Sodium reduction in a hydrocarbon stream using cation exchange resin

Abstract

A process to reduce sodium content in a hydrocarbon stream, the process including contacting the hydrocarbon stream and a diluent to form a mixed stream; contacting the mixed stream and a macroporous cation exchange resin to form a processed stream; and collecting the processed stream, wherein the hydrocarbon stream includes a stream from phenol production and a stream from bisphenol-A production, and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream; the diluent includes a C8-14 hydrocarbon and has a specific gravity of 0.8 to 1.0; the macroporous cation exchange resin has an average particle size of less than 1.5 millimeters, and an adsorption exchange capacity of greater than 2 H+ milliequivalents per milliliter; and the processed stream includes less than 50 parts per million by weight of sodium, based on a total weight of the processed stream.

Description

SODIUM REDUCTION IN A HYDROCARBON STREAM USING CATION EXCHANGE RESINCROSS REFERENCE TO RELATED APPLICATIONSThis application claims priority to European Application No. EP24188731, filed July 16, 2024, which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0001] Provided are processes and systems for reducing sodium content in a hydrocarbon stream.BACKGROUND

[0002] Carbon black can be used for the reinforcement of rubber and as a black pigment. Carbon black can be in the form of a fluffy fine powder with a large surface area and composed of elemental carbon. Carbon black can be manufactured by the controlled vapor-phase pyrolysis and partial combustion of hydrocarbons. Carbon black can also be produced by oil-furnace, impingement, lampblack, or thermal or acetylene processes. Carbon black can be produced using Pyrolysis Fuel Oil (PFO) which is mixture of heavy aromatic hydrocarbons, as a feedstock.

[0003] It can be difficult to produce carbon black of a desirable grade when a feedstock for carbon black production has a sodium content of greater than or equal to 50 parts per million by weight (ppmw), based on a total weight of the feedstock. There remains a need in the art for processes and systems for reducing sodium content in hydrocarbon streams, such that the hydrocarbon stream can be used for carbon black production.SUMMARY

[0004] Provided is a process to reduce sodium content in a hydrocarbon stream, the process including contacting the hydrocarbon stream and a diluent to form a mixed stream; contacting the mixed stream and a macroporous cation exchange resin to form a processed stream; and collecting the processed stream, wherein the hydrocarbon stream includes a stream from phenol production and a stream from bisphenol-A production, and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream, wherein the diluent includes a Cs-i4 hydrocarbon and has a specific gravity of 0.8 to 1.0, wherein themacroporous cation exchange resin has an average particle size of less than 1.5 millimeters, and an adsorption exchange capacity of greater than 2 H+milliequivalents per milliliter, and wherein the processed stream includes less than 50 parts per million by weight of sodium, based on a total weight of the processed stream.

[0005] The mixed stream can include, based on a total weight of the mixed stream, 80 to 85 weight percent (wt%) of the hydrocarbon stream; and 15 to 20 wt% of the diluent.

[0006] The hydrocarbon stream can have a viscosity of 680 to 800 10'6m2 / s (680 to 800 centistokes).

[0007] The mixed stream can have a viscosity of 500 to 650 10'6m2 / s (500 to 650 centistokes).

[0008] The stream from phenol production can include a phenol production product stream; and the stream from bisphenol-A production can include a bisphenol-A production purge stream.

[0009] The hydrocarbon stream can include acetophenone, cumyl phenol, diphenyl methyl pentene, and ashphaltene.

[0010] The macroporous cation exchange resin can include a sulfonate functionalized polystyrene copolymer.

[0011] Contacting the mixed stream and the macroporous cation exchange resin to form the processed stream can include operating conditions including a temperature of 50 to 60 °C, a pressure of less than 500 kilopascals, and a liquid hourly space velocity of 4 to 10 h'1.

[0012] Contacting the mixed stream and the macroporous cation exchange resin can include feeding the mixed stream to a reactor containing the macroporous cation exchange resin.

[0013] Contacting the mixed stream and the macroporous cation exchange resin can include use of more than one reactor containing the macroporous cation exchange resin.

[0014] The process can further include regenerating the macroporous cation exchange resin with a solution including hydrochloric acid at a concentration of 3 to 10 wt%, based on a total weight of the solution, to provide regenerated macroporous cation exchange resin.

[0015] The process can further include washing the regenerated macroporous cation exchange resin with demineralized water to provide washed macroporous cation exchange resin.

