US20080060978A1 - Handling and extracting hydrocarbons from tar sands - Google Patents
Handling and extracting hydrocarbons from tar sands Download PDFInfo
- Publication number
- US20080060978A1 US20080060978A1 US11/761,773 US76177307A US2008060978A1 US 20080060978 A1 US20080060978 A1 US 20080060978A1 US 76177307 A US76177307 A US 76177307A US 2008060978 A1 US2008060978 A1 US 2008060978A1
- Authority
- US
- United States
- Prior art keywords
- oil
- solvent
- tar sands
- bitumen
- sand
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- 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
- C10G1/04—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by extraction
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D11/00—Solvent extraction
- B01D11/02—Solvent extraction of solids
- B01D11/0215—Solid material in other stationary receptacles
- B01D11/0223—Moving bed of solid material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D11/00—Solvent extraction
- B01D11/02—Solvent extraction of solids
- B01D11/0288—Applications, solvents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D11/00—Solvent extraction
- B01D11/02—Solvent extraction of solids
- B01D11/0292—Treatment of the solvent
- B01D11/0296—Condensation of solvent vapours
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Extraction Or Liquid Replacement (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Working-Up Tar And Pitch (AREA)
Abstract
A method and system for handling tar sands and extracting bitumen or oil from the tar sands. The method includes the steps of depositing tar sands in a hopper assembly having a conical bottom. An organic solvent mixture is sprayed on the tar sands through a series of jets near the walls of the hopper. The oil or bitumen in the tar sands is dissolved by the organic solvent mixture. Sand from the tar sands is allowed to separate and fall toward the bottom of the hopper assembly. The sands and liquid in a slurry of fluid are transported from the hopper assembly to a rinse chamber. The slurry of fluid is delivered into the top of the rinse chamber tangentially to cause cyclonic action of the slurry in the rinsing chamber. Solvent introduced at the bottom of the rinse chamber and the solvent mixture is drawn from the top of the rinse chamber. Thereafter, the solvent and hydrocarbon liquid mixture is pumped to a separator in order to separate the oil and bitumen from the solvent. Finally, the clean solvent is returned to be reused by introduction into the rinse chamber in order to form a closed loop process.
Description
- This application claims priority to U.S. Provisional Application No. 60/804,781, filed Jun. 14, 2006.
- 1. Field of the Invention
- The present invention is directed to a method and apparatus for handling tar sands and extracting bitumen or oil from tar sands in an economical and efficient continuous closed loop system.
- 2. Prior Art
- Tar sands, sometimes known as oil sands or bituminous sands, are a combination of clay, sand, water and bitumen. Bitumen is a semisolid form of oil. It is known to mine tar sands to extract the bitumen, which is upgraded into synthetic crude or refined directly into petroleum products.
- Tar sands deposits are found in over 70 countries throughout the world and represent as much as two-thirds of the world's reserves of oil.
- In the processing of tar sands which contain oil-bearing bitumen, the oil-bearing sands must first be mined, the tar sand processed and the sand cleaned sufficiently to alleviate environmental concerns upon disposal or proper placement back into the environment.
- There are various known methods of extracting the bitumen or oil from the tar sands. In one known process, the tar sands are mined and hot water and caustic soda (NaOH) are added to the sand. The resulting slurry is piped to an extraction plant where it is agitated and the oil skimmed from the top.
- In an alternate known cold flow process, oil is pumped out of the sands using progressive cavity pumps which lift oil along with sand. This process only works well where the oil or bitumen is fluid enough to pump.
- In an alternate known cyclic steam stimulation process, a well is put through cycles of steam injection, soaking, and oil production. Oil or bitumen is thereby extracted.
- U.S. Pat. No. 5,998,640 to Haefele et al. discloses a solvent extraction method that utilizes pressure to assist the extraction. By providing a pressure differential, oil free solids may be removed from an oil extraction chamber.
- A large portion of the expense of tar sand processing is materials handling. The material is sticky, and tough. Conveyors, augers, and crushers wear quickly when handling tar sand. Solvent extraction processes are usually considered to be energy intensive and solvent loss is often an issue. The extraction efficiencies are normally no greater than 85%. In addition, cold weather can shut down most operations.
- In order for the extraction of tar sands to be an economical endeavor, the separation process should ideally be low energy, provide a simple material handling method, and recycle most of the chemicals added for processing.
- The present invention also addresses issues concerning energy recycling and solids handling.
- Accordingly, it is a principal object and purpose of the present invention to utilize tar sands as a source of cooling for a solvent condenser.
- It is a further object and purpose of the present invention to provide a handling and extraction system that does not require crushing.
- It is a further object and purpose of the present invention to use an oil/solvent mixture to dissolve, transport and classify the tar sands.
- It is a further object and purpose of the present invention to provide a continuous handling and extraction process at atmospheric pressure in a closed loop system.
- The present invention is directed to a process and a system for handling and extracting hydrocarbon liquids from tar sands. Initially, the tar sands are deposited into an open top hopper assembly. The hopper or dissolution chamber may include a source of an organic solvent liquid mixture on the incoming tar sands. The mixture dissolves the oil or bitumen in the tar sands. Prior to entry into the dissolution chamber, the solvent will be heated by being passed in heat exchange relationship in a solvent heat exchanger.
