DESC:FIELD
The present disclosure relates to carbon black feedstock purification. More specifically, the present disclosure relates to a system and a method for the continuous purification of crude carbon black feedstock.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
Carbon black: The term “carbon black” refers to a material produced by the incomplete combustion of highly aromatic hydrocarbon oil like coal and coal tar, vegetable matter, or petroleum products, including fuel oil, fluid catalytic cracking tar, and ethylene cracking in a limited supply of air.
Carbon black feedstock: The term “carbon black feedstock” refers to a mixture of C12 and higher components including naphthalene, methyl-indenes, anthracene, fluorene and other polyaromatic components. Generally, it is obtained from a high-temperature cracking of petroleum fractions. Carbon black feedstock is used to produce carbon black, a widely used reinforcing agent in the rubber and tire industry. Carbon black feedstock can also be used as a fuel oil blending component.
Crude: The term “Crude” refers to the impurities such as ash, silica, coke grit, Catalyst impurities, metallic complex, and the like in the carbon black feedstock which is generally above 5 µm.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
The carbon black feedstock is mainly an amalgamation of heavy aromatics of petroleum bottom cut-off. The carbon black feedstock contains several impurities such as sediments, toluene insoluble matters, n-pentane insoluble, silica, and the like, which are not desirable in the carbon black manufacturing process. Globally, the petroleum feedstock demand and supply chain fall under the segments of a volatile market due to several internal or external factors. Therefore, consumers tend to compromise with the supplied quality of feedstock.
Carbon black manufacturers have been continuously facing challenges with carbon black feedstock quality and the demand-supply chain as these impurities impact the manufacturing process acutely and deteriorate the product quality and equipment life. This in turn decreases the efficiency of the production line.
Extensive research has been carried out by carbon black manufacturers for decades to find out a system that can cater to refine the feedstock on desirable levels to get rid of these ultrafine impurities. The systems strainer filtration using sieve, centrifugal techniques, and heat and settling methods are conventionally used by carbon black manufacturers. However, most of these systems have limitations in reducing ultrafine impurities at optimum levels. Moreover, these conventionally used systems operate in a non-continuous manner.
Therefore, there is felt a need to provide a system and a method for the continuous purification of crude carbon black feedstock that obviates the drawbacks mentioned hereinabove or at least provides an alternative solution.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.
Another object of the present disclosure is to provide a system for the continuous purification of crude carbon black feedstock.
Still another object of the present disclosure is to provide an automated system for the continuous purification of crude carbon black feedstock.
Yet another object of the present disclosure is to provide a system for the continuous purification of crude carbon black feedstock which is easy to operate.
Still another object of the present disclosure is to provide a system for the continuous purification of crude carbon black feedstock that is durable.
Yet another object of the present disclosure is to provide a system for the continuous purification of crude carbon black feedstock which is cost-effective.
Still another object of the present disclosure is to provide a system for the continuous purification of crude carbon black feedstock that has a minimum maintenance.
Another object of the present disclosure is to provide a method for the continuous purification of crude carbon black feedstock.
Still another object of the present disclosure is to provide a simple and environment-friendly method for the continuous purification of crude carbon black feedstock.
Yet another object of the present disclosure is to provide an economical method for the continuous purification of crude carbon black feedstock.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a system and a method for the continuous purification of crude carbon black feedstock.
In an aspect, the present disclosure relates to a system for continuous purification of a crude carbon black feedstock. The system comprises at least one primary storage unit configured to collect and store the crude feedstock; at least two filtration units, downstream of the at least one primary storage unit configured to receive the crude feedstock and filter the crude feedstock to obtain a filtered feed oil and a residual oil; at least one residual oil collection unit and at least one secondary storage unit, downstream of the at least two filtration units; wherein the at least one residual oil collection unit is configured to receive the residual oil and the at least one secondary storage unit is configured to receive the filtered feed oil; at least one treatment unit, downstream of the at least one residual oil collection unit is configured to receive the residual oil and treat the residual oil to obtain the separated oil and a residue; at least one separated oil collection unit, downstream of the at least one treatment unit configured to receive the separated oil and in fluid communication with the at least two filtration units to filter the separated oil to obtain the filtered oil; a control unit configured to control and coordinate the operations of the units; and wherein the at least two filtration units comprises at least two filtration chambers and are configured parallelly; wherein the system includes a backwash circuit connected between the separated oil collection unit and the at least two filtration units to selectively backwash one of the two filtration units depending upon the pressure drop across the filtration unit.
In an embodiment of the present disclosure, the filtration units comprise a series of ultra-fine filters, wherein the filters have a mesh size in the range of 10 µm to 40 µm.
