Methods of Upgrading Asphaltene Compositions

Abstract

Methods for pyrolyzing asphaltene material includes providing a composition including from 50 to 90 wt % asphaltene material and from 50 to 10 wt % inert material, and pyrolyzing the composition. The presence of the inert material can help to ensure that the asphaltene material does not interfere with the pyrolyzing process and equipment. Method of forming asphaltene pellets can also be used in order to improve asphaltene pyrolysis.

1 . A method comprising:
 providing an asphaltene composition comprising from 50 wt % to 90 wt % asphaltene and from 10 wt % to 50 wt % inert material; and   pyrolyzing the asphaltene composition.   
     
     
         2 . The method as claimed in  claim 1 , wherein the asphaltene comprises asphaltene obtained from a tailings solvent recovery unit. 
     
     
         3 . The method as claimed in  claim 1 , wherein the asphaltene is obtained from the low value product of bituminous material solvent-based extraction processing. 
     
     
         4 . The method as claimed in  claim 1 , wherein the inert material comprises sand and clay. 
     
     
         5 . The method as claimed in  claim 1 , wherein pyrolyzing the asphaltene composition is carried out at a temperature from 350° C. and 525° C. 
     
     
         6 . The method as claimed in  claim 1 , wherein pyrolyzing the asphaltene composition is conducted for a period of time from 5 minutes to 4 hours. 
     
     
         7 . The method as claimed in  claim 1 , further comprising:
 producing pyrolysis products, wherein the pyrolysis products comprise off gas, light gas oil, and carbon black.   
     
     
         8 . The method as recited in  claim 7 , further comprising:
 burning the off gas in a boiler and producing steam;   producing superheated steam from the steam; and   treating the carbon black with the superheated steam and producing hydrogen and carbon dioxide.   
     
     
         9 . The method as claimed in  claim 8 , wherein hydrogen produced by the treating the carbon black with the superheated steam is used in pyrolyzing the asphaltene composition. 
     
     
         10 . The method as claimed in  claim 7 , further comprising mixing catalyst with the asphaltene composition prior to pyrolyzing the asphaltene composition. 
     
     
         11 . The method as claimed in  claim 10 , wherein the catalyst comprises iron, iron oxide, titanium dioxide, iron titanium oxide, calcium titanate, manganese compounds, or combinations thereof. 
     
     
         12 . The method as claimed in  claim 1 , further comprising mixing sulfur scavenger with the asphaltene composition prior to pyrolyzing the asphaltene composition. 
     
     
         13 . The method as claimed in  claim 12 , wherein the sulfur scavenger comprises limestone. 
     
     
         14 . The method as claimed in  claim 1 , wherein pyrolyzing the asphaltene composition takes place in a pyrolysis unit. 
     
     
         15 . The method as claimed in  claim 14 , wherein the pyrolysis unit comprises a rotary kiln, a rotary hearth unit, a fluidized bed unit, or a screw conveyor. 
     
     
         16 . A method comprising:
 providing an asphaltene composition comprising from 50 wt % to 90 wt % asphaltene and from 10 wt % to 50 wt % inert material;   forming asphaltene pellets from the asphaltene composition; and   pyrolyzing the asphaltene pellets.   
     
     
         17 . The method as claimed in  claim 16 , wherein the asphaltene comprises asphaltene obtained from a tailings solvent recovery unit. 
     
     
         18 . The method as claimed in  claim 16 , wherein the asphaltene is obtained from the low value product of bituminous material solvent-based extraction processing. 
     
     
         19 . The method as claimed in  claim 16 , wherein pyrolyzing the asphaltene pellets is carried out at a temperature from 350° C. and 525° C. 
     
     
         20 . The method as claimed in  claim 16 , wherein pyrolyzing the asphaltene pellets is conducted for a period of time from 5 minutes to 4 hours. 
     
     
         21 . The method as claimed in  claim 16 , further comprising the step of mixing catalyst with the asphaltene prior to forming the asphaltene pellets. 
     