[0016] The process can further include drying the washed macroporous cation exchange resin.

[0017] Provided is a process to form carbon black including reducing sodium content in a hydrocarbon stream to form a processed stream; and exposing the processed stream to a temperature of 600 to 800 °C to form carbon black.

[0018] Provided is a process to reduce sodium content in a hydrocarbon stream, the process including contacting the hydrocarbon stream and a diluent to form a mixed stream; feeding the mixed stream to a reactor containing a macroporous strong acid cation exchange resin to form a processed stream; and collecting the processed stream from the reactor, wherein the hydrocarbon stream includes a stream from phenol production and a stream from bisphenol- A production, greater than 95 wt% of hydrocarbons; and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream, wherein the diluent includes a Cs-i4 hydrocarbon and has a specific gravity of 0.8 to 1.0, wherein the macroporous strong acid cation exchange resin includes a sulfonate functionalized polystyrene copolymer, has an average particle size of less than 1.5 millimeters, and has an adsorption exchange capacity of greater than 2 H+milliequivalents per milliliter, wherein feeding the mixed stream to the reactor containing the macroporous strong acid cation exchange resin includes operating conditions including a temperature of 50 to 60 °C, a pressure of less than 500 kilopascals, and a liquid hourly space velocity of 4 to 10 h1, and use of more than one reactor containing the macroporous strong acid cation exchange resin, and wherein the processed stream includes less than 50 parts per million by weight of sodium, based on a total weight of the processed stream.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The following figure illustrates an exemplary embodiment.

[0020] Figure 1 is a schematic of a process to form carbon black, which includes reducing sodium content in a hydrocarbon stream to form a processed stream.DETAILED DESCRIPTION

[0021] Phenol (CeHeO) and acetone can be produced by oxidation of cumene followed by a cleavage reaction. Bisphenol-A (C15H16O2) can be produced by a condensation reaction between acetone and phenol in a condensation reactor.

[0022] Provided are processes and systems for reducing sodium content in a hydrocarbon stream including a waste stream containing C12+ hydrocarbons from phenol production and frombisphenol-A production (also referred to herein collectively as a “starting hydrocarbon stream”) and form a processed stream. The processed stream can be used as feedstock for carbon black production.

[0023] The present inventors have surprisingly discovered that forming a mixed stream from the starting hydrocarbon stream and a diluent and use of a macroporous cation exchange resin allows for reduction of sodium content in the starting hydrocarbon stream having a high viscosity. The composition of the diluent and use of a macroporous cation exchange resin allows for the reduction of sodium content to a desirable level. The starting hydrocarbon stream disclosed herein can have a sodium content of greater than 450 ppmw, based on a total weight of the starting material.Starting Hydrocarbon Stream

[0024] The starting hydrocarbon stream, the sodium content of which is reduced according to the disclosed process, can include greater than 95 wt% of C12+ hydrocarbons and greater than 450 ppmw of sodium, each based on a total weight of the starting hydrocarbon stream, and balance of Ce-n hydrocarbons. The stream from phenol production can include a product stream, a byproduct stream, a purge stream, a waste stream, or a combination thereof of phenol production. The stream from bisphenol-A production can include a product stream, a byproduct stream, a purge stream, a waste stream, or a combination thereof of bisphenol-A production. For example, the starting hydrocarbon stream can include a phenol production product stream and a bisphenol-A production purge stream.

[0025] The starting hydrocarbon stream can include acetophenone (CsHsO), cumyl phenol (CisHigO), diphenyl methyl pentene (C18H20), and ashphaltene, for example, 0 to 5 wt% acetophenone, 10 to 25 wt% cumyl phenol (C15H16O), 2 to 10 wt% diphenyl methyl pentene, and 10 to 25 wt% ashphaltene. The starting hydrocarbon stream can further include Cix hydrocarbons such as, for example, hexene diphenyl; 4-(4-methyl-2,4-diphenyl-2-pentyl)phenol; benzene, l,l'-(l,3,3-trimethyl-l-propene-l,3-diyl)bis-; or a combination thereof.

