Metal Particulate Catalysts for In-Situ Kerogen Conversion
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Solution Overview
Problem
Current methods for extracting and upgrading kerogen from subsurface shale formations are energy-intensive, environmentally uncertain, and require long timeframes, lacking simpler and cost-effective solutions.
Innovation Solution
A process involving the use of metal particulate catalysts, where a fluid containing metal is introduced to the subsurface shale formation, reacting with a reducing agent to form a catalyst that converts kerogen into mobile, recoverable products at temperatures below pyrolysis levels, facilitating in-situ reaction and extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal treatment (retorting) is used to break kerogen into hydrocarbons, then kerogen conversion to mobile products is achieved, but the process is energy-intensive and requires high temperatures
Solution Approach 1:
The patent changes the reaction parameters by introducing metal particulate catalysts that enable kerogen conversion at lower temperatures below pyrolysis levels, reducing energy consumption while maintaining productivity
Solution Approach 2:
Metal particulate catalysts serve as intermediaries that facilitate kerogen breakdown at reduced temperatures, acting as a mediator between the kerogen and the conversion process, thereby reducing the energy input required
2Productivity
If conventional extraction methods are used, then kerogen can be processed, but the processes are environmentally uncertain and require long timeframes
Solution Approach 1:
The patent replaces conventional thermal-mechanical extraction methods with catalytic chemical reactions that operate faster and more efficiently, substituting the slow thermal breakdown process with accelerated catalytic conversion
Solution Approach 2:
The catalytic process enables continuous conversion of kerogen to mobile products without the long downtime and intermittent operation characteristic of conventional methods, maintaining continuous productive action
3Object-affected harmful factors
If metal particulate catalysts are used for in-situ reaction, then environmentally benign processing is achieved, but the process complexity increases
Solution Approach 1:
The metal particulate catalysts are introduced in a form that allows them to self-disperse and self-distribute throughout the shale formation, automatically finding and reacting with kerogen without requiring complex external delivery systems
Solution Approach 2:
The patent simplifies the process by changing the state of metal delivery from complex formulated catalysts to simple ionic metal solutions that naturally precipitate and distribute, reducing operational complexity while maintaining environmental benefits
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process is more environmentally benign, economically viable, and efficient in producing refinery feedstocks, fuel, and lubricant blendstocks, with the ability to create mobile kerogen-based products that can be upgraded into commercial products.
Implementation Method 1
converting the kerogen by contacting the kerogen with a metal particulate catalyst formed from the metal
Implementation Method 2
providing a reducing agent to the subsurface shale formation
Data Source
AI summary
Disclosed herein are methods for extracting a kerogen-based product from subsurface shale formations. The methods utilize in-situ reaction of kerogen involving liquid phase chemistry at ambient temperatures at pressures for the subsurface shale formation. These methods rely on chemically modifying the shale-bound kerogen to render it mobile using metal particulate catalysts. In the methods disclosed herein a fluid comprising metal is provided to the subsurface shale formation comprising kerogen in an inorganic matrix. A reducing agent is provided to the subsurface shale formation. The kerogen is converted by contacting the kerogen with a metal particulate catalyst formed from the metal; and a mobile kerogen-based product is formed. At least a portion of the mobile kerogen-based product is recovered. The kerogen-derived product can be upgraded to provide commercial products.