Separating compositions and methods of use

[0001] This application claims the benefit of priority from Provisional Patent Application No.

60/828501, filed October 6, 2006.

Background [0002] Oil sands, also known as "tar sands" and "bituminous sands", are a mixture of bitumen (tar), sand and water. Bitumen is a heavy, viscous crude oil with a relatively high sulfur content. When properly separated from oil-bearing sand, bitumen can be processed into synthetic crude oil, suitable for use as a raw material for the production of liquid motor fuels, heating oil and petrochemical products. Oil fields are found all over the world. Particularly significant deposits are found in Canada, including the Athabasca oil sands in Alberta, in the United States, including the Utah oil sands, in South America, including the Orinoco oil sands in Venezuela, Africa, including oil sands in Nigeria. Most of the total oil in the world is found in the oil sands.

[0003] Bitumen is very difficult to separate from oil sands in an efficient and environmentally acceptable manner. Modern attempts to separate bitumen from oil sands usually only recover around 85-92% of the available bitumen. In addition, modern attempts to separate bitumen from oil sands are accompanied by the formation of emulsion or "foam" during processing, which requires the use of environmentally harmful organic solvents such as naphtha to break up the emulsion and allow further processing. In addition, bitumen that remains in the sand (and other particulate material such as clay), which is part of the oil sands, contributes to the formation of heavy sludge, often referred to as "waste." Modern waste management practice, which contains unrecovered bitumen, sand (and other particles in the form of particles) and water, includes pumping waste into large waste pools, in which sand and other particulate components slowly settle and build up over several years.

Summary [0004] Current embodiments describe compositions and methods for separating bitumen from oil sands in an efficient and environmentally acceptable manner, and for recovering residual bitumen from existing waste pools.

[0005] In accordance with one aspect of the present invention, there is provided an aqueous separating composition for separating bitumen from oil sands and waste, comprising: a wetting agent; solubilizing agent; and a dispersant with flocculating properties; wherein the release composition has a pH of 7.0 to 8.5, contains a wetting agent in an amount of 0.001% to 2.5% by weight, which is 2,5,8,11-tetramethyl6-dodecin-5,8-diol ethoxylate, and a solubilizing agent in an amount of 0.1% to 4.0% by weight, which is an aromatic phosphate ester of formula:

R¹

<img file="PL2069467T3_D0001.tif" />

₁ in which R¹ is a C1-C5 linear or branched alkyl group an = 1 to 8; and which contains a dispersant with flocculating properties in an amount of from 0.25% to 4.5% by weight, which is a pyrophosphate salt. [0006] According to another aspect of the present embodiments, there is provided a separating composition for separating bitumen from oil sands or from waste, containing from 0.001% to 2.5% by weight 2,5,8,11-tetramethyl-6-dodecin-5 ethoxylate 8-diol; from 0.1% to 4.0% by weight of an aromatic phosphate ester with the formula:

<img file="PL2069467T3_D0002.tif" />

₁ in which R¹ is a C1-C5 linear or branched alkyl group an = 1 to 8; from 0.001% to 4.5% by weight of sodium pyrophosphate; from 0.001% to 4.5% by weight of tetrapotassium pyrophosphate; from 2% to 9.5% by weight of sodium hydroxide; and from 1.7% to 8.6% by weight of phosphoric acid, wherein the pH of the precipitation composition is from 7.0 to 8.5.

[0007] In accordance with another aspect of the present embodiments, a method for separating bitumen from oil sands is provided, comprising contacting an aqueous separating composition containing a wetting agent, solubilizing agent and dispersant with flocculating properties with oil sands containing bitumen and sand; heating the separating composition and oil sands; mixing the precipitation composition and oil sands; and recovery of bitumen and sand as separate products.

[0008] In accordance with another aspect of the present embodiments, a method for separating bitumen from waste is provided, comprising contacting the aqueous separating composition containing wetting agent, solubilizing agent and dispersant having flocculating properties with waste containing bitumen and sand; heating the separating composition and waste; mixing the precipitation composition and waste; and recovery of bitumen and sand as separate products

Detailed Description [0009] As used herein, "substantially free" means an amount less than about 0.1%.

[0010] In one embodiment, a composition is provided comprising a release composition comprising a wetting agent in an amount of 0.001% to 2.5% by weight of the release composition, a solubilizing agent and a dispersant having flocculating properties, wherein the pH of the release composition is over 7.5.