- The tar sand is introduced at the top of the hopper. Below there is a inert gas blanket (inert blank zone A) is created by introduction of a inert gas such as nitrogen or cooled combustion exhaust to displace oxygen from the tar sand. This prevents oxygen from entering into the process. The layer of tar sand underneath the inert gas blanket acts as a solvent vapor absorbing media. Since fresh tar sand is introduced on a continuous basis new absorption media constantly replenishes the absorption layer (absorption zone B) Therefore, this layer never becomes saturated with solvent vapor. As an added insurance to prevent solvent vapor incursion into zone A, solvent vapor sucked out in a downward fashion through zone B. The solvent vapor inert gas mixture exhaust can be treated with a gas scrubber. The layer below is dissolved by contacting the tar sand with a warm solvent oil mixture (leach zone C). The resultant sand slurry passes the through a screen basket which retains rock, gravel, and coarse sand. This basket is emptied when it becomes full. The sand slurry combines with the recirculation loop fluid in mixing
T 28. - Solvent vapors are prevented from leaving the dissolution chamber by a closed loop system. Solvent laden gas is drawn into ducts and removed and pumped to a chiller unit which assists in converting vaporized solvent to liquid.
- Solvent vapors are prevented from leaving the dissolution chamber by having a layer of tar sands (absorption zone B) and by a closed loop system . . . to liquid. Any remaining vapors are stripped out with a gas scrubber.
- The mixture of fine sand and liquid containing solvent and oil or bitumen is then transported from the base of the hopper to a rinse chamber in a fluid slurry. The slurry enters into a tangential cyclone port near the top of the rinse chamber. Centrifugal force will cause the sand to separate from the solvent. Slurry liquid gathers at the center and top of the rinse chamber while the sand moves downward in the rinse chamber.
- A portion of the recirculating solvent and hydrocarbon liquid mixture is drawn off from the recirculation line to a pump where it is sent into a further cyclone separator to further polish off or remove small solid particles such as sand. The fluid which is free of sand is then pumped to two heat exchangers. Steam is circulated into the heat exchangers. As the combination solvent and liquid hydrocarbons are heated, the solvent will vaporize before the oil or bitumen to be recovered. The vaporized solvent will pass to the top of the heat exchangers to a vapor collection chamber where the vapors are directed to a condenser to condense the clean solvent vapors into liquid solvent. The liquid solvent is thereafter directed back to a solvent storage tank for clean solvent. A portion of the solvent vapors directed through port (26) to the recirculation loop heat exchanger (22) to provide indirect heat to the recirculation loop solvent oil mixture, while the balance is directed to the condenser.
- A shaft assembly in the rinse chamber may include a motor or motors. The shaft assembly and motors rotate a first tray in a first direction against the series of stationary plows. Downward progression of the sand in the rinse chamber is facilitated by the relative motion of the plows relative to the rotating tray. Rotation of the first tray relative to the plows tends to lift the solvent saturated sand upward out of the bowl of the first tray above the fluid line so that the sand moves to the second tray. The sand residing in the second tray is heated both indirectly and directly with steam and direct steam injection. The heated sand which no longer contains liquid solvent has the remaining solvent vapors displaced with an inert gas (200) The solvent free sand will fall by gravity to a rotary valve where it is permitted to exit through the duct which has a inert gas blanket to prevent oxygen from entering the system.
-
FIG. 1 is a simplified diagrammatic view of a system of handling and extracting hydrocarbons from tar sands constructed in accordance with the present invention; -
FIG. 2 is an enlarged view of a cyclone separator and rinse chamber used as a part of the system shown inFIG. 1 ; -
FIG. 3 is a sectional view taken along section line 3-3 ofFIG. 2 ; and -
FIG. 4 is a diagrammatic sequential flow chart of the system shown inFIG. 1 . - The embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope of the instant invention.
- While the invention has been described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the invention's construction and the arrangement of its components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification.
- The present invention is directed to a method and apparatus for handling and extracting oil from tar sands. The tar sands material is initially gathered or excavated from a deposit in various ways which are not a part of the invention. For example, the material is peeled off the tar sand deposit and dumped directly into an oil extraction or hopper assembly as large chunks sized from approximately ¼ to 12 inches (¼″ to 12″). While occasional large rocks may be crushed or removed, a key feature of the present invention is that the tar sands generally do not have to be crushed as a part of the process.
- Referring to the drawings in detail,
FIG. 1 illustrates a schematic diagram of a system 10 of handling and extracting hydrocarbon from tar sands. - The system 10 may be located near a tar sands deposit so transportation and handling costs are low. In one embodiment, the tar sands 13 are initially peeled off a deposit in sheets, such as one foot wide sheets. The tar sands material 13 is then dumped into an oil extraction hopper or
dissolution assembly 12. Thehopper assembly 12 may be configured as an open topped cylinder or an open topped cone. - The hopper consist of four zones The inert gas blanket zone (zone A) which prevents oxygen from entering the hopper by providing a constant flow of inert gas such as nitrogen or combustion exhaust into this zone. The solvent absorption zone (zone B) where the continued introduction fresh tar sands into this zone absorbs any solvent vapors escaping from the leach zone. In leach zone (zone C) a heated solvent/oil mixture contacts the tar sand by one or more sources. The rock basket (optional) which prevents rocks, gravel and coarse sand from entering the mixing T (18) In this area solvent vapor maybe removed by a vacuum pump to retard the migration of vapor into zone A.
- The hopper or
dissolution chamber 12 may include asource 8 near the outer walls of the cone which provides an organic solvent liquid mixture, such as a hexane or pentane with bitumen, on the incoming tar sands as depicted byarrows 6. The solvent/bitumen mixture dissolves the oil or bitumen in the tar sands. It will be appreciated that other solvents may be utilized within the spirit and scope of the present invention. - Solvent is introduced to the
dissolution chamber 12 from a solvent recirculation loop 14. The flow of solvent controls the rate and how well the nonporous rocks are washed. The flow of solvent and oil out through a mixingT 18, determines the concentration of sand transported to the rinse chamber (to be described) as a slurry. In one preferred iteration, a concentration of 5% sand in the outgoing slurry is acceptable. - Prior to entry into the
dissolution chamber 12, the solvent will be heated by being passed in heat exchange relationship in asolvent heat exchanger 22. - Solvent vapors and/or solvent are introduced into the heat exchanger as shown at
arrow 24. Steam maybe used but it is less desirable. Solvent vapor and condensate exitsheat exchanger 22 as shown atarrow 26. - The mid portion of the hopper or
dissolution chamber 12 containssources 6 which are below the surface of the deposited tar sand. The solvent/bitumen mixture dissolves the oil or bitumen in the tar sands. The eroded sand from zone C falls to the bottom of thehopper 12 above the conical base of thehopper 12. - The sand flows through the rock basket which retains the rock etc while passing the sand to the bottom of the dissolution chamber.
