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CA2630392A1 - Bitumen froth treatment experimental system and method - Google Patents

Bitumen froth treatment experimental system and method Download PDF

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Publication number
CA2630392A1
CA2630392A1 CA 2630392 CA2630392A CA2630392A1 CA 2630392 A1 CA2630392 A1 CA 2630392A1 CA 2630392 CA2630392 CA 2630392 CA 2630392 A CA2630392 A CA 2630392A CA 2630392 A1 CA2630392 A1 CA 2630392A1
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Canada
Prior art keywords
admixture
settling
settling tank
solvent
hydrocarbonaceous slurry
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CA 2630392
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French (fr)
Inventor
Yicheng Long
Martin Niemiec
Elco Dick Hollander
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Shell Canada Energy Ltd
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Individual
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Priority to CA 2630392 priority Critical patent/CA2630392A1/en
Publication of CA2630392A1 publication Critical patent/CA2630392A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D21/00Separation of suspended solid particles from liquids by sedimentation
    • B01D21/02Settling tanks with single outlets for the separated liquid
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N15/00Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
    • G01N15/04Investigating sedimentation of particle suspensions
    • G01N15/042Investigating sedimentation of particle suspensions by centrifuging and investigating centrifugates
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N35/00Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
    • G01N2035/00465Separating and mixing arrangements
    • G01N2035/00534Mixing by a special element, e.g. stirrer
    • G01N2035/00544Mixing by a special element, e.g. stirrer using fluid flow

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

There is provided a method of determining settling rate of a settling component which is derived, at least in part, from a hydrocarbonaceous slurry. The method includes admixing a hydrocarbonaceous slurry and a solvent to produce an admixture. The hydrocarbonaceous slurry includes a hydrocarbon component, water and solid particulate material. The admixture is flowed to a settling tank, and thereby effecting filling of the settling tank with the admixture.
The flow of the admixture to the settling tank is ceased upon filling of the settling tank with the admixture to a predetermined level. After the flow of the admixture has ceased, a settling rate of a settling component is measured as the settling component moves downwardly within the settling tank.

Description

BITUMEN FROTH TREATMENT EXPERIMENTAL SYSTEM AND METHOD
FIELD OF THE INVENTION

This invention relates to the processing of hydrocarbon deposits and, more particularly, to the design of unit operations for effecting the processing of hydrocarbon deposits.

BACKGROUND OF THE INVENTION

[0001] Oil sands deposits are a valuable source of petroleum. In order to recover marketable petroleum products from oil sands deposits, bitumen is extracted from the oil sands and is then upgraded to produce petroleum products. Typically, bitumen is extracted using the hot water extraction process. In extracting bitumen from the oil sands using the hot water extraction process, a bitumen froth is produced from which a bitumen intermediate product must be separated from water and solid particulate material. To effect such separation, the bitumen froth is typically mixed with a solvent and then subjected to gravity separation in a gravity settling tank to produce a solvent-diluted bitumen product in the overflow, while the water and the solid particulate material settles to the bottom of the tank.
[0002] Configuration of the gravity settling tank, as well as relative proportions of the bitumen froth and solvent being combined, influence the separation of a bitumen product from the bitumen froth.
[0003] Experiments are typically conducted using lab-scale equipment to dictate these design parameters. For example, it is known to provide a glass vessel for receiving a bitumen froth sample and a suitable solvent. An impeller is installed within the glass vessel to effect mixing of the bitumen froth sample and the solvent by agitation. To conduct an experiment to measure settling rate of the solid particulates and/or the water of the mixed contents, the impeller is turned off and the solid particulates and/or the water is observed to move downwardly within the glass vessel, thereby enabling measurement of a settling rate.
[0004] Unfortunately, it is questionable whether the measured settling rate using the above-described experimental system is relevant for extrapolation to the design of gravity settling tanks for use in commercial scale bitumen froth treatment systems.
For instance, in I

commercial scale bitumen froth treatment systems, mixing of the bitumen froth and the solvent does not necessarily require an impeller tank mixer. Rather, the mixing action occurs upstream of the gravity settling tank in static in-line mixers.

