Note: Descriptions are shown in the official language in which they were submitted.
,
,
SLURRY TREATMENT METHOD AND APPARATUS
FIELD OF THE INVENTION
[0001] The present invention relates to extraction of bitumen from tar sands.
BACKGROUND OF THE INVENTION
[0002] Oil sands, also known as "tar sands" and "bituminous sands," are a
mixture of bitumen (tar), sand, and water. Bitumen is a heavy, viscous crude
oil,
having relatively high sulfur content. When properly separated from the oil
sands,
bitumen may be processed to synthetic crude oil suitable for use as a
feedstock for
the production of liquid motor fuels, heating oil, and petrochemicals. Oil
sand fields
exist throughout most of the world. Particularly significant deposits exist in
Canada,
including the Athabasca oil sands in Alberta, the United States, including the
Utah oil
sands, South America, including the Orinoco oil sands in Venezuela, and
Africa,
including the Nigerian oil sands. A majority of all of the known oil in the
world is
contained in oil sands.
[0003] Bitumen can be derived from a slurry containing tar sands using high
shear mixing equipment. The tar sands are highly abrasive on the machinery
used
to separate the bitumen from the sand and water. Conventional mixing equipment
is
subject to high wear rates that result from high speed operation on the
abrasive tar
sand slurry. Slower speed equipment is less effective at bitumen derivation.
[0004] The impellers used in the high-speed mixing equipment may have a
useful life of only a few of hours before needing to be replaced. Naturally,
this
requires frequent downtime for the machinery, which means the equipment is
rendered unusable and valuable work time is lost due to frequent repairs.
Using less
abrasion-prone materials, such as
1
CA 2786316 2018-06-05
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
ceramics, for the impellers has been proposed in the past, but has not
adequately relieved the
problem of extending the usable life of the mixing equipment.
[0005] Accordingly, there is a need and desire to provide a method and
apparatus for
deriving bitumen from tar sand slurry that has an extended usable lifetime.
SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention advantageously provide a method of
extracting bitumen from tar sands that has an extended usable lifetime. An
embodiment of
the invention includes a method of extracting bitumen from tar sands, the
method comprising
providing an apparatus for mixing fluids, the apparatus comprising: a housing
defining a
substantially cylindrical interior chamber bounded by spaced substantially
planar side walls
joined by a cylindrical peripheral wall; a substantially cylindrical rotor
rotatably mounted
within the interior chamber, the rotor having an axis, spaced substantially
planar sides, and a
cylindrical peripheral surface joining the planar sides; the cylindrical
peripheral surface of the
rotor and the cylindrical peripheral wall of the chamber defining an annular
space
therebetween having a substantially uniform dimension in the axial direction
of the rotor; at
least two arrays of spaced bores formed in the peripheral surface of the
rotor, each bore of
each array extending radially into the rotor a predetermined distance and
opening into the
annular space, the each array of spaced bores being arranged in a row that
extends around the
cylindrical peripheral surface of the rotor and being spaced from other arrays
such that a void
zone therebetween is created where no bores are formed in the peripheral
surface of the rotor;
at least one fluid inlet in the housing positioned to introduce fluid into the
chamber at
predetermined locations adjacent one of the substantially planar sides of the
rotor; multiple
inlets being substantially aligned to equalize pressure on the rotor as fluid
is introduced into
the chamber through the fluid inlets; anda fluid outlet in the housing
positioned for
2
withdrawal of fluid from the chamber at a third predetermined location
adjacent the
cylindrical peripheral surface of the rotor, the third predetermined location
being aligned
within the void zone for withdrawal of fluid after it has passed a row of
bores and to
minimize cavitation damage at the location of the fluid outlet; and providing
a separation
composition comprising: 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 of
greater than 7.5.
[0006-a] Another
embodiment of the invention relates to a method of
extracting bitumen from tar sands which are defining slurries comprising
bitumen, sand
particles and water, at least a portion of the bitumen being adhere to the
sand particles,
the method comprising:
= introducing the tar sands to a hydrosonic apparatus for mixing fluids,
the
apparatus comprising:
a housing defining a substantially cylindrical interior chamber bounded by
spaced substantially planar side walls joined by a cylindrical peripheral
wall;
a substantially cylindrical rotor rotatably mounted within the interior
chamber, the
rotor having an axis, spaced substantially planar sides, and a cylindrical
peripheral surface joining the planar sides;
the cylindrical peripheral surface of the rotor and the cylindrical peripheral
wall of
the chamber defining an annular space therebetween having a substantially
uniform dimension in the axial direction of the rotor;
at least two arrays of spaced bores formed in the peripheral surface of the
rotor,
each bore of each array extending radially into the rotor a predetermined
distance and opening into the annular space, the each array of spaced bores
being arranged in a row that extends around the cylindrical peripheral surface
of
the rotor and being spaced from other arrays such that a void zone
3
CA 2786316 2018-02-28
,
,
therebetween is created where no bores are formed in the peripheral surface of
the rotor;
at least one fluid inlet in the housing positioned to introduce fluid into the
chamber at predetermined locations adjacent one of the substantially planar
sides of the rotor; multiple inlets being substantially aligned to equalize
pressure
on the rotor as fluid is introduced into the chamber through the fluid inlets;
a fluid outlet in the housing positioned for withdrawal of fluid from the
chamber at
a third predetermined location adjacent the cylindrical peripheral surface of
the
rotor, the third predetermined location being aligned within the void zone for
withdrawal of fluid after it has passed a row of bores and to minimize
cavitation
damage at the location of the fluid outlet; and
at least one imput inlet for introducing a separation composition to the
hydrosonic apparatus;
= introducing the separation composition to the hydrosonic apparatus via at
least
one input inlet, said separation composition comprising:
- a wetting agent in the amount of from 0.001% to 2.5% by weight of the
separating composition,
- a hydrotropic agent and
- a dispersant having flocculating characteristics,
wherein the separating composition has a pH of greater than 7.5;
= mixing the tar sands and the separation composition to form a mixture;
= heating the mixture to a desired temperature;
= forcing the mixture through at least one cavitation zone to generate
cavitation
induced shock waves that propagate through the mixture;
4
CA 2786316 2018-02-28
,
,
= applying high intensity energy discharge to a local area of the mixture
to scour
the sand particles of the tar sands; and
releasing bitumen.
