work properly and be capable of being
securely locked and
sealed. The container 8 shall be weatherproof, previous patches and repairs
should be carefully
checked. The container 8 should be free from major damage, with no broken
flooring or
protrusions such as nail, bolts, glass, sharp edges, etc, which can cause
injury to persons or damage
the flexitank 11. Furthermore, the container 8 should be clean, dry and free
of residues and
persistent odors from previous cargo. Carefully sweep the floor and check by
eyes and hand for
any rough edges, projections, splinters, screw heads or weld patches. Take off
the nail and sharp
items on the floor, make sure the container wall is good enough and the
container number is clear
for tracking; Heavy duty tape and extra cardboards should be used to cover and
protect potential
trouble spots.
The corrugated papers 13 are placed afterwards, such that the contact area of
fully loaded flexitank
and container 8 can be covered by corrugated papers 13. The corrugated papers
13 should be fixed
by tape at interval. The corrugated papers 13 have a dimension at least 48
inch in height.
The fitting includes unfolding the flexitank 11, laying the flexitank 11 and
opening the flexitank
11 forwards or backwards, and tying the strips to secure rings inside the
container 8, place the
bulkhead 14 and steel safety bars 15 in the front, make the flange and valve
in the right position,
close the container 8 and move on the trailer by forklift or crane lift if
needed. Ensure that flexitank
11 unfolds properly and does not trap itself in corners, the room 16 is spared
for the ball valve 19
at the bottom of flexitank 11 in case of bottom loading or discharge.
The flexitank 11 can be manufactured with two inner layers co-extruded linear
low density
polyethylene film 12, the flexitank 11 can withstand the temperature in a
range of 82 C to -57 C.
Three inch ball valve 18 or 19 associated with the flexitank 11 has a good
resistance to pressure.
There is no block when valve 18 or 19 is opened, which make the bitumen flow
through freely.
Flange on the valve 18 or 19 of the flexitank 11 is used to reduce the
pressure against the flexitank
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surface thus reduce the risk of failures. Additionally, safety pin is added on
the ball valve 18 or 19
to help to source thefting activities if happened during transportation. The
special design of
pressure release valve 17 on the top can help to release vapor pressure. It
would keep the flexitank
11 safe during loading and transportation. And the loading and discharge ball
valve 18 or 19 can
be either at the top or at the bottom.
Once the fitting is ready, remove all old labels and stickers, and keep the
right door of container
open and the left door closed with warning placard. In the embodiment shown in
Fig. 4 and Fig. 5,
attach the hose 20 with female camlock connection to the male adapter of
flexitank valve 18 or 19.
Be sure that the ball valve 18 or 19 is on open position. Start loading the
flexitank 11 slowly. Once
approximately three cubes bitumen have been filled, loading rate of plum can
be increased. The
hose 20 can be three or four inches in dimension. And the loading rate is
close to one cubic meter
per minute. Check constantly for leaks in hoses and connections, In the
process of loading the
wings of flexitank 11 will slowly open out against container sides and
bulkhead. Warm bitumen
is loaded at an elevated temperature 40 C to 82 C. After loading is
completed, close the valve 18
or 19, drain feeding hose 20, disconnect hose 20 from the flexitank 11 and
replace valve cap.
Visually check the exterior of the standard container to ensure no damage has
occurred during
loading process. Little bulging of container walls may happen. Once the
loading is completed,
make sure the surrounding of value 18 or 19 on the flexitank 11 is clean.
Packing list and material
safety data sheet are prepared and attached with the flexitank 11.
Referring to Fig. 6, once the bitumen cools down below 60 C, each container 8
is sealed and
labeled with bulk liquid non-dangerous goods placard on the left door and
sides of the container
8. Afterwards, the flexitank 11 in the sea container 8 is delivered to the
intermodal yard, and
processed by rail-sea intermodal transport. The containers have to meet the
rail, road and sea
weight guideline.
Once the sea container 8 is arrived at the destination. The flexitank 11
discharge process can be
three different ways.
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Referring to Fig. 4 and Fig. 5, in case of the flexitank 11 has a temperature
below 60 `C and above
body temperature at the destination, attach the discharge hose 20 with female
camlock connection
to the male adapter of flexitank valve 18 or 19. Be sure that the valve 18 or
19 is on the open
position. Start discharging the flexitank 11 slowly at the beginning and end
of the process, the
average discharge rate is close to one cubic meter per minute. Discharge hose
20 inspected to
ensure excessive strain is not applied to the hose. Check constantly for
potential leaks in hoses 20
and connections. Drained all residual product from flexitank 11 and dispose
the flexitank 11 on
the basis of local environmental regulations. Do not open left hand door until
discharge completed.
In case of the bitumen has a temperature below body temperature, the discharge
of congeal bitumen
will be challenge. Referring to Fig. 7, one way to discharge the bitumen can
be tilt the container 8
upward or downward, take off the bulkhead 14 and safety bars 15. Turning now
to Fig. 8, cut the
edges of the flexitank, as the flexitank has inner layer films 12, the inner
layer 12 contacts with all
the bitumen inside the flexitank and it can be pull out directly to the holder
22, which spare only
one direction to release the bitumen. The holder 22 can squeeze the flexitank
inner layer films 12
to crystal and discharge the bitumen to the bitumen pool 21. In this way, the
bitumen inside the
flexitank can be released, and the flexitank is used one time only.
There is another way to discharge the bitumen when the flexitank temperature
drops much lower
than the body temperature. Referring to Fig. 9 and Fig. 10, immerse a heater
22 and a straw 23
into the valve 18 or 19. The heater 22 helps to increases the temperature of
nearby bitumen to body
temperature. The congeal bitumen from the valve 18 or 19 can be mobilized. And
the straw 23
suck the heated bitumen back simultaneously as the heater 22 works. The heater
22 can be driven
by electricity or hot water and has a maximum temperature of 60 'C. Once the
discharge process is
over, the flexitank 11 is disposed based on local environmental regulations.
The above describes the thought process of crude bitumen shipment by flexitank
and sea container.
The method and system of designing bitumen shipment can offer solutions to
global transport of
water, wine, edible oils, food and beverages, industrial and petroleum
products, pharmaceuticals,
and agricultural commodities.
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DESCRIPTION OF DRAWINGS
Fig. 1 Flow Chart of Method and System for Transporting Bitumen in Flexitank;
Fig. 2 Illustration of Method and System for Transporting Bitumen in
Flexitank;
Fig. 3 Fitting of Flexitank in Sea Container;
Fig. 4 Top View of Fitted Flexitank in the Sea Container;
Fig. 5 Flexitank Bottom Loading or Discharge;
Fig. 6 Flexitank Top Loading or Discharge;
Fig. 7 Flexitank Tilt Upward or Downward;
Fig. 8 Squeeze Flexitank to Crystal;
Fig. 9 Flexitank Bottom Discharge with Heater and Straw;
Fig. 10 Flexitank Top Discharge with Heater and Straw.
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