SUMMARY OF THE INVENTION
[0005] In one aspect, there is provided a method of determining settling rate of a settling component which is derived, at least in part, from a hydrocarbonaceous slurry.
The method includes admixing a hydrocarbonaceous slurry and a solvent to produce an admixture. The hydrocarbonaceous slurry includes a hydrocarbon component, water and solid particulate material. The admixture is flowed to a settling tank, and thereby effecting filling of the settling tank with the admixture. The flow of the admixture to the settling tank is ceased upon filling of the settling tank with the admixture to a predetermined level. After the flow of the admixture has ceased, a settling rate of a settling component is measured as the settling component moves downwardly within the settling tank.
[0006] In another aspect, there is provided a methodology for designing a gravity settling tank. The method includes determining an optimal ratio of mass of solvent to mass of hydrocarbon component in a hydrocarbonaceous slurry, wherein the solvent is configured to be admixed with the hydrocarbonaceous slurry, and wherein the determination includes performing a plurality of experiments. Each one of the plurality of experiments is performed in accordance with an experimental method. The experimental method includes admixing a solvent and a hydrocarbonaceous slurry, wherein the hydrocarbonaceous slurry includes a hydrocarbon component, water and solid particulate material, wherein the experimental ratio of the mass of the solvent to the mass flowrate of the hydrocarbon component of the hydrocarbonaceous slurry is pre-selected. The admixture is flowed to an experimental settling tank, and thereby effect filling of the experimental settling tank with the admixture. The flow of the admixture to the experimental settling tank is ceased upon filling of the experimental settling tank with the admixture to a predetermined level. After flow of the admixture to the experimental settling tank has ceased, a settling rate of a settling component is measured as the settling component moves downwardly within the experimental settling tank. The optimal ratio of mass of solvent to mass of hydrocarbon component in a hydrocarbonaceous slurry is the experimental ratio, of a respective one of the experiments, for which is observed an optimal combination of settling rate and amount of asphaltene precipitation. A gravity settling tank is configured based upon the settling rate and the optimal ratio of mass of solvent to mass of hydrocarbon component in the hydrocarbonaceous slurry of the respective experiment for which the optimal ratio is observed.
[0007] BRIEF DESCRIPTION OF DRAWINGS
[0008] The system and method of the preferred embodiments of the invention will now be described with the following accompanying drawings:
[0009] Figure 1 is a schematic illustration of an experimental system for measuring setting rates and determining design parameters for configuration of a gravity settling tank used in treating bitumen froth during processing of oil sands; measuring setting rate and;
[0010] Figure 2 is a graph of an example settling curve of a water-solid particulate material - asphaltene aggregate, for the purpose of illustrating the determination of settling rate;
[0011] Figure 3 is a data table of the data plotted in the example settling curve of Figure 2;
[0012] Figure 4 is a graph of a modified example settling curve of Figure 1, after the data points recorded after compaction have been removed, and also illustrating the slope of the modified example sampling curve from which settling rate is determined;
[0013] Figure 5 is a graph of a settling curves from five separate settling tests; and [0014] Figure 6 is a data table of the data plotted in Figure 5 from five separate settling tests.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0015] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as distance, operating conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. 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 parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
[0016] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contain errors necessarily resulting from the standard deviation found in their respective testing measureinents.
1.0 Definitions [0017] The following definitions aid in understanding the description that follows.