[0007]
Another embodiment of the invention includes an apparatus for
extracting bitumen from tar sands, the apparatus including: a housing defining
a
substantially cylindrical interior chamber bounded by spaced substantially
planar side
walls joined by a cylindrical peripheral wall; a substantially cylindrical
rotor rotatably
mounted within the interior chamber, the rotor having an axis, spaced
substantially
planar sides, and a cylindrical peripheral surface joining the planar sides;
the cylindrical
peripheral surface of the rotor and the cylindrical peripheral wall of the
chamber defining
an annular space therebetween having a substantially uniform dimension in the
axial
direction of the rotor; a first array of spaced bores formed in the peripheral
surface of
the rotor, each bore of the first array extending radially into the rotor a
predetermined
distance and opening into the annular space, the first array of spaced bores
being
arranged in a first row that extends around the cylindrical peripheral surface
of the rotor;
a second array of spaced bores formed in the peripheral surface of the rotor,
each bore
of the second array extending radially into the rotor a predetermined distance
and
opening into the annular space, the second array of spaced bores being
arranged in a
second row that extends around the cylindrical peripheral surface of the
rotor, the first
and second rows of bores being spaced apart in the axial direction of the
rotor and
defining a void zone therebetween such that no bores are formed in the
peripheral
surface of the rotor; a first fluid inlet in the housing positioned to
introduce fluid into the
chamber at a first predetermined location adjacent one of the substantially
planar sides
of the rotor; a second fluid inlet in the housing positioned to introduce
fluid into the
chamber at a second predetermined location adjacent the other one of the
substantially
planar sides of the rotor, the second fluid inlet being substantially axially
aligned with
the first fluid inlet to equalize pressure on the rotor as fluid is introduced
into the
chamber through the fluid inlets; and a fluid outlet in the housing positioned
for
4a
CA 2786316 2018-02-28
withdrawal of fluid from the chamber at a third predetermined location
adjacent the
cylindrical peripheral surface of the rotor, the third predetermined location
being aligned
within the void zone for withdrawal of fluid after it has passed a row of
bores and to
minimize cavitation damage at the location of the fluid outlet, wherein the
apparatus is
configured to receive a separation composition comprising: 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 of greater than 7.5.
[0007-a] Another
embodiment of the invention relates to a hydrosonic
apparatus for extracting bitumen from tar sands which are defining slurries
comprising
bitumen, sand particles and water, at least a portion of the bitumen being
adhere to the
sand particles, the apparatus comprising:
a housing defining a substantially cylindrical interior chamber bounded by
spaced
substantially planar side walls joined by a cylindrical peripheral wall;
a substantially cylindrical rotor rotatably mounted within the interior
chamber, the rotor
having an axis, spaced substantially planar sides, and a cylindrical
peripheral surface
joining the planar sides;
the cylindrical peripheral surface of the rotor and the cylindrical peripheral
wall of the
chamber defining an annular space therebetween having a substantially uniform
dimension in the axial direction of the rotor;
a first array of spaced bores formed in the peripheral surface of the rotor,
each bore of
the first array extending radially into the rotor a predetermined distance and
opening
into the annular space, the first array of spaced bores being arranged in a
first row that
extends around the cylindrical peripheral surface of the rotor;
a second array of spaced bores formed in the peripheral surface of the rotor,
each bore
of the second array extending radially into the rotor a predetermined distance
and
opening into the annular space, the second array of spaced bores being
arranged in a
4b
CA 2786316 2018-02-28
second row that extends around the cylindrical peripheral surface of the
rotor, the first
and second rows of bores being spaced apart in the axial direction of the
rotor and
defining a void zone therebetween such that no bores are formed in the
peripheral
surface of the rotor;
a first fluid inlet in the housing positioned to introduce fluid into the
chamber at a first
predetermined location adjacent one of the substantially planar sides of the
rotor;
a second fluid inlet in the housing positioned to introduce fluid into the
chamber at a
second predetermined location adjacent the other one of the substantially
planar sides
of the rotor, the second fluid inlet being substantially axially aligned with
the first fluid
inlet to equalize pressure on the rotor as fluid is introduced into the
chamber through
the fluid inlets;
a fluid outlet in the housing positioned for withdrawal of fluid from the
chamber at a third
predetermined location adjacent the cylindrical peripheral surface of the
rotor, the third
predetermined location being aligned within the void zone for withdrawal of
fluid after it
has passed a row of bores and to minimize cavitation damage at the location of
the fluid
outlet, and
at least one input outlet for introducing a separation composition to the
hydrosonic
apparatus;
wherein the apparatus is configured to
= receive the separation composition, said separation composition
comprising:
- a wetting agent in the amount of from 0.001% to 2.5% by weight of the
separating composition,
- a hydrotropic agent and
- a dispersant having flocculating characteristics,
wherein the separating composition has a pH of greater than 7.5;
4c
CA 2786316 2018-02-28
= mix the tar sands and the separation composition to form a mixture;
= heat the mixture to a desired temperature;
= force the mixture through at least one cavitation zone to generate
cavitation
induced shock waves that propagate through the mixture;
= apply high intensity energy discharge to a local area of the mixture to
scour the
sand particles of the tar sands; and
= release bitumen.