In an embodiment of the present disclosure, the system comprises a first pumping unit downstream of the at least one primary storage unit configured to transfer the crude feedstock from the primary storage unit to the at least two filtration units; a second pumping unit downstream of the at least one secondary storage unit configured to transfer the filtered feed oil from the secondary storage unit to the production plant; a third pumping unit downstream of the at least one residual oil collection unit configured to transfer the residual oil from the at least one residual oil collection unit to the treatment unit; and a fourth pumping unit downstream of the at least one separated oil collection unit configured to transfer the separated oil from the at least one separated oil collection unit to the at least two filtration units.
In an embodiment of the present disclosure, the primary storage unit comprises at least one storage tank having at least one inlet valve to receive the crude feedstock, at least one outlet valve configured to discharge the crude feedstock to the first pumping unit, and a level sensing device configured to sense a level of a fluid in the at least one storage tank in communication with a control unit.
In an embodiment of the present disclosure, the treatment unit comprises a series of ultra-fine filters, wherein the filters have a mesh size in the range of 10 µm to 40 µm.
In an embodiment of the present disclosure, the separated oil discharged from the treatment unit is divided into a first part of the separated oil and a second part of the separated oil; wherein the first part of the separated oil is transferred to the secondary storage unit, and; the second part of the separated oil is collected at the separated oil collection unit.
In an embodiment of the present disclosure, the control unit comprises a Programmable Logic Controller (PLC) panel configured to receive; a level value from the level sensing device of the primary storage tank; a level value from the level sensing device of the residual oil collection unit; level value from the level sensing device of the secondary storage unit; differential pressure transmitter reading of the at least two filtration units; and temperature sensing device readings of the at least two filtration units; wherein the PLC panel is further configured to operate the first pumping unit, the second pumping unit, the third pumping unit, and the fourth pumping unit.
In an embodiment of the present disclosure, the system comprises a three-way valve downstream of the at least two filtration units and the at least one treatment unit.
In an embodiment of the present disclosure, the crude feedstock has impurities with a particle size in the range of 5 µm to 150 µm.
The system of the present disclosure is an online continuous purification system that can be retrofitted in place of the coarse-type batch process filtration system.
In an embodiment, the filtered feed oil has impurities with a particle size of less than 10 µm.
In an embodiment, the residual oil has impurities with a particle size in the range of 7 µm to 100 µm.
In an embodiment, the first part of the separated oil has impurities with a particle size of less than 10 µm.
In an embodiment, the second part of the separated oil has impurities with a particle size in the range of 7 µm to 100 µm.
In another aspect, the present disclosure relates to a method for the continuous purification of a crude carbon black feedstock. In the method, the crude feedstock having impurities with a particle size in the range of 5 µm to 150 µm is obtained; the crude feedstock is passed through a filtration units having a series of ultra-fine mesh filters to obtain a filtered feed oil having impurities in the range of 0.1% to 0.2% and a residual oil having impurities in the range of 0.5% to 10%; the residual oil is passed through at least one residual oil collection unit and the filtered feed oil is passed to a secondary storage unit, the residual oil is passed from the residual oil collection unit to at least one treatment unit, the residual oil is treated in the treatment unit to obtain separated oil having impurities less than 0.2% and residue; a first part of the separated oil is transferred to the secondary storage unit and a second part of the separated oil is recirculated as a backwashing fluid from the treatment unit to the filtration units, and the residue is removed from the treatment unit; separately, continuously measuring a differential pressure drop across a first set of filtration unit having a first series of ultra-fine mesh filters, and comparing the differential pressure with a set-differential pressure to obtain a difference value; the crude feedstock is diverted through a second set of filtration unit having a second series of ultra-fine mesh filters when the difference value obtained in the previous step is in the range of 1.5 bar to 2 bar.
In an embodiment of the present disclosure, the crude carbon black feedstock comprises a carbon content and complexes including impurities in the range of 80% to 94% and hydrogen, Sulphur, and other complexes including impurities in the range of 6% to 20%.
In an embodiment of the present disclosure, the filtering is initiated by opening an air vent valve present near the first series of ultra-fine filters present in the first set of the filtration unit.