[0018] "Hydrocarbon component" refers to a hydrocarbon or a mixture of hydrocarbons.
[0019] For example, a suitable hydrocarbon component is a mixture of heavy hydrocarbons. "Heavy hydrocarbon" refers to a viscous hydrocarbon fluid that has a specific gravity of greater than 0.93 at 60 degrees Fahrenheit.
[0020] For example, the hydrocarbon component is a mixture including a plurality of hydrocarbons. For example, the hydrocarbon component is a mixture including a plurality of hydrocarbons, wherein the specific gravity of the mixture is greater than one (1) at 60 degrees Fahrenheit. A suitable example of this type of hydrocarbon component is an ultra-heavy hydrocarbon. For example, the ultra-heavy hydrocarbon is bitumen.
[0021] "Solid particulate material" is solid particulate material of any kind whatsoever.
For example, the solid particulate material includes a mineral. For example, the solid particulate material includes a maximum diameter within the range of 0.2 microns to 10 centimetres. A
suitable solid particulate material is, for example, sand, clay, rock, or at least one heavy metal, or any combination thereof. For example, a suitable solid particulate material is derived from hydrocarbonaceous material.
[0022] "Hydrocarbonaceous material" includes solid particulate material and a hydrocarbon component, wherein the hydrocarbon component is dispersed on or within the solid particulate material. For example, a suitable hydrocarbonaceous material is oil shale, oil sands, or any combination thereof.
[0023] "Hydrocarbonaceous slurry" is a mixture including a hydrocarbon component, water, and solid particulate material. For example, the hydrocarbonaceous slurry is a bituminous froth product derived from the processing of tar sands. For example, the bituminous froth product includes an asphaltene. For example, with respect to the processing of oil sands to produce the bituminous froth product, the processing of oil sands includes crushing the oil sands to produce crushed oil sands, admixing the crushed tar sands with at least hot water to produce an aqueous oil sands slurry. A bituminous froth product and a settled product is then separated from the aqueous oil sands slurry, wherein the separation is effected at least in part by gravity.
An embodiment of this example of oil sands processing is described in U.S.
Patent No.
3,330,757.
[0024] "Bituminous froth product" includes bitumen. For example, the bituminous froth product includes 20 to 80 weight % bitumen based on the total weight of the bituminous froth product, 10 to 70 weight % water based on the total weight of the bituminous froth product, and 2 to 30 weight % solid particulate material based on the total weight of the bituminous froth product. As a fizrther example, the bituminous froth product includes 40 to 70 weight % bitumen based on the total weight of the bituminous froth product, 20 to 40 weight %
water based on the total weight of the bituminous froth product, and 5 to 20 weight % solid particulate material based on the total weight of the bituminous froth product. For example, the bituminous froth product includes 60 weight % bitumen based on the total weight of the bituminous froth product, 30 weight % water based on the total weight of the bituminous froth product, and 10 weight %
solid particulate material based on the total weight of the bituminous froth product.
[0025] "Solvent" is a material configured to effect solvation of at least a portion of the hydrocarbon component of the hydrocarbonaceous slurry. For example, a suitable solvent is a hydrocarbon diluent configured to effect solvation of at least a portion of the hydrocarbon component of the hydrocarbonaceous slurry for improving gravity separation of the at least a portion of the hydrocarbon component from the water and the solid particulate material. For example, a suitable solvent is a paraffinic solvent, a naphthenic solvent, or an aromatic solvent.
An example of a suitable paraffinic solvents is any of propane, butane, pentane, hexane, heptane, octane, or hexadecane, or any combination thereof. Examples of suitable paraffinic solvents are also identified in U.S. Patent No. 5,876,592.
[0026] "Settling component" includes solid particulate material. For example, the settling component is an aggregate mixture including water, solid particulate material, asphaltenes, and entrained solvent-diluted bitumen.

