DESC:TECHNICAL FIELD
[0001] The present disclosure relates to a method for obtaining a bituminous material that affords efficient recovery and/or recycling of distillates in an economical manner.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Bitumen, also known as asphalt, is a substance produced through distillation of crude oil. It finds wide varieties of applications and is particularly known for its waterproofing and adhesive properties. Bitumen is primarily obtained by vacuum distillation of crude oil or blends of crude oil. Bitumen includes a non-distillable fraction of crude oil, technically referred to as vacuum residue. Bitumen production processes separates the lighter, low boiling point fractions from the crude oil resulting in a product with high boiling point, high molecular weight with very low volatility.
[0004] A variety of grades of bitumen are produced either directly by refining or by blending and the same may further be subjected to further processing to alter the physical properties in order meet the specifications. Grades VG 10 bitumen and VG 30 bitumen are most widely used bituminous materials. Existing facilities (refineries) and processes produces bituminous materials by blending appropriate amounts of vacuum residue (VR) with slop material(s) and then the resultant bituminous material is blown in a bitumen blowing unit (BBU) to meet the desired specifications. However, there is a scope for improvement in the existing processes to make them economical at the industrially scale.
[0005] The present invention satisfies the existing needs, as well as others, and generally overcomes the deficiencies found in the state-of-art. Particularly, the present disclosure provides an economical process for production of bituminous material at an industrial scale.
[0006] All publications referred to hereinabove are incorporated in their entirety by way of reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

OBJECTS
[0007] It is an object of the present disclosure to provide a method for obtaining bituminous material that overcomes one or more disadvantages of the processes known in the art.
[0008] Another object of the present disclosure is to provide a method for obtaining bituminous material that is economical and industrially viable.
[0009] Another object of the present disclosure is to provide a method for obtaining bituminous material that precludes the requirement of input of additional energy.
[0010] Another object of the present disclosure is to provide a method for obtaining bituminous material that aids in reducing over flash requirement.
[0011] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the exemplary embodiments of the invention.

SUMMARY
[0012] The present disclosure relates to a method for obtaining a bituminous material that affords efficient recovery and/or recycling of distillates in an economical manner.
[0013] An aspect of the present disclosure relates to a method for obtaining a bituminous material, the method comprising: (a) routing a catalytic cracking residue stream into a vacuum distillation unit (VDU) for recovering a combined stream comprising a vacuum residue (VR) and a heavier aromatic rich fraction, wherein the combined stream comprises the heavier aromatic rich fraction and the vacuum residue (VR) in a weight ratio ranging from 1:4 to 1:50; and (b) blending the combined stream with a slop material in an amount ranging from 5-25 wt.% to obtain the bituminous material. The method of the present disclosure is particularly suitable for implementation in a refinery setting that employs at least one crude distillation unit (CDU) or atmospheric distillation unit, at least one vacuum distillation unit (VDU) and at least one catalytic cracking unit (CCU) such as fluid catalytic cracking unit (FCCU).
[0014] In an embodiment, the catalytic cracking residue stream is a Fluid Catalytic Cracking Unit (FCCU) residue stream (CLO) having a boiling point ranging from 340°C to 600°C. In an embodiment, the catalytic cracking residue stream is a Fluid Catalytic Cracking Unit (FCCU) residue stream (CLO) having a kinematic viscosity ranging from 10 to 50 cSt when measured at 50°C.
[0015] In an embodiment, the vacuum residue (VR) has a kinematic viscosity ranges from 103 to 109 cSt when measured at 50°C and from 102 to 105 cSt when measured at 100°C. In an embodiment, the vacuum residue (VR) has a penetration in the range 10-25 dmm when measured at 25°C.
[0016] In an embodiment, the slop material has an absolute viscosity ranging from 50-90 Poise when measured at 60°C.
[0017] In an embodiment, the catalytic cracking residue stream is fed to the vacuum distillation unit either at a feed stage or at a stage above the feed stage.
