CA2098656A1 - Extractor and process for extracting one material from a multi-phase feed material - Google Patents
Extractor and process for extracting one material from a multi-phase feed materialInfo
- Publication number
- CA2098656A1 CA2098656A1 CA 2098656 CA2098656A CA2098656A1 CA 2098656 A1 CA2098656 A1 CA 2098656A1 CA 2098656 CA2098656 CA 2098656 CA 2098656 A CA2098656 A CA 2098656A CA 2098656 A1 CA2098656 A1 CA 2098656A1
- Authority
- CA
- Canada
- Prior art keywords
- extractor
- housing
- outlet
- extractant
- strainer
- 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.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D11/00—Solvent extraction
- B01D11/02—Solvent extraction of solids
- B01D11/0215—Solid material in other stationary receptacles
- B01D11/0223—Moving bed of solid material
- B01D11/0226—Moving bed of solid material with the general transport direction of the solids parallel to the rotation axis of the conveyor, e.g. worm
Abstract
ABSTRACT OF THE DISCLOSURE
An extractor in which material to be extracted is caused to move by a screw conveyor within a housing or trough in counter current to an extracting liquid (extractant). The motion of the screw conveyor is intermittently reversible, and the gentle agitation of the raw material with the extracting liquid causes material to be extracted to separate from the raw material and moved with the extactant to a liquids outlet. The housing is pressurized and the process of the invention run at elevated pressure. Extractant is injected into the raw material using jets on the screw conveyor. A strainer at the liquids outlet is charged with fine particulates as a filter medium. The housing is enlarged to assist in gas removal from the housing.
Extracted liquids are processed in a like extractor to remove additional fine material, and extracted solids additionally processed to remove further liquids from the solid material.
An extractor in which material to be extracted is caused to move by a screw conveyor within a housing or trough in counter current to an extracting liquid (extractant). The motion of the screw conveyor is intermittently reversible, and the gentle agitation of the raw material with the extracting liquid causes material to be extracted to separate from the raw material and moved with the extactant to a liquids outlet. The housing is pressurized and the process of the invention run at elevated pressure. Extractant is injected into the raw material using jets on the screw conveyor. A strainer at the liquids outlet is charged with fine particulates as a filter medium. The housing is enlarged to assist in gas removal from the housing.
Extracted liquids are processed in a like extractor to remove additional fine material, and extracted solids additionally processed to remove further liquids from the solid material.
Description
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TITLE OF THE INVEil~TION:
Extractor and Processi for Extracting One Material from a Multi-phase Feed Material ~M~ OF INVE~TOR:
Peter W. Smith FIELD OF T}lllS INVBNTION
This invention relates to apparatus and ~ -processes used for the extraction of one material from i~ 15 another material.
BACKGROUND AI~D SUMMARY OF THE INVENTION :: -:
An estimated 800 - 1,000 billion barrels of oil lie in tar sands located in Northern Alberta, -Canada. Of this amount, about 7f~i lies under sufficiently thin overburden to make surface mining economically attractive. Existing processes for the extraction of the oil from the tar sand begin with stripping of the overburden, followed by surface mining of the tar sand. The mined tar sand is then processed using a variety of high shear processes at atmospheric conditions, such as using revolving conditioning drums which mix the tar sand with a caustic solution, water and steam. These high shear -~ `
processes result in a high degree of undesirable ~ ~i dispersion of clays contained in the oil sand deposit.
Also, extracted bitumen must be processed in separate settling cells to remove sand and mineral from the bitumen.
This invention in one aspect provides a low ;~
shear, high pressure process that is intended to overcome the problems in the existing methods that result in high clay dispersion and inefficient oil ~`~
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'~!.;r extraction. Separation of bitumen is enhanced through increased density differences between the bitumen and extractant.
In one aspect of the invention, an extractor described in United States patent no. 4,363,264 to Lang et al is adapted for high pressure use to enhance separation of bitumen from tar sand. In Lang et al, there is described a counter current extractor in which material to be extracted is caused to move by a screw conveyor within a housing or trough in counter current to an extracting liquid (extractant). The motion of the screw conveyor is intermittently reversible, and the gentle agitation of the feed material with the extracting liquid causes material to be extracted to separate from the feed material and moved with the extractant to a ]iquids outlet.
In one aspect of the invention, the housing is pressurized and the process of the invention run at elevated pressure. In a further aspect, extractant is injected into tha feed material using jets on the screw conveyor. In a still further aspect, a strainer at the liquids outlet is charged with fine particulates as a filter medium.
In still further aspects of the invention, the housing is enlarged to assist in gas removal from the housing. Extracted liquids are processed in a like extractor to remove additional fine material, and extracted solids additionally processed to remove further liquids from the solid material.
These and other aspects of the invention are described in the description that follows.
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TITLE OF THE INVEil~TION:
Extractor and Processi for Extracting One Material from a Multi-phase Feed Material ~M~ OF INVE~TOR:
Peter W. Smith FIELD OF T}lllS INVBNTION
This invention relates to apparatus and ~ -processes used for the extraction of one material from i~ 15 another material.
BACKGROUND AI~D SUMMARY OF THE INVENTION :: -:
An estimated 800 - 1,000 billion barrels of oil lie in tar sands located in Northern Alberta, -Canada. Of this amount, about 7f~i lies under sufficiently thin overburden to make surface mining economically attractive. Existing processes for the extraction of the oil from the tar sand begin with stripping of the overburden, followed by surface mining of the tar sand. The mined tar sand is then processed using a variety of high shear processes at atmospheric conditions, such as using revolving conditioning drums which mix the tar sand with a caustic solution, water and steam. These high shear -~ `
processes result in a high degree of undesirable ~ ~i dispersion of clays contained in the oil sand deposit.
Also, extracted bitumen must be processed in separate settling cells to remove sand and mineral from the bitumen.
This invention in one aspect provides a low ;~
shear, high pressure process that is intended to overcome the problems in the existing methods that result in high clay dispersion and inefficient oil ~`~
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'~!.;r extraction. Separation of bitumen is enhanced through increased density differences between the bitumen and extractant.
In one aspect of the invention, an extractor described in United States patent no. 4,363,264 to Lang et al is adapted for high pressure use to enhance separation of bitumen from tar sand. In Lang et al, there is described a counter current extractor in which material to be extracted is caused to move by a screw conveyor within a housing or trough in counter current to an extracting liquid (extractant). The motion of the screw conveyor is intermittently reversible, and the gentle agitation of the feed material with the extracting liquid causes material to be extracted to separate from the feed material and moved with the extractant to a ]iquids outlet.
In one aspect of the invention, the housing is pressurized and the process of the invention run at elevated pressure. In a further aspect, extractant is injected into tha feed material using jets on the screw conveyor. In a still further aspect, a strainer at the liquids outlet is charged with fine particulates as a filter medium.
In still further aspects of the invention, the housing is enlarged to assist in gas removal from the housing. Extracted liquids are processed in a like extractor to remove additional fine material, and extracted solids additionally processed to remove further liquids from the solid material.
