CA2235938C - Apparatus for preparing a pumpable oil sand and water slurry - Google Patents

Apparatus for preparing a pumpable oil sand and water slurry Download PDF

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Publication number
CA2235938C
CA2235938C CA002235938A CA2235938A CA2235938C CA 2235938 C CA2235938 C CA 2235938C CA 002235938 A CA002235938 A CA 002235938A CA 2235938 A CA2235938 A CA 2235938A CA 2235938 C CA2235938 C CA 2235938C
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CA
Canada
Prior art keywords
slurry
vessel
oil sand
lumps
wall
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA002235938A
Other languages
French (fr)
Other versions
CA2235938A1 (en
Inventor
Real Joseph Honorius Doucet
Brian Wilbert Raymond
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Suncor Energy Inc
Canadian Natural Upgrading Ltd
Original Assignee
Suncor Inc
Shell Canada Ltd
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 Suncor Inc, Shell Canada Ltd filed Critical Suncor Inc
Priority to CA002235938A priority Critical patent/CA2235938C/en
Publication of CA2235938A1 publication Critical patent/CA2235938A1/en
Application granted granted Critical
Publication of CA2235938C publication Critical patent/CA2235938C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00Liquid carbonaceous fuels
    • C10L1/32Liquid carbonaceous fuels consisting of coal-oil suspensions or aqueous emulsions or oil emulsions
    • C10L1/328Oil emulsions containing water or any other hydrophilic phase
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01FMIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/50Mixing liquids with solids
    • B01F23/53Mixing liquids with solids using driven stirrers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B02CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02CCRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C17/00Disintegrating by tumbling mills, i.e. mills having a container charged with the material to be disintegrated with or without special disintegrating members such as pebbles or balls
    • B02C17/02Disintegrating by tumbling mills, i.e. mills having a container charged with the material to be disintegrated with or without special disintegrating members such as pebbles or balls with perforated container
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B03SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03BSEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
    • B03B9/00General arrangement of separating plant, e.g. flow sheets
    • B03B9/02General arrangement of separating plant, e.g. flow sheets specially adapted for oil-sand, oil-chalk, oil-shales, ozokerite, bitumen, or the like
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B07SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07BSEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B1/00Sieving, screening, sifting, or sorting solid materials using networks, gratings, grids, or the like
    • B07B1/18Drum screens
    • B07B1/22Revolving drums
    • B07B1/24Revolving drums with fixed or moving interior agitators

Abstract

An apparatus for preparing a pumpable oil sand and water slurry comprises a rotatable vessel having a perforated tubular wall in which vessel the slurry is crushed and mixed and slurry comprising lumps smaller than a predetermined size falls through the perforated wall into e.g. a slurry pump box, whereas oversized lumps are transported via an open end of the tubular towards an oversize reject facility.

