Abstract: Processes are provided for separating bitumen from oil sands and from other bitumen-containing compositions.

Abstract: For refining oil-containing solids, in particular oil sand or oil shale, there is proposed a process with the following steps: supplying the oil-containing solids to a reactor and expelling an oil-containing vapor at a temperature of 300 to 1000° C., supplying the oil-containing vapor expelled in the reactor to a cracker, in which the heavy oil components are broken down, separating the products obtained in the cracker and withdrawing the product streams, introducing the solids left in the reactor including the unevaporated fraction of heavy hydrocarbons into a furnace, burning the heavy hydrocarbons left in the solids in the furnace at a temperature of 600 to 1500° C., preferably 1050 to 1200° C., recirculating hot solids from the furnace into the reactor, wherein the oxidizing atmosphere of the furnace is separated from the atmosphere of the reactor by a blocking device.

Abstract: A process line for separating oil sand slurry comprising coarse solids, fines, bitumen and water, into a first product comprising bitumen, fines and water and a second product comprising coarse solids, fines and water is provided comprising a plurality of countercurrently operating solid/liquid separators arranged in series along a pipeline, wherein the underflow of one separator is fed to the next separator in series and the overflow of each separator is fed to the preceding separator, the underflow of the last separator being the second product and the overflow from the first separator being the first product.

Abstract: A process for bitumen extraction from hydrocarbonaceous solids, such as tar sand or oil shale, is performed in fluidized bed of a swirl reactor. This provides active interaction of three phases: 1) liquid phase—bituminous oil with solvent; 2) solid phase—sand grains, clay; 3) gaseous phase—steam and gasses. The process also involves the step of pressure decrease inside the reactor to activate a gas desorption dissolved in bituminous sand mixture. The process of separation of the bitumen and sand combines centrifuging and discharging individual products for further processing.

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 extracting oil from sand. The method includes extracting a mass containing sand and oil and translating the sand and oil to a mixing tank. A solution containing terpenes is injected into the mixing tank using an eddy pump and the eddy pump creates a vortex within the mixing tank in order to separate the sand from the oil. The separated sand and oil is then moved from the mixing tank to a separation tank wherein pumps in the mixing tank continue to act upon the sand and oil to separate the two apart so that a water and sand mixture is in an upper portion of the mixing tank while oil is translated to a bottom portion of the separation tank. The sand and water can then be translated to an accumulation tank while the oil is taken to a collection tank for use.

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: 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 system and process is disclosed for retorting oil shale and extracting shale oil and other hydrocarbons therefrom, in which a cased heat delivery well is drilled generally vertically through an overburden and then through a body of oil shale to be retorted to the bottom thereof, generally horizontally under the body of oil shale to be retorted, and then back to the earth surface. Heat energy is transmitted conductively to the body of oil shale to be retorted from a closed loop heat delivery module in the well, the module comprising a fluid transmission pipe containing a heating fluid heated to at least a retorting temperature. Heat energy is also transmitted to the body of oil shale to be retorted above the fluid transmission pipe by vapor conduits that conduct retort vapors upward through the body of oil shale to be retorted; the ascending retort vapors condense and reflux, delivering their latent heat of vaporization to the body of oil shale to be retorted, and the condensed retort liquids descend.

Abstract: A mined ore processing apparatus to process mined ores, such as oil sands ore, into granular material is disclosed. An ore processor bed receives the ore to be processed. The ore processor bed has a frame supporting several rotating elements each separately driven to provide independent rotation rate and direction from the other. The ore processing bed is operable as a sizing device to decimate mined ore supply into granular material and separating it from rocks and other large lump mineral materials found in situ. The ore processing bed may be oriented to provide an upward inclination, which, when combined with alternating rotating element rotation directions, provides a crushing action to the ore material to crush larger rock. Alternately, a rock crusher is also provided to disintegrate oversized materials.

Abstract: A system and process for concentrating hydrocarbons in a bitumen feed comprising bitumen, water and solids. The system comprises an inclined plate separator, a hydrocarbon cyclone and a centrifuge. The inclined plate separator separates the bitumen feed into a first overflow stream and a first underflow stream, the first overflow stream having a first bitumen concentration greater than that of the first underflow stream. The hydrocarbon cyclone separates the first underflow stream into a second overflow stream and a second underflow stream. The centrifuge separates the second overflow stream into a third overflow stream and a third underflow stream, the third overflow stream having a third bitumen concentration that is greater than that of the third underflow stream.

