Bitumen Extraction Filter Press with Solvent Recovery
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Solution Overview
Problem
Current methods for extracting bitumen from sedimentary deposits and dewatering fluid tailings, including mature fine tails, are inefficient, leading to environmental hazards and high operational costs, with a need for improved recovery rates and solidification of tailings for land reclamation.
Innovation Solution
A process using filter presses with cross-linked polyethylene filter plates and suitable cloths, employing solvents like natural gas condensate or hot water/steam to extract bitumen, followed by vacuum treatment to remove residual solvents and dewater tailings, with optional addition of flocculating agents and additional solids to enhance separation and solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extraction methods are used, then operational costs are high and recovery rates are low, but the process is simple and well-established
Solution Approach 1:
The patent applies parameter changes by modifying the extraction conditions through controlled heating and solvent application. The filter press system uses temperature control and sequential solvent treatment to enhance bitumen recovery from tailings, transforming the extraction efficiency without fundamentally changing the process architecture.
Solution Approach 2:
The patent replaces conventional mechanical extraction methods with a chemical-solvent based system. Instead of relying solely on physical separation and mechanical processing, the invention uses solvents to dissolve and extract bitumen from tailings, significantly improving recovery rates while maintaining operational feasibility.
2Object-affected harmful factors
If dewatering is not performed efficiently, then environmental hazards increase, but the process remains simple
Solution Approach 1:
The patent extracts water from tailings through efficient dewatering processes. The filter press system separates water from solid tailings materials, producing drier, more stable tailings for land reclamation while reducing environmental hazards associated with wet tailings storage and handling.
Solution Approach 2:
The patent utilizes phase transitions in the dewatering process. By applying heat and vacuum, the system promotes evaporation and phase change of water from liquid to vapor, facilitating water removal from tailings and producing drier solids suitable for reclamation.
3Productivity
If solvent extraction is used, then bitumen recovery improves, but solvent emissions and heat loss increase
Solution Approach 1:
The patent converts potential harm into benefit by capturing and condensing solvent vapors that would otherwise be emitted. The system uses condensation equipment to recover solvent from exhaust streams, transforming what would be a loss (solvent emission and heat loss) into a recoverable resource that can be reused in the extraction process.
4Reliability
If tailings are not solidified, then land reclamation is ineffective, but the process requires additional treatment steps
Solution Approach 1:
The patent applies preliminary action by performing dewatering and solidification treatments on tailings before final land reclamation. The filter press system prepares tailings in advance by removing excess water and stabilizing the material, ensuring that when tailings are placed on land, they are already in a suitable condition for effective reclamation.
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 method achieves high bitumen recovery rates, reduces environmental hazards by producing clean solids, and facilitates efficient dewatering of tailings, enabling effective land reclamation and minimizing heat loss and solvent emissions.
Implementation Method 1
pumping the slurry into a chamber between two filter plates in a filter press to form a filter cake, wherein the chamber is lined by filter cloths, and wherein, during the pumping, filtrate is forced through the filter cloths and out of the chamber
Implementation Method 2
exposed to water (hot liquid water or steam) and vacuum to remove residual solvents
Implementation Method 3
exposed to water (hot liquid water or steam) and vacuum to remove residual solvents
Implementation Method 4
exposed to water (hot liquid water or steam) and vacuum to remove residual solvents
Implementation Method 5
a flare may be used on the exhaust from the vacuum pump to burn off volatile hydrocarbons which have not been condensed out
Implementation Method 6
optional addition of flocculating agents and additional solids to enhance separation and solidification
Data Source
AI summary
A process for extraction of bitumen and other oil products from sand, other sedimentary deposits and from mine tailings, may comprise flowing solvent through these bitumen-containing materials held in a filter press, where elevated pressures and temperatures may be used. After exposure to solvent the sedimentary deposits may be exposed to hot water, steam and/or vacuum to remove residual solvents. Further embodiments of the bitumen extraction process may include substituting the solvent with hot water or steam. Filter press systems for extracting bitumen are also described.