Abstract: The present invention describes a process for the production of carbon black starting from a 360+ cut known as a slurry cut obtained from a FCC or RFCC unit, to which a vacuum residue type cut may be added, said process using a specific hydrotreatment unit.

Abstract: A method of concurrently retorting dissimilar hydrocarbonaceous resource streams comprising at least two rotary kilns arranged in a series and closely coupled in an air-tight continuous process flow configuration so as to create a virtual singular rotary kiln yet having distinct residence times and temperature differentials and material processing zones also having continuous thermal coupling and process efficiency achieved by passing along from the first rotary kiln all of the hot spent inorganic waste materials between and into the at least second rotary kiln to then have other dissimilar hydrocarbonaceous matter added therein and differentially heated until the hot inorganic waste materials are released from the at least the second rotary kiln and the increasing residual waste matter volume generated in the combined serial process is ultimately discharged into a secondary heat recovery system.

Abstract: A process for upgrading unconventional or heavy oils such as, tar sands, shale oil, or bitumen. This process may include a coking scheme in which oil-containing solids, of suitable size, are fed directly into the riser of an FCC unit. Contacting a hot stream of solids causes vaporization and produces a gaseous product stream. The gaseous product may be separated out in a separating vessel and coked or unconverted oil-containing solids may be transferred to a gasifier for combustion at high temperatures to remove the coke and residual oil. Syngas from the gasifier may be converted to hydrogen using a water gas shift reaction. The hydrogen may be used for hydroprocessing.

Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed. In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.

Abstract: A system, apparatus and method for hydrocarbon extraction from feedstock material that is or includes organic material, such as oil shale, coal, lignite, tar sands, animal waste and biomass. A retort system including at least one retort vessel may include a monolithic dome structure surrounded by a process isolation barrier, the dome structure being sealingly engaged with the process isolation barrier. The dome structure and the process isolation barrier define a retort chamber, at least a portion of which may comprise a subterranean chamber. A lower end of the dome retort structure provides an exit for collected hydrocarbons and spent feedstock material. Systems may include a plurality of such dome retort structures. A control system may be used for controlling one or more operating parameters of a retorting process performed within such a dome retort structure for extraction and collection of hydrocarbons.

Abstract: A system for producing petroleum products from oil shale includes one or plural kiln lines made up of plural series-connected, indirect-fired, inclined rotary kilns. Plural kiln lines are operated for parallel processing. Oil shale is advanced through kilns in succession and exhausted from each kiln line substantially free of hydrocarbons. Successive kilns along the advancement of oil shale are maintained at successively higher temperatures. A fuel distinct from hydrocarbons in oil shale, such as syngas from a gasifier or hydrogen gas from a separator, drives pyrolysis to extract hydrocarbons. A refining unit located proximate to the kiln lines upgrades extracted hydrocarbons into petroleum products and separates the petroleum products by criteria. A heat extraction unit recovers heat from exhausted oil shale for reuse in kilns. A method involves drying oil shale followed by heating dry oil shale in successively hotter pyrolysis environments.

Abstract: A process for the conversion of biomass to a liquid fuel is presented. The process includes the production of diesel and naphtha boiling point range fuels by hydrotreating and hydrocracking of lignin in the biomass in a one step process.

Abstract: The present invention discloses a process for dry distillation and decarbonization of oil shale species using fluidized bed. The shale oil contained in oil shale having certain size distribution in fluidizing condition is gasified by using high temperature dry gas and/or high temperature stream as heat carrier and fluidizing medium, meanwhile, dry gas dissolves some organics in oil shale, that is, fluidizing, dry distillating and deoiling. The powder which has removed shale oil is fluidized by high temperature air under oxygen-rich condition. The carbon in oil shale is combusted, i.e. fluidizing decarbonization.

Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed; In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.

Abstract: A process for upgrading unconventional or heavy oils such as, tar sands, shale oil, or bitumen. This process may include a coking scheme in which oil-containing solids, of suitable size, are fed directly into the riser of an FCC unit. Contacting a hot stream of solids causes vaporization and produces a gaseous product stream. The gaseous product may be separated out in a separating vessel and coked or unconverted oil-containing solids may be transferred to a gasifier for combustion at high temperatures to remove the coke and residual oil. Syngas from the gasifier may be converted to hydrogen using a water gas shift reaction. The hydrogen may be used for hydroprocessing.