Abstract: The present invention relates to hydrocarbon extraction method and apparatus therefor.

Abstract: A process is disclosed for converting Tar Sand to fuels and/or valuable chemicais. The process comprises the steps of a) activating Tar Sand to make it more susceptible to conversion; c) partially converting the Tar Sand to a solubilized material; and d) subjecting the unconverted Tar Sand to a second conversion step. The process optionally comprises a step b) of adding a solvent to the activated Tar Sand. In a preferred embodiment the solubilized Tar Sand obtained in step c) is removed before the unconverted Tar Sand is subjected to step d).

Abstract: A use of a fluorocarbon polymer as a surface of a vessel or conduit in a paraffinic froth treatment (PFT) process, for reducing fouling. The foulant comprises asphaltenes. The surface has an average water contact angle of greater than 90 degrees, a standard deviation of water contact angles divided by the average water contact angle of less than 0.1, and impurities of less than 1000 ppmw. The fluorocarbon polymer may be a polytetrafluoroethylene (PTFE)-based polymer. The surface may be substantially free of colorants, fillers, and plasticizers.

Abstract: An apparatus for processing bitumen froth comprising a cyclone body having an elongated conical inner surface defining a cyclone cavity extending from an upper inlet region with a diameter DC to a lower apex outlet with a diameter DU of not less than about 40 mm; an inlet means forming an inlet channel extending into the upper inlet region of said cyclone cavity; and a vortex finder forming an overflow outlet of a diameter DO extending into the upper inlet region of said cyclone cavity toward said lower apex outlet and having a lower end extending an excursion distance below said inlet channel, said excursion distance being operable to permit a portion of bitumen that passes through said inlet channel to exit said overflow outlet without having to make a spiral journey down said cyclone cavity, wherein a lower end of the vortex finder within the cyclone cavity is disposed a free vortex height (FVH) distance from said lower apex outlet.

Abstract: A method and apparatus for recovering bitumen as froth from a feed stream having solids, water and bitumen is provided using a separating vessel having mounted thereon a downpipe assembly, the downpipe assembly having at least one downpipe and a nozzle in fluid communication with each downpipe, for aerating a stream of middlings withdrawn from the separating vessel and reintroducing the aerated middlings back to the separating vessel.

Abstract: A bitumen recovery process is provided which includes the step of providing a bitumen froth or a component derived from the bitumen froth as a feed material, wherein the bitumen froth is produced in a primary separation process from a slurry comprising oil sand and water. Further, the process includes the step of subjecting the feed material to froth flotation in a column flotation cell in order to recover a bitumen product from the feed material. Preferably, the froth flotation cell includes an underwash zone, wherein a bitumen-rich fraction of the feed material is passed through the underwash zone as the bitumen-rich fraction rises within the column flotation cell.

Abstract: A process for the treatment of a tailings stream is provided. The tailings stream comprises water, sand and clay fines and is produced from bitumen extraction process of an oil sands ore. The process for treating the tailings stream comprises contacting a polysilicate microgel, a polyacrylamide and one or both of a multivalent metal compound and a low molecular weight cationic organic polymer with a tailings stream to flocculate sand and clay fines.

Abstract: An apparatus, system, and method are disclosed for separating minerals from mineral feedstock—for example bitumen from tar sand. The apparatus includes residence chambers for contacting solvent and tar sand. The solvent-tar sand contact occurs in at least two stages. The drained miscella from the first stage is sent to a flashing module to separate the miscella into recovered solvent, a bitumen stream, and a volatile hydrocarbons stream. Solvent is recycled from the final stage and reused in the residence chambers. An energy recovery module recovers the energy from the volatile hydrocarbons stream. A solvent stripper removes the solvent residue from the drained tar sand to create a cleaned sand stream, and the solvent stripper recycles the solvent vapors to energize and assist the separation process. The apparatus enables a water-free, energy efficient, and nearly complete recovery of bitumen from tar sand.

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: A process for the extraction and recovery of bitumen from oil sands and a process for the treatment of tailings are disclosed. Bitumen is recovered in a process comprising contacting a polysilicate microgel with an ore sand oil to produce a froth comprising bitumen and a tailings stream comprising water, sand and clay fines. Preferably the tailings stream is dewatered and recovered water may be recycled to the extraction process. Polysilicate microgel may be carried through to a dewatering step and enhances flocculation in dewatering said tailings.

