DESCRIPTION
FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
1. Title of the Invention:
Additive Composition for Reducing Coke and Increasing Distillate
during Pyrolysis of a Feedstock, and Method of Use Thereof.
2. Applicant(s):
(a) Name : DORF KETAL CHEMICALS (INDIA) Private Limited
(b) Nationality : An Indian Company
(c) Address : Dorf Ketal Tower, D’Monte Street, Orlem, Malad (W),
MUMBAI –400 064, Maharashtra, INDIA
3. Preamble to the Description:
COMPLETE SPECIFICATION:
The following specification particularly describes the Invention and the manner in
which it is to be performed.
1
Dorf4082IN
2
1 TITLE OF INVENTION:
2 Additive Composition for Reducing Coke and Increasing Distillate during
3 Pyrolysis of a Feedstock, and Method of Use Thereof.
4 CROSS REFERENCE:
5 The present application claims priority from the Indian (IN) Patent Application
No. 202121004082 dated 29th 6 January 2021 (29/01/2021).
7 TECHNICAL FIELD OF THE INVENTION:
8 Firstly, the present invention is not for the purpose of defence.
9 The present invention relates to an additive composition for simultaneously
10 reducing coke formation and increasing distillate yield during pyrolysis of a feedstock,
11 and method of use thereof, and the additive composition may be called as a coke reducing
12 additive composition.
13 Particularly, in one embodiment, the present invention relates to a coke reducing
14 additive composition capable of simultaneously (a) reducing coke formation and (b)
15 increasing distillate yield during pyrolysis of a feedstock in the presence of a plastic
16 material, wherein the feedstock is a vacuum residue (VR), plastic material is a waste
17 plastic material or an olefin polymer (OP), including polypropylene plastic (PP) material,
18 or a mixture thereof, and the coke reducing additive composition comprises a
19 naphthenate, preferably a calcium naphthenate, or sodium naphthenate, or a mixture
20 thereof.
21 Particularly, in another embodiment, the present invention relates to method for
22 simultaneously (a) reducing coke formation and (b) increasing distillate yield during
23 pyrolysis of a feedstock in the presence of a plastic material, wherein the feedstock is a
24 vacuum residue (VR), plastic material is a waste plastic material or an olefin polymer
25 (OP), including polypropylene plastic (PP) material, or a mixture thereof, and the coke
26 reducing additive composition comprises a naphthenate, preferably a calcium
27 naphthenate, or sodium naphthenate, or a mixture thereof.
28 Particularly, in still another embodiment, the present invention relates to use of a
29 coke reducing additive composition for simultaneously (a) reducing coke formation and
30 (b) increasing distillate yield during pyrolysis of a feedstock in the presence of a plastic
31 material, wherein the feedstock is a vacuum residue (VR), plastic material is a waste
32 plastic material or an olefin polymer (OP), including polypropylene plastic (PP) material,
Dorf4082IN
3
1 or a mixture thereof, and the coke reducing additive composition comprises a
2 naphthenate, preferably a calcium naphthenate, or sodium naphthenate, or a mixture
3 thereof.
4 Particularly, in yet another embodiment, the present invention relates to a coke
5 reducing additive composition capable of simultaneously (a) reducing formation of
6 coke deposits on walls of the processing unit; and (b) reducing fouling caused due to
7 deposits of coke products on walls of the processing unit during pyrolysis of a feedstock
8 in the presence of a plastic material, wherein the feedstock is a vacuum residue (VR),
9 plastic material is a waste plastic material or an olefin polymer (OP), including
10 polypropylene plastic (PP) material, or a mixture thereof, and the coke reducing additive
11 composition comprises a naphthenate, preferably a calcium naphthenate, or sodium
12 naphthenate, or a mixture thereof, and to a method of employing the coke reducing
13 additive composition, and to a method of use of the coke reducing additive composition
14 of the present invention.
15 Particularly, in yet another embodiment, the present invention relates to a method
16 to convert a waste plastic into a useful chemical commodity.
17 BACKGROUND OF THE INVENTION:
18 During pyrolysis of a feedstock, such as a vacuum residue (VR), formation of a
19 coke results in substantial decrease in yield of a distillate. For example, as per Expt. 1 of
20 Table – I, during the pyrolysis of 100g of a vacuum residue (VR), about 38.37g of coke is
21 formed, and about 61.63g of distillate comprising about 42.02g of liquid distillate and
22 about 19.61g of gas distillate is formed; similarly as per Expt. 12 of Table – III, during
23 the pyrolysis of 100g of a vacuum residue (VR), about 38.4g of coke is formed, and about
24 61.6g of distillate comprising about 42.6g of liquid distillate and about 19g of gas
25 distillate is formed.
26 However, during pyrolysis of a plastic material, such as a waste plastic material or
27 an olefin polymer (OP), including polypropylene plastic (PP) material, formation of a
28 coke is substantially reduced resulting in substantial increase in yield of a distillate. For
29 example, as per Expt. 2 of Table – I, during the pyrolysis of 100g of olefin polymer (OP),
30 including polypropylene plastic (PP) material, about 0.9g of coke is formed, and about
31 99.1g of distillate comprising about 85.48g of liquid distillate and about 13.62g of gas
32 distillate is formed; similarly as per Expt. 13 of Table – III, during the pyrolysis of 100g
33 of olefin polymer (OP), including polypropylene plastic (PP), about 0.4g of coke is
Dorf4082IN
4
1 formed, and about 99.6g of distillate comprising about 90.5g of liquid distillate and about
2 9.1g of gas distillate is formed.
3 However, when pyrolysis of a feedstock is carried-out in the presence of a plastic
4 material, then formation of coke is substantially increased again resulting in substantial
5 decrease in yield of a distillate. For example, as per Expt. 3 of Table – I, during the
6 pyrolysis of 50g of a vacuum residue (VR) and 50g of an olefin polymer (OP), including
7 polypropylene plastic (PP) material, i.e. during pyrolysis of a combination of a VR and
8 PP in a 1:1 wt. ratio, about 29.76g of coke is formed, hence the yield of a distillate is
9 substantially reduced to about 70.24g comprising about 54.6g of liquid distillate and
10 about 15.64g of gas distillate. This is unexpected behaviour of a plastic material including
11 olefin polymer (OP), including polypropylene plastic (PP) material when processed along
12 with a vacuum residue during the vacuum residue pyrolysis.
13 Therefore, a coke product is formed during pyrolysis or cracking or hydrocracking
14 of a feedstock, or during vacuum residue (VR) pyrolysis, or during pyrolysis of vacuum
15 residue (VR) in the presence of a plastic material, which results in decrease in yield of
16 distillate including liquid distillate and gas distillate.
17 The coke formed during pyrolysis or cracking or hydrocracking of a feedstock, or
18 during the vacuum residue (VR) pyrolysis, or during the vacuum residue (VR) pyrolysis
19 in the presence of an olefin polymer (OP), including the polypropylene plastic (PP)
20 material, may be referred to as pyrolytic coke which gets formed and deposited on metal
21 surfaces in contact with a hydrocarbon feedstock undergoing pyrolytic or cracking
22 processing.
23 Therefore, the coke formation is unavoidable part of a thermal pyrolysis or
24 cracking process, and is undesirable because the yield of the distillate reduces
25 substantially.
