Abstract: Methods and systems for preparing bitumen-laden solvent for downstream processing are described. The bitumen-laden solvent can be treated with various materials, such as water and emulsion breakers, followed by treating the bitumen-laden solvent in a desalter. The desalted bitumen-laden solvent can then be subjected to downstream processing, such as upgrading in a nozzle reactor.

Abstract: Systems and methods for hydrocarbon extraction from hydrocarbon-containing material. Such systems and methods relate to extracting hydrocarbon from hydrocarbon-containing material employing a non-aqueous extractant. Additionally, such systems and methods relate to recovering and reusing non-aqueous extractant employed for extracting hydrocarbon from hydrocarbon-containing material.

Abstract: A method and system for extracting hydrocarbon products from waste tailings of a froth flotation unit and a paraffinic froth treatment process are provided. Bitumen and asphaltenes from the waste tailings are extracted using a serial addition of an aromatic solvent, followed by a polar-non-polar solvent. The method and system divert valuable hydrocarbons from tailings ponds. The hydrocarbon product can be used as a coating material or an emulsion fuel, for example.

Abstract: In solvent-assisted bitumen extraction, a native marker, for example: sulfur, nickel, vanadium, iron copper, or manganese, is used to control the solvent to bitumen ratio in a process stream such as a stream from a froth separation unit (FSU) and/or to measure hydrocarbon loss in a tailings solvent recovery unit (TSRU).

Abstract: A method for the pyrolytic extraction of hydrocarbons such as shale oil from kerogen. Oil shale containing kerogen which has been ground into particulate form, is cascaded downwardly between a plurality of rotating trays within a heated processing chamber. As the hydrocarbons are volatized within the chamber, the volatiles are collected and condensed within a condenser or other suitable recovery apparatus.

Abstract: A composition for use in extracting oil, the composition comprising: (a) a mixture comprising, by weight, 50-55% of an aromatic alkyl, 15-19% d-limonene, 6.5-7% polyethylsorbitan monoleate, 15-15.5% PEG sorbitan monostearate, 3.4-9.9% tall fatty acid, and EDTA in an amount up to 1%; and (b) water in an amount such that the mixture is diluted to 1%-2% by weight of the composition.

Abstract: A separation process and system for extracting hydrocarbons from a mixture. In some embodiments, a process for separating a bitumen froth stream containing bitumen froth, water and fine solids into a bitumen enriched froth stream and a water and fine solids stream, comprises: (a) receiving the bitumen froth stream in a concentrator vessel, (b) distributing the bitumen froth stream in the concentrator vessel as a substantially uniform and generally horizontal flow of the bitumen froth stream at a first flow velocity, (c) slowing the bitumen froth stream to a second flow velocity, slower than the first flow velocity, in a separation region of the concentrator vessel to promote separation of the bitumen froth from the water and fine solids, and then (d) collecting a bitumen enriched froth stream and (e) collecting a separate water and fine solids stream. Related embodiments of systems and apparatus may also be provided.

Abstract: Chemical compounds that are N-acyl amino acids or derivatives thereof having long chain N-acyl groups were found to have oil-releasing activity. Solutions containing these compounds may be introduced into oil reservoirs or onto oil-contaminated surface sites to release oil from oil-coated surfaces. The released oil may be recovered for further processing or waste disposal.

Abstract: A water-based separating composition for separating hydrocarbons from hydrocarbon-containing material includes at least about 71% by weight water, a hydrotropic agent, a dispersant having flocculating characteristics, a wetting agent, and at least one acid and at least one base in amounts sufficient to provide the separating composition with a pH of about 7 to about 8.5. The hydrotropic agent and the dispersant having flocculating characteristics are different.

Abstract: A process for the extraction and recovery of bitumen from oil sands and a process for the treatment of tailings are disclosed. Bitumen is recovered in a process comprising contacting a polysilicate microgel with an ore sand oil to produce a froth comprising bitumen and a tailings stream comprising water, sand and clay fines. Preferably the tailings stream is dewatered and recovered water may be recycled to the extraction process. Polysilicate microgel may be carried through to a dewatering step and enhances flocculation in dewatering said tailings.

