CA2665579A1 - Separating compositions and methods of use - Google Patents
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- CA2665579A1 CA2665579A1 CA002665579A CA2665579A CA2665579A1 CA 2665579 A1 CA2665579 A1 CA 2665579A1 CA 002665579 A CA002665579 A CA 002665579A CA 2665579 A CA2665579 A CA 2665579A CA 2665579 A1 CA2665579 A1 CA 2665579A1
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- separating composition
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- 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
- C10G1/047—Hot water or cold water extraction processes
Abstract
Compositions and methods are provided for separating bitumen from oil sands in an efficient and env.pi.onmentally acceptable manner, and for recoveiing iesidual bitumen from existing tailings ponds.
Description
U.S. Patent Application Attorney Docket Na.: 29790-2 Title:
SEPARATING COMPOSITIONS AND METHODS OF USE
Inventors:
Robert C. Yeggy 7311 Kingswood Dr'ive West Chester, Ohio 45069 Citizenship: USA
Vito J. Attavilla 2183 Springer- Avenue Cincinnati, Ohio 45208 Citizenship: USA
PREPAItE-D BY: BENBSCI-f FItILDLANDEEt COPLAN & ARONOFF
LLP
SUtTE 2300 200 PC3BL.tc SQUARE
Ct.-rva.AND, OHr0 44114-2378 SEPARATING COMPOSITIONS AND METHODS OF USE
Related U.S. Application Data [0001] This application claims the benefit of priority from U.S. Provisional Application No, 60/828,501 filed on October 6, 2006. The entire disclosure of the earlier application is hereby incorporated by reference, Background [00021 Oil sands, also known as "tar sands" and "bituminous sands," are a mixture of bitumen (tar), sand, and water.. Bitumen is a heavy, viscous crude oil, having r elativel,y high sulfur content. When pr'operly separated from the oil sands, bitumen may be processed to synthetic crude oil suitable for use as a feedstock for the pr'oduction of liquid motor fuels, lleating oil, and petrochemicals. Oil sand fields exist throughout most of'tlie world, Particularly significant deposits exist in Canada, including the Athabasca oil sands in Alberta, the United States, including the Utah oil sands, South America, including the Orinoco oil sands in Venezuela, and Africa, including the Nigerian oil sands, A majority of all of the known oil in the world is contained in oil sands.
SEPARATING COMPOSITIONS AND METHODS OF USE
Inventors:
Robert C. Yeggy 7311 Kingswood Dr'ive West Chester, Ohio 45069 Citizenship: USA
Vito J. Attavilla 2183 Springer- Avenue Cincinnati, Ohio 45208 Citizenship: USA
PREPAItE-D BY: BENBSCI-f FItILDLANDEEt COPLAN & ARONOFF
LLP
SUtTE 2300 200 PC3BL.tc SQUARE
Ct.-rva.AND, OHr0 44114-2378 SEPARATING COMPOSITIONS AND METHODS OF USE
Related U.S. Application Data [0001] This application claims the benefit of priority from U.S. Provisional Application No, 60/828,501 filed on October 6, 2006. The entire disclosure of the earlier application is hereby incorporated by reference, Background [00021 Oil sands, also known as "tar sands" and "bituminous sands," are a mixture of bitumen (tar), sand, and water.. Bitumen is a heavy, viscous crude oil, having r elativel,y high sulfur content. When pr'operly separated from the oil sands, bitumen may be processed to synthetic crude oil suitable for use as a feedstock for the pr'oduction of liquid motor fuels, lleating oil, and petrochemicals. Oil sand fields exist throughout most of'tlie world, Particularly significant deposits exist in Canada, including the Athabasca oil sands in Alberta, the United States, including the Utah oil sands, South America, including the Orinoco oil sands in Venezuela, and Africa, including the Nigerian oil sands, A majority of all of the known oil in the world is contained in oil sands.
[0003] Bitumen is very difficult to separate from oil sands in an efficient and environmentally acceptable manner. Current efforts to separate bitumen from oil sands typically yield only about 85-92% of the available bitumen. Moreover, current efforts to separate bitumen from oil sands include the creation of' emrtlsions, or "froth,,, during processing, recluiring tlle use of environmentally harmful organic solvents such as naphtha to "crack" the emulsions and allow for ftrrtller processing. In addition, the bitumen that remains in the sand (and other particulate matter, sucli as clay) component of the oil sands contributes to the creation of a heavy sludge, often referred to as "tailings." Current practice for the disposal of the tailings, which are comprised of urrrecovered bitumen, sand (and other particulate matter), and water is to pump the tailings into huge tailings ponds, where the sand and other particulate matter slowly settle and stratify over the course of several ,years, Summary [0004] The present exemplary embodiments describe compositions and methods for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing tailings ponds.
[0005) According to one aspect of the present embodiments, a composition is provided, comprising a separating composition comprising a wetting agent in the amount of from about 0,001 % to about 2.5 /Q by weight of the separating composition, a hydrotropic agent, and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7,5.
100061 According to another aspect of the present embodiments, a separating composition is provided, comprising from about 0.001% to about 2-5% by weight of a wetting agent; from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0,25%
to about 4.5% by weight of a dispersant having flocculating characteristics.
[0007] According to another aspect of the present embodiments, a separating composition for separating bitumen from oil sands or tailings is provided, comprising from about 0.001 /a to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1 % to about 4.0% by weight of an aromatic phosphate ester having the formula:
o n P03K2 wherein R' is a Ci-C5 linear or branched alkyl group and n= 1 to 8; from about 0,001% to about 4,5 /n by weight of sodium pyrophosphate; from about 0,001% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2% to about 95% by weight of sodium hydroxide;
and from about 1.7% to about 8.6% by weight of phosphoric acid, wherein the separating composition has a pH of from about 7.0 to about 8.5.
[0008] According to another aspect of the present embodiments, a method for separating bitumen from oil sands is provided, comprising contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with oil sands comprising bitumen and sand; heating the separating composition and the oil sands; agitating the separating composition and the oil sands; and recovering the bitumen and sand as separate products.
100091 According to another aspect of the present embodiments, a method for separating bitumen from tailings is provided, comprising contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with tailings comprising bitumen and sand; heating the separating composition and the tailings; agitating the separating composition and the tailings; and recovering the bitumen and sand as separate products.
Detailed Description [00101 As used herein, the term "about" means "apprnximately," and, in any event, may indicate as much as a 10% deviation from the number being modified.
[0011] As used herein, "essentially free" means an amount less than about 0.1%.
[00121 In one embodiment, a composition is provided, comprising a separating composition cornprising a wetting agent in the amount of from about 0.001 % to about 2.5% by weight of the separating composition, a hydrotropic agent, and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7.5.
[00131 Suitable wettirig agents may include, for example, one or more of DYNOLxm 607 Surfactant (Air Products and Chemicals, Inc.), SURFYNOLO 420 (Air Products and Chemicals, Inc.), SURFYNOLO 440 (Air Products and Chemicals, Inc.), SURI~'YNOLO
