Bitumen
froth is a water-in-bitumen emulsion (∼30 wt % water,
60 wt % bitumen, and 10 wt % of solids) stream obtained during the
water-based extraction process of mined oil sands. The separation
of water (to 2 wt % or less) and solids (to 0.5 wt % or less) from
the froth is necessary to prevent corrosion, catalyst deactivation,
and fouling in downstream processes. In naphthenic froth treatment
(NFT), aromatic naphtha is added to reduce the density and viscosity
of bitumen to aid in this separation, which often requires the addition
of demulsifiers and centrifugation. This work looks at simulating
the dewatering of froth using a bench-scale mixer and heptol 80/20
(80 vol % heptane; 20 vol % toluene) as a simulated naphtha solvent.
Power dissipation during mixing, water contents, image analysis of
micrographs, and acoustic spectroscopy were used to examine the dewatering
process as a function of time for three froth samples with different
compositions. Gravity drainage, in the absence of additives, led to
a residual water content, after 2 h, ranging from 1.7 to 3.7 wt %
for the three different samples, consistent with the typical residual
water reported for these systems. Micrographs of the diluted froth
show the eventual disappearance of large water drops and the prevalence
of smaller emulsified drops (<10 μm) in the residual water.
An examination of this residual water using acoustic spectroscopy
showed that up to 0.8 wt % water is in the form of ∼0.3 μm
submicron drops that cannot be removed by gravity or centrifugation.
A dewatering model using an initial drop size distribution (DSD) of
water drops also supports the existence of a substantial amount of
submicron drops. A low-shear dewatering test suggests that most of
this submicron water was in the froth before simulated froth treatment,
formed potentially during bitumen extraction and transportation, prior
to solvent dilution and dewatering. Cryo-SEM imaging further supports
this hypothesis. Studies of water solubilization in toluene–asphaltene
and toluene–naphthenic acid systems suggest that up to 0.5
wt % of this submicron water could be originated from water–asphaltene
association. The presence of high solid contents in the froth correlated
with high residual water and submicron water contents, pointing to
the potential role of solids in the formation of submicron drops.