Integrated Anode Grade Coke Production via Solvent Deasphalting
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Solution Overview
Problem
Conventional crude oil treatment processes involve distillation and multiple steps, which are inefficient and prone to catalyst deactivation due to contaminants like organic nickel and vanadium compounds, leading to increased costs and reduced process performance.
Innovation Solution
A process that solvent deasphaltizes crude oil to separate asphalt and deasphalted oil, followed by hydrocracking without distillation, using catalysts to remove sulfur and nitrogen, and then subjecting the unconverted DAO to delayed coking, while gasifying asphalt to produce hydrogen for the hydrocracking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional distillation and multiple treatment steps are used, then crude oil can be processed to produce desired products, but the process becomes inefficient and prone to catalyst deactivation
Solution Approach 1:
The invention extracts and removes asphalt from crude oil through solvent deasphalting before the hydrocracking process. This extraction step prevents asphalt contaminants from deactivating catalysts in subsequent treatment steps, thereby improving process efficiency and reducing the need for multiple sequential treatments.
Solution Approach 2:
The invention performs solvent deasphalting as a preliminary action before hydrocracking and other treatment steps. By removing asphalt contaminants in advance, the process prevents catalyst deactivation and improves overall efficiency, eliminating the need for multiple sequential treatment steps.
2Manufacturing precision
If catalysts are used in hydrocracking to remove sulfur and nitrogen, then product quality improves, but catalyst life is reduced due to deactivation by contaminants
Solution Approach 1:
The invention extracts asphalt contaminants from crude oil through solvent deasphalting before hydrocracking. This removes nitrogen-containing compounds and other contaminants that would otherwise deactivate catalysts, thereby extending catalyst life while maintaining high product quality.
Solution Approach 2:
The invention applies preliminary anti-action by using solvent deasphalting to prevent catalyst deactivation before the hydrocracking process begins. This preliminary removal of asphalt contaminants protects catalysts from nitrogen poisoning and extends their operational life.
3Reliability
If multiple treatment steps are implemented, then impurities can be removed, but operating costs increase
Solution Approach 1:
The invention uses solvent deasphalting to extract and remove asphalt contaminants in a single efficient step before hydrocracking. This prevents catalyst deactivation and eliminates the need for multiple sequential treatment steps, thereby reducing operating costs while maintaining reliable impurity removal.
Solution Approach 2:
The invention performs asphalt removal as a preliminary action that prevents downstream catalyst deactivation and eliminates the need for multiple treatment steps. This single upfront step achieves the same impurity removal reliability as multiple sequential steps would, at lower operating cost.
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 simplifies crude oil processing, eliminates the need for distillation, extends catalyst life, reduces operating costs, and produces high-quality distillates and anode grade coke, while maintaining process efficiency.
Implementation Method 1
separating asphalt from the whole crude oil
Implementation Method 2
treating the deasphalted oil via hydrotreatment/hydrocracking with a catalyst, to remove materials such as sulfur and nitrogen
Implementation Method 3
treating the deasphalted oil via hydrotreatment/hydrocracking with a catalyst
Implementation Method 4
the recovered, asphalt containing fraction can be gasified, to produce hydrogen
Implementation Method 5
The hydrotreated or unconverted DAO fraction is then subjected to delayed coking
Data Source
AI summary
The invention relates to processes for producing anode grade coke from whole crude oil. The invention is accomplished by first deasphalting a feedstock, followed by processing resulting DAO and asphalt fractions. The DAO fraction is hydrotreated or hydrocracked, resulting in removal of sulfur and hydrocarbons, which boil at temperatures over 370° C., and gasifying the asphalt portion in one embodiment. This embodiment includes subjecting hydrotreated and/or unconverted DAO fractions to delayed coking. In an alternate embodiment, rather than gasifying the asphalt portion, it is subjected to delayed coking in a separate reaction chamber. Any coke produced via delayed coking can be gasified.