CA1085763A - Solvent extraction process - Google Patents
Solvent extraction processInfo
- Publication number
- CA1085763A CA1085763A CA283,955A CA283955A CA1085763A CA 1085763 A CA1085763 A CA 1085763A CA 283955 A CA283955 A CA 283955A CA 1085763 A CA1085763 A CA 1085763A
- Authority
- CA
- Canada
- Prior art keywords
- solvent
- contactor
- water
- sand
- stream
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
- C10G1/04—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by extraction
Abstract
ABSTRACT
A continuous solvent extraction process for tar-sand uses a closed rotary contactor. A tar-sand/water slurry stream and a solvent stream are passed countercurrent through the contactor and three phases are formed: tar-sand solids at the bottom of the contactor, a barrier layer of water in which the solids are contained and an uppermost solvent phase. The solids during their travel through the contactor are repeatedly lifted off the bottom of the contactor and tumbled through the solvent phase so that the bitumen oils content of the tar-sand is progressively dissolved in the solvent. A solvent stream containing the dissolved bitumen oils is removed from one end of the contactor and discard stream con-sisting essentially of sand and water is removed from the other end.
A continuous solvent extraction process for tar-sand uses a closed rotary contactor. A tar-sand/water slurry stream and a solvent stream are passed countercurrent through the contactor and three phases are formed: tar-sand solids at the bottom of the contactor, a barrier layer of water in which the solids are contained and an uppermost solvent phase. The solids during their travel through the contactor are repeatedly lifted off the bottom of the contactor and tumbled through the solvent phase so that the bitumen oils content of the tar-sand is progressively dissolved in the solvent. A solvent stream containing the dissolved bitumen oils is removed from one end of the contactor and discard stream con-sisting essentially of sand and water is removed from the other end.
Description
1~8~763 ~ his invention relates to a sol~ent extraction process for the extraction of bitumen oils fr~m tar-sand as found in various areas of the world. Tar-sand is found in the form of particles each of which consists of 5. a nucleus of sand and fines which is wetted and surrounded by water, in turn enclosed by a layer of a mixture of oils, referred to herein as "bitumen oils".
The oil content of tar-sand found in Alberta, Canada for example consists of approximately 60% bitumen-like 10. materials, 20% heavy petroleum oils, 18% lighter oils similar to kerosene and naphtha, and 2% gasoline, all percentages being by weight.
There is no great theoretical problem in separating the bitumen oils from the other constituents of tar-15. sand and indeed one process for doing so is incommercial operation, using hot water to break down the tar-sand particles and separate the bitumen oils. That process is only marginally viable commercially, having a relatively low extraction rate, low ef~iciency, and high 20. capital and operating costs. In addition, as large quantities of water are to be disposed of, much of it seriously contaminated with oils and other chemicals, the hot water process can be damaging to the environment.
There have also been many theoretical proposals for 25. extracting the bitumen oils with solvents but none of those has been adopted on a commercial scale. Those ¦ proposals have moreover required large volumes of solvent, greatly exceeding the extracted bitumen oils on a weight -to weight basi~, and have necessitated complicated , 1 `
'.
; 2 .
~08S763 equipment. As the solvent is applied directly to the tar-sand particles, there are high solvent losses because of the retention of solvent by the sand, and there are difficulties in separating the fines from the solvent.
Further, the large volumes of solvent required for the process present a fire hazard while the dissemination of solvent vapour is environmentally unacceptable.
The present invention resides in a continuous peocess for the solvent extraction of bitumen oils from tar-sand, in which process tar-sand is supplied at a supply point to a contactor and passed through the contactor towards a discharge point; a stream of solvent is passed through the contactor, the solvent being of lesser density than, and substantially immiscible with, water; water is supplied to and withdrawn from the contactor, the solvent stream and the water providing a solvent phase and a water phase in the contactor substantially distinct from each other, which is sustantially filled by the solvent phase, the water phase and solids of the tar-sand, with a barrier 20 layer formed by the water phase between the solvent phase and solids; solids of the tar-sand are repeatedly showered through the liquid phases in the contactor as the tar-sand passes through the contactor towards the discharge point, whereby the solids are contacted with the solvent phase and bitumen oils are progressively - dissolved in the solvent phase; a bitumen oils-containing solvent phase is removed from the contactor; and a discard stream, comprising said withdrawn water and sand which is substantially free of bitumen oils and solvent, is removed ; 30 from the contactor at the A
' ' ~ ' ' : ' ~085763 àischarge point. ~ecause of the repeated showering of the tar-sand solids through the solvent phase as those solids move through the contactor, an efficient stripping of the bitumen oils from those solids is effected so that 5. a high extraction rate, which may reach as high as 99.9%, is achievable, while the water layer, in which the sand is contained, keeps the solvent losses low. Preferably, the solvent stream and the tar-sand/water stream move through the contactor in countercurrent.
10. It is preferred to add water to the tar-sand prior to entry to the contactor so that it may be pumped to the contactor as a slurry. However, the tar-sand may enter the contactor with only a proportion of the total water of the tar-sand and water stream, the remaining 15. water being then introduced independently into the con-tactor to form that stream. It is advantageous to break up the tar-sand with water in a digester, so that the bitumen oils may be dissolved more readily in the solvent stream.
20. The amount of water in the feed stream is determined, firstly, by the possible need to pump the tar-sand/water slurry, if formed, to the contactor; secondly, by the need for the tar-sand/water stream to flow reasonably freely through the contactor; and thirdly, by the need 25. to have the sand in the contactor adequately surrounded by water to prevent the solvent coming in contact with the sand, except while the latter is being showered ~
through the former. In practice, it has been found that the water should constitute at least 20~, advantageously ovcr 40%, and preferably 50~,0, of the tar-sand/water stream on entry, by weight. The amount of water can exceed the stated percentage, but the efficiency of the system demands that a minimum amount of water be used 5. consistent with its required function. Generally, there-fore, the percentage is of the order of 50.
The solvent of the solvent stream being less dense than, and substantially immiscible with, water, the solvent and water form two separate phases, and any 10. solvent adhering to the solids on being showered through the contactor is caused rapidly to migrate back to the solvent phase. The solvent in the solvent stream is dependent on the nature of the tar-sand and may be between 10% and 85% by weight of the bitumen oils of the 15. tar-sand. The solvent is therefore preferably present in an amount by weight less than the extracted bitumen oils;
it is possible to exceed the figure of 85%, but no significant benefit is achieved thereby and an excessive amount of solvent adversely affects the economy of the 20. solvent recovery stage. Advantageously, the solvent is between 15% and 85% by weight of the bitumen oils, and preferably between 20% and 80%.
The preferred solvent is a hydrocarbon oil or a mixture of such oils and advantageously falls within the 25. boiling range of kerosene (200C-295C). The solvent may in fact be kerosene, but may alternatively be a fraction of the extracted bitumen oils, having a similar i boiling range.
Normally, the solvent stream discharged from the .. .
.. . .
contactor and having the bitumen oils dissolved therein, is passed to a solvent recovery plant, from which the recovered solvent is recycled to the contactor.
Alternatively, the solution of the bitumen oils in the 5. solvent may pass to a refining plant, which supplies a product which is suitable as the solvent of the solvent stream entering the contactor.
