Abstract: A process for prolonging catalyst activity may comprise contacting heavy hydrocarbon feedstock, wherein the heavy hydrocarbon feedstock is essentially free of residue, and hydrogen with catalyst in a hydroprocessing unit operating at a pressure of greater than or equal to 100 bars. The process may further comprise performing hydrocracking, hydrodesulfurization, and hydrodenitrogenation in a single stage of the hydroprocessing unit to create a hydroprocessed effluent. The process may further comprise regenerating spent catalyst in a catalyst regeneration unit. Additionally, the process may further comprise passing regenerated catalyst back to the hydroprocessing unit without rejuvenating the spent catalyst.

Abstract: A method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream, a medium-light stream, a medium-heavy stream, and a heavy stream; passing the medium-heavy stream to a hydrocracker to produce a hydrocracked medium-heavy stream; passing the heavy stream to a delayed coker to produce a cracked heavy stream; and passing the medium-light stream, the hydrocracked medium-heavy stream, and the cracked heavy stream to a catalytic reformer to produce an aromatics stream.

Abstract: A method of hydroprocessing a hydrocarbon feed may comprise fractionating a hydrocarbon feed into “n” fractions, wherein “n” is at least 2; hydroprocessing an (n?1)th fraction of the hydrocarbon feed in an (n?1)th hydroprocessing reaction zone of a hydroprocessing unit, thereby producing an (n?1)th effluent The method may further comprise hydroprocessing the nth fraction and the (n?1)th effluent in an nth hydroprocessing reaction zone, thereby producing an nth effluent. The (n?1)th hydroprocessing reaction zone may be upstream of the nth hydroprocessing reaction zone. The (n?1)th fraction may have a greater boiling point range than the nth fraction. Hydrogen and the hydrocarbon feed may be in co-current flow in the hydroprocessing unit.

Abstract: Embodiments of the present disclosure are directed to a method of processing a hydrocarbon feed includes fractionating the hydrocarbon feed into a light stream and a heavy stream, hydrotreating the heavy stream to form a hydrotreated heavy stream, combining the light stream and the hydrotreated heavy stream to form a upgraded feed stream, and feeding the upgraded feed stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream may comprise hydrocarbons boiling at less than 343° C. and the heavy stream may comprise hydrocarbons boiling at greater than 343° C. The FCC reaction zone may be operated in a down-flow configuration and the FCC may be operated under high severity conditions.

Abstract: A process for upgrading a hydrocarbon feed includes contacting the hydrocarbon feed with hydrogen in the presence of a ring opening catalyst in a naphthene conversion unit, the contacting causing naphthenes in the hydrocarbon feed to react to produce a converted effluent comprising isoparaffins and normal paraffins. The process includes separating the converted effluent in a paraffin separation system to produce an isoparaffin-rich stream and an n-paraffin-rich stream. The process includes contacting the isoparaffin-rich stream with hydrogen in the presence of an isomerization catalyst in a reverse isomerization unit, the contacting causing isomerization to produce an isomerate comprising an equilibrium mixture of normal paraffins and isoparaffins. The process include separating the isomerate in the paraffin separation system to produce the isoparaffin-rich stream and the n-paraffin-rich stream, and passing the n-paraffin-rich stream to a steam cracker to produce a cracker effluent comprising olefins.

Abstract: A method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream, a middle stream and a heavy stream; hydrotreating the heavy stream to form a hydrotreated heavy stream; feeding the light stream to a first Fluid Catalytic Cracking (FCC) reaction zone; feeding the middle stream to a second FCC reaction zone; and feeding the hydrotreated heavy stream to a third Fluid Catalytic Cracking (FCC) reaction zone. The light stream may comprise hydrocarbons boiling at less than 200° C. The middle stream may comprise hydrocarbons boiling at from 200° C. to 370° C. The heavy stream may comprise hydrocarbons boiling at greater than greater than 370° C. Each of the first and second FCC reaction zones may operate under more severe operating conditions than the third FCC reaction zone.

