WO2005072256A2 - Retort heating apparatus and methods - Google Patents
Retort heating apparatus and methods Download PDFInfo
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- WO2005072256A2 WO2005072256A2 PCT/US2005/001952 US2005001952W WO2005072256A2 WO 2005072256 A2 WO2005072256 A2 WO 2005072256A2 US 2005001952 W US2005001952 W US 2005001952W WO 2005072256 A2 WO2005072256 A2 WO 2005072256A2
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- Prior art keywords
- feed material
- recited
- retort
- heating
- baffle
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Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B1/00—Retorts
- C10B1/02—Stationary retorts
- C10B1/04—Vertical retorts
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B47/00—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion
- C10B47/18—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge
- C10B47/20—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion with moving charge according to the moving bed type
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
- C10B53/06—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of oil shale and/or or bituminous rocks
Definitions
- the present invention relates to systems and methods for implementing a novel retort heating apparatus. Specifically, the present invention relates to systems and processes for producing hydrocarbon gases and liquids and other by-products from solid matter, particularly from oil shale using a retort heating apparatus.
- Oil consumption in the United States has been estimated to be about 20 million barrels/day.
- the U.S. domestic production of oil is estimated to be about 6 million barrel/day. This imbalance between consumption and demand on the one hand, and production on the other hand, emphasizes the need for continued development in the field of alternative fuel source technology.
- the Green River oil shale formation that extends over eastern Utah, western Colorado, and a tip of southern Wyoming, is estimated to contain over one trillion barrels of recoverable oil, which makes of this formation the richest oil formation in the world. In theory, this formation could provide a world-wide supply of oil for about 150 years. In other words, the amount of oil in the Green River shale formation has been estimated to exceed the combined amounts of oil in known oil reserves in the entire world and of oil discovered so far. Other oil shale deposits are known to exist in the U.S. and also in other countries worldwide. Oil shale contains a rich hydrocarbon source known as kerogen. Kerogen can be broken down into oil vapors and organic liquids by retorting processes.
- Retorting is a process by which kerogen is decomposed into derivatives such as oil, gas and other compounds. Retorting is also known as destructive distillation, which is the decomposition of kerogen by heat in a closed container and collection of the volatile products produced.
- a number ⁇ f fluid bed retorts have been developed. Generally, each of these systems allows crushed feed material to flow downward by gravity through a heated column as oil vapor is drawn off the column.
- most conventional retorts function to convert oil shale to oil, conventional systems have such poor efficiency that they are not economical to operate.
- many conventional systems have systemic problems that preclude their continued operation without shutting down and cleaning out the retort chamber.
- conduits have been provided within a retort.
- the conduits are heated by passing a heated gas therethrough.
- the particles are heated so as to emit the oil vapor.
- the primary problem with this approach is that the conduits do not uniformly heat the particles. For example, some particles pass through the retort without ever contacting the conduits. Other particles become stacked on top of the conduits preventing their passage through the retort.
- Figure 1 illustrates a process flow diagram of a method of retorting feed material having organic precursors, according to one embodiment of the invention
- Figure 2 is an elevated side view of a retort in accordance with an embodiment of the present invention
- Figure 3 is a perspective view of a modular unit of the retort shown in Figure 2
- Figure 4 is a perspective view of a baffle of the modular unit shown in Figure 3
- Figure 5 is an elevated side view of the baffle shown in Figure 4
- Figures 5 A-5I are elevated side views of alternative embodiments of the baffle shown in Figure 5
- Figure 6 is a perspective view of an alternative embodiment of the baffle shown in Figure 4
- Figure 7 is a perspective view of the baffle shown in Figure 4 further comprising an insulating plug
- Figure 8 is a cross sectional top view of the modular unit shown in Figure 3
- Figure 9 is a perspective view of another alternative embodiment of the baffle shown in Figure 4;
- Figure 9 is a perspective view of another alternative embodiment of the baffle shown
- the present invention is directed to retort systems and methods for using retort systems so as to extract oil and other hydrocarbons from materials that contain oil, oil precursors, or other organic materials.
- a material that contains oil precursors is oil shale. That is, oil shale in its natural state does not contain oil but rather contains organics that when processed, such as through a retort system, can be converted into oil and hydrocarbon gases.
- An exemplary type of oil shale is mahogany oil shale, found in the Green River oil shale formation, which extends over eastern Utah, western Colorado, and a tip of southern Wyoming.
- the present invention is not limited to extracting oil products from oil shale. Rather, the present invention contemplates that any material containing oil, oil precursors, or other organic materials can be processed using the methods and retort systems disclosed herein. Examples of such other materials that can be processed include: corn, grains, plants, wood, straw, animal waste, contaminated soil containing oil, coal, and other similar materials.
- Figure 1 Depicted in Figure 1 is one embodiment of a retort system 10 incorporating features of the present invention. Retort system 10 is illustrated by way of a process flow diagram. For purposes of discussing retort system 10 and the related methods, oil shale is used as an exemplary feed material.
- a feed material 12 is obtained from a site.
- feed material 12 is extracted, such as by mining, from an oil shale deposit.
- Feed material 12 is then delivered to a size separator 14 which separates feed material 12 based on size.
- the oversized material is sent to a crusher 16 for reducing the size of the material to the desired particle size.
- the undersized material is sent to pelletizer 18 which forms the undersized material into pellets of the appropriate particle size.
- Feed material 12 having the desired size may be sent to a washer 20 which removes dust and at least a portion of any water soluble minerals and other components from feed material 12. As discussed further below, removal of the water soluble components increases the efficiency of the retort process.
- the washed feed material 12 is sent to a dryer 22 which removes the moisture from feed material 12. Depending on the type of dryer 22 used, dust and water vapor are typically formed during the drying process. Separator 24 removes and separates the dust and water vapor from dryer 22.
- the dust may then be sent back to pelletizer 18 to be recycled into the system.
- the dried feed material 12 is elevated by a conveyer 26 to a storage bin 28.
- the feed material is then selectively fed from storage bin 28 into retort 32 by way of an automatic feeder 30.
- a programmable logic control (PLC) 34 controls the operation of retort 32 and other components of system 10.
- Feed material 12 is heated within retort 32 causing the oil precursors within the oil shale to convert to oil vapor and various hydrocarbon gases.
- the oil vapor, hydrocarbon gases, water vapor and dust formed in retort 32 are drawn off and sent to a separator 36.
- Separator 36 may comprise a number of process steps for separating the oil vapor, hydrocarbon gases, water vapor, and dust.
- the oil vapor is condensed into oil which can then either be sold in that form or further processed into commercial products such as gasoline, diesel fuel, and the like.
- the hydrocarbon gases are separated into their various components such as methane, propane, butane, and the like. These gases can be sold or used as fuel for retort system 10.
- the separated dust may be sent back to pelletizer 18 to be recycled into the system. Water and other products (e.g., nitrogen products) may also be extracted or separated from the liquid oil products, as will be discussed further below.
- Spent material (or solids) exiting retort 32 may be sent to a heat exchanger 38 which uses the heat from the spent material as a source of power.
- the spent material can then be used in a variety of different ways.
- the spent material can be washed or otherwise processed to remove all remaining minerals or other desirable components.
- the spent material having a residual carbon content can also be burned as fuel or simply used as back fill. Due to the filtration properties of the spent oil shale material, such material can be effectively back filled into abandoned mines and other areas to prevent leaching of contaminates. It is appreciated that the above described process steps and related apparatus used before and after retort 32 are merely one example of an inventive retort system.
- the first step is to obtain a feed material 12 that contains oil, an oil precursor, or other organics. This may consists of mining the feed material from a source deposit, reclaiming soil from a contaminated site, gathering waste product, harvesting organic material, and the like. In the embodiment where the feed material is oil shale, the feed material is generally mined from an oil shale deposit.
- the mining process and retort process occur in the same general area.
- material is mined from one site and then transported to retort system 10 at another site.
- a mechanical mining system is generally used.
