Abstract: Devices, systems, and processes are provided for retorting and extracting hydrocarbons from oil shale. A heat transfer fluid includes at least one liquefied petroleum gas (LPG) component such as, for example, propane or butane. The heat transfer fluid moves through a heat delivery loop to retort oil shale, thereby facilitating the production of recoverable hydrocarbons. While the heat transfer fluid moves through the heat delivery loop, cracking of a portion of the heat transfer fluid may produce various hydrocarbon materials that may be provided to a product stream.

Abstract: A heating system for a subterranean mineral formation according to embodiments of the present invention includes a casing positioned in a bore in the subterranean mineral formation, the casing having an outer surface and an inner surface, a heating element positioned within the casing, a surface connection system having a first end coupled to the heating element within the casing and a second end at a top ground surface above the subterranean mineral formation, a heat transfer fluid contained within the casing, the heat transfer fluid configured to transfer heat between the heating element and the inner surface of the casing, wherein at least a portion of the heat transfer fluid is undergoing phase changes between liquid and gas in order to regulate a temperature of the casing. Fins may be included on the outside of the casing to enhance heat transfer.

Abstract: Devices, systems, and processes are provided for retorting and extracting hydrocarbons from oil shale. A heat transfer fluid includes at least one liquefied petroleum gas (LPG) component such as, for example, propane or butane. The heat transfer fluid moves through a heat delivery loop to retort oil shale, thereby facilitating the production of recoverable hydrocarbons. While the heat transfer fluid moves through the heat delivery loop, cracking of a portion of the heat transfer fluid may produce various hydrocarbon materials that may be provided to a product stream.

Abstract: Heaters are presented to aid in the recovery of hydrocarbon from underground deposits. A heater is provided to a well that has been drilled through an oil-shale deposit. A fuel and an oxidizer are provided to the heater and flue gases are recovered. The heater has a counterflow design and provides a nearly uniform temperature along the heater length. The heater may be designed to operate at different temperatures and depths to pyrolyze or otherwise heat underground hydrocarbon deposits to form a product that is easily recovered and which is useful without substantial further processing. Various counterflow heaters are described including heaters having, down the heater length, distributed reaction zones, distributed catalytic oxidation of the fuel, and discrete or continuous heat generation. The heaters may also utilize inert gases from product recovery or from heater flue gases to control the heater temperature.

Abstract: A heating system for a subterranean mineral formation according to embodiments of the present invention includes a casing positioned in a bore in the subterranean mineral formation, the casing having an outer surface and an inner surface, a heating element positioned within the casing, a surface connection system having a first end coupled to the heating element within the casing and a second end at a top ground surface above the subterranean mineral formation, a heat transfer fluid contained within the casing, the heat transfer fluid configured to transfer heat between the heating element and the inner surface of the casing, wherein at least a portion of the heat transfer fluid is undergoing phase changes between liquid and gas in order to regulate a temperature of the casing. Fins may be included on the outside of the casing to enhance heat transfer.

Abstract: A sub-surface hydrocarbon production system comprising an energy delivery well extending from the surface to a location proximate a bottom of the hydrocarbons to be produced. A production well extends from the surface to a location proximate the hydrocarbon and a convection passage extends between the energy delivery well and the production well thereby forming a convection loop. The energy delivery well and the production well intersect at a location proximate the hydrocarbon such that the convection loop is in the form of a triangle. Preferably, the convection passage extends upwardly from a point at which the convection passage intersects the production well. The system also includes a heater, such as an electric heater or down-hole burner, disposed in the energy delivery well.

