US010772162B2

( 12) United States Patent ( 10) Patent No .: US 10,772,162 B2

Parsche (45) Date of Patent : * Sep . 8 , 2020
( 54 ) RADIO FREQUENCY HEATING OF ( 56 ) References Cited
PETROLEUM ORE BY PARTICLE
SUSCEPTORS U.S. PATENT DOCUMENTS
( 71 ) Applicant: HARRIS CORPORATION , 2,371,459 A 3/1945 Mittelmann
Melbourne, FL (US ) 2,411,198 A 11/1946 Eltgroth
(Continued )
(72) Inventor: Francis Eugene Parsche , Palm Bay,
FL (US ) FOREIGN PATENT DOCUMENTS
CA 1199573 1/1986
( 73 ) Assignee : HARRIS CORPORATION , CA 2678473 8/2009
Melbourne, FL (US )
(Continued )
( * ) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 OTHER PUBLICATIONS
U.S.C. 154 ( b ) by 373 days .
This patent is subject to a terminal dis PCT Notification of Transmittal of the International Search Report
claimer . and the Written Opinion of the International Searching Authority, or
the Declaration , in PCT /US2010 /025761, dated Feb. 9 , 2011 , pp .
( 21 ) Appl. No .: 15 /715,247 1-13 See Priority U.S. Appl. No. 14/ 705,182 , filed May 6 , 2015 .
( Continued )
(22 ) Filed : Sep. 26 , 2017
( 65 ) Prior Publication Data Primary Examiner Quang T Van
(74 ) Attorney, Agent, or Firm — Allen , Dyer, Doppelt +
US 2018/0020508 A1 Jan. 18 , 2018 Gilchrist, P.A.
Related U.S. Application Data
( 62 ) Division of application No. 14 / 705,182 , filed on May ( 57 ) ABSTRACT
6 , 2015 , now Pat. No. 9,872,343 , which is a division A method is for heating a petroleum ore and may include
(Continued ) providing a mixture of about 10% to about 99 % by volume
( 51 ) Int. Cl. of the petroleum ore and about 1 % to about 50% by volume
of a composition. The composition may have isoimpedance
H05B 6/10 ( 2006.01 ) magnetodielectric material susceptor particles. The
C10G 1/00 ( 2006.01 ) isoimpedance magnetodielectric material susceptor particles
( Continued ) may have an electrical conductivity greater than 1x107 S / m
( 52 ) U.S. Cl . at 20 ° C. The method may include applying RF energy to the
CPC H05B 6/106 ( 2013.01 ) ; C10G 1/00 mixture at a power and frequency sufficient to heat the
( 2013.01 ) ; CIOG 1/02 ( 2013.01 ) ; H05B 6/80 isoimpedance magnetodielectric material susceptor par
( 2013.01 ); ticles , and continuing to apply the RF energy for a sufficient
( Continued ) time to allow the isoimpedance magnetodielectric material
( 58 ) Field of Classification Search susceptor particles to heat the mixture to an average tem
CPC C10G 1/00 ; C10G 1/02 ; C10G 2300/1033 ; perature greater than about 212 ° F. ( 100 ° C. )
H05B 6/106 ; HO5B 6/80 ; HO5B 2214/03
( Continued ) 21 Claims , 2 Drawing Sheets

1
SUSCEPTOR RE - USE

PETROLEUM
ORE SUSCEPTOR PETROLEUM
MIXER HEATING PRODUCT
CONTAINER REMOVAL
SUSCEPTORS
6 7
2 ELECTROMAGNETIC
FIELD APPLIED

5
ANTENNA
 US 10,772,162 B2
Page 2

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Koolman , M. , Huber, N. , Diehl , D. and Wacker, B. , “ Electromag tures of Heat and Mass Exchange in the Face Zone of /N.B./ 29
netic Heating Method to Improve Steam Assisted /N.B./23 Gravity Boreholes upon Injection of a Solvent with a Simultaneous Elec
Drainage ”, SPE117481 , presented at the 2008 SPE International tromagnetic Effect” , Journal of Engineering Physics and Thermophys
Thermal Operations and Heavy Oil Symposium held in Calgary, ics , 71 ( 1 ) , 1998 , pp . 161-165 . See Priority U.S. Appl. No. 14/705,182 ,
Alberta , Canada, Oct. 20-23 , 2008 , pp . 1-13 . See Priority U.S. Appl. filed May 6 , 2015 .
Spencer, H.L. , Bennett, K.A. and Bridges , J.E. “ Application of the
No. 14/ 705,182 , filed May 6 , 2015 . IITRI/Uentech Electromagnetic Stimulation Process N.B.i 30 to
Kovaleva , L.A. , Nasyrov, N.M. and Khaidar, A.M. , Mathematical Canadian Heavy Oil Reservoirs" Paper 42 , Fourth International
Modelling of High - Frequency Electromagnetic Heating of the Bottom Conference on Heavy Oil Crude and Tar Sands, UNITARIUNDP,
Hole Area of Horizontal Oil Wells, Journal of Engineering Physics Edmonton , Albe Canada, Aug. 7-12 , 1988 , pp . 1-8 . See Priority
and Thermo Physics, 77 ( 6 ) , 2004 , pp . 1184-1191 . See Priority U.S. U.S. Appl. No. 14 /705,182 , filed May 6 , 2015 .
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McGee , B.C.W. and Donaldson , RD . , " Heat Transfer Fundamentals Bitumen from Tar Sand Deposits with the Radio Frequency Pro
for Electro -thermal Heating of Oil Reservoirs ” , CIPC 2009-024 , cess ” , SPE Reservoir Engineering , Jan. 1986 , pp . 85-94 . See
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for Hydrocarbon Recovery and Environmental Remediation ”, Jour
U.S. Appl. No. 14 /705,182 , filed May 6 , 2015 . nal of Canadian Petroleum Technology, Distinguished Author Series,
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Heavy and Extra -Heavy Crude Oil D Reservoirs” SPE78980 , pre John Wiley & Sons , Inc. , London , Chapman Hall, Limited, 1952 ,
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Sahni, A. and Kumar, M. “ Electromagnetic Heating Methods for
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U.S. Patent Sep. 8, 2020 Sheet 1 of 2 US 10,772,162 B2

