Renewable Needle Coke Production via Catalytic Cracking and Coking
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Solution Overview
Problem
The production of needle coke from conventional petroleum resources faces challenges in replacing fossil fuels with renewable sources due to stringent performance criteria, making it difficult to replicate the properties of needle coke using renewable resources.
Innovation Solution
A method involving processing renewable feedstocks in the presence of a cracking catalyst under fluidized catalytic cracking conditions to obtain heavy cycle oil, followed by delayed coking and calcination to produce needle coke, which reduces fossil carbon content and maintains or improves the material's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional petroleum resources are used to produce needle coke, then the material achieves high crystallinity and structured properties, but the process relies on fossil fuels and cannot meet renewable energy goals
Solution Approach 1:
The patent changes the fundamental parameter of feedstock origin from fossil petroleum to renewable resources (vegetable oils, animal fats, algae). By processing these renewable feedstocks through catalytic cracking to produce heavy cycle oil, which is then coked and calcined, the method achieves needle coke with properties comparable to conventional petroleum-based needle coke, thus resolving the contradiction between maintaining performance criteria and achieving renewability
Solution Approach 2:
The patent creates a copy of the conventional needle coke production process but substitutes the feedstock source. The same catalytic cracking, coking, and calcination steps are used to process renewable feedstocks instead of petroleum, producing a copy of needle coke that meets the same performance criteria while being renewable in origin
2Object-affected harmful factors
If renewable feedstocks are used to replace fossil fuels, then carbon footprint is reduced, but the ability to replicate needle coke properties becomes difficult
Solution Approach 1:
The patent systematically changes the feedstock parameter from fossil-based to renewable-based sources. By optimizing the catalytic cracking conditions and processing parameters for renewable feedstocks, the method produces heavy cycle oil with suitable properties that can be converted into needle coke with high crystallinity and structured characteristics, thereby reducing carbon footprint while maintaining manufacturing precision of the final product properties
Solution Approach 2:
The patent introduces heavy cycle oil as an intermediary product between the renewable feedstock and the final needle coke. This intermediary stage allows for the transformation and refinement of the renewable feedstock into a form that can produce needle coke with desired properties, serving as a bridge that enables both renewability and product quality
3Reliability
If stringent performance criteria for needle coke are maintained, then product quality is ensured, but replacement of fossil fuels with renewable sources becomes challenging
Solution Approach 1:
The patent changes the feedstock parameter to renewable sources and adjusts the processing parameters accordingly. By optimizing catalytic cracking conditions, coking temperatures, and calcination parameters for renewable feedstocks, the method maintains compliance with stringent performance criteria while making the replacement process feasible and efficient
Solution Approach 2:
The patent maintains continuous useful action through a streamlined process where renewable feedstocks are continuously processed through catalytic cracking, coking, and calcination stages. This continuous processing ensures consistent production of high-quality needle coke that meets performance criteria while being manufactured from renewable sources, thereby ensuring both reliability and ease of manufacture
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 method effectively produces renewable needle coke with properties comparable or improved to those from conventional petroleum sources, addressing the challenge of replacing fossil fuels while reducing carbon footprint.
Implementation Method 1
processing a feed comprising one or more renewable feedstocks in the presence of a cracking catalyst to obtain a heavy cycle oil
Implementation Method 2
delayed coking the heavy cycle oil under coking conditions to obtain an intermediate coke product
Implementation Method 3
calcining the intermediate coke product to obtain needle coke
Data Source
AI summary
A method for making needle coke includes processing a feed comprising one or more renewable feedstocks in the presence of a cracking catalyst under fluidized catalytic cracking conditions to obtain a heavy cycle oil, delayed coking the heavy cycle oil under coking conditions to obtain an intermediate coke product, and calcining the intermediate coke product under calcinating conditions to obtain needle coke.