US20140008272A1 - Method for the energy-efficient and environmentally friendly obtention of light oil and/or fuels on the basis of crude bitumen from oil shales and/or oil sands - Google Patents

Method for the energy-efficient and environmentally friendly obtention of light oil and/or fuels on the basis of crude bitumen from oil shales and/or oil sands Download PDF

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US20140008272A1
US20140008272A1 US14/005,774 US201214005774A US2014008272A1 US 20140008272 A1 US20140008272 A1 US 20140008272A1 US 201214005774 A US201214005774 A US 201214005774A US 2014008272 A1 US2014008272 A1 US 2014008272A1
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oil
carbon
process chamber
sulfur
crude bitumen
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Thomas Stumpf
Ulf Boenkendorf
Leonhard Baumann
Roland Möller
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Ecoloop GmbH
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Ecoloop GmbH
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    • 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
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/04—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by extraction
    • 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
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/02—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/06—Continuous processes
    • C10J3/12—Continuous processes using solid heat-carriers
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/20—Apparatus; Plants
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/82—Gas withdrawal means
    • C10J3/84—Gas withdrawal means with means for removing dust or tar from the gas
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/02—Dust removal
    • C10K1/024—Dust removal by filtration
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/1003—Waste materials
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/202—Heteroatoms content, i.e. S, N, O, P
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40—Characteristics of the process deviating from typical ways of processing
    • C10G2300/4081—Recycling aspects
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0903—Feed preparation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0903—Feed preparation
    • C10J2300/0906—Physical processes, e.g. shredding, comminuting, chopping, sorting
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0946—Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0983—Additives
    • C10J2300/0996—Calcium-containing inorganic materials, e.g. lime
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/40—Gasification
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/32—Hydrogen storage

Definitions

  • the present invention relates to a method for energy-efficient, environmentally friendly extraction of light oil and/or fuels from crude bitumen from oil shale and/or oil sands (A) by thermal exploitation of carbon-containing compounds (E) occurring in this extraction.
  • Naturally occurring oil sands or oil shale comprise natural rock and contain up to 20% of a bitumen mixture.
  • This bitumen mixture essentially contains organic carbon compounds with different molecular weights and boiling points.
  • bitumen mixture To make these carbon compounds accessible to purposeful extraction, the bitumen mixture must first be separated from the natural rock component.
  • the rock mass containing bitumen is carried away using overburden dredgers or wheel loaders and transported to the processing plants with heavy road vehicles.
  • the processing is done as a rule in the following process steps:
  • bitumen layer Carrying away the upper bitumen layer to the second extraction step, where residues of water and fine particles are separated out.
  • the bitumen is usually dissolved in an organic solvent (as a rule, “naphtha”, which is a product of the light-oil recovery process). What is obtained is so-called crude bitumen.
  • the crude bitumen is sent to ensuing bitumen processing (“upgrading”).
  • This liquefied crude bitumen is carried purposefully into underground collection points and pumped from there to the surface, by means of suitable pumping technology.
  • the crude bitumen (possibly from both recovery methods) is combined in the next processing plant (“upgrading”). There, the following process steps are usually performed:
  • the gaseous hydrocarbons from the distillation are separated by fractionated condensation into naphtha, kerosene, and gas oil; naphtha is as a rule at least partially returned to the process
  • desulfurization can be done in the further step. This is usually done by means of hydrogenation and separating out of the elemental sulfur.
  • the pet coke remaining behind in the distillation of the crude bitumen (step 9) contains sulfur in concentrations of up to 10%. This is fundamentally a valuable energy carrier. However, because of its high sulfur content, it cannot readily be used in combustion processes, such as for generating water vapor or hot water. Ensuring environmentally sound thermal exploitation is therefore questionable and is possible, if at all, only at disproportionate expense for flue gas desulfurization.
  • the object has therefore arisen of furnishing a method which does not have the disadvantages of the prior art but permits energy-efficient exploitation of carbon carriers contained in oil sands and/or oil shale, which handles fossil fuels (such as natural gas) sparingly, and which on its own can generate sufficient energy carriers to supply the requisite energy demand for the exploitation process, at least in part.
  • the carbon-containing compounds contain sulfur and by substoichiometric oxidation with oxygen-containing gas in a countercurrent gasifier operated with a moving bed of bulk material are converted, with the addition of alkaline substances, at temperatures ⁇ 1800° C. into low-sulfur gaseous cleavage products, and these cleavage products are then converted by superstoichiometric oxidation into perceptible heat, and are used for generating heated aqueous process media for a physical comminution of the oil sands and/or oil shale and/or for separating the crude bitumen out of the rock mass and/or as process heat for a thermal fractionation of the crude bitumen.
