CA2185256A1 - Recovery and upgrading of bitumen from tar-sands - Google Patents
Recovery and upgrading of bitumen from tar-sandsInfo
- Publication number
- CA2185256A1 CA2185256A1 CA002185256A CA2185256A CA2185256A1 CA 2185256 A1 CA2185256 A1 CA 2185256A1 CA 002185256 A CA002185256 A CA 002185256A CA 2185256 A CA2185256 A CA 2185256A CA 2185256 A1 CA2185256 A1 CA 2185256A1
- Authority
- CA
- Canada
- Prior art keywords
- bitumen
- steam
- gas
- coke
- water
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
- B03B9/00—General arrangement of separating plant, e.g. flow sheets
- B03B9/02—General arrangement of separating plant, e.g. flow sheets specially adapted for oil-sand, oil-chalk, oil-shales, ozokerite, bitumen, or the like
-
- 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
- C10G1/002—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal in combination with oil conversion- or refining processes
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
- C10G1/02—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
- C10G1/04—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by extraction
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
- C10G1/04—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by extraction
- C10G1/047—Hot water or cold water extraction processes
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
- C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
Landscapes
- Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Geology (AREA)
- Coke Industry (AREA)
Abstract
This patent relates to new or improved methods for recovery of bitumen or heavy oil from tar-sands(T.S) and to upgrading the same into marketable petroleum products and energy producing fuels: and to tailings disposal in dry form rather than in undesirable tailings ponds.
Description
CANADIAN PATENT APPI.ICATION
tlt ARD UPGRADING OF BITUMI~N FROM TAR- SANDS
This patent relates to new or improved methods for recovery of bitumen or heavy oil from tar-sands~T.S) and to upgrading the same into marketable petroleum products and energy producing fuels: and to tailings disposal in dry form rather than in undesirable tailing~ ponds.
Bitumen and heavy-oll are found ln many countrles but in northern Alberta and Saskatchewan they constltute one of the largest hydrogen carbon bodies ln the world.
These hydrogen carbon bodles are re~lstant to flow at amblent temperatures and can not be recovered by conventional oll-well drllllng.
Some deposlts exi~t close enough to the earth surface to be economically recovered by strlp mlnlng. 2 mlnlng operatlon~ now produce ~-15 % of Canadas, oll requirements;
another ~-10% is produced from oll-well stlmulatlon by ~team, these hydrogen carbon bodles are too deep for surface mining.
The ob~ect of this inventlon is for new or improved methods to more economically recover and upgrade this abundant resource into marketable petroleum products and utllity fuels. The inventlon will show that the depleted sand taillngs now belng dlsposed of ln undesirable taillng ponds, can be disposed of in dry form, and the clay fines can be disposed of as a coverlng over the sand taillngs.
The flnes making a desirable base for reforestation.
Reforestation over tailings pond~ is and will be an expensive operation.
The clay fines associated with tar-sands are rich in alumina ore and will be readily available with abundant coke for aluminum production (now under study), another reason for disposing of the fines over the sand rather than in a tailings pond.
Coke constitutes +-20% of bitumen varying from field to field. The coke contains ~- 6% sulfur making it an unacceptable fuel (now being primarily stock piled). Stack gas treatment to make coke an environmentally acceptable fuel is very expensive. It will be an ob~ect of this invention to introduce a method to lime treat the bitumen in the coking process, so that the sulfur in the coke fuel will be disposed of in ash form (CAS0-4) rather than as 50-2 with the flue gases. It is our understanding that Syncrude stock piles most of the coke because it is environmentally unacceptable as a fuel, an unacceptable managemnet of an abundant energy resource.
Fluld and Flexi-Coklng are proven methods for upgrading bitumen into bitumen distillate, coke and fuel gas. This invention accomplishes what these systems do(and more), yet in a much simpler and more economical way.
This Patents is a further development and upgrading of patents al~eady registered, they are: Canadian Patent No 2,052,085,~ filed 9/23/91; No 2,092,121 filed 6/23/93 No 2,123,719 filed 5/17/94 and No 2,159,514 filed 10/31/95.
218~2S6 A DESCRIPTION OF THE INvr..~ION WITH REFERENCE TO THE
DRAWINGS:
Fig-2 shows a vessel for bitumen separation from tar-sands and a method for sand disposal.
Fig-2A shows heating associated with bitumen separation.
