Ultra-low water input oil sands recovery process
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C10G-002/00
C10B-053/06
C10J-003/62
C10B-049/16
C10L-001/08
C10L-001/06
C10G-001/00
C10K-003/06
출원번호
US-0694375
(2015-04-23)
등록번호
US-9605212
(2017-03-28)
우선권정보
CA-2849850 (2014-04-23)
발명자
/ 주소
Thé, Jesse
Fraser, Roydon Andrew
Ordouei, Mohammad Hossein
출원인 / 주소
Lakes Environmental Research Inc.
인용정보
피인용 횟수 :
1인용 특허 :
7
초록▼
A method of processing oil sands material including bitumen. The method includes subjecting the oil sands material to a predistillation process. The predistillation process includes heating the oil sands material to between approximately 350° C. and approximately 400° C., to produce atmospheric gas
A method of processing oil sands material including bitumen. The method includes subjecting the oil sands material to a predistillation process. The predistillation process includes heating the oil sands material to between approximately 350° C. and approximately 400° C., to produce atmospheric gas oil from the bitumen, and intermediate dried oil sands material, and heating the intermediate dried oil sands material to between approximately 535° C. and at least approximately 600° C., to produce vacuum gas oil and coked oil sands material comprising carbon-heavy hydrocarbons and sand. The method also includes subjecting the coked oil sands material to gasification, to produce barren hot oil sands material, and syngas comprising hydrogen and carbon monoxide gases.
대표청구항▼
1. A method of processing raw oil sands material comprising bitumen, the method comprising: (a) subjecting an oil sands material comprising the raw oil sands material to a predistillation process comprising: (i) heating the oil sands material to between approximately 350° C. and approximately 400° C
1. A method of processing raw oil sands material comprising bitumen, the method comprising: (a) subjecting an oil sands material comprising the raw oil sands material to a predistillation process comprising: (i) heating the oil sands material to between approximately 350° C. and approximately 400° C., to produce atmospheric gas oil from the bitumen, and intermediate dried oil sands material;(ii) heating the intermediate dried oil sands material to between approximately 535° C. and at least approximately 600° C., to produce vacuum gas oil and coked oil sands material comprising carbon-heavy hydrocarbons and sand;(b) heating the coked oil sands material to approximately 900° C., to produce a dry barren hot oil sands material; and syngas comprising hydrogen and carbon monoxide gases; and(c) mixing the barren hot oil sands material with the raw oil sands material to form the oil sands material, for transfer of heat energy from the barren hot oil sands material to the raw oil sands material for partially heating the oil sands material in the predistillation process. 2. A method according to claim 1 additionally comprising: (d) refining the atmospheric gas oil to provide at least one of liquefied petroleum gas and gasoline; and(e) refining the vacuum gas oil to provide at least one of jet fuel, diesel fuel, and gas oil. 3. A method according to claim 1 in which the syngas is further subjected to at least one gas-to-liquid process to provide at least one of gasoline, diesel fuel, naphtha, and petrochemical feedstock. 4. A method of processing raw oil sands material comprising free water and bitumen produced from a mine, comprising: (a) preheating a preheat oil sands material comprising the raw oil sands material to between approximately 100° C. and approximately 150° C. to convert the free water to steam, to release the free water from the raw oil sands material and to form a dried oil sands material from the preheat oil sands material;(b) in a first predistillation step, heating the dried oil sands material to between approximately 350° C. and approximately 400° C. to partially vaporize the bitumen, to provide atmospheric gas oil from the bitumen, and intermediate dried oil sands material;(c) in a second predistillation step, heating the intermediate dried oil sands material to between approximately 535° C. and at least approximately 600° C. to further at least partially vaporize the bitumen, to provide vacuum gas oil, and coked oil sands material comprising carbon-heavy hydrocarbons and sand;(d) in a gasifier, heating the coked oil sands material to approximately 900° C. for gasification thereof, to provide syngas comprising hydrogen and carbon monoxide gases retaining syngas heat energy therein, and a dry barren hot oil sands material retaining sand heat energy therein; and(e) mixing at least a portion of the barren hot oil sands material with the raw oil sands material to form the preheat oil sands material for transferring at least a portion of the sand heat energy to the raw oil sands material, to at least partially preheat the preheat oil sands material. 5. A method according to claim 4 in which the steam is added to the coked oil sands material during the gasification thereof, to provide at least a portion of the hydrogen gas in the syngas. 