Abstract: A method for recovery of bitumen from a bitumen-containing froth utilizes solvent and a single, froth settling vessel having a plurality of internals therein. The froth is first diluted with enough solvent to reduce the viscosity of the froth and the diluted froth is added to the vessel above the internals. Additional of the solvent is added to the vessel, either below the internals, intermediate the internals or both and is flowed counter-current to the diluted froth which is flowing downwardly over the plurality of internals. A gradient of solvent concentration relative to hydrocarbon concentration is formed through the internals which act as multiple stages of separation. The product, being bitumen and other light components, are carried with the solvent to the top of the vessel. The heavier components such as water, solids and asphaltene aggregates fall to the bottom of the vessel by gravity.

Abstract: A method of extracting hydrocarbon-containing organic matter from a hydrocarbon-containing material includes the steps of providing a first liquid comprising a turpentine liquid; contacting the hydrocarbon-containing material with the turpentine liquid to form an extraction mixture; extracting the hydrocarbon material into the turpentine liquid; and separating the extracted hydrocarbon material from a residual material not extracted.

Abstract: A method of extracting hydrocarbon-containing organic matter from a hydrocarbon-containing material includes the steps of providing a first liquid comprising a turpentine liquid; contacting the hydrocarbon-containing material with the turpentine liquid to form an extraction mixture; extracting the hydrocarbon material into the turpentine liquid; and separating the extracted hydrocarbon material from a residual material not extracted.

Abstract: The present invention provides a method for extracting bitumen from an oil sand feed stream (10), the method comprising at least the steps of: (a) providing an oil sand feed stream (10); (b) contacting the oil sand feed stream (10) with a liquid (40) comprising an aliphatic hydrocarbon solvent thereby obtaining a solvent-diluted oil sand slurry (20); (c) filtering the solvent-diluted oil sand slurry (20), thereby obtaining a first bitumen-enriched filtrate (30), a second bitumen-depleted filtrate (40) and a bitumen-depleted sand (50); (d) reusing the second filtrate (40) obtained in step (c) in the contacting of step (b); and (e) removing solvent (90) from the first bitumen-enriched filtrate thereby obtaining a bitumen-enriched stream (80).

Abstract: The present invention provides a method for extracting bitumen from an oil sand feed stream (10), the method comprising at least the steps of: (a) providing an oil sand feed stream (10); (b) contacting the oil sand feed stream (10) with a liquid (20) comprising an aliphatic hydrocarbon solvent thereby obtaining a solvent-diluted oil sand slurry (30); (c) depositing the solvent-diluted oil sand slurry (30,35) as a filter cake (32) on a filter medium (31) and filtering the solvent-diluted oil sand slurry (30,35), thereby obtaining a solids-enriched stream (50) and a filtrate (60), wherein during the filtering the pressure above the filter cake (32) is at least 1.7 bara; and (d) lowering the pressure of the solids-enriched stream (50) to below 1.2 bara.

Abstract: This invention is directed to a process for separating a solute from a solute-bearing material. A substantial amount of solute is extracted from the solute-bearing material by contacting particles of the solute-bearing material with globules of an extraction solvent. The particle size of the solute-bearing material and the globule size of the extraction solvent are balanced such that little if any solute or extraction solvent remains in the solute-bearing material.

Abstract: A process and composition for removing heavy oil and bitumen from oil sands is disclosed. The composition comprises an emulsion of d-limonene in water, with an optional anionic surfactant as an emulsifying agent. The emulsion is contacted with an oil sand slurry until the aqueous and hydrocarbon phases separate. The process may take place at temperatures less than about 80° C. and with low concentrations of the d-limonene.