26 The US patent No. 10,745,629 to Kirtika Kohli et al discloses a process for
27 processing vacuum residues, but the disclosure and teaching of this patent are limited to
28 process for making a waste plastic as a hydrogen donating agent for hydro-conversion of
29 heavy crude oil and vacuum residues.
30 The US patent publication no. US 2021/087473A1 to Pradeep et al discloses a
31 process for conversion of a waste plastic into lighter distillate products by thermal
32 cracking of a mixture of a fresh hydrocarbon feedstock and the waste plastic to obtain a
Dorf4082IN
5
1 light Coker gasoil, a heavy Coker gasoil and a coke fuel oil along with a vapor fraction
2 and separating into fuel gas, LPG and naphtha.
3 The US patent no. US 4,409,093 to Roby Bearden, Jr. et al discloses a method for
4 decreasing the amount of coke produced during the cracking of hydrocarbon feedstock to
5 lower molecular weight products by processing a feedstock containing at least two metal
6 contaminants selected from the class consisting of Ni, V, and Fe to avoid formation of
7 deposits of these contaminants on the catalyst by partially passivating the catalyst.
8 The US patent no. US 5,128,023 to Dwight K. Reid et al discloses a method and
9 compositions for inhibiting the formation and deposition of pyrolytic coke on metal
10 surfaces in contact with a hydrocarbon feedstock undergoing pyrolytic processing by
11 adding a coke inhibiting amount of a combination of: a boron compound and a
12 dihydroxybenzene compound, specifically ammonium biborate and hydroquinone in the
13 presence of glycollic-type solvents and water along with a co-solvent such as butyl
14 carbitol or ethylene glycol.
15 The US patent no. US 5,858,208 to Robert L. Flanders et al discloses a method for
16 improving conversion during fluidized catalytic cracking of a feed stream containing
17 vanadium by adding an effective amount of a composition comprising one overbase
18 complex of a magnesium or aluminium salt and an organic acid (fatty acid) complexing
19 agent, and an antimony compound.
20
21
22
23 However, the prior art is silent about a technical solution to the presently faced
24 problems of increase in coke formation and simultaneous decrease in yield of the distillate
25 during pyrolysis of a feedstock or a plastic material or a mixture of a feedstock and a
26 plastic material, and to convert a waste plastic into a useful chemical commodity.
Dorf4082IN
6
1 NEED OF THE INVENTION:
2 Therefore, the industry desires to have an additive and a method to simultaneously
3 (a) reduce coke formation and (b) increase yield of distillate during cracking of a
4 feedstock, during vacuum residue (VR) pyrolysis, or during vacuum residue (VR)
5 pyrolysis in the presence of a plastic material including a waste plastic material or an
6 olefin polymer (OP), including polypropylene plastic (PP) material, and (c) to reduce to
7 formation of coke deposits on walls of the processing unit, and (d) to reduce fouling
8 caused due to deposits of coke products on walls of the processing unit, and to convert a
9 waste plastic into a useful chemical commodity.
10 PROBLEM TO BE SOLVED BY THE INVENTION:
11 Accordingly, aim of the present invention is to solve the above-discussed
12 problems of the prior art, i.e. to provide an additive and a method to simultaneously (a)
13 reduce coke formation and (b) increase yield of distillate during pyrolytic or cracking
14 processing of a feedstock, during vacuum residue (VR) pyrolysis, or during vacuum
15 residue (VR) pyrolysis in the presence of a plastic material including a waste plastic
16 material or an olefin polymer (OP), including polypropylene plastic (PP) material, and (c)
17 to reduce to formation of coke deposits on walls of the processing unit, and (d) to reduce
18 fouling caused due to deposits of coke products on walls of the processing unit, and to
19 convert a waste plastic into a useful chemical commodity.
20 OBJECTS OF THE INVENTION:
21 Therefore, main object of the present invention is to provide a coke reducing
22 additive composition and a method of employing thereof and a method of use thereof to
23 simultaneously (a) reduce coke formation and (b) increase yield of distillate during
24 pyrolytic or cracking processing of a feedstock, or during vacuum residue (VR) pyrolysis,
25 or during vacuum residue (VR) pyrolysis in the presence of a plastic material including a
26 waste plastic material or an olefin polymer (OP), including polypropylene plastic (PP)
27 material, and (c) to reduce to formation of coke deposits on walls of the processing unit,
28 and (d) to reduce fouling caused due to deposits of coke products on walls of the
29 processing unit, which may also be referred to as a Coker unit, a pyrolytic furnace, a
30 steam cracking furnace, and to convert a waste plastic into useful chemical commodity.
31 Other objects and advantages of the present invention will become more apparent
32 from the following description when read in conjunction with examples, which are not
33 intended to limit scope of present invention.
Dorf4082IN
7
1 DESCRIPTION and EMBODIMENTS OF THE INVENTION:
2 With aim to solve the above-discussed problems of the prior art, i.e. problem of
3 increase in coke formation, and problem of decrease in yield of distillate, and problem of
4 formation of deposits of coke on metal surfaces of a pyrolysis or a cracking furnace, and
5 problem of fouling caused due to deposits of coke product on metal surfaces of a
6 pyrolysis or a cracking furnace, the inventors have found that addition of a naphthenate,
7 preferably of sodium naphthenate or a sodium salt or a sodium salt of an organic acid, and
8 more preferably of calcium naphthenate or a calcium salt or a calcium salt of an organic
9 acid in a feedstock, or in a plastic material, or in a combination of a feedstock and a
10 plastic material, surprisingly and unexpectedly, simultaneously: (a) reduces coke
11 formation and (b) increases yield of distillate during pyrolytic or cracking processing of a
12 feedstock, or of a plastic material, or of a combination of a feedstock and a plastic
13 material, or particularly during vacuum residue (VR) pyrolysis, or more particularly
14 during vacuum residue (VR) pyrolysis in the presence of a plastic material including a
15 waste plastic material or an olefin polymer (OP), including polypropylene plastic (PP)
16 material, and (c) reduces formation of coke deposits on walls of the processing unit, and
17 (d) reduces fouling caused due to deposits of coke products on walls of the processing
18 unit, and (e) converts the waste plastic into a useful chemical commodity.
19 Accordingly, in first embodiment, the present invention relates to a coke reducing
20 additive composition for simultaneously:
21 (a) reducing coke formation, and (b) increasing yield of distillate;
22 (c) converting a waste plastic into useful chemical commodity; and
23 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
24 reducing fouling caused due to deposits of coke products on walls of the
25 processing unit,
26 during pyrolytic or cracking processing of a material comprising:
27 (i) a feedstock,
28 (ii) a plastic material, or
29 (iii) a feedstock in the presence of a plastic material;
30 wherein the coke reducing additive composition comprises a naphthenate,
31 preferably sodium naphthenate or a sodium salt or a sodium salt of an organic
32 acid, and more preferably calcium naphthenate or a calcium salt or a calcium
33 salt of an organic acid, or a mixture thereof.
