Abstract: A system and process for recovering heat from a bitumen froth treatment plant use a sealed closed-loop heat transfer circuit. The system has a heat removal exchanger associated with the plant and receiving hot froth treatment process stream; heat recovery exchanger; the circuit; and an oil sands process fluid line. The circuit includes piping circulating heat exchange media having uncontaminated and low fouling properties. The piping includes a supply line to the heat removal exchanger and a return line for providing heated media to the recovery exchanger. The circuit has a pump for pressurizing the heat exchange media; a pressure regulator for regulating pressure of the media. The pump and the pressure maintain the media under pressure in liquid phase. The oil sands process fluid is heated producing a cooled media for reuse in the heat removal exchanger. High and low temperature heat removal exchangers can be used.

Abstract: A system and process for recovering heat from a bitumen froth treatment plant use a sealed closed-loop heat transfer circuit. The system has a heat removal exchanger associated with the plant and receiving hot froth treatment process stream; heat recovery exchanger; the circuit; and an oil sands process fluid line. The circuit includes piping circulating heat exchange media having uncontaminated and low fouling properties. The piping includes a supply line to the heat removal exchanger and a return line for providing heated media to the recovery exchanger. The circuit has a pump for pressurizing the heat exchange media; a pressure regulator for regulating pressure of the media. The pump and the pressure maintain the media under pressure in liquid phase. The oil sands process fluid is heated producing a cooled media for reuse in the heat removal exchanger. High and low temperature heat removal exchangers can be used.

Abstract: A method for controlling fouling of a settler vessel overflow system comprises maintaining at least a minimum stream flow in the overflow system by recirculating a portion of the overflow stream. A system for performing the method is also disclosed.

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: 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 heat and water integration process for an oil sands operation includes subjecting warm oil sands tailings to thickening to produce thickened tailings and warm water overflow; subjecting the warm water overflow to direct steam injection (DSI) to produce steam heated thickener water; providing the steam heated thickener water to a unit of the oil sand operation; and producing the warm oil sands tailings from the oil sands operation. The oil sand operation unit may be an oil sand ore preparation unit and/or a primary separation unit, for example. The heated thickener water can replace water taken from pond inventories. The DSI may use excess, low quality, wet, low pressure and/or blow-down steam. The process enables improved heat and water usage in oil sands processing.

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: 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: 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 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 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.

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: Processes and apparatus for the treatment of product streams from mineral processing operations, including the treatment of tailings which result from oil sand processing operations. The processes and apparatus relate to the recovery of a diluent solvent from bitumen froth tailings and to the thickening of tailings from a bitumen froth stream and a middlings stream resulting from an oil sand extraction process. In one aspect the processes and apparatus relate particularly to the recycling of product streams to maximize process efficiencies. In a second aspect the processes and apparatus relate particularly to the thickening of tailings to produce an underflow component, a clarified overflow component and an unclarified overflow component.