Abstract: Direct steam injection (DSI) heating techniques can use a heater to heat a process stream in bitumen froth treatment. The DSI heater can include a diffuser with multiple side-by-side rows of outlets perpendicular to a longitudinal axis of the diffuser, and a piston plug that moves axially within the diffuser to selectively cover rows of outlets to vary steam injection. The piston plug has first and second annular seals and is moved between different axial positions in a stepwise fashion such that when one or more rows of outlets are completely covered, the first annular seal is located in between adjacent rows and the second annular seal abuts against the diffuser to inhibit passage of steam so as to prevent cavitation. The DSI heater can include various other features, such as particular seal unit constructions and diffuser outlet configurations.

Abstract: A method for pre-treating bitumen froth for mixing with solvent for froth treatment includes heating the froth to a froth-solvent mixing temperature below the solvent flash temperature and suitably high to provide reduced bitumen viscosity sufficiently low for complete mixing of the solvent and the froth prior to introduction into a separation apparatus. A method of improving energy use in froth treatment includes reducing heat provided to the solvent, increasing heat provided to the froth prior to adding the solvent to reduce bitumen viscosity and adding the temperature-reduced solvent to the heated froth. A froth treatment separation process includes trim heating first and second solvent streams to adjust the first and second stage separation temperatures.

Abstract: Techniques provided herein relate to regulating at least one operating parameter of a paraffinic froth treatment (PFT) operation and controlling the quality of the produced bitumen in response to a determined concentration of at least one residual metal in a PFT process stream. Determination of the residual metal concentration is based on acquired NIR spectral measurements of the PFT process stream. An alkaline agent dosage in primary extraction operation can be for example regulated in response to a difference between a determined calcium concentration and a calcium concentration specification.

Abstract: The field of the invention is oil sands processing. A solvent treatment system and process for treating a bitumen-containing stream include contacting that stream with a solvent-containing stream to produce an in-line flow of solvent diluted material; supplying the solvent diluted material into a separation vessel with axi-symmetric phase and velocity distribution and/or particular mixing and conditioning features. The solvent addition, mixing and conditioning may be performed with particular CoV, Camp number, co-annular pipeline reactor, pipe wall contact of low viscosity fluid, flow diffusing and/or flow straightening. The processes enable improved performance of downstream unit operations such as separation of high diluted bitumen from solvent diluted tailings.

Abstract: Direct steam injection (DSI) heating techniques can use a heater to heat a process stream in bitumen froth treatment. The DSI heater can include a diffuser with multiple side-by-side rows of outlets perpendicular to a longitudinal axis of the diffuser, and a piston plug that moves axially within the diffuser to selectively cover rows of outlets to vary steam injection. The piston plug has first and second annular seals and is moved between different axial positions in a stepwise fashion such that when one or more rows of outlets are completely covered, the first annular seal is located in between adjacent rows and the second annular seal abuts against the diffuser to inhibit passage of steam so as to prevent cavitation. The DSI heater can include various other features, such as particular seal unit constructions and diffuser outlet configurations.

Abstract: Techniques described herein relate to producing bitumen while monitoring various aspects of paraffinic froth treatment (PFT) operations using near infrared (NIR) spectrometry and chemometric analysis to continuously monitor and enable measurements of physical and chemical properties of various streams in PFT operations, which can be done in real time online and can facilitate process control. NIR spectrometry can be used to acquire NIR spectra measurements from a PFT process stream and the NIR spectra measurements and chemometric analysis can, in turn, be used to determine composition characteristics of the PFT process stream as well as operational features of a PFT process unit. For example, NIR spectra can be used to determine upward velocity in a PFT settler to facilitate settler operation for diluted bitumen quality control. NIR spectra can be obtained using reflectance or transmission probes which can be positioned within particular phase of a stratified PFT process stream.

Abstract: Techniques are described for producing a bitumen product and recovering solvent from a solvent-diluted heavy hydrocarbon stream, which can have configurations and operation of an indirect heat exchanger to enhance performance. The system can have three solvent recovery stages. The indirect heat exchanger can have a location and operation to mitigate risks associated with exchanger failures. The solvent-diluted hydrocarbon stream can be preheated with a downstream solvent-depleted stream, and the pressure of the latter can be higher than that of the former to avoid solvent leaking into the hydrocarbon-enriched stream. The heat exchanger can be located in between the second and third stages, so that solvent leaked into the second stage output can be removed in the third stage so that the final product hydrocarbon stream can remain at low solvent contents.