Dorf4082IN
8
1 Accordingly, in accordance with a preferred embodiment of the first embodiment,
2 it relates to a coke reducing additive composition for simultaneously:
3 (a) reducing coke formation, and (b) increasing yield of distillate;
4 (c) converting a waste plastic into useful chemical commodity; and
5 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
6 reducing fouling caused due to deposits of coke products on walls of the
7 processing unit,
8 during pyrolytic or cracking processing of: a feedstock in the presence of a
9 plastic material;
10 wherein the feedstock is a vacuum residue, preferably the feedstock is a
11 vacuum residue comprising asphaltene;
12 wherein the plastic material is a waste plastic material, an olefin polymer
13 (OP), or a mixture thereof; and
14 wherein the coke reducing additive composition comprises a naphthenate,
15 preferably sodium naphthenate or a sodium salt or a sodium salt of an organic
16 acid, and more preferably calcium naphthenate or a calcium salt or a calcium
17 salt of an organic acid, or a mixture thereof.
18 In accordance with the present preferred embodiment of the present invention, the
19 olefin polymer (OP) includes a polypropylene plastic (PP) material.
20 Accordingly, in accordance with a more preferred embodiment of the first
21 embodiment, it relates to a coke reducing additive composition for simultaneously:
22 (a) reducing coke formation, and (b) increasing yield of distillate;
23 (c) converting a waste plastic into useful chemical commodity; and
24 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
25 reducing fouling caused due to deposits of coke products on walls of the processing
26 unit,
27 during pyrolytic or cracking processing of: a feedstock in the presence of a plastic
28 material;
29 wherein the feedstock is a vacuum residue comprising asphaltene;
30 wherein the plastic material is a waste plastic material, an olefin polymer (OP)
31 including a polypropylene plastic (PP) material, or a mixture thereof; and
32 wherein the coke reducing additive composition comprises calcium naphthenate.
Dorf4082IN
9
1 Accordingly, in second embodiment, the present invention relates to a method for
2 simultaneously:
3 (a) reducing coke formation, and (b) increasing yield of distillate;
4 (c) converting a waste plastic into useful chemical commodity; and
5 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
6 reducing fouling caused due to deposits of coke products on walls of the processing
7 unit,
8 during pyrolytic or cracking processing of a material comprising:
9 (i) a feedstock,
10 (ii) a plastic material, or
11 (iii) a feedstock in the presence of a plastic material;
12 wherein the method comprises adding a coke reducing additive composition of the
13 present invention in a processing unit containing the feedstock, the plastic material,
14 or the feedstock in the presence of the plastic material; and
15 wherein the coke reducing additive composition comprises a naphthenate,
16 preferably sodium naphthenate or a sodium salt or a sodium salt of an organic acid,
17 and more preferably calcium naphthenate or a calcium salt or a calcium salt of an
18 organic acid, or a mixture thereof.
19 Accordingly, in accordance with a preferred embodiment of the second
20 embodiment, the present invention relates to a method for simultaneously:
21 (a) reducing coke formation, and (b) increasing yield of distillate;
22 (c) converting a waste plastic into useful chemical commodity; and
23 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
24 reducing fouling caused due to deposits of coke products on walls of the processing
25 unit,
26 during pyrolytic or cracking processing of: a feedstock in the presence of a plastic
27 material;
28 wherein the feedstock is a vacuum residue, preferably the feedstock is a vacuum
29 residue comprising asphaltene;
30 wherein the plastic material is a waste plastic material, an olefin polymer (OP), or a
31 mixture thereof;
Dorf4082IN
10
1 wherein the method comprises adding a coke reducing additive composition of the
2 present invention in a processing unit containing the feedstock in the presence of
3 the plastic material; and
4 wherein the coke reducing additive composition comprises a naphthenate,
5 preferably sodium naphthenate or a sodium salt or a sodium salt of an organic acid,
6 and more preferably calcium naphthenate or a calcium salt or a calcium salt of an
7 organic acid, or a mixture thereof.
8 In accordance with the present preferred embodiment of the present invention, the
9 olefin polymer (OP) includes a polypropylene plastic (PP) material.
10 Accordingly, in accordance with a more preferred embodiment of the second
11 embodiment, the present invention relates to a method for simultaneously:
12 (a) reducing coke formation, and (b) increasing yield of distillate;
13 (c) converting a waste plastic into useful chemical commodity; and
14 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
15 reducing fouling caused due to deposits of coke products on walls of the processing
16 unit,
17 during pyrolytic or cracking processing of: a feedstock in the presence of a plastic
18 material;
19 wherein the feedstock is a vacuum residue comprising asphaltene;
20 wherein the plastic material is a waste plastic material, an olefin polymer (OP)
21 including a polypropylene plastic (PP) material, or a mixture thereof; and
22 wherein the method comprises adding a coke reducing additive composition of the
23 present invention in a processing unit containing the feedstock in the presence of
24 the plastic material; and
25 wherein the coke reducing additive composition comprises calcium naphthenate.
26 Accordingly, in third embodiment, the present invention relates to a use of a coke
27 reducing additive composition for simultaneously:
28 (a) reducing coke formation, and (b) increasing yield of distillate;
29 (c) converting a waste plastic into useful chemical commodity; and
30 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
31 reducing fouling caused due to deposits of coke products on walls of the processing
32 unit,
Dorf4082IN
11
1 during pyrolytic or cracking processing of a material comprising:
2 (i) a feedstock,
3 (ii) a plastic material, or
4 (iii) a feedstock in the presence of a plastic material;
5 wherein the use comprises treating the feedstock, the plastic material, or the
6 feedstock in the presence of the plastic material with the coke reducing additive
7 composition of the present invention in a processing unit containing the feedstock,
8 the plastic material, or the feedstock in the presence of the plastic material; and
9 wherein the coke reducing additive composition comprises a naphthenate,
10 preferably sodium naphthenate or a sodium salt or a sodium salt of an organic acid,
11 and more preferably calcium naphthenate or a calcium salt or a calcium salt of an
12 organic acid, or a mixture thereof.
13 Accordingly, in accordance with a preferred embodiment of the third embodiment,
14 the present invention relates to a use of a coke reducing additive composition for
15 simultaneously:
16 (a) reducing coke formation, and (b) increasing yield of distillate;
17 (c) converting a waste plastic into useful chemical commodity; and
18 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
19 reducing fouling caused due to deposits of coke products on walls of the
20 processing unit,
21 during pyrolytic or cracking processing of: a feedstock in the presence of a plastic
22 material;
23 wherein the feedstock is a vacuum residue, preferably the feedstock is a vacuum
24 residue comprising asphaltene;
25 wherein the plastic material is a waste plastic material, an olefin polymer (OP), or
26 a mixture thereof;
27 wherein the use comprises treating the feedstock in the presence of the plastic
28 material with the coke reducing additive composition of the present invention in a
29 processing unit containing the feedstock and the plastic material; and
30 wherein the coke reducing additive composition comprises a naphthenate,
31 preferably sodium naphthenate or a sodium salt or a sodium salt of an organic
32 acid, and more preferably calcium naphthenate or a calcium salt or a calcium salt
33 of an organic acid, or a mixture thereof.
Dorf4082IN
12
1 In accordance with the present preferred embodiment of the present invention, the
2 olefin polymer (OP) includes a polypropylene plastic (PP) material.