These and other aspects of the invention are described in the description that follows.
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BRIEF DESCRIPTION OF THE DRAWII~:S
There will now be described preferred embodiments of the invention, with reference to the drawings, by way of illustration, in which like numerals denote like elements and in which:
Figure 1 is a schematic of a pressurized extractor according to the invention;
Figure 2 is a schematic, partly cut away, of an extractor according to the invention;
Figure 3 i6 a cross section through the extractor of Figure 2;
Figure 4 is a detail showing the raw material inlet end of the extractor of Figure 2;
Figure 5 is a schematic of an extractor for use in tar sands processing;
Figure 6 is a schematic showing an exemplary mobile tar sands processing using apparatus according to the invention;
Figure 7 is a diagram showing tar sand processing steps for the system of Figure 6;
Figure 8 is a schematic showing an alternative process for the processing of tar sand according to one aspect of the .invention;
Figure 9 is a schematic showing an alternative processing apparatus for mature fine tailings; and Figure 10 is a schematic showing a further embodiment of an extractor according to the invention.
DETAIh~iD DESCRIPTIO~ OF PREFERRED ~iMBODIMENTS
Pressure tight in relation to an object means the object is sealed to such an extent that the object can withstand pressures over 1 atmosphere up to 60me preselected limit, for example 100 atmospheres.
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As seen in Figs. 1, 2, 3 and 4 the extractor comprises an elongated pressure tight tubular housing 11, in which is disposed a screw or helical conveyor 12 which is arranged to be rotated about its longitudinal axis by drive means or motor 13. The tubular housing 11 may be round or elliptical in cross-section or other suitable smooth shape sultable for fluid flow. As shown in Figures 1 and 2, the housing 11 is circular, and as shown in Figures 3 and 4 is also elongated in the vertical direction to form a somewhat oval shape. The helical conveyor and drive means together form a drive train for material within the housing to move the material from one feed material (crushed, mined, tar sands, for example) inlet end of the housing to the other, outlet end. The housing 11 is provided with an inlet hopper 14, and ; inlet valve 50 at a feed point at the feed material inlet end of the housing. The hopper 14 is disposed above the lower end of the screw which is preferably inclined slightly upwardly towards an outlet discharge port 32 for the (mainly) solid material which has been treated at the other end of the housing. A dischar~e line 16 at the feed material inlet end of the housing 11 is provided for the discharge of llquid. The liquid discharged through line 16 will include material extracted from the feed material as well as extractant. Extractant is charged into the housing 11 through charging line 17 at or adjacent the other end of the housing 11 and injection ports 52 on the helical conveyor 12. A further injection port S2a may be located at the solids inlet port below the hopper 14. One or more of the ports 52 could be used for injecting one extractant, such as steam, and others may be used for injecting one or more other . :
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extractants or mixtures of extractants, as for example hydrocarbon.
A reversing means 22 is provided between the drive means 13 and the screw conveyor 12 which may be S used to intermittently reverse the direction of rotation of the screw conveyor 12. The motor 13 is operatively connected to the spindle 23 of the screw conveyor 12 through a hydraulic drive 60, which may orm part of the drive means, the drive 60 being selected so that the spindle 23, and the screw conveyor 12, is rotated at about 1 R.P.M. when the motor 13 is running at a suitable operating speed.
The spindle 23 is supported in bearings 27 and 28 mounted at either end of the housing 11.
The screw conveyor 12 includes a helical flight 29 disposed about the spindle 23. The flight 29 is provided with circumferential directed slits 30 and a plurality of radially extending ribs 31 disposed on the side of the flight 29 which is not active in moving material to be extracted from the inlet to the outlet end of the housing 11. Extractant injection ;
nozzles 52 are also mounted on the same side of flights 29 as ribs 31. Extractant, which may function as a heating medium, is provided to these nozzles 52 through the spindle 23 and flights 29 which are made -~ `
hollow for this purpose. Material to be extracted is ;~
charged into the housing through the hopper 14 and inlet valve 50 at the lower end of the housing 11 and i `
i i6 discharged from the housing 11 at the outlet end 32 through line 15 and outlet valve 51 in the end plate 33 of the housing 11. Rotating seals 54 equipped with i flushing fluid 59 are utilized to seal the materials -~ ~
in the extractor body 11 from the outside. ~ `
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Extractant is passed into the spindle 23, via steam valve 61, and emitted through injection ports 52. Dissolved and entrained gases are removed from the extractor pressure casing 11 via discharge line 55, preferably in an enlarged portion 66 of the housing 11 ~s shown in Figure 1.
At the lower, inlet, end of the housing 11 is a skrainer to strain the extracted liquid prior to its discharge from the housing 11. The strainer comprises an end plate 34 disposed across the housing 11. The strainer plate 34 is provided with apertures 35. A screw 36 and backing plate 37 are provided behind the end plate 34 and are connected to the spindle 23 and adapted to rotate therewith.
As the strainer rotates, it is cleaned by admission of extractant through line 65 and cleaning nozzle 64 which are mounted within the extractor housing 11. Sand or other inert particulates may be injected by means 64 shown in Figure 4 against the strainer face 34 of the extractor 10 through line 65 adjacent the strainer to assist in removing clay fines adhering to the bitumen product or being carried along with the wash water. The inert particulate is injected on the conveyor side of the strainer (from where the bitumen stream flows).
Extracted fluids which may consist of two or more pha~es are removed via discharge line 16 to separator 56. Product is removed via discharge line 62 from the separator 56. A heat exchanger 18 is provided on return line 20 from discharge line 62 to heat recycled product and return it to a central portion of the housing 11 nearer to the feed inlet. Maintaining a high bitumen or other product content at and near the inlet end of the housing is beneficial in ,~ 2~g~6a6 improving the extraction of bitumen. Extractant liquid, typically water, is recycled via lines 19 and 17 to the extractor.
Liquid passing back to the extractor via line 17 may pass through heat exchanger 58, where it is cooled, to provide cooling in the final part of the extractor prior to discharge of the extracted material via line 15 and discharge valve 51. The line 19 with heated recycled extractant is discharged into the housing 11 between 1/10 and 1/2 of the way along the housing 11 from the outlet end 32. Pressure housing 11 i8 provided with an insulated heated jacket 46. A
heati~g medium passes into the jacket through lines 47 and out through lines 48. The first part of the extractor adjacent the inlet end is for heating, the central portion is for extraction and the last part, near the outlet end, may be used for cooling the processed feed material.
In use, material to be extracted is introduced into the lower end of the pressure housing 11 and the screw conveyor 12 is rotated to commence the movement of the material along the housing 11.
Extractant is fed into the screw conveyor 12 via the spindle 23 and injection ports 52. ~dditionally, heated extractant is fed into the housing 11 through line 17.
As the material to be extracted progresses along the housing 1~1 it is compressed by the flight 29 ~orming a compacted mass of partly extracted material.
When the direction of rotation of the screw conveyor 12 is reversed, the ribs 31 bite into the compacted mass causing it to open up and admit fresh extractant.