465 (Air Products and Chemicals, Inc.), SURFYNOLO 485 (Air Products and Chemicals, Inc.), DYNOLxm 604 Srrrfactant (Air Products and Chemicals, Inc.), TOMADOL 91-1.5 (Tornall Products, Inc.), TOMADOLO 91-6 (Tomah Products, Inc.), TOMADOLO 91-8 (Tomah Products, Inc), TOMADOL 1--.3 (Tomah Products, Inc.), TOMADOLO 1-5 (Tomah Products, Inc.), TOMADOLO 1-7 (Tomah Products, Inc.), TOMADOLO 1-73B (Tomah Products, Inc.), TOMADOLO 1-9 (Tomah Products, Inc.), TOMADOLO 2.3-1 (Tomah Products, Inc.), TOMADOLO 2.3-.3 (Tomah Products, Inc.), TOMADOLO 23-5 (Tomah Products, Inc.), TOMADOLO 23-6.5 (Tornah Products, Inc.), TOMADOLO 25-3 (Tomah Products, Inc.), TOMADOL 1z 25-7 (Tomah Products, Inc.), TOMADOLO 25-9 (Tomah Products, Inc.), TOMADOLO 25-12 (Tomah Products, Inc.), TOMADOLO 45-7 (Tomah Products, Inc.), TOMADOLO 45-1.3 (Tomah Products, Inc.), TRITONrM X-207 Surfactant (Dow Chemical Company), TRITONTM CA Surfactant (Dow Chemical Company), NOVECTM
Fluorosurfactant FC-4434 (3M Company), POLYFOX-IM AT-l I18B (Omnova Solutions, Inc.), ZONYLO
(Dupont), ZONYLO 225 (Dupont), ZONYLO 321 (Dupont), ZONYLO 8740 (Dupont), ZONYLO 8834L (Dupont), ZONYLO 8857A (Dupont), ZONYLO 8952 (Dupont), ZONYLO
9027 (Dupont), ZONYL 9.338 (Dupont), ZONYLO 9360 (Dupont), ZONYLO 9361 (Dupont), ZONYLO 9582 (Dupont), ZONYLO 9671 (Dupont), ZONYLO FS-300 (Dupont), ZONYLO
FS-500 (Dupoi-kt), ZONYLO FS-610 (Dupont), ZONYLO 1033D (Dupont), ZONYL FSE
(DuPont), ZONYLO FSK (DuPont), ZONYLO FSH (DuPont), ZONYL Et FSJ (DuPont), ZONYLO FSA (DuPont), ZONYLO FSN-100 (DuPont), LUTENSOLO OP .30-70% (BASF), LUTENSOL A 12 N (BASF), LUTENSOL A 3 N(BASF), LUTENSOLO A&5 N(BASF), LIJTENSOLO A 9 N(BASF), LUTENSOLO AO 3 (BASF), LUTENSOLO AO 4 (BASF), LUTENSOL Ct AO 8 (BASF), LUTENSOLO AT 25 (BASF), LUTENSOL 1z AT 55 PRILL
SURFACTANT (BASF), LUTENSOLO CF 10 90 SURFACTANT (BASF), LUTENSOLO
DNP 10 (BASF), LUTENSOLO NP 4(BASF), LUTENSOLO NP 10 (BASF), LUTENSOLO
NP-100 PASTILLE (BASF), LUTENSOL NP-6 (BASF), LUTENSOLO NP-70-70% (BASF), LUTENSOLO NP-5O (BASF), LUTENSOLO NP 9 (BASF), LUTENSOLO ON 40 SURFACTANT (BASF), LUTENSOLOO ON 60 (BASF), LUTENSOLO OP-10 (BASF), LUTENSOLO TDA 10 SiJRFACTANT (BASF), LUTENSOLO TDA :3 SURFACTANT
(BASF), LUTENSOLO TDA 6 SURFACTANT (BASF), LUTENSOLO TDA 9 SURFACTANT (BASF), LUTENSOLO XL 69 (BASF), LUTENSOLO XL 100 (BASF), LUTENSOLO XL 140 (BASF), LUTENSOLO XL 40 (BASF), LUTENSOL 42 XL 50 (BASF), LUTENSOLOO XL 60 (BASF), LUTENSOL XL 70 (BASF), LUTENSOL XL 79 (BASF), LUTENSOLO XL 80 (BASF), LUTENSOLO XL 89 (BASF), LUTENSOLO XL 90 (BASF), LUTENSOLO XL 99 (BASF), LUTENSOLO XP 100 (BASF), LUTENSOLO XP 140 (BASF), LUTENSOLO XP 30 (BASF), LUTENSOLO XP 40 (BASF), LUTENSOLO XP 50 (BASF), LUTENSOLO XP 60 (BASF), LiJTENSOLO XP 69 (BASF), LUTENSOLO XP 70 (BASF), LUTENSOLO XP 79 (BASF), LUTENSOLO XP 80 (BASF), LUTENSOLO XP 89 (BASF), LUTENSOL V XP 90 (BASF), LUTENSOLO XP 99 (BASF), MACOLO 16 SURFACTANT
(BASF), MACOL O CSA 20 POLYETHER (BASF), MACOLO LA 12 SURFACTANT
(BASF), MACOLO LA 4 SURFACTANT (BASF), MACOLO LF 110 SURFACTANT
(BASF), MACOL LF 125A SURFACTANT (BASF), MAZONO 1651 SURFACTANT
(BASF), MAZOXO LDA Lauramine OXIDE (BASF), PLURAFAC A08A Surfactant (BASF), PLURAFACO B-26 Surfactant (BASF), PLURAFACO B25-5 Surfactant (BASF), PLURAFACO D25 Surfactant (BASF), PLURAFACO LF 1200 Surfactant (BASF), PLURAFACO LF 2210 Surfactant (BASF), PLURAFAC LF 4030 Sur-factant (BASF), PLURAFAC LF 7000 Surfactant (BASF), PLURAFACO RA-20 Surfactant (BASF), PLURAFACO RA 30 Surfactant (BASF), PLURAFACO RA 40 Surfactant (BASF), PLURAFACO RCS 43 Surfactant (BASF), PLURAFACO RCS 48 Surfactant (BASF), PLURAFACO S205LF Surfactant (BASF), PLURAFACO S305LF Surfactant (BASF), PLURAFACO S505LF Surfactant (BASF), PLURAFACO SL 62 Surfactant (BASF), PLURAF'ACO SL 92 Surfactant (BASF), PLURAFACO SL-22 Surfactant (BASF), PLURAFACO SL-42 Surfactant (BASF), PLURAFACO SLF .37 Surfactant (BASF), PLURAFACO SLF-I8 Surfactant (BASF), PLURAFACO SLF'-18B-45 Surfactant (BASF), PLURAFACO L1220 Surfactant (BASF), PLURONICO 10R5 SURFACTANT (BASF), PLURONICO 17R2 (BASF), PLURONIC 17R4 (BASF), PLURONICOO 25R2 (BASF), PLURONICO 25R4 (BASF), PLURONICO 31RI (BASF), PLUROMCO F108 CAST SOLID
100061 According to another aspect of the present embodiments, a separating composition is provided, comprising from about 0.001% to about 2-5% by weight of a wetting agent; from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0,25%
to about 4.5% by weight of a dispersant having flocculating characteristics.
[0007] According to another aspect of the present embodiments, a separating composition for separating bitumen from oil sands or tailings is provided, comprising from about 0.001 /a to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1 % to about 4.0% by weight of an aromatic phosphate ester having the formula:
o n P03K2 wherein R' is a Ci-C5 linear or branched alkyl group and n= 1 to 8; from about 0,001% to about 4,5 /n by weight of sodium pyrophosphate; from about 0,001% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2% to about 95% by weight of sodium hydroxide;
and from about 1.7% to about 8.6% by weight of phosphoric acid, wherein the separating composition has a pH of from about 7.0 to about 8.5.
[0008] According to another aspect of the present embodiments, a method for separating bitumen from oil sands is provided, comprising contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with oil sands comprising bitumen and sand; heating the separating composition and the oil sands; agitating the separating composition and the oil sands; and recovering the bitumen and sand as separate products.
100091 According to another aspect of the present embodiments, a method for separating bitumen from tailings is provided, comprising contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with tailings comprising bitumen and sand; heating the separating composition and the tailings; agitating the separating composition and the tailings; and recovering the bitumen and sand as separate products.
Detailed Description [00101 As used herein, the term "about" means "apprnximately," and, in any event, may indicate as much as a 10% deviation from the number being modified.
[0011] As used herein, "essentially free" means an amount less than about 0.1%.
[00121 In one embodiment, a composition is provided, comprising a separating composition cornprising a wetting agent in the amount of from about 0.001 % to about 2.5% by weight of the separating composition, a hydrotropic agent, and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7.5.
[00131 Suitable wettirig agents may include, for example, one or more of DYNOLxm 607 Surfactant (Air Products and Chemicals, Inc.), SURFYNOLO 420 (Air Products and Chemicals, Inc.), SURFYNOLO 440 (Air Products and Chemicals, Inc.), SURI~'YNOLO
465 (Air Products and Chemicals, Inc.), SURFYNOLO 485 (Air Products and Chemicals, Inc.), DYNOLxm 604 Srrrfactant (Air Products and Chemicals, Inc.), TOMADOL 91-1.5 (Tornall Products, Inc.), TOMADOLO 91-6 (Tomah Products, Inc.), TOMADOLO 91-8 (Tomah Products, Inc), TOMADOL 1--.3 (Tomah Products, Inc.), TOMADOLO 1-5 (Tomah Products, Inc.), TOMADOLO 1-7 (Tomah Products, Inc.), TOMADOLO 1-73B (Tomah Products, Inc.), TOMADOLO 1-9 (Tomah Products, Inc.), TOMADOLO 2.3-1 (Tomah Products, Inc.), TOMADOLO 2.3-.3 (Tomah Products, Inc.), TOMADOLO 23-5 (Tomah Products, Inc.), TOMADOLO 23-6.5 (Tornah Products, Inc.), TOMADOLO 25-3 (Tomah Products, Inc.), TOMADOL 1z 25-7 (Tomah Products, Inc.), TOMADOLO 25-9 (Tomah Products, Inc.), TOMADOLO 25-12 (Tomah Products, Inc.), TOMADOLO 45-7 (Tomah Products, Inc.), TOMADOLO 45-1.3 (Tomah Products, Inc.), TRITONrM X-207 Surfactant (Dow Chemical Company), TRITONTM CA Surfactant (Dow Chemical Company), NOVECTM
Fluorosurfactant FC-4434 (3M Company), POLYFOX-IM AT-l I18B (Omnova Solutions, Inc.), ZONYLO
(Dupont), ZONYLO 225 (Dupont), ZONYLO 321 (Dupont), ZONYLO 8740 (Dupont), ZONYLO 8834L (Dupont), ZONYLO 8857A (Dupont), ZONYLO 8952 (Dupont), ZONYLO
9027 (Dupont), ZONYL 9.338 (Dupont), ZONYLO 9360 (Dupont), ZONYLO 9361 (Dupont), ZONYLO 9582 (Dupont), ZONYLO 9671 (Dupont), ZONYLO FS-300 (Dupont), ZONYLO
FS-500 (Dupoi-kt), ZONYLO FS-610 (Dupont), ZONYLO 1033D (Dupont), ZONYL FSE
(DuPont), ZONYLO FSK (DuPont), ZONYLO FSH (DuPont), ZONYL Et FSJ (DuPont), ZONYLO FSA (DuPont), ZONYLO FSN-100 (DuPont), LUTENSOLO OP .30-70% (BASF), LUTENSOL A 12 N (BASF), LUTENSOL A 3 N(BASF), LUTENSOLO A&5 N(BASF), LIJTENSOLO A 9 N(BASF), LUTENSOLO AO 3 (BASF), LUTENSOLO AO 4 (BASF), LUTENSOL Ct AO 8 (BASF), LUTENSOLO AT 25 (BASF), LUTENSOL 1z AT 55 PRILL
SURFACTANT (BASF), LUTENSOLO CF 10 90 SURFACTANT (BASF), LUTENSOLO