[0008] There
has thus been outlined, rather broadly, certain embodiments
of the invention in order that the detailed description thereof herein may be
better
understood, and in order that the present contribution to the art may be
better
appreciated. There are, of course, additional embodiments of the invention
that will be
described below and which will form the subject matter of the claims appended
hereto.
[0009] In this
respect, before explaining at least one embodiment of the
invention in detail, it is to be understood that the invention is not limited
in its application
to the details of construction and to the arrangements of the components set
forth in the
following description or illustrated in the drawings. The
invention is capable of
embodiments in addition to those described and of being practiced and carried
out in
various ways. Also, it is to be understood that the phraseology and
terminology
employed herein, as well as the abstract, are for the purpose of description
and should
not be regarded as limiting.
4d
CA 2786316 2018-02-28
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
[0010] As such, those skilled in the art will appreciate that the conception
upon which
this disclosure is based may readily be utilized as a basis for the designing
of other structures,
methods and systems for carrying out the several purposes of the present
invention. It is
important, therefore, that the claims be regarded as including such equivalent
constructions
insofar as they do not depart from the spirit and scope of the present
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above-mentioned and other features and advantages of this
disclosure, and
the manner of attaining them, will become more apparent and the disclosure
itself will be
better understood by reference to the following description of various
embodiments of the
disclosure taken in conjunction with the accompanying figures, wherein:
[0012] FIG. 1 is a partially sectioned view illustrating an embodiment of an
apparatus
for mixing fluids, for example, a slurry (Bitumen/sand/water-chemistry).
DETAILED DESCRIPTION OF THE INVENTION
[0013] In the following detailed description, reference is made to the
accompanying
drawings, which form a part hereof and show by way of illustration specific
embodiments in
which the invention may be practiced. These embodiments are described in
sufficient detail
to enable those skilled in the art to practice them, and it is to be
understood that other
embodiments may be utilized, and that structural, logical, processing, and
electrical changes
may be made. It should be appreciated that any list of materials or
arrangements of elements
is for example purposes only and is by no means intended to be exhaustive. The
progression
of processing steps described is an example; however, the sequence of steps is
not limited to
that set forth herein and may be changed as is known in the art, with the
exception of steps
necessarily occurring in a certain order.
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
[0014] As used herein, the term "about" means "approximately," and may
indicate as
much as a 10% deviation from the number being modified. As used herein,
"essentially free"
means an amount less than about 0.1%.
[0015] The invention will now be described with reference to the drawing
figures in
which like reference numerals refer to like parts throughout. Embodiments of
the invention
include bitumen-removal machinery combined with organic chemistry to remove
the bitumen
from tar sands while reducing wear on the equipment.
[0016] As depicted in FIG. 1, a hydrosonic mixer 11 comprises a cylindrical
housing
12 defining an internal cylindrical chamber 15. In the illustrated embodiment,
the housing 12
is formed by a casing 13 capped by an end plate 14 secured to the casing with
bolts 16. The
housing 12 may be formed in other ways such as, for example, a central
cylindrical shell
capped by two end plates.
[0017] A cylindrical rotor 17 is disposed within the cylindrical chamber 15 of
the
housing and is mounted on an axially extending shaft 18. The shaft 18 is
supported on either
side of the rotor 17 within bearing assemblies 19 that, in turn, are mounted
within bearing
assembly housings 21. The bearing assembly housings 21 are secured to the
housing 12 by
means of appropriate fasteners such as bolts 22. The shaft 18 projects from
one of the
bearing housings 21 for being coupled to a motive means such as an electric
motor (not
shown). It will thus be seen that the rotor 17 may be spun or rotated within
the cylindrical
chamber 15 in the direction of arrows 23 by activating the motor coupled to
the shaft 18.
[0018] The rotor 17 has a peripheral surface that is formed with one or more
circumferentially extending arrays of irregularities in the form of relatively
shallow holes or
bores 24. Embodiments may include a rotor 17 that is provided with two arrays
of bores 24
separated by a void 26, the purpose of which is described in more detail
below. It should be
understood, however, that fewer or more than two arrays of bores may be
provided in the
6
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
peripheral surface of the rotor as desired depending upon the intended
application of the
hydrosonic mixer 11. Further, irregularities other than holes or bores also
may be provided.
The rotor 17 is sized relative to the cylindrical chamber 15 in which it is
housed to define a
space, referred to herein as a cavitation zone 32, between the peripheral
surface of the rotor
and the cylindrical wall of the chamber 15.
[0019] Inlet ports 25 are provided in the housing 12 for supplying fluids to
be mixed
to the interior chamber 15 within the housing. Supply conduits 30 are coupled
to the inlet
ports 25. A liquid supply conduit 27 is coupled to the supply conduits 30 for
supplying liquid
such as Bitumen slurry to the hydrosonic mixer 11. A supply conduit 28
communicates with
the liquid supply conduit 27 for introducing and entraining additives/make up
chemistry
within the stream of liquid flowing through the liquid supply conduit 27.
[0020] The mixer 11 will likely not effectively separate the Bitumen from the
sand
components without an appropriate tar sand slurry being used. Embodiments may
include a
composition comprising a separating composition comprising 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 of greater than 7.5%.
