Needle Coke Production from Aromatic Polymer Mixtures
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Solution Overview
Problem
Conventional processes for producing needle-grade coke are hindered by the presence of contaminants like nitrogen and metals in typical feedstocks, making it difficult to achieve high-quality coke production.
Innovation Solution
The method involves converting aromatic polymer dissolved in aromatic bottoms from an aromatic recovery complex through delayed coking, followed by fractionation and calcination to produce needle-grade coke, utilizing a homogenous catalyst and potentially hydrodearylation to reduce contaminant levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional feedstocks like vacuum residues are used for delayed coking, then the process can convert fossil fuel residues into coke, but the high nitrogen and metal content prevents production of high-quality needle-grade coke
Solution Approach 1:
The patent extracts and removes harmful contaminants (nitrogen and metals) from the feedstock before coking. This is achieved by using aromatic bottoms from an aromatic recovery complex that has already been processed to remove these contaminants, thereby enabling production of high-quality needle-grade coke
Solution Approach 2:
The patent changes the chemical composition parameters of the feedstock by using aromatic polymer material dissolved in aromatic bottoms instead of conventional vacuum residues. This parameter change results in a feedstock with lower nitrogen and metal content, suitable for producing high-quality coke
2Manufacturing precision
If aromatic polymer material is dissolved in aromatic bottoms, then a suitable feedstock for needle-grade coke production is obtained, but the process complexity increases with mixing and fractionation steps
Solution Approach 1:
The aromatic bottoms serve multiple functions: they act as a solvent for the aromatic polymer material, a transport medium in the coking process, and a source of valuable aromatic products after fractionation. This multi-functionality reduces the need for separate processing steps
Solution Approach 2:
The patent recovers valuable aromatic products from the aromatic bottoms through fractionation, transforming a waste stream into a valuable resource. This recovery process justifies the added complexity by producing high-value outputs
3Productivity
If delayed coking is performed on aromatic polymer mixture, then needle-grade coke and volatile components are produced, but additional fractionation and calcination steps are required
Solution Approach 1:
The patent implements continuous delayed coking where the aromatic polymer mixture is continuously converted to coke and volatile components over an extended period. This continuous process allows for steady production of high-quality coke while managing the complexity through systematic processing
4Productivity
If homogenous catalyst is used in delayed coking, then the coking process efficiency is improved, but the catalyst selection and process control become more complex
Solution Approach 1:
The patent optimizes catalyst parameters by selecting specific homogenous catalysts (such as those based on groups 4-7 metals) and controlling their concentration, temperature, and pressure conditions. This parameter optimization improves coking efficiency while managing complexity through standardized catalyst selection criteria
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 a lower contaminant concentration in the coke, enabling the production of high-quality needle-grade coke and valuable aromatic products, while also providing an economical use of low-value hydrocarbon streams and alternative waste polymer disposal methods.
Implementation Method 1
delayed coking the aromatic polymer mixture to obtain petroleum green coke and volatile components
Implementation Method 2
converting an aromatic polymer material and an aromatic bottoms to needle-grade coke... delayed coking the aromatic polymer mixture
Implementation Method 3
fractionating the volatile components to obtain distillate products
Implementation Method 4
calcining the petroleum green coke to obtain needle coke
Implementation Method 5
mixing the aromatic polymer material with the aromatic bottoms to obtain an aromatic polymer mixture
Data Source
AI summary
Methods and systems for converting an aromatic polymer material and aromatic bottoms to needle-grade coke. An embodiment of a method includes supplying aromatic bottoms from an aromatic recovery complex; mixing the aromatic polymer material with the aromatic bottoms to obtain an aromatic polymer mixture comprising the aromatic polymer material and the aromatic bottoms; delayed coking the aromatic polymer mixture to obtain petroleum green coke and volatile components; fractionating the volatile components to obtain distillate products; and calcining the petroleum green coke to obtain needle coke.