DNP 10 (BASF), LUTENSOLO NP 4(BASF), LUTENSOLO NP 10 (BASF), LUTENSOLO
NP-100 PASTILLE (BASF), LUTENSOL NP-6 (BASF), LUTENSOLO NP-70-70% (BASF), LUTENSOLO NP-5O (BASF), LUTENSOLO NP 9 (BASF), LUTENSOLO ON 40 SURFACTANT (BASF), LUTENSOLOO ON 60 (BASF), LUTENSOLO OP-10 (BASF), LUTENSOLO TDA 10 SiJRFACTANT (BASF), LUTENSOLO TDA :3 SURFACTANT
(BASF), LUTENSOLO TDA 6 SURFACTANT (BASF), LUTENSOLO TDA 9 SURFACTANT (BASF), LUTENSOLO XL 69 (BASF), LUTENSOLO XL 100 (BASF), LUTENSOLO XL 140 (BASF), LUTENSOLO XL 40 (BASF), LUTENSOL 42 XL 50 (BASF), LUTENSOLOO XL 60 (BASF), LUTENSOL XL 70 (BASF), LUTENSOL XL 79 (BASF), LUTENSOLO XL 80 (BASF), LUTENSOLO XL 89 (BASF), LUTENSOLO XL 90 (BASF), LUTENSOLO XL 99 (BASF), LUTENSOLO XP 100 (BASF), LUTENSOLO XP 140 (BASF), LUTENSOLO XP 30 (BASF), LUTENSOLO XP 40 (BASF), LUTENSOLO XP 50 (BASF), LUTENSOLO XP 60 (BASF), LiJTENSOLO XP 69 (BASF), LUTENSOLO XP 70 (BASF), LUTENSOLO XP 79 (BASF), LUTENSOLO XP 80 (BASF), LUTENSOLO XP 89 (BASF), LUTENSOL V XP 90 (BASF), LUTENSOLO XP 99 (BASF), MACOLO 16 SURFACTANT
(BASF), MACOL O CSA 20 POLYETHER (BASF), MACOLO LA 12 SURFACTANT
(BASF), MACOLO LA 4 SURFACTANT (BASF), MACOLO LF 110 SURFACTANT
(BASF), MACOL LF 125A SURFACTANT (BASF), MAZONO 1651 SURFACTANT
(BASF), MAZOXO LDA Lauramine OXIDE (BASF), PLURAFAC A08A Surfactant (BASF), PLURAFACO B-26 Surfactant (BASF), PLURAFACO B25-5 Surfactant (BASF), PLURAFACO D25 Surfactant (BASF), PLURAFACO LF 1200 Surfactant (BASF), PLURAFACO LF 2210 Surfactant (BASF), PLURAFAC LF 4030 Sur-factant (BASF), PLURAFAC LF 7000 Surfactant (BASF), PLURAFACO RA-20 Surfactant (BASF), PLURAFACO RA 30 Surfactant (BASF), PLURAFACO RA 40 Surfactant (BASF), PLURAFACO RCS 43 Surfactant (BASF), PLURAFACO RCS 48 Surfactant (BASF), PLURAFACO S205LF Surfactant (BASF), PLURAFACO S305LF Surfactant (BASF), PLURAFACO S505LF Surfactant (BASF), PLURAFACO SL 62 Surfactant (BASF), PLURAF'ACO SL 92 Surfactant (BASF), PLURAFACO SL-22 Surfactant (BASF), PLURAFACO SL-42 Surfactant (BASF), PLURAFACO SLF .37 Surfactant (BASF), PLURAFACO SLF-I8 Surfactant (BASF), PLURAFACO SLF'-18B-45 Surfactant (BASF), PLURAFACO L1220 Surfactant (BASF), PLURONICO 10R5 SURFACTANT (BASF), PLURONICO 17R2 (BASF), PLURONIC 17R4 (BASF), PLURONICOO 25R2 (BASF), PLURONICO 25R4 (BASF), PLURONICO 31RI (BASF), PLUROMCO F108 CAST SOLID
SURFACTANT (BASF), PLURONIC Ct F108 NF CAST SOLID SURFACTANT (BASF), PLURONICO F I08 NF PRILL SURFACTANT (BASF), PLURONICO F108 PASTILLE
SURFACTANT (BASF), PLURONICO F127 CAST SOLID SURFACTANT (BASF), PLURONIC rr F127 NF PRILL Surfactant (BASF), PLURONIC FI27NF 500BHT CAST
SOLID SURFACTANT (BASF), PLURONICO F38 CAST SOLID SURFACTANT (BASF), PLURONIC @ PASTILLE (BASF), PLURONIC F68 LF PASTILLE SURFACTANT (BASF), PLURONIC @ F68 CAST SOLID SURFACTANT (BASF), PLUROMCO F77 CAST SOLID
SURFACTANT (BASF), PLURONICO F-77 MICRO PASTILLE SURFACTANT (BASF), PLURONIC F87 CAST SOLID SURFACTANT (BASF), PLURONICO F88 CAST SOLID
SURFACTANT (BASF), PLURONICO F98 CAST SOLID SURFACTANT (BASF), PLURONICO L10 SURFACTANT (BASF), PLURONICO L10I SURFACTANT (BASF), PLURONICO L121 SURFACTANT (BASF), PLURONICO L.31 SURFACTANT (BASF), PLURONIC L92 SURFACTANT (BASF), PLURONIC N-3 SURFACTANT (BASF), PLURONICO P103 SURFACTANT (BASF), PLURONICO P105 SURFACTANT (BASF), PLURONIC P123 SURFACTANT (BASF), PLURONIC P65 SURFACTANT (BASF), PLURONICO P84 SURFACTANT (BASF), PLURONICO P85 SURFACTANT (BASF), TETRONICO 1107 rnicro-PASTILLE SURFACTANT (BASF), TETRONICO 1107 SURFACTANT (BASF), TETRONIC 1301 SURFACTANT (BASF), TETRONICO 1304 SURFACTANT (BASF), TETRONICO 1.307 Surl'actant (BASF), TETRONICO 1307 SURFACTANT PASTILLE (BASF), TETRONICO 150RI SURFACTANT (BASF), TETRONICO 304 SURFACTANT (BASF), TETRONIC O 701 SURFACTANT (BASF), TETRONICOO 901 SURFACTANT (BASF), TETRONICO 904 SURFACTANT (BASF), _8_ TETRONICO 908 CAST SOLID SURFACTANT (BASF), and TETRONICO 908 PASTILLE
SURFACTANT (BASF), and mixtures thereof.
[0014] The wetting agent may include one or more ethoxylated acetylenic alcohols, such as, for example, 2,5,8,11 -tetrameth,yl-6-dodecyn-5,8-diol ethoxylate.
[0015] Suitable hydrotropic agents may include, for example, one or more of TRITONO H-66 (Dow Chemical Company), TRITONO H-55 (Dow Chemical Company), TRITONO QS-44 (Dow Chemical Company), TRITONO XQS-20 (Dow Chemical Company), TRITONO X-15 (Uniorr Carbide Corporation), TRITONO X-35 (Union Carbide Corporation), TRITONO X-45 (Union Carbide Corporation), TRITONO X-1 14 (Union Carbide Corporation), TRITONO X- 100 (Union Carbide Corporation), TRITON X-165 (70%) active (Union Carbide Corporation), TRITONO X-305 (70%) active (Union Carbide Corporation), TRITONOO
(70%) active (Union Carbide Corporation), TRITON BG Nonionic Surfactant (Union Carbide Corporation), TERGITOLO MinFoam IX (Dow Chemical Company), TERGITOLO L-61 (Dow Chemical Company), TERGITOLO L-64 (Dow Chemical Company), TERGITOLO L-81 (Dow Chemical Company), TERGITOLO L-101 (Dow Chemical Company), TERGITOLO NP-4 (Dow Chemical Company), TERGITOLO NP-6 (Dow Chemical Company), TERGITOLO NP-7 (Dow Chemical Company), TERGITOLO NP-8 (Dow Chemical Company), TERGITOLO NP-9 (Dow Cherrr'rcal Company), TERGITOLO NP-I 1(Dow Chemical Company), TERGITOLO
NP-12 (Dow Chemical Company), TERGITOLO NP-13 (Dow Chemical Company), TERGITOLO
NI'-15 (Dow Chemical Company), TERGITOLO NP-30 (Dow Chemical Company), TERGITOLO NP-40 (Dow Chemical Company), SURFYNOLO 420 (Air Products and Chemicals, Inc.), SURFYNOLO 440 (Air Products and Chemicals, Inc.), SURFYNOL O
(Air Products and Chemicals, Inc.), SURFYNOL 485 (Air Products and Chemicals, Inc ), MAPT-IOSQ 58 ESTER (BASF), MAPHOS 60 A Surfactant (BASF), MAPHOSqD 66 H
ESTER (BASF), MAPHOSC.~ 8135 ESTER (BASF), MAPHOS M-60 ESTER (BASF), 6660 K
Hydrotroping Phosphate Ester Salt (Burlington Chemical), Burofac 7580 Aromatic Phospliate Ester (Burlington Chemical), and Burofac 9125 (Burlington Chemical), and mixtures thereof.
[00161 The hydrotropic agent may be one or more aromatic phosphate esters, such as, for example, an aromatic phosphate ester having the formula:
Ri I / C O
rr P03K2 wherein R' is a Cj-C5 linear or branched alkyl group and n= 1 to 8.
[00171 Suitable dispersants having flocculating characteristics may include, for example, one or more of sodium acid pyraphosphate, tetrapotassium pyrophosphate, monosodium phosphate (H6NaO6P), monoammonium phosphate ((NH4)PO4), sodium acid phospliate, trisodium phosphate, sodium tripolyphosphate, sodium trimetaphosphate, sodium laurel phosphate, sodium phosphate, pentapotassium triphosphate, potassium triphosphate, tetraborate potassium tripolyphosphate, potassium phosphate - monobasic, potassium phosphate - dibasic, monopotassium phosphate, and tripotassium phosphate, and mixtures thereof.
100181 The dispersant having flocculating characteristics may include one or more pyrophosphate salts, including, for example, one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.
-IO-(0019] In one embodiment, the hydrotropic agerit may be present in the amount of from about 0.1% to about 4.0% by weight of the separating composition. The dispersant having flocculating characteristics may be present in the amount of from about 0.25 /o to about 4.5% by weight of the separating composition.
[00201 In one embodiment, the separating composition may further comprise a strong base, such as, for example, hydroxides of alkali metals and alkaline earth metals, such as, for example, NaOH, KOH, Ba(OH)2, CsOH, SrOH, Ca(OH)2, LiOH, RbOH, NaH, LDA, and NaNH2. As used lierein, a"str-ong base" is a chemical compound having a pH of greater than about 13, . The strong base may be present in the amount of from about 2% to about 9.5% by weight of the separating composition.
[0021] In one embodiment, the separating composition may further comprise a heavy acid, such as, for example, phosphoric acid, nitric acid, sulfuric acid, hydronic acid, hydrobromic acid, perchloric acid, fluoromatic acid, magic acid (I~'SO3HSbF5), carborane super acid [H(CHBjjCljt)], triflic acid, ethanoic acid, and acetylsalicylic acid, As used herein, a "heavy" acid is an acid having a specific gravity greater than about 1.5. The 1leavy acid may be present in the amount of from about 1.7% to about 8.6% by weight of the separating composition.