Abstract: Processes are described for extracting hydrocarbon from a mineable deposit, such as bitumen from oil sands. The integration of solvent-based extraction processes with aqueous extraction processes is described. In one embodiment, water is removed from an aqueous bituminous feed that is then directed into a solvent-based extraction process. In another embodiment, a stream produced through solvent extraction is directed into a water-based extraction process. In the solvent-based extraction processes, agglomeration of fines may be employed to simplify subsequent solid-liquid separation. The process permits recovery of hydrocarbon that has conventionally may have been too difficult to recover from oil sands processing, and thus has previously been lost. Advantageously, a fungible product can be formed more efficiently according to certain integrated processes described herein.

Abstract: The invention pertains to utilization of high power density microwave energy to reduce organic compounds to carbon and their constituents, primarily in a gaseous state. The process includes, but is not limited to, scrap tires, plastics, asphalt roofing shingles, computer waste, medical waste, municipal solid waste, construction waste, shale oil, and PCB/PAH/HCB-laden materials. The process includes the steps of feeding organic material into a microwave applicator and exposing the material to microwave energy fed from at least two linear polarized sources in non-parallel alignment to each other, and collecting the material. The at least two sources of microwave energy are from a bifurcated waveguide assembly, whose outputs are perpendicular to each other and fed through waveguide of proper impedance, such that the microwave sources are physically and electrically 90° out of phase to each other. The microwave frequency is between 894 and 1000 MHz, preferably approximately 915 MHz.

Abstract: A process for the treatment of a tailings stream is provided. The tailings stream comprises water, sand and clay fines and is produced from bitumen extraction process of an oil sands ore. The process for treating the tailings stream comprises contacting a polysilicate microgel, a polyacrylamide and one or both of a multivalent metal compound and a low molecular weight cationic organic polymer with a tailings stream to flocculate sand and clay fines.

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 method for recovering a tailings bitumen from a froth treatment tailings, including providing a first feed material which is derived from the froth treatment tailings, conditioning the first feed material in order to produce a conditioned first feed material, providing a second feed material which is derived from the conditioned first feed material, and subjecting the second feed material to solvent extraction in order to produce an extract containing an amount of the tailings bitumen. The method may further include dewatering the conditioned first feed material in order to produce the second feed material and may further include clarifying the extract to produce a clarified extract containing an amount of the tailings bitumen.

Abstract: A chemical composition and methods for use in the recovery of viscous oil and other desired hydrocarbons from subterranean reservoirs and from excavated material comprising oil sands or oil shale, and to remediate contaminated soil and subterranean reservoirs. Adding the composition to viscous oil renders it pipelineable by significantly reducing its viscosity. The chemical composition comprises an alkane, an ether, and an aromatic hydrocarbon. The composition is an organic solvent mixture that interacts highly favorably with non-polar hydrocarbons but is mostly immiscible with water and acts as a diluent, lowering the viscosity and raising the specific gravity of viscous oil. Additional water and heat are not required. Methods of using the composition in subterranean reservoirs and with excavated material including oil sands or oil shale and contaminated soil and subterranean reservoirs needing remediation, are highly efficient, economical, and reduce or eliminate adverse environmental consequences.

Abstract: Process for the recovery of oils from a solid matrix comprising: subjecting said solid matrix to extraction by mixing with at least one organic solvent having a boiling point lower than or equal to 160° C., preferably ranging from 60° C. to 140° C., operating at a temperature ranging from 5° C. to 40° C., preferably ranging from 15° C. to 30° C., and at atmospheric pressure (1 atm), obtaining a solid-liquid mixture; subjecting said solid-liquid mixture to separation, obtaining a liquid phase comprising said oils and said organic solvent and a solid phase comprising said solid matrix; recovering said organic solvent from said liquid phase.

Abstract: A water-based separating composition for separating hydrocarbons from hydrocarbon containing material includes at least about 73% by weight water, a hydrotropic agent, a dispersant having flocculating characteristics, at least one acid and at least one base in amounts sufficient to provide the separating composition with a pH of about 7 to about 8.5. The hydrotropic agent and the dispersant having flocculating characteristics are different.

