Bitumen separation process and apparatus for problem ores

Abstract

A process for separating from an oil sand slurry solids and bitumen is provided, comprising introducing the oil sand slurry into a separation zone comprising an upper zone and a lower zone; intercepting a settling path of the solids in the separation zone by bringing the solids into contact with at least one intercepting surface to direct the solids to the lower zone; and producing a reduced solids upper zone to allow the bitumen to rise through the upper zone with reduced hindrance from the solids.

We claim: 
     
         1 . A process for separating solids and bitumen present in an oil sand slurry, comprising:
 (a) introducing the oil sand slurry into a separation zone comprising an upper zone and a lower zone;   (b) intercepting a settling path of the solids in the separation zone by bringing the solids into contact with at least one intercepting surface to direct the solids to the lower zone; and   (c) producing a reduced solids upper zone to allow the bitumen to rise through the upper zone with reduced hindrance from the solids.   
     
     
         2 . The process as claimed in  claim 1 , whereby the separation zone is present in a bitumen separation vessel and the at least one intercepting surface is at least one inclined plate. 
     
     
         3 . The process as claimed in  claim 2 , further comprising at least two inclined plates which form an inclined plate assembly. 
     
     
         4 . The process as claimed in  claim 1 , wherein the oil sand slurry is introduced into the separation zone so that the solids contact the at least one intercepting surface at or near the center of the at least one intercepting surface. 
     
     
         5 . The process as claimed in  claim 3 , wherein the at least two inclined plates are substantially parallel to each other. 
     
     
         6 . The process as claimed in  claim 3 , wherein the at least two inclined plates are angled downwardly and to one side. 
     
     
         7 . The process as claimed in  claim 3 , wherein the at least two inclined plates are angled downwardly and towards the center of the separation zone. 
     
     
         8 . An apparatus for separating from an oil sand slurry solids and bitumen, comprising:
 (a) a vessel having a separation zone, the separation zone further comprising an upper zone and a lower zone;   (b) a feed well for feeding the oil sand slurry into the separation zone; and   (c) at least one separation element having an intercepting surface positioned in the separation zone in a vertically downward orientation;   
       whereby the solids present in the oil sand slurry are caused by gravity to settle along the at least one separation element to the lower zone and the bitumen is caused by a decrease in specific gravity due to the settling of the solids to flow upwardly to the upper zone. 
     
     
         9 . The apparatus as claimed in  claim 8 , wherein the at least one separation element is at least one inclined plate. 
     
     
         10 . The apparatus as claimed in  claim 9 , further comprising at least two inclined plates which form an inclined plate assembly. 
     
     
         11 . The apparatus as claimed in  claim 10 , wherein the at least two inclined plates are substantially parallel to one another. 
     
     
         12 . The process as claimed in  claim 10 , wherein the at least two inclined plates are angled downwardly and to one side. 
     
     
         13 . The process as claimed in  claim 10 , wherein the at least two inclined plates are angled downwardly and towards the center of the separation zone. 
     
     
         14 . A process for extracting bitumen from problem oil sand ores having low bitumen content and/or high fines content, comprising:
 (a) mixing the problem oil sand ore with heated water to produce an oil sand slurry;   (b) conditioning the oil sand slurry for a period of time sufficient to substantially disperse oil sand lumps and promote the release and coalescence of bitumen flecks from the sand grains;   (c) introducing the conditioned oil sand slurry into a separation zone comprising an upper zone and a lower zone;   (d) intercepting a settling path of the solids in the separation zone by bringing the solids into contact with at least one intercepting surface to direct the solids to the lower zone; and   (e) producing a reduced solids upper zone to allow the bitumen to rise through the upper zone with reduced hindrance from the solids.   
     
     
         15 . The process as claimed in  claim 14 , whereby the separation zone is present in a bitumen separation vessel and the at least one intercepting surface is at least one inclined plate. 
     
     
         16 . The process as claimed in  claim 15 , further comprising at least two inclined plates which form an inclined plate assembly. 
     
     
         17 . The process as claimed in  claim 14 , wherein the oil sand slurry is introduced into the separation zone so that the solids contact the at least one intercepting surface at or near the center of the at least one intercepting surface. 
     
     
         18 . The process as claimed in  claim 16 , wherein the at least two inclined plates are substantially parallel to each other. 
     
     
         19 . The process as claimed in  claim 16 , wherein the at least two inclined plates are angled downwardly and to one side. 
     
     
         20 . The process as claimed in  claim 16 , wherein the at least two inclined plates are angled downwardly and towards the center of the separation zone.