At the same time steam or other heatîng medium passing through injection ports 5~ helps to open the structure j i,~ , "~ "~"~ "~" ""~ "j ~"~
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of the material. This opening up of compacted mass of material being extracted contributes significantly to the performance of the extractor and results in improved yields of extracted matter. A pressure safety valve 57 is mounted on the extractor housing 11 for relief of pressure over some selected level, as may be required for safety purposes.
In the operation of an apparatus according to one exemplary aspect of th~e invention, oil may be extracted from oil sand as illustrated in Figures 1 and 5, 6 and 7. The overburden 71 is first stripped to expose the underlying tar sand 72. An excavator 73 mines the tar sand which is conveyed by trucks 74 to a conveyor 75 with a conventional crusher (not shown) and thence to a tar sand extraction plant 76 constructed in accordance with for example Figures 1 and 5. The primarily solid waste from the solids discharge end of the extractor is spread using spreader 77 on a tailings pile 78. Overburden 79 is relocated onto the tailings. The steps of stripping 81, mining 82, crushing 83, extracting 84, disposal 85 and overburden replacement 86 are illustrated diagrammatically in Figure 7.
Within the tar sand extraction plant, tar sand, containing approximately 10% bitumen in the example here described, is crushed or screened in accordance with known practice to remove oversized materials, before it is admitted to the feed bin 14.
Valves at the bottom of the feed bin 14 discharge the tar sand into the extractor 10 at a controlled rate.
The inlet valve 50 is preferably of the star valve type and set to maintain a back pressure on the extractor of 20 atmospheres.
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g The extractor 10 provides three functions:
heating, extraction and cooling. In the first part of the extractor 10, the tar sand meets an oncoming stream of steam, injected through the housing 11, and through injection ports 52 situated in the screw conveyor, and in the inlet nozzle. An enlarged section 66 on the top of the extractor facilitates the removal of dissolved and entrained gases.
The tar sand mass is then heated rapidly to an operating temperature of 220C, by the admission of further steam injection through ports 52, and using the steam jacket 46 on the exterior of the extractor.
The motion of the screw conveyor 12 is intermittently reversed, and the resulting pulsation of the oil sand, plus steam injection through jets 52 in the trailing face of the screw conveyor allows the steam, and condensate formed from the steam, to gently permeate the tar sand mass as it moves slowly through the extractor. The viscosity of the entrained bitumen drops from approximately 800,000 mPas to approximately 7 mPas. Under these conditions, the bitumen becomes mobile and permeates through the tar sand mass.
The action of the steam jets 52, steam condensate and recycled l quid through line 58 sweeps the bitumen through the extractor 10 towards the inlet end, eventually passing the feed point and arriving at the strainer situated at the feed end of the screw.
The bitumen~water mixture passes through the strainer 34, and into the separator 56.
Fines are re-tained within the mass of tar sand which is moving gently through the extractor 10 to the discharge port. If improved fines separation is required, then additional clean 8and or other inert ~a9~
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1 0 , particulates can be injected adjacent tO the stainer face on the tar sand side of the strainer plate. -The bitumen-water mixture passes then into the separator 56, which is shown as a separate vessel, but can be formed as an extension of the extractor shell.
~ uring the process, the density of the bitumen drops from 1 r kg/m3 to approximately 880 kg/m3 at 220C. Simultaneously, the density of water drops to 840 Kg/m3. The 40 Kg/m3 difference in density is si.gnificantly greater than the approximately 5 Kg/m3 density difference achieved in existing technology. This density difference allows good separation between bitumen and water to be achieved without the requirement for added diluent. Further, the removal of entrained and dissolved air and gases at the commencement of the extraction process ensures that bitumen is produced as a consistent liquid, rather than as a ~roth as in current technology. The bitumen product may be pumped from the separator using normal centrifugal type pumps 63, rather than the extremely specialist screw pumps used in existing technology. Water is recycled from the separator back -~
to the extractor using pumps 67. The extracted tar sand paGse6 out of the extractor through valve 51 less the bitumen, but in other ways unchanged.
The gentle naturei of the extraction, which takes place under the influence of steam and water only, without the requirement for chemicals, maintains the clay in the tar sand bed.
At the solids outlet of the extractor the extracted tar sand is still at 2~0C, and contains added water, which has effectively taken up the space within the tar sand mass vacated by extracted bitumen. ~-.r;~
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The extracted tar sand may be passed into a heat recovery system 87, as illustrated in Figure 7, where its pressure is reduced to atmospheric. Under these conditions, the additional water flashes into steam, effectively bringing back the water content of the tar sand to its original level. The flash steam can be condensed into a high quality condensate, suitable with little or no treatment for use as boiler feed water. Additional cooling of the tar sand mass from 100C can be accomplished by heat exchange with incoming cold water, if this ls desired for reasons of heat econo~y.
The spent tar sand ~tailings) is thus a consistent material, which can be disposed of in land fill sites, as illustrated in Figure 6, later to he covered with overburden and reclaimed into the natural environment.
Figure 7 also illustrates a heat source for the steam which may burn high sulphur bitumen or petroleum coke from bitumen upgrading operations with -low emissions of SO2 and the overall processing of tar sand. A conventional limestone quarry with crusher 91 ~i~
and conventional fluid bed boiler 92 are used to produce steam extractant for the extraction process.
Spent ash may be deposited along with waste material from the extractor as tailings by adding the ash to the waste material at 87. Fuel for the fluid bed boiler may be obtained from bitumen tank 93. Bitumen processing may produce hot bitumen shipments 94, bitumen diluted with lighter hydrocarbons for a pipeline 95 and/or bitumen emulsion for a pipeline 96. ~;
- The extractor mechanism can be driven mechanically or hydraulically. In principle the extractor simulates the action of an underground '', ~ '.' ~
~ = ' ~"~ 2 ~ 6 ~. . , reservoir undergoing steam injection, although in a surface facility. The production of high quality bitumen product, together with a -non segregating tailings opens up the possibility of producing bitumen very close to the face where tar sand is being mined, since large settlers, flotation machines and diluent centrifuges as required in current technology are not required for the production of clean bitumen directly from tar sand with this process.
Ref~rring to Figure 8, the extraction process can for convenience be carried out in a number of extractors.
For example, screened or crushed tar sand is admitted through a feed bin 14 and inlet valve to the primary extractor lOa, where it undergoes heating with steam, through direct injection and from the steam jacket around the extractor. The primary extractor lOa serves to heat the tar sand, to facilitate air and gas removal, also a bitumen/water stream is removed.
Preferred operating conditions for bitumen extraction are 220C and 20 atmospheres. The bitumen~water mixture is passed to a second extractor lOb, through line 97. The second extractor lOb operates as a bitumen washer and separator. Here, the bitumen is washed against clean wash water obtained from a third extractor lOc through line 98. Each of the extractors lOa, lOb and lOc is constructed as the extractor shown in Figures 1, 2, 3, 4 and 5. The bitumen/water feed passes through the extractor lOb where it is gently moved by the internal spiral, which provides multi-staged contacting and extraction capability against a wash water stream.