Abstract: Production of bitumen from bitumen froth can include separating the froth into a solvent diluted tailings and solvent diluted bitumen, and then the diluted tailings can be treated to recover solvent for reuse in the froth separation. The solvent recovery from tailings can employ a distributor for use in a tailings solvent recovery unit (TSRU). The distributor can include slot-shaped pressure let-down apertures and a closed curved end portion to introduce the tailings into a separation vessel. The distributor construction can have various advantages, such as facilitating manufacturing as well as effective mitigation of pre-flashing and solids segregation issues, for enhanced bitumen production and solvent recovery operations.

Abstract: A tailings solvent recovery unit (TSRU) recovers a solvent from a solvent diluted tailings and includes a separation apparatus which has a flash vessel, tailings outlet, solvent outlet and an inlet spray system for supplying the diluted tailings to the flash vessel. The spray nozzle system may include multiple nozzles arranged around the periphery of the flash vessel for flash-atomization over its cross-section of the flashing chamber, a nozzle sized and configured to provide choked flow of the diluted tailings, multiple nozzles each being operable in an on/off mode to regulate a total feed flow, or multiple nozzles associated with a distributor and multiple feed conduits.

Abstract: A process for operating a bitumen froth treatment operation in turndown mode includes adding solvent to bitumen froth to produce diluted bitumen froth and separating it into diluted bitumen and solvent diluted tailings and in response to a reduction in bitumen froth flow recirculating part of the diluted bitumen into the bitumen froth and returning part of the solvent diluted tailings into the step of separating. A method for turndown of separation vessel for PFT includes sustaining the feed flow to vessel; maintaining solvent-to-bitumen ratio in the diluted bitumen froth; and retaining water, minerals and asphaltenes in a lower section of the vessel while sustaining an outlet flow. The use of diluted bitumen derived from PFT as a viscosity modifying agent of the bitumen froth and an associated process are also provided.

Abstract: A paraffinic solvent recovery process for treating high paraffin diluted bitumen includes supplying the latter to flashing apparatus; separating into flashed paraffinic solvent and diluted bitumen underflow; and returning a portion of the underflow as returned diluted bitumen into the high paraffin diluted bitumen prior to introduction into the flashing apparatus, at temperature and amount to shift asphaltene precipitation equilibrium to reduce asphaltene precipitation. The process includes pre-heating the high paraffin diluted bitumen by transferring heat from hot dry bitumen, flashed paraffinic solvent and/or a portion of diluted bitumen underflow. Flashed paraffinic solvent may contain residual light end bitumen contaminants that increase asphaltenes solubility and the process may include removing contaminants to produce reusable paraffinic solvent at given solvent-to-bitumen ratio range to maintain given asphaltene precipitation.

Abstract: The field of the invention is oil sands processing. A solvent treatment system and process for treating a bitumen-containing stream include contacting that stream with a solvent-containing stream to produce an in-line flow of solvent diluted material; supplying the solvent diluted material into a separation vessel with axi-symmetric phase and velocity distribution and/or particular mixing and conditioning features. The solvent addition, mixing and conditioning may be performed with particular Co V, Camp number, co-annular pipeline reactor, pipe wall contact of low viscosity fluid, flow diffusing and/or flow straightening. The processes enable improved performance of downstream unit operations such as separation of high diluted bitumen from solvent diluted tailings.

Abstract: A solvent diluted bitumen is produced by a method that includes adding paraffinic solvent to bitumen froth to form a solvent diluted bitumen froth, and discharging the solvent diluted bitumen froth into a vessel, such that settlement of the solvent diluted bitumen froth in the interior of the vessel establishes a heavier phase zone, a lighter phase zone, and an interface. A discharge point is located above the interface and within the lighter phase zone. Lighter phases separate up toward an overflow outlet of the vessel while heavier phases separate down toward an underflow outlet of the vessel. The solvent diluted bitumen is collected from the overflow outlet, and a solvent diluted underflow stream is collected from the underflow outlet.

Abstract: In the field of oil sands processing, a process for heating an oil sands slurry stream such as bitumen froth containing bitumen and water and having variable heating requirements includes injecting steam directly into the froth at a steam pressure through a plurality of nozzles to achieve sonic steam flow; operating the plurality of the nozzles to vary steam injection by varying a number of the nozzles through which the injecting of the steam occurs in response to the variable heating requirements; and subjecting the oil sands slurry stream to backpressure sufficient to enable sub-cooling relative to the boiling point of water. A corresponding system is also provided.

