# US 7,744,753 B2 · Coking apparatus and process for oil-containing solids > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,744,753 B2 - Document ID: US7744753B2 - Status: Granted - Kind: B2 - Application number: 11/751,987 - Filed: 2007-05-22 - Published: 2008-11-27 - Granted: 2010-06-29 - Earliest claimed: 2007-05-22 - Assignees: Uop LLC - Inventors: Gavin P. Towler - Web page: https://patentgrep.com/patent/US7744753B2 ## CPC - C10G 1/02: by distillation - C10J 3/463: {in stationary fluidised beds} - C10J 3/482: {Gasifiers with stationary fluidised bed} - C10J 3/74: Construction of shells or jackets - C10J 3/84: with means for removing dust or tar from the gas - C10J 2300/0946: Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale - C10J 2300/0956: Air or oxygen enriched air - C10J 2300/0959: Oxygen - C10J 2300/1656: Conversion of synthesis gas to chemicals - C10J 2300/1807: Recycle loops, e.g. gas, solids, heating medium, water - C10J 2300/1846: Partial oxidation, i.e. injection of air or oxygen only - C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES - C10J: PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES (synthesis gas from liquid or gaseous hydrocarbons C01B; underground gasification of minerals E21B43/295); CARBURETTING AIR OR OTHER GASES ## Abstract A process for upgrading unconventional or heavy oils such as, tar sands, shale oil, or bitumen. This process may include a coking scheme in which oil-containing solids, of suitable size, are fed directly into the riser of an FCC unit. Contacting a hot stream of solids causes vaporization and produces a gaseous product stream. The gaseous product may be separated out in a separating vessel and coked or unconverted oil-containing solids may be transferred to a gasifier for combustion at high temperatures to remove the coke and residual oil. Syngas from the gasifier may be converted to hydrogen using a water gas shift reaction. The hydrogen may be used for hydroprocessing. ## Claims ### Claim 1 A coking process, comprising: grinding oil-containing solids to produce oil-containing solids suitable for introduction into a riser; injecting a fluidizing medium into said riser; feeding said oil-containing solids suitable for introduction into a riser directly into said riser; contacting said directly-fed oil-containing solids with a hot stream of solids; cracking a portion of the hydrocarbons from said directly-fed oil-containing solids; separating gaseous products from said directly-fed oil-containing solids in a separator vessel; transferring coked oil-containing solids into a gasifier; introducing a stream of gas comprising oxygen-containing gases into said gasifier; and recovering syngas from said gasifier. ### Claim 2 (depends on 1) The process of claim 1, further comprising converting said syngas to hydrogen. ### Claim 3 (depends on 2) The process of claim 2, wherein said converting step is accomplished using a water gas shift reaction. ### Claim 4 (depends on 2) The process of claim 2, further comprising hydroprocessing a hydrocarbon using said hydrogen. ### Claim 5 (depends on 4) The process of claim 4, further comprising combining said gaseous products and said hydroprocessed hydrocarbon. ### Claim 6 (depends on 5) The process of claim 5, wherein said combining step produces a synthetic crude oil blend. ### Claim 7 (depends on 1) The process of claim 1, wherein the temperature within said gasifier is between about 650° C. and about 1200° C. ### Claim 8 (depends on 1) The process of claim 1, wherein the temperature within said gasifier is between about 700° C. and about 900° C. ### Claim 9 (depends on 1) The process of claim 1, wherein in said grinding step, said oil-containing solids comprises bitumen. ### Claim 10 (depends on 1) The process of claim 1, wherein in said grinding step, said oil-containing solids comprises tar sands. ### Claim 11 (depends on 1) The process of claim 1, wherein in said grinding step, said oil-containing solids comprises shale oil. ### Claim 12 (depends on 1) The process of claim 1, wherein said oil-containing solids have diameters between about 50 microns and about 1 mm. ### Claim 13 (depends on 1) The process of claim 1, wherein said hot stream of solids comprises recycled oil-containing solids from said gasifier. ### Claim 14 (depends on 1) The process of claim 1, wherein the concentration of oil in said oil-containing solids entering said riser is greater than the oil-containing solids exiting said riser. ### Claim 15 A coking process, comprising: grinding oil-containing solids to produce oil-containing solids suitable for introduction into a riser; injecting a fluidizing medium into said riser; feeding said oil-containing solids suitable for introduction into a riser directly into said riser; contacting said directly-fed oil-containing solids with a hot stream of solids; cracking a portion of the hydrocarbons from said directly-fed oil-containing solids; separating gaseous products from said directly-fed oil-containing solids in a separator vessel; transferring coked oil-containing solids into a gasifier; introducing a stream of gas comprising oxygen-containing gases into said gasifier; recovering syngas from said gasifier; recycling a hot stream of solids from said gasifier to said riser; converting said syngas to hydrogen using a water gas shift reaction; hydroprocessing a hydrocarbon using said hydrogen; and wherein the concentration of oil in said oil-containing solids entering said riser is greater than in a hot stream of oil-containing solids exiting said riser. ### Claim 16 (depends on 15) The process of claim 15, further comprising blending said gaseous products and said hydroprocessed hydrocarbon to produce a synthetic crude oil blend.