Petroleum coke treatment apparatus, process, and treatment system

Patent metadata

Field	Value
Publication number	US-2024059568-A1
Application number	US-202218260362-A
Country	US
Kind code	A1
Filing date	Jan 10, 2022
Priority date	Jan 11, 2021
Publication date	Feb 22, 2024
Grant date	—

Abstract

An apparatus, a process and a system for treating petroleum coke are provided. The apparatus includes an activation unit that is an annular furnace reactor. The system includes a first reactor, the apparatus as a second reactor, a washing and separating unit, a cooling unit, a dissolving and separating unit, a washing and drying unit, optionally a regenerating unit, optionally a drying and calcining unit and optionally an evaporation-crystallization unit. The process for producing carbon materials uses the system for treating petroleum coke. The apparatus, the process and the system can achieve continuous production, and have advantages of high activation efficiency and stable properties of the resultant carbon material products.

First claim

1 . An annular furnace reactor, comprising:
a housing, which forms a sealed annular space divided into an inlet/outlet zone, a high-temperature zone and a cooling zone, wherein the high-temperature zone comprises a heating section and a constant temperature section; a rotary table, which is located inside the housing and arranged along the annular space thereof, wherein the rotary table rotates relative to the housing, so that the rotary table receives a feed material which is a mixture of petroleum coke and an activator in the inlet/outlet zone, carries the mixed feed material of petroleum coke and the activator into the high-temperature zone and the cooling zone in sequence, and then discharges in the inlet/outlet zone; and baffles, which are located inside the housing and fixed thereon, and are spaced arranged above the rotary table, wherein the baffles comprise a plurality of guiding holes.

2 . The annular furnace reactor of claim 1 , wherein the heating section is operated by fuel gas or electric thermal radiation heating, and the heating section is heated for a time of 30-300 minutes, preferably 60-180 minutes; and
the constant temperature section is operated by using microwave heating, at a constant temperature of 700-1000° C., preferably 800-950° C. for a time of 10-120 minutes, preferably 20-60 minutes.

3 . The annular furnace reactor of claim 1 , further comprising:
one or more carrier gas inlets located in the inlet/outlet zone, preferably, three carrier gas inlets located at the starting point, middle point and ending point of the inlet/outlet zone, respectively; and a gas outlet located in the high-temperature zone, preferably in the constant temperature section of the high-temperature zone.

4 . The annular furnace reactor of claim 1 , wherein the baffles are arranged perpendicular to the surface of the rotary table, the plurality of guiding holes are arranged at the upper one-third to half of the baffles, the guiding holes are formed at an opening rate of 20% to 30%, and the inlet side of the guiding holes has a hole diameter greater than that of the outlet side;
preferably, the guiding holes are in a circular cone shape.

5 . The annular furnace reactor of claim 1 , wherein the inlet/outlet zone comprises a discharge system, which is fixed inside the housing and comprises:
a spiral discharge device, which outputs a discharge material horizontally from its top; a conveyor belt, which is inclined, with one end located at the top of the spiral discharge device, to deliver the discharge material to the top of the spiral discharge device; and a lifting surface, which is inclined to pick up the discharge material on the rotary table to the other end of the conveyor belt.

6 . The annular furnace reactor of claim 5 , wherein
the lifting surface comprises: a primary lifting surface, which picks up particles of the materials with a particle size distribution greater than D10 to the conveyor belt, and a secondary lifting surface, which picks up particles of the materials with a particle size distribution lower than D10 to the conveyor belt; preferably, the lowest end of the primary lifting surface is in a non-contact state with the surface of the rotary table, and is made of rigid materials and in a serrated shape, and the lowest end of the secondary lifting surface is in contact with the surface of the rotary table and is made of flexible materials.

7 . An apparatus for treating petroleum coke, comprising the annular furnace reactor of claim 1 as an activation unit.