Abstract: The invention provides a liquefaction process using comminuted fuel solids from a steam-driven shear field, with controlled water content and optionally coated with a catalyst. The method allows fuel solids to be liquefied efficiently during comminution or when they are supplied in the form of a slurry or as free-standing solids.

Abstract: The invention concerns a method for energy conversion of solid fuels in particular containing carbon comprising a first step which consists in reacting said fuels in a first energy conversion reactor (2, 20). The invention is characterized in that it comprises a second step which consists in injecting oxygen brought to the output of said reactor (2, 20), the reaction of the first step being carried out in at least a circulating fluidized bed (30, 31, 40) and in that the metal oxides circulate between two interconnected circulating fluidized beds (30, 31, 40) converting the fuel and oxidizing the oxides.

Abstract: A retort heating apparatus includes a perimeter wall bounding a central compartment. A partition wall is disposed within the central compartment so as to separate the central compartment into at least a heating chamber and a vapor chamber. The partition wall has a plurality of spaced apart apertures formed thereon so as to provide fluid communication between the heating chamber and the collection chamber. A plurality of spaced apart baffles are disposed within the heating chamber between the perimeter wall and the partition wall. A collection plate is disposed within the vapor chamber at a downward curved or sloped orientation. The collection plate has lower end disposed at or adjacent to the partition wall and an opposing upper end disposed at or toward the perimeter wall.

Abstract: The invention relates to a continuous process for producing synthetic crude oil from oil bearing material, e.g., oil shale or tar sand, through continuous feeding and calcining, hydrocracking and hydrogenating kerogen or bitumen.

Abstract: A vibrating bed pyrolysis system has a vibrating bed which is supplied with hot solid particles. Dry coal particles are rapidly heated by the hot solid particles to drive off hydrocarbon vapors. The vapors are condensed in a jet condenser, and products are flowed to a header tank. A portion of the liquid product is stored at room temperature for later use. A small portion of the liquid product is pumped from the header tank and cooled to ambient temperature and is sprayed in the jet condenser, which is positioned above the vibrating pyrolysis bed. A dryer bed vibrated by the same vibrating machine which vibrates the pyrolysis bed is supplied with hot solid particles and the crushed coal. Moisture in the coal particles is evaporated, and water vapors entrain coal fines before the coal particles are passed to the pyrolysis bed. The hot solid particles are taken from a fluidized bed combustor and are returned to the combustor with the coal char particles by entrainment into the gas lift system.

Abstract: A vibrating bed pyrolysis system has a vibrating bed which is supplied with hot solid particles. Dry coal particles are rapidly heated by the hot solid particles to drive off hydrocarbon vapors. The vapors are condensed in a jet condenser, and products are flowed to a header tank. A portion of the liquid product is stored at room temperature for later use. A small portion of the liquid product is pumped from the header tank and cooled to ambient temperature and is sprayed in the jet condenser, which is positioned above the vibrating pyrolysis bed. A dryer bed vibrated by the same vibrating machine which vibrates the pyrolysis bed is supplied with hot solid particles and the crushed coal. Moisture in the coal particles is evaporated, and water vapors entrain coal fines before the coal particles are passed to the pyrolysis bed. The hot solid particles are taken from a fluidized bed combustor and are returned to the combustor with the coal char particles by entrainment into the gas lift system.

Abstract: A system and process for educing hydrocarbons from shale. The system comprises a retort vessel which has an integral apparatus for mixing raw and recycle shale that embodies raw shale pulverizing and has an integral apparatus for finally pulverizing the raw shale particulates that have descended through a fluidized bed. The system further comprises: a burner which generates process heat; heat transfer apparatus which extracts heat for use in the process; and means for recovering such heat. The process involves recovery of significant amounts of process energy including: the recovery of heat from retort vapors; the recovery of heat from spent shale; recovery and utilization of the heat of combustion; and recycling of gases for the operation of mechanical pulverizing apparatus.

Abstract: A method for mild gasification of crushed coal in a single vertical elongated reaction vessel providing a fluidized bed reaction zone, a freeboard reaction zone, and an entrained reaction zone within the single vessel. Feed coal and gas may be fed separately to each of these reaction zones to provide different reaction temperatures and conditions in each reaction zone. The reactor and process of this invention provides for the complete utilization of a coal supply for gasification including utilization of caking and non-caking or agglomerating feeds in the same reactor. The products may be adjusted to provide significantly greater product economic value, especially with respect to desired production of char having high surface area.

