Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Contents lists available at ScienceDirect Journal of Industrial and Engineering Chemistry journal homepage: www.elsevier.com/locate/jiec Development of correlations between deasphalted oil yield and Hansen solubility parameters of heavy oil SARA fractions for solvent deasphalting extraction Jun Woo Park a,1, Min Yong Kim a,b,1, Soo Ik Im a, Kang Seok Go b, Nam Sun Nho b,⇑, Ki Bong Lee a,⇑ a b Department of Chemical and Biological Engineering, Korea University, 145 Anam-ro, Seongbuk-gu, Seoul 02841, Republic of Korea Climate Change Research Division, Korea Institute of Energy Research (KIER), 152 Gajeong-ro, Yuseong-gu, Daejeon 34129, Republic of Korea a r t i c l e i n f o Article history: Received 19 October 2021 Revised 8 December 2021 Accepted 11 December 2021 Available online 17 December 2021 Keywords: Solvent deasphalting Solvent extraction Deasphalted oil Hansen solubility parameters Heavy oil upgrading SARA analysis a b s t r a c t Solvent deasphalting (SDA) is a heavy oil upgrading process that selectively extracts deasphalted oil (DAO) and rejects asphaltenes. In this study, a quantitative analysis was conducted to predict DAO yields in the SDA process using relative energy difference (RED); the RED was calculated from Hansen solubility parameters (HSPs) of the feedstock and extraction solvent along with the extraction conditions, such as temperature and solvent-to-oil ratio (SOR). SDA extraction experiments were performed in a continuous bench-scale unit using vacuum residue (VR) and a mixture of bunker C fuel oil (BC) and VR as feedstocks. The HSPs of saturate, aromatic, resin, and asphaltene fractions derived from the VR and BC were measured using solubility tests, wherein the fractions were dissolved in 37 different solvents. Finally, simple and accurate correlations between the DAO yield and corresponding modified RED were acquired and used to explain the effects of temperature and SOR on the DAO yield. Ó 2021 The Korean Society of Industrial and Engineering Chemistry. Published by Elsevier B.V. All rights reserved. Introduction The International Energy Agency expects petroleum demands to increase from 96.8 mbbl/day in 2017 to 111.1 mbbl/day in 2040 [1]. As the reserves of crude oil have reduced and its quality has degraded, many attempts to utilize unconventional oils, such as heavy oil, extra-heavy oil, and oil sands bitumen, are ongoing to balance the increasing demand for oil and its supply [2,3]. Although the reserves of heavy oil are sufficiently large, the asphaltenes constituents contain significant amounts of sulfur and heavy metals (V and Ni), which are attributable to coke formation and catalyst poisoning. Therefore, unconventional oils cannot be directly applied to the refining processes designed for conventional oils, necessitating more advanced heavy oil upgrading processes [4–7]. Heavy oil upgrading processes can be classified into hydrogen addition and carbon rejection. Hydrogen addition processes, such as catalytic and non-catalytic hydrogenation, increase the H/C ratio of hydrocarbon feedstock, require harsh reaction conditions (i.e., high temperature and high pressure), and impose high operating ⇑ Corresponding authors. 1 E-mail addresses: nsroh@kier.re.kr (N.S. Nho), kibonglee@korea.ac.kr (K.B. Lee). These authors contributed equally. costs. In comparison, carbon rejection processes, such as thermal cracking and solvent extraction, are based on H/C rearrangement without hydrogen supply; some fractions are converted to have higher H/C ratios, while others are converted to have lower H/C ratios. Carbon rejection also has advantage of relatively low capital and operating costs [8,9]. One particular carbon rejection process, solvent deasphalting (SDA), has been receiving attention owing to its relative simplicity, low operating costs, and moderate operating conditions [10]. In the SDA processes, C3–C6 alkane solvents are traditionally used for treating heavy feedstocks, such as atmospheric and vacuum residue (VR). The feedstock is separated into deasphalted oil (DAO) and pitch. The DAO is soluble in the solvent and has higher H/C ratios than the feedstock, and the pitch is insoluble in the solvent and has lower H/C ratios than the feedstock. The produced DAO with very low asphaltene content can be used as the feedstock for upgrading processes, such as fluid catalytic cracking, hydrocracking, and lubricant manufacturing [10,11]. The SDA process is advantageous for the selective removal of asphaltenes and requires lower energy consumption than other reaction-based upgrading processes. However, the liquid–liquid extraction mechanism in the SDA process is complex, and has not yet been clearly explained, despite extraction being the main step in determining the yield and quality of DAO. The optimal operating conditions of the SDA https://doi.org/10.1016/j.jiec.2021.12.015 1226-086X/Ó 2021 The Korean Society of Industrial and Engineering Chemistry. Published by Elsevier B.V. All rights reserved. Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. test the applicability of the proposed correlations for blended heavy oil feedstock. n-Pentane (HPLC grade, Duksan Chemical Co.) was used as the SDA extraction solvent. Column chromatography was used to prepare SAR fractions from VR and BC; n-heptane, toluene, dichloromethane, and methanol (HPLC grade, Daejung Chemical & Metals Co.) were selected as the mobile-phase solvents, and activated alumina (0.05–0.15 mm, neutral, Brockmann Activity I, Sigma Aldrich) was the stationary-phase adsorbent. The elemental compositions of the feedstock were measured using an organic elemental analyzer (Thermo Scientific FLASH, EA-2000) and elemental analyzer (Thermo Scientific FLASH, EA1112). The nickel and vanadium contents were measured using an X-ray fluorescence spectrometer (Oxford Instruments, XSupreme 8000, ASTM D4294). The micro-carbon residue of the feedstock was detected using a micro-carbon residue tester (Alcor, MCRT-160, ASTM D4530). The viscosity of the feedstock was measured using a rheometer (Thermo Scientific, HAAKE RheoStress 6000). The boiling point distribution and American Petroleum Institute (API) gravity of the feedstock and DAO were measured using simulated distillation (SIMDIS, ACG2123, ASTM D7500) analysis and a density meter (Anton Paar, DMA 4500, ASTM D5002), respectively. The molecular weight of the feedstock and DAO was measured using gel-permeation chromatography (Waters, 515 HPLC pump). Here, tetrahydrofuran (HPLC grade, J.T. Baker) was used as the solvent at a flow rate of 1 mL/min; the measurement was carried out at 40 °C. process required to produce the desired DAO are generally determined based on repeated experiments, because predictive models for the yield and quality of DAO are not well established. Previous studies on the SDA process have focused on testing various operating conditions in the extraction [12–18] and solvent recovery steps [19–21], and most research only presented experimental results of the yield and quality of DAO. Although some researchers have attempted to obtain a fundamental understanding of the extraction by introducing a solubility parameter, the relationship between the DAO yield and solubility parameter was only qualitatively analyzed [17,18]. Al-Sabawi et al. showed that the DAO yield was related to the Hildebrand solubility parameter of n-pentane/modifier mixtures; however, this relationship did not reflect all the DAO yields and solubility parameters in the npentane/modifier mixtures [17]. Long et al. found that the DAO yield increased with increasing feedstock ratio of coal tar to VR because the Hildebrand solubility parameter difference between the extraction solvent and coal tar was smaller than that between the extraction solvent and VR [18]. This indicates that the Hildebrand solubility parameter difference between two components is inversely (negatively) correlated to their mutual solubility. However, this explanation did not account for the trend in the DAO yield in some feedstock ratios. The explanations for the solution phenomena that only use the Hildebrand solubility parameter are inappropriate for polar systems [22,23]. To overcome this limitation, Hansen restructured the Hildebrand solubility parameter into dispersion, polar, and hydrogen bonding solubility parameters [24]. Furthermore, the concept of relative energy difference (RED) as a mutual solubility index was introduced; RED values of less than 1.0 indicate complete dissolution, and values greater than 1.0 indicate partial dissolution or insolubility. However, the comparison of systems that have different compositions but identical components was still impossible, because the theory based on the original Hildebrand solubility parameter and Hansen solubility parameters (HSPs) did not consider the compositional effect of the solution. Later, a modified RED was developed, which enabled HSPs to be used in the comparison of systems having various compositions [25]. In this study, a quantitative analysis was conducted by applying the modified RED to predict the DAO yield in the SDA process at various operating conditions, including temperature and solventto-oil ratio (SOR). To the best of our knowledge, the application of the modified RED to heavy oil extraction was first proposed in this study. VR and bunker C fuel oil (BC) were used as heavy oil feedstocks, which were separated into saturate, aromatic, resin, and asphaltene (SARA) fractions. The HSPs of the fractions were obtained from the solubility test by dissolving the fractions in various solvents. To account for the effects of temperature and SOR on the DAO yield, a modified RED was introduced, which was calculated from the HSPs of the extraction solvent and SAR fractions of the feedstock at various temperatures and SORs. Finally, quantitative correlations were made between the DAO yield and corresponding modified RED for the application to SDA extraction to decide operating variables such as temperature, pressure, and SOR for different types of feedstocks to produce desired DAO. Asphaltene precipitation and SAR analysis of feedstock and DAO Asphaltene