Two-stage process for the conversion of tar sand to liquid fuels and specialty chemicals

Abstract

A process is disclosed for converting Tar Sand to fuels and/or valuable chemicais. The process comprises the steps of a) activating Tar Sand to make it more susceptible to conversion; c) partially converting the Tar Sand to a solubilized material; and d) subjecting the unconverted Tar Sand to a second conversion step. The process optionally comprises a step b) of adding a solvent to the activated Tar Sand. In a preferred embodiment the solubilized Tar Sand obtained in step c) is removed before the unconverted Tar Sand is subjected to step d).

1 . A process for converting Tar Sand to fuels and/or chemicals comprising the steps of: a) Activating the Tar Sand to make it more susceptible to conversion; b) Optionally adding a solvent; c) Partially converting the activated Tar Sand to form solubilized material; d) Subjecting the unconverted Tar Sand from step c) to a conversion process. 
   
   
       2 . The process of  claim 1  wherein step a) comprises the addition of an inorganic material. 
   
   
       3 . The process of  claim 1  wherein step a) comprises the addition of an organic material. 
   
   
       4 . The process of  claim 2  wherein the inorganic material is in particulate form. 
   
   
       5 . The process of  claim 2 , wherein the inorganic material is selected from the group consisting of cationic clays, anionic days, natural clays, hydrotalcite-like materials, layered materials, ores, minerals, metal oxides, hydroxides of metals of the alkaline and alkaline earth groups, and mixtures thereof. 
   
   
       6 . The process of  claim 1  wherein step a) comprises adding one or more additives that react to form a new phase. 
   
   
       7 . The process of  claim 6  wherein at least one of the additives added in step a) reacts to form a new crystalline phase. 
   
   
       8 . (canceled) 
   
   
       9 . The process of  claim 6 , wherein the Tar Sand in step a) is in particulate form, and at least one of the additives added in step a) reacts to form a new phase distributed within the Tar Sand particle. 
   
   
       10 . The process of  claim 1  comprising, after step c) and before step d), the additional step of separating unconverted Tar Sand from the solubilized material. 
   
   
       11 . The process of  claim 10  wherein the separation involves a filtration device, such as a filter press, a centrifuge, a membrane filter, or a nano-filter. 
   
   
       12 - 14 . (canceled) 
   
   
       15 . The process of  claim 2  wherein the inorganic material has catalytic properties. 
   
   
       16 . The process of  claim 3  wherein the organic material has catalytic properties. 
   
   
       17 - 25 . (canceled) 
   
   
       26 . The process of  claim 1  wherein the conversion process of step d) is a hydrothermal process. 
   
   
       27 . The process of  claim 1  wherein the conversion process of step d) is a pyrolysis process or a flash pyrolysis process. 
   
   
       28 . The process of  claim 1  wherein the conversion process of step d) is a gasification process. 
   
   
       29 . The process of  claim 1  wherein the conversion process of step d) is a refinery process selected from the group consisting of gasification, thermal cracking, catalytic cracking, hydrocracking, and combinations thereof. 
   
   
       30 . The process of  claim 1  wherein the conversion process of step d) involves more than one process step. 
   
   
       31 . The process of  claim 1  wherein the conversion of step d) is a gasification process producing a synthesis gas, and wherein the synthesis gas is subsequently converted into a liquid hydrocarbon mixture. 
   
   
       32 . The process of  claim 1  comprising the additional step of converting the product of strep d) and/or step c) to a liquid fuel, suitable for use in an internal combustion engine. 
   
   
       33 . The process of  claim 32  wherein the additional step comprises conversion in a unit selected from an FCC unit, a Hydrocracking unit, a Hydrotreating unit, a Thermal Cracking unit, and combinations thereof 
   
   
       34 . The process of  claim 1  wherein is the product produced in step c) and/or step d) is blended with crude-oil derived hydrocarbons prior to processing in a refinery. 
   
   
       35 . The process of  claim 1  wherein step d) comprises converting the unconverted Tar Sand to electrical energy. 
   
   
       36 . The process of  claim 1  wherein, prior to step d), the unconverted Tar Sand from step c) is submitted to electromagnetic and/or ultrasound energy, optionally in the presence of a polar solvent. 
   
   
       37 . The process of  claim 1  wherein, prior to step d), the unconverted Tar Sand from step c) is submitted to intimate mixing with an additive, optionally in the presence of a solvent.