Integrated Bitumen Extraction Apparatus for Oil Sands
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for extracting bitumen from oil sand struggle with the efficient handling and processing of rejects, particularly when using non-aqueous solvents, as they require separate devices for mixing, screening, and solvent removal, leading to challenges in handling coarse solids and solvent vapor management.
Innovation Solution
An apparatus comprising three sections - a mixing section for contacting oil sand with solvent, a screening section for separating undersized and oversized materials, and a drying/solvent removal section for processing oversized material, all rotating around a common axis within a housing that minimizes solvent vapor leakage and eliminates the need for separate devices, allowing for integrated processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate devices are used for mixing, screening, and solvent removal, then each function can be optimized independently, but the overall device complexity increases and the number of rotary seals increases
Solution Approach 1:
The patent combines mixing, screening, and solvent removal functions into a single integrated apparatus with three rotating sections. The first section performs mixing of oil sand with solvent, the second section screens the slurry to separate undersized and oversized materials, and the third section removes solvent from oversized material. This merging eliminates the need for separate devices while maintaining functional optimization through dedicated zones for each operation.
Solution Approach 2:
The single apparatus performs multiple functions simultaneously: mixing (first section), screening (second section), and solvent removal (third section). The rotating sections enable each function to be performed in its optimal environment while all functions are housed in one universal device, reducing overall system complexity.
2Reliability
If separate devices are used for mixing, screening, and solvent removal, then each function can be optimized independently, but the overall height requirement increases
Solution Approach 1:
The patent transitions from a vertical stacking arrangement (which would increase height) to a horizontal circular arrangement of three rotating sections. The sections are arranged in a plane and rotate around a common axis, allowing mixing, screening, and solvent removal to occur side-by-side rather than stacked vertically, thus reducing the overall height requirement while maintaining functional optimization.
3Productivity
If non-aqueous solvent is used for extraction, then bitumen recovery efficiency improves, but solvent vapor management becomes more challenging
Solution Approach 1:
The patent creates a closed, vapor-tight environment within the housing that contains the non-aqueous solvent. The rotating sections are sealed within the housing, preventing solvent vapor from escaping to the surrounding environment. This inert, enclosed atmosphere allows efficient bitumen recovery using non-aqueous solvents while managing vapor containment.
Solution Approach 2:
The patent converts the potential harm of solvent vapor leakage into a benefit by designing a vapor-tight system where solvent vapors are contained and can be condensed and reused. The condensed solvent is returned to the mixing section, transforming what would be a harmful leakage into a recoverable resource that maintains productivity while eliminating vapor release.
4Reliability
If coarse solids are transported between separate devices, then each processing stage can be optimized, but handling difficulty increases
Solution Approach 1:
The patent eliminates the need to transport coarse solids between separate devices by integrating all processing stages in one continuous apparatus. The first section mixes solvent with oil sand, the second section screens the slurry, and the third section removes solvent from oversized material, all without requiring transport of coarse solids between separate equipment pieces, thus reducing handling difficulty while maintaining processing optimization.
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 solution simplifies the handling of rejects, reduces the overall height and number of rotary seals, and integrates mixing, screening, and solvent removal operations, enhancing efficiency and reducing solvent vapor escape, especially when using non-aqueous solvents.
Implementation Method 1
contacting the oil sand stream with a solvent in the first section thereby obtaining a solvent-diluted oil sand slurry
Implementation Method 2
screening the solvent-diluted oil sand slurry in the second section, thereby obtaining oversized material and undersized material
Implementation Method 3
removing solvent from the oversized material in the third section thereby obtaining solvent-depleted oversized material
Data Source
AI summary
The present invention provides an apparatus, at least comprising:a housing containing a first section, a second section and a third section;the first section having a first inlet for oil sand, a second inlet for solvent and an outlet for solvent-diluted oil sand slurry;the second section having an inlet for the solvent-diluted oil sand slurry, a screen allowing undersized material to pass and an outlet for oversized material; andthe third section having an inlet for oversized material and an outlet for solvent-depleted oversized material;wherein the first section, the second section and the third section can rotate during use around a common rotation axis (A-A′).