Description

APPARATUS FOR PREPARING A PUMPABLE OiL SAND AND WATER
SLURRY
The invention relates to an apparatus far preparing a pumpable oil sand and water slurry.
Preparation of such a slurry from mined oil sand is often necessary in order to enable transportation of the oil sand and water slurry through a pipeline in a scheme where the slurry is conditioned and separated into its respective components, namely bitumen, entrained water and solids including coarse sand and fine tails.
In a conventional oil sand mining operation, the oil 1C sand bearing material is strip mined using bucket wheels, draglines or earth moving shovels and conveyed to an extraction plant on conveyor belts or trucks. The mined material usually contains clumps of sand which generally have less hardness or a work index typically less than 11 and harder material such as shales, sandstones and rock having a work index typically over 14. Hydrocarbons are typically bound up with the sand and nc>t with the harder material. The mined material is crushed and sized so that the largest lumps of harder material are rejected. The remaining material is mixed with water and conditioned, generating a bitumen froth from which the bitumen can be extracted.
Conventionally, the mixing with the water and conditioning has taken place in a conditioning drum to which the feed has been sized to no greater than around six inches in diameter. Alternately, as described in Canadian patent number 2,000,984 and U:> patent number 5,264,118 the oil sand may be mixed with water in a mixer circuit comprising a cylindrical chamber of a 3C1 vertically oriented, open topped mixer vessel, to produce a slurry suitable for conditioning in a pipeline
- 2 -conveying the slurry to an extraction plant. In this case the feed needs to be sized to reduce lumps to less than about one-third of the internal diameter of the pipeline.
The performance'of whatever conditioning means is selected :is normally influenced by the characteristics imparted to the slurry during its preparation. Examples of slurry characteristics that impact subsequent conditioning include lump size, slurry density, amount of mechanical energy imparted to the slurry, amount of thermal energy imparted to the slurry and the addition of chemicals.
It is therefore an object of the present invention to provide an apparatus for preparing a pumpable oil sand and water slurry in which rejection of harder material can be selectively controlled, as can the size of any lumps of oil sand and such that an efficient removal of any oversized lumps takes place.
It is also an object of the present invention to provide an apparatus that will selectively break clumps of oil sand in which hydrocarbons are present and reject harder material in which hydrocarbons are absent.
It is also an object of the present invention to provide an apparatus for preparing a pumpable oil sand and water slurry which can be manufactured cheaply and which can be operated with a minimal requirement for maintenance, cleaning and/or repair.
The invention provides an apparatus for preparing a pumpable oil sand and water slurry, comprising inlet means for oil sand and water, means for crushing oil sand lumps and means for separating a slurry containing oil sand lumps of which the largest lumps are no greater than a predetermined size from oversized lumps, wherein the said
- 3 -crushing and separation means comprise a rotatable vessel having a substantially tubular perforated wall, and means for rotating said vessel about an axis that is at least partially horizontal in orientation such that slurry therein is sequentially lifted and induced to tumble back towards a lower portion of the vessel whereby lumps of oil sand are crushed and mixed with water, slurry comprising lumps smaller than said predetermined size being pressed through the perforated wall and wherein said inlet means are located near one end of said tubular wall and an outlet for oversized lumps is located at an opposite end of said tubular wall.
Optionally the tubular wall of the vessel has a substantially tubular, prismatic or frusto-conical shape.
Preferably the axis of rotation is substantially horizontal. Optionally the axis of rotation has a slight downward inclination in the direction from the inlet means towards the outlet in such a way that the slurry gradually moves towards the outlet.
It is also preferred that lifting bars or triangular plows are secured to the tubular wall such that the bars or plows are oriented and adjacent to the inner surface of said wall. Suitably the lifting bars or plows are oriented in a substantially axial orientation or may be tilted or have a substantially helical shape and the orientation of the helix is such that when the vessel is rotated said bars move the oil sand and water slurry towards the outlet..
Optionally wherein a slurry pump box is arranged underneath the bottom of the perforated tubular wall of the vessel and a slurry conduit is provided through which slurry - 3a -can be pumped from said box into an agitated slurry storage tank, which tank is equipped with a slurry recirculation conduit through which slurry can be recirculated to the inlet means.
It is observed that it is known in the art of coal mining and handling to use cylindrical rotary breakers with a perforated tubular wall to crush coal particles and separate fine from coarse coal particles. The use of such rotary coal breakers is described in the book Coai in Canada, Edited by T.H. Patching, special Volume 31, pages 238 and 239. The known rotary coal breakers,