[0021] Suitable wetting agents may include, for example, one or more of
DYNOLTM
607 Surfactant (Air Products and Chemicals, Inc.), SURFYNOLO 420 (Air Products
and
Chemicals, Inc.), SURFYNOLO 440 (Air Products and Chemicals, Inc.), SURFYNOLO
465
(Air Products and Chemicals, Inc.), SURFYNOL(R) 485 (Air Products and
Chemicals, Inc.),
DYNOLTM 604 Surfactant (Air Products and Chemicals, Inc.), TOMADOLO 91-2.5
(Tomah
Products, Inc.), TOMADOLO 91-6 (Tomah Products, Inc.), TOMADOLO 91-8 (Tomah
Products, Inc.), TOMADOLO 1-3 (Tomah Products, Inc.), TOMADOLO 1-5 (Tomah
Products, Inc.), TOMADOUR) 1-7 (Tomah Products, Inc.), TOMADOUR) 1-73B (Tomah
7
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
Products, Inc.), TOMADOL 1-9 (Tomah Products, Inc.), TOMADOL 23-1 (Tomah
Products, Inc.), TOMADOL 23-3 (Tomah Products, Inc.), TOMADOL 23-5 (Tomah
Products, Inc.), TOMADOL 23-6.5 (Tomah Products, Inc.), TOMADOL 25-3 (Tomah
Products, Inc.), TOMADOL 25-7 (Tomah Products, Inc.), TOMADOL 25-9 (Tomah
Products, Inc.), TOMADOL 25-12 (Tomah Products, Inc.), TOMADOL 45-7 (Tomah
Products, Inc.), TOMADOL 45-13 (Tomah Products, Inc.), TRITONTm X-207
Surfactant
(Dow Chemical Company), TRITONTm CA Surfactant (Dow Chemical Company),
NOVECTM Fluorosurfactant FC-4434 (3M Company), POLYFOXTM AT-1118B (Omnova
Solutions, Inc.), ZONYL 210 (Dupont), ZONYL 225 (Dupont), ZONYL 321
(Dupont),
ZONYL 8740 (Dupont), ZONYL 8834L (Dupont), ZONYL 8857A (Dupont),
ZONYL 8952 (Dupont), ZONYL 9027 (Dupont), ZONYL 9338 (Dupont), ZONYL
9360 (Dupont), ZONYL 9361 (Dupont), ZONYL 9582 (Dupont), ZONYL 9671
(Dupont), ZONYL FS-300 (Dupont), ZONYL FS-500 (Dupont), ZONYL FS-610
(Dupont), ZONYL 1033D (Dupont), ZONYL FSE (DuPont), ZONYL FSK (DuPont),
ZONYL FSH (DuPont), ZONYL FSJ (DuPont), ZONYL FSA (DuPont), ZONYL
FSN-100 (DuPont), LUTENSOLTm OP 30-70% (BASF), LUTENSOLO A 12 N (BASF),
LUTENSOUR) A 3 N (BASF), LUTENSOUR) A 65 N (BASF), LUTENSOUR) A 9 N
(BASF), LUTENSOLO AO 3 (BASF), LUTENSOLO AO 4 (BASF), LUTENSOLO AO 8
(BASF), LUTENSOLO AT 25 (BASF), LUTENSOLO AT 55 FRILL SURFACTANT
(BASF), LIJTENSOLO CF 10 90 SURFACTANT (BASF), LUTENSOLO DNP 10 (BASF),
LUTENSOUR)NP 4 (BASF), LUTENSOUR) NP 10 (BASF), LUTENSOUR) NP-100
PASTILLE (BASF), LUTENSOLO NP-6 (BASF), LUTENSOLO NP-70-70% (BASF),
LUTENSOLO NP-50 (BASF), LUTENSOLO NP 9 (BASF), LUTENSOLO ON 40
SURFACTANT (BASF), LUTENSOLO ON 60 (BASF), LUTENSOLO OP-10 (BASF),
LUTENSOUR) TDA 10 SURFACTANT (BASF), LTJTLNSOUR) TDA 3 SURFACTANT
8
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
(BASF), LUTENSOL O TDA 6 SURFACTANT (BASF), LUTENSOL O TDA 9
SURFACTANT (BASF), LUTENSOL XL 69 (BASF), LUTENSOL XL 100 (BASF),
LUTENSOL XL 140 (BASF), LUTENSOL XL 40 (BASF), LUTENSOL XL 50
(BASF), LUTENSOL XL 60 (BASF), LUTENSOL XL 70 (BASF), LUTENSOL XL
79 (BASF), LUTENSOL XL 80 (BASF), LUTENSOL XL 89 (BASF), LUTENSOL
XL 90 (BASF), LUTENSOL XL 99 (BASF), LUTENSOL XP 100 (BASF),
LUTENSOL XP 140 (BASF), LUTENSOL XP 30 (BASF), LUTENSOL XP 40
(BASF), LUTENSOL XP 50 (BASF), LUTENSOL XP 60 (BASF), LUTENSOL XP 69
(BASF), LUTENSOL XP 70 (BASF), LUTENSOL XP 79 (BASF), LUTENSOL XP 80
(BASF), LUTENSOL XP 89 (BASF), LUTENSOL XP 90 (BASF), LUTENSOL XP 99
(BASF), MACOL 16 SURFACTANT (BASF), MACOL CSA 20 POLYETHER (BASF),
MACOL LA 12 SURFACTANT (BASF), MACOL LA 4 SURFACTANT (BASF),
MACOL LF 110 SURFACTANT (BASF), MACOL LF 125A SURFACTANT (BASF),
MAZONO 1651 SURFACTANT (BASF), MAZOXO LDA Lauramine OXIDE (BASF),
PLURAFACO AO8A Surfactant (BASF), PLURAFACO B-26 Surfactant (BASF),
PLURAFACO B25-5 Surfactant (BASF), PLURAFACO D25 Surfactant (BASF),
PLURAFACER) LF 1200 Surfactant (BASF), PLURAFACKR) LF 2210 Surfactant (BASF),
PLURAFACO LF 4030 Surfactant (BASF), PLURAFACO LF 7000 Surfactant (BASF),
PLURAFACO RA-20 Surfactant (BASF), PLURAFACO RA 30 Surfactant (BASF),
PLURAFACO RA 40 Surfactant (BASF), PLURAFACO RCS 43 Surfactant (BASF),
PLURAFACER) RCS 48 Surfactant (BASF), PLURAFAC(R) S205LF Surfactant (BASF),
PLURAFACO S305LF Surfactant (BASF), PLURAFACO S505LF Surfactant (BASF),
PLURAFACO SL 62 Surfactant (BASF), PLURAFACO SL 92 Surfactant (BASF),
PLURAFACO SL-22 Surfactant (BASF), PLURAFACO SL-42 Surfactant (BASF),