- The upper portion of the
hopper 12 acts like a leach field in which the oil is leached from the tar sand. Once the oil and bitumen is dissolved, the sand flows to the bottom of the dissolution chamber. - As an option, a perforated screen (not shown) may be employed spaced above the conical base of the dissolution chamber. The perforated metal screen or grating only allows fully eroded sand to pass onto the rinse chamber for further processing. In that case, the tar sand will not enter the slurry transport system until it is small enough to pass through the perforated metal screen.
- A
valve 28 modulates the flow of oil solvent to leach zone C which controls the rate of sand erosion in the leach zone which in turn determines the rate sand flowing to mixingT 18. - Vapors are prevented from leaving the
top dissolution chamber 12 by removing vapors from rock basket area. This retards the upward migration of vapor through vapor absorption zone B towards the top of the hopper shown byarrow 15. Near the bottom of thehopper 12, solvent laden gas is drawn intoducts 36 and removed and pumped withgas pump 30 to achiller unit 32 which assists in converting the vaporized solvent in to liquid. This followed by a gas scrubber unit. The resulting gas is directed to the bottom ofconical tray 108 throughport 200 - The
dissolution chamber 12 reduces or eliminates the need for a crusher and insures a high level of extraction. Surface oil is effectively removed from rocks occurring in the tar sand. Since the flow solvent is functioning in lieu of the crushing agent, there is little to wear out in the system. - The present invention uses the oil/solvent mixture to wash the tar sands in lieu of a crusher. This has several benefits. The oil/solvent mixture only dissolves oil/sand aggregates, while leaving the non oil bearing rocks essentially untouched. Moreover, the hot oil/solvent mixture heats up the tar sand to maximize the dissolution speed.
- In many cases, the majority of the tar sand has a particle size of less than 1/16 of an inch. At this particle size, the washing of the oil and bitumen from the tar sand is rapid and efficient. The oil/solvent fine sand mixture provides an ideal mixture for easy transport of the mixture at the mining site to the wash chamber and desolventization chamber. The combination oil/solvent provides the proper amount of viscosity, lubrication, and density to facilitate the transport of the dissolved tar sand as slurry through a pipe. These features eliminate the crushing operation and expensive transport tar sand from the mining pit to the processing area.
- The mixture of fine sand and liquid containing solvent and oil or bitumen, is then transported from the base of the
hopper 12 to near a top of a rinsechamber 40 in a pipe as a fluid slurry. The liquid oil or bitumen is then harvested from the rinse chamber 14 as will be described herein. The slurry enters into a tangential cyclone port 54 located at the top of the rinsechamber 40. Since only fine sand particles are allowed to enter, the slurry line transportation is simple and uniform. Since the slurry is pumped into the rinsechamber 40, centrifugal force will cause the sand to separate from the solvent as illustrated byarrows 42. Once the sand enters the rinse chamber, the cyclone action of the rinse chamber configuration allows most of the sand to be removed from the oil solvent mixture before returning to therecirculation line 44 where it is recirculated back to the nozzles previously described and the motive power for the oil solvent sand mixture transport. Then the oil solvent mixture flows through the dissolution chamber ports and returns to cyclone intake port. - Since the sand is removed prior to returning to the recirculation pump, wear issues are minimized for the pump and spray nozzles.
- The slurry enters the top of the rinse
chamber 40 tangentially which causes a cyclonic action within the rinsingchamber 40. Due to centrifugal force, slurry liquid gathers at the center of the rinse chamber while the sand in the slurry moves toward the outer walls of the rinse chamber. - By the time the tar sands reach the rinse
chamber 40, the vast majority of oil is dissolved out of the tar sands. The remaining oil is removed by displacement washing. The rinsechamber 40 configuration allows oil solvent mixture to be removed from the rinse chamber on a continuous basis as a dirt free oil and solvent mixture. A mass flow meter measures the density of the mixture continuously such that oil solvent which is harvested maintains a constant concentration of oil. This permits uniform processing conditions independently of pay dirt oil concentration. - Oil free solvent is also introduced at and pumped to the bottom of the rinse
chamber 40. As the dissolved sand progresses down the rinsechamber 40, the solvent progresses up the chamber in a counter current fashion as shown byarrows 56. - Solvent is removed via
recirculation line 44 and moved bypump 43 in a loop past the connection with thedissolution chamber 12 mixingT 18. - A portion of the recirculating solvent and hydrocarbon liquid mixture is drawn off from the
recirculation line 44 vialine 46 to apump 48 where it is sent into afurther cyclone separator 50. Thecyclone separator 50 serves to further polish off or remove small solid particles, such as sand, which are returned to therecirculation line 44. - The fluid which is free of sand is then pumped via
line 52 to twoheat exchangers heat exchangers inputs 64 and 66 and then out therefrom throughoutputs - As the combination solvent and liquid hydrocarbons are heated in the
heat exchangers arrows 58, the vaporized solvent will pass to the top of theheat exchangers line 24 torecirculation heat exchanger 24, while the remaining vapors fromduct condenser 74. The liquid solvent is thereafter directed vialine 76 back to asolvent storage tank 78 for clean solvent. - At the same time, the liquid which is primarily hydrocarbon oil and bitumen is drawn off via
lines 77 tooil storage tank 75. - The interior of the rinse chamber is kept at a pressure less than atmospheric pressure which eliminates any need for a depressurization chamber for removing desolventized sand from the process. This, in turn, permits continuous production of desolventized sand without interruption. Accordingly, the desolventization or rinse
chamber 40 is kept at atmospheric pressure or less to prevent solvent vapors from leaving the desolventized sand exit port. - Turning to a consideration of
FIG. 2 which shows a portion of the rinsechamber 40, and continuing consideration of the system 10 inFIG. 1 , a siphonchamber 80 is provided surrounding the rinsechamber 40 and is in fluid communication therewith. In the preferred embodiment shown, the siphonchamber 80 substantially circumnavigates the rinse chamber. The siphonchamber 80 is connected via line orlines gas pump 30 which insures that a vacuum will be provided to the siphonchamber 80. Liquid solvent is provided from thesolvent storage tank 76 vialine 86 to the siphon chamber by action of a pump 38. - At the same time, solvent is allowed to travel via