precipitation was performed by following a modified ASTM D4124 method. First, 1 g of VR or BC sample and 100 mL of n-heptane were mixed in an Erlenmeyer flask, and heated to 90 ± 5 ℃, while being stirred for 30 min; the temperature of the mixture was kept constant for an additional 30 min. The mixture was then cooled without stirring under ambient conditions for 1 h, followed by vacuum filtering through filter paper (32–34 mm diameter, 1.5 lm pore size). The asphaltene component that did not pass through the filter paper was collected, and the maltene component was obtained from the filtered solution after removing n-heptane by heating. The modified ASTM D4124 method for SAR analysis was performed to further characterize the maltene component using open-column chromatography. First, 110 g of activated alumina, after thermal treatment at 200 °C for 24 h, was wet-packed with n-heptane in a glass column with 1.5-mm diameter and 1-m length. Then, 0.9 g of DAO, 0.5 g of VR-derived maltene, or 0.5 g of BC-derived maltene was dissolved in 5 mL of dichloromethane and transferred through the column. After confirming that the oil sample was adsorbed on the alumina, the elution solvents, which are presented in Table 1, were changed sequentially. The mixture of the eluted fraction and solvent was continuously drained from the bottom of the column and collected in stainless steel beakers. After evaporating the eluted solvents, each eluted SAR fraction was obtained, as presented in Fig. 1. The weight of each fraction was measured, and its proportion was calculated based on the weight of the original oil sample. To analyze the DAO samples, the DAO was assumed to comprise saturate, aromatic, and resin fractions. Moreover, the weight ratio of each SAR fraction in the DAO to the feedstock (DAO_SAT, DAO_ARO, and DAO_RES yields) was calculated as follows: Experimental section Materials and analytical methods used for characterizing feedstocks and products DAO SAT yield ðwt%Þ ¼ DAO yield ðwt%Þ Two types of heavy oils—VR and 50% w/w BC and VR (BC/VR)— were used as the feedstocks for the SDA extraction. Oil blending is common in oil refining; therefore, the BC/VR mixture was used to Proportion of saturate fraction in DAO ðwt%Þ 457 ð1Þ Jun Woo Park, Min Yong Kim, Soo Ik Im et al. Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 respectively. The HSP for a mixture of several solutes can be calculated as follows [26]: Table 1 Sequence of eluant solvents in SAR column chromatography. Sequence Eluant solvent Volume (mL) 1 2 3 4 5 n-Heptane Toluene Toluene Toluene/methanol (50:50) Dichloromethane/methanol (90:10) 150 33 67 75 150 Eluate dðd;p;hÞ;mixture ¼ Rni¼1 dðd;p;hÞ;i ui Saturate where d(d,p,h),i is the HSP, and ui is the volume fraction of solute i. Eq. (7) was used for calculating the HSP of the mixed BC/VR feedstock. The solubility is changed by the properties of the material as well as pressure, temperature, and the solute and solvent compositions. n-Pentane possesses dp and dh of zero and the extraction was conducted at supercritical and subcritical conditions. Thus, the following empirical correlation was used to calculate dd [27]: Aromatic Resin dd;solvent ¼ dd;ref ðV ref =V Þ1:13 ð7Þ ð8Þ Because the original RED did not consider the compositional effect among components, a modified RED was proposed, which includes the contribution of the compositions to the entropy of mixing (DSmix) and enthalpy of mixing (DHmix) for the radius of the HSP sphere [25]. The modified RED is calculated by substituting Reff for R0 as follows: DSmix ðxÞ=DHmix ðxÞ Reff ðx ¼ 0:5Þ DSmix ðx ¼ 0:5Þ=DHmix ðx ¼ 0:5Þ Fig. 1. Photograph of asphaltene and fractions eluted from the SAR column chromatography. Reff ðxÞ ¼ DAO ARO yield ðwt%Þ ¼ DAO yield ðwt%Þ Rsolvent ðx ¼ 0:5Þ ¼ ð9Þ 1600 VM ð10Þ 1 1 Reff ðx ¼ 0:5Þ ¼ 1= þ R0 Rsolvent ðx ¼ 0:5Þ ð11Þ DSmix ¼ R½xlnx þ ð1 xÞlnð1 xÞ ð12Þ HSP theory DHmix ¼ bxð1 xÞ ð13Þ The Hildebrand solubility parameter, defined as the square root of the cohesive energy density, was introduced to account for solution phenomena; it can be described as follows [25]: 1 b ¼ ½ðdd1 dd2 Þ2 þ ðdp1 dp2 Þ2 þ ðdh1 dh2 Þ2 2 ð14Þ Proportion of aromatic fraction in DAO ðwt%Þ ð2Þ DAO RES yield ðwt%Þ ¼ DAO yield ðwt%Þ Proportion of resin fraction in DAO ðwt%Þ d2 ¼ EV DHV RT ¼ V V ð3Þ where Reff is the modified HSP radius of the solute, which is obtained by applying DHmix, DSmix, and the mole fraction (x). The x value was calculated from the number-average molecular weight, which was measured using gel-permeation chromatography, and the composition of each SARA fraction derived from the VR or the mixture of VR and BC. Parameter Rsolvent is the HSP radius of the solvent, which was not defined in the original HSP theory; VM is the molar volume (cm3/mol); and b is the interaction parameter between the solute and solvent. The modified RED is expressed as a function of the HSP of the solute and solvent, temperature, pressure, and composition of a system. ð4Þ where d is the Hildebrand solubility parameter, EV is the molar energy of vaporization, V is the molar volume, DHV