CA1058541A - Method and apparatus for separation of bitumen from tar sands - Google Patents
Method and apparatus for separation of bitumen from tar sandsInfo
- Publication number
- CA1058541A CA1058541A CA234,394A CA234394A CA1058541A CA 1058541 A CA1058541 A CA 1058541A CA 234394 A CA234394 A CA 234394A CA 1058541 A CA1058541 A CA 1058541A
- Authority
- CA
- Canada
- Prior art keywords
- bitumen
- tar sand
- water
- tar
- sand
- 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
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- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
Abstract
ABSTRACT OF DISCLOSURE
Method and apparatus for separation of bitumen from tar sand involving an electric flotation cell formed of a container in which is placed a charge of unsepa-rated tar sand to a first level and which is then filled with water to a second level and electrodes positioned in the cell in relation to the tar sand such that on application of a voltage to the electrodes an electric current flows through the tar sand and water. It has been found that after application of the electrical energy to the tar sands agitation and then separation takes place with the bitumen being floated to the upper surface.
Method and apparatus for separation of bitumen from tar sand involving an electric flotation cell formed of a container in which is placed a charge of unsepa-rated tar sand to a first level and which is then filled with water to a second level and electrodes positioned in the cell in relation to the tar sand such that on application of a voltage to the electrodes an electric current flows through the tar sand and water. It has been found that after application of the electrical energy to the tar sands agitation and then separation takes place with the bitumen being floated to the upper surface.
Description
i8S4~L
Thi~ inV~ntion xel~tes. to a method and apparatus ~or extrac-tion o~ separation of bitumen from tar sand and more partlcularly to an eIec`tric flotation cell for carrying out the separation.
Tar sand has been defined as sand saturated with a highly viscous crude hydrocarbon material not recover-able in its natural state through a well ~y ordinary product-ion methods. Tar sand, which s~ould probably be called bituminous sand since the h~drocar~on is a bitumen ~-i.e.
a carbon disulfide-soluhle oil~, is a mixture of sand, water, and ~itumen. The sand component is predominantly quartz in the form of rounded or subangular partlcles each of which is wet with a film of water. Surrounding the wetted said grains Q ~0~4 and somewhat illing the void volume_~q*~,them is a film of bitumen. The balance of the void volume is ~illed with ~ater or sometimes gas. The extraction or separation o~
the bitumen from the sand has been an intriguing but economic-ally difficult probelm for many years. At the present time the only economic method of extraction is the Hot Water Process developed by Dr. K.A. Clark at the Alberta Research Council and used commercially at Fort McMurray, Alberta, on the Athabasca oil sands.
There have been a large number of proposals of various kinds for electrically heating the tar sands in situ. One such method is described in U.S. Patent No:
3,862,662, dated January 28, 1975 and entitled "Method and Apparatus for Electrical Heating of Hydrocarbonaceous Formations". Other patents concerned with this approach are U.S. patents Nos. 3,848,671; 3,857,776; 3,732,465; 3,718,186 and 3,642,066.
It is an o~ject of the present invention to provide a method and apparatus for separation of bitumen from ~.~58~
taX ~and ~hich i~ ~el~ti~ely econom~c and ~ich does no~
require excessive amounts o~ hot ~ater.
This and other objects of the invention are achieved ~y a method and apparatus involving an electric flotation cell formed of a container in which is placed a charge of unseparated tar sand to a first level and which is then filled with water to a second level and electrodes positioned in the cell in relation to the tar sand such that on application of a voltage ~o ~he electrodes an electric lQ current flows through the ~ar sand and water. It has ~een found t~at after application of the el;ectrical energy to the tar sands agitation and then separation takes place with the bitumen being floated to the upper surface.
The water may ~e put into the c~ll first or ~oth the water and the tar sand at the same time.
In drawings which illustrate embodiments of the invention, Figure l is a schematic view o a floatation cell with electrodes, 2Q Figure 2 is a cross-section of an experimental cell at the start of the separation process, Figure 3 i5 similar to figure Z but after t~e process has proceeded ~or a time, Figure 4 is similar to f1gures Z and 3 but shows the process after completion, Figure 5 shows a typical form of upper electrode for the cell, and Figure 6 shows an altèrnative method of applying electrical energy to the cell, usable at microwave 3Q frequencies.
