Slurry Treatment Method and Apparatus

Abstract

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

1 . 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; and   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   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.   
     
     
         2 . The method of  claim 1 , wherein:
 the hydrotropic agent is present in the amount of from about 0.1% to about 4.0% by weight of the separating composition; and   the dispersant having flocculating characteristics is present in the amount of from about 0.25% to about 4.5% by weight of the separating composition.   
     
     
         3 . The method of  claim 1 , wherein the wetting agent comprises an alkoxylated alcohol surfactant. 
     
     
         4 . The method of  claim 1 , wherein the wetting agent comprises 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate. 
     
     
         5 . The method of  claim 1 , wherein the hydrotropic agent comprises a phosphorylated nonionic surfactant. 
     
     
         6 . The method of  claim 1 , wherein the hydrotropic agent comprises an aromatic phosphate ester having the formula: 
       
         
           
           
               
               
           
         
         wherein R 1  is a C 1 -C 5  linear or branched alkyl group, and 
         wherein n=1 to 8. 
       
     
     
         7 . The method of  claim 1 , wherein the dispersant having flocculating characteristics comprises a pyrophosphate salt. 
     
     
         8 . The method of  claim 1 , wherein the dispersant having flocculating characteristics comprises one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate. 
     
     
         9 . The method of  claim 1 , wherein the pH of the separating composition is from about 7.6 to about 8.5. 
     
     
         10 . The method of  claim 1 , wherein:
 the separation composition further comprises a strong base; and   the strong base is present in the amount of from about 2% to about 9.5% by weight of the separating composition.   
     
     
         11 . The method of  claim 1 , wherein the separation composition is essentially free of organic solvent. 
     
     
         12 . The method of  claim 1 , wherein the separation composition further comprises hydrocarbon containing materials, wherein the ratio of the separating composition to the hydrocarbon containing materials is from about 2:3 to about 3:2. 
     
     
         13 . An apparatus for extracting bitumen from tar sands, 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 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 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.   
     
     
         14 . The apparatus of  claim 13 , wherein:
 the hydrotropic agent is present in the amount of from about 0.1% to about 4.0% by weight of the separating composition; and   the dispersant having flocculating characteristics is present in the amount of from about 0.25% to about 4.5% by weight of the separating composition.   
     
     
         15 . The apparatus of  claim 13 , wherein the wetting agent comprises an alkoxylated alcohol surfactant. 
     
     
         16 . The apparatus of  claim 13 , wherein the hydrotropic agent comprises a phosphorylated nonionic surfactant. 
     
     
         17 . The apparatus of  claim 13 , wherein the dispersant having flocculating characteristics comprises a pyrophosphate salt. 
     
     
         18 . The apparatus of  claim 13 , wherein the dispersant having flocculating characteristics comprises one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate. 
     
     
         19 . The apparatus of  claim 13 , wherein:
 the separation composition further comprises a strong base; and   the strong base is present in the amount of from about 2% to about 9.5% by weight of the separating composition.   
     
     
         20 . The apparatus of  claim 13 , wherein the separation composition is essentially free of organic solvent.