[0022] In one embodiment, the pH of the separating composition may be greater than 7.5. The pH of the separating composition may also be from about 7.0 to about $.5. The pH of the separating composition may also be from about 7.6 to about 7. $, - II -[0023[ In another embodiment, the composition may be essentially free of organic solvent. As used herein, the term "organic solvent" refers to solvents that are organic compounds and contain carbon atoms such as, for example, naplltha, [0024] In addition to the separating composition, the composition may also comprise hydrocarbon containing mater'ials, such as oil sands, tailings, and the like. The ratio of the separating composition to the hydrocarbon containing materials may be from about 2:3 to about 3:2, [0025] In yet another embodiment, a separating composition is provided, comprising fiom about 0.001 % to about 2.5% by weight of a wetting agent; from about 0.1 % to about 4.0% by weiglit of a hydrotropic agent; and from about 0,25% to about 4.5% by weight of a dispersant having flocculating cllaracteristics. The separating composition may have a pH of greater than 7,5; from about 7.0 to about 8.5; or from about 7.6 to about 7 8.
The wetting agent may be, for example, 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate. The hydrotropic agent may be, for example, MAPHOSQ 66H aromatic phosphate ester. The dispersant having flocculating characteristics may be, for example, one or more of sodium acid pyrophosphate and tetrapotassiuin pyrophosphate.
[00261 The separating composition may further comprise a strong base, which may be, for example, sodium hydroxide.. The strong base may be present in the amount of from about 2% to about 9,5% by weight of the separating composition. The separating composition may further comprise a heavy acid, which may be, for example, pliosplroric acid.
The heavy acid may be present in the amount of from about 13% to about 8.6% by weight of the separating conlposition. The separating composition may also be essentially free of organic solvent.
[0027] In one embodiment, a separating composition for separating bitumen from oil sands or tailings is provided, comprising from about 0.001% to about 2.5%
by weight of 2,5,8,1 1-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4,0% by weight of' an aromatic phosphate ester having the formula:
ir O
0 n P03Kz wherein R' is a Cj-C5 linear or branched alkyl group and n= I to 8; from about 0% to about 4,5% by weight of sodium pyrophosphate; from about 0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2.0% to about 9.5% by weight of sodium hydroxide;
and from about 1..7 /Q to about 8.6% by weight of phosphoric acid. The separating composition may have a pH of from about 7.0 to about 8.5. The separating composition may also be essentially free of organic solvent, j0028] In one embodiment, a method for separating bitumen from oil sands is provided, comprising contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with oil sands comprising bitumen and sand; heating the separating composition and the oil sands;
agitating the separating composition and the oil sands; arld recovering the bitumen and sand as separate products. The pH of the separating composition may be greater than 7..5; from about 7.0 to about 8.5; or from about 7.6 to about 7.8.
[0029] In one embodiment, the separating composition used in the exemplary method may be comprised of from about 0.001 %, to about 2.5% by weight of a wetting agent;
from about 0.1% to about 4,0% by weight of a hydrotropic agent; and from about 0,.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
j0030] In another embodiment, the separating composition used in the exemplary method may be comprised of from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4.0% by weight of an aromatic phosphate ester having the formula:
Ri ir I ,,, J"-~ o O n P0a K2 wherein R' is a CI-C5 linear or branched alkyl group and n = 1 to 8; from about 0% to about 4 5% by weight of sodium pyrophosphate; from about 0% to about 4,5% by weight of tetr=apotassium pyrophosphate; fram about 2% to about 9.5% by weight of sodium hydroxide;
and from about 1 .7% to about 8.6% by weight of phosphoric acid.
(0031] Witla respect to the process conditions under which the exemplary method may be carried out, the separating composition and the oil sands may be heated to greater than 25 C; ii om about .32 C to about 72 C; or from about 54 C to about 60 C. Any source of heat within the ambit of those skilled in the art may be used. Similarly, any device capable of providing sufficient agitation may be used to agitate the separating composition and the oil sands, including, for example, a high shear mixer, high speed attritor, high speed dispersers, fluidized beds, and the like, or any other device capable of providing sufficient agitation within the ambit of those skilled in the art.
j00321 In one embodiment, the ratio of the separating composition to the oil sands may be from about 2:3 to about 3:2. In another embodiment, the ratio of the separating composition to the oil sands may be about 1:1.
[0033] The recovered bitumen may be essentially emulsion-free. The exemplary method may be performed without the addition of organic solvent.
[0034] In some circumstances, it may prove desirable to subject the separated, recovered bitumen to a second or subsequent aliquot of separating composition.
In such a case, the exemplary method further comprises contacting the separated, recovered bitumen with a second or subsequent aliquot of fresh separating composition; heating the fresh separating composition and the bitumen; agitating the fresh separating composition and the recovered biturnen; and recover-ing the resulting bitumen, Such a "rinse" cycle may be repeated until the bitumen is essentially free of any sand or other particulate matter.
[0035] In another embodiment, the separating composition may be recyclable Thus, the exemplary method further comprises recovering the separating composition; contact'rng the recovered separating composition with a second or subsequent aliquot of oil sands comprising bitumen and sand; heating the recovered separating composition and the second or subsequent aliquot of oil sands; agitating the recovered separating composition and the secoird or sribsecluent aliquot of oil sands; and recovering the bitumen and sand as separate products.
[0036] In another embodiment, a method is disclosed for piocessing existing tailings, both to salvage remaining bitumen and to allow for redeposit of the essentially bitumen-fi=ee sand. The method may comprise contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with tailings comprising bitumen and sand; heating the separating composition and the tailings; agitating the separating composition and the tailings; and recovering the bitumen and sand as separate products. The pH of the separating composition may be greater than 7.5; from about 7.0 to about 8.5; or from about 7.6 to about 7.8.
100371 In one embodiment, the separating composition used in the exemplary method for processing existing tailings may be comprised of from about 0.001 /a to about 2.5%
by weight of a wetting agent; from about 0.1% to about 4.0% by weight of a IZ,ydrotropic agent;
and from about 0.25% to about 4.5 /fl by weight of a dispersant having flocculating characteristics.
[0038] In another embodiment, the separating composition used in the exemplary method for processing existing tailings may be comprised of from about 0,001%
to about 2.5%
by weight of 2,5,8,11 -tetrametliyl-6-dodecyn-5,8-diol ethoxylate; from about 0. I 1o to about 4.0%
by weight of an aromatic phosphate ester having the formula:
RI
O n F'03Kz wherein R' is a Q-C5 linear or branched alkyl group and n= 1 to 8; from about 0% to about 4.5% by weight of' sodium pyrophosphate; from about 0% to about 4.5 /n by weight of' tetrapotassium pyrophosphate; from about 2% to about 9.5% by weight of sodium hydroxide;
and frozn about 1.7% to about 8.6% by weight of phosphoric acid.
[0039J With respect to the process conditions under which the exemplary method foz processing existing tailings may he carried out, the separating composition and the tailings _16_ may be heated to greater than 25 C; from about 32 C to about '12 C; or from about 54 C to about 60 C. Any source of lleat within the ambit of those skilled in the art may be used.
Similarly, any device capable of providing sufficient agitation may be used to agitate the separating composition and the tailings, including, for example, a high shear mixer, high speed attritor, high speed dispersers, fluidized beds, and the like, or any other device capable of providing suff cient agitation within the ambit of those skilled in the art.
100401 In one embodiment, the ratio of the separating composition to the tailings may be from about 2:3 to about 3:2. In another embodiment, ratio of the separating composition to the tailings may be about 1:1.
[0041) The recovered bitumen may be essentially emulsion-free, The exemplary method may be performed without the addition of organic solvent.
[0042] In some circumstances, it may prove desirable to subject the separated, recovered bitumen from the tailings to a second or subsequent aliquot of separating composition.
In such a case, the exemplary method further comprises contacting the separated, recovered bitumen with a second or subsequent aliquot of fresh sepaiating composition;
heating the fresh separating composition and the bitumen; agitating the fresh separating composition and the recovered bitumen; and recovering the resulting bitumen. Such a "rinse" cycle may be repeated until the bitumen is essentially free of any sand or other particulate matter.
[00431 In aiiother embodiment, the separating composition may be rec,yclabEe.
Thus, the exemplary method for processing existing tailings would further comprise recovering the separating composition; contacting the recovered separating composition with a second or subsequent aliquot of tailings comprising bitumen and sand; heating the recovered separating composition and the second or subsequent aliquot of tailings; agitating the recovered separating composition and the second or subsequent aliquot of tailings; and recovering the bitumen and sand as separate products.
[00441 The present embodiments have been described mainly in the context of lab-scale results. However, it should be appreciated that the results described herein are meant to embody the entire process by which oil sands are obtained, the extraction of'bitumen from the oil sands, and the further processing of'the extracted bitumen, By way of example, mining shovels dig oil sand ore and load it into trucks or other transportation means. The trucks take the oil sands to crushers where the oil sands are broken down in size. The broken down oil sands are added to a mixing tank and contacted with the separating composition as described herein., The separated bitumen is augered and pumped to storage, and then fi.rrther refined to produce synthetic crude oil suitable for use as afeedstocle for the production of liquid motor fuels, heating oil, and petrochemicals, 100451 The following examples are provided to illustrate various embodiments and shall not be considered as limiting in scope.
(00461 EXAMPLE 1- Separation of Bitumen frorn Athabasca Oil Sands [00471 300 g of the following separating composition having a pH of about 7, 8 was prepared and placed in a 1 L beaker:
265197 g H20 13.5 g Phosphoric acid 75%
a.75 g Sodium acid pyrophosphate 15 g Caustic soda 50%
4,8 g Tetrapotassium pyrophosphate 60%
0.75 g MAPHOS 66 H ESTER
0.003 g DYNOLO 607 Surfactant [0048] The beaker containing the separating composition was charged with .300 g of Athabasca oil sands. The resultant slurry was heated to between 54 C and 60 C. A high shear lab mixer was lowered into the beaker and the slurry was stirred at 3500 rpm for 3 minutes.
The mixer was removed fTom the beaker. Over the course of the next 5-30 minutes, complete phase separation occurred within the beaker. Four separate, distinct phases were observed, The top, first layer contained bitumen, The second layer contained the separating composition. The third layer contained clay, The bottom, fourth layer contained sand aiid other particulate matter.