Referring to fi~ure 1 a schematic view of an electric flota~ion ceIl is shown gen~rally as a cylindrical -585~
container lQ m~de o~ insulatIn~ material e.g. ~lass~ perspex.
The ~Ottom oE the cell ll i5 a metal plate acting as one electrode. It is also posslble to operate with a "CAN" shaped lower electrode. This latter form would have certain advantages in that the portion of the cell containing the tar sand charge and su~ject to highly abrasive agitation would be Qf metal. The cell is filled with a charge of raw tar sand 12 and filled with water 13. A me~al electrode 14 is positioned centrally of the container and touches or is close to the upper surface of the tar sand. An electric voltage is applied from a suitable power source 15 across the electrodes. It has been found that the frequency of operation can be from DC to high frequency RF and even into ~ the microwave range. The latter of course requires a special type of applicator. Standard mains frequency of 60 cycle has ~een found to operate successfully.
Figures 2, 3, 4, and 5 show stages in operation of an experimental cell. In figure 2 a charge of tar sand 12 is placed in the cell and covered with water to a predetermined depth.
Although the process will operate with a depth of water less than that of the tarsand, it has been found preferably to use a depth one or more times that o~
the tarsand. The upper electrode which is in the form of a metal grid 14a fastened to the end of the central conductor 14 rests near the upper surface of the tar sand. Voltage is applied to conductor 14 and bottom plate electrode 11 result.ing in a intense electric field through the tar sand layer. This causes violent agitation of the tar sand and water to a level 3~ 16 as shown in ~igure 3 with a frot~ layer 17 forming on the upper surface of the ~ater. It has ~een observed that sand and other particles e.g. clay, continuously fall through `~`
~5~54~
the muc~ les~ a~ltated ~ater region 18. ~t the end o~
fe~ minute$ the cell appears as in flgure 4 with a deep flotation la~er 17 at the top and a sand residue 19 at the bottom. If desired the cell can be left for a period e.g.
several minutes ~o one hour or more to achieve settling and clarification of water.
Because the water is heated during the process it is economic to reuse the water as often as possible.
The froth on the top of the liquid column lQ entrains and contains a relatively high percentage o~ the ~itumen with the sand, clays and other residues remaining at the ~ottom. This flotation layer can be readily removed and passed to further processing stages.
It~is also considered that it w~uld be , advantageous to the process to use additives to control the pH value of the cell contents. A typical additive would be 1 NaOH.
The upper electrode can be in various shapes, ; the simplest being the rod of figure 1. A grid shaped 2Q structure as shown in figure 5 appears to be quite effective.
The bottom electrode has the form of a flat plate. It has been observed that, in operation, voids or bubbles form at or near the surface o this electrode which adversely effects the e.nergy application to the tar sands.
It has been found that if water is introduced or injected at the bottom, then this water flowing outwardly breaks up or removes these voids and restores effective operation.
A suitable valve 20 is shwon in figure 2 for doing this. It is spring-loaded and is fed from chamber 21 connected to a pump ~not shown~ via tube 22 Figure 6 illustrates a suitable a suita~le means of applying microwave energy to column 10. ~aveguide ~4--1~)5~35~1 25 connected.to a micro~ve ~o.~er. .SQUrCe ~not s~.ownl is.con-nected to the bottom o~ the cell th.rough a plate:26 whi.ch is suc~ as to allow pass~ge o~ the energy into the tar sands 16.
Preliminar~ data has been obtained on t~sts conducted on tarsand separation using the electric flotation cell descri~ed a~ove. The ~ollowing is a typical test run on a lakoratory model sho~ing mater;al and energy bahances:
TypicaL T_st Run lQ 1. A 2.Q kgm charge of tar sand was mixed with 20Q ml H2O
and placed in the separator with 5Q of H2O at 75F. The resulting water column helght was approximately 10 inches.