[0026] The starting hydrocarbon stream can include a stream from phenol production and a stream from bisphenol-A production. The stream from phenol production can include, for example, 5 to 10 wt% phenol, 20 to 30 wt% aromatic ketone, 10 to 15 wt% aromatic alcohol, 15to 20 wt% phenol derivatives, 10 to 15 wt% styrene dimers, or a combination thereof; and substituted benzene, styrene, phenol, and bisphenol-A derivatives, or a combination thereof.Diluent

[0027] The highly viscous starting hydrocarbon stream can have a viscosity of 680 to 800 10'6m2 / s (680 to 800 centistokes), include a Cs-i4 hydrocarbon, and have a specific gravity of 0.8 to 1.0, 0.85 to 0.98, 0.90 to 0.98, or 0.95 to 0.98. Contacting the starting hydrocarbon stream and a diluent to form mixed stream can reduce the viscosity of the starting hydrocarbon stream and allow the mixed stream to flow through the reactor, for example, column, containing the macroporous cation exchange resin.Mixed Stream

[0028] The mixed stream formed by contacting the starting hydrocarbon stream and the diluent can include, based on a total weight of the mixed stream, 80 to 85 wt% of the starting hydrocarbon stream and 15 to 20 wt% of the diluent. The mixed stream can have a viscosity of 400 to 650 10'6m2 / s (400 to 650 centistokes) or 500 to 650 10'6m2 / s (500 to 650 centistokes).Cation Exchange Resin

[0029] The mixed stream is contacted with a macroporous cation exchange resin to reduce sodium content to form a processed stream. Contacting the mixed stream and the macroporous cation exchange resin can include feeding the mixed stream to a reactor containing the macroporous cation exchange resin.

[0030] The macroporous cation exchange resin can include a liquid acid, a solid acid, or a combination thereof. Suitable acids can include a Bronsted acid, a Lewis acids, or a combination thereof. The macroporous cation exchange resin can include a homogenous cation exchange resin, a heterogeneous cation exchange resin, or a combination thereof. Suitable cation exchange resins can include sulfuric acid, acetic acid, formic acid, hydrochloric acid, sulfamic acid, methanesulfonic acid, phosphoric acid, trifluoroacetic acid, thionyl chloride, resin, or a combination thereof.

[0031] The macroporous cation exchange resin has an average particle size of less than 1.5 millimeters to provide a desirable reaction rate and an adsorption exchange capacity ofgreater than 2 H+milliequivalents per milliliter, for example, greater than 2 and less than 3 H+milliequivalents per milliliter (meq / ml) , or less than 2 H+meq / ml , or less than 1 H+meq / ml. The macroporous cation exchange resin can include a strong acidic cation exchange resin group linked to a substituted styrene group, for example, the macroporous cation exchange resin can include a sulfonate functionalized polystyrene copolymer. The macroporous cation exchange resin has average pore sizes of 100 to 1,000 nanometers.

[0032] Characteristics of the macroporous cation exchange resin can include a polystyrene copolymer matrix structure, nuclear sulphonic functional group, physical form of moist spherical beads, hydrogen ionic form, 16 to 50 Screen Size U.S.S. (wet), 0.3 to 1.2 millimeter particle size, total exchange capacity of 1.0 - 1.7 (Na) & 1.0 - 1.63 (H), swelling of Na+to H+of about 6 - 10 %, moisture content of about 56±3% (H) & 53±3% (Na), backwash settled density of 700 to 850 grams per liter H+, or 800 to 830 grams per liter H+, and 700 to 900 grams per liter Na+, or 830 to 870 grams per liter Na+, insoluble in all common solvents, or a combination thereof. Other properties of the macroporous cation exchange resin can include swelling of less than 10%, thermal stability at temperatures of less than or equal to 150 °C, an operating temperature of 100 to 110 °C, a pH range of 0 to 14, or a combination thereof.

[0033] The mixed stream is contacted with the macroporous cation exchange resin at a temperature of 40 to 70 °C, for example, 40 to 60 °C or 50 to 60 °C, a pressure of less than 5 bar gauge (500 kilopascals), for example, atmospheric pressure (1 bar or 101 kilopascals), a liquid hourly space velocity of 4 to 10 h’1, or a combination thereof.

