Abstract: An improved hydrocarbon cracking process includes a first reactor such as a nozzle reactor positioned in series with a second reactor such as a tubular reactor. A cracking fluid such as steam or natural gas is reacted with heavy hydrocarbon material in the first reactor. The first reactor may provide a tremendous amount of thermal and kinetic energy that initiates cracking of heavy hydrocarbon materials. The second reactor provides sufficient residence time at high temperature to increase the conversion of heavy hydrocarbon materials to the desired level. The cracking fluid functions as a hydrogen donor in the cracking reactions so that very little of the heavy hydrocarbon material becomes hydrogen depleted and forms coke even if the heavy hydrocarbon material is repeatedly recycled through the process.

Abstract: Methods for preparing solvent-dry, stackable tailings. The methods may include a primary leaching or extraction process that separates most of the bitumen from a material comprising bitumen and produces first solvent-wet tailings. The first solvent-wet tailings are washed with a second solvent that removes the first solvent from the tailings. Second solvent remaining in the tailings is removed to thereby produce solvent-dry, stackable tailings.

Abstract: A nozzle reactor includes a passage having one or more regions with a converging-diverging shape. The nozzle reactor accelerates a reacting fluid to supersonic velocities and mixes it with a feed material. The reacting fluid and the feed material may be pre-heated. The high speed collision between the reacting fluid and the feed material at elevated temperatures causes the materials to react.

Abstract: A hydrocarbon upgrading method is described. The method can generally include a step of providing a nozzle reactor, a step of injecting hydrocarbon residuum into the feed passage of the nozzle reactor, and a step of injecting a cracking material into the main passage of the nozzle reactor, and a step of collecting a product stream exiting the exit opening of the main passage of the nozzle reactor. The hydrocarbon residuum used in the method can be obtained from a hydroconversion-type upgrader, such as an ebullating bed hydrocracker.

Abstract: The present invention provides a method for extracting bitumen from an oil sand stream, the method including the steps of: (a) providing an oil sand stream; (b) contacting the oil sand stream with a liquid comprising a solvent thereby obtaining a solvent-diluted oil sand slurry; (c) separating the solvent-diluted oil sand slurry, thereby obtaining a first solids-depleted stream and a first solids-enriched stream; (d) filtering the first solids-enriched stream obtained in step (c), thereby obtaining bitumen-depleted sand and at least a first filtrate; (e) increasing the S/B weight ratio of at least a part of the first filtrate by combining it with a stream having a higher S/B weight ratio thereby obtaining a combined stream; and (f) separating the combined stream, thereby obtaining a second solids-depleted stream and a second solids-enriched stream.

Abstract: A process for producing biofuels and biolubricants from lipid material includes reacting lipid material with a motive fluid in a reactor. The reactor may be configured to cause a high energy collision between the motive fluid and the lipid material that facilitates the reactions that result in biofuels and biolubricants. A heavy fraction of the effluent may be repeatedly recycled back through the reactor until most, if not all, of the lipid material has been converted.

Abstract: The present invention provides a method for extracting bitumen from an oil sand stream, the method including the steps of: (a) providing an oil sand stream; (b) contacting the oil sand stream with a liquid comprising a solvent thereby obtaining a solvent-diluted oil sand slurry; (c) separating the solvent-diluted oil sand slurry, thereby obtaining a first solids-depleted stream and a first solids-enriched stream; (d) filtering the first solids-enriched stream obtained in step (c), thereby obtaining bitumen-depleted sand and at least a first filtrate; (e) separating at least a part of the first filtrate thereby obtaining a second solids-depleted stream and a second solids-enriched stream; and (f) reusing at least a part of the second solids-enriched stream as obtained in step (e) in the contacting of step (b) or the separating of step (c).

Abstract: A method for processing asphaltenes is disclosed. The method can include separating asphaltenes from an asphaltene-containing composition and oxidizing the separated asphaltenes to form oxidation products. Alternatively, the method can include oxidizing asphaltenes within an asphaltene-containing composition without first separating the asphaltenes. Once formed, the oxidation products can be combined with other hydrocarbons. The amount of oxidation can be limited to an amount sufficient to produce a mixture suitable for the desired application. This method can be used to upgrade asphaltenes from a variety of sources, including oil sands. The oxidation step can be performed, for example, by introducing an oxidizing agent and, in some cases, a catalyst into the asphaltenes. A solvent or miscibility agent also can be introduced to improve mixing between the oxidizing agent and the asphaltenes.

Abstract: The present invention provides a method for extracting bitumen from an oil sand stream that includes the steps of: providing an oil sand stream; contacting the oil sand stream with a liquid comprising a solvent thereby obtaining a solvent-diluted oil sand slurry; separating the solvent-diluted oil sand slurry, thereby obtaining a solids-depleted stream and a solids-enriched stream; increasing the S/B weight ratio of the solids-enriched stream thereby obtaining a solids-enriched stream having an increased S/B weight ratio and a liquid stream; filtering the solids-enriched stream having an increased S/B weight ratio, thereby obtaining bitumen-depleted sand. In another embodiment, the invention is a system for practicing this method.