2.0 Detailed Description of a First Group of Embodiments [0027] There is provided an experimental method for measuring setting rate.
[0028] The experimental method includes admixing a hydrocarbonaceous slurry with at least a solvent to produce an admixture. For example, the admixing effects precipitation of asphaltenes from the hydrocarbonaceous slurry. The ratio of the mass of the solvent to the mass of the hydrocarbon component in the hydrocarbonaceous slurry is pre-selected.
For example, the ratio is between 0.5 and 6. As a further example, the ratio is between 1.0 and 4Ø
[0029] For example, the admixing includes combining the hydrocarbonaceous slurry and the solvent to produce a preliminary mixture, and then flowing the preliminary mixture through a tortuous path. For example, the preliminary mixture is flowed through a static mixer. An example of a suitable static mixer is any one of a Sulzer-Chem TechTM static mixer or a KenicsTM static mixer.
[0030] Alternatively, the experimental method includes admixing a flow of hydrocarbonaceous slurry with a flow including a solvent to produce an admixture. For example, the admixing effects precipitation of alphatenes from the hydrocarbonaceous slurry. The ratio of the mass flowrate of the solvent flow to the mass flowrate of the hydrocarbon component in the hydrocarbonaceous slurry is pre-selected. For example, the ratio is between 0.5 and 6. As a further example, the ratio is between 1.0 and 4Ø For example, the admixing includes combining the hydrocarbonaceous slurry flow and the solvent flow to produce a preliminary mixture flow, and then flowing the preliminary mixture flow through a tortuous path, such as that defined by a static mixer, of the kind discussed above.
[0031] The admixture, including the settling component, is flowed to a settling tank. For example, the velocity of the admixture being flowed into the settling tank (ie, the "in-filling velocity") is greater than the settling rate (prior to selecting in-filling velocities suitable for the experimental method, a preliminary experiment is conducted using the system configured for use in practising the experimental method, for the purpose of determining, or at least estimating a suitable range of in-filling velocities which would satisfy this criterion).
For example, the in-filling velocity is at least ten (10) times greater than the settling rate.
Upon filling of the settling tank with the admixture to a predetermined level, the flow of the admixture is ceased. For example, the settling tank is substantially completely filled with the admixture. For example, the pressure within the settling tank is high enough such that each one of the components of the admixture does not substantially evaporate. In this respect, for example, the composition of the admixture flowing into the settling tank is substantially the same as the composition of the admixture within the settling tank. In another respect, for example, the pressure within the tank is greater than the vapour pressure of a portion of the admixture disposed within the settling tank and exposed to a vapour space, wherein the vapour pressure is determined at the temperature of the admixture portion. For example, the pressure within the tank is greater than the vapour pressure of a portion of the admixture disposed within the tank, and exposed to a vapour space, by at least one (1) psi, wherein the vapour pressure is determined at the temperature of the admixture portion. For example, the pressure within the tank is greater than the vapour pressure of a portion of the admixture disposed within the tank, and exposed to a vapour space, by at least two (2) psi, wherein the vapour pressure is determined at the temperature of the admixture portion. For example, the pressure within the tank is within the range of 0 psig to 400 psig. As a further example, the pressure within the tank is within the range of 0 psig to 200 psig. For example, the temperature of the admixture portion in the settling tank is within the range of 20 C
to 180 C. As a further example, the temperature of the admixture portion is within the range of 20 C to 90 C.
[0032] After the flow of the admixture to the settling tank has ceased, the settling rate of the settling component of the admixture is measured as the settling component moves downwardly within the settling tank to provide a characteristic measured settling rate associated with the respective experiment. For example, where asphaltenes have been precipitated during the admixing, the settling component includes asphaltenes. As a further example, the settling component is an aggregate mixture including water, solid particulate material, asphaltenes, and entrained solvent-diluted bitumen.
[0033] There is also provided a methodology for designing a gravity settling tank. The methodology includes determining an optimal combination of design parameters.
The determination includes performing a plurality of experiments. Each one of the plurality of experiments is performed in accordance with the experimental method described above. For each one of the plurality of experiments, the respective pre-selected ratio of the mass of the solvent to the mass of the hydrocarbon component in hydrocarbonaceous slurry is a characteristic ratio associated with the respective experiment. From the plurality of experiments, an optimal experiment, with which is associated a respective ratio of the mass of the solvent to the mass of the hydrocarbon component of the hydrocarbonaceous slurry (hereinafter, the "optimal ratio of the mass of the solvent to the mass of hydrocarbon component of the hydrocarbonaceous slurry"), is selected.
[0034] An optimal experiment is selected from the plurality of experiments as that experiment for which is observed an optimal combination of settling rate, ratio of mass of solvent to mass of hydrocarbon component in a hydrocarbonaceous slurry, and solvent-diluted bitumen product quality. Design of a settling tank for continuous operation is based on settling rate and the optimal ratio of mass of solvent to mass of hydrocarbon component of the hydrocarbonaceous slurry associated with the optimal experiment. Other design considerations for the gravity settling tank, as understood by a person of ordinary skill in the art, include desired residual mineral solids, desired residual water, and desired asphaltenes in the product overflow, and the hydraulics of the dynamic system.

