Abstract: A method of increasing a dwell time of a slurry facility at a given ore processing location by using a mobile oil sands mining system. The method involves coordinating the operation of at least two mining conveyors to facilitate mining at least one arc-shaped sector of ore that otherwise would not be within operational reach of the slurry facility at the ore processing location. The method increases the slurry facility's operational time at the ore processing location before relocation thereof is required to keep the slurry facility within operational reach of at least one receding mine face.

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: An extraction system and process for extracting bitumen from a slurry containing bitumen, solids and water. The system comprises a cyclone separation facility for separating the slurry into a solids component stream and a bitumen froth stream with the bitumen froth stream including water and fine solids. The bitumen froth stream is then delivered to a froth concentration facility for separating the bitumen froth stream into a final bitumen enriched froth stream, and a water and fine solids stream. The final bitumen enriched froth stream is suitable for further processing. The system of the present invention is preferably mobile so that the cyclone extraction facility and the froth concentration facility can move with the mine face at an oil sands mining site, however, it is also contemplated that the system can be retrofitted to existing fixed treatment facilities to improve the operational efficiency of such fixed facilities.

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: A slurry apparatus for creating a slurry from oil sand ore has a frame and a slurry box supported by the frame. Water is mixed with the ore to form a slurry that is retained in the slurry box. The slurry apparatus may include a screen disposed at an angle relative to the horizontal over an open top of the slurry box and configured to permit sized ore to fall through the screen into the slurry box. The apparatus may include at least one crushing device cooperating with the screen to facilitate creating the slurry. A related method and system for creating a slurry may also be provided.

Abstract: A mobile slurry apparatus for creating a slurry from oil sand ore has a frame and a slurry box supported by the frame. Water is mixed with the ore to form a slurry that is retained in the slurry box. The frame base has a first set of spaced apart support points for supporting the frame in a stationary mode, and a second set of spaced apart support points for supporting the frame in a moving mode. The second set of spaced apart support points is closer together than the first set of support points and defines a lifting region disposed beneath a center of gravity of the slurry apparatus in a moving mode when the slurry box is empty. Thus, a single moving device can be positioned beneath the second set of support points for lifting and moving the slurry apparatus.

Abstract: An extraction system and process for extracting bitumen from a slurry containing bitumen, solids and water. The system comprises a cyclone separation facility for separating the slurry into a solids component stream and a bitumen froth stream with the bitumen froth stream including water and fine solids. The bitumen froth stream is then delivered to a froth concentration facility for separating the bitumen froth stream into a final bitumen enriched froth stream, and a water and fine solids stream. The final bitumen enriched froth stream is suitable for further processing. The system of the present invention is preferably mobile so that the cyclone extraction facility and the froth concentration facility can move with the mine face at an oil sands mining site, however, it is also contemplated that the system can be retrofitted to existing fixed treatment facilities to improve the operational efficiency of such fixed facilities.

Abstract: An extraction system and process for extracting bitumen from a slurry containing bitumen, solids and water. The system comprises a cyclone separation facility for separating the slurry into a solids component stream and a bitumen froth stream with the bitumen froth stream including water and fine solids. The bitumen froth stream is then delivered to a froth concentration facility for separating the bitumen froth stream into a final bitumen enriched froth stream, and a water and fine solids stream. The final bitumen enriched froth stream is suitable for further processing. The system of the present invention is preferably mobile so that the cyclone extraction facility and the froth concentration facility can move with the mine face at an oil sands mining site, however, it is also contemplated that the system can be retrofitted to existing fixed treatment facilities to improve the operational efficiency of such fixed facilities.

Abstract: A method of increasing a dwell time of a slurry facility at a given ore processing location by using a mobile oil sands mining system. The method involves coordinating the operation of at least two mining conveyors to facilitate mining at least one arc-shaped sector of ore that otherwise would not be within operational reach of the slurry facility at the ore processing location. The method increases the slurry facility's operational time at the ore processing location before relocation thereof is required to keep the slurry facility within operational reach of at least one receding mine face.

Abstract: An extraction system and process for extracting bitumen from a slurry containing bitumen, solids and water. The system comprises a cyclone separation facility for separating the slurry into a solids component stream and a bitumen froth stream with the bitumen froth stream including water and fine solids. The bitumen froth stream is then delivered to a froth concentration facility for separating the bitumen froth stream into a final bitumen enriched froth stream, and a water and fine solids stream. The final bitumen enriched froth stream is suitable for further processing. The system of the present invention is preferably mobile so that the cyclone extraction facility and the froth concentration facility can move with the mine face at an oil sands mining site, however, it is also contemplated that the system can be retrofitted to existing fixed treatment facilities to improve the operational efficiency of such fixed facilities.