Fig . 1
SUSCEPTOR RE - USE
1

PETROLEUM
ORE SUSCEPTOR PETROLEUM
MIXER HEATING PRODUCT
CONTAINER REMOVAL
SUSCEPTORS
3 4 6 7
2 ELECTROMAGNETIC
FIELD APPLIED

5
ANTENNA

Fig . 2.
26

23

25
22

21
o
24
o
00 ooo o
U.S. Patent Sep. 8, 2020 Sheet 2 of 2 US 10,772,162 B2

Fig . 3
DISTILLED WATER PARTICLE SUSCEPTOR
LOSS TANGENT
( DIMENSIONLESS )
10

0.1

0.01

0.001
1.00E + 04 1.00E + 05 1.00E + 06 1.00E + 07 1.00E + 08 1.00E + 09 1.00E + 10
FREQUENCY , HERTZ
 US 10,772,162 B2
1 2
RADIO FREQUENCY HEATING OF tar sands, or heavy oil into more viscous bitumen crude oil,
PETROLEUM ORE BY PARTICLE and to distill , crack , or refine the bitumen crude oil into
SUSCEPTORS usable petroleum products.
The conventional methods of heating bituminous ore , oil
CROSS REFERENCE TO RELATED 5 sands, tar sands , and heavy oil suffer from numerous draw
APPLICATIONS backs . For example, the conventional methods typically
utilize large amounts of water, and also large amounts of
This specification is related to the following patents, each energy . Moreover, using conventional methods, it has been
of which is incorporated by reference herein : U.S. Pat . No. difficult to achieve uniform and rapid heating, which has
8,887,810 issued Nov. 18, 2014 ; U.S. Pat. No. 8,674,274 10 limitedoil shalesuccessful
, tar sands processing
, and heavyofoilbituminous ore, oil sands
. It can be desirable , both,
issued Mar. 18 , 2014 ; U.S. Pat . No. 8,101,068 issued Jan. 24 , for environmental reasons and efficiency /cost reasons to
2012 ; U.S. Pat . No. 8,133,384 issued Mar. 13 , 2012 ; U.S. reduce or eliminate the amount of water used in processing
Pat . No. 8,494,775 issued Jul . 23 , 2013 ; U.S. Pat. No. bituminous ore , oil sands, oil shale , tar sands, and heavy oil ,
8,729,440 issued May 20, 2014 ; U.S. Pat. No. 8,120,369 15 and also provide a method of heating that is efficient and
issued Feb. 21 , 2012 and U.S. Pat . No. 8,128,786 issued
Mar. 6 , 2012 .
environmentally friendly, which is suitable for post -excava
tion processing of the bitumen , oil sands, oil shale , tar sands,
FIELD OF THE INVENTION
and heavy oil .
One potential alternative heating method is RF heating.
20 “ RF” is most broadly defined here to include any portion of
The disclosure concerns a method for heating materials by the electromagnetic spectrum having a longer wavelength
application of radio frequency (“ RF ” ) energy, also known as than visible light. Wikipedia provides a definition of “ radio
electromagnetic energy. In particular, the disclosure con frequency ” as comprehending the range of from 3 Hz to 300
cerns an advantageous method for RF heating of materials GHz , and defines the following sub ranges of frequencies:
with a low or zero electric dissipation factor, magnetic 25
dissipation factor, and electrical conductivity , such as petro
leum ore . For example, the disclosure enables efficient, Name Symbol Frequency Wavelength
low - cost heating of bituminous ore , oil sands, oil shale , tar Extremely ELF 3-30 Hz 10,000-100,000 km
sands, or heavy oil . low frequency
30 Super SLF 30-300 Hz 1,000-10,000 km
BACKGROUND OF THE INVENTION low frequency
Ultra ULF 300-3000 Hz 100-1,000 km
low frequency
The disclosure concerns a method for heating materials by Very VLF 3-30 kHz 10-100 km
application of radio frequency ( “RF ” ) energy, also known as low frequency
electromagnetic energy . In particular, the disclosure con 35 Low
Medium
frequency LF
MF
30-300 kHz
300-3000 kHz
1-10 km
100-1000 m
cerns an advantageous method for RF heating of materials frequency
High frequency
with a low or zero electric dissipation factor, magnetic Very
HF
VHF
3-30 MHz
30-300 MHZ
10-100 m
1-10 m
dissipation factor, and electrical conductivity, such as petro high frequency
leum ore . For example, the disclosure enables efficient, 40 Ultra
high frequency
UHF 300-3000 MHz 10-100 cm
low - cost heating of bituminous ore , oil sands, oil shale , tar Super SHF 3-30 GHz 1-10 cm
sands, or heavy oil . high frequency
Bituminous ore , oil sands, tar sands, and heavy oil are Extremely EHF 30-300 GHz 1-10 mm
typically found as naturally occurring mixtures of sand or high frequency
clay and dense and viscous petroleum . Recently, due to 45
depletion of the world's oil reserves, higher oil prices , and “ RF heating ,” then , is most broadly defined here as the
increases in demand, efforts have been made to extract and heating of a material, substance, or mixture by exposure to
refine these types of petroleum ore as an alternative petro RF energy. For example, microwave ovens are a well -known
leum source. Because of the extremely high viscocity of example of RF heating.
bituminous ore , oil sands, oil shale , tar sands, and heavy oil , 50 The nature and suitability of RF heating depends on
however, the drilling and refinement methods used in several factors. In general, most materials accept electro
extracting standard crude oil are typically not available . magnetic waves , but the degree to which RF heating occurs
Therefore , bituminous ore , oil sands, oil shale, tar sands , and varies widely. RF heating is dependent on the frequency of
heavy oil are typically extracted by strip mining, or in situ the electromagnetic energy , intensity of the electromagnetic
techniques are used to reduce the viscocity of viscocity by 55 energy , proximity to the source of the electromagnetic
injecting steam or solvents in a well so that the material can energy, conductivity of the material to be heated , and
be pumped . Under either approach , however, the material whether the material to be heated is magnetic or non
extracted from these deposits can be a viscous , solid or magnetic . Pure hydrocarbon molecules are substantially
semisolid form that does not easily flow at normal oil nonconductive, of low dielectric loss factor and nearly zero
pipeline temperatures, making it difficult to transport to 60 magnetic moment. Thus, pure hydrocarbon molecules them
market and expensive to process into gasoline , diesel fuel, selves are only fair susceptors for RF heating, e.g. they may
and other products. Typically, the material is prepared for heat only slowly in the presence of RF fields. For example,
transport by adding hot water and caustic soda (NaOH ) to the dissipation factor D of aviation gasoline may be 0.0001