3.0 Detailed Description of Embodiments of a System for Facilitating Practice of Above-Described Methodologies [0035] Referring to Figure 1, there is provided a system 10 for facilitating practice of any of the above-described methodologies for measuring settling properties and designing a gravity settling tank.
[0036] The system 10 includes a hydrocarbonaceous slurry tank 12 and a solvent tank 14.
[0037] For example, with respect to the hydrocarbonaceous slurry tank 12, an iinpeller mixer 16 is installed within the tank 12 for facilitating homogenization of the contents of tank 12. As a further example, with respect to the hydrocarbonaceous tank 12, the tank 12 has an internal volume of 0.5 to 15 litres. For example, the internal volume is 15 litres. As a further example, with respect to the hydrocarbonaceous slurry tank 12, the tank 12 is heated by a heater 20. For example, with respect to the heating of the tank 12, examples of a suitable heater 20 include an immersion water bath or a heating jacket. As a further example, with respect to the heating of the tank 12, the temperature of the contents of the tank 12 is maintained within the range of from 25 C to 90 C.
[0038] For example, with respect to the solvent tank 14, an impeller mixer 18 is installed within the tank 14 for facilitating homogenization of the contents of tank 14.
As a further example, with respect to the solvent tank 14, the tank 14 has an internal volume of 0.5 to 15 litres. For example, the internal volume is 15 litres. As a further example, with respect to the solvent tank 14, the tank 14 is heated by a heater 22. Examples of a suitable heater 22 include an immersion water bath or a heating jacket. As a further example, with respect to the heating of the tank 14 by the heater 22, the temperature of the contents of the tank 14 is maintained within the range of from 25 C to 90 C.
[0039] For example, with respect to the heating of the tanks 12 and 14, instead of heating each of the tanks 12 and 14 separately and independently from each other, each of the tanks 12 and 14 can be heated by the same source. For example, both of the tanks 12 and 14 could be immersed within the same water bath to effect the heating.
[0040] The hydrocarbonaceous slurry tank 12 is fluidly coupled to a hydrocarbonaceous slurry pump 24, and the solvent tank 14 is fluidly coupled to a solvent pump 26. For example, with respect to the pumps 24 and 26, the pumps 24 and 26 are heated by a water bath 13. For example, with respect to each of the pumps 24 and 26, each of the pumps 24 and 26 is capable of discharging fluids at steady flowrates of up to 100 litres per minute, and the volume per pump shot is adjustable from 0.1 litres to 5 litres. The adjustable pump discharge rate and volume per pump shot allow the operator to change fluid discharge velocity and also the relative ratio of volumetric flowrates of the dispensed hydrocarbonaceous slurry and solvent.
For example, suitable pumps include a plunger-type pump or a piston pump. For example, a suitable pump is a ECS-SERIESTM plunger-type pump Serial No. SPPM 3039, manufactured by Advanced Process Technology Inc.
[0041] Each of the discharge of the pump 24 and the discharge of the pump 26 is fluidly coupled to a fluid conduit 28 for combining and effecting admixing of the hydrocarbonaceous slurry being discharged from the pump 24 with the solvent being discharged from the pump 26.
For example, with respect to the fluid conduit 28, the fluid conduit 28 includes a tortuous path for effecting admixing of the hydrocarbonaceous slurry with the solvent to produce an admixture. For example, with respect to the tortuous path of the fluid conduit 28, the tortuous path is provided by a static mixer 32. For example, with respect to the static mixer 32, an example of a suitable static mixer 32 is any of the Sulzer-Chem TechTM static mixers and/or KenicsTM static mixers. For example, with respect to the static mixer 32, the static mixer 32 is heated by a heater 30. Examples of a suitable heater 30 include a water bath or a heating jacket.
For example, with respect to the heating of the static mixer 32 by the heater 30, the temperature of the contents of the static mixer 30 is within the range of from 25 C to 90 C.
[0042] The fluid conduit 28 is fluidly coupled to a settling tank 34, for effecting flow of the admixture to the settling tank 34. For example, with respect to the settling tank 34, the settling tank 34 includes an observation window for facilitating viewing of settling phenomena within the tank 34. For example, with respect to the window, the window has a height within the range of from 50 centimetres to 200 centimetres, which is found to allow sufficient time for observing the settling phenomena. As a further example, the tank 34 is in the form of a glass column including a wall portion which functions as the observation window.
[0043] For example, to enhance visual observation of various phases present in the tank 34, the hydrophobicity/hydrophilicity of the interior wall of the observation window is altered by chemical treatment. For example, the chemical treatment is effected with dichlorodimethylsilane.
[0044] The settling phenomena can be observed either visually or instrumentally. For example, with respect to instrumental observation of the settling phenomena, the interior of the tank 34 is illuminated, and the settling particles and interfaces are recorded with a camera.
[0045] As a further example, with respect to the settling tank 34, the settling tank 34 has an inside diameter which varies from 3 centimetres to 10 centimetres. As a further example, with respect to the settling tank 34, the settling tank 34 is heated by a heater 36. Examples of a suitable heater 36 include an immersion water bath, a forced air heating bath, or a heating jacket.
For example, the temperature of the contents of the settling tank is within the range of from 25 C
to 150 C. For example, this temperature range is from 25 C to 90 C. As a further example, with respect to the settling tank 34, the settling tank 34 is configured to withstand internal fluid pressures of up to 100 psig.
[0046] The settling tank 34 is fluidly coupled to and vents to the receiving tank 55. The receiving tank 55 is provided to receive any overflow from the settling tank 34. As well, the receiving tank 55 is provided to contain fluid during cleaning and flushing of the settling tank 34.
[0047] For example, temperatures within each one of the tanks 12, 14, and 34, and the static mixer 32, is regulated by one or more thermostats.
[0048] For example, each one of the tanks 12, 14, 34, and 55 is fluidly coupled to a nitrogen storage and supply system 50. The nitrogen storage and supply system functions to maintain a desired operating pressure within the system 10.