[0018] In an embodiment, the bituminous material is any of: VG10 bitumen, VG20 bitumen, VG30 bitumen and VG40 bitumen.
[0019] In an embodiment, the method further includes a step of blowing the bituminous material in a bitumen blowing unit (BBU) to afford any of: VG10 bitumen, VG20 bitumen, VG30 bitumen and VG40 bitumen.
[0020] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0022] FIG. 1 illustrates an exemplary implementation of the process of the present disclosure in a refinery.
[0023] FIG. 2 illustrates an exemplary schematic showing the feed stage, a stage above the feed stage and input of CLO stream in vacuum distillation unit in accordance with an embodiment of the present disclosure.
[0024] FIG. 3 illustrates an exemplary graph showing profile for LVGO, HVGO and VR with varying CLO quantity in accordance with an embodiment of the present disclosure.
[0025] FIG. 4 illustrates a graph depicting optimum stage for entry of CLO stream in vacuum distillation unit in accordance with an embodiment of the present disclosure.
[0026] FIG. 5 illustrates a graph depicting comparison of distillation profiles (D1160) of products LVGO, HVGO and VR obtained from conventional process and that obtained in accordance with embodiments of the present disclosure.
[0027] FIG. 6A-6C illustrate graphs depicting properties of the bituminous materials obtained in accordance with embodiments of the present disclosure in comparison to standard residue feedstocks and bitumen blowing unit (BBU) feedstock.

DETAILED DESCRIPTION
[0028] The following is a detailed description of embodiments of the present invention. The embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
[0029] The present disclosure relates to a method for obtaining a bituminous material that affords efficient recovery and/or recycling of distillates in an economical manner.
[0030] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0031] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability.
[0032] Unless the context requires otherwise, throughout the specification which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.”
[0033] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0034] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0035] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable.
[0036] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein.
[0037] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0038] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0039] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0040] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0041] The term “catalytic cracking residue stream”, “clarified oil” and “CLO” as has been used herein throughout the present disclosure denotes a complex combination of hydrocarbons produced as the decanted part of settled residual fraction from distillation of the products from a catalytic cracking process. It includes hydrocarbons having carbon numbers predominantly greater than C20 and boiling point ranging from 340°C to 600°C. Particularly suitable in the invention of the present disclosure is a clarified oil (CLO) having kinematic viscosity ranging from 10 to 50 cSt at 50°C and boiling point ranging from 340°C to 600°C.
[0042] The term “vacuum residue” or “VR” as has been used interchangeably and synonymously herein throughout the present disclosure denotes left over fraction of the crude oil, which is obtained at the bottom of Vacuum Distillation Column (VDU), also known as short residue (SR) having initial boiling point more than 500°C. VR is typically used as the starting material for bitumen production. VR generally possess high viscosity, low Penetration and high softening point. The vacuum residue (VR) particularly suitable for the purposes of the invention of present disclosure has Penetration in the range from 10 to 25 dmm when measured at 25°C, has a softening point in the range from about 35 to about 55 °C, and has a kinematic viscosity ranging from 103 to 109 cSt at 50oC and from 102 to 105 cSt at 100oC.
[0043] The term “slop material” as used herein throughout the present disclosure refers to the intermediate material obtained between Vacuum Gas oil (VGO) and Vacuum residue (VR) from vacuum distillation column (VDU). Such material does not match the requisite properties of any of VGO and VR. It is generally used as recycle stream for balancing column heat and for blending purpose in VR for production of straight run bitumen. The slop material particularly suitable for the purposes of the invention of present disclosure has absolute viscosity ranging from 50-90 Poise when measured at 60°C and a flash point greater than about 230°C.