Abstract: Methods and systems for in situ extraction of bitumen from deposits of bitumen-containing material are described. The methods and systems can generally include establishing freeze walls within the deposit of bitumen-containing material to establish a confined zone into which solvents can be injected in order to extract bitumen from the bitumen-containing deposits. Different types of solvents can be sequentially injected in order to extract bitumen and also help reduce the amount of solvent left behind in the deposit.

Abstract: A process for separating bitumen from bitumen ore material includes extracting bitumen with a hydrocarbon solvent to produce a bitumen-enriched solvent phase and tailings. The tailings are dried or stripped in a dryer to remove any remaining hydrocarbon solvent. The amount of solvent discharged in the tailings may be less than 4 bbl per 1000 bbl of recovered bitumen.

Abstract: Methods and systems for preparing bitumen-laden solvent for downstream processing are described. The bitumen-laden solvent can be treated with various materials, such as water and emulsion breakers, followed by treating the bitumen-laden solvent in a desalter. The desalted bitumen-laden solvent can then be subjected to downstream processing, such as upgrading in a nozzle reactor.

Abstract: A nozzle reactor system for increasing the conversion rate of material feed injected into the nozzle reactor system. The system includes two or more nozzle reactors aligned in parallel. A main stream of material to be upgraded is divided such that one stream is produced for each nozzle reactor in the system. Each nozzle reactor includes an interior reactor chamber and an injection passage and material feed passage that are each in material injecting communication with the interior reactor chamber. Furthermore, the injection passage is aligned transversely to the injection passage. The injection passage is configured to accelerate cracking material passed therethrough to a supersonic speed. The product produced from each of the nozzle reactors is combined into one product stream.

Abstract: Methods and systems for integrating bitumen extraction processes with bitumen upgrading processes are disclosed. The methods and systems can include recovering an emulsion of hydrocarbon and water from a Steam Assisted Gravity Drainage extraction process, breaking the emulsion, using the water from the emulsion to make steam, upgrading the hydrocarbon from the emulsion using the steam, separating diluent from the upgraded hydrocarbon, and using the diluent to break SAGD-produced emulsion.

Abstract: Methods and systems of upgrading hydrocarbon material, such as bituminous material, are described. The methods and systems can reduce or eliminate the need for the use of atmospheric and/or vacuum distillation towers by instead using clyconic separation apparatus. The methods and systems can include the use of one or more cyclonic separation apparatus aligned in series in order to separate out a high boiling point fraction of the hydrocarbon material and then upgrading the high boiling point hydrocarbon material in a nozzle reactor.

Abstract: Methods and systems for upgrading hydrocarbon are described. The system can include a combustor and a nozzle reactor. The combustor can be used to produce a motive fluid suitable for use in the nozzle reactor. The motive fluid produced by the combustor and a hydrocarbon stream can be injected into the nozzle reactor to upgrade the hydrocarbon material. The systems and methods can also be integrated with a steam assisted gravity drainage system.

Abstract: Methods and systems for upgrading hydrocarbon on offshore platforms are described. Hydrocarbon material can be extracted from deposits under bodies of water and upgraded on offshore platforms, such as through the use of one or more nozzle reactors. The upgraded hydrocarbon material produced by the nozzle reactor, can than be transported back to shore through pipelines, in part due to the improved viscosity of the upgraded material.

Abstract: A bitumen extraction method can include the use of a two or more mixing drums aligned in series for spraying solvent over bituminous material and/or tailings loaded in the mixing drums while the mixing drums rotate. Such mixing can result in the dissolution of bitumen into the solvent, which then allows for the separation of a “dilbit” stream from the bituminous material.

Abstract: Methods for preparing solvent-dry, stackable tailings. The method can include the steps of adding a first quantity of solvent to a bitumen material to form a first mixture, separating a first quantity of bitumen-enriched solvent from the first mixture and thereby creating solvent-wet tailings, and adding a quantity of water to the solvent-wet tailings to separate a solvent component from the solvent-wet tailings and thereby forming solvent-dry, stackable tailings. The solvent used in the methods can include paraffinic solvent, such as pentane.

Abstract: A method of extracting bitumen from bituminous material. In some embodiments, the method may include loading a bitumen material in a column, followed by feeding a first quantity of solvent into the column. The method may also include collecting the bitumen-enriched solvent exiting the column. A quantity of the bitumen-enriched solvent may then be fed into the column. In some embodiments, the method may include simultaneously loading bitumen material and a solvent in a column, followed by feeding additional solvent into the column. The method may also include collecting bitumen-enriched solvent exiting the column, and feeding a quantity of the bitumen-enriched solvent into the column.