Abstract: Heater embodiments are presented to aid in the recovery of hydrocarbon from underground deposits. In one embodiment, a heater is provided to a well that has been drilled through an oil-shale deposit. A fuel and an oxidizer are provided to the heater and flue gases are recovered. The heater has a counterflow design and provides a nearly uniform temperature along the heater length. The heater may be designed to operate at different temperatures and depths to pyrolyze or otherwise heat underground hydrocarbon deposits to form a product that is easily recovered and which is useful without substantial further processing. Various embodiments of a counterflow heater are described including heaters having, down the heater length, distributed reaction zones, distributed catalytic oxidation of the fuel, and discrete or continuous heat generation. The heaters may also utilize inert gases from product recovery or from heater flue gases to control the heater temperature.

Abstract: A process for retorting and extracting sub-surface hydrocarbons. The process comprises drilling an energy delivery well extending from the surface to a location proximate a bottom of the hydrocarbons. The hydrocarbons are heated from the bottom to form a retort, the retort extending along a portion of the energy delivery well. A vapor tube is extended to a location proximate the retort, the vapor tube having an entrance corresponding to the region of the retort along the energy delivery well that is nearest the surface exit.

Abstract: A sub-surface hydrocarbon production system comprising an energy delivery well extending from the surface to a location proximate a bottom of the hydrocarbons to be produced. A production well extends from the surface to a location proximate the hydrocarbon and a convection passage extends between the energy delivery well and the production well thereby forming a convection loop. The energy delivery well and the production well intersect at a location proximate the hydrocarbon such that the convection loop is in the form of a triangle. Preferably, the convection passage extends upwardly from a point at which the convection passage intersects the production well. The system also includes a heater, such as an electric heater or down-hole burner, disposed in the energy delivery well.

Abstract: A process for retorting and extracting sub-surface hydrocarbons. The process comprises drilling an energy delivery well extending from the surface to a location proximate a bottom of the hydrocarbons. The hydrocarbons are heated from the bottom to form a retort, the retort extending along a portion of the energy delivery well. A vapor tube is extended to a location proximate the retort, the vapor tube having an entrance corresponding to the region of the retort along the energy delivery well that is nearest the surface exit.

Abstract: A system and process for extracting hydrocarbons from a subterranean body of oil shale within an oil shale deposit located beneath an overburden. The system comprises an energy delivery subsystem to heat the body of oil shale and a hydrocarbon gathering subsystem for gathering hydrocarbons retorted from the body of oil shale. The energy delivery subsystem comprises at least one energy delivery well drilled from the surface of the earth through the overburden to a depth proximate a bottom of the body of oil shale, the energy delivery well extending generally downward from a surface location above a proximal end of the body of oil shale to be retorted and continuing proximate the bottom of the body of oil shale. The energy delivery well may extend into the body of oil shale at an angle.

Abstract: A system and process for extracting hydrocarbons from a subterranean body of oil shale within an oil shale deposit located beneath an overburden. The system comprises an energy delivery subsystem to heat the body of oil shale and a hydrocarbon gathering subsystem for gathering hydrocarbons retorted from the body of oil shale. The energy delivery subsystem comprises at least one energy delivery well drilled from the surface of the earth through the overburden to a depth proximate a bottom of the body of oil shale, the energy delivery well extending generally downward from a surface location above a proximal end of the body of oil shale to be retorted and continuing proximate the bottom of the body of oil shale. The energy delivery well may extend into the body of oil shale at an angle.

Abstract: The present invention provides a process for thermosetting pitch fibers in reduced times, at low concentrations of oxygen and at higher temperatures than previously possible. Additionally, the present invention provides a pitch fiber which has an oxygen diffusion rate to the center of the fiber which is competitive with the rate of oxidation at the fiber's surface. Further, the present invention provides a high density pitch fiber batt which thermosets without loss of fiber structure.

Abstract: The present invention provides a process for thermosetting pitch fibers in reduced times, at low concentrations of oxygen and at higher temperatures than previously possible. Additionally, the present invention provides a pitch fiber which has an oxygen diffusion rate to the center of the fiber which is competitive with the rate of oxidation at the fiber's surface. Further, the present invention provides a high density pitch fiber batt which thermosets without loss of fiber structure.

