HDC Pitch Pelletization Using Polymer Additives
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Solution Overview
Problem
Slurry HDC pitch is challenging to handle due to its high metals content and high Conradson carbon residue, leading to storage, shipping, and stability issues, and requires further processing to achieve a suitable softening point for pelletization without altering the slurry HDC process or impacting product slate.
Innovation Solution
A small amount of polymer additive, such as polyethylenes, polypropylenes, or polycarbonates, is mixed with the HDC pitch to increase its softening point, allowing for the production of solid pellets with a softening point of at least 65°C (150°F) to 93°C (200°F), enhancing transportation capabilities without affecting the slurry HDC process or product slate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the softening point of HDC pitch is increased by deep cuts and high initial boiling points, then the softening point is improved, but the slurry HDC process conditions must be altered which adversely impacts the product slate
Solution Approach 1:
A polymer additive is introduced as an intermediary substance that modifies the softening point of HDC pitch without requiring changes to the slurry HDC process conditions. The polymer additive acts as a mediator between the pitch molecules, increasing intermolecular forces and thereby raising the softening point while leaving the original hydroconversion process intact and the product slate unchanged.
Solution Approach 2:
The softening point parameter of HDC pitch is modified by adding a polymer additive with specific molecular characteristics. This changes the physical-chemical parameters of the pitch system through compositional modification rather than process parameter changes, allowing the softening point to be increased to at least 65°C (150°F) or 93°C (200°F) without affecting the slurry HDC operation.
2Ease of manufacture
If liquid pitch is fluxed to be sold or used as fuel oil, then the pitch can be utilized, but it cannot be fluxed economically with a reasonable amount of flux and may contain solids preventing fluxing
Solution Approach 1:
The invention transforms the pitch from a difficult-to-handle liquid requiring expensive fluxing into a free-flowing solid pellet that requires no fluxing. The polymer additive enables the pitch to be pelletized directly, eliminating the need for economic fluxing operations and associated costs.
3Ease of operation
If pitch is pelletized without sufficient softening point, then transportation is enabled, but agglomeration occurs when pellets are subjected to load stresses
Solution Approach 1:
The softening point parameter is increased through polymer additive incorporation, ensuring that the pellets maintain structural integrity at transportation temperatures. The modified thermal properties prevent agglomeration under load stresses while enabling free-flowing characteristics during transport.
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
The method effectively increases the softening point of HDC pitch pellets, ensuring they remain free-flowing during transport and offering a higher heating value than petcoke or coal, making them a suitable alternative for fuel, while maintaining the integrity of the slurry HDC process and product slate.
Implementation Method 1
a small amount of a polymer additive to increase the softening point of the slurry HDC pitch
Implementation Method 2
mixing the stream of HDC pitch with the stream of polymer additive to produce a mixture of HDC pitch and polymer additive
Implementation Method 3
pelletizing the mixture of HDC pitch and polymer additive to produce pellets having a softening point of at least 65°C (150°F)
Data Source
Figure 1
AI summary
A system and method for producing solid pellets from a slurry HDC pitch is disclosed which utilizes a polymer additive that is mixed with the pitch to increase the softening point of the solid pellets.