[0049) The beaker contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 45 g of bitumen was recovered, representing greater than 99% of all of the available bitumen in the sample of oil sands.
[0050] The sand was also recovered and determined to be greater than 99% free of' bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted tllrough a 20-25 mesh sieve.
[0051 ] To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle. The toluene was decanted from the sand. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99.86 g of sand remained.
[0052] In a separate 1 L beaker was placed a fresh 300 g aliquot of the separating composition. To the fresh separating composition was added 45 g of the separated, recovered bitumen. The separating composition and the bitumen were heated to 72 C and were stirred at 2000 rpm for .3 minutes. The beaker contents were allowed to cool and were separated as described above. The resultant bitumen was effectively completely free of contaminants.
[0053] The original separating composition was removed from the first 1 L
beaker after the bitumen was removed. 275 g of this separating composition was added to a 1 L beaker.
The beaker was charged with 275 g of a new aliquot of Athabasca oil sancls,.
The slurry was heated to 72 C and was stirred at .3000 rpm for 3 minutes.
[0054] The beaker contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
free of' contarninants, including sand and clay, Approximately 41 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of oil sands., [0055] The sand was also recovered and determined to be greater than 99% free of bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted through a 20-25 mesh sieve.
[0056] To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle, The toluene was decanted from the sarrd. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for 8 hours to evaporate aiiy remaining toluene. Thereafter, the sand was weighed. 99,83 g of sand remained.
100571 EXAMPLE 2 - Separation of Bitumenfrom Athabasca Tailin sg Pond [00581 200 g of the separating composition was prepared as in Example 1, The separating coinposition was placed in a 1 L beaker. The beaker was charged with 300 g of tailings from an Athabasca tailings pond. The slurry was heated to 72 C and was stirred at 3000 rpm for 2 minutes. The mixer was removed from the beaker. Over the course of the next 5-30 minutes, complete phase separation occurred within the bealcer, Four separate, distinct phases were observed.. The top, first layer contained bitumen. The second layer contained the separating composition. The third layer contained clay. The bottom, fourth layer contained sand and other particulate matter.
[0059] The beaker contents were allowed to cool, at which time the bituinen was removed from the bealcer. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 12 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of tailings.
[00601 The sand was also recovered and determined to be greater than 99% free of bituinen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted through a 20-25 mesh sieve.
[00611 To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle. The toluene was decanted from the sand. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
fbr 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99.76 g of sand reirrained.
100621 EXAMPLE 3 - Separation of Bitumen from Utah Oil Sands [0063[ .300 g of the separating composition was prepared as in Example 1 and was placed in a I L beaker. The beaker containing the separating composition was charged with 300 g ofIJtah oil sands. The resultant slurry was heated to between 54 C and 60 C, A high shear lab mixer was lowered into the beaker and the slurry was stirred at .3500 rpm for 3 minutes, The mixer was removed from the beaker. Over the course of the next 5-30 minutes, complete phase separaticrn occurred within the beaEcer. Four separate, distinct phases were obseived. The top, first layer contained bitunlen. The second layer contained the separating composition,. The third layer contained clay. The bottom, fourth layer contained sand and other particulate matter.
[00641 The beaker contents were allowed to cool, at which time the bitumen was removed fz-om the beaker. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 40 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of oil sands, [0065] The sand was also recovered and determined to be greater than 99% free of bitumen The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sif'ted through a 20-25 mesh sieve.
[00661 In a separate 1 L bealcer was placed a fresh 300 g aliquot of the separating con7position. To the fresh separating composition was added 40 g of the separated, recovered bitumen. The separating composition and the bitumen were heated to 72 C and were stirred at 2000 rpm for 3minutes. The beaker contents were allowed to cooled and selaarated occurred as described above. The resultant bitumen was effectivcly completely free of contaminants.
[00671 The original separating composition was removed from the first IL
beaker after the bitumen was removed. 275 g of this separating composition was added to a I L bealcer.
The beaker was charged with. 275 g of a new aliquot of Utah oil sands, The slurry was heated to 72 C and was stirred at 3000 rpm for 3 minutes. The mixer was removed from the beaker. Over the course of the next 5-30 minutes, complete phase separation occurred within the bealcer. Four separate, distinct phases were observed. The top, first layer contained bitumen- The second layer contained the separating composition. The third layer contained clay. The bottom, fourth layer contained sand and other particulate matter, [0068] The bealcer contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 44 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of oil sands.
[00691 The sand was also r'ecovered and detern.iined to be greater than 99%
hee of bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted througll a 20-25 mesh sieve.
[0070] To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurx,y was agitated, then allowed to settle. The toluene was decanted from the sand. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99.85 g of' sand remained.
[0071] EXAMPLE 4- Separation of Bitumen from Utah Tailings Pond [00721 300 g of the separating composition was prepared as in Example 1. The separating composition was placed in a I L beaker. The beaker was charged with 300 g of tailings from a Utah tailings pond. The slurry was heated to 72 C and was stirred at .3000 rpm for .3 minutes, The mixer was removed from the beaker. Over the course of the next 5-.30 n-iinutes, complete phase separation occurred within the beaker. Four separate, distinct phases were observed. The top, first layer contained bitumen. The second layer contained the separating composition. The third layer contained clay. The bottom, fourth layer contained sand and other particulate rnatter..
[0073] The beaker contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
ftee of cpntaminants, including sand and clay. Approximately 4 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample oftailings.
[0074] The sand was also recovered and determined to be greater than 99% free of bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted through a 20-25 mesh sieve_ [007Sj To further quantify the amount of bitumen remaining in the sand, 100 00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle. The toluene was decanted from the sand, The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for- 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99..77 g of sand remained.
[0076] Unless specifically stated to the contrary, the numerical parameters set forth in the specification, including the attached claims, are approximations that may vary depending on the desired properties sought to be obtained according to the exemplary embodiments, At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical pararneter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
[00771 Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements-[0078] Furthermore, while the systems, methods, and so on have been illustrated by describing examples, and wliile the examples have been described in considerable detail, it is not the intention of the applicant to restrict, or in any way, limit the scope of the appended claims to such detail, It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the systems, methods, and so on provided herein. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Thus, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims. The preceding description is not meant to limit the scope of the invention, Rather, the scope of the invention is to be determined by the appended claims and tlreir equivalents.
[0079] Finally, to the extent that the term "includes" or "including" is employed in the detailed description or the claims, it is intended to be inclusive in a manner similar to the term "comprising," as that term is interpreted whcn employed as a transitional word in a claim..
Furthermore, to the extent that the term "or" is employed in the claims (e.g., A or B) it is intended to mean "A or B or both." When the applicants intend to indicate "only A or B, but not both," then the term "only A or B but not both" will be eniployed.. Similarly, when the applicants intend to indicate "one and only one" of A, B, or C, the applicants will employ the pluase "one and only one." Thus, use of the term "or" herein is the inclusive, and not the exclusive use, See Bryan A. Garner, A Dictionary of Modern Legal iJsage 624 (2d. Ed. 1995).
_26..
SURFACTANT (BASF), PLURONICO F127 CAST SOLID SURFACTANT (BASF), PLURONIC rr F127 NF PRILL Surfactant (BASF), PLURONIC FI27NF 500BHT CAST
SOLID SURFACTANT (BASF), PLURONICO F38 CAST SOLID SURFACTANT (BASF), PLURONIC @ PASTILLE (BASF), PLURONIC F68 LF PASTILLE SURFACTANT (BASF), PLURONIC @ F68 CAST SOLID SURFACTANT (BASF), PLUROMCO F77 CAST SOLID
SURFACTANT (BASF), PLURONICO F-77 MICRO PASTILLE SURFACTANT (BASF), PLURONIC F87 CAST SOLID SURFACTANT (BASF), PLURONICO F88 CAST SOLID
SURFACTANT (BASF), PLURONICO F98 CAST SOLID SURFACTANT (BASF), PLURONICO L10 SURFACTANT (BASF), PLURONICO L10I SURFACTANT (BASF), PLURONICO L121 SURFACTANT (BASF), PLURONICO L.31 SURFACTANT (BASF), PLURONIC L92 SURFACTANT (BASF), PLURONIC N-3 SURFACTANT (BASF), PLURONICO P103 SURFACTANT (BASF), PLURONICO P105 SURFACTANT (BASF), PLURONIC P123 SURFACTANT (BASF), PLURONIC P65 SURFACTANT (BASF), PLURONICO P84 SURFACTANT (BASF), PLURONICO P85 SURFACTANT (BASF), TETRONICO 1107 rnicro-PASTILLE SURFACTANT (BASF), TETRONICO 1107 SURFACTANT (BASF), TETRONIC 1301 SURFACTANT (BASF), TETRONICO 1304 SURFACTANT (BASF), TETRONICO 1.307 Surl'actant (BASF), TETRONICO 1307 SURFACTANT PASTILLE (BASF), TETRONICO 150RI SURFACTANT (BASF), TETRONICO 304 SURFACTANT (BASF), TETRONIC O 701 SURFACTANT (BASF), TETRONICOO 901 SURFACTANT (BASF), TETRONICO 904 SURFACTANT (BASF), _8_ TETRONICO 908 CAST SOLID SURFACTANT (BASF), and TETRONICO 908 PASTILLE
SURFACTANT (BASF), and mixtures thereof.
[0014] The wetting agent may include one or more ethoxylated acetylenic alcohols, such as, for example, 2,5,8,11 -tetrameth,yl-6-dodecyn-5,8-diol ethoxylate.