- the mechanical mining system may comprise a "long wall mining system” for seams of oil shale that are typically less than about 10 m.
- the mechanical mining system may comprise a "room and pillar mining system” for larger seams.
- a mid-seam miner may also be used to cut corridors through the solid rock.
- the feed material that is processed in retort system 10 has a relatively small diameter.
- separator 14 comprises a screening apparatus.
- the screening apparatus separates the feed material into undersized, optimal-sized, and oversized particles.
- the optimal-sized feed material has a maximum diameter in a range between about 1 mm to about 15 mm with about 2 mm to about 10 mm being more common. It is appreciated that other dimensions can also be used and that the diameter of the optimal-sized feed material may differ depending on the design of retort 32 and the type of feed material.
- the optimal-sized feed material is passed from separator 14 to washer 20 which will be discussed below in greater detail.
- the undersized feed material is sent to pelletizer 18.
- Pelletizer 18 forms the particles of undersized feed material into pellets of optimal-sized diameter using a standard pelletizing process. In one embodiment, an oil-based binder using liquid products from the present retort system is used to form the pellets. Other commercial binders can also be used. After the pellets are formed, they are either passed back through separator 14 or sent directly to washer 20. In one alternative, the undersized feed material is initially mixed with water or processed with other conventional solutions to extract desired minerals from the material. Once the minerals are removed,, the remaining feed material is then pelletized.
- Crusher 16 can comprise any conventional type of rock crusher capable of crushing oil shale. Examples of crushers that can be used include hammer mills, jaw crushers, rollers and the like.
- the crushed material is sent again to separator 14 to separate out the optimal-sized feed material, the undersized material, and the oversized material. The above processes are repeated until all of the feed material has the optimal size.
- separator 14 can comprise any conventional type of screening or separator system capable of separating the feed material particles by size.
- separator 14 can comprise a cyclonic separator that separates the crushed material based on size and density.
- the initial feed material typically has a diameter of less than about 8 cm. It is again noted that where the feed material has an initial set diameter, such as in processing corn, separator 14, crusher 16 and pelletizer 18 may not be required. IV. WASHING FEED MATERIAL Once the feed material is sized, it is passed through washer 20. Although this step is. not required, it is commonly used where the feed material has a high mineral content and/or a high dust content. That is, washer 20 is used at least in part to remove minerals and fine particulates, such as dust, from the feed material. The dust that is washed out may be sent back to pelletizer 18, as discussed above, and recycled through retort system 10 as feed material.
- the minerals that are washed out of the feed material may be further processed or purified to produce a marketable commodity.
- mahogany oil shale found in Vernal, Utah has a high sodium carbonate (NaCO 3 ) content.
- the mahogany oil shale feed material is washed with hot water.
- the temperature of the water determines in part how much sodium carbonate is drawn out of the oil shale. For example, water at a temperature of 100° C will take out about 10% of the sodium carbonate while water at 200° C will take out about 20% of the sodium carbonate.
- the washing step also appears to increase the yield of oil production.
- Washer 20 can comprise one or more sprayers, baths, scrubbers, streams, or other conventional washers used for removing dust or extracting minerals from rock. Combinations of the foregoing can also be used. Where the minerals are water soluble, the washing can be accomplished with water that is typically heated. In other embodiments, other types of solutions can be used to extract minerals, clean, or otherwise treat the feed material prior to further processing. It is also appreciated that the feed material can be passed through a number of different washers using the same or different solutions.
- the feed material is sent to dryer 22 to remove moisture therefrom.
- the feed material is typically dried to a temperature in a range between about 100° C to about 120° C.
- the feed material is typically dried without exposure to a direct flame or to a sufficiently elevated temperature that could cause oil or oil precursors in the feed material to combust. Rather, in one embodiment, drying is accomplished by injecting hot air or gas into dryer 22.
- the feed material may be dried through the use of heating elements. In either event, the feed material is typically dried in such a way that the particles of feed material do not stick together as the moisture is removed. As such, rotary type dryers are typically used.
- Dryer 22 can comprise a single dryer or multiple dryers that are disposed either in series or parallel.
- the term "dried feed material" refers to feed material from which substantially all of the water has been removed. In one embodiment the water content is reduced to less than about 10% ⁇ f the total weight of feed material and water; in another embodiment the water content is reduced to less than about 5% of the total weight of feed material and water; in still other embodiments the water content is reduced t ⁇ less than about 3% of the total weight of feed material and water. As will be discussed below in greater detail, the water is removed by way of dryer 22 to prevent the formation of mud balls within retort 32.
- Removing substantially all of the water in the context of the present invention means that the water that was naturally contained in the feed material has been removed from such material under the conditions prevailing in the dryer. Residual water content may remain due to, for example, exposure to and abso ⁇ tion of atmospheric moisture. Even if the feed material is not washed, the feed material is still typically passed through dryer 22 so as to substantially removed the ambient water content. Separator 24 is provided to remove the water vapor and/or any dust formed during the drying step. The removal of water vapor and dust is helpful to prevent the conglomeration of the feed material in dryer 22. Conglomeration of the feed material can be detrimental in that it can produce particles that are larger than the optimal size feed material prepared at separation step 14.
- separator 24 comprises a filtration system through which heated air from dryer 22 passes. The filtration system removes both the dust particles and the water vapor.
- a filtration system comprises a conventional bag house which is known to those skilled in the art. It is appreciated that dust filtration equipment may also be implemented in connection with other steps of the process besides drying. For example, a dust filtration system can also be used in association with crusher 16.
- separator 24 comprises a vacuum that vacuums the water vapor and dust coming off of dryer 22. In turn, the vacuumed water vapor and dust are sent to a cyclonic separator and/or an electrostatic precipitator for separation.
- a scrubber can be used to separate the dust from the water vapor.
- the dust is typically recycled back through pelletizer 18.
- the water vapor can be passed through a heat exchanger or turbine to generate power prior to being released to the atmosphere.
- the water vapor and dust may be condensed into a slurry and sent to pelletizer 18 to recycle the dust back into the retort.
- separator 24 can be integral with or separate from dryer 22. In addition to removal of the water vapor from the feed material, dryer 22 also functions to initially heat the feed material prior to passing into retort 32.
- Initial heating of the feed material increases the efficiency and operation of retort 32. Should the feed material cool below a predetermined base level, for example 80° C, prior to entering retort 32, it may be cost efficient to reheat the feed material so as to increase its base temperature and to substantially drive off an absorbed moisture. In contrast to having dryer 22 separated from retort 32, dryer 22 can be placed directly above or adjacent to retort 32. This embodiment may be advantageous where drying is occurring in a humid environment in order to prevent the abso ⁇ tion of moisture from the surrounding atmosphere. This embodiment would also minimize heat loss from the feed material. In this embodiment, heat for dryer 22 could be obtained by a heat exchanger powered by retort 32 or by heated vapor passing through retort 32. VI.
- conveyor 26 elevates the feed material to storage bin 28 which is disposed above retort 32.
- An automatic feeder 30 controls delivery of the feed material from storage bin 28 to retort 32. It is appreciated that conveyor 26, storage bin 28, and feeder 30 can come in a variety of different configuration, can be placed in different orders, and can even be eliminated in some cases. For example, as will be discussed below in greater detail, the bulk material travels down through retort 32 under the force of gravity.
- conveyor 26 includes a bucket elevator 26A. Bucket elevator 26A transports feed material to storage bin 28.
- conveyor 26 can comprise a conveyor belt, auger pipe or any other conventional type of conveyor.
- Storage bin 28 comprises a surge bin 28A disposed above retort 32.
- Surge bin 28A feeds into retort 32 through automatic feeder 30.
- the surge bin 28A located above retort 32 is large enough to contain a supply of feed material for about one hour of operation of retort 32. That is, if the mining and/or feed material preparation processes (e.g., washing and drying) were shut down, the retort 32 could still operate for about 1 hour before having to shut down.
- means are provided for feeding the feed material into retort 32 while preventing the free flow of air into retort 32.
