SOLIDIFICATION TECHNIQUES FOR LOW SOFTENING POINT PETROLEUM PITCH

Abstract

This alternative fuel is a reclaimed waste product which has a solid, particulate consistency at ambient temperature. The fuel comprises a composite of petroleum pitch and a powder coating. The powder coating penetrates into the surface of the pitch. The powder coating is recycled ash, pulverized coal, or pulverized petroleum coke.

Claims

1. A reclaimed waste product which has a solid, particulate consistency at ambient temperature comprising a composite of petroleum pitch and a powder coating.

2. The product of claim 1 wherein the pitch is lower softening point petroleum pitch.

3. The product of claim 1 wherein the pitch is solvent deasphalted (SDA) petroleum pitch.

4. The product of claim 1 wherein the powder coating is pulverized coal.

5. The product of claim 1 wherein the powder coating is recycled coal ash.

6. The product of claim 1 wherein the powder coating penetrates the surface of the pitch.

7. The product of claim 1 wherein the product is fuel.

8. The product of claim 1 wherein the product is in the form of pastilles.

9. The product of claim 1 wherein the product is in the form of briquets.

10. A method for producing a reclaimed waste product which has a solid, particulate consistency at ambient temperature comprising the steps of: cooling petroleum pitch; coating the cooling pitch with a powder coating during the step of cooling; and allowing the powder coating to penetrate more deeply into the pitch during the step of cooling.

11. The method of claim 10 wherein the pitch is lower softening point petroleum pitch.

12. The method of claim 10 wherein the pitch is solvent deasphalted (SDA) petroleum pitch.

13. The method of claim 10 wherein the powder coating is pulverized coal.

14. The method of claim 10 wherein the powder coating is recycled coal ash.

15. The method of claim 10 wherein the powder coating penetrates the surface of the pitch.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0007] The following details various embodiments of the invention.

[0008] The invention will allow penetration into the coal fired power sector fuel market by providing a way to solidify solvent deasphalted (SDA) pitch and prevent clumping for improved performance. Recycled waste ash, pulverized coal, or petroleum coke is used as a penetrating dust coating. In a preferred embodiment, the powder coating is coal ash. As previously discussed, the powder coating penetrates the surface of the pitch. Preferably, the product is fuel in the form of a pastille. Alternative forms of the product can be briquets or flakes. The powder coating, when applied early within the cooling step of the pitch, will partially penetrate the surface of a pastille. Once fully solidified, the low melt point SDA pitch fuel will ship as a solid without significant dusting, melting or conglomerating within truck, rail, or barge equipment.

[0009] The product is used as a fungible coal additive within coal handling equipment such as hoppers, conveyers, and pulverizers. The invention will reduce ash generation within the coat fired power sector. For an equivalent heat demand, the use of recycled ash, sourced from the power plant itself with the pitch, will produce less total ash when using SDA pitch as a coal additive. The use of a penetrated ash coating will prevent gumming of the petroleum pitch during the pulverizing, preheat, and fuel eduction steps.

[0010] The invention will provide flame stabilization via early ignition when the SDA pitch is coated with pulverized coal. The use of penetrated coal powder will also prevent gumming of petroleum pitch during pulverizing, preheat, and fuel eduction steps. Additionally, the coal coating will provide increased surface area for the SDA pitch which will increase the ignition surface area for a higher Btu content solidified SDA pitch. The fuel will then burn earlier and hotter thus stabilizing the flame and provide more thorough combustion of the coal fuel balance. The use of a powder coating to solve dusting, melting, and conglomerating issues associated with logistics will avoid an alternate logistics solution which would require an increase to the SDA pitch softening point. This use of powder coating decreases the deasphalted oil (DOA) quality within the SDA Unit and avoids the financial penalties within downstream hydrotreating and FCC Units. DOA is the primary product generated in the SDA Unit and its physical properties are tightly controlled to avoid contaminants.

[0011] These embodiments enhance the ability to provide additional outlets for petroleum pitch via a new solidification process and will open opportunities for low CAPEX bottom of the barrel upgrading. With the new International Marine Organization rules, costs associated with low sulfur cutter stocks such as ULSD are expected to increase and high sulfur pitch/asphalt/VTBs prices are expected to decrease. Removing sulfur from SDA pitch is not economically feasible without installation of high CAPEX, traditional refining techniques such as delayed coking. A lower CAPEX, faster installation option for bottoms upgrading is provided with SDA/ROSE technologies. Providing an outlet market for pitch will enable smaller refineries which cannot hurdle the economies of scale associated with coker CAPEX providing an alternative option to produce high quality DAO feed for FCC/Hydrocracker units via low CAPEX SDA/ROSE installations.

[0012] The advantages of this invention are noted. Currently any issues associated with melting and conglomeration of petroleum pitch is handled by producing a higher softening point product. This in turn produces lower quality DAO. By using penetrated powder coating, the logistical issues are resolved, and low melt point SDA pitch can continue to be produced Without downgrading DAO quality. Also, by solidifying into 24 mm pastilles versus larger briquet type product, the fuel will have a shorter residence time within the power plant's pulverizers, thus reducing potential melt and conglomeration risk. The solidified pitch is also superior with a 35% higher Btu content, lower ash content, and lower mercury content when compared to coal Once the solidified fuel market is developed, bottom of the barrel upgrading options for low CAPEX SDA/ROSE installations will be very competitive versus delated coker applications.

[0013] The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not a limitative sense, the scope of the invention being defined solely by the appended claims.