PLURAFACER) SLF 37 Surfactant (BASF), PLURAFACER) SLF-18 Surfactant (BASF),
9
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
PLURAFAC SLF-18B-45 Surfactant (BASF), PLURAFACO L1220 Surfactant (BASF),
PLURONIC 10R5 SURFACTANT (BASF), PLURONIC 17R2 (BASF), PLURONIC
17R4 (BASF), PLURONIC 25R2 (BASF), PLURONIC 25R4 (BASF), PLURONIC
31R1 (BASF), PLURONIC F108 CAST SOLID SURFACTANT (BASF), PLURONIC
F108 NF CAST SOLID SURFACTANT (BASF), PLURONIC F108 NF FRILL
SURFACTANT (BASF), PLURONIC F108 PASTILLE SURFACTANT (BASF),
PLURONIC F127 CAST SOLID SURFACTANT (BASF), PLURONIC F127 NF FRILL
Surfactant (BASF), PLURONIC F127NF 500BHT CAST SOLID SURFACTANT (BASF),
PLURONIC F38 CAST SOLID SURFACTANT (BASF), PLURONIC PASTILLE
(BASF), PLURONIC F68 LF PASTILLE SURFACTANT (BASF), PLURONIC F68
CAST SOLID SURFACTANT (BASF), PLURONIC F77 CAST SOLID SURFACTANT
(BASF), PLURONIC F-77 MICRO PASTILLE SURFACTANT (BASF), PLURONIC
F87 CAST SOLID SURFACTANT (BASF), PLURONIC F88 CAST SOLID
SURFACTANT (BASF), PLURONIC F98 CAST SOLID SURFACTANT (BASF),
PLURONIC L10 SURFACTANT (BASF), PLURONIC L101 SURFACTANT (BASF),
PLURONIC L121 SURFACTANT (BASF), PLURONIC L31 SURFACTANT (BASF),
PLURONIC L92 SURFACTANT (BASF), PLURONIC N-3 SURFACTANT (BASF),
PLURONIC P103 SURFACTANT (BASF), PLURONIC P105 SURFACTANT (BASF),
PLURONIC P123 SURFACTANT (BASF), PLIURONICO P65 SURFACTANT (BASF),
PLIURONICO P84 SURFACTANT (BASF), PLURONIC P85 SURFACTANT (BASF),
TETRONICER) 1107 micro-PASTILLE SURFACTANT (BASF), TETRONICER) 1107
SURFACTANT (BASF), TETRONICO 1301 SURFACTANT (BASF), TETRONICO 1304
SURFACTANT (BASF), TETRONICO 1307 Surfactant (BASF), TETRONICO 1307
SURFACTANT PASTILLE (BASF), TETRONICO 150R1 SURFACTANT (BASF),
TETRONICER) 304 SURFACTANT (BASF), TETRONIC(R) 701 SURFACTANT (BASF),
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
TETRONIC 901 SURFACTANT (BASF), TETRONICO 904 SURFACTANT (BASF),
TETRONICO 908 CAST SOLID SURFACTANT (BASF), and TETRONICO 908
PASTILLE SURFACTANT (BASF), and mixtures thereof.
[0022] The wetting agent may include one or more ethoxylated acetylenic
alcohols,
such as, for example, 2,5,8,11-tetramethy1-6-dodecyn-5,8-diol ethoxylate.
[0023] Suitable hydrotropic agents may include, for example, one or more of
TRITON H-66 (Dow Chemical Company), TRITON H-55 (Dow Chemical Company),
TRITON QS-44 (Dow Chemical Company), TFITON XQS-20 (Dow Chemical
Company), TRITON X-15 (Union Carbide Corporation), TRITON X-35 (Union
Carbide
Corporation), TRITON X-45 (Union Carbide Corporation), TRITON X-114 (Union
Carbide Corporation), TRITON X-100 (Union Carbide Corporation), TRITON X-165
(70%) active (Union Carbide Corporation), TRITON X-305 (70%) active (Union
Carbide
Corporation), TRITON X-405 (70%) active (Union Carbide Corporation), TRITON
BG
Nonionic Surfactant (Union Carbide Corporation), TERGITOLO MinFoam 1X (Dow
Chemical Company), TERGITOLO L-61 (Dow Chemical Company), TERGITOLO L-64
(Dow Chemical Company), TERGITOLO L-81 (Dow Chemical Company), TERCITOLO L-
101 (Dow Chemical Company), TERGITOUR) NP-4 (Dow Chemical Company),
TERGITCOL NP-6 (Dow Chemical Company), TERGITOLO NP-7 (Dow Chemical
Company), TERGITOLO NP-8 (Dow Chemical Company), TERGITOLO NP-9 (Dow
Chemical Company), TERGITOLO NP-11 (Dow Chemical Company), TERGITOLO NP-12
(Dow Chemical Company), TERGITOLCR) NP-13 (Dow Chemical Company), TERCITOUR)
NP-15 (Dow Chemical Company), TERGITOLO NP-30 (Dow Chemical Company),
TERGITOLO NP-40 (Dow Chemical Company), SURFYNOLO 420 (Air Products and
Chemicals, Inc), SURFYNOLO 440 (Air Products and Chemicals, Inc.), SURFYNOLO
465
(Air Products and Chemicals, Inc.), SURFYNOUR) 485 (Air Products and
Chemicals, Inc.),
11
CA 02786316 2012-07-04
WO 2011/084392
PCT/US2010/060167
MAPHOS 58 ESTER (BASF), MAPHOS 60 A Surfactant (BASF), MAPHOS 66H
ESTER (BASF), MAPHOS 8135 ESTER (BASF), MAPHOS M-60 ESTER (BASF),
6660 K Hydrotroping Phosphate Ester Salt (Burlington Chemical), Burofac 7580
Aromatic
Phosphate Ester (Burlington Chemical), and Burofac 9125 (Burlington Chemical),
and
mixtures thereof The hydrotropic agent may be one or more aromatic phosphate
esters, such
as, for example, an aromatic phosphate ester having the formula:
%.....õ...,
RI-1-1
1 ..
