Abstract: A process is disclosed using a dispersion of supercritical fluid and oil to upgrade a hydrocarbon feedstock such as a heavy oil into an upgraded hydrocarbon product or synthetic crude with highly desirable properties such as low sulfur content, low metals content, lower density (higher API), lower viscosity, lower residuum content, etc. The process utilizes a capillary mixer to form the dispersion. The process does not require external supply of hydrogen nor does it use externally supplied catalysts.

Abstract: A method of transporting heavy hydrocarbons can include blending a kerogen oil with a bitumen to form a blended oil sufficient to render the blended oil transportable through an extended pipeline. The blended oil can be substantially free of additional diluents or viscosity modifiers and can be readily pumped through the extended pipeline from a source location to a destination location.

Abstract: Various systems and methods are described that can be used as part of a process to separate bitumen from oil sands. The process may include adding a hydrocarbon solvent to a bitumen containing extract. The tailings from this process may contain a significant amount of solvent. The solvent may be recovered from the tailings with a tailings solvent recovery unit that utilizes negative pressure to significantly reduce the cost of the process in comparison to a conventional steam stripping unit. In one embodiment, the tailings may also separated prior to entering the tailings solvent recovery unit with a gravity separation apparatus or a cyclonic separation apparatus, such as a hydrocyclone.

Abstract: Various methods and systems for obtaining bitumen from tar sands are disclosed. The disclosed methods and/or systems can be used to economically achieve a high degree of bitumen recovery from tar sands. The method may include a primary leaching or extraction process that separates most of the bitumen from the tar sands and results in a bitumen-enriched component and a bitumen-depleted component. The bitumen-enriched component includes mainly solvent and bitumen. The bitumen-depleted component includes mainly water and mineral solids with some residual bitumen and solvent. The bitumen-depleted component may be mixed with liquefied petroleum gas, e.g., propane and/or butane, to further separate the residual solvent and bitumen. The disclosed system can include separators configured to separate the various components at the various stages in the process.

Abstract: Kerogen in oil shale is converted to bitumen, oil, gases and coke via a retorting process. The vaporizable oil and gases are then recovered. Following the retorting process, bitumen is recovered via solvent extraction. The overall conversion process is enhanced by calculating conditions to optimize recovery of both oil and bitumen. This can be accomplished by either separately calculating conditions for which production of vaporizable oil and production of bitumen are optimized, or calculating conditions for which production of vaporizable oil and production of bitumen are optimized by applying a maximizing function to combined vaporizable oil and bitumen data. An advantage of this technique is that greater efficiency is achieved because the time duration of heating associated with the retorting process can be reduced and product yields increased.

Abstract: A method of treating slop oil and slops from the SAG-D (steam assisted gravity-drainage) very heavy oil-bitumen crude oil production in such locations as Alberta and Saskatchewan provinces in Canada, Russia, Venezuela, Saudi Arabia, and Kern County, Calif., involves mixing the slop oil and slops with chemicals to help separate out water from the slop oil and slops.

Abstract: A method of extracting bitumen from tar sands includes providing an apparatus for mixing fluids, the apparatus including: a housing, a substantially cylindrical rotor rotatably mounted within the interior chamber, a first array of spaced bores formed in the peripheral surface of the rotor, a second array of spaced bores formed in the peripheral surface of the rotor, a first fluid inlet in the housing, a second fluid inlet in the housing, and a fluid outlet in the housing positioned for withdrawal of fluid from the chamber to minimize cavitation damage at the location of the fluid outlet, and providing a separation composition at the second predetermined location, the separation composition including: a wetting agent in the amount of from about 0.001% to about 2.5% by weight of the separating composition, a hydrotropic agent, and a dispersant having flocculating characteristics, wherein the separating composition has a pH greater than 7.5.

Abstract: A method of extracting bitumen from bituminous material. In some embodiments, the method may include loading a bitumen material in a column, followed by feeding a first quantity of first solvent into the column. The method may also include collecting the bitumen-enriched solvent exiting the column. A quantity of the bitumen-enriched solvent may then be fed into the column. In some embodiments, the method may include simultaneously loading bitumen material and a first solvent in a column, followed by feeding additional first solvent into the column. The method may also include collecting bitumen-enriched solvent exiting the column, and feeding a quantity of the bitumen-enriched solvent into the column.

Abstract: In one aspect, the present invention provides a method for recovering bitumen from an oil sand, the method comprising: (a) contacting a bitumen-containing oil sand with a first solvent mixture of cyclohexane and ethanol to provide an extraction mixture comprising a sand phase and an organic phase; (b) separating the sand phase from the organic phase comprising bitumen, ethanol and cyclohexane; (c) separating an azeotropic mixture comprising cyclohexane and ethanol from the organic phase; and (d) recovering bitumen from the organic phase. The first solvent mixture comprises from about 95 to about 65 percent cyclohexane and from about 5 to about 35 percent ethanol.

