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Title:
SPHERICAL REACTION CHAMBER FOR SONIC REACTORS
Document Type and Number:
WIPO Patent Application WO/2015/149158
Kind Code:
A1
Abstract:
An optimized reaction chamber for a sonic reactor or sonicator is disclosed. The optimized reaction chamber is designed to have a spherical shape to enable higher operating pressure and temperature inside the reaction chamber, allowing utilization of propane in liquid phase and other type of solvents for enhanced yield/production volume in the separation of deasphalted oil and asphaltenes in heavy oil feedstocks (HOF). The optimized spherical reaction chamber is made of carbon steel and built with less peripheral components to attach it to the main body of the sonicator, thus reducing the weight of the sonicator and reducing effects from potential contaminants in the HOF that may be caused by the material used to build the spherical reaction chamber. The spherical reaction chamber includes a series of substantially horizontal baffles that direct a flow of the changing reactant mixture within the substantially spherical reaction chamber during a residence time period.

Inventors:
AGOLLI ART (CA)
HANSEN VAUGHN ASHLEY (CA)
MCKAY N WAYNE (CA)
BONDE KEVIN (CA)
NARAGHIAN EHSAN (CA)
Application Number:
PCT/CA2015/000225
Publication Date:
October 08, 2015
Filing Date:
April 01, 2015
Export Citation:
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Assignee:
PETROSONIC ENERGY INC (CA)
International Classes:
B01J19/10; B01F11/02; C10G21/00; C10G31/00
Domestic Patent References:
WO2003090945A12003-11-06
WO2005118277A22005-12-15
Foreign References:
US5110443A1992-05-05
CA2815882A12012-05-03
EP2789674A12014-10-15
Attorney, Agent or Firm:
HAUGEN, J. Jay (2900 Manulife Place - 101 Stree, Edmonton Alberta T5J 3V5, CA)
Download PDF:
Claims:
CLAIMS

What is claimed is:

1. A hydrocarbon recovery system comprising:

a substantially spherical reaction chamber for combining a first mixture comprising a heavy oil feedstock and a solvent; and

a sonic reactor for applying vibrations to the first mixture, the combining the first mixture comprising the heavy oil feedstock and the solvent and the applying vibrations to the first mixture causing a changing reactant mixture during a residence time period.

2. The system of claim 1, wherein the substantially spherical reaction chamber comprises a spherical vessel including an upper hemispherical portion and a lower hemispherical portion, wherein the upper hemispherical portion is joined to the lower hemispherical portion to form the spherical vessel.

3. The system of claim 1, wherein the substantially spherical reaction chamber includes an inlet nozzle located at an upper hemisphere of the substantially spherical reaction chamber for introducing the first mixture comprising the heavy oil feedstock and the solvent into the substantially spherical reaction chamber.

4. The system of claim 3, wherein the combining the first mixture comprising a heavy oil feedstock and a solvent, the applying vibrations to the first mixture, and the causing the changing reactant mixture during the residence time period, results in a second mixture following the residence time period; wherein the substantially spherical reaction chamber includes an outlet nozzle located at a lower hemisphere of the substantially spherical reaction chamber for removing the second mixture from the substantially spherical reaction chamber.

5. The system of claim 4, wherein the substantially spherical reaction chamber includes a series of substantially horizontal baffles that direct a flow of the changing reactant mixture within the substantially spherical reaction chamber from the inlet nozzle to the outlet nozzle during the residence time period.

6. The system of claim 1, wherein the combining the first mixture comprising the heavy oil feedstock and the solvent, the applying vibrations to the first mixture, and the causing the changing reactant mixture during the residence time period, results in a second mixture following the residence time period; wherein the substantially spherical reaction chamber includes an outlet nozzle located at a lower hemisphere of the substantially spherical reaction chamber for removing the second mixture from the substantially spherical reaction chamber.

7. The system of claim 1, wherein the substantially spherical reaction chamber includes a series of substantially horizontal baffles that direct a flow of the changing reactant mixture within the substantially spherical reaction chamber during the residence time period.

8. The system of claim 7, wherein the series of substantially horizontal baffles include, in sequence, a first substantially horizontal baffle, a second horizontal baffle, and a third horizontal baffle, wherein the first horizontal baffle is located at an upper hemisphere of the substantially spherical reaction chamber, and wherein the second horizontal baffle and the third horizontal baffle are located at a lower hemisphere of the substantially spherical reaction chamber.

