Recovery of hydrocarbon values by controlled eduction and oxidation of oil shale

Claim 2

In the process for recovering oil from oil shale wherein hot reducing or inert gases are passed in cross-flow fashion through a moving quiescent bed of crushed shale in a direction normal to the direction of travel of said bed to heat the shale particles in said bed to oil-educing temperatures and strip the oils from the shale, leaving a non-vaporizable carbonaceous residue in the spent shale, the improvement which comprises: in a first zone, passing hot reducing or inert gases through said moving bed at a temperature and flow rate sufficient to heat only a portion of the layers of particles at the gas inlet side of the bed to oil educing temperatures and to establish within said bed a temperature range below that at which adverse chemical reactions involving the shale would occur; thereafter, prior to the time when the particles in those regions of the bed which are farthest from the gas inlet side have reached oil-educing temperatures but while the particles at the gas inlet side remain above oil educing temperatures, transferring said bed to a second zone; in said second zone, directing oxygen-containing gases through the bed from said gas inlet side, whereby a substantial portion of the carbonaceous residue in the spent shale regions of the bed is oxidized, producing and transferring heat to the deeper regions within said bed, the oxygen mass flow rate of said oxygen-containing gases being initially set and thereafter incrementally adjusted at downstream locations such that as the bed proceeds through said second zone, the carbonaceous residue in the remaining portions of the bed continues to be oxidized through to the gas outlet side of the bed while at the same time the temperature profile of the bed is maintained within the temperature range established in the first zone.

Claim 3

The shale oil recovery process of claim 1 wherein the gases are downdrafted through the bed in each zone and the pressure drop through the bed is maintained essentially the same in each zone.

Claim 4

The shale oil recovery process of claim 1 wherein the moving quiescent bed of crushed shale is stratified with the larger particles of crushed shale at the gas inlet side of the bed and the smaller particles proximate to the gase outlet side.

Claim 5

A process for the substantial recovery of organic heating values from shale which does not result in a significantly adverse effect on the subsequent processing of the shale to recover solid minerals therefrom, which process comprises the steps of: forming a moving, quiescent, gas permeable bed of crushed shale particles on a traveling grate; directing said moving bed into a first zone wherein hot reducing or inert gases having a temperature of from about 800° to about 1500° F. are drafted through said bed in a direction which is normal to the direction of travel of the bed; maintaining the residence time of said bed in said first zone long enough to create in said bed only adjacent the gas inlet surface of said bed a region wherein the shale particles have been heated to oil educing temperatures and to establish within the bed a temperature profile which is below those temperatures at which adverse reactions involving the shale would occur; stripping and recovering substantially all of the vaporizable hydrocarbon materials from the particles in said region; and thereafter directing said moving bed while it remains hot into a second zone wherein oxygen-containing gases which have not been heated are drafted through said bed, the amount of oxygen in the unheated gases being sufficient to cause oxidation of the non-vaporizable carbonaceous material retained on and in those particles in said region from which the vaporizable materials have been stripped and to cause such oxidation to take place at a controlled rate which matches the heat absorbing capacity of the gases entering the bed; whereby further heat is generated and transferred to the gases passing through said bed, thus raising the temperatures of the deeper regions within the bed until oil educing temperatures are reached in said regions of said bed; incrementally changing the mass flow rate of oxygen in the unheated gases directed at the bed at predetermined locations downstream from the initial entry of the bed into said second zone as necessary to correspond to the additional heat required to be generated as progressively deeper regions of said bed are oxidized, and to maintain the temperature profile within the bed.

Claim 6

A process for the substantial recovery of organic heating values from shale which does not result in a significantly adverse effect on the subsequent processing of the shale to recover solid minerals therefrom, which process comprises the steps of: forming a moving, quiescent, gas permeable bed of crushed shale particles on a traveling grate; directing said moving bed into a first zone wherein hot reducing or inert gases having a temperature of from about 800° to about 1500° F. are drafted through said bed in a direction which is normal to the direction of travel of the bed; maintaining the residence time of said bed in said first zone long enough to create in said bed only adjacent the gas inlet surface of said bed a region wherein the shale particles have been heated to oil educing temperatures and to establish within the bed a temperature profile which is below those temperatures at which adverse reactions involving the shale would occur; stripping and recovering substantially all of the vaporizable hydrocarbon materials from the particles in said region; and thereafter directing said moving bed while it remains hot into a second zone wherein oxygen-containing gases which have not been heated are drafted through said bed, the amount of oxygen in the unheated gases being sufficient to cause oxidation of the non-vaporizable carbonaceous material retained on and in those particles in said region from which the vaporizable materials have been stripped and to cause such oxidation to take place at a controlled rate which matches the heat absorbing capacity of the gases entering the bed; whereby further heat is generated and transferred to the gases passing through said bed, thus raising the temperatures of the deeper regions within the bed until oil educing temperatures are reached in said regions of said bed; incrementally changing the mass flow rate of oxygen in the unheated gases directed at the bed at predetermined locations downstream from the initial entry of the bed into said second zone as necessary to correspond to the additional heat required to be generated as progressively deeper regions of said bed are oxidized, and to maintain the temperature profile within the bed.

Claim 7

The process as in claim 4, wherein the residence time of the bed in the first zone is minimized by transferring the bed directly to the second zone as soon as that portion of the bed adjacent the gas inlet surface has reached a temperature above about 800° F.

Claim 8

The process as in claim 4, wherein the heated and unheated gases are downdrafted through the bed and the pressure drop through the bed is maintained essentially the same in each zone.

Claim 9

The process as in claim 4, wherein the moving quiescent bed of crushed shale is stratified with the larger particles of crushed shale at the gas inlet surface of the bed and the smaller particles proximate to the gas outlet surface.

Claim 10

The process as in claim 4 wherein the oxygen-containing gases are directed through said bed at flow rates sufficient to permit cooling of the hydrocarbon depleted regions of the bed at the same time as oxidation is occurring in the deeper regions of the bed.