Abstract: The present invention is directed to a method comprising contacting an oil sand with a suitable solvent to generate a solvated oil sand slurry; separating solvent-diluted bitumen from the solvated oil sand slurry to generate (a) a solvent-diluted bitumen and (b) a slurry with increased solids concentration; and filtering the slurry with increased solids concentration. The method of the present invention may be used to produce a low ash bitumen product and dry tailings from oil sands.

Abstract: A process for extracting bitumen from problem oil sand ores having low bitumen content and/or high fines content is provided, comprising: mixing the problem oil sand ore with heated water to produce an oil sand slurry; conditioning the oil sand slurry for a period of time sufficient to substantially disperse oil sand lumps and promote the release and coalescence of bitumen flecks from the sand grains; removing a sufficient amount of solids from the conditioned oil sand slurry in a de-sander circuit; and subjecting the solids-reduced oil sand slurry to gravity separation in a bitumen separation vessel to allow the bitumen to float to the top of the vessel to form clean bitumen froth.

Abstract: The systems and methods described herein provide for extracting bitumen from oil sands at ambient or subambient temperature, for example at temperatures between 0 degrees Centigrade and about 20 degrees Centigrade. The process includes the steps of forming a slurry by mixing the oil sands with water, adding an extractant to the slurry, agitating the extractant with the slurry, and collecting bitumen that separates from the slurry.

Abstract: A method for the pyrolytic extraction of hydrocarbons such as shale oil from kerogen containing oil shale. Oil shale which has been ground into particulate form, is cascaded downwardly between a plurality of rotating trays within a heated processing chamber. As the hydrocarbons are volatized within the chamber, the volatiles are collected and condensed within a condenser or other suitable recovery apparatus.

Abstract: In a method for enhancing the efficiency of bitumen recovery from oil sands ore, CaO lime (or Ca(OH)2) is mixed into an oil sands ore-water slurry prior to or during the operation of slurry-based bitumen extraction processes. The lime is introduced at dosages effective to reduce the electro-chemical attraction between clay particles and bitumen in the slurry, thereby promoting detachment of clay particles from bitumen droplets in the ore-wafer slurry. This occurs because water-soluble asphaltic acids formed at the bitumen-water interface act as surfactants which reduce or eliminate the activity of Ca2+ and Mg2+ ions binding the clay particles and bitumen together. The detachment of clay particles promotes the attachment of air bubbles to the bitumen droplets, thereby forming a bitumen-rich froth which will float to the surface of the ore-water slurry, thus facilitating bitumen recovery.

Abstract: An inline bitumen froth steam heater system including steam injection and static mixing devices is provided. The system heats and de-aerates input bitumen froth without creating downstream processing problems with the bitumen froth such as emulsification or live steam entrainment. The system is a multistage unit that injects and thoroughly mixes steam with bitumen resulting in output bitumen material having temperature of about 190° F. The system conditions a superheated steam supply to obtain saturated steam at about 300° F. The saturated steam is contacted with bitumen froth flow and mixed in a static mixer stage. The static mixers provide surface area and rotating action that allows the injected steam to condense and transfer its heat to the bitumen froth. The mixing action and increase in temperature of the bitumen froth results in reduction in bitumen viscosity and allows the release of entrapped air from the bitumen froth.

Abstract: Modified resins are disclosed for removing a wide variety of solids and/or ionic species from the liquids in which they are suspended and/or dissolved. These modified resins are especially useful as froth flotation depressants in the beneficiation of many types of materials (e.g., mineral and metal ores), including the beneficiation of impure coal comprising clay impurities, as well as in the separation of valuable bitumen from solid contaminants such as sand. The modified resins are also useful for treating aqueous liquid suspensions to remove solid particulates, as well as for removing metallic ions in the purification of water. The modified resins comprise a base resin that is modified with a coupling agent, which is highly selective for binding to solid contaminants and especially siliceous materials such as sand or clay.

Abstract: A method and a system for obtaining bitumen from tar sand are disclosed. The disclosed method can include two extraction steps, such as a first extraction step using a light aromatic solvent and a second extraction step using a volatile hydrocarbon solvent. The light aromatic solvent and the volatile hydrocarbon solvent both can be recycled and used in multiple extractions. Each extraction and recycling step can include a separation. The disclosed system can include separators configured to perform these separations. Some of these separators also can function as mixers. Using the disclosed method and system, it is possible to achieve a high degree of bitumen recovery while minimizing undesirable complications, such as swelling of clays in the tar sand and/or precipitation of asphaltenes.

