Treatment of waste oil distillation residue by supercritical solvent deasphalting to produce lubricating oil

Abstract

The present disclosure provides a process and system for deasphalting a waste oil distillate residue including VTAE, the process including feeding the waste oil distillate residue and a supercritical solvent to an asphaltene separator, the asphaltene separator outputting an overhead having deasphalted oil and a bottoms distillate including pitch.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application having Serial No. 63 / 517,411, filed August 3, 2023, which is incorporated herein by reference. TECHNICAL FIELD

[0003] The present invention relates to treating residual oil by a supercritical deasphalting process to produce a lube oil grade deasphalted oil and a residual or pitch. BACKGROUND

[0004] Used motor oil distillation residue (UMOR), including vacuum tower asphalt extender (VTAE), also known as re-refined engine oil bottoms (REOB) and similar products derived from commercial hydrocarbon products such as generator oil, lubricating oil, motor oil, and the like, are generally considered to be non-distillable residues produced by the recovery of used oil through atmospheric distillation and subsequent vacuum distillation. Due to distillation not being considered a viable option, the primary use of these oils is as a blending agent in fuels and paving grade binders to achieve low temperature performance. Similarly, virgin crude oil residues (VC) produced by atmospheric or vacuum distillation processes are generally not usable as commercial products. Instead, the VC is typically a blending component, rather than being sold on the consumer market as a hydrocarbon product.

[0005] While the use of these used motor oil distillation residue oils allows for some degree of recovery of the material, they are low value utilization of the material. SUMMARY

[0006] Exemplary embodiments of treating used motor oil distillation residue by supercritical solvent deasphalting to produce lube oil can substantially eliminate one or more problems resulting from limitations and disadvantages of the related art.

[0007] Additional features and advantages of the present invention will be set forth in the description below, and in part will be apparent from the description, or can be learned by practice of the present invention. The objectives and other advantages of the present invention will be realized and attained by the structure particularly pointed out in the written description and claims thereof as well as the appended drawings.

[0008] In an example, a process is provided, including feeding an oil feed comprising used motor oil distillation residue to an asphaltene separator; feeding a solvent to the asphaltene separator to achieve a solvent to oil ratio of 10: 1 to 15: 1 in the asphaltene separator; and allowing the used motor oil distillation residue to at least partially mix with the solvent while the solvent is above supercritical pressure, wherein a bottoms stream of the asphaltene separator can comprise pitch and an overhead stream of the asphaltene separator can comprise deasphalted oil.

[0009] In the example, the supercritical solvent may include propane, butane, isobutane, or any mixture thereof.

[0010] In the example, the process may include maintaining the solvent in the asphalt separator at a temperature below the solvent's critical temperature.

[0011] In the example, the process may include feeding oil, which may contain waste oil distillation residue, as a mixture of oil and solvent into an asphalt separator. In the example, the oil-solvent mixture may include a solvent-to-oil ratio of 0.5:1 to 15:1.

[0012] In the example, the supercritical solvent feed may include a solvent supplied separately from the oil.

[0013] In the example, the process may include feeding a mixture of oil and solvent, including waste oil distillation residue, into the first stage of the asphaltene separator, and feeding a supercritical solvent into the second stage of the asphaltene separator, wherein the first stage is located above the second stage in the asphaltene separator.

[0014] In the example, the process may include feeding a supercritical solvent to achieve a solvent-to-oil ratio of 12:1.

[0015] In the example, the process may include maintaining the solvent temperature in the asphalt separator at a temperature below the solvent's critical temperature.

[0016] In the example, the process may include mixing crude oil residue (VC) with waste oil distillation residue to form a mixed feed of waste oil distillation residue and VC to be fed into an asphaltene separator. In the example, the mixed feed of waste oil distillation residue and VC may include a ratio of approximately 70 to 30 VC to waste oil distillation residue. In the example, the solvent to oil ratio in the asphaltene separator may be 13:1.

[0017] In the example, the process may include maintaining the solvent temperature in the asphalt separator at a temperature below the solvent's critical temperature.

[0018] In the example, the process may include heating the material inside the asphalt separator in the area between the extraction packing and the coalescing plate packing.

[0019] In the example, the process may include maintaining the bituminous separator at a pressure greater than about 4.2 MPa.

[0020] In the example, a process is provided, comprising feeding waste oil distillation residue into an asphalt separator; feeding solvent into the asphalt separator; and mixing the waste oil distillation residue with the solvent at least partially at a pressure above its supercritical pressure, wherein the bottom effluent of the asphalt separator may include asphalt, and the top distillate of the asphalt separator may include deasphalted oil.

[0021] In the example, a process is provided, comprising feeding an oil mixture, which may contain crude oil residue (VC) and waste engine oil distillation residue in a ratio of 70:30, into an asphaltene separator; feeding a solvent into the asphaltene separator; and causing the oil mixture to be at least partially mixed with the solvent when the solvent is above its supercritical pressure; wherein the bottom effluent of the asphaltene separator may include asphalt, and the top distillate of the asphaltene separator may include deasphalted oil.

[0022] It should 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. Attached Figure Description

[0023] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and form part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0024] In the attached diagram:

[0025] Figure 1 A schematic diagram of a process is shown, in which UMOR residual oil feed and solvent are provided to an asphalt separator to produce DAO and asphalt.

[0026] Figure 2 A schematic diagram of a process is shown, in which an asphalt separator receives a solvent and a mixture of UMOR and VC to produce DAO and asphalt.

[0027] Figure 3 An example of a simplified plant system diagram is shown that can be used for deasphalting processes of UMOR residual oil using solvents.