the sand, which produces a slurry that can be piped to the and distilled water 0.157 at 3 GHz , such that RF fields apply
extraction plant, where it is agitated and crude bitumen oil 65 heat 1570 times faster to the water in emulsion to oil .
froth is skimmed from the top . In addition, the material is ( “ Dielectric materials and Applications ", A. R. Von Hippel
typically processed with heat to separate oil sands, oil shale, Editor, John Wiley and Sons , New York, N.Y., 1954 ) .
 US 10,772,162 B2
3 4
Thus far, RF heating has not been a suitable replacement process. The petroleum ore can comprise, for example,
for conventional processing methods of petroleum ore such bituminous ore , oil sands , tar sands, oil shale, or heavy oil
as bituminous ore , oil sands, tar sands, and heavy oil . Dry that has been extracted via strip -mining or drilling. If the
petroleum ore itself does not heat well when exposed to RF extracted petroleum ore is a solid or includes solids with a
energy. Dry petroleum ore possesses low dielectric dissipa- 5 volume greater than about 1 cubic centimeter, the petroleum
tion factors ( 8 " ), low ( or zero ) magnetic dissipation factors ore can be crushed, ground, or milled to a slurry, powder, or
( u " ), and low or zero conductivity . Moreover, while water small-particulate state prior to RF heating. The petroleum
may provide some susceptance at temperatures below 212 ° ore can comprise water, but alternatively contains less than
F. ( 100 ° C. ) , it is generally unsuitable as a susceptor at 10% , less than 5 % , or less than 1 % by volume ofwater. Most
higher temperatures, and may be an undesirable additive to 10 preferably, the petroleum ore can be substantially free of
added water.
petroleum ore , for environmental, cost , and efficiency rea The petroleum ore used in the present method is typically
sons .
non -magnetic or low -magnetic, and non - conductive or low
SUMMARY OF THE INVENTION conductive. Therefore, the petroleum ore alone is not gen
15 erally suitable for RF heating. For example , exemplary
An aspect of the present invention is a method for RF petroleum ore when dry, e.g. free from water, may have a
heating of materials with a low or zero dielectric dissipation dielectric dissipation factor ( 8 " ) less than about 0.01 , 0.001 ,
factor, magnetic dissipation factor, and electrical conductiv or 0.0001 at 3000 MHz . Exemplary petroleum ore may also
ity. For example, the present invention may be used for RF have a negligible magnetic dissipation factor ( u " ), and the
heating of petroleum ore, such as bituminous ore, oil sands , 20 exemplary petroleum ore may also have an electrical con
tar sands , oil shale, or heavy oil . An exemplary embodiment ductivity of less than 0.01 , 0.001 , or 0.0001 S.m- 1 at 20 ° C.
The presently disclosed methods, however, are not limited to
of the present method comprises first mixing about 10% to petroleum
about 99 % by volume of a substance such as petroleum ore products with any specific magnetic or conduc
with about 1 % to about 50 % by volume of a substance tive properties, and can be useful to RF heat substances with
comprising susceptor particles. The mixture is then sub- 25 a higher dielectric dissipation factors ( € " ), magnetic dissi
jected to a radio frequency in a manner which creates pation factor ( u " ), or electrical conductivity. The presently
heating of the susceptor particles. The radio frequency can are disclosed methods are also not limited to petroleum ore , but
be applied for a sufficient time to allow the susceptor widely applicable to RF heating of any substance that has
particles to heat the surrounding substance through conduc dielectric dissipation factor ( 8 " ) less than about 0.05,0.01 , or
tion , so that the average temperature of the mixture can be 30 0.001 at 3000 MHz . It is also applicable to RF heating of any
greater than about 212 ° F. ( 100 ° C. ) . After the mixture has substance that has have a negligible magnetic dissipation
achieved the desired temperature, the radio frequency can be factor ( u " ), or an electrical conductivity of less than 0.01
discontinued, and substantially all of the susceptor particles S -m- ?, 1x10-4 S - m- ?, or 1x10-6 S - m- 1 at 20 ° C.
can optionally be removed , resulting in a heated substance Susceptor Particles
The presently disclosed method utilizes one or more
that can be substantially free of the susceptor particles used 35 susceptor
in the RF heating process . materials in conjunction with the petroleum ore to
Other aspects of the invention will be apparent from this provide improved RF heating. A " susceptor " is herein
disclosure . defined as any material which absorbs electromagnetic
energy and transforms it to heat . Susceptors have been
BRIEF DESCRIPTION OF THE DRAWINGS 40 suggested for applications such as microwave food packing ,
thin - films, thermosetting adhesives, RF -absorbing poly
FIG . 1 is a flow diagram depicting a process and equip mers , and heat - shrinkable tubing. Examples of susceptor
ment for RF heating of a petroleum ore using susceptor materials are disclosed in U.S. Pat . Nos . 5,378,879 ; 6,649 ,
particles. 888 ; 6,045,648 ; 6,348,679 ; and 4,892,782 , which are incor
FIG . 2 illustrates susceptor particles distributed in a 45 porated by reference herein .
petroleum ore (not to scale) , with associated RF equipment. In the presently disclosed method, the one or more
FIG . 3 is a graph of the dissipation factor of water as a susceptors are for example in the form of susceptor particles.
function of frequency versus loss tangent. The susceptor particles can be provided as a powder, granu
lar substance , flakes, fibers, beads , chips , colloidal suspen
DETAILED DESCRIPTION OF THE 50 sion, or in any other suitable form whereby the average
PREFERRED EMBODIMENTS volume of the susceptor particles can be less than about 10
cubic mm . For example, the average volume of the susceptor
The subject matter of this disclosure will now be particles can be less than about 5 cubic mm , 1 cubic mm , or
described more fully, and one or more embodiments of the 0.5 cubic mm . Alternatively, the average volume of the