In an embodiment, the increase in the differential pressure, the filtration is automatically switched from the first ultra-fine filter to the second ultra-fine filter, by closing the air vent valve and by the action of an interlocking mechanism.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The system and the method for the continuous purification of crude carbon black feedstock of the present disclosure will now be described with the help of the accompanying drawing, in which:
FIGURE 1: illustrates a schematic diagram of the carbon black feedstock purification process in accordance with an embodiment of the present disclosure;
FIGURE 2: illustrates a schematic diagram of the primary storage unit for carbon black feedstock in accordance with an embodiment of the present disclosure;
FIGURE 3: illustrates a schematic diagram of the carbon black feedstock purification process that includes a sensing device and a three way-valve in accordance with an embodiment of the present disclosure
FIGURE 4: illustrate the reduction of toluene insoluble matter after purification in accordance with an embodiment of the present disclosure;
FIGURES 5A and 5B: illustrate an electron microscopic view of toluene insoluble matters in a raw sample, magnified to 100x and 500x levels of the original, in accordance with an embodiment of the present disclosure;
FIGURES 6A and 6B: illustrate an electron microscopic view of the same toluene insoluble matter in CBFS after filtration, magnified to 100x and 500x levels of the original, in accordance with an embodiment of the present disclosure; and
LIST OF REFERENCE NUMERALS USED IN THE DESCRIPTION AND DRAWING:
101 primary storage unit
102 a and 102 b filtration units
103 residual oil collection unit
104 three-way valve
105 treatment unit
106 secondary storage unit
107 discharge to plant
108 discharge of waste residue
109 separated oil collection unit
110 control unit
201 first pumping unit
202 second pumping unit
203 third pumping unit
204 fourth pumping unit
301 level sensing device of the primary storage unit (101)
303 level sensing device of the residual oil collection unit (103)
306 level sensing device of the secondary storage tank (106)
DETAILED DESCRIPTION
The present disclosure relates to a system and a method for the continuous purification of crude carbon black feedstock.
Embodiments of the present disclosure will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
The carbon black feedstock is mainly an amalgamation of heavy aromatics of petroleum bottom cut-off. The carbon black feedstock contains several impurities such as sediments, toluene insoluble matters, n-pentane insoluble, silica, and the like, which are not desirable in the carbon black manufacturing process. Globally, the petroleum feedstock demand and supply chain fall under the segments of a volatile market due to several internal or external factors. Therefore, consumers tend to compromise with the supplied quality of feedstock.
Carbon black manufacturers have been continuously facing challenges with carbon black feedstock quality and the demand-supply chain as these impurities have an impact on the manufacturing process acutely and deteriorate the product quality and equipment life. This in turn decreases the efficiency of the production line.
Extensive study and research have been carried out by carbon black manufacturers for decades to find out a system that can cater to refine the feedstock on desirable levels to get rid of these ultrafine impurities. The systems strainer filtration using sieve, centrifugal techniques, and heat and settling methods are conventionally used by the carbon black manufacturers. However, most of these systems have limitations in reducing ultrafine impurities at optimum levels. Moreover, these conventionally used systems operate in a non-continuous manner.
To overcome the above challenge, there was a need to develop an efficient technology that would replace the batch process filtration system, thereby reducing the contamination in carbon black feedstock.
The present disclosure provides a system and a method for the continuous purification of crude carbon black feedstock.
In an aspect, the present disclosure provides a system for the continuous purification of crude carbon black feedstock.
Referring to Figure 1, the system for the continuous purification of crude carbon black feedstock 1000 (hereinafter referred to as “system 1000”) is shown.
The system (1000) comprises at least one primary storage unit (101), at least two filtration units (102a and 102b), at least one residual oil collection unit (103), a three-way valve (104), at least one treatment unit (105), at least one secondary storage unit (106), at least one separated oil collection unit (109) and a control unit (110).
In the system (1000) of the present disclosure, at least two filtration units (102a and 102b) are disposed downstream of the at least one primary storage unit (101). The filtration units are configured to receive the crude feedstock from the primary storage unit and filter the crude feedstock to obtain a filtered feed oil and a residual oil. The at least one residual oil collection unit (103) is disposed downstream of the at least two filtration units (102a and 102b) and is configured to receive the residual oil obtained from the filtration unit. Further, the at least one secondary storage unit (106) is disposed downstream of the at least two filtration units (102a and 102b) and is configured to receive and store the filtered feed oil obtained from the filtration unit. The at least one treatment unit (105) is disposed downstream of the at least one residual oil collection unit (103) and is configured to receive the residual oil from the residual oil collection unit for further treatment. In the treatment unit, the residual oil is treated to obtain a separated oil and a residue. At least one separated oil collection unit (109) downstream of the at least one treatment unit (105), configured to receive the separated oil and in fluid communication with the at least two filtration units (102a and 102b) to filter said separated oil to obtain said filtered oil. Further, the at least one control unit (110) is configured to control and coordinate the operations of the units (101, 102a, 102b, 103, 105, 106, 109).
The separated oil discharged from the treatment unit (105) is divided into two parts a first part and a second part. The second part of the separated oil is collected in the separated oil collection unit (109) which is disposed downstream of the treatment unit (105) and the first part of the separated oil is stored in the secondary storage unit (106).
The second part of the separated oil needs to be processed further, therefore the separated oil collection unit (109) is in fluid communication with the at least two filtration units (102a and 102b), and treating the second part of the separated oil as a backwashing fluid and transferred to the filtration unit for further filtration and obtain the filtered oil.
In an exemplary embodiment, the filtered oil obtained initially at the time of purification of the crude feedstock through the filtration units (102a, 102b) is considered as a mother filtered oil and the filtered oil obtained at later stages such as, from the backwashing of the second part of the separated oil, and the first part of the separated oil that stored in the secondary storage unit is considered as a child filtered oil.