[0028] Figure 4 Another plant system diagram example is shown that can be used for deasphalting processes of UMOR residual oil using solvents. Detailed Implementation

[0029] Reference will now be made in detail to embodiments of the invention, examples of which are shown in the accompanying drawings.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Unless otherwise stated, all patents, patent applications, published applications and publications, websites and other published materials mentioned throughout this disclosure are incorporated herein by reference in their entirety. Where a term has multiple definitions, the definition in this section shall prevail. In the reference to URLs or other such identifiers or addresses, it should be understood that such identifiers may change and information on the Internet may vary, but equivalent information can be found by searching the Internet. References to them demonstrate the availability and public dissemination of such information.

[0031] As used herein, unless the context clearly indicates otherwise, the singular forms “a / an” and “the” contain plural references.

[0032] As used herein, the terms first, second, third, etc., can describe various elements, components, regions, layers, and / or segments, which should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Terms such as “first,” “second,” and other numerical terms used herein do not imply order or sequence unless the context clearly indicates otherwise. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, region, layer, or segment discussed below may be referred to as a second element, component, region, layer, or segment.

[0033] As used herein, ranges and quantities can be expressed as “about” a specific value or range. “About” also includes precise quantities. Thus, “about 5%” means about 5% other than 5%. The term “about” means within the typical experimental error expected for the intended application or purpose.

[0034] As used herein, “and / or” includes any and all combinations of one or more of the associated enumerated items.

[0035] As used in this article, "combination" refers to any association between two or more items. Association can be spatial or refers to using two or more items for a common purpose.

[0036] As used herein, “include” and “include” should be interpreted as “includes but not limited to” and “including but not limited to”, respectively.

[0037] As used herein, "optional" or "optionally" means that an event or condition described below may or may not occur, and the description includes instances where the event or condition occurs and instances where it does not occur. For example, an optional component in a system means that the component may or may not exist in the system.

[0038] As used in this article, “generally” means “mostly but not entirely in accordance with the specification”.

[0039] For the purposes of this disclosure, Undistilled Oil Residue (UMOR) refers to non-distillable residues generated from the recovery of waste oil derived from commercial hydrocarbon products such as generator oil, lubricating oil, engine oil, etc. In examples, UMOR may include one or more residues from commercial hydrocarbons, such as asphalt flux, asphalt blown product, engine oil residue (EOR), refining heavy vacuum distillation bottoms (RHVDB), refining heavy vacuum distillation oil (RHVDO), refining engine oil residue (REOB), refining vacuum distillation bottoms (RVTB), vacuum distillation bottoms (VTB), vacuum distillation asphalt binder (VTAB), vacuum distillation asphalt extender (VTAE), waste engine oil residue (WEOR), waste oil distillation bottoms (WODB), and similar materials. In examples, UMOR may include VTAE obtained by atmospheric distillation and subsequent vacuum distillation of waste engine oil. In examples, UMOR may include approximately 10-12 wt% residue remaining after atmospheric and vacuum distillation processes of waste engine oil. For example, waste engine oil can be collected from various sources. This waste engine oil, i.e., 100% waste engine oil, can be processed by atmospheric distillation, in which about 5%-10% of the lightest content is distilled off. The residue from atmospheric distillation can then be processed by vacuum distillation, which can distill off an additional 75%-85 wt% of the feed. Therefore, the residual residue, or UMOR, from vacuum distillation can include about 10-12 wt% of the initially collected waste engine oil. One use of UMOR can be as a blending component for No. 6 fuel oil. In addition, due to its high British Thermal Unit (BTU) content, No. 6 fuel oil is suitable for powering surface vessels and for other marine industrial applications. While useful, these applications of UMOR may not extract the maximum value from the material.

[0040] Similarly, for the purposes of this disclosure, crude oil residue (VC) refers to the residue at the bottom of the barrel produced during the distillation of crude oil by vacuum distillation or atmospheric distillation. VC is commonly used as a blending component in residual fuel oils or asphalt.

[0041] In the examples, the processes and / or systems described herein can be used to extract products from waste oil distillation residue (UMOR) or a mixture of UMOR and VC. In the examples, the products extracted from UMOR and / or a mixture of UMOR and VC using the processes and / or systems described herein can be more valuable and / or more desirable than using the mixture of UMOR and / or UMOR and VC as a blending component or fuel. In the examples, the processes and / or systems described herein can be used to extract deasphalted oil quality (DAO) from lubricating oil. In the examples, the processes and systems described herein can produce a residue product called asphalt, which can meet the performance component requirements for road asphalt. In the examples, the processes and systems described herein can be used to process UMOR and / or a mixture of UMOR and VC to produce both DAO and asphalt products that meet the performance requirements for road asphalt.

[0042] In the examples, a process and system for deasphalting waste engine oil distillation residue (UMOR) are described. In the examples, a process and system for extracting DAO from UMOR are described. In the examples, a process and system for extracting asphalt from UMOR that meets the performance component requirements of road asphalt are described. In the examples, UMOR may include VTAE. In the examples, UMOR may be mixed with VC. In the examples, the processes and systems described may include supercritical fluid extraction (SFE) processes. In the examples, the processes described herein may employ ROSE supplied by KBR. ® The solvent deasphalting system is used to perform this process.

[0043] In the example, such as Figure 1 As shown in the process diagram, process 100 may include a solvent feed 102 from solvent source 104 and a UMOR feed 106 from UMOR source 108. In this example, solvent feed 102 and UMOR feed 106 may be introduced into asphaltene separator 110. In this example, the solvent and UMOR may be mixed in asphaltene separator 110. In this example, the top product 112 of asphaltene separator 110 may include DAO. In this example, the bottom product 114 of asphaltene separator 110 may include asphalt. In this example, asphalt may be used as an asphalt component.