The bitumen oils component of tar-sand has a mean specific gravity greater than that of water at 20C, but 10. its specific gravity falls with increasing temperature.
The solution of the bitumen oils in the solvent must be lighter than water and the temperature of the feed stream and the solvent are chosen to that end. The temperature of the feed stream, at least at entry to the contactor is 15. preferably between 20~C and 95C and, for better efficiency, may be between 50C and 75C. Thermal efficiency may be improved by recycling hot water from the discard stream to form the slurry; recycling of water has the further advantage of reducing the volume discharged 20. to the environment. The recycle water stream may also contain water utilised in heat exchangers in a solvent recovery plant.
The contactor is completely filled by the two streams, receptacles within the contactor being rotated to raise 25. the solids of the tar-sand/water stream and shower them through the solvent stream. Thus, the contactor may be a solids/liquid contactor similar to the liquid/liquid contactor described in British patent specification No.
972035, although the buckets are modified to ensure - . - -.... , ~ .
108~763 scooping of the solids from the bottom of the contactor.
The structure of the contactor may also be modi~ied by rotating the contactor drum as a whole, the receptacles or buckets for effecting showering being carried by, and 5. rotated with, the drum. The axis of the cylindrical contactor does not depart radically from the horizontal, although it may be inclined downwards towards the discharge point at an angle of less than 8 for example, in order to aid the movement of the solids of the tar-10. sand through the contactor. The supplies of the solvent stream and the tar-sand/water slurry are chosen so that the interface between the solvent phase and the water phase is constant, preferably approximately at the contactor axis.
15. The contactor should not rotate 90 rapidly as to agitate the contents unduly and to form an emulsion therein and the speed of rotation should be such that a clear interface between the solvent and water phases ls maintained.
20. The contactor may be externally heated and/or cooled;
thus that part of the contactor ad~acent the supply point, may be heated in order to reduce the amount of heating of the tar-sand/water slurry prior to entry.
The size of the contactor is dependent on the desired 25. throughput of tar-sand. In a large installation there may be a number of the contactors arranged in parallel.
The invention will be more readily understood by way of example from the following description of a tar-sand solvent extraction process in accordance therewith, .
reference being made to the accompanying drawings, in which:-Figure 1 is a flow diagram of one form of theprocess;
5. Figure 2 is a radial section through the contactor used in the process; and Figure 3 is a flow diagram illustrating a modifi-cation of the process of Figure 1.
Raw tar-sand, suitably broken down, is fed at 12 into 10. a rotary di~ester 13, where it is mixed with hot water through line 14 from a hot water reservoir tank 15 and broken down into slurry ~orm. The recycled water from tank 15 is pumped by a pump 16 through a fuel-~ired heater 17 so that the temperature of the water on entry to the 15. digester 13 is about 96C. Steam may be added to the - digester 13 through steam line 18, but normally is not required. The slurry of tar-sand in water exiting from digester 13 flows over a scalping screen 20, which removes foreign bodies. The slurry passes through screen 20 to a 20. head tank 21, where more hot water from recycle line 14 is added as necessary to bring the temperature o~ the slurry to about 65C and to maintain the solids in suspension.
The hot tar-sand/water slurry is pumped by pump 22 from tank 21 to a solids/liquid contactor 23, the slurry 25. entering the contactor near the bottom of the unit.
The contactor 23 is generally as described in British patent speci~ication No. 972035, to which reference should :
be made, but is modi~ied in minor respects to make it suitable as a solids/liquid contactor. That contactor is ,~
' 8.
108~763 shown diagrammatic,ally in axial section in the accomp-, anying Figure 1 and in radial section in the accompanying Figure 2, and as illustrated consists of a stationary shell 24 in ~hich a rotor is mounted for rotation about 5. its axis. The rotor includes a number of axially-spaced circular discs 25 which separate the interior of the shell 24 into a series of compartments. The edge of each disc 25 is spaced from the wall of shell 24, so that adjacent compartments are in communication via annular gaps between 10. the discs and shell. In each compartment, there are a series of spaced buckets or receptacles 26 which are carried between the discs of that compartment. Some or all of the buckets have their leading edges extended across the gap between the discs 25 and the shell 24 to 15. act as scrapers and to ensure solids at the bottom of the shell are scooped by the buckets; in Figure 2, two of the buckets are shown as so extended at 27. The final compartment, i.e. that at the right hand end of the contactor, are not provided with buckets 26J to facllitate 20. removal of the stripped sand.
The hot tar-sand/water slurry enters the contactor 23 as a stream at one end of the contactor, passes progress-ively from compartment to compartment of the contactor via the circumferential gaps and is discharged as a discard 25. stream through a line 28 at the bottom of the other end of the contactor. At the same time solvent for the bitumen oils of the tar-sand is introduced on line 30 into the top of the contactor 2~ as a countercurrent solvent stream and discharges through line 31 at the top of the end of the ~08S~63 contactor through which the tar-s~nd slurry enters. The solvent is pumped by pump 32 from a solvent storage tank 33, and may be heated in a steam heater ~4, before entering the contactor 23. The solvent stream being virtually 5. immiscible with water forms a distinct and separate phase above the feed stream; the operation of the system is so arranged that the interface between the two phases remains approximately static at or adjacent the axis o~ the con-tactor. That a~is does not depart substantially from the 10. horizontal, but may be inclined downwardly at a small angle less than 8 to the horizontal from the entry end to the discharge end of the tar-sand/water stream, in order to ~-assist the flow of the solids of the tar-sand through the contactor.
15. As the tar-sand/water stream passes through the contactor 23 (from left to right in Figure 1), it is con-tinuously treated in each compartment by the rotary buckets 26 (Figure 2), solids of the tar-sand being scooped up and raised by the buckets, and discharged progressively from 20. those buckets in the upper half of the shell 24, so that they are tumbled, or showered, through the solvent stream 35. Being denser than either the solvent or water, the solids discharged from the buckets 26 rapidly pass through the solvent stream 35 and settle at the bottom of the 25. shell 24. The rotary buckets 26 also carry down solvent from stream 35 and into the tar-sand/water stream 36, being discharged as droplets which rapidly return upwardly ; into the solvent stream 35.
Thus, during the progress of the tar-sand through , .~ .
` 10.
, . .
108~763 the contactor 23, the tar-sand particles are first dis-integrated, if they have not been so treated prior to entry, and the solids are repeatedly showered through the solvent of the solvent stream in each successive 5. compartment of the contactor, so that the bitumen oils are progressively dissolved in the solvent stream and the sand and fines of the feed stream are progressively stripped of bitumen oils. Finally the sand and fines, without significant bitumen oils, are discharged with water 10. through the discharge line 28.
The contents of the contactor 23 form three phases, the lowermost of which is sand which rapidly settles at the bottom of the container 24, the middle layer being water, in which the sand is located, and the uppermost being sol-15. vent. The presence of an enveloping volume of water for the sand has the important function of forming a barrier separating the solvent from the sand and causing rapid displacement of any solvent retained on the sand. The consequence is that, by the time the sand reaches the dis-; 20. charge end of the contactor, lt has little or no adhering solvent. The discard stream on line 28 is almost entirely made up of water, sand and fines, while the solvent stream discharge on line 31 consists almost entirely of a solution of the extracted bitumen oils in the solvent. The process 25. performed in the contactor 23 is thus a continuous, counter-current, multi-stage, extraction.