Separation required a total electrical energy input of 0.4 Kw-hr. The original charge when mlxed with 200 ml of H2O
consisted of 12.2% Bitumen, 10.1% H2O and 77.7~ solids Csand and clay fines~. The u~graded bitumen consisted of 54.4%
Bitu~m~ , 31.9~ H2O and 13.7% solids. The tailings consisted of ~r3~ Bitumen, 20.4% H20 and 78.3% solids.
Thi~ inV~ntion xel~tes. to a method and apparatus ~or extrac-tion o~ separation of bitumen from tar sand and more partlcularly to an eIec`tric flotation cell for carrying out the separation.
Tar sand has been defined as sand saturated with a highly viscous crude hydrocarbon material not recover-able in its natural state through a well ~y ordinary product-ion methods. Tar sand, which s~ould probably be called bituminous sand since the h~drocar~on is a bitumen ~-i.e.
a carbon disulfide-soluhle oil~, is a mixture of sand, water, and ~itumen. The sand component is predominantly quartz in the form of rounded or subangular partlcles each of which is wet with a film of water. Surrounding the wetted said grains Q ~0~4 and somewhat illing the void volume_~q*~,them is a film of bitumen. The balance of the void volume is ~illed with ~ater or sometimes gas. The extraction or separation o~
the bitumen from the sand has been an intriguing but economic-ally difficult probelm for many years. At the present time the only economic method of extraction is the Hot Water Process developed by Dr. K.A. Clark at the Alberta Research Council and used commercially at Fort McMurray, Alberta, on the Athabasca oil sands.
There have been a large number of proposals of various kinds for electrically heating the tar sands in situ. One such method is described in U.S. Patent No:
3,862,662, dated January 28, 1975 and entitled "Method and Apparatus for Electrical Heating of Hydrocarbonaceous Formations". Other patents concerned with this approach are U.S. patents Nos. 3,848,671; 3,857,776; 3,732,465; 3,718,186 and 3,642,066.
It is an o~ject of the present invention to provide a method and apparatus for separation of bitumen from ~.~58~
taX ~and ~hich i~ ~el~ti~ely econom~c and ~ich does no~
require excessive amounts o~ hot ~ater.
This and other objects of the invention are achieved ~y a method and apparatus involving an electric flotation cell formed of a container in which is placed a charge of unseparated tar sand to a first level and which is then filled with water to a second level and electrodes positioned in the cell in relation to the tar sand such that on application of a voltage ~o ~he electrodes an electric lQ current flows through the ~ar sand and water. It has ~een found t~at after application of the el;ectrical energy to the tar sands agitation and then separation takes place with the bitumen being floated to the upper surface.
The water may ~e put into the c~ll first or ~oth the water and the tar sand at the same time.
In drawings which illustrate embodiments of the invention, Figure l is a schematic view o a floatation cell with electrodes, 2Q Figure 2 is a cross-section of an experimental cell at the start of the separation process, Figure 3 i5 similar to figure Z but after t~e process has proceeded ~or a time, Figure 4 is similar to f1gures Z and 3 but shows the process after completion, Figure 5 shows a typical form of upper electrode for the cell, and Figure 6 shows an altèrnative method of applying electrical energy to the cell, usable at microwave 3Q frequencies.
Referring to fi~ure 1 a schematic view of an electric flota~ion ceIl is shown gen~rally as a cylindrical -585~
container lQ m~de o~ insulatIn~ material e.g. ~lass~ perspex.
The ~Ottom oE the cell ll i5 a metal plate acting as one electrode. It is also posslble to operate with a "CAN" shaped lower electrode. This latter form would have certain advantages in that the portion of the cell containing the tar sand charge and su~ject to highly abrasive agitation would be Qf metal. The cell is filled with a charge of raw tar sand 12 and filled with water 13. A me~al electrode 14 is positioned centrally of the container and touches or is close to the upper surface of the tar sand. An electric voltage is applied from a suitable power source 15 across the electrodes. It has been found that the frequency of operation can be from DC to high frequency RF and even into ~ the microwave range. The latter of course requires a special type of applicator. Standard mains frequency of 60 cycle has ~een found to operate successfully.