[0044] In the examples, the solvent may be a near-supercritical solvent used in the asphaltene separator. In the examples, the solvent to UMOR ratio in the asphaltene separator may be about 10 to 1 or higher. In the examples, the solvent to UMOR ratio in the asphaltene separator may not exceed about 15 to 1. In the examples, the solvent to UMOR ratio in the asphaltene separator may be in the range of about 10 to 1 to about 15 to 1. In the examples, the solvent to UMOR ratio in the asphaltene separator may be 10 to 1, 11 to 1, 12 to 1, 13 to 1, 14 to 1, or 15 to 1.

[0045] In the example, such as Figure 1 As shown in the schematic diagram, solvent feed 102 and UMOR feed 106 can be introduced into asphaltene separator 110 as separate feeds. In the example, UMOR feed 106 and solvent feed 102 can be provided at different locations or stages of asphaltene separator 110. In the example, UMOR feed 106 can be provided at a stage of asphaltene separator 110 higher than solvent feed 102.

[0046] In the example, at least a portion of the solvent may be fed into the asphalt separator along with the UMOR. For example, the UMOR feed may include solvent in a solvent standard volume to UMOR standard volume ratio of approximately 0.5:1 to 15:1.

[0047] In the example, the UMOR feed may include a solvent in a solvent standard volume to UMOR standard volume ratio of approximately 0.5:1 to approximately 2:1. In the example, the UMOR feed may include a solvent in a solvent to UMOR ratio of approximately 1:1.

[0048] In the example, all solvents can be fed together with UMOR to the asphaltene separator. In the example, UMOR feed 106 and solvent feed 102 can be combined before being fed to asphaltene separator 110. In the example, the combined UMOR feed 106 and solvent feed 102 can include a solvent-to-UMOR ratio of approximately 10:1 to approximately 15:1. In the example, at least a portion or all of the solvent can be provided by a separate solvent feed. In the example, a separate solvent feed consisting only of solvent or a solvent solution can be provided.

[0049] In the example, the recovery rate of DAO from the top 112 of the asphalt separator 110 as described herein can be in the range of at least about 30% of the feed, and in the example, the recovery rate of DAO can be in the range of about 30% to about 70%, for example, about 30%, 40%, 50%, 60%, 70%, or in the range of 50% to 70%, or in the range of about 60% to about 70%, or in the range of about 65% to about 70%. In the example, the remainder may include bottom bitumen product.

[0050] In this example, the top and / or bottom of the asphaltene separator may undergo further processing and / or purification. For example, the overhead effluent may be processed through one or more separation steps to separate the DAO from the solvent. In this example, the separated solvent may be recycled back to the asphaltene separator. In this example, the separated DAO may be used or further processed as needed.

[0051] In the example, UMOR can be mixed with VC. In the example, UMOR can include VTAE and be mixed with VC. Figure 2 It shows the relationship with Figure 1 A similar process diagram example, but in which UMOR feed is mixed with VC. As shown, process diagram 200 may include UMOR source 202 and VC source 204. In the example, UMOR feed 206 from UMOR source 202 may be mixed with VC feed 208 from VC source 204 to form mixed oil feed 210. In the example, any mixing ratio of VC to UMOR can be used. In the example, the ratio of VC to UMOR in mixed oil feed 210 may be at least about 2:1. In the example, the mixed oil feed may include about 70% VC and 30% UMOR. Mixed oil feed 210 may be introduced into asphalt separator 212.

[0052] Solvent feed 214 from solvent source 216 can also be fed to asphalt separator 212. (See previous reference...) Figure 1 The mixed oil feed 210 may also include at least a portion of the solvent. In an example, the mixed oil feed 210 may include a solvent standard volume to mixed oil standard volume ratio ranging from about 0.5:1 to about 2:1. In an example, the mixed oil feed may include a solvent with a solvent-to-mixed oil ratio of about 1:1. In an example, the mixed oil feed may include all solvent to be fed to the separator. In an example, the solvent feed 214 and the mixed oil feed 210 may be combined before being fed to the asphalt separator 212. In an example, the combined mixed oil feed 210 and solvent feed 214 include a solvent-to-mixed oil ratio of about 10:1 to about 15:1.

[0053] In this example, the solvent from feed 214 can be mixed with the mixed oil feed 210 in the asphalt separator 212. Top product 218 and bottom product 220 are obtained from the asphalt separator 212. In this example, top product 218 may include DAO. In this example, bottom product 220 may include asphalt product. In this example, the asphalt product may be a product that can be used as an asphalt component.

[0054] The techniques and systems described herein can be implemented in various ways. Examples of specific implementations are provided below with reference to the accompanying drawings.

[0055] Figure 3 A simplified plant system diagram 300 is shown that can be used for the process described herein.

[0056] like Figure 3As shown, process and system 300 may include oil feed 302 and solvent feed 304. In an example, oil feed 302 may include UMOR, or a combination of UMOR and VC. In an example, oil feed 302 may include UMOR and is substantially free of VC. In an example, oil feed 302 may include a mixture of VTAE and VC. In an example, as previously described, the ratio of VC to UMOR in oil feed 302 may be 2:1 or higher. In an example, oil feed 302 may include an oil that may contain 70% VC and 30% UMOR. In an example, the oil feed may be provided as a liquid solution upon heating. In an example, the oil feed may include up to about 1 wt% solids. In an example, the oil feed may have a specific gravity of about 0.93 to about 0.95. In an example, the oil feed may include an ash content of about 4 wt% to about 6 wt%.

[0057] In this example, oil feed 302 may include a solvent. In this example, the solvent present in oil feed 302 may be the same as or different from the solvent provided in solvent feed 304. In this example, the solvent in oil feed 302 may be the same as the solvent provided in solvent feed 304. In this example, the ratio of the standard volume of solvent to the standard volume of oil in the oil feed may be in the range of 0.5:1 to 15:1. In this example, the solvent-to-oil ratio as described herein should be understood as the ratio of solvent in the oil feed to the total oil in the oil feed, where the total oil includes the total UMOR and VC that may be present in the oil feed.

