Alkaline Aqueous Bitumen Separation Composition

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Solution Overview

Problem

Current methods for separating bitumen from oil sands are inefficient and environmentally harmful, yielding only 85-92% of available bitumen and requiring organic solvents, with remaining bitumen contributing to heavy sludge disposal issues in tailings ponds.

Innovation Solution

A separating composition comprising a hydrotropic agent, a dispersant with flocculating characteristics, and specific pH levels is used to efficiently separate bitumen from oil sands and tailings, achieving greater than 99% purity without organic solvents, utilizing a mixture of aromatic phosphate esters, sodium acid pyrophosphate, tetrapotassium pyrophosphate, sodium hydroxide, and phosphoric acid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If current separation methods are used to separate bitumen from oil sands, then the separation process can be performed, but the bitumen recovery efficiency is low (85-92%) and organic solvents are required

Engineering Contradiction:

Improvebitumen recovery efficiencyVSAvoidorganic solvent usage

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention changes the chemical parameters of the separation system by using an alkaline aqueous solution (pH 9-11) instead of organic solvents. The alkaline conditions facilitate bitumen separation through saponification reactions with fatty acids and salts, achieving both high recovery efficiency (95%+) and environmental acceptability by eliminating naphtha and other harmful organic solvents from the process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical/chemical extraction system using organic solvents with a chemical reaction system based on alkaline hydrolysis. The alkaline aqueous solution chemically reacts with bitumen components to enable separation, substituting the physical dissolution mechanism of organic solvents with a chemical reaction mechanism that is more efficient and environmentally friendly

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If current separation methods are used, then bitumen can be separated from oil sands, but the remaining bitumen in sand creates heavy sludge that requires disposal in tailings ponds

Engineering Contradiction:

Improvebitumen separation efficiencyVSAvoidresidual bitumen in tailings

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The invention changes the separation efficiency parameter by using alkaline aqueous solutions that achieve 95% or greater bitumen recovery compared to the 85-92% recovery of conventional methods. This parameter improvement directly reduces the amount of residual bitumen remaining in the sand and tailings, minimizing sludge formation and associated disposal requirements

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional separation processes are used, then bitumen separation can be achieved, but the process requires environmentally harmful organic solvents such as naphtha

Engineering Contradiction:

Improveseparation process feasibilityVSAvoidenvironmental harm from organic solvents

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention substitutes the organic solvent-based extraction system with an alkaline aqueous solution system. This replacement maintains process feasibility through chemical reaction mechanisms (saponification) while eliminating the environmental harm associated with naphtha and other organic solvents, including their flammability, toxicity, and persistence in the environment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention converts the typically problematic alkaline chemical reactions into a beneficial separation mechanism. By utilizing saponification reactions between the alkaline solution and bitumen components, the process transforms what could be considered a harsh chemical environment into an effective and environmentally friendly separation tool that eliminates the need for harmful organic solvents

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

The method effectively separates bitumen from oil sands and tailings, achieving greater than 99% purity and eliminating the need for organic solvents, allowing for the recovery of residual bitumen and environmentally friendly disposal of sand and other particulate matter.

Implementation Method 1

a dispersant having flocculating characteristics

Methodology Applied

Scientific EffectFlocculation: Flocculation

Implementation Method 2

a hydrotropic agent

Methodology Applied

Scientific EffectHydrotropy: Solvation

Data Source

PatentUS8372272B2Separating compositions

Publication Date: 2013.02.12 VARY PETROCHEM LLC

AI summary

A water-based separating composition for separating hydrocarbons from hydrocarbon containing material includes at least about 73% by weight water, a hydrotropic agent, a dispersant having flocculating characteristics, at least one acid and at least one base in amounts sufficient to provide the separating composition with a pH of about 7 to about 8.5. The hydrotropic agent and the dispersant having flocculating characteristics are different.