Figures 2, 3, 4, and 5 show stages in operation of an experimental cell. In figure 2 a charge of tar sand 12 is placed in the cell and covered with water to a predetermined depth.
Although the process will operate with a depth of water less than that of the tarsand, it has been found preferably to use a depth one or more times that o~
the tarsand. The upper electrode which is in the form of a metal grid 14a fastened to the end of the central conductor 14 rests near the upper surface of the tar sand. Voltage is applied to conductor 14 and bottom plate electrode 11 result.ing in a intense electric field through the tar sand layer. This causes violent agitation of the tar sand and water to a level 3~ 16 as shown in ~igure 3 with a frot~ layer 17 forming on the upper surface of the ~ater. It has ~een observed that sand and other particles e.g. clay, continuously fall through `~`
~5~54~
the muc~ les~ a~ltated ~ater region 18. ~t the end o~
fe~ minute$ the cell appears as in flgure 4 with a deep flotation la~er 17 at the top and a sand residue 19 at the bottom. If desired the cell can be left for a period e.g.
several minutes ~o one hour or more to achieve settling and clarification of water.
Because the water is heated during the process it is economic to reuse the water as often as possible.
The froth on the top of the liquid column lQ entrains and contains a relatively high percentage o~ the ~itumen with the sand, clays and other residues remaining at the ~ottom. This flotation layer can be readily removed and passed to further processing stages.
It~is also considered that it w~uld be , advantageous to the process to use additives to control the pH value of the cell contents. A typical additive would be 1 NaOH.
The upper electrode can be in various shapes, ; the simplest being the rod of figure 1. A grid shaped 2Q structure as shown in figure 5 appears to be quite effective.
The bottom electrode has the form of a flat plate. It has been observed that, in operation, voids or bubbles form at or near the surface o this electrode which adversely effects the e.nergy application to the tar sands.
It has been found that if water is introduced or injected at the bottom, then this water flowing outwardly breaks up or removes these voids and restores effective operation.
A suitable valve 20 is shwon in figure 2 for doing this. It is spring-loaded and is fed from chamber 21 connected to a pump ~not shown~ via tube 22 Figure 6 illustrates a suitable a suita~le means of applying microwave energy to column 10. ~aveguide ~4--1~)5~35~1 25 connected.to a micro~ve ~o.~er. .SQUrCe ~not s~.ownl is.con-nected to the bottom o~ the cell th.rough a plate:26 whi.ch is suc~ as to allow pass~ge o~ the energy into the tar sands 16.
Preliminar~ data has been obtained on t~sts conducted on tarsand separation using the electric flotation cell descri~ed a~ove. The ~ollowing is a typical test run on a lakoratory model sho~ing mater;al and energy bahances:
TypicaL T_st Run lQ 1. A 2.Q kgm charge of tar sand was mixed with 20Q ml H2O
and placed in the separator with 5Q of H2O at 75F. The resulting water column helght was approximately 10 inches.
Separation required a total electrical energy input of 0.4 Kw-hr. The original charge when mlxed with 200 ml of H2O
consisted of 12.2% Bitumen, 10.1% H2O and 77.7~ solids Csand and clay fines~. The u~graded bitumen consisted of 54.4%
Bitu~m~ , 31.9~ H2O and 13.7% solids. The tailings consisted of ~r3~ Bitumen, 20.4% H20 and 78.3% solids.
2. Materials Balance (to nearest gram) ~a) feed stock: Bitumen268 gm H2O (75F)222 gm solids1709 gm Cb~ process water (75F1 5000 gm OUTPUT
~a) upgraded bitumen Bitumen241 gm H2O (.165F)141 gm solids 61 gm C~ tai.lings Bitumen 27 gm 3Q H2~ C165 F).43Q gm solids1648 gm Cc~ reusea~le water C165fl 4651 gm 5~L~
~a) upgraded bitumen Bitumen241 gm H2O (.165F)141 gm solids 61 gm C~ tai.lings Bitumen 27 gm 3Q H2~ C165 F).43Q gm solids1648 gm Cc~ reusea~le water C165fl 4651 gm 5~L~
3. Electxical Energy Input: 3.44 x lQ cal C~.4 kw-hr x 8.6 x 1a5 c~
~w-hr (b~ Heat Value of Recovered ~itumen: 2.24 x la6 cal (241 gm x 0.93 x 104 cal, gm ..