[0058] In the example, the ratio of solvent standard volume to oil standard volume in the oil feed can be in the range of 0.5:1 to 2:1. In the example, the ratio of solvent to oil in the oil feed can be 1:1.

[0059] In the example, oil feed 302 and solvent feed 304 can be completely mixed before being fed into the asphaltene extractor 306. In the example, oil feed 302 and solvent feed 304 can be mixed to produce a single feed to the asphaltene extractor 306. In the example, oil feed 302 and solvent feed 304 can be mixed to produce a single feed with a solvent-to-oil ratio ranging from about 10:1 to about 15:1.

[0060] In the example, the oil feed can be fed into the asphalt separator 306 at a temperature of about 100°C to about 70°C (210 F to 160 F) and a pressure of about 4.1 MPa to about 4.41 MPa (600 to 640 psi).

[0061] In the example, the flow rate of oil feed 302 can be adjusted as needed. In the example, the flow rate can be low, such as about 0.5 BPSD to about 1 BPSD. In the example, the flow rate can be high, such as, for example, about 500 BPSD to about 10,000 BPSD. In the example, the range of oil feed 302 can vary from about 0.5 BPSD to 10,000 BPSD. Other flow rates are also possible. In the example, the flow rate of oil feed 302 and / or the flow rate of solvent feed 304 can be controlled to obtain a total solvent to oil ratio of about 10:1 to about 15:1 in the asphaltene extractor 306. In the example, the solvent to oil ratio in the asphaltene extractor 306 is maintained at about 12:1. In the example, the solvent to oil ratio in the asphaltene extractor 306 is maintained at about 13:1.

[0062] In the example, oil feed 302 and solvent feed 304 can be introduced into asphaltene separator 306. In the example, oil feed 302 and solvent feed 304 can be fed at the same or different stages of asphaltene separator 306. In the example, as shown, oil feed 302 can be fed at a stage of asphaltene separator 306 that can be fed above a stage of asphaltene separator 306 that can feed solvent feed 304. In the example, when referring to a stage, "higher" means a vertical position. Therefore, describing a first stage as higher than a second stage means that the first stage is physically located above or closer to the top portion of the tower or separator, while the second stage is physically located below or closer to the bottom portion of the tower or separator.

[0063] In the example, solvent feed 304 may include a solvent, which may include or be propane, butane, isobutane, or any mixture thereof. In the example, the solvent may be fed into asphalt separator 306 at a temperature of about 54°C to about 95°C (129 F to 203 F) and a pressure of about 4.1 MPa to about 4.41 MPa (600 psi to 640 psi).

[0064] In this example, the asphalt separator 306 can operate in a temperature range of approximately 54°C to approximately 95°C. In this example, operating temperatures below 54°C may lead to scaling, while temperatures above 95°C may lead to oil precipitation.

[0065] In the example, the solvent supplied to the asphalt separator 306 can achieve near-supercritical conditions at the operating temperature and pressure of the asphalt separator 306. In the example, the solvent can be maintained under near-supercritical conditions inside the asphalt separator 306. In the example, the asphalt separator 306 can be operated to maintain the solvent just above its critical pressure. In the example, the asphalt separator 306 can be operated to maintain the solvent below its critical temperature. In the example, the asphalt separator 306 can be operated at a temperature just below its critical temperature, for example, about 10 to 20 degrees below its critical temperature. In the example, the solvent may include propane, and the asphalt separator 306 can operate in a temperature range of about 70°C to about 85°C. In the example, the asphalt separator can operate at a pressure above 4.2 MPa, i.e., above the critical pressure of propane. For example, the asphalt separator 306 can operate at a pressure of about 4.25 MPa to about 4.6 MPa. In the examples, the asphaltene separator 306 can operate at pressures of approximately 4.25 MPa, 4.30 MPa, 4.35 MPa, 4.40 MPa, 4.45 MPa, 4.50 MPa, 4.55 MPa, and 4.60 MPa, or within any range defined by any two of these examples. Other operating temperatures and pressures are also within the range of this disclosure to maintain the solvent under near-supercritical conditions within the asphaltene separator.

[0066] In the example, the asphaltene separator 306 may include two or more stages. In the example, the asphaltene separator 306 may include two, three, or more than three stages. In the example, the asphaltene separator 306 may include tower packing. Different suitable packings may be used. In the example, the asphaltene separator 306 may include one or more packing sections 320a, 320b, etc. In the example, the packing of packing section 320 may be coalescing plate packing. In the example, the coalescing plate packing may include structured packing. In the example, the packing may be extraction packing. In the example, the extraction packing may include structured packing. Combinations of these are also possible. In the example, the asphaltene separator 306 may include coalescing plate packing 322 in its top portion. In the example, oil feed 302 may be introduced below the coalescing plate packing section of the asphaltene separator 306. In the example, the asphaltene separator 306 may include extraction packing 324 in its lower portion. In the example, oil feed 302 may be introduced above the extraction packing section of the asphaltene separator 306. In this example, solvent feed 304 can be introduced below the extraction packing section of asphaltene separator 306. In this example, solvent feed 304 can be combined with oil feed 302 before being fed into asphaltene separator 306.

[0067] In the example, the extraction packing 324 of the asphalt separator 306 can have a density of 144 kg / m³. 3 Approximately 256 kg / m 3 (9lbs / ft) 3 Approximately 16 lbs / ft 3 The packing density is within the range of ). In the example, the specific surface area of ​​the extraction packing 324 can be approximately 42 m². 2 / m 3 To approximately 65.6 m 2 / m 3 (13 ft) 2 / ft 3 approximately 20 ft 2 / ft 3 Within the range of ), other types of packing materials may also be used. In the examples, the coalescing plate packing commonly referred to herein for asphaltene separator 306 and DAO separator 312 may exhibit a higher bulk density and / or specific surface area than the extraction packing 324. In the examples, the coalescing plate packing 322 for the asphaltene separator and / or DAO separator may be configured to have a theoretical plate equivalent Haggard (HETP) value of about 160 mm to about 2300 mm, determined by an atmospheric distillation system with low relative volatility and generally acceptable liquid / vapor distribution. In the examples, the coalescing plate packing 322 may exhibit any suitable nominal tilt angle, such as 45° or 60°.