invention are shown. This invention may, however, be 55 susceptor particles can be less than about 0.1 cubic mm , 0.01
embodied in many different forms and should not be con cubic mm , or 0.001 cubic mm . For example, the susceptor
strued as limited to the embodiments set forth herein . Rather, particles can be nanoparticles with an average particle
these embodiments are examples of the invention , which has volume from 1x10- cubic mm to 1x10-6 cubic mm , 1x10-7
the full scope indicated by the language of the claims . cubic mm , or 1x10-8 cubic mm .
In an exemplary method , a method for heating a petro- 60 Depending on the preferred RF heating mode , the sus
leum ore such as bituminous ore , oil sands, tar sands , oil ceptor particles can comprise conductive particles, magnetic
shale, or heavy oil using RF energy is provided . particles, or polar material particles. Exemplary conductive
Petroleum Ore particles include metal, powdered iron (pentacarbonyl E
The presently disclosed method can be utilized to either iron ), iron oxide , or powdered graphite . Exemplary mag
heat a petroleum ore that has been extracted from the earth , 65 netic materials include ferromagnetic materials include iron ,
prior to distillation , cracking , or separation processing, or nickel, cobalt , iron alloys , nickel alloys , cobalt alloys , and
can be used as part of a distillation , cracking , or separation steel , or ferromagnetic materials such as magnetite, nickel
 US 10,772,162 B2
5 6
zinc ferrite, manganese - zinc ferrite, and copper - zinc ferrite . induction RF heating can be from about 50 Hz to about 3
Exemplary polar materials include butyl rubber ( such as GHz . Alternatively, the RF frequency can be from about 10
ground tires ) , barium titanate powder, aluminum oxide pow kHz to about 10 MHz , 10 MHz to about 100 MHZ , or 100
der, or PVC flour. MHz to about 2.5 GHz . The power of the RF energy, as
Mixing of Petroleum Ore and Susceptor Particles 5 radiated from the RF source , can be for example from about
Preferably, a mixing or dispersion step is provided , 100 KW to about 2.5 MW , alternatively from about 500 KW
whereby a composition comprising the susceptor particles is to about 1 MW , and alternatively, about 1 MW to about 2.5
mixed or dispersed in the petroleum ore. The mixing step MW .
can occur after the petroleum ore has been crushed , ground, In another exemplary embodiment, RF energy can be
or milled , or in conjunction with the crushing, grinding, or 10 applied in a manner that causes the susceptor particles to
milling of the petroleum ore . The mixing step can be heat by magnetic moment heating, also known as hysteresis
conducted using any suitable method or apparatus that heating. Magnetic moment heating is a form of induction RF
disperses the susceptor particles in a substantially uniform heating, whereby heat is generated by a magnetic material.
manner. For example, a sand mill , cement mixer, continuous Applying a magnetic field to a magnetic material induces
soil mixer, or similar equipment can be used . 15 electron spin realignment, which results in heat generation.
An advantageous capability of the presently disclosed Magnetic materials are easier to induction heat than non
methods can be the fact that large amounts of susceptor magnetic materials , because magnetic materials resist the
particles can optionally be used without negatively affecting rapidly changing magnetic fields of the RF source . The
the chemical or material properties of the processed petro electron spin realignment of the magnetic material produces
leum ore . Therefore , a composition comprising susceptor 20 hysteresis heating in addition to eddy current heating. A
particles can for example be mixed with the petroleum ore metal which offers high resistance has high magnetic per
in amount from about 1 % to about 50% by volume of the meability from 100 to 500 ; non -magnetic materials have a
total mixture . Alternatively , the composition comprising permeability of 1. One advantage of magnetic moment
susceptor particles comprises from about 1 % to about 25 % heating can be that it can be self- regulating. Magnetic
by volume of the total mixture, or about 1 % to about 10 % 25 moment heating only occurs at temperatures below the Curie
by volume of the total mixture . point of the magnetic material, the temperature at which the
Radio Frequency Heating magnetic material loses its magnetic properties.
After the susceptor particle composition has been mixed Magnetic moment RF heating can be performed using
in the petroleum ore, the mixture can be heated using RF magnetic susceptor particles. Exemplary susceptors for
energy. An RF source can be provided which applies RF 30 magnetic moment RF heating include ferromagnetic mate
energy to cause the susceptor particles to generate heat. The rials or ferromagnetic materials . Exemplary ferromagnetic
heat generated by the susceptor particles causes the overall materials include iron, nickel , cobalt , iron alloys , nickel
mixture to heat by conduction. The preferred RF frequency, alloys , cobalt alloys , and steel. Exemplary ferromagnetic
power, and source proximity vary in different embodiments materials include magnetite, nickel - zinc ferrite, manganese
depending on the properties of the petroleum ore , the 35 zinc ferrite, and copper - zinc ferrite . In certain embodiments,
susceptor particle selected , and the desired mode of RF the RF source used for magnetic moment RF heating can be
heating the same as that used for induction heating a loop antenna
In one exemplary embodiment, RF energy can be applied or magnetic near - field applicator suitable for generation of a
in a manner that causes the susceptor particles to heat by magnetic field, such as an induction heating coil , a chamber
induction . Induction heating involves applying an RF field 40 or container containing loop antenna, or a magnetic
to electrically conducting materials to create electromag near - field applicator. The exemplary RF frequency for mag
netic induction . An eddy current is created when an electri netic moment RF heating can be from about 100 kHz to
cally conducting material is exposed to a changing magnetic about 3 GHz . Alternatively, the RF frequency can be from
