CA2182653C - Method of and means for producing combustible products from heavy fuel residue - Google Patents

Method of and means for producing combustible products from heavy fuel residue Download PDF

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Publication number
CA2182653C
CA2182653C CA 2182653 CA2182653A CA2182653C CA 2182653 C CA2182653 C CA 2182653C CA 2182653 CA2182653 CA 2182653 CA 2182653 A CA2182653 A CA 2182653A CA 2182653 C CA2182653 C CA 2182653C
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Prior art keywords
asphaltene
pyrolyzer
fuel
oil shale
carbonaceous material
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Expired - Fee Related
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CA 2182653
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French (fr)
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CA2182653A1 (en
Inventor
Benjamin Doran
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Ormat Industries Ltd
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Ormat Industries Ltd
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Priority claimed from US08/511,999 external-priority patent/US6365038B1/en
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Abstract

A method for producing combustible products such as a low viscosity liquid fuel and fuel gas is provided in which asphaltene is pyrolyzed together with a low grade solid fuel containing materials or minerals which have catalytic properties such as oil shale, certain types of low grade coal, etc. Preferably, according to the present invention the step of pyrolyzing asphaltene together with oil shale is carried out by adding asphaltene to a pyrolyzer, adding oil shale to a pyrolyzer, combusting carbonaceous material remaining in the pyrolyzer by supplying the remaining carbonaceous material to a combustor preferably separate from the pyrolyzer and adding ash produced by the combustion of the carbonaceous material to the pyrolyzer. Such pyrolysis is advantageous since oil shale and other such materials have many catalytic qualities which can aid in the cracking of the asphaltene as well as in capturing sulfur or compounds of sulfur. In addition, in a further embodiment of the present invention, a method of producing combustible products such as low viscosity fuel and fuel gas is also provided comprising pyrolyzing asphaltene together with ash produced from low grade fuel such as oil shale. In this embodiment less fuel is obtained. Moreover, the present invention comprises providing apparatus for carrying the above mentioned method steps of the present invention.

Description

'CA 02182653 2007-08-01 . _ 1 ._ METHOD OF AND MEANS FOR PRODUCING
COMBUSTIBLE PRODUCTS FROM HEAVY FUEL RESIDUE
Description 1. Technical Field This invention relates to a method of and means for producing combustible products from heavy residue oil and more particularly to a method of and means for producing combustible products from asphaltene.
2. Background of the Invention Recently the requirement for better quality and lighter fuels for among other things to comply with the air pollution regulations has been increasing. Conventionally, distillation of fuel leaves a heavy residue having bitumen characteristics which is cracked using a catalyzer such that cracking takes place at a temperature of a few hundred degrees Celcius or higher. After this cracking, an even less friendly residue remains called asphaltene which is difficult and uneconomical to crack since it poisons the catalysts and also requires high temperatures which usually results in large investments.
Thus, conventionally, asphaltene is blended with another fuel of relatively high caloric or heating value and then sold since asphaltene itself does not possess good qualities for combustion. Evenso, under present conditions more and more asphaltene is being produced.
In U.S. Patent No. 5,372,708, a process for the thermal dissolution of oil shale which is rich in mineral constituents is disclosed. In the process disclosed in the '708 patent, a mixture of these so-called low grade oil shales with a fraction of heavy fuel having a boiling point above 350 C. is cracked and a hydrocarbon fuel having a boiling point upto 350 C. is recovered from the gases and vapors leaving the cracking reactor with the residue produced having mineral constituents being recovered and used as a raw material for various purposes, such as chemical products, like asphaltene, etc.

