Extruder systems and processes for production of petroleum coke and mesophase pitch

A system for production of consistently sized and shaped optically anisotropic mesophase pitch from vacuum residue, the system comprising:

• an extrusion system, the extrusion system comprising an extruder fluidly coupled to a processed vacuum residue inlet;
• heating elements disposed proximate the extrusion system and along a horizontal profile of the extruder from the processed vacuum residue inlet to an outlet of the extruder;
• a venting zone to remove hydrocarbon off-gases from the extruder along the horizontal profile of the extruder from the processed vacuum residue inlet to the outlet of the extruder;
• and
• a physical shaper disposed proximate the outlet of the extruder for shaping the consistently sized and shaped mesophase pitch at the outlet of the extruder for production of carbon fibers.