9. The system of claim 8, wherein the first horizontal baffle, the second horizontal baffle, and the third horizontal baffle each include a drain hole.

10. The system of claim 1, wherein the substantially spherical reaction chamber for combining the first mixture comprising the heavy oil feedstock and the solvent is coupled to the sonic reactor for applying vibrations to the first mixture by a non-pressurized connecting bracket.

11. The system of claim 1, wherein the substantially spherical reaction chamber for combining the first mixture comprising the heavy oil feedstock and the solvent is coupled to a first end of the sonic reactor for applying vibrations to the first mixture, further comprising a second substantially spherical reaction chamber for combining a third mixture comprising a second heavy oil feedstock and a second solvent, wherein the second substantially spherical reaction chamber is coupled to a second end of the sonic reactor for applying vibrations to the first mixture comprising the heavy oil feedstock and the solvent, and wherein the sonic reactor applies vibrations to the third mixture comprising the second heavy oil feedstock and the second solvent.

12. The system of claim 1, wherein the substantially spherical reaction chamber is a vessel made of a carbon steel material.

13. A substantially spherical reaction chamber for combining a first mixture comprising a heavy oil feedstock and a solvent, for use in combination with a sonic reactor for applying vibrations to the first mixture comprising the heavy oil feedstock and the solvent, the combining the first mixture comprising the heavy oil feedstock and the solvent and the applying vibrations to the first mixture causing a changing reactant mixture during a residence time period; wherein the substantially spherical reaction chamber includes a series of substantially horizontal baffles that direct a flow of the changing reactant mixture within the substantially spherical reaction chamber during the residence time period.

14. The substantially spherical reaction chamber of claim 13, wherein the series of substantially horizontal baffles include, in sequence, a first substantially horizontal baffle, a second horizontal baffle, and a third horizontal baffle, wherein the first horizontal baffle is located at an upper hemisphere of the substantially spherical reaction chamber, and wherein the second horizontal baffle and the third horizontal baffle are located at a lower hemisphere of the substantially spherical reaction chamber.

15. The substantially spherical reaction chamber of claim 14, wherein the first horizontal baffle, the second horizontal baffle, and the third horizontal baffle each include a drain hole.

16. The substantially spherical reaction chamber of claim 13, wherein the substantially spherical reaction chamber includes an inlet nozzle located at an upper hemisphere of the substantially spherical reaction chamber for introducing the heavy oil feedstock and the solvent into the substantially spherical reaction chamber.

17. The substantially spherical reaction chamber of claim 16, wherein the combining the first mixture comprising a heavy oil feedstock and a solvent, the applying vibrations to the first mixture comprising the heavy oil feedstock and the solvent, and the causing a changing reactant mixture during the residence time period, results in a second mixture following the residence time period; wherein the substantially spherical reaction chamber includes an outlet nozzle located at a lower hemisphere of the substantially spherical reaction chamber for removing the second mixture from the substantially spherical reaction chamber.

18. A substantially spherical reaction chamber for combining a mixture comprising a heavy oil feedstock and a solvent, for use in combination with a sonic reactor for applying vibrations to the mixture comprising the heavy oil feedstock and the solvent, the combining the mixture comprising the heavy oil feedstock and the solvent and the applying vibrations to the mixture comprising the heavy oil feedstock and the solvent causing a changing reactant mixture during a residence time period; wherein the substantially spherical reaction chamber comprises a spherical vessel including an upper hemispherical portion and a lower hemispherical portion, and wherein the upper hemispherical portion is joined to the lower hemispherical portion to form the spherical vessel.

19. The substantially spherical reaction chamber of claim 18, wherein the substantially spherical reaction chamber is made of a carbon steel material.

20. The substantially spherical reaction chamber of claim 18, wherein the substantially spherical reaction chamber is coupled to the sonic reactor by a non-pressurized connecting bracket.

Description:
SPHERICAL REACTION CHAMBER FOR SONIC REACTORS

CROSS-REFERENCE TO RELATED APPLICATIONS

[1] The present application claims benefit of U.S. Provisional Application Serial No.

61/974,253, filed April 2, 2014, which is incorporated by reference in its entirety.

TECHNICAL FIELD

[2] This disclosure relates generally to heavy crude oil sonication devices, and more particularly to a novel design for reaction chambers in sonication devices.

