CA1120418A - Process and apparatus for thermally processing heavy hydrocarbon-containing liquids - Google Patents
Process and apparatus for thermally processing heavy hydrocarbon-containing liquidsInfo
- Publication number
- CA1120418A CA1120418A CA000337359A CA337359A CA1120418A CA 1120418 A CA1120418 A CA 1120418A CA 000337359 A CA000337359 A CA 000337359A CA 337359 A CA337359 A CA 337359A CA 1120418 A CA1120418 A CA 1120418A
- Authority
- CA
- Canada
- Prior art keywords
- solids
- zone
- recycle
- combustion zone
- annular space
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G9/28—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid material
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- Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
Abstract
"PROCESS AND APPARATUS FOR THERMALLY PROCESSING
HEAVY HYDROCARBON-CONTAINING LIQUIDS"
ABSTRACT OF THE DISCLOSURE
There is provided an apparatus comprising rotating inner and outer concentric tubes. The inner tube provides a vapor zone and the annular space between the tubes provides a combustion zone. Hot particulate solids, such as sand, are advanced along an endless path through the vapor zone, back through the combustion zone and back into the vapor zone IN the vapor zone, oil is sprayed on the hot solids. The mixture is mixed and cascaded to obtain heat transfer from the solids to the oil thereby generating hydrocarbon vapors and coke deposit on on the solids. The vapors are removed by suction from the vapor zone. 'The coked solids are trans-ferred into the combustion zone and cascaded and lifted and dropped therein to mix with added oxygen. Coke is burned to heat the solids which are then returned to the vapor zone. The vapors generated in the combustion zone are removed by suction. Segregation of the atmospheres in the two zones is achieved by a combination of maintaining equal pressures in the zones and using the solids, being transferred from one zone to the other, to block gas flow."
HEAVY HYDROCARBON-CONTAINING LIQUIDS"
ABSTRACT OF THE DISCLOSURE
There is provided an apparatus comprising rotating inner and outer concentric tubes. The inner tube provides a vapor zone and the annular space between the tubes provides a combustion zone. Hot particulate solids, such as sand, are advanced along an endless path through the vapor zone, back through the combustion zone and back into the vapor zone IN the vapor zone, oil is sprayed on the hot solids. The mixture is mixed and cascaded to obtain heat transfer from the solids to the oil thereby generating hydrocarbon vapors and coke deposit on on the solids. The vapors are removed by suction from the vapor zone. 'The coked solids are trans-ferred into the combustion zone and cascaded and lifted and dropped therein to mix with added oxygen. Coke is burned to heat the solids which are then returned to the vapor zone. The vapors generated in the combustion zone are removed by suction. Segregation of the atmospheres in the two zones is achieved by a combination of maintaining equal pressures in the zones and using the solids, being transferred from one zone to the other, to block gas flow."
Description
43~
BACKGROUND OF THE INVENTION_ _ _ The present invention relates to an apparatus and process for thermally processing a heavy hydrocarbon-containing feed stock whereby at least a portion of the hydrocarbons are thermally cracked and vaporized to produce a gaseous product.
Large deposi-ts of bituminous sands and heavy oil-bearing formations are found in various areas of the world. The wellhead products obtained by in situ recovery from these sources usually comprise a liquid containing a range oF hydrocarbons, water, steam, sulphur, entrained fine solids, metals, entrainecl gases and special agents added during recovery. The hydrocarbons may in large part be characterized by an API gravity less than about 25 API., In conventional oil refinery processes a high v;scosity, low API tower bottoms stream of hydrocarbons is obtained during processing by atmospheric and vacuum distillation methods. These tower bottoms require thermal cracking to be utilized in a downstream reFining process.
The apparatus and process of the present invention is pro-vided to process the above-described heavy hydrocarbon-containing liquids.
SUMMARY OF THE INVENTION
__ .
In accordance with one aspect of this invention, there is provided an apparatus for thermally treating heavy hydrocarbon-containing liquids, such as refinery bottoms or product from an in situ heavy oil recovery process.
The apparatus comprises concentric, radially spaced inner and outer tubes having recycle and product ends. The tubes are secured together and may be rotated about a common horizontal axis. Advance elements are provided on the inner surfaces of both tubes for advancing a charge of particulate solids through the inner tube and back through the annular space formed between the tubes. The charge of particulate solids may comprise coke, sand or the like. Rotation of the tubes causes the solids to follow an oval path through an inner processing zone defined by the inner tube, ;nto and back through the annular space (which includes a combustiorl zone), and then back into the recycle end of the inner tube. Rotation of the tubes also effects cascading of the contained solids; this cascading action may be amplified by providing lifter elements on one or both inner surfaces of the tubes. The lifter elements func-tion to lift and drop the solids as the tubes rotate.
A stationary recycle end assembly is provided to seal the recycle end of the outer tube. Also, a stationary product end assembly is sealably associated with the outer tube or an end wall forming part of the outer tube, to close the product end of such tube. The seals that are involved are of a ring type and, although substantially gas-tight, there will be minor gas leakage past them, which is taken advantage of in a manner to be described.
Means are provided for sealing the recycle end oF the inner tube. Such means include recycle means which connect the recycle end of the annular space with the inner processing zone. Such recycle means are operative to return at least a portion of the solids moving through the annular space back into the recycle end of the inner processing zone.
The recycle means are adapted to cooperate with the solids being returned to prevent significant gas movement between the inner processing zone and the annular space.
Means are also provided for sealing the product end of the inner tube. Said means include means for transferring carbon-carrying solids from the inner processing zone to the cornbustion zone. Said transfer means are adapted to cooperate with the carbon-carryiny solids being transferred to prevent significant gas movement between the inner processing zone and the annular space.
Feed means, extending into the inner processing zone, are provided for depositing the hydrocarbon-containing liquid onto the particulate solids being advanced therethrough.
Means, such as a conduit and fan, are provided ~or withdraw;ng hydrocarbon vapours from the inner processing zone. Similar rneans are also provided for withdraw;ng combust;on gases From the annu'lar space.
Finally, means are provided for introduc;ny oxygen-containing gas into the combustion zone to effect combustion therein as described below.
In operation, the charge of sol;ds circulates continuously through the inner processing zone and the annular space. The solids are hot as they enter the recycle end of the inner tube. The hydrocarbons-containing liquid is deposited on them and at least a portion of such hydrocarbons vaporize and are cracked, thereby generating gaseous hydro-carbon vapours and simultaneously forming a carbon deposit on the solids particles (termed hereafter 'coked solids'). The constant cascading effects intimate mixing of the liquid and solids and promotes uniform heat transfer. l'he coked solids are then discharged into the combustion zone where at least part of the coke is burned to heat the solids. Sup-plemental heat may be supplied by a burner to assist in raising the temperature of the solids. Combustion-heated solids are then recycled into the inner tube to repeat the process.
The process is characterized by several features. By pro-viding separate means for w;thdrawing the combustion and product gases in combination with recycling and transfer means operative to provide sealing functions at the ends of the inner tube, there is thereby provided a particular system for segregating the two gaseous streams. This system is compatible with the utilization of an open cylindrical processing zone and an open annular space in the processor.
Because these spaces are open, a desirable degree of mixing may be obtained therein simply by the cascad;ng action effected by rotat;on of the tubes.
In another aspect of the invention, a process is provided for vaporizing and c~acking a heavy hydrocarbon-containing liquid, such process employing direct thermal treatment effected in an apparatus having horizon-tal, substantially concentric, rad;ally spaced inner and outer rotatable tubes in which one axial end is the feed end and the opposite axial end is the product end, said inner tube forming an open cylindrical inner processing zone, sa;d tubes forming between them an open annular space having a combustion zone, said apparatus having assemblies for sealing the ends of the outer tube. The process comprises: continuously advancing hot particulate sol~ds through the inner tube from the Feed end to the product end and back through the annular space; depositing the hydrocarbons as a liquid onto the hot solids; cascading and mixing the solids and hydrocarbons as they advance through the inner processing zone to achieve beneficial heat transfer and thereby vaporize hydro-carbons and form carbon on the solids; withdrawing the hydrocarbon vapors produced in the inner tube; transFerring carbon-coated solids from the product end of the inner tube into the combustion zone in the annular space; cascading and mixing the carbon-coated solids in the combustion zone while introducing oxygen-containing gas thereinto to burn at least part of the carbon and heat the remainder o-f the solids;
transferring burned hot solids from the feed end of the annular space into the feed end of the inner tube; withdrawing vapors produced in:the combustion zonei and preventing substantial gas flow between the inner processing zone and the combustion zone by blocking gas flow with the solids being transferred and maintaining substantially equal pressures in said zones.
_ESCRIPTION_OF THE _ AWINGS
Figure 1 is a schematic diagram illustrating the process and apparatus of the present invention and one possible arrangement of external equipment for simple condensing of the hydrocarbon vapors to provide a pumpable liquid and a cooled coke by-product that can be used dS a feed for boilers or furnaces for production of heat energy.
Figure 2 is an elevation, mostly in section, -taken along the rotational axis of the inner and outer tubes, illustrating de-tails and representative features in the construction and operation of the inner and outer tubes and end frames of the invention.
Figure 3 is a cross-sectional view taken along line llOX of Figure 2 and illustrates the arrangement and operating principles of the recycle ring portion of the invention.
Figure 4 is a cross-sectional view taken along line lllX of Figure 2 and illustrates the arrangement of pipes and nozzles for the oxygen-bearing gas system.
Figure 5 is a cross-sectional view -taken along line 112X of Figure 2 and illustrates the product end seal and solid particle discharge from the inner tube to the outer tube. A cross section through the seal is included for further clarification.
