US 5,316,664 A · Process for recovery of hydrocarbons and rejection of sand

Abstract

A process suitable for operation at a mine site for recovering a hydrocarbon from a hydrocarbon bearing sand comprising the steps of mixing a chemical additive with a chemical composition and with a hydrocarbon bearing sand containing hydrocarbon and residual solids including clay, at a temperature to form a slurry. The chemical composition comprises an aqueous phase and a minor amount of a chemical agent selected from the group consisting of at least one ethoxylated alkylphenol compound, at least one ethoxylated dialkylphenol compound, MIBC, SC-177, Petronate HL, Calcium Lignosulfonate, NaOH and mixtures thereof. The slurry is conditioned and aerated to produce essentially sludge-free tailings and a mixture of hydrocarbon, aqueous phase and residual solids including clay. The process further comprises the step of separating in a short-residence time apparatus the mixture of the hydrocarbon, the aqueous phase and the residual solids including clay from the essentially sludge-free tailings.

Claims83

Dependent claims

A process for recovering a hydrocarbon from a hydrocarbon bearing sand comprising the steps of:

(a) mixing a chemical additive with a chemical composition and with a hydrocarbon bearing sand containing hydrocarbon and residual solids including clay, at a temperature to form a slurry not containing a sodium ion from an addition of a caustic, wherein said chemical composition comprises an aqueous phase and a minor amount of a chemical agent selected from the group consisting of at least one ethoxylated alkylphenol compound, at least one ethoxylated dialkylphenol compound and mixtures thereof;
(b) aerating the formed slurry of step (a) to produce essentially sludge-free tailings and a mixture of hydrocarbon, aqueous phase and residual solids including clay not containing a sodium ion from a caustic;
(c) separating said mixture of said hydrocarbon, said aqueous phase and said residual solids including clay from the essentially sludge-free tailings.

A process for recovering bitumen from tar sands comprising the steps of:

(a) mixing a chemical additive with a chemical agent and with an aqueous phase and with tar sands containing bitumen and residual solids including clay, at a temperature to form a slurry not containing a sodium ion from an addition of a caustic, wherein said chemical agent is selected from the group consisting of at least one ethoxylated alkylphenol compound, at least one ethoxylated dialkylphenol compound and mixtures thereof;
(b) pumping the formed slurry of step (a) towards at least one mixer;
(c) aerating the pumped slurry of step (b) to assist in the production of essentially sludge-free tailings and a mixture of bitumen, aqueous phase and residual solids including clay not containing a sodium ion from an addition of a caustic;
(d) agitating the aerated slurry of step (c) with said at least one mixer to further assist in the production of essentially sludge-free tailings and said mixture of bitumen, aqueous phase and residual solids including clay not containing a sodium ion from an addition of a caustic;
(e) separating said mixture of said bitumen and said aqueous phase and said residual solids including clay from the agitated slurry of step (d) to produce essentially sludge-free tailings;
and
(f) separating said aqueous phase and said residual solids including clay from said step (e) mixture comprising said bitumen, said residual solids including clay, and said aqueous phase to produce said bitumen as being essentially free of residual solids including clay.

4 more elements

A process for the extraction and recovery of a hydrocarbon from water wet tar sands comprising:

(a) introducing a water wet tar sand and water into a conditioning zone to form a tar sand slurry having a temperature ranging from about 100.degree. F. to about 130.degree. F.;
(b) agitating the formed tar sand slurry of step (a) to form an agitated tar sand slurry;
(c) aerating the formed agitated tar sand slurry to form an aerated tar sand slurry comprising a first mixture including first fines, first water, first hydrocarbon and first solids;
(d) separating in a primary separating zone the first solids from the first hydrocarbon and first water and first fines of the aerated tar sand slurry to produce a second mixture comprising a second hydrocarbon, a second fines, and a second water;
(e) separating the second hydrocarbon from the second mixture of step (d) to produce a third mixture comprising third fines, third water, and third solids;
(f) introducing the first solids into a secondary separating zone to produce a fourth mixture comprising fourth fines, fourth water, fourth hydrocarbon, and fourth solids;
(g) separating in the secondary separating zone the fourth solids from the fourth fines, fourth water and fourth hydrocarbon;
(h) passing the fourth fines, the fourth water and fourth hydrocarbon into the conditioning zone of step (a);
(i) introducing the fourth solids into a tertiary separating zone to produce a fifth mixture comprising fifth fines, fifth water, fifth hydrocarbons and fifth solids;
(j) separating in the tertiary separating zone the fifth solids from the fifth fines, fifth water and fifth hydrocarbon;
and
(k) admixing the fifth fines, the fifth water and fifth hydrocarbon with the fifth solids prior to said introducing step (f).