Abstract: A process line for excavating and processing oil sands ore near a mine face. A mobile excavator excavates ore along the length of a mobile mining conveyor. A mobile comminutor receives and comminutes the excavated ore and transfers the comminuted ore to the mobile mining conveyor. The mobile mining conveyor conveys the comminuted ore to a transfer conveyor that conveys the comminuted ore to a mobile slurry facility. The mobile slurry facility combines the comminuted ore with process water to produce a slurry and pumps and conditions the slurry through a hydro-transport pipeline to a mobile extraction facility as a slurry feed. The mobile extraction facility receives the slurry feed and directs the slurry feed and a water stream as inputs to a three stage countercurrent cyclone separator. The cyclone separator produces a bitumen rich stream and a tailings stream.

Abstract: A relocatable oil sand slurry preparation system is provided for preparing an aqueous oil sand slurry amenable to pipeline conveyance while producing minimum overall rejects, comprising (a) a relocatable rotary digester for slurrying oil sand and water and digesting oil sand lumps to form a pumpable slurry, the rotary digester having a feed end for receiving oil sand and water, a slurrying chamber comprising a plurality of lifters for slurrying the oil sand and water, and a trommel screen end for screening out oversize rejects from the oil sand slurry which falls through the trommel screen; and (b) a relocatable rejects recirculation unit operably associated with the rotary digester for receiving oversize rejects and delivering the rejects back to the rotary digester for further digestion. In a preferred body, relocatable oil sand slurry preparation system further comprises a rejects crusher for crushing oversize rejects prior to delivering rejects back to the rotary digester.

Abstract: A mobile slurry apparatus for creating a slurry from oil sand ore has a frame and a slurry box supported by the frame. Water is mixed with the ore to form a slurry that is retained in the slurry box. The frame base has a first set of spaced apart support points for supporting the frame in a stationary mode, and a second set of spaced apart support points for supporting the frame in a moving mode. The second set of spaced apart support points is closer together than the first set of support points and defines a lifting region disposed beneath a center of gravity of the slurry apparatus in a moving mode when the slurry box is empty. Thus, a single moving device can be positioned beneath the second set of support points for lifting and moving the slurry apparatus.

Abstract: A mobile slurry apparatus for creating a slurry from oil sand ore has a frame and a slurry box supported by the frame. Water is mixed with the ore to form a slurry that is retained in the slurry box. The frame base has a first set of spaced apart support points for supporting the frame in a stationary mode, and a second set of spaced apart support points for supporting the frame in a moving mode. The second set of spaced apart support points is closer together than the first set of support points and defines a lifting region disposed beneath a centre of gravity of the slurry apparatus in a moving mode when the slurry box is empty. Thus, a single moving device can be positioned beneath the second set of support points for lifting and moving the slurry apparatus.

Abstract: An extraction system and process for extracting bitumen from a slurry containing bitumen, solids and water. The system comprises a cyclone separation facility for separating the slurry into a solids component stream and a bitumen froth stream with the bitumen froth stream including water and fine solids. The bitumen froth stream is then delivered to a froth concentration facility for separating the bitumen froth stream into a final bitumen enriched froth stream, and a water and fine solids stream. The final bitumen enriched froth stream is suitable for further processing. The system of the present invention is preferably mobile so that the cyclone extraction facility and the froth concentration facility can move with the mine face at an oil sands mining site, however, it is also contemplated that the system can be retrofitted to existing fixed treatment facilities to improve the operational efficiency of such fixed facilities.

Abstract: A relocatable oil sand slurry preparation system is provided for preparing an aqueous oil sand slurry amenable to pipeline conveyance while producing minimum overall rejects, comprising (a) a relocatable rotary digester for slurrying oil sand and water and digesting oil sand lumps to form a pumpable slurry, the rotary digester having a feed end for receiving oil sand and water, a slurrying chamber comprising a plurality of lifters for slurrying the oil sand and water, and a trommel screen end for screening out oversize rejects from the oil sand slurry which falls through the trommel screen; and (b) a relocatable rejects recirculation unit operably associated with the rotary digester for receiving oversize rejects and delivering the rejects back to the rotary digester for further digestion. In a preferred body, relocatable oil sand slurry preparation system further comprises a rejects crusher for crushing oversize rejects prior to delivering rejects back to the rotary digester.