US 4,415,434 A · Multiple stage desalting and dedusting process

Abstract

A process is provided to dedust oil derived from solid hydrocarbon-containing material, such as oil shale, coal or tar sand in multi-stage desalters. In the process, water is dispersed into the oil before entering each desalter to form an emulsion. The desalter separates the emulsion into a stream of oil having a substantially lower concentration of dust and a dusty stream of water containing most of the dust. In one embodiment, the sludge-like dusty stream from the first desalter is combusted in a lift pipe and used as heat carrier material in the retort. In other embodiments, the dusty stream from the first desalter is centrifuged or filtered and thereafter heated in a dryer to remove residual oil and water from the stream before the stream is combusted in the lift pipe and used as heat carrier material in the retort and dryer. Effluent water from the second and third desalters as well as from the centrifuge or filter are recycled upstream and dispersed in the oil.

Claims50

Dependent claims

A process for producing and dedusting oil from solid hydrocarbon-containing material, comprising the steps of:

feeding solid hydrocarbon-containing material to a retort;
feeding solid heat carrier material to said retort;
retorting said solid hydrocarbon-containing material by mixing said solid hydrocarbon-containing material with said solid heat carrier material in said retort at a sufficient retorting temperature to liberate an effluent product stream of hydrocarbons and entrained particulates of dust derived from said solid hydrocarbon-containing material;
separating a fraction of normally liquid oil mixed with a substantial portion of said entrained particulates from said effluent product stream in a separator;
dispersing water into said fraction after said fraction has been removed from said separator to form an emulsion;
separating said emulsion in a desalter into a dedusted stream of normally liquid oil having a substantially lower concentration of particulates than said fraction and a particulate laden residual stream having a higher concentration of said particulates than said fraction;
and
combusting said particulate laden residual stream after said particulate laden residual stream has been removed from said desalter to form a spent stream for use as at least part of said solid heat carrier material in said retort.

5 more elements

A process for dedusting shale oil, comprising the steps of:

(a) mixing from 10% to 50% by volume water with shale oil laden with shale particulates ranging in size from less than 1 micron to 1000 microns to form a first emulsion;
(b) separating said first emulsion in a first desalter into a first dedusted stream of shale oil containing from 0.15% to 1.5% by weight shale particulates and a first stream of water containing from 23% to 60% by weight shale particulates and from 0.5% to 1% by weight shale oil;
(c) removing said first dedusted stream of shale oil from said first desalter;
(d) mixing from 2% to 7% by volume water with said removed first dedusted stream to form a second emulsion;
(e) separating said second emulsion in a second desalter into a second dedusted stream of shale oil containing from 0.0015% to 0.15% by weight shale particulates and a second stream of water containing a substantially lower concentration of shale particulates than said first stream of water;
(f) centrifuging said first stream of water into a purified stream of water and a centrifuge sludge having a higher concentration of shale particulates than said first stream of water;
(g) recirculating said purified stream of water for use in step (a) or (d);
(h) mixing said centrifuge sludge with solid heat carrier material in a dryer at a sufficient drying temperature to separate said centrifuge sludge into a third dedusted stream consisting of normally liquid shale oil and less than 5% by weight shale dust and a residual stream consisting of less than 10% by weight normally liquid shale oil and a higher concentration of shale dust than said centrifuge sludge;
(i) combusting said residual stream in a lift pipe to form a spent stream;
and
(j) using said spent stream as part of said solid heat carrier material in said dryer.

8 more elements

A process for dedusting shale oil, comprising the steps of:

(a) mixing from 10% to 50% by volume water with shale oil laden with shale particulates ranging in size from less than 1 micron to 1000 microns to form a first emulsion;
(b) separating said first emulsion in a first desalter into a first dedusted stream of shale oil containing from 0.15% to 1.5% by weight shale particulates and a first stream of water containing from 23% to 60% by weight shale particulates and from 0.5% to 1% by weight shale oil;
(c) removing said first dedusted stream of shale oil from said first desalter;
(d) mixing from 2% to 7% by volume water with said removed first dedusted stream to form a second emulsion;
(e) removing said second dedusted stream of shale oil from said second desalter;
(f) mixing from 2% to 7% by volume water with said removed second dedusted stream to form a third emulsion;
(g) separating said third emulsion in a third desalter into a third dedusted stream of shale oil containing from 0.0015% to 0.0150% by weight shale particulates and a third stream of water containing a substantially lower concentration of shale particulates than said second stream of water;
(h) centrifuging said first stream of water into a purified stream of water and a centrifuge sludge having a higher concentration of shale particulates than said first stream of water;
(i) mixing said centrifuge sludge with solid heat carrier material in a dryer at a sufficient drying temperature to separate said centrifuge sludge into a fourth dedusted stream consisting of normally liquid shale oil and less than 5% by weight shale dust and a residual stream consisting of less than 10% by weight normally liquid shale oil and a higher concentration of shale dust than said centrifuge sludge;
(j) combusting said residual stream in a lift pipe to form a spent stream;
and
(k) using said spent stream as part of said solid heat carrier material in said dryer.