  • solid residues from the aqueous separation of crude bitumen from the rock mass and/or solid residues from the thermal fractional distillation of the crude bitumen can be used.
  • a refinement of the method is especially advantageous in which the countercurrent gasifier is embodied as a vertical process chamber with a calcination zone and an oxidation zone, in which the calcined carbon- and sulfur-containing residues oxidize with oxygen-containing gas, and the gaseous reaction products are drawn off at the top of the vertical reaction chamber, in the form of a vertical shaft furnace, through which a bulk material that itself is not oxidized flows continuously from top to bottom, and the oxygen-containing gas is introduced at least partially below the oxidation zone, thereby further advancing the rising gas stream.
  • the advantage of an inert bulk material is that the mechanical properties of the pile can be more easily varied and adapted to the essential aspects of the method.
  • alkaline substances examples include metal oxides, metal carbonates, metal hydroxides or mixtures thereof, which are metered into the gas phase above the calcination zone and/or are admixed with the carbon-containing compounds before entering the vertical process chamber.
  • Elements of the alkali metals or elements of the alkaline earth metals, especially calcium, are preferred for forming the metal oxides, carbonates of hydroxides, since particularly in the form of calcium oxide, catalytic effects have a favorable effect on the courses of the method.
  • the sulfur-binding mechanisms proceed especially advantageously by addition of alkaline substances under reductive conditions, in which the gaseous sulfur compounds occurring in the countercurrent gasifier at temperatures of above 400° C. from the ingredients of the carbon-and sulfur-containing residues are converted by chemical reaction with the alkaline substances into solid sulfur compounds, and these solid sulfur compounds are at least partially carried out with the gaseous reaction products, and are removed from the gas phase by fine-material separation at temperatures above 300° C. In this way, the sulfur can be removed from the process especially economically.
  • a calcium-catalyzed reformation of substantial proportions is performed, at temperatures of above 400° C., of the resultant cleavage products, containing oil and/or tar, that have a chain length of greater than C4, into carbon monoxide, carbon dioxide, and hydrogen.
  • the moving bed of bulk material is preferably formed by additional metering of coarse material, in order to increase the flowability of the bulk material and/or its gas permeability, and the coarse material is admixed with the carbon-containing compounds before entering the vertical process chamber.
  • coarse material mineral substances and/or other inorganic substances, such as mixtures of substances, having a particle size in the range of from 2 mm to 300 mm, and especially preferably oil sand and/or oil shale, can be used. The latter case is especially preferred, since as a result, a method course in which resources occurring on site can be used and exploited directly is made possible.
  • wood and/or other biogenic materials as coarse material, with a suitable particle size, can also be advantageous. Often, these materials are available in the vicinity of the site where the method is performed, so given the short transportation distances, their use is favorable for the sake of overall energy efficiency.
  • Inert bulk material can be separated off at the lower end of the vertical process chamber from the fine material and ashes produced and can be returned at least partially to the process as coarse material, so that the distances the masses have to be moved can be kept short. It can also be advantageous to convert the carbon-containing compounds before their use in the countercurrent gasifier by agglomeration into particles with a particle size in the range between 2 mm and 300 mm, in order to improve the flowability of the bulk material and/or its gas permeability, as is done with the additional metering in of coarse material.
  • FIG. 1 shows one example of an integrated method for producing light oil and fuels by breaking down the oil sands and oil shale in open pit mining.
  • the oil sands and oil shale (A) quarried by open pit mining are mechanically comminuted via breaker systems ( 1 ). This is usually done by mixing in hot water or also water vapor ( 2 ). Hot water/water vapor is produced in boiler systems ( 3 ).
  • the suspension resulting from the mechanical comminution is delivered to a first extraction stage ( 4 ).
  • a separation of the phases is performed by settling.
  • a water/sediment phase (B) forms as the lower phase. It is separated off and usually deposited in artificial lagoons or lakes ( 6 ).
  • the upper phase ( 7 ) essentially contains crude bitumen. It is separated off and delivered to the next process step (C).
  • a middle phase ( 8 ) forms as a rule; besides water/sediment, it can also contain significant amounts of crude bitumen.