line 88 to an excesssolvent chamber 90 whereby solvent is allowed to pass as shown byarrows 92 into aninner container 95 having an open top and return vialine 94 to the liquidsolvent storage tank 76. The level of the open top of theinner container 95 is adjustable byhandle 93. The solvent level 97 in the rinsechamber 40 and in the excesssolvent chamber 90 is maintained at a level as shown byarrows 96. - The vapor
pressure equalization line 202 insures the pressure is the same between desolventization zone of the rinse chamber and the excesssolvent chamber 90. Without this feature the level control system will not work, if the desolventization area has a pressure which is different from the siphonoverflow chamber 90. - The same level of solvent is also maintained above the mixing
T 18 of the hopper assembly so that the siphon will not be broken between the rinse chamber and the hopper T. The hopper T is located at a position low enough that gases are not sucked into the recirculation loop which could break the siphon. - A
shaft assembly 100 may include a motor ormotors chamber 40. The shaft assembly and motors rotate a firstconical tray 106 in a first direction against a series of stationary plows 98. In one non-limiting embodiment, the first tray is rotated approximately 10 revolutions per minute (rpm). - The
shaft assembly 100 will also rotate a secondconical tray 108, which is coaxial therewith, in an opposite direction from rotation of the first tray. As best seen in the sectional view inFIG. 3 , extending from the second tray is a series ofblades 99. In one preferred embodiment, the shaft assembly includes a shaft within a shaft to rotate the first and second tray. - Downward progression of the sand in the rinse chamber is facilitated by the relative motion of the
plows 98 relative to therotating tray 106. It will be appreciated that either the bowl or the trays may rotate. The rotation of thefirst tray 106 relative to theplows 98 tends to lift the solvent saturated sand upward out of the bowl of the first tray above thefluid line 96 so that the sand moves to thesecond tray 108. The sand residing in thesecond tray 108 is heated directly and indirectly with steam. Steam heat is applied to achamber 110 viainlet 112 and is circulated therefrom viaoutlet 114. The sand will tend to vaporize the solvent which is drawn off tochamber 122 vialine 116 toduct 79. The clean sand with the solvent removed will fall by gravity to avalve 124 with rotating paddles. - As best seen in
FIG. 1 , as the valve paddles rotate, the clean sand will exit the system as shown byarrow 118 and may be transported by any mechanism, such as byconveyor 120. - The bird feeder style P-trap allows removal of the rinsed tar sand from the bottom of the rinse chamber in a controlled manner with a minimum amount of solvent associated with the sand. The rinse
chamber 40 is arranged such that the liquid level is maintained by a siphon tube arrangement. The siphon is established by introducing a vacuum at the top of the chamber to remove all gases from the upper rinse chamber and siphon tube areas. - The system will operate as a closed loop process. A key to starting the system up is establishing a siphon system. Solvent must be introduced into the bowl of the rinse
chamber 40 and mixingT 28 to create a P trap seal which allows the siphon loops to be created. The solvent can be introduced via the recirculation pump loop and the siphon pump loop. Once the siphons are established, the solvent is supplied through the siphon pump loop. - In the case of the recirculation loop, once a seal is initiated, a vacuum is placed on the rinse
chamber 40 to keep the solvent level near the top of the rinsechamber 40. The siphon pump is turned on to insure the solvent level in the bowl remains constant. This is accomplished by siphon overflow stand pipe and a flow meter. The pump speed is adjusted such that the standpipe overflow is equal to or greater than zero. The rinsechamber 40 and the recirculation pump loop fill with solvent. Once the recirculation loop and rinse chamber is full of solvent, the siphon loop is established and application of a vacuum is no longer required as long as air does not enter the upper portion of the rinse chamber. In this case, vacuum valve is open to remove the air trapped in the upper portion of the rinse chamber. Once the siphon loop is established, the recirculation pump may be started. The siphon loop allows the solvent level to remain constant in the dissolution chamber even when the solvent recirculation pump is off. This feature also allows for the continuous introduction of tar sands into the dissolution chamber without interruption. The tar sand in the dissolution chamber is gradually dissolved and transported to the rinse chamber as slurry. The amount of flow through the bottom T and the upper portion of the dissolution chamber is modulated to maintain the proper level solvent in the dissolution chamber to prevent the entrainment of air into the recirculation loop and the level solvent from getting too high in the dissolution chamber. - The fresh solvent used to displacement wash sand in the rinse
chamber 40 is added around the bottom perimeter of the rinsechamber 40 by an annular ring. The annular ring of solvent is contained by the lower wall of the rinse chamber and a tube on the outside of the chamber, which is sealed between the rinse chamber wall and the top of outside tube. This annular ring is also controlled by a siphon tube. - The rate of clean sand removal from the rinse
chamber 40 is dictated by the plow configuration and the number and movement of the plows relative to the sand. The movement of the plows relative to the sand is achieved by the rotation of the plow or the bowl, which forms the annular P trap. -
FIG. 4 illustrates a simplified schematic diagram of the procedure to handle and extract hydrocarbons from tar sands. Initially, thehopper assembly 12 is loaded with tar sand and solvent is injected or sprayed onto the incoming tar sand as shown bybox 130. Through use of thegas pump 30 and closed loop system, a vacuum is applied in order to assist in keeping the level of solvent at a desired level as shown atbox 132. - Once the recirculation loop, rinse chamber and siphon pump loop are full of solvent, the application of vacuum is no longer required as long as gases to do not enter the upper portion of the rinse chamber or the siphon pump loop in sufficient quantities to break either of these siphons. In this case, a vacuum valve is open to remove the gases trapped in the upper portion of the rinse chamber or the siphon pump loop.
