Sintering Aid Composition from Hydrocracking Residue
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Solution Overview
Problem
Existing sintering aid compositions for manufacturing carbonaceous articles in the metallurgical industry lack control over mechanical impurities and volatile components, leading to unsatisfactory mechanical strength and environmental concerns due to the release of carcinogenic substances.
Innovation Solution
A sintering aid composition made from a concentrated residue from slurry-phase hydrocracking of heavy oil feedstock, characterized by a specific range of aromatic hydrocarbons, weight loss profiles, and controlled mechanical impurities, which enhances the mechanical strength and reduces environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional coal pitch is used as a sintering aid, then the charge can be bound together, but carcinogenic substances are released causing environmental harm
Solution Approach 1:
The invention changes the chemical composition parameters of the sintering aid by using petroleum-derived residues with controlled properties (aromatic content 15-30%, sulfur content 0.5-5%, ash content 0.1-2.5%) instead of traditional coal pitch, thereby maintaining binding capability while eliminating carcinogenic substance release
Solution Approach 2:
The invention uses readily available petroleum residues (atrasburg, bitumen, deasphalted oil) as substitutes for coal pitch, providing a cost-effective and environmentally friendly alternative that can be easily sourced and processed
2Quantity of substance
If heavy residues are processed to manufacture useful products, then valuable products are obtained, but a large number of unclaimed products are generated that must be utilized
Solution Approach 1:
The invention makes the sintering aid composition universally applicable by using petroleum residues that can serve multiple purposes: as binders for carbonaceous articles, as utilization vehicles for heavy residue processing by-products, and as environmentally friendly alternatives to coal pitch in metallurgical applications
Solution Approach 2:
The invention converts the previously problematic heavy residues and unclaimed processing products into beneficial sintering aid composition, transforming waste materials into valuable binders for manufacturing high-strength carbonaceous articles
3Strength
If bituminous residue with high swelling and Roga index is used as sintering aid, then binding strength is improved, but control over mechanical impurities and volatile components is lost resulting in unsatisfactory mechanical strength
Solution Approach 1:
The invention optimizes the parameter range of the sintering aid composition by specifying precise limits: aromatic content 15-30%, sulfur content 0.5-5%, ash content 0.1-2.5%, mechanical impurities 0.1-5%, and volatile components 30-70%, thereby achieving both adequate binding strength and controlled mechanical properties
Solution Approach 2:
The invention implements quality control feedback by monitoring and adjusting the composition parameters of the sintering aid, ensuring that mechanical impurities and volatile components remain within specified ranges to guarantee consistent mechanical strength of the produced carbonaceous articles
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 proposed sintering aid composition enables the production of high-strength carbonaceous articles with reduced environmental impact by efficiently utilizing residual products from hydrocracking, thereby addressing the limitations of traditional coal pitches.
Implementation Method 1
the weight loss in the temperature range from 290 to 570° C. is about 95 wt. % of the total weight loss
Data Source
AI summary
The present invention relates to petrochemistry, specifically to a sintering aid composition for manufacturing carbonaceous articles for the metallurgical industry. The sintering aid composition for manufacturing carbonaceous articles consists of a concentrated residue from slurry-phase hydrocracking of heavy oil feedstock, has a content of aromatic hydrocarbons in the range from 23 to 27 wt. %, wherein the sintering aid composition is characterised by a total weight loss from 50 wt. % to 51 wt. % in the temperature range from 30 to 850° C., wherein the weight loss in the temperature range from 290 to 570° C. is about 95 wt. % of the total weight loss. Performance characteristics of the sintering aid are improved to manufacture high-strength carbonaceous articles for the metallurgical industry.