Language selection

Search

Patent 1146897 Summary

Third-party information liability

Some of the information on this Web page has been provided by external sources. The Government of Canada is not responsible for the accuracy, reliability or currency of the information supplied by external sources. Users wishing to rely upon this information should consult directly with the source of the information. Content provided by external sources is not subject to official languages, privacy and accessibility requirements.

Claims and Abstract availability

Any discrepancies in the text and image of the Claims and Abstract are due to differing posting times. Text of the Claims and Abstract are posted:

  • At the time the application is open to public inspection;
  • At the time of issue of the patent (grant).
(12) Patent: (11) CA 1146897
(21) Application Number: 355671
(54) English Title: RECOVERY OF BITUMEN FROM TAR SANDS SLUDGE USING ADDITIVES
(54) French Title: SEPARATION DU BITUME DES SABLES BITUMINEUX A L'AIDE D'ADDITIFS
Status: Expired
Bibliographic Data
(52) Canadian Patent Classification (CPC):
  • 196/24
(51) International Patent Classification (IPC):
  • C10G 1/04 (2006.01)
(72) Inventors :
  • ELANCHENNY, VYTHILINGAM (United States of America)
  • ERSKINE, HAROLD L., JR. (United States of America)
  • SEITZER, WALTER H. (United States of America)
(73) Owners :
  • SUNCOR ENERGY INC. / SUNCOR ENERGIE INC. (Canada)
(71) Applicants :
(74) Agent: GOWLING LAFLEUR HENDERSON LLP
(74) Associate agent:
(45) Issued: 1983-05-24
(22) Filed Date: 1980-07-08
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract



ABSTRACT

Improved method for the treatment of sludge from
a water storage retention pond used to store the tailings
discharged from a tar sands water extraction process. The
method involves mixing the sludge, prior to its processing,
with an effective amount of a bitumen flotation promoter, e.g.,
an ammonium lignin sulfonate whereby a froth is formed. The
froth is separated and processed. The use of the promoter
increases substantially the recovery of the bitumen from the
sludge.


Claims

Note: Claims are shown in the official language in which they were submitted.


CLAIMS:

1. In the method of recovering bitumen from sludge
by agitating and aerating sludge recovered from a retention
pond used to store tailings from water extraction of bitumen
from tar sands, and separating resulting froth containing
bitumen formed during the agitation and aeration, the improve-
ment comprises:
admixing with the sludge an effective amount
of a bitumen flotation promoter selected
from the group consisting of phosphates, creo-
sotes, phenols, phenol derivatives, starches,
modified starches, lignin sulfonates and
polycarboxylates.

2. Improvement according to Claim 1 wherein the
amount of additive is in the range between from about 10 parts
to about 10,000 parts of additive per million parts by weight
of sludge.

3. Improvement according to Claim 2 wherein the sludge
is from a hot water bitumen extraction tar sands process.

4. Composition comprising tar sands sludge contain-
ing more than 10 wt.% solids including 0.5 to 20 wt.% bitumen
and an effective amount of bitumen flotation promoter selected
from the group consisting of phosphates, creosotes, phenols,
phenol derivatives, starches, modified starches, lignin sul-
fonates and polycarboxylates to enhance the separation of the
bitumen from the sludge when the composition is agitated and
aerated.

22


5. Composition according to Claim 4 wherein the
amount of the promoter is in the range between from about 10
parts to about 10,000 parts of additive per million parts by
weight of sludge.

23

Description

Note: Descriptions are shown in the official language in which they were submitted.


1146897




BACKGROUND OF THE INVENTION


The present invention relates generally to an improvement
in the recovery of bitumen from tar sands. The invention further
relates to an improvement in the recovery of bitumen in water
processes of extracting bitumen from tar sands. This invention
particularly relates to the improved treatment of tailings dis-
charged from a water extraction process and the improved treatment
of tailings retained in a water storage retention pond. More par-
ticularly, this invention relates to an improved method of treat-
ing the sludge layer from a retention pond to recover bitumen
froth therefrom using certain additives.


