Effect of Sodium Dodecyl Benzenesulfonate on the Coke Formation

Dec 8, 2014 - The results showed that the order of reducing the total coke yield was ... restraining the adsorption of asphaltene on the reactor surfa...
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The Effect of Sodium Dodecyl Benzene Sulfonate (SDBS) on the Coke Formation during Slurry-bed Hydrocracking of an Atmospheric Residue from Karamay Chuan Li, Junle Song, Xingwang Wang, and Wenan Deng Energy Fuels, Just Accepted Manuscript • Publication Date (Web): 08 Dec 2014 Downloaded from http://pubs.acs.org on December 9, 2014

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The Effect of Sodium Dodecyl Benzene Sulfonate (SDBS) on the Coke Formation during Slurry-bed Hydrocracking of an Atmospheric Residue from Karamay Chuan Li*, Junle Song, Xingwang Wang, Wenan Deng State Key Laboratory of Heavy Oil, China University of Petroleum, Qingdao, Shandong 266580, PR China Chuan Li, E-mail: [email protected]; [email protected]

Abstract: The effect of sodium dodecyl benzene sulfonate (SDBS) on the coke formation during slurry-bed hydrocracking of an atmospheric residue from Karamay (KAR) was studied, and other 3 kinds of surfactants, dodecyl trimethyl ammonium bromide (DTAB), oleic acid (OA) and coconut amine (CA), were used to compare with SDBS to deduce the reason of SDBS restraining the coke formation. The functional groups on the asphaltene surface and the effects of surfactants on the mean particle diameter of catalyst, colloidal stability of reaction system and adsorptivity of asphaltene were investigated to find the reason of surfactant restraining the coke formation. The results showed that the order of reducing total coke yield was CA>SDBS>OA≈none>DTAB, and the order of reducing the coke on the reactor surface (Cokesur) was SDBS>OA≈none>CA>DTAB. SDBS was the best surfactant to restrain coke formation during slurry-bed hydrocracking of KAR. The effects of surfactants on the colloidal stability of reaction system were in accord with the effects of surfactants on total coke yield, and the effects of surfactants on the adsorptivity of asphaltene were in accord with the effects of surfactants on Cokesur, which meant SDBS strengthening the colloidal stability of system and lengthening the induction period of coking was an important factor to reduce the total 1

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coke yield, and restraining the adsorption of asphaltene on the reactor surface is the key factor to reduce Cokesur. The analysis of XPS data shows the KAR asphaltene is basic, and SDBS has acidic functional group and suitable straight alkane chain length, making SDBS can react with the basic KAR asphaltene particle to realize the effects on the colloidal stability of reaction system and the adsorptivity of KAR asphaltene. Key words: Surfactant; Coke formation; Colloidal stability; Adsorptivity of asphaltene; Slurry-bed hydrocracking 1. Introduction Slurry-bed hydrocracking of residue is one of the processes converting heavy oil to light oils. 1-4 The residue mixed with unsupported dispersed catalysts enters the reactor, and conducts cracking reactions at 420~460 °C under hydrogen pressure of 10~20 MPa. 5 Lots of cracking reactions at high temperature lead to high conversion of residue, but cause the question of coking at the same time, which is the bottleneck to industrialize this technology. Much effort about process flow, structure of reactor, catalyst and additive has been made to reduce coke formation, especially coke formation on the reactor surface, during slurry-bed hydrocracking of residue.

6-9

Among these investigations,

adding some surfactants to restrain coking is a relatively simple method to solve this problem.

