System and method for extracting liquid and solid hydrocarbons and their derivatives
A system and method for extracting liquid and solid hydrocarbons and their derivatives from natural and man-made hydrocarbon sources, including but not limited to oil sands, bitumen, asphalt, roofing shingles, and other hydrocarbon articles of manufacture. The hydrocarbon sources are prepared by dissolving, crushing and/or grinding. The prepared hydrocarbon sources are subjected to agitation where the solvent and hydrocarbon source as thoroughly mixed. The results of the agitation are then separated in one or both of a mesh screen shaker and a centrifuge. The mesh screen shaker subjects the materials to medium frequency oscillations. The centrifuge subjects the materials to high G-forces. The combined processes separate the hydrocarbons from solids and residual solids to less than 0.2% by weight.
1. A process for extracting raw hydrocarbons from hydrocarbon containing material, comprising the steps of:
preparing the hydrocarbon containing material to create a prepared hydrocarbon ore;
adding a hydrocarbon solvent to the prepared hydrocarbon ore to create a hydrocarbon slurry;
agitating the hydrocarbon slurry in an extraction tank;
transferring the hydrocarbon slurry from the extraction tank to a mechanical separator; and
mechanically separating raw hydrocarbons from the hydrocarbon slurry comprising shaking the hydrocarbon slurry in a screen mesh shaker to produce a first extractant product, wherein the screen mesh shaker comprises an angle adjuster on a frame and the angle adjuster pivots the frame between fifteen degrees below and fifteen degrees above a horizontal plane.
2. The process of claim 1 , wherein the preparing step comprises one or more of tearing, crushing, and grinding of the hydrocarbon containing material.
3. The process of claim 1 , wherein the agitating step further comprises adding a secondary solvent to the prepared hydrocarbon ore; and the mechanically separating step further comprises recovering the secondary solvent from the raw hydrocarbons.
4. The process of claim 1 , wherein the screen mesh shaker separates solid particles having a diameter greater than 300 microns in diameter from the first extractant product.
5. The process of claim 1 , wherein the mechanically separating step further comprises the step of spinning the hydrocarbon slurry in a centrifuge to produce a first extractant product.
6. The process of claim 5 , wherein the centrifuge spins the hydrocarbon slurry applying G-forces greater than 3,000 Gs.
7. The process of claim 1 , wherein the mechanically separating step further comprises the step of spinning the first extractant product in a centrifuge to produce a second extractant product.
8. The process of claim 7 , wherein the second extractant product comprises less than 0.2% solids by weight.
9. The process of claim 1 , wherein the hydrocarbon solvent comprises a very short chain hydrocarbon.
10. The process of claim 1 , wherein the hydrocarbon slurry comprises about 60%-70% solids by weight.
11. The process of claim 1 , wherein the first extractant product comprises about 1%-5% solids by weight.
12. A system for extracting raw hydrocarbons from hydrocarbon containing material, comprising:
an agitating device having an extraction tank for mixing the hydrocarbon containing material with a solvent and producing a hydrocarbon slurry;
a first separating device in fluid communication with an outlet on the agitating device for receiving the hydrocarbon slurry and producing a first hydrocarbon extractant said first separating device comprising, a shaking device having a screen mesh basket in fluid communication with the outlet on the agitating device, the shaking device having a vibrating motor for vibrating a screen mesh bed;
said shaking device further comprising:
a frame defining a longitudinal axis and a lateral axis, wherein the longitudinal axis and the lateral axis are orthogonal to each other;
wherein the screen mesh basket is adapted for engagement with the frame and to receive the hydrocarbon slurry from the agitating device;
wherein the screen mesh basket is adapted for disengagement from the frame to periodically remove solids therefrom;
wherein the vibrating motor is engaged with the frame for vibrating the frame and the screen mesh basket along the longitudinal axis of the frame;
an angle adjustment motor for orienting the frame with the screen mesh basket, at a predetermined inclination angle (ϕ) measured around the lateral axis relative to the longitudinal axis;
a second separating device in fluid communication with an outlet on the first separating device for receiving the first hydrocarbon extractant and producing a second hydrocarbon extractant; and
a hydrocarbon recovery tank in fluid communication with an outlet on the second separating device for receiving the second hydrocarbon extractant.
13. The system of claim 12 , wherein the second separating device comprises a centrifugal device in fluid communication with the outlet on the first separating device, the centrifugal device having a spinning motor for subjecting the first hydrocarbon extractant to G-forces greater than 3,000 Gs.
14. The system of claim 12 , further comprising:
a feeder device for receiving hydrocarbon slurry from the agitating device, and for transferring a predetermined volume of hydrocarbon slurry to the shaking device; and
a by-pass valve for returning excess hydrocarbon slurry from the shaking device to the agitating device.
15. The system of claim 12 , wherein the shaking device further comprises a collection pan for receiving underflow from the screen mesh basket when the shaking device is in operation.
16. The system of claim 12 , wherein the inclination angle (ϕ) is in a range of 15° above and 15° below a horizontal plane.
17. The system of claim 12 , wherein the screen mesh basket is made from a mesh selected from the group consisting of a woven metal cloth, a combination of at least one metal cloth and a backing cloth, and a corrugated mesh.
18. The system of claim 12 , wherein the vibrating device further comprises a second vibrating motor for vibrating the frame and the screen mesh basket back and forth along the lateral axis.