BACKGROUND

[3] The increasing demand for petroleum products has moved the oil industry towards using heavy oil feedstocks (HOF), but producers continues to face processing problems and higher costs. Current refining processes for heavy oils are highly expensive than processes for light oil feedstocks. Refineries are required to process large volumes of heavy oil to equate same volume of final products. Additionally, the industry faces stringent regulations imposed by government authorities regarding the specifications for fuels and environmental issues.

[4] As known, upgrading of heavy oil or bitumen has problems. One of those problems relates to the fact that asphaltenes and heavy fractions have to be removed to create value and product yield. Besides, residues formed in the processing are undesirable waste materials, which cannot be removed by conventional methods, thus reducing the overall yield of valuable hydrocarbon materials from the upgrading process. Removal of asphaltenes from HOF and refinery residues, per existing art, has resulted in large ratios of solvent to heavy crude oil or solvent to residues ratios. Moreover, the related processing is less efficient because involves costly processing times.

[5] Asphaltenes, residue, solvent and deasphalted oil may be separated inside the reactor chamber of a sonic reactor. The sonication process applied by the sonic reactor includes the application of low-frequency, high-amplitude, and high energy for improved processing of heavy oil feedstocks. The sonication process reduces processing time depending on the solvent- HOF mixture being processed and enables continuous production modes. [6] Sonic reactors with cylindrical reaction chambers present limitations related to operating pressure and temperature, to allow use of less expensive solvents which require higher pressures to maintain a liquid phase. Weight of the assembly including the reaction chamber affects the continuous production volume since the natural frequency of the resonant bar may decrease as the weight of the reaction chamber increases, thus reducing capabilities to operate at higher pressures and temperatures.

[7] Since viability of upgrading of heavy oil or bitumen is constantly changing due to production mix, refining infrastructure costs, and oil pricing, there is a need for sonic reactors that provide more effective processing time and more economical HOF upgrading processes to address current limitations of reaction chamber weight, operating pressure and temperature, and cost effective utilization of solvents.

SUMMARY

[8] The present disclosure provides a spherical reaction chamber, and a sonic reactor incorporating the spherical reaction chamber, wherein one of the spherical reaction chambers may be coupled to one or both ends of the sonic reactor. The spherical reaction chamber may be designed and operated to improve separation of asphaltenes from HOF materials in processing mixtures of solvents and the HOF materials in the sonic reactor (in the present disclosure, such design and operation is sometimes called an "optimized" spherical reaction chamber, and the term "optimized" also is sometimes used herein to refer to operating conditions of the spherical reaction chamber).

[9] According to embodiments, the spherical reaction chamber may be built by assembling two hemispherical portions or sections including a plurality of baffles to direct the flow along the whole chamber. The spherical reaction chamber assembly may also have less weight by employing connecting brackets in substitution of heavy flanges to enable operation at higher pressure and temperature. Brackets may be used as non-pressurized attachments and may not be required to hold pressure. Spherical geometry of the chamber may have reduced stresses than other geometric designs, such as stresses that may be present in chambers of cylindrical geometric design. Spherical reaction chambers may be capable of holding higher pressure than cylindrical reaction chambers having same thickness. Operation at higher pressures may enable the utilization of solvents that require higher pressures to be maintained in the liquid phase.

[10] According to an embodiment, the spherical reaction chamber, which may be manufactured of carbon steel material, may be coupled to current sonic reactors and used in substitution of cylindrical reaction chambers, which may be built of aluminum. This substitution of reaction chamber material reduces a potential for contamination of processed HOF.

[11] In another aspect of present disclosure the spherical reaction chamber may allow more production volume in comparison to existing reaction chambers of other geometric design while using comparable dimensions, such as wall thickness of the chamber.

[12] In an embodiment, a hydrocarbon recovery system comprises a substantially spherical reaction chamber for combining a first mixture comprising a heavy oil feedstock and a solvent; and a sonic reactor for applying vibrations to the first mixture, the combining the first mixture comprising the heavy oil feedstock and the solvent and the applying vibrations to the first mixture causing a changing reactant mixture during a residence time period.

[13] In another embodiment, a substantially spherical reaction chamber for combining a first mixture comprising a heavy oil feedstock and a solvent, is provided for use in combination with a sonic reactor for applying vibrations to the first mixture comprising the heavy oil feedstock and the solvent, the combining the first mixture comprising the heavy oil feedstock and the solvent and the applying vibrations to the first mixture causing a changing reactant mixture during a residence time period; wherein the substantially spherical reaction chamber includes a series of substantially horizontal baffles that direct a flow of the changing reactant mixture within the substantially spherical reaction chamber during the residence time period.