[0034] Contacting the mixed stream and the macroporous cation exchange resin to reduce sodium content in the mixed stream and form the processed stream can include use of more than one reactor containing the macroporous cation exchange resin (also referred to herein as a “lead-lag configuration”). A sodium content in the starting hydrocarbon stream fed to a first, e.g., lead, column can be, for example, 300 to 600 ppmw. A sodium content in a stream exiting the first column for example, at a bottom of the lead column, can be, for example, 80 to 120 ppmw. The stream exiting the first column can be fed to a second, e.g., lag, column, for example, to a top of the lag column, and a sodium content in a processed stream exiting the lag column, for example, at a bottom of the lag column, can be, for example, less than 50 ppmw, or 10 to 50 ppmw, or 0 to 10 ppmw.Regeneration

[0035] As used herein, regeneration refers to treatment of the macroporous cation exchange resin before use of the macroporous cation exchange resin. Such treatment can occur prior to a first use of the macroporous cation exchange resin or prior to subsequent use of the macroporous cation exchange resin. For example, prior to a first use of the macroporous cation exchange resin, the macroporous cation exchange resin can be supplied with sodium as stabilizer. Regeneration prior to a first use can unblock active sites and remove sodium. Use of the macroporous cation exchange resin can result in sodium adsorption and utilization of active sites of the macroporous cation exchange resin. The macroporous cation exchange resin can be regenerated, allowing for further use of the macroporous cation exchange resin.

[0036] The macroporous cation exchange resin can be regenerated with dilute hydrochloric acid to provide regenerated macroporous cation exchange resin. The dilute hydrochloric acid, can include, for example, less than 10 wt%, or 3 to 10 wt%, of hydrochloric acid, based on a total weight of a solution including the hydrochloric acid.

[0037] The regenerated macroporous cation exchange resin can be washed with demineralized water to provide washed macroporous cation exchange resin. The washed macroporous cation exchange resin can be dried, for example, using methanol to remove moisture from the macroporous cation exchange resin.Carbon Black Formation

[0038] Following reduction of sodium content in the starting hydrocarbon stream to provide a processed stream including less than 50 ppmw of sodium, based on a total weight of the processed stream, carbon black can be formed using the processed stream. The processed stream, for example, at a flow of 3 to 7 tons per hour is exposed to a temperature of 600 to 800 °C to form carbon black with a yield of 40 to 60 percent. In some embodiments, the flow is at 4 to 7 tons per hour or, preferably, 5 to 7 tons per hour. The carbon black can meet characteristics for various grades, for example, N234, N660, N770, or N880.

[0039] A more complete understanding of the components, processes, and methods disclosed herein can be obtained by reference to the accompanying drawing. The figure (also referred to herein as “FIG.”) are merely schematic representations based on convenience and theease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the assemblies or components thereof and / or to define or limit the scope of the exemplary embodiments. Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawing, and are not intended to define or limit the scope of the disclosure.

[0040] FIG. 1 is a schematic of a process to form carbon black. As depicted in FIG. 1, the process includes contacting the hydrocarbon stream 10 and a diluent 20 to form a mixed stream 30. In some embodiments, the mixed stream 30 includes 10 to 20 wt% or 15 to 20 wt% of the diluent and 80 to 90 wt% or 80 to 85 wt% of the hydrocarbon stream 10. The mixed stream 30 and a macroporous cation exchange resin 40 are contacted to form a processed stream 50. The mixed stream 30 and the macroporous cation exchange resin 40 can be contacted to form the processed stream 50 in column 1000. The process further includes collecting the processed stream 50. The hydrocarbon stream 10 includes a stream 1 from phenol production 100 and a stream 2 from bisphenol-A production 200 and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream. In some embodiments, the mixed stream 30 includes 60 to 65 wt% of stream 1 and 10 to 25 wt% of stream 2. The diluent includes a Cs-i4 hydrocarbon and has a specific gravity of 0.8 to 1.0, 0.85 to 0.98, 0.90 to 0.98, or 0.95 to 0.98. The macroporous cation exchange resin 40 has an average particle size of less than 1.5 millimeters, and an adsorption exchange capacity of greater than 2 H+milliequivalents per milliliter. In some embodiments, the average particle size is 0.5 to 1.5 millimeters, or preferably 1.0 to 1.5 millimeters, or more preferably 1.2 to 1.5 millimeters. The volume of resin in the column may be 50 to 200 milliliters, or preferably 100 to 200 milliliters, or more preferably 150- 200 milliliters. The processed stream 50 includes less than 50 parts per million by weight of sodium, based on a total weight of the processed stream 50. Accordingly, the sodium content in the hydrocarbon stream 10 is reduced to form the processed stream 50. In some embodiments, the sodium content in the hydrocarbon stream is reduced to less than 50 parts per million (e.g., 50 to 10 parts per million), or preferably less than 10 parts per million, or more preferably less than 5 parts per million. The process further includes exposing the processed stream 50 to a temperature of 600 to 800 °C to form carbon black 60. The processed stream 50 can be exposed to the temperature of 600 to 800 °C to form carbon black 60 in heater or furnace 2000.