Abstract: A method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream, a middle stream, and a heavy stream; hydrotreating the heavy stream to form a hydrotreated heavy stream; and feeding the light stream, middle stream, and the hydrotreated heavy stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream may be exposed to more severe FCC cracking conditions than the middle stream and the middle stream may be exposed to more severe FCC cracking conditions than the hydrotreated heavy stream, within the same FCC reaction zone. The single FCC reaction zone may be operated in a down-flow configuration and under high severity conditions.

Abstract: According to one embodiment of the present disclosure, a method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream, a middle stream, and a residue stream, hydrotreating the residue stream to form a hydrotreated residue stream; and feeding the light stream, middle stream, and the hydrotreated residue stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream and the hydrotreated residue streams may be exposed to more severe FCC cracking conditions than the middle stream, within the same FCC reaction zone. The single FCC reaction zone may be operated in a down-flow configuration and the single FCC reaction zone may be operated under high severity conditions.

Abstract: Embodiments of the present disclosure are directed to a method of processing a hydrocarbon feed includes fractionating the hydrocarbon feed into a light stream and a heavy stream, hydrotreating the heavy stream to form a hydrotreated heavy stream, combining the light stream and the hydrotreated heavy stream to form a upgraded feed stream, and feeding the upgraded feed stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream may comprise hydrocarbons boiling at less than 540° C. and the heavy stream may comprise hydrocarbons boiling at greater than 540° C. The FCC reaction zone may be operated in a down-flow configuration and the FCC may be operated under high severity conditions.

Abstract: A method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream and a heavy stream, where the light stream includes hydrocarbons boiling at less than 370° C., and the heavy stream includes hydrocarbons boiling at greater than greater than 370° C., hydrotreating the heavy stream to form a hydrotreated heavy stream, feeding the light stream to a first Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a light product stream which includes light olefins, and feeding the hydrotreated heavy stream to a second Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a heavy product stream which includes light olefins, where the first FCC reaction zone operates under more severe operating conditions than the second FCC reaction zone.

Abstract: According to one embodiment of the present disclosure, a method of processing a hydrocarbon feed includes fractionating the hydrocarbon feed into a light stream and a heavy stream; hydrotreating the heavy stream to form a hydrotreated heavy stream; feeding the light stream and the hydrotreated heavy stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream which includes light olefins. The light stream may be exposed to more severe FCC cracking conditions than the heavy stream, within the same FCC reaction zone. The single FCC reaction zone may be operated in a down-flow configuration and the FCC may be operated under high severity conditions. The light stream may include hydrocarbons boiling at less than 371° C. and the heavy stream may include hydrocarbons boiling at greater than 371° C.

Abstract: This disclosure relates to reaction container systems providing for headspace-based condensation, coalescing devices, and other features.

Abstract: Rotating elements receivable within an extractor trough of an extractor configured for non-aqueous extraction of bitumen from oil sands are described. The rotating element can include a shaft operatively couplable to a motor, and projections extending outwardly from the shaft and being removably secured thereto. The rotating element can also include a shaft mounting structure couplable to a shaft, comprising a shaft receiving hub configured for receiving the shaft therein. The rotation of the rotating element can provide digestion and extraction of bitumen from the oil sands while advancing solids in a downstream direction within the extractor trough, as solvent diluted bitumen flows in an upstream direction toward a liquid outlet. Methods for servicing a rotating element and for manufacturing a non-aqueous extraction (NAE) extractor are also provided.

Abstract: Separation of asphaltenes from residual oil is carried out with naphtha as solvent. In particular, straight run naphtha obtained from the same crude oil source as the residual oil feed is used as the solvent. The mixture of deasphalted oil and solvent is passed to a hydroprocessing zone, without typical separation and recycle of the solvent back to the solvent deasphalting unit. Asphalt is separated from the residual oil (residue from atmospheric or vacuum distillation); the mixture of deasphalted oil and naphtha solvent is passed to the hydroprocessing unit.