Tar sands are also known as oil sands or bituminous
sands. The sand deposits are found in numerous locations
throughout the world, e.g., Canada, United States, Venezuela,
Albania, Rumania, Malagasy and U.S.S.R. The largest deposit,




.. 1 ~


and the only one of present commercial importance is in the
northeast of the Province of Alberta, Canada.


Tar sand is a three-component mixture of bitumen,
mineral and water. Bitumen is the component for the
extraction of which tar sands are mined and processed.
The bitumen content is variable, averaging 12 wt.% of the
deposit, but ranging from 0 to 18 wt.%. Water typically runs
3 to 6 wt.% of the mixture, increasing as bitumen content de-
creases. The mineral content constitutes the balance.


Several basic extraction methods have been known for
many years for separating the bitumen from the sands. In a
"cold-water" method, the separation is accomplished by mixing
the sands with a solvent capable of dissolving the bitumen.
The resulting mixture is then introduced into a large volume
of water, water with a surface agent added, or a solution of
a neutral salt in water. The combined mass is then subjected
to a pressure or gravity separation.


The "hot-water" process for primary extraction of
bitumen from tar sands consists of three major process steps
(a fourth step, final extraction, is used to clean up the
recovered bitumen for further processing). In the first step,
called conditioning, tar sand is mixed with water and heated
with open steam to form a pulp of 70-85 wt.% solids. Sodium
hydroxide or other reagents are added as required to maintain
the pH in the range of about 8.0-8.5. In the second step,
called separation, the conditioned pulp is diluted further so

that settling can take place. The bulk of the sand-sized
particles (greater than 325 mesh screen) rapidly settles and


1~68~7

is withdrawn as sand tailings. Most of the bitumen rapidly
floats (settles upward) to form a coherent mass known as bitu-
men froth which is recovered by skimming the settling vessel.
An aqueous middlings layer containing some mineral and bitumen
is formed between these layers. A scavenger step may be con-
ducted in the middlings layer from the primary separation step
to recover additional amounts of bitumen therefrom. This step
usually comprises aerating the middlings. The froths recovered
from the primary and scavenger step can be combined, diluted
with naphtha and centrifuged to remove more water and residual
mineral. The naphtha is then distilled off and the bitumen is
coked to a high quality crude suitable for further processing.
Hot water processes are described in U.S. Patents Nos.
3,487,003; 3,496,0g3; 3,502,565; 3,502,566; 3,502,575; 3,526,585;
3,951,800; 3,951,779; 3,509,641 and 3,751,358. Tailings can
be collected from the aforementioned processing steps and gen-
erally will contain solids as well as dissolved chemicals. The
tailings are collected in a retention pond in which additional
separation occurs. The tailings can also be considered as
processing water containing solids which are discharged from
the extraction process. The tailings comprise water, both
the natural occurring water and added water, bitumen and mineral.


The mineral particle size distribution is particularly
significant to operation of the hot water process and to sludge
accumulation. The terms sand, silt and clay are used in
this specification as particle size designations. Sand is
siliceous material which will not pass through a 325 mesh
screen. Silt will pass through a 325 mesh screen, but is
larger than two microns and can contain siliceous material.


97

Clay is smaller than 2 microns and also can contain siliceous
material. The word fines as used herein refers to a combina-
tion of silt and clay.


Conditioning tar sands for the recovery of bitumen
consists of heating the tar sand/water feed mixture to process
temperature (180~200F), physical mixing of the pulp to uniform
composition and consistency, and the consumption (by chemical
reaction) of the caustic or other added reagents. Among the
added reagents are phosphates as disclosed in U. D. Patent
No. 3,422,000; sodium hydroxide and sodium tripolyphosphate
as disclosed in U.S. Patent No. 3,556,982; alkali metal bicar-
bonates as disclosed in U.S. Patent No. 4,120,777; and the
product resulting from the addition of ammonium hydroxide to
a~ueous tannic acid as disclosed in U.S. Patent No. 3,953,317.
Also non-foaming wetting agents including nonionic detergents
are often added. Under the aforementioned conditions, bitumen
is stripped from the individual sand grains and mixed into the
pulp in the form of discrete droplets of a particle size on
the same order as that of the sand grains. During conditioning,
a large fraction of the clay particles become well dispersed and
mixed throughout the pulp. The conditioning process which
prepares bitument for efficient recovery during the following
process steps also prepares the clays to be the most difficult
to deal with in the tailings disposal operation.


