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EP1361262A1 - Installation et procédé pour l' hydroextraction sous conditions supercritiques de schiste bitumineux - Google Patents

Installation et procédé pour l' hydroextraction sous conditions supercritiques de schiste bitumineux Download PDF

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Publication number
EP1361262A1
EP1361262A1 EP02010622A EP02010622A EP1361262A1 EP 1361262 A1 EP1361262 A1 EP 1361262A1 EP 02010622 A EP02010622 A EP 02010622A EP 02010622 A EP02010622 A EP 02010622A EP 1361262 A1 EP1361262 A1 EP 1361262A1
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EP
European Patent Office
Prior art keywords
oil
solvent
shale
kerogen
flow
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EP02010622A
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German (de)
English (en)
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John S. Rendall
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RP INTERNATIONAL Pty Ltd
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Individual
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/006—Combinations of processes provided in groups C10G1/02 - C10G1/08
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal

Definitions

  • the present invention relates to processes for extracting the kerogen bituminous matter from oil shale to produce a pipelineable crude oil, and more particularly to extraction processes and apparatus that depend on supercritical hydrogen-donating (H-donating) solvents applied to carbonaceous oil shales with high kerogen contents and low Fischer Assay yields.
  • H-donating supercritical hydrogen-donating
  • Retort and solvent processes are conventionally applied to the job of extracting the kerogen from the oil shales. Retorting processes are divided into in-situ and surface types. All such conventional processes require large amounts of heat. Retorting especially requires expensively high temperatures up to 574°C, and the gaseous heat transfer media used in surface retorting also need very large processing vessels for efficient production.
  • Retort reaction times and conditions must be carefully controlled to avoid visbreaking or cracking the heavy oil into hydrocarbon products with molecular weights that are too low. If the retort reaction times and conditions get too far out of control, largely unusable residual carbon output increases.
  • the important hydrocarbons bound in oil shale are collectively called kerogen and have a mixture of high molecular weight components.
  • Kerogen is conventionally converted to more convenient forms by heating it to 350°C, or higher, to yield a range of hydrocarbons with lower molecular weights, e.g., methane to light oil. Retorting processes normally operate near 500°C. Extended reaction time leads to conversion of primary bitumen products to other lower molecular weight products and residual carbon. Retorting also typically produces unacceptable environmental emissions, relatively low yields of bitumen and requires heavy water usage.
  • the challenges in the processing of oil shale include limiting the production of gas products like methane to enough to fuel the process, and keeping the production of unusable carbon residue at a minimum. Thus, it is without the conversion to secondary lighter products. Upgrading to the desired final products is more efficient in downstream processing.
  • Kerogen in oil shale is relatively insoluble in most organic solvents at or below their normal boiling points. But if the environmental pressure is increased to raise the boiling point to higher than 600°K, solvents like toluene will dissolve the kerogen. Solvent extraction separates shale oil from spent shale without vaporization. The converted hydrocarbon products result from dissolution under reaction conditions, e.g., heating the oil shale and a solvent to 380°C-540°C. Sometimes hydrogenation is also needed for good conversion. In general, solvent processes have better yields than retorting processes.
  • a process embodiment of the present invention is a method for producing pipelineable synthetic crude oil from oil shales.
  • Such process combines a low-boiling-point organic solvent fraction with an H-donating-mid-distillate fraction and raises temperature to make kerogen in oil shales soluble, and raises pressure conditions to keep the solvents in their liquid phase at those temperatures.
  • the solvent is recovered from the extracted kerogen in a three-stage solvent-recovery unit that is followed by a flash recovery that uses a pressure letdown and draws off the resulting solvent vapors.
  • An advantage of the present invention is that a process for kerogen extraction from oil shale is provided that produces higher yields of oil with reduced gas production.
  • Another advantage of the present invention is that a process for kerogen extraction from oil shale is provided that produces hydro-visbroken crude oil which is stable enough for conventional pipeline transfer to .refineries.
  • a still further advantage of the present invention is that a process for kerogen extraction from oil shale is provided that produces a minimum of environmental contamination.
  • Another advantage of the present invention is that a process for kerogen extraction from oil shale is provided that recycles its solvents and heat.
  • Fig. 1 is a functional block diagram of an oil-shale processing plant embodiment of the present invention that implements a process for kerogen extraction from oil shale.
  • An oil-shale processing plant embodiment of the present invention is diagrammed in Fig. 1 and is referred to herein by the general reference numeral 100.
  • the principle product produced is synthetic crude oil that is suitable for pipeline transportation.
  • An oil shale input feed 102 is crushed by a size reducer 104.
  • a crushed oil shale flow 106 is mixed with a recirculating solvent and input to a water remover 108. Any waste water 110 is removed from the system.
  • a recovered solvent vapor flow 112 is added, condensed for heat recovery and a slurry flow 114 is output.
  • a heat exchanger 116 provides a recovered-heat flow 118 and outputs an oil product flow 120. Hot oil product flow 122 is received from further down.
  • a kerogen converter 124 outputs a slurry 126- Reaction gases are drawn off in a flow 128.
  • An oil separator 130 outputs an oily solids flow 132 and the oil product flow 122.