- 4 -however, do not comprise water inlet means and are not used to prepare a pumpable slurry as is the case with the apparatus according to the invention.
In order to facilitate an optimum flow of slurry through the perforations in the tubular wall of the apparatus according to the invention it is preferred that the perforations in said wall have an average width which is between 5 and 10 cm. The holes located nearer to the inlet means can be spaced further apart. than those 1C) located nearer to the outlet means for oversized lumps to in order to encourage slurry preparation when the oil sand and water first enter the vessel.
The density of the slurry being prepared can be controlled via the ratio of oil sand to water entering 15 the vessel.
The amount of mechanical energy imparted to the slurry can be controlled via the speed of rotation of the vessel and residence time of the contents, which is impacted by hole spacing and the rate at which the oil 20 sand and water proceed toward the exit. The preferred speed of rotation is between 40o and 650 of critical speed. When used in this specification the term critical speed refers to the speed at which centrifugal forces exerted to the slurry in the vessel are about equal to 25 gravity forces and the slurry thus stops tumbling through the vessel.
The amount of thermal energy imparted to the slurry can be controlled via the water temperature in order to minimize the risk of plugging. It is preferred that said 3C1 perforated wall has substantially open ends which provide the inlet means for oil sand and water and the outlet for oversized lumps.
These and other features, objects, aspects and advantages of the apparatus according t:o the invention 35 are disclosed in the accompanying claims, abstract and drawings. In the drawings:
- 5 -Fig. 1 depicts a schematic view of a rotary oil sand lump breaking apparatus according to the invention and Fig. 2 depicts an oil sand processing scheme in which use is made of rotary oil sand lump breaking apparatus _'i according to the invention.
Referring now to Fig. 1 there is shown an oil sand and water slurry preparation apparatus according to the invention.
The apparatus comprises a rotary drum 1 having perforations 2 in its tubular side wall and having substantially open front ends. The right hand front end comprises inlet means 3 which include t:he end of a conveyor belt 4 on which oil sand is fed into the drum l, a water inlet nozzle 5 and an oil sand and water recycling conduit 6. The left hand front end of the drum 1 forms the outlet 7 for oversized lumps and rocks.
The perforations 2 are circular and have a diameter which is between 5 and 10 cm so that only oil sand lumps of a smaller size which a pumpable as a slurry can fall through the perforations into a hopper 8 and pump box 9 from where the thus prepared pumpable slurry is pumped via a slurry conduit 10 into a slurry storage tank 11 in which mixing impeller 12 are present to agitate the slurry and to further break any lumps.
At least part of the thus created ~>lurry may be pumped from the storage tank 11 into conduit 13 for further processing and another part of the slurry may be recycled into the drum 1 via the recycling conduit 6.
The schematic drawing does not show that a series of lifting bars are welded, bolted or otherwise secured to the inner wall of the drum 1. These lifting bars have a substantially longitudinal orientation or may have a slightly helical orientation to assist the slurry to move gradually towards the outlet 7.
When the drum 1 rotates in use about its longitudinal axis the lifting bars assist in sequentially lifting the
- 6 -slurry and inducing the slurry to tumble back towards the bottom of the drum 1 thereby breaking oil sand lumps and squeezing slurry including small size lumps through the perforations 2. The drum 1 thus provides an efficient apparatus for preparing a pumpable slurry and for removing any oversize lumps and rocks from the slurry with a minimum risk of plugging of the apparatus and slurry conduits.
Fig. 2 shows a schematic oil sand processing scheme in which use is made of a rotary slurry preparation drum 20 according to the invention.
In this processing scheme oil sand is first collected from an oil sand feed 21 and crushed in a conventional crusher 22 and transported via a conveyor belt to the I5 drum 20 as illustrated by arrow 23. Warm water is mixed with the oil sand at the inlet 24 of the drum 20 as illustrated by arrow 25.
The drum 20 rotates ablaut a substantially horizontal axis of rotation and lifting bars (not shown) assist in crushing of the lumps and inducing slurry and small sized lumps to be squeezed through the perforations 26 whereas oversize lumps and rocks will exit the drum via the downstream end 27 of the drum 20 and are collected by a truck 28.
The slurry that is squ~=_ezed through the perforations 26 is collected in a slurry pump box 29 and subsequently pumped into a slurry conditioning tank 30 in which the slurry is recycled or otherwise agitated to further condition the slurry before pumping a substantially homogeneous slurry containing finely dispersed oil sand into primary and secondary flotation tanks 31 and 32, respectively in which a bitumen froth is skimmed from the slurry and fed into a froth storage tank 33. Tailings are removed from the bottom of the secondary flotation tank 32 and fed to a tailings storage pond 34.