- automatic feeder 30 comprises a rotary valve 30 A.
- Rotary valve 30A operates to selectively deliver feed material into retort 32 while preventing the free flow of air into retort 32. That is, rotary valve 30A provides a rotatable seal between retort 32 and the atmosphere. Rotary valves are well known to those skilled in the art and are not further disclosed herein. Rotary valve 30A may be operated at varying rates in order to increase or decrease the flow of feed material into retort 32.
- feeder 30 comprises a series of slotted grates that selectively slide between an open and closed position. The slotted grates bound at least one compartment. During operation a first grate opens allowing the feed material within storage bin 28 to pass into a compartment through the slots.
- the first grate closes.
- the second gate then opens allowing the feed material to travel from the compartment to retort 32.
- the second grate closes and the first grate opens again allowing, the feed material to enter the compartment.
- This process is continually repeated so that the feed material can be delivered to retort 32 without exposing the interior of retort 32 to the free flow of air.
- the grates can be operated at such a rate that the desired feed flow rate is maintained.
- Other mechanisms for automatically feeding the feed material into retort 32 include screw conveyors, augers, and the like. Still other embodiments of such elements that perform analogous functions are contemplated within the scope of this invention.
- the feed material may be stored in a main storage container before being transported to surge bin 28A on retort 32.
- the main storage container may service more than one retort.
- material is conveyed by a plurality of bucket elevators or other conveying mechanisms to a surge bin located on each retort.
- storage bin 28 may comprise a pair or series of surge bins. The feed material is fed from the first surge bin into successive surge bins until it arrives at the desired retort.
- the series of surge bins are located at subsequent lower levels so that gravitational forces can be used to deliver feed material from one surge bin to the next surge bin.
- a bucket elevator or other conveying mechanism may elevate material from one surge bin to the next surge bin.
- different configurations exist for conveying and feeding the feed material to retort 32.
- MODULAR RETORT As mentioned above, depicted in Figure 2 is one embodiment of retort 32 inco ⁇ orating features of the present invention.
- the term "retort” refers to a heating unit for heating various forms of hydrocarbon compounds.
- retort 32 is comprised of multiple, substantially identical modular units 102A-102F that are vertically stacked. Each modular unit 102 has a substantially similar block-shaped configuration such that in one embodiment modular units 102 can be interchangeable.
- modular unit 102A-102F This modular assembly and uniform shape enables retort 32 to be easily disassembled, moved and reassembled.
- the modular assembly also simplifies manufacture and enables easy adjustment of retort 32 so as to accommodate processing of different feed materials at different parameters. That is, the number of modular units 102 in retort 32 is chosen in part based on the composition of the feed material to be treated and the desired products.
- the components of modular unit 102A-102F will now be discussed primarily with reference to modular unit 102B. It is understood, however, that the remaining modular units 102A and 102C-F have substantially the same components. As depicted in Figure 3, modular unit 102B has a top end 113 and an opposing bottom end 115.
- outer housing 106 and inner housing 110 Extending between opposing ends 113 and 115 is an outer housing 106 and a concentrically disposed inner housing 110.
- Each of outer housing 106 and inner housing 110 has a substantially rectangular or square transverse cross section. It is appreciated, however, that housings 106 and 110 can be any desired configuration such as, but not limited to, circular, oval, irregular or other polygonal shape.
- Outer housing 106 and inner housing 110 are typically formed of a metal such as steel,. stainless steel, or cast iron. Other materials, however, can also be used. In one embodiment, housing 106 and 110 are each comprised of stainless steel sheets having a thickness in a range between about 3 mm to about 10 mm. Disposed between outer housing 106 and inner housing 110 is a thermal insulation layer 108.
- insulation layer 108 is comprised of a refractory material having a thickness in a range between about 10 cm to about 30 cm.
- the refractory material can be comprised of brick or other refractory material known in the art.
- inner housing 110 can be eliminated so that insulation layer 108 is openly exposed within retort 32.
- Housings 106 and 110 and insulation layer 108 combine to form a perimeter wall 117.
- Perimeter wall 117 bounds a central compartment 116 and comprises a front wall 119, a back wall 121, and a pair of opposing side walls 123 and 125 extending therebetween.
- Central compartment 116 is divided by a vertically disposed partition wall 118 extending between front wall 119 and back wall 121.
- Partition wall 118 can be constructed of the same materials as previously discussed with regard to inner housing 110. Partition wall 118 divides central compartment 116 into a heating chamber 120 and a vapor chamber 122. In one embodiment both heating chamber 120 and vapor chamber 122 have a depth extending between front wall 119 and back wall 121 in a range between about 2 m to about 3 m and a width extending between partition wall 118 and a corresponding side wall in a range between about 0.5 m to about 1 m. Likewise, each modular unit 102 typically has a height in a range between about 2 m to about 3 m. Of course the above dimensions are simply one example and other dimensions can also be used.
- means are provided for heating perimeter wall 117 and/or partition wall 118.
- electrical heating elements 109 ( Figure 8) are disposed within insulation layer 108 adjacent to inner housing 110. Heating elements 109 can be disposed all along inner housing 110 and can also be disposed on or within partition wall 1 9 for heating perimeter wall 117 and partition wall 118.
- conduits can be formed on or through perimeter wall 117 and partition wall 118 so that heated gases or heated fluid can be passed therethrough.
- Other conventional mechanism can also be used to heat perimeter wall 117 and/or partition wall 118. Extending between side wall 125 and partition wall 118 so as to be disposed within heating chamber 120 is an array of spaced apart baffles 126.
- each baffle 126 comprises an elongated body 138 having an inverted substantially V-shaped transverse cross section.
- Body 138 has a top surface 135 and an opposing bottom surface 137 each extending between a first end 139 and an opposing second end 141.
- First end 139 terminates at a first end face 140 while second end 141 terminates at a second end face 142.
- body 138 also has height h and width w each in a range between about 5 cm to about 15 cm.
- Body 138 also has a thickness t extending between top surface 135 and bottom surface 137 in a range between about 2 cm to about 4 cm. Other dimensions can also be used.
- Top surface 135 has a first side face 50 and an opposing second side face 52 which are each disposed in diverging planes so as to have a substantially inverted V-shaped configuration.
- each of side faces 50 and 52 are disposed in a plane forming an inside angle ⁇ relative to the horizontal in a range between about 45° to about 85° with about 55° to about 75° being more common and about 63° being, even more common.
- Side faces 50 and 52 can also form an inside angle between the faces in a range between about 1° to about 70° with about 20° to about 60° being more common.
- Side faces 50 and 52 intersect along a narrow ridge 53. Narrow ridge 53 ensures that the feed material moves down one of side faces 50 and 52 as opposed to vertically stacking on top of ridge 53.
- top surface 135 functions in part to deflect the feed material as it passes down through heating channel 120 so that the feed material is maintained in a continuous and dynamic mixing flow.
- top surface 135 can have a variety of different configurations, if the apex of top surface 135 becomes too flat, a few of the particles of feed material can rest and stagnate thereon. Due to the heat subjected to the stagnate particles, the particles fuse together creating a larger surface area on which more particles can fuse. The fused particles continue to grow until they block the flow of the feed material through the baffles 126.
- top surface 135 can cause the feed material to travel at different speeds as it passes over top surface 135. Again, this change in speed can result in stacking of some of feed material within retort 32.
- narrowing the apex or ridge 53 of top surface 135 forces the feed material to flow down side face 50 or 52, thereby eliminating stagnate particles.
- the extent to which ridge 53 can be rounded is dependent on a number of factors such as the size of the feed material and the speed of the feed material passing through retort 32. The rounding of ridge 53 can also be adjusted based on the application of external forces such as the vibration of retort 32.
- ridge 53 has a radius of curvature that is less than four times the maximum diameter of the feed material, more commonly less than twice maximum diameter of the feed material, and even more commonly less than maximum diameter of the feed material.
- the radius of curvature or ridge 53 can be equal to or less than about 0.5 times the maximum diameter of the feed material.
- Other dimensions can also be used.