The bitumen oils solution from the contactor 23 is directed on line 31 to storage tank 38, from which it is ; passed to a solvent recovery plant which separates the 11.
' . , , ~ , - , .--solvent from the bitumen oils and recycles the soivent back to the solvent tank 33. For that purpose, the solution in tank 38 is pumped by pump 40 through a heat exchanger 41, in which the temperature is raised, to a 5. heater 42, which is fired with gas or oil. The solution at a temperature of about 350C passes to a fractionating column 4~, in which the components of the feed separate in the usual way. Overhead vapour is taken from the column through line 44 to condenser 45, which may be a 10. tubular unit or a direct spray type. The water and light oils condensate from condenser 45 separate in tank 46, the water of the lower layer being recycled to the hot water tank 15 through line 47. The light oils of the upper layer in tank 46 flow to a storage tank 48, and a 15. portion is pumped back through line 50 to the column 43 as reflux, while the remainder is directed to a further tank 51 for bitumen oils, which are pumped to a refinery.
A fraction falling within the kerosene boiling range, e.g. 200C to 295C, is taken as a side-stream from column 20. 4~ and passed to a stripper 54, which has steam injected at its base at 55 to drive off the lighter components and to trim the composition of the received solvent fraction.
The vaporised lighter components are returned to the column 43, while the trimmed solvent fraction leaves the ?5. base of stripper 54, is cooled to about 65C in cooler 56, and then flows to the solvent storage tank 3~. Solvent tank 33 is also supplied on line 57 with make-up solvent as required. The bottom product of the column 4~ - the high boiling point bitumen oils - leaves the bottom of the - ~ . -1~5763 column and, after cooling in heat exchanger 41, i5 pumped through a product cooler 58 to the bitumen oils storage tank 51. Warm cooling water from product cooler 58, as well as from heat exchangers 34, 45, and 56 pass ~ia the 5. line 47 to the hot water tank 15.
The solvent fraction obtained from the distillation column 43 and stripped in the stripper 54 contains, not only the recovered solvent, but also fractions of the bitumen oils contained in the tar-sand falling within the 10. same boiling range. Accordingly, ~he system is self-sufficient in solvent, solvent being required to be supplied externally on line 57, only at start-up. The solvent recovery system is normally operated at atmos-pheric pressure, but in some circumstances it may be 15. advantageous to operate it under reduced pressure.
The discard stream of sand, fines and water, freed from bitumen oils and solvent, flows on line 28 from con-; tractor 23 to the sand clean-up unit. That unit includes a conical separator 60. Separator 60 is closed and the , 20. discard stream entering on line 28 passes through a sleeved section 61, which is designed to eliminate surface turbulence in the water at the top of the separator. The heavier sand rapidly settles into the base of the separator and the water with the fines flows under the sleeve section 25. 61 and over the periphery of the separator into a launder `~ 62. Steam is injected into the base of the separator at 63 close to the valved outlet 64. The steam performs two functions: firstly, it maintains a free flow of sand leaving the separator and, secondly, it effects the removal ;, . 1~.
~085763 of any dissolved solvent that may be present in the water.
The steam, plus any solvent vapours, leaves the top of the separator 60 and is condensed in condenser 65, hot condensate flowing into the hot water tank 15, together 5. with the warm cooling water. Alternati~ely, the steam from separator 60 may be condensed in a direct spray condenser.
The water and fines, which overflow from the separator 60 pass from the launder 62 to a centrifugal 10. separator 66, which concentrate the fines into a slurry which is mixed with the sand leaving the valved outlet 64.
The water, substantially freed from fines, leaves the centrifugal separator 66 and is returned to hot water tank 15 on line 67. The hot water in tank 15, as above des-15. cribed, is recycled to the digester 1~; if some residualsolvent is vaporised from the separator 60 into the hot water recycle circuit, it is absorbed and utilised in the contactor 23, and does not represent a loss of solvent in the overall system. The sand from separator 60 and the 20. fines slurry from centrifugal separator 66 have a water content approximately equal to the weight of water plus bitumen oils entering the process in the raw tar-sand.
The sand/fines/water effluent on line 68 may therefore be returned to the sand pits without the need for large 25. settling lagoons.
Table I gives the mass balance of the system shown ; in Figure 1 and described above, and gives the weights, the heat contents and the temperatures of the materials at different points of the system. All quantities are ' 14.
10~3~763 given by weight and it will be observed that the solvent (3.8) is only a small portion of the bitumen oils con-tained in the tar-sand (19.2). The process is therefore highly economical in solvent usage.
5. The preferred solvent to be used at start-up is kerosene, the solvent ~raction obtained from the dis-tillation column 43 having the same boiling range as kerosene. It ls, however, possible to use another solvent, or mixture of solvents, during start-up, the 10. solvent fraction from column 43 being modified as necessary. Suitable solvents, other than kerosene, are hydrocarbon liquids, such as pentane, hexane, heptanes, naphthas, and light oils such as diesel oil, and mixtures thereof. If the chosen solvent is highly volatile, the 15. process is operated under sufficient pressure to maintain it in the liquid phase. It is also possible to employ a start-up solvent, such as one of those listed above, differing from the self-generated sol~ent derived from the distillation column 43. In that case, the start-up 20. solvent is progressively replaced by the selected side-stream, self-generated, solvent.
It is not always necessary to provide a solvent recovery plant, exemplified by the distillation column 43 and associated equipment. Indeed, in some cases, it may 25. be economically advantageous not to have the solvent recovery plant, and, instead, to pump the bitumen solution from solution tank 38 to the refinery and to derive fresh I solvent from the refinery. That arrangement is illustrated j in Figure 3 which shows a system substantially identical 15.
.. , ~ . . .. ~.~ .: .
with that of Figure 1, apart from the omission of the solvent recovery plant. The refinery is indicated schematically at 72 and receives the bitumen oils solution from tank 38 via liné 70. The refinery 72 5. produces as a by-product suitable solvent by normal processing methods and that solvent is fed to the solvent tank 33 on line 57. The solvent from the refinery is not immediately recovered as such, as a first step in the refining process, but may be produced 10. as a commercial product downstream in the up-grading process after preliminary treatment such as hydrocracking.
The solvent thus supplied to the extraction process is effectively fresh solvent.
Table II is a mass balance, given by way of example, 15. f the process of Figure 3.
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The oil content of tar-sand found in Alberta, Canada for example consists of approximately 60% bitumen-like 10. materials, 20% heavy petroleum oils, 18% lighter oils similar to kerosene and naphtha, and 2% gasoline, all percentages being by weight.
There is no great theoretical problem in separating the bitumen oils from the other constituents of tar-15. sand and indeed one process for doing so is incommercial operation, using hot water to break down the tar-sand particles and separate the bitumen oils. That process is only marginally viable commercially, having a relatively low extraction rate, low ef~iciency, and high 20. capital and operating costs. In addition, as large quantities of water are to be disposed of, much of it seriously contaminated with oils and other chemicals, the hot water process can be damaging to the environment.