5.0 Examples [0049] Embodiments of the present invention will be described in further detail with reference to the following non-limitative examples [0050] A test froth composition has been provided including 65 weight %
bitumen based on the total weight of the test froth composition, 26 weight % water based on the total weight of the test froth composition, and 9 weight % solid particulate material. The solid particulate material includes mineral solids, such as clays and silicas. The solvent provided is n-Hexane.
[0051] Five settling tests have been conducted at different temperatures and different ratios of mass of test solvent to mass of bitumen (of the test froth composition). Each of the tests involved admixing the test froth composition and the test solvent using the system 10. The admixture is flowed to the settling tank 34 until the settling tank is substantially filled with the admixture. When the settling tank is substantially filled with the admixture, the admixture flow is stopped and settling of the settling component, as measured by a downwardly descending interface between solvent-diluted bitumen and aggregate phases, is observed as a function of time, wherein the settling component is defined by the interface.
[0052] The process of deterrnining settling rate is now explained with reference to an example settling curve of Figure 2, being based on data (see Figure 3) of observed interface level as a function of time, while the interface level descends within the settling tank 34. Settling rate is determined by measuring the slope of the graph in Figure 2 prior to the occurrence of aggregate compaction. From the graph in Figure 2, the occurrence of compaction is determined to occur at 3.52 minutes. The settling rate of the settling component (in this case, the aggregate) is defined by the slope of a straight line passing through, or interpolated between, all the data points prior to the occurrence of compaction are plotted (see Figure 4). In this case, the slope of the line generated from the data plotted in Figure 4 is 259. Therefore, the corresponding settling rate is determined to be 259 millimetres/minute.
[0053] Returning to discussion of the five settling tests, data from the five settling tests are illustrated in the settling curves of Figure 5 and the data table of Figure 6. Each test included recording the settling component interface level as a function of time. The settling rates of a respective settling component of each one of the settling tests have been determined by measuring the slope of the line from the data prior to the onset of compaction.
[0054] It will be understood, of course, that modifications can be made in the embodiments of the invention described herein without departing from the scope and purview of the invention as defined by the appended claims.

