Method of Processing a Bituminous Feed Using Agglomeration in a Pipeline

Abstract

The present disclosure relates to a method of processing a bituminous feed. The bituminous feed is contacted with an extraction liquor to form a slurry. The slurry is then flowed through a pipeline. A bridging liquid is added to the slurry to assist agglomeration. Agitation is also used to assist agglomeration. The result is an agglomerated slurry comprising agglomerates and a low solids bitumen extract. The agglomerates are then separated from the low solids bitumen extract. Performing the agglomeration in a pipeline as opposed to in a conventional agitating vessel may provide certain advantages, such as improved sealing in order to contain the potentially flammable mixture of oil sands slurry from the atmosphere, production of smaller and more uniform agglomerates due to improved mixing of the bridging liquid into the oil sands slurry, and the flexibility to have a long residence time for the extraction and agglomeration processes.

1 . A method of processing a bituminous feed, the method comprising:
 a) contacting the bituminous feed with an extraction liquor to form a slurry, wherein the extraction liquor comprises a solvent;   b) flowing the slurry through a pipeline and adding a bridging liquid to the slurry before and/or within the pipeline, and agitating solids within the slurry within the pipeline to form an agglomerated slurry comprising agglomerates and a low solids bitumen extract; and   c) separating the agglomerates from the low solids bitumen extract,   wherein the agitation is provided by turbulent flow of the slurry within the pipeline.   
     
     
         2 . The method of  claim 1 , wherein the bridging liquid is added to the slurry at least one of within the pipeline and before the pipeline. 
     
     
         3 .- 5 . (canceled) 
     
     
         6 . The method of  claim 1 , wherein the pipeline comprises internal structures for promoting the agitation by turbulent flow of the slurry within the pipeline. 
     
     
         7 . The method of  claim 1 , wherein an average flow velocity of the slurry flow within the pipeline is higher than a limiting settling velocity of the slurry. 
     
     
         8 . The method of  claim 1 , wherein step b) comprises:
 flowing the slurry in an extraction zone of the pipeline where the bridging liquid is below a level to accomplish agglomeration; then flowing the slurry in an agglomeration zone of the pipeline where the bridging liquid is at a level to accomplish agglomeration.   
     
     
         9 . The method of  claim 8 , wherein the agglomeration zone comprises:
 a nucleation zone where the formation of agglomerates is initiated by the addition of the bridging liquid;   an agglomerate growth zone where agglomerates growth occurs by further addition of the bridging liquid; and   a comminution zone where agglomerates of large size are comminuted by increased shear forces acting on the slurry.   
     
     
         10 . The method of  claim 8 , wherein an average flow velocity of the slurry flow within the extraction zone is one of 1 to 5 msec and greater than 2 m/sec. 
     
     
         11 . (canceled) 
     
     
         12 . The method of  claim 8 , wherein a residence time of the slurry flow within the extraction zone is one of greater than 5 minutes and 1 to 5 minutes. 
     
     
         13 . (canceled) 
     
     
         14 . The method of  claim 8 , wherein a pipeline diameter in the extraction zone is 0.5 to 1.5 m. 
     
     
         15 . The method of  claim 8 , wherein a pipeline diameter in the agglomeration zone is smaller than a pipeline diameter in the extraction zone. 
     
     
         16 . The method of  claim 8 , wherein a portion of the slurry flowing out of the agglomeration zone is recycled upstream of the agglomeration zone. 
     
     
         17 . The method of  claim 1 , wherein a portion of the pipeline is posited at an angle of 5° to 45° to horizontal. 
     
     
         18 . The method of  claim 1 , wherein a portion of the pipeline comprises static mixers disposed therein. 
     
     
         19 . The method of  claim 1 , the bridging liquid is added to the slurry in a concentration of less than 20 wt % of the slurry. 
     
     
         20 . The method of  claim 1 , wherein the pipeline connects a slurry system for producing the slurry, to a processing facility for separating the agglomerates from the low solids bitumen extract. 
     
     
         21 . The method of  claim 1 , further comprising recovering the solvent from the low solids bitumen extract to form a bitumen product. 
     
     
         22 . 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 %. 
     
     
         23 . The method of  claim 1 , wherein the bridging liquid is one of water and an aqueous solution. 
     
     
         24 . (canceled) 
     
     
         25 . The method of  claim 1 , wherein at least 80 wt. % of the agglomerates of step c) are between 0.1 and 1 mm. 
     
     
         26 . The method of  claim 1 , wherein the solvent comprises an organic solvent or a mixture of organic solvents. 
     
     
         27 . The method of  claim 1 , wherein the solvent comprises at least 50 wt. % cyclohexane. 
     
     
         28 . The method of  claim 1 , wherein a ratio of the solvent to bitumen in the slurry is less than 2:1. 
     
     
         29 . (canceled)