- After the solvent contacts the tar sands in the hopper assembly, the slurry of solvent, hydrocarbon liquids, and small sand particles are transported in a slurry to the rinse chamber as shown at
box 134. Liquid solvent and hydrocarbon liquid is thereafter drawn off from the rinse chamber by force of the recirculation pump shown atbox 136 and directed to the recirculation loop heat exchanger. A portion of the liquid is removed by an oil solvent pump and transported to solvent/oil heat exchanger. The hydrocarbon oil and bitumen are harvested and delivered to astorage tank 75 as shown atbox 140. The solvent, in the form of vapors, are drawn off and condensed as shown atbox 142 and also pumped back to the rinse chamber as shown atbox 144. - The sand at the base of the rinse chamber is delivered to the steam heating tray or cone where the sand and solvent therein are heated, as shown at
box 148. The solvent vapors are delivered back to thesolvent condenser 142 while the clean sand which is tree of hydrocarbon oil and solvent is removed from the rinse chamber as shown atbox 146. - The invention uses the tar sands themselves as the cooling source for condensing the solvent which is vaporized from the clean sand. The heat of condensation is used to heat up the incoming tar sand. This is accomplished by using an oil/solvent recirculation pump. The oil/solvent is pumped through the cooling side of the
heat exchanger box 150. The solvent condenses on the heating side of the heat exchanger. The hot oil/solvent mixture is introduced onto the cold tar sand. The heat is transferred to the tar sand. The oil mixture continues through the recirculation loop and eventually returns to the heat exchanger to be reheated. The recirculation loop heat exchanger can maintain a temperature approaching the condensation temperature of the solvent. - In this manner, the majority of energy for heating the tar sands is provided by this heat exchanger loop and a significant portion of the cooling requirement is provided by the heat exchanger. In some cases, the heating requirements for the sand are about the same as the condensation requirements.
- An additional benefit of this approach is that the hot oil/solvent mixture increases the dissolution rate of the tar sand regardless of incoming tar sand temperature.
- The second aspect of this invention is dissolution, classification, and transport of the tars sand through the process on a continuous process. A considerable amount of expense is normally incurred during the mining, transport, and crushing of tar for processing. In addition, the degree of extraction is a function of the size of the oil bearing sand agglomerates. Traditionally, this is dealt with through the use of a crusher. Crushers are expensive to buy, maintain, and operate. They are prone to jamming and the wear on the crush hammers is extensive. In addition, they are not selective in the crushing process and do not separate the oil bearing sand from the nonporous rock which typically accompany the tar sand. Crushers usually process the tar sand at ambient conditions or with the addition of heat. Cold tar sand is less sticky but harder to crush into small particles. As the particle size requirement falls below one inch the energy and cost of operation grows rapidly.
- Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.
Claims (13)
1. A method for handling tar sands and extracting bitumen or oil from said tar sands, which method comprises:
depositing tar sands into a hopper assembly:
contacting an organic solvent mixture with said tar sands in said hopper assembly;
dissolving said oil or bitumen in said tar sands with said organic solvent;
allowing sand from said tar sands to separate and fail toward a bottom of said hopper assembly;
transporting said separated sands and said liquid in a slurry of fluid from said hopper assembly to a top of a rinse chamber;
delivering said slurry of fluid into a top of said rinse chamber tangentially to cause cyclonic action of the slurry in said rinsing chamber to separate said sands from said fluid;
drawing and removing said solvent and said oil or bitumen mixture from said rinse chamber;
drawing said solvent and said oil/bitumen mixture to a separator to separate said oil/bitumen from said solvent; and
returning said solvent to said hopper assembly to be reused to form a closed loop process.
2. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 wherein said hopper has a conical bottom.
3. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 including the additional step of separating solids below a certain size with a perforated screen in said hopper assembly above said conical bottom.
4. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 including maintaining an inert gas blanket at a top of the hopper assembly.
5. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 wherein said separated sands from said rinsing chamber are heated to remove solvent.
6. A method for handling tar sands and extracting bitumen or oil as set forth in claim 5 wherein said separated sands are heated by steam heat.
7. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 wherein said organic solvent is heated in a heat exchanger prior to said step of providing on said tar sands.
8. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 including maintaining a layer of said tar sand above an area where organic solvent contacts said tar sand to maintain a vapor absorption barrier.
9. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 wherein said organic solvent is a mixture of hexane and bitumen.
10. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 including maintaining liquid spring line in said hopper assembly.
11. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 including maintaining a liquid spring line in said rinse chamber.
12. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 including maintaining a common liquid spring line in both said hopper assembly and said rinse chamber.