field due to relative motion of the field source and conductor; about 10 kHz to about 10 MHz , 10 MHz to about 100 MHZ ,
or due to variations of the field with time . This can cause a 45 or 100 MHz to about 2.5 GHz . The power of the RF energy ,
circulating flow or current of electrons within the conductor. as radiated from the RF source , can be for example from
These circulating eddies of current create electromagnets about 100 KW to about 2.5 MW , alternatively from about
with magnetic fields that opposes the change of the magnetic 500 KW to about 1 MW , and alternatively, about 1 MW to
field according to Lenz's law . These eddy currents generate about 2.5 MW .
heat . The degree of heat generated in turn , depends on the 50 In a further exemplary embodiment, the RF energy source
strength of the RF field , the electrical conductivity of the and susceptor particles selected can result in dielectric
heated material, and the change rate of the RF field . There heating. Dielectric heating involves the heating of electri
can be also a relationship between the frequency of the RF cally insulating materials by dielectric loss . Voltage across a
field and the depth to which it penetrate the material; in dielectric material causes energy to be dissipated as the
general, higher RF frequencies generate a higher heat rate . 55 molecules attempt to line up with the continuously changing
Induction RF heating can be for example carried out using electric field .
conductive susceptor particles. Exemplary susceptors for Dielectric RF heating can be for example performed using
induction RF heating include powdered metal , powdered polar, non - conductive susceptor particles . Exemplary sus
iron ( pentacarbonyl E iron ), iron oxide , or powdered graph ceptors for dielectric heating include butyl rubber ( such as
ite . The RF source used for induction RF heating can be for 60 ground tires ) , barium titanate , aluminum oxide , or PVC .
example a loop antenna or magnetic near - field applicator Water can also be used as a dielectric RF susceptor, but due
suitable for generation of a magnetic field . The RF source to environmental, cost , and processing concerns, in certain
typically comprises an electromagnet through which a high embodiments it may be desirable to limit or even exclude
frequency alternating current (AC ) passed . For example, water in processing of petroleum ore . Dielectric RF heating
the RF source can comprise an induction heating coil , a 65 typically utilizes higher RF frequencies than those used for
chamber or container containing a loop antenna, or a mag induction RF heating. At frequencies above 100 MHz an
netic near - field applicator. The exemplary RF frequency for electromagnetic wave can be launched from a small dimen
 US 10,772,162 B2
7 8
sion emitter and conveyed through space . The material to be insulative coating. The iron powder susceptors have a low
heated can therefore be placed in the path of the waves , conductivity together in bulk and small particle size such
without a need for electrical contacts . For example, domestic that RF magnetic fields are penetrative. The susceptor pow
microwave ovens principally operate through dielectric der particles must be small relative the radio frequency skin
heating, whereby the RF frequency applied is about 2.45 5 depth , e.g. particle diameter d <VW /nouc ) where wavelength
GHz . The RF source used for dielectric RF heating can be is the wavelength in air, o is conductivity of iron , u is the
for example a dipole antenna or electric near field applicator. permeability of the iron, and c is the speed of light.
An exemplary RF frequency for dielectric RF heating can be The susceptor particles need not be solids , and in another
from about 100 MHz to about 3 GHz . Alternatively, the RF embodiment liquid water may be used . The water can be
frequency can be from about 500 MHz to about 3 GHz . 10 mixed with or suspended in emulsion with the petroleum
Alternatively, the RF frequency can be from about 2 GHz to ore . The dissipation factor of pure , distilled water is pro
about 3 GHz . The power of the RF energy , as radiated from vided as FIG . 3 , although particles can modify effective loss
the RF source, can be for example from about 100 KW to tangent due to polarization effects. As can be appreciated
about 2.5 MW , alternatively from about 500 KW to about 1 water molecules may have insufficient dissipation in the
MW , and alternatively, about 1 MW to about 2.5 MW . 15 VHF ( 30 to 300 MHz) region . The use of sodium hydroxide
The reflection of incident RF energy such as an incident (lye) is specifically therefore identified as a means of
electromagnetic wave can reduce the effectiveness of RF enhancing the dissipation of water for use as a RF susceptor.
heating . It may be desirable for the RF fields or electromag In general, the hydronium ion content of water ( OH- ) can be
netic waves to enter the materials and susceptors to dissi varied need with salts , acids and bases , etc to modify loss
pate. Thus, in one embodiment the susceptor particles can 20 characteristics. Water is most useful between 0 and 100 C as
have the property of equal permeability and permittivity, e.g. ice and steam have greatly reduced susceptance, e.g. they
Un = e , to eliminate wave reflections at an air- susceptor inter
may not heat appreciably as indicated by the critical points
faces . This can be explained as follows: wave reflections on Mollier diagrams.
occur according to the change in characteristic impedance at In yet another embodiment, the RF energy source used
the material interfaces: mathematically r- ( 2 , -2 ) / ( 21 + 22 ) 25
can be far - field RF energy, and the susceptor particles
where I is the reflection coefficient and Z1 and Z¡ are the selected act as mini -dipole antennas that generate heat . One
characteristic or wave impedances of the individual mate property of a dipole antenna is that it can convert RF waves
rials 1 and 2. Whenever Zi =Z2 zero reflection occurs. As the to electrical current. The material of the dipole antenna,
characteristic wave impedance of a material is Z = 120 (Vu , therefore, can be selected such that it resistively heats under
an ), whenever I , FE ,, Z = 1200 =377 ohms. In turn , there 30 an electrical current. Mini -dipole RF heating can be prefer
