Abstract: A method is provided for producing a marketable bitumen product having low solids and essentially no water. The method can be integrated into existing solvent extraction processes for extracting bitumen from mined oil sand. A high-solids diluted bitumen is produced from a solvent extraction process and then mixed with a light solvent (LS) stream in at least a first mixer to produce a diluted bitumen-LS mixture. The diluted bitumen-LS mixture is subjected to separation in at least a first separator to produce low-solids diluted bitumen and high-solids asphaltene-rich tails. The LS is removed from the low-solids diluted bitumen to produce the marketable bitumen product.

Abstract: A conduit having an interior surface and an exterior surface and having a length (x) and an interior circumference (y) is provided, comprising: an interior liner for lining the interior surface of the conduit; and at least two independent continuity wires embedded into the interior liner, each continuity wire extending substantially the length of the conduit and each continuity wire being capable of being monitored independently; whereby each continuity wire is configured to span a portion of the conduit's interior circumference without overlapping with another continuity wire.

Abstract: A method of improving the quality of diluted bitumen product in a bitumen froth treatment process is provided comprising: adding a demulsifier to bitumen froth to produce a mixture of bitumen froth and demulsifier, wherein the demulsifier is added at a dosage sufficient to reduce bitumen water content in the diluted bitumen product; subjecting the mixture of bitumen froth and demulsifier to a mixing energy input of greater than about 100 J/kg; adding a hydrocarbon diluent to the mixed mixture of bitumen froth and demulsifier to produce a diluent diluted bitumen froth; and subjecting the diluent diluted bitumen froth to a separation process to produce the diluted bitumen product. In one embodiment, demulsifier is first added to naphtha to form a demulsifier-diluent mixture which is then added to bitumen froth to form a diluted bitumen froth prior to subjecting the diluted bitumen froth to a mixing energy input of greater than about 100 J/kg.

Abstract: The invention is directed to a process for removing ammonia from mine depressurization water involving introducing the water into a tank or collection pond; injecting a sufficient amount of an oxidizing gas into the water to yield aerated water; and holding the aerated water within the tank or collection pond for a pre-determined residence time to perform air-stripping on the aerated water to facilitate the volatilization of ammonia; nitrification to convert ammonia into nitrate and nitrite; or both.

Abstract: The invention is directed to a process for extracting bitumen from poor oil sand ore involving mixing the poor oil sand ore with heated water to produce a slurry, and conditioning the slurry to yield a poor ore stream. In a separate train, good oil sand ore is mixed with heated water to produce a slurry, and conditioned to yield a good ore stream. Both the conditioned poor ore and good ore streams are combined in specified proportions to yield a blended slurry which is then fed to a primary separation vessel to produce primary bitumen froth.

Abstract: A method for reducing rag layer volume in a stationary bitumen froth treatment process is provided, comprising subjecting dilfroth having a naphtha diluent to bitumen ratio of about 0.7 to gravity settling in a splitter vessel to produce an overflow stream of raw dilbit and an underflow stream of splitter tails; mixing the splitter tails with a naphtha diluent to give a mixture having a naphtha diluent to bitumen ratio of less than about 6:1 in a scrubber feed tank; and subjecting the mixture to gravity settling and agitation in a scrubber vessel to produce an overhead stream of scrubber hydrocarbons and an underflow stream of scrubber tails.

Abstract: The invention is directed to a process for separating bitumen froth into an upper bitumen-rich, reduced-solids layer, and a lower concentrated solids layer using a cone-bottomed, raked froth tank. The process involves introducing bitumen froth into the froth tank; rotating at least one movable picket through the bitumen froth; recovering the upper bitumen-rich, reduced-solids layer; and withdrawing the lower concentrated solids layer from the tank.

Abstract: A method for extracting hydrocarbons from a poor processing bitumen froth is provided comprising subjecting a bitumen, solids and water slurry to flotation in a flotation device to produce the poor processing bitumen froth; optionally subjecting the poor processing bitumen froth to centrifugation to remove a portion of the water from the poor processing bitumen froth; and subjecting the poor processing bitumen froth to supercritical extraction in a pressure vessel using a supercritical fluid to produce a hydrocarbon stream suitable for further upgrading.

Abstract: A process of extracting bitumen from oil sand ores having a fines content up to about 60% and a bitumen content higher than about 6% is provided, comprising: determining a dosage (wt %) of caustic necessary to yield a desired primary bitumen recovery; determining an amount of caustic (wt %) and an amount of sodium triphosphate (wt %) which yields substantially the same desired primary bitumen recovery or greater as the dosage of caustic (wt %) alone; mixing the oil sand ore with heated water to produce an oil sand slurry; and adding the amounts of caustic (wt %) and sodium triphosphate (wt %) before, during or after mixing the oil sand ore with heated water to condition the oil sand slurry and to improve bitumen recovery from the oil sand ore; whereby the sum of the amounts of caustic (wt %) and sodium triphosphate (wt %) is substantially equal to the dosage of caustic (wt %) alone.