3 Accordingly, in accordance with a more preferred embodiment of the third
4 embodiment, the present invention relates to a use of a coke reducing additive
5 composition for simultaneously:
6 (a) reducing coke formation, and (b) increasing yield of distillate;
7 (c) converting a waste plastic into useful chemical commodity; and
8 (d) reducing formation of coke deposits on walls of the processing unit, and (e)
9 reducing fouling caused due to deposits of coke products on walls of the
10 processing unit,
11 during pyrolytic or cracking processing of: a feedstock in the presence of a plastic
12 material;
13 wherein the feedstock is a vacuum residue comprising asphaltene;
14 wherein the plastic material is a waste plastic material, an olefin polymer (OP)
15 including a polypropylene plastic (PP) material, or a mixture thereof; and
16 wherein the use comprises treating the feedstock in the presence of the plastic
17 material with the coke reducing additive composition of the present invention in a
18 processing unit containing the feedstock and the plastic material; and
19 wherein the coke reducing additive composition comprises calcium naphthenate.
20 It may be noted that regarding the second and third embodiments, the scope of the
21 present invention may not be limited by the manner to mix the feedstock and plastic
22 material and addition of the additive of the present invention. Therefore, the mixing of the
23 feedstock and the plastic material and addition of the present additive may be carried-out
24 in any manner known to a person skilled in the art.
25 In accordance with one of the embodiments of the present invention, a viable
26 economic route to enhance the liquid distillate product yield and to reduce the coke
27 formation during the pyrolysis of the feedstock, preferably of the vacuum residue
28 feedstock, or during the pyrolysis of the plastic material, preferably of the waste plastic
29 material or the olefin polymer including polypropylene plastic material, is to add to the
30 vacuum residue feedstock, and the plastic material at the beginning of the pyrolysis,
31 which has been surprisingly and unexpectedly found to enhance the liquid distillate
Dorf4082IN
13
1 product yield, but has also been found to simultaneously lower the yield of the solid coke
2 fraction.
3 Feedstock:
4 It may be noted that the scope of present invention may not be limited by the
5 feedstock or a composition thereof.
6 However, in accordance with one of the embodiments of the present invention, the
7 feedstock of the above-described embodiments is a hydrocarbon feedstock.
8 In accordance with one of the preferred embodiments of the present invention, the
9 feedstock may be selected from the group comprising crude oil, vacuum residue,
10 atmospheric residue, asphalted pitch, shale oil, coal tar, clarified oil, residual oils, heavy
11 waxy distillates, foots oil, slop oil or mixture thereof.
12 In accordance with one of the more preferred embodiments of the present
13 invention, the feedstock is a vacuum residue feedstock.
14 In accordance with one of the even more preferred embodiments of the present
15 invention, the feedstock is a vacuum residue feedstock comprising asphaltene.
16 Plastic material:
17 It may be noted that the scope of present invention may not be limited by the
18 selection of a plastic material.
19 However, in accordance with one of the embodiments of the present invention, the
20 plastic material of the above-described embodiments may be selected from a group
21 comprising a waste plastic material, an olefin polymer (OP), a low density polyethylene
22 (LDPE), a high density polyethylene (HDPE), a mix plastic, a polystyrene, a
23 polypropylene, a polyethylene, or a mixture thereof.
24 In accordance with one of the preferred embodiments of the present invention, the
25 plastic material is a waste plastic material, an olefin polymer (OP), or a mixture thereof.
26 In accordance with one of the more preferred embodiments of the present
27 invention, the olefin polymer (OP) includes a polypropylene plastic (PP) material.
28 In accordance with one of the more preferred embodiments of the present
29 invention, the waste plastic material includes a packaging material.
30 Olefin Polymer (OP):
Dorf4082IN
14
1 In accordance with one of the embodiments of the present invention, the olefin
2 polymer (OP) of the above-described embodiments includes a polymer made from
3 monomers. For example, the olefin polymer (OP) includes a polymer made from, without
4 limitation, ethylene, propylene, butane, butadiene. The olefin polymer (OP) may be
5 prepared by any known polymerisation method, which may preferably be either a Ziegler
6 process or a free radical process.
7 Processing Unit:
8 It may be noted that the scope of present invention may not be limited by the
9 selection of a processing unit.
10 However, in accordance with one of the embodiments of the present invention, the
11 processing unit of the above-described embodiments may be a pyrolytic furnace, a Coker
12 unit, a Micro-Coker reactor, a steam cracking furnace, or any furnace for pyrolysis of a
13 feedstock.
14 Amount of Coke Reducing Additive:
15 In accordance with one of the embodiments of the present invention, the amount
16 of the coke reducing additive of the present invention may vary as per amounts of the
17 feedstock and the plastic material being processed.
18 In accordance with one of the preferred embodiments of the present invention, the
19 coke reducing additive of the present invention may be added to a processing unit for
20 processing the feedstock, the plastic material, or the feedstock in the presence of a plastic
21 material, preferably for processing the vacuum residue in the presence of an olefin
22 polymer (OP) including the polypropylene plastic material in an amount selected from the
23 group comprising:
24 a) about 1 ppm to about 5000 ppm,
25 b) about 5 ppm to about 3000 ppm,
26 c) about 5 ppm to about 2000 ppm,
27 d) about 5 ppm to about 1000 ppm, or
28 e) about 5 ppm to about 500 ppm.
29 Amount of Feedstock and Plastic Material:
30 In accordance with the present invention, its scope may not be limited to the
31 amount of the feedstock and the plastic material, because the present invention may be
Dorf4082IN
15
1 applied to any processing unit processing any amount of the feedstock, or the plastic
2 material, or the feedstock in the presence of the plastic material.
3 However, in accordance with one of the embodiments of the present invention, the
4 feedstock, preferably the vacuum residue and the plastic material, preferably the olefin
5 polymer (OP) may be added or mixed in a weight ratio of the feedstock to the plastic
6 material varying from about 0.1 to 99.9 to about 99.9 to 0.1.
7 It may be noted that as per the present invention, the pyrolysis includes thermal
8 pyrolysis, hydrocracking or cracking of a feedstock.
9 It may be noted that as per the present invention, the amount referred in the
10 present invention including the Tables may be referred to as in “wt. %” or “% by wt.”.
11 Further embodiments of the present invention would be apparent from the
12 accompanying examples, which are for the illustration purpose and not intended to limit
13 scope of the present invention.
14 EXAMPLES:
15 In the following examples, a vacuum residue (VR) is charged with or without
16 olefin polymer (OP) including polypropylene plastic (PP) material into a reactor of a
17 Coker unit. For a blank example, no additive; and for an invention example, a coke
18 reducing additive of the present invention is added. The composition of the experiment,
19 the amount of coke formed, the amount of liquid distillate formed, and the amount of gas
20 distillate formed for each of the Examples are given in the following tables – Table – I,
21 Table – II, and Table – III. As one of the exemplary embodiment, the experiments are
22 carried out as follows:
23 However, in accordance with one of the exemplary embodiments of the present
24 invention, a feedstock may be first charged in a reactor of a processing unit provided with
25 a transfer tube to facilitate passage of volatile lower boilers into collectors for liquid
26 distillates and gaseous fractions, temperature of the reactor may be raised to a temperature
27 of greater than about 600degC to about 700degC and inner temperature within the reactor
28 may be maintained between about 440 – about 500degC during the course of reaction, in
29 a manner that the transfer tube capable of facilitating passage of the volatile lower boilers
30 (preferably of temperature of < 370degC) into the collectors for the liquid distillates and
31 the gaseous fractions, is maintained at a temperature of about 240degC to about 245degC,
Dorf4082IN
16
1 during the pyrolysis. A typical processing time may be maintained at about 4h, preferably
2 under stirring at about 195rpm to about 205rpm , and the reactor is then cooled to a
3 temperature of about 140degC or low, preferably to a room temperature (RT), and the
4 liquid distillate is separated and analyzed (for example by HT-GC, i.e. high temperature5 gas chromatography), and the gas fraction is also quantified (for example by weight
6 basis).