would be no wave reflection for that material at an air ably performed using carbon fiber, carbon fiber floc, or
interface , as air is also Z =377 ohms. An example of a carbon fiber cloth ( e.g. , carbon fiber squares ) susceptors .
isoimpedance magnetodielectric ( u , = ,) susceptor material, Carbon fibers or carbon fiber floc preferably are less than 5
without reflection to air, is light nickel zinc ferrite which can cm long and less than 0.5 MW .
have u , = en = 14 . As background , other than refractive prop- 35 In each of the presently exemplary embodiments, RF
erties , nonconductive materials of ure , may be invisible in energy can be applied for a sufficient time to allow the
the electromagnetic spectrum where this occurs . With suf heated susceptor particles to heat the surrounding hydrocar
ficient conductivity, U » = , susceptor materials have excellent bon oil , ore, or sand . For example, RF energy can be applied
RF heating properties for high speed and efficiency. for sufficient time so that the average temperature of the
The susceptor particles may be proportioned in the hydro- 40 mixture can be greater than about 212 ° F. ( 100 ° C. ) . Alter
carbon ore to obtain J , = ? , from the mixture overall, for natively, RF energy can be applied until the average tem
reduced reflections at air interface and increased heating perature of the mixture is , for example, greater than 300 ° F.
speed . The logarithmic mixing formula log Em = 0 , log & j ' + 02 ( 150 ° C.), or 400 ° F. ( 200 ° C. ) . Alternatively, RF energy can
log az ' may be used to adjust the permittivity of the mixture be applied until the average temperature of the mixture is ,
overall by the volume ratios e of the components and the 45 for example, greater than 700 ° F. ( 400 ° C. ) . In a variation on
permittivities E of components, 1 and 2. In the case of the exemplary embodiment the RF energy can be applied as
semiconducting susceptor particles the size, shape , and part of a distillation or cracking process, whereby the
distribution of particles may however affect the material mixture can be heated above the pyrolysis temperature of the
polarizability and some empiricism may be required. The hydrocarbon in order to break complex molecules such as
paper “ The Properties Of A Dielectric Containing Semicon- 50 kerogens or heavy hydrocarbons into simpler molecules
ducting Particles Of Various Shapes ” , R. W. Sillars , Journal (e.g. light hydrocarbons ). It is presently believed that the
of The Institution Of Electrical Engineers (Great Britain ), suitable length of time for application of RF energy in the
Vol. 80 , April 1937 , No. 484 may also be consulted . presently disclosed embodiments can be preferably from
In another embodiment of the present invention , pentac about 15 seconds , 30 seconds, or 1 minute to about 10
arbonyl E iron powder is advantageous as a magnetic (H) 55 minutes, 30 minutes , or 1 hour. After the hydrocarbon /
field susceptor. In the pentacarbonyl, E iron powder embodi susceptor mixture has achieved the desired average tem
ment, iron susceptor powder particles in the 2 to 8 micron perature , exposure of the mixture to the radio frequency can
range are utilized . A specific manufacture is type EW be discontinued . For example, the RF source can be turned
(mechanically hard CIP grade, silicated 97.0% Fe , 3 um avg . off or halted , or the mixture can be removed from the RF
particle size ) by BASF Corporation, Ludwigshafen, Ger- 60 source .
many (www.inorganics.BASF.com ). This powder may also Removal /Reuse of Susceptor Particles
be produced by GAF Corporation at times in the United In certain embodiments, the present disclosure also con
States . Irrespective of manufacture , sufficiently small bare templates the ability to remove the susceptor particles after
iron particles ( EQ ) are washed in 75 percent phosphoric acid the hydrocarbon /susceptor mixture has achieved the desired
(“ Ospho" by Marine Enterprises Inc. ) to provide an insula- 65 average temperature.
tive oxide outer finish , FePO4 . In other words , the susceptor If the susceptor particles are left in the mixture, in certain
particles may be conductive susceptor particles having an embodiments this may undesirably alter the chemical and
 US 10,772,162 B2
9 10
material properties of primary substance. One alternative is aluminum oxide powder, or PVC flour. A mixer 3 is pro
to use a low volume fraction of susceptor, if any . For vided for dispersing the second susceptor particle substance
example, U.S. Pat . No. 5,378,879 describes the use of into the first substance. The mixer 3 may comprise any
permanent susceptors in finished articles, such as heat suitable mixer for mixing viscous substances, soil , or petro
shrinkable tubing, thermosetting adhesives, and gels , and 5 leum ore , such as a sand mill , soil mixer, or the like . The
states that articles loaded with particle percentages above mixer maybe separate from container 1 or container 2 , or the
15 % are generally not preferred, and in fact, are achievable may be part of container 1 or container 2. A heating
in the context of that patent only by using susceptors having mixer
vessel 4 is also provided for containing a mixture of the first
relatively lower aspect ratios. The present disclosure pro substance and the second substance during heating. The
vides the alternative of removing the susceptors after RF 10
heating. By providing the option of removing the susceptors heating
container
vessel may also be separate from the mixer 3 ,
1 , and container 2 , or it may be part of any or all
after RF heating, the present disclosure can reduce or of those components . Further, an antenna 5 is provided,
eliminate undesirable altering of the chemical or material
properties of the petroleum ore , while allowing a large which is capable of emitting electromagnetic energy as
volume fraction of susceptors to be used. The susceptor 15 described herein to heat the mixture. The antenna 5 may be
particle composition can thus function as a temporary heat a separate component positioned above , below, or adjacent
ing substance , as opposed to a permanent additive . to the heating vessel 4 , or it may comprise part of the heating