Figure 6 is a cross-sectional view taken along the line 113X of Figure 5 and illustrates the product end seal.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus lOX comprises concentric, radially spaced inner and outer tubes llX, 12X. The two tubes are connected together in the manner previously described and are rotated about the;r common long axis. The ends of the inner tube terminate in end frames which rotate with the tube and seal its ends to contain generated gases, the recycle end frarne being merely a seal plate 200X while the product end frame 91X provides an inner to outer tube seal arrangement as well as - 5a -L ~8 functioning as~ the means for transferr;`ng solids from inner tube into the annular space between the tubes. A vapor discharge pipe 86X extends through the product end frame 91X i:nto the inner tube llX. The inlet and outlet ends of the outer tube 12X extend into sta~.ionary end assembly 14X and partially stationary end assembly 15X respectively. Roller mounted rings 45X, 46X are connected -to the outer tube so that the tubes may be rotated by a motor 51X and ring gear 52X.
The tubes define or form a s.equence af processing zones. More particularly, at its inlet end the inner tube llX forms a mixing zone 32X ~herein recycled hot solids are mi:xed to provi;de temperature equilibrium pri.or to contact with hydrocarbon-bearing liquid~ Down-stream of the mixing zone, the inner tube provides a vapor zone 33X
wherein the liquid is deposited on the hot recycled solids and hydro-carbons are vaporized and cracked. The mixing and vapor zones together form an inner proces.sing zone whi.ch is a substanti:ally open cylindrical space. A combus.ti.on zone 34X i.s provided i:n the open annular space formed between the tubes, wherein carbon-coated solids are burned to provide required heat for the process. At the leFt hand end of the annular space, a recycle zone 35X ;.s provided wh.erein may be conducted screening, oversize particle rejection, undersize particle recycle and intermittent cruishi.ng of overs.ize parti:cle operations. Fi.nally, there is.
provided in the inlet end assembly 14X a cooling zone 36X~ wh.ere.i:n overs;:ze parti.cles are cooled and discharged.
The majority of the combus.tion takes place in the combustion zone 34X in the annular space between the two tubes, however some com-bustion will also take place i.n the space be ~een the stati.onary end assembly 15X and product end frame 91X~ Thus the terrn l'ciombus.ti.on zone" as used i.n the claims.should be taken to refer to both the annular s:pace between the two tubes and the space between the ends o-F the t~o tubes at ~ 30 the product end. It i.s concei.vable that the outer tubular member could be extended to enlarge the combustion zone, ;f desired.
,--, ~ .
The tubes are in;tially charged with solids, for ex-ample coke or sand particles. These solids are advanced through the m;xing, vapor and combust;on zones 32X, 33X, 34X, us;ng advancing elements attached to the inner sur~aces of the tubes, as previously described. More particularly, longitud;nally - 6a -e~tending rows of cldva~cing elernents 38X, 39X and 40X formed along the inner surf~ce of the inner tube and similar advancing elements 43X, 9qX formed alon~ the inner surface of the outer . tube cause the solids to move through the two tubes as they are rotated about their long axis. The number of elements as well as their size and degree of inclination may be varied to optimize the rate of advance through each zone.
Feed liquid containing heavy hydrocarbons is sprayed or deposited on the hot solids as they advance through . 10 the vapor zone 33X. Preferably, the feed liquid is pre-heated by heat exchange with the produced vapors in the coolers 17X, 18X. The pre-heated feed liquid may then be flashed in charnber 906X and pro~uced gaseous liyht enas and water vapor returned to the condenser l9X. The pre-heated li~uid is introduced into the vapor zone 33X through pipe 407X and sprayed on the ~loving solids through the nozzles 408X~ The continuous mixing and cascading of the solids in the vapor zone ensures a uniform temperature of these particles so that hot and cold spots are minimized as the.liquid is applied. Control of the rate of liquid application Jnay be utilized to ensure rapid vaporizing of the hydrocarbons and close control of the contact time and hence the dearee o:~ cracking occurring i.n the vapor zone.
The ends of the inner tube are sealed to prevent the uncontrolled escape of the ~ases generated in the vapor zone 33X. At the l-ecycle end, the plate 200X provides a closure ~hi.ch is penetrated only by tlle hot air pipe header 96Xa and the hot solids recycle pipes 66X. At the product end, an end zssen~bly 91X provides a ~necllanical and moving solids seal asainst !.he escape of gases.
The carbon-coated particles are continuousl~
transferred from the vapor zone 33X of the inner tube into the annular combustion zone`39X def;nea bet~een the t~o t~bes.
In this c,onnectiOn, an cnd c~ssernbly ~lX or accomplishing this is now described, Re~er to Figs. 2 and 6 . The end assembly 91X is fastened to the prod~ct end of the inner tube llX and is illustrated in Figure . 5 ~. The assembly is formed by two radial end plates 201X, ~02X fastened together by a series of baffles 90X whic}l form compar~nents. Carbon-coated particles are fecl i.~ltO these conpartments through :
openings 95X located in the inner radial plate 201X. As the , tubes rotate, the particles in the compartments move towards the central axis and, at a suitable angle, are discharged to the outer tube by way of a circular slot 92X located around rotating vapor discharge pipe segment 86Xa in the plane of the outer radial plate. The controlled discharging stream o solid particles forms a seal during the clischarge period. The , _ 7a -~ 2~
circular slot 92X is further sealed during the remaining 360 degrees of rotation by an adjusta~le stat;onary seal plate 93X. Adjusting mechanism 94X mai.ntai:ns the clearance bet~een the stationary seal plate 93X and the rotating circular opening 92X. Mechanism 94X is hinged so that oversize or tramp material exiting through the seal openings 92X will momentarily move the seal plate away from its normal position allowing the oversize or tramp material to discharge into the outer tube 12X.
The outer tube 12X includes an inwardly projecting lip 15X. A stationary recycle end assembly 301X is provided to seal the recycle end of the outer tube. The assembly 301X
comprises the ring element 302X and the ring seal 85X which cooperate to close off the aperture formed by the lip 15X.
The vapor discharge pipe 86X is made up of an external stationary section 86Xb, securely fastened to the ring element 302X, and a rotating portion 86Xa which is fastened to and rotates with the assembly 91X. The statlonary recycle end assembly 301X includes a rotary pipe seal 88X which seals around discharge pipe 86X.
Means are provided for supplying oxygen, as in the Form of air, to the central portion of the combustion zone 34X. Such means may comprise a burner 23X, supplied with air by a fan 405X, which forces pre-heated air through the centre rotating pipe assembly 96X. The pipe assembly 96X is shown in Figures 2 and 4 and comprises stationary pipe 96Xb, rotating pipe header 96Xa and a number of rad;ally extending pipes 96Xc terminating at injection nozzles ~06X. The stationary pipe 96Xb and rotating pipe header 96Xa are connected by a suitable pipe seal 78X. High velocity combustion air exists from the noz-zles ~06X and create~-turbulent conditions in the solid particle flows in the combustion zone. The combination of ejection velocity and the cascading of the sol;ds in the combustion zone provide . , .
~z~
intimate mixing of the ca~ on-coated particles and oY.ygen, li enabling rapid and complete combustion to take place.
The heated solid materials continue their travcl to~ard the recycle or let hand of the apparatus where a screening element separates oversi%ea r~aterial and recycle fixtures divert part or all of the undersize material back into the inner tube. More particularl~, the screening and recycle fixture indicated generally at 62X, which may best j be described by joint reference to Figures 2 and 3 , 1 screens an oversize product and an undersize proauct on screen 67X. This screen has an opening si~e that is determined by the re~uirements of downstream coke users and by the recycle j~
particle size requirernents. A series of two or more recycle pipes 66X coupled to plates 65X, 67X, 64X and 63X and placed at approximately equal intervals along the inner tube llX
circullference, are used -to lift and move recycled particles ~ack into the ;nner tube ~hile substantially retaining a solid particle seal between the inner and outer tube atmosphere Undersize particles are collected in the area 64X between partial tubes 63X and 69X and move along this confined area until obstructed by plate 65X. The tapered recycle tube 66X
contains the recycle until a degree of rotation is achieved so that the solid particles are discharged at a controlled rate into the inner tube llX The rate of material flo~ is adjustable by means oE varying the outlet opening 69X by adjusting plate 68X.
The o~-ersized fraction falls from the screen 67X in-.o a cc~e pl-ocescing cnd cooling system 40ax.
A variable po--J~:ioll of the oversized particles may be cruslled ~hile still on the screen and recombined ~ith ii,e undersized lraction for rec~cling into the inner tube. i~iore part;cu]a~ , the en~ structure 14X comprises ~n i~ acting roller 403X For crushing oversized solids on the screen 67X.
The exhaust combustion gases from the area between the inner tube and outer tube flow through this annulus to the recycle end of the outer tube, then fl~w upwards along the stationary end frame where they combine with any steamiproduced from coke quenching. The combined exhaust gas flow exits to cyclones 401X for a coarse particle separation, through coolers 24X where sensible heat is recuperated, then scrubbed in a wet dust extractor 25X where the physical dust particles are removed. S~lphur dioxide (S02) in the exhaust gas stream is reacted ~ith water and then ~ith calcium (Ca) ions to pro-duce calcium sulphate which is removed and disposed of as a waste sludge. The scrubbed sulphurless gas flow is expelled to a discharge stack by ~an 26X.
Auxiliary burners 23X are used to preheat ~he unit for startup, ma;ntaining temperature trim during operation, and for maintaining temperature during upset operating conditions. These burners can be located in the combustion air stream as illustrated or mounted for direct -Firing into the outer tube annulus at either the feed or discharge end of the apparatus.
