Non-aqueous Solvent Bitumen Extraction Process
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Solution Overview
Problem
Current methods for extracting bitumen from oil sands require large quantities of process water and face challenges in separating bitumen from the aqueous phase, leading to inefficiencies and environmental concerns such as the need for tailings ponds.
Innovation Solution
A non-aqueous solvent-based extraction process that involves contacting oil sand with a solvent to create a solvent-diluted slurry, separating solids, filtering to obtain bitumen-depleted sand and filtrate, and reusing process streams to maintain solvent content, eliminating the need for water and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aqueous extraction processes are used to extract bitumen from oil sand, then bitumen can be separated from the oil sand, but extremely large quantities of process water are required and issues arise with removing bitumen from the aqueous phase and removing water from the bitumen-depleted sand
Solution Approach 1:
The invention changes the fundamental parameter of the extraction medium from aqueous (water-based) to non-aqueous (organic solvent-based). This parameter change eliminates the need for large quantities of process water while maintaining effective bitumen extraction capability, as the organic solvent can dissolve bitumen without forming problematic emulsions that require additional separation steps
Solution Approach 2:
The invention extracts and removes water from the extraction system entirely by using non-aqueous solvents. This eliminates the harmful association between large water consumption and bitumen extraction, solving the contradiction by taking out the problematic substance (water) while preserving the extraction function
2Quantity of substance
If non-aqueous solvent based extraction processes are used to reduce the need for process water, then water consumption is reduced, but process efficiency needs to be improved
Solution Approach 1:
The invention implements continuous recycling of the non-aqueous solvent through the process system. The solvent that becomes depleted of bitumen is continuously regenerated and reused, maintaining continuous useful action throughout the system. This eliminates water consumption while achieving high process efficiency through the continuous circulation and reuse of the extraction medium
Solution Approach 2:
The invention recovers and reuses the non-aqueous solvent after it has performed its extraction function. Instead of discarding the solvent or requiring continuous fresh water input, the system recovers the solvent from the bitumen-depleted stream and regenerates it for continued use, thereby eliminating water consumption while maintaining high process efficiency
3Quantity of substance
If aqueous extraction processes are used, then bitumen can be extracted from oil sand, but the need for tailings ponds arises due to water usage
Solution Approach 1:
The invention converts the potential harm of requiring large quantities of water (which would create tailings ponds and environmental issues) into a benefit by using non-aqueous solvents. The harmful water requirement is transformed into a beneficial water-free process that eliminates tailings pond needs while maintaining effective bitumen extraction
Solution Approach 2:
The invention extracts and removes water from the extraction system, eliminating the source of the environmental harm. By taking out water entirely and using non-aqueous solvents instead, the process eliminates the need for tailings ponds and associated environmental issues while preserving the bitumen extraction function
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 efficiently extracts bitumen with reduced water usage, eliminating the need for tailings ponds and enhancing process efficiency, while maintaining high bitumen recovery rates and minimizing environmental footprint.
Implementation Method 1
contacting the oil sand stream with a liquid comprising a solvent thereby obtaining a solvent-diluted oil sand slurry
Implementation Method 2
separating the solvent-diluted oil sand slurry, thereby obtaining a first solids-depleted stream and a first solids-enriched stream
Implementation Method 3
filtering the first solids-enriched stream obtained in step (c), thereby obtaining bitumen-depleted sand and at least a first filtrate
Data Source
AI summary
The present invention provides a method for extracting bitumen from an oil sand stream, the method including the steps of: (a) providing an oil sand stream; (b) contacting the oil sand stream with a liquid comprising a solvent thereby obtaining a solvent-diluted oil sand slurry; (c) separating the solvent-diluted oil sand slurry, thereby obtaining a first solids-depleted stream and a first solids-enriched stream; (d) filtering the first solids-enriched stream obtained in step (c), thereby obtaining bitumen-depleted sand and at least a first filtrate; (e) separating at least a part of the first filtrate thereby obtaining a second solids-depleted stream and a second solids-enriched stream; and (f) reusing at least a part of the second solids-enriched stream as obtained in step (e) in the contacting of step (b) or the separating of step (c).