Dissimilar Hydrocarbon Feedstock Mixing via Static and High Shear Stages
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Solution Overview
Problem
The challenge lies in forming stable liquid mixtures from dissimilar hydrocarbon feedstock materials, which often differ in chemical composition, polarity, solubility, and physical state, making them difficult to process using conventional conversion and refining equipment.
Innovation Solution
The method involves mixing dissimilar hydrocarbon feedstock materials using static inline mixers to form an intermediate blend, which is then further mixed with high shear mixers to create a well-mixed hydrocarbon feedstock blend. Additionally, an oil-soluble catalyst precursor can be dispersed into the blend to enhance downstream processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dissimilar hydrocarbon feedstock materials are mixed to form a blend, then the versatility and utilization of low quality heavy oil feedstocks is improved, but the stability and homogeneity of the mixture deteriorates due to differences in chemical composition, polarity, solubility, and physical state
Solution Approach 1:
The patent applies preliminary action by pre-treating dissimilar feedstock materials before mixing. Low quality heavy oil feedstocks undergo hydroprocessing or other preprocessing steps to modify their chemical composition and physical properties in advance, making them more compatible with other feedstocks. This preliminary modification ensures that when materials are blended, they form stable homogeneous mixtures suitable for subsequent processing, thus resolving the contradiction between versatility and stability.
Solution Approach 2:
The patent employs parameter changes by adjusting key physical and chemical parameters of feedstock materials to achieve compatibility. Temperature, pressure, and chemical composition parameters are modified during preprocessing to ensure that dissimilar feedstocks can be mixed stably. For example, heating feedstocks to specific temperatures or adjusting their molecular weight distribution enables stable blending of materials with initially incompatible properties, maintaining both versatility and composition stability.
2Device complexity
If conventional mixing methods are used for dissimilar feedstocks, then the process simplicity is maintained, but the mixing efficiency and homogeneity of the final blend deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the mixing process into multiple sequential stages. First, feedstocks are pre-mixed in separate preparation units to achieve partial homogeneity, then combined in a main mixing unit. This segmented approach allows each stage to optimize for specific requirements, achieving high overall homogeneity without requiring an overly complex single-step mixing system.
Solution Approach 2:
The patent uses an intermediary carrier fluid or solvent to facilitate mixing of dissimilar feedstocks. This intermediary substance acts as a medium that is compatible with multiple feedstock types, enabling them to mix uniformly. The carrier fluid temporarily holds the feedstock components in suspension or solution, ensuring homogeneous distribution before the final blend is formed, thus achieving high manufacturing precision with moderate process complexity.
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 results in hydrocarbon feedstock blends that are sufficiently stable and uniform, allowing them to be processed effectively using various conversion and refining equipment, thereby overcoming the difficulties associated with processing dissimilar feedstocks.
Implementation Method 1
mixing the first and second hydrocarbon feedstock materials by one or more static inline mixers to form an intermediate blend
Implementation Method 2
further mixing the intermediate blend by one or more high shear mixers to form the hydrocarbon feedstock blend
Implementation Method 3
an oil-soluble catalyst precursor can be dispersed into the blend to enhance downstream processing efficiency
Implementation Method 4
an oil-soluble catalyst precursor can be dispersed into the blend
Data Source
AI summary
Methods and systems for mixing dissimilar hydrocarbon feedstock materials to form hydrocarbon feedstock blends for subsequent processing. The dissimilar hydrocarbon feedstock materials can differ by chemical composition, polarity, solubility, and/or physical state and include one or more of biomass-derived materials, non-petroleum-derived oils or fats, polymers, fabrics or textiles, paper or cardboard, rubber, waste products, pyrolysis products of the foregoing, or petroleum-derived materials. Efficient and thorough mixing of the dissimilar hydrocarbon feedstock materials is performed by static inline mixing to form an intermediate blend, which is further mixed by high shear mixing to form the hydrocarbon feedstock blend. The methods and systems may involve other processing equipment e.g., strainers, filters, pumps, furnaces, heat exchangers, reactors, separators, tanks, and/or distillation columns. The hydrocarbon feedstock blend may be further processed by hydrocracking or hydroconversion e.g., by ebullated bed, fixed bed, or slurry bed reactor), solvent deasphalting, coking, fluid catalytic cracking, hydroprocessing, or hydrotreating.