The outer tube 12X is constructed of a metal shell having a substantially full lining 60X o~ refractory material.
This lining is desirably constructed of arl insulating refractory material which exhibits abrasion resistance and contain a coarse grog. The lining provides thermal insulation to prevent excessive process heat being lost through the outer shell as well as providing protection against abrasion and chemical attack.
In addition to advancing the solid particles through the inner tube llX and outer tube 12X by means of the inclined elements 38X, 39X, 40X, 43X and 44X it is desirable in certain zones, to lift and drop the solid particles re-peatedly. The outer tube surface is partially equipped with l~Z~L~
If it ls desirable to obtain a very pure recovery stream vf hydrocarbon vapoxs, the pressure in the vaporization zone is maintained at a level slightly greater than the pressure in the combustion zone. This pressure control prevents migration of the combustion produced gases into the vaporization zone. Similarly, if it is desirable to maximize recovery of hydrocarbons, the pressure in the vaporiza-tion zone is maintained at a level slightly lower than -the pressure in -the combustion zone.
Oxygen-bearing gases for the combustion process are injected into the solid particles being transported along _ lla -~1~ ! . .
flat or cup plate lifters lOOX as illustrated on Figure 4 and Figure ~. Cup lifters have a greater lifting capacity and a larger area of discharge thus ensuxing better contact between the falling solid particles ancl the combustion air molecules. The lifting mechanisms lOOX are removably secured by balls, where possible, to the outer tube 12X.
The end closures 14X and 15X are suitably insulated with refractory to minimize heat losses from the process area and to protect metal surfaces from exposure to chemical attack and corrosion.
The rotating apparatus and stationary end frames are operated at near ambient pressure conditions and gas flows remain substantially separated as a result of the cornbination of differential pressure control and rotating sand seals. An exhaust fan, exhaust gas scrubbing and cleaning system, as well as a cooling system with cyclones is provided for containment of the gases resulting from combustion of the carbon and any steam generated during final quenching of the excess coke particles. This exhaust system controls the flow of exhaust gases so that the entire length of the outer tube is maintained at a slight negative pressure with respect to ambient pressure outside the apparatus. This ensures a slight inflow of air which will be largely consumed in the combustion process and form part of the hea-t balance requirements. The hydrocarbon bearing vapors are continuously extracted from the product end of the inner tube by a series of fans, compressors, vapor cleaning equipment and condensors combined with coolers. These systems control the rate of vapor flow so that the pressure differential between the inner tube and the outer tube at the product end of the apparatus is maintained near zero.
, - ' ' , ' .
- ~ 11 the outer c})am~er through a series o non~plugginy nozzles~
T}lese nozzles are located far enough away from the product end vf the apparatus so that most of the oxygen is consumed by reaction with the coke, even u,nder upset conditions where ' flow reversal might tend to move these gases towards the product end rather tha'n the normal exit through the e~haust end of the apparatus.
The outer tube along with rotating and stationary end closures are suitably lined with refractory and insulation to prevent excess heat loss and exposure of the exterior structure to high temperature stresses The inner and outer tube motion results in weaxing of the contacting surfaces. ;
The structure of the inner and outer contact surfaces, as ~ell as the liting and advancing elements is designed in easily handled units so that maintenance and replacement of ~orn components can ~e readily accomplished.
.... . ...... .... ......... .. ;
,era'tion'of 'th'e' Apparatus For the purpose of the description to follo~?, it is assumed that tI-,e feed liquid is a 15 to 18 API, asphaltic J~ase crude oil that has approximately 4 percent by ~leight of ~ater ana solias entrained in it. Ini-tially, the unit lOX
4~1~
is brought up to near operating temperature by using burner 23X
which supplies hot air at approximately 1200F to the combustion zone. Steam is fed into the unit vapour chamber to purge out any remaining oxygen bearing gases. As the unit is being heated it is slowly rotated to ensure even heating of the complete rotating mass.
When the temperature reaches app~oximately 900 to 1000~ feed liquid is slowly applied into the vapour zone 33X. As the exterior handliny equipment temperature stabilizes, the feed rate to tne unit is increased and its rotating speed increased to the normal operating level. The rotation of the unit causes the solid particles to move through all zones of the unit as previously described.
During normal operation feed liquid containing hydrocarbons is fed through a combination of heat exchangers such as l~X and l7X which preheat the oil so that any liquids that do not require cracking can be flashed and vapourized. Fo~ typical heavy oil feeds this temperature is in the 600 to 700F range. The flash chamber 406X receives the pre-heated liquid feed and separates a vapour composed of steam and light hydrocarbons which is fed directly -to the primary vapour condensor l9X, and the remaining feed liquid is pumped or fed by gravity to pipe 407X. Pipe 407X is suspended in the area of the inner and outer tube rotating axis but is coupled to stat;onary vapour discharge pipe 86Xb such that it does not rotate with the tubes. Sprays 408X
mounted at certain intervals along the bottom of pipe 407X control the location and coverage o~ the liquid application to the surface of the moving solld particles so that a smooth continuous rate of cracking reactions take place. The rotation of the inner tube llX co-operates with the advancing elements 38X, 39X and 40X and variable lifting elements 56X so that the solid part;cles are continuously being gently mixed and moved under the sprays 408X thus ensuring an even temperature amongst the solid partîcles and a uniform rate of carbon build-up on the solid particles. The temperature of the recycle particles for a f 15 to 18 ~PI crude should be in the range of 1000 to 1200F as the particles enter zone 32X and not below 850F ~hen the particles ex;.t the inner tube after passing through the spray zone 33X. Spray pipe 407X can be rotated by an external mechanism up -to 90 degrees From vertical in either a clockwise or anti clock~ise direction so that the sprays can be properly directed onto the solid particles and partially onto the inner tube llX ;f this is desirable for the process.
The solid particles, cooled durîng their reacting period under the liquid sprays 408X, continue being moved by advancing elements 40X
towards the discharge seal end assembly 91X. The solid particles enter the seal assembly through openings 95X and are elevated by contact with plate 90X and the rotation of the apparatus until they are discharged to the outer tube 12X by gravity through slot 92X.
The feed liquid upon contact with the recycled, hot, solid particles cracks to form hyd.rocarbon vapours which fill the internal area formed by inner tube llX and the end closures of tube llX.
Vapour flow control fan 400X applies a slight suction to cyclones l~X, vapour pipe 86X and inner tube zone 32X and 33X. As vapours are pro-duced they flow through discharge pipe 86X, then through cyclones 16X
where coarse solids are removed. Vapour fan 400X may serve as a second du~t extractor by recycling condenser heavy liquid products through the fan so that the liquid droplets may contact the fine particles and absorb them. The vapour fan discharges the hydrocarbon vapour into a condenser l9X where the vapours are cooled and condensed by contact with packed trays and liquid sprays. The combined condensed liquids are fed through suitable heat exchangers 17X and 18X then a portion of that liquid is recycled to the condenser for cooling of further incoming vapours. A relatively small portion of the vapour stream contains hydrocarbons th.at remain as gases at temperatures of 100 to 200F and these are further cooled in cooler 20X, pumped to storage by compressor 21X and further cooled by cooler 22X if so required. lhe vapour temperature exiting pipe 86X is in the order of 700 to 900F while the final temperature of the ex;ting liquid and gas products will be close to ambient temperatures.
Once the solid particles, w;th their deposits of reaction carbon, are discharged ~rom seal end assem~ly 91X they contact the sur~ace arrangement of outer tube 12X. The combination of drum rotation and inclined advancing elements 43X moves these particles back into the combustion zone. Lifters lOOX act to lift these particles and drop them through the atmosphere of combustion gases so that oxygen present in the gas can efficiently react with the surface carbon. This reaction produces heat which is absorbed by the par~icles thereby increasing its temperature. Sufficient combustion gas is added so that the particles temperature increases from approximately 900F to the range of 1000F to 1300F.
Combustion air is supplied at a pressure of 5 to lS inches water gauge and is passed through a combination of heat exchangers 404X and 23X such that the gas is heated to more than 500F. This preheated combustion air flows through pipes 96Xa~ 96Xb, 96Xc and exits through a series of high velocity nozzles 406X that ensure turbulent mixing of gas molecules and carbonized par~icles. Any oxygen not consumed in this initial contact at the nozzles is available to react with carbon throughout zones 34X and 35X as a combination of lifters lOlX which extend throughout zone 35X repeatedly lifts and drops the solid particles through the gas atmosphere.
The solid particles are progressively moved towards the recycle and screening assembly 62X during the combustion process.
Upon arriving at this assembly, they are fed onto the screen segments 67X where oversize is handled as previously described. The undersize particles, along with crushed fine particles as required, are collected in the segmented annulus under the screen and, as the apparatus lOX
~z~
ro-tates, the particles enter openings 64X and continue moving down the annulus until they contact plate 65X. As the apparatus continues to rotate the particles are lifted by plate 65X until an angle i5 reached where the particles start to discharge into the inner tube llX through tube 66X, opening 68X and d;scharge rate adjustment 69X. Once these particles are deposited in the inner tube they are progressively moved and mixed in zone 32X by the arrangement of i.nclined elements 38X and the configuration of the inner tube sections 56X. The solid particles move under the feed applicators sprays and the cracking reaction and cycle is repeated.
The exhaust gases from the combustion zone, any air leakage through the rotat;ng seals, as well as any steam resulting from coke quenching, is removed continuously From the units by suction ~rom the exhaust system. Exhaust gases pass through the stat;onary end frame 14X, pass up through discharge pipe and control dampers 80X and 81X, pass through coarse particle removal cyclones 401X, pass through cooling heat exchangers 24X then are scrubbed.for removal of fine particulates and noxious gases prior to injection to atmosphere by a suitably designed stack system.