[0041] By use of the disclosed processes and systems, product streams, byproduct streams, purge streams, waste streams, or a combination thereof of phenol production, bisphenol-A production, or a combination thereof can be used for carbon black formation. Advantages of the disclosed processes and systems include use of available hydrocarbon streams including a stream from phenol production and a stream from bisphenol-A production and with sodium content of greater than or equal to 50 ppmw, based on a total weight of the hydrocarbon stream, for carbon black formation.

[0042] This disclosure is further illustrated by the following example, which is non-limiting.EXAMPLE

[0043] Two columns connected in series were filled with macroporous cation exchange resin, the characteristics of which can be found in Table 1. Each column had a length of 30 centimeters (cm), diameter of about 1 cm, volume capacity of between 100 to 200 milliliters, and was packed with about 65 to 75 grams of the macroporous cation exchange resin in 20 cm of the column.Table 1Prior to use, the macroporous cation exchange resin was regenerated using 5% hydrochloric acid. Thereafter, the regenerated macroporous cation exchange resin was thoroughly washed with demineralized water and then dried using methanol.

[0044] A hydrocarbon stream having a sodium content of 300 to 490 ppmw, based on a total weight of the hydrocarbon stream, and including a phenol production product stream and a bisphenol-A production purge stream was mixed with a diluent composed of Cs-i4 hydrocarbon stream having a specific gravity of 0.8 to 1.0 to form a mixed stream. The mixed stream included 10 to 20 wt% of diluent (Cs-u) and 80 to 90 wt% of the hydrocarbon stream.

[0045] The mixed stream was added to the top of a first column and passed through macroporous cation exchange resin therein to reduce a sodium content in the mixed stream. A bottoms product of the first column was added to the top of a second column and passed through the macroporous cation exchange resin therein to reduce sodium content in the bottom’s product of the first column. The temperature of each of the columns was maintained between 50-60 °C at atmospheric pressure and a liquid hourly space velocity through each of the columns was maintained at 8 h'1. Characteristics of the mixed stream fed to the first column and the processed stream exiting the second column can be found in Table 2. Testing of the processed stream was conducted at more than one laboratory.Table 2

[0046] The process and system disclosed herein includes at least the following:

[0047] Aspect 1 : A process to reduce sodium content in a hydrocarbon stream, the process comprising: contacting the hydrocarbon stream and a diluent to form a mixed stream; contacting the mixed stream and a macroporous cation exchange resin to form a processed stream; and collecting the processed stream, wherein the hydrocarbon stream comprises a streamfrom phenol production and a stream from bisphenol-A production, and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream, wherein the diluent comprises a Cs-i4 hydrocarbon and has a specific gravity of 0.95 to 0.98, wherein the macroporous cation exchange resin has a particle size of less than 1.5 millimeters, and an adsorption exchange capacity of less than 3 H+milliequivalents per milliliter, and wherein the processed stream comprises less than 50 parts per million by weight of sodium, based on a total weight of the processed stream.

[0048] Aspect 2: The process of Aspect 1, wherein the mixed stream comprises, based on a total weight of the mixed stream, 80 to 85 wt% of the hydrocarbon stream; and 15 to 20 wt% of the diluent.

[0049] Aspect 3: The process of Aspect 1 or Aspect 2, wherein the hydrocarbon stream has a viscosity of 680 to 800 10'6m2 / s (680 to 800 centistokes).

[0050] Aspect 4: The process of any of the preceding aspects, wherein the mixed stream has a viscosity of 500 to 650 10'6m2 / s (500 to 650 centistokes).

[0051] Aspect 5: The process of any of the preceding aspects, wherein: the stream from phenol production comprises a phenol production product stream; and the stream from bisphenol-A production comprises a bisphenol-A production purge stream.

[0052] Aspect 6: The process of any of the preceding aspects, wherein the hydrocarbon stream comprises acetophenone, cumyl phenol, diphenyl methyl pentene, and ashphaltene.