     
         22 . The method as claimed in  claim 21 , wherein the catalyst is selected from the group consisting of iron, iron oxide, titanium dioxide, iron titanium oxide (ilmenite), calcium titanate (perovskite), and manganese compounds. 
     
     
         23 . The method as claimed in  claim 16 , wherein pyrolyzing asphaltene pellets takes place in a pyrolysis unit. 
     
     
         24 . The method as claimed in  claim 23 , wherein the pyrolysis unit comprises a rotary kiln, a rotary hearth unit, a fluidized bed unit, or a screw conveyor. 
     
     
         25 . A method of forming asphaltene pellets from asphaltenes, the method comprising:
 providing asphaltenes;   preparing a mixture comprising the asphaltenes and a first organic binding agent; and   extruding the mixture comprising the asphaltenes and the first organic binding agent.   
     
     
         26 . The method as recited in  claim 25 , wherein the first organic binding agent comprises a light aromatic compound. 
     
     
         27 . The method as recited in  claim 26 , wherein the light aromatic compound is selected from the group consisting of Aromatic 100, Aromatic 150, biodiesel, and combinations thereof. 
     
     
         28 . The method as recited in  claim 25 , wherein the ratio of organic binding agent to asphaltene material in the mixture ranges from 1:200 to 40:200 on a weight basis. 
     
     
         29 . The method as recited in  claim 25 , further comprising dividing the extruded mixture into individual pieces. 
     
     
         30 . The method as recited in  claim 25 , wherein the asphaltene is obtained from the low value product of bituminous material solvent-based extraction processing 
     
     
         31 . The method as recited in  claim 25 , wherein the mixture further comprises a sulfur scavenger. 
     
     
         32 . The method as recited in  claim 31 , wherein the sulfur scavenger comprises an alkali or earth alkali compound. 
     
     
         33 . The method as recited in  claim 31 , wherein the ratio of sulfur scavenger to asphaltene material in the mixture ranges from 5:100 to 30:100 on a weight basis. 
     
     
         34 . The method as recited in  claim 25 , wherein the mixture further comprises inert material. 
     
     
         35 . The method as recited in  claim 34 , wherein the ratio of inert material to asphaltenes in the mixture ranges from 5:1 to 1:2 on a weight basis. 
     
     
         36 . A method of forming asphaltene pellets from asphaltenes, the method comprising comprising:
 providing asphaltenes;   feeding the asphaltenes into a disc pelletizer;   rotating the disc pelletizer;   feeding a first organic binding agent into the disc pelletizer while the disc pelletizer rotates; and   removing asphaltene pellets from the disc pelletizer.   
     
     
         37 . The method as recited in  claim 36 , wherein the first organic binding agent comprises a light aromatic compound. 
     
     
         38 . The method as recited in  claim 37 , wherein the light aromatic compound is selected from the group consisting of Aromatic 100, Aromatic 150, biodiesel, and combinations thereof. 
     
     
         39 . The method as recited in  claim 36 , wherein the ratio of total amount of first organic binding agent added to the asphaltenes in the disc pelletizer ranges from 1:200 to 40:200 on a weight basis. 
     
     
         40 . The method as recited in  claim 36 , wherein the asphaltenes is obtained from the low value product of bituminous material solvent-based extraction, processing. 
     
     
         41 . A method of forming asphaltene pellets from asphaltenes, the method comprising:
 providing asphaltenes;   mixing the asphaltenes with a first organic binding agent to form a mixture;   feeding the mixture into a balling drum;   operating the balling drum; and   removing asphaltene pellets from the balling drum.   
     
     
         42 . The method as recited in  claim 41 , wherein the first organic binding agent comprises a light aromatic compound. 
     
     
         43 . The method as recited in  claim 42 , wherein the light aromatic compound is selected from the group consisting of Aromatic 100, Aromatic 150, biodiesel, and combinations thereof. 
     
     
         44 . The method as recited in  claim 41 , wherein the ratio of first organic binding agent to asphaltene material in the mixture ranges from 1:200 to 40:200 on a weight basis. 
     
     
         45 . The method as recited in  claim 41 , wherein the asphaltene material is obtained from the low value product of bituminous material solvent-based extraction processing.