System and method for reducing mutagen levels contained within a volume of petroleum aromatic extracts. The petroleum aromatic extracts are mixed with at least one solvent. This produces a mixture. Once mixed, some of the petroleum aromatic extracts dissolve. Others settle in the mixture. The petroleum aromatic extracts that have settled on the mixture are removed from the mixture and are ready for use. The mixture is heated to evaporate the solvent from the mixture. The evaporated solvent can be recaptured and reused. The residuum of the mixture contains petroleum aromatic extracts that can be partially recovered using traditional hydroprocessing techniques.

We disclose a process for purification of hydrocarbons, suitable for a wide range of contexts such as refining bunker fuels to yield low-sulphur fuels, cleaning of waste engine oil (etc) to yield a usable hydrocarbon product, recovery of hydrocarbons from used tyres, recovery of hydrocarbons from thermoplastics etc, as well as the treatment of crude oils, shale oils, and the tailings remaining after fractionation and like processes. The method comprises the steps of heating the hydrocarbon thereby to release a gas phase, contacting the gas with an aqueous persulphate electrolyte within a reaction chamber, and condensing the gas to a liquid or a liquid/gas mixture and removing its aqueous component. It also comprises subjecting the reaction product to an electrical field generated by at least two opposing electrode plates between which the reaction product flows; this electrolytic step regenerates the persulphate electrolyte which can be recirculated within the process. The process is ideally applied in an environment at lower than atmospheric pressure, such as less than 1500 Pa. A wide range of hydrocarbons can be treated in this way. Used hydrocarbons such as engine oils and sulphur-contaminated fuels are prime examples, but there are a wide range of others such as hydrocarbons derived from the pyrolysis of a material having a hydrocarbon content. One such example is a mix of used rubber (such as end-of-life tyres) and used oils (such as engine oils, waste marine oils), which can be pyrolysed together to yield a hydrocarbon liquid which can be treated as above, and a residue that provides a useful solid fuel.

Embodiments of the disclosure produce a method and system for deasphalting a hydrocarbon feed. The hydrocarbon feed and a first solvent is combined using a Taylor-Couette mixer to form a mixed stream. The mixed stream and a second solvent are introduced to an extractor to produce a first deasphalted oil stream and a pitch stream. The first deasphalted oil stream is introduced to a solvent recovery unit to recover the first solvent and the second solvent via a recovered solvent stream and to produce a second deasphalted oil stream.

Embodiments of the disclosure produce a method and system for deasphalting a hydrocarbon feed. The hydrocarbon feed and a first solvent is combined using a Taylor-Couette mixer to form a mixed stream. The mixed stream and a second solvent are introduced to an extractor to produce a first deasphalted oil stream and a pitch stream. The first deasphalted oil stream is introduced to a solvent recovery unit to recover the first solvent and the second solvent via a recovered solvent stream and to produce a second deasphalted oil stream.

A process for upgrading heavy oil is provided, which integrates thermal cracking, hydrogenolysis, and catalytic aquathermolysis. A catalytic hydrogen-aquathermolysis reactor receives a heavy oil feed, water and hydrogen. In addition catalytic materials and a viscosity reducing agent are introduced. The catalytic hydrogen-aquathermolysis reactor is operated at conditions effective to produce an upgraded heavy oil product.

A process for upgrading heavy oil is provided, which integrates thermal cracking, hydrogenolysis, and catalytic aquathermolysis. A catalytic hydrogen-aquathermolysis reactor receives a heavy oil feed, water and hydrogen. In addition catalytic materials and a viscosity reducing agent are introduced. The catalytic hydrogen-aquathermolysis reactor is operated at conditions effective to produce an upgraded heavy oil product.

There is a process for the selective recovery of transition metals from an organic stream containing transition metals. The organic stream and possibly a first extractor if solid, are melted up to the liquid state. The extractor consists of an ionic liquid or a mixture of two or more ionic liquids and the ionic liquid contains an ammonium salt as cation and as anion an anion with chelating properties. A melted organic stream and a first extractor, optionally melted, are fed to a first liquid-liquid extraction unit working at a temperature of at least 150° C. where the liquid-liquid extraction is carried out obtaining a liquid mixture containing an ionic liquid, or a mixture of two or more ionic liquids, and metals. After extraction, the liquid mixture is cooled at a temperature between 0° C. and 70° C. and becomes biphasic; then the cooled mixture is sent to a first separation unit, to separate a liquid phase that contains ionic liquids and metals, and a metal-depleted solid phase. After the first separation, the separated metal-depleted solid phase is optionally sent to a washing unit to which a solvent is fed, so as to eliminate the residual ionic liquid by transferring it into the solvent and obtaining a metal-depleted solid phase. Then the separate liquid phase containing ionic liquids and metals is sent into a liquid-liquid precipitation and separation unit, adding a counter-solvent, thereby obtaining a solid phase containing the metals and a liquid stream containing counter-solvent and ionic liquids.

Process and apparatus for two-stage solvent extraction of hydrocarbon products is disclosed. The process comprises passing a heavy hydrocarbon feed stream and a first fresh solvent to a first extraction column to generate a first overhead stream and a first bottom stream. The first overhead stream is passed to a first stripping column to generate a first product stream and a first stripped solvent stream. The first bottom stream is passed to a second extraction column to generate a second overhead stream and a second bottom stream. A second fresh solvent stream is passed to a second extraction column. The second overhead stream is passed to a second stripping column to generate a second product stream and a second stripped solvent stream. Passing the first stripped solvent stream and the second stripped solvent stream to a solvent recovery column and passing the second bottom stream to a pitch stripper.

Process and apparatus for two-stage solvent extraction of hydrocarbon products is disclosed. The process comprises passing a heavy hydrocarbon feed stream and a first fresh solvent to a first extraction column to generate a first overhead stream and a first bottom stream. The first overhead stream is passed to a first stripping column to generate a first product stream and a first stripped solvent stream. The first bottom stream is passed to a second extraction column to generate a second overhead stream and a second bottom stream. A second fresh solvent stream is passed to a second extraction column. The second overhead stream is passed to a second stripping column to generate a second product stream and a second stripped solvent stream. Passing the first stripped solvent stream and the second stripped solvent stream to a solvent recovery column and passing the second bottom stream to a pitch stripper.

A process for removing metals in a petroleum oil material. The process comprises causing the petroleum oil material to react with a removing agent which comprises a phosphoric acid ester. A microwave irradiation environment was created during the reaction to provide the required energy essential for separating such contaminations from the oil chemical network. The process of the invention is applied at ambient pressure and low temperature compared to the conventional metal removal processes. The process of the invention can be readily scaled up and integrated into an industrial facility.