[14] In a further embodiment, a substantially spherical reaction chamber for combining a mixture comprising a heavy oil feedstock and a solvent, is provided for use in combination with a sonic reactor for applying vibrations to the mixture comprising the heavy oil feedstock and the solvent, the combining the mixture comprising the heavy oil feedstock and the solvent and the applying vibrations to the mixture comprising the heavy oil feedstock and the solvent causing a changing reactant mixture during a residence time period; wherein the substantially spherical reaction chamber comprises a spherical vessel including an upper hemispherical portion and a lower hemispherical portion, and wherein the upper hemispherical portion is joined to the lower hemispherical portion to form the spherical vessel.

[15] Numerous other aspects, features, and benefits of the present disclosure may be made apparent from the following detailed description taken together with the drawing figures, which may illustrate the embodiments of the present disclosure, incorporated herein for reference.

[16] Additional features and advantages of an embodiment will be set forth in the description which follows, and in part will be apparent from the description. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the exemplary embodiments in the written description and claims hereof as well as the appended drawings.

[17] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[18] Non-limiting embodiments of the present disclosure are described by way of example with reference to the accompanying figures which are schematic and are not intended to be drawn to scale. Unless indicated as representing the background art, the figures represent aspects of the disclosure.

[19] FIG. 1 shows a side view of a cylindrical sonic reactor chamber sub-assembly mounted at one end of a sonic reactor as known in prior art.

[20] FIG. 2 illustrates an isometric view of an optimized spherical reaction chamber, according to an embodiment.

[21] FIG. 3 depicts an exploded view of an optimized spherical reaction chamber subassembly, which may be mounted at each end of a sonic reactor, according to an embodiment.

[22] FIG. 4 shows an elevation view of an optimized spherical reaction chamber, according to an embodiment. [23] FIG. 5 represents a plan view of an optimized spherical reaction chamber, according to an embodiment.

[24] FIGS. 6A to 6B illustrate configurations of baffles employed in an optimized spherical reaction chamber, according to an embodiment. FIG. 6A shows details for baffle inside upper connecting hemisphere of the spherical reaction chamber. FIG. 6B and FIG. 6C depict details for baffles located inside the lower connecting hemisphere of the spherical reaction chamber.

DETAILED DESCRIPTION

[25] The present disclosure is here described in detail with reference to embodiments illustrated in the drawings, which form a part here. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of the present disclosure. The illustrative embodiments described in the detailed description are not meant to be limiting of the subject matter presented here. Furthermore, the various components and embodiments described herein may be combined to form additional embodiments not expressly described, without departing from the spirit or scope of the invention.

[26] Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used here to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated here, and additional applications of the principles of the inventions as illustrated here, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

[27] As used in the present disclosure, "heavy oil feedstock" or "HOF" refers to materials that contain heavy oil with a specific gravity under 16 API (American Petroleum Institute) grade. In an embodiment, "asphaltenes" refers to molecular substances present in heavy oils and bitumens, which may precipitate in n-alkanes solvent. In an embodiment, "bitumen" refers to a sticky, black and highly viscous liquid or semi-solid form of petroleum, also known as asphalt. Bitumen may be found in natural deposits or may be a refined product. [28] In an embodiment, solvents are mixed with HOF materials to achieve separation of asphaltenes from HOF. In an embodiment, separation of asphaltenes from HOF results in deasphalted oil (DAO), and asphaltenes, as separated products. Separation of DAO and asphaltenes from HOF may be improved with sonication treatment in a sonic reactor. In an embodiment, sonication increases a reaction rate between HOF and solvents during a residence time, and may provide the additional benefit of increasing DAO and asphaltenes yields. As used in the present disclosure, "sonic reactor" refers to a device for upgrading heavy oil feedstock (HOF) by at least sonication. As used in the present disclosure, "sonication" refers to a process of applying sound energy to agitate particles in a material. In an embodiment, a sonication system or process applies sound energy that is sufficient to effect one or more desired end uses. As used in the present disclosure, "reaction chamber" refers to structure defining a cavity within a sonic reactor, or an in-line vessel or device defining a cavity coupled to a sonic reactor.

