Mining and processing system for oil sand ore bodies

Abstract

A process line for use in an oil sands ore body mining operation is provided, which comprises: a semi-mobile crushing station for receiving as-mined oil sand ore and comminuting the oil sand ore to a first size; a semi-mobile compact slurry preparation unit for receiving the comminuted oil sand ore and mixing the oil sand ore with water to form an oil sand slurry; and a semi-mobile solids removal assembly for removing a portion of the coarse solids from the oil sand slurry prior to extracting from the slurry an enriched bitumen froth.

Description

FIELD OF THE INVENTION[0001]The present invention relates to mining technology and a process line for increasing the efficiency of an ore mining operation.BACKGROUND OF THE INVENTION[0002]Oil sand ore, such as is mined in the Fort McMurray region of Alberta, generally comprises water-wet sand grains held together by a matrix of viscous bitumen. Typically, a “low grade” oil sand ore will contain between about 6 to 10 wt.% bitumen with about 25 to 35 wt. % fines. An “average grade” oil sand ore will typically contain at least 10 wt. % bitumen to about 12.5 wt. % bitumen with about 15 to 25 wt. % fines and a “high grade” oil sand ore will typically contain greater than 12.5 wt. % bitumen with less than 15 wt. % fines. “Fines” are generally defined as those solids having a size less about 44 μm.[0003]Oil sand lends itself to liberation of the sand grains from the bitumen, preferably by slurrying the oil sand with heated water, allowing the bitumen to move to the aqueous phase. For many ...

AI Technical Summary

Benefits of technology

This patent describes a process line that uses semi-mobile technology to minimize the distance trucks need to travel and the amount of waste that needs to be handled. The line consists of a crushing station, a slurry preparation unit, and a solids removal assembly. The crushing station breaks down the oil sand ore, the slurry preparation unit mixes it with water to create a slurry, and the solids removal assembly removes a portion of the coarse solids from the slurry before extracting the enriched bitumen froth. Overall, this technology aims to reduce the cost and environmental impact of the oil sand mining process.

Problems solved by technology

Even though the applicant's primary crushers are semi-mobile, in order to relocate the semi-mobile crushers, a ˜20 m tall Mechanically Stabilized Earth (MSE) wall needs to be constructed, which takes 12-18 months and costs a great deal of money.

Thus, due to the time and expense, it is impractical to relocate the primary crushers to keep them close to the mining face.

Operating costs for these semi-remote mineable oil sand ore bodies will increase significantly from today's costs, due to long truck hauls and long-distance waste hydrotransport.

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