8 . A process for treating petroleum coke, comprising the steps of:
(1) adding a feed of petroleum coke and an activator into a first reactor and subjecting to a first treatment under anon-reactive atmosphere, to obtain a first gas phase material and a first solid phase material; (2) adding the first solid phase material and the first gas phase material obtained in step (1) into a second reactor and subjecting to a second heat treatment, to obtain a second gas phase material and a second solid phase material; (3) subjecting the second solid phase material obtained in step (2) to cooling, mixing with water and liquid-solid separation, to obtain a first liquid phase material and a third solid phase material, wherein the third solid phase material is subjected to further washing and drying to obtain a porous carbon material; optionally, (4) contacting and reacting the first liquid phase material obtained in step (3) with a precipitant, wherein the reaction effluent is subjected to liquid-solid separation to obtain a second liquid phase material and a fourth solid phase material, and wherein the fourth solid phase material is dried, calcined and then recycled as the precipitant; and optionally, (5) subjecting the second liquid phase material obtained in step (4) to evaporation-crystallization to obtain a third gas phase material and a fifth solid phase material, wherein the fifth solid phase material is reused as the activator.

9 . The process for treating petroleum coke of claim 8 , further comprising the step of:
subjecting the feed of petroleum coke to drying and pulverizing in advance, wherein the dried feed of petroleum coke has a water content of not more than 2 wt %, preferably not more than 1 wt %, and the pulverized feed of petroleum coke has a particle size of not greater than 200 μm, preferably not greater than 150 μm.

10 . The process for treating petroleum coke of claim 8 , wherein the first treatment in step (1) is operated at a temperature of 200-500° C., preferably 350-450° C., and
the activator and the feed of petroleum coke in step (1) are in a mass ratio of 0.5:1-8:1, preferably 1:1-5:1.

11 . The process for treating petroleum coke of claim 8 , wherein the activator in step (1) is an alkali metal compound which is one or more selected from the group consisting of potassium hydroxide, sodium hydroxide, potassium carbonate and sodium carbonate; preferably is a mixture of one or two of potassium hydroxide and sodium hydroxide with one or two of potassium carbonate and sodium carbonate; more preferably is a mixture of potassium hydroxide and potassium carbonate; and most preferably is a mixture of potassium hydroxide and potassium carbonate, wherein potassium carbonate is in a content of 1-30 wt %, preferably 5-20 wt %.

12 . The process for treating petroleum coke of claim 8 , wherein the second reactor is the annular furnace reactor that comprises:
a housing, which forms a sealed annular space divided into an inlet/outlet zone, a high-temperature zone and a cooling zone, wherein the high-temperature zone comprises a heating section and a constant temperature section; a rotary table, which is located inside the housing and arranged along the annular space thereof, wherein the rotary table rotates relative to the housing, so that the rotary table receives a feed material which is a mixture of petroleum coke and an activator in the inlet/outlet zone, carries the mixed feed material of petroleum coke and the activator into the high-temperature zone and the cooling zone in sequence, and then discharges in the inlet/outlet zone; and baffles, which are located inside the housing and fixed thereon, and are spaced arranged above the rotary table, wherein the baffles comprise a plurality of guiding holes.

13 . A system for treating petroleum coke, comprising:
a first reactor for receiving and treating a feed of petroleum coke and an activator, to obtain a first gas phase material and a first solid phase material; a second reactor for receiving and treating the first gas phase material and the first solid phase material, to obtain a second gas phase

Assignees

• China Petroleum & Chem Corp
• Sinopec Dalian Res Inst Petroleum & Petrochemicals Co Ltd

Inventors

• Zhang Shudong
• Zhang Changan
• Song Yongyi
• Liu Jihua
• Fang Xiangchen
• Ma Rui
• Cai Haile
• Zhao Liping
• Liao Changjian
• Meng Fanfei
• Wang Haibo
• Zhang Qingjun
• Wang Chao

Classifications

• B01J19/126

  Microwaves · CPC title

• B01J8/10

  moved by stirrers or by rotary drums or rotary receptacles {or endless belts} · CPC title

• B01J6/008

  Pyrolysis reactions (of hydrocarbons C10G9/00) · CPC title

• B01J6/002

  using rotating drums · CPC title

• C01B32/39 Primary

  Apparatus for the preparation thereof · CPC title