Abstract: An apparatus, system, and method are disclosed for separating minerals from mineral feedstock—for example bitumen from tar sand. The apparatus includes residence chambers for contacting solvent and tar sand. The solvent-tar sand contact occurs in at least two stages. The drained miscella from the first stage is sent to a flashing module to separate the miscella into recovered solvent, a bitumen stream, and a volatile hydrocarbons stream. Solvent is recycled from the final stage and reused in the residence chambers. An energy recovery module recovers the energy from the volatile hydrocarbons stream. A solvent stripper removes the solvent residue from the drained tar sand to create a cleaned sand stream, and the solvent stripper recycles the solvent vapors to energize and assist the separation process. The apparatus enables a water-free, energy efficient, and nearly complete recovery of bitumen from tar sand.

Abstract: An apparatus, system, and method are disclosed for separating minerals from mineral feedstock—for example bitumen from tar sand. The apparatus includes residence chambers for contacting solvent and tar sand. The solvent-tar sand contact occurs in at least two stages. The drained miscella from the first stage is sent to a flashing module to separate the miscella into recovered solvent, a bitumen stream, and a volatile hydrocarbons stream. Solvent is recycled from the final stage and reused in the residence chambers. An energy recovery module recovers the energy from the volatile hydrocarbons stream. A solvent stripper removes the solvent residue from the drained tar sand to create a cleaned sand stream, and the solvent stripper recycles the solvent vapors to energize and assist the separation process. The apparatus enables a water-free, energy efficient, and nearly complete recovery of bitumen from tar sand.