[0015] Suitable hydrotropic agents may include, for example, one or more of TRITONO H-66 (Dow Chemical Company), TRITONO H-55 (Dow Chemical Company), TRITONO QS-44 (Dow Chemical Company), TRITONO XQS-20 (Dow Chemical Company), TRITONO X-15 (Uniorr Carbide Corporation), TRITONO X-35 (Union Carbide Corporation), TRITONO X-45 (Union Carbide Corporation), TRITONO X-1 14 (Union Carbide Corporation), TRITONO X- 100 (Union Carbide Corporation), TRITON X-165 (70%) active (Union Carbide Corporation), TRITONO X-305 (70%) active (Union Carbide Corporation), TRITONOO
(70%) active (Union Carbide Corporation), TRITON BG Nonionic Surfactant (Union Carbide Corporation), TERGITOLO MinFoam IX (Dow Chemical Company), TERGITOLO L-61 (Dow Chemical Company), TERGITOLO L-64 (Dow Chemical Company), TERGITOLO L-81 (Dow Chemical Company), TERGITOLO L-101 (Dow Chemical Company), TERGITOLO NP-4 (Dow Chemical Company), TERGITOLO NP-6 (Dow Chemical Company), TERGITOLO NP-7 (Dow Chemical Company), TERGITOLO NP-8 (Dow Chemical Company), TERGITOLO NP-9 (Dow Cherrr'rcal Company), TERGITOLO NP-I 1(Dow Chemical Company), TERGITOLO
NP-12 (Dow Chemical Company), TERGITOLO NP-13 (Dow Chemical Company), TERGITOLO
NI'-15 (Dow Chemical Company), TERGITOLO NP-30 (Dow Chemical Company), TERGITOLO NP-40 (Dow Chemical Company), SURFYNOLO 420 (Air Products and Chemicals, Inc.), SURFYNOLO 440 (Air Products and Chemicals, Inc.), SURFYNOL O
(Air Products and Chemicals, Inc.), SURFYNOL 485 (Air Products and Chemicals, Inc ), MAPT-IOSQ 58 ESTER (BASF), MAPHOS 60 A Surfactant (BASF), MAPHOSqD 66 H
ESTER (BASF), MAPHOSC.~ 8135 ESTER (BASF), MAPHOS M-60 ESTER (BASF), 6660 K
Hydrotroping Phosphate Ester Salt (Burlington Chemical), Burofac 7580 Aromatic Phospliate Ester (Burlington Chemical), and Burofac 9125 (Burlington Chemical), and mixtures thereof.
[00161 The hydrotropic agent may be one or more aromatic phosphate esters, such as, for example, an aromatic phosphate ester having the formula:
Ri I / C O
rr P03K2 wherein R' is a Cj-C5 linear or branched alkyl group and n= 1 to 8.
[00171 Suitable dispersants having flocculating characteristics may include, for example, one or more of sodium acid pyraphosphate, tetrapotassium pyrophosphate, monosodium phosphate (H6NaO6P), monoammonium phosphate ((NH4)PO4), sodium acid phospliate, trisodium phosphate, sodium tripolyphosphate, sodium trimetaphosphate, sodium laurel phosphate, sodium phosphate, pentapotassium triphosphate, potassium triphosphate, tetraborate potassium tripolyphosphate, potassium phosphate - monobasic, potassium phosphate - dibasic, monopotassium phosphate, and tripotassium phosphate, and mixtures thereof.
100181 The dispersant having flocculating characteristics may include one or more pyrophosphate salts, including, for example, one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.
-IO-(0019] In one embodiment, the hydrotropic agerit may be present in the amount of from about 0.1% to about 4.0% by weight of the separating composition. The dispersant having flocculating characteristics may be present in the amount of from about 0.25 /o to about 4.5% by weight of the separating composition.
[00201 In one embodiment, the separating composition may further comprise a strong base, such as, for example, hydroxides of alkali metals and alkaline earth metals, such as, for example, NaOH, KOH, Ba(OH)2, CsOH, SrOH, Ca(OH)2, LiOH, RbOH, NaH, LDA, and NaNH2. As used lierein, a"str-ong base" is a chemical compound having a pH of greater than about 13, . The strong base may be present in the amount of from about 2% to about 9.5% by weight of the separating composition.
[0021] In one embodiment, the separating composition may further comprise a heavy acid, such as, for example, phosphoric acid, nitric acid, sulfuric acid, hydronic acid, hydrobromic acid, perchloric acid, fluoromatic acid, magic acid (I~'SO3HSbF5), carborane super acid [H(CHBjjCljt)], triflic acid, ethanoic acid, and acetylsalicylic acid, As used herein, a "heavy" acid is an acid having a specific gravity greater than about 1.5. The 1leavy acid may be present in the amount of from about 1.7% to about 8.6% by weight of the separating composition.
[0022] In one embodiment, the pH of the separating composition may be greater than 7.5. The pH of the separating composition may also be from about 7.0 to about $.5. The pH of the separating composition may also be from about 7.6 to about 7. $, - II -[0023[ In another embodiment, the composition may be essentially free of organic solvent. As used herein, the term "organic solvent" refers to solvents that are organic compounds and contain carbon atoms such as, for example, naplltha, [0024] In addition to the separating composition, the composition may also comprise hydrocarbon containing mater'ials, such as oil sands, tailings, and the like. The ratio of the separating composition to the hydrocarbon containing materials may be from about 2:3 to about 3:2, [0025] In yet another embodiment, a separating composition is provided, comprising fiom about 0.001 % to about 2.5% by weight of a wetting agent; from about 0.1 % to about 4.0% by weiglit of a hydrotropic agent; and from about 0,25% to about 4.5% by weight of a dispersant having flocculating cllaracteristics. The separating composition may have a pH of greater than 7,5; from about 7.0 to about 8.5; or from about 7.6 to about 7 8.
The wetting agent may be, for example, 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate. The hydrotropic agent may be, for example, MAPHOSQ 66H aromatic phosphate ester. The dispersant having flocculating characteristics may be, for example, one or more of sodium acid pyrophosphate and tetrapotassiuin pyrophosphate.
[00261 The separating composition may further comprise a strong base, which may be, for example, sodium hydroxide.. The strong base may be present in the amount of from about 2% to about 9,5% by weight of the separating composition. The separating composition may further comprise a heavy acid, which may be, for example, pliosplroric acid.
The heavy acid may be present in the amount of from about 13% to about 8.6% by weight of the separating conlposition. The separating composition may also be essentially free of organic solvent.
[0027] In one embodiment, a separating composition for separating bitumen from oil sands or tailings is provided, comprising from about 0.001% to about 2.5%
by weight of 2,5,8,1 1-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4,0% by weight of' an aromatic phosphate ester having the formula:
ir O
0 n P03Kz wherein R' is a Cj-C5 linear or branched alkyl group and n= I to 8; from about 0% to about 4,5% by weight of sodium pyrophosphate; from about 0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2.0% to about 9.5% by weight of sodium hydroxide;
and from about 1..7 /Q to about 8.6% by weight of phosphoric acid. The separating composition may have a pH of from about 7.0 to about 8.5. The separating composition may also be essentially free of organic solvent, j0028] In one embodiment, a method for separating bitumen from oil sands is provided, comprising contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with oil sands comprising bitumen and sand; heating the separating composition and the oil sands;
agitating the separating composition and the oil sands; arld recovering the bitumen and sand as separate products. The pH of the separating composition may be greater than 7..5; from about 7.0 to about 8.5; or from about 7.6 to about 7.8.
[0029] In one embodiment, the separating composition used in the exemplary method may be comprised of from about 0.001 %, to about 2.5% by weight of a wetting agent;
from about 0.1% to about 4,0% by weight of a hydrotropic agent; and from about 0,.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
j0030] In another embodiment, the separating composition used in the exemplary method may be comprised of from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4.0% by weight of an aromatic phosphate ester having the formula:
Ri ir I ,,, J"-~ o O n P0a K2 wherein R' is a CI-C5 linear or branched alkyl group and n = 1 to 8; from about 0% to about 4 5% by weight of sodium pyrophosphate; from about 0% to about 4,5% by weight of tetr=apotassium pyrophosphate; fram about 2% to about 9.5% by weight of sodium hydroxide;
and from about 1 .7% to about 8.6% by weight of phosphoric acid.
(0031] Witla respect to the process conditions under which the exemplary method may be carried out, the separating composition and the oil sands may be heated to greater than 25 C; ii om about .32 C to about 72 C; or from about 54 C to about 60 C. Any source of heat within the ambit of those skilled in the art may be used. Similarly, any device capable of providing sufficient agitation may be used to agitate the separating composition and the oil sands, including, for example, a high shear mixer, high speed attritor, high speed dispersers, fluidized beds, and the like, or any other device capable of providing sufficient agitation within the ambit of those skilled in the art.
j00321 In one embodiment, the ratio of the separating composition to the oil sands may be from about 2:3 to about 3:2. In another embodiment, the ratio of the separating composition to the oil sands may be about 1:1.
[0033] The recovered bitumen may be essentially emulsion-free. The exemplary method may be performed without the addition of organic solvent.
[0034] In some circumstances, it may prove desirable to subject the separated, recovered bitumen to a second or subsequent aliquot of separating composition.
In such a case, the exemplary method further comprises contacting the separated, recovered bitumen with a second or subsequent aliquot of fresh separating composition; heating the fresh separating composition and the bitumen; agitating the fresh separating composition and the recovered biturnen; and recover-ing the resulting bitumen, Such a "rinse" cycle may be repeated until the bitumen is essentially free of any sand or other particulate matter.
[0035] In another embodiment, the separating composition may be recyclable Thus, the exemplary method further comprises recovering the separating composition; contact'rng the recovered separating composition with a second or subsequent aliquot of oil sands comprising bitumen and sand; heating the recovered separating composition and the second or subsequent aliquot of oil sands; agitating the recovered separating composition and the secoird or sribsecluent aliquot of oil sands; and recovering the bitumen and sand as separate products.
[0036] In another embodiment, a method is disclosed for piocessing existing tailings, both to salvage remaining bitumen and to allow for redeposit of the essentially bitumen-fi=ee sand. The method may comprise contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with tailings comprising bitumen and sand; heating the separating composition and the tailings; agitating the separating composition and the tailings; and recovering the bitumen and sand as separate products. The pH of the separating composition may be greater than 7.5; from about 7.0 to about 8.5; or from about 7.6 to about 7.8.
100371 In one embodiment, the separating composition used in the exemplary method for processing existing tailings may be comprised of from about 0.001 /a to about 2.5%
by weight of a wetting agent; from about 0.1% to about 4.0% by weight of a IZ,ydrotropic agent;
and from about 0.25% to about 4.5 /fl by weight of a dispersant having flocculating characteristics.