Abstract: A process for forming a deaerated oil sand slurry is provided comprising: providing a first vessel having an overhead space and a bottom space; delivering oil sand and a low vapor pressure hydrocarbon liquid into the overhead space and mixing the oil sand and hydrocarbon liquid to release air trapped in the oil sand and form the deaerated slurry; optionally adding an inert gas stream to the overhead space to displace the air released from the oil sand; and collecting the deaerated slurry in the bottom space to form a slurry layer to prevent gas exchange between the first vessel and downstream extraction equipment.

Abstract: Extracting and separating solid particulates from a drilling fluid includes combining a stream of drilling fluid containing solid particulates with a liquefied gas to form a mixture having a reduced viscosity and/or density. The mixture enters a centrifugal separator at a pressure sufficient to keep the liquefied gas in a liquid phase where rotational forces promote the separation of at least a portion of the solid particulates from the mixture. At least a portion of the solid particulates are removed to form a fluid stream having reduced solids content. In embodiments the liquefied gas can be selected from the group consisting of an inert gas, an alkane gas, an alkene gas, an alkyne gas, a noble gas, and combinations thereof. The liquefied gas can be removed from the fluid stream after the centrifugal separator and recycled back to be mixed with the stream of drilling fluid containing solid particulates.

Abstract: This disclosure describes systems, methods, and devices for phytochemical extraction. One example extraction system includes two solvent columns, a material column, and a dewaxing column. The solvent columns store and provide solvent for stripping target chemicals from plant material in the material column. The solvent mixed with target chemicals passes into the dewaxing column, where the target chemicals are separated from waxes and lipids. Cooling is applied to elements of the system by way of an open-loop CO2 refrigeration method. Solvent is moved from the solvent columns to the material column by creating a pressure differential between the two solvent columns.

Abstract: A cross-scale wide-spectrum particle size plugging formula granularity analysis method includes: performing a size classification on a plugging material of a plugging formula; obtaining a particle size distribution of the plugging material by performing procession on each particle plugging material via a laser granularity analysis method and an imaging granularity analysis method, according to difference sizes thereof; obtaining the particle size distribution of the plugging formula by a weighted summation way, according to a granularity interval and an addition of each particle plugging material.

Abstract: The invention relates to an emulsification device for continuously producing emulsions, nano-emulsions, and/or dispersions having a liquid crystalline structure, comprising a) at least one mixing system, b) at least one drive for the stirring element, and c) at least one delivery unit for each component or each component mixture.

Abstract: A liquid-liquid contact device includes: an internal casing surrounding an inner chamber for providing countercurrent contact between a light liquid and a heavy liquid; an external casing surrounding the internal casing so as to form an outer chamber around the internal casing; a light liquid introduction tube guiding the light liquid to the inner chamber; and a heavy liquid introduction tube guiding the heavy liquid to the inner chamber. The internal casing has an upper opening and a lower opening which opens at a location below the upper opening. The external casing has a heavy liquid discharge outlet through which the heavy liquid is allowed to be discharged from the outer chamber, and a light liquid discharge outlet which is disposed above the heavy liquid discharge outlet and through which the light liquid is allowed to be discharged from the outer chamber.

Abstract: Many embodiments described herein facilitate continuous biomass extraction and centrifugation. The biomass extraction and centrifugation system may include biomass and solvent feed tanks, a plurality of vessels, and a centrifuge. The biomass and solvent feed tanks may be fluidly coupled to the plurality of vessels, which may in turn be fluidly coupled to the centrifuge. In this manner, the system may be arranged and configured to run in a continuous manner with a substantially constant and repeatable extraction result.

Abstract: A liquid-liquid extraction unit includes an extraction/separation tank (10) into which an aqueous phase in bubble form is admitted from an upper inlet (20) in one sidewall and an organic phase in bubble form is admitted from a lower inlet (30) in the one sidewall. The upward moving organic phase is contacted with the downward moving aqueous phase. After contact, the organic phase is discharged through an upper outlet (40) in an opposite sidewall and the aqueous phase is discharged through a lower outlet (50) in the opposite sidewall.