[29] In an embodiment, "residence time period" (also referred to herein as "residence time") refers to the length of time that an entity remains in a reservoir, during which the entity is subjected to reaction conditions. In a particular embodiment, "residence time period" and "residence time" refers to the length of time that a reactant mixture remains in a reaction chamber, during which the entity is subjected to reaction conditions. In an embodiment, a "reaction mixture" refers a mixture within a reaction chamber wherein the mixture includes at least HOF and solvent. "Changing reaction mixture" refers to a reactant mixture that changes during a residence time period. The changes of the changing reactant mixture may include physical changes such as separation of components, and may include chemical reactions. (The word "mixture" as used in the present disclosure, and terms incorporating this word, do not follow the common definition that precludes chemical reactions). In other embodiments such as continuous flow processes, the residence time period may refer to an average length of time that an entity remains in a reservoir that is maintained at or near a steady state condition.

[30] Common solvents used for asphaltenes separation include propane (C 3 H 8 ), butane

(C 4 H 8 ), light naphtha, and other n-alkanes solvents, amongst others. Different solvents may produce different yields of asphaltenes. Lighter solvents, such as propane, may produce higher asphaltenes yield of about 20%, while heavier solvents such as pentane (C5H12) may produce a lower yield. Selection of solvents to be used in an asphaltene and de-asphalted oils (DAO) separation process is disclosed in U.S. Pat. Pub. No. 20140262961, entitled "SOLVENT SELECTION PROCESS".

[31] A number of variables may affect asphaltenes yield. Such variables may include for example pressure, temperature, type of HOF, and available processing equipment. Combinations of these variables with selection of solvents may increase or reduce asphaltenes yield and may vary the different properties of DAO and asphaltenes. Separation of asphaltenes from HOF by the use of solvents also may depend upon solvent ratio. Higher solvent ratios may require a higher volume of solvent to use during sonication, which in turn may demand larger solvent storage vessels. Use of heaviest solvents require a higher solvent ratio because of their higher molecular weights. Hence, a lower solvent ratio may provide a lower asphaltenes yield.

[32] Additionally, optimization of the sonication process may relate to residence time in the reaction chamber. Operating pressure and temperature parameters may affect the time required to complete optimal sonication in a continuous-flow upgrading process.

Cylindrical Reaction Chamber

[33] FIG. 1 shows sonic reactor chamber sub-assembly 100, which may include cylindrical reaction chamber 102, as known in prior art. Cylindrical reaction chamber 102 may be attached to each end of a sonic reactor (not shown) by connecting bracket 104, flange 106, and flange 108. Cylindrical reaction chamber 102 may be connected to resonant bar 110 using flange 108 and to the main assembly of the sonic reactor using flange 106. HOF may be fed into the cylindrical reaction chamber 102 at inlet 112. Resonant bar 110 vibrates as part of the operation of the sonic reactor.

[34] Cylindrical reaction chamber 102 may present operating limitations related to weight, increasing pressure and temperature, when seeking to use less expensive solvents that may require higher pressures to maintain a liquid phase. Weight of the cylindrical reaction chamber 102 may also affect the sonic reactor chamber sub-assembly 100 in continuous production volume. The natural frequency of the resonant bar 110 may decrease with weight of the cylindrical reaction chamber 102, thus reducing capabilities to operate at higher pressures and temperatures, in order to achieve optimal separation by sonication of HOF to separate DAO, solvent, asphaltenes, and residues. Additionally, cylindrical reaction chamber 102 may be built of aluminum, but use of this material may engender potential contaminants in processed HOF.

[35] Cylindrical reaction chamber 102 may operate within a range of about 30 psi to about 70 psi at a range of temperatures of about 100 °C to about 300 °C without reaching the boiling point of any volatile materials. This range of operation may allow use of solvents such as butane, pentane, hexane, heptane, and octane, amongst others, which may maintain a liquid phase at the pressure and temperature ranges of separation within cylindrical reaction chamber 102. Additionally, the cylindrical shape of cylindrical reaction chamber 102 may present constraints to production, since the pressure distribution and level of stresses in cylindrical vessels may restrict the range of operation in regards to pressure and temperature design parameters as a result of limitations of space and weight of the components. With cylindrical reaction chamber 102 sonication of HOF may be performed to produce a volume of sonicated mixture of HOF-solvent within a range of about 1 ,000 American gallons per day.