Removal of the susceptor particle composition can vary vessel 4. Optionally, a further component, susceptor particle
depending on the type of susceptor particles used and the removal component 6 may be provided, which is capable of
consistency, viscocity , or average particle size of the mix- 20 removing substantially all of the second substance compris
ture . If necessary or desirable, removal of the susceptor ing susceptor particles from the first substance. Susceptor
particles can be performed in conjunction with an additional particle removal component 6 may comprise, for example, a
mixing step . If a magnetic or conductive susceptor particle magnet, centrifuge, or filter capable of removing the sus
is used , substantially all of the susceptor particles can be ceptor particles. Removed susceptor particles may then be
removed with one or more magnets, such as quiescent or 25 optionally reused in the mixer, while a heated petroleum
direct - current magnets. In the case of a polar dielectric product 7 may be stored or transported.
susceptor, substantially all of the susceptor particles can be Referring to FIG . 2 , a petroleum ore including an exem
removed through flotation or centrifuging. Carbon fiber, plar heating vessel is described . Susceptor particles 210 are
carbon floc, or carbon fiber cloth susceptors can be removed distributed in petroleum ore 220. The susceptor particles
through flotation , centrifuging, or filtering. For example, 30 may
removal of the susceptor particles can be performed either ticles ,comprise
such as
any of the above - discussed susceptor par
conductive , dielectric, or magnetic particles.
while the petroleum ore / susceptor mixture is still being RF The petroleum ore 220 may contain any concentration of
heated , or within a sufficient time after RF heating has been hydrocarbon molecules , which themselves may not be suit
stopped so that the temperature of the petroleum ore
decreases by no more than 30 % ,and alternatively, no more 35 able susceptors
sufficient for RFto theheating
proximity .Anofantenna
mixture 230particles
susceptor is placed210in
than 10% . For example, it is exemplary that the petroleum and petroleum ore 220 to cause heating therein , which may
ore maintain an average temperature of greater than 200 ° F.
( 93 ° C. ) during any removal of the susceptor particles, be near field or far field or both . The antenna 230 may be a
alternatively an average temperature of greater than 200 ° F. bowtie dipole although the invention is not so limited , and
( 93 ° C. ) . 40 any form for antenna may be suitable depending on the
Another advantage of the exemplary embodiments of the trades. A vessel 240 may be employed, which may take the
present disclosure can be that the susceptor particles can form of a tank , a separation cone , or even a pipeline . A
optionally be reused after they are removed from a heated method for stirring the mixture may be employed , such as a
mixture. pump ( not shown ) . Vessel 240 may omitted in some appli
Alternatively, in certain instances it may be appropriate to 45 cations, such as heating dry ore on a conveyor. RF shielding
leave some or all of the susceptor particles in some or all of 250 can be employed as is common . Transmitting equipment
the material of the mixture after processing . For example, if 260 produces the time harmonic, e.g. RF, current for antenna
the particles are elemental carbon , which is non -hazardous 230. The transmitting equipment 260 may contain the vari
and inexpensive, it may be useful to leave the particles in the ous RF transmitting equipment features such as impedance
mixture after heating, to avoid the cost of removal. For 50 matching equipment (not shown ), variable RF couplers ( not
another example, a petroleum ore with added susceptor shown ), and control systems (not shown ), and other such
material can be pyrolyzed to drive off useful lighter fractions features.
of petroleum , which are collected in vapor form essentially Referring to FIG . 3 , the dissipation factor of pure , distilled
free of the susceptor material, while the bottoms remaining water is provided , although particles can modify effective
after pyrolysis may contain the susceptor and be used or 55 loss tangent due to polarization effects. As can be appreci
disposed of without removing the susceptor. ated water molecules may have insufficient dissipation in the
Referring to FIG . 1 , a flow diagram of an embodiment of VHF ( 30 to 300 MHz ) region .
the present disclosure is provided . A container 1 is included ,
which contains a first substance with a dielectric dissipation EXAMPLES
factor, epsilon , less than 0.05 at 3000 MHz . The first 60
substance , for example, may comprise a petroleum ore , such The following examples illustrate several of the exem
as bituminous ore , oil sand, tar sand , oil shale , or heavy oil . plary embodiments of the present disclosure . The examples
A container 2 contains a second substance comprising are provided as small - scale laboratory confirmation
susceptor particles. The susceptors particles may comprise examples. However, one of ordinary skill in the art will
any of the susceptor particles discussed herein , such as 65 appreciate , based on the foregoing detailed description, how
powdered metal, powdered metal oxide, powdered graphite, to conduct the following exemplary methods on an industrial
nickel zinc ferrite, butyl rubber, barium titanate powder, scale .
 US 10,772,162 B2
11 12
Example 1 : RF Heating of Petroleum Ore without ( c ) continuing to apply the RF energy for a sufficient time
Particle Susceptors to allow the isoimpedance magnetodielectric material
susceptor particles to heat the mixture to an average
A sample of 1/4 cup of Athabasca oil sand was obtained at temperature greater than about 212 ° F. ( 100 ° C. ) .
an average temperature of 72 ° F. (22 ° C. ) . The sample was 5 2. The method of claim 1 , further comprising removing
contained in a Pyrex glass container. A GE DE68-0307A the isoimpedance magnetodielectric material susceptor par
microwave oven was used to heat the sample at 1 KW at ticles from the petroleum ore .
2450 MHz for 30 seconds ( 100% power for the microwave 3. The method of claim 1 , wherein the isoimpedance