Fig-3 shows bitumen upgrading associated with lime treatment Fig-4 shows gasification of lime treated coke, electric production by steam and co gas turbines, oil-well steam stlmulation by turbine electric generators and hydrogen production by steam reformlng of coker gas.
Fig-2...is an elevation slde view of the vessel deslgned to separate bitumen from the tar-sands (T.S.). T.S. 6 are directed into the vessel. Beater lmpellers 5 driven by motor and drive 4 scrub and impel the T.S. through the vat, freeing the bitumen from the sand. CO gas turbine 2 generates electricity and heats the circulatio~ water which is injected into the dlscharge end of the vat as rinse water 3, all water enters the vat as rinse water.
The high pressure rinse water i9 designed to wash the bitumen and fines upward, washing the sand for dlsposal through gate 26 and sand pumps 11. Plpe 18 directs the washed sand to sand water separation 1~A, the sand 12 is disposed of over tailings field 19 in da~p form (not a tailings pon~).
The water is recovered through pipe 13 for re-heating and re-circulation. The separated bitumen rises upward in vat 25 for discharge with water and fines over weir 8. Pump 10 will direct the bitu~en effluent to adjacent or remote Fig-3 for upgrading. The prime objectives is to separate and dispose of the sand at the ~ine f~ce, generate electricity with the coker gas burning turbine which will at the same time provide necessary heat for bitumen separation. Fig-2 shows the fines 15 from Fig-3 being returned for disposal over the sand tailinqs 1~, the water 16 from the fines 15 will be recovered by well 17. The fines 15 are designed to be an acceptable base for reforestation: should aluminum production (now under consideration) materialize, an ~bundance of fines,(alumina impregnated ore) coke and coke gas in close proximity would be attractive for aluminum develo~ment.
FIG-2A...is an elevation side and end view of the bitumen separator shown in Fig-1, the end view shows 4 separation vats 25 supported on pipes 24 resting on I beam skids 20.
Insulated corrugated steel walls, floors and ceilings (for expansion and contraction) will form an enclosure surrounding the vats, designed as a heat chamber to heat the vat walls externally. The enclosure will be designed for temperatures -1000*F, walls of steel or other suitable material will be designed for temperatures of this order, with insulation values as required.
The plpes 24 supporting the vats 25 will be of sufficient length to accommodate circulation water pipes 22, which are heated in the same enclosure as the vats.
The circulation water 13 will pass through the pipes 22 under high velocity to prevent pipe scaling. The circulation water will be heated to a temperature most desirable for bitumen separation, and be injected into the discharge end of each vat as rinse water. As already identified in - 2185~5 FIG-2, pipes 22 and vats 25 are heated by CO ga~ burning turbines 2 that produce electricity and supply the heat, to heat the circulation water. Thi~ drawing shows rin~e water 3 being drawn upward through pipe 28 for disCharge downward by impeller blade 27 and motor 21. The bitumen is recovered and sand disposed of as already stated under Fig 2. We believe this to be a most economical way to recover the bitumen and dispose of the sand, at the same time generating electricity for the mining operation with a lot of electricity for other purposes. Note, the solvent 54 fig -3 may be piped and discharged into vat 25 fig-2A.
FIG-3...Bitumen 64 from FIG-2,2A, or from wells Fig-4, is mixed with solvent 54 to reduce its viscosity, treated with a polymer 63, to floculate contained fines 46 and pumped into verssel B. The floculated fines 46 and water 47 migrate downward for recovery (disposal) at the base of vessel B; the solvent treated bitumen rises upward in the vessel with remnants vf fines and water for distillation at the top of the vessel. Hot volatiles (bitumen distillate, lime treated coker gas and steam) 39 from vessel C flow into and down through heat exchanger 48,49 volatizing and recovering the bitumen of vessel B up to -500*F; these lighter volatiles 54 of the bitumen will be used as a solvent to reduce the incoming bitumen 64, then they will be discharged to vessel 58. From 58 they will join the bitumen distillate from vessel A again acting as a solvent to reduce the heavier distillate.
The heavier fractions of the bitumen will require +-1000*F for volatization; this residue will overflow vessel B and be pumped (42) with lime 41 (cyclone 40) into fluidized bed 38 of vessel C. The fluidized bed 38 is fired by burning coke oxidized by pre-heated air 33 supplied by pump 44; sufficient coke will be burned to supply the heat requirements of vessel B and C. The main body of the coke not burnt, but having its temperature raised above 1000*F in the presence of lime, will be discharged from vessel C by augurs 67- (65) with contained sulfur as CASO-4.