Abstract: A method of preventing egress of a vapor from an encapsulated volume can include forming a substantially impermeable vapor barrier along an inner surface of the encapsulated volume. The encapsulated volume includes a permeable body of comminuted hydro carbonaceous material. Further, the vapor barrier can include an insulating layer capable of maintaining a temperature gradient of at least 400° F. across the insulating layer. The permeable body can be heated sufficient to liberate hydrocarbons therefrom and the hydrocarbons can be collected from the permeable body. The vapor barrier layer can be a single or multiple layer construction, depending on the specific materials chosen.

Abstract: A bitumen extraction method can include the use of a two or more mixing drums aligned in series for spraying solvent over bituminous material and/or tailings loaded in the mixing drums while the mixing drums rotate. Such mixing can result in the dissolution of bitumen into the solvent, which then allows for the separation of a “dilbit” stream from the bituminous material.

Abstract: Methods for preparing solvent-dry, stackable tailings. The method can include the steps of adding a first quantity of solvent to a bitumen material to form a first mixture, separating a first quantity of bitumen-enriched solvent from the first mixture and thereby creating solvent-wet tailings, and adding a quantity of water to the solvent-wet tailings to separate a solvent component from the solvent-wet tailings and thereby forming solvent-dry, stackable tailings. The solvent used in the methods can include paraffinic solvent, such as pentane.

Abstract: A method of extracting bitumen from bituminous material. In some embodiments, the method may include loading a bitumen material in a column, followed by feeding a first quantity of solvent into the column. The method may also include collecting the bitumen-enriched solvent exiting the column. A quantity of the bitumen-enriched solvent may then be fed into the column. In some embodiments, the method may include simultaneously loading bitumen material and a solvent in a column, followed by feeding additional solvent into the column. The method may also include collecting bitumen-enriched solvent exiting the column, and feeding a quantity of the bitumen-enriched solvent into the column.

Abstract: The invention relates to a class of novel surfactants that have utility in the recovery and/or extraction of oil.

Abstract: Systems and methods for cooling and processing materials are disclosed.

Abstract: A process for the separation of high purity organic fractions from oil sands is disclosed.

Abstract: The invention relates to an improved bitumen recovery process. The process includes adding water to a bitumen-froth/solvent system containing asphaltenes and mineral solids. The addition of water in droplets increases the settling rate of asphaltenes and mineral solids to more effectively treat the bitumen for pipeline transport, further enhancement, refining, or any other application of reduced-solids bitumen.

Abstract: The disclosure relates to improved bitumen recovery processes and systems. In particular, the disclosure teaches processes and systems for recovering heavy crude oil while avoiding fouling of equipment by recycling at least a portion of a product bitumen from a solvent recovery unit for mixing with an overhead bitumen stream that may be a diluted bitumen stream containing solvent and bitumen. The overhead bitumen stream is a near-incompatible stream and the stream of mixed overhead bitumen stream and the treated bitumen stream is a compatible stream that will not foul equipment upon heating.

Abstract: Embodiments of a method and a system for recovering energy, materials or both from asphaltene-containing tailings are disclosed. The asphaltene-containing tailings can be generated, for example, from a process for recovering hydrocarbons from oil sand. Embodiments of the method can include a flotation separation and a hydrophobic agglomeration separation. Flotation can be used to separate the asphaltene-containing tailings into an asphaltene-rich froth and an asphaltene-depleted aqueous phase. The asphaltene-rich froth, or an asphaltene-rich slurry formed from the asphaltene-rich froth, then can be separated into a heavy mineral concentrate and a light tailings. Hydrophobic agglomeration can be used to recover an asphaltene concentrate from the light tailings. Another flotation separation can be included to remove sulfur-containing minerals from the heavy mineral concentrate. Oxygen-containing minerals also can be recovered from the heavy mineral concentrate.

