Single Solvent Bitumen Extraction from Oil Sand Ore
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Solution Overview
Problem
Current bitumen extraction methods from oil sands, such as the Clark hot water extraction process, are inefficient in separating fines from bitumen, leading to high water and energy usage, and the formation of large tailings ponds that pose environmental concerns, while solvent-based methods struggle with efficient separation due to high viscosity and solvent evaporation issues.
Innovation Solution
A batch process using a single light paraffinic solvent in a container under pressure, where the solvent mixes with oil sand ore, allowing fines to settle, followed by water addition to displace the solvent-bitumen mixture, and subsequent separation, significantly reducing equipment and energy needs, and eliminating the need for large tailings ponds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hot water extraction process is used to separate bitumen from oil sands, then bitumen can be extracted, but large amounts of water and energy are consumed and large tailings ponds are formed
Solution Approach 1:
The patent changes the extraction medium from water to a hydrophobic solvent (such as heavy oil or synthetic crude), fundamentally altering the chemical parameters of the extraction system. This parameter change enables bitumen extraction while avoiding water consumption and tailings pond formation, as the hydrophobic solvent naturally separates from water and carries bitumen without requiring large water volumes for the process
Solution Approach 2:
The patent introduces a hydrophobic solvent as an intermediary substance between the oil sands and the separation system. This intermediary solvent selectively interacts with bitumen, extracting it from the sand matrix while its hydrophobic nature ensures easy separation from water, thereby eliminating the need for large tailings ponds and reducing water consumption
2Productivity
If solvent-based extraction is used, then bitumen can be separated, but high viscosity and solvent evaporation cause separation inefficiency
Solution Approach 1:
The patent selects solvents with specific physical parameters - particularly those with lower viscosity and appropriate boiling points (such as heavy oil or synthetic crude). By changing the solvent parameters from traditional high-viscosity solvents to these optimized options, the system achieves better mixing and separation efficiency while reducing evaporation losses and improving overall process productivity
Solution Approach 2:
The patent employs solvents that can be easily replaced or regenerated rather than requiring complex recovery systems. The selected solvents (heavy oil or synthetic crude) have properties that allow them to be used effectively and then discarded or replaced without significant loss, avoiding the need for expensive and complex solvent recovery equipment while maintaining high separation 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 method reduces capital and energy costs, minimizes water usage, and effectively separates fines from bitumen, allowing for efficient bitumen recovery with less environmental impact by eliminating the need for large tailings ponds.
Implementation Method 1
a light paraffinic solvent is added to a quantity of ore in a container and the solvent mixes with the ore
Implementation Method 2
the fines are allowed to settle out
Implementation Method 3
some water is added to displace the solvent and bitumen upward out of the solids
Data Source
AI summary
A single solvent method and machine for separating bitumen from oil sand ore are disclosed. The method includes the use of a single light paraffinic solvent, such as propane or butane as the agent to separate the bitumen from mined oil sand ore. Since light paraffinic solvents are vapors at atmospheric pressure and temperatures, the ore is placed in a pressurized container so that the solvent remains in a liquid state. When the container is pressurized, by the addition of the solvent itself, the liquid solvent is mixed with the ore to effect separation. The proposed machine settles more than 80% of the solids out under gravity in a modest period of time. The solvent-bitumen mixture is drained after the cleaning cycle, the container is depressured to a vapor recovery system and the remaining solids dumped out. The fine solids, drained with the liquids, are separated from the liquid mixture with relative ease by the use of current technology in other downstream equipment.