The other process step, called separation, is
actually the bitumen recovery step, the separation having
already occurred dur~ng conditioning. The conditioned tar

sand pulp is screened to remove rocks and unconditionable
lumps of tar sands and clay. The reject material, "screen




--4--

~6~'7

oversize", is discarded. The screened pulp is further diluted
with water to promote two settling processes. Globules
of bitumen, essentially mineral-free, float upward to form
a coherent mass of froth on the surface of the separation
units; and, at the same time, mineral particles, particularly
the sand size material, settle down and are removed from the
bottom of the separation unit as sand tailings. These two
settling processes take place through a medium called the
middlings. The middlings consist primarily of water, bitumen
particles and suspended fines.


The particular sizes and densities of the sand
and of the bitumen particles are relatively fixed. The
parameter which influences the settling processes most is
the viscosity of the middlings. Characteristically, as the
suspended material content rises above a certain threshold,
which varies according to the composition of the suspended
fines, viscosity rapidly achieves high values with the effect
that the settling processes essentially stop. Little or no
bitumen is recovered and all streams exiting the unit have
about the same composition as the feed. As the feed suspended
fines content increases, more water must be used in the process
to maintain middlings viscosity within the operable range.


The third step of the hot water process is scavenging.
The feed suspended fine content sets the process water require-
ment through the need to control middlings viscosity which, as
noted before, is governed by the clay/water ratio. It is usu-
ally necessary to withdraw a drag stream of middlings to main-

tain the separation unit material balance, and this stream of
middlings can be scavenged for recovery of incremental amounts



t~71

of bitumen. Air flotation is an effective scavenging method
for this middlings stream.


Final extraction or froth clean-up is usually accom-
plished by centrifugation. Froth from primary extraction is
diluted with naphtha, and the diluted froth is then subjected
to a two stage centrifugation. This process yields an oil pro-
duct of essentially purel but diluted, bitumen. Water and mineral
and any unrecovered bitumen removed from the froth constitutes
an additional tailing stream which must be disposed.


In the terminology of extractive processing, tailings
are a throwaway material generated in the course of extracting
the valuable material from the non-valuable material. And in
tar sands processing tailings consist of the whole tar sand
plus net additions of process water less only the recovered
bitumen product. Tar sand tailings can be subdivided into
three categories: (1) screen oversize; (2) sand tailings -
the fraction that settles rapidly, and (3) middlings - the
fraction that settles slowly. Screen oversize is typically
collected and handled as a separate stream.


Tailings disposal is all the operations required to
place the tailings in a final resting place. Because the tail-
ings contain bitumen emulsions, finely dispersed clay with poor
settling characteristics and other contaminants, water pollution
considerations prohibit discarding the tailings into rivers,
lakes or other natural bodies. Currently the tailings are stored

in retention ponds (also referred to as evaporation ponds) which
involve large space requirements and the construction of expen-
sive enclosure dikes. A portion of the water in the tailings


'7

can be recycled back into the water extraction process as an
economic measure to conserve water. Currently two main operat-
ing modes for tailings disposal are (1) dike building -
hydraulic conveying of tailings followed by mechanical com-
paction of the sand tailings fraction; and (2) overboarding -
hydraulic transport with no mechanical compaction.