10,11

But unfortunately, there are no reports demonstrating the reason of surfactant restraining coking definitely. So investigators can not chose the suitable surfactant according to the properties of feed oil. Asphaltene usually be treated as the predecessor of coke, 12 so studying the effects of surfactant on asphaltene should be a right way to reveal the reason of surfactant restraining coking. At present, a large number of literatures about the effects of different surfactants on the properties of asphaltene have been reported. 13-21 These investigations increased understanding of the effects of surfactants with different chain length and functional group on the properties of asphaltene, such as the polarity, 2

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the associativity, the dispersity, etc. But the relationship between the properties of asphaltene and restraining coke formation has not been determined. This investigation was based on the process of coking, studying the effects of 4 kinds of surfactants on the hydrogenation ability of catalyst, the colloidal stability of reaction system and the adsorptivity of asphaltene, and combining with the effects of these surfactants on the coke formation to find the reason of surfactant restraining the coke formation during slurry-bed hydrocracking of residue. 2. Experimental Section 2.1. Materials The feedstock in the slurry-bed hydrocracking experiments was an atmospheric residue from Karamay (KAR) (density at 20 °C - 0.9670 g·cm-3; viscosity at 80 °C - 2104 mm2·s-1; sulfur – 0.63 wt.%; nitrogen – 0.77 wt.%; H/C atomic ratio – 1.61; C7 asphaltene – 0.75 wt.%; Conradson carbon residue (CCR) – 8.89 wt.%; and heavy metals: V – 51.2 µg·g-1, Ni – 46.7 µg·g-1). The catalyst was a self-manufactured oil-soluble catalyst, and the surfactants were sodium dodecyl benzene sulfonate (SDBS), dodecyl trimethyl ammonium bromide (DTAB), oleic acid (OA) and coconut amine (CA). SDBS and OA are the surfactants with acidic functional group and OA has longer alkane side chain than SDBS. DTAB and CA have basic functional group with different alkane side chain length. 2.2. Apparatus and methods 2.2.1. The slurry-bed hydrocracking reactions The slurry-bed hydrocracking reaction was conducted in a 500 mL autoclave. A certain amount of KAR with 50 µg·g-1 catalyst expressed as metal atoms, 200 µg·g-1 surfactant and 200 µg·g-1 sulfur was put in the reactor stirred thoroughly at 800 rpm, and the slurry-bed hydrocracking reaction was processed at 435 °C under a hydrogen pressure of 12 MPa for 10 min, 20 min, 30 min, 40 min, 50 min and 60 min. Then the reactor was cooled by cold water to cease the reaction. 3

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The oil products contained catalyst and coke in liquid phase (Cokeliq) were collected and weighted. About 15 g oil products were used to measure the colloidal stability and the left were distilled to obtain light oil (SDBS>OA≈none>DTAB, and the order of reducing Cokesur was SDBS>OA≈none>CA>DTAB. SDBS was the best surfactant to restrain coke formation during slurry-bed hydrocracking of KAR.

Table 1. The yield of liquid product with different surfactants Surfactant

The yield of liquid product (wt.%) 7

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Light oil

AR

None*

45.14

51.23

SDBS

44.25

52.18

DTAB

45.62

51.02

OA

45.10

51.25

CA

44.03

52.87

*none means the reaction system adds no surfactant. 0

2

4

6

2.0

8

10

total coke cokesur cokeliq

1.5

Coke yield (wt.%)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

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1.0

0.5

0.0 1 none

2 3 4 OA SDBS DTAB The type of surfactant

5 CA

Figure 2. The coke yield with different surfactants 3.2. Effects of surfactants on the mean particle diameter of catalyst and the colloidal stability of reaction system Some investigations show that the mean particle diameter of catalyst is smaller, the hydrogenation activity of catalyst during slurry-bed hydrocracking is better.

