Abstract: Staged crushing combined with water addition and mixing is practiced at the mine site to prepare an oil sand slurry ready for hydrotransport. More particularly, as-mined oil sand is crushed to conveyable size (e.g. ?24?) using a mobile crusher. The pre-crushed ore product is conveyed to a dry ore surge bin. Ore is withdrawn from the bin and elevated to the upper end of a slurry preparation tower having downwardly aligned process components to enable gravity feed. The ore is further crushed in stages to pumpable size (e.g. ?4?) by a stack of crushers and water is added during comminution. The ore and water are mixed in a mixing box and delivered to a pump box. The surge bin and tower are relocatable. Screening and oversize reject treatment have been eliminated to achieve compactness and enable relocatability.

Abstract: A relocatable oil sand slurry preparation system is provided for preparing an aqueous oil sand slurry amenable to pipeline conveyance while producing minimum overall rejects, comprising (a) a relocatable rotary digester for slurrying oil sand and water and digesting oil sand lumps to form a pumpable slurry, the rotary digester having a feed end for receiving oil sand and water, a slurrying chamber comprising a plurality of lifters for slurrying the oil sand and water, and a trommel screen end for screening out oversize rejects from the oil sand slurry which falls through the trommel screen; and (b) a relocatable rejects recirculation unit operably associated with the rotary digester for receiving oversize rejects and delivering the rejects back to the rotary digester for further digestion. In a preferred body, relocatable oil sand slurry preparation system further comprises a rejects crusher for crushing oversize rejects prior to delivering rejects back to the rotary digester.

Abstract: A process line for separating oil sand slurry comprising coarse solids, fines, bitumen and water, into a first product comprising bitumen, fines and water and a second product comprising coarse solids, fines and water is provided comprising a plurality of countercurrently operating solid/liquid separators arranged in series along a pipeline, wherein the underflow of one separator is fed to the next separator in series and the overflow of each separator is fed to the preceding separator, the underflow of the last separator being the second product and the overflow from the first separator being the first product.

Abstract: A powder form of a hard phase component, selected from the group consisting of boron carbide, silicon carbide and a mixture of boron carbide and silicon carbide, is combined with an aluminum alloy matrix powder and applied to a metal substrate using plasma transferred arc (“PTA”) welding to produce a hardfaced structure having a wear-resisting carbide metal matrix composite overlay. The metal substrate can be any metal structure, such as an aluminum, aluminum alloy, steel or carbon steel structure, where wear resistance is desirable. Further, a process for hardfacing a metal substrate is disclosed comprising feeding a hard phase powder, selected from the group consisting of boron carbide, silicon carbide and a mixture of boron carbide and silicon carbide, and an aluminum alloy metal matrix powder to an operative PTA welding torch and welding to form a carbide metal matrix composite overlay fused to a metal substrate.

Abstract: An aqueous aerated oil sand slurry is conditioned in a pipeline and then spun within an elongate vessel of circular cross-section, to cause bitumen droplets in the slurry to coalesce. This increases the probability that the droplets will become aerated by contact with air bubbles. The slurry is then subjected to separation of the sand and bitumen.

Abstract: Staged crushing combined with water addition and mixing is practiced at the mine site to prepare an oil sand slurry ready for hydrotransport. More particularly, as-mined oil sand is crushed to conveyable size (e.g. —24?) using a mobile crusher. The pre-crushed ore product is conveyed to a dry ore surge bin. Ore is withdrawn from the bin and elevated to the upper end of a slurry preparation tower having downwardly aligned process components to enable gravity feed. The ore is further crushed in stages to pumpable size (e.g. —4?) by a stack of crushers and water is added during comminution. The ore and water are mixed in a mixing box and delivered to a pump box. The surge bin and tower are relocatable. Screening and oversize reject treatment have been eliminated to achieve compactness and enable relocatability.

Abstract: A process line for separating oil sand slurry comprising coarse solids, fines, bitumen and water, into a first product comprising bitumen, fines and water and a second product comprising coarse solids, fines and water is provided comprising a plurality of countercurrently operating solid/liquid separators arranged in series along a pipeline, wherein the underflow of one separator is fed to the next separator in series and the overflow of each separator is fed to the preceding separator, the underflow of the last separator being the second product and the overflow from the first separator being the first product.

Abstract: A relocatable oil sand slurry preparation system is provided for preparing an aqueous oil sand slurry amenable to pipeline conveyance while producing minimum overall rejects, comprising (a) a relocatable rotary digester for slurrying oil sand and water and digesting oil sand lumps to form a pumpable slurry, the rotary digester having a feed end for receiving oil sand and water, a slurrying chamber comprising a plurality of lifters for slurrying the oil sand and water, and a trommel screen end for screening out oversize rejects from the oil sand slurry which falls through the trommel screen; and (b) a relocatable rejects recirculation unit operably associated with the rotary digester for receiving oversize rejects and delivering the rejects back to the rotary digester for further digestion. In a preferred body, relocatable oil sand slurry preparation system further comprises a rejects crusher for crushing oversize rejects prior to delivering rejects back to the rotary digester.

