Abstract: A method for extracting bitumen from an oil sand slurry involves limiting the size of rock and clay lumps in the slurry to a first size, conditioning the slurry in a pipeline, screening the slurry through a rotary screening apparatus to remove the lumps that are larger than a second size, and subjecting the slurry to gravity separation to separate the bitumen as a bitumen froth. A fastener assembly for securing a screen panel to a drum shell of a rotary screening apparatus includes an outer insert for insertion into an aperture of a drum shell, an inner insert for insertion through an aperture of the screen panel and into an inward facing pocket of the outer insert, and a bolt for securing together the outer and inner inserts. An insert for removable insertion into an aperture of a drum of a rotary screening apparatus defines a screening aperture.

Abstract: A feed diffuser for use in a rotating screen having drain holes is provided, comprising a flow chamber having an upstream end and a downstream end and defining a flow path for a slurry having solid material larger than the drain holes flowing between the upstream end and the downstream end; the flow chamber having an intermediate portion disposed between the upstream end and the downstream end; the intermediate portion having a first opening; the flow chamber having an inclined floor, the lowest point of the inclined floor being adjacent to the first opening; whereby the inclined floor is sufficiently inclined such that when the slurry flows down the flow path, the larger solid material is directed towards the first opening.

Abstract: A feed diffuser for use in a rotating screen having drain holes is provided, comprising a flow chamber having an upstream end and a downstream end and defining a flow path for a slurry having solid material larger than the drain holes flowing between the upstream end and the downstream end; the flow chamber having an intermediate portion disposed between the upstream end and the downstream end; the intermediate portion having a first opening; the flow chamber having an inclined floor, the lowest point of the inclined floor being adjacent to the first opening; whereby the inclined floor is sufficiently inclined such that when the slurry flows down the flow path, the larger solid material is directed towards the first opening.

Abstract: A process and process line for mining and blending a plurality of different grade oil sand ore is provided comprising forming an open stockyard for blending and stockpiling the different grades of oil sand ore, whereby the blending of the different grades of oil sand ore is managed by haul trucks dumping the different grades of oil sand ore at a dispatched coordinate either on the perimeter of the stockyard or in the stockyard pit.

Abstract: A slurry preparation tower is provided comprising an intake opening through which oil sand enters the slurry preparation tower; a first sizer device operative to comminute oil sand passing through the first sizer device to a first upper size threshold; a second sizer device operative to comminute oil sand passing through the second sizer device to a second upper size threshold, wherein the second upper size threshold is less than the first upper size threshold; a first solvent supply device for adding solvent to the oil sand prior to or during its comminution in the first sizer device; and a plurality of deflector plates positioned between the first sizer device and the second sizer device to assist in the mixing of the first comminuted oil sand and solvent.

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 line for use in an oil sands ore body mining operation is provided, which comprises: a semi-mobile crushing station for receiving as-mined oil sand ore and comminuting the oil sand ore to a first size; a semi-mobile compact slurry preparation unit for receiving the comminuted oil sand ore and mixing the oil sand ore with water to form an oil sand slurry; and a semi-mobile solids removal assembly for removing a portion of the coarse solids from the oil sand slurry prior to extracting from the slurry an enriched bitumen froth.

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 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 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 for separating from an oil sand slurry solids and bitumen is provided, comprising introducing the oil sand slurry into a separation zone comprising an upper zone and a lower zone; intercepting a settling path of the solids in the separation zone by bringing the solids into contact with at least one intercepting surface to direct the solids to the lower zone; and producing a reduced solids upper zone to allow the bitumen to rise through the upper zone with reduced hindrance from the solids.

Abstract: A system for forming an oil sand slurry from mined oil sand is provided, comprising a slurry preparation tower having an intake opening through which oil sand enters the slurry preparation tower, a first sizer device to comminute the oil sand passing through it, a second sizer device to further comminute the oil sand, and a pump box for receiving oil sand that has passed through the second sizer and feeding it to a pump; at least one conveyor, having a discharge end, for transporting mined oil sand to the slurry preparation tower; a metal detector for detecting a piece of metal in the mined oil sand and transmitting a signal; and a metal rejection device operative to, in response to the signal from the metal detector, reject a portion of oil sand containing the piece of metal before the portion of oil sand enters the slurry preparation tower.

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 system for forming an oil sand slurry from mined oil sand is provided, comprising a slurry preparation tower having an intake opening through which oil sand enters the slurry preparation tower, a first sizer device to comminute the oil sand passing through it, a second sizer device to further comminute the oil sand, and a pump box for receiving oil sand that has passed through the second sizer and feeding it to a pump; at least one conveyor, having a discharge end, for transporting mined oil sand to the slurry preparation tower; a metal detector for detecting a piece of metal in the mined oil sand and transmitting a signal; and a metal rejection device operative to, in response to the signal from the metal detector, reject a portion of oil sand containing the piece of metal before the portion of oil sand enters the slurry preparation tower.

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: 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: 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: As-mined oil sand is crushed to −5 inch by a sequentially arranged pair of double roll crushers. The crushed oil sand is fed into a hopper feeding a jet pump. Water or recycled slurry is fed under pressure as motive fluid to the jet pump. The motive fluid jet(s) produced internally by the jet pump are operative to fluidize the oil sand and the components of the slurry mix turbulently in the jet pump's tubular mixer. It is found that the slurry issuing from the jet pump is aerated and largely free of lumps.

Abstract: As-mined oil sand is crushed to −5 inch by a sequentially arranged pair of double roll crushers. The crushed oil sand is fed into a hopper feeding a jet pump. Water or recycled slurry is fed under pressure as motive fluid to the jet pump. The motive fluid jet(s) produced internally by the jet pump are operative to fluidize the oil sand and the components of the slurry mix turbulently in the jet pump's tubular mixer. It is found that the slurry issuing from the jet pump is aerated and largely free of lumps.