9 more elements

A process for producing and dedusting shale oil, comprising the steps of:

(a) introducing raw oil shale into a retort;
(b) introducing solid heat carrier material including spent oil shale into said retort;
(c) retorting said raw oil shale in said retort by mixing said raw oil shale and said solid heat carrier material in said retort at a sufficient retorting temperature to liberate an effluent product stream of hydrocarbons and entrained particulates of oil shale dust ranging in size from less than 1 micron to 1000 microns;
(d) separating a particulate laden shale oil fraction from said effluent product stream in a separator.
(e) mixing from 10% to 50% by volume water with said removed particulate laden shale oil fraction to form a first emulsion;
(f) separating said first emulsion in a first desalter into a first dedusted stream consisting of normally liquid shale oil and from 1500 ppm to 15,000 ppm by weight oil shale dust and a first particulate laden water stream consisting of 39% to 76% by weight water, 23% to 60% by weight oil shale dust and 0.5% to 1% by weight normally liquid shale oil;
(g) removing said first dedusted stream from said first desalter;
(h) mixing from 2% to 7% by volume water with said removed first dedusted stream to form a second emulsion;
(i) separating said second emulsion in a second desalter into a second dedusted stream of normally liquid shale oil containing from 15 ppm to 1500 ppm by weight oil shale dust and a second stream of water having a substantially lower concentration of oil shale dust than said first particulate laden water stream;
and
(j) recycling said second stream of water from said second desalter upstream of said first desalter for use in step (e) without centrifuging said second stream of water;
and
(k) processing said first stream of water from said first desalter in an apparatus selected from the group consisting of a combustor lift pipe, rotary filter, centrifuge, dryer and combinations thereof, separate and apart from said second stream of water from the second desalter.

10 more elements

A process for producing and dedusting shale oil, comprising the steps of:

(a) introducing raw oil shale into a retort;
(b) introducing solid heat carrier material including spent oil shale into said retort;
(c) retorting said raw oil shale in said retort by mixing said raw oil shale and said solid heat carrier material in said retort at a sufficient retorting temperature to liberate an effluent product stream of hydrocarbons and entrained particulates of oil shale dust ranging in size from less than 1 micron to 1000 microns;
(d) separating a particulate laden shale oil fraction consisting of normally liquid shale oil and from 10% to 50% by weight oil shale dust from said effluent product stream;
(e) dispersing 10% to 50% by volume water in said removed particulate laden shale oil fraction to form a first emulsion;
(f) separating said emulsion in a first desalter into a first dedusted stream consisting of normally liquid shale oil and from 1500 ppm to 15,000 ppm by weight oil shale dust and a first particulate laden water stream consisting of 39% to 76% by weight water, 23% to 60% by weight oil shale dust and 0.5% to 1% by weight normally liquid shale oil;
(g) removing said first dedusted stream from said first desalter;
(h) dispersing 2% to 7% by volume water into said removed first dedusted stream from said first desalter to form a second emulsion;
(i) separating said second emulsion in a second desalter into a second dedusted stream of normally liquid shale oil containing from 15 ppm to 1500 ppm by weight oil shale dust and a second stream of water having a substantially lower concentration of oil shale dust than said first particulate laden water stream;
(j) recycling said second stream of water from said second desalter directly upstream of said first desalter without centrifuging said second stream of water for use in step (e);
(k) removing said second dedusted stream from said second desalter;
(l) dispersing 2% to 7% by volume water into said removed second dedusted stream from said second desalter to form a third emulsion;
(m) separating said third emulsion in a third desalter into a third dedusted stream of normally liquid shale oil containing from 15 ppm to 150 ppm by weight oil shale dust and a third stream of water having a substantially lower concentration of oil shale dust than said second stream of water;
and
(n) recycling said third stream of water from said third desalter upstream of said second desalter for use in step (h).

12 more elements

A process for producing and dedusting shale oil, comprising the steps of:

(a) introducing raw oil shale into a retort;
(b) introducing solid heat carrier material derived from said oil shale into said retort;
(c) retorting said raw oil shale in said retort by mixing said raw oil shale and said solid heat carrier material in said retort at a sufficient retorting temperature to liberate an effluent product stream of hydrocarbons and entrained particulates of shale dust ranging in size from less than 1 micron to 1000 microns;
(d) separating a particulate laden shale oil fraction from said effluent product stream in a separator;
(e) mixing from 10% to 50% by volume water with said removed particulate laden shale oil fraction to form a first emulsion;
(f) separating said first emulsion in a first desalter into a first dedusted stream consisting of normally liquid shale oil and from 1500 ppm to 15,000 ppm by weight shale dust and a first particulate laden water stream consisting of 39% to 76% by weight water, 23% to 60% by weight shale dust and 0.5% to 1% by weight normally liquid shale oil;
(g) removing said first dedusted stream from said first desalter;
(h) mixing from 2% to 7% by volume water with said removed first dedusted stream to form a second emulsion;
(i) separating said second emulsion in a second desalter into a second dedusted stream of normally liquid shale oil containing from 15 ppm to 1500 ppm by weight shale dust and a second stream of water having a substantially lower concentration of shale dust than said first particulate laden water stream;
(j) recycling and using said second stream of water in step (e);
(k) centrifuging said first particulate laden water stream into a purified stream of water and a centrifuge sludge having a higher concentration of shale dust than said first particulate laden water stream;
(l) recirculating and using said purified stream of water in step (e) or (h);
(m) mixing said centrifuge sludge with solid heat carrier material in a dryer at a sufficient drying temperature to separate said centrifuge sludge into a third dedusted stream consisting of normally liquid shale oil and less than 5% by weight shale dust and a residual stream consisting of less than 10% by weight normally liquid shale oil and a higher concentration of shale dust than said centrifuge sludge;
(n) combusting said residual stream in a lift pipe to form a spent stream;
and
(o) using said spent stream as part of said solid heat carrier material in said dryer and said retort.