- Depicted in Figures 5A-5I are a plurality of different bodies 138A-I each having a corresponding top surface 135 with a ridge 53. As depicted in Figure 5A, it is appreciated that top surface 135 can have an inverted substantially U-shaped configuration. It is noted with regard to Figures 5B and 5C that the body need not be symmetrical.
- bottom surface 137 also has a substantially inverted V-shaped transverse cross section. As a result, bottom surface 137 at least partially bounds a collection channel 149 extending along the length of body 138. Bottom surface 137 is configured in part to capture oil vapors and gases emitted from the feed material. To achieve this function, bottom surface 137 can come in a variety of different configurations.
- bottom surface 137 can have an inverted substantially U-shaped configuration or can have any number of curved, rounded, sloped, irregular, or combined surfaces that form a cupped surface capable of capturing gas and oil vapors.
- means are provided for selectively heating baffle 126.
- a plurality of spaced apart channels 144 extend from first end face 140 of body 138 to or toward second end face 142.
- Disposed within channels 144 is a conventional electrical resistance filament 146.
- filaments 146 can be disposed on bottom surface 137 or otherwise disposed on body 138 so as to heat body 138.
- fluid conduits are formed within body 138.
- Heated gases or fluids are pumped or otherwise passed through the fluid conduits so as to heat body 138.
- the material for body 138 is chosen so as to withstand the desired operational temperature range. In one embodiment, body 138 is heated to a temperature in a range between about 400° C to about 600° C. Examples of materials that can be used for body 138 include cast iron, iron alloys, stainless steel, beryllium, beryllium alloys, ceramic, graphite with a titanium carbide surface treatment, or copper alloys, such as materials comprising 99% Cu and about 1% of other elements, such as Cr, Be, or combinations thereof. Other materials having the desired properties can also be used. As different baffles 126 may be heated to different temperatures and subject to different load forces, different bodies 138 can be made of different materials and have different sizes. Depending on the hardness of the material for body 138, drilling channels
- body 138 may comprise a plurality of smaller segments 156 having a similar cross-sectional configuration. Channels 144 are formed in segments 156. Subsequently, segments 156 are assembled together to form body 138 of baffle 126. Alternatively, areas where channels 144 are to be drilled in body 138 may be constructed of a softer metal, such as copper, that can be drilled with conventional equipment. In another alternative embodiment as depicted in Figure 6, an insulation layer 158 is formed or otherwise secured on bottom surface 137. Insulation layer 158 thus partially bounds collection channel 149.
- Insulation layer 158 has a temperature lower than top surface 135 during operation so that as the oil vapor is collected and passed through collection channel 149, the oil vapor is not super heated and converted into a non-condensable gas. If the oil vapors are over heated, they can thermally crack. This produces non-condensable vapors and also leaves carbon (coke) deposits on the surface of the baffles.
- Insulation layer 158 can comprise ceramic, other refractory materials, or other insulation materials that can withstand the operating temperatures.
- one or more spaced apart fins 155 can be formed so as to outwardly project from top surface 135 of body 138.
- Fins 155 are disposed so as to transversely extend across body 138 and are used to more efficiently conduct the heat energy to the feed material. Fins 155 can be made of the same material as body 138. In the embodiment illustrated in Figure 7, an insulating plug 150 is secured at first end 139 of body 138. Plug 150 is typically comprised of a refractory material or other insulating material capable of withstanding the operating temperatures. Although plug 150 is shown having a substantially cylindrical configuration, in alternative embodiments plug 150 can have any desired cross-sectional shape. Channels 154 extend through plug 150. Insulated wiring 148 that is coupled with electrical resistance filament 146 extends through channels 154 and projects from plu 150.
- wiring 148 extends to programmable logic control (PLC) 34 ( Figure 1) that provides electricity for selectively heating filaments 146.
- PLC programmable logic control
- extra channels 144 and 154 can be used to secure plug 150 to body 138.
- a bolt can be passed through a corresponding channel 154 on plug 150 and then screwed into the threaded channel 144 so as to secure plug 150 to body 138.
- Other connecting assemblies as understood by those of skill in the art can also be used.
- plug 150 can be formed directly on body 138 or body 138 can be frictionally held within a corresponding slot formed on plug 150.
- a plurality of spaced apart sockets 143 are formed on side wall 123 so as to extend through outer housing 106 and at least a portion of insulation layer 108.
- Sockets 143 have a configuration complementary to plugs 150.
- An aperture 145 extends through inner housing 110 in alignment with each socket 143.
- Apertures 145 have a configuration complementary to the transverse cross sectional configuration of body 138.
- a plurality of substantially triangular apertures 166 ( Figure 3) extend through partition wall 118 in alignment with apertures 145.
- baffles 126 remain removably disposed within sockets 134 and apertures 145, 166. In this configuration baffles 126 can be accessed and removed from outside of perimeter wall 117. As such, baffles 126 can be individually removed, exchanged and/or replaced. Baffles 126 can also be accessed for a number of tasks such as cleaning and temperature testing.
- baffles 126 may be integrally formed with or otherwise rigidly secured to side wall 123 and/or partition wall 118.
- some of baffles 126 are rigidly secured to side wall 123 and partition wall 118 so as to provide structural support to modular unit 102 while other baffles 126 can be removably mounted.
- some baffles 126 can be heated while others are not.
- some baffles 126 can be designed without a collection channel 149. See for example, Figures 5B-5E.
- select baffles are designed for heating and/or mixing.
- select baffles can be designed with a collection channel 149 but may not be heated.
- These baffles are designed for mixing, the feed material and collecting vapors.
- a single retort can thus be designed having a number of different types, sizes and configurations of baffles.
- baffle 162 comprises a tubular body 163 having, a top surface 135 A and an opposing bottom surface 137A. Each tubular body 163 extends between partition wall 118 and side wall 123.
- Body 163 also has an interior surface 165 that bounds a compartment 160 extending along the length of body 163.
- One embodiment of the means for heating baffle 162 comprises inserting body 138 into compartment 160 of baffle 162 and heating body 138 using one of the embodiments as previously discussed.
- body 138 used in conjunction with plug 150 can be removably disposed within compartment 160.
- body 138 can be selectively removed for replacement, cleaning, inspection or the like even during operation of retort 32.
- body 138 rests directly against top surface 135A for optimal heating of top surface 135A.
- a gap 164 is formed between body 138 and bottom surface 137A. Gap 164 provides an insulation layer between body 138 and bottom surface 137A to prevent super heating of the oil vapors that are collected within collection channel 149.
- a physical insulation layer can be disposed between body 138 and bottom surface 137A.
- body 138 can comprise any number of alternative configurations of heating elements that are capable of heating baffle 162.
- Baffle 162 may be comprised of any material such as stainless steel, cast iron, ceramic,, graphite, or the like that is capable of withstanding the operating loads and temperatures.
- the triangular apertures 166 formed on partition wall 118 are further depicted in Figure 10. As shown therein, each aperture 166 has an inverted substantially V-shaped top edge 151 and a substantially flat bottom edge 153. Top edge 151 has a contour complementary to top surface 135 of baffle 126.
- baffle 126 is supported on bottom edge 153 while a close tolerance if formed between top surface 135 of baffle 126 and top edge 151 of aperture 166.
- the residual of aperture 166 not occupied by baffle 126 forms an opening 170 extending through partition wall 118. Opening 170 enables, collection channel 149 of baffle 126 to communicate through partition wall 118.
- the portion of bottom edge 153 not directly supporting baffle 126 is tapered to a fine edge so as to prevent the unwanted buildup of dust or particles on bottom edge 153.
- Figure 10 also discloses one configuration for an ordered array of baffles
- Figure 10 is a side view of partition wall 118 showing apertures 166 disposed in staggered rows.
- a first row 185 is shown where apertures 166, and thus baffles 126, are horizontally separated by a distance Di.
- distance Di is in a range between about 5 cm to about 15 cm and is typically equal to the width w of body 138. Other dimensions can also be used.