It will be a coke inventory of non polluting fuel proposed for fig-4. An alternative to coke inventory is to direct the coke hot from vessel C (38) into vessel C-1 (68-A) fig-3 or into vessel C-2 (38) fig-4: in vessel C-1 with the addition of steam (69) a synthesis gas (70-A) free of nitrogen is produced, a high BTU fuel gas used widely for hydrogen and other chemical production. The lime and CASO-4 (71-A) are rejected by augur 67: the coke from vessel C (38) can also be discharged hot into vessel C-2 (38) fig-4. Coke gas produced from 1050*F coke feed will contain about 2/3 less nitrogen than inventory feed by cyclone.
The coke and lime of fluidized bed 38 will be continuously recycled by steam jets 35 released into circulation pipes 36. Hydrogen from the steam will enrich the coker gas of the fluidized bed.
Bitumen volatiles, lime treated coker gas and steam 39 will rise from bed 38 C at slightly above atmospheric pressure providing the heat requirements for vessel B.
The bitumen volatiles and steam will condense as they merge downwards through the heat exchanger 48-49. Pump 51 will discharge t~e condensed bitumen volatiles into hot storage and settling tanks A.
The co~er gas 52 and probably most of the steam will rise upward for recovery and be discharged (compressor 61) to storage 60, steam as condensate (66) will be removed.
The system is defined as revised fluid coking with lime.
2185~256 FIG-4...fig-2 of this Patent application identified separation and recovery of the bitumen from crushed tar-sands. Fig-3 identified bitumen upgrading into bitumen distillate, lime treated coke and lime treated coker gas.
Fig-4 shows the utilization of lime treated coke now being mostly stock piled because of its sulfur content, or requiring very expensive stack gas treatment to make the coke an environmentally acceptable fuel.
Vessel C-2, fig-4 has a fluidized bed 38 designed to gasify lime treated coke: 2 methods are shown for discharge of the coke into vessel C-2. 1, inventory coke 65 at ambient temperature is directed by cyclone into fluidized bed 38, hot air through discharge heads 34 will oxidize the lime treated coke. Water 71 and steam injection 35 adds hydrogen to the coke gas raising its quality.
Method 2, lime treated coke (+-1050*F) from vessel C-38 fig 3 is fed into fluidized bed 38 C2 fig-4; the temperature of the coke feed will only have to be raised from +-1050*F to a desired gasification temperature of say 1500*F. It will be seen that the coke gas from method 2 will contain about 1/3 the nitrogen of gas produced by inventory coke 65.
The hot gases and steam will rise from fluid bed 38 and pass downward over water tubes 92 turning the treated water 32 of the tubes into steam. Approaching the bottom of the tubes (92) the gases cool, the steam turning to condensate 76. The hot condensate 76 is returned (71) back into fluid be 38. The condensate water 76 will be maintained at a fixed level. The lime treated coker gas 79 will be recovered from the bottom of Fig-D and discharged by compressor 95 to storage 83. Conventional gas clean up will make this lime treated coker gas a basic fuel in heavy oil and chemical production.
Fig-4-E shows a coker gas fired turbine 2 turning an electric generators (1,2,3) and its hot exhaust gases turning steam from tubes 92 into super steam in tubes 80,81, the super steam passing through steam turbines 85 will propel electric generators 2. Fig-4 is designed to show how coke now being stockpiled as an enviromentally unacceptable fuel can,( by lime treating in the coking process), be turned into a valuable fuel for energy production.
Fig-4-F shows a coker gas fired turbine generating electricity and firing a steam boiler for oil well steam stimulation. We believe this will bring substantial saving to the industry now using natural gas as a fuel for oil well stimulation.
tlt ARD UPGRADING OF BITUMI~N FROM TAR- SANDS
This patent relates to new or improved methods for recovery of bitumen or heavy oil from tar-sands~T.S) and to upgrading the same into marketable petroleum products and energy producing fuels: and to tailings disposal in dry form rather than in undesirable tailing~ ponds.
Bitumen and heavy-oll are found ln many countrles but in northern Alberta and Saskatchewan they constltute one of the largest hydrogen carbon bodies ln the world.