Optimized Spherical Reaction Chamber for Sonic Reactors

[36] FIG. 2 illustrates an isometric view of an optimized spherical reaction chamber

200, according to an embodiment. Spherical reaction chamber 200 may be coupled to current sonic reactors, in substitution of cylindrical reaction chambers 102. Spherical reaction chamber 200 may be made with carbon steel with suitable tensile properties and chemical stability, or any suitable material. The material of spherical reaction chamber 200 affects the application of low frequency, high amplitude vibrational energy, during a residence time of HOF-solvent mixtures in spherical reaction chamber 200. Furthermore, materials such as carbon steel reduce potential contamination effects of the chamber material on processed HOF mixtures.

[37] Spherical reaction chamber 200 may be made and assembled using two hemispherical sections to facilitate manufacturing. Upon completion of the whole assembly of spherical reaction chamber 200, the upper connecting hemisphere 202 and lower connecting hemisphere 204, may be welded using suitable welding material and appropriately blended. In the present disclosure, the terms "upper hemispherical portion" and "lower hemispherical portion" refer to hemispherical sections or portions that are joined to form the spherical vessel of a substantially spherical reaction chamber 200. The terms "upper hemisphere" and "lower hemisphere" are more general, referring to the upper and lower halves (hemispheres) of a substantially spherical reaction chamber 200 regardless of whether these hemispheres are hemispherical portions or are joined during manufacturing of substantially spherical reaction chamber 200. Substantially spherical reaction chamber 200 (herein sometimes called spherical reaction chamber) does not need to be a perfect sphere, and may deviate from perfectly spherical form due variations in shape, surface features, and the like.

[38] Spherical reaction chamber 200 may hold approximately twice the pressure of cylindrical reaction chamber 102 with the same wall thickness and diameter. As also known, the normal (tensile) stress in the walls of a pressure vessel is proportional to the pressure and radius of the vessel, and inversely proportional to the thickness of the walls, which may be a significant factor in the design of spherical reaction chamber 200. The thickness of walls is proportional to the radius of the spherical geometry of spherical reaction chamber 200 and inversely proportional to the maximum allowed normal stress of the suitable carbon steel material that may be employed for the walls of the hemispherical sections of spherical reaction chamber 200. Additionally, the minimum mass of a pressure vessel scales with the pressure and volume in the vessel, and it is inversely proportional to the strength to density ratio of the construction material. Additionally, for a given pressure, the thickness of the walls scales with the radius of the tank, the mass of the vessel (which scales as length x radius x thickness of the wall for a cylindrical vessel) scales with the volume that may be held in the vessel, which scales as length x radius squared.

[39] For spherical reaction chamber 200, the equation for the stress in the walls is shown below:

P(R+0.2t)

( Equation 1) σ =—— Ait —

[41] For cylindrical reaction chamber 102, the equation for the circumferential stress in the walls is shown below:

, c - „ _ P(R+0.6t)

( Equation 2) <J = ———

[42] [43] In equations (1) and (2), P is the design pressure, R is the specified radius, t is the wall thickness, and E is the joint efficiency factor.

[44] As it may be seen from comparing equation (1) with equation (2), stress for a cylindrical vessel design is twice as much as the stress for a spherical vessel design, which in turn may indicate that spherical reaction chamber 200 is a superior design for sonication of HOF.

[45] Connecting hemispheres 202, 204 may include a plurality of substantially horizontal baffles (not shown) welded inside their respective shells. The baffles may be interrelated to each other to direct the flow of oil to suitable path out of spherical reaction chamber 200 and to provide suitable residence time for the needed separation of asphaltenes during sonication.

[46] HOF and solvents may be introduced into spherical reaction chamber 200 through inlet nozzle 206, which may be located on the upper connecting hemisphere 202. Sonicated products may be removed from spherical reaction chamber 200 to another section of the upgrading plant (not shown) via outlet nozzle 208, which may be located on the lower connecting hemisphere 204.

[47] Additionally, spherical reaction chamber 200 may include at least one high point vent 210 and at least one low point drain 212, respectively located on top and bottom of spherical reaction chamber 200 to facilitate cleaning the spherical vessel. At least one inspection nozzle 214 may be located on lower connecting hemisphere 204.

[48] FIG. 3 depicts an exploded view of an optimized spherical reaction chamber subassembly 300, which may be mounted at each end of a sonic reactor (not shown), according to an embodiment.

