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US20090120844A1 - Process for simultaneous recovery and cracking/upgrading of oil from solids - Google Patents

Process for simultaneous recovery and cracking/upgrading of oil from solids Download PDF

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Publication number
US20090120844A1
US20090120844A1 US12/300,549 US30054907A US2009120844A1 US 20090120844 A1 US20090120844 A1 US 20090120844A1 US 30054907 A US30054907 A US 30054907A US 2009120844 A1 US2009120844 A1 US 2009120844A1
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United States
Prior art keywords
oil
sand
solids
cracking
upgrading
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Abandoned
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US12/300,549
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English (en)
Inventor
Olav Ellingsen
Bjarte Sorebo Ellingsen
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TARBLASTER AS
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TARBLASTER AS
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Assigned to TARBLASTER AS reassignment TARBLASTER AS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ELLINGSEN, OLAV, SOREBO ELLINGSEN, BJARTE
Publication of US20090120844A1 publication Critical patent/US20090120844A1/en
Abandoned legal-status Critical Current

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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
    • C10G1/02—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation

Definitions

  • the present invention is related to a process for recovery of oil from tar sand (also called oil sands) and/or oil shale and upgrading the oil in the same process.
  • Tar sand is found in enormous quantities in a number of countries, the greatest resources are found in Canada and consist of heavy oil and sand in natural resources in different depths. These resources have been the subject of intensive research in an effort to develop technologies for recovery of the oil from the sand. Thus, a number of different technologies exist.
  • Alberta's most important mineral resources are oil and natural gas, and they account for about 90 percent of Alberta's income from mining. Alberta produces approximately two-thirds of Canada's oil and more than three-quarters of its natural gas. Nearly half of Alberta's oil is mined from vast oil sands, which are deposits of a heavy crude oil called bitumen. Alberta's oil sands represent the largest known deposits of bitumen in the world. The oil sands occur in three major areas of the province: the Athabasca River Valley in the northeast, the Peace River area in the north, and the Cold Lake region in east central Alberta. Bitumen is more costly to mine than conventional crude oil, which flows naturally or is pumped from the ground. This is because the thick black oil must be separated from the surrounding sand and water to produce a crude oil that can be further refined.
  • the bitumen which contrary to normal crude found in deep reservoir, does not have the same light fractions as these, have been evaporated off over thousands of years.
  • the bitumen thus consists of heavy molecules with a density exceeding 1.000 kg/dm 3 (less than 10 API) and a viscosity 1000 times higher than light crude.
  • the tar sand contains sulphur over 4% by weight and hundreds of ppm with heavy metals.
  • the content of organic matter in tar-sand can range from 5% by weight up to 20% by weight, and thus extraction of oil from tar sand involves huge mass transport.
  • bitumen Because of the composition of the bitumen, it has to be upgraded before it can be refined in a refiner as light crude.
  • oil shale is shale containing organic matter known as keorgens which can not be washed or dissolved as for the bitumen in tar sand.
  • keorgens organic matter
  • tar sand oil shale contains a number of unwanted constituents, which cause environmental constrains.
  • technologies for recovering oil from tar sand there exist a number of different technologies for recovering oil from oil shale.
  • the present invention is related to an energy self sustained process where a number of the obstacles with the existing technologies are solved, and which in addition to the oil recovery, upgrades the oil into a lighter product than any other existing technologies, remove sulphur in the order of 40% and heavy metals in the order of 90%.
  • the process disposes of tailings with limited environmental constraints as the inorganic matter (sand) is disposed of in dry condition.
  • the process is a rapid “dry-wet” fluidised process where the sand is mixed into a fluidised reactor fuelled with part of the organic components in the tar sand.
  • the combustion gases strip off the oil from the sand, together they act as a pneumatic carrier transporting sand and its associated gases to a cyclone reactor where the sand is separated from the gas stream, which then is routed to a condenser system.
  • a portion of the condensed oil can be routed back into the stream via an atomisation nozzle for a second cracking whereby the process recovers and upgrades the oil in one operation without the need for upgrading units.
  • combustion gasses and hydrocarbon gasses are accelerated and retarded in a riser of varying diameter.
  • FIG. 1 is a flow diagram of the process described herein;
  • FIG. 2 shows an alternate 10 bbl/day plant
  • FIG. 3 shows a rig layout
  • FIG. 4 shows the rig during testing
  • FIG. 5 shows oil sand, recovered oil, and clean sand from the test.
  • the lay-out of the rig is shown in FIG. 3 .
  • FIG. 4 shows the rig during testing.
  • x s weight part sand (including metals and sulphur), example 80%
  • dt temperature difference between operating temperature and feed temperature of sand K
  • Density of oil recovered from the fluidiser 21 API.