  • This middle phase can be delivered to a second extraction stage ( 9 ).
  • a second separation is performed, in which the lower water/sediment phase (D) is separated off and likewise deposited in artificial lagoons or lakes ( 6 ).
  • the upper phase ( 10 ) essentially contains crude bitumen and is likewise delivered to the next process stage (C).
  • the crude bitumen can be mixed with organic solvents, such as naphtha ( 11 ), which is obtained as a product in the later bitumen refining process.
  • organic solvents such as naphtha ( 11 )
  • undissolved residues also called pet coke, can occur here.
  • the dissolved crude bitumen is delivered to a distillation stage ( 12 ), where the volatile ingredients are evaporated off by adding heat by means of hot steam ( 13 ) from the boiler systems and using suitable distillation equipment; additional pet coke (E) remains behind, as a nonvolatile ingredient.
  • This pet coke comprises carbon-rich residues, which have a high thermal value but can contain up to 10% sulfur.
  • the volatile ingredients ( 14 ) are separated, for instance via fractionated condensation ( 15 ), into various boiling fractions, which can comprise light oil ( 16 ), naphtha ( 11 ), and various fuels ( 17 ), among other things.
  • the method of the invention provides for replacing this natural gas entirely or in part with synthesis gas ( 20 ) generated in the countercurrent gasifier ( 19 ), and using this synthesis gas as fuel in the boiler systems.
  • the production of the synthesis gas is done by gasification of carbon-containing materials in a countercurrent gasifier ( 19 ), which is embodied as a vertical process chamber.
  • a bulk material ( 21 ) flows through this process chamber from top to bottom.
  • the bulk material can preferably comprise material of a coarse particle size, and as the bulk material, it is also suitable to use sediment (B) and/or (D).
  • the bulk material can also be formed partially by the oil sand/oil shale (A); in this case, it can also be advantageous for the material, before being used as bulk material, to be comminuted mechanically to a particle size of less than 20 cm. Further residues from the method described above can be added to this bulk material before it enters the countercurrent gasifier.
  • the pet coke (E) which because of its high carbon content has a high thermal value, is particularly well suited.
  • the mixture of bulk material and residues flows through the vertical process chamber ( 19 ) by gravity from top to bottom.
  • the countercurrent gasifier has burner lances ( 22 ) in its middle region, which ensure constant- load firing in the vertical process chamber and the stationary development of a burning zone ( 23 ).
  • These burner lances can be fueled by fossil fuels ( 24 ) and oxygen-containing gas ( 25 ).
  • synthesis gas from the countercurrent gasifier ( 20 ), or the crude bitumen (C) dissolved in naphtha can also be used.
  • oxygen-containing gas ( 26 ) is introduced. This gas serves first to cool down the bulk material before in a cooling zone ( 27 ) before it leaves the vertical process chamber. The oxygen-containing gas is thus preheated as it continues to flow upward in the vertical process chamber.
  • the oxygen from the oxygen-containing gas reacts with the carbon-containing materials in the bulk material by oxidation, and the quantity of oxygen-containing gas is adjusted such that a total lambda of less that 0.5 is established in the vertical process chamber.
  • a burning zone ( 23 ) is formed, in which residues of the carbon-containing material react with oxygen to form CO 2 .
  • the oxygen decreases further, so that finally, only low-temperature carbonization can occur, until still farther upward, all the oxygen is finally consumed, and a pyrolysis zone ( 28 ) forms,
  • the pyrolysis coke is transported with the bulk material farther downward in the vertical process chamber, where it is converted partly into CO at temperatures above 800° C. with the CO 2 components from the burning zone by Boudouard conversion and likewise gasified. Some of the pyrolysis coke also reacts in this zone by the water-gas reaction with water vapor, which is likewise present in the hot gases, forming CO and hydrogen. Finally, at temperatures below 1800° C., residues of the pyrolysis coke are practically completely combusted and thermally utilized in the burning zone ( 23 ) along with the oxygen-containing gas flowing in from below. As a result, it is possible for the countercurrent gasifier to be supplied with virtually all the energy needed for the gasification. This is also known as an autothermal gasification process.
  • Water ( 29 ) can also be metered into the cooling zone via water lances ( 30 ).
  • the synthesis gas formed in the vertical process chamber is extracted at the upper end by suction ( 31 ), so that in the upper gas chamber ( 32 ), a slight underpressure of from 0 to 200 mbar is established.