is the molar enthalpy of vaporization, R is the gas constant, and T is the temperature. However, the Hildebrand solubility parameter alone cannot adequately describe the dissolution of polar substances. To overcome this limitation, Hansen reconfigured the Hildebrand solubility parameter to include dispersion (dd), polarity (dp), and hydrogen bonding (dh) solubility parameters, resulting in a threedimensional parameter system that can provide better predictions for equilibrium, where polar and hydrogen bonding interactions are significant factors [24]. This three-parameter system is called the HSP. Additionally, to quantify the solvation ability of a solvent, the RED was defined, as presented in Eq. (6). When RED < 1, the system is stabilized in one phase (i.e., a solution); when RED > 1, the system is partially miscible or immiscible [26]. d2 ¼ d2d þ d2p þ d2h Ra ¼ RED ¼ R0 Measurement of HSPs The HSPs of widely used solvents can be obtained from previous studies [28]. However, it is difficult to obtain the parameters for calculating theoretically defined HSPs of oil samples. Therefore, the HSPs of oil samples are best determined through solubility tests [27–31]. For the initial screening of the candidate solvents, previous studies were referred to, and the HSP of bitumenderived maltene was obtained as dd = 17.5 Mpa0.5, dp = 5.8 Mpa0.5, dh = 2.5 Mpa0.5, and R0 = 6.7 [27,29]. Most solvents were selected based on the RED range between the solvent and bitumen-derived maltene of 0.8–1.2. Following the solubility test with the first group of solvents, the HSP of each SARA fraction was updated. Additional solvents were also selected based on the updated RED between the solvent and SARA fractions in the range of 0.8–1.2. Additionally, solvents well-known for their ability to dissolve asphaltene were added. In total, 37 solvents were tested in this study. ð5Þ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ffi 2 4ðdd1 dd2 Þ2 þ dp1 dp2 þ ðdh1 dh2 Þ2 R0 ð6Þ where Ra is the Hansen distance, the distance between HSPs of solute and solvent in the 3D space, which represents the solubility parameter difference between the solute and solvent; and R0 is the radius of the virtual sphere centered on the solute HSP and represents a cutoff value that is used to distinguish between good and bad solvents. Subscripts 1 and 2 indicate the solute and solvent, 458 Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. higher density than BC/VR, and the boiling point range of the VR was more concentrated at high temperatures compared to that of the BC/VR. Moreover, the VR contains more resins and asphaltenes than the BC/VR mixture, which explains why VR has a higher density and viscosity than BC/VR. In the solubility test, 0.1 mL of solvent was added to approximately 0.01 g of SAR fractions derived from the VR or BC. In the case of asphaltene, approximately 0.01 g of asphaltene fraction derived from the VR or BC was mixed with 0.2 mL of solvent because of the high viscosity of asphaltene. The mixture was immersed in a sealed vial, and allowed to stand for approximately 3 h to determine the solubility of asphaltene. The solvents were then classified into three categories based on their ability to dissolve the SARA samples: (1) completely soluble, (2) partially soluble, or (3) insoluble, which were assigned values of 1, 0.5, and 0, respectively. The HSPs of the SARA samples were calculated using an opensource software devised by the HSP developers [32]. After setting R0, the software adjusted a solute HSP with the lowest fitting error, so that the HSPs of solvents in the ‘‘completely soluble” category were placed (as much as possible) inside the sphere and those of the solvents in the other categories outside the sphere. The fitting error is defined as follows: Fitting Error ¼ 1 n Y Effect of extraction temperature and SOR on the yield and properties of DAO Fig. 3 shows the DAO yield obtained in the SDA extraction experiments conducted at different temperatures and SORs. The decrease in the extraction temperature and increase in the SOR caused an increase in the DAO yield for both the VR and BC/VR feedstocks. The DAO yield is known to be highly dependent on the extraction temperature because temperature significantly affects the solvation ability of a solvent [20,33,34]. The temperature increase entails increasing molar volume and decreasing surface tension [31], resulting in a lower value of the dispersion energy parameter (dd) of n-pentane and higher modified RED between n-pentane and SAR fractions derived from both feedstocks, owing to the lower dd value of n-pentane compared to that of the feedstocks. Previous studies also reported that the DAO yield was improved by increasing the SOR [33,34]; however, the effect of the SOR on the DAO yield cannot be explained using the original HSP theory. This trend could be theoretically described using the modified RED. An increase in SOR (x in Eq. (9)) increases both DSmix and DHmix; however, the increasing rate of DSmix is higher than that of DHmix, leading to an increase in the radius of the HSP sphere (Reff), which corresponds to a decrease in the modified RED (because Reff is the denominator of RED). This explains why the DAO yield increases with increasing SOR. Fig. 4 depicts the inverse relationship between the yield and API gravity of the DAO produced at various extraction temperatures and SORs of both the VR and BC/VR feedstocks, implying that the heavier components were extracted into DAO in the case of higher DAO yield [18,33]. Notably, for the same SDA feedstock, although the operating conditions of the temperature and SOR differed, the density of the DAO products was similar in the case of identical DAO yields. Fig. 5 shows the boiling point distribution obtained using SIMDIS analysis for the DAO products. The operating conditions presented in the abscissa are listed in the order of increasing modified RED between n-pentane and SAR fractions derived from the feedstocks. The DAO produced at higher extraction temperatures and lower SORs, corresponding to relatively higher modified RED values and lower DAO yields, tends to have a lower boiling point distribution. Fig. 6 shows the molecular weight distribution measured via gel-permeation chromatography of the feedstocks and DAO produced at various temperatures and SORs. At higher extraction temperatures, DAO with low average molecular weights could be attained, implying that high-molecular-weight components were excluded from the DAO. The molecular weight distribution of the DAO also narrowed and shifted to lower values as the extraction temperature was increased. The analytical results of the API gravity, boiling point distribution, and molecular weight distribution revealed that higher-quality DAO could be attained at higher extraction temperatures and lower SORs in the SDA process. Fig. 7 shows the proportions of SAR fractions in the DAO derived from the VR and BC/VR feedstocks for different DAO yields. As the DAO yield increased, the proportions of the aromatic and resin fractions increased, but that of the saturate fraction decreased. This trend is consistent with the API gravity decrease that accompanied higher DAO yields. For the same DAO yield of approximately 70 wt %, the proportion of the saturate fraction was higher and that of the aromatic fraction was lower in the BC/VR-derived DAO compared !1=n ð15Þ Ai i Ai ¼ 8 > < > : ðgood solventsÞ 1 expðRa R0 Þ expðR0 Ra Þ ðwrong-in bad solventsÞ ð16Þ ðwrong-out bad solventsÞ where n is the number of tested solvents. Notably, if there is an outlier with a fairly large difference between Ra and R0, the fitting error increases sharply because of its exponential form. Each HSP and fitting error were calculated with varying R0 values to one decimal place. Among the fitting errors calculated by changing R0, the HSP of the solute and R0 were finally determined based on the result yielding the lowest fitting error. SDA extraction experiment in a bench-scale unit The SDA extraction experiments were performed on a 0.1 barrel per day scale using the continuous extraction unit, as presented in Fig. 2. The feedstock oil flowed to the top of the extraction column, while the solvent flowed to the bottom, resulting in countercurrent extraction. The flow rate of the feedstock was fixed at 0.7 kg/h; the weight-based SOR was 7, 5, and 3 for the VR feedstock, and 8 and 6 for the BC/VR mixture feedstock. A small amount of solvent was mixed with the feedstock to ensure fluidity. For the VR feedstock, both the feedstock and solvent were heated to extraction temperatures of 160, 170, 180, and 190 ℃ using an electrical heating jacket. For the mixed BC/VR feedstock, the extraction temperatures were set to 185, 190, and 200 ℃. Both the feedstock and solvent were pressurized to 43 bar. Overall, 12 and 6 extraction experiments were conducted for the VR and mixed BC/VR feedstocks, respectively. For each extraction experiment, the temperature, pressure, and solvent and feedstock flow rates in the column were kept constant for 1 h to maintain steady-state operation, followed by the production of DAO and pitch for 1 h. The weight of the extracted DAO was measured after the evaporation of the solvent at 150 °C for 24 h. Results and discussion Characteristics of feedstock The properties of the VR and mixed BC/VR feedstocks are listed in Table 2. Based on the API gravity, viscosity, and heteroatom (N, S, and O) and heavy metal (Ni and V) contents, both VR and BC/VR can be classified as heavy oil. The VR has a lower H/C ratio and 459 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Fig. 2. Schematic of experimental apparatus for SDA extraction. HSPs of SARA fractions derived from feedstocks Table 2 Characteristics and SARA fractions of the feedstock. Properties VR BC/VR (50% w/w) Elemental analysis (wt%) C: 83.7 H: 10.0 N: 0.6 O: 0.7 S: 5.5 4.1 56 320 20.53 382.8–745.6 9.53/30.71/ 40.37/19.39 240–46,400 1025 C: 84.8 H: 10.3 N: 0.4 O: 0.6 S: 5.2 8.9 27 137.5 17.04 157.8–745.2 9.95/35.51/ 38.58/15.95 124–24,460 845 API gravity (°) Ni (wt. ppm) V (wt. ppm) MCR (wt.