Bitumen Formulation Using Hydroconversion Residues
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Solution Overview
Problem
Conventional bitumen production methods rely heavily on bitumen crudes and expensive modification techniques, resulting in bitumens of mediocre quality and are constrained by the availability of conventional bitumen bases, particularly in regions with declining refinery capacity and stringent sulfur emission standards.
Innovation Solution
Formulating bitumens using high amounts of ebullated bed hydroconversion residues, specifically the asphalt resulting from solvent deasphalting of vacuum residues, combined with a heavy aromatic cut, to create bitumens that meet European standards for road construction without relying on bitumen crudes or expensive modification processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bitumen bases from direct distillation of bitumen crudes are used, then bitumen production is simplified, but production is constrained by limited availability of bitumen crudes and declining refinery capacity
Solution Approach 1:
The patent substitutes expensive, limited bitumen crudes with abundant, cheaper vacuum residues from ebullated bed hydroconversion. These residues, previously used only as low-value bunker fuels, are repurposed as bitumen bases, effectively replacing scarce conventional resources with plentiful alternative feedstocks.
Solution Approach 2:
The patent fundamentally changes the chemical parameters of the bitumen base by using hydroconverted residues with modified molecular structure. The hydroconversion process alters the feedstock properties, creating a new class of bitumen bases that differ chemically from conventional direct distillation residues, thereby expanding the available resource base.
2Manufacturing precision
If bitumen blowing (partial oxidation) is used to modify residue properties, then bitumen quality is improved, but production cost increases significantly
Solution Approach 1:
The patent converts the previously harmful high sulfur content and impurities of vacuum residues into beneficial characteristics. By selecting residues from ebullated bed hydroconversion, the sulfur and impurities have already been reduced during the hydroconversion process, transforming what would normally be undesirable properties into acceptable or even advantageous features for bitumen production.
Solution Approach 2:
The hydroconversion process itself performs the modification function that would otherwise require separate bitumen blowing operations. The hydroconversion treatment pre-modifies the residues, eliminating the need for additional expensive oxidation treatments, thereby making the system self-sufficient and reducing external processing requirements.
3Quantity of substance
If visbreaking residues are used as bitumen base, then production cost is reduced, but thermal oxidation stability of the resulting bitumen is mediocre
Solution Approach 1:
The patent changes the chemical parameters of the residue by using hydroconverted feedstock instead of simple visbreaking treatment. The hydroconversion process fundamentally alters the molecular structure and chemical composition, creating residues with superior thermal oxidation stability compared to conventional visbreaking residues, while maintaining cost-effectiveness.
4Object-affected harmful factors
If strict sulfur emission standards are implemented, then environmental compliance is improved, but demand for high sulfur bunker fuels decreases
Solution Approach 1:
The patent makes the hydroconversion residues multi-functional. Instead of being limited to a single use as bunker fuel, these residues are now suitable for multiple applications including bitumen production, road construction, and other paving applications. This diversification of use creates new demand channels independent of the bunker fuel market.
Solution Approach 2:
The patent changes the application parameters by transitioning from fuel use to construction material use. The residues are applied in completely different service conditions (road surfacing rather than combustion), where sulfur emission standards do not apply, thereby opening new markets for the same material.
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 enables the production of bitumens with enhanced thermal oxidation stability and quality, maximizing the value of previously difficult-to-enhance residues, while adhering to stringent environmental standards and reducing dependency on conventional bitumen sources.
Implementation Method 1
a process for the ebullated bed hydroconversion of a heavy liquid hydrocarbon feedstock
Implementation Method 2
an asphalt resulting from the solvent deasphalting of the vacuum residue
Data Source
AI summary
Between 40% and 75% by weight of a first bitumen base B1 an asphalt obtained by a solvent deasphalting of a first vacuum residue R1 resulting from the distillation of an effluent hydroconverted by a process for the ebullated bed hydroconversion of a heavy hydrocarbon feedstock, andBetween 25% and 60% by weight of a second bitumen base B2 and/or of a flux F, F at least one heavy aromatic cut with a hydrogen content of greater than 8.5% by weight, B2, R1 or a second vacuum residue R2 resulting from a distillation of a crude oil or a mixture of R1 and R2.