The exhaust system rate of discharge is controlled by a suitable damper arrangement such that the rotating apparatus is kept under a very slight negative pressure. Lt will also be appreciated that the pressures required for proper operation are dependent on the type and character oF the feed and recycle materials so that internal pressure relationships may be altered to obtain the desired gas flows thro~gh apparatus lOX. Thus, while subatmospheric pressures are con-sidered preferable ;n the vapour release and combustion zones, super atmospheric pressure may be desirable under certain feed and recycle conditions. In the preferred form of the invention ~he pressures in the vapour release zone 33~ and the combustion zones 34X are maintained substant;ally equal to minimize any cross flow of process~gases between the two tubes. These pressures are maintained by proper positioning of the damper 80Xa and by proper positioning of dampers and other control means, indicated generally in Figure 1 on the vapour compressor 21 and the fans supplying the combustion air and the various cooler air flows.
By these means, hydrocarhon vapours in zone 33X and the combustion gases in zone 34X are prevented from flowing through slots 92X or openings 64X
and work in co-operation with their respective sand and mechanical seal arrangements to maintain a separation between the gases.
Although not specifically illustrated, it will be understood that conventional instrumentation will be provided to control the following:
1. Liquid feed rate based on temperature pro~ile and capacity of the hydrocarbon vapour condensing and cleaning systems.
BACKGROUND OF THE INVENTION_ _ _ The present invention relates to an apparatus and process for thermally processing a heavy hydrocarbon-containing feed stock whereby at least a portion of the hydrocarbons are thermally cracked and vaporized to produce a gaseous product.
Large deposi-ts of bituminous sands and heavy oil-bearing formations are found in various areas of the world. The wellhead products obtained by in situ recovery from these sources usually comprise a liquid containing a range oF hydrocarbons, water, steam, sulphur, entrained fine solids, metals, entrainecl gases and special agents added during recovery. The hydrocarbons may in large part be characterized by an API gravity less than about 25 API., In conventional oil refinery processes a high v;scosity, low API tower bottoms stream of hydrocarbons is obtained during processing by atmospheric and vacuum distillation methods. These tower bottoms require thermal cracking to be utilized in a downstream reFining process.
The apparatus and process of the present invention is pro-vided to process the above-described heavy hydrocarbon-containing liquids.
SUMMARY OF THE INVENTION
__ .
In accordance with one aspect of this invention, there is provided an apparatus for thermally treating heavy hydrocarbon-containing liquids, such as refinery bottoms or product from an in situ heavy oil recovery process.
The apparatus comprises concentric, radially spaced inner and outer tubes having recycle and product ends. The tubes are secured together and may be rotated about a common horizontal axis. Advance elements are provided on the inner surfaces of both tubes for advancing a charge of particulate solids through the inner tube and back through the annular space formed between the tubes. The charge of particulate solids may comprise coke, sand or the like. Rotation of the tubes causes the solids to follow an oval path through an inner processing zone defined by the inner tube, ;nto and back through the annular space (which includes a combustiorl zone), and then back into the recycle end of the inner tube. Rotation of the tubes also effects cascading of the contained solids; this cascading action may be amplified by providing lifter elements on one or both inner surfaces of the tubes. The lifter elements func-tion to lift and drop the solids as the tubes rotate.
A stationary recycle end assembly is provided to seal the recycle end of the outer tube. Also, a stationary product end assembly is sealably associated with the outer tube or an end wall forming part of the outer tube, to close the product end of such tube. The seals that are involved are of a ring type and, although substantially gas-tight, there will be minor gas leakage past them, which is taken advantage of in a manner to be described.
Means are provided for sealing the recycle end oF the inner tube. Such means include recycle means which connect the recycle end of the annular space with the inner processing zone. Such recycle means are operative to return at least a portion of the solids moving through the annular space back into the recycle end of the inner processing zone.
The recycle means are adapted to cooperate with the solids being returned to prevent significant gas movement between the inner processing zone and the annular space.
Means are also provided for sealing the product end of the inner tube. Said means include means for transferring carbon-carrying solids from the inner processing zone to the cornbustion zone. Said transfer means are adapted to cooperate with the carbon-carryiny solids being transferred to prevent significant gas movement between the inner processing zone and the annular space.
Feed means, extending into the inner processing zone, are provided for depositing the hydrocarbon-containing liquid onto the particulate solids being advanced therethrough.
Means, such as a conduit and fan, are provided ~or withdraw;ng hydrocarbon vapours from the inner processing zone. Similar rneans are also provided for withdraw;ng combust;on gases From the annu'lar space.
Finally, means are provided for introduc;ny oxygen-containing gas into the combustion zone to effect combustion therein as described below.
In operation, the charge of sol;ds circulates continuously through the inner processing zone and the annular space. The solids are hot as they enter the recycle end of the inner tube. The hydrocarbons-containing liquid is deposited on them and at least a portion of such hydrocarbons vaporize and are cracked, thereby generating gaseous hydro-carbon vapours and simultaneously forming a carbon deposit on the solids particles (termed hereafter 'coked solids'). The constant cascading effects intimate mixing of the liquid and solids and promotes uniform heat transfer. l'he coked solids are then discharged into the combustion zone where at least part of the coke is burned to heat the solids. Sup-plemental heat may be supplied by a burner to assist in raising the temperature of the solids. Combustion-heated solids are then recycled into the inner tube to repeat the process.
The process is characterized by several features. By pro-viding separate means for w;thdrawing the combustion and product gases in combination with recycling and transfer means operative to provide sealing functions at the ends of the inner tube, there is thereby provided a particular system for segregating the two gaseous streams. This system is compatible with the utilization of an open cylindrical processing zone and an open annular space in the processor.
Because these spaces are open, a desirable degree of mixing may be obtained therein simply by the cascad;ng action effected by rotat;on of the tubes.
In another aspect of the invention, a process is provided for vaporizing and c~acking a heavy hydrocarbon-containing liquid, such process employing direct thermal treatment effected in an apparatus having horizon-tal, substantially concentric, rad;ally spaced inner and outer rotatable tubes in which one axial end is the feed end and the opposite axial end is the product end, said inner tube forming an open cylindrical inner processing zone, sa;d tubes forming between them an open annular space having a combustion zone, said apparatus having assemblies for sealing the ends of the outer tube. The process comprises: continuously advancing hot particulate sol~ds through the inner tube from the Feed end to the product end and back through the annular space; depositing the hydrocarbons as a liquid onto the hot solids; cascading and mixing the solids and hydrocarbons as they advance through the inner processing zone to achieve beneficial heat transfer and thereby vaporize hydro-carbons and form carbon on the solids; withdrawing the hydrocarbon vapors produced in the inner tube; transFerring carbon-coated solids from the product end of the inner tube into the combustion zone in the annular space; cascading and mixing the carbon-coated solids in the combustion zone while introducing oxygen-containing gas thereinto to burn at least part of the carbon and heat the remainder o-f the solids;
transferring burned hot solids from the feed end of the annular space into the feed end of the inner tube; withdrawing vapors produced in:the combustion zonei and preventing substantial gas flow between the inner processing zone and the combustion zone by blocking gas flow with the solids being transferred and maintaining substantially equal pressures in said zones.
_ESCRIPTION_OF THE _ AWINGS
Figure 1 is a schematic diagram illustrating the process and apparatus of the present invention and one possible arrangement of external equipment for simple condensing of the hydrocarbon vapors to provide a pumpable liquid and a cooled coke by-product that can be used dS a feed for boilers or furnaces for production of heat energy.
Figure 2 is an elevation, mostly in section, -taken along the rotational axis of the inner and outer tubes, illustrating de-tails and representative features in the construction and operation of the inner and outer tubes and end frames of the invention.
Figure 3 is a cross-sectional view taken along line llOX of Figure 2 and illustrates the arrangement and operating principles of the recycle ring portion of the invention.
Figure 4 is a cross-sectional view taken along line lllX of Figure 2 and illustrates the arrangement of pipes and nozzles for the oxygen-bearing gas system.
Figure 5 is a cross-sectional view -taken along line 112X of Figure 2 and illustrates the product end seal and solid particle discharge from the inner tube to the outer tube. A cross section through the seal is included for further clarification.
Figure 6 is a cross-sectional view taken along the line 113X of Figure 5 and illustrates the product end seal.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus lOX comprises concentric, radially spaced inner and outer tubes llX, 12X. The two tubes are connected together in the manner previously described and are rotated about the;r common long axis. The ends of the inner tube terminate in end frames which rotate with the tube and seal its ends to contain generated gases, the recycle end frarne being merely a seal plate 200X while the product end frame 91X provides an inner to outer tube seal arrangement as well as - 5a -L ~8 functioning as~ the means for transferr;`ng solids from inner tube into the annular space between the tubes. A vapor discharge pipe 86X extends through the product end frame 91X i:nto the inner tube llX. The inlet and outlet ends of the outer tube 12X extend into sta~.ionary end assembly 14X and partially stationary end assembly 15X respectively. Roller mounted rings 45X, 46X are connected -to the outer tube so that the tubes may be rotated by a motor 51X and ring gear 52X.