Abstract: An improved process is disclosed for producing a unique metals-containing anisotropic pitch suitable for carbon fiber manufacture. Soluble, aromatic-organometallic compounds are added to a carbonaceous feedstock which is substantially free of mesophase pitch and the resulting composition is heat soaked to produce an isotropic pitch product containing mesogens and soluble, aromatic-organometallic compounds. Next, the pitch product is solvent fractionated to separate mesogens which contain metals from the organometallic compounds. The metals-containing mesogens are heated to a temperature sufficient to cause fusion to produce a metals-containing mesophase pitch. In another method, the carbonaceous feedstock is heat soaked to produce an isotropic pitch product containing mesogens and high molecular weight, soluble, aromatic-organometallic compounds are added to the mesogen containing isotropic pitch product prior to solvent fractionation.

Abstract: The present invention provides a process for thermosetting pitch fibers in reduced times, at low concentrations of oxygen and at higher temperatures than previously possible. Additionally, the present invention provides a pitch fiber which has an oxygen diffusion rate to the center of the fiber which is competitive with the rate of oxidation at the fiber's surface. Further, the present invention provides a high density pitch fiber batt which thermosets without loss of fiber structure.

Abstract: An improved process is disclosed for producing a unique metals-containing anisotropic pitch suitable for carbon fiber manufacture. Soluble, aromatic-organometallic compounds are added to a carbonaceous feedstock which is substantially free of mesophase pitch and the resulting composition is heat soaked to produce an isotropic pitch product containing mesogens and soluble, aromatic-organometallic compounds. Next, the pitch product is solvent fractionated to separate mesogens which contain metals from the organometallic compounds. The metals-containing mesogens are heated to a temperature sufficient to cause fusion to produce a metals-containing mesophase pitch.In another method, the carbonaceous feedstock is heat soaked to produce an isotropic pitch product containing mesogens and high molecular weight, soluble, aromatic-organometallic compounds are added to the mesogen containing isotropic pitch product prior to solvent fractionation.

Abstract: An improved process is disclosed for producing a unique metals-containing anisotropic pitch suitable for carbon fiber manufacture. Soluble, aromatic-organometallic compounds are added to a carbonaceous feedstock which is substantially free of mesophase pitch and the resulting composition is heat soaked to produce an isotropic pitch product containing mesogens and soluble, aromatic-organometallic compounds. Next, the pitch product is solvent fractionated to separate mesogens which contain metals from the organometallic compounds. The metals-containing mesogens are heated to a temperature sufficient to cause fusion to produce a metals-containing mesophase pitch.In another method, the carbonaceous feedstock is heat soaked to produce an isotropic pitch product containing mesogens and high molecular weight, soluble, aromatic-organometallic compounds are added to the mesogen containing isotropic pitch product prior to solvent fractionation.

Abstract: Isotropic pitch containing mesogens is combined with a solvent and subjected to dense phase or supercritical conditions and the mesogens are phase separated. In one aspect the isotropic pitch containing mesogens is fluxed with a solvent to solubilize the mesogens, the flux mixture is filtered to remove nonsolubles and the mesogens are phase separated by use of the same solvent under dense phase or supercritical conditions of temperature and pressure. The phase separation conditions are such that the mesogens are recovered as mesophase.

Abstract: An internally-fired vertical shaft kiln for calcining coke wherein a downwardly moving coke bed has a co-current preheat gas stream in the upper portion of the kiln and a counter-current combustion gas stream in the lower portion of the kiln. Both gases are removed at the midportion of the kiln. Combustion air is introduced to the kiln through an inclined grate at the bottom of the kiln which retains a layer of coke thereon for internal combustion. The calcined coke moves over the combusting coke layer on the grate and then through a passage to a cooling chamber where a gas stream is passed through the calcined coke for cooling. The gas stream heated in the cooling chamber can be used as the co-current gas preheat stream in the upper section of the kiln.