At one commercial location, for dike building,
tailings are conveyed hydraulically to the disposal area and
discharged onto the top of a sand dike which is constructed
to serve as an impoundment for a pool of liquid contained in-
side. On the dike, sand settles rapidly and a slurry of water,
silt, clay and minor amounts of bitumen, as well as any chemical
used during processing flows into the pond interior. The
settled sand is mechanically compacted to build the dike
to a higher level. The slurry which drains into the pond
interior commences stratification in settling over a time scale
of months and years. As a result of this long term settling,
three layers form. The top layer, e.g., 5-10 feet of the pool,
i8 a layer of relatively clear water containing minor amounts
of solid, e.g., up to 5 wt.% and any dissolved chemicals. This
layer of pond water can be recycled to the water extraction
process without interfering with extraction of bitumen from
tar sands. Below this clear water layer is a continuity in
solid contents. Over a fe~ feet, solids content increases to
about 10-15 wt.% and thereafter, solids contents increase
regularly toward the pond bottom. In the deeper parts of the
pond solid contents of over 50 wt.% have been measured. This
second layer is commonly called the sludge layer. In general


~6~

the sludge layer can be characterized as having more than
10 wt.% of solids (which is defined as mineral plus bitumen).
More particularly the sludge can be characterized as having
20 wt.% to 50 wt.% solids. Also the sludge can be characterized
as having about 0.5 to about 20 wt.% bitumen. The solids con-
tents of the sludge layer increase regularly from top to bottom
by a factor of about 4-5. Portions of the solids are clays.
The clays, dispersed during processing, apparently have partially
reflocculated into a fragile gel network. Through this gel,
particles of larger-than-clay sizes are slowly settling. Gen-
erally this sludge layer cannot be recycled to the separation
step because no additional bitumen is extracted. A third layer
formed of sand also exists.


Overboarding is the operation in which tailings are
discharged over the top of the sand dike directly into the
liquid pool. A rapid and slow settling process occurs but
this distinction is not as sharp as in the previously described
dike building and no mechanical compaction is carried out.
The sand portion of the tailings settles rapidly to form a
gently sloping beach, extending from the discharge point
toward the pond interior. As the sand settles, a slurry drains
into the pool and commences long-term settling. Water in ponds
prepared by both dike building and overboarding can be in-
cluded in the general definition of sludge in the present de-
scription.


Methods for treating sludge formed in a retention
pond used to store tailings from a hot water extraction of

bitumen from tar sands are disclosed in Canadian Patents Nos.
975,696; 975,697; 975,698; 975,699 and 975,700. The first




mentioned Canadian Patent discloses removing sludge from a
pond, placing the sludge in an air scavenger treating zone
wherein the sludge is aerated and agitated concurrently to
form an upper bitumen froth layer and a lower tailings of
water and mineral water. The lower tailings can be discharged
into a retention pond. The upper bitumen froth is sent to a
settling zone wherein two layers are formed, an upper bitumen
layer reduced in mineral matter and water and a lower layer
comprised substantially of mineral matter and water with minor
amounts of bitumen. The latter lower layer is recycled back
to the air scavenger treating zone while the upper bitumen
layer is processed further to recover the bitumen. This
Canadian patent and the others also disclose that sodium sili-
cate can improve bitumen recovery when used in connection with
the aeration and agitation. Canadian Patent No. 975,697 dis-
closes a process similar to that described in the previous patent
with an additional step in that a portion of the lower layer,
which otherwise would be recycled back to the air scavenger
treating zone, is returned to the retention pond. Canadian
Patent No. 975,690 discloses feeding the sludge from a retention
pond to an air pressure zone wherein the sludge is aerated at
superatmospheric pressure to aerate bitumen in the sludge.
Canadian Patent No. 975,699 discloses feeding sludgé recovered
from a retention pond to aeration and settling zones and per-
mitting the sludge to form an upper froth layer and a lower
tailings layer. Canadian Patent No. 975,700 discloses feeding
sludge to an air scavenger treating zone wherein the sludge
is aerated and agitated concurrently and resulting froth is
aerated and agitated concurrently and resulting froth is
separated in the scavenger treating zone, while the tailings


11~6~97

are returned to the pond. However, none of the foregoing
Canadian patents disclose or suggest that the additives that
the applicants disclose would be suitable for treating sludge
removed from a retention pond.


