The
water-based extraction process has been almost exclusively
used in the current industry for Athabasca oil sands extraction to
produce bitumen and heavy oil. However, the current method is facing
various challenges, primarily including high energy intensity, poor
processability with poor-quality ores, large consumption of fresh
water, and concerns on considerable volume of tailings. Although the
technology of using nonaqueous solvent as extraction medium has numerous
advantages, problems such as solvent loss to tailings and high capital/operating
costs are difficult to address. A biodiesel-assisted ambient aqueous
bitumen extraction (BA3BE) process has been herein proposed
as an alternative to water-based and solvent-based extraction processes.
The results showed a significant improvement in both froth quality
and bitumen recovery (increased from ∼10% to ∼80% with
biodiesel addition) for processing poor-quality ores at ambient temperature
(25 °C), which is much lower than the temperatures used in the
current industrial practice (40–55 °C). The aqueous tailings
generated in the BA3BE process were found to feature faster
settling and enhanced densification, which is favorable for recovering
processing water and improving land reclamation. Furthermore, the
innovative BA3BE extraction process requires similar facilities
and procedures as the current industrial processes, which can be considered
as an advantage for commercialization.