7 In accordance with one of the preferred exemplary embodiments of the present
8 invention, the temperature of the reactor is raised to greater than about 600degC and inner
9 temperature within the reactor is maintained between about 440 - 500degC during the
10 course of reaction. A transfer tube facilitating passage of volatile lower boilers (< about
11 370degC) into the collectors for liquid distillates and gaseous fractions is maintained at
12 245degC, during the experiment. Typical reaction or run time is maintained at about 4h
13 under stirring at about 200rpm. Post reaction or run, the reactor is cooled to about
14 140degC.
15 For experimental results, a reference may be drawn to the experimental data
16 presented in the following tables: Table – I, Table – II, and Table - III, which are not
17 intended to limit the scope of the present invention.
18 Composition of the VR feedstock:
19 Composition of the VR feedstock used in experiments of Table – I and Table – II is:
MCR (wt%) SARA Analysis (wt%)
Saturate Asphaltene Resin Arometic
20.48 10.88 23.21 27.68 38.22
20 Composition of the VR feedstock used in experiments of Table – III is:
MCR (wt%) SARA Analysis (wt%)
Saturate Asphaltene Resin Arometic
21.24 14.10 21.37 31.90 32.63
21 The vacuum reside (VR) feedstock was arranged from a petroleum refinery and
22 characterization was carried out by way of MCR and SARA analysis.
23 MCR is Micro Carbon Residue, and is a laboratory test used to determine the
24 amount of carbonaceous residue formed after evaporation and pyrolysis of petroleum
Dorf4082IN
17
1 materials under certain conditions. The test is used to provide some indication of a
2 material's coke-forming tendency.
3 In the present examples, the MCR has been measured by ASTM D4530 method.
4 SARA Analysis: Hydrocarbon samples are tested by Intertek for Saturates,
5 Asphaltenes, Resins and Aromatics (SARA). SARA analysis of heavy crudes is carried6 out for heavy oils, including vacuum distillates, atmospheric and vacuum residues,
7 bitumens and asphalts. SARA oil testing measures Saturates, Asphaltenes, Resins,
8 Aromatics in a heavy crude oil, distillate and feedstock.
9 In the present examples, the SARA analysis has been carried out by ASTM D2007
10 method.
11 Composition of the Polypropylene (PP) used as a Plastic Material in experiments of
12 Tables – I, II and III is:
13 The polypropylene (PP) having a melting point of about 103degC is used. It may
14 be noted that the polypropylene (like other polymers) may have a range of melting points.
15 In the present examples, the melting point of the PP used was measured by differential
16 scanning calorimetric evaluation and by this technique, the melting point of PP was found
17 to be about 103degC.
18 Table – I
Expt. Category Composition Coke
(% by
wt)
Liquid
Distillate
(% by wt)
Gas
Distillate
(% by
wt)
Total
Distillates
Formed
(% by wt)
Vacuum
Residue
(VR)
(g)
Polypropylene
Plastic
material (PP)
(g)
Additive
(ppm)
(Activity
50%)
Expt. 1 100 Nil Nil 38.37 42.02 19.61 61.63
Expt. 2 Nil 100 Nil 0.9 85.48 13.62 99.1
Expt. 3 50 50 Nil 29.76 54.6 15.64 70.24
Expt. 4 -
Invention
Additive is Ca
Naphthenate
(Present
Invention)
50 50 9.8 25.0 58.3 16.7 75.00
Expt. 5 -
Invention
Additive is Ca
Naphthenate
(Present
Invention)
50 50 19.6 22.3 58.9 18.8 77.77
Dorf4082IN
18
1 It may be noted that when effect of PP in VR pyrolysis was evaluated, specifically
2 on the amount of distillate products post-pyrolysis, for example for a VR:PP combination
3 in 1:1 wt. ratio, there was an unexpected increase in the distillate amount from 61.63g (in
4 absence of PP and/or additive) to around 70.24g in the presence of PP (compare Expt. 1
5 and 3). This indicates that PP promotes enhancement of the distillate amount, during the
6 pyrolysis of VR. Besides this, PP also allows for the reduction of coke, from around
7 38.37g (in absence of PP) to 29.76g (in the presence of PP).
8 However, when the additive of the present invention, i.e. Ca Naphthenate was
9 added to a VR:PP combination in 1:1 wt. ratio, it was surprisingly and unexpectedly
10 observed that it results in further increase of the total distillate formation by increasing the
11 formation of the liquid distillate and the gas distillate, and further reduction of coke
12 formation – re Expt. 4 and Expt. 5 vs. Expt. 3.
13 Therefore, the experimental data in Table-I demonstrates that the present additive
14 i.e. Ca Naphthenate has surprising and unexpected technical advantage to reduce the coke
15 formation and increase the total distillate formation by increasing the formation of the
16 liquid distillate and the gas distillate, hence the composition comprising the VR, the PP
17 and the present additive i.e. Ca Naphthenate has a synergistic effect during pyrolysis of
18 VR in presence of PP.
19 Further, the reduction in coke formation results in reduction of formation of
20 deposits hence, fouling on the metal surfaces of the processing unit is either avoided or is
21 reduced.
22 Table – II
Expt. Category Composition Coke
(% by
wt)
Liquid
Distillate
(% by wt)
Gas
Distillate
(% by wt)
Total
Distillates
Formed
(% by wt)
Vacuum
Residue
(VR) (g)
Polypropylene
Plastic
material
(PP) (g)
Additive
(ppm)
(Activity
50%)
Expt. 6 90 10 Nil 40.58 42.4 17.02 59.42
Expt. 7 –
Invention Additive
is Ca Naphthenate
(Present Invention)
90 10 9.8 37.01 44.43 18.56 62.99
Expt. 8 95 5 Nil 42.33 38.92 18.75 57.67
Expt. 9 –
Invention Additive
is Ca Naphthenate
(Present Invention)
95 5 9.8 40.36 40.77 18.87 59.64
Dorf4082IN
19
Expt. 10 98 2 Nil 41.79 38.67 19.54 58.21
Expt. 11 –
Invention Additive
is Ca Naphthenate
(Present Invention)
98 2 9.8 39.97 40.1 19.93 60.03
1 The experimental data in Table-II confirms that the claimed additive Ca
2 Naphthenate has surprising and unexpected technical advantage to simultaneously reduce
3 the coke formation and increase the total distillates formation by increasing the formation
4 of the liquid distillate and the gas distillate – re experimental data of Expt. 7 vs. Expt. 6,
5 Expt. 9 vs. Expt. 8, and Expt. 11 vs. Expt. 10.
6 It may be noted that in the Expts. 7, 9 and 11 the amount of present additive has
7 been kept constant at 9.8ppm, however, the VR/PP ratios are different for the Expts. 6-7,
8 8-9 and 10-11, and these experiments confirm synergistic effect of the present additive
9 composition.
