WO2014007905A1 - Procédés pour récupérer le pétrole et l'eau à partir des résidus de sables bitumineux - Google Patents

Procédés pour récupérer le pétrole et l'eau à partir des résidus de sables bitumineux Download PDF

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Publication number
WO2014007905A1
WO2014007905A1 PCT/US2013/037279 US2013037279W WO2014007905A1 WO 2014007905 A1 WO2014007905 A1 WO 2014007905A1 US 2013037279 W US2013037279 W US 2013037279W WO 2014007905 A1 WO2014007905 A1 WO 2014007905A1
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WO
WIPO (PCT)
Prior art keywords
tailings
water
oil
filters
drying apparatus
Prior art date
Application number
PCT/US2013/037279
Other languages
English (en)
Inventor
Aronjol David ROSENTHAL
Original Assignee
General Electric Company
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by General Electric Company filed Critical General Electric Company
Publication of WO2014007905A1 publication Critical patent/WO2014007905A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D3/00—Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping
    • B01D3/10—Vacuum distillation
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F9/00—Multistage treatment of water, waste water or sewage
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/04—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by extraction
    • C10G1/045—Separation of insoluble materials
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/24—Treatment of water, waste water, or sewage by flotation
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/40—Devices for separating or removing fatty or oily substances or similar floating material
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/44—Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/13—Treatment of sludge; Devices therefor by de-watering, drying or thickening by heating
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00—Nature of the contaminant
    • C02F2101/30—Organic compounds
    • C02F2101/32—Hydrocarbons, e.g. oil
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/10—Nature of the water, waste water, sewage or sludge to be treated from quarries or from mining activities
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/34—Nature of the water, waste water, sewage or sludge to be treated from industrial activities not provided for in groups C02F2103/12 - C02F2103/32
    • C02F2103/36—Nature of the water, waste water, sewage or sludge to be treated from industrial activities not provided for in groups C02F2103/12 - C02F2103/32 from the manufacture of organic compounds
    • C02F2103/365—Nature of the water, waste water, sewage or sludge to be treated from industrial activities not provided for in groups C02F2103/12 - C02F2103/32 from the manufacture of organic compounds from petrochemical industry (e.g. refineries)