0
0 -
R POIK,
wherein R' is a C1-05 linear or branched alkyl group and n = 1 to 8, e.g., an
integer between
one and eight.
[0024] Suitable dispersants having flocculating characteristics may include,
for
example, one or more of sodium acid pyrophosphate, tetrapotassium
pyrophosphate,
monosodium phosphate (H6Na06P), monoammonium phosphate ((NH4)P0 4), sodium
acid
phosphate, trisodium phosphate, sodium tripolyphosphate, sodium
trimetaphosphate, sodium
laurel phosphate, sodium phosphate, pentapotassium triphosphate, potassium
triphosphate,
tetraborate potassium tripolyphosphate, potassium phosphate-monobasic,
potassium
phosphate-dibasic, monopotassium phosphate, and tripotassium phosphate, and
mixtures
thereof
[0025] The dispersant having flocculating characteristics may include one or
more
pyrophosphate salts, including, for example, one or more of sodium acid
pyrophosphate and
tetrapotassium pyrophosphate.
12
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
[0026] In one embodiment, the hydrotropic agent may be present in the amount
of
from about 0.1% to about 4.0% by weight of the separating composition. The
dispersant
having flocculating characteristics may be present in the amount of from about
0.25% to
about 4.5% by weight of the separating composition.
[0027] In one embodiment, the separating composition may further comprise a
strong
base, such as, for example, hydroxides of alkali metals and alkaline earth
metals, such as, for
example, NaOH, KOH, Ba(OH) 2, Cs0H, Sr0H, Ca(OH) 2, LiON, RbOH, NaH, LDA, and
NaNH2. As used herein, a "strong base" is a chemical compound having a pH of
greater than
about 13. The strong base may be present in the amount of from about 2% to
about 9.5% by
weight of the separating composition.
[0028] The separating composition may further comprise a heavy acid, such as,
for
example, phosphoric acid, nitric acid, sulfuric acid, hydronic acid,
hydrobromic acid,
perchloric acid, fluoromatic acid, magic acid (FSO3HSbF5), carborane super
acid
[H(CHBi iClii)], triflic acid, ethanoic acid, and acetylsalicylic acid. As
used herein, a
"heavy" acid is an acid having a specific gravity greater than about 1.5. The
heavy acid may
be present in the amount of from about 1.7% to about 8.6% by weight of the
separating
composition.
[0029] The pH of the separating composition may be greater than 7.5. The pH of
the
separating composition may also be from about 7.0 to about 8.5. The pH of the
separating
composition may also be from about 7.6 to about 7.8. The composition may be
essentially
free of organic solvent. As used herein, the term "organic solvent" refers to
solvents that are
organic compounds and contain carbon atoms such as, for example, naphtha. In
addition to
the separating composition, the composition may also comprise hydrocarbon
containing
materials, such as oil sands, tailings, and the like. The ratio of the
separating composition to
the hydrocarbon containing materials may be from about 2:3 to about 3:2.
13
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
[0030] A separating composition may be provided, comprising from about 0.001%
to
about 2.5% by weight of a wetting agent; from about 0.1% to about 4.0% by
weight of a
hydrotropic agent; and from about 0.25% to about 4.5% by weight of a
dispersant having
flocculating characteristics. The separating composition may have a pH of
greater than 7.5;
from about 7.0 to about 8.5; or from about 7.6 to about 7.8. The wetting agent
may be, for
example, 2,5,8,11-tetramethy1-6-dodecyn-5,8-diol ethoxylate. The hydrotropic
agent may be,
for example, MAPHOSO 66H aromatic phosphate ester. The dispersant having
flocculating
characteristics may be, for example, one or more of sodium acid pyrophosphate
and
tetrapotassium pyrophosphate.
[0031] The separating composition may further comprise a strong base, which
may
be, for example, sodium hydroxide. The strong base may be present in the
amount of from
about 2% to about 9.5% by weight of the separating composition. The separating
composition may further comprise a heavy acid, which may be, for example,
phosphoric acid.
The heavy acid may be present in the amount of from about 1.7% to about 8.6%
by weight of
the separating composition. The separating composition may also be essentially
free of
organic solvent.