[49] As it may be seen, connecting hemisphere 204 may include a welded bracket 302 molded on the spherical chamber for attaching at least one spherical reaction chamber 200 to each horizontal end of sonic reactor. In one embodiment, welded bracket 302 is a non- pressurized part, i.e. is not required to hold pressure in the operation of the sonic reactor. The weight of spherical reaction chamber 200 may be reduced by eliminating the flanged closures at both ends of the sonic reactor, as shown in cylindrical reaction chamber sub-assembly 100. [50] During normal operation, an incoming mixture of HOF and solvent (also herein called a first mixture of HOF and solvent) may be introduced into spherical reaction chamber 200 through inlet nozzle 206 located on upper connecting hemisphere 202. In an embodiment (FIG. 4), inlet nozzle 206 is oriented in angular relation to center axis of spherical reaction chamber 200. This center axis extends through baffles 308, 310, 312, which may be a series of baffles interrelated to direct the flow of a reactant mixture of HOF and solvent (also herein called a changing reactant mixture) to a path out of spherical reaction chamber 200. The sonic reactor's resonant bar 110 may resonate at low-frequency, high-amplitude, high vibrational energy for an optimal mass transfer. Spherical reaction chamber 200 may have a higher internal pressure than internal pressures normally employed in the operation for a cylindrical reaction chamber 102, e.g. for the same volume of production. The operating pressure and temperature may be adjusted based on the physical properties of the suitable solvents for enhanced operation of the sonic reactor. An optimized residence time of HOF/solvent mix in spherical reaction chamber 200 may substantially increase production as compared to existing reaction chambers with different geometric design. An output flow of sonicated products from spherical reaction chamber 200 to other sections in the processing plant (herein sometimes called a "second mixture") may be removed through outlet nozzle 208, located on the lower connecting hemisphere 204. In an embodiment (FIG. 4), outlet nozzle 208 is oriented in angular relation to center axis of spherical reaction chamber 200.

[51] The optimized spherical reaction chamber 200 for a sonic reactor may handle solvents that require higher pressures to maintain a liquid phase. This flexibility in operating pressures can improve cost effective production volume in comparison to production using existing cylindrical reaction chambers with comparable dimensions, such as wall thickness of the chamber, and other applicable operating conditions.

[52] Minimizing the weight of spherical reaction chamber 200 may enhance the continuous production volume, since the natural frequency of the sonic wave produced by the resonant bar may not be decreased by the lower weight of spherical reaction chamber 200, thus enhancing the capabilities to operate at higher pressures and temperatures. Therefore, sonic reactors employing spherical reaction chambers 200 may be able to increase operating pressure and temperature, employing less expensive solvents that normally require higher pressures to maintain a liquid phase.

[53] Spherical reaction chamber 200 may operate within a range of about 0 psig to about 660 psig with limited operation pressure fluctuation at a range of operating temperatures of about 80 °F to about 340 °F without reaching the boiling point of any volatile materials. In an embodiment, the operating pressure may be about 710 psig, with a minimum temperature of about -20 °F and maximum temperature of about 400 °F.

[54] This range of operation may allow use of solvents such as propane and other suitable LPGs, which may maintain a liquid phase at the pressure and temperature ranges during sonication within spherical reaction chamber 200. Additionally, the spherical shape of spherical reaction chamber 200 may present added benefits including but not limited to removing weight in a range from about 50 pounds to about 70 pounds by not using heavy flanges to attach the spherical reaction chamber 200 to both the resonant bar (not shown) and the main assembly of the sonic reactor.

[55] The high pressure may enable the spherical reaction chamber 200 to achieve desired optimize performance by handling a plurality of cost effective solvents, such as propane and other suitable LPGs, compressible to be maintained at liquid phase while maintaining higher pressure conditions inside the spherical reaction chamber 200.

[56] Spherical reaction chamber sub-assembly 300 may also include flange 108, connecting bolts 304, and nuts 306.

[57] A series of baffles 308, 310, 312 may be inter-related to direct the flow of HOF and solvent to suitable path out of spherical reaction chamber 200 and to provide suitable residence time for the needed separation of asphaltenes during sonication. Baffles 308, 310, 312 may be may be welded inside the vessel formed of joined hemispherical portions 202, 204. A single segment baffle 312 may be welded to upper shell of hemispherical portion 202 and single segment baffles 310, 308 may be welded to lower shell of hemispherical portion 204.