or for combusting in the cracker for producing hot gases which heat the mixture being cracked.
It is therefore an object of the present invention to provide a new and improved method of and means for producing combustible gases from heavy fuel residue such as asphaltene which substantially overcomes or significantly reduces the disadvantages outlined above.
Brief Description of the Invention In accordance with present invention, a method for producing combustible products such as a low viscosity liquid fuel and fuel gas is provided comprising pyrolyzing asphaltene together with a low grade solid fuel containing materials or minerals which have catalytic properties such as oil shale, certain types of low grade coal, etc.
Preferably according to the present invention the step of pyrolyzing asphaltene together with oil shale is carried out by adding asphaltene to a pyrolyzer, adding oil shale to a pyrolyzer, combusting carbonaceous material remaining in the pyrolyzer by supplying the remaining carbonaceous material to a combustor preferably separate from the pyrolyzer and adding ash produced by the combustion of the carbonaceous material to the pyrolyzer for supplying the heat for the pyrolysis process.
Such pyrolysis is advantageous since oil shale and other such materials have many catalytic qualities which can aid in the cracking of the asphaltene as well as in capturing sulfur or compounds of sulfur. Furthermore, the use of ash for providing the heat for the pyrolysis process is also advantageous since more catalysts are added to the material being pyrolyzed.
In addition, in a further embodiment of the present invention, a method of producing combustible products such as low viscosity fuel and fuel gas is also provided comprising pyrolyzing asphaltene together with ash produced from low grade fuel such as oil shale. In this embodiment less fuel is obtained.

2a In accordance with a first aspect of the present invention, there is provided a method for producing combustible products including a low viscosity liquid fuel and fuel gas from asphaltene comprising the step of pyrolyzing the asphaltene together with oil shale.
In accordance with a second aspect of the present invention, there is provided a method for producing a low viscosity liquid fuel and fuel gas from asphaltene and oil shale comprising the steps of:
a) pyrolyzing in a pyrolyzer asphaltene together with oil shale for producing combustible products and carbonaceous material and capturing sulfur compounds;
b) combusting said carbonaceous material for producing hot ash and flue gases; and c) adding said hot ash to said pyrolyzer.
In accordance with a third aspect of the present invention, there is provided a continuous method for producing a low viscosity liquid fuel and fuel gas from asphaltene and oil shale and for recovering waste heat, comprising the steps of:
a) conveying asphaltene to a pyrolyzer; and b) conveying oil shale to the pyrolyzer; and c) conveying hot ash to the pyrolyzer; thereby producing, in the pyrolyzer, a hot-ash-oil-shale-asphaltene mixture; and d) pyrolyzing the hot-ash-oil-shale-asphaltene mixture thereby producing volatile combustible products and non-volatile carbonaceous material;
e) conveying said volatile combustible products to a utilization device which combusts the volatile combustible 2b products thereby recovering the useful energy in the volatile combustible products; and f) conveying said non-volatile carbonaceous material to a combustor; and g) combusting in the combustor said carbonaceous material thereby producing hot ash and flue gases; and h) conveying said hot ash to said pyrolyzer; and i) conveying said flue gases to a waste heat converter; and j) recovering waste heat from the hot flue gases in the waste heat convertor.
In accordance with a fourth aspect of the present invention, there is provided a method for producing combustible products comprising the steps of:
a) combusting oil shale in a combustor and producing hot ash and flue gases;
b) supplying asphaltene to a pyrolyzer;
c) supplying said hot ash to said pyrolyzer containing said asphaltene and producing said combustible products and carbonaceous material; and d) supplying said carbonaceous material to said combustor and combusting said oil shale together with said carbonaceous material.

In accordance with a fifth aspect of the present invention, there is provided an apparatus for producing combustible products including a low viscosity liquid fuel and fuel gas from asphaltene comprising:
30, a) a pyrolyzer;

b) means for adding asphaltene to the pyrolyzer; and c) means for adding oil shale to the pyrolyzer.