  • a solvent extractor 134 outputs a solids flow 136 and an oil/solvents mixture 138. Any heat that can be removed from mixture 138 is returned in a heated solvents flow 140.
  • a last solvent recovery stage 142 outputs a spent shale flow 144 and is assisted with a waste water wash.
  • a filter cake flow 148 is added to the last solvent recovery stage 142 with a wash water flow 150. Such filter cake flow 148 is produced by an extracted-oil solids filter 152 that removes solids from the oil product flow 120 and forwards filtered product oil flow 153.
  • a distillation column 154 outputs a final-product synthetic crude oil 156.
  • a heat exchanger 158 outputs a flow 160 and receives a flow 162.
  • a flow 164 is forwarded for hydrogen production and sulphur recovery.
  • a recycle solvent 166 is provided by the distillation column 154 to the pulverized oil shale flow 106.
  • An H-donor flow 167 is added to flow 166 from an H-donor generator 168.
  • a mid-distillate flow 169 from the distillation column 154 is sent to the H-donor generator 168.
  • a hydrogen plant sulfur recovery unit 171 produces a hydrogen flow 172, sulfur free fuel gas flows 173 and 178 and a sulfur flow 180.
  • a fuel flow 173 is provided to run a power plant 174.
  • the output from the power plant 174 is electricity 176.
  • a sulphur flow 180 is output from the sulphur plant 171.
  • Pratzer '3115 describes the extraction of oil from oil shale with the aid of elevated temperatures and pressures so that solvents with tetralin may be employed for highly efficient oil shale processing.
  • the reactor effluent is described as being filtered, and the resulting filter cake rinsed with toluene. Again, such did not describe a practical or complete system that recovered the solvent from the synthetic crude oil.
  • the H-donor generator 168 starts with a mid-distillate fraction of naphthalene (C 10 H 8 ) with a molecular-weight-128, e.g., in flow 169, and chemically reacts this with hydrogen using a catalyst.
  • decalin C 10 H 18
  • tetralin C 10 H 12
  • Typical oil-shale production requires about two percent by weight hydrogen for the benefits described.
  • About twenty percent of the total solvent mix used in the extraction/conversion is preferably H-donor mid-distillate fraction.
  • Method embodiments of the present invention combine crushed oil shale with a mixture of toluene or other low-boiling-point range organic solvent, and tetralin/decalin or other mid-distillate. This is then fed into a slurry mixer and heated by a solvent recovery from a spent shale. Any water in the oil shale is eliminated. The slurry is then pumped with a recycle product oil stream into an autoclave where moderate temperatures and elevated pressures are used to convert substantially kerogen to a hydro visbroken stable crude oil with some gas production. The oil product is then separated under similar temperature and pressure conditions from the spent shale.
  • the oil product left after taking part for recycling is distilled for the solvent mix by a low-boiling-point fraction and a mid-distillate fraction.
  • This mid-distillate fraction is hydrotreated and recycled to make up for any hydrogen used up.
  • the spent shale is washed counter-current with the low-boiling-point solvent fraction under supercritical pressure and temperature conditions. This enables easy solids separation and continued conversion of the residual kerogen.
  • the final residue of spent shale with clean low-boiling-point solvent at supercritical temperature/pressure conditions is let-down gradually in stages with almost all the low-boiling-point solvent evaporating for recovery and reuse with the final stage sprayed with water to release any remaining solvent through steam stripping.
  • the oil product is filtered before storage and pipelining to market.
  • the gas produced is rich in methane and is used for hydrogen production needed for the mid-distillate hydrotreating. This step provides for the needed heat/power and hydrogen for the process.
  • This art is well known and there are several methods commercially available.
  • Some embodiments of the present invention include the use of at least one autoclave wherein high pressure leaching is used to convert kerogen to oil.
  • Such autoclave preferably includes an internal venturi draft tube to keep the slurry mixed.
  • a pressurized extraction vessel continues the conversion process and acts to solubilize the converted oil.
  • a series of pressurized solvent washing shale decanters are used in which shale moves counter-current to the solvent. Distillation columns, settling tanks and a plurality of pumps and heat exchangers are used to transfer and recycle components.
  • the kerogen converter 124 preferably includes an autoclave and provides residence times of five to thirty minutes, depending on the oil shale ore.
  • the kerogen is converted by pyrolysis with an H-donor distillate providing hydrogen to deal with olefin formation and unsaturated hydrocarbons. Some sulphur will detach as hydrogen sulfide.
  • the reaction is chemical and continues through the entire section under elevated temperature and pressure, e.g., kerogen converter 124, oil separator 130, and three-stage solvent extractor 134.
  • the gas flow 128 produced by the reaction comprises methane, ethane, hydrogen, and some hydrogen sulfide.
  • the oil flow 126 is separated in stage 130 by a pressure vessel.
  • the three-stage solvent extractor 134 can be implemented similar to the three pressure decanters 712, 730, and 740, in Fig. 2 of Rendall '267.
  • the oil is removed in flow 122.
  • the oil separator 130 agglomerates the fines which settle out with the solids output flow 132.
  • the hot product oil is fed to distillation column 154 via a heat exchanger 116 to heat the incoming slurry then through an extracted-oil solids filter 152 before the pressure is let down to provide the energy needed for distillation.
  • the solids with oil exit in flow 132 to a three-stage solvent extractor 134, wherein fresh hot solvent at about 400°C and about 700 PSIG is fed from flow 140 counter-current to the output spent shale.
  • the solvent-residue flash recovery unit 142 consists essentially of depressurizing the residue in a vessel fed from flow 136 thereby releasing most of the low-boiling-point solvent via flow 112 as a vapor to heat the incoming slurry at water removal water remover 108.