Abstract: This disclosure describes systems, methods, and devices for phytochemical extraction. One example extraction system includes two solvent columns, a material column, and a dewaxing column. The solvent columns store and provide solvent for stripping target chemicals from plant material in the material column. The solvent mixed with target chemicals passes into the dewaxing column, where the target chemicals are separated from waxes and lipids. Cooling is applied to elements of the system by way of an open-loop CO2 refrigeration method. Solvent is moved from the solvent columns to the material column by creating a pressure differential between the two solvent columns.

Abstract: A method of manufacturing a solvent extraction settler comprises manufacturing at the site of manufacture, such as in an engineering workshop, a plurality of self-supporting settler element modules (2, 3, 4, 5) each having exterior dimensions, strength and handling and securing means (6) conforming to shipping container standards, transporting the modules (2, 3, 4, 5) to the site of installation as normal freight by transport equipment, such as trucks, trailers and container ships, capable of handling and transporting shipping container standard compatible units, and assembling the modules (2, 3, 4, 5) into a complete settler at the site of installation. The settler comprises a module group (1) consisting of a plurality of self-supporting settler element modules (2, 3, 4, 5) each having exterior dimensions, strength and handling and securing means (6) conforming to ISO shipping container standards to enable ISO compatible transportability.

Abstract: Oil-based mud cuttings are cleaned of drilling fluid and mud additives. After sorting and rinsing the cuttings with diesel, the cuttings are put in a syringe, which is repeatedly filled and emptied of diesel. The cuttings are then washed in the syringe with pentane. The cuttings are then crushed and exposed to a solvent a second time. Instead of placing the cuttings in the syringe, alternatively, the cuttings remain on a sieve and the syringe is used to spray the cuttings with diesel, followed by pentane.

Abstract: The present invention relates to a process for continuous extraction of an aqueous and/or fat-containing liquid phase F comprising aroma chemicals with a gas G in the liquid or supercritical state.

Abstract: The invention describes processes to selectively remove or reduce the mineral acid content substantially from compositions comprising a solvent and levulinic acid, wherein the levulinic acid was derived from the reaction between various biomass materials and a mineral acid or an organic acid catalyst.

Abstract: A method for removing sulfolane from hydrocarbon streams by serial separation using raffinate wash column and at least one raffinate wash drum. The separation may be particularly useful in retrofitting existing separation facilities to produce motor fuels meeting the specifications requiring lower sulfolane content. A method is provided for the purification of a hydrocarbon-containing stream having a sulfolane therein. The method includes separating a first sulfolane-depleted stream from a hydrocarbon stream in a first counter-current separation unit and then separating a second sulfolane-depleted stream from the first sulfolane-depleted stream in a second counter-current separation unit. The first and second counter-current separation units are preferably different and chosen from a raffinate wash column or at least one raffinate wash drum. An apparatus for performing the methods is also described.

Abstract: A kneading apparatus has a housing and first and second rotary shafts mounted in the housing in parallel to one another for undergoing rotation about respective axes in opposite directions at unequal speeds to one another for kneading an object. The first and second rotary shafts have respective first and second stirring members arranged helically at a predetermined helical pitch and at predetermined angular pitch intervals, with the second stirring members being arranged with an inverse helix from that of the first stirring members. Side blocking plates disposed in the housing partially block the kneaded object and move it between the first and second rotary shafts. The side blocking plates are spaced apart from one another to provide a space above the first and second rotary shafts such that the kneaded object can pass through the space in the axial direction of the first and second rotary shafts.

Abstract: Disclosed are processes for producing crude oil and bitumen products of relatively high quality from oil sand. The processes for producing the high quality crude oil and bitumen products involve a Phase I and/or Phase II extraction solvent. According to the Phase I process, a high quality bitumen-derived crude oil can be produced using a Phase I type solvent. According to the Phase II process, a substantial amount of the bitumen on the oil sand can be extracted using a Phase II type solvent, while producing a relatively dry tailings by-product. The Phase I and Phase II extraction processes can be carried out independently or in conjunction with one another.