[0068] In the example, a heated reflux zone 326 may exist within the asphaltene separator 306. In the example, the heated reflux zone may include one or more heating units. In the example, the heating unit may be an external heating unit, a heating blanket, a steam pipe, or any combination thereof. In the example, the heated reflux zone may be configured to introduce heat to raise the temperature of the material passing through the reflux zone by approximately 8°C to approximately 14°C. In the example, the temperature increase may be gradual along the length of the reflux zone. In the example, the heated reflux zone 326 may be located between two or more packing sections 320a and 320b in the asphaltene separator 306. In the example, the heated reflux zone 326 may be located above the extraction packing section 324 of the asphaltene separator 306 and below the coalescing plate packing section 322 of the separator 306.

[0069] In this example, the bituminous separator 306 can include any suitable inner diameter. In this example, the inner diameter of the bituminous separator 306 can range from approximately 1.5 meters to approximately 6 meters.

[0070] In the example, the bottom 308 of the asphalt separator 306 may include oil bitumen. In the example, the top 310 of the asphalt separator may include a stream containing DAO.

[0071] In the example, the top of the column 310 may optionally be introduced into a DAO separator 312. In the example, the DAO separator 312 may include a system configured to raise the temperature of the solution fed into the DAO separator 312 to a point above the solvent's critical temperature. In the example, the solvent in the DAO separator 312 may be under supercritical conditions. In the example, the solvent in the DAO separator 312 may be above both the supercritical temperature and supercritical pressure. In the example, under these conditions, the solubility of DAO in the solvent decreases. In the example, at the solvent's critical temperature, DAO may become almost insoluble in the solvent. In the example, this may allow the separation of DAO from the solvent, with the solvent being recovered as the top product and the DAO as the bottom product.

[0072] In the example, the DAO separator may include packing in the packing section 328. In the example, the packing in the DAO separator may include coalescing slab packing. In the example, the coalescing slab packing may include structured packing. In the example, the feed to the DAO separator 312 may be below the coalescing slab packing. In the example, the DAO separator 312 may be configured to separate solvent from the DAO. In the example, the DAO separator 312 may include a DAO separator bottom 314 containing the DAO. In the example, the DAO separator 312 may include a DAO separator top 316. In the example, the DAO separator top 316 may include solvent. In the example, the DAO separator top 316 may include only solvent. In the example, the DAO separator top 316 may include solvent with a concentration of at least 100%.

[0073] In this example, solvent from the top of the DAO separator 316 can be recycled via recovery line 318. In this example, recycling can include storing solvent in a solvent tank for later use and / or feeding the solvent directly to the asphaltene separator 306. In this example, a combination of both can be implemented. In this example, recycling to the asphaltene separator 306 can be achieved via a third separate feed to the asphaltene separator 306, by mixing with solvent feed 304, by mixing with oil feed 302, or any combination thereof.

[0074] Figure 4 A schematic diagram of another example of a plant system 400 that can be used in the process described herein is shown.

[0075] In this example, plant system 400 may include feed system 402. In this example, feed system 402 may include oil source 404. In this example, feed system 402 may include mixer 406. In this example, feed system 402 may include oil feed 408. In this example, feed system 402 may include solvent circulation pump 410. In this example, feed system 402 may include solvent feed 412.

[0076] In the example, as previously described, oil source 404 may include UMOR, or a combination of UMOR and VC. In the example, oil source 404 may include a mixture of VC and UMOR in a ratio of 2:1 or higher. In the example, oil source 404 may include an oil mixture of 70% VC and 30% UMOR. In the example, oil source 404 may include additional oil or non-oil components.

[0077] As shown in the figure, in this example, oil source 404 can supply UMOR and / or UMOR combined with VC to mixer 406. In this example, mixer 406 can also receive dilution solvent. For example, at least a first portion of solvent from solvent circulation pump 410 can be used as dilution solvent feed 414 and introduced into mixer 406. In this example, mixer 406 dilutes UMOR or UMOR / VC mixture from oil source 404 by mixing UMOR or UMOR / VC mixture from oil source 404 with dilution solvent feed 414 from solvent circulation pump 410 to form oil-solvent feed 408. In this example, oil-solvent feed 408 can have a solvent-to-oil ratio of approximately 0.5:1 to 15:1 based on the standard volume of solvent and the standard volume of premixed oil source.

[0078] In the example, the oil-solvent feed 408 may have a first portion of solvent with a solvent-to-oil ratio ranging from approximately 0.5:1 to 2:1, based on a standard volume of solvent and a standard volume of premixed oil source. In the example, the ratio is 1:1. In the example, a second portion of solvent from the solvent circulation pump 410 may be used as the separator solvent feed 412.

[0079] In this example, all solvent from solvent circulation pump 410 may be mixed with UMOR and / or UMOR with VC in mixer 406. In this example, oil-solvent feed 408 may include all solvent to be fed to asphaltene separator 416. In this example, oil-solvent feed 408 may have a solvent-to-oil ratio of approximately 10:1 to approximately 15:1 based on the standard volume of solvent and the standard volume of premixed oil source.

[0080] In the example, the oil-solvent feed 408 and the separator solvent feed 412 can be introduced into the asphalt separator 416. In the example, the asphalt separator 416 can be as previously referenced. Figure 3 As stated above.