  • the residue of spent shale is further cooled from about 200°C-300°C in a rotary drum with the remaining solvent from flow 148 joining flow 112.
  • Filter residue from extracted-oil solids filter 152 feeds the depressurizing vessel in solvent-residue flash recovery unit 142.
  • the water from hydrogen plant 171 and/or waste water from water remover 108 can be used to cool the solids and dampen the spent shale residue for dust control during mine backfill.
  • the solvent-residue flash recovery unit 142 is any such system as described in Rendall '267 including depressurizing vessels and a cooling (rotary drum).
  • the heat from the flow 136 is transferred via solvent and water (steam) vapors to the water removal water remover 108. It would aid water disposal to use acid water from the hydrogen/sulfur plant hydrogen plant 171 to cool the hot spent shale while waste water flow 110 is disposed of in flow 144 for dust control.
  • the recycle solvent to three-stage solvent extractor 134 flow 140 is fed from the distillation column 154 via flow 162 to a heat exchanger 158. This is necessary at elevated pressure of about 400 PSIG.
  • the heat can be provided by the oil/solvent output three-stage solvent extractor 134 via flow 138 at about 400°C and leaves the heat exchanger 158 at flow 160 with temperatures about 150°C to the distillation column 154.
  • Auxiliary heat to flow 140 can also be provided by flow heat fuel gas from power plant 174.
  • the hot oil from kerogen conversion from oil separator 130 flows at about 600 PSIG and 400°c.
  • Flow 122 heats incoming slurry in heat exchanger 116 from which it leaves at about 600 PSIG and 150°C.
  • An oil product flow 120 is forwarded via an extracted-oil solids filter 152.
  • the filter residue is fed via flow 148 to the solvent recovery solvent-residue flash recovery unit 142, for disposal of the fines.
  • the filter can be of the metal porous cartridge type such as are readily commercially available, a pressurized rotary drum filter with engineered fabric for high temperatures about 150°C such as supplied by CJ (Zyex Hi tech yarn) or any other suitable for process conditions. All are used in refineries for removal of catalyst fines before oil product distillation.
  • the preferred route is a metal porous cartridge type.
  • the distillation column 154 is fed the product oil flow 153 and recycle solvent at about 150°C.
  • Flow 153 is a depressurized flow and additional heat can be provided by a fuel gas flow 178.
  • the distillation column 154 is conventional system with a mid-distillate metered off-take at about 200°C in flow 169 for hydrotreating in H-donor 168.
  • the recycle solvent off take at about 120°C is metered to flow 166 feeding the slurry of the incoming raw oil shale for water removal in water remover 108.
  • the ratio of mid-distillate flow 169 hydrotreated in H-donor 168 mixing with the recycle solvent flow 166 via flow 167 is about twenty percent of mid-distillate H-donor in the flow 114 proceeding under elevated temperature about 400°C and pressure about 600 PSIG to the kerogen converter 124.
  • the H-donor 168 for hydrotreating the mid-distillate from flow 169 is practiced by industry today, as referenced books for catalysts including, "Oil and Gas Journal Refining-Catalyst Compilations". Such catalysts usually use alumina support with combinations of cobalt molybdenum nickel etc. as active agents.
  • the technologies are similar to those described in "Petroleum Processing Handbook” edited by John S. Meketta, published by Marcel Dekken, June 1992 or "Upgrading Petroleum Residue and Heavy Oils” by Murray S. Greg, published by Marcel Dekker Inc., NY, NY 1994.
  • the hydrogen plant 171 receives hydrogen, hydrocarbon gases, including some light ends, some ammonia (NH 4 ) and hydrogen sulfide H 2 S from flow 172.
  • the hydrogen is separated, concentrated, and reused by compressors.
  • the hydrogen sulfide is converted to sulfur by a conventional Claus plant. Some of the fuel gas is used for further hydrogen production via a reformer for methane/light ends, and the rest for heat needed for process and electric power.
  • About six to fifteen percent by weight of the kerogen is converted gases dependant on the source of the oil shale and the processing conditions for extraction of the kerogen.
  • About two percent by weight of the produced oil is the hydrogen necessary for chemical reactions to produce a suitable pipelineable oil with the required viscosity and stability. Up to four percent by weight hydrogen has also been reported on particularly aromatic kerogens, producing more gas.
  • the whole hydrogen system produces electric power. All these items in power plant 174 via flow 173 can only be quantified in specificity depending on the oil shale source and the size of the facility by those skilled in the art.
  • the Fischer Assay was developed for the oil shale industry to determine the efficiency of oil extraction processes.
  • the Fischer Assay measures the recovery ratio of hydrocarbons from the oil shale. In prior art retorting processes, a Fischer Assay recovery of 80-100% is typical, and recoveries exceeding 100% are difficult to achieve.
  • Rendall '267 describes fifteen batch runs in which oil shale was treated with toluene under supercritical conditions ranging up to 400°C and 1200 PSIG pressure for recovery of up to 120% of Fischer Assay of hydrocarbons.
  • oil shale has been slurried in toluene in a batch stirred reactor and heated to temperatures up to 400°C and held for periods ranging from zero minutes up to two hours.
  • Method embodiments of the present invention for "carbonaceous" oil shales allow almost all of the kerogen to be produced as oil and gas (a 5-15% fraction).
  • Julia Creek, Queensland, Australia, oil shales, CRA report 1967-1988 show an average of 17-18% kerogen.
  • the Fischer Assay yield is about H-donor 70 liters/ton (14-15 gallons) representing about seven percent kerogen which is only 30% of what potentially could be available from the recovery method of the present invention. This is adequately borne out by independent research on other Chinese, Australian and Eastern US shales shown in the references. The decrepitation observed on Colorado oil shales does not occur in carbonaceous oil shales.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
EP02010622A 2002-05-10 2002-05-10 Installation et procédé pour l' hydroextraction sous conditions supercritiques de schiste bitumineux Withdrawn EP1361262A1 (fr)