Steam at 220C or higher is applied to the steam jacket 46 of the first extractor lOa through ~: .
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line 104 and to the conveyor through line 106 and may also be applied to the raw material intake in or below the hopper 14. Wash water may be applied through line 105. Tar sand that has been processed through the first extractor lOa is passed through star valve 51 along line 15a to the extractor lOc. Cool water at 10C is applied to extractor lOc through line 108, and steam is taken from the steam jacket 46 of extractor lOc on line 109. Cooled spent tar sand is produced on line 15c. Steam at 220C or more is applied to jacket 46 of extractor lOb through line 110, and cleaned bitumen is taken from the extractor lOb through line 15b. Wash water at 220C is taken from extractor lOb along line 107.
The density differences between bitumen and water, and this operation at high temperature where the bitume~ viscosity is maintained low, facilitates the disengagement of mineral and water droplets. A
clean bitumen stream is removed from the bitumen washer-separator lOb. The wash water stream passes into the primary extractor lOa through lines 105 and 107 to complete its recycle.
The tar sand exits the primary extractor lOa, still at 220C through an outlet star valve or similar device. It passes to a secondary recovery-heat recovery extractor lOc, where its pressure is dropped to atmospheric conditions or lower. U n d e r this situation, considerable dewatering of the tar sand takes place, through equilibrium evaporation.
The evaporated wat~r may be returned as wash water to the bitumen waæher separator lOb, or since it has been produced by evaporation and condensation, it will be close to boiler water quality and could be used for that purpose. The cold spent tar sand, from : :
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extractor 10c, with its water content reduced to below 30% is suitable for direct back filling in the mine pit or disposal by other means.
Referring to Figure 9, there is shown a further embodiment of an extraction system according to the invention. This example considers the application of the extractor to recovery of bitumen from mature fine tailings, which exist in large quantities on the tar sand operations in northern i 10 Alberta, Canada.
In this case, mature fine tailings 101 are recovered by conventional dredging, and pumped into an extractor 10, constructed for example as shown in Figures 1 - 5, whicl may be mounted directly on a dredging barge (not shown). Bitumen is extracted and processed using separator 56 to produce bitumen as ~
shown at 102. ~-Waste, `or processed feed material, is discharged through line 15 with valve 51 to a mixer/flash tank 38. Fluid bed boiler ash 39 from a fluid bed boiler such as element 92 shown in Figure 7, ~;~
and crushed limestone 40 are fed into the tank 38 through valves 41 and 42. In the tank 38, the pressure is dropped to atmospheric or lower pressure and water vapour .is released from the waste material and ;
extracted through line 43, cond~nser 44 to be produced as water at 45. Partially dewatered engineered fill is produced from the tank 38 through line 49, which may be used as backfill without the use of dykes. i`
Operation of the extractor at a similar high ~ ~-pressure, with steam injection recovers bitumen through the pulsating flow and constant opening of the ~i`
atructure of the fine tailings by the action of the ~
screw and contained steam jets. ~; -~ g ~ ~ ~
Bitumen at low viscosity is obtained as outlined in previous examples. This bitumen will contain more fines than that produced from tar sand, and an additional washing stage as outlined in Figure 8 is required if the bitumen is required for further upgrading.
However, a further alternative is to utilize this reclaimed bitumen as fuel for raising steam to operate the process. In this case, the bitumen is burned to produce steam.
The mature fine tailings can be utilized as feedatock for mineral abstraction, or manufactured into a geotechnically stable mass through a mixture of sand, fluid bed boiler ash, lime, crushed limestone and similar materials prior to being replaced in the tailings ponds or other disposal area.
Bitumen quality can be improved through the injection of these materials such as sand, fluid bed boiler ash, crushed limestone into the extractor against the stainer plate 34. This provides for additional segregation between the fines and recovered bitumen whilst at the same time creating a stable material which can be backfilled without the requirement for dyke containment.
The extractant used in the above examples is a mixture of steam and water. In these examples, the extractant prov`ides the functions of delivering heat to raise the temperature to the operating condition, where bitumen viscosity drops significantly from its value at the feed location. Additionally, the extractant assists in sweeping the bitumen away from its contained position within the tar sand mass.
Under these circumstances, the extractant does not dissolve the bitumen but assists the ~. .
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extractor to perform a physical separation or displacement process, based on achieving different physical properties, notably viscosity and density, than those utilized in existing technology.
The counter current extractor can also be utilized with extractants that fulfil the function of a solvent, as well as a heat transfer medium. In this class falls the use of liquid or super critical carbon dioxide. In this case, the carbon dioxide is used to 10 dissolve all or part of the bitumen, and separate it from the tar sand.
The examples cover the injection of sand and other filter aids to improve the separation of fines and bitumen. Operation of the extractor with the 15 in~ection of filter aids constitutes a new process which has been named counter current elution filtration.
The operation of the invention is not exclusively countercurrent, although for oil 20 extraction this is believed advantageous, but may he co-current, in which case the liquids inlet and outlet lines are reversed. Also, intermittent reversal of the screw conveyor, though preferred is not essential in one aspect of the invention. The apparatus and process 25 may be applied to the processing of other feed materials, besides tar sands, for example in food processing. Examples of feed materials include mature fine tailings, oil contaminated soil and minerals.
Feed materials to which the apparatus and process of 30 the invention may be applied have the characteristic of including a valuable component mixed with a larger amount of less valuable component.
Instead of using a valve 50 on the feed material inlet, to ensure that pressure is malntained :
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on the extractor, the extractor can be built with a large chimney 68, several tens of meters high as the feed material inlet. The height of the chimney 68 may reach 100 meters to place a pressure head on the extractor in the order of 20 atmospheres. Likewise, the processed raw material outlet 15 of the extractor 10 is replaced with a like chimney 69 of similar height. Evidently, the weight of the chimneys 68 and 69 does not rest on the extractor 10 but is externally supported by means not shown. Other than the chimneys 68 and 69 the extractor of Figure 10 functions in like ~ ~ ;
manner to the extractors shown in Figures 1 - 5O ;~
A person skilled in the art could make immaterial modifications to the invention described and claimed in this patent without departing from the essence of the invention.
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BRIEF DESCRIPTION OF THE DRAWII~:S
There will now be described preferred embodiments of the invention, with reference to the drawings, by way of illustration, in which like numerals denote like elements and in which:
Figure 1 is a schematic of a pressurized extractor according to the invention;
Figure 2 is a schematic, partly cut away, of an extractor according to the invention;
Figure 3 i6 a cross section through the extractor of Figure 2;
Figure 4 is a detail showing the raw material inlet end of the extractor of Figure 2;
Figure 5 is a schematic of an extractor for use in tar sands processing;
Figure 6 is a schematic showing an exemplary mobile tar sands processing using apparatus according to the invention;
Figure 7 is a diagram showing tar sand processing steps for the system of Figure 6;
Figure 8 is a schematic showing an alternative process for the processing of tar sand according to one aspect of the .invention;
Figure 9 is a schematic showing an alternative processing apparatus for mature fine tailings; and Figure 10 is a schematic showing a further embodiment of an extractor according to the invention.
