Method of Processing a Bituminous Feed Using an Emulsion

Abstract

The present disclosure relates to a method of processing a bituminous feed. The bituminous feed is contacted with a bridging liquid-in-extraction liquor emulsion to form a slurry. Solids in the slurry are agglomerated, using agitation, to form an agglomerated slurry comprising agglomerated solids and a low solids bitumen extract. The agglomerates are then separated from the low solids bitumen extract. Emulsifying the bridging liquid prior to contacting it with the oil sands may reduce the amount of energy required for the agglomeration process. Other potential benefits may include the production of smaller and more uniform agglomerates. The former may lead to higher bitumen recoveries and the latter may improve the solid-liquid separation rate.

1 . A method of processing a bituminous feed, the method comprising:
 a) contacting the bituminous feed with a bridging liquid-in-extraction liquor emulsion, to form a slurry, wherein the extraction liquor comprises a solvent;   b) agglomerating solids within the slurry, using agitation, to form an agglomerated slurry comprising agglomerates and a low solids bitumen extract; and   c) separating the agglomerates from the low solids bitumen extract.   
     
     
         2 . The method of  claim 1 , wherein the emulsion comprises bridging liquid droplets, at least 80 wt. % of which are sized between one of 1 and 100 μm and 1 and 10 μm. 
     
     
         3 . (canceled) 
     
     
         4 . The method of  claim 1 , wherein the emulsion comprises 5 wt. % to 50 wt. % of the bridging liquid. 
     
     
         5 . The method of  claim 1 , wherein the emulsion is one of unstable and stable. 
     
     
         6 . (canceled) 
     
     
         7 . The method of  claim 1 , further comprising, prior to step a), forming the emulsion. 
     
     
         8 . The method of  claim 7 , wherein the forming of the emulsion comprises one of (i) adding an additive to facilitate the formation of the emulsion, (ii) using an ultrasonic emulsifier, (iii) using a tubular mixer, static mixer, blender, liquid jet mixer, or a combination thereof. 
     
     
         9 . The method of  claim 8 , wherein the additive comprises one of an alkaline solution and a surfactant. 
     
     
         10 - 12 . (canceled) 
     
     
         13 . The method of  claim 1 , wherein the emulsion is mixed with the bituminous feed using a liquid jet. 
     
     
         14 . The method of  claim 1 , further comprising recovering the solvent from the low solids bitumen extract to form a bitumen product. 
     
     
         15 . The method of  claim 14 , further comprising washing the agglomerates of step c) with one of (i) the solvent recovered from the low solids bitumen extract and (ii) a solvent, which solvent is the same as or different from the solvent of step a), to extract additional bitumen and to form washed agglomerates. 
     
     
         16 . (canceled) 
     
     
         17 . The method of  claim 1 , further comprising recovering solvent from one of (i) the agglomerates, which have been separated from the low solids bitumen extract and (ii) the washed agglomerates. 
     
     
         18 . (canceled) 
     
     
         19 . The method of  claim 1 , wherein the extraction liquor comprises the solvent of step a) and bitumen in an amount of 10 to 50 wt. %. 
     
     
         20 . The method of  claim 1 , further comprising, prior to step a), contacting the bituminous feed with additional extraction liquor to begin extraction. 
     
     
         21 . The method of  claim 1 , wherein the bridging liquid is one of water and an aqueous solution. 
     
     
         22 . (canceled) 
     
     
         23 . The method of  claim 1 , wherein at least 80 wt. % of the agglomerates of step c) are between 0.1 and 1 mm. 
     
     
         24 . The method of  claim 1 , wherein the agglomerated slurry has a solids content of 20 to 70 wt. %. 
     
     
         25 . The method of  claim 1 , wherein the solvent comprises an organic solvent or a mixture of organic solvents, wherein the solvent comprises a paraffinic solvent, a cyclic aliphatic hydrocarbon, or a mixture thereof, and wherein the paraffinic solvent comprises an alkane, a natural as condensate, a distillate from a fractionation unit, or a combination thereof, containing more than 40% small chain paraffins of 5 to 10 carbon atoms. 
     
     
         26 - 27 . (canceled) 
     
     
         28 . The method of  claim 25 , wherein the alkane comprises a normal alkane, an iso-alkane, or a combination thereof and wherein the alkane comprises heptane, iso-heptane, hexane, iso-hexane, pentane, iso-pentane, or a combination thereof. 
     
     
         29 . (canceled) 
     
     
         30 . The method of  claim 28 , wherein the cyclic aliphatic hydrocarbon comprises a cycloalkane of 4 to 9 carbon atoms and wherein the cycloalkane comprises cyclohexane, cyclopentane, or a mixture thereof. 
     
     
         31 . (canceled) 
     
     
         32 . The method of  claim 1 , wherein one of (i) the solvent comprises at least 50 wt. % cyclohexanebu, (ii) the extraction liquor comprises residual solids, (iii) the bridging liquid comprises solid fines, (iv) bridging liquid has a solids content of less than 40 wt. % and (v) the agglomeration is effected in one or more vessels. 
     
     
         33 - 36 . (canceled) 
     
     
         37 . The method of  claim 1 , wherein step b) comprises agitating by mixing, shaking, or rolling. 
     
     
         38 . The method of  claim 1 , wherein a ratio of one of the solvent to bitumen in the agglomerated slurry is less than 2:1 and emulsion to slurry is in a range of 1.5 to 0.1 by weight. 
     
     
         39 - 40 . (canceled)