These hydrogen carbon bodles are re~lstant to flow at amblent temperatures and can not be recovered by conventional oll-well drllllng.
Some deposlts exi~t close enough to the earth surface to be economically recovered by strlp mlnlng. 2 mlnlng operatlon~ now produce ~-15 % of Canadas, oll requirements;
another ~-10% is produced from oll-well stlmulatlon by ~team, these hydrogen carbon bodles are too deep for surface mining.
The ob~ect of this inventlon is for new or improved methods to more economically recover and upgrade this abundant resource into marketable petroleum products and utllity fuels. The inventlon will show that the depleted sand taillngs now belng dlsposed of ln undesirable taillng ponds, can be disposed of in dry form, and the clay fines can be disposed of as a coverlng over the sand taillngs.
The flnes making a desirable base for reforestation.
Reforestation over tailings pond~ is and will be an expensive operation.
The clay fines associated with tar-sands are rich in alumina ore and will be readily available with abundant coke for aluminum production (now under study), another reason for disposing of the fines over the sand rather than in a tailings pond.
Coke constitutes +-20% of bitumen varying from field to field. The coke contains ~- 6% sulfur making it an unacceptable fuel (now being primarily stock piled). Stack gas treatment to make coke an environmentally acceptable fuel is very expensive. It will be an ob~ect of this invention to introduce a method to lime treat the bitumen in the coking process, so that the sulfur in the coke fuel will be disposed of in ash form (CAS0-4) rather than as 50-2 with the flue gases. It is our understanding that Syncrude stock piles most of the coke because it is environmentally unacceptable as a fuel, an unacceptable managemnet of an abundant energy resource.
Fluld and Flexi-Coklng are proven methods for upgrading bitumen into bitumen distillate, coke and fuel gas. This invention accomplishes what these systems do(and more), yet in a much simpler and more economical way.
This Patents is a further development and upgrading of patents al~eady registered, they are: Canadian Patent No 2,052,085,~ filed 9/23/91; No 2,092,121 filed 6/23/93 No 2,123,719 filed 5/17/94 and No 2,159,514 filed 10/31/95.
218~2S6 A DESCRIPTION OF THE INvr..~ION WITH REFERENCE TO THE
DRAWINGS:
Fig-2 shows a vessel for bitumen separation from tar-sands and a method for sand disposal.
Fig-2A shows heating associated with bitumen separation.
Fig-3 shows bitumen upgrading associated with lime treatment Fig-4 shows gasification of lime treated coke, electric production by steam and co gas turbines, oil-well steam stlmulation by turbine electric generators and hydrogen production by steam reformlng of coker gas.
Fig-2...is an elevation slde view of the vessel deslgned to separate bitumen from the tar-sands (T.S.). T.S. 6 are directed into the vessel. Beater lmpellers 5 driven by motor and drive 4 scrub and impel the T.S. through the vat, freeing the bitumen from the sand. CO gas turbine 2 generates electricity and heats the circulatio~ water which is injected into the dlscharge end of the vat as rinse water 3, all water enters the vat as rinse water.
The high pressure rinse water i9 designed to wash the bitumen and fines upward, washing the sand for dlsposal through gate 26 and sand pumps 11. Plpe 18 directs the washed sand to sand water separation 1~A, the sand 12 is disposed of over tailings field 19 in da~p form (not a tailings pon~).
The water is recovered through pipe 13 for re-heating and re-circulation. The separated bitumen rises upward in vat 25 for discharge with water and fines over weir 8. Pump 10 will direct the bitu~en effluent to adjacent or remote Fig-3 for upgrading. The prime objectives is to separate and dispose of the sand at the ~ine f~ce, generate electricity with the coker gas burning turbine which will at the same time provide necessary heat for bitumen separation. Fig-2 shows the fines 15 from Fig-3 being returned for disposal over the sand tailinqs 1~, the water 16 from the fines 15 will be recovered by well 17. The fines 15 are designed to be an acceptable base for reforestation: should aluminum production (now under consideration) materialize, an ~bundance of fines,(alumina impregnated ore) coke and coke gas in close proximity would be attractive for aluminum develo~ment.
FIG-2A...is an elevation side and end view of the bitumen separator shown in Fig-1, the end view shows 4 separation vats 25 supported on pipes 24 resting on I beam skids 20.
