Oil sands extraction

Abstract

A process for the separation of inorganic material from unconditioned oil sands is described. The process include the steps of (a) contacting unconditioned oil sands with a light aliphatic solvent being capable of dissolving bitumen and dispersing asphaltenes present in the oil of unconditioned oil sands; under conditions permitting dispersion of the asphaltenes, to thereby produce a mass; wherein the light aliphatic solvent being selected from the group consisting of pentane, hexane, iso-hexane, neo-hexane, heptane and mixtures thereof; (b) agglomerating a significant portion of fines and coarse inorganic material from said mass obtained in step (a) and dissolving a significant portion of bitumen in the solvent, wherein the amount of solvent is adjusted to maintain dispersion of the asphaltenes, and (c) separating the agglomerated inorganic material and non-agglomerated coarse inorganic material from said mass to obtain a slurry of organic material comprising dissolved bitumen, dispersed asphaltenes and non-agglomerated fines.

1 - 51 . (canceled) 
     
     
         52 . A process for the separation of inorganic material from unconditioned oil sands, the process comprising:
 (a) contacting unconditioned oil sands with a light aliphatic solvent being capable of dissolving bitumen and dispersing asphaltenes present in the oil of unconditioned oil sands; under conditions permitting dispersion of the asphaltenes, to thereby produce a mass; wherein the light aliphatic solvent being selected from the group consisting of pentane, hexane, iso-hexane, neo-hexane, heptane and mixtures thereof;   (b) agglomerating a significant portion of fines and coarse inorganic material from said mass obtained in step (a) and dissolving a significant portion of bitumen in the solvent, wherein the amount of solvent is adjusted to maintain dispersion of the asphaltenes, and   (c) separating the agglomerated inorganic material and non-agglomerated coarse inorganic material from said mass to obtain a slurry of organic material comprising dissolved bitumen, dispersed asphaltenes and non-agglomerated fines.   
     
     
         53 . A process according to  claim 52 , wherein the unconditioned oil sands are selected from unconditioned oil-wet or unconditioned water-wet sands. 
     
     
         54 . A process according to  claim 52 , wherein the at least one light aliphatic solvent is selected amongst such having a boiling point lower than about 100° C. 
     
     
         55 . A process according to  claim 52 , wherein the slurry of step (c) is first classified by a classifier, followed by clarifier, and optionally followed by centrifugal separation means. 
     
     
         56 . A process according to  claim 55 , wherein said centrifugal separation means is selected from a centrifuge and a hydrocyclone. 
     
     
         57 . A process according to claim  1 , further comprising:
 (d) separating fines from the slurry obtained in step (c), under conditions permitting at least partial dissolution of the asphaltenes.   
     
     
         58 . A process according to  claim 57 , further comprising:
 (e) treating the organic material under conditions permitting at least partial re-dispersion of the asphaltenes contained in said organic material.   
     
     
         59 . A process according to  claim 58 , further comprising:
 (f) separating the asphaltenes from the organic material to obtain a substantially asphaltene-free and fines-free bitumen liquor.   
     
     
         60 . A process according to  claim 57 , wherein step (d) is carried out under one or both of temperature and pressure to dissolve at least part of the asphaltenes. 
     
     
         61 . A process according to  claim 52 , further comprising treating the slurry of step (c) under conditions permitting separation of the bitumen liquor from the asphaltenes and fines associated therewith, and subsequently treating the asphaltenes and fines associated therewith to selectively separate the fines from the asphaltenes. 
     
     
         62 . A process according to  claim 61 , wherein prior to the selective separation, the asphaltenes and fines are treated by one or both of temperature and pressure to dissolve at least part of the asphaltenes. 
     
     
         63 . A process according to  claim 61 , wherein the selective separation is carried out under one or both of temperature and pressure to dissolve at least part of the asphaltenes. 
     
     
         64 . A process according to  claim 61 , wherein the separation of the bitumen liquor from the asphaltenes and the fines associated therewith or the selective separation of the fines from the asphaltenes is carried out in a centrifugal-based means selected from the group consisting of a centrifuge, a hydrocyclone, and any combination thereof. 
     
     
         65 . A process according to  claim 61 , wherein in the selective separation, the asphaltenes and fines associated therewith are treated with at least one solvent capable of dissolving at least a portion of the asphaltenes. 
     
     
         66 . A process according to  claim 65 , wherein the at least one solvent is selected from the group consisting of hexanes, benzene, toluene, xylenes, naphtha, chloroform, trichloromethane, tetrachloromethane, trichloroethane, limonene and mixtures thereof. 
     
     
         67 . A process according to  claim 52 , wherein said contacting and agglomeration steps are carried out in the same mechanical unit. 
     
     
         68 . A process for the separation of inorganic material from unconditioned oil sands, the process comprising:
 (a) contacting unconditioned oil sands with a solvent consisting at least one light aliphatic solvent being capable of dissolving bitumen and dispersing asphaltenes present in the oil of unconditioned oil sands; under conditions permitting dispersion of the asphaltenes, optionally utilizing a grinding medium, to produce a mass;   (b) agglomerating in the same mechanical unit at least a portion of fines and coarse inorganic material in said mass obtained in step (a); and adjusting the amount of solvent to maintain dispersion of the asphaltenes; and   (c) separating the agglomerated inorganic material and non-agglomerated coarse inorganic material from said mass to obtain a slurry comprising at least partially dissolved bitumen, at least partially dispersed asphaltenes and non-agglomerated fines.   
     
     
         69 . A process for the separation of inorganic material from unconditioned oil sands, the process comprising:
 (a) contacting unconditioned oil sands with a light aliphatic solvent being capable of dissolving bitumen and dispersing asphaltenes present in the oil of unconditioned oil sands; under conditions permitting dispersion of the asphaltenes, to thereby produce a mass; wherein the light aliphatic solvent being selected from the group consisting of pentane, hexane, iso-hexane, neo-hexane, heptane and mixtures thereof;   (b) agglomerating a significant portion of fines and coarse inorganic material from said mass obtained in step (a) and dissolving a significant portion of bitumen in the solvent, wherein the amount of solvent is adjusted to maintain dispersion of the asphaltenes, and   (c) separating the agglomerated inorganic material and non-agglomerated coarse inorganic material from said mass to obtain a slurry of organic material comprising dissolved bitumen, dispersed asphaltenes and non-agglomerated fines,   wherein said contacting and agglomeration steps are carried out in the same mechanical unit.