%) Boiling point distribution (℃) SARA analysis (wt%): saturate/ aromatic/resin/asphaltene Viscosity (mPas) Molecular weight (Mn) The experimental solubility-levels for SARA fractions were measured and REDs between the solvents and SARA fractions were calculated for the VR and BC/VR feedstocks, as listed in Tables 3 and 4, respectively. Here, the abbreviations for the SARA fractions derived from VR and BC are based on the feedstock and the first three letters of the SARA fractions; for example, VR_SAT represents the saturate fraction obtained from VR. Based on the calculated solubility levels, the HSP of each SARA fraction was obtained, as shown in Table 5. The HSPs and R0 values of VR_SAT, VR_RES, and VR_ASP are identical to those of BC_SAT, BC_RES, and BC_ASP, respectively, although there are slight differences between the results for the ‘‘partially soluble” and ‘‘insoluble” categories. This is because the HSPs were determined using only the ‘‘completely soluble” category of the solvents. The HSPs of VR_ARO and BC_ARO exhibit minor differences because the solvents isobutyl acetate and dichloromethane have different solvation abilities. Notably, the VR and BC have similar HSPs despite having different physical properties. The HSPs of the SARA fractions derived from different heavy oils are expected to have similar values. In both the VR and BC feedstocks, dd tends to increase in the order of saturates < aromatics < resins < asphaltenes. In particular, with the VR-derived DAO, indicating that the BC/VR-derived DAO was of higher quality than the VR-derived DAO, despite having identical yields. Fig. 3. DAO yield at different extraction temperatures and SORs of (a) VR and (b) BC/VR feedstocks. 460 Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. Fig. 4. Relationship between the yield and API gravity of DAO produced at various extraction temperatures and SORs from (a) VR and (b) BC/VR feedstocks. Fig. 5. Boiling point distribution of feedstock and DAO produced at various extraction temperatures and SORs from (a) VR and (b) BC/VR feedstocks. SORX_Y refers to the DAO produced at an operating condition of Y °C and SOR X. Fig. 6. Molecular weight distribution curves of feedstock and DAO produced at various extraction temperatures and SORs from (a) VR with SOR 7, (b) VR with SOR 5, (c) VR with SOR 3, (d) BC/VR with SOR 8, and (e) BC/VR with SOR 6. 461 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Fig. 7. Proportion of SAR fractions derived from (a) VR and (b) BC/VR feedstocks for various yields of DAO. Table 3 Solubility-levels and REDs between solvents and SARA fractions derived from VR. Solvent SAT ARO RES ASP RED_SAT RED_ARO RED_RES RED_ASP Heptane Benzene Toluene Diethylamine Isopropyl ether o-Xylene 1,2,4-Trichlorobenzene 2-Ethylhexyl acrylate Dimethyl phthalate Ethyl ether Chloroform Butyl acetate Isobutyl acetate Isoamyl acetate (3-methylbutyl acetate) Acetone Ethyl acetate 1,4-Dioxane Methyl acetate Tetrahydrofuran Isopropyl acetate Methyl acrylate 1-Decanol Dimethyl sulfoxide N,N-Dimethylformamide Diethylene glycol monomethyl ether Isooctyl alcohol Benzyl alcohol 2-Chlorophenol Triethylamine 1,2-Epoxy butane Diethylene glycol monoethyl ether acetate 1,2,3,4-Tetrahydronaphthalene Butyraldehyde Cyclopentanone N,N-dimethyl acetamide Methyl chloride Dichloromethane 1 1 1 1 1 1 0.5 1 0 1 1 1 1 1 0 1 0.5 0 1 0.5 0.5 1 0 0 0 0 0 0 1 1 0 1 0 0.5 0 1 1 1 1 1 1 0.5 1 0.5 1 0 1 1 1 0.5 0.5 0 1 0.5 0 1 0 0 0 0 0 0 0 0 0 1 1 0 0.5 0 0.5 0 1 1 0 0.5 1 1 0.5 1 0.5 0.5 0 0.5 1 0.5 0.5 0.5 0 0 0.5 0 1 0 0 0 0 0 0 0 0 0.5 0 1 0 0.5 0.5 0.5 0.5 0.5 1 0 0.5 0.5 0 0 1 1 0 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0.5 0 0 0 1 0 0.5 0 0.5 1 0.42 0.58 0.46 0.67 0.79 0.42 1.24 0.64 1.48 0.66 0.67 0.66 0.72 0.74 1.41 0.88 1.00 1.11 1.00 0.99 1.25 1.11 2.37 2.09 1.65 1.72 1.77 1.98 0.44 0.99 1.08 0.89 1.33 1.56 1.75 0.75 1.00 0.84 0.83 0.58 0.37 1.01 0.64 1.18 0.73 1.36 0.97 0.78 0.85 0.96 1.03 1.43 1.01 1.25 1.20 1.10 1.26 1.45 1.42 2.51 2.24 1.92 2.08 2.08 2.32 0.67 0.91 1.29 0.99 1.31 1.47 1.86 0.72 0.96 1.73 1.28 0.99 0.56 1.71 0.99 1.03 1.21 1.10 1.45 0.66 1.01 1.24 1.29 1.44 1.03 1.21 1.21 0.91 1.47 1.50 1.41 2.53 2.21 1.92 2.30 2.02 2.30 1.25 0.98 1.25 1.12 1.31 1.28 1.77 0.98 0.50 2.17 1.29 0.99 1.02 2.35 0.99 1.03 1.76 1.54 1.97 0.62 1.39 1.71 1.71 2.12 1.48 1.15 1.76 1.25 1.98 2.06 1.61 3.30 2.91 2.49 3.01 2.43 2.65 1.35 1.59 1.65 0.99 1.98 1.84 2.40 1.54 0.64 RED between asphaltene and n-heptane is higher than that between resin and n-heptane. It seems that the asphaltene with relatively high dispersive interactions in the feedstock was separated first through asphaltene precipitation, while the resin having medium dispersive interactions remained in the maltene fraction [27]. In the HSP calculation, the outlier was defined as a solvent with a theoretical solubility-level (estimated from the RED) that differed from the experimental solubility-level. In the solubility test for VR_SAT and BC_SAT, four outliers were observed: 1-decanol (RED = 1.11), tetrahydrofuran (RED = 1.00), isopropyl acetate (RED = 0.99), and 1,4-dioxane (RED = 1.00). Although the saturate fraction was theoretically partially dissolved