Solvent-Based Bitumen Extraction from Oil Sand
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Solution Overview
Problem
Current methods for extracting bitumen from oil sands are inefficient, requiring large quantities of process water and facing challenges in separating bitumen from the aqueous phase, and often result in 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, followed by filtration and multiple separation steps to achieve efficient bitumen recovery without using water, thereby eliminating the need for tailings ponds and increasing overall bitumen recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aqueous extraction processes are used to recover 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 patent changes the fundamental parameter of the extraction medium from aqueous (water-based) to non-aqueous (solvent-based). This parameter change eliminates the need for large quantities of process water while maintaining effective bitumen separation through the use of solvents that can selectively dissolve bitumen from the oil sand mixture.
Solution Approach 2:
The patent introduces a non-aqueous solvent as an intermediary substance to facilitate bitumen extraction. The solvent acts as a mediator that selectively dissolves bitumen from the oil sand, allowing for efficient separation without requiring large amounts of water and avoiding the complications of water-bitumen emulsion separation.
2Productivity
If multiple separation steps are implemented to increase bitumen recovery, then overall bitumen recovery is enhanced, but process complexity increases
Solution Approach 1:
The patent segments the bitumen extraction process into distinct sequential steps: initial solvent extraction, filtration to separate solids, and a second extraction step on the filtered solids. This segmentation allows for progressive bitumen recovery while maintaining clear process boundaries that simplify control and operation despite multiple stages.
Solution Approach 2:
The patent implements continuous bitumen extraction through multiple sequential steps where the output of one step becomes the input of the next. The filtrate from the first extraction is processed further, and the filtered solids undergo a second extraction, ensuring continuous recovery of bitumen without interrupting the overall process flow.
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 efficiently extracts bitumen from oil sands with reduced water usage, eliminating the need for tailings ponds and enhancing bitumen recovery through multiple solvent contacts and separations, resulting in a more efficient and environmentally friendly extraction method.
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 comprising at least the steps of, a) providing an oil sand stream; b) contacting the oil sand stream with a liquid comprising a solvent to obtain a solvent-diluted oil sand slurry; c) separating the oil sand slurry to obtain a first solids-depleted stream and a first solids-enriched stream; d) filtering the first solids-enriched stream obtained in step c) to obtain bitumen-depleted sand and at least a first filtrate; e) separating at least a part of the first filtrate to obtain a second solids-depleted stream and a second solids-enriched stream; and f) contacting at least a part of the second solids-enriched stream from step e) with solvent to obtain a solvent-diluted second solids-enriched stream; and g) separating the solvent-diluted second solids-enriched stream to obtain a third solids-enriched stream and a third solids-depleted stream.