Abstract: A powder form of a hard phase component, selected from the group consisting of boron carbide, silicon carbide and a mixture of boron carbide and silicon carbide, is combined with an aluminum alloy matrix powder and applied to a metal substrate using plasma transferred arc (“PTA”) welding to produce a hardfaced structure having a wear-resisting carbide metal matrix composite overlay. The metal substrate can be any metal structure, such as an aluminum, aluminum alloy, steel or carbon steel structure, where wear resistance is desirable. Further, a process for hardfacing a metal substrate is disclosed comprising feeding a hard phase powder, selected from the group consisting of boron carbide, silicon carbide and a mixture of boron carbide and silicon carbide, and an aluminum alloy metal matrix powder to an operative PTA welding torch and welding to form a carbide metal matrix composite overlay fused to a metal substrate.

Abstract: A bitumen/steam pre-mixer and atomizing nozzle combine to produce a jet of minute liquid droplets (bitumen) in carrier gas (steam). The jet is injected into a draft tube mixer positioned in a fluid bed of hot coke particles suspended in steam and contained within a fluid coking reactor. The movement of the jet through the draft tube passageway induces a stream of coke particles in steam to be drawn into the passageway, where the jet and stream mix vigorously and bitumen droplets have an enhanced probability of contacting coke particles.

Abstract: As-mined oil sand is crushed to −5 inch by a sequentially arranged pair of double roll crushers. The crushed oil sand is fed into a hopper feeding a jet pump. Water or recycled slurry is fed under pressure as motive fluid to the jet pump. The motive fluid jet(s) produced internally by the jet pump are operative to fluidize the oil sand and the components of the slurry mix turbulently in the jet pump's tubular mixer. It is found that the slurry issuing from the jet pump is aerated and largely free of lumps.

Abstract: As-mined oil sand is crushed to −5 inch by a sequentially arranged pair of double roll crushers. The crushed oil sand is fed into a hopper feeding a jet pump. Water or recycled slurry is fed under pressure as motive fluid to the jet pump. The motive fluid jet(s) produced internally by the jet pump are operative to fluidize the oil sand and the components of the slurry mix turbulently in the jet pump's tubular mixer. It is found that the slurry issuing from the jet pump is aerated and largely free of lumps.

Abstract: In order to collect, heat and deaerate raw bituminous froth prior to upgrading that froth to synthetic crude oil, a central collection zone is provided for collecting the raw froth which is transferred therefrom to a deaeration zone by means of a conduit having a plurality of steam injection means disposed therein and oriented to urge the froth toward the deaeration zone. The deaeration zone may include a plurality of baffles across which the heated froth is distributed in order to facilitate the release of gases as the froth spills over the baffles. An outlet in a lower portion of the deaeration zone permits transfer by pumping or other means for further treatment of the froth.

Abstract: A process for treating retention pond sludge containing greater than 20% solids including minerals and bitumen and associated with the aqueous extraction of bitumen from tar sands to provide water substantially reduced in solids content which comprises agitating the sludge with water to provide a diluted sludge with a solids concentration in the range of 6 to 18% by weight, and thereafter settling the sludge to form a lower layer having a solids content substantially higher than that of the sludge an upper layer of bituminous froth, and a middle layer of water having a substantially lower solids content than said undiluted sludge and recovering said upper layer.

Abstract: In a hot water process for extracting bitumen from tar sands comprising forming a mixture of tar sands and water, settling the mixture in a primary extraction zone to form an upper bitumen froth layer, a middlings layer and a sand tailings layer, passing a part of the middlings layer to an air scavenger zone to recover additional bitumen therefrom, the improvement which comprises adding the aerated bitumen-depleted aerated middlings material from the air scavenger zone to the mixture of tar sands and water before the settling step.

Abstract: The present invention relates to a novel consumable guide nozzle suitable for use in the electroslag welding.

Abstract: A method for reducing the sludge content of a retention pond associated with the hot water process for extracting bitumen from tar sands which comprises admixing a sludge stream containing at least 12% solids by weight with a hot water extraction process waste water stream containing at least 20% sand; settling the mixture in a settling zone to form an upper layer substantially reduced in mineral matter and a lower layer comprised of a sand-sludge mixture and dispersing said lower layer over a sand pile zone to provide additional sand layers thereon containing at least a part of the sludge in the interstices of said additional sand layers.

Abstract: An apparatus in which bituminous froth is concurrently heated and deaerated while flowing by gravity from one zone to another.

Abstract: A method for removing bitumen from mineral particles recovered from bituminous froth recovered as a product of aqueous extraction of tar sands which method comprises scrubbing the minerals with a liquid hydrocarbon solvent containing at least 10 weight percent aromatics and thereafter separating the minerals from the solvent and subsequently drying the minerals.

Abstract: A tank with an upwardly concave bottom, a rotatable center shaft running on the vertical axis of the tank from the top of the tank to the bottom, middlings outlets at the side of the tank, a sands discharge outlet at the bottom of the tank, an overflow means connected at the side of the tank, a sand rake connected to the center shaft to rotate with the shaft and positioned to move settled sand toward the sand discharge outlet and a means for rotating the center shaft, the improvement which comprises a combination of two or more saucer-shaped deflecting baffles located in the cell and concentric with the shaft and affixed thereto, the lowest baffle being located immediately above the sand rake, and inverted to the bottom of the cell and having a skirt extending downward from the outer periphery thereof and at least one other deflecting baffle being located in between the feed well and the lower baffle.