Abstract: The invention provides a process for alcohol production from a cellulosic material wherein a said cellulosic material is subjected to acid hydrolysis to yield an aqueous hydrolysate, said hydrolysate is introduced into a separator at a hydrolysate inlet, an extraction solvent is introduced into said separator at at least two extraction solvent inlets, a residue containing oligosaccharides is removed from said separator at a residue discharge outlet, and acid-containing extraction solvent is removed from said separator at an extraction solvent discharge outlet, wherein removal of said extraction solvent from said separator through said discharge outlet occurs downstream of at least one said extraction solvent inlet and upstream of at least one other said extraction solvent inlet.

Abstract: The invention relates to treating a hydrocarbon-comprising emulsion with an aqueous component to form an aqueous component-treated emulsion, and processing the treated emulsion to recover the hydrocarbon. The aqueous component is contacted with the hydrocarbon-comprising emulsion in a manner and proportion so as to promote coalescence of the like phases while minimizing shear, which results in a decreased viscosity of the emulsion and a shift away from the emulsion inversion region toward a water-continuous state.

Abstract: A food processing vat is provided with blade assemblies that extend from opposing sides of a rotating shaft. The blade assemblies may be curved or otherwise face different directions at different locations along their respective lengths. The vat may have a pair of rotating shafts and the rotation of the shafts may be timed so that the blade assemblies of the shafts simultaneously travel through a common swept volume. The blade assemblies may be positioned on the shafts so that they intermesh through each other while simultaneously moving through the common volume.

Abstract: Embodiments of a feedwell discharge a solvent treated bitumen-containing froth feed to a froth settling vessel at a Richardson number less than 1.0. Feed is discharged from feedwell inlets to the vessel, either located at a center of the vessel or at a perimeter wall of the vessel along a substantially horizontal path across the vessel. The high velocity maximizes the horizontal path. As the velocity is reduced along the path and as a result of collision in the vessel with the perimeter wall or with feed entering the vessel from an opposing inlet, the feed separates into diluted bitumen and solvent which rises in the vessel for discharge as an overflow product and a waste stream, comprising water, solids and asphaltenes, which settles to the bottom of the vessel to be discharged as an underflow. A relatively uniform clarification zone forms above the inlets submerged in the vessel.

Abstract: The present invention provides new techniques related to magnetically controllable and/or steerable froth for use in separation processes of mineral-bearing ore and bitumen. Apparatus is provided featuring a processor configured to contain a fluidic medium having a material-of-interest and also having a surfactant with magnetic properties so as to cause the formation of a froth layer that contains at least some of the material-of-interest and is magnetically responsive; and a magnetic field generator configured to generate a magnetic field and provide non-mechanical mixing and steering/driving of the froth layer in the processor. The material-of-interest may be mineral-bearing ore particles or bitumen. The processor includes a flotation tank, a primary separation vessel (PSV), or a pipe, including a tailings pipeline.

Abstract: The present invention relates to a system and a method for the extraction of hydrocarbons from drill cuttings in drilling mud. The system for extracting hydrocarbons from drill cuttings includes at least one extraction tank, a carbon dioxide tank fluidly connected to the at least one extraction tank, and at least one separation tank in fluid communication with the at least one extraction tank. The method for extracting hydrocarbons from drill cuttings consists of exposing the drill cuttings to liquid carbon dioxide, solubilizing hydrocarbons from the drill cuttings with the liquid carbon dioxide, heating the liquid carbon dioxide and the soluble hydrocarbons to convert liquid carbon dioxide to carbon dioxide vapor, separating the hydrocarbons from the carbon dioxide vapor, and collecting the separated hydrocarbons.

Abstract: Systems and methods for using different output from gas to liquids (GTL) plants are described.