2c In accordance with a sixth aspect of the present invention, there is provided a method for producing combustible products comprising the steps of:

(a) combusting oil shale in a combustor and producing hot ash and flue gases;
(b) supplying asphaltene to a pyrolyzer;
(c) supplying said hot ash to said pyrolyzer containing said asphaltene and pyrolizing said hot ash and asphaltene to produce said combustible products and carbonaceous material; and (d) supplying said carbonaceous material to said combustor and combusting said oil shale together with said carbonaceous material.
3 Moreover, the present invention comprises providing apparatus for carrying the above mentioned method steps of the present invention.

In accordance with a seventh aspect of the present invention, there is provided an apparatus for producing combustible products, the apparatus comprising:

(a) a pyrolyzer constructed and arranged to pyrolize a mixture comprising asphaltene and hot ash and to produce combustible products and carbonaceous material;
(b) an asphaltene supply input means operatively connected to the pyrolyzer;
(c) a combustor constructed and arranged to receive the carbonaceous material from the pyrolyzer and a supply of oil shale from a source, and to combust the carbonaceous material and the oil shale to produce an output of hot ash and an output of flue gases, wherein the combustor (i) comprises a first output means to deliver the hot ash to the pyrolyzer, and a second output means to receive and discharge the flue gases; and (ii) is constructed and arranged to selectively receive the supply of oil shale and provide output of hot ash to capture substantially all sulfur compounds in the pyrolyzer.

3a Brief Description of the Drawinas Embodiments of the present invention are described by way of the example with reference to the accompany.ing drawings wherein:
Fig. 1 is a block diagram which represents, in a schematic way, apparatus for carrying out the present invention;
Fig. 2 is a block diagram which represents another embodiment of apparatus for- carrying out the present invention;
Fig. 2A.is a block diagram 'which represerits a further embodiment of apparatus for carrying out the present invention;
Fig. 2B is a block diagram which, represents.
another embodiment of part of apparatus f or carrying out the. present invention; and Fig. 3 is a block diagram which represents a still further embodiment of apparatus for carrying out the present invention.
Detailed Description Referring now.to Fig. 1, reference numeral .10 '25 designates apparatus for producing combustible products such as low viscosity liquid fuel and fuel gas from heavy oil residue. As shown in Fig. 1, heavy oil residue or asphaltene. is added to pyrolyzer 15 using means 12 while low grade fuel preferably oil shale is also added to the pyrolyzer using means 17. As a result of - the pyrolysis of asphaltene and the oil shale combustible products such as low viscosity liquid fuel and fuel gas is extracted via means 16 and is used in utilization means 18, for example in an internal combustion (i.c.) engine such as a diesel or gas engine or in a gas turbine as fuel. When used in a gas turbine, the fuel may be used directly
4 ih the combustion chamber of the gas turbine or may be used to indirectly heat compressed air exiting the compressor of the gas turbine in an indirect heat exchanger.
In the preferred embodiment of the present invention as shown in Fig. 2, pyrolysis is carried out in pyrolyzer 15 by utilizing ash produced when carbonaceous material remaining in the pyrolyzer is transported by supply means 14 for combustion in combustor 20. As can be seen from Fig. 2, hot ash is extracted from combustor 20 and fed to pyrolyzer 15 via first feed means 19 in order to maintain pyrolysis taking place therein preferably at a temperature of between about 400 and 550 C. and also preferably at about atmospheric pressure. Also here, as shown, combustible products such as low viscosity fuel and fuel gas can be used in utilization means 18, for example in an internal combustion (i.c.) engine such as a diesel or gas engine or in a gas turbine as fuel. When used in a gas turbine, the fuel may be used directly in the combustion chamber of the gas turbine or may be used to indirectly heat compressed air exiting the compressor of the gas turbine in an indirect heat exchanger.
Flue gases in line 22, exiting from combustor 20, are supplied to waste heat converter 26, where useful energy, such as electric power, is produced. Any ash that is not so required is extracted from combustor 20 via line 24.
In measurements checked by Fisher standard assay techniques using apparatus according to the embodiment described in relation to Fig. 2, when 10 to 35% of the total amount of a mixture of asphaltene and oil shale is asphaltene, a fuel in the amount of 20 to 50% of the amount of asphaltene used in the mixture was obtained i.e., for every kg of asphaltene used in the mixture, 200 to 500 gram of low viscosity liquid fuel and fuel gases was obtained. At present this is considered the best mode for carrying out the present invention.
Alternatively, as shown in Fig. 2A, hot ash extracted from combustor 20 via second means 24, hot flue gases exiting the combustor via stack 22 as well as low viscosity liquid fuel and fuel gas produced from the pyrolyzer which has a relatively high calorific or heating value of above approximately 3,000 kcal/kg can be used in waste heat converter 26 for producing electric power.
The carbonaceous material obtained in the process is quire
5 high quality having a calorific or heating value of around 800 to 1,500 kcal/kg and this carbonaceous material can be combusted quite easily.
Due to this, if preferred, in the alternative embodiment of the apparatus 40 shown in Fig. 2B, ash extracted at 24 can be pyrolyzed together with asphaltene to produce further combustible products such as low viscosity fuel and fuel gas.
However, the amount of fuel produced here when the asphaltene is pyrolyzed with the ash is less than the amount produced when the low grade fuel itself is pyrolyzed with the asphaltene in pyrolyzer 15 for example.
Referring to Fig. 3, in a further embodiment of the present invention, rather than supplying the low grade fuel to the pyrolyzer, it is supplied to combustor 60. In this manner, substantially all ash produced in combustor 60 is used for supplying heat to pyrolyzer 55 for pyrolyzing asphaltene supplied by asphaltene supply 51 via supply means 52 to pyrolyzer 55.
Furthermore, while in the above description, the use of low grade fuel such as oil shale, certain types of low grade coal, etc., is disclosed, the present invention also contemplates the use, rather than the use of these low grade fuels, of relatively cheap minerals which contain materials that can act as a catalyst for producing low viscosity fuel and fuel gases in the manner disclosed previously.
The advantages and improved results furnished by the method and apparatus of the present invention are apparent from the foregoing description of the preferred embodiment of the
6 invention. Various changes and modifications, may be made without departing from the spirit and scope of the invention as described in the appended claims.