Abstract: Carbon disulfide is used as a solvent to extract bitumen from oil sands in an anhydrous countercurrent flow process that is compatible with existing procedures for upgrading bitumen. The solution is then fractionated to separate the carbon disulfide from the bitumen product. The bitumen is then treated with hydrogen to decompose the remaining carbon disulfide. The process should provide high yields and meet environmental concerns.

Abstract: A process for treating a bitumen froth containing bitumen, solid mineral material and water, including subjecting a first mixture containing the bitumen froth and a first amount of a paraffinic solvent to first gravity separation, thereby producing a first overflow stream and a first underflow stream, wherein the first gravity separation is performed so that the first underflow stream contains between about 5 percent and about 40 percent by weight of the asphaltenes contained in the first mixture. A second mixture containing the first underflow stream and a second amount of the paraffinic solvent is subjected to second gravity separation in order to recover bitumen from the first underflow stream.

Abstract: A process is provided for recovering heavy minerals from aqueous oil sand tailings, the oil sand tailings having heavy minerals, other coarse solids such as silica, fines, residual bitumen and water, including desliming the oil sand tailings in a desliming means by removing a portion of free fines and residual bitumen from the oil sand tailings; attritioning the oil sand tailings in an attritioner to remove adhered fines and residual bitumen from the heavy minerals and other coarse solids; and subjecting the deslimed and attritioned tailings to separation in a separation means to separate the heavy minerals from the other coarse solids present in the deslimed and attritioned tailings and produce a concentrated heavy minerals fraction.

Abstract: The present invention provides method for recovering fossil-based materials from oil sources using multifunctional, multipolymeric continuous composition spectrum surfactant mixtures. The invention also provides methods for reducing the loss of volatile organic compounds (VOCs) from oil storage containers using multifunctional, multipolymer surfactants. The multifunctional, multipolymer surfactants are characterized by a hydrophobic part and a hydrophilic part. The hydrophobic part of the polymer surfactants includes functionalities that impart a polarity of greater than 0 Debye to the hydrophobic part. The polymer surfactants are further characterized by molecular weights that are above their entanglement weights. The result is polymer surfactants and their continuous composition surfactant-thickener mixtures with demulsifying characteristics.

Abstract: A system for separating hydrocarbons from a solid source including a primary separation tank including a first hydrocarbon removing device to remove hydrocarbons from a slurry of water and solids. Further, the system including a transfer device between the primary separation tank and a secondary separation tank, wherein the transfer device is configured to transfer solids from the slurry to the secondary separation tank. Further still, the system including a second hydrocarbon removal device, a fine particle separation device to remove remaining solids in the secondary separation tank, and a product collection tank to receive hydrocarbons removed from the primary and secondary separation tanks.

Abstract: A method and system for recovering fluid (e.g. liquid) hydrocarbons from both naturally-occurring and man-made mixtures of hydrocarbons and mineral substrates by the exploiting of buoyant beads.

Abstract: The invention relates to a chemical composition and a process for using the chemical composition to remove and recover petroleum hydrocarbons from a contaminated substrate including an ammonia compound; a nitrogen-containing compound; and an aqueous carrier solution.

Abstract: Method for release of organic materials from shale oil and like solid substances, by treating shale oil powder in a liquid medium, with vortical movements, wave movements, acoustic turbulent streams, or combinations thereof. The treatment causes foaming of the liquid medium followed by separation of the foam from the liquid medium, whereby the foam is enriched with organic materials released from the shale oil powder. The foam can be placed in a liquid organic solvent and treated with vortical movements, wave movements, acoustic turbulent streams, or combinations thereof. The treatment causes the extraction of hydrocarbons into the solvent, and the inorganic shale material to precipitate. The remaining inorganic sold material can be utilized in the manufacture of construction materials. The obtained solution of the extracted hydrocarbons into the solvent represents a synthetic fuel, which could be used after slight reforming as motor fuel, jet fuel, or the like.

Abstract: An improved method and apparatus for preparing and oil sand slurry. Mined oil sand ore is deposited into a rotatable breaker tube. As the rotary breaker rotates, the ore is advanced and broken. Process fluid may be differentially distributed throughout the length of the rotary breaker, forming an oil sand slurry and assisting in the comminution and ablation of the ore. The comminuted oil sand and process fluid passes through perforations in the interior surface of the rotary breaker, and are collected in a hopper below, while oversized ore lumps are ejected out of the discharge end of the rotary breaker. The rotatable breaker tube is resistant to backflow at higher infeed rates.