[0044] The term “VG 10 bitumen” used herein stands for viscosity grade 10 i.e. the softest grade of bitumen as per IS 73:2013 specifications. It has absolute viscosity ranging from 800-1200 poise at 60°C and Penetration value ranging from 80-100 dmm at 25°C. VG-10 is mostly used in spraying applications such as surface dressing and Paving in very cold climate. It is also used to produce Bitumen Emulsion and Modified Bitumen products.
[0045] The term “VG 20 bitumen” used herein stands for viscosity grade 20 i.e. relatively harder than VG 10 grade of bitumen as per IS 73:2013 specifications. It has absolute viscosity in range from 1600-2400 poise at 600C and has min penetration value of 60 dmm at 250C. VG-20 is mostly used in paving applications in low traffic areas.
[0046] The term “VG 30 bitumen” used herein stands for viscosity grade 30 i.e. medium to hard grade of bitumen as per IS 73:2013 specification. It has absolute viscosity ranging from 2400-3600 poise at 60°C and Penetration value range from 45-70 dmm when measured at 25°C. VG-30 is especially used to construct roads having moderate traffic loads. It is also used to produce Modified Bitumen products.
[0047] The term “VG 40 bitumen” used herein stands for viscosity grade 40 i.e. medium to hard grade of bitumen as per IS 73:2013 specification. It has absolute viscosity in range from 3200-4800 poise at 600C and has min penetration value range of 35 dmm at 250C. VG-40 is used to construct roads having high traffic loads in cities.
[0048] An aspect of the present disclosure relates to a method for obtaining a bituminous material, the method comprising: (a) routing a catalytic cracking residue stream into a vacuum distillation unit (VDU) for recovering a combined stream comprising a vacuum residue (VR) and a heavier aromatic rich fraction, wherein the combined stream comprises the heavier aromatic rich fraction and the vacuum residue (VR) in a weight ratio ranging from 1:4 to 1:50; and (b) blending the combined stream with a slop material in an amount ranging from 5-15 wt.% to obtain the bituminous material. The method of the present disclosure is particularly suitable for implementation in a refinery setting that employs at least one crude distillation unit (CDU) or atmospheric distillation unit, at least one vacuum distillation unit (VDU) and at least one catalytic cracking unit (CCU) such as fluid catalytic cracking unit (FCCU).
[0049] In an embodiment, the combined stream comprises the heavier aromatic rich fraction in an amount ranging from 2-20 wt.% and the vacuum residue (VR) in an amount ranging from 80-98 wt.%. In an embodiment, the catalytic cracking residue stream is a Fluid Catalytic Cracking Unit (FCCU) residue stream (CLO) having a boiling point ranging from 340°C to 600°C. In an embodiment, the catalytic cracking residue stream is a Fluid Catalytic Cracking Unit (FCCU) residue stream (CLO) having a kinematic viscosity ranging from 10 to 50 cSt when measured at 50°C.
[0050] In an embodiment, the vacuum residue (VR) has a kinematic viscosity ranges from 103 to 109 cSt when measured at 50°C and from 102 to 105 cSt when measured at 100°C. In an embodiment, the vacuum residue (VR) has a penetration in the range 10-25 dmm when measured at 25°C.
[0051] In an embodiment, the slop material has an absolute viscosity ranging from 50-90 Poise when measured at 60°C.
[0052] In an embodiment, the catalytic cracking residue stream is fed to the vacuum distillation unit either at a feed stage or at a stage above the feed stage.
[0053] In an embodiment, the bituminous material is any of: VG10 bitumen, VG20 bitumen, VG30 bitumen and VG40 bitumen.
[0054] In an embodiment, the method further includes a step of blowing the bituminous material in a bitumen blowing unit (BBU) to afford any of: VG10 bitumen, VG20 bitumen, VG30 bitumen and VG40 bitumen.
[0055] FIG. 1 illustrates an exemplary implementation of the process of the present disclosure in a refinery. As can be seen from FIG. 1, the refinery includes a crude distillation unit (CDU), a vacuum distillation unit (VDU) and one or more catalytic cracking units such as a fluid catalytic cracking unit (FCCU).