Claims (2)

What is claimed is:
1. A method for producing combustible products comprising the steps of:

(a) combusting oil shale in a combustor and producing hot ash and flue gases;

(b) supplying asphaltene to a pyrolyzer;

(c) supplying said hot ash to said pyrolyzer containing said asphaltene and pyrolizing said hot ash and asphaltene to produce said combustible products and carbonaceous material; and (d) supplying said carbonaceous material to said combustor and combusting said oil shale together with said carbonaceous material.
2. A method according to claim 1, wherein the amount of oil shale supplied to the combustor and the amount of hot ash supplied by the combustor are selected to substantially capture sulfur compounds present in said pyrolyzer.
CA 2182653 1995-08-07 1996-08-02 Method of and means for producing combustible products from heavy fuel residue Expired - Fee Related CA2182653C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/511,999 1995-08-07
US08/511,999 US6365038B1 (en) 1991-04-11 1995-08-07 Method of producing combustible products from heavy fuel residue

Publications (2)

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CA2182653A1 CA2182653A1 (en) 1997-02-08
CA2182653C true CA2182653C (en) 2010-02-16

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CA (1) CA2182653C (en)
IL (1) IL119014A (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104194812B (en) * 2014-09-03 2016-04-13 中国矿业大学(北京) A kind of method suppressing pyrolytic process low-rank coal or resinous shale efflorescence
CN104560097B (en) * 2015-01-06 2016-03-23 晏子俊 Outer hot rotary type bitubular gas retort

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IL119014A0 (en) 1996-11-14
CA2182653A1 (en) 1997-02-08
IL119014A (en) 2002-09-12
BR9603329A (en) 1998-05-05

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