Insulated corrugated steel walls, floors and ceilings (for expansion and contraction) will form an enclosure surrounding the vats, designed as a heat chamber to heat the vat walls externally. The enclosure will be designed for temperatures -1000*F, walls of steel or other suitable material will be designed for temperatures of this order, with insulation values as required.
The plpes 24 supporting the vats 25 will be of sufficient length to accommodate circulation water pipes 22, which are heated in the same enclosure as the vats.
The circulation water 13 will pass through the pipes 22 under high velocity to prevent pipe scaling. The circulation water will be heated to a temperature most desirable for bitumen separation, and be injected into the discharge end of each vat as rinse water. As already identified in - 2185~5 FIG-2, pipes 22 and vats 25 are heated by CO ga~ burning turbines 2 that produce electricity and supply the heat, to heat the circulation water. Thi~ drawing shows rin~e water 3 being drawn upward through pipe 28 for disCharge downward by impeller blade 27 and motor 21. The bitumen is recovered and sand disposed of as already stated under Fig 2. We believe this to be a most economical way to recover the bitumen and dispose of the sand, at the same time generating electricity for the mining operation with a lot of electricity for other purposes. Note, the solvent 54 fig -3 may be piped and discharged into vat 25 fig-2A.
FIG-3...Bitumen 64 from FIG-2,2A, or from wells Fig-4, is mixed with solvent 54 to reduce its viscosity, treated with a polymer 63, to floculate contained fines 46 and pumped into verssel B. The floculated fines 46 and water 47 migrate downward for recovery (disposal) at the base of vessel B; the solvent treated bitumen rises upward in the vessel with remnants vf fines and water for distillation at the top of the vessel. Hot volatiles (bitumen distillate, lime treated coker gas and steam) 39 from vessel C flow into and down through heat exchanger 48,49 volatizing and recovering the bitumen of vessel B up to -500*F; these lighter volatiles 54 of the bitumen will be used as a solvent to reduce the incoming bitumen 64, then they will be discharged to vessel 58. From 58 they will join the bitumen distillate from vessel A again acting as a solvent to reduce the heavier distillate.
The heavier fractions of the bitumen will require +-1000*F for volatization; this residue will overflow vessel B and be pumped (42) with lime 41 (cyclone 40) into fluidized bed 38 of vessel C. The fluidized bed 38 is fired by burning coke oxidized by pre-heated air 33 supplied by pump 44; sufficient coke will be burned to supply the heat requirements of vessel B and C. The main body of the coke not burnt, but having its temperature raised above 1000*F in the presence of lime, will be discharged from vessel C by augurs 67- (65) with contained sulfur as CASO-4.
It will be a coke inventory of non polluting fuel proposed for fig-4. An alternative to coke inventory is to direct the coke hot from vessel C (38) into vessel C-1 (68-A) fig-3 or into vessel C-2 (38) fig-4: in vessel C-1 with the addition of steam (69) a synthesis gas (70-A) free of nitrogen is produced, a high BTU fuel gas used widely for hydrogen and other chemical production. The lime and CASO-4 (71-A) are rejected by augur 67: the coke from vessel C (38) can also be discharged hot into vessel C-2 (38) fig-4. Coke gas produced from 1050*F coke feed will contain about 2/3 less nitrogen than inventory feed by cyclone.
The coke and lime of fluidized bed 38 will be continuously recycled by steam jets 35 released into circulation pipes 36. Hydrogen from the steam will enrich the coker gas of the fluidized bed.
Bitumen volatiles, lime treated coker gas and steam 39 will rise from bed 38 C at slightly above atmospheric pressure providing the heat requirements for vessel B.
The bitumen volatiles and steam will condense as they merge downwards through the heat exchanger 48-49. Pump 51 will discharge t~e condensed bitumen volatiles into hot storage and settling tanks A.
The co~er gas 52 and probably most of the steam will rise upward for recovery and be discharged (compressor 61) to storage 60, steam as condensate (66) will be removed.
The system is defined as revised fluid coking with lime.
2185~256 FIG-4...fig-2 of this Patent application identified separation and recovery of the bitumen from crushed tar-sands. Fig-3 identified bitumen upgrading into bitumen distillate, lime treated coke and lime treated coker gas.
Fig-4 shows the utilization of lime treated coke now being mostly stock piled because of its sulfur content, or requiring very expensive stack gas treatment to make the coke an environmentally acceptable fuel.