[0056] In normal operation, the crude is fed to the crude distillation unit (CDU) or atmospheric distillation unit to recover distillates therefrom and the remainder of the residues (LR or bottoms) obtained therefrom are fed to the vacuum distillation unit (VDU). In vacuum distillation unit (VDU), vacuum distillates are recovered and are sent to the catalytic cracking unit, such as to fluidised bed catalytic cracking units (FCCU). The left over fraction of the crude oil, which is obtained at the bottom of Vacuum Distillation Column (VDU), also known as short residue (SR) or vacuum residue (VR), typically has an initial boiling point of more than 500°C. Apart from VR, intermediate materials are also obtained from vacuum distillation column (VDU), properties whereof neither matches with any of Vacuum Gas oil (VGO) and Vacuum residue (VR), which are typically known as slop material. The slop material is generally used as recycle stream for balancing column heat and for blending purpose in VR for production of straight run bitumen. In the catalytic cracking units high octane gasoline and the like products are recovered from the vacuum distillates. A complex combination of hydrocarbons is also produced as the decanted part of settled residual fraction from distillation of the products from a catalytic cracking process, which is known as catalytic cracking residue stream (such as clarified oil or CLO). The residue stream includes hydrocarbons having carbon numbers predominantly greater than C20 (>C-20) with boiling point ranging from 340°C to 600°C. The operation of distillation of crudes of different varieties, including the apparatus/columns, working of and process parameters of crude distillation unit (CDU), vacuum distillation unit (VDU) and catalytic cracking unit (CCU/FCCU), is well known in the state of art and hence, details thereof is omitted from the instant disclosure.
[0057] It could be noted that clarified oil (CLO) obtained from FCCU/CCU bottoms (i.e. the catalytic cracking residue stream) has good amount of distillates (<565 boiling point), which typically is being used as a cutter stock for evacuation of FO/LSHS. To recover the distillates from CLO, in accordance with an embodiment of the present disclosure, at least a part of the CLO stream is fed to the vacuum distillation unit (VDU) (shown as CLO-R in FIG. 1) to recover distillates therefrom and for obtaining a heavier aromatic rich fraction therefrom.
[0058] The inventors of the present disclosure, during a series of experiments, also noted that when the catalytic cracking residue stream is fed to the vacuum distillation unit at a stage above the feed stage, requirement of input of additional energy (such as additional furnace duty) can be precluded affording a significant energy saving, and consequently a huge economic advantage. Accordingly, in an embodiment, the CLO stream (i.e. the catalytic cracking residue stream) is fed to the vacuum distillation unit at a stage above the feed stage. In an exemplary implementation, the CLO stream is fed to the vacuum distillation unit at the 9th stage (as shown in FIG. 2). In another embodiment, the CLO stream is fed to the vacuum distillation unit at a feed stage. The feed stage may be the 10th stage, as illustrated in FIG. 2.
[0059] In an embodiment, the catalytic cracking residue stream is a Fluid Catalytic Cracking Unit residue stream (FCCU-CLO). In an embodiment, the FCCU-CLO has a boiling point ranging from 340°C to 600°C. In an embodiment, the FCCU-CLO has a kinematic viscosity ranging from 10 to 50 cSt when measured at 50°C.
[0060] In an embodiment, the catalytic cracking residue stream is a Catalytic Cracking Unit residue stream (CCU-CLO). In an embodiment, the CCU-CLO has a boiling point ranging from 340°C to 600°C. In an embodiment, the CCU-CLO has a kinematic viscosity ranging from 10 to 50 cSt when measured at 50°C.