A control unit (110) is configured to control and coordinate the operations of the at least one primary storage unit (101), the at least two filtration units (102a and 102b), the at least one residual oil collection unit (103). The control is also configured to control and coordinate the operation of a three-way valve (104), the at least one treatment unit (105), the at least one secondary storage unit (106), and the at least one separated oil collection unit (109).
The at least two filtration units (102a and 102b) comprise at least two filtration chambers and are configured parallelly and in fluid communication with each other.
The system (1000) includes a backwash circuit connected between the separated oil collection unit (109) and the filtration units (102a and 102b), and also connected to the control unit (110), and configured to backwash one of the two filtration units (102a or 102b) at a time depending upon the pressure difference across the filtration unit. The connected control unit is used to control the filtration unit by differential pressure across the filtration unit (102a or 102b).
In accordance with an embodiment of the present disclosure, the filtration unit (102a and 102b) comprises a series of ultra-fine filters, wherein the filter has a mesh size in the range of 10 µm to 40 µm.
In accordance with an embodiment of the present disclosure, the system (1000) comprises a first pumping unit (201) downstream of the at least one primary storage unit (101) configured to transfer crude feedstock from the primary storage unit (101) to the filtration unit (102a, 102b). The system also includes a second pumping unit (202) downstream of the at least one secondary storage unit (106) configured to transfer the filtered feed oil from the secondary storage unit (106) to the production plant (not shown). A third pumping unit (203) downstream of the at least one residual oil collection unit (103) and is configured to transfer residual oil from the residual oil collection unit (103) to the treatment unit (105); and a fourth pumping unit (204) downstream of the at least one separated oil collection unit (109) configured to transfer the separated oil from the separated oil collection unit (109) to the filtration unit (102a, 102b).
In accordance with the present disclosure, the first pumping unit (201), second pumping unit (202), third pumping unit (203), and fourth pumping unit (204) are provided with a variable frequency drive (VFD).
In accordance with an embodiment of the present disclosure, the primary storage unit (101) comprises at least one storage tank (101a) having at least one inlet valve (101b) to receive a crude feedstock and at least one outlet valve (101c) configured to discharge the crude feedstock to the first pumping unit (201). The storage unit also has a level sensing device (301) configured to sense the level of a fluid in the storage tank (101a) in communication with the control unit (110).
In accordance with an embodiment of the present disclosure, the treatment unit (105) comprises a series of ultra-fine filters, wherein the filter has a mesh size in the range of 10 µm to 40 µm.
In accordance with an embodiment of the present disclosure, the control unit (110) comprises a PLC panel configured to receive a level value from the level sensing device (301) of the primary storage tank (101a); a level value from the level sensing device (303) of the residual oil collection unit (103); a level value from the level sensing device (306) of the secondary storage unit (106); differential pressure transmitters reading of the at least two filtration units (102a and 102b) respectively; temperature sensing devices reading of the at least two filtration units (102a and 102b) respectively.
The PLC panel is also configured to operate the first pumping unit (201), the second pumping unit (202), the third pumping unit (203) and the fourth pumping unit (204).
In accordance with an embodiment of the present disclosure, the system comprises a three-way valve (104) downstream of the at least two filtration units (102a and 102b), and the at least one treatment unit (103).
In accordance with an embodiment of the present disclosure, the crude carbon black feedstock has impurities with a particle size in the range of 5 µm to 150 µm.
In accordance with the embodiments of the present disclosure, the filtered feed oil has impurities with a particle size of less than 10 µm with 86% filtration efficiency.
In accordance with the embodiments of the present disclosure, the residual oil has impurities with a particle size in the range of 7 µm and 100 µm.
In accordance with the embodiments of the present disclosure, the first part of the separated oil has impurities with a particle size of less than 10 µm.
In accordance with the embodiments of the present disclosure, the second part of the separated oil has impurities with a particle size in the range of 7 µm to 100 µm.
In accordance with the embodiments of the present disclosure, the raw material from the refineries is collected in the primary storage tank (101a). The raw material in the primary storage tank (101a) is a carbon black feedstock.
In accordance with the present disclosure, the feed oil temperature in the primary storage tank (101a) is increased to a value in the range of 60°C to 95°C. Maintaining the feed temperature in the range of 60°C to 95°C is essential for efficient filtration. A feed temperature below 60°C reduces the pumping efficiency and in turn the overall capacity of filtration, increasing the operating and maintenance cost. In an exemplary embodiment, the feed temperature is 80°C. In another exemplary embodiment, the feed temperature is 95°C.
In accordance with the embodiments of the present disclosure, the specific gravity of the feed before pre-heating is in the range of 1.05 to 1.2. Upon pre-heating, the specific gravity is reduced to a value in the range of 1.01 to 1.1.