The tubes define or form a s.equence af processing zones. More particularly, at its inlet end the inner tube llX forms a mixing zone 32X ~herein recycled hot solids are mi:xed to provi;de temperature equilibrium pri.or to contact with hydrocarbon-bearing liquid~ Down-stream of the mixing zone, the inner tube provides a vapor zone 33X
wherein the liquid is deposited on the hot recycled solids and hydro-carbons are vaporized and cracked. The mixing and vapor zones together form an inner proces.sing zone whi.ch is a substanti:ally open cylindrical space. A combus.ti.on zone 34X i.s provided i:n the open annular space formed between the tubes, wherein carbon-coated solids are burned to provide required heat for the process. At the leFt hand end of the annular space, a recycle zone 35X ;.s provided wh.erein may be conducted screening, oversize particle rejection, undersize particle recycle and intermittent cruishi.ng of overs.ize parti:cle operations. Fi.nally, there is.
provided in the inlet end assembly 14X a cooling zone 36X~ wh.ere.i:n overs;:ze parti.cles are cooled and discharged.
The majority of the combus.tion takes place in the combustion zone 34X in the annular space between the two tubes, however some com-bustion will also take place i.n the space be ~een the stati.onary end assembly 15X and product end frame 91X~ Thus the terrn l'ciombus.ti.on zone" as used i.n the claims.should be taken to refer to both the annular s:pace between the two tubes and the space between the ends o-F the t~o tubes at ~ 30 the product end. It i.s concei.vable that the outer tubular member could be extended to enlarge the combustion zone, ;f desired.
,--, ~ .
The tubes are in;tially charged with solids, for ex-ample coke or sand particles. These solids are advanced through the m;xing, vapor and combust;on zones 32X, 33X, 34X, us;ng advancing elements attached to the inner sur~aces of the tubes, as previously described. More particularly, longitud;nally - 6a -e~tending rows of cldva~cing elernents 38X, 39X and 40X formed along the inner surf~ce of the inner tube and similar advancing elements 43X, 9qX formed alon~ the inner surface of the outer . tube cause the solids to move through the two tubes as they are rotated about their long axis. The number of elements as well as their size and degree of inclination may be varied to optimize the rate of advance through each zone.
Feed liquid containing heavy hydrocarbons is sprayed or deposited on the hot solids as they advance through . 10 the vapor zone 33X. Preferably, the feed liquid is pre-heated by heat exchange with the produced vapors in the coolers 17X, 18X. The pre-heated feed liquid may then be flashed in charnber 906X and pro~uced gaseous liyht enas and water vapor returned to the condenser l9X. The pre-heated li~uid is introduced into the vapor zone 33X through pipe 407X and sprayed on the ~loving solids through the nozzles 408X~ The continuous mixing and cascading of the solids in the vapor zone ensures a uniform temperature of these particles so that hot and cold spots are minimized as the.liquid is applied. Control of the rate of liquid application Jnay be utilized to ensure rapid vaporizing of the hydrocarbons and close control of the contact time and hence the dearee o:~ cracking occurring i.n the vapor zone.
The ends of the inner tube are sealed to prevent the uncontrolled escape of the ~ases generated in the vapor zone 33X. At the l-ecycle end, the plate 200X provides a closure ~hi.ch is penetrated only by tlle hot air pipe header 96Xa and the hot solids recycle pipes 66X. At the product end, an end zssen~bly 91X provides a ~necllanical and moving solids seal asainst !.he escape of gases.
The carbon-coated particles are continuousl~
transferred from the vapor zone 33X of the inner tube into the annular combustion zone`39X def;nea bet~een the t~o t~bes.
In this c,onnectiOn, an cnd c~ssernbly ~lX or accomplishing this is now described, Re~er to Figs. 2 and 6 . The end assembly 91X is fastened to the prod~ct end of the inner tube llX and is illustrated in Figure . 5 ~. The assembly is formed by two radial end plates 201X, ~02X fastened together by a series of baffles 90X whic}l form compar~nents. Carbon-coated particles are fecl i.~ltO these conpartments through :
openings 95X located in the inner radial plate 201X. As the , tubes rotate, the particles in the compartments move towards the central axis and, at a suitable angle, are discharged to the outer tube by way of a circular slot 92X located around rotating vapor discharge pipe segment 86Xa in the plane of the outer radial plate. The controlled discharging stream o solid particles forms a seal during the clischarge period. The , _ 7a -~ 2~
circular slot 92X is further sealed during the remaining 360 degrees of rotation by an adjusta~le stat;onary seal plate 93X. Adjusting mechanism 94X mai.ntai:ns the clearance bet~een the stationary seal plate 93X and the rotating circular opening 92X. Mechanism 94X is hinged so that oversize or tramp material exiting through the seal openings 92X will momentarily move the seal plate away from its normal position allowing the oversize or tramp material to discharge into the outer tube 12X.
The outer tube 12X includes an inwardly projecting lip 15X. A stationary recycle end assembly 301X is provided to seal the recycle end of the outer tube. The assembly 301X
comprises the ring element 302X and the ring seal 85X which cooperate to close off the aperture formed by the lip 15X.
The vapor discharge pipe 86X is made up of an external stationary section 86Xb, securely fastened to the ring element 302X, and a rotating portion 86Xa which is fastened to and rotates with the assembly 91X. The statlonary recycle end assembly 301X includes a rotary pipe seal 88X which seals around discharge pipe 86X.
Means are provided for supplying oxygen, as in the Form of air, to the central portion of the combustion zone 34X. Such means may comprise a burner 23X, supplied with air by a fan 405X, which forces pre-heated air through the centre rotating pipe assembly 96X. The pipe assembly 96X is shown in Figures 2 and 4 and comprises stationary pipe 96Xb, rotating pipe header 96Xa and a number of rad;ally extending pipes 96Xc terminating at injection nozzles ~06X. The stationary pipe 96Xb and rotating pipe header 96Xa are connected by a suitable pipe seal 78X. High velocity combustion air exists from the noz-zles ~06X and create~-turbulent conditions in the solid particle flows in the combustion zone. The combination of ejection velocity and the cascading of the sol;ds in the combustion zone provide . , .
~z~
intimate mixing of the ca~ on-coated particles and oY.ygen, li enabling rapid and complete combustion to take place.
The heated solid materials continue their travcl to~ard the recycle or let hand of the apparatus where a screening element separates oversi%ea r~aterial and recycle fixtures divert part or all of the undersize material back into the inner tube. More particularl~, the screening and recycle fixture indicated generally at 62X, which may best j be described by joint reference to Figures 2 and 3 , 1 screens an oversize product and an undersize proauct on screen 67X. This screen has an opening si~e that is determined by the re~uirements of downstream coke users and by the recycle j~
particle size requirernents. A series of two or more recycle pipes 66X coupled to plates 65X, 67X, 64X and 63X and placed at approximately equal intervals along the inner tube llX
circullference, are used -to lift and move recycled particles ~ack into the ;nner tube ~hile substantially retaining a solid particle seal between the inner and outer tube atmosphere Undersize particles are collected in the area 64X between partial tubes 63X and 69X and move along this confined area until obstructed by plate 65X. The tapered recycle tube 66X
contains the recycle until a degree of rotation is achieved so that the solid particles are discharged at a controlled rate into the inner tube llX The rate of material flo~ is adjustable by means oE varying the outlet opening 69X by adjusting plate 68X.
The o~-ersized fraction falls from the screen 67X in-.o a cc~e pl-ocescing cnd cooling system 40ax.
A variable po--J~:ioll of the oversized particles may be cruslled ~hile still on the screen and recombined ~ith ii,e undersized lraction for rec~cling into the inner tube. i~iore part;cu]a~ , the en~ structure 14X comprises ~n i~ acting roller 403X For crushing oversized solids on the screen 67X.
The exhaust combustion gases from the area between the inner tube and outer tube flow through this annulus to the recycle end of the outer tube, then fl~w upwards along the stationary end frame where they combine with any steamiproduced from coke quenching. The combined exhaust gas flow exits to cyclones 401X for a coarse particle separation, through coolers 24X where sensible heat is recuperated, then scrubbed in a wet dust extractor 25X where the physical dust particles are removed. S~lphur dioxide (S02) in the exhaust gas stream is reacted ~ith water and then ~ith calcium (Ca) ions to pro-duce calcium sulphate which is removed and disposed of as a waste sludge. The scrubbed sulphurless gas flow is expelled to a discharge stack by ~an 26X.
Auxiliary burners 23X are used to preheat ~he unit for startup, ma;ntaining temperature trim during operation, and for maintaining temperature during upset operating conditions. These burners can be located in the combustion air stream as illustrated or mounted for direct -Firing into the outer tube annulus at either the feed or discharge end of the apparatus.
The outer tube 12X is constructed of a metal shell having a substantially full lining 60X o~ refractory material.
This lining is desirably constructed of arl insulating refractory material which exhibits abrasion resistance and contain a coarse grog. The lining provides thermal insulation to prevent excessive process heat being lost through the outer shell as well as providing protection against abrasion and chemical attack.
In addition to advancing the solid particles through the inner tube llX and outer tube 12X by means of the inclined elements 38X, 39X, 40X, 43X and 44X it is desirable in certain zones, to lift and drop the solid particles re-peatedly. The outer tube surface is partially equipped with l~Z~L~
If it ls desirable to obtain a very pure recovery stream vf hydrocarbon vapoxs, the pressure in the vaporization zone is maintained at a level slightly greater than the pressure in the combustion zone. This pressure control prevents migration of the combustion produced gases into the vaporization zone. Similarly, if it is desirable to maximize recovery of hydrocarbons, the pressure in the vaporiza-tion zone is maintained at a level slightly lower than -the pressure in -the combustion zone.
Oxygen-bearing gases for the combustion process are injected into the solid particles being transported along _ lla -~1~ ! . .
flat or cup plate lifters lOOX as illustrated on Figure 4 and Figure ~. Cup lifters have a greater lifting capacity and a larger area of discharge thus ensuxing better contact between the falling solid particles ancl the combustion air molecules. The lifting mechanisms lOOX are removably secured by balls, where possible, to the outer tube 12X.