- a second row 187 of apertures 166/baffles 126 having the same horizontal separation as first row 185 are vertically disposed below first row 185 by a vertical distance D 2 .
- Distance D extends, between the bottom of first row 185 and the top of second row 187.
- distance D 2 is in a range between about 5 cm to about 40 cm with about 5 cm to about 10 cm being more common, although other dimensions can also be used. Although not required, in one embodiment the distance D 2 is equal to the height h of baffles 126.
- Apertures 166 in second row 187 are centrally disposed between apertures 166 of first row 185.
- a third row 189 of apertures 166 is vertically disposed below second row 187 so as to be in alignment with apertures 166 of first row 185. This staggering of alternate rows is repeated for additional rows of apertures 166.
- half apertures 174 are formed at alternating ends of rows 185, 187, and 189.
- a half baffle 176 which comprise one leg of baffle 126, is disposed within each half aperture 174.
- Half baffles 176 can be heated or not heated. In either event, half baffles 176 periodically deflect the feed material away from front wall 119 and back wall 121 so as to engage against the next lower baffle 126.
- the half baffles 176 mitigate the vertical movement of vapors up the wall thus bypassing the collectors.
- baffles 126 As mentioned above and discussed below in greater detail, during operation the feed material is passed down through heating chamber 120 so that the feed material contacts and passes over baffles 126. As the feed material is heated by baffles 126, the oil and oil precursors are converted into gases and/or oil vapors that are subsequently collected.
- the size, configuration, spacing, staggering, and other parameters of baffles 126 are designed in part to ensure that the feed material is uniformly heated and mixed as it travels down retort 32.
- the parameters for baffles 126 are also set to ensure that the feed material can freely flow down through the baffles 126 under the force of gravity at a desired speed without significant stacking, clogging, or fusing together.
- baffles 126 For example, by having the distance Di between baffles 126 equal to the width w of baffles 126 and then by staggering the rows of baffles as discussed above, there are no straight paths down through baffles 126. Rather, the feed material is required to continually contact and move around baffles 126 to obtain the desired heating. Furthermore, by vertically spacing the rows of baffles 126 as discussed above, the moving and mixing of the feed material is substantially constant. As a result, the feed material is uniformly heated and no two particles are left in contact for a sufficient period of time to permit them to fuse together so as to form a clinker. Finally, the parameters for baffles 126 also prevent portions of the feed material particles from stacking or otherwise becoming stagnant within retort 32.
- alternating rows of baffles 126 can be placed so that the outer ends 230 of baffles 126 are vertically aligned as opposed to overlapping.
- alternating rows of baffles 126 can be positioned so that a small vertical gar> 167 is formed between outer ends 230 of adjacent vertical rows of baffles.
- Gap 167 has a width smaller than the smallest diameter of the feed material.
- baffles 126 need not extend between opposing side walls but can extend as a cantilever from one side wall. Likewise, different baffles 126 can extend from different side walls in a cantilever fashion. Each baffle 126 can serve the same function or different baffles 126 can serve different functions. For example, some baffles 126 can be designed for heating while other are designed to collect vapors. In the various embodiments of the present invention, it is also envisioned that the need not all extend in the same direction. For example, some baffles can be rotated horizontally so as to be 90° or other angles relative to other baffles.
- FIG. 13 depicted in Figure 13 is another alternative embodiment of a retort 32A having opposing side walls 178 and 179 bounding a heating chamber 120A.
- Baffles 175 are vertically staggered and projecting from alternating side walls. Baffles 175 extend toward each other so that the free ends are vertically aligned or overlapping. Accordingly, as the feed material passes through heating chamber 120, the feed material is forced to travel around each of the baffles 175 so as to provided substantially uniform mixing of the feed material.
- the baffles 175 are heated as discussed above.
- means are provided for heating the feed material within the heating chamber of the retort.
- the means for heating comprises the various means for heating the baffles as discussed herein.
- the means for heating comprises the various means for heating the side wall of the retort as discussed herein.
- various pipes or tubes can be disposed within the heating chamber.
- Heated gasses or liquids could then be passed through the pipes or tubes so as to heat the feed material.
- Electrical conduits can also be disposed directly within the heating chamber.
- heated gas can be pumped into heating chamber so as to heat the feed material.
- the present invention also envisions that other conventional systems can be used for heating the feed material within the heating chamber.
- any one or combinations of the above systems can be used to heat the feed material within the heating chamber so as to extract the oil vapor and other gases.
- vapor chamber 122 communicates externally through a vapor port 128 extending through side wall 123.
- a collection plate 130 is disposed within vapor chamber 122.
- Collection plate 130 has a top surface 129 and an opposing bottom surface 131 each extending between opposing side edges 132 and 133. Side edges 132 and 133 extend to and can connect with front wall 119 and back wall 121, respectively. Collection plate 130- also includes an outer edge 134 and an inner edge 136 and is disposed at an inside angle ⁇ relative to the horizontal ( Figure 14). In one embodiment the angle ⁇ is in a range between about 50° to about 75° with about 60° to about 65° being more common, although other angles can also be used. Outer edge 134 of collection plate 130 extends to and can be coupled with side wall 123 at a location at or below vapor port 128.
- Inner edge 136 is disposed below the bottom end of partition wall 118 so that a return slot 210 is formed between partition wall 118 and inner edge 136 of collection plate 130.
- Return slot 210 typically has a height in a range between about 1 cm to about 6 cm and provides fluid communication between heating chamber 120 and vapor chamber 122.
- formation of retort 32 entails vertical stacking of modular units 102 in the form of a tower.
- means are provided for joining adjacent modular units 102.
- a flange 111 outwardly projects at top end 113 and bottom end 115 of each unit 1 2.
- Flanges 111 may be formed integrally with outer housing 106 or attached thereto.
- flanges 111 from adjacent modular units 102 are connected by means known in the art such as, but not limited to, bolting, clamps, screws and like.
- a sealing gasket (not shown) can also be disposed between each modular unit 102 so as to prevent the leaking of air therebetween.
- insulation layer 108 extends below outer housing 106 and inner housing 110 so as to form a tenon 112.
- insulation layer 108 extends below outer housing 106 and inner housing 110 so as to form a mortise 114.
- each modular unit 102 is configured to be received within the corresponding mortise 114 of the adjacent modular unit 102 so as to provide a secure engaging fit between modular units 102 when stacked. It is appreciated that any number of conventional brackets, flanges, clamps, connectors or the like can be used to secure adjacent modular units 102 together.
- the assembled modular units 102 are typically secured to a framework (not shown), such as a building or support frame, to enhance support and structural stability.
- the framework is independent of modular units 102 and assembled during or after retort 32 is assembled.
- the framework is formed integrally with the modular units 102 and is connected to the framework of an adjacent modular unit 102 to form the retort stack.
- Retort 32 formed by the stacked modular units 102, functions and has features substantially the same as a single modular unit 102.
- retort 32 also includes a partition wall 118', a heating chamber 120', and a vapor chamber 122' which simply comprise the aligned partition walls 118,. aligned heating chambers 120, and aligned vapor chambers 122, respectively, of the stacked modular units 102.
- Elements which are common between retort 32 and a single modular unit 102 will be identified by like reference characters with the common reference characters for retort 32 further including an '"".
- retort 32 is shown and described as being comprised of multiple modular units 102, retort 32 can be formed with an integral continuous perimeter wall 117' or can be formed from any number of discrete members that are removably or permanently secured together.
- heating chamber 120' extends in a continuous fashion the full height of retort 32.
- Feed mechanism 30, as shown in Figure 2 is mounted directly above heating chamber 120' so as to selectively feed the feed material into the top of heating chamber 120'.
- discharging mechanism 33 is disposed at the base of retort 32 in communication with heating chamber 120'.
- Discharge mechanism 33 expels the spent feed material from heating chamber 120' at a desired rate so as to produce the flaw of feed material through heating chamber 120'.
- Discharge mechanism 33 is typically designed so that it permits the continuous extraction of spent material while preventing any significant exterior air flow from entering heating chamber 120'.
