A shale pyrolysis system includes a retort with a first side and a second side. The second side is opposite the first side and the first side and the second side include descending angled surfaces at alternating angles to produce zig-zag motion of shale descending through the retort. Corners of the retort that change direction of the shale are rounded. The system includes steam distributors coupled to the first side and collectors coupled to the second side to produce crossflow of steam and heat across the descending shale from the first side to the second side, and a steam temperature control subsystem coupled to the steam distributors and configured to deliver higher-temperature steam to one or more upper sections of the retort and lower-temperature steam to one or more lower sections of the retort.

A shale pyrolysis system includes a retort with a first side and a second side. The second side is opposite the first side and the first side and the second side include descending angled surfaces at alternating angles to produce zig-zag motion of shale descending through the retort. Corners of the retort that change direction of the shale are rounded. The system includes steam distributors coupled to the first side and collectors coupled to the second side to produce crossflow of steam and heat across the descending shale from the first side to the second side, and a steam temperature control subsystem coupled to the steam distributors and configured to deliver higher-temperature steam to one or more upper sections of the retort and lower-temperature steam to one or more lower sections of the retort.

An open system pyrolysis of a first hydrocarbon source rock sample obtained from a natural system is performed within a pyrolysis chamber by maintaining the pyrolysis chamber at a substantially constant temperature. Hydrocarbons are recovered from the pyrolysis chamber released by the first hydrocarbon source rock sample. A thermo-vaporization is performed within the pyrolysis chamber on the pyrolyzed sample at a substantially constant temperature. A first hydrocarbon expulsion efficiency of hydrocarbon source rock is determined. A second hydrocarbon rock sample is ground to a grain size less than or equal to or less than 250 micrometers. A second pyrolysis is performed on the ground hydrocarbon source rock sample by maintaining the chamber at a substantially constant temperature. A second hydrocarbon expulsion efficiency of the hydrocarbon source rock in the natural system is determined. The first hydrocarbon expulsion efficiency is verified using the second hydrocarbon expulsion efficiency.

An open system pyrolysis of a first hydrocarbon source rock sample obtained from a natural system is performed within a pyrolysis chamber by maintaining the pyrolysis chamber at a substantially constant temperature. Hydrocarbons are recovered from the pyrolysis chamber released by the first hydrocarbon source rock sample. A thermo-vaporization is performed within the pyrolysis chamber on the pyrolyzed sample at a substantially constant temperature. A first hydrocarbon expulsion efficiency of hydrocarbon source rock is determined. A second hydrocarbon rock sample is ground to a grain size less than or equal to or less than 250 micrometers. A second pyrolysis is performed on the ground hydrocarbon source rock sample by maintaining the chamber at a substantially constant temperature. A second hydrocarbon expulsion efficiency of the hydrocarbon source rock in the natural system is determined. The first hydrocarbon expulsion efficiency is verified using the second hydrocarbon expulsion efficiency.

This disclosure provides a method of making a high-fixed-carbon material comprising pyrolyzing biomass to generate intermediate solids and a pyrolysis vapor; condensing the pyrolysis vapor to generate pyrolysis liquid; blending the pyrolysis liquid with the intermediate solids, to generate a mixture; and further pyrolyzing the mixture to generate a high-fixed-carbon material. A process can comprise: pyrolyzing a biomass-comprising feedstock in a first pyrolysis reactor to generate a first biogenic reagent and a first pyrolysis vapor; introducing the first pyrolysis vapor to a condensing system to generate a condenser liquid; contacting the first biogenic reagent with the condenser liquid, thereby generating an intermediate material; further pyrolyzing the intermediate material in a second pyrolysis reactor to generate a second biogenic reagent and a second pyrolysis vapor; and recovering the second biogenic reagent as a high-yield biocarbon composition. The process can further comprise pelletizing the intermediate material. Many process and system configurations are disclosed.

A method of continuously recovering hydrocarbons from carbon ores can include providing first and second vessels containing rubblized carbon ore. A cooling fuel gas can be introduced into the first vessel. The cooling fuel gas can include oxygen and a recycle gas from the second vessel, which includes hydrocarbons and oxidation products. The oxygen can be consumed through oxidation in an oxidation zone in the first vessel. The temperature of the oxidation zone can be controlled by limiting the oxygen concentration in the cooling fuel gas. This can produce a hot oxidation product gas that heats rubblized carbon ore in a pyrolysis zone downstream of the oxidation zone. Gaseous and vapor hydrocarbons can be produced in the pyrolysis zone. The vapor hydrocarbons can be condensed in a condensing zone downstream of the pyrolysis zone and then collected. The remaining gaseous hydrocarbons and oxidation products can be recycled as the recycle gas. The oxidation zone and the pyrolysis zone can continuously move through the rubblized carbon ore in a downstream direction. Optionally, by using nitrogen free oxygen for the oxidation, a nitrogen free stream of carbon dioxide is produced suitable for carbon dioxide capture and management. This can also eliminate the production of NOx in the oxidation process.

A distillation system including a retort and a distillation column. The retort includes an inlet end, an outlet end opposite the inlet end and including an outlet opening, a rotatable drum configured to heat a product therein and move the product between the inlet end and the outlet end. The distillation column is coupled to the outlet end of the retort and configured to receive the product therein upon exiting the outlet opening of the retort. The distillation column includes a solid particle trap section positioned above the outlet opening, a packing section positioned above the solid particle trap section and including screen at a bottom end thereof, a dust filter therein, and a first bubble tray section positioned above the packing section and including a first outlet feed for outflow of a first fluid product.

The process is for thermally treating a feed material. The process comprises at least one step performed in a rotating kiln operating under positive pressure with a pressure control system and wherein in the process a sweep gas, that is an inert gas or a substantially non-reactive gas, is injected into the rotating kiln or in the feed stream entering the rotating operating kiln; or at least one step performed in a rotating kiln operating under positive pressure managing system; or at least one step performed in a rotating kiln wherein a sweep gas is injected in the rotating kiln or in the feed stream entering the rotating operating kiln. In step a), or in b) or in step c), the conditions of the thermal treatment are managed in order that the exit stream, after cooling, result in at least one liquid phase that is preferably essentially an oily liquid phase.

A method of reducing settling of residual comminuted hydrocarbonaceous material during processing can comprise forming a constructed permeability control infrastructure which defines a substantially encapsulated volume; introducing a composite comminuted hydrocarbonaceous material into the control infrastructure to form a permeable body, said composite hydrocarbonaceous material comprising a comminuted hydrocarbonaceous material and a structural material; and heating the permeable body sufficient to remove hydrocarbons therefrom such that the hydrocarbonaceous material is substantially stationary during heating, exclusive of subsidence and settling. The structural material can provide structural integrity to the permeable body sufficient to maintain convective flow of fluids throughout the permeable body during heating.

A method of reducing settling of residual comminuted hydrocarbonaceous material during processing can comprise forming a constructed permeability control infrastructure which defines a substantially encapsulated volume; introducing a composite comminuted hydrocarbonaceous material into the control infrastructure to form a permeable body, said composite hydrocarbonaceous material comprising a comminuted hydrocarbonaceous material and a structural material; and heating the permeable body sufficient to remove hydrocarbons therefrom such that the hydrocarbonaceous material is substantially stationary during heating, exclusive of subsidence and settling. The structural material can provide structural integrity to the permeable body sufficient to maintain convective flow of fluids throughout the permeable body during heating.