Vessel C-2, fig-4 has a fluidized bed 38 designed to gasify lime treated coke: 2 methods are shown for discharge of the coke into vessel C-2. 1, inventory coke 65 at ambient temperature is directed by cyclone into fluidized bed 38, hot air through discharge heads 34 will oxidize the lime treated coke. Water 71 and steam injection 35 adds hydrogen to the coke gas raising its quality.
Method 2, lime treated coke (+-1050*F) from vessel C-38 fig 3 is fed into fluidized bed 38 C2 fig-4; the temperature of the coke feed will only have to be raised from +-1050*F to a desired gasification temperature of say 1500*F. It will be seen that the coke gas from method 2 will contain about 1/3 the nitrogen of gas produced by inventory coke 65.
The hot gases and steam will rise from fluid bed 38 and pass downward over water tubes 92 turning the treated water 32 of the tubes into steam. Approaching the bottom of the tubes (92) the gases cool, the steam turning to condensate 76. The hot condensate 76 is returned (71) back into fluid be 38. The condensate water 76 will be maintained at a fixed level. The lime treated coker gas 79 will be recovered from the bottom of Fig-D and discharged by compressor 95 to storage 83. Conventional gas clean up will make this lime treated coker gas a basic fuel in heavy oil and chemical production.
Fig-4-E shows a coker gas fired turbine 2 turning an electric generators (1,2,3) and its hot exhaust gases turning steam from tubes 92 into super steam in tubes 80,81, the super steam passing through steam turbines 85 will propel electric generators 2. Fig-4 is designed to show how coke now being stockpiled as an enviromentally unacceptable fuel can,( by lime treating in the coking process), be turned into a valuable fuel for energy production.
Fig-4-F shows a coker gas fired turbine generating electricity and firing a steam boiler for oil well steam stimulation. We believe this will bring substantial saving to the industry now using natural gas as a fuel for oil well stimulation.
Claims (4)
1 A method to recover and upgrade bitumen (heavy oil) obtained from mining or oil wells into petroleum poducts, consisting of the following steps: separating and recovering the bitumen from crushed tar sands, disposing of the sand in a dry form rather than in tailings ponds; directing said bitumen from mining or wells to an up-grader:
separating water and fines from the bitumen, heat the bitumen to a desired temperature to recover the lighter distillates to be used first as solvent then recovered:
discharge the bitumen residue with lime to a fluidized bed for coking; burn a portion of the lime treated coke to volatize the bitumen residue; discharge the residue volatiles, lime treated coker gas and steam into a heat exchanger designed to heat the incoming solvent treated bitumen; recover the gas oil and solvent for further up-grading: recover the lime treated coke and coker gas as energy fuels for steam and gas turbines, oil-well steam stimulation, hydrogen and chemical production, aluminum production and associated operations.
separating water and fines from the bitumen, heat the bitumen to a desired temperature to recover the lighter distillates to be used first as solvent then recovered:
discharge the bitumen residue with lime to a fluidized bed for coking; burn a portion of the lime treated coke to volatize the bitumen residue; discharge the residue volatiles, lime treated coker gas and steam into a heat exchanger designed to heat the incoming solvent treated bitumen; recover the gas oil and solvent for further up-grading: recover the lime treated coke and coker gas as energy fuels for steam and gas turbines, oil-well steam stimulation, hydrogen and chemical production, aluminum production and associated operations.
2 A method to separate and recover bitmen from crushed tar sands and dispose of the sand tailings in an enviromentally acceptable manner at the mine sight as in claim 1: Crushed tar sands discharged with or without caustic? into a series of vats supported on steel post and I beams, said vats having along their bottoms beater impellers mounted on a pipe shaft rotated by appropriate electric drives, said beater impellers designed to free the bitumen from the sand, moving the sand to the discharge end of the vats; circulation water recovered heated and directed as high pressure rinse water into the sand discharge end of the vats, said rinse water designed to wash the sand and direct the bitumen upward in the vat for recovery over weirs and discharge to an up-grader:
sand tailings from the vats pumped as slurry to the top of the tailings field; circulation water separated from the sand by conventional means and returned to the bitumen separator for re-heating and re-circulation; sand disposed of in damp form rather than in a tailings pond: a method to heat the circulation water and tar-sands; water tubes suspended in space provided beneath the vats, insulated floor walls and ceiling forming an insulated enclosure to facilitate the heating of the vat walls and water tubes;
coker gas burning turbines driving a electric generator and exhausting its heat into the enclosure to heat the vat walls and the water tubes;the enclosure having a chimney for release of stack gases: on sight electrical generatrion for mine requirements and export by turbine generator supplying heat for bitumen separation.