The end closures 14X and 15X are suitably insulated with refractory to minimize heat losses from the process area and to protect metal surfaces from exposure to chemical attack and corrosion.
The rotating apparatus and stationary end frames are operated at near ambient pressure conditions and gas flows remain substantially separated as a result of the cornbination of differential pressure control and rotating sand seals. An exhaust fan, exhaust gas scrubbing and cleaning system, as well as a cooling system with cyclones is provided for containment of the gases resulting from combustion of the carbon and any steam generated during final quenching of the excess coke particles. This exhaust system controls the flow of exhaust gases so that the entire length of the outer tube is maintained at a slight negative pressure with respect to ambient pressure outside the apparatus. This ensures a slight inflow of air which will be largely consumed in the combustion process and form part of the hea-t balance requirements. The hydrocarbon bearing vapors are continuously extracted from the product end of the inner tube by a series of fans, compressors, vapor cleaning equipment and condensors combined with coolers. These systems control the rate of vapor flow so that the pressure differential between the inner tube and the outer tube at the product end of the apparatus is maintained near zero.
, - ' ' , ' .
- ~ 11 the outer c})am~er through a series o non~plugginy nozzles~
T}lese nozzles are located far enough away from the product end vf the apparatus so that most of the oxygen is consumed by reaction with the coke, even u,nder upset conditions where ' flow reversal might tend to move these gases towards the product end rather tha'n the normal exit through the e~haust end of the apparatus.
The outer tube along with rotating and stationary end closures are suitably lined with refractory and insulation to prevent excess heat loss and exposure of the exterior structure to high temperature stresses The inner and outer tube motion results in weaxing of the contacting surfaces. ;
The structure of the inner and outer contact surfaces, as ~ell as the liting and advancing elements is designed in easily handled units so that maintenance and replacement of ~orn components can ~e readily accomplished.
.... . ...... .... ......... .. ;
,era'tion'of 'th'e' Apparatus For the purpose of the description to follo~?, it is assumed that tI-,e feed liquid is a 15 to 18 API, asphaltic J~ase crude oil that has approximately 4 percent by ~leight of ~ater ana solias entrained in it. Ini-tially, the unit lOX
4~1~
is brought up to near operating temperature by using burner 23X
which supplies hot air at approximately 1200F to the combustion zone. Steam is fed into the unit vapour chamber to purge out any remaining oxygen bearing gases. As the unit is being heated it is slowly rotated to ensure even heating of the complete rotating mass.
When the temperature reaches app~oximately 900 to 1000~ feed liquid is slowly applied into the vapour zone 33X. As the exterior handliny equipment temperature stabilizes, the feed rate to tne unit is increased and its rotating speed increased to the normal operating level. The rotation of the unit causes the solid particles to move through all zones of the unit as previously described.
During normal operation feed liquid containing hydrocarbons is fed through a combination of heat exchangers such as l~X and l7X which preheat the oil so that any liquids that do not require cracking can be flashed and vapourized. Fo~ typical heavy oil feeds this temperature is in the 600 to 700F range. The flash chamber 406X receives the pre-heated liquid feed and separates a vapour composed of steam and light hydrocarbons which is fed directly -to the primary vapour condensor l9X, and the remaining feed liquid is pumped or fed by gravity to pipe 407X. Pipe 407X is suspended in the area of the inner and outer tube rotating axis but is coupled to stat;onary vapour discharge pipe 86Xb such that it does not rotate with the tubes. Sprays 408X
mounted at certain intervals along the bottom of pipe 407X control the location and coverage o~ the liquid application to the surface of the moving solld particles so that a smooth continuous rate of cracking reactions take place. The rotation of the inner tube llX co-operates with the advancing elements 38X, 39X and 40X and variable lifting elements 56X so that the solid part;cles are continuously being gently mixed and moved under the sprays 408X thus ensuring an even temperature amongst the solid partîcles and a uniform rate of carbon build-up on the solid particles. The temperature of the recycle particles for a f 15 to 18 ~PI crude should be in the range of 1000 to 1200F as the particles enter zone 32X and not below 850F ~hen the particles ex;.t the inner tube after passing through the spray zone 33X. Spray pipe 407X can be rotated by an external mechanism up -to 90 degrees From vertical in either a clockwise or anti clock~ise direction so that the sprays can be properly directed onto the solid particles and partially onto the inner tube llX ;f this is desirable for the process.
The solid particles, cooled durîng their reacting period under the liquid sprays 408X, continue being moved by advancing elements 40X
towards the discharge seal end assembly 91X. The solid particles enter the seal assembly through openings 95X and are elevated by contact with plate 90X and the rotation of the apparatus until they are discharged to the outer tube 12X by gravity through slot 92X.
The feed liquid upon contact with the recycled, hot, solid particles cracks to form hyd.rocarbon vapours which fill the internal area formed by inner tube llX and the end closures of tube llX.
Vapour flow control fan 400X applies a slight suction to cyclones l~X, vapour pipe 86X and inner tube zone 32X and 33X. As vapours are pro-duced they flow through discharge pipe 86X, then through cyclones 16X
where coarse solids are removed. Vapour fan 400X may serve as a second du~t extractor by recycling condenser heavy liquid products through the fan so that the liquid droplets may contact the fine particles and absorb them. The vapour fan discharges the hydrocarbon vapour into a condenser l9X where the vapours are cooled and condensed by contact with packed trays and liquid sprays. The combined condensed liquids are fed through suitable heat exchangers 17X and 18X then a portion of that liquid is recycled to the condenser for cooling of further incoming vapours. A relatively small portion of the vapour stream contains hydrocarbons th.at remain as gases at temperatures of 100 to 200F and these are further cooled in cooler 20X, pumped to storage by compressor 21X and further cooled by cooler 22X if so required. lhe vapour temperature exiting pipe 86X is in the order of 700 to 900F while the final temperature of the ex;ting liquid and gas products will be close to ambient temperatures.
Once the solid particles, w;th their deposits of reaction carbon, are discharged ~rom seal end assem~ly 91X they contact the sur~ace arrangement of outer tube 12X. The combination of drum rotation and inclined advancing elements 43X moves these particles back into the combustion zone. Lifters lOOX act to lift these particles and drop them through the atmosphere of combustion gases so that oxygen present in the gas can efficiently react with the surface carbon. This reaction produces heat which is absorbed by the par~icles thereby increasing its temperature. Sufficient combustion gas is added so that the particles temperature increases from approximately 900F to the range of 1000F to 1300F.
Combustion air is supplied at a pressure of 5 to lS inches water gauge and is passed through a combination of heat exchangers 404X and 23X such that the gas is heated to more than 500F. This preheated combustion air flows through pipes 96Xa~ 96Xb, 96Xc and exits through a series of high velocity nozzles 406X that ensure turbulent mixing of gas molecules and carbonized par~icles. Any oxygen not consumed in this initial contact at the nozzles is available to react with carbon throughout zones 34X and 35X as a combination of lifters lOlX which extend throughout zone 35X repeatedly lifts and drops the solid particles through the gas atmosphere.
The solid particles are progressively moved towards the recycle and screening assembly 62X during the combustion process.
Upon arriving at this assembly, they are fed onto the screen segments 67X where oversize is handled as previously described. The undersize particles, along with crushed fine particles as required, are collected in the segmented annulus under the screen and, as the apparatus lOX
~z~
ro-tates, the particles enter openings 64X and continue moving down the annulus until they contact plate 65X. As the apparatus continues to rotate the particles are lifted by plate 65X until an angle i5 reached where the particles start to discharge into the inner tube llX through tube 66X, opening 68X and d;scharge rate adjustment 69X. Once these particles are deposited in the inner tube they are progressively moved and mixed in zone 32X by the arrangement of i.nclined elements 38X and the configuration of the inner tube sections 56X. The solid particles move under the feed applicators sprays and the cracking reaction and cycle is repeated.
The exhaust gases from the combustion zone, any air leakage through the rotat;ng seals, as well as any steam resulting from coke quenching, is removed continuously From the units by suction ~rom the exhaust system. Exhaust gases pass through the stat;onary end frame 14X, pass up through discharge pipe and control dampers 80X and 81X, pass through coarse particle removal cyclones 401X, pass through cooling heat exchangers 24X then are scrubbed.for removal of fine particulates and noxious gases prior to injection to atmosphere by a suitably designed stack system.
The exhaust system rate of discharge is controlled by a suitable damper arrangement such that the rotating apparatus is kept under a very slight negative pressure. Lt will also be appreciated that the pressures required for proper operation are dependent on the type and character oF the feed and recycle materials so that internal pressure relationships may be altered to obtain the desired gas flows thro~gh apparatus lOX. Thus, while subatmospheric pressures are con-sidered preferable ;n the vapour release and combustion zones, super atmospheric pressure may be desirable under certain feed and recycle conditions. In the preferred form of the invention ~he pressures in the vapour release zone 33~ and the combustion zones 34X are maintained substant;ally equal to minimize any cross flow of process~gases between the two tubes. These pressures are maintained by proper positioning of the damper 80Xa and by proper positioning of dampers and other control means, indicated generally in Figure 1 on the vapour compressor 21 and the fans supplying the combustion air and the various cooler air flows.
By these means, hydrocarhon vapours in zone 33X and the combustion gases in zone 34X are prevented from flowing through slots 92X or openings 64X
and work in co-operation with their respective sand and mechanical seal arrangements to maintain a separation between the gases.
Although not specifically illustrated, it will be understood that conventional instrumentation will be provided to control the following:
1. Liquid feed rate based on temperature pro~ile and capacity of the hydrocarbon vapour condensing and cleaning systems.
2. Hydrocarbon vapour removal rate adjusted to hold the pressure clif-ferential between the vapour zone and the combustion ~one at zero.