[0081] In the example, oil-solvent feed 408 and separator solvent feed 412 can be fed into asphalt separator 416 at the same or different stages. In the example, oil-solvent feed 408 will include all solvent to be fed into asphalt separator 416. In the example, separator solvent feed 412 will be absent and / or shut off. In the example, as shown, oil-solvent feed 408 can be fed into asphalt separator 416 at a higher stage than separator solvent feed 412. In the example, oil-solvent feed 408 can enter the top distributor of asphalt separator 416. In the example, separator solvent feed 412 can enter the bottom distributor of asphalt separator 416.

[0082] In the example, in the asphalt separator 416, the solvent can contact the UMOR in a countercurrent manner on the separator packing bed. In the example, the solvent in the asphalt separator 416 can be used as an extraction solvent. In the example, the packing can include anti-fouling extraction packing.

[0083] In the example, the total solvent flowing through the asphalt separator 414 (i.e., the solvent from the dilution solvent feed 414 mixed in the oil-solvent feed 408 plus any solvent from the separator solvent feed 412 (if present)) can be about 10 to about 15 standard volume solvents per standard volume of oil.

[0084] In this example, the asphalt separator 416 is configured to operate under conditions that bring the solvent to near-supercritical conditions. Under these conditions, asphalt can be insoluble in the solvent and thus precipitate from the solution. In this example, the asphalt can flow downwards and exit through the bottom 418 of the asphalt separator 416 under interface level control. In this example, some of the dissolved solvent may also exit through the bottom 418 of the container as part of the asphalt-solvent solution. In this example, the bottom 418 may be directed to one or more flash and stripping sections 420 and 422 to recover the solvent from the asphalt product 424.

[0085] The asphalt-solvent solution from the asphalt separator 416 can be heated by the asphalt flash heater 456 and fed into the asphalt flash tank 420 under liquid interface level control from the asphalt separator 416. In this example, the feed temperature to the asphalt flash tank 420 can be controlled by adjusting the heating medium to the asphalt flash heater 456. In this example, sufficient heat can be added to the system to maintain a recommended circulation temperature, which can be selected to provide efficient solvent circulation in the asphalt flash tank 420 and the downstream asphalt stripping tower 422. In this example, at the asphalt flash tank 420, the pressure can be reduced to flash most or a substantial portion of the solvent to the top of the tower. In this example, the solvent at the top of the asphalt flash tank 420 can be directed to the condenser 458, then to the solvent buffer tank 452 for temporary storage, and subsequently circulated by the solvent circulation pump 450.

[0086] In the example, asphalt and residual solvent from the asphalt flash tank 420 can be fed to the asphalt stripping tower 422 under level control from the asphalt flash tank 420. In the example, at the asphalt stripping tower 422, the pressure can be reduced again to flash additional and / or most of the residual solvent to the top of the tower.

[0087] In the example, in the asphalt stripping tower 422, the asphalt product can be contacted with dry, superheated, low-pressure stripping steam to strip additional and / or residual solvent, thereby reducing the solvent content in the bottom product stream. In the example, the stripping steam can enter the asphalt stripping tower 422 from below the bottom tray under flow control. In the example, the flow rate in the asphalt stripping tower 422 can be set to achieve efficient stripping.

[0088] In this example, the overhead solvent from the asphalt stripping tower 422 can be introduced into the solvent condenser 460 and then into the solvent compressor 462. In this example, the solvent condenser 460 can be configured to cool the solvent vapor from the asphalt stripping tower 422 and / or the deasphalted oil stripping tower 442. In this example, the solvent compressor 462 can be configured to compress the cooled solvent vapor output from the solvent condenser 460. In this example, the solvent effluent from the solvent compressor 462 can be introduced into the condenser 458 and then into the solvent buffer tank 452, after which it is circulated by the solvent circulation pump 450.

[0089] In the example, the solvent and deasphalted oil solution containing most of the solvent from the asphalt separator 416 can flow out with the overhead distillate 426 of the asphalt separator 416.

[0090] In this example, the deasphalted oil yield can be effectively controlled by the operating temperature of the asphalt separator 416. For example, a higher operating temperature may result in a decrease in the deasphalted oil product extracted from the overhead distillate 426. In this example, a lower operating temperature may result in an increase in the deasphalted oil in the overhead distillate 426. In this example, the operating temperature of the asphalt separator 416 may affect the quality of the deasphalted oil. For example, at lower temperatures, the deasphalted oil product in the overhead distillate 426 may have poorer quality.

[0091] In this example, the extraction temperature in the asphalt separator 416 can be controlled primarily by controlling the conditions of the solvent feed 412. Therefore, in this example, the deasphalted oil yield can be controlled by controlling the temperature of the solvent fed into the asphalt separator 416.

[0092] In this example, the overhead distillate 426 can be further processed. In this example, the overhead distillate 426 can be used as DAO separator feed 428 to DAO separator 430. In this example, the DAO separator feed 428 can be heated before being fed to DAO separator 430. In this example, the DAO separator feed 428 can be heated to achieve supercritical solvent circulation conditions before entering DAO separator 430. In this example, the DAO separator feed 428 can be heated via ROSE heat exchanger 432. In this example, the ROSE heat exchanger 432 can be configured to exchange heat between the recovered solvent 434 and the DAO separator feed 428. In this example, the DAO separator feed 428 can be heated by preheater 436 or further heated.

[0093] In the example, the DAO separator 430 can be referenced as previously stated. Figure 3 The DAO separator 430 is set up and operated as described above. In the example, the operating conditions of the DAO separator 430 can be set to achieve the density difference required for good separation. In the example, the DAO separator 430 can be operated to induce supercritical phase separation. In the example, the low density characteristics of the solvent in this region can be utilized by raising the temperature of the solvent above its critical temperature. In the example, as the temperature of the solvent rises above its critical point, the density of the solvent decreases significantly to near the value of a dense gas. In the example, at higher temperatures, the solubility of the deasphalted oil in the solvent may decrease and / or become almost insoluble. In the example, the low density of the solvent and the insolubility of the deasphalted oil can lead to phase separation. In the example, at least about 90% of the solvent in the solvent plus deasphalted oil stream constituting the DAO separator feed 428 can be recovered through supercritical phase separation in the DAO separator 430.