oven ). The resulting average temperature after heating was magnetodielectric material susceptor particles comprise
125 ° F. ( 51 ° C.). 10 nickel - zinc ferrite susceptor particles .
4. The method of claim 1 , wherein the isoimpedance
Example 2 : RF Heating of Petroleum Ore with magnetodielectric material susceptor particles have a per
Magnetic Particle Susceptors meability and a permittivity of about 14 .
5. The method of claim 1 , wherein the petroleum ore
A sample of 1/4 cup ofAthabasca oil sand was obtained at 15 comprises less than 10 % by volume of water.
an average temperature of 72 ° F. (22 ° C. ) . The sample was 6. The method of claim 1 , wherein the isoimpedance
contained in a Pyrex glass container. 1 Tablespoon of nickel magnetodielectric material susceptor particles comprise a
zinc ferrite nanopowder (PPT # FP350 CAS 1309-31-1 ) at plurality of component particles having different permeabili
an average temperature of 72 ° F. ( 22 ° C. ) was added to the ties and permittivities.
Athabasca oil sand and uniformly mixed . A GE DE68- 20 7. The method of claim 6 , wherein the plurality of
0307A microwave oven was used to heat the mixture at 1 component particles comprises semiconductor particles.
KW at 2450 MHz for 30 seconds ( 100 % power for the 8. The method of claim 1 , wherein the petroleum ore
microwave oven ). The resulting average temperature of the comprises at least one of bituminous ore , oil sands, tar sands ,
mixture after heating was 196 ° F. ( 91° C.). oil shale and heavy oil .
25 9. A method for heating a petroleum ore comprising :
Example 3 : (Hypothetical Example) RF Heating of forming a mixture of about 10 % to about 99 % by volume
Petroleum Ore with Conductive Susceptors of the petroleum ore and about 1 % to about 50% by
volume of a composition comprising isoimpedance
A sample of 1/4 cup of Athabasca oil sand is obtained at an magnetodielectric material susceptor particles, the
average temperature of 72 ° F. (22 ° C. ) . The sample is 30 isoimpedance magnetodielectric material susceptor
contained in a Pyrex glass container. 1 Tablespoon of particles having an electrical conductivity greater than
powdered pentacarbonyl E iron at an average temperature of 1x107 S /m at 20 ° C .; and
72 ° F. ( 22 ° C. ) is added to the Athabasca oil sand and applying radio frequency (RF ) energy to the mixture so
uniformly mixed . A GE DE68-0307A microwave oven is that the isoimpedance magnetodielectric material sus
used to heat the mixture at 1 KW at 2450 MHz for 30 35 ceptor particles heat the mixture to an average tem
seconds ( 100 % power for the microwave oven) . The result perature greater than about 212 ° F. ( 100 ° C. ) .
ing average temperature of the mixture after heating will be 10. The method of claim 9 , further comprising removing
greater than the resulting average temperature achieved the isoimpedance magnetodielectric material susceptor par
using the method of Example 1 . ticles from the petroleum ore .
40 11. The method of claim 9 , wherein the isoimpedance
Example 4 : (Hypothetical Example) RF Heating of magnetodielectric material susceptor particles comprise
Petroleum Ore with Polar Susceptors nickel - zinc ferrite susceptor particles .
A sample of 1/4 cup of Athabasca oil sand is obtained at an
12. The method of claim 9 , wherein the isoimpedance
magnetodielectric material susceptor particles have a per
average temperature of 72 ° F. (22° C.). The sample is 45 meability and a permittivity of about 14 .
contained in a Pyrex glass container. 1 Tablespoon of butyl 13. The method of claim 9 , wherein the petroleum ore
rubber ( such as ground tire rubber) at an average tempera comprises less than 10 % by volume of water.
ture of 72 ° F. (22 ° C. ) is added to the Athabasca oil sand and 14. The method of claim 9 , wherein the isoimpedance
uniformly mixed . A GE DE68-0307A microwave oven is magnetodielectric material susceptor particles comprise a
used to heat the mixture at 1 KW at 2450 MHz for 30
seconds ( 100 % power for the microwave oven) . The result
50 plurality of component particles having different permeabili
ties and permittivities .
ing average temperature of the mixture after heating will be 15. The method of claim 14 , wherein the plurality of
greater than the resulting average temperature achieved component particles comprises semiconductor particles.
using the method of Example 1 . 16. The method of claim 9 , wherein the petroleum ore
The invention claimed is : 55 comprises at least one of bituminous ore , oil sands, tar sands ,
1. A method for heating a petroleum ore comprising: oil shale and heavy oil .
(a ) providing a mixture of about 10 % to about 99 % by 17. A method for heating a petroleum ore comprising:
volume of the petroleum ore and about 1 % to about forming a mixture of about 10 % to about 99 % by volume
50 % by volume of a composition comprising isoimped of the petroleum ore and about 1 % to about 50% by
ance magnetodielectric material susceptor particles, the 60 volume of a composition comprising nickel- zinc ferrite
isoimpedance magnetodielectric material susceptor susceptor particles, the nickel- zinc ferrite susceptor
particles having an electrical conductivity greater than particles having an electrical conductivity greater than
1x107 S / m at 20 ° C .; 1x107 S /m at 20 ° C .; and
( b ) applying radio frequency (RF ) energy to the mixture applying radio frequency (RF ) energy to the mixture so
at a power and frequency sufficient to heat the 65 that the nickel -zinc ferrite susceptor particles heat the
isoimpedance magnetodielectric material susceptor mixture to an average temperature greater than about
particles; and 212 ° F. ( 100 ° C.) .
 US 10,772,162 B2
13 14
18. The method of claim 17 , further comprising removing
the nickel- zinc ferrite susceptor particles from the petroleum
ore .
19. The method of claim 17 , wherein the nickel -zinc
ferrite susceptor particles have a permeability and a permit- 5
tivity of about 14 .
20. The method of claim 17 , wherein the petroleum ore
comprises less than 10 % by volume of water.
21. The method of claim 17 , wherein the petroleum ore
comprises at least one of bituminous ore , oil sands , tar sands , 10
oil shale and heavy oil .