Method of processing a bituminous feed with feedback control

Abstract

Described herein is a method of processing a bituminous feed. The bituminous feed is contacted with an extraction liquor to form a slurry. A bridging liquid is added to the slurry, and, solids are agitated within the slurry to form an agglomerated slurry comprising agglomerates and a low solids bitumen extract. In order to control agglomeration, the slurry is analyzed and the processing method is adjusted accordingly.

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) adding a bridging liquid to the slurry, and agitating solids within the slurry, to form an agglomerated slurry comprising agglomerates and a low solids bitumen extract;   c) measuring at least one property of the agglomerated slurry, the agglomerates, or the low solids bitumen extract; and   d) comparing the at least one property to a target range, and where the at least one property that is measured does not fall within the target range, adjusting at least one parameter of the method of processing the bituminous feed, for controlling the agglomeration,   wherein the at least one property comprises a particle size distribution of the agglomerates as an indication of agglomerate content or a density of the low solids bitumen extract as an indication of a fines content of the low solids bitumen extract; and   wherein the at least one parameter comprises an amount of added bridging liquid relative to an amount of added bituminous feed, or a position at which at least a portion of the bridging liquid is added to the slurry.   
     
     
         2 . The method of  claim 1 , wherein the at least one property further comprises one of (i) at least one property of the slurry prior to agglomeration, (ii) at least one property of the bituminous feed, (iii) a fines content of the low solids bitumen extract, (iv) clay chemistry, (v) a rheological property of the agglomerated slurry, (vi) a filtration rate of the agglomerated slurry and (vii) bitumen content of the low solids bitumen extract. 
     
     
         3 . (canceled) 
     
     
         4 . The method of  claim 1 , wherein the at least one parameter further comprises one of (i) an amount of added bridging liquid relative to an amount of added bituminous feed, ii a composition of the bridging liquid, (iii) a position at which at least a portion of the bridging liquid is added to the slurry, (iv) an agglomeration residence time, (v) an amount of extraction liquor added relative to an amount of added bituminous feed, (vi) a level of agitation provided to the slurry, and (vii) a shear environment of the agglomeration. 
     
     
         5 . The method of  claim 1 , wherein the at least one parameter further comprises an extraction residence time. 
     
     
         6 . The method of  claim 5 , wherein the extraction residence time is greater than 5 minutes. 
     
     
         7 . (canceled) 
     
     
         8 . The method of  claim 4 , wherein the agglomeration residence time is 1 to 5 minutes. 
     
     
         9 . (canceled) 
     
     
         10 . The method of  claim 2 , wherein the at least one property of the bituminous feed comprises water content. 
     
     
         11 . The method of  claim 2 , wherein the at least one property of the bituminous feed comprises insoluble inorganics content. 
     
     
         12 . The method of  claim 1 , wherein the adding the bridging liquid to the slurry comprises adding a combination of at least two different bridging liquid streams. 
     
     
         13 . The method of  claim 12 , wherein the at least one parameter comprises relative amounts of the at least two different bridging liquid streams, recycling at least a portion of the agglomerated slurry into step a), recycling at least a portion of the agglomerated slurry between steps a) and b), or recycling at least a portion of the agglomerates into step b). 
     
     
         14 . The method of  claim 1 , wherein the bridging liquid is added to the slurry in a concentration of between one of (i) 1 and 20 wt % of the slurry and (ii) 1 and 10 wt % of the slurry. 
     
     
         15 . (canceled) 
     
     
         16 . The method of  claim 1 , further comprising separating the agglomerates from the low solids bitumen extract. 
     
     
         17 . The method of  claim 16 , further comprising recovering the solvent from the low solids bitumen extract to form a bitumen product. 
     
     
         18 . 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 %. 
     
     
         19 . The method of  claim 1 , wherein the bridging liquid is one of water and an aqueous solution. 
     
     
         20 . (canceled) 
     
     
         21 . The method of  claim 1 , wherein at least 80 wt. % of the agglomerates of step c) are between 0.1 and 1 mm. 
     
     
         22 . The method of  claim 1 , wherein the agglomerated slurry has a solids content of 20 to 70 wt %. 
     
     
         23 . The method of  claim 1 , wherein the solvent comprises an organic solvent or a mixture of organic solvents. 
     
     
         24 . The method of  claim 1 , wherein the solvent comprises at least 50 wt. % cyclohexane. 
     
     
         25 . The method of  claim 1 , wherein the agglomeration is effected in one or more vessels. 
     
     
         26 . The method of  claim 1 , wherein step b) comprises agitating by mixing, shaking, or rolling. 
     
     
         27 . The method of  claim 1 , wherein a ratio of the solvent to bitumen in the agglomerated slurry is less than 2:1. 
     
     
         28 . The method of  claim 1 , wherein the bituminous feed is derived from oil sands.