- vapor chamber 122' is partitioned at spaced intervals by collection plates 130. Vapor chamber 122' thus comprises a plurality of vapor compartments 212 which are identified by the dashed lines. Each collection compartment 212 is bounded above by bottom surface 131 of a collection plate 130 and is bounded below by top surface 129 of a collection plate 130.
- each collection compartment 212 has a corresponding vapor port 128 and return slot 210. It is also appreciated that the top and bottom of vapor chamber 122' are covered so as to prevent the escape of oil vapors thereat. Operation of retort 32 initially entails filling heating chamber 120' with the feed material. Although the feed material could simply be feed into the top of empty heating chamber 120' by feed mechanism 30, the initial feed material would rapidly fall down through the empty heating chamber 120' striking baffles 126. As a result, the initial feed material would at least partially break apart spreading dust and other fine particles within retort 32.
- heating chamber 120' is initially filed with an inert fill material.
- the fill material is clean and sufficiently hard that it will not break apart as it is dispensed into heating chamber 120', such aaby feed mechanism 30.
- the fill material will not break down or give off unwanted vapors as it is subject to the processing of retort 32.
- fill material can comprise utelite, vermiculite, pearllite or other forms of ceramic.
- Other hard and inert materials, such as pieces of metal, graphite, or the like, can also be used.
- the fill material is typically within the same size range as the feed material but can also be larger or smaller.
- heating chamber 120' is also filled with an inert heavy gas, such as carbon dioxide or nitrogen, so as to substantially remove all of the air, and more importantly oxygen, from heating chamber 120'.
- the air is removed so that as the fill material is fed into heating chamber 120', the heat from baffles 126 does not cause the feed material to combust.
- discharge mechanism 33 begins to discharge the fill material from the bottom of heating chamber 120'.
- feed mechanism 30 begins to dispense the feed material into the top of heating chamber 120'. As a result, the feed materials beings to descend down through heating chamber 120'.
- both feed mechanism 30 and discharge mechanism 33 operate to either feed or discharge the feed material while substantially preventing the free flow of external air into heating chamber 120'. Due to the lack of oxygen, the feed material cannot combust within heating chamber 120'.
- the rate at which the fill material, and subsequently the spent feed material, is extracted from heating chamber 120' by discharge mechanism 33 determines the flow rate of the feed material through heating chamber 120'. This flow rate is regulated so that the feed material continuously flows through retort 32 without formation of any stationary pocket of feed material.
- the feed material flows through heating chamber 120' at a rate of about 908 kg/hour (2,000 lbs per hour). This equates to a vertical travel of about 15 cm per minute (six inches per minute).
- a full-size retort 32 will process about 765 cubic meters per day (1,000 cubic yards per day) of feed material.
- the feed material travels down through heating chamber 120', the feed material passes over and around the array of baffles 126.
- the surrounding feed material and the internal structure of heating chamber 120' forces the descending feed material to follow generally curved paths, such as approximately helical paths, sinusoidal paths, undulating paths, irregularly meandering paths, and/or other curved paths.
- the dynamic flow of the feed material through baffles 126 uniformly mixes the feed material and minimizes any constant contact by two feed material particles descending through heating chamber 120'.
- baffles 126 By minimizing constant contact of particles, the formation of clinkers, where two or more particles bind together, can be minimized or eliminated.
- the formation of clinkers can block the flow the feed material through baffles 126 and reduce efficiency of oil vapor extraction.
- a portion of the feed material directly contacts and moves along the heated top surface 135 of the first row of baffles 126.
- all of baffles 126 within retort 32 are the same temperature or are within a temperature range of between about 400° C to about 600° C.
- the feed material is introduced at the elevated temperature from dryer 22 and then is continually heated as it descends within heating chamber 122' until the feed material is about 400° C to about 600° C at the bottom end of heating chamber 122'.
- the amount of water vapor within heating chamber 122' is minimized.
- Significant amounts of water vapor are detrimental in that the water vapor can combine with dust particles to form mud balls or otherwise aggregate feed materials particles which can then block the flow of the feed material.
- top surface 135 of baffles 126 that portion of the feed material rapidly absorbs energy which is used for heating the feed material and/or converting the oil, oil precursors, and other organics into- oil vapor and hydrocarbon gases.
- baffles 126 As the feed material in direct contact with top surface 135 passes over baffles 126, the feed material freely rolls underneath the first row of baffles 126. The heated feed material directly below baffles 126 is exposed to an open space 152 in vertical alignment with collection channel 149. As a result of the staggering of rows of baffles 126, the other feed material particles that did not directly contact the first row of baffles 126 are now aligned for contacting the next row of heated baffles 126. Thus, the feed material moves through the array of baffles 124 in a fluidized manner so that the feed material is continually mixed and periodically contacts heated baffles 126. As a result, the feed material has a substantially uniform temperature at each vertical stage of heating chamber 120'.
- uniform heating of the feed material ensures optimal extraction of the oil vapor and hydrocarbon gases from all of the feed material. Furthermore, uniform heating of the feed material along heating chamber 120' ensures that substantially the same types of oil vapor and hydrocarbon gas are being emitted at the same vertical stages. This enables at least partial fractional vaporization of the oil vapors and hydrocarbon gases at the time of formation. For example, as the feed material is heated, the feed material initially gives off any remaining moisture in the form of water vapor. The feed material remains at a temperature at about 100° C until all of the moisture is removed. Once the moisture is gone, the feed material increases in temperature stages as different types of oil vapors are generated.
- the different types of oil vapors that are generated at successfully higher temperatures are typically: light naphthalene, heavy naphthalene, light kerosene, heavy kerosene, light diesel, heavy diesel, and residual gas oil.
- hydrocarbon gases continue to form such as butane, methane, and propane.
- a gas jet 147 ( Figure 14) aligned with each collection channel 149 can be used to push or otherwise direct the gases and oil vapor into collection compartment 212.
- a gas jet 147 ( Figure 14) aligned with each collection channel 149 can be used to push or otherwise direct the gases and oil vapor into collection compartment 212.
- a small amount of dust is generated. This dust if often carried by the gas and oil vapor into vapor compartments 212.
- means are provided for reducing dust in the gas and oil vapor prior to removal of the gas and oil vapor from vapor chamber 122'.
- vapor compartments 212 are bounded above and below by collection plates 130 as discussed above.
- the velocity of the gas and oil vapor decreases causing at least a portion of the dust to settle within collection compartment 212 under the force of gravity onto top surface 129 of the lower collection plate 130.
- the dust slides down collection plate 130 and back into heating chamber 120' through the corresponding return slot 210.
- the dust may again become entrained in the gas or oil vapor as it falls within heating chamber 120', at least a majority of such dust will now enter the next lower collection compartment 212.
- the dust continues to travel down through the vapor compartments 212 until it is removed through discharge mechanism 33.
- collection plates 130 comprise a metal planar sheet that covers the entire collection compartment 212. Alternatively, collection plates 130 may cover a portion or majority of collection compartment 212. During assembly, collection plates 130 may be provided separate from modular units 102 and subsequently attached thereon. Alternatively, collection plates 130 may be constructed at the same time as inner housing 110 and partition wall 118 and maintained as a permanent fixture of modular units 102. Collection plates 130 may be connected to inner housing 110 and/or partition wall 118 by any means known in the art such as, but not limited to, welding, bolting, riveting, soldering, and the like.
- collection plate 130 can be connected directly to partition wall 118 and a return slot can be formed through collection plate 130.
- Collection plates 130 can also be used in fractionalizing the gas and oil vapors generated from the feed material. As previously discussed, the uniformly heated feed material generates different oil vapors and hydrocarbon gases at different vertical stages within heating chamber 120'. Accordingly, by selectively placing collection plates 130 at different vertical regions where the different gases and oil vapors are generated, one or more collection compartment 212 can be used to primarily collect a discrete gas or oil vapor. Each separated gas or oil vapor is then passed through the corresponding vapor port 128 to a discrete separator 36 for further processing as discussed below.