sand tailings from the vats pumped as slurry to the top of the tailings field; circulation water separated from the sand by conventional means and returned to the bitumen separator for re-heating and re-circulation; sand disposed of in damp form rather than in a tailings pond: a method to heat the circulation water and tar-sands; water tubes suspended in space provided beneath the vats, insulated floor walls and ceiling forming an insulated enclosure to facilitate the heating of the vat walls and water tubes;
coker gas burning turbines driving a electric generator and exhausting its heat into the enclosure to heat the vat walls and the water tubes;the enclosure having a chimney for release of stack gases: on sight electrical generatrion for mine requirements and export by turbine generator supplying heat for bitumen separation.
3 A method to up-grade bitumen (heavy oil) from mining or from oil wells into bitumen distillate, lime treated coke and lime treated coker gas as in claim 1: consisting of, bitumen reduction by solvent addition, treating the bitumen effluent with a polymer to floculate fines;
discharge the bitumen effluent into a separating and heating vessel; recovering or disposing of fines and water downward in the vessel; heat the bitumen with remnants of fines and water to a desirable temperature for recovery of naphtha etc. as a solvent for reducing bitume; discharge the bitumen residue with lime into a fluidized coking vessel: oxidize the coke with hot air, burn sufficient coke to supply the heat required in both vessels; recover unburned coke as an inventory of environmentally acceptable fuel: direct the bitumen distillate (gas oil) from the fluidized bed together with lime treated coker gas and steam to the heat exchanger to heat the incoming solvent treated bitumen:
recover and pump the bitumen distillate (gas oil) from the bottom of the heat exchanger into heated (insulated) settling tank for settling out of fines and water; discharge the bitumen distillate (gas oil) together with solvent (naphtha etc) to an adjacent or remote up-grader: recover lime treated coker gas, remove the steam as condensate, pass coker gas through clean-up: alternative, discharge lime treated coke from fluidized bed hot (+-1050*F) into a steam gasification vessel for coke gasification by steam, recover the gas nitrogen free for hydrogen and chemical production also as nitrogen free fuel; dispose of lime and CASO-4 from the steam gasification vessel.
discharge the bitumen effluent into a separating and heating vessel; recovering or disposing of fines and water downward in the vessel; heat the bitumen with remnants of fines and water to a desirable temperature for recovery of naphtha etc. as a solvent for reducing bitume; discharge the bitumen residue with lime into a fluidized coking vessel: oxidize the coke with hot air, burn sufficient coke to supply the heat required in both vessels; recover unburned coke as an inventory of environmentally acceptable fuel: direct the bitumen distillate (gas oil) from the fluidized bed together with lime treated coker gas and steam to the heat exchanger to heat the incoming solvent treated bitumen:
recover and pump the bitumen distillate (gas oil) from the bottom of the heat exchanger into heated (insulated) settling tank for settling out of fines and water; discharge the bitumen distillate (gas oil) together with solvent (naphtha etc) to an adjacent or remote up-grader: recover lime treated coker gas, remove the steam as condensate, pass coker gas through clean-up: alternative, discharge lime treated coke from fluidized bed hot (+-1050*F) into a steam gasification vessel for coke gasification by steam, recover the gas nitrogen free for hydrogen and chemical production also as nitrogen free fuel; dispose of lime and CASO-4 from the steam gasification vessel.