Abstract: A method of extracting hydrocarbon-containing organic matter from a hydrocarbon-containing material includes the steps of providing a first liquid comprising a turpentine liquid; contacting the hydrocarbon-containing material with the turpentine liquid to form an extraction mixture; extracting the hydrocarbon material into the turpentine liquid; and separating the extracted hydrocarbon material from a residual material not extracted.

Abstract: A method, system, and device for separating oil from oil sands or oil shale is disclosed. The method includes heating the oil sands, spinning the heated oil sands, confining the sand particles mechanically, and recovering the oil substantially free of the sand. The method can be used without the addition of chemical extraction agents. The system includes a source of centrifugal force, a heat source, a separation device, and a recovery device. The separation device includes a method of confining the sands while allowing the oil to escape, such as through an aperture.

Abstract: Reduction of sulfur-containing and nitrogen-containing compounds from hydrocarbon feeds is achieved by first contacting the entire feed with a hydrotreating catalyst in a hydrotreating reaction zone operating under mild conditions to convert the labile organosulfur and organonitrogen compounds. An extraction zone downstream of the hydrotreating reaction zone separates an aromatic-rich fraction that contains a substantial amount of the remaining refractory organosulfur and organonitrogen compounds. The aromatic-lean fraction is substantially free of organosulfur and organonitrogen compounds, since the non-aromatic organosulfur and organonitrogen compounds were the labile organosulfur and organonitrogen compounds which were initially removed by mild hydrotreating. The aromatic-rich fraction is oxidized to convert the refractory organosulfur and organonitrogen compounds to oxidized sulfur-containing and nitrogen-containing hydrocarbon compounds.

Abstract: Deep desulfurization of hydrocarbon feeds containing undesired organosulfur and organonitrogen compounds to produce a hydrocarbon product having low levels of sulfur-containing and nitrogen-containing compounds, is achieved by first subjecting the entire feed to an extraction zone to separate an aromatic-rich fraction containing a substantial amount of the refractory organosulfur and organonitrogen compounds and an aromatic-lean fraction containing a substantial amount of the labile organosulfur and organonitrogen compounds. The aromatic-lean fraction is contacted with a hydrotreating catalyst in a hydrotreating reaction zone operating under mild conditions to convert the labile organosulfur and organonitrogen compounds. The aromatic-rich fraction is oxidized to convert the refractory organosulfur and organonitrogen compounds to oxidized organosulfur and organonitrogen compounds.

Abstract: An apparatus and process is provided for improved asphaltene separation from heavy hydrocarbon or bitumen with low process complexity through mass transfer using solvent and counter-current flows, with three sections: an upper DAO/solid-asphaltene separation zone, a middle solvent mixing and segregation zone, and a bottom clarification zone. Solvent mixed with heavy hydrocarbon forms a process feed introduced to the process vessel's upper zone and exposed to counter-current solvent removing DAO from solid asphaltene particles in the feed, the particles fall through the middle zone and are mixed with introduced solvent, which introduced solvent segregates DAO-rich solution in the upper zone (for extraction from that zone) from solvent-rich mixtures in the middle mixing and lower clarification zones. Solvent flows and precipitate movement are controlled to optimize mass transfer in process, resulting in high DAO recovery and dry, solid asphaltene product.

Abstract: Embodiments of extraction unit and an analysis method are provided. In one embodiment, the analysis method includes the steps of providing a feed stream and a species-selective solvent to the distillation column, drawing a vapor sample from the distillation column, condensing the vapor sample, and analyzing at least a portion of the condensed vapor sample.

Abstract: The present invention provides a method for extracting bitumen from an oil sand stream, the method including the steps of: (a) providing an oil sand stream; (b) contacting the oil sand stream with a solvent thereby obtaining a first solvent-diluted oil sand slurry; (c) screening the first solvent-diluted oil sand slurry, thereby obtaining a first oversized material and a first undersized material; (d) contacting the first oversized material with a solvent thereby obtaining a second solvent-diluted oil sand slurry; (e) screening the second solvent-diluted oil sand slurry, thereby obtaining a second oversized material and a second undersized material; (f) optionally filtering the first undersized material obtained in step (c), thereby obtaining a solids-depleted stream and a solids-enriched stream; (g) optionally removing solvent from the solids-depleted stream obtained in step (f) thereby obtaining a bitumen-enriched stream.