[0032] A separating composition for separating bitumen from oil sands or
tailings
may be provided, comprising from about 0.001% to about 2.5% by weight of
2,5,8,11-
tetramethy1-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4.0% by
weight of an
aromatic phosphate ester having the formula:
R
0
n PO K
'3
14
CA 02786316 2012-07-04
WO 2011/084392
PCT/US2010/060167
wherein Rl is a C1-05 linear or branched alkyl group and n = 1 to 8, e.g., an
integer between
one and eight; from about 0% to about 4.5% by weight of sodium pyrophosphate;
from about
0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2.0% to
about
9.5% by weight of sodium hydroxide; and from about 1.7% to about 8.6% by
weight of
phosphoric acid. The separating composition may have a pH of from about 7.0 to
about 8.5.
The separating composition may also be essentially free of organic solvent.
[0033] A method for separating bitumen from oil sands may be provided,
comprising
contacting a separating composition comprising a wetting agent, a hydrotropic
agent, and a
dispersant having flocculating characteristics with oil sands comprising
bitumen and sand;
heating the separating composition and the oil sands; agitating the separating
composition
and the oil sands; and recovering the bitumen and sand as separate products.
The pH of the
separating composition may be greater than 7.5; from about 7.0 to about 8.5;
or from about
7.6 to about 7.8.
[0034] The separating composition used in the exemplary method may be
comprised
of from about 0.001% to about 2.5% by weight of a wetting agent; from about
0.1% to about
4.0% by weight of a hydrotropie agent; and from about 0.25% to about 4.5% by
weight of a
dispersant having flocculating characteristics.
[0035] The separating composition used in the exemplary method may be
comprised
of from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethy1-6-dodecyn-
5,8-diol
ethoxylate; from about 0.1% to about 4.0% by weight of an aromatic phosphate
ester having
the formula:
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
RI 4
I ..
. , 00,04F 0
0
n PO'dcr -3
wherein R' is a C1-05 linear or branched alkyl group and n = 1 to 8, e.g., an
integer between
one and eight; from about 0% to about 4.5% by weight of sodium pyrophosphate;
from about
0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2% to
about 9.5%
by weight of sodium hydroxide; and from about 1.7% to about 8.6% by weight of
phosphoric
acid.
[0036] With respect to the process conditions under which the method may be
carried
out, the separating composition and the oil sands may be heated to greater
than 25 C; from
about 32 C to about 72 C; or from about 54 C to about 60 C. Any source of
heat within
the ambit of those skilled in the art may be used.
[0037] The ratio of the separating composition to the oil sands may be from
about 2:3
to about 3:2. In another embodiment, the ratio of the separating composition
to the oil sands
may be about 1:1.
[0038] The recovered bitumen may be essentially emulsion-free. The exemplary
method may be performed without the addition of organic solvent.
[0039] In some circumstances, it may prove desirable to subject the separated,
recovered bitumen to a second or subsequent aliquot of separating composition.
In such a
case, the exemplary method further comprises contacting the separated,
recovered bitumen
with a second or subsequent aliquot of fresh separating composition; heating
the fresh
separating composition and the bitumen; agitating the fresh separating
composition and the
16
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
recovered bitumen; and recovering the resulting bitumen. Such a "rinse" cycle
may be
repeated until the bitumen is essentially free of any sand or other
particulate matter.
[0040] The separating composition may be recyclable. Thus, the method may
further
comprise recovering the separating composition; contacting the recovered
separating
composition with a second or subsequent aliquot of oil sands comprising
bitumen and sand;
heating the recovered separating composition and the second or subsequent
aliquot of oil
sands; agitating the recovered separating composition and the second or
subsequent aliquot of
oil sands; and recovering the bitumen and sand as separate products.
[0041] Embodiments may further include a method for processing existing
tailings,
both to salvage remaining bitumen and to allow for redeposit of the
essentially bitumen-free
sand. The method may comprise contacting a separating composition comprising a
wetting
agent, a hydrotropic agent, and a dispersant having flocculating
characteristics with tailings
comprising bitumen and sand; heating the separating composition and the
tailings; agitating
the separating composition and the tailings; and recovering the bitumen and
sand as separate
products. The pH of the separating composition may be greater than 7.5; from
about 7.0 to
about 8.5; or from about 7.6 to about 7.8.
[0042] The separating composition used in the method for processing existing
tailings
may be comprised of from about 0.001% to about 2.5% by weight of a wetting
agent; from
about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about
0.25% to about
4.5% by weight of a dispersant having flocculating characteristics.
[0043] The separating composition used in the method for processing existing
tailings
may be comprised of from about 0.001% to about 2.5% by weight of 2,5,8,11-
tetramethy1-6-
dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4.0% by weight of an
aromatic
phosphate ester having the formula:
17
CA 02786316 2012-07-04
WO 2011/084392
PCT/US2010/060167
RI 4
I ..
0
n PO'dcr -3
wherein R' is a C1-05 linear or branched alkyl group and n = 1 to 8, e.g., an
integer between
one and eight; from about 0% to about 4.5% by weight of sodium pyrophosphate;
from about
0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2% to
about 9.5%
by weight of sodium hydroxide; and from about 1.7% to about 8.6% by weight of
phosphoric
acid.
[0044] With respect to the process conditions under which the method for
processing
existing tailings may be carried out, the separating composition and the
tailings may be
heated to greater than 25 C; from about 32 C to about 72 C; or from about
54 C to about
60 C. Any source of heat within the ambit of those skilled in the art may be
used.
[0045] The ratio of the separating composition to the tailings may be from
about 2:3
to about 3:2. In another embodiment, ratio of the separating composition to
the tailings may
be about 1:1.
[0046] The recovered bitumen may be essentially emulsion-free. The method may
be
performed without the addition of organic solvent.