  • Density of oil recovered in the riser 29.3 API. Density of oil drained from the oil condenser: 25.15 API.
  • FIG. 5 shows oil sand, recovered oil and clean sand from the test.
  • A) shows the vertical fluidised reactor which have a fluidising mesh B) positioned a distance from the bottom of the vessel.
  • the space between the bottom and the fluidised mesh B) is a plenum C) which receives the combustion gasses from a combustor D) which can be fuelled either by gas and/or recovered oil.
  • the combustion gasses will heat and fluidise the solids (sand) E) entrained in the reactor A).
  • the pressure from the combustion gasses built up in the reactor will cause the solids and the entrained gasses which consists of combustion gasses, steam and hydrocarbon gasses, to be pneumatically transported through a riser JJ) into a reactor cyclone G) which is so designed that, contrary to ordinary cyclones, the solids are spinning several hundred times in the cylindrical part of cyclone before falling down the conical part H) and back into the fluidiser.
  • superheated steam is injected into the cyclone by the pipe I) to strip off hydrocarbons between the falling solids in the cyclone which falls into the reactor A) via a dip-leg.
  • Oil sand is injected into the reactor A) by a feed system Cc) and Dd).
  • the same amount of sand injected into the reactor A) has to be drained from the reactor. This is done through the pipe arrangement K) where the sand is transported to a fluidising combustor L) where remaining coke is burned off by injection of air through M).
  • the exhaust gasses from L) are passed through a gas cleaning and heat recovery system N) before it is vented to air.
  • the “clean” solids from L) are routed to a solid/liquid heat exchanger O) which is heating cooling water from the heat exchanger Z) delivered from the water supply pump P).
  • the hot water is further transported to a boiler Q) located in the combustor L).
  • the boiler is producing steam where a part of this is routed to a super-heater R) located in the plenum C) of the reactor A).
  • the superheated steam is routed to the injection nozzle S) for steam atomisation of oil, the dip-leg J) on the reactor cyclone H) and the dip-leg T) on the separation cyclone U).
  • the cooled “clean” sand can be disposed of from the heat exchanger O) to a land fill as the sand will be dry and free from any volatile hydrocarbons.
  • Excess steam not being superheated is routed through pipe V) for preheating of feed, process purposes or for generating electricity through a steam turbine system.
  • the gaseous stream is routed to a condenser W) set to about 95 C whereby the main part of the oil gas is condensed into liquid oil.
  • the gas is condensed by the mean of the recovered oil as the oil collected at the bottom of the condenser is pumped by the pump X) through a heat exchanger Z) and cooled by water delivered by the pump P).
  • the cooled oil is routed to the top of the condenser and condenses the incoming oil gasses. As the level of the oil rises in the condenser, the product is drained off through the pipe BB).
  • the non-condensable gasses and steam are routed to a second condenser CC) which is cooled by water injected from the pump P). Condensed water is drained off from the condenser through the pipe DD) and is collected in a settling tank EE). In the settling tank EE), light oil brought over from the oil condenser CC) will be decanted off through the pipe FF) to the product line from the oil condenser W) and routed to a receiver via pipe AA). Water is drained off through the pipe GG) to drain.
  • Non-condensable in the condenser CC is exhausted through the pipe HH) either to air or to a gas cleaning system depending on the local emission requirements.
  • a portion of the product is returned to the riser JJ) through the pipe NN) by a high pressure pump LL) to the atomisation nozzle S) attached to the riser JJ).
  • the atomisation nozzle S) receives the steam for the atomisation of the oil from the super heater R).
  • Excess formed combustion gasses in the reactor which are not needed for the transport of the sand in the riser JJ), can be vented from the reactor via the pipe OO) into a gas cleaning and heat recovery system not shown.
  • the gas or oil supply for the combustion can gradually be turned off whereby the injected air will cause an internal combustion of the formed hydrocarbon gasses in the reactor A) whereby the process will be self sustained by energy extracted from the tar sand itself.
  • the combustor can be fuelled with a part of the recovered oil delivered by the pump LL).
  • One preferred embodiment is to form a part of the riser as a Laval nozzle where the atomisation nozzle(s) S) is(are) located either in the narrowest part of the ejector or where the ejector starts to expand.
  • the entire process is a high intensive thermal process with a high energy density because of the velocity of the gas and sand stream. Because of the velocities in the process, the intensive heat exchange between sand and oil and the low partial pressure of the hydrocarbon gasses caused by the combustion gasses and steam, the process can operate at a temperature in the range of 300-500 C. Apart from reduced thermal stress and energy consumption, this low temperature reduces polymerisation of the cracked product.
  • FIG. 2 shows an illustration of a 10.000 bbl/day plant.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
US12/300,549 2006-05-15 2007-05-10 Process for simultaneous recovery and cracking/upgrading of oil from solids Abandoned US20090120844A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CA2546940 2006-05-15
CA2546940A CA2546940C (en) 2006-05-15 2006-05-15 Process for simultaneous recovery and cracking/upgrading of oil from solids
PCT/NO2007/000170 WO2007133089A1 (en) 2006-05-15 2007-05-10 Process for simultaneous recovery and cracking/upgrading of oil from solids