- each collection plate 130 can be different for each modular unit 102 based on the feed material, processing parameters, and desired fractional vaporization.
- a single modular unit 102 can have two or more vapor ports 128 and collection plates 130 while in other embodiments vapor ports 128 and collection plates 130 can be eliminated from at least some of modular units 102.
- Process logic control (PLC) 34 as shown in Figure 1 can be used to control the temperature at various levels of retort 32.
- Baffles 126 are connected at least indirectly to process logic control 34 to control the temperature of each baffle 126.
- Process logic control 34 can include feedback loops in order to adjust the temperature of the baffles to obtain a certain temperature profile.
- Other process variables can also be controlled by process logic control 34.
- process logic control 34 can control the flow rate of feed material through retort 32 in order to produce the optimum yield.
- process logic control 34 can either increase the temperature of baffles 126 and/or slow down the flow of feed material through heating chamber 120'. It is appreciated that all of the components of retort system 10 can be connected with process logic control 34. In turn, process logic control 34 can be positioned on-sight or off-sight for remote operation of retort system 10. Depicted in Figure 16 is an alternative embodiment of a modular unit 214. Like elements between modular units 102 and 214 are identified by like reference characters.
- Modular unit 214 comprises a first heating chamber 120A and a second heating chamber 120B that are separated by a central vapor chamber 122.
- a first partition wall 118A is disposed between first heating chamber 120 A and vapor chamber 122 while a second partition wall 118B is disposed between second heating chamber 120B and vapor chamber 122.
- An array of baffles 126 are disposed in each heating chamber 120 A and 120B.
- Collection plate 130 can be positioned within vapor chamber 122 so as slope toward heating chamber 120A or 120B. Furthermore, collection plate 130 can have a substantially inverted V-shaped transverse cross section so that one side slopes toward heating chamber 120 A while the other side slopes toward heating chamber 120B.
- modular unit 214 increases production output while minimizing material cost and required operating space.
- two or more modular units 214 can be stacked to form a retort.
- an integral retort can be formed having the configuration of modular unit 214.
- retort 32 and the alternatives thereto can be used independently or in parallel with one or more other retorts.
- a facility can be established having desired production rates based on the number of retorts formed.
- discharge mechanism 33 comprises a hopper 196 operating in conjunction with a rotary valve 33B.
- Rotary valve 33B is substantially the same as rotary valve 30A and operates to remove the spend feed material while preventing the free flow of air into heating chamber 120'.
- sliding grates 35 as previously discussed as an alternative to rotary valve 30A can be used.
- Other alternatives for rotary valve 30A can also be used.
- discharging mechanism 33 can also be provided with a liquid extraction outlet (not shown) for any liquid oil that condenses in heating chamber 120'.
- the feed material comprises Green River oil shale
- the spent material is discharged at a temperature of about 400° C to about 600° C.
- heat exchanger 38 is formed with hopper 196 of discharge mechanism 33.
- hopper 196 has an outer sidewall 198 and an inner sidewall 200.
- a heating exchange tube 202 is coiled or otherwise disposed between the outer sidewall 198 and inner sidewall 200. Any suitable heat exchange fluid is run through exchange tube 202 so that the fluid absorbs the heat energy from the spent feed material as the spent feed material passes through hopper 196.
- the fluid from heat exchange tube 202 can then be used for other parts of the retort system, such as, for example, in a dryer 22 at the entrance of retort 32 or can be used to produce electricity to operate retort system 10.
- hopper 196 feeds the spent feed material into a pipe 220 having a boundary wall 222.
- a heat exchange tube 224 is coiled within boundary wall 222 so as to encircle pipe 220.
- An auger 226 is disposed within pipe 220 for selectively moving the spent material along pipe 220. Accordingly, as the spent feed material is moved along pipe 220, the heat energy from the spent feed material is transferred to the heat exchange fluid passing through exchange tube 224.
- the spent feed material can be passed through multiple heat exchangers or other conventional energy recovery systems.
- the cooled spent feed material leaving heat exchanger 38 is further used for power generation by being burned.
- Spent oil shale feed material can have an energy value of about 1,400 BTU/lb. Such material can thus be burned to operate a conventional power generating, plant, such as a steam power generation plant. In turn, the generated electricity can be sold or used to operate retort system 12.
- the hot spent feed material can be directly burned for power generation without passing through a heat exchanger. The higher temperature of the spent feed would help facilitate complete combustion of the carbon.
- the spent material is typically processed to extract any minerals retained therein.
- the spent material in the mahogany shale located in Vernal, Utah, aluminum and sodium carbonate are found in the spent material.
- the aluminum can be processed from the spent material to produce a low-cost pure aluminum product which can be sold on the market.
- additional sodium carbonate can be extracted from the spent feed material.
- the spent material at the exit of retort 32 is broken up into finer particles to allow for washing of the spent material to extract these valuable minerals.
- the resulting spent feed material also have good filtration properties.
- the spent material can be used as a fill material, for example in mines or landfills, to prevent leaching of undesired materials such as heavy metals. IX.
- retort 32 may be designed to substantially fractionalize the oil vapor so that different grades of oil vapor may be collected in different collection chambers 122. For example, as previously discussed, oil vapors of light naphthalene, heavy naphthalene, light kerosene, heavy kerosene, light diesel, heavy diesel, and residual gas oil can be separately collected at the time of formation from the feed material.
- the separately collected streams of the different grades of oil vapor comprise at least 60%, more commonly at least 75% and preferably at least 90% by volume the primary grade of the oil vapor being collected.
- secondary components such as water vapor, hydrocarbon gases and/or dust can also mixed with the oil vapor. This combination of components is referred to herein as "smoke.”
- the smoke can be further processed as separate streams, thus requiring discrete separators and condensers for each stream, or one or more of the streams of smoke can be combined prior to further processing. In order to create a more refined oil product, it is desirable to initially separate out any dust and water vapor from the oil vapor.
- smoke collected in a vapor chamber 122 is drawn out in the form of a stream through vapor port 128 of retort 32 by a vacuum 180.
- the smoke is delivered to a scrubber 182.
- Scrubber 182 traps suspended particles by direct contact with a spray of water or other liquid.
- scrubber 182 comprises a spray tower.
- a suitable liquid spray may consist of water or an oil based material, for example, diesel, gasoline, or oil generated from the shale itself.
- the spray liquid is a liquid that is readily found in the present retort and can be separated from the liquid product and recycled back into the system.
- the liquid product containing the spray liquid and dust particles from scrubber 182 is sent to centrifuge 184 to separate the dust particles from the spray liquid.
- Other separation techniques may also be used to separate the spray liquid from the dust such as, but not limited to, cyclonic separation, filtration methods, adso ⁇ tion methods and the like.
- the spray liquid can be recycled back to scrubber 182.
- the dust can be sent to the pelletizer and recycled through the system as feed material. It will be appreciated that the number of sprays in scrubber 182 will depend on system design requirements.
- a plurality of scrubbers 182 may be used in series to remove dust from the oil vapor. Scrubber 182 is merely representative of this step. Depicted in Figure 18 is a modified method and system for the separation of the dust particles.
- a first step 250 the smoke passing, out of vapor chamber 122 is cooled to or near the bubble point of the mixture of hydrocarbons in the gaseous phase.
- This cooling can be accomplished in a number of ways.
- the cooling can be accomplished by a heat exchanger, by introducing a cooled gas stream, by spraying liquid hydrocarbons into the smoke so that a portion of the liquid hydrocarbons evaporate to cool the smoke, or other conventional techniques.
- a liquid hydrocarbon stream is introduced so as to produce liquid droplets that do not evaporate under the temperature and pressure present in the smoke.
- the liquid droplets are formed by adding the liquid hydrocarbon stream through a spray nozzle or atomizer.
- the droplets can also be formed through the application of a centrifugal force.
- a suitable liquid spray may consist of water or any oil based material, for example, diesel gasoline.