Initially, the outlet valve of the primary storage tank (101c) is opened with a proximity switch. The proximity switch senses the pressure inside the primary storage tank (101a) and transfers the feed to the filtration unit (102a) with the help of the first pump unit (201). The first pump unit (201) includes pump A and pump B, wherein pump B is a stand-by pump and is used in case of the maintenance of pump A. The outlet valve(s) of pump A and pump B, pumps the oil to the filtration unit by measuring the differential pressure drop across the filtration unit (102a).
In accordance with an embodiment of the present disclosure, the filtration unit (102a) and (102b) comprises a series of filters each, wherein the filter sizes are in the range of 10 µm to 40 µm.
The filtration units (102a) and (102b) are arranged in parallel, wherein while the filtration unit (102a) is operational, the filtration unit (102b) is on standby and backwashing mode.
In accordance with an embodiment of the present disclosure, the filter material is stainless steel.
In accordance with the embodiments of the present disclosure, the differential pressure range across the series of filters is in the range of 1.5 bar to 2 bar. In a case, when the differential pressure across the series of filters of the first set of filtration unit (102a) reaches above 1.5 bar, the air vent valve present near the filtration unit (102b) is opened and the flow of the feed is completely diverted through the second set of filtration unit (102b). Simultaneously, the filtration (102a) is subjected to backwashing using a backwashing fluid from the separated oil collection unit (109).
Upon filtration, the filtered feed oil is collected in a secondary storage unit (106), and the residual oil is collected in a residual oil collection unit (103). The residual oil is thereafter fed to a treatment unit (105) using a third pumping unit (203). In the treatment unit (105), the residual oil is subjected to a series of filters, wherein the filter sizes are in the range of 10 µm to 40 µm to obtain a separated oil and the residue.
The separated oil is further divided into two parts a first part and a second part based on the particle impurities present in the separated oil. The first part of the separated oil is considered as a filtered oil and by operating the three-way valve (104) passed to the secondary storage unit. The second part of the separated oil that has more impurities is collected in the separated oil collection unit and thereafter transferred from the separated oil collection unit (109) to the filtration units (102a and 102b), and the residue is removed from the treatment unit.
The three-way valve (104) is configured to pass the filtered feed oil from the filtration units (102a and 102b) to the secondary storage unit (106) while blocking the flow from the treatment unit (105) to the secondary storage unit (106). In the case when the first part of the separated oil is supplied to the secondary storage unit (106), the flow from the filtration units (102a and 102b) is blocked.
In another embodiment, a secondary storage unit (106) collects the filtered feed oil from the filtration unit and is used for the production units, where a pump unit of the secondary storage unit automatically switches off by an indication of a tank level on getting filled with the filtered feed oil fully.
In an embodiment, the interlocking mechanism uses different operating conditions such as indicating the tank level of the storage tank before and after filtration, inlet and outlet temperature of raw material present in the storage tank, and measuring the inlet and outlet differential pressure.
In an embodiment of the present disclosure, an increase in the differential pressure, the filtration is automatically switched from the first ultra-fine filter to the second ultra-fine filter, by closing the air vent valve and by the action of an interlocking mechanism.
Referring to Figure 4, Figure 4 depicts the graph which charts how toluene Insoluble matter in the system was significantly decreased and those are supported by scanning electron microscopy in accordance with an embodiment of the present disclosure. The raw sample contains inorganic impurities of 0.8% and FB, FC, FD, FE, and FH are the filtered oil using the ultra-filtration system, which shows the reduction of 86% of the impurities level of the raw samples. The same can be seen in the electron microscopic images as depicted in Figures 5A, 4B, and 6A, 6B.
In accordance with an embodiment of the present disclosure, Figures 5A, and 5B depict an electron microscopic view of toluene insoluble matters in the raw sample, magnified to 100x and 500x levels respectively of the original, in accordance with an embodiment of the present disclosure.
In accordance with an embodiment of the present disclosure. Figures 6A and 6B depict an electron microscopic view of the same toluene insoluble matter in CBFS after filtration, magnified to 100x and 500x levels respectively of the original.
In another aspect, the present disclosure relates to a method for the continuous purification of crude carbon black feedstock. In the method, the crude feedstock having impurities with a particle size in the range of 5 µm to 150 µm is obtained. The crude feedstock is passed through a first series of ultra-fine mesh filters to obtain filtered feed oil having impurities in the range of 0.1% to 0.2% and residual oil having impurities in the range of 0.5% to 10%. The residual oil is passed to a treatment unit (105) and the filtered feed oil is passed to a secondary storage unit (106).The residual oil is treated to obtain separated oil having impurities less than 0.2%. The first part of the separated oil is transferred to the secondary storage unit and stored, and the second part of the separated oil is recirculated as a backwashing fluid, and the residue is removed.