Abstract: A process for catalytic multi-stage hydrogenation and liquefaction of coal to produce high yields of low-boiling hydrocarbon liquids containing low concentrations of nitogen compounds. First stage catalytic reaction conditions are 700.degree.-800.degree. F. temperature, 1500-3500 psig hydrogen partial pressure, with the space velocity maintained in a critical range of 10-40 lb coal/hr ft.sup.3 catalyst settled volume. The first stage catalyst has 0.3-1.2 cc/gm total pore volume with at least 25% of the pore volume in pores having diameters of 200-2000 Angstroms. Second stage reaction conditions are 760.degree.-870.degree. F. temperature with space velocity exceeding that in the first stage reactor, so as to achieve increased hydrogenation yield of low-boiling hydrocarbon liquid products having at least 75% removal of nitrogen compounds from the coal-derived liquid products.

Abstract: A process for retorting oil shale in a vertical retort. Recycle gas containing steam and produced gas is separated from the retort off-gas and used to heat the oil shale. The steam is present in amount by volume of the recycle gas of at least 40% and preferably 70%. The minimum particle size of the oil shale is such that the particles are retained on a screen having 1/4 inch openings. The maximum particle size is such that the particles are capable of passing through a screen having 3 inch openings.

Abstract: A process and apparatus for the production of coke, asphalt and jet fuel m a feed of fossil fuels containing volatile carbon compounds therein is disclosed. The process includes the steps of pyrolyzing the feed in an entrained bed pyrolyzing means, separating the volatile pyrolysis products from the solid pyrolysis products removing at least one coke from the solid pyrolysis products, fractionating the volatile pyrolysis products to produce an overhead stream and a bottom stream which is useful as asphalt for road pavement, condensing the overhead stream to produce a condensed liquid fraction and a noncondensable, gaseous fraction, and removing water from the condensed liquid fraction to produce a jet fuel-containing product. The disclosed apparatus is useful for practicing the foregoing process. the process provides a useful method of mass producing and jet fuels from materials such as coal, oil shale and tar sands.

Abstract: Recycled oil solvents for coal extraction have their content of saturated cyclic species reduced by thermal cracking at 470.degree. to 540.degree. C. for a few minutes, restoring their effectiveness as solvents for coal.

Abstract: The process for obtaining oil, gas and other products from pyrobituminous shales and the like includes introducing crushed shale into a retort and contacting the crushed shale in the top portion of the retort with a stream of retort gases. Hot gases are injected at an intermediate point of the retort and a stream of cold gases are injected at the bottom of the retort. The gaseous retorted matter above the zone where the shale undergoes pyrolysis is removed and directed to a cyclone from separation of heavy liquid components from a gaseous stream. The gaseous stream is then purified and compressed with a portion of the compressed stream being heated and reinjected as the steam of hot gases into the retort. The other portion of the compressed stream of gases is cooled and a liquid component consisting primarily of water and heavy oil is separate therefrom in a spray tower.

Abstract: A process for the pyrolysis of carbonaceous materials at an elevated temperature or an elevated temperature and an elevated pressure in which a fuel is burned in the presence of a combustion supporting material, in an amount sufficient to supply at least the stoichiometric amount of oxygen for combustion of all of the fuel, to produce an effluent containing significant amounts of nitrogen and carbon dioxide and having an elected temperature, passing the effluent to a pyrolysis zone, wihtout removal of components therefrom, to thereby create an elevated temperature within the pyrolysis zone and pyrolyzing the carbonaceous material in the pyrolysis zone in the presence of the effluent from the burning step and at an elevated temperature. The burning step may additionally be carried out at a high flame velocity to produce an effluent having an elevated pressure and the carbonaceous material may thus additionally be pyrolyzed at an elevated pressure.

Abstract: A method and apparatus for utilizing tar sands having a broad range of bitumen content is disclosed. More particularly, tar sands are pyrolyzed in a cyclone retort with high temperature gases recycled from the cyclone retort to produce oil and hydrocarbon products. The spent tar sands are then burned at 2000.degree. F. in a burner to remove residual char and produce a solid waste that is easily disposable. The process and apparatus have the advantages of being able to utilize tar sands having a broad range of bitumen content and the advantage of producing product gases that are free from combustion gases and thereby have a higher heating value. Another important advantage is rapid pyrolysis of the tar sands in the cyclone so as to effectively utilize smaller sized reactor vessels for reducing capitol and operating costs.