[0094] In this example, the separation temperature in the DAO separator 430 can be controlled by adjusting the flow rate of the heating medium to the preheater 436 under temperature control. In this example, the pressure in the DAO separator 430 can be maintained by adjusting the flow rate of the recovered solvent from the recovered solvent pump 450 to the recovered solvent 448 of the high-pressure system under pressure control.

[0095] In the example, a deasphalted oil-solvent solution containing less than about one standard volume of dissolved solvent per standard volume of deasphalted oil product can be drawn from the bottom distillate 438 of the DAO separator 430 under interface level control. In the example, the deasphalted oil-solvent solution in the bottom distillate 438 can be introduced into a deasphalted oil flash tank and deasphalted oil stripping sections 440 and 442 to recover additional solvent and output deasphalted oil 444.

[0096] In this example, the deasphalted oil-solvent solution from the bottom distillate 438 of the DAO separator 430 is discharged under level control from the DAO separator 430. In this example, sufficient heat can be present in the system to maintain a recommended circulation temperature, selected to provide efficient solvent circulation in the flash tank and downstream stripping column. At the flash tank, pressure can be reduced, and most of the solvent flashes to the top of the column. In this example, the solvent flashed to the top of the column at the deasphalted oil flash tank 440 can be introduced into the condenser 458 for cooling, then into the solvent buffer tank 452, and subsequently circulated by the solvent circulation pump 450.

[0097] In the example, the deasphalted oil and residual solvent streams from the flash tank can be fed into the deasphalted oil stripping tower 442 under level control from the flash tank. At the deasphalted oil stripping tower 442, the pressure can be reduced again to flash additional solvent or most of the residual solvent to the top of the tower.

[0098] In the example, in the deasphalted oil stripping tower 442, the deasphalted oil can be contacted with superheated low-pressure (LP) stripping steam in the deasphalted oil stripping tower 442 to strip residual solvent, thereby reducing the solvent content in the product stream. In the example, the stripping steam can be superheated in a steam heater (not shown). In the example, the stripping steam can be fed into the deasphalted oil stripping tower 442 from below the bottom tray under flow control. The flow rate of the steam in the deasphalted oil stripping tower 442 can be adjusted to achieve efficient stripping.

[0099] In this example, the overhead solvent from the deasphalted oil stripping tower 442 can be directed to the condenser 460 and then to the solvent compressor 462. In this example, the solvent effluent from the solvent compressor 462 can be directed to the condenser 458 and then to the solvent buffer tank 452, after which it is circulated by the solvent circulation pump 450.

[0100] In this example, the overhead distillate of the DAO separator 430 may include recovered solvent 434 under supercritical conditions. In this example, the recovered solvent 434 may supply circulating solvent 446. In this example, the circulating solvent 446 may be introduced into the solvent circulation pump 410 and fed to the asphaltene separator 416.

[0101] In this example, heat can be recovered from the recovered solvent 434 at heat exchanger 432. In this example, the recovered solvent 434 can be additionally cooled in a solvent fine-tuning cooler 454 before becoming the circulating solvent 446. In this example, the solvent fine-tuning cooler 454 can use a coolant such as cooling water to cool the solvent to a relatively low temperature, which may be desirable for extraction control in the asphaltene separator 416. In this example, an optional bypass (not shown) around the cooler can be employed to help control the temperature at the bottom of the asphaltene separator 416.

[0102] In this example, recovered solvent 448 from recovered solvent pump 450 can be combined with circulating solvent 446 directly upstream of the suction inlet of solvent circulation pump 410. In this example, the pressure of DAO separator 430 can control the flow rate of recovered solvent 448 from solvent buffer tank 452 to replenish the solvent in the circulating solvent 446 stream that is removed as a solvent entrainment from the combined separator bottom distillate with the product.

[0103] In this example, the combined recovered solvent 448 and circulating solvent 446 can enter a solvent circulation pump 410, which can be configured to pressurize the solvent flow sufficiently to flow to the asphaltene separator 416. In this example, the solvent circulation pump 410 can provide the solvent flow rate required for solvent-to-oil ratio control in the asphaltene separator 416. In this example, the solvent circulation pump 410 can provide the pump head required to compensate for hydraulic pressure drop in the circulating solvent 446 loop. In this example, the total solvent flow rate can be measured at the outlet of the solvent circulation pump 410. In this example, the total solvent flow rate can be used to control the solvent-to-oil ratio in the asphaltene separator 416 and / or the amount of solvent entering the bottom distributor of the asphaltene separator 416. In this example, the total solvent flow rate can be manually adjusted to the unit feed to achieve the desired solvent-to-oil ratio in the asphaltene separator 416.

[0104] Solvent deasphalting of UMOR or UMOR blended with VC, as described above, can be a refining process that regenerates UMOR or UMOR with VC into high-quality base oil. Solvent deasphalting processes can remove impurities (such as asphalt) from the "bottom" portion of waste engine oil, resulting in high-quality base oil that can be used as a feedstock for producing new lubricants. In the example, the viscosity modifiers and impurities from the discarded waste engine oil "bottom" can be blended into a road asphalt product by upgrading asphalt molecules from conventional VC and viscosity modifier copolymers from a UMOR source.

[0105] In the example, the process and system described herein can be used to produce DAO that meets the quality requirements of bright oil base oils. In the example, the DAO produced by the process described herein can exhibit a specific gravity of approximately 0.86 to 0.87.

