Oil Sands Extraction Using Light Aliphatic Solvents
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Solution Overview
Problem
Current oil sands extraction processes face inefficiencies in recovering high-quality bitumen free from fine inorganic particles, leading to material handling challenges, mineral contamination, solvent loss, and high energy requirements.
Innovation Solution
A process involving the use of a light aliphatic solvent, such as pentane or hexane, to contact unconditioned oil sands, followed by grinding and agglomeration to separate inorganic material, allowing for the efficient separation of bitumen and asphaltenes without complete dissolution of organic material, thereby reducing mineral contamination and solvent loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complete dissolution of organic material is achieved using solvent extraction, then recovery efficiency is improved, but energy requirements and solvent loss increase
Solution Approach 1:
The patent applies partial action by using a solvent system that achieves partial dissolution of organic material rather than complete dissolution. The solvent mixture (first solvent and second solvent in specific ratios) is designed to dissolve sufficient bitumen for effective extraction while leaving some organic material undissolved, thereby reducing the energy required for solvent recovery and minimizing solvent losses while maintaining acceptable recovery efficiency.
2Productivity
If solvent extraction is used to separate bitumen from mineral matrix, then recovery efficiency is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The patent segments the solvent extraction process into distinct stages: (1) initial extraction with a first solvent to dissolve bitumen, (2) separation of the solvent mixture, and (3) additional extraction with a second solvent. This segmentation allows each stage to be optimized independently, simplifying the overall process operation and reducing complexity while maintaining high recovery efficiency through the coordinated action of multiple solvent systems.
3Productivity
If traditional solvent extraction methods are used, then bitumen recovery is improved, but mineral contamination and fines separation become problematic
Solution Approach 1:
The patent changes the parameters of the solvent system by using a specific mixture of first and second solvents in controlled ratios, and by adjusting extraction conditions (temperature, pressure, contact time). These parameter changes enable the solvent system to selectively dissolve bitumen while leaving mineral particles and fines largely undissolved, improving separation quality and reducing mineral contamination in the recovered bitumen while maintaining high recovery efficiency.
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 achieves efficient and cost-effective separation of bitumen and asphaltenes from oil sands, minimizing fines and mineral material, and allows for the production of high-quality bitumen with reduced asphaltenes and inorganic content, while also enabling flexible processing of various oil sands and production of different final products.
Implementation Method 1
contacting unconditioned oil sands with at least one light aliphatic solvent selected from the group consisting of pentane, hexane, iso-hexane, neo-hexane, cyclohexane, heptane and mixtures thereof
Implementation Method 2
utilizing a grinding medium, to produce a mass
Implementation Method 3
transferring the mass obtained in step (a) into an agglomerator to allow formation of agglomerated inorganic material
Implementation Method 4
separating the agglomerated inorganic material and non-agglomerated coarse inorganic material from said mass
Implementation Method 5
separating the agglomerated inorganic material and non-agglomerated coarse inorganic material from said mass
Data Source
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AI summary
A process for the separation of high purity organic fractions from oil sands is disclosed.