Abstract: Of the many compositions and methods provided herein, one method includes a method comprising: contacting tar resident in a well bore with a treatment fluid comprising a styrene-acrylate polymer; and allowing the styrene-acrylate polymer to interact with the tar to at least partially reduce the tendency of the tar to adhere to a surface. Another method provided herein includes a method for treating tar sand comprising: contacting the tar sand with a treatment fluid comprising an aqueous fluid and a styrene-acrylate polymer, the tar sand comprising tar and sand; and allowing the styrene-acrylate polymers to interact with the tar to at least partially separate the tar from the sand.

Abstract: The present disclosure relates to a system and method of providing water management and utilization during the process of dewatering and retorting of oil shale. More specifically, the process described relates to co-producing potable and non-potable water, for various uses, during the extraction of petroleum from shale oil deposits. Generally, the process allows the production of multiple streams of waters or varying salinity and pressures at least one of which is of high enough pressure for reinsertion into geological formations or reservoirs, and another which may supply a potable water source. In one embodiment, the high pressure required for reinserting the non-potable water into geological formation or reservoirs may be utilized for producing the potable water supply. In another embodiment, the non-potable water supply may also be used for entraining and sequestering undesired emissions, such as CO2.

Abstract: Methods for obtaining bitumen from bituminous material. The methods may include a dissolution step where a first solvent is added to material comprising bitumen to dissolve the bitumen contained therein. The majority of the dissolved bitumen is then removed from the mixture of first solvent and material comprising bitumen by filtering or settling the mixture of first solvent and material comprising bitumen. Any residual dissolved bitumen is then removed from the mixture of first solvent and material comprising bitumen by adding additional first solvent to the mixture to displace the residual dissolved bitumen from the mixture.

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: The invention relates to improved bitumen recovery processes and systems. The process may include providing a bitumen froth feed stream, separating the stream in a froth separation unit to produce a diluted bitumen stream, treating the diluted bitumen stream in an electrostatic desalter to produce a treated bitumen stream, and separating the treated bitumen stream into a solvent recycle stream and a bitumen product stream. The system may include a combined AC/DC desalter with a control unit for optimizing the treatment process to produce a product bitumen stream using less solvent and smaller separators than conventional bitumen froth treatment plants and processes.

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 disclosure relates to improved bitumen recovery processes and systems. In particular, the disclosure teaches processes and systems for recovering heavy crude oil while avoiding fouling of equipment by recycling at least a portion of a product bitumen from a solvent recovery unit for mixing with an overhead bitumen stream that may be a diluted bitumen stream containing solvent and bitumen. The overhead bitumen stream is a near-incompatible stream and the stream of mixed overhead bitumen stream and the treated bitumen stream is a compatible stream that will not foul equipment upon heating.

Abstract: Methods for preparing solvent-dry, stackable tailings. The methods 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. The first solvent-wet tailings are washed with a second solvent that removes the first solvent from the tailings. Second solvent remaining in the tailings is removed to thereby produce solvent-dry, stackable tailings.

Abstract: The present invention provides a composition and method for separating bitumen from oil sands deposits. The invention includes a chemical composition having organic chemicals that can be used to stimulate the separation of one or more constituent components from oil sands. The chemical composition can be used for bitumen recovery from oil sands deposits and similar applications. The invention also includes a process for recovering bitumen and similar hydrocarbon oils from oil sands using the chemical composition. The chemical composition includes a peroxide and one or more additive compounds blended in an aqueous carrier solution. The additive compound is preferably a nitrogen-containing compound, an alcohol compound, or a combination of both. The aqueous carrier solution is of sufficient volume operable to disperse at least one of the peroxide and the additive compound in the aqueous carrier solution.

Abstract: Disclosed is a system for processing oil sands to remove bitumen, the viscous petroleum product adhered to the sands, from the sands itself. The processing system is designed to be substantially air tight, preventing outside air from entering and volatile chemicals from escaping from the system. Mined oil sands are delivered to the system, which creates a slurry of oil sands and solvent in a slurry chamber. The slurry is transported to a dissolution chamber which conditions the slurry before the slurry is sent to an extraction chamber. A plurality of trays and scrapers further conditions the slurry to remove bitumen. The use of heavy, aromatic solvents and light, paraffinic solvents in sequence improves bitumen recovery while allowing environmentally safe processing of the sands to occur in a later step. The sands are dried and the solvent recovered for recycling and reuse in the system. Clean, dry sands are returned to the source of mined oil sands for reclamation.