  • alkaline substances ( 33 ) are admixed with the bulk material before it enters the vertical process chamber.
  • metal oxides, metal hydroxides, or metal carbonates are especially suitable, and the use of fine-granular calcium oxide is especially preferred, since because of its reactivity and large surface area it reacts spontaneously with the gaseous sulfur compounds formed and thereby forms solid sulfur compounds, which are quite predominantly removed from the vertical process chamber together with the synthesis gas that is extracted by suction.
  • Still other contaminants, such as chlorine, hydrogen chloride, or even heavy metals, can be bound highly effectively to the CaO and removed from the process in the same way.
  • the synthesis gas extracted by suction contains dust, which essentially comprises the solid sulfur compounds, fine-granular alkaline substances, other contaminants, and inert particles.
  • This synthesis gas containing dust can be treated in the gas chamber of the vertical process chamber, or after leaving the vertical process chamber, in the presence of water vapor and fine-granular calcium oxide at temperatures of over 400° C. This temperature can be established by suitable adjustment of the quantity of oxygen-containing gas ( 26 ) at the lower end of the vertical process chamber or by means of the calorific output of the burner lances ( 22 ) in the burning zone.
  • burner lances 34
  • burner lances 34
  • This thermal posttreatment in the presence of water vapor and calcium oxide ensures that the oils and tars still present in the synthesis gas will be split off by the catalytic action of the calcium oxide.
  • the dust-containing synthesis gas is then freed of dust at temperatures above 300° C. by way of hot-gas filtration ( 35 ).
  • the filter dust ( 36 ) containing sulfur is spun out of the process and either disposed of or put to an alternative use.
  • the resultant synthesis gas is practically sulfur-fee and can be used as fuel in the boiler systems ( 3 ). Depending on conditions on site or on the requirements of the boiler systems, it may be necessary to cool down the synthesis gas using gas coolers ( 38 ) and to free it of condensates, before it can be used in the boiler systems.
  • the condensate ( 39 ) that occurs can be used again at least partially as a cooling and gasification medium via the water lances ( 30 ) in the vertical process chamber.
  • the combustion of the cleaned synthesis gas ( 20 ) permits the boiler systems to be operated without requiring that the flue gas ( 40 ) be treated by means of complicated flue gas desulfurization.
  • the bulk material mixture ( 41 ) emerging from the lower end of the vertical process chamber essentially contains coarse-particle bulk material, ash residues, and fine-granular bulk material.
  • the fine-granular bulk material may still contain slight amounts of sulfur products and other contaminants.
  • the entire bulk material stream can be stored ( 42 ) in its entirety. However, it is especially preferable to screen the bulk material mixture ( 43 ), with the coarse fraction ( 44 ) preferably put at least partially into circulation and used again as bulk material in the vertical process chamber.
  • the fine screened fraction ( 45 ), together with the filter dust ( 36 ) that contains sulfur, is spun out of the process and disposed of or put to an alternative use.
  • FIG. 2 shows an example of an integrated method for extracting light oils and fuels, in which the crude bitumen is quarried by the subsurface in-situ method.
  • the crude bitumen is not obtained by breaking down the soil and extracting it; instead, it is liquefied by melting in the earth's crust and brought to the surface via pumping systems.
  • a further technology contemplates the use of special burner lances ( 8 ), by way of which partial combustion of the crude bitumen in the earth's crust is initiated. This can be done for instance by superstoichiometric combustion of fossil fuels ( 9 ) with oxygen-containing gas ( 10 ), as a result of which the excess oxygen-containing gas ( 10 ) effects a partial combustion of the crude bitumen in the soil and thereby furnishes energy for the liquefaction of the crude bitumen.
  • Synthesis gas can also be used as fuel for the partial combustion via the special burner systems ( 8 ).
  • the in-situ method is also combined with the open-pit mining of FIG. 1 .
  • crude bitumen is extracted, which is then combined in process stage ( 3 ) and further refined.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Combustion & Propulsion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
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US14/005,774 2011-03-18 2012-03-16 Method for the energy-efficient and environmentally friendly obtention of light oil and/or fuels on the basis of crude bitumen from oil shales and/or oil sands Abandoned US20140008272A1 (en)

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CA2830454A1 (en) 2012-09-27
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DE102011014345A1 (de) 2012-09-20
CN103547657A (zh) 2014-01-29
EP2686403A1 (de) 2014-01-22
WO2012126591A1 (de) 2012-09-27

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