4 A method to produce and utilize lime treated coke and lime treated coke gas of claims 1 and 3 as environmentally acceptable fuels in steam electric generation, also as fuel for gas fired turbine electric steam generation, and as fuel in the production of hydrogen, chemicals, aluminum or other fuel requirements;
lime treated coke of claims 1 and 3 directed cold into a fluidized bed oxidized by pre-heated air: said lime treated coke being burnt in a fluidized bed producing lime treated coker gas and steam, ash discharged as CASO-4 (gypsum): coker gas and steam passing downward over an enclosure of water pipes designed to produce steam; said CO gas and steam exchanging their heat to the water tubes;
steam condensing to hot water in a condensate sump, CO
gas recovered as environmentally acceptable fuel:
condensate water pumped with steam back into the fluidized bed: water tubes designed to produce steam, heated by steam and CO gas from the fluidized bed turned to steam, before or after passing into a super steam section heated by an electric co-generating CO gas fired turbine: lime treated coker gas of claims 1,3 and 4 generating electricity and firing boilers for steam to stimulate production in heavy oil wells; lime treated coker gas as in claims 1,3 and 4 generating electricity and heat for bitumen separation from tar-sands as in claim 1,2; lime treated coker gas used in the production of hydrogen and other chemicals;
and lime treated coke and coke gas in the production of aluminum as in claim 1: lime treated coke from fluidized coker bed fed hot (+-1050*F) into fluidized bed for gasification, said gasification of hot feed resulting in coker gas with about 2/3 less nitrogen than cold coke feed.
lime treated coke of claims 1 and 3 directed cold into a fluidized bed oxidized by pre-heated air: said lime treated coke being burnt in a fluidized bed producing lime treated coker gas and steam, ash discharged as CASO-4 (gypsum): coker gas and steam passing downward over an enclosure of water pipes designed to produce steam; said CO gas and steam exchanging their heat to the water tubes;
steam condensing to hot water in a condensate sump, CO
gas recovered as environmentally acceptable fuel:
condensate water pumped with steam back into the fluidized bed: water tubes designed to produce steam, heated by steam and CO gas from the fluidized bed turned to steam, before or after passing into a super steam section heated by an electric co-generating CO gas fired turbine: lime treated coker gas of claims 1,3 and 4 generating electricity and firing boilers for steam to stimulate production in heavy oil wells; lime treated coker gas as in claims 1,3 and 4 generating electricity and heat for bitumen separation from tar-sands as in claim 1,2; lime treated coker gas used in the production of hydrogen and other chemicals;
and lime treated coke and coke gas in the production of aluminum as in claim 1: lime treated coke from fluidized coker bed fed hot (+-1050*F) into fluidized bed for gasification, said gasification of hot feed resulting in coker gas with about 2/3 less nitrogen than cold coke feed.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002185256A CA2185256A1 (en) | 1996-09-11 | 1996-09-11 | Recovery and upgrading of bitumen from tar-sands |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002185256A CA2185256A1 (en) | 1996-09-11 | 1996-09-11 | Recovery and upgrading of bitumen from tar-sands |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2185256A1 true CA2185256A1 (en) | 1998-03-12 |
Family
ID=4158882
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002185256A Abandoned CA2185256A1 (en) | 1996-09-11 | 1996-09-11 | Recovery and upgrading of bitumen from tar-sands |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2185256A1 (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7704400B2 (en) * | 2006-03-30 | 2010-04-27 | Paul Costinel | Method and apparatus for washing particulate matter |
| US7726491B2 (en) | 2002-09-19 | 2010-06-01 | Suncor Energy Inc. | Bituminous froth hydrocarbon cyclone |
| US7736501B2 (en) | 2002-09-19 | 2010-06-15 | Suncor Energy Inc. | System and process for concentrating hydrocarbons in a bitumen feed |
| US8968580B2 (en) | 2009-12-23 | 2015-03-03 | Suncor Energy Inc. | Apparatus and method for regulating flow through a pumpbox |
| CN113840808A (en) * | 2019-05-24 | 2021-12-24 | 淡水河谷公司 | Method for dry heaping tailings in iron ore beneficiation process |
-
1996
- 1996-09-11 CA CA002185256A patent/CA2185256A1/en not_active Abandoned
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7726491B2 (en) | 2002-09-19 | 2010-06-01 | Suncor Energy Inc. | Bituminous froth hydrocarbon cyclone |
| US7736501B2 (en) | 2002-09-19 | 2010-06-15 | Suncor Energy Inc. | System and process for concentrating hydrocarbons in a bitumen feed |
| US7704400B2 (en) * | 2006-03-30 | 2010-04-27 | Paul Costinel | Method and apparatus for washing particulate matter |
| US8968580B2 (en) | 2009-12-23 | 2015-03-03 | Suncor Energy Inc. | Apparatus and method for regulating flow through a pumpbox |
| CN113840808A (en) * | 2019-05-24 | 2021-12-24 | 淡水河谷公司 | Method for dry heaping tailings in iron ore beneficiation process |
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| Date | Code | Title | Description |
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| FZDE | Discontinued |