- the spray liquid is a liquid that is readily found in the present retort and can be separated from the liquid product and recycled back into the system.
- the gas stream is accelerated.
- the acceleration increases the impact between the dust particles and liquid droplets.
- the acceleration can be accomplished in a number of different ways. For example, acceleration can be produced by reducing the cross sectional area of the line through which the smoke is traveling, changing the direction of flow, or applying a centrifugal force.
- step 256 the wetting dust particles are separated from the remainder of the gas stream. This separation can be accomplished using any number of conventional techniques such as gravity settling, centrifugal or acceleration separation, filtration, or the like. In turn the wetted particles can be reprocessed as discussed above while the remaining, gas stream is processed as discussed below.
- Condenser 186 preferably comprises one of various packing materials, for example, ceramic balls, metal caps, or steel wool. Preferably, the packing material is cooled with an oil-based liquid. This prevents the packing material from becoming too hot and forming undesirable coke products.
- the oil vapors and water vapors condense into a liquid product and are drawn off the bottom of the condenser.
- the liquid oil and liquid water can be separated by known decanting or distillation processes illustrated generally as separator 188.
- the liquid oil contains about 2% nitrogen compounds. These nitrogen compounds can be further extracted through processes known in the art to produce pure nitrogen products at separator 188.
- the gas oil product contains pyridine nitrogen, which contains anti-strip constituents that make this extracted product a high quality asphalt additive. This pyridine nitrogen can be extracted through known solvent extraction processes. Conventional oil extraction processes lead to the abstention of nitrogen- containing condensed oil, and this nitrogen content makes subsequent oil refining difficult.
- any combustible gas not condensed are drawn off the top of the condenser by vacuum 190.
- the composition of the combustible gas depends on the type of feed material. Methane and propane with inert gases are usually the main components of the combustible gas that is generated in retort 32. This combustible gas can be combusted to generate power.
- Power generation is a preferred use of the combustible gas that is released in the retort, and this generated power can be recycled in the process of retort system 12, such as to generate the heat and/or the electric power that are supplied to retort 32 or to any other device in retort system 12.
- This power may also be sold on the market.
- the uncondensed oil vapors may be collected and separated to be sold on the market.
- the oil produced from this process is about 10% naphthalene, 40% kerosene, 40% diesel and 10% gas oil.
- the extracted oil comprises premium grade oil that has been analyzed and determined to be of higher quality than Wyoming Sweet.
- separator 36 comprises a cyclonic separator 192 which separates the water vapor from the oil vapor and dust.
- the dust and oil vapor are then sent through an electrostatic precipitator 194.
- the electrostatic precipitator 194 separates the dust from the oil vapor.
- a scrubber can be used to separate the dust from the oil vapor.
- the oil vapor then goes to a condenser 186.
- the liquid oil can then be further processed by separator 188 into its constituent parts. Combustible gas is drawn out by a vacuum 190 and processed for power.
- the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics.
- the described embodiments are to be considered in all respects only as illustrative and not restrictive.
- the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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Abstract
Description
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Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BRPI0507259-0A BRPI0507259A (en) | 2004-01-29 | 2005-01-21 | diffuser for use in heating and mixing a feedstock within a retort, retort heater for processing feedstock and method for processing a feedstock |
CN200580003596.XA CN1993162B (en) | 2004-01-29 | 2005-01-21 | Retort heating apparatus and methods |
EP05711783A EP1973621A4 (en) | 2004-01-29 | 2005-01-21 | Retort heating apparatus and methods |
AU2005208782A AU2005208782A1 (en) | 2004-01-29 | 2005-01-21 | Retort heating apparatus and methods |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/767,838 US7264694B2 (en) | 2004-01-29 | 2004-01-29 | Retort heating apparatus and methods |
US10/767,871 US7229547B2 (en) | 2004-01-29 | 2004-01-29 | Retort heating systems and methods of use |
US10/767,838 | 2004-01-29 | ||
US10/767,871 | 2004-01-29 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2005072256A2 true WO2005072256A2 (en) | 2005-08-11 |
WO2005072256A3 WO2005072256A3 (en) | 2006-06-08 |
Family
ID=34830627
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2005/004794 WO2005072481A2 (en) | 2004-01-29 | 2005-01-21 | Retort heating systems and methods of use |
PCT/US2005/001952 WO2005072256A2 (en) | 2004-01-29 | 2005-01-21 | Retort heating apparatus and methods |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2005/004794 WO2005072481A2 (en) | 2004-01-29 | 2005-01-21 | Retort heating systems and methods of use |
Country Status (4)
Country | Link |
---|---|
EP (2) | EP1973622A2 (en) |
AU (1) | AU2005208782A1 (en) |
BR (1) | BRPI0507259A (en) |
WO (2) | WO2005072481A2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014130486A1 (en) | 2013-02-19 | 2014-08-28 | Sri International | Hybrid indirect/direct contractor for thermal management of counter-current processes |
WO2017005680A1 (en) * | 2015-07-06 | 2017-01-12 | Sabic Global Technologies B.V. | Fluid distribution in a fluidized bed reactor |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2814587A (en) * | 1954-01-25 | 1957-11-26 | Shell Dev | Method and apparatus for recovering shale oil from oil shale |
US2786125A (en) * | 1954-10-08 | 1957-03-19 | Wiegand Co Edwin L | Electric heaters |
US3377266A (en) * | 1964-10-12 | 1968-04-09 | Ivan S. Salnikov | Electrothermal pyrolysis of oil shale |
US4165216A (en) * | 1977-03-23 | 1979-08-21 | Enerco, Inc. | Continuous drying and/or heating apparatus |
EP0134530A3 (en) * | 1983-07-29 | 1985-09-11 | Japan Australia Process Coal Company | A process for removing mineral inpurities from coals and oil shales |
US4601812A (en) * | 1985-01-07 | 1986-07-22 | Conoco Inc. | Oil shale retorting process |
US4948468A (en) * | 1989-02-22 | 1990-08-14 | The New Paraho Corporation | Oil shale retort apparatus |
-
2005
- 2005-01-21 WO PCT/US2005/004794 patent/WO2005072481A2/en active Application Filing
- 2005-01-21 WO PCT/US2005/001952 patent/WO2005072256A2/en active Application Filing
- 2005-01-21 EP EP05713602A patent/EP1973622A2/en not_active Withdrawn
- 2005-01-21 EP EP05711783A patent/EP1973621A4/en not_active Withdrawn
- 2005-01-21 AU AU2005208782A patent/AU2005208782A1/en not_active Abandoned
- 2005-01-21 BR BRPI0507259-0A patent/BRPI0507259A/en not_active Application Discontinuation
Non-Patent Citations (1)
Title |
---|
See references of EP1973621A4 * |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014130486A1 (en) | 2013-02-19 | 2014-08-28 | Sri International | Hybrid indirect/direct contractor for thermal management of counter-current processes |
EP2959252A4 (en) * | 2013-02-19 | 2016-03-16 | Stanford Res Inst Int | Hybrid indirect/direct contractor for thermal management of counter-current processes |
US9920964B2 (en) | 2013-02-19 | 2018-03-20 | Sri International | Hybrid indirect/direct contactor for thermal management of counter-current processes |
WO2017005680A1 (en) * | 2015-07-06 | 2017-01-12 | Sabic Global Technologies B.V. | Fluid distribution in a fluidized bed reactor |
US10207239B2 (en) | 2015-07-06 | 2019-02-19 | Sabic Global Technologies B.V. | Fluid distribution in a fluidized bed reactor |
Also Published As
Publication number | Publication date |
---|---|
BRPI0507259A (en) | 2007-06-26 |
WO2005072481A3 (en) | 2006-01-26 |
WO2005072481A2 (en) | 2005-08-11 |
AU2005208782A1 (en) | 2005-08-11 |
EP1973621A4 (en) | 2010-08-04 |
WO2005072256A3 (en) | 2006-06-08 |
EP1973622A2 (en) | 2008-10-01 |
EP1973621A2 (en) | 2008-10-01 |
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