Separately, continuously measuring a differential pressure across a first set of filtration units having a first set of ultra-fine filters, and comparing the differential pressure with a set-differential pressure to obtain a difference value. The crude feedstock oil is diverted through a second set of filtration units having a second series of ultra-fine mesh filters when the difference value obtained in the previous steps is in the range of 1.5 bar to 2 bar.
In accordance with an embodiment of the present disclosure, the crude carbon black feedstock comprises carbon content and complexes that include impurities in the 80% to 94% and hydrogen, sulphur, and other complexes that include impurities in the range of 6% to 20%.
In accordance with an embodiment of the present disclosure, the Carbon black feedstock has a specific gravity in the range of 1.05 to 1.4 when measured in accordance with ASTM D1298, viscosity in the range of 24 to 120, when measured in accordance with ASTM D445/D2161, ash content of 0.1 to 1 wt%, when measured as per ASTM D428, toluene insoluble matter of 0.05% to 2 wt% depending on the associated impurity level and when measured as per ASTM D893, sulphur content in the range of 0.1wt% to 3 wt% when measured as per ASTM D129, n pentane insoluble of 5% to 20 wt% depending on the associated impurity level and when measured as per ASTM D893 and water by distillation of 0.1 vol % to 2 vol% depending on the grades of feedstock, and when measured as per ASTM D95.
In accordance with an embodiment of the present disclosure, the crude feedstock is a mixture of renewable carbon black feedstock and of liquid aliphatic or aromatic, saturated or unsaturated hydrocarbons or a mixture of these, or can be coal tar distillates or residual oils which are produced during the catalytic cracking of petroleum fractions or during olefin production through cracking of naphtha or gas oil.
In accordance with an embodiment of the present disclosure, treating comprises subjecting the residual oil through a series of filters to obtain separated oil and residue.
In accordance with an embodiment of the present disclosure, the filtering is initiated by opening an air vent valve present near the first series of ultra-fine filters present in the first set of filtration unit (102a).
In accordance with an embodiment of the present disclosure, the first ultra-fine filter, on increase in the differential pressure, automatically switches with a standby filter by closing the air vent valve and by the action of the interlocking mechanism.
In accordance with an embodiment of the present disclosure, the interlocking mechanism uses different operating conditions such as indicating the tank level of the storage tank before and after filtration, inlet and outlet temperature of the raw material present in the storage tank, and measuring the inlet and outlet differential pressure.
The filtered feed oil in the secondary storage unit has the following specifications:
• specific gravity in the range of 1.05 to 1.2 when measured in accordance with ASTM D1298;
• viscosity in the range of 25 to 60 SUS, when measured in accordance with ASTM D445/D2161;
• ash content of 0.1wt% to 1 wt%, when measured as per ASTM D428;
• toluene insoluble matter of 0.05 wt% to 5 wt% when measured as per ASTM D893;
• sulphur content in the range of 0.1 wt% to 3 wt% when measured as per ASTM D129;
• n pentane insoluble of 5 wt% to 20 wt% when measured as per ASTM D893; and
• water by distillation of 0.1 vol % to 2 vol %, when measured as per ASTM D95.
The system for the continuous purification of crude carbon black feedstock increases the efficiency of carbon black production lines as well as the quality of carbon black. The system is efficient in removing ultrafine impurities like sediments, toluene insoluble matters, and silica associated with feedstock. Thus, increases the life of the equipment. Furthermore, being a closed loop and a continuous system, it has no spillage and contamination with land and water.
The method for the continuous purification of crude carbon black feedstock is simple to operate, economical, and environment friendly.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Experiment 1: Continuous purification of crude carbon black feedstock, in accordance with the present disclosure:
20MT of crude feedstock was passed through a filtration unit having a filter with mesh sizes in the range of 10 µm to 40 µm and using a pump of capacity 250 kg/hr to obtain the filtered feed oil. The differential pressure across the filtration unit was continuously monitored. When 1.5 bar differential pressure was reached, the air vent of the second filter was opened and the entire feed flow was diverted to the second filter. Simultaneously, the first filter was subjected to backwashing using mother-filtered oil for 30 minutes).
Feed characteristics:
Specific gravity in the range of 1.05 to 1.4 when measured in accordance with ASTM D1298;
viscosity in the range of 24 to 120, when measured in accordance with ASTM D445/D2161;
ash content of 1 wt%, when measured as per ASTM D428;
toluene insoluble matter of 0.05 to 2wt% when measured as per ASTM D893;
sulphur content in the range of 0.1 wt% to 3 wt% when measured as per ASTM D129;
n-pentane insoluble of 5 to 20 wt% when measured as per ASTM D893; and
water by distillation of 1 vol %, when measured as per ASTM D95.