[58] FIG. 4 shows an elevation view 400 of an optimized spherical reaction chamber

200, depicting the vertical location of baffle 308 and baffle 310 inside the shell of lower connecting hemisphere 204, and the vertical location of baffle 312, inside the shell of upper connecting hemisphere 202. The radial surface of each of these baffles may be in contact with corresponding inside radial surface of connecting hemispheres 202, 204. Baffle 308 and baffle 312 may be welded with the radial edge on the side of spherical reaction chamber 200 including outlet nozzle 208 and inlet nozzle 206, respectively, and baffle 310 may be welded at the opposite side, to direct the flow along a path extending across the whole chamber.

[59] Also shown in FIG. 4, inlet nozzle 206 has a vertical angular orientation of about

45° in relation to inspection nozzle 214, and in relation to vertically extending vent 210. An appropriate vertical location of baffles 308, 310, 312, each including a drain hole, may be employed to maintain a desired output flow of DAO, solvent, asphaltenes, and residues, thus providing a suitable path out of spherical reaction chamber 200. Further, each of baffles 308, 310, 312 may include a drain hole, as another way of maintaining a desired output flow of DAO, solvent, asphaltenes, and residues.

[60] FIG. 5 represents a plan view 500 of an optimized spherical reaction chamber 200, depicting the location of vent 210, and angular location of about 45° from inlet nozzle 206 in relation to outlet nozzle 208.

[61] FIG. 6 shows configuration of baffles 600 inside an optimized spherical reaction chamber 200 for sonic reactors, including baffle 308, baffle 310, and baffle 312. Each baffle type may exhibit a different size configuration, except the same radial dimension and the same size of drain hole 602.

[62] Baffles 308, 310, 312 may be inter-related to direct the flow of HOF and solvent to a suitable path out of spherical reaction chamber 200 and to provide an appropriate residence time for the separation of asphaltenes during sonication.

[63] FIG. 6A shows the configuration of baffle 312, including a chamfer angle beveled on the lower radial edge, which may be used for welding inside the shell of upper connecting hemisphere 202. Also shown is drain hole 602 of about 1/4 inch diameter, located at about the center line of baffle 312. [64] FIG. 6B depicts the configuration of baffle 310, including a chamfer angle beveled on the upper radial edge, which may be used for welding inside the shell of lower connecting hemisphere 204. Also shown is drain hole 602 of about 1/4 inch diameter, located at about the center line of baffle 310.

[65] FIG. 6C illustrates the configuration of baffle 308, including a chamfer angle beveled on the upper radial edge, which may be used for welding inside the shell of lower connecting hemisphere 204. Also shown is drain hole 602 of about 1/4 inch diameter, located at about the center line of baffle 308.

[66] As seen in FIG. 6, chamfer angle beveled on baffles 308, 310, 312 may be about

38°.

[67] While various aspects and embodiments have been disclosed, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[68] The foregoing method descriptions and the interface configuration are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by one of skill in the art the steps in the foregoing embodiments may be performed in any order. Words such as "then," "next," etc. are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods. Although process flow diagrams may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function.

[69] The various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed here may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.

[70] Embodiments implemented in computer software may be implemented in software, firmware, middleware, microcode, hardware description languages, or any combination thereof. A code segment or machine-executable instructions may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.

[71] The actual software code or specialized control hardware used to implement these systems and methods is not limiting of the invention. Thus, the operation and behavior of the systems and methods were described without reference to the specific software code being understood that software and control hardware can be designed to implement the systems and methods based on the description here.

[72] When implemented in software, the functions may be stored as one or more instructions or code on a non-transitory computer-readable or processor-readable storage medium. The steps of a method or algorithm disclosed here may be embodied in a processor- executable software module which may reside on a computer-readable or processor-readable storage medium. A non-transitory computer-readable or processor-readable media includes both computer storage media and tangible storage media that facilitate transfer of a computer program from one place to another. A non-transitory processor-readable storage media may be any available media that may be accessed by a computer. By way of example, and not limitation, such non-transitory processor-readable media may comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other tangible storage medium that may be used to store desired program code in the form of instructions or data structures and that may be accessed by a computer or processor. Disk and disc, as used here, include compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk, and Blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media. Additionally, the operations of a method or algorithm may reside as one or any combination or set of codes and/or instructions on a non- transitory processor-readable medium and/or computer-readable medium, which may be incorporated into a computer program product.