Abstract: Apparatuses, systems, and methods are disclosed for shale pyrolysis. A retort for shale pyrolysis may include a pyrolysis zone, a combustion zone, and a cool down zone. The pyrolysis zone may include one or more pyrolysis zone heat exchangers that transfer heat from a working fluid to shale for heating and pyrolyzing the shale. The combustion zone may include one or more injectors that inject oxygen to combust coke residue in the pyrolyzed shale. The cool down zone may include one or more cool down zone heat exchangers that cool the shale by transferring heat to the working fluid. In a further embodiment, the working fluid is circulated to heat the pyrolysis zone heat exchangers.

Abstract: Systems and methods for thermocatalytic treatment of material are provided. The system can have a charging region to supply starting material, a preconditioning zone in which preconditioned material is formed from the starting material, a pyrolysis zone in which pyrolyzed material is formed from the preconditioned material, and a separation unit for separation of the pyrolyzed material. In the preconditioning zone and the pyrolysis zone, a heater can be provided for heating of the material. Also provided in the pyrolysis zone are recirculation means with which a solid portion of the pyrolyzed material can be recirculated directly into the region of the pyrolysis zone facing toward the preconditioning zone.

Abstract: Methods, systems, and devices for liquid hydrocarbon fuel production, hydrocarbon chemical production, and aerosol capture are provided. For example, a carbon-oxygen-hydrogen (C—O—H) compound may be heated to a temperature of at least 800 degrees Celsius such that the C—O—H compound reacts through a non-oxidation reaction to generate at least a hydrocarbon compound that may be at least a component of a liquid hydrocarbon fuel or a hydrocarbon chemical. The liquid hydrocarbon fuel may be a liquid when at a temperature of 20 degrees Celsius. The C—O—H compound may include biomass. In some cases, the hydrocarbon compound produced through the non-oxidation reaction includes a hydrocarbon aerosol form as the hydrocarbon compound at least as it is produced or cools. Some embodiments include aerosol capture methods, systems, and devices, which may include passing a hydrocarbon aerosol form through a material in a liquid phase in order to gather the aerosol material.

Abstract: Described herein are biofuel pyrolysis devices and methods of use thereof. The devices described herein include a reactor having a plurality of chambers wherein the chambers of the reactor can be arranged to have at least one aerobic chamber and anaerobic chamber. In certain aspects, the devices described herein can be used for distilling biomass and for potentially generating torrefied products, which include, but are not limited to, torrefied biomass. In certain aspects, the method describe herein include, but are not limited to, introducing biomass onto at least one tray of a plurality of trays in a first chamber of the reactor, heating the biomass in the first chamber with heated vapor from at least one vapor inlet, and transferring the biomass from an upper tray to at least one of the following: a lower tray, a biomass outlet, another chamber (i.e., at least a second chamber), or any combination thereof.

Abstract: The present invention is directed to the upgrading of heavy hydrocarbon feedstock that utilizes a short residence pyrolytic reactor operating under conditions that cracks and chemically upgrades the feedstock. The process of the present invention provides for the preparation of a partially upgraded feedstock exhibiting reduced viscosity and increased API gravity. This process selectively removes metals, salts, water and nitrogen from the feedstock, while at the same time maximizes the yield of the liquid product, and minimizes coke and gas production. Furthermore, this process reduces the viscosity of the feedstock in order to permit pipeline transport, if desired, of the upgraded feedstock with little or no addition of diluents.

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: 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 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 method for pyrogasification of organic wastes that employs a vertical furnace filled with metal masses in the shape of metal toroids (2) previously raised to a high temperature (500 to 1100° C.) and organic materials to be pyrolyzed. It also employs a furnace for heating toroids transported by an Archimedes screw driven by a gear motor, as well as a separator for recovering the mineral residues, whereby separation between the toroids and residues is effected with the aid of a screen and an Archimedes screw driven by a gear motor.

Abstract: The present invention is directed to the upgrading of heavy hydrocarbon feedstock. The process of the present invention provides for the preparation of a partially upgraded feedstock exhibiting reduced viscosity and increased API gravity. This process reduces the viscosity of the feedstock in order to permit pipeline transport of the upgraded feedstock with little or no addition of diluents. The method for upgrading a heavy hydrocarbon feedstock comprises introducing a particulate heat carrier into an upflow reactor, introducing the heavy hydrocarbon feedstock into the upflow reactor at a location above that of the particulate heat carrier, allowing the heavy hydrocarbon feedstock to interact with the heat carrier to produce a product stream, separating the product stream from the particulate heat carrier, regenerating the particulate heat carrier, and collecting a gaseous and liquid product from the product stream.

Abstract: The present invention is directed to the upgrading of heavy hydrocarbon feedstock that utilizes a short residence pyrolytic reactor operating under conditions that cracks and chemically upgrades the feedstock. The process of the present invention provides for the preparation of a partially upgraded feedstock exhibiting reduced viscosity and increased API gravity. This process selectively removes metals, salts, water and nitrogen from the feedstock, while at the same time maximizes the yield of the liquid product, and minimizes coke and gas production. Furthermore, this process reduces the viscosity of the feedstock in order to permit pipeline transport, if desired, of the upgraded feedstock with little or no addition of diluents.

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 hot solids process wherein a predetermined output, which is designed to be suitable for use as an input to a petrochemical process, is capable of being generated through the use of the hot solids process. The mode of operation of such a hot solids process is designed to be such that preferably a portion of the otherwise normally unusable product output, which is produced from a petrochemical process, is designed to be utilized as an input to the hot solids process for purposes of generating from the hot solids process the predetermined output that is suitable for use as an input to a petrochemical process.

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 present development is a multistage process for converting solid hydrocarbon resources into synthetic oil. The process comprises a raw hydrocarbon material treatment stage, followed by a pyrolysis stage, and then a synthetic liquid upgrading stage. Throughout the process, heat is transferred to the hydrocarbon resources via recyclable ceramic spheres.

Abstract: The present invention is directed to the upgrading of heavy hydrocarbon feedstock that utilizes a short residence pyrolytic reactor operating under conditions that cracks and chemically upgrades the feedstock. The process of the present invention provides for the preparation of a partially upgraded feedstock exhibiting reduced viscosity and increased API gravity. This process selectively removes metals, salts, water and nitrogen from the feedstock, while at the same time maximizes the yield of the liquid product, and minimizes coke and gas production. Furthermore, this process reduces the viscosity of the feedstock in order to permit pipeline transport, if desired, of the upgraded feedstock with little or no addition of diluents.

Abstract: A process for the reductive hydrogenation of insufficiently hydrogenated, non-volatile carbonaceous materials to produce vaporizable products wherein the feed materials are brought into initial solution under pressure 300-500.degree. C. with or without the addition of recycle solvent with or without added catalyst. The catalyst may, as an option, be added during agglomeration, if that technique is used, as an oily precursor or as a slurry of a somewhat hydrophobic {namosize} nanosize particulate catalyst or catalyst precursor. Short-contact-time reactors providing plug-type flow and high shear are used. The resultant ashy slurry is passed, highly dispersed, into a fluidized or moving bed of solids that may be inert or catalytic at 350-500.degree. C. and 100-3500 psi where a reducing gas passing up through the bed reductively increases the volatility and decreases the molecular weight of the feed in what is the equivalent of reaction of the feed on each particle in an extremely piston flow manner.

Abstract: A process for the thermal conversion of the organic component associated with tar sands to lower boiling, higher value products. The conversion is achieved by subjecting the organic component containing from about 1 to 20 wt. % native solids to elevated temperatures and pressures. Compared to conventional thermal conversion processes, such as visbreaking, much higher conversion of the organic component can be achieved owing to the presence of native solids on which coke is deposited instead of fouling the process equipment. This higher conversion is also associated with enhanced removal of sulfur and metals.

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: First, nitrogen oxides are reduced by firing coal in substoichiometric air conditions in a first stage oxidation unit of a combustor to reduce NO.sub.x from fuel bound nitrogen. Hydrated lime, Ca(OH).sub.2, is introduced into the first stage oxidation unit to produce calcium sulfide. The calcium sulfide becomes tied up in a slag eutectic which is removed prior to entry of the fuel gas to a second stage oxidation unit at the entrance of a furnace where additional preheated air is added to the fuel gas.

Abstract: Method to convert refuse derived fuel (RDF) into a combustible gas, whereby the refuse derived fuel is gasified and the derived gas undergoes a process of catalytic cracking in which at least one alkaline additive or an equivalent product is used, the gas being passed through a cyclone separator to collect the particulate solids and thereafter undergoing a cooling process with recovery of hot air before being passed through sleeve filters, the ashes of the gasification and the particulate solids being sent to a dump for ashes, the ashes of gasification being riddled beforehand to gather the fines, which are mixed with fines coming from the sleeve filters and are employed as further catalysts in the catalytic cracking process.

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 the recovery of oil from solid hydrocarbonaceous material and particularly from oil shale by retorting fresh feed shale and heat medium particles using a fluidized bed. The invention uses a self supporting dense phase fluidized bed in a retort without the need to use an external fluid for fluidization.Also described is a control system for the method whereby feed stock input rate is controlled as a function of flow rate of oil vapour products given off, and whereby heat medium particle input rate is controlled as a function of the temperature of either the retort bed or of the oil vapor product.

Abstract: Dewaxing processes for hydrocarbon feedstocks are disclosed using novel catalysts comprising specific silicoaluminophosphates of U.S. Pat. No. 4,440,871. The products of the instant dewaxing processes are characterized by lower pour points than the hydrocarbon feedstock.

Abstract: Burned oil shale recycled as heat transfer solids in retorting process conditioned under reducing conditions with hydrocarbon to improve product yield.

Abstract: Oil shale is well mixed and efficiently, effectively, and economically retorted in a special gravity flow retorting process and system which utilizes novel arrangements of internal baffles in a static mixer.

Abstract: Oil-containing solids are dried and heated by contacting them in a drying zone with superheated steam admitted to the zone at a temperature in excess of 200.degree. C. The heated solids may be distilled to remove hydrocarbons therefrom and the resulting proceduce and/or combustion products of the distillation or other combustion products are used to heat a mixed vapor remainder, after separation of said carbon from the vapors formed during the drying, to the temperature of 1200.degree. C. for recirculation to the drying zone.

Abstract: An improved process for retorting a solid carbonaceous material at elevated temperatures wherein a portion of the spent solids withdrawn from the retort is heated to a temperature within the range from about 1600.degree. F. to about 2400.degree. F. and then recycled to the retort as a source of heat at a temperature within the range from about 650.degree. F. to about 1600.degree. F. When the improved process of this invention is operated in this manner, the amount of liquid product obtained is maximized and the amount of gaseous product minimized. Moreover, the integrity of the particles thus recycled is improved and the amount of fines in the liquid product correspondingly reduced.

Abstract: Oil shale is well mixed and efficiently, effectively, and economically retorted in a special gravity flow retorting process and system which utilizes novel arrangements of internal baffles in a static mixer.