Abstract: A process for two-stage catalytic co-processing of coal and heavy petroleum hydrocarbon liquid fractions to produce increased yields of low-boiling hydrocarbon liquid and gas products. In the process, the particulate coal is slurried with a petroleum residuum and optionally with a process-derived hydrocarbon liquid solvent and fed into a first stage catalytic reaction zone operated at relatively mild conditions which promote controlled rate liquefaction of the coal while simultaneously hydrogenating the petroleum and hydrocarbon recycle oils at conditions favoring hydrogenation reactions. The first stage reactor is maintained at 650.degree.-800.degree. F. temperature, 1000-4000 psig hydrogen partial pressure and 10-100 lb/hr/ft.sup.3 space velocity for the total coal and oil feed. From the first stage reaction zone, the partially hydrogenated effluent material is passed directly to the close-coupled second stage catalytic reaction zone maintained at more severe conditions of 750.degree.-900.degree. F.

Abstract: A fluidized-bed bioreactor system for the conversion of coal into microbially solubilized coal products. The fluidized-bed bioreactor continuously or periodically receives coal and bio-reactants and provides for the production of microbially solubilized coal products in an economical and efficient manner. An oxidation pretreatment process for rendering coal uniformly and more readily susceptible to microbial solubilization may be employed with the fluidized-bed bioreactor.

Abstract: A process for two-stage catalytic hydrogenation and liquefaction of coal to produce increased yields of low-boiling hydrocarbon liquid and gas products. In the process, the particulate coal is slurried with a process-derived liquid solvent and fed at temperature below about 650.degree. F. into a first stage catalytic reaction zone operated at conditions which promote controlled rate liquefaction of the coal, while simultaneously hydrogenating the hydrocarbon recycle oils at conditions favoring hydrogenation reactions. The first stage reactor is maintained at 650.degree.-800.degree. F. temperature, 1000-4000 psig hydrogen partial pressure, and 10-60 lb coal/hr/ft.sup.3 reactor space velocity. The partially hydrogenated material from the first stage reaction zone is passed directly to the close-coupled second stage catalytic reaction zone maintained at a temperature at least about 25.degree. F. higher than for the first stage reactor and within a range of 750.degree.-875.degree. F.

Abstract: The invention relates to a hydrocarbon-containing solids retorting process, such as, for example, shale, coal, tar sands, etc., the particles of which are below 6 mm in size, at a vertical entrainment regime, with superheated steam.As an alternative to the process, the preheating of the solid charge to be fed to the reactor is foreseen, by a stream of retorted solids, removed from the primary separator, when effecting separation of the solid and gaseous phases from the retorting products. Heat exchange to the reactor is augmented by the use of static mixing devices provided in said reactor.

Abstract: Method for the production of liquid products, particularly, tar, from organic bulk materials.The invention relates to a method, whereby in an apparatus in one or a multiple of refining stages, organic bulk goods are refined to economically significant base materials, so that they are suitable, either directly or indirectly, for the production of gasifier or diesel fuel.The technical object is to utilize a fluidizing medium, with the help of which it is possible to produce, in a reaction chamber, an increased yield of liquid products, especially tar.According to the invention, the problem is solved by supplying a hydrocarbonaceous gas, especially a gas containing methane and hydrogen, as a fluidizing medium in the individual refining stages, whereby, under the particular refining conditions, there results a decrease of the portion of methane and hydrogen, and a comparative increase of the portion of the liquid product, especially of the portion of tar.

Abstract: An improved coking process for normally solid carbonaceous materials wherein the yield of liquid product from the coker is increased by adding ammonia or an ammonia precursor to the coker. The invention is particularly useful in a process wherein coal liquefaction bottoms are coked to produce both a liquid and a gaseous product. Broadly, ammonia or an ammonia precursor is added to the coker ranging from about 1 to about 60 weight percent based on normally solid carbonaceous material and is preferably added in an amount from about 2 to about 15 weight percent.

Abstract: Sub-bituminous coal is directly liquefied in two stages by use of a liquefaction solvent containing insoluble material as well as 850.degree. F.+ material and 850.degree. F.- material derived from the second stage, and controlled temperature and conversion in the second stage. The process is in hydrogen balance.