Catalytic retorting process for oil sands and oil shale

Abstract

Disclosed is a method of retorting an oil sands or oil scale material to recover the hydrocarbon values therein in the form of crude oil products. Dried crushed material is directed to a retort unit in which the material is heated in the present of a catalyst to generate a gas byproduct containing the desired hydrocarbon values and a solid byproduct containing carbon. The gas byproduct is treated in a condenser to cool the gas to recover desired crude oil products. The solids byproduct is calcined in a heated gas after which the calcined solids byproduct is separated from the heated gas.

What is claimed is: 
     
         1 . A method of retorting an oil sands or oil scale material to recover the hydrocarbon values therein in the form of crude oil products, comprising
 inserting dried crushed material to a retort unit in which the material is heated in the present of a catalyst to generate a gas byproduct containing the desired hydrocarbon values and a solid byproduct comprising (i) spent material with residue carbon and (ii) carbonized catalyst;   directing the gas byproduct to a condenser to cool the gas to recover desired crude oil products;   heat treating the solids byproduct in heated gas in a calciner, to burn the carbon off the catalyst and thereby regenerate the catalyst;   separating the heat treated solids byproduct from the heated gas;   separating the regenerated catalyst and the spent material in the heat treated solids byproduct, and   recycling the regenerated catalyst to the retort unit.   
     
     
         2 . The method of  claim 1  wherein the spent material is recycled to the retort unit. 
     
     
         3 . The method of  claim 1  wherein the material is oil sands. 
     
     
         4 . The method of  claim 1  wherein the material is oil shale.