Production and use of a premium fuel grade petroleum coke

• US 20060032788A1
• Filed: 07/11/2005
• Published: 02/16/2006
• Est. Priority Date: 08/20/1999
• Status: Active Grant

• Current Assignee: Roger G. Etter
• Original Assignee: Roger G. Etter
• Inventors: Etter, Roger G.
• Granted Patent: US 9,475,992 B2
• Time in Patent Office: Days
• US Class Current: 208/131
• CPC Class Codes: C10B 55/00 Coking mineral oils, bitumen, tar, and the like or mixtures thereof with solid carbonaceous material cracking oils C10G
• CPC Class Codes: C10B 57/005 After-treatment of coke, e.g. calcination desulfurization
• CPC Class Codes: C10B 57/06 containing additives
• CPC Class Codes: C10G 9/005 Coking (in order to produce liquid products mainly)
• CPC Class Codes: C10L 5/00 Solid fuels produced by solidifying fluid fuels C10L7/00
• CPC Class Codes: C10L 9/00 Treating solid fuels to improve their combustion
• CPC Class Codes: C10L 9/02 by chemical means
• CPC Class Codes: C10L 9/04 by hydrogenating
• CPC Class Codes: C10L 9/10 by using additives

Abstract

A premium “fuel-grade” petroleum coke is produced by modifying petroleum coking technology. Coking process parameters are controlled to consistently produce petroleum coke within a predetermined range for volatile combustible material (VCM) content. The invention includes a process of producing a coke fuel, the method comprising steps: (a) obtaining a coke precursor material derived from crude oil and having a volatile organic component; and (b) subjecting the coke precursor material to a thermal cracking process for sufficient time and at sufficient temperature and under sufficient pressure so as to produce a coke product having volatile combustible materials (VCMs) present in an amount in the range of from about 13% to about 50% by weight. Most preferably, the volatile combustible materials in the coke product typically may be in the range of from about 15% to about 30% by weight. The present invention also provides methods for (1) altering the coke crystalline structure, (2) improving the quality of the coke VCM, and (3) reducing the concentration of coke contaminants. Fuels made from the inventive coke product and methods of producing energy through the combustion of such fuels are also included. Finally, novel environmental control techniques are developed to take optimal advantage of the unique characteristics of this upgraded petroleum coke.

Claims

1. A process of producing coke, said process comprising the steps:

(a) obtaining a coke precursor material derived from carbonaceous origin;

(b) subjecting said coke precursor material to a delayed coking process, said delayed coking process performed for sufficient time and at sufficient temperature and under sufficient pressure so as to promote the production of porous sponge coke; and

(c) adding at least one chemical compound of predetermined quality and predetermined quantity to said porous sponge coke in a coke quenching portion of said delayed coking process;

whereby said at least one chemical compound substantially improves the fuel properties, combustion characteristics, ash characteristics, or environmental impacts of said coke when used in a combustion process.

2. A process according to claim 1 wherein said coke precursor material is derived from crude oil, coal, shale oil, or tar sands.

3. A process according to claim 1 wherein said coke is comprised of said sponge coke in an amount in the range of from about 40 to 100% by weight.

4. A process according to claim 1 wherein volatile combustible materials (VCMs) are present in said sponge coke in an amount in the range of from about 13% to about 50% by weight.

5. A process according to claim 1 wherein said at least one chemical compound is selected from the group consisting of chemical adsorbents, sulfur sorbents, hydrocarbon compounds, oxygen-containing compounds, ionizing agents, and any combination thereof.

6. A process according to claim 5 wherein said sulfur sorbents are selected from the group consisting of hydrated lime, limestone, hydrated dolomitic lime, calcium compounds, magnesium compounds, sodium compounds, potassium compounds, alkali metal compounds, alkaline earth compounds, and any combination thereof.

7. A process according to claim 1 wherein said coke precursor material is subjected to an efficient desalting process prior to step (b) and sodium levels are reduced to less than about 15 ppm by weight.

8. A coke made in accordance with a process according to claim 1.

9. A process of making coke, said process comprising:

(a) providing a coke feed comprising a material derived from carbonaceous origin;

(b) subjecting said coke feed to a delayed coking process, said delayed coking process incorporating a process means to promote the production of coke having increased porosity and improved adsorption characteristics; and

(c) adding at least one chemical compound of predetermined quality and predetermined quantity to said coke in a coke quenching portion of said delayed coking process wherein the increased porosity and improved adsorption characteristics aid in the addition of said at least one chemical compound.

10. A process according to claim 9 wherein said material derived from carbonaceous origin is derived from the group consisting of crude oil, coal, tar sands, and shale oil.

11. A process according to claim 9 wherein said coke is comprised of sponge coke in an amount in the range of from about 40 to 100% by weight.

12. A process according to claim 9 wherein volatile combustible materials (VCMs) are present in said coke in an amount in the range of from about 13% to about 50% by weight.

13. A process according to claim 9 wherein said process means is selected from the group consisting of increasing thermal process quench in a coking vessel, lowering heater outlet temperature, increasing coking vessel pressure, adding at least one additive to said coke feed, and any combination thereof.

14. A process according to claim 9 wherein said process means changes the crystalline structure of said coke.

15. A process according to claim 9 wherein said coke has sufficient porosity and sufficient physical and chemical properties to provide low to medium grades of adsorption quality carbon.

16. A process according to claim 9 wherein said coke has a surface area of about 600 square meters per gram or greater.

17. A process according to claim 9 wherein said at least one chemical compound is selected from the group consisting of chemical adsorbents, sulfur sorbents, hydrocarbon compounds, oxygen-containing compounds, ionizing agents, and any combination thereof.

18. A process according to claim 17 wherein said sulfur sorbents are selected from the group consisting of hydrated lime, limestone, hydrated dolomitic lime, calcium compounds, magnesium compounds, sodium compounds, potassium compounds, alkali metal compounds, alkaline earth compounds, and any combination thereof.

19. A process according to claim 17 wherein adding at least one predetermined hydrocarbon compound to a coke quench media promotes an increase of the VCM content of said coke to within the range of from about 13% to about 50% by weight.

20. A coke made in accordance with a process according to claim 9.