[0061] In accordance with embodiments of the present disclosure, feeding of the catalytic cracking residue stream into a vacuum distillation unit (VDU) affords recovery of a combined stream that includes vacuum residue (VR) (conventionally obtained as a left over fraction of the crude oil at the bottom of Vacuum Distillation Column) and a heavier aromatic rich fraction (obtained owing to vacuum distillation of the catalytic cracking residue stream fed to the VDU). It could be noted that by controlling the operation, such as, by controlling the amount(s) of catalytic cracking residue stream and/or bottom (LR) residues obtained from the CDU being fed to Vacuum Distillation Unit (VDU), production of a combined steam having the heavier aromatic rich fraction and the vacuum residue (VR) in a weight ratio ranging from 1:4 to 1:50 can be obtained. The combined steam can advantageously be blended with a slop material to produce a bituminous material.
[0062] In an embodiment, the combined stream comprises the heavier aromatic rich fraction in an amount ranging from 2-20 wt.% and the vacuum residue (VR) in an amount ranging from 80-98 wt.%. In an embodiment, the combined stream comprises the heavier aromatic rich fraction in an amount ranging from 2-15 wt.% and the vacuum residue (VR) in an amount ranging from 85-98 wt.%. In an embodiment, the combined stream comprises the heavier aromatic rich fraction in an amount ranging from 2-10 wt.% and the vacuum residue (VR) in an amount ranging from 90-98 wt.%.
[0063] In an embodiment, the combined stream is blended in an amount ranging from 75-95 wt.% with a slop material in an amount ranging from 5-25 wt.% to obtain the bituminous material. In an embodiment, the combined stream is blended in an amount ranging from 80-95 wt.% with a slop material in an amount ranging from 5-20 wt.% to obtain the bituminous material. In an embodiment, the combined stream is blended in an amount ranging from 85-95 wt.% with a slop material in an amount ranging from 5-15 wt.% to obtain the bituminous material.
[0064] In an embodiment, the combined stream is blended in an amount ranging from 85-95 wt.% with a slop material in an amount ranging from 5-15 wt.% to obtain a bituminous material, said bituminous material being a VG-30 bitumen as per IS 73:2013 specification having an absolute viscosity ranging from 2400-3600 poise when measured at 60°C and Penetration value ranging from 45-70 dmm when measured at 25°C, wherein the combined stream comprises a heavier aromatic rich fraction in an amount of about 1-5 wt.% with a vacuum residue (VR) in an amount ranging from 95-99 wt.%.
[0065] In an embodiment, the combined stream is blended in an amount ranging from 85-95 wt.% with a slop material in an amount ranging from 5-15 wt.% to obtain a bituminous material, said bituminous material being a VG-10 bitumen as per IS 73:2013 specification having an absolute viscosity ranging from 800-1200 poise when measured at 60°C and Penetration value ranging from 80-100 dmm when measured at 25°C, wherein the combined stream comprises a heavier aromatic rich fraction in an amount of about 3-10 wt.% with a vacuum residue (VR) in an amount ranging from 90-97 wt.%.
[0066] In an embodiment, the combined stream is blended in an amount ranging from 85-95 wt.% with a slop material in an amount ranging from 5-15 wt.% to obtain a bituminous material, said bituminous material being a VG-10 bitumen as per IS 73:2013 specification having an absolute viscosity ranging from 800-1200 poise when measured at 60°C and Penetration value ranging from 80-100 dmm when measured at 25°C, wherein the combined stream comprises a heavier aromatic rich fraction in an amount of about 5-15 wt.% with a vacuum residue (VR) in an amount ranging from 85-95 wt.%.
[0067] In an embodiment, the method further includes a step of blowing the bituminous material in a bitumen blowing unit (BBU) to afford any of: VG10 bitumen, VG20 bitumen, VG30 bitumen and VG40 bitumen. A person skilled in the art is expected to be well versed with the operation of blowing in a bitumen blowing unit (BBU) and consequently, detailed operation such as process parameters, time period of blowing and the likes are not described herein.