Publications (1)

Publication Number Publication Date
US20090120844A1 true US20090120844A1 (en) 2009-05-14

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US12/300,549 Abandoned US20090120844A1 (en) 2006-05-15 2007-05-10 Process for simultaneous recovery and cracking/upgrading of oil from solids

Country Status (10)

Country Link
US (1) US20090120844A1 (es)
EP (1) EP2029695A4 (es)
CN (1) CN101484550A (es)
AU (1) AU2007250630B2 (es)
BR (1) BRPI0711480A2 (es)
CA (1) CA2546940C (es)
MX (1) MX2008014630A (es)
NO (1) NO20085143L (es)
RU (1) RU2434049C2 (es)
WO (1) WO2007133089A1 (es)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NO331801B1 (no) * 2009-01-09 2012-04-02 Tarblaster As Fremgangsmate for samtidig utvinning og krakking av olje fra olje/faststoff blandninger
GB201200155D0 (en) 2012-01-06 2012-02-15 Statoil Asa Process

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2534051A (en) * 1946-11-22 1950-12-12 Standard Oil Dev Co Method for fluidized low-temperature carbonization of coal
US2537153A (en) * 1946-10-08 1951-01-09 Standard Oil Dev Co Fluidized carbonization process
US2729597A (en) * 1949-04-30 1956-01-03 Hydrocarbon Research Inc Process for rendering solid carbonaceous materials non-agglomerative
US2764531A (en) * 1952-08-01 1956-09-25 Exxon Research Engineering Co Process and apparatus for retorting oil shale
US4094767A (en) * 1976-11-10 1978-06-13 Phillips Petroleum Company Fluidized bed retorting of tar sands
US4264435A (en) * 1978-04-05 1981-04-28 The Dow Chemical Company Crude oil cracking using partial combustion gases
US4276021A (en) * 1979-08-08 1981-06-30 Dravo Corporation Method of recovering heat from hot granular solids
US4326944A (en) * 1980-04-14 1982-04-27 Standard Oil Company (Indiana) Rapid hydropyrolysis of carbonaceous solids
US4369100A (en) * 1977-09-27 1983-01-18 Sawyer Harold T Method for enhancing chemical reactions
US4507195A (en) * 1983-05-16 1985-03-26 Chevron Research Company Coking contaminated oil shale or tar sand oil on retorted solid fines
US5076910A (en) * 1990-09-28 1991-12-31 Phillips Petroleum Company Removal of particulate solids from a hot hydrocarbon slurry oil
US5914027A (en) * 1994-09-12 1999-06-22 Thermtech A/S Thermo-mechanical cracking and hydrogenation

