Alberta Oil Sands Technology and Research Authority

Alberta Oil Sands Tech and Research Authority

William Taciuk

Gordon Taciuk

Sean Goodwin

Roderick Caple

Steve Odut

Charlie Wheeler

Adrian Begley

Roman Koszarycz

Used oil is treated in a reactor to remove contaminants. The reactor comprises a rotating vessel housed within a heating chamber. The inside of the vessel is indirectly heated by conduction through the vessel walls. The vessel contains a permanently resident charge of non-ablating, coarse granular solids. Within the vessel, the oil is vaporized and pyrolyzed, producing a hydrocarbon vapor. Coke is formed as a byproduct. Contaminants, such as metals and halides become associated with the coke. The coarse granular solids scour and comminute the coke to form fine solids. The fine solids are separated from the coarse solids and are removed from the vessel. The hydrocarbon vapors are separated from any fine solids and are routed to a vapor condensation system for producing a substantially contaminant-free product oil. The contaminant-rich solids are collected for disposal.

Thermal apparatus and process for removing contaminants from oil

Used oil is treated in a reactor to remove contaminants. The reactor comprises a rotating vessel forming an internal reaction chamber. The vessel is housed within a heating chamber. The inside of the vessel is indirectly heated by conduction through the vessel walls. The reaction chamber contains a permanently resident charge of non-ablating, granular coarse solids. Within the reaction chamber, the oil is vaporized and pyrolyzed, producing a hydrocarbon vapour. Coke is formed as a byproduct. Contaminants, such as metals and halides, become associated with the coke. The coarse solids scour and comminute the coke to form fine solids. The fine solids are separated within the reaction chamber from the coarse solids and are removed from the vessel through a pipe located at the axis of the vessel. The hydrocarbon vapours are also removed from the vessel through the axial pipe, as a separate stream. Residual fine solids are separated in a cyclone from the vapour stream. The cleaned vapour stream is then condensed to produce a substantially contaminant-free product oil. The contaminant-rich solids are collected for disposal.

Oil sand is treated to prevent the production of sulfur dioxide ('SO.sub.2 ') from a known rotating kiln-type processor. Lime or calcium oxide ('CaO') is added with the oil sand feed to the kiln. In the kiln, the CaO is mixed with the sulfur-containing bitumen of the oil sand and preheated. The preheated mixture is then pyrolysed, forming coke which is modified by the added CaO to reduce its tendency to produce SO.sub.2 when combusted. The modified coke is then combusted with air, producing substantially no SO.sub.2.

Prevention of sulfur gas emissions from a rotary processor using lime

The processor is of the type incorporating horizontal, concentric, co-extensive inner and outer tubular members which rotate together. The processor is modified in the following respects:

Dry thermal processor

A dry thermal processor is provided for recovering hydrocarbons from oil sand solids. The processor comprises concentric, radially spaced, horizontal inner and outer tubular members connected for rotation together. The inner member provides a substantially open preheat zone and vaporization zone while the outer member provides, in the annular space between the tubular members, a substantially open combustion zone and heat transfer zone. The ends of the outer member are sealed by stationary feed end and product end structures. Advance means move the oil sand solids from the feed end structure through the preheat and vaporization zones to the product end structure and back through the combustion and heat transfer zones. In the preheat zone the oil sands are progressively heated and dehydrated by heat transferred through walls of the inner member from hot solids being dropped thereon in the heat transfer zone. Rotation of the inner member causes size reduction of the oil sand feed in the preheat zone, and oversize is discharged directly into the annular space at the second end of the preheat zone. In the vaporization zone, the preheated oil sands are mixed with hot sand solids recycled from the combustion zone to thereby vaporize the hydrocarbon content of the oil sands and produce a coke residue on the sands. These coked sands are transferred into the combustion zone where they are struck by air to support combustion of the coke. This combustion together with supplemental heat provide the heat requirements of the processor.

Process for recovery of hydrocarbons from inorganic host materials

In the apparatus, concentric, radially spaced tubes are secured to each other and rotated about a common horizontal long axis. Selectively placed and configured lift elements repeatedly lift and drop feed material in the two tubes. Advance elements cause the feed material introduced into the feed end of the structure to advance through the inner tube where it is progressively heated, dehydrated and its hydrocarbon content is largely vaporized. The hydrocarbon vapors are removed from the opposite product end of the structure. The remaining solid material falls from the end of the inner tube into a combustion zone in the outer tube. Oxygen supplying means are provided for causing the carbon coatings on the particles in the combustion zone to burn to produce heat employed in the processing of the feed material. The solid particles in the outer tube are moved back toward the feed end by advancing elements. Recycle fixtures divert a portion of the hot, solid material which has had its carbon coating burned off back into the inner tube to be mixed with the incoming feed material. Means are described for processing the hydrocarbon vapors removed from the inner tube and for cleaning combustion gases and vapors removed from the feed end of both tubes.

Apparatus and process for recovery of hydrocarbon from inorganic host

A dry thermal processor for recovering hydrocarbons from oil sand solids comprises concentric, radially spaced, horizontal inner and outer tubular members connected for rotation together. The inner member provides a substantially open preheat zone and vaporization zone while the outer member provides, in the annular space between the tubular members, a substantially open combustion zone and heat transfer zone. The ends of the outer member are sealed by stationary feed end and product end structures. Advance means move the oil sand solids from the feed end structure through the preheat and vaporization zones to the product end structure and back through the combustion and heat transfer zones. Rotation of the inner member causes size reduction of the oil sand feed in the preheat zone, and oversize is discharged directly into the annular space at the second end of the preheat zone. Separate means are provided for removing the gases produced in the zones, said means maintaining the gaseous atmospheres in the preheat zone, vaporization zone and annular space substantially segregated from each other.

Apparatus and process for recovery of hydrocarbons from inorganic host

There is provided an apparatus comprising rotating inner and outer concentric tubes. The inner tube provides a vapor zone and the annular space between the tubes provides a combustion zone. Hot particulate solids, such as sand, are advanced along an endless path through the vapor zone, back through the combustion zone and back into the vapor zone. In the vapor zone, oil is sprayed on the hot solids. The mixture is mixed and cascaded to obtain heat transfer from the solids to the oil, thereby generating hydrocarbon vapors and coke deposition on the solids. The vapors are removed by suction from the vapor zone. The coked solids are transferred into the combustion zone and cascaded and lifted and dropped therein to mix with added oxygen. Coke is burned to heat the solids which are then returned to the vapor zone. The vapors generated in the combustion zone are removed by suction. Segregation of the atmospheres in the two zones is achieved by a combination of maintaining equal pressures in the zones and using the solids, being transferred from one zone to the other, to block gas flow.

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Calgary, Canada

William Taciuk