[0068] The advantageous process of the present disclosure affords cost effective production of bituminous material. Particularly, the advantageous process of the present disclosure, by feeding the catalytic cracking residue stream to the vacuum distillation unit (VDU) either at a feed stage or at a stage above the feed stage affords precluding the requirement of input of additional energy, and by using heavier aromatic rich fraction obtained from the VDU for production of bituminous material affords slop saving making the instant process highly economical at an industrial scale. The skilled artisans would readily appreciate that the advantageous process can easily be implemented in existing refineries by employing crude distillation unit (CDU), vacuum distillation unit (VDU) and one or more catalytic cracking units (CCU/FCCU).
EXAMPLES
[0069] ROUTING OF CLO STREAM TO A VACUUM DISTILLATION UNIT (VDU)
[0070] Residue stream (i.e. clarified oil or CLO stream) obtained from Fluid Catalytic Cracking Unit (FCCU) was routed to vacuum distillation unit (VDU); the CLO stream was introduced at the 9th stage of the column. The mass flow of liquid from and vapor to for all stages were compared with the base case and the same is reported in Table 1 below. It could be noted that the distribution of liquid from is observed near 9th stage and below stage and some of light vapors has vaporized for recovery. The results for distillate recovery are provided in Table 2 below. The recovery of distillates (LVGO and HVGO) was found to be about 40 wt.%. The profile for LVGO, HVGO and VR with varying CLO quantity are depicted in FIG. 3. The studies for estimation of optimum stage for entry of CLO stream were also carried out and the same is depicted in FIG. 4. It could be concluded that the optimum stage for introduction/feeding of catalytic cracking residue stream to the vacuum distillation unit is 9th stage. Although optimum entry stage for CLO was found to be at the 9th stage (i.e. a stage above the feed stage), it could be noted that CLO may also be fed at the feed stage i.e., at 10th stage, whereupon similar distillate recovery could be expected. Based on this observation, it was concluded that the process affords flexibility as to feeding of CLO to VDU to obtain recovery of distillates.

Table 1: Comparison of mass flow for liquid from and vapor to for base case and CLO in VDU
Stage
liquid from (T/D) delta vapor to (T/D) delta
base case CLO in VDU base case CLO in VDU
1 4800 4800 0 184 184 0
2 4801 4801 0 184 184 0
3 5117 5123 6 500 506 6
4 25 7 -18 500 498 -2
5 16 2 -13 490 493 3
6 8 1 -8 483 491 8
7 7860 7906 47 1734 1797 63
8 9756 9804 49 3630 3695 65
9 92 336 244 3646 3705 59
10 3047 3263 216 457 489 31
11 2898 3100 202 308 325 17
12 2770 2955 185 180 180 0

Table 2: Improvement in distillates by CLO (300T/D) recycling in VDU column
Streams Base CLO in VDU column Improvement % Improvement
LVGO, T/D 291 299 8 2.70
HVGO, T/D 3080 3188 108 36.05
VR, T/D 2770 2954 184 61.26

[0071] The quality of products LVGO, HVGO and VR were compared for distillation profile (D1160) and the results are depicted in FIG. 5, wherein it can be seen that there is no substantial difference in distillation profiles of the products. It could also be observed that the quantity of CLO residues going into VR stream is always less than 10wt.% and thus, the issue of fine catalyst is not likely to be a major concern.
[0072] PRODUCTION OF BITUMINOUS MATERIAL
[0073] D1160 distillation experiments were carried out, at laboratory scale, using residue stream (i.e. clarified oil or CLO streams) obtained from Fluid Catalytic Cracking Unit/ FCCU (denoted as CLO-FCCU) and Catalytic Cracking Unit/CCU (denoted as CLO-CCU). Distillation profile of the residue stream from FCCU and CCU are provided in Table 3 below. Other properties and SARA analysis of the residue stream from FCCU and CCU are provided in Table 4 below.