There have also been many theoretical proposals for 25. extracting the bitumen oils with solvents but none of those has been adopted on a commercial scale. Those ¦ proposals have moreover required large volumes of solvent, greatly exceeding the extracted bitumen oils on a weight -to weight basi~, and have necessitated complicated , 1 `
'.
; 2 .
~08S763 equipment. As the solvent is applied directly to the tar-sand particles, there are high solvent losses because of the retention of solvent by the sand, and there are difficulties in separating the fines from the solvent.
Further, the large volumes of solvent required for the process present a fire hazard while the dissemination of solvent vapour is environmentally unacceptable.
The present invention resides in a continuous peocess for the solvent extraction of bitumen oils from tar-sand, in which process tar-sand is supplied at a supply point to a contactor and passed through the contactor towards a discharge point; a stream of solvent is passed through the contactor, the solvent being of lesser density than, and substantially immiscible with, water; water is supplied to and withdrawn from the contactor, the solvent stream and the water providing a solvent phase and a water phase in the contactor substantially distinct from each other, which is sustantially filled by the solvent phase, the water phase and solids of the tar-sand, with a barrier 20 layer formed by the water phase between the solvent phase and solids; solids of the tar-sand are repeatedly showered through the liquid phases in the contactor as the tar-sand passes through the contactor towards the discharge point, whereby the solids are contacted with the solvent phase and bitumen oils are progressively - dissolved in the solvent phase; a bitumen oils-containing solvent phase is removed from the contactor; and a discard stream, comprising said withdrawn water and sand which is substantially free of bitumen oils and solvent, is removed ; 30 from the contactor at the A
' ' ~ ' ' : ' ~085763 àischarge point. ~ecause of the repeated showering of the tar-sand solids through the solvent phase as those solids move through the contactor, an efficient stripping of the bitumen oils from those solids is effected so that 5. a high extraction rate, which may reach as high as 99.9%, is achievable, while the water layer, in which the sand is contained, keeps the solvent losses low. Preferably, the solvent stream and the tar-sand/water stream move through the contactor in countercurrent.
10. It is preferred to add water to the tar-sand prior to entry to the contactor so that it may be pumped to the contactor as a slurry. However, the tar-sand may enter the contactor with only a proportion of the total water of the tar-sand and water stream, the remaining 15. water being then introduced independently into the con-tactor to form that stream. It is advantageous to break up the tar-sand with water in a digester, so that the bitumen oils may be dissolved more readily in the solvent stream.
20. The amount of water in the feed stream is determined, firstly, by the possible need to pump the tar-sand/water slurry, if formed, to the contactor; secondly, by the need for the tar-sand/water stream to flow reasonably freely through the contactor; and thirdly, by the need 25. to have the sand in the contactor adequately surrounded by water to prevent the solvent coming in contact with the sand, except while the latter is being showered ~
through the former. In practice, it has been found that the water should constitute at least 20~, advantageously ovcr 40%, and preferably 50~,0, of the tar-sand/water stream on entry, by weight. The amount of water can exceed the stated percentage, but the efficiency of the system demands that a minimum amount of water be used 5. consistent with its required function. Generally, there-fore, the percentage is of the order of 50.
The solvent of the solvent stream being less dense than, and substantially immiscible with, water, the solvent and water form two separate phases, and any 10. solvent adhering to the solids on being showered through the contactor is caused rapidly to migrate back to the solvent phase. The solvent in the solvent stream is dependent on the nature of the tar-sand and may be between 10% and 85% by weight of the bitumen oils of the 15. tar-sand. The solvent is therefore preferably present in an amount by weight less than the extracted bitumen oils;
it is possible to exceed the figure of 85%, but no significant benefit is achieved thereby and an excessive amount of solvent adversely affects the economy of the 20. solvent recovery stage. Advantageously, the solvent is between 15% and 85% by weight of the bitumen oils, and preferably between 20% and 80%.
The preferred solvent is a hydrocarbon oil or a mixture of such oils and advantageously falls within the 25. boiling range of kerosene (200C-295C). The solvent may in fact be kerosene, but may alternatively be a fraction of the extracted bitumen oils, having a similar i boiling range.
Normally, the solvent stream discharged from the .. .
.. . .
contactor and having the bitumen oils dissolved therein, is passed to a solvent recovery plant, from which the recovered solvent is recycled to the contactor.
Alternatively, the solution of the bitumen oils in the 5. solvent may pass to a refining plant, which supplies a product which is suitable as the solvent of the solvent stream entering the contactor.
The bitumen oils component of tar-sand has a mean specific gravity greater than that of water at 20C, but 10. its specific gravity falls with increasing temperature.
The solution of the bitumen oils in the solvent must be lighter than water and the temperature of the feed stream and the solvent are chosen to that end. The temperature of the feed stream, at least at entry to the contactor is 15. preferably between 20~C and 95C and, for better efficiency, may be between 50C and 75C. Thermal efficiency may be improved by recycling hot water from the discard stream to form the slurry; recycling of water has the further advantage of reducing the volume discharged 20. to the environment. The recycle water stream may also contain water utilised in heat exchangers in a solvent recovery plant.
The contactor is completely filled by the two streams, receptacles within the contactor being rotated to raise 25. the solids of the tar-sand/water stream and shower them through the solvent stream. Thus, the contactor may be a solids/liquid contactor similar to the liquid/liquid contactor described in British patent specification No.
972035, although the buckets are modified to ensure - . - -.... , ~ .
108~763 scooping of the solids from the bottom of the contactor.
The structure of the contactor may also be modi~ied by rotating the contactor drum as a whole, the receptacles or buckets for effecting showering being carried by, and 5. rotated with, the drum. The axis of the cylindrical contactor does not depart radically from the horizontal, although it may be inclined downwards towards the discharge point at an angle of less than 8 for example, in order to aid the movement of the solids of the tar-10. sand through the contactor. The supplies of the solvent stream and the tar-sand/water slurry are chosen so that the interface between the solvent phase and the water phase is constant, preferably approximately at the contactor axis.
15. The contactor should not rotate 90 rapidly as to agitate the contents unduly and to form an emulsion therein and the speed of rotation should be such that a clear interface between the solvent and water phases ls maintained.
20. The contactor may be externally heated and/or cooled;
thus that part of the contactor ad~acent the supply point, may be heated in order to reduce the amount of heating of the tar-sand/water slurry prior to entry.
The size of the contactor is dependent on the desired 25. throughput of tar-sand. In a large installation there may be a number of the contactors arranged in parallel.
The invention will be more readily understood by way of example from the following description of a tar-sand solvent extraction process in accordance therewith, .
reference being made to the accompanying drawings, in which:-Figure 1 is a flow diagram of one form of theprocess;
5. Figure 2 is a radial section through the contactor used in the process; and Figure 3 is a flow diagram illustrating a modifi-cation of the process of Figure 1.
Raw tar-sand, suitably broken down, is fed at 12 into 10. a rotary di~ester 13, where it is mixed with hot water through line 14 from a hot water reservoir tank 15 and broken down into slurry ~orm. The recycled water from tank 15 is pumped by a pump 16 through a fuel-~ired heater 17 so that the temperature of the water on entry to the 15. digester 13 is about 96C. Steam may be added to the - digester 13 through steam line 18, but normally is not required. The slurry of tar-sand in water exiting from digester 13 flows over a scalping screen 20, which removes foreign bodies. The slurry passes through screen 20 to a 20. head tank 21, where more hot water from recycle line 14 is added as necessary to bring the temperature o~ the slurry to about 65C and to maintain the solids in suspension.