13. A method for handling tar sands and extracting bitumen or oil as set forth in claim 1 including maintaining less than atmospheric pressure in said rinse chamber.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/761,773 US20080060978A1 (en) | 2006-06-14 | 2007-06-12 | Handling and extracting hydrocarbons from tar sands |
PCT/US2007/071100 WO2007146992A2 (en) | 2006-06-14 | 2007-06-13 | Handling and extracting hydrocarbons from tar sands |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US80478106P | 2006-06-14 | 2006-06-14 | |
US11/761,773 US20080060978A1 (en) | 2006-06-14 | 2007-06-12 | Handling and extracting hydrocarbons from tar sands |
Publications (1)
Publication Number | Publication Date |
---|---|
US20080060978A1 true US20080060978A1 (en) | 2008-03-13 |
Family
ID=38669455
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/761,773 Abandoned US20080060978A1 (en) | 2006-06-14 | 2007-06-12 | Handling and extracting hydrocarbons from tar sands |
Country Status (2)
Country | Link |
---|---|
US (1) | US20080060978A1 (en) |
WO (1) | WO2007146992A2 (en) |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090294332A1 (en) * | 2008-06-02 | 2009-12-03 | Korea Technology Industry, Co., Ltd. | System For Separating Bitumen From Oil Sands |
WO2010068614A1 (en) * | 2008-12-09 | 2010-06-17 | Gtc Technology Us, Llc | Heavy hydrocarbon removal systems and methods |
WO2010111141A1 (en) * | 2009-03-21 | 2010-09-30 | Ausc Global Energy Llc | System and method for extracting bitumen from tar sand |
US20110132809A1 (en) * | 2009-12-09 | 2011-06-09 | GREEN TECHNOLOGY LLC A Nevada Limited Liability Company | Separation and extraction of desired recoverable materials from source materials |
US20110186545A1 (en) * | 2010-01-29 | 2011-08-04 | Applied Materials, Inc. | Feedforward temperature control for plasma processing apparatus |
EP2366759A1 (en) | 2010-03-17 | 2011-09-21 | Siemens Aktiengesellschaft | Method and device for extracting hydrocarbons from oil sand |
US20120132397A1 (en) * | 2010-06-08 | 2012-05-31 | Applied Materials, Inc. | Temperature control in plasma processing apparatus using pulsed heat transfer fluid flow |
US20140216985A1 (en) * | 2009-09-23 | 2014-08-07 | Shell Oil Company | Closed loop solvent extraction process for oil sands |
US20150014221A1 (en) * | 2013-07-09 | 2015-01-15 | New York University | Composition, method, and apparatus for crude oil remediation |
US8957265B2 (en) | 2009-12-09 | 2015-02-17 | Green Technology Llc | Separation and extraction of hydrocarbons from source material |
US9639097B2 (en) | 2010-05-27 | 2017-05-02 | Applied Materials, Inc. | Component temperature control by coolant flow control and heater duty cycle control |
US10252921B1 (en) | 2016-06-09 | 2019-04-09 | Paul Charles Wegner | Process and apparatus for enhancing boron removal from water |
US10274270B2 (en) | 2011-10-27 | 2019-04-30 | Applied Materials, Inc. | Dual zone common catch heat exchanger/chiller |
US10683223B1 (en) | 2016-04-01 | 2020-06-16 | Paul C. Wegner | Process to remove transition metals from waste water |
US11066317B1 (en) | 2018-10-26 | 2021-07-20 | Paul Charles Wegner | System for removal of nitrate and chrome from water |
US11767245B1 (en) | 2019-10-31 | 2023-09-26 | Paul Charles Wegner | Process for boron removal from water |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10323774A1 (en) * | 2003-05-26 | 2004-12-16 | Khd Humboldt Wedag Ag | Process and plant for the thermal drying of a wet ground cement raw meal |
WO2011021092A2 (en) | 2009-08-17 | 2011-02-24 | Brack Capital Energy Technologies Limited | Oil sands extraction |
US10519380B2 (en) | 2010-10-13 | 2019-12-31 | Epic Oil Extractors, Llc | Hydrocarbon extraction of oil from oil sand |
CA2814707C (en) * | 2010-10-13 | 2018-06-05 | Epic Oil Extractors, Llc | Hydrocarbon extraction of oil from oil sand |
US10508242B2 (en) | 2010-10-13 | 2019-12-17 | Epic Oil Extractors, Llc | Vapor phase hydrocarbon extraction of oil from oil sand |
CN109569017B (en) * | 2018-11-30 | 2021-10-22 | 江西润井康生物科技有限公司 | Raw materials extraction equipment is used in cosmetics production |
Citations (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2965557A (en) * | 1959-06-12 | 1960-12-20 | Cities Service Res & Dev Co | Recovery of oil from bituminous sands |
US3553098A (en) * | 1968-10-15 | 1971-01-05 | Shell Oil Co | Recovery of tar from tar sands |
US4120775A (en) * | 1977-07-18 | 1978-10-17 | Natomas Company | Process and apparatus for separating coarse sand particles and recovering bitumen from tar sands |
US4539098A (en) * | 1984-06-22 | 1985-09-03 | Phillips Petroleum Company | Upgrading carbonaceous materials |
US4737267A (en) * | 1986-11-12 | 1988-04-12 | Duo-Ex Coproration | Oil shale processing apparatus and method |
US5273647A (en) * | 1991-12-13 | 1993-12-28 | Tuszko Wlodzimierz J | Negative pressure hydrocyclone separation method and apparatus |
US5534136A (en) * | 1994-12-29 | 1996-07-09 | Rosenbloom; William J. | Method and apparatus for the solvent extraction of oil from bitumen containing tar sand |