24

The catalyst with

small mean particle diameter should have good activity to restrain the coke formation. But as shown in Figure 3, SDBS could increase the mean particle diameter of catalyst, and the order of reducing mean particle diameter of catalyst was OA>CA>DTAB>none>SDBS which did not conform to the order of reducing total coke yield and the order of reducing Cokesur. So, the effect of surfactant on the catalyst was not the key factor of reducing coke formation. 8

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Energy & Fuels 0

4

6

8

10 10

8 7

Mean particle diameter (µ m)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

2

8

6 6

5 4

4 3 2 2 1 0

0 1 none

2 3 4 OA SDBS DTAB The type of surfactant

5 CA

Figure 3. The effects of surfactants on mean particle diameter of catalyst As demonstrated in Fig. 4, prolonging reaction time could reduce the colloidal stability of system, and the colloidal stabilities of system with no surfactant and with DTAB or OA decreased quickly after reacting 40 min which illustrated the system begin producing coke quickly. While the colloidal stabilities of system with CA and SDBS decreased quickly after reacting 50 min, which meant CA and SDBS could strengthen the colloidal stability of system and lengthen the induction period

of

coking.

The

order

of

strengthening

colloidal

stability

of

system

was

CA>SDBS>OA≈none>DTAB which was in consonance with the order of reducing total coke yield, but did not conform to the order of reducing Cokesur. So, the surfactant strengthening the colloidal stability was an important factor to decrease the total coke yield, but was not the key factor to reduce Cokesur.

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Energy & Fuels 0

2

4

6

8

10 10

4.5

none SDBS DTAB 8 OA CA

4.0

3.5

Value of CSP

6

3.0 4 2.5 2 2.0

1.5

0 10

20

30

40

50

60

Reaction time (min)

Figure 4. The effects of surfactants on colloidal stability of reaction system 3.3. Effects of surfactants on the adsorptivity of asphaltene As shown in Figure 5, all of adsorption rate increased as adsorption time increasing. But surfactants could change the adsorption rate. The order of decreasing adsorption rate was SDBS>OA≈none>CA>DTAB, which was in accord with the order of reducing Cokesur. 0

2

4

6

8

10 10

none SDBS DTAB OA CA

1.5

Adsorption rate (%)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

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8

6 1.0 4

0.5 2

0.0

0 0

20

40

60

80

Adsorption time (min)

Figure 5. The effects of surfactants on the adsorption rate of asphaltene with different adsorption time when the reaction time is 60 min Furthermore, the adsorption rate increased with adsorption time linearly when the reaction system had no surfactant and was added DTAB, CA and OA. But when adding SDBS, the increased extent of adsorption rate was in accord with other conditions basically before adsorbing 40 min, and 10

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then slowed down gradually. This phenomenon meant asphaltene molecules adsorbed on the surface of steel disc to form a single-molecule layer of asphaltene at the beginning of adsorption, and all of the surfactants had no effect on this step basically. Then the asphaltene molecules would keep adsorbing to form a multi-molecule layer of asphaltene. In this step, DTAB, CA and OA could not restrain the formation of multi-molecule layer of asphaltene except SDBS. The addition of SDBS could decrease the adsorption rate of multi-molecule layer of asphaltene by blocking the interaction between asphaltene molecules. As shown in Table 2, the effects of surfactants on the adsorption of asphaltene with other reaction time and adsorption time were similar to the situation shown in Fig. 5. So, the surfactant restraining the adsorption of asphaltene on the reactor surface should be the key factor of reducing Cokesur.

Table 2. The effects of surfactants on the adsorption rate of asphaltene with different reaction time and adsorption time Adsorption rate in different adsorption time (%) Surfactant