SUMMARY OF THE INVENTION


Present invention is an improved method for processing
sludge formed in a retention pond used to store tailings obtained
from the water extraction of bitumen from tar sands. The
process involves removing sludge from a retention pond, agitating
and aerating concurrently the sludge in the presence of a
bitumen flotation promoter, e.g., ammonium lignin sulfonate,
which facilitates the separation of bitumen from the sludge.
The resulting froth, containing bitumen, is separated from the
treated mixture, and can be processed in a similar manner to
the froth obtained from the primary and scavenger steps. Also
present invention involves a composition comprising sludge
and an effective amount of bitumen flotation promoter.


DESCRITPION OF THE DRAWING


The attached drawing is a schematic representation
of one of applicants' embodiments as it relates to a hot
water extraction process.



DETAILED DESCRIPTION


Referring now to a single figure, tar sands are
fed into the system through a line 1 and pass to a conditioning
drum (or muller) 30. Water and steam are introduced to the




--10--


drum 30 through another line 2. The total water so introduced
in liquid and vapor form is a minor amount based on the weight
of the tar sands processed. The tar sands conditioned with
water, pass through a line 3 to the feed sump 31 which serves
as a zone for diluting the pulp with additional water via
line 20 before passage to the separation zone 32. The addi-
tional water 20 may be clear pond water.


The pulp tar sands are continuously flushed from
the feed sump 31 through a line 4 into separator zone 32.
The settling zone within the separator 32 is relatively quies-
cent so that bitumen froth rises to the top and is withdrawn via
line 5 while the bulk of the sand settles to the bottom as a
tailings layer which is withdrawn through line 6.


A middlings tailings stream is w_thdrawn through line
7 to be processed as described below. Another middlings stream,
which is relatively bitumen-rich compared to the stream with-
drawn through line 7, is withdrawn from the unit via line 8 to
a flotation scavenger zone 33. In this zone, an air flotation
operation is conducted to cause the formation of additional
bitumen froth which passes from the scavenger zone through
line 9 in mixture with the primary froth from the separator
32 to a froth settler 34. A bitumen-lean water stream is
removed from ~he bottom of the scavenger zone 33 through line
10 to be further processed as described below. In the settler
zone 34, some further bitumen-lean water is withdrawn from the
froth and removed through line 11 to be mixed with the
bitumen-lean water stream from the flotation scavenger zone 33,
the sand tailings stream from the separation zone 32 and a

portion of the lower middlings withdra~m via line 21 from the


37

separation zone 32. The bitumen froth from the settler 34 is
removed through line 12 for further treatment.


The bitumen-lean water from the froth settler 34,
the scavenger zone 33 and the separator 32, all of which make
up a tailing discharge stream which can be collected and
handled via a dike building or overboarding operation previously
described. The tailing discharge stream via line 13 can be
fed to distribution pipe 14. The distribution piping provides
for continuous and uniform delivery of the effluent 15 to the
pond 35. The latter can be considered another separation zone;
it is a zone of quietness. Both the dike building and over-
boarding operation result in what is commonly referred to as
a pond, particularly a retention pond. And as previously
described, three layers are formed in the pond. They are (1)
a top water layer relatively free of clay and bitumen and which
can be recycled; (2) a middle layer consiting of bitumen
and mineral (defined as not being soluble in toluene); and
(3) a bottom layer having a relatively high concentration of
sand. The middle layer of the pond is often referred to as
sludge.


The sludge is continuously being formed in a time
span of many months and even years. As a result its character-
istics are different from those of the middlings layer
drawn off from the separation zone 32 via lines 7 and 8.
Some of the differences include that the middlings layer
has a higher pH (e.g., about 8.4) whereas the sludge can
have a lower pH (e.g., about 7.3). The differences in pH

reflect changes which are not fully understood but which are


~G~5~7

occurring in the pond. Another difference between the sludge
and middlings streams (via lines 7 and 8) is the weight percent
of mineral, e.g., the middlings stream contains about a lower
8-12 wt.% whereas the sludge contains a higher weight %.