Claims (21)

1. A method of determining settling rate of a settling component which is derived, at least in part, from a hydrocarbonaceous slurry, comprising:

admixing a hydrocarbonaceous slurry and a solvent to produce an admixture, wherein the hydrocarbonaceous slurry includes a hydrocarbon component, water and solid particulate material;

flowing the admixture to a settling tank, and thereby effecting filling of the settling tank with the admixture;

ceasing the flow of the admixture to the settling tank upon filling of the settling tank with the admixture to a predetermined level; and after the flow of the admixture has ceased, measuring a settling rate of a settling component as the settling component moves downwardly within the settling tank.
2. The method as claimed in claim 1, wherein the admixing is effected by combining a flow of a hydrocarbonaceous slurry with a flow of a solvent to produce a combined flow, and flowing the combined flow through a tortuous path to effect mixing of the hydrocarbonaceous slurry and the solvent.
3. The method as claimed in claim 2, wherein the tortuous path is defined by a static mixer.
4. The method as claimed in claim 1, wherein the hydrocarbonaceous slurry includes bitumen.
5. The method as claimed in claim 4, wherein the hydrocarbonacous slurry includes 20 to 80 weight % bitumen based on the total weight of the hydrocarbonaceous slurry, 10 to 70 weight % water based on the total weight of the hydrocarbonaceous slurry, and 2 to 30 weight % solid particulate matter based on the total weight of the hydrocarbonaceous slurry.
6. The method as claimed in claim 5, wherein the solid particulate material includes a mineral.
7. The method as claimed in claim 5, when the solid particulate material includes a maximum diameter of less than about 10 centimetres.
8. The method as claimed in claim 5, wherein the solid particulate material includes a maximum diameter within the range of from about 0.2 microns to about 10 centimetres.
9. The method as claimed in claim 4, wherein hydrocarbonaceous slurry includes 40 to 70 weight % bitumen based on the total weight of the hydrocarbonaceous slurry, 20 to 40 weight % water based on the total weight of the hydrocarbonaceous slurry, and 5 to 30 weight % of solid particulate matter based on the total weight of the hydrocarbonaceous slurry.
10. The method as claimed in claim 9, wherein the solid particulate material includes a mineral.
11. The method as claimed in claim 9, wherein the solid particulate material includes a maximum diameter of less than about 10 centimetres.
12. The method as claimed in claim 9, wherein the solid particulate material includes a maximum diameter within the range of from about 0.2 microns to about 10 centimetres.
13. The method as claimed in claim 1, wherein the hydrocarbonaceous slurry includes a bituminous froth product.
14. The method as claimed in claim 1, wherein the hydrocarbonaceous slurry is a bituminous froth product.
15. The method as claimed in claim 1, wherein the pressure of the admixture disposed within the settling tank is sufficiently high such that each one of the components of the admixture disposed within the settling tank does not substantially evaporate.
16. The method as claimed in claim 1, wherein the pressure within the tank is greater than the vapour pressure of a portion of the admixture disposed within the settling tank and exposed to a vapour space, wherein the vapour pressure is determined at the temperature of the admixture portion.
17. The method as claimed in claim 1, wherein the pressure within the settling tank is greater than the vapour pressure of a portion of the admixture disposed within the settling tank, and exposed to a vapour space, by at least about one (1) psi, wherein the vapour pressure is determined at the temperature of the admixture portion.
18. The method as claimed in claim 1, wherein the pressure within the settling tank is greater than the vapour pressure of a portion of the admixture disposed within the settling tank, and exposed to a vapour space, by at least about two (2) psi, wherein the vapour pressure is determined at the temperature of the admixture portion.
19. A methodology for designing a gravity settling tank comprising:

determining an optimal ratio of mass of solvent to mass of hydrocarbon component in a hydrocarbonaceous slurry, wherein the solvent is configured to be admixed with the hydrocarbonaceous slurry, and wherein the determination includes performing a plurality of experiments, and wherein each one of the plurality of experiments is performed in accordance with an experimental method, wherein the experimental method includes:

admixing a solvent and a hydrocarbonaceous slurry, wherein the hydrocarbonaceous slurry includes a hydrocarbon component, water and solid particulate material, wherein the experimental ratio of the mass of the solvent to the mass flowrate of the hydrocarbon component of the hydrocarbonaceous slurry is pre-selected;

flowing the admixture to an experimental settling tank, and thereby effect filling of the experimental settling tank with the admixture;

ceasing the flow of the admixture to the experimental settling tank upon filling of the experimental settling tank with the admixture to a predetermined level; and after flow of the admixture to the experimental settling tank has ceased, measuring a settling rate of a settling component as the settling component moves downwardly within the experimental settling tank;