10 Further, the reduction in coke formation results in reduction of formation of
11 deposits hence, fouling on the metal surfaces of the processing unit is either avoided or is
12 reduced.
13 Table – III
Expt. Category Composition Coke
(% by
wt)
Liquid
Distillate
(% by wt)
Gas
Distillate
(% by wt)
Total
Distillates
Formed
(% by wt)
Vacuum
Residue
(VR) (g)
Polypropyl
ene Plastic
material
(PP) (g)
Additive
(ppm)
Expt. 12 100 Nil Nil 38.4 42.6 19 61.6
Expt. 13 Nil 100 Nil 0.4 90.5 9.1 99.6
Expt. 14 98 2 Nil 37.3 46 16.7 62.7
Expt. 15 - Invention
Additive is Ca
Naphthenate
(Present
Invention)
98 2 4.9 35.5 46.3 18.2 64.5
Expt. 16 - Invention
Additive is Na
Naphthenate
(Present
Invention)
98 2 4.9 35.7 46.3 18 64.3
Expt. 17 –
Comparative
Additive is Fe
Naphthenate
(Comparative
Example)
98 2 4.9 38.7 40.9 20.4 61.3
Dorf4082IN
20
1 The experimental data in Table-III confirms that the claimed additive Ca
2 Naphthenate and Na Naphthenate have a surprising and unexpected technical advantage
3 to simultaneously reduce the coke formation and increase the total distillates formation –
4 re experimental data of Expt. 15 and 16 vs. Expt. 14.
5 Further, the reduction in coke formation results in reduction of formation of
6 deposits hence, fouling on the metal surfaces of the processing unit is either avoided or is
7 reduced.
8 Converting Waste Plastic into a useful Chemical Commodity,
9 As per one of the embodiments of the present invention, the Expt. data of Expt.
10 no. 2 in Table – I [and Expt. No. 13 in Table – III] confirms that during pyrolysis of 100g
11 of the plastic material comprising an olefin polymer like PP in absence of Ca Naphthenate
12 additive allows formation of various liquid distillate fractions as mentioned in below
13 Table - IV, hence in one embodiment, the present invention also relates to a process to
14 convert waste plastic into useful products.
15 Table - IV

Feed 100% PP
Amount of Liquid distillate obtained 85.48
Composition of product fractions in liquid
distillate*
Wt (%)
Naphtha 20
Kerosene 21
Diesel 35
Fuel Oil 24
16 TECHNICAL ADVANTAGES OF THE INVENTION:
17 As can be observed from the foregoing experimental data, the technical
18 advantages have been achieved by the present invention.
19 Based on the above-discussed experimental results of the present invention, the
20 inventors, without being bound by the theory or the mechanism, have found that the coke
Expt. 18 –
Comparative
Additive is Mg
Naphthenate
(Comparative
Example)
98 2 4.9 38.2 44.2 17.6 61.8
Dorf4082IN
21
1 reducing additive of the present invention has provided a technical solution to the existing
2 technical problems of the industry to simultaneously:
3 (a) reduce coke formation;
4 (b) increase yield of distillate;
5 (c) convert a waste plastic into a useful chemical commodity;
6 (d) reduce formation of coke deposits on walls of the processing unit; and
7 (e) reduce fouling caused due to deposits of coke products on walls of the processing
8 unit,
9 during the pyrolysis of a feedstock, or a plastic material, or a feedstock in the presence of
10 a plastic material, and still being an economical.
11 ***************XXXXXXX**************
Dorf4082IN
22
Clean Version
Amended Claims for National Phase Entry
Amendments have been marked on Claims amended under Article 34 of PCT and as annexed to IPRP(II)
We Claim:
1 1. A method for simultaneously:
2 (a) reducing coke formation;
3 (b) increasing yield of distillate;
4 (c) converting a waste plastic into a useful chemical commodity;
5 (d) reducing formation of coke deposits on walls of the processing unit; and
6 (e) reducing fouling caused due to deposits of coke products on walls of the
7 processing unit,
8 during a pyrolytic or cracking processing of a material comprising:
9 (i) a combination of a feedstock in the presence of a plastic material;
10 wherein the method comprises a step of adding a coke reducing additive
11 composition comprising sodium naphthenate, calcium naphthenate, or a mixture
12 thereof in a processing unit containing the feedstock in the presence of the plastic
13 material.
14 2. The method as claimed in claim 1, wherein the feedstock is selected from the
15 group comprising crude oil, vacuum residue, atmospheric residue, asphalted pitch,
16 shale oil, coal tar, clarified oil, residual oils, heavy waxy distillates, foots oil, slop
17 oil or mixture thereof, preferably the feedstock is a vacuum residue feedstock,
18 wherein the vacuum residue feedstock comprises asphaltene.
19 3. The method as claimed in claim 1 or 2, wherein the plastic material is selected
20 from a group comprising a waste plastic material, an olefin polymer (OP), a low
21 density polyethylene (LDPE), a high density polyethylene (HDPE), a mix plastic,
22 a polystyrene, a polypropylene, a polyethylene, or a mixture thereof, preferably
23 the plastic material is a waste plastic material, an olefin polymer (OP), or a
24 mixture thereof, wherein the olefin polymer (OP) comprises a polypropylene
25 plastic (PP) material.
26 4. The method as claimed in any one of the preceding claims 1 to 3, wherein the
27 coke reducing additive composition is added to the processing unit in an amount
28 varying from:
29 a) about 1 ppm to about 5000 ppm,
30 b) about 5 ppm to about 3000 ppm,
Dorf4082IN
23
1 c) about 5 ppm to about 2000 ppm,
2 d) about 5 ppm to about 1000 ppm, or
3 e) about 5 ppm to about 500 ppm.
4 5. A use of a coke reducing additive composition for simultaneously:
5 (a) reducing coke formation;
6 (b) increasing yield of distillate;
7 (c) converting a waste plastic into a useful chemical commodity;
8 (d) reducing formation of coke deposits on walls of the processing unit; and
9 (e) reducing fouling caused due to deposits of coke products on walls of the
10 processing unit,
11 during a pyrolytic or cracking processing of a material comprising:
12 (i) a combination of a feedstock in the presence of a plastic material;
13 wherein the use comprises a step of treating the feedstock in the presence of the
14 plastic material with a coke reducing additive composition comprising sodium
15 naphthenate, calcium naphthenate, or a mixture thereof in a processing unit
16 containing the feedstock in the presence of the plastic material.
17 6. The use as claimed in claim 5, wherein the feedstock is selected from the group
18 comprising crude oil, vacuum residue, atmospheric residue, asphalted pitch, shale
19 oil, coal tar, clarified oil, residual oils, heavy waxy distillates, foots oil, slop oil or
20 mixture thereof, preferably the feedstock is a vacuum residue feedstock, wherein
21 the vacuum residue feedstock comprises asphaltene.
