Petroleum Process Oil Production via Fractional Distillation
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Solution Overview
Problem
Current methods for producing petroleum-based plasticizer oils fail to meet EU standards due to high levels of polycyclic aromatic hydrocarbons (PAHs), resulting in carcinogenic products that are either expensive or complex to produce.
Innovation Solution
A simplified process involving fractional distillation of by-product fractions from secondary petrochemical processes, specifically using feedstocks with initial boiling points above 200°C and containing at least 85% aromatic constituents, under reduced or atmospheric pressure, with a reflux ratio of no less than 0.1, to produce low-viscosity high aromatic petroleum-based process oils with less than 10 mg/kg of specific PAHs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If selective solvent extraction methods are used to produce high aromatic plasticizer oils, then the aromatic content can reach up to 96%, but the PAHs level significantly exceeds the standard (between 20 and 500 mg/kg)
Solution Approach 1:
The invention segments the extraction process into multiple stages with different solvents. First, aromatic constituents are extracted using a selective solvent, then the extract undergoes further treatment with additional solvents or processing steps to remove PAHs while preserving the aromatic content, achieving both high aromatic concentration and low PAHs levels
Solution Approach 2:
The invention introduces intermediary processing steps between extraction and final product formation. These intermediaries include additional purification stages, solvent combinations, or treatment processes that selectively remove PAHs from the aromatic extract without compromising the desired aromatic constituents
2Object-affected harmful factors
If targeted organic synthesis methods are used to produce plasticizer oils meeting PAHs standards, then the product is non-carcinogenic and meets requirements, but the production cost becomes nearly the same as polyurethane semi-finished product
Solution Approach 1:
The invention changes the parameters of the extraction process, including solvent selection, extraction conditions, and purification parameters, to achieve PAHs removal through physical-chemical separation rather than expensive organic synthesis. This approach maintains product safety while significantly reducing production costs by using readily available solvents and simpler processing
3Reliability
If multiple stages including vacuum distillation, selective solvent refining, low temperature dewaxing, and catalytic treatment are used to produce low pour point petroleum base oils, then the product quality is improved, but the process complexity increases
Solution Approach 1:
The invention merges multiple processing functions into a unified extraction and purification system. By combining aromatic extraction, PAHs removal, and purification steps into an integrated process using selective solvents and coordinated processing stages, the invention reduces the number of separate units and operations while maintaining product quality
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 achieves a product with over 90% aromatic constituents and PAH levels below 10 mg/kg, meeting EU standards and providing a cost-effective, non-carcinogenic petroleum-based process oil suitable for rubber and polyurethane applications.
Implementation Method 1
fractional distillation of by-product fractions from secondary petrochemical processes
Data Source
AI summary
A method for producing a low-viscosity high-aromatic non-carcinogenic petroleum-based process oil which can be used as a plasticizer oil or an extender oil in the manufacture of synthetic rubber and tyres is described. The oil is obtained from by-product fractions of secondary petrochemical processes by fractional distillation, wherein the used by-product fractions of secondary petrochemical processes are products of catalytic cracking, or products of catalytic reforming, or aromatic extracts, or mixtures thereof, which have an initial boiling point of no less than 200° C. and above and a final boiling point of no less than 360° C. at atmospheric pressure, and contain no less than 85% of aromatic constituents and no more than 10.0 mg/kg of the sum of the following polycyclic aromatic hydrocarbons: benz[a]anthracene; chrysene; benzo[b]fluoranthene; benzo[i]fluoranthene; benzo[k]fluoranthene; benzo[e]pyrene; benzo[a]pyrene; and dibenzo[a,h]anthracene.