The hot tar-sand/water slurry is pumped by pump 22 from tank 21 to a solids/liquid contactor 23, the slurry 25. entering the contactor near the bottom of the unit.
The contactor 23 is generally as described in British patent speci~ication No. 972035, to which reference should :
be made, but is modi~ied in minor respects to make it suitable as a solids/liquid contactor. That contactor is ,~
' 8.
108~763 shown diagrammatic,ally in axial section in the accomp-, anying Figure 1 and in radial section in the accompanying Figure 2, and as illustrated consists of a stationary shell 24 in ~hich a rotor is mounted for rotation about 5. its axis. The rotor includes a number of axially-spaced circular discs 25 which separate the interior of the shell 24 into a series of compartments. The edge of each disc 25 is spaced from the wall of shell 24, so that adjacent compartments are in communication via annular gaps between 10. the discs and shell. In each compartment, there are a series of spaced buckets or receptacles 26 which are carried between the discs of that compartment. Some or all of the buckets have their leading edges extended across the gap between the discs 25 and the shell 24 to 15. act as scrapers and to ensure solids at the bottom of the shell are scooped by the buckets; in Figure 2, two of the buckets are shown as so extended at 27. The final compartment, i.e. that at the right hand end of the contactor, are not provided with buckets 26J to facllitate 20. removal of the stripped sand.
The hot tar-sand/water slurry enters the contactor 23 as a stream at one end of the contactor, passes progress-ively from compartment to compartment of the contactor via the circumferential gaps and is discharged as a discard 25. stream through a line 28 at the bottom of the other end of the contactor. At the same time solvent for the bitumen oils of the tar-sand is introduced on line 30 into the top of the contactor 2~ as a countercurrent solvent stream and discharges through line 31 at the top of the end of the ~08S~63 contactor through which the tar-s~nd slurry enters. The solvent is pumped by pump 32 from a solvent storage tank 33, and may be heated in a steam heater ~4, before entering the contactor 23. The solvent stream being virtually 5. immiscible with water forms a distinct and separate phase above the feed stream; the operation of the system is so arranged that the interface between the two phases remains approximately static at or adjacent the axis o~ the con-tactor. That a~is does not depart substantially from the 10. horizontal, but may be inclined downwardly at a small angle less than 8 to the horizontal from the entry end to the discharge end of the tar-sand/water stream, in order to ~-assist the flow of the solids of the tar-sand through the contactor.
15. As the tar-sand/water stream passes through the contactor 23 (from left to right in Figure 1), it is con-tinuously treated in each compartment by the rotary buckets 26 (Figure 2), solids of the tar-sand being scooped up and raised by the buckets, and discharged progressively from 20. those buckets in the upper half of the shell 24, so that they are tumbled, or showered, through the solvent stream 35. Being denser than either the solvent or water, the solids discharged from the buckets 26 rapidly pass through the solvent stream 35 and settle at the bottom of the 25. shell 24. The rotary buckets 26 also carry down solvent from stream 35 and into the tar-sand/water stream 36, being discharged as droplets which rapidly return upwardly ; into the solvent stream 35.
Thus, during the progress of the tar-sand through , .~ .
` 10.
, . .
108~763 the contactor 23, the tar-sand particles are first dis-integrated, if they have not been so treated prior to entry, and the solids are repeatedly showered through the solvent of the solvent stream in each successive 5. compartment of the contactor, so that the bitumen oils are progressively dissolved in the solvent stream and the sand and fines of the feed stream are progressively stripped of bitumen oils. Finally the sand and fines, without significant bitumen oils, are discharged with water 10. through the discharge line 28.
The contents of the contactor 23 form three phases, the lowermost of which is sand which rapidly settles at the bottom of the container 24, the middle layer being water, in which the sand is located, and the uppermost being sol-15. vent. The presence of an enveloping volume of water for the sand has the important function of forming a barrier separating the solvent from the sand and causing rapid displacement of any solvent retained on the sand. The consequence is that, by the time the sand reaches the dis-; 20. charge end of the contactor, lt has little or no adhering solvent. The discard stream on line 28 is almost entirely made up of water, sand and fines, while the solvent stream discharge on line 31 consists almost entirely of a solution of the extracted bitumen oils in the solvent. The process 25. performed in the contactor 23 is thus a continuous, counter-current, multi-stage, extraction.
The bitumen oils solution from the contactor 23 is directed on line 31 to storage tank 38, from which it is ; passed to a solvent recovery plant which separates the 11.
' . , , ~ , - , .--solvent from the bitumen oils and recycles the soivent back to the solvent tank 33. For that purpose, the solution in tank 38 is pumped by pump 40 through a heat exchanger 41, in which the temperature is raised, to a 5. heater 42, which is fired with gas or oil. The solution at a temperature of about 350C passes to a fractionating column 4~, in which the components of the feed separate in the usual way. Overhead vapour is taken from the column through line 44 to condenser 45, which may be a 10. tubular unit or a direct spray type. The water and light oils condensate from condenser 45 separate in tank 46, the water of the lower layer being recycled to the hot water tank 15 through line 47. The light oils of the upper layer in tank 46 flow to a storage tank 48, and a 15. portion is pumped back through line 50 to the column 43 as reflux, while the remainder is directed to a further tank 51 for bitumen oils, which are pumped to a refinery.
A fraction falling within the kerosene boiling range, e.g. 200C to 295C, is taken as a side-stream from column 20. 4~ and passed to a stripper 54, which has steam injected at its base at 55 to drive off the lighter components and to trim the composition of the received solvent fraction.
The vaporised lighter components are returned to the column 43, while the trimmed solvent fraction leaves the ?5. base of stripper 54, is cooled to about 65C in cooler 56, and then flows to the solvent storage tank 3~. Solvent tank 33 is also supplied on line 57 with make-up solvent as required. The bottom product of the column 4~ - the high boiling point bitumen oils - leaves the bottom of the - ~ . -1~5763 column and, after cooling in heat exchanger 41, i5 pumped through a product cooler 58 to the bitumen oils storage tank 51. Warm cooling water from product cooler 58, as well as from heat exchangers 34, 45, and 56 pass ~ia the 5. line 47 to the hot water tank 15.
The solvent fraction obtained from the distillation column 43 and stripped in the stripper 54 contains, not only the recovered solvent, but also fractions of the bitumen oils contained in the tar-sand falling within the 10. same boiling range. Accordingly, ~he system is self-sufficient in solvent, solvent being required to be supplied externally on line 57, only at start-up. The solvent recovery system is normally operated at atmos-pheric pressure, but in some circumstances it may be 15. advantageous to operate it under reduced pressure.
The discard stream of sand, fines and water, freed from bitumen oils and solvent, flows on line 28 from con-; tractor 23 to the sand clean-up unit. That unit includes a conical separator 60. Separator 60 is closed and the , 20. discard stream entering on line 28 passes through a sleeved section 61, which is designed to eliminate surface turbulence in the water at the top of the separator. The heavier sand rapidly settles into the base of the separator and the water with the fines flows under the sleeve section 25. 61 and over the periphery of the separator into a launder `~ 62. Steam is injected into the base of the separator at 63 close to the valved outlet 64. The steam performs two functions: firstly, it maintains a free flow of sand leaving the separator and, secondly, it effects the removal ;, . 1~.