DETAIh~iD DESCRIPTIO~ OF PREFERRED ~iMBODIMENTS
Pressure tight in relation to an object means the object is sealed to such an extent that the object can withstand pressures over 1 atmosphere up to 60me preselected limit, for example 100 atmospheres.
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As seen in Figs. 1, 2, 3 and 4 the extractor comprises an elongated pressure tight tubular housing 11, in which is disposed a screw or helical conveyor 12 which is arranged to be rotated about its longitudinal axis by drive means or motor 13. The tubular housing 11 may be round or elliptical in cross-section or other suitable smooth shape sultable for fluid flow. As shown in Figures 1 and 2, the housing 11 is circular, and as shown in Figures 3 and 4 is also elongated in the vertical direction to form a somewhat oval shape. The helical conveyor and drive means together form a drive train for material within the housing to move the material from one feed material (crushed, mined, tar sands, for example) inlet end of the housing to the other, outlet end. The housing 11 is provided with an inlet hopper 14, and ; inlet valve 50 at a feed point at the feed material inlet end of the housing. The hopper 14 is disposed above the lower end of the screw which is preferably inclined slightly upwardly towards an outlet discharge port 32 for the (mainly) solid material which has been treated at the other end of the housing. A dischar~e line 16 at the feed material inlet end of the housing 11 is provided for the discharge of llquid. The liquid discharged through line 16 will include material extracted from the feed material as well as extractant. Extractant is charged into the housing 11 through charging line 17 at or adjacent the other end of the housing 11 and injection ports 52 on the helical conveyor 12. A further injection port S2a may be located at the solids inlet port below the hopper 14. One or more of the ports 52 could be used for injecting one extractant, such as steam, and others may be used for injecting one or more other . :
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extractants or mixtures of extractants, as for example hydrocarbon.
A reversing means 22 is provided between the drive means 13 and the screw conveyor 12 which may be S used to intermittently reverse the direction of rotation of the screw conveyor 12. The motor 13 is operatively connected to the spindle 23 of the screw conveyor 12 through a hydraulic drive 60, which may orm part of the drive means, the drive 60 being selected so that the spindle 23, and the screw conveyor 12, is rotated at about 1 R.P.M. when the motor 13 is running at a suitable operating speed.
The spindle 23 is supported in bearings 27 and 28 mounted at either end of the housing 11.
The screw conveyor 12 includes a helical flight 29 disposed about the spindle 23. The flight 29 is provided with circumferential directed slits 30 and a plurality of radially extending ribs 31 disposed on the side of the flight 29 which is not active in moving material to be extracted from the inlet to the outlet end of the housing 11. Extractant injection ;
nozzles 52 are also mounted on the same side of flights 29 as ribs 31. Extractant, which may function as a heating medium, is provided to these nozzles 52 through the spindle 23 and flights 29 which are made -~ `
hollow for this purpose. Material to be extracted is ;~
charged into the housing through the hopper 14 and inlet valve 50 at the lower end of the housing 11 and i `
i i6 discharged from the housing 11 at the outlet end 32 through line 15 and outlet valve 51 in the end plate 33 of the housing 11. Rotating seals 54 equipped with i flushing fluid 59 are utilized to seal the materials -~ ~
in the extractor body 11 from the outside. ~ `
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Extractant is passed into the spindle 23, via steam valve 61, and emitted through injection ports 52. Dissolved and entrained gases are removed from the extractor pressure casing 11 via discharge line 55, preferably in an enlarged portion 66 of the housing 11 ~s shown in Figure 1.
At the lower, inlet, end of the housing 11 is a skrainer to strain the extracted liquid prior to its discharge from the housing 11. The strainer comprises an end plate 34 disposed across the housing 11. The strainer plate 34 is provided with apertures 35. A screw 36 and backing plate 37 are provided behind the end plate 34 and are connected to the spindle 23 and adapted to rotate therewith.
As the strainer rotates, it is cleaned by admission of extractant through line 65 and cleaning nozzle 64 which are mounted within the extractor housing 11. Sand or other inert particulates may be injected by means 64 shown in Figure 4 against the strainer face 34 of the extractor 10 through line 65 adjacent the strainer to assist in removing clay fines adhering to the bitumen product or being carried along with the wash water. The inert particulate is injected on the conveyor side of the strainer (from where the bitumen stream flows).
Extracted fluids which may consist of two or more pha~es are removed via discharge line 16 to separator 56. Product is removed via discharge line 62 from the separator 56. A heat exchanger 18 is provided on return line 20 from discharge line 62 to heat recycled product and return it to a central portion of the housing 11 nearer to the feed inlet. Maintaining a high bitumen or other product content at and near the inlet end of the housing is beneficial in ,~ 2~g~6a6 improving the extraction of bitumen. Extractant liquid, typically water, is recycled via lines 19 and 17 to the extractor.
Liquid passing back to the extractor via line 17 may pass through heat exchanger 58, where it is cooled, to provide cooling in the final part of the extractor prior to discharge of the extracted material via line 15 and discharge valve 51. The line 19 with heated recycled extractant is discharged into the housing 11 between 1/10 and 1/2 of the way along the housing 11 from the outlet end 32. Pressure housing 11 i8 provided with an insulated heated jacket 46. A
heati~g medium passes into the jacket through lines 47 and out through lines 48. The first part of the extractor adjacent the inlet end is for heating, the central portion is for extraction and the last part, near the outlet end, may be used for cooling the processed feed material.
In use, material to be extracted is introduced into the lower end of the pressure housing 11 and the screw conveyor 12 is rotated to commence the movement of the material along the housing 11.
Extractant is fed into the screw conveyor 12 via the spindle 23 and injection ports 52. ~dditionally, heated extractant is fed into the housing 11 through line 17.
As the material to be extracted progresses along the housing 1~1 it is compressed by the flight 29 ~orming a compacted mass of partly extracted material.
When the direction of rotation of the screw conveyor 12 is reversed, the ribs 31 bite into the compacted mass causing it to open up and admit fresh extractant.
At the same time steam or other heatîng medium passing through injection ports 5~ helps to open the structure j i,~ , "~ "~"~ "~" ""~ "j ~"~
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of the material. This opening up of compacted mass of material being extracted contributes significantly to the performance of the extractor and results in improved yields of extracted matter. A pressure safety valve 57 is mounted on the extractor housing 11 for relief of pressure over some selected level, as may be required for safety purposes.
In the operation of an apparatus according to one exemplary aspect of th~e invention, oil may be extracted from oil sand as illustrated in Figures 1 and 5, 6 and 7. The overburden 71 is first stripped to expose the underlying tar sand 72. An excavator 73 mines the tar sand which is conveyed by trucks 74 to a conveyor 75 with a conventional crusher (not shown) and thence to a tar sand extraction plant 76 constructed in accordance with for example Figures 1 and 5. The primarily solid waste from the solids discharge end of the extractor is spread using spreader 77 on a tailings pile 78. Overburden 79 is relocated onto the tailings. The steps of stripping 81, mining 82, crushing 83, extracting 84, disposal 85 and overburden replacement 86 are illustrated diagrammatically in Figure 7.