Definitions

  • the subject matter disclosed herein relates to methods for recovering oil and water from oil sands tailings. More specifically, oils sands tailings are sent to a drying apparatus.
  • Oil sands are naturally occurring mixtures of sand, clay, water, and about 10-12 % by weight of oil deposits.
  • the oil may be bituminous petroleum, or in some areas, such as the Orinoco Belt in Venezuela, it may be heavy or extra-heavy crude oil.
  • Aqueous-based methods to extract oil from oil sands include Clark Hot Water Extraction (CHWE) or steam-assisted gravity-drainage (“SAGD").
  • the oil sands are mined from the surface. Hot water at about 50-80 °C is added to the oil sands to form a slurry. The slurry is then transferred to a flotation vessel. The slurry may be agitated or aerated to break-up oil sands agglomerates and encourage frothing. The slurry is then allowed to settle, wherein the solids settle to the bottom and the oil and any entrained air will float to the slurry surface. The bitumen froth is skimmed of the top of the slurry and recovered. The recovered bitumen froth may comprise about 30% water and 10% solids by weight. The CHWE process requires about 7 to 9 barrels of water for every produced barrel of oil.
  • produced water Roughly three barrels of this oily and bituminous containing process water are produced per barrel of recovered oil.
  • the SAGD produced water normally contains about 1-60% solids and has a temperature of about 95 °C.
  • the tailings are mostly water with some oil and a substantial amount of sandy solids.
  • the OSTW are transferred to tailing ponds where sedimentation occurs. Once the OSTW are in the tailings ponds, the sand quickly settles. Fine tailings suspended in the ponds take about two years to settle and form Mature Fine Tails ("MTF"). MTF are about 33 % solids by weight.
  • Oil Sands Tailings Water (contaminated with oil products, Mature Fine Tails, Ultra-Fine Tails and other materials) will be fed into a vacuum drying apparatus (this mixture can include chemistries to properly bind the material prior to drying), the dried material will be released from the apparatus to be sent to a disposal site (land fill, mines, etc.) and the water/oil mixture will be fed into an oil/water separation apparatus.
  • a vacuum drying apparatus this mixture can include chemistries to properly bind the material prior to drying
  • the dried material will be released from the apparatus to be sent to a disposal site (land fill, mines, etc.) and the water/oil mixture will be fed into an oil/water separation apparatus.
  • the oil (separated in the oil/water separation apparatus) will be released to be reclaimed in the Upgrading and/or Extraction facility of the plant (this oil can be mixed with chemistries to aid the reclaiming/upgrading process), the water will be sent to a water clarifying device (Air Flotation, Etc.) to be combined with water chemistries to aid in the clarification of the water.
  • the product/effluent water (from the clarifying device), depending on water quality can be fed into an Ultra Purifying process to allow for quick utilization of the water in the upgrading/extraction/utilities/SAGD portions of the plant.
  • This combined recycling/reclamation process will reclaim the materials in the tailings water; reclaim the tailings water to be recycled (via evaporation and/or clarification and/or ultra- purification) and reclaim the oil in the tailings water to be upgraded at the facility.
  • a method for recovering water and oil from tailings may comprise feeding the tailings to a drying apparatus, wherein the tailings are separated to form a concentrated tailings product and a fluid stream.
  • the fluid stream may be recovered.
  • Suitable drying apparatuses include, but are not limited to, nutsche filters, horizontal plate filters, filter presses, tube filters, bag filters, leaf filters, centrifugal filters, rotary drum filters, disk filters, and cartridge filters.
  • a vacuum may be applied to the drying apparatus.
  • the drying apparatus is mounted on a mobile skid or frame so that it may be moved between tailings ponds and operated at the tailings pond site.
  • the method may comprise using a water separator to separate said fluid stream into an oil stream and an aqueous stream.
  • Suitable water separators include, but are not limited to, gravity separators or parallel plate separators.
  • the aqueous stream may be further processed by sending it to a clarification device.
  • Suitable clarification devices include dissolved gas flotation (DGF) or dissolved air flotation (DAF) devices.
  • DGF dissolved gas flotation
  • DAF dissolved air flotation
  • the clarified aqueous stream may be fed to an ultra water purification process.
  • Suitable ultra water purification processes include, but are not limited to, microfiltration, ultrafiltration, reverse osmosis, and biofiltration.
  • the tailings are tailings from a hydrocarbon extraction or mining process.
  • the tailings may be oil sands tailings.
  • at least a portion of the tailings may be from a tailings pond.
  • the concentrated tailings product may have an average shear strength of equal to or greater than about 10 kPa. Such tailings are suitable as trafficable deposits as required under Directive 074.
  • At least a portion of the recovered fluid stream is reused in said hydrocarbon extraction or mining process.
  • the oil stream separated from the fluid stream may be fed to the oil upgrading section of the extraction process.
  • the oil stream may be used on site to operate the drying apparatus.
  • the aqueous stream may be recycled for reuse in the hydrocarbon extraction or mining process, or upgrading for use as utility water.
  • FIG. 1 shows one embodiment of recovering oil and water from oil sands tailings.
  • FIG. 1 shows one embodiment recovering oil and water from oil sands tailings.
  • the process may be a batch or continuous process and may be automated.
  • Tailings comprising water, fine clays, silts, left-over bitumen, salts and soluble organic and inorganic compounds, and fine or ultra-fine tailings are obtained directly from the oil extraction or mining process or from a tailing pond (2).
  • Tailings from a tailing pond may also comprise mature fine tailings.
  • Mature fine tailings (“MFT") are fluid tailings made from fine tailings that settle over the course of several months or years. The solids-content is about 30 wt% based on a total MTF weight.
  • the tailings (4) are fed to a drying apparatus (6).
  • the solid particles such as sand, silt, clay, mature fine tailings, and fine tailings are dried to form a concentrated tailings product, or cake (8).
  • a suitable drying apparatus is a cake filter.
  • filters are well known in the art and include, but are not limited to, nutsche filters, horizontal plate filters, filter presses, tube or bag filters, leaf filters, centrifugal filters, rotary drum filters, disk filters, and cartridge filters.
  • a vacuum may be applied or maintained using any conventional method, such as steam jets or vacuum pumps.
  • Vacuum drying has the added advantage of lowering the boiling point of water and any solvents or bitumen in the tailings, thereby decreasing the temperature required to produce the cake.
  • the vacuum drying process may occur at elevated temperatures.
  • the concentrated tailings product, or cake may have an average shear strength of greater than 10 kPa, making it suitable for direct disposal (10) under Directive 074.
  • Fluid from the drying apparatus (6) may be sent to an oil/water separator (14).
  • the fluid may be a mixture of oil and water and may be a vapor, a liquid, or a vapor/liquid mixture.
  • Suitable water separators are well known by those of skill in the art and include, but are not limited to, gravity separators and parallel plate separators.
  • Oil from the oil/water separator is reclaimed (16) and sent elsewhere for further processing or use (18).