Abstract: Processes and systems are described for solvent extraction of bitumen from oil sands. Fines agglomeration is employed to simplify subsequent separation. A high quality bitumen product can be formed, which meets or exceeds downstream processing and pipeline requirements. An embodiment comprises combining a first solvent and a bituminous feed to form an initial slurry, which is optionally separated into fine solids and coarse solids. Slurry solids are agglomerated. A low solids bitumen extract from the agglomerated slurry is mixed with a second solvent having a similar or lower boiling point than the first. The mixture is separated, solvent recovered, and a high grade bitumen product is formed. Exemplary systems comprise a mixbox, agglomerator, separator unit with optional countercurrent washer and deep cone settler, and TSRU. Processes are provided for fractionating a hydrocarbon fluid into heavier and lighter fractions. The lighter fraction may be used in solvent extraction of bitumen.

Abstract: A process for the extraction and recovery of bitumen from oil sands and a process for the treatment of tailings are disclosed. Bitumen is recovered in a process comprising contacting a polysilicate microgel with an ore sand oil to produce a froth comprising bitumen and a tailings stream comprising water, sand and clay fines. Preferably the tailings stream is dewatered and recovered water may be recycled to the extraction process. Polysilicate microgel may be carried through to a dewatering step and enhances flocculation in dewatering said tailings.

Abstract: A process for extraction of bitumen and other oil products from sand, other sedimentary deposits and from mine tailings, may comprise flowing solvent through these bitumen-containing materials held in a filter press, where elevated pressures and temperatures may be used. After exposure to solvent the sedimentary deposits may be exposed to hot water, steam and/or vacuum to remove residual solvents. Further embodiments of the bitumen extraction process may include substituting the solvent with hot water or steam. Filter press systems for extracting bitumen are also described.

Abstract: A process is described for bitumen extraction from oil sands. Solvent extraction is used, incorporating fines agglomeration to simplify subsequent separation. A high quality bitumen product is formed, having water and solids content that exceeds downstream processing and pipeline requirements. An embodiment of the process comprises combining a first solvent and a bituminous feed to form an initial slurry, which is optionally separated into fine solids and coarse solids. Solids are agglomerated to form an agglomerated slurry. A low solids bitumen extract from the agglomerated slurry is mixed with a second solvent to form a solvent-bitumen low solids mixture, the second solvent having a similar or lower boiling point than the first solvent. The mixture is separated to produce high grade and low grade bitumen extracts. The first and second solvents are recovered from the high grade bitumen extract, leaving a high grade bitumen product.

Abstract: Methods for preparing solvent-dry, stackable tailings. The methods may include a primary leaching or extraction process that separates most of the bitumen from a material comprising bitumen and produces first solvent-wet tailings. The first solvent-wet tailings are washed with a second solvent that removes the first solvent from the tailings. Second solvent remaining in the tailings is removed to thereby produce solvent-dry, stackable tailings.

Abstract: A spinning fluids reactor, includes a reactor body (24) having a circular cross-section and a fluid contactor screen (26) within the reactor body (24). The fluid contactor screen (26) having a plurality of apertures and a circular cross-section concentric with the reactor body (24) for a length thus forming an inner volume (28) bound by the fluid contactor screen (26) and an outer volume (30) bound by the reactor body (24) and the fluid contactor screen (26). A primary inlet (20) can be operatively connected to the reactor body (24) and can be configured to produce flow-through first spinning flow of a first fluid within the inner volume (28). A secondary inlet (22) can similarly be operatively connected to the reactor body (24) and can be configured to produce a second flow of a second fluid within the outer volume (30) which is optionally spinning.

Abstract: Methods of producing organic materials, and in particular methods of producing petroleum materials and organic compounds such as aromatic acids, phenols, and aliphatic poly-carboxylic acids using an oxidative hydrothermal dissolution (OHD) process are disclosed.

Abstract: A filter device for filtering a suspension includes at least one filter for continuous creation of a filter cake including particles from the suspension, at least one dispensing device configured to apply at least one first wash liquid to the filter cakes, at least one steaming unit configured to steam the filter cake using steam; at least one removal device configured to remove a surface layer of the filter cake facing away from the at least one filter, wherein the filter device is configured to convey the filter cake to the at least one removal device, the at least one dispensing device and the at least one steaming device, and at least one transport device configured to transport the removed surface layer of the filter cake away from the filter device.