6. A method according to claim 4 in which at least a part of the sand heat energy in the barren oil sands material is transferred to the dried oil sands material in the first predistillation step. 7. A method according to claim 4 in which at least a part of the sand heat energy in the barren oil sands material is transferred to the intermediate dried oil sands material in the second predistillation step. 8. A method according to claim 4 in which, prior to the gasification of the coked oil sands material, at least a portion of the syngas heat energy from previously produced syngas is transferred to the coked oil sands material, to heat the coked oil sands material to between approximately 650° C. and approximately 750° C. 9. A method according to claim 4 additionally comprising heating fresh water to between approximately 450° C. and approximately 500° C. to generate fresh water steam, and injecting the fresh water steam into the gasifier. 10. A method according to claim 4 additionally comprising heating air to between approximately 650° C. and approximately 750° C. to generate hot air, and injecting the hot air into the gasifier. 11. A method according to claim 4 additionally comprising: mixing the syngas with at least one additional gas to produce a balanced syngas comprising preselected gases in predetermined proportions. 12. A method according to claim 11 in which said at least one additional gas comprises a natural gas-derived syngas resulting from combustion of natural gas. 13. A method according to claim 11 in which the balanced syngas is subjected to a gas-to-liquids process to provide at least one of gasoline, diesel fuel, naphtha, and petrochemical feedstock. 14. A method according to claim 4 in which the raw oil sands are comminuted, prior to preheating, and screened such that only particles of the raw oil sands material below a predetermined particle size are included in the oil sand material. 15. A method according to claim 4 additionally comprising, before step (d), comminuting the coked oil sands material such that only the coked oil sands material below a preselected particle size is subjected to the gasification. 16. A method according to claim 4 in which at least a part of the barren hot oil sands material is transported to the mine for backfilling therein. 17. A method of processing raw oil sands material comprising free water and bitumen produced from a mine, comprising: (a) preheating a preheat oil sands material comprising the raw oil sands material to between approximately 100° C. and approximately 150° C. to convert the free water to steam, to release the free water from the raw oil sands material and to form a dried oil sands material from the preheat oil sands material;(b) in a predistillation process, heating the dried oil sands material to between approximately 535° C. and at least approximately 600° C. to at least partially vaporize the bitumen, to provide atmospheric gas oil and vacuum gas oil from the bitumen, and to provide coked oil sands material comprising carbon-heavy hydrocarbons and sand;(c) in a gasifier, heating the coked oil sands material to approximately 900° C. for gasification thereof, to provide syngas comprising hydrogen and carbon monoxide gases retaining syngas heat energy therein, and a dry barren hot oil sands material retaining sand heat energy therein; and(d) mixing at least a portion of the barren hot oil sands material with the raw oil sands material to form the preheat oil sands material for transferring at least a portion of the sand heat energy to the raw oil sands material, to at least partially preheat the preheat oil sands material. 18. A method according to claim 17 in which the steam is added to the coked oil sands material during the gasification thereof, to provide at least a portion of the hydrogen gas in the syngas. 19. A method according to claim 17 in which at least a part of the sand heat energy in the barren oil sands material is transferred to the dried oil sands material in the predistillation process. 20. A method according to claim 17 in which, prior to the gasification of the coked oil sands material, at least a portion of the syngas heat energy from previously produced syngas is transferred to the coked oil sands material, to heat the coked oil sands material to between approximately 650° C. and approximately 750° C. 21. A method according to claim 17 additionally comprising, before step (c), comminuting the coked oil sands material such that only the coked oil sands material below a preselected particle size is subjected to the gasification. 22. A method according to claim 17 in which at least a part of the barren hot oil sands material is transported to the mine for backfilling therein.
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이 특허에 인용된 특허 (7)
Spars Byron G. (Mill Valley CA) Klett Robert J. (San Francisco CA) Wallman P. Henrik (Berkeley CA), Coking contaminated oil shale or tar sand oil on retorted solid fines.
Hanson Francis V. (Salt Lake City UT) Miller Jan D. (Salt Lake City UT) Oblad Alex G. (Salt Lake City UT), Process for obtaining products from tar sand.
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