Within the tar sand extraction plant, tar sand, containing approximately 10% bitumen in the example here described, is crushed or screened in accordance with known practice to remove oversized materials, before it is admitted to the feed bin 14.
Valves at the bottom of the feed bin 14 discharge the tar sand into the extractor 10 at a controlled rate.
The inlet valve 50 is preferably of the star valve type and set to maintain a back pressure on the extractor of 20 atmospheres.
"'' '' :: :
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.
g The extractor 10 provides three functions:
heating, extraction and cooling. In the first part of the extractor 10, the tar sand meets an oncoming stream of steam, injected through the housing 11, and through injection ports 52 situated in the screw conveyor, and in the inlet nozzle. An enlarged section 66 on the top of the extractor facilitates the removal of dissolved and entrained gases.
The tar sand mass is then heated rapidly to an operating temperature of 220C, by the admission of further steam injection through ports 52, and using the steam jacket 46 on the exterior of the extractor.
The motion of the screw conveyor 12 is intermittently reversed, and the resulting pulsation of the oil sand, plus steam injection through jets 52 in the trailing face of the screw conveyor allows the steam, and condensate formed from the steam, to gently permeate the tar sand mass as it moves slowly through the extractor. The viscosity of the entrained bitumen drops from approximately 800,000 mPas to approximately 7 mPas. Under these conditions, the bitumen becomes mobile and permeates through the tar sand mass.
The action of the steam jets 52, steam condensate and recycled l quid through line 58 sweeps the bitumen through the extractor 10 towards the inlet end, eventually passing the feed point and arriving at the strainer situated at the feed end of the screw.
The bitumen~water mixture passes through the strainer 34, and into the separator 56.
Fines are re-tained within the mass of tar sand which is moving gently through the extractor 10 to the discharge port. If improved fines separation is required, then additional clean 8and or other inert ~a9~
~ ~ :
1 0 , particulates can be injected adjacent tO the stainer face on the tar sand side of the strainer plate. -The bitumen-water mixture passes then into the separator 56, which is shown as a separate vessel, but can be formed as an extension of the extractor shell.
~ uring the process, the density of the bitumen drops from 1 r kg/m3 to approximately 880 kg/m3 at 220C. Simultaneously, the density of water drops to 840 Kg/m3. The 40 Kg/m3 difference in density is si.gnificantly greater than the approximately 5 Kg/m3 density difference achieved in existing technology. This density difference allows good separation between bitumen and water to be achieved without the requirement for added diluent. Further, the removal of entrained and dissolved air and gases at the commencement of the extraction process ensures that bitumen is produced as a consistent liquid, rather than as a ~roth as in current technology. The bitumen product may be pumped from the separator using normal centrifugal type pumps 63, rather than the extremely specialist screw pumps used in existing technology. Water is recycled from the separator back -~
to the extractor using pumps 67. The extracted tar sand paGse6 out of the extractor through valve 51 less the bitumen, but in other ways unchanged.
The gentle naturei of the extraction, which takes place under the influence of steam and water only, without the requirement for chemicals, maintains the clay in the tar sand bed.
At the solids outlet of the extractor the extracted tar sand is still at 2~0C, and contains added water, which has effectively taken up the space within the tar sand mass vacated by extracted bitumen. ~-.r;~
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The extracted tar sand may be passed into a heat recovery system 87, as illustrated in Figure 7, where its pressure is reduced to atmospheric. Under these conditions, the additional water flashes into steam, effectively bringing back the water content of the tar sand to its original level. The flash steam can be condensed into a high quality condensate, suitable with little or no treatment for use as boiler feed water. Additional cooling of the tar sand mass from 100C can be accomplished by heat exchange with incoming cold water, if this ls desired for reasons of heat econo~y.
The spent tar sand ~tailings) is thus a consistent material, which can be disposed of in land fill sites, as illustrated in Figure 6, later to he covered with overburden and reclaimed into the natural environment.
Figure 7 also illustrates a heat source for the steam which may burn high sulphur bitumen or petroleum coke from bitumen upgrading operations with -low emissions of SO2 and the overall processing of tar sand. A conventional limestone quarry with crusher 91 ~i~
and conventional fluid bed boiler 92 are used to produce steam extractant for the extraction process.
Spent ash may be deposited along with waste material from the extractor as tailings by adding the ash to the waste material at 87. Fuel for the fluid bed boiler may be obtained from bitumen tank 93. Bitumen processing may produce hot bitumen shipments 94, bitumen diluted with lighter hydrocarbons for a pipeline 95 and/or bitumen emulsion for a pipeline 96. ~;
- The extractor mechanism can be driven mechanically or hydraulically. In principle the extractor simulates the action of an underground '', ~ '.' ~
~ = ' ~"~ 2 ~ 6 ~. . , reservoir undergoing steam injection, although in a surface facility. The production of high quality bitumen product, together with a -non segregating tailings opens up the possibility of producing bitumen very close to the face where tar sand is being mined, since large settlers, flotation machines and diluent centrifuges as required in current technology are not required for the production of clean bitumen directly from tar sand with this process.
Ref~rring to Figure 8, the extraction process can for convenience be carried out in a number of extractors.
For example, screened or crushed tar sand is admitted through a feed bin 14 and inlet valve to the primary extractor lOa, where it undergoes heating with steam, through direct injection and from the steam jacket around the extractor. The primary extractor lOa serves to heat the tar sand, to facilitate air and gas removal, also a bitumen/water stream is removed.
Preferred operating conditions for bitumen extraction are 220C and 20 atmospheres. The bitumen~water mixture is passed to a second extractor lOb, through line 97. The second extractor lOb operates as a bitumen washer and separator. Here, the bitumen is washed against clean wash water obtained from a third extractor lOc through line 98. Each of the extractors lOa, lOb and lOc is constructed as the extractor shown in Figures 1, 2, 3, 4 and 5. The bitumen/water feed passes through the extractor lOb where it is gently moved by the internal spiral, which provides multi-staged contacting and extraction capability against a wash water stream.
Steam at 220C or higher is applied to the steam jacket 46 of the first extractor lOa through ~: .
'''' ", ~ 2 ~
line 104 and to the conveyor through line 106 and may also be applied to the raw material intake in or below the hopper 14. Wash water may be applied through line 105. Tar sand that has been processed through the first extractor lOa is passed through star valve 51 along line 15a to the extractor lOc. Cool water at 10C is applied to extractor lOc through line 108, and steam is taken from the steam jacket 46 of extractor lOc on line 109. Cooled spent tar sand is produced on line 15c. Steam at 220C or more is applied to jacket 46 of extractor lOb through line 110, and cleaned bitumen is taken from the extractor lOb through line 15b. Wash water at 220C is taken from extractor lOb along line 107.
The density differences between bitumen and water, and this operation at high temperature where the bitume~ viscosity is maintained low, facilitates the disengagement of mineral and water droplets. A
clean bitumen stream is removed from the bitumen washer-separator lOb. The wash water stream passes into the primary extractor lOa through lines 105 and 107 to complete its recycle.
