Hydrocarbon Solvent Extraction of Bitumen from Oil Sands

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Solution Overview

Problem

Conventional oil extraction methods from oil sands, particularly those that are oil wet, are inefficient and environmentally harmful due to high water and energy consumption, and produce significant contamination, with no commercially viable method effectively extracting bitumen from both water wet and oil wet conditions.

Innovation Solution

A three-stage sequential extraction process involving agitation, shaking, and high-G force centrifugation to separate hydrocarbons from raw materials like oil sands, using a hydrocarbon solvent to create a slurry and then separating solids from the crude oil using a screen mesh shaker and centrifuge, reducing residual solids to less than 0.1% for refining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional hot water process is used to extract bitumen from water wet oil sands, then extraction efficiency is improved, but water consumption and energy usage increase significantly

Engineering Contradiction:

Improvebitumen extraction efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the extraction parameter from hot water to hydrocarbon-based solvents (pentane, hexane, heptane, or octane), operating at ambient or reduced temperatures. This parameter change maintains high extraction efficiency while dramatically reducing energy consumption and water usage, directly resolving the technical contradiction between extraction efficiency and energy/water consumption

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional hot water process is used to extract bitumen, then extraction efficiency is improved, but contamination and water waste increase

Engineering Contradiction:

Improvebitumen extraction efficiencyVSAvoidcontamination

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces water-based extraction with hydrocarbon-based solvent extraction (pentane, hexane, heptane, or octane). This parameter change eliminates water contamination issues while maintaining high extraction efficiency. The hydrocarbon solvents are easily separable from bitumen through decantation or filtration, producing minimal harmful waste and resolving the contradiction between extraction efficiency and contamination generation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs inexpensive, readily available hydrocarbon solvents (common laboratory chemicals) that can be used in small quantities, easily separated from the product, and disposed of or recovered with minimal environmental impact. This approach contrasts with the large volumes of contaminated water requiring treatment in conventional processes

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If traditional hot water process is applied to oil wet oil sands, then extraction is possible, but effectiveness is significantly reduced

Engineering Contradiction:

Improvebitumen extraction effectivenessVSAvoidadaptability to different wettability conditions

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent employs hydrocarbon-based solvents (pentane, hexane, heptane, or octane) that universally extract bitumen from both water wet and oil wet oil sands with high effectiveness. The solvent's chemical properties enable it to interact with bitumen regardless of the rock surface wettability condition, making the extraction process universally effective across different oil sand types and resolving the contradiction between extraction effectiveness and adaptability to different wettability conditions

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 process reduces water and energy usage, minimizes contamination, and effectively extracts hydrocarbons from both water wet and oil wet oil sands, achieving a high yield of usable crude oil with minimal residual solids.

Implementation Method 1

A hydrocarbon solvent is added to the prepared hydrocarbon ore to create a hydrocarbon slurry

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 2

A final processing step, using high G-forces, separates most of the residual solids from the processed crude oil

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Data Source

PatentUS11713420B2System and method for extracting liquid and solid hydrocarbons and their derivatives

Publication Date: 2023.08.01 PETROTEQ ENERGY INC

AI summary

A system and method for extracting liquid and solid hydrocarbons and their derivatives from natural and man-made hydrocarbon sources, including but not limited to oil sands, bitumen, asphalt, roofing shingles, and other hydrocarbon articles of manufacture. The hydrocarbon sources are prepared by dissolving, crushing and/or grinding. The prepared hydrocarbon sources are subjected to agitation where the solvent and hydrocarbon source as thoroughly mixed. The results of the agitation are then separated in one or both of a mesh screen shaker and a centrifuge. The mesh screen shaker subjects the materials to medium frequency oscillations. The centrifuge subjects the materials to high G-forces. The combined processes separate the hydrocarbons from solids and residual solids to less than 0.2% by weight.