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3501394A (en) * 1967-04-17 1970-03-17 Mobil Oil Corp Gas lift retorting process for obtaining oil from fine particles containing hydrocarbonaceous material
SU1029830A3 (ru) * 1974-05-31 1983-07-15 Стандарт Ойл Компани (Фирма) Способ получени углеводородных фракций из углеродсодержащего сырь
US4105502A (en) * 1976-06-25 1978-08-08 Occidental Petroleum Corporation Simplified liquefaction pyrolysis process and apparatus therefor
DE3023670C2 (de) * 1980-06-25 1982-12-23 Veba Oel Entwicklungsgesellschaft mbH, 4660 Gelsenkirchen-Buer Verfahren und Vorrichtung zum Schwelen von Ölschiefer
US4412910A (en) * 1981-10-21 1983-11-01 Westinghouse Electric Corp. Recovery of fuel from oil shale
US4415433A (en) * 1981-11-19 1983-11-15 Standard Oil Company (Indiana) Fluid bed retorting process with multiple feed lines
KR0171501B1 (ko) * 1996-08-28 1999-03-20 이성래 폐유 재생 장치 및 방법
US6709573B2 (en) * 2002-07-12 2004-03-23 Anthon L. Smith Process for the recovery of hydrocarbon fractions from hydrocarbonaceous solids
NO20040615L (no) * 2004-02-11 2005-08-12 Ellycrack As Lav temperatur katalytisk krakking og omdannelsesprosess for oppgradering av tung raolje

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2537153A (en) * 1946-10-08 1951-01-09 Standard Oil Dev Co Fluidized carbonization process
US2534051A (en) * 1946-11-22 1950-12-12 Standard Oil Dev Co Method for fluidized low-temperature carbonization of coal
US2729597A (en) * 1949-04-30 1956-01-03 Hydrocarbon Research Inc Process for rendering solid carbonaceous materials non-agglomerative
US2764531A (en) * 1952-08-01 1956-09-25 Exxon Research Engineering Co Process and apparatus for retorting oil shale
US4094767A (en) * 1976-11-10 1978-06-13 Phillips Petroleum Company Fluidized bed retorting of tar sands
US4369100A (en) * 1977-09-27 1983-01-18 Sawyer Harold T Method for enhancing chemical reactions
US4264435A (en) * 1978-04-05 1981-04-28 The Dow Chemical Company Crude oil cracking using partial combustion gases
US4276021A (en) * 1979-08-08 1981-06-30 Dravo Corporation Method of recovering heat from hot granular solids
US4326944A (en) * 1980-04-14 1982-04-27 Standard Oil Company (Indiana) Rapid hydropyrolysis of carbonaceous solids
US4507195A (en) * 1983-05-16 1985-03-26 Chevron Research Company Coking contaminated oil shale or tar sand oil on retorted solid fines
US5076910A (en) * 1990-09-28 1991-12-31 Phillips Petroleum Company Removal of particulate solids from a hot hydrocarbon slurry oil
US5914027A (en) * 1994-09-12 1999-06-22 Thermtech A/S Thermo-mechanical cracking and hydrogenation

Also Published As

Publication number Publication date
AU2007250630B2 (en) 2011-08-18
CA2546940A1 (en) 2007-11-15
RU2434049C2 (ru) 2011-11-20
BRPI0711480A2 (pt) 2011-11-16
NO20085143L (no) 2008-12-15
RU2008149093A (ru) 2010-06-20
WO2007133089A1 (en) 2007-11-22
EP2029695A1 (en) 2009-03-04
CA2546940C (en) 2010-09-21
MX2008014630A (es) 2009-02-06
AU2007250630A1 (en) 2007-11-22
CN101484550A (zh) 2009-07-15
EP2029695A4 (en) 2011-11-02

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Owner name: TARBLASTER AS, NORWAY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ELLINGSEN, OLAV;SOREBO ELLINGSEN, BJARTE;REEL/FRAME:021822/0541

Effective date: 20081030

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION