Method for recovery of hydrocarbon oils from oil shale and other carbonaceous solids

Abstract

A continuous, efficient surface method for thermal recovery of hydrocarbons from a solid feedstock is described that includes a self-contained process that produces hydrogen for upgrading the hydrocarbons to produce motor fuel. The hydrogen also is used as a clean burning fuel for the thermal processing. The hydrogen is produced as a component of synthesis gas formed by gasification of coal. The synthesis gas is processed to remove and dispose of carbon dioxide and by-product sulfur. Combustion of the hydrogen to provide indirect heating of the solid feedstock maximizes hydrocarbons that can be upgraded and reduces or eliminates the emission of carbon dioxide into the atmosphere.

1 . A surface method for continuously producing hydro treated and/or hydro cracked liquid hydrocarbons from a solid feedstock, said method comprising:
 preparing a first solid feedstock to a predetermined size and moisture content;   preparing a second solid feedstock to complement first solid feedstock;   providing a reactor suited for processing said first solid feedstock at substantially atmospheric pressure;   providing sufficient thermal energy to said reactor to operate said reactor;   preheating a reactor sweep gas;   feeding said first solid feedstock into said reactor to thermally liberate hydrocarbons from said first solid feedstock;   directing said preheated reactor sweep gas through said reactor to remove said hydrocarbons from said reactor;   cooling said hydrocarbons to condense liquid hydrocarbons;   separating said liquid hydrocarbons from gaseous hydrocarbons, other reactor off-gases and reactor sweep gas;   treating said liquid hydrocarbon with hydrogen to produce a hydro treated and/or hydro cracked liquid hydrocarbon;   gasifying or reforming said second solid feedstock to produce a syngas; and   processing said syngas to produce an amount of hydrogen sufficient to hydro treat said liquid hydrocarbons, producing said hydro treated liquid hydrocarbons and also to provide said clean burning fuel to heat said reactor.   
     
     
         2 . The method of  claim 1 , wherein said first solid feedstock is oil shale. 
     
     
         3 . The method of  claim 1 , wherein said first solid feedstock is tar sands. 
     
     
         4 . The method of  claim 1 , wherein said second solid feedstock is coal. 
     
     
         5 . The method of  claim 1 , wherein said reactor is an indirectly heated kiln. 
     
     
         6 . The method of  claim 5 , wherein said kiln is a rotary kiln. 
     
     
         7 . The method of  claim 1 , wherein said condensing is accomplished using a coolant. 
     
     
         8 . The method of  claim 7 , wherein said coolant is water. 
     
     
         9 . The method of  claim 1 , wherein off-gases produced in said reactor are captured and utilized in said method to provide a source of heat. 
     
     
         10 . The method of  claim 1 , wherein spent said first solid feedstock is collected from said reactor, said spent first solid feedstock being mixed with said second solid feedstock during said gasifying. 
     
     
         11 . The method of  claim 1 , wherein fines produced during said preparing of said first solid feedstock are mixed with said second solid feedstock during said gasifying. 
     
     
         12 . The method of  claim 1 , wherein said gaseous hydrocarbons and said reactor off-gases are mixed with said second solid feedstock during said gasifying. 
     
     
         13 . The method of  claim 1 , wherein said gasifying is accomplished in a device selected from a group consisting of an entrained gasifier, a fixed gasifier and a fluid bed gasifier. 
     
     
         14 . The method of  claim 1 , wherein said syngas is processed to remove particulates and contaminants from said syngas. 
     
     
         15 . The method of  claim 14 , wherein said contaminants include sulfur and carbon dioxide. 
     
     
         16 . The method of  claim 1 , wherein said gasifying or reforming of said second solid feedstock is performed physically proximate to said reactor. 
     
     
         17 . The method of  claim 1 , where the treating of said liquid hydrocarbon with hydrogen to produce hydro treated and or hydro cracked liquid hydrocarbon is preformed physically proximate to said reactor. 
     
     
         18 . The method of  claim 1 , wherein said thermal energy is provided by burning said second solid feedstock directly. 
     
     
         19 . The method of  claim 1 , wherein said second solid feedstock is selected from the group consisting of coal, natural gas, gilsonite, spent shale and shale fines. 
     
     
         20 . The method of  claim 1 , wherein said reactor is a stationary reactor having a solid screw feed system and transport system. 
     
