CA2236183C - Process and apparatus for converting oil shale or tar sands to oil - Google Patents
Process and apparatus for converting oil shale or tar sands to oil Download PDFInfo
- Publication number
- CA2236183C CA2236183C CA 2236183 CA2236183A CA2236183C CA 2236183 C CA2236183 C CA 2236183C CA 2236183 CA2236183 CA 2236183 CA 2236183 A CA2236183 A CA 2236183A CA 2236183 C CA2236183 C CA 2236183C
- Authority
- CA
- Canada
- Prior art keywords
- hydrogen
- reactor
- feed
- fluidizing medium
- product stream
- 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 - Lifetime
Links
Landscapes
- Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
- Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
Abstract
The invention relates to a continuous process for producing synthetic crude oil from oil bearing material, e.g., oil shale or tar sand, through continuous feeding and calcining, hydrocracking and hydrogenating kerogen or bitumen.
Claims (72)
1. A process for producing an oil from a hydrocarbon bearing feed, comprising the steps of:
providing a feed comprising tar sand;
introducing said feed in a fluidizable form into a fluidized bed reactor;
introducing a fluidizing medium having a gas comprising hydrogen into the fluidized bed reactor;
fluidizing said feed with said fluidizing medium in the reactor to comprise a fluidized bed;
continuously reacting said feed with said hydrogen;
continuously producing a reactor product stream comprising a hydrocarbon; and producing an oil.
providing a feed comprising tar sand;
introducing said feed in a fluidizable form into a fluidized bed reactor;
introducing a fluidizing medium having a gas comprising hydrogen into the fluidized bed reactor;
fluidizing said feed with said fluidizing medium in the reactor to comprise a fluidized bed;
continuously reacting said feed with said hydrogen;
continuously producing a reactor product stream comprising a hydrocarbon; and producing an oil.
2. The process of Claim 1, further comprising the step of continuously discharging a spent solid from said fluidized bed reactor.
3. The process of any one of Claim 1 or 2, in which said fluidizing medium is vol. % hydrogen or greater
4. The process of any one of Claim 1 or 2, in which said fluidizing medium is wt. % hydrogen or greater.
5. The process of any one of Claim 1 or 2, in which said fluidizing medium is 99.8 vol. % hydrogen or greater.
6. The process of any one of Claims 1 to 5, in which said reactor product stream comprises an off gas having a hydrogen composition of 81 wt. % or greater.
7. The process of Claim 1 or 2, wherein said tar sand comprises bitumen.
8. The process of Claim 7, further comprising the step of continuously reacting said bitumen with said hydrogen to continuously produce said reactor product stream.
9. The process of Claim 2 in which said spent solid is spent tar sand.
10. A process for producing oil from a hydrocarbon bearing feed, comprising the steps of:
providing a feed comprising oil shale;
introducing said feed in a fluidizable form into a fluidized bed reactor;
introducing a fluidizing medium having a gas comprising hydrogen into the fluidized bed reactor;
fluidizing said feed with said fluidizing medium in the reactor to comprise a fluidized bed;
continuously reacting said feed with said hydrogen;
continuously producing a reactor product stream comprising a hydrocarbon; and producing an oil.
providing a feed comprising oil shale;
introducing said feed in a fluidizable form into a fluidized bed reactor;
introducing a fluidizing medium having a gas comprising hydrogen into the fluidized bed reactor;
fluidizing said feed with said fluidizing medium in the reactor to comprise a fluidized bed;
continuously reacting said feed with said hydrogen;
continuously producing a reactor product stream comprising a hydrocarbon; and producing an oil.
11. The process of Claim 10, further comprising the step of continuously discharging a spent solid from said fluidized bed reactor.
12. The process of Claim 10 or 11, wherein said oil shale comprises kerogen.
13. The process of Claim 12, further comprising the step of continuously reacting said kerogen with said hydrogen to continuously produce said reactor product stream.
14. The process of Claim 13, in which said spent solid is spent oil shale.
15. The process of any one of Claims 10 to 14, in which said fluidizing medium is 95 vol. % hydrogen or greater.
16. The process of any one of Claims 10 to 14, in which said fluidizing medium is 98 wt. % hydrogen or greater.
17. The process of any one of Claims 10 to 14, in which said fluidizing medium is 99.8 vol. % hydrogen or greater.
18. The process of any one of Claims 10 to 17, in which said reactor product stream comprises an off gas having a hydrogen composition of 81 wt. % or greater.
19. The process of any one of Claims 10 to 18, further comprising the step of supplying a hydrogen stream comprising a recycle gas stream comprising hydrogen and fresh make-up hydrogen to said fluidized bed reactor.