[0053] Aspect 7: The process of any of the preceding aspects, wherein the macroporous cation exchange resin comprises a sulfonate functionalized polystyrene copolymer.

[0054] Aspect 8: The process of any of the preceding aspects, wherein contacting the mixed stream and the macroporous cation exchange resin to form the processed stream comprises operating conditions comprising a temperature of50 to 60 °C, a pressure of less than 500 kilopascals, and a liquid hourly space velocity of 4 to 10 h'1.

[0055] Aspect 9: The process of any of the preceding aspects, wherein contacting the mixed stream and the macroporous cation exchange resin comprises feeding the mixed stream to a reactor containing the macroporous cation exchange resin.

[0056] Aspect 10: The process of Aspect 9, wherein contacting the mixed stream and the macroporous cation exchange resin comprises use of more than one reactor containing the macroporous cation exchange resin.

[0057] Aspect 11 : The process of any of the preceding aspects, further comprising regenerating the macroporous cation exchange resin with a solution including hydrochloric acid at a concentration of 3 to 10 wt%, based on a total weight of the solution, to provide regenerated macroporous cation exchange resin.

[0058] Aspect 12: The process of Aspect 11, further comprising washing the regenerated macroporous cation exchange resin with demineralized water to provide washed macroporous cation exchange resin.

[0059] Aspect 13: The process of Aspect 12, further comprising drying the washed macroporous cation exchange resin.

[0060] Aspect 14: A process to form carbon black comprising: reducing sodium content in a hydrocarbon stream to form a processed stream according to the process of any of the preceding aspects; and exposing the processed stream to a temperature of 600 to 800 °C to form carbon black.

[0061] Aspect 15: A process to reduce sodium content in a hydrocarbon stream, the process comprising: contacting the hydrocarbon stream and a diluent to form a mixed stream; feeding the mixed stream to a reactor containing a macroporous strong acid cation exchange resin to form a processed stream; and collecting the processed stream from the reactor, wherein the hydrocarbon stream comprises a stream from phenol production and a stream from bisphenol-A production, greater than 95 wt% of hydrocarbons; and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream, wherein the diluent comprises a Cs-i4 hydrocarbon and has a specific gravity of 0.95 to 0.98, wherein the macroporous strong acid cation exchange resin comprises a sulfonate functionalized polystyrene copolymer, has an average particle size of less than 1.5 millimeters, and has an adsorption exchange capacity of less than 3 H+milliequivalents per milliliter, wherein feeding the mixed stream to the reactor containing the macroporous strong acid cation exchange resin comprises operating conditions comprising a temperature of 50 to 60 °C, a pressure of less than 500 kilopascals, and a liquid hourly space velocity of 4 to 10 h’1, and use of more than one reactor containing the macroporous strong acid cation exchange resin, and wherein the processed stream comprises less than 50 parts per million by weight of sodium, based on a total weight of the processed stream.

[0062] Although the disclosed subject matter and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosed subject matter as defined by the appended claims. Moreover, the scope of the disclosed subject matter is not intended to be limited to the particular embodiments described in the specification. Accordingly, the appended claims are intended to include within their scope such alternatives.

[0063] In general, the invention may alternately comprise, consist of, or consist essentially of, any appropriate components herein disclosed. The invention may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any components, materials, ingredients, adjuvants or species used in the prior art compositions or that are otherwise not necessary to the achievement of the function and / or objectives of the present invention. The endpoints of all ranges directed to the same component or property are inclusive and independently combinable (e.g., ranges of “less than or equal to 25 wt%, or 5 wt% to 20 wt%,” is inclusive of the endpoints and all intermediate values of the ranges of “5 wt% to 25 wt%,” etc.). Disclosure of a narrower range or more specific group in addition to a broader range is not a disclaimer of the broader range or larger group. “Combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. Furthermore, the terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to denote one element from another. The terms “a” and “an” and “the” herein do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Thus, reference to “an” element in a claim followed by reference to “the” element is inclusive of one element and a plurality of the elements. “Or” means “and / or.” The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the film(s) includes one or more films). Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth, means that a particular element (e.g., feature, structure, and / or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.

[0064] The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). The notation “+ 10%” means that the indicated measurement can be from an amount that is minus 10% to an amount that is plus 10% of the stated value. The terms “front”, “back”, “bottom”, and / or “top” are used herein, unless otherwise noted, merely for convenience of description, and are not limited to any one position or spatial orientation. “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs. A “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like.