US5772127A (en) * | 1997-01-22 | 1998-06-30 | Alberta Energy Ltd | Slurrying oil sand for hydrotransport in a pipeline |
US5998640A (en) * | 1996-02-13 | 1999-12-07 | Haefele; Gary R. | Method for recovering oil from an oil-bearing solid material |
US6004455A (en) * | 1997-10-08 | 1999-12-21 | Rendall; John S. | Solvent-free method and apparatus for removing bituminous oil from oil sands |
US20070131590A1 (en) * | 2005-12-12 | 2007-06-14 | Rj Oil Sands Inc. | Separation and recovery of bitumen oil from tar sands |
US20070205141A1 (en) * | 2006-03-03 | 2007-09-06 | M-I L.L.C. | Separation of tar from sand |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4357230A (en) * | 1980-09-25 | 1982-11-02 | Carrier Corporation | Extraction of oil using amides |
BR8204258A (en) * | 1981-07-23 | 1983-07-19 | Duo Ex Corp | PROCESS AND APPARATUS FOR EXTRACTION OF BITUME AND PROCESS FOR EXTRACTION OF PETROLEUM FROM SHALE PETROLIFERO |
EP0081016A1 (en) * | 1981-12-04 | 1983-06-15 | Solv-Ex Corporation | A process and apparatus for extracting bitumen oil from bitumen containing mineral |
-
2007
- 2007-06-12 US US11/761,773 patent/US20080060978A1/en not_active Abandoned
- 2007-06-13 WO PCT/US2007/071100 patent/WO2007146992A2/en active Application Filing
Patent Citations (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2965557A (en) * | 1959-06-12 | 1960-12-20 | Cities Service Res & Dev Co | Recovery of oil from bituminous sands |
US3553098A (en) * | 1968-10-15 | 1971-01-05 | Shell Oil Co | Recovery of tar from tar sands |
US4120775A (en) * | 1977-07-18 | 1978-10-17 | Natomas Company | Process and apparatus for separating coarse sand particles and recovering bitumen from tar sands |
US4539098A (en) * | 1984-06-22 | 1985-09-03 | Phillips Petroleum Company | Upgrading carbonaceous materials |
US4737267A (en) * | 1986-11-12 | 1988-04-12 | Duo-Ex Coproration | Oil shale processing apparatus and method |
US5273647A (en) * | 1991-12-13 | 1993-12-28 | Tuszko Wlodzimierz J | Negative pressure hydrocyclone separation method and apparatus |
US5534136A (en) * | 1994-12-29 | 1996-07-09 | Rosenbloom; William J. | Method and apparatus for the solvent extraction of oil from bitumen containing tar sand |
US5998640A (en) * | 1996-02-13 | 1999-12-07 | Haefele; Gary R. | Method for recovering oil from an oil-bearing solid material |
US5772127A (en) * | 1997-01-22 | 1998-06-30 | Alberta Energy Ltd | Slurrying oil sand for hydrotransport in a pipeline |
US6004455A (en) * | 1997-10-08 | 1999-12-21 | Rendall; John S. | Solvent-free method and apparatus for removing bituminous oil from oil sands |
US20070131590A1 (en) * | 2005-12-12 | 2007-06-14 | Rj Oil Sands Inc. | Separation and recovery of bitumen oil from tar sands |
US20070205141A1 (en) * | 2006-03-03 | 2007-09-06 | M-I L.L.C. | Separation of tar from sand |
Cited By (38)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8277642B2 (en) | 2008-06-02 | 2012-10-02 | Korea Technology Industries, Co., Ltd. | System for separating bitumen from oil sands |
WO2009147622A2 (en) * | 2008-06-02 | 2009-12-10 | Korea Technology Industry, Co., Ltd. | System for separating bitumen from oil sands |
WO2009147622A3 (en) * | 2008-06-02 | 2010-04-08 | Korea Technology Industry, Co., Ltd. | System for separating bitumen from oil sands |
US20090294332A1 (en) * | 2008-06-02 | 2009-12-03 | Korea Technology Industry, Co., Ltd. | System For Separating Bitumen From Oil Sands |
WO2010068614A1 (en) * | 2008-12-09 | 2010-06-17 | Gtc Technology Us, Llc | Heavy hydrocarbon removal systems and methods |
KR101693758B1 (en) | 2008-12-09 | 2017-01-06 | 쥐티씨 테크놀로지 유에스,엘엘씨 | Heavy hydrocarbon removal systems and methods |
US9370728B2 (en) | 2008-12-09 | 2016-06-21 | Gtc Technology Us Llc | Heavy hydrocarbon removal systems and methods |
KR20110122099A (en) * | 2008-12-09 | 2011-11-09 | 쥐티씨 테크놀로지 유에스,엘엘씨 | Heavy hydrocarbon removal systems and methods |
US8455709B2 (en) | 2008-12-09 | 2013-06-04 | Gtc Technology Us, Llc | Heavy hydrocarbon removal systems and methods |
WO2010111141A1 (en) * | 2009-03-21 | 2010-09-30 | Ausc Global Energy Llc | System and method for extracting bitumen from tar sand |
US9598643B2 (en) | 2009-03-21 | 2017-03-21 | Lila Hau Yuk Chan | System and method for extracting bitumen from tar sand |
US20140216985A1 (en) * | 2009-09-23 | 2014-08-07 | Shell Oil Company | Closed loop solvent extraction process for oil sands |
US9688916B2 (en) * | 2009-12-09 | 2017-06-27 | Green Technology Llc | Separation and extraction of hydrocarbons from source material |
US8957265B2 (en) | 2009-12-09 | 2015-02-17 | Green Technology Llc | Separation and extraction of hydrocarbons from source material |
US8597470B2 (en) | 2009-12-09 | 2013-12-03 | Green Technology Llc | Separation and extraction of bitumen from tar sands |
US8722949B2 (en) | 2009-12-09 | 2014-05-13 | Green Technology Llc | Coal liquefaction |