[0038] In another embodiment, the separating composition used in the exemplary method for processing existing tailings may be comprised of from about 0,001%
to about 2.5%
by weight of 2,5,8,11 -tetrametliyl-6-dodecyn-5,8-diol ethoxylate; from about 0. I 1o to about 4.0%
by weight of an aromatic phosphate ester having the formula:
RI
O n F'03Kz wherein R' is a Q-C5 linear or branched alkyl group and n= 1 to 8; from about 0% to about 4.5% by weight of' sodium pyrophosphate; from about 0% to about 4.5 /n by weight of' tetrapotassium pyrophosphate; from about 2% to about 9.5% by weight of sodium hydroxide;
and frozn about 1.7% to about 8.6% by weight of phosphoric acid.
[0039J With respect to the process conditions under which the exemplary method foz processing existing tailings may he carried out, the separating composition and the tailings _16_ may be heated to greater than 25 C; from about 32 C to about '12 C; or from about 54 C to about 60 C. Any source of lleat within the ambit of those skilled in the art may be used.
Similarly, any device capable of providing sufficient agitation may be used to agitate the separating composition and the tailings, including, for example, a high shear mixer, high speed attritor, high speed dispersers, fluidized beds, and the like, or any other device capable of providing suff cient agitation within the ambit of those skilled in the art.
100401 In one embodiment, the ratio of the separating composition to the tailings may be from about 2:3 to about 3:2. In another embodiment, ratio of the separating composition to the tailings may be about 1:1.
[0041) The recovered bitumen may be essentially emulsion-free, The exemplary method may be performed without the addition of organic solvent.
[0042] In some circumstances, it may prove desirable to subject the separated, recovered bitumen from the tailings to a second or subsequent aliquot of separating composition.
In such a case, the exemplary method further comprises contacting the separated, recovered bitumen with a second or subsequent aliquot of fresh sepaiating composition;
heating the fresh separating composition and the bitumen; agitating the fresh separating composition and the recovered bitumen; and recovering the resulting bitumen. Such a "rinse" cycle may be repeated until the bitumen is essentially free of any sand or other particulate matter.
[00431 In aiiother embodiment, the separating composition may be rec,yclabEe.
Thus, the exemplary method for processing existing tailings would further comprise recovering the separating composition; contacting the recovered separating composition with a second or subsequent aliquot of tailings comprising bitumen and sand; heating the recovered separating composition and the second or subsequent aliquot of tailings; agitating the recovered separating composition and the second or subsequent aliquot of tailings; and recovering the bitumen and sand as separate products.
[00441 The present embodiments have been described mainly in the context of lab-scale results. However, it should be appreciated that the results described herein are meant to embody the entire process by which oil sands are obtained, the extraction of'bitumen from the oil sands, and the further processing of'the extracted bitumen, By way of example, mining shovels dig oil sand ore and load it into trucks or other transportation means. The trucks take the oil sands to crushers where the oil sands are broken down in size. The broken down oil sands are added to a mixing tank and contacted with the separating composition as described herein., The separated bitumen is augered and pumped to storage, and then fi.rrther refined to produce synthetic crude oil suitable for use as afeedstocle for the production of liquid motor fuels, heating oil, and petrochemicals, 100451 The following examples are provided to illustrate various embodiments and shall not be considered as limiting in scope.
(00461 EXAMPLE 1- Separation of Bitumen frorn Athabasca Oil Sands [00471 300 g of the following separating composition having a pH of about 7, 8 was prepared and placed in a 1 L beaker:
265197 g H20 13.5 g Phosphoric acid 75%
a.75 g Sodium acid pyrophosphate 15 g Caustic soda 50%
4,8 g Tetrapotassium pyrophosphate 60%
0.75 g MAPHOS 66 H ESTER
0.003 g DYNOLO 607 Surfactant [0048] The beaker containing the separating composition was charged with .300 g of Athabasca oil sands. The resultant slurry was heated to between 54 C and 60 C. A high shear lab mixer was lowered into the beaker and the slurry was stirred at 3500 rpm for 3 minutes.
The mixer was removed fTom the beaker. Over the course of the next 5-30 minutes, complete phase separation occurred within the beaker. Four separate, distinct phases were observed, The top, first layer contained bitumen, The second layer contained the separating composition. The third layer contained clay, The bottom, fourth layer contained sand aiid other particulate matter.
[0049) The beaker contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 45 g of bitumen was recovered, representing greater than 99% of all of the available bitumen in the sample of oil sands.
[0050] The sand was also recovered and determined to be greater than 99% free of' bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted tllrough a 20-25 mesh sieve.
[0051 ] To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle. The toluene was decanted from the sand. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99.86 g of sand remained.
[0052] In a separate 1 L beaker was placed a fresh 300 g aliquot of the separating composition. To the fresh separating composition was added 45 g of the separated, recovered bitumen. The separating composition and the bitumen were heated to 72 C and were stirred at 2000 rpm for .3 minutes. The beaker contents were allowed to cool and were separated as described above. The resultant bitumen was effectively completely free of contaminants.
[0053] The original separating composition was removed from the first 1 L
beaker after the bitumen was removed. 275 g of this separating composition was added to a 1 L beaker.
The beaker was charged with 275 g of a new aliquot of Athabasca oil sancls,.
The slurry was heated to 72 C and was stirred at .3000 rpm for 3 minutes.
[0054] The beaker contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
free of' contarninants, including sand and clay, Approximately 41 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of oil sands., [0055] The sand was also recovered and determined to be greater than 99% free of bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted through a 20-25 mesh sieve.
[0056] To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle, The toluene was decanted from the sarrd. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for 8 hours to evaporate aiiy remaining toluene. Thereafter, the sand was weighed. 99,83 g of sand remained.
100571 EXAMPLE 2 - Separation of Bitumenfrom Athabasca Tailin sg Pond [00581 200 g of the separating composition was prepared as in Example 1, The separating coinposition was placed in a 1 L beaker. The beaker was charged with 300 g of tailings from an Athabasca tailings pond. The slurry was heated to 72 C and was stirred at 3000 rpm for 2 minutes. The mixer was removed from the beaker. Over the course of the next 5-30 minutes, complete phase separation occurred within the bealcer, Four separate, distinct phases were observed.. The top, first layer contained bitumen. The second layer contained the separating composition. The third layer contained clay. The bottom, fourth layer contained sand and other particulate matter.
[0059] The beaker contents were allowed to cool, at which time the bituinen was removed from the bealcer. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 12 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of tailings.
[00601 The sand was also recovered and determined to be greater than 99% free of bituinen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted through a 20-25 mesh sieve.
[00611 To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle. The toluene was decanted from the sand. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
fbr 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99.76 g of sand reirrained.
100621 EXAMPLE 3 - Separation of Bitumen from Utah Oil Sands [0063[ .300 g of the separating composition was prepared as in Example 1 and was placed in a I L beaker. The beaker containing the separating composition was charged with 300 g ofIJtah oil sands. The resultant slurry was heated to between 54 C and 60 C, A high shear lab mixer was lowered into the beaker and the slurry was stirred at .3500 rpm for 3 minutes, The mixer was removed from the beaker. Over the course of the next 5-30 minutes, complete phase separaticrn occurred within the beaEcer. Four separate, distinct phases were obseived. The top, first layer contained bitunlen. The second layer contained the separating composition,. The third layer contained clay. The bottom, fourth layer contained sand and other particulate matter.
[00641 The beaker contents were allowed to cool, at which time the bitumen was removed fz-om the beaker. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 40 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of oil sands, [0065] The sand was also recovered and determined to be greater than 99% free of bitumen The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sif'ted through a 20-25 mesh sieve.
[00661 In a separate 1 L bealcer was placed a fresh 300 g aliquot of the separating con7position. To the fresh separating composition was added 40 g of the separated, recovered bitumen. The separating composition and the bitumen were heated to 72 C and were stirred at 2000 rpm for 3minutes. The beaker contents were allowed to cooled and selaarated occurred as described above. The resultant bitumen was effectivcly completely free of contaminants.
[00671 The original separating composition was removed from the first IL
beaker after the bitumen was removed. 275 g of this separating composition was added to a I L bealcer.
The beaker was charged with. 275 g of a new aliquot of Utah oil sands, The slurry was heated to 72 C and was stirred at 3000 rpm for 3 minutes. The mixer was removed from the beaker. Over the course of the next 5-30 minutes, complete phase separation occurred within the bealcer. Four separate, distinct phases were observed. The top, first layer contained bitumen- The second layer contained the separating composition. The third layer contained clay. The bottom, fourth layer contained sand and other particulate matter, [0068] The bealcer contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
free of contaminants, including sand and clay. Approximately 44 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample of oil sands.
[00691 The sand was also r'ecovered and detern.iined to be greater than 99%
hee of bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted througll a 20-25 mesh sieve.
[0070] To further quantify the amount of bitumen remaining in the sand, 100.00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurx,y was agitated, then allowed to settle. The toluene was decanted from the sand. The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99.85 g of' sand remained.
[0071] EXAMPLE 4- Separation of Bitumen from Utah Tailings Pond [00721 300 g of the separating composition was prepared as in Example 1. The separating composition was placed in a I L beaker. The beaker was charged with 300 g of tailings from a Utah tailings pond. The slurry was heated to 72 C and was stirred at .3000 rpm for .3 minutes, The mixer was removed from the beaker. Over the course of the next 5-.30 n-iinutes, complete phase separation occurred within the beaker. Four separate, distinct phases were observed. The top, first layer contained bitumen. The second layer contained the separating composition. The third layer contained clay. The bottom, fourth layer contained sand and other particulate rnatter..
[0073] The beaker contents were allowed to cool, at which time the bitumen was removed from the beaker. The bitumen was determined to be greater than 99%
ftee of cpntaminants, including sand and clay. Approximately 4 g of bitumen was recovered, representing greater than 99% of the available bitumen in the sample oftailings.