wherein the optimal ratio of mass of solvent to mass of hydrocarbon component in a hydrocarbonaceous slurry is the experimental ratio, of a respective one of the experiments, for which is observed an optimal combination of settling rate and amount of asphaltene precipitation;

and configuring a gravity settling tank based upon the settling rate and the optimal ratio of mass of solvent to mass of hydrocarbon component in the hydrocarbonaceous slurry of the respective experiment for which the optimal ratio is observed.
20. The methodology as claimed in claim 19, wherein the admixing of the hydrocarbonaceous slurry and the solvent includes:

combining the hydrocarbonaceous slurry with the solvent to produce an intermediate mixture; and flowing the intermediate mixture through a tortuous path to effect mixing of the hydrocarbonaceous slurry and the solvent.
21. The methodology as claimed in claim 19, wherein the admixing is effected by combining a flow of a hydrocarbonaceous slurry with a flow of a solvent to produce a combined flow, and flowing the combined flow through a tortuous path to effect mixing of the hydrocarbonaceous slurry and the solvent.
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US9207019B2 (en) 2011-04-15 2015-12-08 Fort Hills Energy L.P. Heat recovery for bitumen froth treatment plant integration with sealed closed-loop cooling circuit
US9546323B2 (en) 2011-01-27 2017-01-17 Fort Hills Energy L.P. Process for integration of paraffinic froth treatment hub and a bitumen ore mining and extraction facility
US9587176B2 (en) 2011-02-25 2017-03-07 Fort Hills Energy L.P. Process for treating high paraffin diluted bitumen
US9587177B2 (en) 2011-05-04 2017-03-07 Fort Hills Energy L.P. Enhanced turndown process for a bitumen froth treatment operation
US9676684B2 (en) 2011-03-01 2017-06-13 Fort Hills Energy L.P. Process and unit for solvent recovery from solvent diluted tailings derived from bitumen froth treatment
US9791170B2 (en) 2011-03-22 2017-10-17 Fort Hills Energy L.P. Process for direct steam injection heating of oil sands slurry streams such as bitumen froth
US10041005B2 (en) 2011-03-04 2018-08-07 Fort Hills Energy L.P. Process and system for solvent addition to bitumen froth
US10226717B2 (en) 2011-04-28 2019-03-12 Fort Hills Energy L.P. Method of recovering solvent from tailings by flashing under choked flow conditions
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US9546323B2 (en) 2011-01-27 2017-01-17 Fort Hills Energy L.P. Process for integration of paraffinic froth treatment hub and a bitumen ore mining and extraction facility
US9587176B2 (en) 2011-02-25 2017-03-07 Fort Hills Energy L.P. Process for treating high paraffin diluted bitumen
US10125325B2 (en) 2011-02-25 2018-11-13 Fort Hills Energy L.P. Process for treating high paraffin diluted bitumen
US9676684B2 (en) 2011-03-01 2017-06-13 Fort Hills Energy L.P. Process and unit for solvent recovery from solvent diluted tailings derived from bitumen froth treatment
US10041005B2 (en) 2011-03-04 2018-08-07 Fort Hills Energy L.P. Process and system for solvent addition to bitumen froth
US10988695B2 (en) 2011-03-04 2021-04-27 Fort Hills Energy L.P. Process and system for solvent addition to bitumen froth
US9791170B2 (en) 2011-03-22 2017-10-17 Fort Hills Energy L.P. Process for direct steam injection heating of oil sands slurry streams such as bitumen froth
US9207019B2 (en) 2011-04-15 2015-12-08 Fort Hills Energy L.P. Heat recovery for bitumen froth treatment plant integration with sealed closed-loop cooling circuit
US10226717B2 (en) 2011-04-28 2019-03-12 Fort Hills Energy L.P. Method of recovering solvent from tailings by flashing under choked flow conditions
US9587177B2 (en) 2011-05-04 2017-03-07 Fort Hills Energy L.P. Enhanced turndown process for a bitumen froth treatment operation
US11261383B2 (en) 2011-05-18 2022-03-01 Fort Hills Energy L.P. Enhanced temperature control of bitumen froth treatment process
US10954448B2 (en) 2017-08-18 2021-03-23 Canadian Natural Resources Limited High temperature paraffinic froth treatment process

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