Liquid Phase Additive for Delayed Coking Coke Reduction
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Solution Overview
Problem
Existing methods for thermal cracking of petroleum residue by delayed coking fail to effectively reduce coke yield and increase liquid and/or gaseous product yield, particularly at normal coking temperatures, due to limitations in additive effectiveness and residence time.
Innovation Solution
A liquid phase additive composition comprising alkyl nitrates, petroleum sulphonates, aliphatic, aromatic, cyclohexylamines, hindered phenol-based compounds, phosphate esters, and aliphatic alcohols is used in the thermal cracking process, mixed with petroleum residue before heating, to enhance product yield and reduce coke formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing additives are used in delayed coking at normal temperatures (480-500°C), then the process operates under standard conditions, but the additives fail to effectively reduce coke yield and increase liquid product yield
Solution Approach 1:
The patent modifies the chemical composition parameters of the additive system by incorporating specific metal overbases (Ca, Mg, Sr, Al, Zn, Si, Ba) in optimized concentrations. This changes the chemical reactivity parameters of the system, enabling effective coke reduction and liquid yield enhancement at normal coking temperatures where conventional additives fail.
Solution Approach 2:
The invention uses a composite additive system combining multiple metal overbases rather than single-metal additives. This composite approach creates synergistic effects among different metal compounds, improving the overall effectiveness of reducing coke yield and increasing liquid product yield in the delayed coking process.
2Productivity
If residence time in the coke drum is increased to allow coking reactions to complete, then conversion is improved, but additive effectiveness decreases
Solution Approach 1:
The additive is introduced into the system before the coking reactions begin in the coke drum. By performing the additive injection and initial mixing actions beforehand, the additive is positioned to act on the feedstock at the optimal moment, maintaining its effectiveness throughout the extended residence time required for complete coking conversion.
Solution Approach 2:
The patent employs a formulation approach where the additive system is designed to function effectively throughout the entire residence time period. The additive composition is optimized to provide sufficient activity duration, effectively 'sacrificing' the additive's stability to ensure it remains active throughout the extended residence time required for complete conversion.
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 additive composition significantly reduces coke yield by up to 20.45 wt% and increases liquid and gaseous product yields, while maintaining furnace stability and ash content, even at higher residence times.
Implementation Method 1
process for thermal cracking of petroleum residue by delayed coking
Implementation Method 2
heating the reactor at a temperature ranging from 450 to 600 °C
Data Source
AI summary
The present invention relates to a liquid phase additive comprising an alkyl nitrate; a petroleum sulphonates; an aliphatic, aromatic, cyclohexylamines or hetroalkylated lower amines; a hindered phenol based compounds; a phosphate esters and an aliphatic alcohols for use in delayed coking process with decreased coke yield and increased yield of liquid and/or gaseous product and a process for preparing the liquid phase additive. The present invention also relates to a process for thermal cracking of petroleum residue producing petroleum coke and lighter hydrocarbon products by using liquid phase additive.