~c~ Heat Value o~ ~ecovered Bitumen' _ 6.'5 Electrical Energy Input Cd~ Percentage o~ Bitumen Unrecovered ~ bitume~ 'ih' tailings ~ 10%
Bi:tumen in feedstock The following are average results for a series of tests with different water~column heights. It should be pointed out ~hat, although the trends are readily apparent, the wide range o~ constituent makeups in handling small samples results in deviations rom these aver~gè
results by as much as 1~%.
Avera~e results 1. Water column height between 20-24 inches ~10-12Q H2O) (a) sample size 2000 gm (~) average recovered b1tumen 213 gm ~c~ average electrical energy input 0.52 kw-hr.
~d~ average upgraded bitumen: bitumen 69%
H2O 22.5~
solids 8.5%
heat v'alue o'E recove'red bitumen 4~4 (e)~ average of electrical energy input ~2) water column height 4 inches (2QH2O) (results of a single test~
~a~ sample sine 2200 gm (b~ recovered bitumen 128.2 gm (c~ electrical energy input .37 kw-hr.
Cd~ upgraded bitumen: bltumen 4~7 H2~ 32.6 solids , 17.7 Heat value of recovered bitumen . 3.7 e~ .
~S~54~
RECYCLING
. _ .
It is important to note that t~e energ~
costs of producing the'bitumen have been calculated by assuming that each sample'requires fresh water that must be heated. However, the bulk of the water column is reuseable several times and for each successive sample separated the energy cost will be reduced.
One such test of recycling was carried out and the results are summarized ~elow~
lQ 1st Sample:
Ca~ recovered b;tumen 181.5 gm (~) electrical energy input 0.45 kw-hr.
Lc~ ' ~eat'va'lue o~ re'co've'r'ed b'i'tum'e'n '' electrical~energy input~ ' = 4-4 2nd sample:
'(a2 recovered bitumen 116.6 gm ~) electrical energy input 0.13 kw-hr.
Cc) ' heat' value of reco~ered b~'tumen electrical energy input '~' 2 9.8 3rd sample: ' ' Ca) recovered bitumen 88 gm Cb~ electrical energy input 0.08, kw-hr.
Cc~ ' he'at''Val'ue of r'ec'o~ered'bitumen' ~ 12 electrical ener~y input The limit to water recycling has not yet been determined, put presumably beyond a certain point the bitumen will become excessively sandy as the residual silt load in the water column increases.
~w-hr (b~ Heat Value of Recovered ~itumen: 2.24 x la6 cal (241 gm x 0.93 x 104 cal, gm ..
~c~ Heat Value o~ ~ecovered Bitumen' _ 6.'5 Electrical Energy Input Cd~ Percentage o~ Bitumen Unrecovered ~ bitume~ 'ih' tailings ~ 10%
Bi:tumen in feedstock The following are average results for a series of tests with different water~column heights. It should be pointed out ~hat, although the trends are readily apparent, the wide range o~ constituent makeups in handling small samples results in deviations rom these aver~gè
results by as much as 1~%.
Avera~e results 1. Water column height between 20-24 inches ~10-12Q H2O) (a) sample size 2000 gm (~) average recovered b1tumen 213 gm ~c~ average electrical energy input 0.52 kw-hr.
~d~ average upgraded bitumen: bitumen 69%
H2O 22.5~
solids 8.5%
heat v'alue o'E recove'red bitumen 4~4 (e)~ average of electrical energy input ~2) water column height 4 inches (2QH2O) (results of a single test~
~a~ sample sine 2200 gm (b~ recovered bitumen 128.2 gm (c~ electrical energy input .37 kw-hr.