22 7. The use as claimed in claim 5 or 6, wherein the plastic material is selected from a
23 group comprising a waste plastic material, an olefin polymer (OP), a low-density
24 polyethylene (LDPE), a high-density polyethylene (HDPE), a mix plastic, a
25 polystyrene, a polypropylene, a polyethylene, or a mixture thereof, preferably the
26 plastic material is a waste plastic material, an olefin polymer (OP), or a mixture
27 thereof, wherein the olefin polymer (OP) comprises a polypropylene plastic (PP)
28 material.
29 8. The use as claimed in any one of the preceding claims 5 to 7, wherein the coke
30 reducing additive composition is used in an amount varying from:
31 a) about 1 ppm to about 5000 ppm,
32 b) about 5 ppm to about 3000 ppm,
33 c) about 5 ppm to about 2000 ppm,
34 d) about 5 ppm to about 1000 ppm, or
35 e) about 5 ppm to about 500 ppm.
Dorf4082IN
24
1 9. A method for:
(a) reducing coke formation;
(b) increasing yield of distillate;
2 (c) converting a waste plastic into a useful chemical commodity;
(d) reducing formation of coke deposits on walls of the processing unit; and
(e) reducing fouling caused due to deposits of coke products on walls of the
processing unit,
3 by pyrolysis of a plastic material, wherein the method comprises adding a coke
4 reducing additive composition comprising sodium naphthenate, calcium
5 naphthenate, or a mixture thereof in a processing unit containing the plastic
6 material in the presence of a feedstock.
7
Dated: this 21
st day of July 2023.
E-Signed & E-Filed
[Dr. Ramesh Kumar MEHTA]
Patent Attorney for the Applicants
Registration No. IN/PA-267
of Mehta & Mehta Associates
Dorf4082IN
22
Marked Version
Amended Claims for National Phase Entry
Amendments have been marked on Claims amended under Article 34 of PCT and as annexed to IPRP(II)
We Claim:
1 1. A method for simultaneously:
2 (a) reducing coke formation;
3 (b) increasing yield of distillate;
4 (c) converting a waste plastic into a useful chemical commodity;
5 (d) reducing formation of coke deposits on walls of the processing unit; and
6 (e) reducing fouling caused due to deposits of coke products on walls of the
7 processing unit,
8 during a pyrolytic or cracking processing of a material consisting of comprising:
9 (i) a combination of a feedstock in the presence of a plastic material;
10 wherein the method consists of comprises a step of adding a coke reducing
11 additive composition comprising sodium naphthenate, calcium naphthenate, or a
12 mixture thereof in a processing unit containing the feedstock in the presence of the
13 plastic material.
14 2. The method as claimed in claim 1, wherein the feedstock is selected from the
15 group comprising crude oil, vacuum residue, atmospheric residue, asphalted pitch,
16 shale oil, coal tar, clarified oil, residual oils, heavy waxy distillates, foots oil, slop
17 oil or mixture thereof, preferably the feedstock is a vacuum residue feedstock,
18 wherein the vacuum residue feedstock comprises asphaltene.
19 3. The method as claimed in claim 1 or 2, wherein the plastic material is selected
20 from a group comprising a waste plastic material, an olefin polymer (OP), a low
21 density polyethylene (LDPE), a high density polyethylene (HDPE), a mix plastic,
22 a polystyrene, a polypropylene, a polyethylene, or a mixture thereof, preferably
23 the plastic material is a waste plastic material, an olefin polymer (OP), or a
24 mixture thereof, wherein the olefin polymer (OP) comprises a polypropylene
25 plastic (PP) material.
26 4. The method as claimed in any one of the preceding claims 1 to 3, wherein the
27 coke reducing additive composition is added to the processing unit in an amount
28 varying from:
29 a) about 1 ppm to about 5000 ppm,
30 b) about 5 ppm to about 3000 ppm,
Dorf4082IN
23
1 c) about 5 ppm to about 2000 ppm,
2 d) about 5 ppm to about 1000 ppm, or
3 e) about 5 ppm to about 500 ppm.
4 5. A use of a coke reducing additive composition for simultaneously:
5 (a) reducing coke formation;
6 (b) increasing yield of distillate;
7 (c) converting a waste plastic into a useful chemical commodity;
8 (d) reducing formation of coke deposits on walls of the processing unit; and
9 (e) reducing fouling caused due to deposits of coke products on walls of the
10 processing unit,
11 during a pyrolytic or cracking processing of a material consisting of comprising:
12 (i) a combination of a feedstock in the presence of a plastic material;
13 wherein the use consists of comprises a step of treating the feedstock in the
14 presence of the plastic material with a coke reducing additive composition
15 comprising sodium naphthenate, calcium naphthenate, or a mixture thereof in a
16 processing unit containing the feedstock in the presence of the plastic material.
17 6. The use as claimed in claim 5, wherein the feedstock is selected from the group
18 comprising crude oil, vacuum residue, atmospheric residue, asphalted pitch, shale
19 oil, coal tar, clarified oil, residual oils, heavy waxy distillates, foots oil, slop oil or
20 mixture thereof, preferably the feedstock is a vacuum residue feedstock, wherein
21 the vacuum residue feedstock comprises asphaltene.
22 7. The use as claimed in claim 5 or 6, wherein the plastic material is selected from a
23 group comprising a waste plastic material, an olefin polymer (OP), a low-density
24 polyethylene (LDPE), a high-density polyethylene (HDPE), a mix plastic, a
25 polystyrene, a polypropylene, a polyethylene, or a mixture thereof, preferably the
26 plastic material is a waste plastic material, an olefin polymer (OP), or a mixture
27 thereof, wherein the olefin polymer (OP) comprises a polypropylene plastic (PP)
28 material.
29 8. The use as claimed in any one of the preceding claims 5 to 7, wherein the coke
30 reducing additive composition is used in an amount varying from:
31 a) about 1 ppm to about 5000 ppm,
32 b) about 5 ppm to about 3000 ppm,
33 c) about 5 ppm to about 2000 ppm,
34 d) about 5 ppm to about 1000 ppm, or
35 e) about 5 ppm to about 500 ppm.
Dorf4082IN
24
1 9. A method for:
(a) reducing coke formation;
(b) increasing yield of distillate;
2 (c) converting a waste plastic into a useful chemical commodity;
(d) reducing formation of coke deposits on walls of the processing unit; and
(e) reducing fouling caused due to deposits of coke products on walls of the
processing unit,
3 by pyrolysis of a plastic material, wherein the method consists of comprises
4 adding a coke reducing additive composition comprising sodium naphthenate,
5 calcium naphthenate, or a mixture thereof in a processing unit containing the
6 plastic material in the presence of a feedstock.
7
Dated: this 21
st day of July 2023.
E-Signed & E-Filed
[Dr. Ramesh Kumar MEHTA]
Patent Attorney for the Applicants
Registration No. IN/PA-267
of Mehta & Mehta Associates
Dorf4082IN
25
Original Claims
Claims:
1 1. A coke reducing additive composition for simultaneously:
2 (a) reducing coke formation;
3 (b) increasing yield of distillate;
4 (c) converting a waste plastic into a useful chemical commodity;
5 (d) reducing formation of coke deposits on walls of the processing unit; and
6 (e) reducing fouling caused due to deposits of coke products on walls of the
7 processing unit,
8 during a pyrolytic or cracking processing of a material comprising:
9 (i) a feedstock,
10 (ii) a plastic material, or
11 (iii) a feedstock in the presence of a plastic material;
12 wherein the coke reducing additive composition comprises a naphthenate,
13 preferably sodium naphthenate or a sodium salt or a sodium salt of an organic
14 acid, and more preferably calcium naphthenate or a calcium salt or a calcium salt
15 of an organic acid, or a mixture thereof.