20. The process of any one of Claims 1 to 19, wherein a gas stream comprising hydrogen entrains the feed.
21. The process of any one of Claims 1 to 20, wherein said fluidizing medium is at a first temperature and is conveyed through a first heat exchanger to raise the temperature of said fluidizing medium to a second temperature prior to entering a fired heater.
22. The process of any one of Claims 1 to 21, wherein said fluidizing medium is conveyed to a fired heater which heats said fluidizing medium to a higher temperature than that of the reactor.
23. The process of Claim 22, wherein said heater provides superheated steam for gas compression.
24. The process of any one of Claims 1 to 23, wherein the fluidizing medium is introduced into the reactor at a flow rate which exceeds the minimum required for complete reaction of said feed with hydrogen by a factor of between 15 and about 26.
25. The process of any one of Claims 1 to 24, wherein the flow rate of hydrogen exceeds the minimum required for complete reaction of the feed with hydrogen by a factor of about 21.
26. The process of any one of Claims 1 to 24, wherein the fluidized bed has a fluidized bed temperature and the fluidizing medium entering the reactor has a fluidizing medium temperature, wherein the fluidizing medium temperature is greater than said fluidized bed temperature.
27. The process of any one of Claims 1 to 26, wherein the fluidizing medium comprises make-up hydrogen and a recycled hydrogen, and wherein the reactor product stream includes a recyclable unreacted hydrogen.
28. The process of any one of Claims 1 to 27, further comprising:
separating a gas mixture from the reactor product stream, the gas mixture containing unreacted hydrogen;
purifying the gas mixture to form a recycle gas stream comprising hydrogen in a concentration of 98 wt. % hydrogen or greater; and returning at least a portion of the recycle gas stream to the reactor.
separating a gas mixture from the reactor product stream, the gas mixture containing unreacted hydrogen;
purifying the gas mixture to form a recycle gas stream comprising hydrogen in a concentration of 98 wt. % hydrogen or greater; and returning at least a portion of the recycle gas stream to the reactor.
29. The process of Claim 28, further comprising the step of maintaining a combined level of methane and ethane in the recycle gas stream by control of the equilibrium point of the reaction for formation of said methane and ethane within the reactor.
30. The process of Claim 29, in which said combined level of methane and ethane in the recycle gas stream is 2 vol. % or less of the total volume of the recycle stream.
31. The process of any one of Claims 28 to 30, wherein the recycle gas stream pressure is not lower than about 450 psig.
32. The process of any one of Claims 28 to 31, further comprising the step of admixing make-up hydrogen with a the recycle gas stream prior to returning the recycle gas stream to the reactor.
33. The process of any one of Claims 1 to 3 and 10 to 15, wherein the fluidizing medium comprises at least about 95 vol. % hydrogen and wherein said hydrogen has a flow rate into the reactor of at least 26 times the flow rate required for complete reaction of said feed with hydrogen.
34. The process of any one of Claims 1 to 33, wherein the hydrogen flow rate into the reactor is 26 times the flow rate required for complete reaction of said feed with hydrogen, and wherein the reaction temperature is in a range of about 800°F to about 1200°F.
35. The process of any one of Claims 1 to 33, in which the feed is fed to the reactor at a plurality of locations.
36. The process of any one of Claims 1 to 35, wherein said step of introducing said feed includes admixing said feed with a portion of said fluidizing medium forming a dispersible feed.
37. The process of Claim 36, wherein said step of introducing said feed comprises injecting said dispersible feed at a plurality of locations at an upper portion of said reactor.
38. The process of any one of Claims 1 to 36, wherein the feed is introduced into the fluidized bed reactor near the bottom portion thereof.
39. The process of Claim 35 or 37, wherein said plurality of locations is two locations.
40. The process of Claim 35 or 37, wherein said plurality of locations comprises at least three locations.
41. The process of Claim 35 or 37, wherein said plurality of locations is three locations.
42. The process of Claim 35 or 37, wherein said locations are circumferentially positioned about the reactor.
43. The process of any one of Claims 1 to 42, wherein said step of introducing said feed utilizes fan feeding.
44. The process of any one of Claims 1 to 43, further comprising a step of reducing the size of said feed to produce a fluidizable feed prior to the feeding step.
45. The process of any one of Claims 1 to 44, further comprising a step of feeding said feed in admixture with a first gas stream comprising hydrogen to said reactor.
46. The process of any one of Claims 1 to 45, in which said step of reacting is conducted at a temperature between 800°F and 1200°F.
47. The process of any one of Claims 1 to 45, in which and said step of reacting is conducted at a temperature between about between 800°F and 900°F.