It will be understood that the foregoing detailed description with reference to the drawings is illustrative only and should not be construed as a limitation to the claims.

Claims (12)

CLAIMS:
1. An apparatus for preparing a pumpable oil sand and water slurry, comprising inlet means for oil sand and water, means for crushing oil sand lumps and means for separating a slurry containing oil sand lumps of which the largest lumps are no greater than a predetermined size from oversized lumps, wherein the said crushing and separation means comprise a rotatable vessel having a substantially tubular perforated wall, and means for rotating said vessel about an axis that is at least partially horizontal in orientation such that slurry therein is sequentially lifted and induced to tumble back towards a lower portion of the vessel whereby lumps of oil sand are crushed and mixed with water, slurry comprising lumps smaller than said predetermined size being pressed through the perforated wall and wherein said inlet means are located near one end of said tubular wall and an outlet for oversized lumps is located at an opposite end of said tubular wall.
2. The apparatus of claim 1 wherein said tubular wall has a substantially cylindrical shape.
3. The apparatus of claim 2 wherein the vessel is rotatable about an axis of rotation which is substantially horizontal.
4. The apparatus of any one of claims 1 to 3 wherein the vessel is rotatable about an axis of rotation which has a downward inclination in the direction from the inlet means towards the outlet.
5. The apparatus of any one of claims 1 to 4 wherein lifting bars or plows are secured to the tubular wall such that the bars are oriented parallel and adjacent to the inner surface of said wall.
6. The apparatus of claim 5 wherein said lifting bars are oriented in substantially lengthwise of the vessel.
7. The apparatus of claim 5 or 6 wherein said lifting bars have a substantially helical shape and the orientation of the helix is such that when the vessel is rotated said bars move the oil sand and water slurry towards the outlet.
8. The apparatus of any one of claims 1 to 4 wherein triangular plows are secured to the inner surface of the tubular wall which plows are tilted downwards such that when the vessel is rotated the plows move the oil sand and water slurry towards the outlet.
9. The apparatus of any one of claims 1 to 8 wherein when in use the rotatable vessel is rotated at a speed of rotation which is between 40% and 65% of the critical speed.
10. The apparatus of any one of claims 1 to 9 wherein said vessel wall has perforations of an average width which is between 5 and 10 cm.
11. The apparatus of any one of claims 1 to 10 wherein a slurry pump box is arranged underneath the bottom of the perforated tubular wall of the vessel and a slurry conduit is provided for delivery of slurry from said box into an agitated slurry storage tank, which tank is equipped with a slurry recirculation conduit for recirculation of slurry to the inlet means.
12. The apparatus of any one of claims 1 to 11 wherein said perforated wall has substantially open ends which ends provide the inlet means and the outlet for oversized lumps.
CA002235938A 1997-04-29 1998-04-27 Apparatus for preparing a pumpable oil sand and water slurry Expired - Lifetime CA2235938C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002235938A CA2235938C (en) 1997-04-29 1998-04-27 Apparatus for preparing a pumpable oil sand and water slurry

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CA2203962 1997-04-29
CA2203962 1997-04-29
CA002235938A CA2235938C (en) 1997-04-29 1998-04-27 Apparatus for preparing a pumpable oil sand and water slurry

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CA2235938C true CA2235938C (en) 2003-04-01

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7677397B2 (en) 2004-07-30 2010-03-16 Suncor Energy Inc. Sizing roller screen ore processing apparatus
US8025341B2 (en) 2005-11-09 2011-09-27 Suncor Energy Inc. Mobile oil sands mining system
US8328126B2 (en) 2008-09-18 2012-12-11 Suncor Energy, Inc. Method and apparatus for processing an ore feed
US8393561B2 (en) 2005-11-09 2013-03-12 Suncor Energy Inc. Method and apparatus for creating a slurry
US9016799B2 (en) 2005-11-09 2015-04-28 Suncor Energy, Inc. Mobile oil sands mining system

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7984866B2 (en) 2005-09-23 2011-07-26 Canadian Oil Sands Limited Partnership Relocatable oil sand slurry preparation system
CA2679908A1 (en) * 2009-09-23 2011-03-23 Shell Internationale Research Maatschappij B.V. Closed loop solvent extraction process for oil sands
CA2759610A1 (en) * 2010-11-29 2012-05-29 Marathon Oil Canada Corporation Methods and apparatus for bitumen extraction
CN114682481B (en) * 2022-04-02 2023-08-25 十堰市郧固建材工贸有限公司 Preparation method of energy-saving heat-preservation high-strength concrete

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7677397B2 (en) 2004-07-30 2010-03-16 Suncor Energy Inc. Sizing roller screen ore processing apparatus
US8136672B2 (en) 2004-07-30 2012-03-20 Suncor Energy, Inc. Sizing roller screen ore processing apparatus
US8851293B2 (en) 2004-07-30 2014-10-07 Suncor Energy, Inc. Sizing roller screen ore processing apparatus
US8025341B2 (en) 2005-11-09 2011-09-27 Suncor Energy Inc. Mobile oil sands mining system
US8393561B2 (en) 2005-11-09 2013-03-12 Suncor Energy Inc. Method and apparatus for creating a slurry
US9016799B2 (en) 2005-11-09 2015-04-28 Suncor Energy, Inc. Mobile oil sands mining system
US8328126B2 (en) 2008-09-18 2012-12-11 Suncor Energy, Inc. Method and apparatus for processing an ore feed
US8622326B2 (en) 2008-09-18 2014-01-07 Suncor Energy, Inc. Method and apparatus for processing an ore feed

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Publication number Publication date
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Effective date: 20180427