Method and apparatus for separating oil sand particulates from a three-phase stream

A method for separating solid particles from a three-phase hydrocarbon containing stream, said method comprising:

• (a) subjecting at least a portion of a three-phase hydrocarbon containing stream comprising a plurality of solid particles to separation in a separation vessel to thereby produce a first particulate-containing vapor stream and a second particulate-containing liquid stream;
• (b) withdrawing at least a portion of said second particulate-containing liquid stream from said separation vessel via a liquid outlet located in a lower portion of said separation vessel;
• (c) passing said first particulate-containing vapor stream through a first separation zone comprising a first structured packing section located in an upper portion of said separation vessel to thereby produce a first particulate-depleted vapor stream;
• (d) simultaneously with step (c), wetting said first structured packing section with a process liquid;
• (e) passing said first particulate-depleted vapor stream through a second separation zone comprising a second structured packing section to thereby produce a second particulate-depleted vapor stream;
• and
• (f) simultaneously with step (e), wetting said structured packing with a process liquid,
• wherein said three-phase hydrocarbon containing stream has a vapor fraction greater than about 0.5, on a weight basis based on the total weight of the stream,
• wherein the average cross-sectional flow area of said upper portion of said separation vessel is in the range of from about 5 to about 80 percent of the average cross-sectional flow area of said lower portion of said separation vessel.

An apparatus for separating oil sands particulates from a three-phase stream, said apparatus comprising:

• a vertically oriented separation vessel comprising a vapor-solid separation zone and an underlying vapor-liquid separation zone, wherein the average cross-sectional flow area of said vapor-solid separation zone is in the range of from about 5 to about 80 percent of the average cross-sectional flow area of said vapor-liquid separation zone;
• a feed inlet in said separation vessel for introducing a three-phase stream into said vapor-liquid separation zone;
• a liquid outlet in said separation vessel for withdrawing a predominantly liquid stream from said vapor-liquid separation zone;
• a vapor outlet in said separation vessel for withdrawing a predominantly vapor stream from said vapor-solid separation zone;
• a solids flow inhibiting structure located in said vapor-solid separation zone, wherein said solids flow inhibiting structure comprises a first structured packing section and an overlying second structured packing section;
• at least one lower spray header comprising at least one upwardly oriented spray nozzle located at a higher elevation than said first structured packing section and a lower elevation than said second structured packing section and operable to wet at least a portion of said second structured packing section;
• and
• at least one upper spray header comprising at least one downwardly oriented spray nozzle located at a higher elevation than said first structured packing section and a lower elevation than said second structured packing section and operable to wet at least a portion of said first structured packing section.