Cd~ upgraded bitumen: bltumen 4~7 H2~ 32.6 solids , 17.7 Heat value of recovered bitumen . 3.7 e~ .
~S~54~
RECYCLING
. _ .
It is important to note that t~e energ~
costs of producing the'bitumen have been calculated by assuming that each sample'requires fresh water that must be heated. However, the bulk of the water column is reuseable several times and for each successive sample separated the energy cost will be reduced.
One such test of recycling was carried out and the results are summarized ~elow~
lQ 1st Sample:
Ca~ recovered b;tumen 181.5 gm (~) electrical energy input 0.45 kw-hr.
Lc~ ' ~eat'va'lue o~ re'co've'r'ed b'i'tum'e'n '' electrical~energy input~ ' = 4-4 2nd sample:
'(a2 recovered bitumen 116.6 gm ~) electrical energy input 0.13 kw-hr.
Cc) ' heat' value of reco~ered b~'tumen electrical energy input '~' 2 9.8 3rd sample: ' ' Ca) recovered bitumen 88 gm Cb~ electrical energy input 0.08, kw-hr.
Cc~ ' he'at''Val'ue of r'ec'o~ered'bitumen' ~ 12 electrical ener~y input The limit to water recycling has not yet been determined, put presumably beyond a certain point the bitumen will become excessively sandy as the residual silt load in the water column increases.
Claims (5)
1. A method of separation of bitumen from tar sands comprising:
(a) placing a charge of unseparated tar sand and an amount of water in a container, (b) applying electrical energy to the tar sand, (c) continuing the application of electrical energy until the tar sands and liquid have been agitated, mixed and the bitumen separated from the sand, and floated upward to the top of the liquid, and (d) removing the flotation layer for further processing, said layer containing a high proportion of the bitumen occuring in the charge of tar sand.
(a) placing a charge of unseparated tar sand and an amount of water in a container, (b) applying electrical energy to the tar sand, (c) continuing the application of electrical energy until the tar sands and liquid have been agitated, mixed and the bitumen separated from the sand, and floated upward to the top of the liquid, and (d) removing the flotation layer for further processing, said layer containing a high proportion of the bitumen occuring in the charge of tar sand.
2. A separation method as in claim 1 wherein the method of applying electrical energy to the tar sand is by means of electrodes placed at two spaced positions in the container.
3. A separation method as in claim 1 wherein the method of applying electrical energy to the tar sand is by applying microwave energy directly to the tar sand.
4. A separation method as in claim 1, 2, or 3 wherein the amount of water placed in the container results in a level of water above the tar sand one or more times that of the tar sand.
5. A separation method as in claim 1, 2, or 3 further comprising the step of controlling the pH level of the tar sand and water by means of additives.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA234,394A CA1058541A (en) | 1975-08-28 | 1975-08-28 | Method and apparatus for separation of bitumen from tar sands |
| US05/851,169 US4136014A (en) | 1975-08-28 | 1977-11-14 | Method and apparatus for separation of bitumen from tar sands |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA234,394A CA1058541A (en) | 1975-08-28 | 1975-08-28 | Method and apparatus for separation of bitumen from tar sands |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1058541A true CA1058541A (en) | 1979-07-17 |
Family
ID=4103923
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA234,394A Expired CA1058541A (en) | 1975-08-28 | 1975-08-28 | Method and apparatus for separation of bitumen from tar sands |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1058541A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10829694B2 (en) | 2016-03-29 | 2020-11-10 | 3P Technology Corp. | Apparatus and methods for separating hydrocarbons from particulates |
| WO2021232148A1 (en) * | 2020-05-20 | 2021-11-25 | 3P Technology Corp. | Apparatus and methods for controlling separation of hydrocarbons from particulates |
-
1975
- 1975-08-28 CA CA234,394A patent/CA1058541A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10829694B2 (en) | 2016-03-29 | 2020-11-10 | 3P Technology Corp. | Apparatus and methods for separating hydrocarbons from particulates |
| WO2021232148A1 (en) * | 2020-05-20 | 2021-11-25 | 3P Technology Corp. | Apparatus and methods for controlling separation of hydrocarbons from particulates |
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