~085763 of any dissolved solvent that may be present in the water.
The steam, plus any solvent vapours, leaves the top of the separator 60 and is condensed in condenser 65, hot condensate flowing into the hot water tank 15, together 5. with the warm cooling water. Alternati~ely, the steam from separator 60 may be condensed in a direct spray condenser.
The water and fines, which overflow from the separator 60 pass from the launder 62 to a centrifugal 10. separator 66, which concentrate the fines into a slurry which is mixed with the sand leaving the valved outlet 64.
The water, substantially freed from fines, leaves the centrifugal separator 66 and is returned to hot water tank 15 on line 67. The hot water in tank 15, as above des-15. cribed, is recycled to the digester 1~; if some residualsolvent is vaporised from the separator 60 into the hot water recycle circuit, it is absorbed and utilised in the contactor 23, and does not represent a loss of solvent in the overall system. The sand from separator 60 and the 20. fines slurry from centrifugal separator 66 have a water content approximately equal to the weight of water plus bitumen oils entering the process in the raw tar-sand.
The sand/fines/water effluent on line 68 may therefore be returned to the sand pits without the need for large 25. settling lagoons.
Table I gives the mass balance of the system shown ; in Figure 1 and described above, and gives the weights, the heat contents and the temperatures of the materials at different points of the system. All quantities are ' 14.
10~3~763 given by weight and it will be observed that the solvent (3.8) is only a small portion of the bitumen oils con-tained in the tar-sand (19.2). The process is therefore highly economical in solvent usage.
5. The preferred solvent to be used at start-up is kerosene, the solvent ~raction obtained from the dis-tillation column 43 having the same boiling range as kerosene. It ls, however, possible to use another solvent, or mixture of solvents, during start-up, the 10. solvent fraction from column 43 being modified as necessary. Suitable solvents, other than kerosene, are hydrocarbon liquids, such as pentane, hexane, heptanes, naphthas, and light oils such as diesel oil, and mixtures thereof. If the chosen solvent is highly volatile, the 15. process is operated under sufficient pressure to maintain it in the liquid phase. It is also possible to employ a start-up solvent, such as one of those listed above, differing from the self-generated sol~ent derived from the distillation column 43. In that case, the start-up 20. solvent is progressively replaced by the selected side-stream, self-generated, solvent.
It is not always necessary to provide a solvent recovery plant, exemplified by the distillation column 43 and associated equipment. Indeed, in some cases, it may 25. be economically advantageous not to have the solvent recovery plant, and, instead, to pump the bitumen solution from solution tank 38 to the refinery and to derive fresh I solvent from the refinery. That arrangement is illustrated j in Figure 3 which shows a system substantially identical 15.
.. , ~ . . .. ~.~ .: .
with that of Figure 1, apart from the omission of the solvent recovery plant. The refinery is indicated schematically at 72 and receives the bitumen oils solution from tank 38 via liné 70. The refinery 72 5. produces as a by-product suitable solvent by normal processing methods and that solvent is fed to the solvent tank 33 on line 57. The solvent from the refinery is not immediately recovered as such, as a first step in the refining process, but may be produced 10. as a commercial product downstream in the up-grading process after preliminary treatment such as hydrocracking.
The solvent thus supplied to the extraction process is effectively fresh solvent.
Table II is a mass balance, given by way of example, 15. f the process of Figure 3.
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Claims (27)
1. A continuous process for the solvent extraction of bitumen oils from tar-sand, comprising the steps of:
(a) supplying tar-sand at a supply point to a contactor and passing said tar-sand from said supply point towards a discharge point from said contactor;
(b) passing a stream of solvent through said contactor, said solvent being of lesser density than, and substan-tially immiscible with, water;
(c) supplying water to and withdrawing water from said contactor;
(d) said solvent stream and said water providing a solvent phase and a water phase in said contactor substantially distinct from each other, and said contactor being sub-stantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids;
(e) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(f) removing a bitumen oils-containing solvent phase from said contactor; and (g) removing a discard stream at said discharge point, said discard stream comprising said withdrawn water and sand which is substantially free of bitumen oils and solvent.
(a) supplying tar-sand at a supply point to a contactor and passing said tar-sand from said supply point towards a discharge point from said contactor;
(b) passing a stream of solvent through said contactor, said solvent being of lesser density than, and substan-tially immiscible with, water;
(c) supplying water to and withdrawing water from said contactor;
(d) said solvent stream and said water providing a solvent phase and a water phase in said contactor substantially distinct from each other, and said contactor being sub-stantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids;
(e) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(f) removing a bitumen oils-containing solvent phase from said contactor; and (g) removing a discard stream at said discharge point, said discard stream comprising said withdrawn water and sand which is substantially free of bitumen oils and solvent.
2. A continuous process for the solvent extraction of bitumen oils from tar-sand, comprising the steps of:
(a) passing a stream of tar-sand and water to and through a closed contactor towards a discharge point from said contactor;
(b) passing a stream of solvent through said contactor, said solvent being of lesser density than, and substan-tially immiscible with, water;
(c) said solvent stream and said water providing a solvent phase and a water phase in said contactor substantially distinct from each other, and said contactor being substantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids at the bottom of said contactor;
(d) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(e) removing a bitumen oils-containing solvent phase from said contactor; and (f) removing a discard stream at said discharge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent.
(a) passing a stream of tar-sand and water to and through a closed contactor towards a discharge point from said contactor;
(b) passing a stream of solvent through said contactor, said solvent being of lesser density than, and substan-tially immiscible with, water;
(c) said solvent stream and said water providing a solvent phase and a water phase in said contactor substantially distinct from each other, and said contactor being substantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids at the bottom of said contactor;
(d) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(e) removing a bitumen oils-containing solvent phase from said contactor; and (f) removing a discard stream at said discharge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent.
3. A process as claimed in claim 2, further comprising forming a slurry of tar-sand in water and con-tinuously feeding said slurry to a supply point of said contactor to form said tar-sand and water stream.
4. A process as claimed in claim 2, in which water constitutes at least 20% by weight of said tar-sand and water stream.
5. A process as claimed in claim 2, in which water constitutes at least 40% by weight of said tar-sand and water stream.
6. A process as claimed in claim 5, in which water constitutes about 50% by weight of said tar-sand and water stream.
7. A process as claimed in claim 2, in which said solvent is at least 10% by weight of the bitumen oils of the tar-sand.
8. A process as claimed in claim 7, in which the solvent is between 10% and 85% by weight of the bitumen oils.
23.
23.
9. A process as claimed in claim 7, in which the solvent is between 20% and 80% by weight of the bitumen oils.
10. A process as claimed in claim 2, in which said tar-sand and water stream and said solvent stream flow in countercurrent through said contactor.
11. A process as claimed in claim 2, in which the temperature of said tar-sand and water stream, at least at entry to said contactor, is between 20°C and 95°C.
12. A process as claimed in claim 11, in which said temperature is between 50°C and 75°C.
13. A process as claimed in claim 2, in which said solvent is a hydrocarbon solvent or a mixture of hydro-carbon solvents.