none

SDBS

DTAB

Reaction time (min) 0min

20min

40min

60min

80min

0

0

0.14

0.23

0.35

0.48

20

0

0.20

0.39

0.52

0.73

40

0

0.31

0.53

0.81

1.11

0

0

0.12

0.18

0.21

0.24

20

0

0.18

0.25

0.29

0.32

40

0

0.28

0.35

0.40

0.44

0

0

0.18

0.34

0.48

0.60

20

0

0.25

0.50

0.77

0.96

40

0

0.35

0.69

0.98

1.32

11

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OA

CA

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0

0

0.13

0.21

0.34

0.46

20

0

0.19

0.37

0.50

0.70

40

0

0.29

0.51

0.79

1.08

0

0

0.15

0.27

0.44

0.55

20

0

0.23

0.44

0.63

0.82

40

0

0.33

0.62

0.90

1.23

The reason of SDBS taking effect might be explained from the XPS data of KAR asphaltene. The information of functional groups can be obtained from the XPS spectra of KAR asphaltene particles (Figure 6). As listed in Table 3, on the surface of KAR asphaltene, 87.70 mol% of total elements were the carbon atoms existing in C—C and C—H. The functional group of C=O was the main structure of oxygen-containing groups, of which the oxygen atoms accounted for 1.81 mol% of total elements. The nitrogen atoms in pyrrolic N and the sulfur atoms in thiophenic S accounted for 0.51 mol% and 0.06 mol% of total elements respectively. The functional groups of C=O, pyrrolic N and thiophenic S were considered neutral basically. The oxygen atoms in acidic functional group of COO accounted for 0.20 mol% of total elements, besides hydroxyl group and phenolic group might exist in C-O (accounting for 0.25 mol% of total elements), and thiol group and phenyl-sulfhydryl group might exist in aliphatic S (accounting for 0.04 mol% of total elements), which were all acidic. So the amount of total acidic functional groups should be less than 0.49 mol%. While the nitrogen atoms in basic pyridinic N accounted for 2.49 mol% of total elements, which were much more than the acidic functional groups. So the KAR asphaltene should be basic. The surfactant with acidic functional group is easier to react with KAR asphaltene through the acidic functional group and adsorb on the surface of asphaltene molecules gradually than the surfactant with basic functional group. But the interaction of asphaltene and surfactant is not only associated with the functional group of surfactant, but also the side chain length of surfactant. Only the surfactant with a straight 12

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alkane chain length of 6~16 carbons can act with asphaltene effectively.

21

Both SDBS has acidic

functional group and a straight alkane chain length of 12 carbons, so it can act with KAR asphaltene effectively to restrain the coke formation. OA also has an acidic functional group, but the straight alkane chain length of OA is 18 carbons, which will reduce the solubility of OA in oil and cause crystallization to restrain the interaction of OA and KAR asphaltene.

21

DTAB and CA have basic

functional group, so they can not adsorb on the surface of basic KAR asphaltene effectively. So, the reason of SDBS restraining coke formation during slurry-bed hydrocracking of KAR is that SDBS has acidic functional group and suitable straight alkane chain length, which make SDBS can react with the basic KAR asphaltene particle, strengthening the colloidal stability of system and lengthening the induction period of coking to decrease the total coke yield, and restraining the adsorption of asphaltene on the reactor surface to decrease Cokesur.

Figure 6. The XPS spectra of KAR asphaltene particles Table 3. Mole fractions of functional groups containing C, O, N and S on the surface of KAR asphaltene

13

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Atom

Aiy (mol%)

Ciy (mol%)

92.66

87.70

C binding with O

7.34

6.95

C=O

80.39

1.81

10.90

0.25

COO

8.70

0.20

Pyridinic N

83.02

2.49

16.98

0.51

44.90

0.04

55.10

0.06

Group type

Wi (wt.%)

Mi (mol%)

87.31

94.65

C-C, C-H C

O

N

Page 14 of 17

C-O

2.77

2.25

3.23

Pyrrolic N

3.00

Aliphatic S S

0.25

0.10

Thiophenic S

4. Conclusions During the slurry-bed hydrocracking reaction of KAR, SDBS could reduce the total coke yield and Cokesur. SDBS has acidic functional group and suitable straight alkane chain length, making SDBS can react with basic KAR asphaltene. SDBS strengthening the colloidal stability of system and lengthening the induction period of coking was an important factor to reduce the total coke yield, and restraining the adsorption of asphaltene on the reactor surface was the key factor to reduce Cokesur.

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Acknowledgement This work was supported by National Natural Science Foundation Young Investigator Grant Program of China (No. 21106186) and the Fundamental Research Funds for the Central Universities ( No. 14CX05032A).

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