The tar sand exits the primary extractor lOa, still at 220C through an outlet star valve or similar device. It passes to a secondary recovery-heat recovery extractor lOc, where its pressure is dropped to atmospheric conditions or lower. U n d e r this situation, considerable dewatering of the tar sand takes place, through equilibrium evaporation.
The evaporated wat~r may be returned as wash water to the bitumen waæher separator lOb, or since it has been produced by evaporation and condensation, it will be close to boiler water quality and could be used for that purpose. The cold spent tar sand, from : :
~ 2~8~
.... .. ..
extractor 10c, with its water content reduced to below 30% is suitable for direct back filling in the mine pit or disposal by other means.
Referring to Figure 9, there is shown a further embodiment of an extraction system according to the invention. This example considers the application of the extractor to recovery of bitumen from mature fine tailings, which exist in large quantities on the tar sand operations in northern i 10 Alberta, Canada.
In this case, mature fine tailings 101 are recovered by conventional dredging, and pumped into an extractor 10, constructed for example as shown in Figures 1 - 5, whicl may be mounted directly on a dredging barge (not shown). Bitumen is extracted and processed using separator 56 to produce bitumen as ~
shown at 102. ~-Waste, `or processed feed material, is discharged through line 15 with valve 51 to a mixer/flash tank 38. Fluid bed boiler ash 39 from a fluid bed boiler such as element 92 shown in Figure 7, ~;~
and crushed limestone 40 are fed into the tank 38 through valves 41 and 42. In the tank 38, the pressure is dropped to atmospheric or lower pressure and water vapour .is released from the waste material and ;
extracted through line 43, cond~nser 44 to be produced as water at 45. Partially dewatered engineered fill is produced from the tank 38 through line 49, which may be used as backfill without the use of dykes. i`
Operation of the extractor at a similar high ~ ~-pressure, with steam injection recovers bitumen through the pulsating flow and constant opening of the ~i`
atructure of the fine tailings by the action of the ~
screw and contained steam jets. ~; -~ g ~ ~ ~
Bitumen at low viscosity is obtained as outlined in previous examples. This bitumen will contain more fines than that produced from tar sand, and an additional washing stage as outlined in Figure 8 is required if the bitumen is required for further upgrading.
However, a further alternative is to utilize this reclaimed bitumen as fuel for raising steam to operate the process. In this case, the bitumen is burned to produce steam.
The mature fine tailings can be utilized as feedatock for mineral abstraction, or manufactured into a geotechnically stable mass through a mixture of sand, fluid bed boiler ash, lime, crushed limestone and similar materials prior to being replaced in the tailings ponds or other disposal area.
Bitumen quality can be improved through the injection of these materials such as sand, fluid bed boiler ash, crushed limestone into the extractor against the stainer plate 34. This provides for additional segregation between the fines and recovered bitumen whilst at the same time creating a stable material which can be backfilled without the requirement for dyke containment.
The extractant used in the above examples is a mixture of steam and water. In these examples, the extractant prov`ides the functions of delivering heat to raise the temperature to the operating condition, where bitumen viscosity drops significantly from its value at the feed location. Additionally, the extractant assists in sweeping the bitumen away from its contained position within the tar sand mass.
Under these circumstances, the extractant does not dissolve the bitumen but assists the ~. .
O ~ r~ 1~
O ~ ~ V
extractor to perform a physical separation or displacement process, based on achieving different physical properties, notably viscosity and density, than those utilized in existing technology.
The counter current extractor can also be utilized with extractants that fulfil the function of a solvent, as well as a heat transfer medium. In this class falls the use of liquid or super critical carbon dioxide. In this case, the carbon dioxide is used to 10 dissolve all or part of the bitumen, and separate it from the tar sand.
The examples cover the injection of sand and other filter aids to improve the separation of fines and bitumen. Operation of the extractor with the 15 in~ection of filter aids constitutes a new process which has been named counter current elution filtration.
The operation of the invention is not exclusively countercurrent, although for oil 20 extraction this is believed advantageous, but may he co-current, in which case the liquids inlet and outlet lines are reversed. Also, intermittent reversal of the screw conveyor, though preferred is not essential in one aspect of the invention. The apparatus and process 25 may be applied to the processing of other feed materials, besides tar sands, for example in food processing. Examples of feed materials include mature fine tailings, oil contaminated soil and minerals.
Feed materials to which the apparatus and process of 30 the invention may be applied have the characteristic of including a valuable component mixed with a larger amount of less valuable component.
Instead of using a valve 50 on the feed material inlet, to ensure that pressure is malntained :
in ~ r ,-V ~ U3 ~
on the extractor, the extractor can be built with a large chimney 68, several tens of meters high as the feed material inlet. The height of the chimney 68 may reach 100 meters to place a pressure head on the extractor in the order of 20 atmospheres. Likewise, the processed raw material outlet 15 of the extractor 10 is replaced with a like chimney 69 of similar height. Evidently, the weight of the chimneys 68 and 69 does not rest on the extractor 10 but is externally supported by means not shown. Other than the chimneys 68 and 69 the extractor of Figure 10 functions in like ~ ~ ;
manner to the extractors shown in Figures 1 - 5O ;~
A person skilled in the art could make immaterial modifications to the invention described and claimed in this patent without departing from the essence of the invention.
''' ' '~' ' :~
' " " ,~','`'.
' ; ' :
:,
Claims (16)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS
FOLLOWS:
1. An extractor for extracting product from a feed material, the extractor comprising:
a pressure tight elongate tubular housing having a pressure tight inlet at or adjacent an inlet and of the housing and a pressure tight outlet at or adjacent the other, outlet end;
means for introducing an extractant into the housing;
the housing including a liquids outlet spaced from the means for introducing an extractant into the housing; and a drive train for causing material to move from the inlet end to the outlet end.
a pressure tight elongate tubular housing having a pressure tight inlet at or adjacent an inlet and of the housing and a pressure tight outlet at or adjacent the other, outlet end;
means for introducing an extractant into the housing;
the housing including a liquids outlet spaced from the means for introducing an extractant into the housing; and a drive train for causing material to move from the inlet end to the outlet end.
2. The extractor of claim 1 in which the drive train includes a helical conveyor extending from the inlet end to the outlet end and a motor operatively connected to the helical conveyor.
3. The extractor of claim 2 further including:
a strainer plate disposed across the housing at the inlet end;
a port in the housing adjacent the strainer plate; and means for injecting inert particulates into the housing through the port adjacent the strainer.
a strainer plate disposed across the housing at the inlet end;
a port in the housing adjacent the strainer plate; and means for injecting inert particulates into the housing through the port adjacent the strainer.
4. The extractor of claim 3 in which the inert particulate is sand.
5. The extractor of claim 2 in which the means for introducing extractant into the housing is at the outlet end, whereby the extractant flows countercurrent to the feed material, and the liquids outlet is at the inlet end of the housing.