14. A process as claimed in claim 13, in which said solvent or said mixture falls within the boiling range of kerosene.
15. A process as claimed in claim 13, in which said solvent is kerosene
16. A process as claimed in claim 14, in which said 24.
solvent is a fraction distilled from the extracted bitumen oils.
solvent is a fraction distilled from the extracted bitumen oils.
17. A process as claimed in claim 2, in which said bitumen oils-containing solvent phase leaving said con-tactor is passed to a refining plant, and the refining plant supplies as a product the solvent for said solvent stream.
18. A process as claimed in claim 2, in which said bitumen oils-containing solvent phase is treated in a solvent recovery plant in which the bitumen oils are separated from the solvent which is recirculated to said contactor as a major part at least of said solvent stream.
19. A process as claimed in claim 14, in which said bitumen oils-containing solvent phase is treated in a fractionating column from which a fraction having a boiling range corresponding approximately to that of kerosene is withdrawn and used as said solvent stream.
20. A process as claimed in claim 2, in which some of the water is removed from said discard stream and recirculated to form at least a part of the water of said tar-sand and water stream.
21. A process as claimed in claim 2, in which said contactor is a substantially horizontal contactor having a plurality of stages, in each of which said solids are 25.
showered through said liquid phases.
showered through said liquid phases.
22. A process as claimed in claim 2, in which said solids are showered by buckets rotating in said contactor about an axis which does not differ substantially from the horizontal.
23. A process as claimed in claim 2, in which said contactor comprises a rotary drum carrying buckets for raising said solids and showering them through said liquid phases.
24. A continuous process for the solvent extraction of bitumen oils from tar-sand, comprising the steps of:
(a) forming a pumpable slurry of tar-sand in water;
(b) pumping said slurry to a supply point at one end of a substantially horizontal, closed con-tactor, and causing said slurry to move through said contactor to a discharge point at the other end of said contactor;
(c) passing a solvent stream through said contactor in countercurrent to said slurry, said solvent stream consisting essentially of a solvent for said bitumen oils, being substantially immisc-ible with water and having a density less than that of water;
(d) said slurry and said solvent stream substantially filling said contactor and forming three phases, of which the lowermost phase comprises solids of 26.
said slurry saturated with water, the uppermost phase comprises said solvent and solute, and an intermediate phase consisting essentially of water and forming a barrier layer between said solids and said uppermost phase;
(e) repeatedly showering said solids through said uppermost phase and said barrier layer as said slurry passes through said contactor towards said discharge point, whereby said solids are contacted with said solvent and said bitumen oils are progressively dissolved in said solvent stream;
(f) removing said solvent stream with dissolved bitumen oils from said contactor;
(g) removing a discard stream at said discharge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent;
(h) separating a part of the water of said discard stream; and (i) recycling said separated water to constitute at least a part of said slurry.
27.
(a) forming a pumpable slurry of tar-sand in water;
(b) pumping said slurry to a supply point at one end of a substantially horizontal, closed con-tactor, and causing said slurry to move through said contactor to a discharge point at the other end of said contactor;
(c) passing a solvent stream through said contactor in countercurrent to said slurry, said solvent stream consisting essentially of a solvent for said bitumen oils, being substantially immisc-ible with water and having a density less than that of water;
(d) said slurry and said solvent stream substantially filling said contactor and forming three phases, of which the lowermost phase comprises solids of 26.
said slurry saturated with water, the uppermost phase comprises said solvent and solute, and an intermediate phase consisting essentially of water and forming a barrier layer between said solids and said uppermost phase;
(e) repeatedly showering said solids through said uppermost phase and said barrier layer as said slurry passes through said contactor towards said discharge point, whereby said solids are contacted with said solvent and said bitumen oils are progressively dissolved in said solvent stream;
(f) removing said solvent stream with dissolved bitumen oils from said contactor;
(g) removing a discard stream at said discharge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent;
(h) separating a part of the water of said discard stream; and (i) recycling said separated water to constitute at least a part of said slurry.
27.
25. A continuous process for the solvent extraction of solids, comprising the steps of (a) passing a stream of the solids through a contactor in a carrier liquid in which the solids are substantially insoluble;
(b) passing a stream of solvent through the contactor, the solvent being capable of dissolving a constituent of the solids and being of lesser density than, and substantially immiscible with, the carrier liquid which forms a barrier between the solvent stream and the solids disposed at the bottom of the contactor and in the carrier liquid;
(c) during the passage of the solids through the contactor causing the solids repeatedly to pass through the solvent stream and back to the carrier liquid; and (d) removing those constituents of the solids that are not dissolved in the solvent stream from the contactor at a discharge point with the carrier liquid.
(b) passing a stream of solvent through the contactor, the solvent being capable of dissolving a constituent of the solids and being of lesser density than, and substantially immiscible with, the carrier liquid which forms a barrier between the solvent stream and the solids disposed at the bottom of the contactor and in the carrier liquid;
(c) during the passage of the solids through the contactor causing the solids repeatedly to pass through the solvent stream and back to the carrier liquid; and (d) removing those constituents of the solids that are not dissolved in the solvent stream from the contactor at a discharge point with the carrier liquid.
26. A continuous process for the solvent extraction of bitumen oils from tar-sand, comprising the steps of:
(a) continuously supplying tar-sand and water to a closed contactor and causing a slurry of said tar-sand and water to pass through said contactor towards a discharge point from said contactor;
(b) passing a stream of solvent through said contactor in countercurrent to said slurry, said solvent being of lesser density than, and substantially immiscible with, water;
(c) said solvent stream and said water providing respec-tively an upper solvent phase and a lower water phase in said contactor, and said contactor being substantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids;
(d) said solvent phase and said water phase having a substantially constant interface;
(e) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(f) continuously removing a bitumen oils-containing solvent phase from said contactors; and (g) continuously removing a discard stream at said dis-charge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent.
(a) continuously supplying tar-sand and water to a closed contactor and causing a slurry of said tar-sand and water to pass through said contactor towards a discharge point from said contactor;
(b) passing a stream of solvent through said contactor in countercurrent to said slurry, said solvent being of lesser density than, and substantially immiscible with, water;
(c) said solvent stream and said water providing respec-tively an upper solvent phase and a lower water phase in said contactor, and said contactor being substantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids;
(d) said solvent phase and said water phase having a substantially constant interface;
(e) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(f) continuously removing a bitumen oils-containing solvent phase from said contactors; and (g) continuously removing a discard stream at said dis-charge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent.
27. A continuous process for the solvent extraction of bitumen oils from tar-sand, comprising the steps of:
(a) forming a slurry of tar-sand in water and contin-uously feeding said slurry to a supply point of a closed contactor;
(b) passing a stream of said slurry through a closed contactor towards a discharge point from said contactor;
(c) passing a stream of solvent through said contactor, said solvent being of lesser density than, and sub-stantially immiscible with, water;
(d) said solvent stream and said water providing a sol-vent phase and a water phase in said contactor, and said contactor being substantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids at the bottom of said contactor;
(e) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(f) removing a bitumen oils-containing solvent phase from said contactor; and (g) removing a discard stream at said discharge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent.