Abstract: In one aspect, a method for manufacturing a part for a centrifugal slurry pump is provided, comprising: forming a skeleton of the part having an outer dimension smaller than the part; placing the skeleton of the part in a metal enclosure having an interior dimension larger than the outer dimension of the skeleton of the part and thereby forming a space; adding a metal matrix composite powder into the metal enclosure to fill the space; and subjecting the metal enclosure to hot isostatic pressing, thereby allowing bonding of the metal matrix composite to the skeleton of the part to form the part.

Abstract: A process of extracting bitumen from oil sand ores having a fines content up to about 60% and a bitumen content greater than 6% is provided, comprising: determining the fines content and the bitumen content of the oil sand ore; calculating a sufficient amount of caustic to be added in the process using an equation based on the ratio of the fines content to the bitumen content; mixing the oil sand ore with heated water to produce an oil sand slurry; and adding the sufficient amount of caustic before, during or after mixing the oil sand ore with heated water to condition the oil sand slurry and to improve bitumen recovery from the oil sand ore.

Abstract: A improved impeller for use in a centrifugal slurry pump is provided, comprising: a top shroud; a bottom shroud; and a middle portion therebetween, said middle portion having at least one substantially vertical wall defining a slurry flow channel, wherein the top shroud, bottom shroud and middle portion are configured as one piece to together define a first unitary body; at least one vane nose positioned at a leading edge of the at least one substantially vertical wall; and, optionally, a retaining ring mounted over the top shroud to secure the vane nose within the body.

Abstract: A process of dewatering tailings is provided comprising providing overburden having a moisture content ranging from about 15 wt % to about 25 wt % and comminuting the overburden to a first size; providing tailings having a solids content ranging from about 10 wt % to about 60 wt %; adding the tailings to the first sized overburden to form treated overburden and comminuting the treated overburden to a second size; and depositing the second sized treated overburden to produce a solidified deposit.

Abstract: A process for reducing segregation of mining tailings while being deposited below the surface of a column of fluid is provided which comprises introducing the mining tailings into a downpipe having an inlet at or near the surface of the column of fluid and an outlet submerged in the column of fluid; providing at least one pressure drop element in the downpipe to prevent acceleration of the mining tailings and maintain the tailings flow therethrough; and providing a diffusing device at the outlet of the downpipe to reduce the velocity of the mining tailings as the tailings are discharged therefrom.

Abstract: A process for the disposal of oil sands tailings is provided, comprising: optionally diluting the tailings with sufficient water to yield a tailings feed having a solids content in the range of about 18 wt % to about 36 wt %; adding one or both of a coagulant and a flocculant to the tailings feed to form a centrifuge feed; centrifuging the centrifuge feed to produce a centrifuge cake having a solids content of at least about 50% and a centrate having a solids content of less than about 3 wt %; and introducing the centrifuge cake into an overburden containment structure comprised of oil sand overburden, said overburden containment structure comprising a least one trench for holding the centrifuge cake, or into a deep disposal site for additional dewatering of the centrifuge cake through self-weight consolidation and creep.

Abstract: A process for enhancing the solidification of tailings is provided comprising providing overburden having a moisture content ranging from about 15 wt % to about 25 wt % and comminuting the overburden to a first size; providing tailings having a solids content ranging from about 1 wt % to about 70 wt %; adding the tailings to the first sized overburden to form treated overburden and comminuting the treated overburden to a second size; and depositing the second sized treated overburden to produce a substantially solidified deposit.

Abstract: A process is provided for dewatering fluid fine tailings, comprising combining fluid fine tailings with fresh oil sands tailings to create a tailings mixture having a sand to fines ratio of about 1.0 to about 2.0; optionally diluting the tailings mixture with water to an optimal density; adding an aqueous polymeric flocculant to the tailings mixture and mixing the polymeric flocculant and tailings mixture to form a flocculated material; and transferring the flocculated material to a deposition cell for dewatering.

Abstract: A process for flocculating and dewatering oil sands fine tailings in a pipeline is provided, comprising: pumping a tailings feed having a solids content in the range of about 10 wt % to about 45 wt % through a pipeline; injecting an effective amount of a polymeric flocculant into the tailings feed to provide an initial quick dispersion of the polymeric flocculant into the tailings feed; and providing a subsequent conditioning environment to form flocs and release water without overshearing.

Abstract: A process of dewatering tailings such as fluid fine tailings from oil sand extraction is provided comprising mixing the tailings with a sufficient amount of an additive comprising at least one multivalent cation, each multivalent cation being in an amount ranging from about 0.125% to about 0.25% and higher, up to or greater than the solubility limit of the at least one multivalent cation, and depositing the resulting mixture into a containment area to yield a non-segregating, rapidly cracking and dewatering deposit for reclamation and recycle water which can optionally be used in an oil sand bitumen extraction process.

Abstract: A process of dewatering tailings is provided comprising mixing the tailings with a sufficient amount of an additive or a mixture thereof; depositing the resulting mixture into a disposal area; pumping water from the deposit to one or more sumps, and allowing the deposit to reach a sufficient strength; and removing remaining deposit water and rainfall through one or more of a network of ditches, a decant tower, or a plurality of dike drainage structures to yield a non-segregating deposit for reclamation.