[0065] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0066] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims

CLAIMS:

1. A process to reduce sodium content in a hydrocarbon stream , the process comprising: contacting the hydrocarbon stream and a diluent to form a mixed stream; contacting the mixed stream and a macroporous cation exchange resin to form a processed stream; and collecting the processed stream, wherein the hydrocarbon stream comprises a stream from phenol production and a stream from bisphenol-A production, and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream, wherein the diluent comprises a Cs-14 hydrocarbon and has a specific gravity of 0.8 to 1.0, wherein the macroporous cation exchange resin has an average particle size of less than 1.5 millimeters, and an adsorption exchange capacity of greater than 2 H+milliequivalents per milliliter, and wherein the processed stream comprises less than 50 parts per million by weight of sodium, based on a total weight of the processed stream.

2. The process of Claim 1, wherein the mixed stream comprises, based on a total weight of the mixed stream,80 to 85 wt% of the hydrocarbon stream; and15 to 20 wt% of the diluent.

3. The process of Claim 1 or Claim 2, wherein the hydrocarbon stream has a viscosity of 680 to 800 10'6m2 / s (680 to 800 centistokes).

4. The process of any of the preceding claims, wherein the mixed stream has a viscosity of 500 to 650 10'6m2 / s (500 to 650 centistokes).

5. The process of any of the preceding claims, wherein: the stream from phenol production comprises a phenol production product stream; and the stream from bisphenol-A production comprises a bisphenol-A production purge stream.

6. The process of any of the preceding claims, wherein the hydrocarbon stream comprises acetophenone, cumyl phenol, diphenyl methyl pentene, and ashphaltene.

7. The process of any of the preceding claims, wherein the macroporous cation exchange resin comprises a sulfonate functionalized polystyrene copolymer.

8. The process of any of the preceding claims, wherein contacting the mixed stream and the macroporous cation exchange resin to form the processed stream comprises operating conditions comprising a temperature of 50 to 60 °C, a pressure of less than 500 kilopascals, and a liquid hourly space velocity of 4 to 10 h’1.

9. The process of any of the preceding claims, wherein contacting the mixed stream and the macroporous cation exchange resin comprises feeding the mixed stream to a reactor containing the macroporous cation exchange resin.

10. The process of Claim 9, wherein contacting the mixed stream and the macroporous cation exchange resin comprises use of more than one reactor containing the macroporous cation exchange resin.

11. The process of any of the preceding claims, further comprising regenerating the macroporous cation exchange resin with a solution including hydrochloric acid at a concentration of 3 to 10 wt%, based on a total weight of the solution, to provide regenerated macroporous cation exchange resin.

12. The process of Claim 11, further comprising washing the regenerated macroporous cation exchange resin with demineralized water to provide washed macroporous cation exchange resin.

13. The process of Claim 12, further comprising drying the washed macroporous cation exchange resin.

14. A process to form carbon black comprising: reducing sodium content in a hydrocarbon stream to form a processed stream according to the process of any of the preceding claims; and exposing the processed stream to a temperature of 600 to 800 °C to form carbon black.

15. A process to reduce sodium content in a hydrocarbon stream, the process comprising: contacting the hydrocarbon stream and a diluent to form a mixed stream; feeding the mixed stream to a reactor containing a macroporous strong acid cation exchange resin to form a processed stream; and collecting the processed stream from the reactor, wherein the hydrocarbon stream comprises a stream from phenol production and a stream from bisphenol-A production, greater than 95 wt% of hydrocarbons; and greater than 450 parts per million by weight of sodium, based on a total weight of the hydrocarbon stream, wherein the diluent comprises a Cg-14 hydrocarbon and has a specific gravity of 0.8 to 1.0, wherein the macroporous strong acid cation exchange resin comprises a sulfonate functionalized polystyrene copolymer, has an average particle size of less than 1.5 millimeters, and has an adsorption exchange capacity of greater than 2 H+milliequivalents per milliliter, wherein feeding the mixed stream to the reactor containing the macroporous strong acid cation exchange resin comprises operating conditions comprising a temperature of 50 to 60 °C, a pressure of less than 500 kilopascals, and a liquid hourly space velocity of 4 to 10 h’1, and use of more than one reactor containing the macroporous strong acid cation exchange resin, andwherein the processed stream comprises less than 50 parts per million by weight of sodium, based on a total weight of the processed stream.

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