Major obstacles to the commercialization of tar sand are the high costs associated with mining and processing, the upgrading of the raw tar sand oil, and refining the upgraded tar sand oil to produce salable products. In order to encourage tar sand commercialization with much reduced financial risks, new processing technologies need to be developed. The overall objective of this research is to develop a new process that produces (1) oil yields greater than other existing pyrolysis processes, (2) transportation and aviation fuel feedstocks,(3) a diluent to decrease the pour point of bitumen for pipelining, and (4) a solvent for extraction processes. Western Research Institute (WRI) has developed the Recycle Oil Pyrolysis and Extraction (ROPEC) process. The process, in its entirety, consists of four major steps: 1) preheating and extracting the hydrocarbonaceous material with product oil, 2) retorting the extracted material at a lower temperature [T <750 F (400°C)] with recycle product oil, 3) completing the pyrolysis of residue at a higher temperature [T > 750 F (400°C)] in the absence of product oil recycling and 4) combusting the solid residue and pyrolysis gas in an inclined fluidized-bed reactor to produce the required process heat. WRI constructed and operated two reactor systems to test the ROPE process. The smaller system (2 - 4 kg/hr solids throughput capacity) is a 2-inch diameter process development unit (PDU) which is used to conduct a large number of short duration tests to determine optimum operating conditions. The larger system (20 - 40 kg/hr solids throughput capacity) is a 6-inch diameter bench-scale unit (BSU) which is used to conduct longer duration tests to confirm the optimum conditions determined in the 2-inch PDU tests. Previously, eight tests were conducted in the 2-inch PDU using Asphalt Ridge, Utah tar sand to determine the effects of pyrolysis temperature and residence time on the oil yield and product distribution, and also to produce samples for the evaluation of product oil characteristics (Cha, et al. 1987). A 30-hour test was also conducted using Sunnyside, Utah tar sand to obtain preiminary data.The product oil samples were analyzed to determine the distribution of hydrocarbon types, and to relate this distribution to that found in other fuel types. Results from these preliminary tests indicate the ROPE process will assist existing surface and in situ recovery process economics by producing a diluent to decrease the pour point of produced bitumen for pipeline transportation, and by producing a solvent for solvent extraction processes. The ROPE process also produces feedstocks for the production of unleaded gasoline and advanced aviation turbine fuel.