3. Primary combustion air flow through coolers and burners to maintain the correct quantity of oxygen for the required carbon cornbustion to provide the process heat requirements.
4. Burner fuel flow as required to maintain correct temperature profiles.
5. Exhaust system damper control to mainta;n adequate system negative pressure.
6. Cooling water and air flows to maintain temperatures of exiting products such as coke, pumpable liquid hydrocarbon, crack gas and exhaust gases.
7. Control of quantity of crushed and recycled oversize solid particles necessary to maintain an adequate quantity of solids in the rotating unit.
8. Control of temperature profile of the feed liquid passing through the condenser coolers so that proper flashing of low boiling point liquids occur prior to feeding into the rotating unit.
9. Control of coke cooling and quenchin~ systems to ensure proper coke exit temperatures.
10~ Ma;n rotary drive power draw and gross weight of the rotating assembly.
11. Continuous monitoring of gas and vapour quality.
The operating sequences are so designecl that a loss or reduction in feed will reduce all fl~ws automatically and maintain a proper pressure balance, as well as the proper temperature proFiles.
On shut-down, the unit continues to run until all feed liquid in the system has been processed then the rotating unit is stop-ped. The atmosphere inside the inner and outer tubes is purged by use of steam or a suitable inert gas such as nitrogen in order to prevent any air containing oxygen from entering the system.
In the event of an uncontrollecl emergency shut-down, suit-able vents and by-passes are opened to prevent internal process gases pressurizing the un;t and leaking ou ~ward through the rotating seals between outer tube 12X and the stationary end frames. Steam and water quench as ~ell as inert gas addition may also be required to maintain a sa~e atmosphere in and around the apparatus.
Since the inner tube area, outer tube area, lift and advance elements as well as the recycle arrangement and the inner tube product end seal are subject to high temperature stresses, corrosion, and erosion, it is desirable to use specific alloy steels, stainless steels or austenitic steels containing nickel and chromium additives to provide creep strength and resistance to chemical attachA Parts can also be protected by proper use of resistant refractory coatings.
In a unit sized for processing 5000 barrels per day of a 15 to 18 API oil containing 2 to 5 percent by weight of water and sediments, the inner tube has a diameter of approximately 12 feet and a length of approximately 26 feet while the outer tube has a diameter of approximately 17 feet and a length of approximately 30 feet. The speed of rotation, temperatures, pressures, and other variables are set at values which are dependent upon the type and origin of the feed l;quid and the quanti~y of various final products required.
~ 18 -~ 2~ 3 Typical retention times and temperatures- For material in the various 7ones are as ïnd;cated in the following Table I.
TABLE I
Zone Retention Time Temperatu~e 1. Mixing Zone 32X 10 sec. to 1 minute 1000 - l400F
2. Reaction Zone 33X 20 sec. to 3 minlltes 1000 - 1400F to 850F
3. Combust;on Zone 34X 1 minute to 10 minutes 850F to lG00 - 1400F
4. Recycle area 35X ln sec. to 2 minutes 1000 - 1400F
5. Coke cooling 36X 1 minute to 5 minutes 1000 - 1400F to 130F
6. Vapour cooling condensing 2 sec. to 2 minutes 850F to 100 - 150F
7. Exhaust handling 0.5 sec. to 10 secs. 1000 - 1400F to - 100 - 200F.
In certain cases the cooler-condenser is designed so that the high boiling point bottoms from the condenser are recycled back to the apparatus and cracked to extention.
A -Five foot diameter test un;t has been operated as a cracking unit using a Lloydminster Wellhead Crude and Bitumen as present in the oil sands located in the northeastern area of Alberta, Canada.
The results from these particular feed samples are as follows. Condenser bottoms were not recycled so these results represent a 1 pass system operation.
Lloydminster Wellhead Crude Item Feed Product API 16.0 23.3 Viscosity at 77F 1348 c.s. 6.3 c.s.
Sulphur 3.9% 3.2%
Pour Point ~20F less than 50F
Vacuum Distillation - Liquid 47% 86%
Vacuum Distillation - Residue 53% 14%
Coke Produced -- 11%
Crack gas produced -- 5%
Reaction Temperature -- approx. 900F.
Athabasca Oil Sands Bitumen Item Feed Product API 8.8 17.Q
Viscosity at 15QF 180Q c p. 120F - 6 c.p.
S Sulphur 4.3 3.9 Pour Point ~70F - less than -50F
Vacuum Distillation - Liquid11% 94%
Vacuum Distillation - Residue 89% ~%
Coke Produced -- 18%
Crack Gas Produced -- 5%
Reaction Temperature -- approx. 900F
While the preferred forms of the apparatus and process of the invention have been described in detail~ it will be appreciated that changes in size, configurations, materials of construction and general design of the apparatus, or changes in the steps of the process may be made without departing from the spirit of the invention.
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The operating sequences are so designecl that a loss or reduction in feed will reduce all fl~ws automatically and maintain a proper pressure balance, as well as the proper temperature proFiles.
On shut-down, the unit continues to run until all feed liquid in the system has been processed then the rotating unit is stop-ped. The atmosphere inside the inner and outer tubes is purged by use of steam or a suitable inert gas such as nitrogen in order to prevent any air containing oxygen from entering the system.
In the event of an uncontrollecl emergency shut-down, suit-able vents and by-passes are opened to prevent internal process gases pressurizing the un;t and leaking ou ~ward through the rotating seals between outer tube 12X and the stationary end frames. Steam and water quench as ~ell as inert gas addition may also be required to maintain a sa~e atmosphere in and around the apparatus.
Since the inner tube area, outer tube area, lift and advance elements as well as the recycle arrangement and the inner tube product end seal are subject to high temperature stresses, corrosion, and erosion, it is desirable to use specific alloy steels, stainless steels or austenitic steels containing nickel and chromium additives to provide creep strength and resistance to chemical attachA Parts can also be protected by proper use of resistant refractory coatings.
In a unit sized for processing 5000 barrels per day of a 15 to 18 API oil containing 2 to 5 percent by weight of water and sediments, the inner tube has a diameter of approximately 12 feet and a length of approximately 26 feet while the outer tube has a diameter of approximately 17 feet and a length of approximately 30 feet. The speed of rotation, temperatures, pressures, and other variables are set at values which are dependent upon the type and origin of the feed l;quid and the quanti~y of various final products required.
~ 18 -~ 2~ 3 Typical retention times and temperatures- For material in the various 7ones are as ïnd;cated in the following Table I.
TABLE I
Zone Retention Time Temperatu~e 1. Mixing Zone 32X 10 sec. to 1 minute 1000 - l400F
2. Reaction Zone 33X 20 sec. to 3 minlltes 1000 - 1400F to 850F
3. Combust;on Zone 34X 1 minute to 10 minutes 850F to lG00 - 1400F
4. Recycle area 35X ln sec. to 2 minutes 1000 - 1400F
5. Coke cooling 36X 1 minute to 5 minutes 1000 - 1400F to 130F
6. Vapour cooling condensing 2 sec. to 2 minutes 850F to 100 - 150F
7. Exhaust handling 0.5 sec. to 10 secs. 1000 - 1400F to - 100 - 200F.
In certain cases the cooler-condenser is designed so that the high boiling point bottoms from the condenser are recycled back to the apparatus and cracked to extention.
A -Five foot diameter test un;t has been operated as a cracking unit using a Lloydminster Wellhead Crude and Bitumen as present in the oil sands located in the northeastern area of Alberta, Canada.
The results from these particular feed samples are as follows. Condenser bottoms were not recycled so these results represent a 1 pass system operation.
Lloydminster Wellhead Crude Item Feed Product API 16.0 23.3 Viscosity at 77F 1348 c.s. 6.3 c.s.
Sulphur 3.9% 3.2%
Pour Point ~20F less than 50F
Vacuum Distillation - Liquid 47% 86%
Vacuum Distillation - Residue 53% 14%
Coke Produced -- 11%
Crack gas produced -- 5%
Reaction Temperature -- approx. 900F.
Athabasca Oil Sands Bitumen Item Feed Product API 8.8 17.Q
Viscosity at 15QF 180Q c p. 120F - 6 c.p.
S Sulphur 4.3 3.9 Pour Point ~70F - less than -50F
Vacuum Distillation - Liquid11% 94%
Vacuum Distillation - Residue 89% ~%
Coke Produced -- 18%
Crack Gas Produced -- 5%
Reaction Temperature -- approx. 900F
While the preferred forms of the apparatus and process of the invention have been described in detail~ it will be appreciated that changes in size, configurations, materials of construction and general design of the apparatus, or changes in the steps of the process may be made without departing from the spirit of the invention.
