Methods, apparatus, and systems for incorporating bio-derived materials into oil sands processing

Abstract

Methods, processes, apparatus, systems, and compositions are disclosed for improving the sustainability of oil sands processing. In some embodiments, bitumen is combined with biodiluent comprising one or more liquid pyrolysis fractions obtained from pyrolyzing biomass and collecting multiple liquid fractions. The bitumen may be any source of bitumen, such as bitumen obtained from oil sands. In some embodiments, a water-rich pyrolysis liquid displaces water use in an oil sands process. The water-rich pyrolysis liquid may be used for primary separation of bitumen from oil sands or for hydrotransport, for example. Also, biochar produced from biomass pyrolysis may be introduced to an oil sands tailing pond with various benefits. Water may be recycled from a tailing pond. Integration of a pyrolysis and separation process into an oil sands refining process reduces the overall greenhouse-gas emissions on a well-to-refined product basis by 10-70% or more. Various compositions and products are also disclosed.

What is claimed is: 
     
         1 . An oil sands refining process comprising:
 (a) providing a mined oil sands feedstock;   (b) crushing said mined oil sands feedstock to produce crushed oil sands;   (c) combining said crushed oil sands with water for hydrotransport to a separation section;   (d) operating said separation section to separate crushed oil sands into bitumen, coarse sand, and water containing suspended solids;   (e) introducing said coarse sand and said water containing suspended solids to a tailing pond;   (f) providing a biomass feedstock; and   (g) converting said biomass feedstock in a pyrolysis process to at least one low-water pyrolysis liquid containing less than 10 wt % water, a water-rich pyrolysis liquid, and biochar,   wherein said bitumen is diluted with biodiluent comprising said at least one low-water pyrolysis liquid, to form diluted bitumen.   
     
     
         2 . The process of  claim 1 , said process further comprising combining diluent with said bitumen to form said diluted bitumen. 
     
     
         3 . The process of  claim 1 , said process further comprising introducing said diluted bitumen to a unit for refining, upgrading, or chemical conversion. 
     
     
         4 . The process of  claim 3 , said process comprising converting at least a portion of said biodiluent into fuels, chemicals, materials, or energy. 
     
     
         5 . The process of  claim 4 , said process comprising converting at least a portion of said biodiluent into bio-based asphalt or bio-based asphalt cement. 
     
     
         6 . An oil sands refining process comprising:
 (a) providing an oil sands formation;   (b) extracting bitumen from said oil sands formation using an in-situ extraction method;   (c) providing a biomass feedstock;   (d) converting said biomass feedstock in a pyrolysis process to at least one low-water pyrolysis liquid containing less than 10 wt % water, a water-rich pyrolysis liquid, and biochar; and   (e) combining said extracted bitumen with a biodiluent to form diluted bitumen, wherein said biodiluent comprises said at least one low-water pyrolysis liquid.   
     
     
         7 . The process of  claim 6 , said process further comprising combining said extracted bitumen with a diluent to form said diluted bitumen. 
     
     
         8 . The process of  claim 6 , said process further comprising introducing said diluted bitumen to a unit for refining, upgrading, or chemical conversion. 
     
     
         9 . The process of  claim 8 , said process comprising converting at least a portion of said biodiluent into fuels, chemicals, materials, or energy. 
     
     
         10 . The process of  claim 9 , said process comprising converting at least a portion of said biodiluent into bio-based asphalt or bio-based asphalt cement. 
     
     
         11 . A process of biomass refining, said process comprising producing at least one low-water pyrolysis liquid, biochar, and a water-rich pyrolysis liquid, wherein said low-water pyrolysis liquid is suitable for use as a refinery feedstock, wherein said biochar is suitable for use as an oil sands tailing stabilization and carbon-sequestration agent, and wherein said water-rich liquid is suitable for reducing water use in oil sands processing. 
     
     
         12 . The process of  claim 11 , said process comprising converting at least a portion of said low-water pyrolysis liquid into fuels, chemicals, materials, or energy.