13 more elements

A process for producing and dedusting shale oil, comprising the steps of:

(a) introducing raw oil shale into a retort;
(b) introducing solid heat carrier material derived from said oil shale into said retort;
p1 (c) retorting said raw oil shale in said retort by mixing said raw oil shale and said solid heat carrier material in said retort at a sufficient retorting temperature to liberate an effluent product stream of hydrocarbons and entrained particulates of shale dust ranging in size from less than 1 micron to 1000 microns;
(d) separating a particulate laden shale oil fraction consisting of normally liquid shale oil and from 10% to 50% by weight shale dust from said effluent product stream;
(e) dispersing 10% to 50% by volume water in said removed particulate laden shale oil fraction to form a first emulsion;
(f) separating said first emulsion in a first desalter into a first dedusted stream consisting of normally liquid shale oil and from 1500 ppm to 15,000 ppm by weight shale dust and a first particulate laden water stream consisting of 39% to 76% by weight water, 23% to 60% by weight shale dust and 0.5% to 1% by weight normally liquid shale oil;
(g) removing said first dedusted stream from said first desalter;
(h) dispersing 2% to 7% by volume water into said removed first dedusted stream to form a second emulsion;
(i) separating said second emulsion in a second desalter into a second dedusted stream of normally liquid shale oil containing from 15 ppm to 1500 ppm by weight shale dust and a second stream of water having a substantially lower concentration of shale dust than said first particulate laden water stream;
(j) recycling and using said second stream of water in step (e);
(k) removing said second dedusted stream from said second desalter;
(l) dispersing 2% to 7% by volume water into said removed second dedusted stream to form a third emulsion;
(m) separating said third emulsion in a third desalter into a third dedusted stream of normally liquid shale oil containing from 15 ppm to 150 ppm by weight shale dust and third stream of water having a substantially lower concentration of shale dust than said second stream of water;
(n) recycling and using said third stream of water in step (h);
(o) separating said first particulate laden water stream in a centrifuge into a purified stream of water and a centrifuge sludge having a higher concentration of shale dust than said first particulate laden water stream;
(p) mixing said centrifuge sludge with solid heat carrier material in a dryer at a sufficient drying temperature to separate said centrifuge sludge into a fourth dedusted stream consisting of normally liquid shale oil and less than 5% by weight shale dust and a residual stream consisting of less than 10% by weight normally liquid shale oil and a higher concentration of shale dust than said centrifuge sludge;
(q) combusting said residual stream in a lift pipe to form a spent stream;
and
(r) using said spent stream as part of said solid heat carrier material in said dryer.

16 more elements

A process for dedusting oil derived from solid hydrocarbon-containing material, comprising the steps of:

(a) cooling heavy oil selected from the group consisting of shale oil, tar sands oil, coal oil, lignite oil, peat oil and uintaite oil laden with particulates ranging in size from less than 1 micron to 1000 microns selected from the group consisting of oil shale particulates, tar sands particulates, coal particulates, lignite particulates, peat particulates, and uintaite particulates, to a temperature ranging from 100.degree. F. to 250.degree. F.;
(b) dispersing water in said cooled heavy oil laden with said particulates to form a first emulsion;
(c) separating said first emulsion in a first desalter into a first dedusted stream of heavy oil having a substantially lower concentration of said particulates than said particulate laden oil and a first stream of water laden with said particulates;
(d) dispersing water in said first dedusted stream after said first dedusted stream has been removed from said first desalter to form a second emulsion;
(e) separating said second emulsion in a second desalter into a second dedusted stream of heavy oil have a substantially lower concentration of said particulates that said first dedusted stream of heavy oil and a second stream of water having a substantially lower concentration of said particulates than said first stream of water;
(f) removing said first stream of water laden with said particulates from said first desalter;
(g) combusting said removed first stream of water laden with said particulates to form a spent stream;
and
(h) feeding said spent stream to a surface retort for use as solid heat carrier material in retorting raw solid hydrocarbon-containing material.

6 more elements

Dependencies are inferred from the claim text.

Multiple stage desalting and dedusting process

Life of this patent

Multiple stage desalting and dedusting process

Life of this patent

Abstract

Claims50