6. The extractor of claim 5 (first extractor) in combination with a second extractor constructed in accordance with claim 5, the second extractor having its pressure tight inlet connected to the pressure tight outlet of the first extractor.
7. The extractor of claim 5 (first extractor) in combination with a second extractor constructed in accordance with claim 5, the second extractor having its pressure tight inlet connected to the pressure tight outlet of the first extractor and further in combination with a third extractor, the third extractor having its pressure tight inlet connected to the liquids outlet of the first extractor.
8. The extractor of claim 5 further including means for dewatering solids extracted from the extractor.
9. The extractor of claim 5 further including a liquid phase separator connected to the liquids outlet.
10. The extractor of claim 5 in which the helical conveyor includes extractant injection ports disposed along its length.
11. A method of extracting oil from oil contaminated material comprising the steps of:
injecting the oil contaminated material into a tubular pressure tight housing at an inlet end of the housing;
moving the oil contaminated material through the tubular housing from the inlet end of the housing to an outlet end;
contacting the oil contaminated material with extractant under pressure greater than 1 atmosphere to separate liquid phase material from solid phase; and removing the liquid phase material from the housing at or adjacent the inlet end.
injecting the oil contaminated material into a tubular pressure tight housing at an inlet end of the housing;
moving the oil contaminated material through the tubular housing from the inlet end of the housing to an outlet end;
contacting the oil contaminated material with extractant under pressure greater than 1 atmosphere to separate liquid phase material from solid phase; and removing the liquid phase material from the housing at or adjacent the inlet end.
12. The method of claim 11 in which the extractant is liquid or super critical carbon dioxide.
13. The method of claim 11 further including the step of:
gently agitating the oil sand by moving the oil sand with a reversible screw conveyor.
gently agitating the oil sand by moving the oil sand with a reversible screw conveyor.
14. The method of claim 11 in which the extractor includes a strainer disposed across the inlet end of the housing and the method further includes the step of:
injecting inert particulates into the housing adjacent the strainer.
injecting inert particulates into the housing adjacent the strainer.
15. In a process for the extraction of one material from a feed material, in which the feed material is moved from one inlet end to an outlet end of a housing while being treated with an extractant, the improvement comprising:
straining material at the inlet end with a strainer; and injecting inert particulates into the housing adjacent the strainer.
straining material at the inlet end with a strainer; and injecting inert particulates into the housing adjacent the strainer.
16. In apparatus for the extraction of one material from a feed material, the apparatus including a housing having an inlet end and an outlet end and having means to move the feed material from the inlet end to the outlet end, the improvement comprising:
a strainer disposed across the housing at the inlet end;
a port in the housing adjacent the strainer plate; and means for injecting inert particulates into the housing through the port adjacent the strainer.
a strainer disposed across the housing at the inlet end;
a port in the housing adjacent the strainer plate; and means for injecting inert particulates into the housing through the port adjacent the strainer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2098656 CA2098656A1 (en) | 1993-06-17 | 1993-06-17 | Extractor and process for extracting one material from a multi-phase feed material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2098656 CA2098656A1 (en) | 1993-06-17 | 1993-06-17 | Extractor and process for extracting one material from a multi-phase feed material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2098656A1 true CA2098656A1 (en) | 1994-12-18 |
Family
ID=4151809
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2098656 Abandoned CA2098656A1 (en) | 1993-06-17 | 1993-06-17 | Extractor and process for extracting one material from a multi-phase feed material |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2098656A1 (en) |
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8147682B2 (en) | 2006-10-31 | 2012-04-03 | Syncrude Canada Ltd. | Bitumen and thermal recovery from oil sand tailings |
| US9207019B2 (en) | 2011-04-15 | 2015-12-08 | Fort Hills Energy L.P. | Heat recovery for bitumen froth treatment plant integration with sealed closed-loop cooling circuit |
| US9546323B2 (en) | 2011-01-27 | 2017-01-17 | Fort Hills Energy L.P. | Process for integration of paraffinic froth treatment hub and a bitumen ore mining and extraction facility |
| US9587176B2 (en) | 2011-02-25 | 2017-03-07 | Fort Hills Energy L.P. | Process for treating high paraffin diluted bitumen |
| US9676684B2 (en) | 2011-03-01 | 2017-06-13 | Fort Hills Energy L.P. | Process and unit for solvent recovery from solvent diluted tailings derived from bitumen froth treatment |
| US9791170B2 (en) | 2011-03-22 | 2017-10-17 | Fort Hills Energy L.P. | Process for direct steam injection heating of oil sands slurry streams such as bitumen froth |
| US10041005B2 (en) | 2011-03-04 | 2018-08-07 | Fort Hills Energy L.P. | Process and system for solvent addition to bitumen froth |
| US10226717B2 (en) | 2011-04-28 | 2019-03-12 | Fort Hills Energy L.P. | Method of recovering solvent from tailings by flashing under choked flow conditions |
| US11261383B2 (en) | 2011-05-18 | 2022-03-01 | Fort Hills Energy L.P. | Enhanced temperature control of bitumen froth treatment process |
-
1993
- 1993-06-17 CA CA 2098656 patent/CA2098656A1/en not_active Abandoned
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8147682B2 (en) | 2006-10-31 | 2012-04-03 | Syncrude Canada Ltd. | Bitumen and thermal recovery from oil sand tailings |
| US9546323B2 (en) | 2011-01-27 | 2017-01-17 | Fort Hills Energy L.P. | Process for integration of paraffinic froth treatment hub and a bitumen ore mining and extraction facility |
| US9587176B2 (en) | 2011-02-25 | 2017-03-07 | Fort Hills Energy L.P. | Process for treating high paraffin diluted bitumen |
| US10125325B2 (en) | 2011-02-25 | 2018-11-13 | Fort Hills Energy L.P. | Process for treating high paraffin diluted bitumen |
| US9676684B2 (en) | 2011-03-01 | 2017-06-13 | Fort Hills Energy L.P. | Process and unit for solvent recovery from solvent diluted tailings derived from bitumen froth treatment |
| US10041005B2 (en) | 2011-03-04 | 2018-08-07 | Fort Hills Energy L.P. | Process and system for solvent addition to bitumen froth |
| US10988695B2 (en) | 2011-03-04 | 2021-04-27 | Fort Hills Energy L.P. | Process and system for solvent addition to bitumen froth |
| US9791170B2 (en) | 2011-03-22 | 2017-10-17 | Fort Hills Energy L.P. | Process for direct steam injection heating of oil sands slurry streams such as bitumen froth |
| US9207019B2 (en) | 2011-04-15 | 2015-12-08 | Fort Hills Energy L.P. | Heat recovery for bitumen froth treatment plant integration with sealed closed-loop cooling circuit |
| US10226717B2 (en) | 2011-04-28 | 2019-03-12 | Fort Hills Energy L.P. | Method of recovering solvent from tailings by flashing under choked flow conditions |
| US11261383B2 (en) | 2011-05-18 | 2022-03-01 | Fort Hills Energy L.P. | Enhanced temperature control of bitumen froth treatment process |
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