48. The process of any one of Claims 1 to 45, wherein said step of reacting is conducted at a temperature of about 800°F.
49. The process of any one of Claims 19 to 48, wherein the volume ratio of the recycle gas stream to fresh make-up hydrogen is at least 26:1.
50. The process of any one of Claims 1 to 49, wherein the fluidizing medium temperature on entering the reactor is about 1200°F.
51. The process of any one of Claims 1 to 49, wherein the fluidizing medium feed temperature on entering the reactor does not exceed 1200°F.
52. The process of any one of Claims 1 to 51, wherein said step of reacting is at 600 psig.
53. The process of any one of Claims 1 to 52, wherein said step of reacting comprises hydrocracking.
54. The process of any one of Claims 1 to 52, wherein said step of reacting comprises hydrogenation.
55. The process of any one of Claims 1 to 52, wherein said step of reacting comprises a hydrocracking reaction and a hydrogenation reaction.
56. The process of any one of Claims 1 to 55, wherein said reacting occurs in the presence of a catalyst.
57. The process of Claim 56, wherein said catalyst catalyzes hydrocracking.
58. The process of Claim 56, wherein said catalyst catalyzes hydrogenation.
59. The process of any one of Claims 56 to 58, wherein the catalyst is a heavy metal.
60. The process of any one of Claims 1 to 59, wherein said feed comprises a catalyst.
61. The process of any one of Claims 1 to 60, in which the feed has a residence time in the reactor between about 10 to about 20 minutes.
62. The process of any one of Claims 2, 9, 11, and 14, in which said solid is conveyed to at least one separation zone and a cleaned product stream is produced in said separation zone.
63. The process of Claim 62, in which said separation location includes first and second separation zones, and said first separation zone is located in the upper portion of said reactor and produces a first cleaned product stream which is conveyed to a second separation zone to produce a second cleaned product stream.
64. The process of Claim 63, wherein said second cleaned product stream is conveyed to a condenser to form a gas-liquid product stream.
65. The process of Claim 63, wherein said second cleaned product stream at a first temperature is conveyed to a first heat exchanger for cooling said second cleaned product stream to a second lower temperature.
66. The process of Claim 63, wherein said second cleaned product stream at said second lower temperature is conveyed to a condenser to form a gas-liquid product stream.
67. The process of Claim 66, wherein said gas-liquid product stream is conveyed to a separator wherein gas is separated therefrom.
68. The process of Claim 67, in which the gas separated from said reactor product stream is conveyed to an amine scrubber and is scrubbed to produce a first recycle gas stream containing hydrogen.
69. The process according to any one of Claims 2, 9, 11, 14, and 62, in which said spent solid is discharged adjacent to the top portion of said fluidized bed.
70. The process of any one of Claims 2, 9, 11, 14, and 62, wherein air for a fired heater is pre-heated with said spent solid.
71. The process of Claim 70, wherein said heater provides superheated steam for gas compression.
72. The process of any one of Claims 2, 9, 11, 14, and 62, further comprising the step of using said spent solid as land fill.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/058,184 | 1998-04-10 | ||
| US09/058,184 US6139722A (en) | 1995-10-31 | 1998-04-10 | Process and apparatus for converting oil shale or tar sands to oil |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2236183A1 CA2236183A1 (en) | 1999-10-10 |
| CA2236183C true CA2236183C (en) | 2009-08-25 |
Family
ID=22015221
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2236183 Expired - Lifetime CA2236183C (en) | 1998-04-10 | 1998-04-28 | Process and apparatus for converting oil shale or tar sands to oil |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2236183C (en) |
| IL (1) | IL124711A0 (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7726491B2 (en) | 2002-09-19 | 2010-06-01 | Suncor Energy Inc. | Bituminous froth hydrocarbon cyclone |
| US7736501B2 (en) | 2002-09-19 | 2010-06-15 | Suncor Energy Inc. | System and process for concentrating hydrocarbons in a bitumen feed |
| US7914670B2 (en) | 2004-01-09 | 2011-03-29 | Suncor Energy Inc. | Bituminous froth inline steam injection processing |
| US8025341B2 (en) | 2005-11-09 | 2011-09-27 | Suncor Energy Inc. | Mobile oil sands mining system |