in 1-decanol and tetrahydrofuran, it was completely dissolved in the experiment. dd increases sharply from the aromatic to resin fractions, signifying that the resin and asphaltene fractions contain more polycyclic aromatic compounds than the saturate and aromatic fractions. Because dd is highly correlated with the number of aromatic rings per molecule, this trend agrees with well-known facts concerning the structure of the SARA fractions [35–37]. As shown in Table 1, carrier solvents (n-heptane for saturates, toluene for aromatics, and toluene/methanol (50:50) for resins) were used in the order of increasing dp and dh to fractionate the SAR fractions. Therefore, the increasing trend of saturates < aromatics < resins that was observed for both dp and dh is expected. The exception is VR_ARO, which has a lower dp than VR_SAT and VR_RES. Interestingly, the dp value for VR_ASP and BC_ASP is lower than that for VR_RES and BC_RES, although the 462 Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. Table 4 Solubility-levels and REDs between solvents and SARA fractions derived from BC. Solvent SAT ARO RES ASP RED_SAT RED_ARO RED_RES RED_ASP Heptane Benzene Toluene Diethylamine Isopropyl ether o-Xylene 1,2,4-Trichlorobenzene 2-Ethylhexyl acrylate Dimethyl phthalate Ethyl ether Chloroform Butyl acetate Isobutyl acetate Isoamyl acetate (3-methylbutyl acetate) Acetone Ethyl acetate 1,4-Dioxane Methyl acetate Tetrahydrofuran Isopropyl acetate Methyl acrylate 1-Decanol Dimethyl sulfoxide N,N-Dimethylformamide Diethylene glycol monomethyl ether Isooctyl alcohol Benzyl alcohol 2-Chlorophenol Triethylamine 1,2-Epoxy butane Diethylene glycol monoethyl ether acetate 1,2,3,4-tetrahydronaphthalene Butyraldehyde Cyclopentanone N,N-dimethyl acetamide Methyl chloride Dichloromethane 1 1 1 1 1 1 0.5 1 0 1 1 1 1 1 0.5 1 0 0 1 0.5 0.5 1 0 0.5 0 0 0 0 1 1 0.5 1 0.5 0.5 0.5 1 0.5 1 1 1 1 0.5 1 0.5 1 0 1 1 1 1 0.5 0.5 1 0.5 0 1 0.5 0 0 0 0.5 0 0 0 0 1 1 0.5 0.5 0.5 0.5 0.5 1 0.5 0.5 0.5 1 1 0.5 1 0.5 0.5 0 0.5 1 0.5 0.5 0.5 0.5 0.5 0 0 1 0 0 0 0 0.5 0 0 0 0 0.5 1 0 0.5 0.5 0.5 0.5 0.5 1 0 0.5 0.5 0 0 1 1 0.5 0 0 1 0.5 0 0 0.5 0.5 0.5 0 1 0 0 0 0 0 0 0 0 0 0 0.5 0 0.5 0 0.5 0 0.5 1 0.42 0.58 0.46 0.67 0.79 0.42 1.24 0.64 1.48 0.66 0.67 0.66 0.72 0.74 1.41 0.88 1.00 1.11 1.00 0.99 1.25 1.11 2.37 2.09 1.65 1.72 1.77 1.98 0.44 0.99 1.08 0.89 1.33 1.56 1.75 0.75 1.00 0.99 1.00 0.71 0.39 1.07 0.72 1.39 0.70 1.53 0.95 0.77 0.78 0.91 0.99 1.52 0.97 1.35 1.20 1.09 1.25 1.47 1.47 2.79 2.46 2.02 2.20 2.24 2.55 0.84 0.92 1.28 1.17 1.38 1.63 2.01 0.68 1.00 1.73 1.28 0.99 0.56 1.71 0.99 1.03 1.21 1.10 1.45 0.66 1.01 1.24 1.29 1.44 1.03 1.21 1.21 0.91 1.47 1.50 1.41 2.53 2.21 1.92 2.30 2.02 2.30 1.25 0.98 1.25 1.12 1.31 1.28 1.77 0.98 0.50 2.17 1.29 0.99 1.03 2.35 0.99 1.03 1.76 1.54 1.97 0.62 1.39 1.71 1.71 2.12 1.48 1.15 1.76 1.25 1.98 2.06 1.61 3.30 2.91 2.49 3.01 2.43 2.65 1.35 1.59 1.65 0.99 1.98 1.84 2.40 1.54 0.64 Table 5 Comparison of HSPs among SARA fractions. Sample dd (Mpa0.5) dp (Mpa0.5) dh (Mpa0.5) R0 Number of outliers Fitting error (%) VR_SAT VR_ARO VR_RES VR_ASP BC_SAT BC_ARO BC_RES BC_ASP 16.3 16.8 17.7 18.3 16.3 16.6 17.7 18.3 1.1 4.0 5.8 4.7 1.1 4.0 5.8 4.7 2.2 1.4 3.9 4.1 2.2 2.4 3.9 4.1 7.5 6.2 4.9 4.0 7.5 5.4 4.9 4.0 4 3 0 2 4 2 0 2 55 60 0 69 55 38 0 69 tene samples, a small amount of solid asphaltene, such as carboid, remained undissolved even in solvents categorized as completely soluble, making it difficult to classify the solubility level of asphaltene. Because the same phenomenon occurred during the solubility test involving 1,2,4-trichlorobenzene and tetrahydrofuran, these solvents were classified as completely soluble. Conversely, isopropyl acetate was calculated to belong to the completely soluble category, but was experimentally observed to partially dissolve both VR_SAT and BC_SAT. In particular, 1,4dioxane was originally calculated to completely dissolve both VR_SAT and BC_SAT but was experimentally observed to partially dissolve VR_SAT and did not dissolve BC_SAT to any appreciable extent. The solvents included in the outliers for VR_ARO are isobutyl acetate (RED = 0.96), tetrahydrofuran (RED = 1.10), and tetrahydronaphthalene (RED = 0.99), which have acceptable fitting errors. The outliers for BC_ARO are tetrahydrofuran (RED = 1.09) and isoamyl acetate (RED = 0.99), which also fall within an acceptable range. The outliers for VR_ASP and BC_ASP are 1,2,4trichlorobenzene (RED = 1.03) and tetrahydrofuran (RED = 1.25). These two outliers, which were theoretically predicted to partially dissolve asphaltene, were classified as completely soluble based on the solubility test. In the solubility-level classification of asphal- Correlation between RED and weight ratio of each SAR fraction in DAO to the feedstock As explained previously, the modified RED integrated major process variables, such as the HSPs of the SAR fractions of the feedstocks, HSP of n-pentane, extraction temperature, and SORs. Moreover, the SDA extraction results showed that the yield and properties of DAO highly depend on the extraction temperature and SOR. In this respect, the modified RED was expected to correlate with the DAO yield. 