Ethylene Oxide Capped Glycol Ether Bitumen Extraction
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Solution Overview
Problem
Current methods for bitumen recovery from oil sands, such as surface mining and in situ recovery, face challenges due to the viscous nature of bitumen, resulting in low recovery rates, high energy consumption, environmental concerns, and safety hazards, particularly with the use of large amounts of steam and caustic substances.
Innovation Solution
The use of ethylene oxide capped glycol ethers as an extraction aid in the water and/or steam used in bitumen recovery processes, either through surface mining or in situ methods, to enhance the separation of bitumen from oil sands by reducing viscosity and improving recovery efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam extraction methods are used to recover bitumen from oil sands, then bitumen can be extracted from the formation, but the recovery rate is limited (20-25% for CSS, 40-60% for SAGD) and energy consumption is high
Solution Approach 1:
A surfactant is introduced as an intermediary substance between the steam and bitumen to enhance the extraction process. The surfactant reduces interfacial tension and improves bitumen mobilization, allowing for higher recovery rates with reduced steam requirements, thus resolving the contradiction between productivity and energy consumption
Solution Approach 2:
The invention changes the chemical parameters of the extraction system by adding surfactants that modify the interfacial properties between steam, water, and bitumen. This chemical parameter change enhances mass transfer and bitumen mobilization efficiency, improving recovery rates without proportionally increasing energy input
2Ease of operation
If large amounts of steam are used in CSS or SAGD methods, then bitumen viscosity is reduced and flow is improved, but environmental impact increases and operational costs rise
Solution Approach 1:
The surfactant acts as a mediator that enhances bitumen mobilization through chemical action rather than relying solely on thermal energy. This reduces the amount of steam required, thereby decreasing environmental impact while maintaining ease of operation through improved bitumen flowability
Solution Approach 2:
The invention partially replaces the mechanical/thermal system (steam heating) with a chemical system (surfactant action). The surfactant chemically modifies the bitumen-steam-water interface to improve flowability, reducing dependence on high steam volumes and associated environmental harm
3Productivity
If caustic substances like NaOH are used in surface extraction, then bitumen separation from sand is achieved, but safety hazards increase and fine clay particles are formed
Solution Approach 1:
The invention changes the chemical parameter of the extraction system by replacing strong caustics with surfactants that achieve effective bitumen separation through surface activity rather than high pH. This reduces safety hazards and minimizes the formation of fine clay particles while maintaining separation efficiency
Solution Approach 2:
The surfactant serves as a milder, more controllable alternative to caustic substances. It achieves the necessary separation function with fewer harmful side effects, effectively replacing the harsh chemical approach with a more sustainable solution
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 addition of ethylene oxide capped glycol ethers increases bitumen recovery rates, reduces environmental impact, and lowers operational costs by improving the separation process, achieving higher oil recovery with reduced energy consumption and safer handling of materials.
Implementation Method 1
The difficulty with bitumen lies in that it typically is very viscous, sometimes to the point of being more solid than liquid. Thus, bitumen typically does not flow as less viscous, or lighter, crude oils do.
Implementation Method 2
Cyclic Steam Stimulation (CSS) is the conventional 'huff and puff' in situ method whereby steam is injected into the well at a temperature of 250° C. to 400° C. The steam rises and heats the bitumen, decreasing its viscosity.
Implementation Method 3
The use of an ethylene oxide capped glycol ether as an extraction aid in the water and/or steam used in the bitumen recovery process
Implementation Method 4
Air entrained with the water and NaOH attaches to the bitumen, allowing it to float to the top of the slurry mixture and create a froth.
Data Source
AI summary
The present invention relates to an improved bitumen recovery process from oil sands. The oil sands may be surface mined and transported to a treatment area or may be treated directly by means of an in situ process of oil sand deposits that are located too deep for strip mining. Specifically, the present invention involves the step of treating oil sands with an ethylene oxide capped glycol ether described by the structure: RO—(CH2CH(CH3)O)m(C2H4O)nH wherein R is a linear, branched, cyclic alkyl, phenyl, or alkyl phenyl group of greater than 5 carbons and m and n are independently 1 to 3.