[0106] In the example, the asphalt produced by the process described herein can be used as an asphalt additive. In the example, the asphalt can be road grade. In the example, the asphalt can have a specific gravity of 1.00 to 1.07. In the example, the asphalt can have a solids content of about 2.0 wt% to 3.0 wt%. In the example, the asphalt can exhibit a ring and ball softening point of about 95°C to about 125°C.

[0107] In the examples, the system described herein may include one or more control systems, sensors, and other standard components that enable the control and operation of the system.

[0108] In the examples, although not shown, the systems described herein may include one or more sensors commonly used in the art. In the examples, the sensors may be used to monitor the operation of the described system. Non-limiting examples of one or more sensors may include temperature sensors, pressure sensors, flow meters, and other similar sensors.

[0109] In the examples, although not shown, one or more control systems may include one or more controllers, and / or other suitable computing devices that can be used to control one or more portions of the systems described herein. A controller may include one or more processors and memory communicatively coupled to each other. In the illustrated example, the memory may be used to store logical instructions for operating and / or controlling and / or monitoring the operation of the process or system. In the examples, the controller may include or be coupled to input / output devices such as a monitor, keyboard, speaker, microphone, computer mouse, etc. In the examples, one or more controllers may also include one or more communication components, such as transceivers or similar structures, to enable wired and / or wireless communication. In the examples, this enables remote operation of one or more systems described herein.

[0110] In the examples, the memory associated with one or more controllers and / or other suitable computing devices may be a non-transitory computer-readable medium. The memory may store an operating system and one or more software applications, instructions, programs, and / or data to implement the methods described herein and the functions attributed to the various systems. In various implementations, the memory may be implemented using any suitable memory technology, such as static random access memory (SRAM), synchronous dynamic RAM (SDRAM), non-volatile / flash memory, or any other type of memory capable of storing information. The control system may include any number of logical components, program components, and physical components.

[0111] Logical instructions may include one or more software modules and / or other information sufficient to enable autonomous operation, secure procedures, and routine maintenance processes. Any operation of the described system may be implemented in hardware, software, or a combination thereof. In the context of software, an operation represents computer-executable instructions stored on one or more computer-readable storage media that, when executed by one or more processors, perform the referenced operation. Generally, computer-executable instructions include routines, programs, objects, components, data structures, etc., that perform one or more functions or implement specific abstract data types.

[0112] It will be apparent to those skilled in the art that various modifications and variations can be made to the invention without departing from its spirit or scope. Therefore, this invention is intended to cover any modifications and variations that fall within the scope of the appended claims and their equivalents.

Claims

1. A process comprising: The oil containing waste oil distillation residue is fed into the asphalt separator; Solvent is fed into the asphalt separator to achieve a solvent-to-oil ratio of 10:1 to 15:1 within the asphalt separator; and The waste oil distillation residue is at least partially mixed with the solvent when the pressure is above the supercritical level. in, The bottom effluent of the asphalt separator includes asphalt, and The overhead distillate from the asphalt separator includes deasphalted oil.

2. The process according to claim 1, wherein the supercritical solvent comprises propane, butane, isobutane, or any mixture thereof.

3. The process according to claim 1, further comprising maintaining the solvent in the asphalt separator at a temperature below the critical temperature of the solvent.

4. The process according to claim 1, further comprising feeding the oil containing the waste oil distillation residue as a mixture of the oil and the solvent into the asphalt separator.

5. The process according to claim 4, wherein the mixture of oil and solvent comprises a solvent-to-oil ratio of 0.5:1 to 15:

1.

6. The process according to claim 4, wherein the supercritical solvent feed comprises a solvent supplied separately from the oil.

7. The process of claim 6, further comprising feeding a mixture of oil and solvent comprising waste oil distillation residue at a first stage of the asphalt separator, and feeding the supercritical solvent at a second stage of the asphalt separator, wherein the first stage is located at a higher position in the asphalt separator than the second stage.

8. The process according to claim 1, further comprising feeding a supercritical solvent to achieve a solvent-to-oil ratio of 12:

1.

9. The process of claim 8, further comprising maintaining the solvent temperature in the asphalt separator at a temperature below the critical temperature of the solvent.

10. The process according to claim 1, further comprising mixing the primary crude oil residue (VC) with the waste oil distillation residue to form a mixed feed of waste oil distillation residue and VC to be fed into the asphalt separator.

11. The process according to claim 10, wherein the mixed feed of waste oil distillation residue and VC comprises a ratio of about 70 to 30 VC to waste oil distillation residue.

12. The process according to claim 10, wherein the ratio of solvent to oil in the asphalt separator is 13:

1.

13. The process of claim 12, further comprising maintaining the solvent temperature in the asphalt separator at a temperature below the critical temperature of the solvent.

14. The process of claim 10, further comprising heating the material inside the asphalt separator in the region between the extraction packing and the coalescing plate packing.

15. The process of claim 1, further comprising maintaining the asphalt separator at a pressure greater than about 4.2 MPa.

16. A process comprising: Waste engine oil distillation residue is fed into an asphalt separator; The solvent is fed into the asphalt separator; as well as The waste oil distillation residue is at least partially mixed with the solvent when the solvent is at a pressure above its supercritical pressure. in, The bottom effluent of the asphalt separator includes asphalt, and The overhead distillate from the asphalt separator includes deasphalted oil.

17. A process comprising: An oil mixture containing crude oil residue (VC) and waste engine oil distillation residue in a ratio of 70:30 is fed into an asphalt separator. The solvent is fed into the asphalt separator; The oil mixture is at least partially mixed with the solvent when the solvent is above its supercritical pressure; and in The bottom effluent of the asphalt separator includes asphalt, and The overhead distillate from the asphalt separator includes deasphalted oil.

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