  • the reclaimed oil (16) may even be suitable to power or heat the dryer apparatus.
  • Water from the oil/water separator (20) is sent to a water-clarifying device (22), such as a dissolved gas flotation (DGF) or dissolved air flotation (DAF). After leaving the water clarifying device (22), the water may be recycled and used as process water (24), for example in cooling towers or boiler systems, or reused in the oil extraction or mining process.
  • DGF dissolved gas flotation
  • DAF dissolved air flotation
  • the water from the water clarifying device is subject to ultra water purification (26), such as, microfiltration, ultrafiltration, reverse osmosis, or biofiltration before it is used as process water (24), or it may be discharged directly to the environment (not shown).
  • ultra water purification such as, microfiltration, ultrafiltration, reverse osmosis, or biofiltration
  • Some recovery processes may add various water treatment chemicals, and process chemicals at various points in the recovery process (FIG. 1). The details of these chemicals and their uses have been omitted for the sake of brevity, but are well known to those of skill in the art. Accordingly, these and other minor differences in recovery processes do not affect the scope of the invention.
  • Oil Sands Tailings Water [about 25,000 gpm (contaminated with oil products, Mature Fine Tails, Ultra-Fine Tails and other materials; about 20-30% solids, 1-3% oil/bitumen & 70-80 % water)] will be fed into a continuous/batch vacuum drying process (this mixture can include chemistries to properly bind the material prior to drying).
  • the vacuum drying process may utilize a filter press.
  • the filter press may be of any design, including, but not limited to, flush-plate, plate and frame, or recessed plate designs.
  • the concentrated tailings product, or cake, (>10 kPa) will be released from the drying apparatus to be sent to a disposal site (land fill, mines, etc.).
  • the water/oil mixture (about 97% water and 3% oil) will be fed into an oil/water separation apparatus.
  • the oil [about 3% of the 25,000 gpm stream (separated in the oil/water separation apparatus)] will be released to be reclaimed in the Upgrading and/or Extraction facility of the plant. This oil may be mixed with chemistries to aid the reclaiming/upgrading process.
  • the water will be sent to a water clarifying device (Air Flotation, Etc.) to be combined with water chemistries to aid in the clarification of the water [Total mg/1 TSS varies on which pond is being recycled].
  • the product/effluent water [Potentially ⁇ 200 mg/1 of TSS (from the clarifying device)], depending on water quality can be fed into an Ultra Purifying process (to reach boiler spec water) to allow for quick utilization of the water in the upgrading/extraction/utilities/SAGD portions of the plant or the product/effluent water (from the water clarifying device) can be used directly in the upgrading/extraction/utilities/SAGD portions of the plant without Ultra Purifying.
  • This combined recycling/reclamation process will reclaim the materials in the tailings water (MFTs, solids, etc.); reclaim the tailings water to be recycled (via evaporation and/or clarification and/or ultra-purification) and reclaim the oil in the tailings water to be upgraded at the facility.
  • This combined recycling/reclamation process will reclaim the contaminated Fines, Mature Fine Tails, Ultra-Fine Tails and other materials in the tailings water ponds; reclaim the tailings water to be recycled (via evaporation and/or clarification and/or ultra-purification) and reclaim the oil in the tailings water fines to be upgraded at the facility. This will insure that the Oil Sands companies are able to reach their Directive 74 and Containment initiatives that have been given to them by the government.
  • Oil Sands Tailings Water (contaminated with oil products, Mature Fine Tails, Ultra-Fine Tails and other materials) will be fed into a vacuum drying apparatus (this mixture can include chemistries to properly bind the material prior to drying), the dried material will be released from the apparatus to be sent to a disposal site (land fill, mines, etc.) and the water/oil mixture will be fed into an oil/water separation apparatus.
  • a vacuum drying apparatus this mixture can include chemistries to properly bind the material prior to drying
  • the dried material will be released from the apparatus to be sent to a disposal site (land fill, mines, etc.) and the water/oil mixture will be fed into an oil/water separation apparatus.
  • the oil (separated in the oil/water separation apparatus) will be released to be reclaimed in the Upgrading and/or Extraction facility of the plant (this oil can be mixed with chemistries to aid the reclaiming/upgrading process), the water will be sent to a water clarifying device (Air Flotation, Etc.) to be combined with water chemistries to aid in the clarification of the water.
  • the product/effluent water (from the clarifying device), depending on water quality can be fed into an Ultra Purifying process to allow for quick utilization of the water in the upgrading/extraction/utilities/SAGD portions of the plant.
  • This combined recycling/reclamation process will reclaim the materials in the tailings water; reclaim the tailings water to be recycled (via evaporation and/or clarification and/or ultra- purification) and reclaim the oil in the tailings water to be upgraded at the facility.
  • a method for recovering water and oil from tailings may comprise feeding the tailings to a drying apparatus, wherein the tailings are separated to form a concentrated tailings product and a fluid stream.
  • the fluid stream may be recovered.
  • Suitable drying apparatuses include, but are not limited to, nutsche filters, horizontal plate filters, filter presses, tube filters, bag filters, leaf filters, centrifugal filters, rotary drum filters, disk filters, and cartridge filters.
  • a vacuum may be applied to the drying apparatus.
  • the drying apparatus is mounted on a mobile skid or frame so that it may be moved between tailings ponds and operated at the tailings pond site.
  • the method may comprise using a water separator to separate said fluid stream into an oil stream and an aqueous stream.
  • Suitable water separators include, but are not limited to, gravity separators or parallel plate separators.
  • the aqueous stream may be further processed by sending it to a clarification device.
  • Suitable clarification devices include dissolved gas flotation (DGF) or dissolved air flotation (DAF) devices.
  • DGF dissolved gas flotation
  • DAF dissolved air flotation
  • the clarified aqueous stream may be fed to an ultra water purification process.
  • Suitable ultra water purification processes include, but are not limited to, microfiltration, ultrafiltration, reverse osmosis, and biofiltration.
  • the tailings are tailings from a hydrocarbon extraction or mining process.
  • the tailings may be oil sands tailings.
  • at least a portion of the tailings may be from a tailings pond.
  • the concentrated tailings product may have an average shear strength of equal to or greater than about 10 kPa. Such tailings are suitable as trafficable deposits as required under Directive 074.
  • At least a portion of the recovered fluid stream is reused in said hydrocarbon extraction or mining process.
  • the oil stream separated from the fluid stream may be fed to the oil upgrading section of the extraction process.
  • the oil stream may be used on site to operate the drying apparatus.
  • the aqueous stream may be recycled for reuse in the hydrocarbon extraction or mining process, or upgrading for use as utility water.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Wood Science & Technology (AREA)
  • General Chemical & Material Sciences (AREA)
  • Hydrology & Water Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Water Supply & Treatment (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