(a) forming a slurry of tar-sand in water and contin-uously feeding said slurry to a supply point of a closed contactor;
(b) passing a stream of said slurry through a closed contactor towards a discharge point from said contactor;
(c) passing a stream of solvent through said contactor, said solvent being of lesser density than, and sub-stantially immiscible with, water;
(d) said solvent stream and said water providing a sol-vent phase and a water phase in said contactor, and said contactor being substantially filled by said solvent phase, said water phase and solids of said tar-sand with a barrier layer formed by said water phase between said solvent phase and solids at the bottom of said contactor;
(e) repeatedly showering solids of said tar-sand through said liquid phases in said contactor as the tar-sand passes through the contactor towards said discharge point, whereby said solids are contacted with said solvent phase and bitumen oils are progressively dissolved in said solvent phase;
(f) removing a bitumen oils-containing solvent phase from said contactor; and (g) removing a discard stream at said discharge point, said discard stream comprising water and sand which is substantially free of bitumen oils and solvent.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB3298976A GB1527269A (en) | 1976-08-07 | 1976-08-07 | Solvent extraction process |
| GB32989/76 | 1976-08-07 | ||
| GB293977 | 1977-01-25 | ||
| GB2939/77 | 1977-01-25 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1085763A true CA1085763A (en) | 1980-09-16 |
Family
ID=26237871
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA283,955A Expired CA1085763A (en) | 1976-08-07 | 1977-08-03 | Solvent extraction process |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US4160718A (en) |
| CA (1) | CA1085763A (en) |
| SU (1) | SU959629A3 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11512256B2 (en) | 2018-09-07 | 2022-11-29 | Suncor Energy Inc. | Non-aqueous extraction of bitumen from oil sands |
| US11643603B2 (en) | 2019-08-14 | 2023-05-09 | Suncor Energy Inc. | Non-aqueous extraction and separation of bitumen from oil sands ore using paraffinic solvent and deasphalted bitumen |
Families Citing this family (24)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| IT1147716B (en) * | 1980-02-15 | 1986-11-26 | Rtl Contactor Holding Sa | PROCESSING PROCESS FOR HETEROGENEOUS LIQUID MATERIALS PARTICULARLY FOR THE PURPOSE OF EXTRACTION OF OLIBITUMINOSES FROM SANDS CONTAINING THEM |
| WO1984002145A1 (en) * | 1982-11-22 | 1984-06-07 | Solv Ex Corp | A process and apparatus for extracting bitumen oil from bitumen containing mineral |
| US5143598A (en) * | 1983-10-31 | 1992-09-01 | Amoco Corporation | Methods of tar sand bitumen recovery |
| CA1249976A (en) * | 1985-06-28 | 1989-02-14 | Bryan D. Sparks | Solvent extraction spherical agglomeration of oil sands |
| BR8504611A (en) * | 1985-09-20 | 1987-04-28 | Petroleo Brasileiro Sa | PROCESS TO SEPARATE WATER AND SOLIDS FROM FUELS, IN PARTICULAR FROM SHALE OIL |
| US4692238A (en) * | 1986-08-12 | 1987-09-08 | Institute Of Gas Tehnology | Solvent extraction of organic oils and solvent recovery |
| US5723042A (en) * | 1994-05-06 | 1998-03-03 | Bitmin Resources Inc. | Oil sand extraction process |
| CA2123076C (en) * | 1994-05-06 | 1998-11-17 | William Lester Strand | Oil sand extraction process |
| US6712215B2 (en) * | 2000-07-28 | 2004-03-30 | Adolf Frederik Scheybeler | Method and apparatus for recovery of lost diluent in oil sands extraction tailings |
| US7381320B2 (en) * | 2004-08-30 | 2008-06-03 | Kellogg Brown & Root Llc | Heavy oil and bitumen upgrading |
| US7749378B2 (en) * | 2005-06-21 | 2010-07-06 | Kellogg Brown & Root Llc | Bitumen production-upgrade with common or different solvents |
| CA2614606C (en) * | 2005-07-13 | 2008-10-28 | Bitmin Resources Inc. | Oil sand processing apparatus |
| US7984866B2 (en) * | 2005-09-23 | 2011-07-26 | Canadian Oil Sands Limited Partnership | Relocatable oil sand slurry preparation system |
| CA2524110C (en) * | 2005-10-21 | 2009-04-14 | William L. Strand | Bitumen recovery process for oil sand |
| US20080111096A1 (en) * | 2006-11-10 | 2008-05-15 | Veltri Fred J | Composition for extracting crude oil from tar sands |
| US20080110805A1 (en) * | 2006-11-10 | 2008-05-15 | Veltri Fred J | Continuous flow separation and aqueous solution treatment for recovery of crude oil from tar sands |
| US7694829B2 (en) * | 2006-11-10 | 2010-04-13 | Veltri Fred J | Settling vessel for extracting crude oil from tar sands |
| US20080110804A1 (en) * | 2006-11-10 | 2008-05-15 | Veltri Fred J | Slurry transfer line |
| US7919645B2 (en) | 2007-06-27 | 2011-04-05 | H R D Corporation | High shear system and process for the production of acetic anhydride |
| WO2011021092A2 (en) | 2009-08-17 | 2011-02-24 | Brack Capital Energy Technologies Limited | Oil sands extraction |
| CA2734439A1 (en) * | 2011-03-21 | 2012-09-21 | Shell Internationale Research Maatschappij B.V. | A method for extracting bitumen from an oil sand feed stream |
| US9884997B2 (en) * | 2011-09-30 | 2018-02-06 | Mcw Energy Group Limited | Oil from oil sands extraction process |
| US9296954B2 (en) | 2013-05-22 | 2016-03-29 | Syncrude Canada Ltd. In Trust For The Owners Of The Syncrude Project As Such Owners Exist Now And In The Future | Treatment of poor processing bitumen froth using supercritical fluid extraction |
| US9447330B2 (en) * | 2013-12-19 | 2016-09-20 | Epic Oil Extractors, Llc | Process for producing crude oil and bitumen products |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1520752A (en) * | 1920-02-27 | 1924-12-30 | Horwitz Wilhelm | Process for the recovery of petroleum |
| US1487541A (en) * | 1920-04-16 | 1924-03-18 | Coogan Jesse | Apparatus and method of extracting the petroleum content from petroleum-bearing sand or shale |
| US3846276A (en) * | 1973-06-18 | 1974-11-05 | Texaco Inc | Process for separating bitumen from tar sand recovered from deposits by mining |
-
1977
- 1977-08-03 US US05/821,497 patent/US4160718A/en not_active Expired - Lifetime
- 1977-08-03 CA CA283,955A patent/CA1085763A/en not_active Expired
- 1977-08-05 SU SU772510551A patent/SU959629A3/en active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11512256B2 (en) | 2018-09-07 | 2022-11-29 | Suncor Energy Inc. | Non-aqueous extraction of bitumen from oil sands |
| US11643603B2 (en) | 2019-08-14 | 2023-05-09 | Suncor Energy Inc. | Non-aqueous extraction and separation of bitumen from oil sands ore using paraffinic solvent and deasphalted bitumen |
Also Published As
| Publication number | Publication date |
|---|---|
| US4160718A (en) | 1979-07-10 |
| SU959629A3 (en) | 1982-09-15 |
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