Method of processing a bitumen stream using a membrane

Abstract

Disclosed is a method of processing bitumen streams using membrane filtration. In one aspect, membrane filtration replaces paraffinic froth treatment, with one or more filtration steps replacing gravity settling. In another aspect, the bitumen stream is subjected to paraffmic solvent treatment at much higher flow rates, with an “almost cleaned” product being subsequently filtered by the membrane system. In this case, some contaminants are removed by conventional gravity settling equipment, while additional contaminants are removed by membrane filtration. In another aspect, membrane filtration is applied to a bitumen product effluent stream following naphthenic froth treatment. In another aspect, membrane filtration is applied to a bitumen product effluent stream from a solvent-based extraction process. In yet another aspect, membrane filtration is applied to a bitumen product effluent stream from a solvent extraction with solids agglomeration process. In still another aspect, membrane filtration is applied to bitumen produced by SAGD.

1 . A method of processing a bitumen product effluent stream, the method comprising:
 providing a bitumen product effluent stream; and   passing the bitumen product effluent stream through a membrane system with anti-fouling characteristics to filter contaminants out of the bitumen product effluent stream to produce a primary permeate stream and a primary concentrated effluent stream;   wherein the bitumen product effluent stream comprises:
 a) a bitumen product stream from a paraffinic froth treatment; 
 b) a bitumen product stream from a naphthenic froth treatment; 
 c) a bitumen product stream from a solvent-based extraction process; or 
 d) an in situ bitumen production stream. 
   
     
     
         2 .- 3 . (canceled) 
     
     
         4 . The method of  claim 1 , wherein said bitumen product stream has been preconditioned with one of (i) a solvent and (ii) a deasphalting solvent and asphaltenes have been flocculated to the point of precipitation prior to membrane filtration. 
     
     
         5 .- 7 . (canceled) 
     
     
         8 . The method of  claim 1 , wherein said bitumen product effluent stream is b) the bitumen product stream from a paraffinic froth treatment, and wherein said contaminants comprise water, mineral matter, precipitated asphaltenes, wood, coal, or a combination thereof. 
     
     
         9 . The method of  claim 1 , further comprising one of (i) treating said primary concentrated effluent stream with additional solvent after the membrane system and (ii) subjecting said primary concentrated effluent stream to additional membrane filtration to remove additional contaminants and yield a secondary concentrated effluent stream and a secondary permeate stream, wherein said additional contaminants comprise water, mineral matter, precipitated asphaltenes, or a combination thereof. 
     
     
         10 .- 11 . (canceled) 
     
     
         12 . The method of  claim 9 , further comprising adding the additional solvent to the primary concentrated effluent to redissolve precipitated asphaltenes and release asphaltene associated water. 
     
     
         13 . (canceled) 
     
     
         14 . The method of  claim 1 , wherein said bitumen product effluent stream is c) the bitumen product stream from a naphthenic bitumen froth treatment, and wherein said contaminants comprise water, mineral matter, wood, coal, or a combination thereof. 
     
     
         15 . The method of  claim 1 , wherein said bitumen product effluent stream is c) the bitumen product stream from the naphthenic bitumen froth treatment, and wherein solids are retained in said primary concentrated effluent stream during membrane filtration. 
     
     
         16 . The method of  claim 1 , wherein said bitumen product effluent stream is c) the bitumen product stream from the naphthenic bitumen froth treatment, and further comprising subjecting said primary concentrated stream to further membrane filtration to remove additional contaminants and yield a secondary permeate and concentrated effluent stream. 
     
     
         17 . (canceled) 
     
     
         18 . The method of  claim 1 , wherein said bitumen product effluent stream is d) the bitumen product stream from a solvent-based extraction process, and wherein said solvent-based extraction process is a solvent-based extraction with solids agglomeration. 
     
     
         19 . The method of  claim 1 , wherein said bitumen product effluent stream is d) the bitumen product stream from a solvent-based extraction process and wherein said contaminants comprise water, mineral matter, wood, coal, or a combination thereof, and wherein said contaminants further comprise precipitated asphaltenes. 
     
     
         20 . (canceled) 
     
     
         21 . The method of  claim 1 , wherein said bitumen product effluent stream is d) the bitumen product stream from a solvent-based extraction process, and wherein solids are retained in said primary concentrated effluent stream during membrane filtration. 
     
     
         22 . The method of  claim 1 , wherein said bitumen product effluent stream is d) the bitumen product stream from a solvent-based extraction process, and wherein asphaltenes are retained in said primary concentrated effluent stream during membrane filtration. 
     
     
         23 . The method of  claim 1 , wherein said bitumen product effluent stream is d) the bitumen product stream from a solvent-based extraction process, and further comprising subjecting said primary concentrated stream to further membrane filtration to remove additional contaminants and yield a secondary concentrated effluent stream and secondary permeate effluent stream, and wherein said additional contaminants comprise water, mineral matter, asphaltenes, wood, coal, or a combination thereof. 
     
     
         24 . The method of  claim 1 , wherein said bitumen product effluent stream is d) the bitumen product stream from a solvent-based extraction process, and wherein the primary concentrated stream is directed back to the solvent-based extraction process. 
     
     
         25 . The method of  claim 23 , wherein the secondary concentrated stream is directed back to the solvent-based extraction process. 
     
     
         26 .- 27 . (canceled) 
     
     
         28 . The method of  claim 1 , wherein the bitumen product effluent stream is e) the in situ bitumen production stream, and wherein said in situ oil bitumen production stream is one of (i) a steam assisted gravity drainage production stream, (ii) from one of the following in situ production methods: cyclic steam stimulation (CSS), solvent-assisted SAGD (SA-SAGD), steam and as push (SAGP), combined vapor and steam extraction (SAVEX), expanding solvent SAGD (ES-SAGD), constant steam drainage (CSD), liquid addition to steam for enhancing recovery (LASER), cyclic solvent dominated recovery process (CSDRP), water flooding, steam flooding process, or a derivative thereof, and (iii) mixed with a solvent to cause asphaltene precipitation prior to membrane filtration. 
     
     
         29 .- 30 . (canceled) 
     
     
         31 . The method of  claim 28 , wherein said solvent is a C 3  to C 7  alkane, or an isomer thereof. 
     
     
         32 . The method of  claim 1 , wherein the bitumen product effluent stream is e) the in situ bitumen production stream, and wherein said production stream is one of (i) mixed with a solvent and transported through a pipeline over a sufficient distance to facilitate asphaltene precipitation and separation, (ii) first mixed with a first solvent, then subjected to free-water knock-out prior to membrane filtration, and (iii) subjected to a secondary water separation step prior to membrane filtration. 
     
     
         33 .- 34 . (canceled) 
     
     
         35 . The method of  claim 1 , wherein one of (i) said bitumen product effluent or primary concentrated effluent stream is heated to reduce viscosity prior to filtration (ii) said membrane is an ultra-filtration membrane, a micro-filtration membrane, or a nano-filtration membrane and (iii) said anti-fouling characteristics comprise appropriate pore size, controlled roughness, hydrophilicity, appropriate membrane material, anti-fouling coatings, chemical addition to the feed, or high shear. 
     
     
         36 .- 37 . (canceled) 
     
     
         38 . The method of  claim 35 , wherein one of said high shear is produced by high velocity cross-flow at a surface of the membrane system and said high shear is shear above one of 20,000 s −1  and 100,000 s −1 . 
     
     
         39 .- 42 . (canceled)