9 more elements

A process for the extraction and recovery of a hydrocarbon from water wet tar sands comprising:

(a) introducing a water wet sand and water into a conditioning zone to form a tar sand slurry;
(b) agitating the formed tar sand slurry of step (a) to form an agitated tar sand slurry;
(c) aerating the formed tar sand slurry to form an aerated primary feed slurry containing water, hydrocarbon, and solids;
(d) separating the primary feed slurry of step (c) in a primary separating zone by introducing the primary feed slurry into an involuted feed entrance of a hydrocyclone to form (1) a primary overflow stream containing a majority of the hydrocarbon and water and a minority of the solids contained in the primary tar sand slurry and (2) a primary underflow stream containing the balance of the primary feed slurry, said hydrocyclone having a cyclone axis and said involuted feed entrance comprises a rectangular opening having a longitudinal lengthwise dimension parallel to said cyclone axis;
(e) separating the primary underflow stream of step (d) in a secondary separating zone to form (1) a secondary overflow stream containing a majority of the hydrocarbon and water and a minority of the solids contained in the primary underflow stream and (2) a secondary underflow stream containing the balance of the primary underflow stream;
(f) separating the secondary underflow stream of step (e) in a tertiary separating zone to form (1) a tertiary overflow stream containing a majority of the hydrocarbon and water and a minority of the solids contained in the secondary underflow stream and (2) a tertiary underflow stream containing the balance of the secondary underflow stream;
(g) passing the secondary overflow stream produced in step (e) into the conditioning zone of step (a);
(h) admixing the tertiary overflow stream produced in step (f) with the primary underflow stream of step (d) prior to said separating step (e);
(i) admixing wash water with the secondary underflow stream of step (e) prior to said separating step (f);
(j) separating the primary overflow stream of step (d) to produce a concentrated hydrocarbon stream and an underflow stream containing a majority of the water and solids in the primary overflow stream.

7 more elements

A process for the extraction and recovery of a hydrocarbon from water wet tar sands comprising:

(a) introducing a water wet tar sand and water into a conditioning zone to form a tar sand slurry having a temperature ranging from about 100.degree. F. to about 130.degree. F.;
(b) agitating the formed tar sand slurry of step (a) to form an agitated tar sand slurry;
(c) aerating the formed tar sand slurry to form an aerated primary feed slurry containing water, hydrocarbon, and solids;
(d) separating the primary feed slurry of step (c) in a primary separating zone to form (1) a primary overflow stream containing a majority of the hydrocarbon and water and a minority of the solids contained in the primary tar sand slurry and (2) a primary underflow stream containing the balance of the primary feed slurry;
(e) admixing wash water with the primary underflow stream of step (d);
(f) separating the admixed water and primary underflow stream of step (e) in a secondary separating zone to form (1) a secondary overflow stream containing a majority of the hydrocarbon and water and a minority of the solids contained in the primary underflow stream and (2) a secondary underflow stream containing the balance of the primary underflow stream;
(g) passing the secondary overflow stream produced in step (f) into the conditioning zone of step (a);
and
(h) separating the primary overflow stream of step (d) to produce a concentrated hydrocarbon stream and an underflow stream containing a majority of the water and solids in the primary overflow stream.

6 more elements

Dependencies are inferred from the claim text.

Process for recovery of hydrocarbons and rejection of sand

Life of this patent

Process for recovery of hydrocarbons and rejection of sand

Life of this patent

Abstract

Claims83