     
         21 . The method of  claim 1 , wherein said reactor is also suited for operation at elevated pressures. 
     
     
         22 . The method of  claim 20 , wherein said reactor is operated at a pressure which exceeds atmospheric pressure. 
     
     
         23 . The method of  claim 1 , wherein spent said first solid feedstock and off-gas produced in said reactor are subsequently burned to generate electrical energy. 
     
     
         24 . The method of  claim 1 , wherein said reactor sweep gas is formed by heating water to produce steam. 
     
     
         25 . The method of  claim 1 , wherein said second solid feedstock is selected from the group consisting of a solid, liquid and gaseous feedstock. 
     
     
         26 . The method of  claim 24 , wherein said second solid feedstock is selected from the group consisting of gilsonite, petroleum and natural gas. 
     
     
         27 . The method of  claim 1 , further comprising processing spent said first solid feedstock to produce cement. 
     
     
         28 . The method of  claim 1 , wherein the second solid feedstock is further processed to produce a fuel. 
     
     
         29 . The method of  claim 28 , wherein said fuel is further processed to remove particulates and contaminants. 
     
     
         30 . The method of  claim 28 , wherein said fuel is combusted to provide the thermal energy requirements of said reactor. 
     
     
         31 . The method of  claim 1 , wherein said first solid feedstock is preheated. 
     
     
         32 . The method of  claim 31 , wherein said first solid feedstock is preheated using a heated gas selected from the group consisting of effluent gas, a reactor off-gas and gas produced from a combustion of spent said first solid feedstock. 
     
     
         33 . The method of  claim 1 , wherein said sweep gas is preheated using a heated gas selected from the group consisting of effluent gas, a reactor off-gas and gas produced from a combustion of spent said first solid feedstock. 
     
     
         34 . The method of  claim 1 , wherein said second solid feedstock is processed in a quantity sufficient to solely heat said reactor during said processing of said first solid feedstock and produce a quantity of hydrogen sufficient to hydro treat said liquid hydrocarbon. 
     
     
         35 . A continuous surface method for producing hydro treated and/or hydro cracked liquid hydrocarbons from a solid feedstock, said method comprising:
 preparing a first solid feedstock to a predetermined size and moisture content;   preparing a second solid feedstock to complement the first solid feedstock;   providing a reactor suited for processing said first solid feedstock at substantially atmospheric pressure;   heating said reactor;   preheating a reactor sweep gas;   feeding said first solid feedstock into said reactor to thermally liberate hydrocarbons from said first solid feedstock;   directing said preheated reactor sweep gas through said reactor to remove said liberated hydrocarbons from said reactor;   cooling said hydrocarbons to condense liquid hydrocarbons;   separating said liquid hydrocarbons from gaseous hydrocarbons, other reactor off-gases and said reactor sweep gas;   treating said liquid hydrocarbon with hydrogen to produce a hydro treated and/or hydro cracked liquid;   gasifying or reforming said second solid feedstock to produce a syngas;   further processing said syngas to remove particulates, sulfur, carbon dioxide and other contaminants and to produce hydrogen;   combusting a fuel selected from the group consisting of said second solid feedstock, said syngas, spent said first solid feedstock, said reactor off-gas, fines produced during said preparing of said first solid feedstock, and said hydrogen;   utilizing heat produced from said combusting to heat said reactor and said preheating reactor sweep gas; and   preheating said first solid feedstock by direct contact with hot flue gas from said combusting or from gases produced by combusting a fuel selected from the group consisting of said second solid feedstock, said syngas, spent said first solid feedstock, said reactor off-gas, and said hydrogen.   
     
     
         36 . A method of  claim 35 , wherein said second solid feedstock syngas is shifted to produce mostly hydrogen and then cleaned to remove sulfur, carbon dioxide and other contaminants producing a nearly pure hydrogen stream. 
     
     
         37 . A method of  claim 36 , wherein said hydrogen is divided into two portions, the first to hydro treat and/or hydro crack said liquid hydrocarbons and the second portion of said hydrogen combusted with air within the external shell of said reactor to produce principally high temperature steam and nitrogen with no carbon dioxide. 
     
     
         38 . A method of  claims 36  and  37 , which results in little or no emissions of carbon dioxide gas from such process method in order to reduce the impact on global warming.