[0074] The sand was also recovered and determined to be greater than 99% free of bitumen. The sand was placed in a drying oven at 72 C for 8 hours and, after cooling to room temperature, was able to be sifted through a 20-25 mesh sieve_ [007Sj To further quantify the amount of bitumen remaining in the sand, 100 00 g of the dried sand was placed in a beaker. 100 g of toluene was added to the sand. The resultant slurry was agitated, then allowed to settle. The toluene was decanted from the sand, The decanted toluene was visually inspected and found to be clear. The sand was dried again at 72 C
for- 8 hours to evaporate any remaining toluene. Thereafter, the sand was weighed. 99..77 g of sand remained.
[0076] Unless specifically stated to the contrary, the numerical parameters set forth in the specification, including the attached claims, are approximations that may vary depending on the desired properties sought to be obtained according to the exemplary embodiments, At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical pararneter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
[00771 Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements-[0078] Furthermore, while the systems, methods, and so on have been illustrated by describing examples, and wliile the examples have been described in considerable detail, it is not the intention of the applicant to restrict, or in any way, limit the scope of the appended claims to such detail, It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the systems, methods, and so on provided herein. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Thus, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims. The preceding description is not meant to limit the scope of the invention, Rather, the scope of the invention is to be determined by the appended claims and tlreir equivalents.
[0079] Finally, to the extent that the term "includes" or "including" is employed in the detailed description or the claims, it is intended to be inclusive in a manner similar to the term "comprising," as that term is interpreted whcn employed as a transitional word in a claim..
Furthermore, to the extent that the term "or" is employed in the claims (e.g., A or B) it is intended to mean "A or B or both." When the applicants intend to indicate "only A or B, but not both," then the term "only A or B but not both" will be eniployed.. Similarly, when the applicants intend to indicate "one and only one" of A, B, or C, the applicants will employ the pluase "one and only one." Thus, use of the term "or" herein is the inclusive, and not the exclusive use, See Bryan A. Garner, A Dictionary of Modern Legal iJsage 624 (2d. Ed. 1995).
_26..
Claims (25)
1. A composition, comprising:
a separating composition, comprising:
a wetting agent in the amount of from about 0.001 % to about 2.5% by weight of the separating composition;
a hydrotropic agent; and a dispersant having flocculating characteristics;
wherein the separating composition has a pH of greater than 7.5.
a separating composition, comprising:
a wetting agent in the amount of from about 0.001 % to about 2.5% by weight of the separating composition;
a hydrotropic agent; and a dispersant having flocculating characteristics;
wherein the separating composition has a pH of greater than 7.5.
2. The composition of claim 1, wherein the hydrotropic agent is present in the amount of from about 01% to about 4.0% by weight of the separating composition; and the dispersant having flocculating characteristics is present in the amount of from about 0.25% to about 4.5%
by weight of the separating composition.
by weight of the separating composition.
3. The composition of claim 1, wherein the wetting agent comprises an alkoxylated alcohol surfactant.
4. The composition of claim 1, wherein the wetting agent comprises 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate.
5. The composition of claim 1, wherein the hydrotropic agent comprises a phosphorylated nonionic surfactant.
6. The composition of claim 1, wherein the hydrotropic agent comprises an aromatic phosphate ester having the formula:
wherein R1 is a C1-C5 linear or branched alkyl group and n = 1 to 8.
wherein R1 is a C1-C5 linear or branched alkyl group and n = 1 to 8.
7. The composition of claim 1, wherein the dispersant having flocculating characteristics comprises a pyrophosphate salt.
8. The composition of claim 1, wherein the dispersant having flocculating characteristics comprises one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.
9. The composition of claim 1, wherein the pH of the separating composition is from about 7.6 to about 8.5.
10. The composition of claim 1, further comprising a strong base, wherein the strong base is present in the amount of from about 2% to about 9.5% by weight of the separating composition.
11. The composition of claim 1, wherein the composition is essentially free of organic solvent.
12. The composition of claim 1, further comprising hydrocarbon containing materials, wherein the ratio of the separating composition to the hydrocarbon containing materials is from about 2:3 to about 3:2.
13. A separating composition, comprising:
from about 0,001% to about 2.5% by weight of a wetting agent;
from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
from about 0,001% to about 2.5% by weight of a wetting agent;
from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
14. The separating composition of claim 13, wherein the separating composition has a pH of from about 7.0 to about 8.5.
15, The separating composition of claim 13, further comprising a heavy acid, wherein the heavy acid is present in the amount of from about 1,7% to about 8.6% by weight.
16. A separating composition for separating bitumen from oil sands or tailings, comprising:
from about 0.00 1% to about 2,5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate;
from about 0.1 % to about 4.0% by weight of an aromatic phosphate ester having the formula:
wherein R1 is a C1-C5 linear or branched alkyl group and n = 1 to 8;
up to about 4.5% by weight of sodium pyrophosphate;
up to about 4.5% by weight of tetrapotassium pyrophosphate;
from about 2% to about 9.5% by weight of sodium hydroxide; and from about 13% to about 8.6% by weight of phosphoric acid.
from about 0.00 1% to about 2,5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate;
from about 0.1 % to about 4.0% by weight of an aromatic phosphate ester having the formula:
wherein R1 is a C1-C5 linear or branched alkyl group and n = 1 to 8;
up to about 4.5% by weight of sodium pyrophosphate;
up to about 4.5% by weight of tetrapotassium pyrophosphate;
from about 2% to about 9.5% by weight of sodium hydroxide; and from about 13% to about 8.6% by weight of phosphoric acid.
17. The separating composition of claim 16, wherein the separating composition is essentially free of organic solvent.
18. A method for separating bitumen from oil sands, comprising:
contacting a separating composition comprising a wetting agent, a hydrotropic agent and a dispersant having flocculating characteristics with oil sands comprising bitumen and sand;
heating the separating composition and the oil sands;
agitating the separating composition and the oil sands; and recovering the bitumen and sand as separate products.
contacting a separating composition comprising a wetting agent, a hydrotropic agent and a dispersant having flocculating characteristics with oil sands comprising bitumen and sand;
heating the separating composition and the oil sands;
agitating the separating composition and the oil sands; and recovering the bitumen and sand as separate products.
19. The method of claim 18, wherein the separating composition is comprised of:
from about 0.001% to about 2.5% by weight of a wetting agent;
from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
from about 0.001% to about 2.5% by weight of a wetting agent;
from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
20. The method of claim 18, wherein the separating composition is comprised of:
from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate;
from about 0.1% to about 4.0% by weight of an aromatic phosphate ester having the formula:
wherein R1 is a C1-C5 linear or branched alkyl group and n = 1 to 8;
up to about 4.5% by weight of sodium pyrophosphate;
up to about 4.5% by weight of tetrapotassium pyrophosphate;
from about 2% to about 9.5% by weight of sodium hydroxide; and from about 1.7% to about 8.6% by weight of phosphoric acid.
from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate;
from about 0.1% to about 4.0% by weight of an aromatic phosphate ester having the formula:
wherein R1 is a C1-C5 linear or branched alkyl group and n = 1 to 8;
up to about 4.5% by weight of sodium pyrophosphate;
up to about 4.5% by weight of tetrapotassium pyrophosphate;
from about 2% to about 9.5% by weight of sodium hydroxide; and from about 1.7% to about 8.6% by weight of phosphoric acid.
21. The method of claim 18, wherein the heating comprises heating the separating composition and the oil sands to from about 32°C to about 72°C..
22. The method of claim 18, wherein the contacting comprises contacting the separating composition and the oil sands in a ratio of from about 2:3 to about 3:2.
23. The method of claim 18, wherein the method is performed without addition of an organic solvent.
24. A method for separating bitumen from tailings, comprising:
contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with tailings comprising bitumen and sand;
heating the separating composition and the tailings;
agitating the separating composition and the tailings; and recovering the bitumen and saiid as separate products.
contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with tailings comprising bitumen and sand;
heating the separating composition and the tailings;
agitating the separating composition and the tailings; and recovering the bitumen and saiid as separate products.
25. The method of claim 24, wherein the separating composition is comprised of:
from about 0,001% to about 2 5% by weight of a wetting agent;
from about 0. 1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
from about 0,001% to about 2 5% by weight of a wetting agent;
from about 0. 1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.
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- 2007-10-05 CN CN200780037487.9A patent/CN101589135B/en active Active
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- 2007-10-05 US US11/868,031 patent/US7749379B2/en active Active
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US9404686B2 (en) | 2009-09-15 | 2016-08-02 | Suncor Energy Inc. | Process for dying oil sand mature fine tailings |
US9909070B2 (en) | 2009-09-15 | 2018-03-06 | Suncor Energy Inc. | Process for flocculating and dewatering oil sand mature fine tailings |
US10590347B2 (en) | 2009-09-15 | 2020-03-17 | Suncor Energy Inc. | Process for flocculating and dewatering oil sand mature fine tailings |
US9068776B2 (en) | 2009-10-30 | 2015-06-30 | Suncor Energy Inc. | Depositing and farming methods for drying oil sand mature fine tailings |
Also Published As
Publication number | Publication date |
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ES2517597T3 (en) | 2014-11-03 |
EA015626B1 (en) | 2011-10-31 |
EP2069467A2 (en) | 2009-06-17 |
US8147680B2 (en) | 2012-04-03 |
US20100200469A1 (en) | 2010-08-12 |
NO337631B1 (en) | 2016-05-18 |
NO20091322L (en) | 2009-04-06 |
US8414764B2 (en) | 2013-04-09 |
PL2069467T3 (en) | 2015-02-27 |
EA200970356A1 (en) | 2009-10-30 |
US20080085851A1 (en) | 2008-04-10 |
US20120193567A1 (en) | 2012-08-02 |
EP2069467B1 (en) | 2014-07-16 |
DK2069467T3 (en) | 2014-10-20 |
CN101589135B (en) | 2014-04-02 |
UA102990C2 (en) | 2013-09-10 |
WO2008063762A3 (en) | 2008-11-06 |
US7862709B2 (en) | 2011-01-04 |
CA2665579C (en) | 2015-06-30 |
EP2069467A4 (en) | 2009-12-30 |
CN101589135A (en) | 2009-11-25 |
US7749379B2 (en) | 2010-07-06 |
US20110062382A1 (en) | 2011-03-17 |
WO2008063762A2 (en) | 2008-05-29 |
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