Anisotropic Coke Production Using PCP-Oil Feedstock Blends
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Solution Overview
Problem
The growing demand for high-quality needle coke, essential for lithium-ion batteries and steel production, is challenging existing production methods due to increased competition for feedstocks and environmental regulations.
Innovation Solution
A process that incorporates a Purified Coal Product (PCP) with decanted or slurry oil as a feedstock in a delayed coker, enhancing mesophase formation and resulting in high-quality anisotropic and needle coke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If decanted oil or slurry oil is used as feedstock in traditional delayed coker processes, then needle coke production is achieved, but feedstock availability is limited due to competition from marine fuel demands and environmental regulations
Solution Approach 1:
The invention changes the chemical composition parameters of the feedstock by blending purified coal product (PCP) with decanted oil or slurry oil. This parameter change allows the use of alternative feedstock combinations that were previously unsuitable, thereby increasing feedstock availability while maintaining needle coke production. The PCP blend ratio can be adjusted to optimize both yield and anisotropic content.
Solution Approach 2:
The invention creates a composite feedstock system by combining purified coal product (PCP) with traditional oil-based feedstocks (decanted oil or slurry oil). This composite approach leverages the complementary properties of both materials: the oil component provides aromaticity for mesophase formation while the PCP contributes carbon content and structural integrity, resulting in enhanced needle coke yield and quality without relying solely on limited oil feedstocks.
2Manufacturing precision
If purified coal product (PCP) is blended with decanted or slurry oil in a delayed coker, then anisotropic coke yield and quality are increased, but process complexity increases
Solution Approach 1:
The invention applies preliminary action by pre-blending the purified coal product (PCP) with decanted oil or slurry oil before introducing the mixture to the delayed coker. This pre-mixing step ensures homogeneous distribution of PCP particles throughout the oil feedstock, facilitating consistent mesophase formation and anisotropic coke development. The blending is performed using standard mixing equipment, avoiding the need for complex specialized apparatus.
3Object-generated harmful factors
If PCP is used as an alternative feedstock, then mining waste is reduced and renewable energy demands are met, but feedstock processing requirements increase
Solution Approach 1:
The invention changes the physical parameters of the PCP feedstock by controlling particle size distribution (D90 ≤ 100 μm) and moisture content (<5%). These parameter specifications ensure that the PCP can be effectively blended with oil feedstocks and properly processed in the delayed coker. The fine particle size facilitates uniform dispersion while the low moisture content prevents processing issues, balancing waste utilization with manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach increases the yield and quality of needle coke, reduces mining waste, and provides an alternative feedstock that meets the demands of renewable energy technologies.
Implementation Method 1
the oil is reacted under high pressure to first produce a liquid crystal-like product referred to as 'mesophase'
Implementation Method 2
Mesophase is an anisotropic phase, intermediate between the isotropic pitch and anisotropic semi-coke, generated during the pyrolysis of some organic materials
Implementation Method 3
Collision of mesogen molecules during pyrolysis results in the formation of liquid crystals (mesophase) by a process of homogenous self-assembly
Implementation Method 4
Mesophase is composed of macromolecules of different molecular size, bonded by Van der Waals forces in a parallel stacking
Data Source
AI summary
There is provided a process for the production of anisotropic coke, the process comprising providing a purified coal product (PCP), wherein the PCP is in particulate form, and wherein at least about 90% by volume (% v) of the particles are no greater than about 100 μm in diameter; wherein the PCP has an ash content of less than about 10% m and a water content of less than around 5% m. The PCP is combined with a feedstock oil, such as a decant oil, in order to create a combined solid-liquid blend, wherein the solid-liquid blend comprises at least around 0.1% m and at most around 50% m PCP. The solid-liquid blend is subjected to a temperature in excess of 400° C., typically as part of a delayed coker process, for a time period sufficient to induce formation of mesophase, and production of anisotropic coke. Improved yields of valuable needle coke can be obtained via the processes described.