| US8168071B2 (en) | 2005-11-09 | 2012-05-01 | Suncor Energy Inc. | Process and apparatus for treating a heavy hydrocarbon feedstock |
| US8968580B2 (en) | 2009-12-23 | 2015-03-03 | Suncor Energy Inc. | Apparatus and method for regulating flow through a pumpbox |
| US9016799B2 (en) | 2005-11-09 | 2015-04-28 | Suncor Energy, Inc. | Mobile oil sands mining system |
-
1998
- 1998-04-28 CA CA 2236183 patent/CA2236183C/en not_active Expired - Lifetime
- 1998-06-02 IL IL12471198A patent/IL124711A0/en unknown
Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7726491B2 (en) | 2002-09-19 | 2010-06-01 | Suncor Energy Inc. | Bituminous froth hydrocarbon cyclone |
| US7736501B2 (en) | 2002-09-19 | 2010-06-15 | Suncor Energy Inc. | System and process for concentrating hydrocarbons in a bitumen feed |
| US7914670B2 (en) | 2004-01-09 | 2011-03-29 | Suncor Energy Inc. | Bituminous froth inline steam injection processing |
| US8685210B2 (en) | 2004-01-09 | 2014-04-01 | Suncor Energy Inc. | Bituminous froth inline steam injection processing |
| US8225944B2 (en) | 2005-11-09 | 2012-07-24 | Suncor Energy Inc. | System, apparatus and process for extraction of bitumen from oil sands |
| US8168071B2 (en) | 2005-11-09 | 2012-05-01 | Suncor Energy Inc. | Process and apparatus for treating a heavy hydrocarbon feedstock |
| US8096425B2 (en) | 2005-11-09 | 2012-01-17 | Suncor Energy Inc. | System, apparatus and process for extraction of bitumen from oil sands |
| US8480908B2 (en) | 2005-11-09 | 2013-07-09 | Suncor Energy Inc. | Process, apparatus and system for treating a hydrocarbon feedstock |
| US8025341B2 (en) | 2005-11-09 | 2011-09-27 | Suncor Energy Inc. | Mobile oil sands mining system |
| US8800784B2 (en) | 2005-11-09 | 2014-08-12 | Suncor Energy Inc. | System, apparatus and process for extraction of bitumen from oil sands |
| US8968579B2 (en) | 2005-11-09 | 2015-03-03 | Suncor Energy Inc. | System, apparatus and process for extraction of bitumen from oil sands |
| US9016799B2 (en) | 2005-11-09 | 2015-04-28 | Suncor Energy, Inc. | Mobile oil sands mining system |
| US8968580B2 (en) | 2009-12-23 | 2015-03-03 | Suncor Energy Inc. | Apparatus and method for regulating flow through a pumpbox |
Also Published As
| Publication number | Publication date |
|---|---|
| IL124711A0 (en) | 1999-03-12 |
| CA2236183A1 (en) | 1999-10-10 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US7220351B1 (en) | Method and device for catalytic cracking comprising in parallel at least an upflow reactor and at least a downflow reactor | |
| US4157245A (en) | Countercurrent plug-like flow of two solids | |
| US4199432A (en) | Staged turbulent bed retorting process | |
| JP5360495B2 (en) | Catalytic cracking process using high-speed fluidization to produce light olefins from hydrocarbon feedstock | |
| US4430195A (en) | Fluid bed retorting process with lateral flow | |
| US6319395B1 (en) | Process and apparatus for converting oil shale or tar sands to oil | |
| US2573906A (en) | Multistage catalytic conversion of bituminous solids | |
| US4111788A (en) | Staged hydrogenation of low rank coal | |
| US4464247A (en) | Horizontal fluid bed retorting process | |
| US8518334B2 (en) | Coking apparatus and process for oil-containing solids | |
| US3406112A (en) | Catalytic cracking process | |
| US4816137A (en) | Method for cracking residual oils | |
| JPS5945390A (en) | Catalytic hydrogenation for hydrocarbon raw material oil | |
| CA1055915A (en) | Method and system for regenerating fluidizable catalyst particles | |
| US3320152A (en) | Fluid coking of tar sands | |
| US4183800A (en) | Indirect heat retorting process with cocurrent and countercurrent flow of hydrocarbon-containing solids | |
| US2385446A (en) | Catalytic conversion of hydrocarbons | |
| CA2236183C (en) | Process and apparatus for converting oil shale or tar sands to oil | |
| US3281349A (en) | Separating and cracking of shale oil from oil shale | |
| US6139722A (en) | Process and apparatus for converting oil shale or tar sands to oil | |
| US4437973A (en) | Coal hydrogenation process with direct coal feed and improved residuum conversion | |
| US5008005A (en) | Integrated coke, asphalt and jet fuel production process and apparatus | |
| US4332669A (en) | Oil shale retorting process with raw shale preheat prior to pyrolysis | |
| US4744883A (en) | Production of synthesis gas and related products via the cracking of heavy oil feeds | |
| EP0090896A2 (en) | Method for the recovery of fuel from oil shale |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request |