Abstract: A process for extracting bitumen from mined oil sand is provided, comprising: preparing an oil sand slurry comprising oil sand and water; conditioning the oil sand slurry by pumping the oil sand slurry through a hydrotransport pipeline under shear conditions that reduce the formation of water-in-bitumen emulsions in the conditioned oil sand slurry and increase the size of bitumen-air aggregates; and subjecting the conditioned oil sand slurry to gravity separation to produce a bitumen froth having enhanced bitumen recovery and reduced water-in-bitumen emulsions, a middlings layer and sand tailings.

Abstract: A method for processing bitumen froth to produce a diluted bitumen product having a reduced water and solids content is provided, comprising: adding a sufficient amount of water to the bitumen froth and mixing the bitumen froth and water to form a froth/water mixture; diluting the froth/water mixture with naphtha to form a diluted froth; and separating the water and solids from the diluted froth to produce the diluted bitumen product.

Abstract: A process for extracting bitumen from mined oil sand is provided, comprising: preparing an oil sand slurry comprising oil sand and water; conditioning the oil sand slurry by pumping the oil sand slurry through a hydrotransport pipeline under shear conditions that reduce the formation of water-in-bitumen emulsions in the conditioned oil sand slurry and increase the size of bitumen-air aggregates; and subjecting the conditioned oil sand slurry to gravity separation to produce a bitumen froth having enhanced bitumen recovery and reduced water-in-bitumen emulsions, a middlings layer and sand tailings.

Abstract: A method for processing bitumen froth to produce a diluted bitumen product having a reduced water and solids content is provided, comprising: adding a sufficient amount of water to the bitumen froth and mixing the bitumen froth and water to form a froth/water mixture; diluting the froth/water mixture with naphtha to form a diluted froth; and separating the water and solids from the diluted froth to produce the diluted bitumen product.

Abstract: A process for extracting bitumen from weathered oil sand ore is provided, comprising mixing the weathered oil sand ore with heated water and sodium triphosphate to form a weathered oil sand slurry; adding sodium triphosphate to either the weathered oil sand ore, the heated water, or to the weathered oil sand slurry; conditioning the weathered oil sand slurry at a temperature of at least 50° C. to form a conditioned weathered oil sand slurry; and subjecting the conditioned weathered oil sand slurry to gravity separation at a temperature of at least 50° C. to form a bitumen froth product.

Abstract: A process for operating multiple oil sand mine sites for extracting bitumen from oil sand is disclosed, comprising preparing a first conditioned oil sand slurry at a first location using a first oil sand slurry preparation and slurry conditioning process; preparing a second conditioned oil sand slurry at a second location using a second oil sand slurry preparation and slurry conditioning process; combining the first conditioned oil sand slurry and the second conditioned oil sand slurry in at least one slurry distributor to produce a combined oil sand slurry; and distributing the combined oil sand slurry to at least one separation vessel to produce bitumen froth.

Abstract: A process for operating multiple oil sand mine sites for extracting bitumen from oil sand is disclosed, comprising preparing a first conditioned oil sand slurry at a first location using a first oil sand slurry preparation and slurry conditioning process; preparing a second conditioned oil sand slurry at a second location using a second oil sand slurry preparation and slurry conditioning process; combining the first conditioned oil sand slurry and the second conditioned oil sand slurry in at least one slurry distributor to produce a combined oil sand slurry; and distributing the combined oil sand slurry to at least one separation vessel to produce bitumen froth.

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: A process for enhancing the froth quality, improving vessel operability and increasing the froth temperature from an oil sand slurry in a primary separation vessel is provided, comprising introducing the oil sand slurry into a separation vessel; retaining the oil sand slurry within the separation vessel so that separate layers of bitumen froth, middlings and sand tailings are formed; introducing sufficient heated water having a temperature greater than about 80° C. as an evenly distributed underwash layer beneath the bitumen froth layer; and separately removing the bitumen froth, middlings and sand tailings from the separation vessel.

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 cleaning bitumen froth by mixing a sufficient amount of naphtha with the bitumen froth to provide a naphtha-to-bitumen ratio within the range of about 4.0 (w/w) to about 10.0 (w/w) and separating substantially dry diluted bitumen from the water and solids. Also provided is a process for cleaning diluted bitumen by mixing a sufficient amount of naphtha with the diluted bitumen to provide a naphtha-to-bitumen ratio equal to or greater than about 1.8 (w/w) and separating marketable fungible raw bitumen from the water and solids.

Abstract: A process for enhancing the froth quality, improving vessel operability and increasing the froth temperature from an oil sand slurry in a primary separation vessel is provided, comprising introducing the oil sand slurry into a separation vessel; retaining the oil sand slurry within the separation vessel so that separate layers of bitumen froth, middlings and sand tailings are formed; introducing sufficient heated water having a temperature greater than about 80° C. as an evenly distributed underwash layer beneath the bitumen froth layer; and separately removing the bitumen froth, middlings and sand tailings from the separation vessel.

Abstract: The invention is directed to a process for cleaning bitumen froth by mixing a sufficient amount of naphtha with the bitumen froth to provide a naphtha-to-bitumen ratio within the range of about 4.0 (w/w) to about 10.0 (w/w) and separating substantially dry diluted bitumen from the water and solids. Also provided is a process for cleaning diluted bitumen by mixing a sufficient amount of naphtha with the diluted bitumen to provide a naphtha-to-bitumen ratio equal to or greater than about 1.8 (w/w) and separating marketable fungible raw bitumen from the water and solids.

Abstract: A method for processing a bitumen froth comprising bitumen, water and solids including fine solids for reducing the solids concentration in diluted bitumen is provided comprising diluting the bitumen froth with a hydrocarbon diluent to form a dilfroth; adding a sufficient amount of a silicate to the dilfroth to cause a substantial amount of fine solids to associate with the water instead of the diluted bitumen; and allowing the diluted bitumen to separate from the water containing the substantial amount of fine solids to produce a dilbit having less than 3 percent by weight solids.