Low mass loss asphalts from heavy crude oils

Abstract

Systems and methods are provided for forming soft asphalt compositions with improved properties that are derived from distillation of a crude oil (or mixture of crude oils) having an API gravity of 24° or less. In order to form a target asphalt composition from a feedstock having an API gravity of 24° or less, a distillation is performed where at least two fractions are generated that have a T10 distillation point of 430° C. or more. A first fraction can correspond to a distillate fraction having a T10 distillation 2021em165-usoint of 430° C. or more. A second fraction can correspond to a bottoms fraction. Disproportionate blending can then be used to combine a portion of the first fraction with a portion of the second fraction. By using disproportionate blending of a distillate fraction and a bottoms fraction, an asphalt product fraction can be formed that has both a flash point of 270° C. or more and a KV100 between roughly 700 cSt and 1200 cSt.

1 - 17 . (canceled) 
     
     
         18 . A method for forming an asphalt fraction, comprising: separating a plurality of fractions having a T10 distillation point of 430° C. or higher from a feedstock having an API gravity of 24.0° or less, the plurality of fractions comprising at least a distillate fraction and a bottoms fraction having a first kinematic viscosity at 100° C., the plurality of fractions comprising a first weight ratio of the distillate fraction to the bottoms fraction; and blending at least a portion of the distillate fraction with at least a portion of the bottoms fraction to form a product asphalt fraction having a product kinematic viscosity at 100° C. that is lower than the first kinematic viscosity at 100° C., a weight ratio of the at least a portion of the distillate fraction to the at least a portion of the bottoms fraction being higher than the first weight ratio. 
     
     
         19 . The method of  claim 18 , wherein the product asphalt fraction comprises a product kinematic viscosity at 100° C. of 700 cSt to 1200 cSt, or wherein the product asphalt fraction comprises a kinematic viscosity at 135° C. of 135 cSt to 165 cSt, or a combination thereof. 
     
     
         20 . The method of  claim 18 , wherein the product kinematic viscosity at 100° C. is lower than the first kinematic viscosity at 100° C. by 500 cSt or more, or wherein the bottoms fraction comprises a first kinematic viscosity of 5000 cSt or higher, or a combination thereof. 
     
     
         21 . The method of  claim 18 , wherein the product asphalt fraction comprises a flash point of 270° C. or higher, a mass loss during a rolling thin film oven test of 1.0 wt % or less, or a combination thereof. 
     
     
         22 . The method of  claim 18 , wherein the product asphalt fraction comprises a flash point of 302° C. or higher. 
     
     
         23 . The method of  claim 18 , wherein the product asphalt fraction comprises 10 wt % to 90 wt % of a combined weight of the distillate fraction and the bottoms fraction. 
     
     
         24 . The method of  claim 18 , wherein the feedstock comprises an API gravity of 19.0° or less. 
     
     
         25 . The method of  claim 18 , wherein the distillate fraction comprises a T90 distillation point of 550° C. or less. 
     
     
         26 . The method of  claim 18 , wherein the product asphalt fraction comprises a performance grade of 40-XX to 52-XX, or wherein the product asphalt fraction comprises a performance grade of 46-XX. 
     
     
         27 . The method of  claim 18 , wherein the product asphalt fraction comprises a penetration at 25° C. of 300 dmm to 750 dmm, a softening point of 20° C. to 40° C., or a combination thereof. 
     
     
         28 . The method of  claim 18 , wherein the bottoms fraction comprises a performance grade of PG70 or higher. 
     
     
         29 . The method of  claim 18 , wherein the product asphalt fraction comprises substantially all of the distillate fraction. 
     
     
         30 . The method of  claim 18 , further comprising separating the bottoms fraction to form the at least a portion of the bottoms fraction and a remaining portion of the bottoms fraction, the remaining portion of the bottoms fraction comprising 40 wt % or more of a weight of the bottoms fraction. 
     
     
         31 . The method of  claim 30 , further comprising blending at least a portion of the remaining portion of the bottoms fraction with a second bottoms fraction formed by distillation of a second feedstock. 
     
     
         32 . The method of  claim 18 , wherein the product asphalt fraction comprises a flash point of 280° C. or higher, a mass loss during a rolling thin film oven test of 0.5 wt % or less, or a combination thereof. 
     
     
         33 . The method of  claim 18 , wherein the bottoms fraction comprises a performance grade of PG76 or higher.