Table 3: Distillation (D1160) profile of CLO streams
Streams IBP 5% 10% 20% 30% 40% 50% 60% 70% 80% 85%
CLO-FCCU 275 326.1 343.8 364.9 379.2 392.3 406 421.6 442.5 498.6 555
CLO-CCU 202 261.8 299.9 359.1 392.1 413.6 429.2 445.7 468.7 514.1 560

Table 4: Physico-chemical properties of CLO streams
Properties FCCU CLO CCU CLO
Density, g/cc 0.9709 0.9546
API 14.09 16.59
Sulfur, wt.% 0.405 0.37
CCR, wt.% 2.5029 3.7101
SARA Analysis
Saturate, % 39.95 46.4
Aromatic, % 32.36 27.84
Resin, % 27.69 25.76
Asphaltene, % 0 0

[0074] Each of the CLO samples from FCCU and CCU were subjected to vacuum distillation at the lab scale to obtain heavier aromatic rich fractions therefrom (free from -400 °C material). These heavier aromatic rich fractions were then blended in different amounts (amount ranging from 2-8 wt.%) with slop material in an amount of 10 wt.% and vacuum residue (VR) obtained from the vacuum distillation unit (VDU) to obtain the bituminous material. Properties of the resultant bituminous materials viz. penetration (PEN), softening point and viscosities were analyzed in comparison to standard residue feedstocks viz. (i) VR 85%wt + Slop 15%wt and (ii) VR 80%wt+Slop 20%wt and bitumen blowing unit (BBU) feedstock. The comparison data are provided in FIG. 6A through FIG. 6C.
[0075] With regards the Penetration profile, as shown in FIG. 6A, it could be noted that with increasing amounts of heavier aromatic rich fractions, Penetration (PEN) also increases. With regards the softening point and viscosity, as shown in FIG. 6B and 6C, it could be noted that with increasing amounts of heavier aromatic rich fractions, softening point and viscosity decreases. As can be seen from FIG. 6A-6C, when heavier aromatic rich fractions obtained either by subjecting CLO samples from FCCU to VDU (denoted as “FCCU-CLO-R”) or by subjecting CLO samples from CCU to VDU (denoted as “CCU-CLO-R”) in an amount of 2 wt.% is blended with 88 wt.% VR and 10 wt.% slop material, it afford direct production of VG30 bitumen without blowing at Bitrox. It could also be noted that when FCCU-CLO-R in an amount of 6% is blended with 84 wt.% VR and 10 wt.% slop material, it affords direct production of VG10 bitumen without blowing at Bitrox; and when CCU-CLO-R in an amount of 8% is blended with 82 wt.% VR and 10 wt.% slop material, it affords direct production of VG10 bitumen without blowing at Bitrox.
[0076] Based on the series of experiments, it could be concluded that the advantageous process of the present disclosure affords slop saving of 5-10% making the instant process economical, particularly, at an industrial scale. Notably, routing of the catalytic cracking residue stream into a vacuum distillation unit (VDU) affords recovery of 40% of contents thereof as distillates as light vacuum gas oil (LVGO) and heavy vacuum gas oil (HVGO) while the remainder i.e. heavier aromatic rich fraction can advantageously be used for replacing an amount of slop materials for production of bituminous materials. Accordingly, the advantageous process of the present disclosure, by feeding the catalytic cracking residue stream to the vacuum distillation unit (VDU) either at a feed stage or at a stage above the feed stage affords precluding the requirement of input of additional energy (e.g. in form of additional furnace duty), and by using heavier aromatic rich fraction obtained from the VDU for production of bituminous material affords slop saving making the instant process highly economical at an industrial scale. The skilled artisans would readily appreciate that the advantageous process can be implemented in existing refineries employing atmospheric distillation units (CDU), vacuum distillation units (VDU) and/or catalytic cracking units (CCU/FCCU).