The filtered carbon black product had the following characteristics:
• specific gravity in the range of 1.05 to 1.2 when measured in accordance with ASTM D1298;
• viscosity in the range of 25 to 60 SUS, when measured in accordance with ASTM D445/D2161;
• ash content of 0.1 wt% to 0.5 wt%, when measured as per ASTM D428;
• toluene insoluble matter of 0.1 wt% to 0.2 wt% when measured as per ASTM D893;
• sulphur content in the range of 0.1 wt% to 2 wt% when measured as per ASTM D129;
• n-pentane insoluble of 1 wt% to 5 wt% when measured as per ASTM D893; and
• water by distillation of 0.1 vol % to 2 vol %, when measured as per ASTM D95.
Experiment 2: Continuous purification of crude carbon black feedstock, in accordance with the present disclosure:
25 MT of crude feedstock was passed through a filtration unit having a filter with mesh sizes in the range of 10 µm to 40 µm and using a pump of capacity 250kg/hr to obtain the filtered feed oil. The differential pressure across the filtration unit was continuously monitored. When 1.5 bar differential pressure was reached, the air vent of the second filter was opened and the entire feed flow was diverted to the second filter. Simultaneously, the first filter was subjected to backwashing using mother-filtered oil for 30 minutes.
Feed characteristics:
Specific gravity in the range of 1.05 to 1.4 when measured in accordance with ASTM D1298;
viscosity in the range of 24 to 120, when measured in accordance with ASTM D445/D2161;
ash content of 0.1 to 2 wt%, when measured as per ASTM D428;
toluene insoluble matter of 0.05 to 2 wt% when measured as per ASTM D893;
sulphur content in the range of 0.1 wt% to 3 wt% when measured as per ASTM D129;
n-pentane insoluble of 5 to 20 wt% when measured as per ASTM D893; and
water by distillation of 0.1 to 2 vol%, when measured as per ASTM D95.
The filtered carbon black product had the following characteristics:
• specific gravity in the range of 1.05 to 1.2 when measured in accordance with ASTM D1298;
• viscosity in the range of 25 to 60 SUS, when measured in accordance with ASTM D445/D2161;
• ash content of 0.1 wt% to 0.5 wt%, when measured as per ASTM D428;
• toluene insoluble matter of 0.1 wt% to 0.5 wt% when measured as per ASTM D893;
• sulphur content in the range of 0.1 wt% to 2 wt% when measured as per ASTM D129;
• n pentane insoluble of 1.5 wt% to 5 wt% when measured as per ASTM D893; and water by distillation of 0.1 vol % to 2 vol %, when measured as per ASTM D95.
TECHNICAL ADVANCES AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a system for the continuous purification of crude carbon black feedstock, that:
• increases the efficiency of carbon black production lines as well as the quality of carbon black;
• removes ultrafine impurities like sediments, toluene insoluble matters, silica associated in feedstock;
• increases the life of the equipment; and
• has no spillage and contamination with land and water.
and
? a method for the continuous purification of crude carbon black feedstock, that is;
• simple;
• economical; and
• environment friendly.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A system (1000) for continuous purification of a crude carbon black feedstock, said system comprising:
i. at least one primary storage unit (101) configured to collect and store said crude feedstock;
ii. at least two filtration units (102a and 102b) downstream of said at least one primary storage unit (101), configured to receive said crude feedstock, and configured to filter said crude feedstock to obtain a filtered feed oil and a residual oil;
iii. at least one residual oil collection unit (103) and at least one secondary storage unit (106), downstream of said at least two filtration units (102a and 102b); wherein said at least one residual oil collection unit (103) configured to receive said residual oil; and said at least one secondary storage unit (106) configured to receive said filtered feed oil;
iv. at least one treatment unit (105) downstream of said at least one residual oil collection unit (103), configured to receive said residual oil and treat said residual oil to obtain a separated oil and a residue;
v. at least one separated oil collection unit (109) downstream of said at least one treatment unit (105), configured to receive said separated oil and in fluid communication with said at least two filtration units (102a and 102b) to filter said separated oil to obtain said filtered oil;
vi. a control unit (110) configured to control and coordinate the operations of said units (101, 102a, 102b, 103, 105, 106, 109); and
wherein said at least two filtration units (102a, 102b) comprise at least two filtration chambers and are configured parallelly; and
wherein said system (1000) includes a backwash circuit connected between said separated oil collection unit (109) and said filtration units (102a and 102b) to selectively backwash one of the two filtration units depending upon the pressure drop across the filtration unit.
2. The system (1000) as claimed in claim 1, wherein said filtration units (102a, 102b) comprise a series of ultra-fine filters, wherein said filters have a mesh size in the range of 10 µm to 40 µm.