Abstract: A process for treating bitumen froth with paraffinic solvent is provided which uses three stages of separation. Froth and a first solvent are directed to a first stage at a solvent/bitumen ratio for precipitating few or substantially no asphaltenes. A first stage underflow is directed to a second stage and a first stage overflow is directed to a third stage. A second stage underflow is directed to waste tailings and the second stage overflow joins the first stage overflow. A third stage underflow is recovered as an asphaltene by-product and a third stage overflow is recovered as a diluted bitumen product. At least a second solvent is added to one or both of the second or third stages for controlling a fraction of asphaltenes in the third stage underflow. Asphaltene loss to waste tailings is minimized and asphaltenes are now recovered as asphaltene by-product.

Abstract: An apparatus and a method for operating a process line for processing mined oil sand ore into a bitumen-containing slurry. The method may include: collecting, at least at one location, a plurality of measurements from one or more sensors; computing at a central controller a calculated value based on at least one of the plurality of measurements; and, applying an adjustment to an operating variable of a component of the process line to override a target set-point of a regulatory controller for that component based on the calculated value and a target value for the calculated value. The method and apparatus may receive measurement values in at least one step, and apply a correction to future measurement values in another step.

Abstract: An improved system for removing bitumen from tar sands comprises a pretreatment system utilizing a vibratory load hopper for classifying and sizing said tar sand particles communicating with a dryer for heating and drying said tar sand particles to a predetermined temperature thereby controlling the moisture content of said tar sands. An extraction system is also included for accepting said tar sands from the dryer comprising a plurality of extraction vessels arranged in series for transporting said tar sands from a first extraction vessel to a final extraction vessel. Furthermore, a solvent system for supplying a predetermined volume of solvent flow through said extraction vessels is employed, whereby solvent is supplied to the last extraction vessel and a solvent and bitumen mixture is withdrawn from the first extraction vessel.

Abstract: A system and a process for recovering bitumen from oil sands are provided. The system includes a bitumen solvent comprised of at least 75 mol % dimethyl sulfide that is first contact miscible with bitumen, an oil sands material comprised of bitumen, and a contacting apparatus configured to receive the bitumen solvent and the oil sands material and to contact and mix the bitumen solvent and oil sands material to form a bitumen-containing extract and a bitumen-depleted oil sands material. The process includes the steps of providing the oil sands material; contacting the oil sands material with the solvent comprised of at least 75 mol % dimethyl sulfide to form the bitumen-containing extract and the bitumen-depleted oil sands material; and separating the bitumen-containing extract from the bitumen-depleted oil sands material.

Abstract: The invention relates to improved bitumen recovery processes and systems. One process provides for operation of a bitumen froth treatment plant at optimum shear rates in the feed pipe carrying the bitumen froth to the froth settling unit. Another process provides for optimizing the design of a bitumen froth treatment plant by optimizing the diameter of the feed pipe to impart an optimum shear rate to the bitumen froth mixture and further optimizing the volume of the feed pipe to impart an optimum residence time for the bitumen froth stream in the feed pipe. An optimal plant design is also disclosed, the plant including optimal diameter and volume of the feed pipe.

Abstract: The invention provides a method and apparatus of removing contaminants such as salts, hydrocarbon, chemicals, minerals, and metals from materials such as sand, soil, gravel, drill cuttings, and other solids, and reclaiming contaminants and materials for reuse. The invention is scalable in size and capability, economic to construct and operate and reliable in operation and performance. The invention slurries contaminated material with a solution. Transports the slurried material throughout a hydraulic chamber, where the contaminants become more associated with the solution than the material. The invention then separates the processed material and contaminated solution into unique reclaimed components.