Processing of Arroyo Grande tar sand using the Recycle Oil Pyrolysis and Extraction (ROPE®) process

Western Research Institute (WRI), in cooperation with the U.S. Department of Energy (DOE), is developing the Recycle Oil Pyrolysis and Extraction (ROPE® ) process for recovering oil from tar sand and for coprocessing heavy crude oil with tar sand. The ROPE® concept consists of two pyrolysis steps: (1) retorting tar sand at a lower temperature (T< 780°F/415°C) with recycle oil and (2) completing the pyrolysis of the residue at a higher temperature (T > 780°F/415°C) in the absence of recycle oil. The ROPE® process is relatively simple, operates at atmospheric pressure, and uses off-the-shelf equipment items. Process mechanics are gentle, yielding particulate-free liquid distillates. The ROPE® process appears to be capable of producing a variety of products because of the inherent temperature control throughout the process cycle. It produces specialty products such as BTX and advanced aviation fuel feedstocks from tar sand. It also produces diluent feedstocks from tar sand and heavy crude oil that may be used for heavy crude oil and bitumen transportation. WRI constructed and operated a 2-inch-diameter process development unit (PDU) with a throughput of 5 to 10 lb/hr and a 6-inch-diameter bench-scale unit (BSU) with a throughput of 50 to 100 lb/hr to develop the ROPE® process. The experimental results to date and preliminary economic evaluation suggest that the ROPE® process has a strong commercialization potential. The objectives of this study are to (1) evaluate the application of the ROPE® process to a California tar sand using the screw pyrolysis reactor-process development unit (SPR-PDU) reactor, (2) produce kinetics data for the recycle product oil-spent sand interaction, and (3) produce oil for end-use evaluation.