Flash Chemical Ionizing Pyrolysis for Hydrocarbon Conversion
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Solution Overview
Problem
Current petroleum and hydrocarbon refining processes face challenges in achieving high yields of lighter, higher-value hydrocarbon products while minimizing resid and coke production, and require extensive solids handling and equipment, as well as hydrogen addition and feedstock pretreatment.
Innovation Solution
The process employs a flash chemical ionizing pyrolysis (FCIP) method using an emulsion of an iron source material and an alkali or alkaline earth metal chloride source material without a mineral support, which is introduced into a reactor at elevated temperatures and pressures to produce a liquid ionizing pyrolyzate (LIP) with reduced sulfide content and improved oil quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mineral support is used in the chemical ionizing additive, then the pyrolysis process can proceed, but excessive solids are introduced into the reactor system requiring solids removal equipment
Solution Approach 1:
The invention extracts and eliminates the mineral support component from the chemical ionizing additive system. By using only iron source material and alkali/alkaline earth metal chloride source material without mineral support, the process achieves effective pyrolysis conversion while avoiding the introduction of excessive solids that would require complex solids removal equipment.
Solution Approach 2:
The invention replaces the durable but problematic mineral support with inexpensive, water-soluble iron and chloride source materials that dissolve or decompose during the pyrolysis process, leaving minimal solid residue. This approach uses cheap, short-living additive components that fulfill their catalytic function and then dissolve away, eliminating the need for solids handling infrastructure.
2Productivity
If conventional refining processes are used, then hydrocarbon processing can occur, but extensive solids handling and equipment are required
Solution Approach 1:
The invention extracts and removes the mineral support component from the chemical ionizing additive system. By using only iron source material and alkali/alkaline earth metal chloride source material without mineral support, the process achieves effective pyrolysis conversion while avoiding the introduction of excessive solids that would require complex solids removal equipment.
Solution Approach 2:
The invention employs an emulsion system where water and oil components are mixed with the iron and chloride source materials to form a pumpable feedstock. This hydraulic approach allows the additives to be introduced in liquid form, dissolving or dispersing uniformly throughout the feed, thereby eliminating the need for solid handling equipment while maintaining effective additive distribution.
3Productivity
If conventional refining processes are used, then hydrocarbon processing can occur, but hydrogen addition is required
Solution Approach 1:
The invention enables the pyrolysis process to proceed without external hydrogen addition by utilizing the chemical reactions inherent in the thermal decomposition of hydrocarbons. The iron and chloride source materials facilitate cracking and reforming reactions that generate hydrocarbon products directly from the feedstock, making the process self-sufficient regarding hydrogen needs.
4Productivity
If conventional refining processes are used, then hydrocarbon processing can occur, but feedstock pretreatment is required
Solution Approach 1:
The invention changes the physical state and chemical form of the additives by dissolving iron and chloride source materials in water to create an emulsion that can be directly mixed with crude oil feedstock. This parameter change allows the additives to be introduced in a form that is compatible with crude oil without requiring extensive pretreatment such as dewatering or desalting, as the emulsion system tolerates the presence of water and other feedstock impurities.
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 higher conversion rates to liquid oil, reduced coke formation, and improved oil quality with lower density and viscosity, eliminating the need for excessive solids handling and hydrogen addition, and enhancing isomerates production.
Implementation Method 1
flash chemical ionizing pyrolysis (FCIP) reactor maintained at a temperature greater than about 400° C. up to about 600° C.
Implementation Method 2
chemical ionizing pyrolysis of a hydrocarbon using a chemical ionizing additive comprising a mineral support and an oxide and/or acid addition salt of a Group 3-16 metal
Data Source
AI summary
Flash chemical ionizing pyrolysis (FCIP) process. The FCIP includes mixing an iron source material, an alkali or alkaline earth metal chloride source material, an aqueous phase, and an oil component to form a feed emulsion; introducing the feed emulsion into an FCIP reactor at a temperature greater than about 400° C. up to about 600° C., a pressure from 10 to 50 psia and a residence time of 0.1 to 10 seconds, to form an FCIP effluent; and condensing a liquid ionizing pyrolyzate (LIP) from the effluent. The feed emulsion can be free of added solids other than the iron source material, the alkali or alkaline earth metal chloride source material, and any sediment in the oil component.