Composite Feedstock Density Tuning for Carbochlorination
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Solution Overview
Problem
The existing carbochlorination processes face a challenge with feedstocks like petroleum coke being in high demand and unsuitable alternatives, such as bio char and char coal, due to their low particle and poured bulk densities, leading to increased costs and limited availability of suitable carbonaceous materials.
Innovation Solution
A feedstock composite comprising a metal oxide fraction and a carbonaceous fraction with tailored densities, using a binder composition of lignosulfonate, carboxymethylcellulose, and water glass, is developed to agglomerate and enhance the suitability of materials like bio char and pyrolyzed coke for carbochlorination processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If alternative carbonaceous materials like bio char and char coal are used, then production costs are reduced, but the poured bulk density and particle density are too low for suitable carbochlorination processes
Solution Approach 1:
The invention creates a composite feedstock by combining alternative carbonaceous materials (bio char, char coal) with metal oxide particles and binders. This composite structure allows the use of low-cost carbonaceous materials while achieving the required bulk density through the combined properties of all components, resolving the contradiction between cost reduction and density requirements
Solution Approach 2:
The invention changes the bulk density parameter of the carbonaceous feedstock by incorporating metal oxide fractions and binders into the composite structure. This parameter modification enables alternative materials with inherently low density to meet the minimum bulk density requirements for carbochlorination processes while maintaining cost advantages
2Reliability
If petroleum coke is used as carbonaceous feedstock, then the physical properties are suitable for carbochlorination processes, but the demand increases continuously leading to higher prices
Solution Approach 1:
The invention replaces expensive petroleum coke with cheaper alternative carbonaceous materials (bio char, char coal, pyrolyzed coke) in a composite formulation. These alternative materials are inherently less expensive but are made suitable for use through the composite structure that provides the necessary physical properties, thereby reducing feedstock costs while maintaining process reliability
Solution Approach 2:
By formulating a composite feedstock containing alternative carbonaceous materials combined with metal oxides and binders, the invention achieves the required physical properties without relying on expensive petroleum coke, thus resolving the contradiction between reliability and cost
3Productivity
If fine petroleum coke with small particle size is used, then the carbochlorination reaction efficiency is maintained, but the material is discharged from the reactor and becomes unsuitable for further reactions
Solution Approach 1:
The invention modifies the particle size parameters of the carbonaceous feedstock by using larger particles from alternative materials (bio char, char coal) in the composite structure. This parameter change prevents fine particle discharge while maintaining sufficient reaction surface area through the composite formulation, thereby resolving the contradiction between reaction efficiency and material retention
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
Enables the use of less expensive and previously unsuitable carbonaceous materials, such as bio char and pyrolyzed coke, in carbochlorination processes, reducing dependency on petroleum coke and lowering production costs.
Implementation Method 1
a binder composition comprising lignosulfonate, carboxymethylcellulose, and water glass
Data Source
AI summary
The invention relates to a feedstock composite comprising a metal oxide fraction and a carbonaceous fraction, a binder composition and the use thereof for obtaining the feedstock composite. Further, the invention refers to a method for obtaining the feedstock composite.