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008061304A1 (fr) * 2006-11-21 2008-05-29 Technological Resources Pty. Limited Extraction d'hydrocarbures à partir de schiste bitumineux
KR101470458B1 (ko) * 2013-03-11 2014-12-08 주식회사 시알아이 오일셰일로부터 중질유를 회수하는 장치 및 이를 이용한 회수방법
CN110431216A (zh) * 2017-03-14 2019-11-08 沙特阿拉伯石油公司 一体化超临界水和蒸汽裂解工艺
US10927313B2 (en) 2018-04-11 2021-02-23 Saudi Arabian Oil Company Supercritical water process integrated with visbreaker

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4737267A (en) * 1986-11-12 1988-04-12 Duo-Ex Coproration Oil shale processing apparatus and method

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4737267A (en) * 1986-11-12 1988-04-12 Duo-Ex Coproration Oil shale processing apparatus and method

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008061304A1 (fr) * 2006-11-21 2008-05-29 Technological Resources Pty. Limited Extraction d'hydrocarbures à partir de schiste bitumineux
KR101470458B1 (ko) * 2013-03-11 2014-12-08 주식회사 시알아이 오일셰일로부터 중질유를 회수하는 장치 및 이를 이용한 회수방법
US9518228B2 (en) 2013-03-11 2016-12-13 Cri Co., Ltd. Apparatus for collecting intermediate oil from oil shale and collecting method using the same
CN110431216A (zh) * 2017-03-14 2019-11-08 沙特阿拉伯石油公司 一体化超临界水和蒸汽裂解工艺
CN110431216B (zh) * 2017-03-14 2021-08-10 沙特阿拉伯石油公司 一体化超临界水和蒸汽裂解工艺
US10927313B2 (en) 2018-04-11 2021-02-23 Saudi Arabian Oil Company Supercritical water process integrated with visbreaker
US11248180B2 (en) 2018-04-11 2022-02-15 Saudi Arabian Oil Company Supercritical water process integrated with visbreaker

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