US20110132809A1 (en) * | 2009-12-09 | 2011-06-09 | GREEN TECHNOLOGY LLC A Nevada Limited Liability Company | Separation and extraction of desired recoverable materials from source materials |
US8273244B2 (en) * | 2009-12-09 | 2012-09-25 | Green Technology Llc | Separation and extraction of bitumen from tar sands |
US20150159091A1 (en) * | 2009-12-09 | 2015-06-11 | Green Technology Llc | Separation and extraction of hydrocarbons from source material |
US9214315B2 (en) | 2010-01-29 | 2015-12-15 | Applied Materials, Inc. | Temperature control in plasma processing apparatus using pulsed heat transfer fluid flow |
US9338871B2 (en) | 2010-01-29 | 2016-05-10 | Applied Materials, Inc. | Feedforward temperature control for plasma processing apparatus |
US20110186545A1 (en) * | 2010-01-29 | 2011-08-04 | Applied Materials, Inc. | Feedforward temperature control for plasma processing apparatus |
US10854425B2 (en) | 2010-01-29 | 2020-12-01 | Applied Materials, Inc. | Feedforward temperature control for plasma processing apparatus |
EP2366759A1 (en) | 2010-03-17 | 2011-09-21 | Siemens Aktiengesellschaft | Method and device for extracting hydrocarbons from oil sand |
US20110226672A1 (en) * | 2010-03-17 | 2011-09-22 | Urs Peuker | Methods and Devices for Extracting Hydrocarbons From Oil Sand |
US8871083B2 (en) | 2010-03-17 | 2014-10-28 | Siemens Aktiengesellschaft | Methods and devices for extracting hydrocarbons from oil sand |
US9639097B2 (en) | 2010-05-27 | 2017-05-02 | Applied Materials, Inc. | Component temperature control by coolant flow control and heater duty cycle control |
US8916793B2 (en) * | 2010-06-08 | 2014-12-23 | Applied Materials, Inc. | Temperature control in plasma processing apparatus using pulsed heat transfer fluid flow |
US20120132397A1 (en) * | 2010-06-08 | 2012-05-31 | Applied Materials, Inc. | Temperature control in plasma processing apparatus using pulsed heat transfer fluid flow |
US10274270B2 (en) | 2011-10-27 | 2019-04-30 | Applied Materials, Inc. | Dual zone common catch heat exchanger/chiller |
US10928145B2 (en) | 2011-10-27 | 2021-02-23 | Applied Materials, Inc. | Dual zone common catch heat exchanger/chiller |
US20150014221A1 (en) * | 2013-07-09 | 2015-01-15 | New York University | Composition, method, and apparatus for crude oil remediation |
US10683223B1 (en) | 2016-04-01 | 2020-06-16 | Paul C. Wegner | Process to remove transition metals from waste water |
US10252921B1 (en) | 2016-06-09 | 2019-04-09 | Paul Charles Wegner | Process and apparatus for enhancing boron removal from water |
US10604424B1 (en) | 2016-06-09 | 2020-03-31 | Paul Charles Wegner | Process and apparatus for enhancing boron removal from water |
US11180386B1 (en) | 2016-06-09 | 2021-11-23 | Paul Charles Wegner | Process for regenerating resin in an ion exchange vessel |
US11066317B1 (en) | 2018-10-26 | 2021-07-20 | Paul Charles Wegner | System for removal of nitrate and chrome from water |
US11767245B1 (en) | 2019-10-31 | 2023-09-26 | Paul Charles Wegner | Process for boron removal from water |
Also Published As
Publication number | Publication date |
---|---|
WO2007146992A2 (en) | 2007-12-21 |
WO2007146992A3 (en) | 2008-02-14 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20080060978A1 (en) | Handling and extracting hydrocarbons from tar sands | |
US8226820B1 (en) | Handling and extracting hydrocarbons from tar sands | |
US8277642B2 (en) | System for separating bitumen from oil sands | |
US4098648A (en) | Rotary separating and extracting devices | |
US11840897B2 (en) | Multi-stage drilling waste material recovery process | |
US5534136A (en) | Method and apparatus for the solvent extraction of oil from bitumen containing tar sand | |
US4280879A (en) | Apparatus and process for recovery of hydrocarbons from inorganic host materials | |
RU2181612C2 (en) | Method and device for withdrawal of oil from solid oil-containing materials | |
CA2937235C (en) | Bituminous feed processing | |
US20090211106A1 (en) | Treatment of Drill Cuttings | |
US20230159833A1 (en) | Non-aqueous extraction of bitumen from oil sands | |
US9321968B2 (en) | Apparatus and methods for hydrocarbon extraction | |
CA2098656A1 (en) | Extractor and process for extracting one material from a multi-phase feed material | |
CN110394355A (en) | A kind of kitchen garbage continuity removes the gred de- liquid purification system and method | |
CN108439738A (en) | Integral type sludge treatment technique | |
JP2000210502A (en) | Extractor | |
CA2747004C (en) | Apparatus and methods for hydrocarbon extraction | |
US10947456B2 (en) | Systems for the extraction of bitumen from oil sand material | |
US11649404B2 (en) | Ablation process for oil sands subjected to non-aqueous extraction | |
AU775402B2 (en) | Method and apparatus for recovering oil from an oil-bearing solid material | |
US20100176033A1 (en) | System for removing tar oil from sand and method of extracting oil from sand | |
SU682138A3 (en) | Process for isolating hydrocarbons from mineral materials | |
CN108409079A (en) | Integral type sludge treatment equipment |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |