Fluidized Coking Used Oil Co-Processing
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Solution Overview
Problem
Recycling used lubricants to produce new base stocks is challenging due to the presence of undesirable components like chemical additives and metals, which require dedicated and costly processing systems, and future regulations may mandate increased recycling of used oils, necessitating more efficient methods.
Innovation Solution
The method involves co-processing used lubricant oil with a coker feedstock in a fluidized bed coking system, where the used lubricant oil is converted under fluidized coking conditions to deposit metals onto coke particles, which are then removed, and the coker gas oil is hydroprocessed to produce a lubricant base oil with reduced nitrogen content and improved viscosity index.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If dedicated solvent extraction or hydrotreating facilities are used for used oil re-refining, then metal and additive removal is effective, but system complexity and capital cost increase significantly
Solution Approach 1:
The patent combines used oil processing with conventional coker operations by integrating the used oil feed into the existing coker feedstream. This merging allows the coker to handle both traditional heavy feedstocks and used oil containing metals and additives, eliminating the need for separate dedicated processing facilities while maintaining effective contaminant removal through the coking process
Solution Approach 2:
The coker system is made multi-functional by enabling it to process both conventional heavy feedstocks and used lubricant oils. The same coker unit that normally processes heavy gas oils or resids can now also process used oil feeds, providing a universal solution that handles multiple feed types and contaminant removal functions through a single piece of equipment
2Object-affected harmful factors
If purpose-built used oil processing systems are implemented, then contaminant removal capability is enhanced, but integration with conventional refinery operations becomes difficult
Solution Approach 1:
The used oil processing operation is merged with conventional coker operations by feeding used oil into the existing coker feedstream. This integration allows the same equipment to handle both traditional feedstocks and used oil, enabling seamless operation within conventional refinery infrastructure without requiring separate dedicated facilities
3Adaptability or versatility
If conventional coking processes are used for used oil processing, then operational flexibility is maintained, but metal removal efficiency is insufficient
Solution Approach 1:
The coking process effectively extracts and concentrates metals and additives from the used oil feed into the coke solid phase. By taking out these contaminants into the coke that is subsequently removed from the system, the process achieves efficient metal removal while maintaining the operational flexibility of conventional coking operations
Solution Approach 2:
The harmful metals and additives present in used oil are converted into a beneficial form by incorporating them into the coke structure. The coke acts as a vehicle to concentrate and remove these contaminants, transforming the problem of metal removal into a benefit where the coke serves as an effective carrier for contaminant elimination
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 allows for the integration of used lubricant oil processing with conventional refineries, reduces the need for separate metal disposal, and increases the yield of lubricant base stocks with improved viscosity index and reduced processing severity, while being scalable and flexible with varying feedstock availability.
Implementation Method 1
converting a used lubricant oil feed to a coker gas oil product and a coke product under coking conditions
Implementation Method 2
metals present in the used lubricant oil are deposited on the coke particles
Implementation Method 3
The coker gas oil can then be hydroprocessed to form a lubricant base oil
Data Source
AI summary
Systems and methods are provided for co-processing of used lubricant oils with a coker feedstock in a fluidized coking process to form lubricant base stocks. The fluidized coking process can remove contaminants and/or additives from used lubricant oils with modest conversion of the lubricant boiling range portion.