16 2. The coke reducing additive composition as claimed in claim 1, wherein the coke
17 reducing additive composition comprises sodium naphthenate.
18 3. The coke reducing additive composition as claimed in claim 1, wherein the coke
19 reducing additive composition comprises calcium naphthenate.
20 4. The coke reducing additive composition as claimed in any one of the preceding
21 claims 1 to 3, wherein the feedstock is selected from the group comprising crude
22 oil, vacuum residue, atmospheric residue, asphalted pitch, shale oil, coal tar,
23 clarified oil, residual oils, heavy waxy distillates, foots oil, slop oil or mixture
24 thereof.
25 5. The coke reducing additive composition as claimed in claim 4, wherein the
26 feedstock is a vacuum residue feedstock.
27 6. The coke reducing additive composition as claimed in claim 5, wherein the
28 vacuum residue feedstock comprises asphaltene.
29 7. The coke reducing additive composition as claimed in any one of the preceding
30 claims 1 to 6, wherein the plastic material is selected from a group comprising a
31 waste plastic material, an olefin polymer (OP), a low density polyethylene
Dorf4082IN
26
1 (LDPE), a high density polyethylene (HDPE), a mix plastic, a polystyrene, a
2 polypropylene, a polyethylene, or a mixture thereof.
3 8. The coke reducing additive composition as claimed in claim 7, wherein the plastic
4 material is a waste plastic material, an olefin polymer (OP), or a mixture thereof.
5 9. The coke reducing additive composition as claimed in claim 8, wherein the olefin
6 polymer (OP) includes a polypropylene plastic (PP) material.
7 10. The coke reducing additive composition as claimed in any one of the preceding
8 claims 1 to 9, wherein the material comprises a feedstock in the presence of a
9 plastic material.
10 11. A method for simultaneously:
11 (a) reducing coke formation;
12 (b) increasing yield of distillate;
13 (c) converting a waste plastic into a useful chemical commodity;
14 (d) reducing formation of coke deposits on walls of the processing unit; and
15 (e) reducing fouling caused due to deposits of coke products on walls of the
16 processing unit,
17 during a pyrolytic or cracking processing of a material comprising:
18 (i) a feedstock,
19 (ii) a plastic material, or
20 (iii) a feedstock in the presence of a plastic material;
21 wherein the method comprises adding the coke reducing additive composition as
22 claimed in claim 1 in a processing unit containing the feedstock, the plastic
23 material, or the feedstock in the presence of the plastic material.
24 12. The method as claimed in claim 11, wherein the coke reducing additive
25 composition comprises sodium naphthenate.
26 13. The method as claimed in claim 11, wherein the coke reducing additive
27 composition comprises calcium naphthenate.
28 14. The method as claimed in any one of the preceding claims 11 to 13, wherein the
29 material comprises a feedstock in the presence of a plastic material.
30 15. The method as claimed in any one of the preceding claims 11 to 14, wherein the
31 feedstock is selected from the group comprising crude oil, vacuum residue,
32 atmospheric residue, asphalted pitch, shale oil, coal tar, clarified oil, residual oils,
33 heavy waxy distillates, foots oil, slop oil or mixture thereof, preferably the
34 feedstock is a vacuum residue feedstock, wherein the vacuum residue feedstock
35 comprises asphaltene.
Dorf4082IN
27
1 16. The method as claimed in any one of the preceding claims 11 to 15, wherein the
2 plastic material is selected from a group comprising a waste plastic material, an
3 olefin polymer (OP), a low density polyethylene (LDPE), a high density
4 polyethylene (HDPE), a mix plastic, a polystyrene, a polypropylene, a
5 polyethylene, or a mixture thereof, preferably the plastic material is a waste plastic
6 material, an olefin polymer (OP), or a mixture thereof, wherein the olefin polymer
7 (OP) comprises a polypropylene plastic (PP) material.
8 17. The method as claimed in any one of the preceding claims 11 to 16, wherein the
9 coke reducing additive composition is added to the processing unit in an amount
10 varying from:
11 a) about 1 ppm to about 5000 ppm,
12 b) about 5 ppm to about 3000 ppm,
13 c) about 5 ppm to about 2000 ppm,
14 d) about 5 ppm to about 1000 ppm, or
15 e) about 5 ppm to about 500 ppm.
16 18. A use of a coke reducing additive composition for simultaneously:
17 (a) reducing coke formation;
18 (b) increasing yield of distillate;
19 (c) converting a waste plastic into a useful chemical commodity;
20 (d) reducing formation of coke deposits on walls of the processing unit; and
21 (e) reducing fouling caused due to deposits of coke products on walls of the
22 processing unit,
23 during a pyrolytic or cracking processing of a material comprising:
24 (i) a feedstock,
25 (ii) a plastic material, or
26 (iii) a feedstock in the presence of a plastic material;
27 wherein the use comprises treating the feedstock, the plastic material, or the
28 feedstock in the presence of the plastic material with the coke reducing additive
29 composition as claimed in claim 1 in a processing unit containing the feedstock,
30 the plastic material, or the feedstock in the presence of the plastic material.
31 19. The use as claimed in claim 18, wherein the coke reducing additive composition
32 comprises sodium naphthenate.
33 20. The use as claimed in claim 18, wherein the coke reducing additive composition
34 comprises calcium naphthenate.
Dorf4082IN
28
1 21. The use as claimed in any one of the preceding claims 18 to 20 wherein the
2 material comprises a feedstock in the presence of a plastic material.
3 22. The use as claimed in any one of the preceding claims 18 to 21, wherein the
4 feedstock is selected from the group comprising crude oil, vacuum residue,
5 atmospheric residue, asphalted pitch, shale oil, coal tar, clarified oil, residual oils,
6 heavy waxy distillates, foots oil, slop oil or mixture thereof, preferably the
7 feedstock is a vacuum residue feedstock, wherein the vacuum residue feedstock
8 comprises asphaltene.
9 23. The use as claimed in any one of the preceding claims 18 to 22, wherein the
10 plastic material is selected from a group comprising a waste plastic material, an
11 olefin polymer (OP), a low density polyethylene (LDPE), a high density
12 polyethylene (HDPE), a mix plastic, a polystyrene, a polypropylene, a
13 polyethylene, or a mixture thereof, preferably the plastic material is a waste plastic
14 material, an olefin polymer (OP), or a mixture thereof, wherein the olefin polymer
15 (OP) comprises a polypropylene plastic (PP) material.
16 24. The use as claimed in any one of the preceding claims 18 to 23, wherein the coke
17 reducing additive composition is used in an amount varying from:
18 a) about 1 ppm to about 5000 ppm,
19 b) about 5 ppm to about 3000 ppm,
20 c) about 5 ppm to about 2000 ppm,
21 d) about 5 ppm to about 1000 ppm, or
22 e) about 5 ppm to about 500 ppm.
23 25. A method for converting a waste plastic into a useful chemical commodity by
24 pyrolysis of a plastic material.