Applicants' improved method comprises withdrawing
sludge from the pond 35 by known means, for example, line 16
which opening is maintained in the sludge layer and which
line is attached to suction pump 36. Line 17 from the latter,
carries the sludge to treating zone 37. In applicants' in-
vention, an effective amount of the promoter is admixed with
the incoming sludge 17 or added to treating zone 37. The
promoter can be added to the treating zone 37, e.g., via line
18. Other combinations can be used. The resulting froth con-
taining bitumen can be separated and forwarded to additional
processing via line l9 while the remaining material can be
returned to the same pond or a different pond (not shown) via
line 20.


Agitation (not shown) within treating zone 37 can
be by known means such as stirring while the aeration (not
shown) also can be by known means such as forcing air through
a porous pipe in the bottom of the treating zone 37. Other
alternatives and combinations are known to those skilled in
the art. The amount of agitation and aeration can vary over
a wide range with economic considerations suggesting that the
minimum necessary to achieve the desired separation of bitumen
is preferred. Further, the amount of agitation and aeration
may vary depending, in part, on how much promoter is used. As

demonstrated hereinafter, both agitation and aeration may be
necessary, either one by itself is not effective.


'7

The promoter used to contact the sludge in contacting
zone 37 is a material that facilitates the separation of the
bitumen contained in the sludge. The promoter is not a flota-
tion agent in the sense that the latter is used in the con-
centration of minerals wherein the agent concentrates the
minera. (~ discussion as to the theory how such agents work
and a list of many such agents, see Kirk-Othmer, Encyclopedia
of Chemical Technology, 1st Edition, Vol. 6). Since the purpose
of the promoter used herein is to concentrate the bitumen in
a froth and leave behind the mineral it could be classified
as a bitumen flotation promoter, and which is selected from
the group consisting of phosphates including the salts of
alkali metals or NH4, creosotes, phenols, phenol derivatives,
starches, modified starches, lignin sulfonates including the
salts of alkali metals or NH4, and polycarboxylates including
the sodium salts. Preferred phosphates are sodium hexa-
metaphosphate, trisodium phosphate, sodium tripolyphosphate,
sodium pyrophosphate, sodium phosphate, disodium hydrogen
phosphate and monosodium hydrogen phosphate. Creosote, when
obtained by the destructive distillation of wood tar, is a
mixture of phenols and phenol derivatives. The phenols are
a class of aromatic organic compounds in which one or more
hydroxyl groups are attached directly to the benzene ring;
examples are phenol itself (benzophenol1 cresols, xylenols,
resorcinol and naphthols. Examples of phenol derivatives
include alkali metal salts of phenols. Creosote is also ob-
tained by distillation of coal-tar.


Starches are generally derived from corn, potatoes,

~6~7
wheat and other known sources. Modified starches are derived
from starches which have been modified by acetylation, chlori-
nation, acid hydrolysis or enzymatic action. Lignin sulfonates
are metallic or ammonium sulfonates made from lignins of sul-
fite pulp mill liquors. Preferred lignin sulfonates are
potassium, sodium and ammonium. A polycarboxylate can, for
example, result from the polymerization of any of a broad array of
organic acids comprising chiefly alkyl (hydrocarbon) groups
usually in a straight chain terminating in a carboxyl radical
(-COOH). The acid is polymerized and when the terminal acid
groups are reacted with bases, e.g., sodium hydroxide, a
sodium salt of the polycarboxylate results. More preferred
promoters are sodium polycarboxylates and ammonium lignin
sulfonate.


The amount of promoter used is an effective amount
in that it will facilitate the separation of the bitumen from
the sludge and can vary over a wide range. While economics
will determine the amount used in a commercial operation,
generally the range will be about 10 to 10,000 parts of pro-
moter per million parts by weight of sludge with 40 to 5000
parts preferred. The resulting novel composition comprising
the sludge and a bitumen flotation promoter is also appli-
cants' invention. The composition comprises tar sands sludge
containing more than 10 wt.~ solids including 0.5 to 20 wt.~
bitumen and an effective amount of bitumen flotation promoter
which enhances the separation of the bitumen from the sludge
when the composition is agitated and aerated.


The promoter, as indicated previously, can be incor-

porated with the sludge prior to or during the agitation and


~46~

aeration. With different sludges the optimum amount of
promoter can vary as well as the amount of agitation and
aeration. The the optimum amounts can be determined without
undue experimentation.