Abstract: The present invention is a system and method for steam production for oil production. The method includes generating hot driving fluid, indirectly using the hot driving fluid to heat water containing solids and organics, separating solids, and using the steam for generating hot process water or for underground injection. The system includes a non-direct contact heat exchanger connected to a separator for collecting and separating the solids from the gas. The water feed of the present invention can be water separated from produced oil and/or low quality water salvaged from industrial plants, such as refineries and tailings from an oilsands mine.

Abstract: This invention provides a process for producing a crude oil composition from oil sand using a solvent comprised of a hydrocarbon mixture to extract or remove only a portion of the bitumen on the oil sand. The solvent type and the manner by which the extraction process is carried out has substantial impact on the quality of the extracted oil component. The solvent is designed so that it has the desired Hansen solubility parameters that enable the partial extraction of the desired oil composition. The solvent is further designed so that it can be comprised of multiple hydrocarbons having the appropriate boiling point ranges that enable the solvent to be easily recovered and recycle, without the need to externally provide for solvent make-up.

Abstract: Method for recovery of bitumen from tar sand is provided. An aqueous fluid containing a wetting agent and nanoparticles is injected into a first horizontal well at a temperature above reservoir temperature. Bitumen is released from sand grains and flows into a second horizontal well, where it is transported to surface. In a surface treatment facility, a slurry of tar sand is formed and surfactant and nanoparticles are added to the slurry.

Abstract: Disclosed is a system for processing oil sands to remove bitumen, the viscous petroleum product adhered to the sands, from the sands itself. The processing system is designed to be substantially air tight, preventing outside air from entering and volatile chemicals from escaping from the system. Mined oil sands are delivered to the system, which creates a slurry of oil sands and solvent in a slurry chamber. The slurry is transported to a dissolution chamber which conditions the slurry before the slurry is sent to an extraction chamber. A plurality of trays and scrapers further conditions the slurry to remove bitumen. The use of heavy, aromatic solvents and light, paraffinic solvents in sequence improves bitumen recovery while allowing environmentally safe processing of the sands to occur in a later step. The sands are dried and the solvent recovered for recycling and reuse in the system. Clean, dry sands are returned to the source of mined oil sands for reclamation.

Abstract: A froth flotation method and apparatus for extracting a valuable substance from a slurry comprising a mixture of solid phase, liquid phase and said substance. A gas dispersing mechanism (4) feeds gas into the slurry (1) in a flotation vessel (2) to infuse gas bubbles into the slurry. The slurry is agitated in the flotation vessel (2) for dispersing the gas bubbles into the slurry. The gas bubbles capture the valuable substance from the slurry and form a froth phase F above the slurry phase S. The froth phase F exits the vessel by overflow. Continuously moving negative pressure zones (7) are mechanically generated by rake blades (9) in the froth phase (F). The negative pressure zones (7) extend from the froth phase (F) to the slurry phase (S).

Abstract: A method for extracting bitumen from an oil sand feed stream comprises at least the steps of: (a) providing an oil sand feed stream; (b) contacting the oil sand feed stream with an aliphatic hydrocarbon solvent thereby obtaining a solvent-diluted oil sand slurry; (c) separating the solvent-diluted oil sand slurry, thereby obtaining a solids-depleted stream and a solids-enriched stream; and (d) removing solvent from the solids-enriched stream thereby obtaining a dry product comprising sand and bitumen, wherein the bitumen in the dry product comprises at least 40 wt. % asphaltenes.

Abstract: Herein disclosed is a method of removing at least one component from a feed stream, the method including steps of subjecting the feed stream to high shear separation in a high shear device to produce a high shear-treated product stream; and substantially separating the at least one component from the high shear-treated product stream to produce a component-reduced product stream.