463 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Fig. 8. Correlations between (a) DAO_SAT yield and corresponding RED between the HSPs of VR_SAT and n-pentane; (b) DAO_ARO yield and corresponding RED between the HSPs of VR_ARO and n-pentane; and (c) DAO_RES yield and corresponding RED between the HSPs of VR_RES and n-pentane. Fig. 9. Correlations between (a) DAO_SAT yield and corresponding RED between the HSPs of BC/VR_SAT and n-pentane; (b) DAO_ARO yield and corresponding RED between the HSPs of BC/VR_ARO and n-pentane; and (c) DAO_RES yield and corresponding RED between the HSPs of BC/VR_RES and n-pentane. applied to industrial applications using only the HSPs of the feedstocks and a simple linear-mixing rule based on the compositions of feedstocks. Moreover, because these correlations only require the HSP value of the feedstock, they can be applied to the liquid– liquid extraction process, wherein thermodynamic parameters are difficult to measure. The HSP has been used in theoretical analysis of phase equilibrium in various separation technologies [40– 43]. To determine the correlations, six modified RED combinations were calculated using the HSPs of three SAR fractions of the VR and BC/VR, and the HSP of the extraction solvent at different operating conditions. Likewise, six yield combinations of DAO_SAT, DAO_ARO, and DAO_RES derived from each of the two feedstocks were also selected. The modified REDs and yield combinations are plotted in Figs. 8 and 9. For both feedstocks, note that the DAO_ARO and DAO_RES yields have an inversely linear relationship with the corresponding RED, and the R-square values of four correlations exceed 0.89. Although the two points delineated by the circle in Fig. 8b and c were obtained at different operating conditions (one at 160 °C/SOR 3, and the other at 170 °C/SOR 5), they exhibited similar REDs and yields. This implies that a similar DAO yield can likely be obtained at different combinations of SOR and temperature. More energyefficient and less solvent-demanding operating conditions would be more attractive if similar performances could be achieved (e.g., 160 °C and SOR 3 was more favorable than 170 °C and SOR 5). In the VR-derived DAO_SAT yield, a roughly inversely linear relationship was obtained, although the data were significantly scattered. All saturate fractions in the feedstocks were assumed to be transferred to the DAO because almost none were detected in the SARA analysis of pitch using thin-layer chromatography. The scattering of data probably arises because the SAR column chromatography inherently has an absolute mass error [38,39]. In particular, the absolute data range of the DAO_SAT yield is much narrower than those of the DAO_ARO and DAO_RES yields. Additionally, a fluctuation of temperature (approximately 2 °C) in the experiment inevitably introduced errors. Notably, for the BC/VR-derived DAO, the HSP was calculated from the respective HSPs of the BC and VR using Eq. (7), and the correlation was successfully applied to the blended BC/VR feedstock. This suggests that the developed correlations can also be Conclusions A new correlation for DAO yield from heavy oil was developed applying modified REDs with investigating the effects of operating variables. DAO was produced from two types of feedstocks—VR and a mixture of VR and BC—using n-pentane as the solvent through SDA extraction. The experimental and analytical results showed that the DAO yield was inversely correlated to the DAO quality and decreased with increasing extraction temperature (a decrease in solvent density and dd) and decreasing SOR (a decrease in system entropy/enthalpy and solvent Reff). The HSPs of the SARA fractions of feedstocks were determined through solubility tests and used for calculating the modified REDs. The HSPs obtained for each fraction showed good agreement with the well-known structure of each fraction, and were used for calculating the modified REDs, which can quantify the solubility. Based on the results, the weight ratio of each SAR fraction in the DAO to the feedstock (DAO_SAT, DAO_ARO, and DAO_RES yields) was correlated to the corresponding modified RED between the n-pentane solvent and each SAR fraction of the feedstock. Because the modified RED generally increases as the intermolecular interactions between the extraction solvent and feedstock decrease, inversely linear relationships between the modified RED and each of the DAO_SAT, 464 Journal of Industrial and Engineering Chemistry 107 (2022) 456–465 Jun Woo Park, Min Yong Kim, Soo Ik Im et al. DAO_ARO, and DAO_RES yields were observed for both the VR and BC/VR feedstocks. These correlations are expected to be beneficial for predicting the DAO yield under various operating conditions upon calculating a modified RED for the particular conditions. Furthermore, these correlations can be applied to determine the optimal operating conditions for an SDA process to produce DAO with desired specifications. [15] S. 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