Back to results
US 11,453,828 B2Granted
Combined process to produce both a pipelineable crude and carbon fiber from heavy hydrocarbon
OwnerTom Corscadden, Darius Remesat +1inventors
InventorsTom Corscadden, Darius Remesat, David Denton
Life of this patent
Estimating the term…
Abstract
An integrated process that is operated to create both a higher value pipelineable crude and a higher value carbon fiber product from a lower value common heavy hydrocarbon feedstock where the feedstock is processed in a thermal reactor followed by a solvent deasphalting unit with the liquids being gathered and processed to reduce olefins for pipeline transport and the solids are processed to generate a marketable carbon fiber product with any gases generated throughout the entire process reused in the process or sold.
Claims22
A process for treating a heavy hydrocarbon feedstock, comprising:
- thermally treating the hydrocarbon feedstock at a temperature ranging from 700° F. to 790° F. for a residence time ranging from 1 minute to 7 hours to produce a lighter hydrocarbon stream and a heavier hydrocarbon stream;
- solvent deasphalting the heavier hydrocarbon stream with a solvent to precipitate asphaltenes and form solid asphaltene precipitates and produce deasphalted oil;
- separating the deasphalted oil from the solid asphaltene precipitates to produce a solvent-diluted deasphalted oil stream comprising at least a portion of the solvent and a slurry stream comprising the asphaltene precipitates and residual solvent;
- separating the solvent-diluted deasphalted oil stream to produce a recovered solvent stream and a deasphalted oil stream;
- separating the slurry stream to produce a solid asphaltene particulate stream and a recovered solvent stream;
- and
- processing the solid asphaltene particulate stream to produce a carbon fiber precursor.
4 more elements
A system for treating a heavy hydrocarbon feedstock, comprising:
- a thermal reactor configured to receive the heavy hydrocarbon feedstock and operable at a temperature ranging from 700° F. to 790° F. for a residence time of between 1 min and 7 hours to produce a lighter hydrocarbon stream and a heavier hydrocarbon stream;
- a solvent deasphalting separator in fluid communication with the thermal reactor and configured to contact the heavier hydrocarbon stream with a solvent to precipitate asphaltenes and form solid asphaltene precipitates, the solvent deasphalting separator producing a solvent-diluted deasphalted oil stream comprising at least a portion of the solvent and a slurry stream comprising the asphaltene precipitates and residual solvent;
- an inertial separation unit in fluid communication with the solvent deasphalting separator, the inertial separation unit being configured to separate the slurry stream solids to produce a solid asphaltene particulate stream and a recovered solvent stream;
- and
- a processing unit in fluid communication with the inertial separation unit to process the solid asphaltene particulate stream and produce a carbon fiber precursor.
2 more elements
A process for producing a carbon fiber product, comprising:
- thermally treating a hydrocarbon feedstock at a temperature ranging from 700° F. to 790° F. for a residence time ranging from 1 minute to 7 hours to produce a lighter hydrocarbon stream and a heavier hydrocarbon stream;
- solvent deasphalting the heavier hydrocarbon stream with a solvent to precipitate asphaltenes and form solid asphaltene precipitates and produce deasphalted oil;
- separating the deasphalted oil from the solid asphaltene precipitates to produce a solvent-diluted deasphalted oil stream comprising at least a portion of the solvent and a slurry stream comprising the asphaltene precipitates and residual solvent;
- separating the slurry stream to produce a solid asphaltene particulate stream and a recovered solvent stream;
- extruding the solid asphaltene particulate stream to produce extruded asphaltenes;
- spinning the extruded asphaltenes into a continuous thread of asphaltene thread;
- stabilizing the asphaltene thread by heat treatment at 350° F. to 550° F. for up to 1 hour to produce a stabilized asphaltene thread;
- carbonizing the stabilized asphaltene thread by heat treatment at 1823° F. to 3632° F. for up to 1 hour to produce a carbonized carbon fiber;
- and
- conditioning the carbonized carbon fiber to produce the carbon fiber product.
7 more elements
Dependencies are inferred from the claim text.