[0047] In some circumstances, it may prove desirable to subject the separated,
recovered bitumen from the tailings to a second or subsequent aliquot of
separating
composition. In such a case, the exemplary method further comprises contacting
the
separated, recovered bitumen with a second or subsequent aliquot of fresh
separating
composition; heating the fresh separating composition and the bitumen;
agitating the fresh
separating composition and the recovered bitumen; and recovering the resulting
bitumen.
18
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
Such a "rinse" cycle may be repeated until the bitumen is essentially free of
any sand or other
particulate matter.
[0048] The separating composition may be recyclable. Thus, the exemplary
method
for processing existing tailings would further comprise recovering the
separating
composition; contacting the recovered separating composition with a second or
subsequent
aliquot of tailings comprising bitumen and sand; heating the recovered
separating
composition and the second or subsequent aliquot of tailings; agitating the
recovered
separating composition and the second or subsequent aliquot of tailings; and
recovering the
bitumen and sand as separate products.
[0049] The tar sand slurry is provided through the liquid supply conduit 27
and make
up chemistry is supplied through conduit 28. At the junction of the liquid
supply conduit 27
and the make up supply conduit 28, the tar sand slurry and liquid/solid
mixture in the form of
a slurry. Alternatively, other embodiments encompassed by the present
invention may
include only as single inlet where the fluid/slurry enters the apparatus. This
mixture of tar
sand slurry is directed into the cylindrical chamber 15 of the housing 12
through the supply
conduits 30 and inlet ports 25, as shown. Embodiments may include an inlet
port 25 that is
provided on either side of the housing 12 in order to equalize the hydraulic
pressure on the
rotor 17 to prevent undue stress on the bearing assemblies 19. However, this
particular
configuration is not a limitation of the invention and other configurations of
inlet ports may
be provided.
[0050] An outlet port 35 is provided in the housing 12 and, in some
embodiments, is
located in the cylindrical wall of the housing to communicate with the
cavitation zone 32 in a
region of the rotor intermediate or between the arrays of bores 24. Location
of the outlet port
35 in this way ensures that the entire volume of the gas/liquid mixture
traverses at least one
of the arrays of bores 24 and thus moves through a cavitation zone prior to
exiting the
19
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
hydrosonic mixer 11. Further, location of the outlet port 35 within the region
of the inner
chamber 15 aligned with the void 26 of the rotor prevents cavitation damage
that otherwise
might occur if the outlet port 35 were aligned with an array of bores 24. An
outlet conduit 33
is coupled to the outlet port 35 for receiving treated tar sand slurry and
excess air from the
hydrosonic mixer 11 and delivering it to a remote location for separation of
the excess air
from the treated tar sand slurry and subsequent use of the treated tar sand
slurry.
[0051] In operation, the tar sand slurry is pumped through the liquid supply
conduit
27 to the supply conduit 30. Make up chemistry can be supplied through the
supply conduit
28 to the stream of tar sand slurry. The tar sand slurry mixture moves through
the supply
conduits 30 and enters the chamber 15 through supply ports 25 on either side
of the rotor 17.
[0052] From the supply ports 25, the mixture moves toward the periphery of the
rapidly rotating rotor 17 and enters the cavitation zones 32 in the region of
the bores 24.
Within the cavitation zones 32, millions of microscopic cavitation bubbles are
formed in the
mixture within and around the rapidly moving bores 24 on the rotor. Since
these cavitation
bubbles are unstable, they collapse rapidly after their formation. As a
result, the millions of
microscopic cavitation bubbles continuously form and collapse within and
around the bores
24 of the rotor, creating cavitation-induced shock waves that propagate
through the mixture
in a violent, albeit localized, process.
[0053] As the mixture of tar sand slurry the mixture is bombarded by the
microscopic
cavitation bubbles as they form and further are impacted by the cavitation
shock waves
created as the cavitation bubbles collapse. This results in a high shear
environment that
scoures the surface of the sand particles clear of the adhered Bitumen in a
manner that does
not abrade the equipment surfaces in the same manner as other devices.
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
[0054] After the tar sand slurry has been treated, it flows out of the chamber
15
through the outlet port 35. At this point, Released Bitumen can be separated
from the
water/sand mixture via a number of simple mechanical separation methods.
[0055] Unless specifically stated to the contrary, the numerical parameters
set forth in
the specification, including the attached claims, are approximations that may
vary depending
on the desired properties sought to be obtained according to the exemplary
embodiments. At
the very least, and not as an attempt to limit the application of the doctrine
of equivalents to
the scope of the claims, each numerical parameter should at least be construed
in light of the
number of reported significant digits and by applying ordinary rounding
techniques.
[0056] Notwithstanding that the numerical ranges and parameters setting forth
the
broad scope of the invention are approximations, the numerical values set
forth in the specific
examples are reported as precisely as possible. Any numerical value, however,
inherently
contains certain errors necessarily resulting from the standard deviation
found in their
respective testing measurements.
[0057] The processes and devices in the above description and drawings
illustrate
examples of only some of the methods and devices that could be used and
produced to
achieve the objects, features, and advantages of embodiments described herein.
Thus, they
are not to be seen as limited by the foregoing description of the embodiments,
but only
limited by the appended claims. Any claim or feature may be combined with any
other claim
or feature within the scope of the invention.
[0058] The many features and advantages of the invention are apparent from the
detailed specification, and, thus, it is intended by the appended claims to
cover all such
features and advantages of the invention which fall within the true spirit and
scope of the
invention. Further, since numerous modifications and variations will readily
occur to those
skilled in the art, it is not desired to limit the invention to the exact
construction and operation
21
CA 02786316 2012-07-04
WO 2011/084392 PCT/US2010/060167
illustrated and described, and, accordingly, all suitable modifications and
equivalents may be
resorted to that fall within the scope of the invention.
22