After the mixture of sludge and promoter and sludge
has been sufficiently agitated and aerated in treating zone
37 the resulting mixture can be transferred via line 19 to
separation zone 38 wherein the froth is permitted to separate.
In separation zone 37 two layers are formed, an upper bitumen
froth layer reduced in mineral matter and water and a lower
layer comprised substantially of mineral matter and water
with minor amounts of bitumen therein. The separated froth
(upper layer) could be fed via line 21 to the froth settler
zone 34, admixed with separation zone froth and thus processed
in the same manner as the froth obtained from the separation
zone 32. An alternative could be to bypass the froth settler
zone 34 and feed into line 12. The remaining materials (lower
layer), that is, the tailings containing water and the mineral
obtained as a result of the contacting in treating zone 36 can
be returned via line 20 to pond 35 or a different pond (not
shown).


The result of treating the sludge by applicants'
method is that the amount of bitumen remaining in the tailings
from treating zone 36 is substantially reduced. For example,
with one promoter the amount of bitumen removed from the
sludge, depending in part on the concentration of additive used,
ranges from 78 to 82 wt.%. Another result of applicants'

method is that the ratio of bitumen to mineral increases, e.g.,
the sludge can have a bitumen/mineral ratio of 0.27 whereas




-16-


the bitumen froth from the contacting zone 36 has a ratio of
0.89 to 1.5 depending on the concentration of additive and
the type. The higher ratio facilitates treatment of the froth.
Advantages of applicants' method include the fact that more bi-
tumen is ultimately recovered from the tar sands and the amount
of tailings requiring storage can be reduced. Both of the fore-
going economically enhance the tar sands operation.


Essentially, the improvement of the present invention
is the method of recovery of bitumen from sludge by agitating
and aerating sludge recovered from a retention pond used to
store tailings from water extraction of bitumen from tar sands
and separating resulting froth containing bitumen formed during
the agitation and aeration comprises admixing an effective
amount of the bitumen flotation promoter with the tar sands
sludge thereby enhancing the separation of bitumen from the
sludge.


The following examples illustrate the invention.
Comparative examples are also provided.


EXAMPLES


The procedure used to illustrate applicants' method
was as follows. To a Western Machinery Flotation Cell wa~
charged 3000 grams of tar sand sludge consisting of 6 wt.%
bitumen, 22 wt.~ mineral and 72 wt.~ water. The sludge had a
pH of 7.1. The Cell consists of a vessel and means for agita-

tion and aeration. The means for agitation are located about
2/3 down inside the vessel. The agitation means consist of two
parallel plates connected by a series of rods located toward
the outer edges, the effect being that of a cage. Inside the




-17-

97

outer cage is a similar but smaller cage which is turned by
a hollow shaft which goes upward through the outer plate and
is connected to a power source which rotates the inner cage.
The outer cage is connected to the shaft and the inner cage
so that when the inner cage rotates the outer one remains
stationary. The net effect is a high shear agitation. The
hollow shaft provides the means for passing air, or other
gases, down into the material being agitated.


The additives charged to the Cell and the amounts
used are shown in the accompanying Table I. The length of time
for running the cell is also shown in Table I. In the case
of the run containing a promoter, the promoter was added to
the vessel and the machine was run for 15 minutes. After stop-
ping the machine, the froth was removed by scraping it from the
vessel and placing it in a separate container. The sequence
was repeated once and the resulting total froth analyzed. The
analyses are reported in Table I.


The comparative run (1), without additive, involved
running the Cell for three fifteen minute intervals. Compari-
son of the data in accompanying Table I indicates that agitation
and aeration of the sludge by itself caused only a 30 wt.%
bitumen recovery (i.e., the amount of bitumen contained in
the froth over the amount of bitumen contained in the charge
to the cell) despite the additional 15 minutes of operation.


In contrast, use of a promoter in connection with

applicants' method, as demonstrated by runs 2-6 increased
bitumen recovery. The amount of bitumen recovery increased
to 40-82 wt.% despite a 15 minutes shorter operation time com-
pared to Run 1.