Abstract: The invention relates to a class of novel surfactants that have utility in the recovery and/or extraction of oil.

Abstract: Methods for extracting bitumen from bituminous material through the use of a polar solvent. The method may include a primary leaching or extraction process that separates most of the bitumen from a material comprising bitumen and produces first solvent-wet tailings. A polar solvent is added to the first solvent-wet tailings in order to remove the first solvent (plus any entrained bitumen) from the tailings. A mixture of polar solvent and first solvent produced by the addition of the polar solvent to the first solvent-wet tailings may be phase separated by maintaining the polar solvent-first solvent mixture for a period of time. Alternatively, the polar solvent and first solvent may leave the tailings in a phase separated state. Phase separation may occur due to the presence of water in the polar solvent-first solvent mixture. Water may also be added to the mixture of solvents to serve as an antisolvent and initiate phase separation. The separated solvents may then be recovered and reused in the method.

Abstract: The invention provides systems and methods for extracting and upgrading heavy hydrocarbons from substrates such as oil sands, oil shales, and tar sands in a unitary operation. The substrate bearing the hydrocarbon is brought into contact with a supercritical or near-supercritical fluid, a source of hydrogen such as hydrogen gas, and a catalyst. The materials are mixed and heated under elevated pressure. As a consequence of the elevated temperature and pressure, upgraded hydrocarbon-containing material is provided in a single or unitary operation. In some embodiments, sonication can be used to improve the upgrading process. Fluids suitable for use in the process include carbon dioxide, hexane, and water. It has been observed that upgrading can occur within periods of time of a few hours.

Abstract: Systems, methods and compositions for the separation and recovery of hydrocarbons from particulate matter are herein disclosed. According to one embodiment, a method includes contacting particulate matter with at least one ionic liquid. The particulate matter contains at least one hydrocarbon and at least one solid particulate. When the particulate matter is contacted with the ionic liquid, the hydrocarbon dissociates from the solid particulate to form a multiphase system.

Abstract: Various methods and systems for obtaining light hydrocarbon distillate from material comprising bitumen are disclosed. The method may include a primary leaching or extraction process that separates most of the bitumen from the material comprising bitumen and results in a bitumen-enriched solvent phase and first solvent-wet tailings. The bitumen-enriched solvent phase includes mainly solvent and bitumen. The bitumen-enriched solvent phase is injected into a nozzle reactor wherein at least a portion of the bitumen is cracked into light hydrocarbon distillate. The light hydrocarbon distillate may then be used as solvent in the first primary leaching or extraction step.

Abstract: Systems and methods for staging an investment in hydrocarbon processing are provided. In a first stage, a hydrocarbon feed can be apportioned equally or unequally into first and second portions. The first portion can be mixed with one or more oxidants and gasified to provide a first effluent, at least a portion of which can be combusted to provide steam. The second portion can be mixed with one or more solvents to provide one or more fungible hydrocarbon products, at least a portion of which can be sold to generate capital. In a second stage, the hydrocarbon feed can be mixed with one or more solvents and one or more non-catalytic solids and the resultant mixture thermally cracked to provide one or more hydrocarbon products and coked non-catalytic solids. The coked, non-catalytic solids can be regenerated and recycled.

Abstract: Apparatus for modifying bitumen. The apparatus includes a multi-section loop tube reactor A circulation pump (11) circulates bitumen in the reactor (10) and air is introduced at air injection point (13). Bitumen is introduced into the reactor (10) at inlet (14) by variable speed pump P1. A plurality of mixers (15) are located between the air injection point (13) and a head section (24) beyond which is an outlet (27) where modified bitumen is drawn off by variable speed pump P2.

Abstract: Process for the hydroconversion of heavy oils, selected from crude oils, heavy crude oils, bitumens from tar sands, distillation residues, distillation heavy cuts, distillation deasphalted residues, vegetable oils, oils from coal and oil shale, oils from the thermodecomposition of waste material, polymers, biomasses, comprising sending the heavy oil to a hydroconversion area, effected in one or more ebullated bed reactors, wherein hydrogen is introduced, in the presence of a suitable heterogeneous, supported, hydroconversion catalyst, in addition to a suitable hydrogenation catalyst, nano-dispersed in said heavy oil, and sending the stream coming from the hydroconversion area to a separation area, in which the separated liquid fraction, containing the nano-dispersed catalyst, is recycled to the ebullated bed reactor(s).

Abstract: Compositions and methods are provided for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing tailings ponds.

Abstract: A method for separating bitumen from crude oil sands comprises subjecting crude oil sands to vibration selected to cause bitumen to separate from crude oil sands and filtering the separated bitumen from the crude oil sands.

Abstract: Compositions and methods are provided for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing tailings ponds.

Abstract: An integrated process for extracting and refining bitumen comprises hydroconverting bitumen in a reactor to provide valuable products and light oil by-product; separating the light oil by-product from the valuable products; transporting the light oil to oil sands reserves; producing steam in steam generators at the oil sands reserves using a portion of the light oil transported to the oil sands reserves; extracting bitumen from the oil sands reserves using steam produced in the steam generators; blending bitumen extracted from the oil sands reserves and a portion of the light oil transported to the oil sands reserves to form a transport blend; and transporting the transport blend to the reactor.

Abstract: Systems and methods for hydrocarbon extraction from hydrocarbon-containing material. Such systems and methods relate to extracting hydrocarbon from hydrocarbon-containing material employing a non-aqueous extractant. Additionally, such systems and methods relate to recovering and reusing non-aqueous extractant employed for extracting hydrocarbon from hydrocarbon-containing material.

Abstract: Systems and methods for staging an investment in hydrocarbon processing are provided. In a first stage, a hydrocarbon feed can be apportioned equally or unequally into first and second portions. The first portion can be mixed with one or more oxidants and gasified to provide a first effluent, at least a portion of which can be combusted to provide steam. The second portion can be mixed with one or more solvents to provide one or more fungible hydrocarbon products, at least a portion of which can be sold to generate capital. In a second stage, the hydrocarbon feed can be mixed with one or more solvents and one or more non-catalytic solids and the resultant mixture thermally cracked to provide one or more hydrocarbon products and coked non-catalytic solids. The coked, non-catalytic solids can be regenerated and recycled.

Abstract: A method recovering heat and water from a warm slurry, such as warm tailings from a oil sands extraction mining operation, is provided. The method comprises providing the tailings to a vacuum vessel, removing, from the vacuum vessel, warm vapor derived from the tailings, condensing the warm vapor in a condenser to produce water, and recovering the water from the condenser. Cool river or pond water can be warmed with the heat from the vapor for additional uses in the mining operation. Essentially pure water can be obtained in the process. This can also be achieved using one or flash vessels in series to condense the vapor. Power can also be generated from the vapor using a turbine.

Abstract: A method for obtaining heavy oil is disclosed. The method includes mixing a material including heavy oil (e.g., oil sand) with a solvent including biodiesel to form a mixture and separating the mixture into a oil-enriched solvent phase and a residual sand phase. The method also can include introducing a solvent including biodiesel into an in-situ geological formation including heavy oil and collecting a mixture including biodiesel and heavy oil from the formation. For example, the mixture can be collected after the solvent travels through at least a portion of the formation by gravity. A method for producing biodiesel also is disclosed. The method includes microbially digesting asphaltenes to form a liquor including a fatty acid and reacting the fatty acid with an alcohol to produce biodiesel. This method can be used to convert petroleum asphaltenes and/or coal asphaltenes into biodiesel.

Abstract: A method of produced water treatment in an in-situ recovery method of producing bitumen from oil sand, the method has the steps of: separating bitumen from bitumen-mixed fluid so as to leave produced water, the bitumen-mixed fluid having been recovered from the oil sand wells; and filtering the produced water via a microfiltration membrane made of polytetrafluoroethylene.

Abstract: Compositions and processes for separating bitumen from oil sands ore include contacting the oil sand ores with a composition including a carboxylate salt and/or acid and an aqueous liquid carrier. The carboxylate salt and/or acid is a C1-C7 alkyl, and in one embodiment, is a monocarboxylate.

Abstract: A tar sand volatilizer system thermally removes petroleum crude oil from tar sands or shale oil. A series of heated augers or thermal screws are used to elevate material temperature gradually using conductive heat transfer. The thermal screws blades and auger case receive a heated fluid. The screws are driven by variable speed drive systems. The unit is sized for any throughput rate desired. Hot clean material discharges into a rotary cooler and re-hydrator unit. The exhaust gases are pulled through a high temperature filter collector for particulate removal. The particulate free petroleum vapor laden hot gas exits the filter house into a multi stage condenser system with water chillers where the vapor temperature is gradually cooled. A microwave upgrader system processes crude oil using catalyst injected microwave technology to produce a diesel like fuel oil in a continuous process stream.

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.