Table 5: Operating range of CLO routing to VDU column
Basis Crude LR VGO CLO VR
TPD min max min max min max min max
100 45 65 20 40 0.4 2 10 30
Real case - CDU 3 20000 9000 13000 4000 8000 80 400 2000 6000

[0077] Table 5 provides experimental data pertaining to crude oil processing in a refinery routing CLO to VDU column (with CDU, VDU and FCCU units being in operation). As can be seen from table 5, crude oil (about 20000 TPD) was fractionated in CDU at atmospheric condition resulting in long residue (LR) ranging from 9000-13000 TPD. The LR was further subjected to vacuum distillation unit (VDU) resulting in production of VGO ranging from 4000-8000 TPD and vacuum residue (VR) ranging from 2000-6000 TPD. VGO was fed to FCCU resulting in CLO ranging from 80-400 TPD. CLO was routed to the VDU to afford recovery of 35-45% of contents thereof as distillates and the remainder (i.e. heavier aromatic rich fraction) get mixed with VR giving a combined stream.
[0078] While the foregoing description discloses various embodiments of the disclosure, other and further embodiments of the invention may be devised without departing from the basic scope of the disclosure. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES
[0079] The present disclosure provides a method for obtaining bituminous material that overcomes one or more disadvantages of the processes known in the art.
[0080] The present disclosure provides a method for obtaining bituminous material that is economical and industrially viable.
[0081] The present disclosure provides a method for obtaining bituminous material that precludes the requirement of input of additional energy.
[0082] The present disclosure provides a method for obtaining bituminous material that aids in reducing over flash requirement.

,CLAIMS:1. A method for obtaining a bituminous material, the method comprising:
(a) routing a catalytic cracking residue stream into a vacuum distillation unit (VDU) for recovering a combined stream comprising a vacuum residue (VR) and a heavier aromatic rich fraction, wherein the combined stream comprises the heavier aromatic rich fraction and the vacuum residue (VR) in a weight ratio ranging from 1:4 to 1:50; and
(b) blending the combined stream with a slop material in an amount ranging from 5-25 wt.% to obtain the bituminous material.
2. The method as claimed in claim 1, wherein the combined stream comprises the heavier aromatic rich fraction in an amount ranging from 2-20 wt.% and the vacuum residue (VR) in an amount ranging from 80-98 wt.%.
3. The method as claimed in claim 1, wherein the combined stream is blended in an amount ranging from 75-95 wt.% with a slop material in an amount ranging from 5-25 wt.% to obtain the bituminous material.
4. The method as claimed in claim 1, wherein the catalytic cracking residue stream is a Fluid Catalytic Cracking Unit (FCCU) residue stream (CLO) having a boiling point ranging from 340°C to 600°C.
5. The method as claimed in claim 1, wherein the catalytic cracking residue stream is a Fluid Catalytic Cracking Unit (FCCU) residue stream (CLO) having a kinematic viscosity ranging from 10 to 50 cSt when measured at 50°C.
6. The method as claimed in claim 1, wherein the vacuum residue (VR) has a kinematic viscosity ranges from 103 to 109 cSt when measured at 50°C and from 102 to 105 cSt when measured at 100°C.
7. The method as claimed in claim 1, wherein the vacuum residue (VR) has a penetration in the range 10-25 dmm when measured at 25°C.
8. The method as claimed in claim 1, wherein the slop material has an absolute viscosity ranging from 50-90 Poise when measured at 60°C.
9. The method as claimed in claim 1, wherein the catalytic cracking residue stream is fed to the vacuum distillation unit either at a feed stage or at a stage above the feed stage.
10. The method as claimed in claim 1, wherein the bituminous material is any of: VG10 bitumen, VG20 bitumen, VG30 bitumen and VG40 bitumen.
11. The method as claimed in claim 1, wherein the method comprises a step of blowing the bituminous material in a bitumen blowing unit (BBU) to afford any of: VG10 bitumen, VG20 bitumen, VG30 bitumen and VG40 bitumen.