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Claims (8)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An apparatus for thermally treating a heavy hydrocarbon containing liquid comprising:
a substantially horizontal inner tube defining an inner processing zone therein which is substantially an open cylindrical space having recycle and product ends;
an outer -tube having recycle and product ends, gen-erally concentric with the inner tube and circumscribing at least a portion of the inner' tube, the tubes being rigidly interconnected for rotation together and cooperating to form a substantially open annular space, the annular space pro-viding a combustion zone adjacent the product end;
a stationary recycle end assembly connected with the outer tube for sealing its recycle end;
a stationary product end assembly is sealably associated with the outer tube for sealing its product end;
means for rotatably supporting the tubes;
means for rotating the tubes;
inner advancing means in the inner processing area for advancing hot particulate solids therethrough from the recycle end to the product end;
outer advancing meals in the annular space for ad-vancing hot solids from the combustion zone through the an-nular space toward the recycle end;
feed means, extending into the inner processing area, for depositing the liquid therethrough onto particulate solids being advanced therethrough;
vapour removal means, extending into the inner processing area, for removing hydrocarbon vapors from the area;
means, connected with inner tube at the product _ 20 -end, for transferring carbon-carrying solids from the inner processing area to the combustion zone, for use as fuel, said means cooperating with the carbon-carrying solids to prevent significant gas movement between the inner processing zone and the combustion zone;
means for sealing the inner tube at the recycle end;
said means including recycle means, connecting the recycle end of the annular space with the inner processing zone, for re-turning at least a portion of the hot solids from the annular space back into the recycle end of the inner processing area, the recycle means cooperating with the hot solids to prevent significant gas movement between the inner processing zone and the annular space;
means for withdrawing combustion gases from the annu-lar space, said means maintaining a negative pressure, relative to atmospheric pressure, in the annular space; and means for introducing oxygen bearing gas into the combustion zone to support combustion therein to heat the solids passing therethrough.
a substantially horizontal inner tube defining an inner processing zone therein which is substantially an open cylindrical space having recycle and product ends;
an outer -tube having recycle and product ends, gen-erally concentric with the inner tube and circumscribing at least a portion of the inner' tube, the tubes being rigidly interconnected for rotation together and cooperating to form a substantially open annular space, the annular space pro-viding a combustion zone adjacent the product end;
a stationary recycle end assembly connected with the outer tube for sealing its recycle end;
a stationary product end assembly is sealably associated with the outer tube for sealing its product end;
means for rotatably supporting the tubes;
means for rotating the tubes;
inner advancing means in the inner processing area for advancing hot particulate solids therethrough from the recycle end to the product end;
outer advancing meals in the annular space for ad-vancing hot solids from the combustion zone through the an-nular space toward the recycle end;
feed means, extending into the inner processing area, for depositing the liquid therethrough onto particulate solids being advanced therethrough;
vapour removal means, extending into the inner processing area, for removing hydrocarbon vapors from the area;
means, connected with inner tube at the product _ 20 -end, for transferring carbon-carrying solids from the inner processing area to the combustion zone, for use as fuel, said means cooperating with the carbon-carrying solids to prevent significant gas movement between the inner processing zone and the combustion zone;
means for sealing the inner tube at the recycle end;
said means including recycle means, connecting the recycle end of the annular space with the inner processing zone, for re-turning at least a portion of the hot solids from the annular space back into the recycle end of the inner processing area, the recycle means cooperating with the hot solids to prevent significant gas movement between the inner processing zone and the annular space;
means for withdrawing combustion gases from the annu-lar space, said means maintaining a negative pressure, relative to atmospheric pressure, in the annular space; and means for introducing oxygen bearing gas into the combustion zone to support combustion therein to heat the solids passing therethrough.
2. An apparatus as set forth in claim 1, which fur-ther comprises:
means for controlling the vapour removal means and the combustion gas removal means so as to maintain substantially equal pressures in the inner processing area and the annular space.
means for controlling the vapour removal means and the combustion gas removal means so as to maintain substantially equal pressures in the inner processing area and the annular space.
3. An apparatus as. set forth in claim 1, further comprising:
lifting means, connected to the inner surface of the outer tube and extending along at least a portion of the combustion zone, for repeated lifting and dropping of the contents of the zone as the outer tube rotates.
lifting means, connected to the inner surface of the outer tube and extending along at least a portion of the combustion zone, for repeated lifting and dropping of the contents of the zone as the outer tube rotates.
4. An apparatus as set forth in claim 1, further comprising:
means, positioned between the combustion zone and the recycle means, for screening the solids advancing from the combustion zone to recover an oversize fraction;
means, connected with said screening means for removing oversize solids to discharge them from the apparatus;
and means connecting the screening means and the recycle means for transferring undersize solids to the recycle means.
means, positioned between the combustion zone and the recycle means, for screening the solids advancing from the combustion zone to recover an oversize fraction;
means, connected with said screening means for removing oversize solids to discharge them from the apparatus;
and means connecting the screening means and the recycle means for transferring undersize solids to the recycle means.
5. An apparatus as set forth in claim 4, further comprising: .
means associated with the screening means for crushing oversize solids retained by the screening means when actuated.
means associated with the screening means for crushing oversize solids retained by the screening means when actuated.
6. An apparatus as set forth in claim 1, further comprising:
means, connected with the recycle means, for controlling the rate at which solids are recycled.
means, connected with the recycle means, for controlling the rate at which solids are recycled.
7. An apparatus as set forth in claim 1, further comprising:
means, connected with the means for introducing oxygen-bearing gas, for preheating said gas before it is introduced into the combustion zone.
means, connected with the means for introducing oxygen-bearing gas, for preheating said gas before it is introduced into the combustion zone.
8. A process for vaporizing and cracking a heavy hydrocarbon-containing liquid, such process employing direct thermal treatment effected in an apparatus having horizontal, substantially concentric, radially spaced inner and outer rotatable tubes in which one axial end is the feed end and the opposite axial end is the product end, said inner tube forming an open cylindrical inner processing zone, said tubes forming between them an open annular space having a combustion zone. said apparatus having assemblies for sealing the ends of the outer tube, which process comprises:
continuously advancing hot particulate solids through the inner tube from the feed end to the product end and back through the annular space;
depositing the hydrocarbons as a liquid onto the hot solids;
cascading and mixing the solids and hydrocarbons as they advance through the inner processing zone to achieve beneficial heat transfer and thereby vaporize hydrocarbons and form carbon on the solids;
withdrawing the hydrocarbon vapors produced in the inner tube;
transferring carbon-coated solids from the product end of the inner tube into the combustion zone in the annular space;
cascading and mixing the carbon-coated solids in the combustion zone while introducing oxygen-containing gas thereinto to burn at least part of the carbon and heat the remainder of the solids;
transferring burned hot solids from the feed end of the annular space into the feed end of the inner tube;
withdrawing vapors produced in the combustion zone, and preventing substantial gas flow between the inner processing zone and the combustion zone by blocking gas flow with the solids being transferred and maintaining substantially equal pressures in said zones.
continuously advancing hot particulate solids through the inner tube from the feed end to the product end and back through the annular space;
depositing the hydrocarbons as a liquid onto the hot solids;
cascading and mixing the solids and hydrocarbons as they advance through the inner processing zone to achieve beneficial heat transfer and thereby vaporize hydrocarbons and form carbon on the solids;
withdrawing the hydrocarbon vapors produced in the inner tube;
transferring carbon-coated solids from the product end of the inner tube into the combustion zone in the annular space;
cascading and mixing the carbon-coated solids in the combustion zone while introducing oxygen-containing gas thereinto to burn at least part of the carbon and heat the remainder of the solids;
transferring burned hot solids from the feed end of the annular space into the feed end of the inner tube;
withdrawing vapors produced in the combustion zone, and preventing substantial gas flow between the inner processing zone and the combustion zone by blocking gas flow with the solids being transferred and maintaining substantially equal pressures in said zones.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000337359A CA1120418A (en) | 1979-10-11 | 1979-10-11 | Process and apparatus for thermally processing heavy hydrocarbon-containing liquids |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000337359A CA1120418A (en) | 1979-10-11 | 1979-10-11 | Process and apparatus for thermally processing heavy hydrocarbon-containing liquids |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1120418A true CA1120418A (en) | 1982-03-23 |
Family
ID=4115324
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000337359A Expired CA1120418A (en) | 1979-10-11 | 1979-10-11 | Process and apparatus for thermally processing heavy hydrocarbon-containing liquids |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1120418A (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9555342B2 (en) | 2010-05-18 | 2017-01-31 | Envirollea Inc. | Thermal processing reactor for mixtures, fabrication of the reactor, processes using the reactors and uses of the products obtained |
| US9828553B2 (en) | 2013-02-06 | 2017-11-28 | Envirollea Inc. | Thermal process to transform contaminated or uncontaminated feed materials into useful oily products |
| US10655070B2 (en) | 2012-07-23 | 2020-05-19 | Envirollea Inc. | Hybrid thermal process to separate and transform contaminated or uncontaminated hydrocarbon materials into useful products, uses of the process, manufacturing of the corresponding system and plant |
| US11530358B2 (en) | 2017-07-13 | 2022-12-20 | Envirollea Inc. | Process for producing liquid fuel from waste hydrocarbon and/or organic material, reactor, apparatus, uses and managing system thereof |
| US11554378B2 (en) | 2019-02-04 | 2023-01-17 | Envirollea Inc. | Flotation oils, processes and uses thereof |
-
1979
- 1979-10-11 CA CA000337359A patent/CA1120418A/en not_active Expired
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9555342B2 (en) | 2010-05-18 | 2017-01-31 | Envirollea Inc. | Thermal processing reactor for mixtures, fabrication of the reactor, processes using the reactors and uses of the products obtained |
| US10655070B2 (en) | 2012-07-23 | 2020-05-19 | Envirollea Inc. | Hybrid thermal process to separate and transform contaminated or uncontaminated hydrocarbon materials into useful products, uses of the process, manufacturing of the corresponding system and plant |
| US9828553B2 (en) | 2013-02-06 | 2017-11-28 | Envirollea Inc. | Thermal process to transform contaminated or uncontaminated feed materials into useful oily products |
| US11530358B2 (en) | 2017-07-13 | 2022-12-20 | Envirollea Inc. | Process for producing liquid fuel from waste hydrocarbon and/or organic material, reactor, apparatus, uses and managing system thereof |
| US11554378B2 (en) | 2019-02-04 | 2023-01-17 | Envirollea Inc. | Flotation oils, processes and uses thereof |
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