Abstract: An apparatus and method for separating a feed such as bitumen froth feed are provided. The apparatus comprises a vessel having a top, side walls, and a base. An inlet delivers feed to the vessel interior whereby settling of the feed establishes a heavier phase zone in the vicinity of the base and a lighter phase zone above an interface with the heavier phase zone. The height/diameter ratio of the vessel, the dimensions and position of the inlet and the fluid properties of the feed are selected to allow a feed velocity of the feed discharging from the inlet into the interior to dissipate in the lighter phase zone as the discharged feed entrains lighter phases above the interface and spreads across the vessel interior such that the lighter phases of the feed separate up to an overflow outlet and the heavier phases separate down to an underflow outlet.

Abstract: A TSRU for recovering solvent from solvent diluted tailings includes a separation apparatus receiving the tailings and producing solvent and solvent recovered tailings. The separation apparatus includes a vessel, a tailings outlet, a solvent outlet, a tailings inlet for supplying a variable flow of the tailings to the vessel and a tailings recycle line connected to the tailings inlet for recycling part of the solvent recovered tailings into the variable flow of the diluted tailings to produce a flow rate controlled feed for introduction into the vessel. A tailings solvent recovery process includes separating the diluted tailings into recovered solvent and solvent recovered tailings, discharging the solvent recovered tailings, and recycling a portion of the solvent recovered tailings back into the variable flow of the diluted tailings. A method of controlling feed flow rate to a tailings solvent recovery vessel is also provided.

Abstract: A paraffinic solvent recovery process for treating high paraffin diluted bitumen includes supplying the latter to flashing apparatus; separating into flashed paraffinic solvent and diluted bitumen underflow; and returning a portion of the underflow as returned diluted bitumen into the high paraffin diluted bitumen prior to introduction into the flashing apparatus, at temperature and amount to shift asphaltene precipitation equilibrium to reduce asphaltene precipitation. The process includes pre-heating the high paraffin diluted bitumen by transferring heat from hot dry bitumen, flashed paraffinic solvent and/or a portion of diluted bitumen underflow. Flashed paraffinic solvent may contain residual light end bitumen contaminants that increase asphaltenes solubility and the process may include removing contaminants to produce reusable paraffinic solvent at given solvent-to-bitumen ratio range to maintain given asphaltene precipitation.

Abstract: More particularly, the model was a dynamic simulation built in HYSYS™ v7.1. The component slate was simplified and selected to give a vapor and two liquid phases, and have the ability to measure an S/B ratio. All the unit operations were included and modeled as best fit within HYSYS™. Pumps were all modelled as standard HYSYS™ centrifugal pumps with performance curves, settlers were modelled as vertical 3-phase vessels with internal weir enabled—the overflow side of the weir is used to simulate the overflow vessels on the settlers. All proposed controllers were included with generic tuning parameters, which control the system process variable (PV) to match a set point (SP). The control algorithm incorporated master PV controllers such as S/B ratio to relate froth and solvent flows and maintain relative material balance relationship between the process streams involved.

Abstract: A paraffinic solvent recovery process for treating high paraffin diluted bitumen includes supplying the latter to flashing apparatus; separating into flashed paraffinic solvent and diluted bitumen underflow; and returning a portion of the underflow as returned diluted bitumen into the high paraffin diluted bitumen prior to introduction into the flashing apparatus, at temperature and amount to shift asphaltene precipitation equilibrium to reduce asphaltene precipitation. The process includes pre-heating the high paraffin diluted bitumen by transferring heat from hot dry bitumen, flashed paraffinic solvent and/or a portion of diluted bitumen underflow. Flashed paraffinic solvent may contain residual light end bitumen contaminants that increase asphaltenes solubility and the process may include removing contaminants to produce reusable paraffinic solvent at given solvent-to-bitumen ratio range to maintain given asphaltene precipitation.

Abstract: A process for regionalization of mining bitumen-containing oil sands ore for extraction and conversion to produce dry bitumen comprises operating multiple separate oil sands ore mining and extraction facilities or in situ thermal recovery facilities, to produce separate bitumen froth streams; operating a regional paraffinic froth treatment (PFT) hub for receiving a portion of each of the separate bitumen froth streams and treating the bitumen froth streams to produce the dry bitumen; optionally providing a portion of the dry bitumen stream to the bitumen upgrading facility and another portion of the dry bitumen stream to a bitumen market pipeline or remote upgrading facility; and optionally comprising regionalization of water distribution where by-product waters are recovered from the PFT hub and the upgrading facilities and distributed to the mining and extraction facilities for use as extraction processing water to produce the bitumen froth streams.