Role of mineral flotation technology in improving bitumen extraction from mined Athabasca oil sands III. Next generation of water‐based oil sands extraction

Abstract

Current water-based oil sands extraction operations are unsustainable, due to their consumption of large quantities of water and energy, generation of large volumes of fluid fine tailings, and rapid expansion of tailing ponds. From a brief analysis of the historical evolution of water-based oil sands extraction, it has been identified that the use of conventional dispersed air flotation to recover liberated bitumen from oil sand slurries is mainly responsible for the high consumption of water required and the fluid fine tailings generated. Based on mineral flotation principles, a new concept is proposed, whereby water-based oil sands extraction is simplified as a process of transferring hydrophobic bitumen from hydrophilic surfaces (sands) to hydrophobic surfaces (bitumen carriers). Compared to existing bitumen extraction technologies, bitumen liberation from sands is accelerated by attrition/scrubbing, and the liberated bitumen is recovered from the oil sand slurry by hydrophobic coagulation and heavy media separation. This concept is verified from preliminary laboratory tests for processing (above) average grade oil sands. The water required is significantly reduced from 100 to 150 wt% of the ores processed (as seen in current commercial operations) to 30-40 wt% of the ores. Virtually no fluid fine tailings are generated, with the potential of eliminating tailing ponds. The tailings produced after bitumen extraction are paste-like, containing >60 wt% solids, which can be directly disposed of in the mining pit, with little or no further treatment. Future research is needed to justify and refine the concept in large-scale tests and engineer it into commercial operations.

Synergy between Dual Polymers and Sand-to-Fines Ratio for Enhanced Flocculation of Oil Sand Mature Fine Tailings

“…The generation and accumulation of oil sand fine tailings in commercial water-based oil sands extraction in Alberta, Canada, has been posing formidable challenges to the Alberta oil sands industry for maintaining sustainable oil sands operation and further expansion. − Since the mineable oil sands operation commenced in the late 1960s, the oil sands tailing ponds have occupied more than 220 km 2 , and accumulated more than 1.2 billion m 3 of mature fine tailings (MFTs), which contain about 30−35% solids after settling for a few years without consolidation . Great efforts have been devoted by the oil sands operators, research institutions and government organizations, to accelerate the treatment of oil sand fine tailings (e.g., MFTs, or fluid fine tailings (FFT)). − So far, no single treatment technology available can dewater the oil sands fine tailings in an economically efficient, technically effective, and environmentally friendly manner.…”

Assessment of Technological Path of Hydrogen Energy Industry Development: A Review

“…At present, the amount of hydrogen consumed in the industrial sector worldwide each year exceeds 50 billion cubic meters [37]. Approximately 70% of the world's hydrogen is used to synthesize ammonia, and the hydrogen consumption of Eastern Asia and the MENA region's synthetic ammonia is more than 80% [38]. Replacing carbon-based hydrogen with hydrogen from renewable energy will contribute to global carbon emissions reduction [39].…”

Thermoresponsive Starch Nanoparticles for the Extraction of Bitumen from Oil Sands

“…The water consumption can be reduced in oil extraction, but this involves using large amounts of paraffinic and naphthenic solvents to reduce the viscosity of the bitumen and separate it from the sand component, which is even less environmentally friendly and further complicates water treatment [11]. Beyond the CHWE and SAGD processes which are dominant in the oil sands industry, bitumen extraction using ionic liquids [12], organic solvents [13], absorbants [14], and modified floatation techniques [14] have also been explored.…”