Procédés permettant de récupérer de l'eau et du pétrole à partir de résidus, les résidus alimentant un appareil de séchage pour permettre la séparation des résidus et la formation d'un produit concentré à base de résidus et d'un courant de fluide.
PCT/US2013/037279 2012-07-05 2013-04-19 Procédés pour récupérer le pétrole et l'eau à partir des résidus de sables bitumineux WO2014007905A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261668081P 2012-07-05 2012-07-05
US61/668,081 2012-07-05

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WO2014007905A1 true WO2014007905A1 (fr) 2014-01-09

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109020118A (zh) * 2018-08-30 2018-12-18 中国石油天然气集团有限公司 高含砂高粘含油污泥预处理方法及预处理系统

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5143598A (en) * 1983-10-31 1992-09-01 Amoco Corporation Methods of tar sand bitumen recovery
US20070272596A1 (en) * 2006-05-25 2007-11-29 Titanium Corporation Inc. Process for recovering heavy minerals from oil sand tailings
US20100282593A1 (en) * 2007-11-02 2010-11-11 Speirs Brian C Recovery of high water from produced water arising from a thermal hydrocarbon recovery operation using vaccum technologies
US20110036272A1 (en) * 2009-08-17 2011-02-17 Payman Esmaeili System and Method For Treating Tailings From Bitumen Extraction
US20110061610A1 (en) * 2009-09-16 2011-03-17 Speirs Brian C Heat and Water Recovery From Oil Sands Waste Streams

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5143598A (en) * 1983-10-31 1992-09-01 Amoco Corporation Methods of tar sand bitumen recovery
US20070272596A1 (en) * 2006-05-25 2007-11-29 Titanium Corporation Inc. Process for recovering heavy minerals from oil sand tailings
US20100282593A1 (en) * 2007-11-02 2010-11-11 Speirs Brian C Recovery of high water from produced water arising from a thermal hydrocarbon recovery operation using vaccum technologies
US20110036272A1 (en) * 2009-08-17 2011-02-17 Payman Esmaeili System and Method For Treating Tailings From Bitumen Extraction
US20110061610A1 (en) * 2009-09-16 2011-03-17 Speirs Brian C Heat and Water Recovery From Oil Sands Waste Streams

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
"Directive 074: Tailings Performance Criteria and Requirements for Oil Sands Mining Schemes", 3 February 2009 (2009-02-03), XP055067392, Retrieved from the Internet <URL:http://www.aer.ca/documents/directives/Directive074.pdf> [retrieved on 20130619] *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109020118A (zh) * 2018-08-30 2018-12-18 中国石油天然气集团有限公司 高含砂高粘含油污泥预处理方法及预处理系统
CN109020118B (zh) * 2018-08-30 2022-01-18 中国石油天然气集团有限公司 高含砂高粘含油污泥预处理方法及预处理系统

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