-18-

~4689~

Runs 7 and 8 indicate that sodium polyphosphates are
an effective promoter. These runs also indicate that a third
15 minutes of agitation and aeration increases overall bitumen
recovery.


Comparative runs using sodium silicate and agitation
only or aeration only clearly demonstrated the need for both
concurrently.


Three additional runs were performed as previously ~5
described except that the froth was skimmed continuously with
the unit running rather than stopping the unit first and then
skimming the froth. The results of the three runs are shown in
Table II.


--o z--
~ ~ ~1~6~7
~; ~
,,
a) ~ ,~ ~ ~ Ln r~ ~ er ~ o
E~ ~ ~ N 1~ Il) ~ CO CS~Lt~
O ~
~ a~ o o _I o o o _i o oo o
'1 0 ~
m-,
H 1~ m

0
~ ~ ~ ~ ~o
~9 ~
o ~ co co _/ o a~ 1 0
~ O I ~ OD 1` r-- CO ~Lr) ~ ~1
,1 o ~n
a) ~
~; 0
d~ .,1
o

H

S~ ~ ~ O~ ~ ~ ~ O ~ U~
S~ ~ ~
:E: 3
OdP ~0 r~l

o ~ _l ~
~0 ~ 10
~ ~ ~n
m o
m_d~ ~

H ~, o
~ ~4~ ~ ~ -
~ O ~ I O ~
~10 I + ~ O
O ~ I 11
~~ _~ ~
O~--~ + + Z
~~ a~ u~ u) + + + +~d V
P~~ C~ ~ V ~
O ~ ~0

` 0 V
O ~ .,
0 0 0 0 U~ O O O O
1: 0 /~ I o o 11~ r o o L~ 0
~ ~ O ~ ~ ~ I O
O O

_I ~ 0
0
a~ ~
~ ~a
S~ ~ ~ 0
I ~ O
~ ~1 0 ^ P~
_I a) _I ~I n~ 0 ~1
O ~
a) ~ ~ ~ ~= o
.~ ~ ~, e e e~ ~ ~ e O E~
~1 I O 1-l O O~
~ ' æ

zl ~ ~ ~ ~ u~



TABLE II
Promoter Enhances Bitumen Recovery

Amount of ~ Bitumen Recovered
Run Promoter Additive-ppm after 40 minutes
1 None - 69
2 Creosote 100 81
3 Dextrin 200 74
Dextrin is a starch gum formed by the hydrolysis of a starch
and is an example of a modified starch. Others are known to
those skilled in the art. Use of creosote or dextrin (runs 2
and 3) increased the amount of bitumen recovered compared to
the use of no promoter (run 1).


Additives, which when used in the Cell, did not
increase bitumen recovery from the sludge were sodium carbonate,
sodium bicarbonate, sodium n-alkyl sulfates, and petroleum
sulfonates.




-21-

Representative Drawing

Sorry, the representative drawing for patent document number 1146897 was not found.

Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 1983-05-24
(22) Filed 1980-07-08
(45) Issued 1983-05-24
Expired 2000-05-24

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $0.00 1980-07-08
Registration of a document - section 124 $50.00 1997-12-12
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
SUNCOR ENERGY INC. / SUNCOR ENERGIE INC.
Past Owners on Record
ELANCHENNY, VYTHILINGAM
ERSKINE, HAROLD L., JR.
SEITZER, WALTER H.
SUNCOR, INC.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

To view selected files, please enter reCAPTCHA code :



To view images, click a link in the Document Description column. To download the documents, select one or more checkboxes in the first column and then click the "Download Selected in PDF format (Zip Archive)" or the "Download Selected as Single PDF" button.

List of published and non-published patent-specific documents on the CPD .

If you have any difficulty accessing content, you can call the Client Service Centre at 1-866-997-1936 or send them an e-mail at CIPO Client Service Centre.


Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Drawings 1994-01-11 1 26
Claims 1994-01-11 2 39
Abstract 1994-01-11 1 13
Cover Page 1994-01-11 1 13
Description 1994-01-11 21 781