3. The system (1000) as claimed in claim 1, comprises:
i. a first pumping unit (201) downstream of said at least one primary storage unit (101) configured to transfer said crude feedstock from said primary storage unit (101) to said filtration units (102a, 102b);
ii. a second pumping unit (202) downstream of said at least one secondary storage unit (106) configured to transfer filtered feed oil from said secondary storage unit (106) to a production plant;
iii. a third pumping unit (203) downstream of said at least one residual oil collection unit (103) configured to transfer said residual oil from said residual oil collection unit (103) to said treatment unit (105); and
iv. a fourth pumping unit (204) downstream of said at least one separated oil collection unit (109) configured to transfer said separated oil from said separated oil collection unit (109) to said filtration unit (102a, 102b).
4. The system (1000) as claimed in claim 1, wherein said primary storage unit (101) comprises at least one storage tank (101a) having at least one inlet valve (101b) to receive said crude feedstock, at least one outlet valve (101c) configured to discharge said crude feedstock to said first pumping unit (201), and a level sensing device (301) configured to sense a level of a fluid in said storage tank (101a) in communication with said control unit (110).
5. The system (1000) as claimed in claim 1, wherein said treatment unit (105) comprises a series of ultra-fine filters, wherein said filters have a mesh size in the range of 10 µm to 40 µm.
6. The system (1000) as claimed in claim 1, wherein said separated oil discharged from said treatment unit (105) is divided into a first part of said separated oil and a second part of said separated oil; wherein said first part of said separated oil is transferred to said secondary storage unit (106) and; said second part of said separated oil is collected at said separated oil collection unit (109).
7. The system (1000) as claimed in claim 1, wherein said control unit (110) comprises a programmable Logic Controller panel configured to receive the following:
a. level value from said level sensing device (301) of said primary storage unit (101);
b. level value from said level sensing device (303) of said residual oil collection unit (103);
c. level value from said level sensing device (306) of said secondary storage unit (106);
d. differential pressure transmitter reading of said at least two filtration units (102a and 102b);
e. temperature sensing device reading of said at least two filtration units (102a and 102b); and
wherein said Programmable Logic Controller panel is further configured to operate said first pumping unit (201), said second pumping unit (202), said third pumping unit (203), and said fourth pumping unit (204).
8. The system (1000) as claimed in claim 1, wherein said system (1000) comprises a three-way valve (104) downstream of said at least two filtration units (102a and 102b), and said at least one treatment unit (105).
9. The system (1000) as claimed in claim 1, wherein said crude carbon black feedstock has impurities with a particle size in the range of 5µm to 150µm.
10. The system (1000) as claimed in claim 1, wherein said filtered feed oil has impurities with a particle size of less than 10 µm.
11. The system (1000) as claimed in claim 1, wherein said residual oil has impurities with a particle size in the range of 7 µm to 100 µm.
12. The system (1000) as claimed in claim 6, wherein said first part of said separated oil has impurities with a particle size of less than 10µm
13. The system (1000) as claimed in claim 6, wherein said second part of said separated oil has impurities with a particle size in the range of 7µm to 100µm.
14. A method for the continuous purification of a crude carbon black feedstock, said method comprising the following steps:
a. obtaining said crude feedstock having impurities with a particle size in the range of 5 µm to 150 µm;
b. passing said crude feedstock through at least two filtration units (102a and 102b) having a series of ultra-fine mesh filters to obtain a filtered feed oil having impurities in the range of 0.1% to 0.2% and a residual oil having impurities in the range of 0.5% to 10%;
c. passing said residual oil to at least one residual oil collection unit (103) and said filtered feed oil to at least one secondary storage unit (106);
d. passing said residual oil from said residual oil collection unit (103) to at least one treatment unit (105) and treating said residual oil in said treatment unit (105) to obtain a separated oil having impurities < 0.2% and a residue.
e. recirculating a second part of said separated oil as a backwashing fluid to said filtration unit (102a and 102b), transferring a first part of said separated oil to said secondary storage unit (106), and removing said residue (108) from said treatment unit (105);
f. separately, continuously measuring a pressure drop across a first set of filtration unit (102a) having a first series of ultra-fine mesh filters, and comparing said differential pressure with a set-differential pressure to obtain a difference value;
g. diverting said crude feedstock through a second set of filtration unit (102b) having a second series of ultra-fine mesh filters, when the difference value obtained in step (f) is in the range of 1.5 bar to 2 bar; and
h. repeating steps (e), (f) and (g) for said second set of filtration unit (102b).
15. The method as claimed in claim 14, wherein said crude carbon black feedstock comprises a carbon content and complexes that include impurities in the range of 80% to 94% and hydrogen, sulphur, and other complexes that include impurities in the range of 6% to 20%.
16. The method as claimed in claim 14, wherein said filtering is initiated by opening an air vent valve present near said first series of ultra-fine mesh filters in said first set of filtration unit (102a).
17. The method as claimed in claim 14, wherein on increase in the differential pressure, the filtration is automatically switched from said first ultra-fine mesh filter to said second ultra-fine mesh filter, by closing said air vent valve and by the action of an interlocking mechanism.
Dated this 14th day of December, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI