Method for producing resinous pitch
United States Patent 1191 Kawai et a1.  
 :22] Filed: May 16, 1973 :21] Appl. No.2 360,906  
 Related U.S. Application Data :63] Continuation-impart of Ser. No. 165,333, July 22, 1971, abandoned, which is a continuation-in-part of Ser. No. 813,330, April 3, 1969, abandoned.  
 30] Foreign Application Priority Data Apr. 4, 1968 Japan 43-21948 Apr. 20, 1948 Japan 43-26350 Apr. 20, 1968 Japan 43-26351 52] U.S. C1. 208/40; 106/273; 208/22;  
  208/42; 208/67; 208/100; 260/679 R 51] Int. Cl. C106 l/04;C10g 9/00 [4 1 Apr. 15, 1975 [58] Field of Search 106/273, 284, 679 R; 208/10, 41, 68, 73, 74, 40, 108, 100, 22, 40, 42, 67; 264/29, 105  
 [56] References Cited UNITED STATES PATENTS 2,305,440 12/1942 Noel 2.08/22 2,903,409 9/1959 Horse 2118/22 2,944,958 7/1960 Goldthwait et a1v 208/22 3.318801 5/1967 Alexander et a1. 208/40 3.350295 10/1967 Hamner et a1. 2.08/4 3,617,477 11/1971 Gomi 208/40 Primary Examiner-Herbert Levine Attorney, Agent, or FirmFitzpatrick, Cella, Harper &amp; Scinto [57] ABSTRACT A process for producing a resinous pitch composition in powder form, wherein a crude oil or liquid fraction thereof is subjected to thermal cracking for acetylene production to obtain a tarry substance therefrom, the substance is then distilled at a specified temperature and under pressure to result in a pitch product having enhanced properties; and the product is finally ground into powder form.  
 2 Claims, No Drawings METHOD FOR PRODUCING RESINOUS PITCH REFERENCE TO THE RELATED APPLICATIONS This is a continuation-impart application of our copending application Ser. No. 165.333. filed July 22. 1971. for Resinous Pitch Compositions and Formed Articles Thereof. now abandoned, which in turn is a continuation-in-part application Ser. No. 813.330. filed Apr. 3. 1969 for the same title of invention and now abandoned.  
 BACKGROUND OF THE INVENTION 0. Field of Invention This invention relates generally to petroleum hydrocarbon products and&#39; to resinous pitch. More particularly. the invention is concerned with new resinous pitch containing as constituent components thereof aromatic rings or aromatic rings and aliphatic rings. to the production of these pitch. and to the production of materials in powder form by subjecting these pitch compositions to various treatments.  
 b. Discussion of Prior Art As a pitch-like substance generally used as a protecting material. such as a heat-shield material. thermal insulation material. and sealing material. an asphalite known as gilsonite has heretofore been well known. one seller of this material being the American Gilsonite Company.  
  While gilsonite is a very useful material. its quality is not necessarilyconstant in all cases. and the securing of a stable supply quantity is also difficult. since this material is a bituminous material of natural occurrence. Accordingly. there has been a great demand for asynT-thetic material which has a consistent quality and canbe supplied in ample quantity at low price.  
  In an attempt to solve this problem. there have been made a variety of trials to produce materials of a structure and properties similar to those of gilsonite with asphalt fractions from petroleum refineries. However. there has been no success to date in supplying economically a powder material having characteristics equivalent to those of gilsonite.  
  Furthermore. bituminous substances have heretofore been applied as architectural or constructional materials for civil engineering generally by heating these substances to or above their softening temperatures. or by cutting back these substances with suitable light oils. and then applying the resulting fluid-state materials. The purpose of such cutting back is to lower the viscosity of the asphalt or pitch-like substance clue to the dissolving thereof by the addition of the light oils thereby to improve the applicability of the bituminous material and preservability thereof over a long period. Most of the added light oils are caused to be removed by evaporation after application of the bituminous material.  
  Also. there has been known various techniques of producing pitches useful for such purposes from residual oils of petroleum cracking such as. for example. US. Pat. No. 3,318,801, 3.350.295. and so forth.  
  The process US. Pat. No. 3.318.801 is to subject crude petroleum to thermal cracking at a temperature within a normal range of from 1.400 to l .600F (760 to 872C), from which ethylene. propylene. etc. are produced. The bottom oil remaining after production of such hydrocarbons is used as the raw material, which is subjected to soaking at a temperature range of from 750F to 900F (400 to 483C) to obtain pitches.  
  On the other hand. US. Pat. No. 3.350.295 teaches to cause residual oils from petroleum distillation or residual oils from contact-decomposition or thermal decomposition of gas oil fractions to dealkylation reaction in a fluidized coker at a temperature range of from l.300 to 1.600F (704 to 872C). and subsequently to cause the dealkylated substance to oxidation to obtain pitch for manufacturing electrodes.  
  The pitches produced by these existing prior art process exhibit the softening temperature of 250F 121C) and contain the benzene insoluble component of below 25%. It should be recognized that where the temperature range for the thermal cracking differs. these would yield different sorts of cracked residue. and this difference in the resultant product results in difference in the benzene insoluble component and softening point of the substance. The pitches of the prior art process are of such low benzene insoluble component and softening point that they do not meet the purpose of the present invention.  
 SUMMARY OF THE INVENTION In view of the above-described state of the art. it is an object of the present invention to utilize certain findings we have made as described hereinafter in overcoming the above-described difficulties accompanying the prior art. particularly. the use of natural asphalt and asphaltites.  
  More specifically. it is a primary object of the invention to provide synthetic pitch compositions in powder form of a quality in characteristics and applicability equal or superior to those of natural bituminous substances.  
  According to the present invention. briefly summa rized. there is provided a process for producing resinous pitch which comprises steps of causing crude oil or liquid fractions thereof to undergo thermal cracking for acetylene production at a temperature of from l.l00 to 1.500C under normal pressure with a heat medium of combustion flame or high temperature steam for a contact time of from 0.1 to 0.001 second to produce a tarry substance. then heating the thus obtained tarry substance under pressure ranging from normal pressure to 10 kg/cm (atm.) at a temperature of from 250 to 450C to distill light oil fractions including volatile matters. whereby there is obtained a final pitch product of an H/C atomic ratio of from 0.4 to 0.65. containing no nitrogen and oxygen, a softening point of from 150 to 400C. a benzene-insoluble component of from 50 to percent by weight. a specific gravity of from 1.2 to 1.5. and a grindability of from 4 to 200 meshes. a fixed carbon content of from 60 to 85. and mean molecular weight of from 60 to 3.000. and this final pitch product is ground to produce a pitch in powder form.  
  The nature. details. and utility of the present invention will become more apparent from the following detailed description beginning with general considerations and concluding with specific examples of practice constituting preferred embodiments of the invention.  
 bond chains based on paraffinic &#34;type carbon due to X-ray analysis. is composed mainly of aromatic rings.  
 or aromatic rings and aliphatic rings with a few side chains and bond chains based on paraffinic type carbon.  
  We have found that such a pitch composition having a new structure as described above and, moreover. having characteristics equal or superior to those of known natural asphalts and other bituminous materials can be readily prepared by subjecting a crude oil or liquid fraction thereof, naphtha (gasoline fraction), kerosene, gas oil, or fuel oil to first-stage process comprising thermal cracking for acetylene production at a high temperature above 1,lOC and below l,500C under normal pressure with a heat medium of combustion flame or high temperature steam for a contact time of the order of from 0.001 to 0.1 second, subjecting the resulting tarry substance to a second-stage process comprising heat treatment at a temperature of from 250 to 450C under pressure ranging from normal pressure to kg/cm (atm.) to distill light oil fractions from the process material. and to prepare the pitch from the residue thus formed.  
  We have found that, by carrying out ordinary hydrogenation between the first-stage heating process and the second-stage heating process to cause transformation of one portion of the aromatic rings into aliphatic rings and then carrying out the second-stage heating process, a pitch of highly desirable characteristics can also be produced.  
  The purpose or significant mechanism of the firststage reaction comprises cracking the petroleum hydrocarbon at a high-temperature to convert one portion thereof into a gaseous substance containing acetylene and ethylene and, at the same time, to cause one portion thereof to undergo polycondensation, thereby converting the same into a polycondensation product of predominantly fused aromatic rings. During this process, substances such as nitrogen and oxygen which tend to become causes of polar structure are almost discharged into gases and removed.  
  The purpose or significant mechanism of the abovementioned second-stage reaction comprises removing the oily substances in the tarry substance obtained by the first-stage reaction thereby to produce a pitch. We have found that this distilling operation is preferably carried out under pressure ranging from normal pressure to 10 kg/cm and at a temperature range of from 250 to 450C. Below 250C, there would remain some amount of light oil fractions, the principal component of which is aromatic hydrocarbons having a boiling point below 250C such as benzene, toluene, xylene, naphthalene, methylnaphthalene, acenaphthene, indene, and so forth, and which adversely affect the properties of the resulting pitch composition, while, at a process temperature above 450C, there inevitably takes place deterioration of the properties of the pitch due to coking.&#34;  
  The significant mechanism of the hydrogenation process carried out prior to the second-stage heating process is the transformation of a portion of the aromatic rings into aliphatic rings to lower the softening point of the product and to afford great convenience and facility in applications of the powder pitch for the wide range of uses thereof,  
  The tarry substance obtained by the process at a high temperature above&#39; l:,l00C to be used in the production of thispitch composition is a by&#39;-product produced in large quantities in industries such as the petrochemical industry having the object of producing oletins and the gas-producing industry in which crude oils or fuel oils are decomposed at high temperatures and, in most cases. is regarded as a waste material.  
  The pitch in powder form produced in the abovedescribed manner is particularly suitable for use as an insulating material, for which purpose it is necessary that this material have the following characteristics.  
 used as a protective and insulative material, it exhibited marked superiority over conventionally used natural asphalts in water-repelling property and durability relative to effects of water and was far superior also in thermal insulation.  
  Furthermore, in application as a coating on metal surfaces, the pitch of the invention was found to be far superior in adhesivity with respect to the metal surfaces.  
 This material has been found to be highly effective;  
 for protection and thermal insulation of various pipings such as those for chilled water, hot water, and steam and for underground pipings.  
  The terms powder&#34; and powdered form&#34; as used in this specification designate powder material of any particle size passing through a sieve of 4-mesh size.  
  In its use as various protective materials as enumerated above, the pitch according to the present invention can, of course, be used solely but depending on the necessity or intended use, various materials as, for example, bituminous materials such as asphalts, coal tar pitches, and natural asphalts and asphaltites and inorganic substances such as clays, silica, and pearlite may be added to the pitch.  
 PREFERRED EMBODIMENT OF THE INVENTION In order to indicate still more fully the nature and utility of the present invention, the following examples of practice constituting preferred embodiment thereof and results as set forth, it being understood that these examples are presented as illustrative only and that they are not intended to limit the scope of the present invention.  
 EXAMPLE 1 Naphtha was cracked under the conditions of a reaction temperature of 1,200C and a contact time of 0.03 second, whereupon tarry substances and gaseous substances such as acetylene and ethylene were obtained. This tarry substance was divided into three sample lots, which were dry-distilled to remove more light oil fraction containing volatile matter, and thus ground respectively to a mesh size of from to 200 under the follow- Benzene Sample Specific Insoluble No. H/C Gravity Component 1 0.5 l l .3 8 70 2 0.53 l .35 65 3 0.60 l .28 52 Each of the samples thus prepared was placed in a 2 pipe of inner diameter of 3 cm to a thickness (depth) of 5 cm. and an electrode was enclosed therewithin at a position 1 cm from the top thereof. Water pressure was then applied to each sample through the pipe. and the water pressure at which water infiltrated through the sample to the electrode to cause a fluctuation in a meter connected to the electrode was measured as an indication of the water-repellent property of the sample.  
  The results of comparison of the water-repellent properties of these sample compositions with those of two asphalts generally sold on the market as indicated in Table 1 below.  
 Table l SAMPLE (Particles SOFTENING WATER- passing 100-mesh. POINT REPELLENT remaining on PROPERTY 200-mesh sieve) (C) (kg/em l 230 250 1.0 2 I60 170 0.95 3 150 155 0.85 Natural asphalt (A) 60 165 0.5 Natural asphalt (B) 135 I40 0.3  
 and water-repellent property.  
 EXAMPLE 2 A holder structure of concrete was installed outdoors in the ground. and a l-inch pipe was fixed thereto. Next, sample 1 of Example 1 was placed around the pipe to a thickness of 10 cm and was compacted by tamping. A 30-cm layer of earth and sand was then laid to cover the sample 1 and compacted. The sample was then left for three months, after which the pipe was disinterred and was found to be unchanged.  
  In contrast. when the natural asphalt (A) was used in place of sample 1 and installed under the same conditions as set forth above, the pipe was found after three months to have rusted.  
  In addition, a portion of the coating material according to the present invention after compaction by tamping was taken, and the thermal conductivity and density thereof were measured, whereupon the following excellent results were obtained.  
 Density:  
 What we claim is:  
  l. A process for producing a resinous pitch composition which consists essentially of:  
 a. subjecting naphtha to thermal cracking for acetylene production at a temperature of from l,100 to l,500C. under normal pressure with a heat medium selected from the group consisting of combustion flame and high temperature steam for a contact time of from 0.001 to 0.1 second to produce a tarry substance:  
 b. further subjecting said tarry substance to distillation under pressure ranging from normal pressure to l0kg/cm (atm.) at a temperature of from 250 to 450C. to remove light oil fractions including volatile matter therefrom; and  
 c. grinding the heat-treated product into powder form having a particle size range of from 4 to 200 meshes,  
 said ground product being characterized by a softening point of from 150 to 400C, a benzeneinsoluble component of from 50 to by weight. and a specific gravity of from 1.2 to L5.  
  2. The process according to claim 1, further including the step of subjecting the substance obtained from the thermal cracking step to hydrogenation prior to said distillation step to cause transformation of a portion of the aromatic rings in said cracked naphtha into aliphatic rings.  
 Patent No EQ&#39;HN Dated April 15, 1975 Inventor(s) It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:  
 Front page, at &#34;[75] Inventors:&#34;, line 5 thereof, change YOSHIO KAWAI et a1 &#34;Nobuo Hatazawa&#34; Column 1,  
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 [SEAL] to Hiromitsu Makita&#34; line 8, after &#34;application&#34; insert of line 61, after &#34;process&#34; insert of line 10, change &#34;cess&#34; to cesses line 18, change process&#34; to processes.  
 line 67, after &#34;by-product&#34; insert presently line 33, change &#34;market as&#34; to market are A ttest:  
 RUTH C. MASON Arresting Officer C. MARSHALL DANN (mnmissimur ofPaIenIs and Trademarks