Abstract: Bitumen within raw oilsands may be cracked and fully recovered by light hydrocarbon extraction following exposure to modified natural zeolite catalysts under cracking conditions. The recovered bitumen is reduced in viscosity, with lower boiling point distributions. Effective cracking of oilsands bitumen using economical, abundant and readily disposable natural zeolites represents a significant step towards a waterless and environment friendly extraction process.

Abstract: Some embodiments relate to an oil sands processing system comprising a release tube, a water supply nozzle and an intake nozzle forming an inlet of the tube, with the nozzles configured to pass water from the supply nozzle to the intake nozzle across a gap positioned to receive oil sand and air to form a slurry for passage along a flow path, with the intake nozzle diameter being larger than the supply nozzle diameter and the tube further comprising a constriction comprising a diameter that is less than the intake nozzle diameter and greater than the supply nozzle diameter.

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: 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 continuous process for upgrading a heavy hydrocarbon includes the steps of: obtaining a heavy hydrocarbon; heating the heavy hydrocarbon; contacting the heavy hydrocarbon with a solvent at upgrading conditions so as to produce a first product comprising a mixture of upgraded hydrocarbon and solvent and a second product comprising asphaltene waste and water; continuously feeding the first product and the second product to a first separator; heating the first product; and continuously feeding the first product to a second separator to separate the upgraded hydrocarbon from the solvent. A system is also provided.

Abstract: Oil sands and like host materials are leached with a selected leachant to render pumpable the oil (including heavy oil, bitumen or kerogen and asphaltenes) as leachate. In a preferred embodiment, natural deposits are in situ leached and the leachate recovered and removed for treatment. The leachant is separated and recycled. The leachant is selected to be biodegradable and to not precipate asphaltenes, and to comprise monoterpenes of the formula C10H16. The overall process allows environmentally acceptable resource development and contaminated site remediation.

Abstract: An apparatus for processing oil sand to produce a liquid stream comprising water and bitumen and a solid stream comprising solid particles, and a method and control system for controlling the apparatus. The apparatus includes a drum having first and second ends, a conditioning zone adjacent the first end, a compressing zone adjacent the second end and a processing zone therebetween. A rotatable spiral trough, having lifting members therein, extends through each zone for imparting a spiral rolling motion to the oil sand. An oil sand inlet communicates with the conditioning zone, while a water inlet communicates with the processing zone. A liquid stream outlet is located at the first end of the drum, while a solid stream outlet is located adjacent the second end. Preferably, the spiral trough has a width through the compressing zone less than through the processing zone and a height through at least a portion of the compressing zone greater than through the processing and conditioning zones.

Abstract: An apparatus and process are described for processing oily particulate material. The process allows for recovery of the oil and separation of the water from the sand in the oily particulate material. The process involves transferring the oily particulate material into a vacuum tank and processing the oily particulate material in the vacuum tank. The apparatus is related to a vacuum tank for processing oily particulate material. The vacuum tank has a series of air supply pipes for adding compressed air to the material in the vacuum tank. Furthermore, the vacuum tank has air nozzles through which the air is added to the vacuum tank.

Abstract: Embodiments of a method and a system for recovering energy, materials or both from asphaltene-containing tailings are disclosed. The asphaltene-containing tailings can be generated, for example, from a process for recovering hydrocarbons from oil sand. Embodiments of the method can include a flotation separation and a hydrophobic agglomeration separation. Flotation can be used to separate the asphaltene-containing tailings into an asphaltene-rich froth and an asphaltene-depleted aqueous phase. The asphaltene-rich froth, or an asphaltene-rich slurry formed from the asphaltene-rich froth, then can be separated into a heavy mineral concentrate and a light tailings. Hydrophobic agglomeration can be used to recover an asphaltene concentrate from the light tailings. Another flotation separation can be included to remove sulfur-containing minerals from the heavy mineral concentrate. Oxygen-containing minerals also can be recovered from the heavy mineral concentrate.

Abstract: The invention relates to an improved bitumen recovery process. The process includes adding water to a bitumen-froth/solvent system containing asphaltenes and mineral solids. The addition of water in droplets increases the settling rate of asphaltenes and mineral solids to more effectively treat the bitumen for pipeline transport, further enhancement, refining, or any other application of reduced-solids bitumen.