Abstract: An improved system for removing bitumen from tar sands comprises a pre-treatment 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: The present invention relates to an integrated process for the conversion of feedstocks containing coal into liquid products by jointly using at least the following seven process units: coal liquefaction, flash or distillation of the product obtained from the liquefaction, extraction with a solvent to remove the ashes, distillation to separate the solvent, hydroconversion with catalysts in slurry phase, distillation or flash of the production obtained from the hydroconversion, and deasphalting with a solvent.

Abstract: Compositions and methods are provided for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing tailings ponds.

Abstract: Compositions and methods are provided for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing tailings ponds.

Abstract: Compositions and methods are provided for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing tailings ponds.

Abstract: A method of sequestering carbon dioxide emissions during recovery of hydrocarbons from hydrocarbonaceous materials can include forming a constructed permeability control infrastructure. This constructed infrastructure defines a substantially encapsulated volume. A comminuted hydrocarbonaceous material can be introduced into the control infrastructure to form a permeable body of hydrocarbonaceous material. The permeable body can be heated sufficient to remove hydrocarbons therefrom. During heating, the hydrocarbonaceous material is substantially stationary as the constructed infrastructure is a fixed structure. Additionally, during heating, any carbon dioxide that is produced can be sequestered. Removed hydrocarbons can be collected for further processing, use in the process, and/or use as recovered.

Abstract: A constructed permeability control infrastructure can include a permeability control impoundment, which defines a substantially encapsulated volume. The infrastructure can also include a comminuted hydrocarbonaceous material within the encapsulated volume. The comminuted hydrocarbonaceous material can form a permeable body of hydrocarbonaceous material. The infrastructure can further include at least one convection driving conduit oriented in a lower portion of the permeable body to generate bulk convective flow patterns throughout the permeable body. An associated method of recovering hydrocarbons from hydrocarbonaceous materials can include forming a constructed permeability control infrastructure, which defines a substantially encapsulated volume. A comminuted hydrocarbonaceous material can be introduced into the control infrastructure to form a permeable body of hydrocarbonaceous material.

Abstract: A method of recovering minerals from hydrocarbonaceous materials can include forming a constructed permeability control infrastructure. This constructed infrastructure defines a substantially encapsulated volume. A comminuted hydrocarbonaceous material can be introduced into the control infrastructure to form a permeable body of hydrocarbonaceous material. The permeable body can be contacted with an agent sufficient to remove minerals therefrom. The agent is typically a solution containing a solvent, leachant, chelating agent and the like via which minerals can be removed having value, toxic minerals, radioactive minerals and the like.

Abstract: A method of recovering hydrocarbons from hydrocarbonaceous materials can include forming a constructed permeability control infrastructure. This constructed infrastructure defines a substantially encapsulated volume. A comminuted hydrocarbonaceous material can be introduced into the control infrastructure to form a permeable body of hydrocarbonaceous material. The permeable body can be heated sufficient to remove hydrocarbons therefrom. During heating and removal of hydrocarbons and subsequent thereto a positive pressure can be maintained within the encapsulated volume by means of a non-oxidizing gas to expedite flushing of hydrocarbonaceous material, inhibit unwanted entry of oxygen into the encapsulated volume and remove recoverable hydrocarbons following the heating process.

Abstract: A process for the conversion of heavy oils comprising sending the heavy oil to hydrotreatment, of the high severity type, in the presence of high concentrations of a suitable hydrogenation catalyst dispersed in slurry phase, effected in a suitable solid accumulation reactor capable of operating stably in the presence of solids deriving from and generated by the feedstock charged, wherein the hydrogen or mixtures thereof is fed at suitable flow-rates and suitably distributed, obtaining the conversion products in vapour phase directly in the reactor.

Abstract: A method of preventing egress of a vapor from an encapsulated volume can include forming a substantially impermeable vapor barrier along an inner surface of the encapsulated volume. The encapsulated volume includes a permeable body of comminuted hydro carbonaceous material. Further, the vapor barrier can include an insulating layer capable of maintaining a temperature gradient of at least 400° F. across the insulating layer. The permeable body can be heated sufficient to liberate hydrocarbons therefrom and the hydrocarbons can be collected from the permeable body. The vapor barrier layer can be a single or multiple layer construction, depending on the specific materials chosen.

Abstract: The invention pertains to the use of a class of acetylenic surfactants to resolve or break water and oil emulsions. The surfactants are of particular advantage in resolving crude oil emulsions of the type encountered in desalter and similar apparatus designed to extract brines from the crude as they partition to the aqueous phase in the desalter. Also, the surfactants may be used to separate oil from oil sands and similar oil/solids matrices.

Abstract: Compositions and methods are provided for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing tailings ponds.