[0011] Suitable wetting agents may include, for example, one or more agents from the group consisting of the DYNOL ™ 607 surfactant (Air Products and Chemicals, Inc.), SURFYNOL® 420 (Air Products and Chemicals, Inc.), SURFYNOL® 440 (Air Products and Chemicals, Inc.), SURFYNOL® 465 (Air Products and Chemicals, Inc.), SURFYNOL® 485 (Air Products and Chemicals, Inc.), surfactant DYNOL ™ 604 (Air Products and Chemicals, Inc. .) TOMADOL® 91-2.5 (To3 mah Products, Inc.), TOMADOL® 91-6 (Tomah Products, Inc.), TOMADOL® 91-8 (Tomah Products, Inc.), TOMADOL® 1-3 (Tomah Products , Inc.), TOMADOL® 1-5 (Tomah Products, Inc.), TOMADOL® 1-7 (Tomah Products, Inc.), TOMADOL® 1-73B (Tomah Products, Inc.), TOMADOL® 1-9 ( Tomah Products, Inc.), TOMADOL® 23-1 (Tomah Products, Inc.), TOMADOL® 23-3 (Tomah Products, Inc.), TOMADOL® 23-5 (Tomah Products, Inc.), TOMADOL® 23- 6.5 (Tomah Products, Inc.), TOMADOL® 25-3 (Tomah Products, Inc.), TOMADOL® 25-7 (Tomah Products, Inc.), TOMADOL® 25-9 (Tomah Products, Inc.), TOMADOL® 25-12 (Tomah Products, Inc.), TOMADOL® 45-7 (Tomah Products, Inc. ), TOMADOL® 45-13 (Tomah Products, Inc.), TRITON ™ X-207 surfactant (Dow Chemical Company), TRITON ™ CA surfactant (Dow Chemical Company), NOVEC ™ FC4434 fluoro surfactant (3M Company), POLYFOX ™ AT-1118B (Omnova Solutions, Inc.), ZONYL® 210 (Dupont), ZONYL® 225 (Dupont), ZONYL® 321 (Dupont), ZONYL® 8740 (Dupont), ZONYL® 8834L (Dupont), ZONYL® 8857A (Dupont), ZONYL® 8952 (Dupont), ZONYL® 9027 (Dupont), ZONYL® 9338 (Dupont), ZONYL® 9360 (Dupont), ZONYL ® 9361 (Dupont), ZONYL® 9582 (Dupont), ZONYL® 9671 (Dupont), ZONYL® FS-300 (Dupont), ZONYL® FS-500 (Dupont), ZONYL® FS-610 (Dupont), ZONYL® 1033D (Dupont), ZONYL® FSE (DuPont), ZONYL® FSK (DuPont), ZONYL® FSH (DuPont), ZONYL® FSJ (DuPont), ZONYL® FSA (DuPont), ZONYL® FSN-100 (DuPont), LUTENSOL® OP 30-70% (BASF), LUTENSOL® A 12 N (BASF), LUTENSOL® A 3 N (BASF), LUTENSOL® A 65 N (BASF), LUTENSOL® A 9 N (BASF), LUTENSOL® AO 3 (BASF), LUTENSOL® AO 4 (BASF), LUTENSOL® AO 8 (BASF) , LUTENSOL® AT 25 (BASF), surfactant LUTENSOL® AT 55 PRILL (BASF), surfactant LUTENSOL® CF 10 90 (BASF), LUTENSOL® DNP 10 (BASF), LUTENSOL® NP 4 (BASF), LUTENSOL ® NP 10 (BASF), LUTENSOL® NP-100 PASTILLE (BASF), LUTENSOL® NP-6 (BASF), 70% LUTENSOL® NP-70 (BASF), LUTENSOL® NP-50 (BASF), LUTENSOL® NP 9 (BASF) LUTENSOL® ON 40 (BASF), LUTENSOL® ON 60 (BASF), LUTENSOL® OP-10 (BASF) surfactant, LUTENSOL® TDA 10 surfactant (BASF), LUTENSOL® TDA 3 surfactant (BASF), LUTENSOL® TDA 6 (BASF) surfactant, LUTENSOL® TDA 9 (BASF) surfactant, LUTENSOL® XL 69 (BASF), LUTENSOL® XL 100 (BASF), LUTENSOL® XL 140 (BASF), LUTENSOL® XL 40 (BASF), LUTENSOL® XL 50 (BASF), LUTENSOL® XL 60 (BASF), LUTENSOL® XL 70 (BASF), LUTENSOL® XL 79 (BASF), LUTENSOL® XL 80 (BASF), LUTENSOL® XL 89 (BASF), LUTENSOL® XL 90 (BASF), LUTENSOL® XL 99 (BASF), LUTENSOL® XP 100 (BASF), LUTENSOL® XP 140 (BASF), LUTENSOL® XP 30 (BASF), LUTENSOL® XP 40 (BASF), LUTENSOL® XP 50 (BASF), LUTENSOL® XP 60 (BASF), LUTENSOL® XP 69 (BASF), LUTENSOL® XP 70 (BASF), LUTENSOL® XP 79 (BASF), LUTENSOL® XP 80 (BASF), LUTENSOL® XP 89 (BASF), LUTENSOL® XP 90 (BASF), LUTENSOL® XP 99 (BASF), MACOL® 16 surfactant (BASF) MACOL® CSA 20 polyether (BASF), MACOL® LA 12 (BASF) surfactant, MACOL® LA 4 surfactant (BASF), MACOL® LF 110 surfactant (BASF), MACOL® LF 125A surfactant ( BASF), MAZON® 1651 surfactant (BASF), MAZOX® LDA lauramine oxide (BASF), PLURAFAC® AO8A surfactant (BASF), PLURAFAC® B-26 surfactant (BASF), PLURAFAC® B25 surfactant -5 (BASF), PLURAFAC® D25 surfactant (BASF), PLURAFAC® LF 1200 surfactant (BASF), PLURAFAC® LF 2210 surfactant (BASF), PLURAFAC® LF 4030 surfactant (BASF), PLURAFAC® LF 7000 surfactant (BASF), surfactant PLURAFAC® RA-20 (BASF), surfactant PLURAFAC® RA 30 (BASF), surfactant PLURAFAC® RA 40 (BASF), surfactant PLURAFAC® RCS 43 (BASF), PLURAFAC® RCS 48 surfactant (BASF), PLURAFAC® S205LF surfactant (BASF), PLURAFAC® S305LF surfactant (BASF), PLURAFAC® S505LF surfactant (BASF), PLURAFAC® SL 62 surfactant ), PLURAFAC® SL 92 surfactant (BASF), PLURAFAC® SL-22 surfactant (BASF), PLURAFAC® SL-42 surfactant (BASF), PLURAFAC® SLF 37 surfactant (BASF), PLURAFAC® SLF-18 surfactant (BASF), PLURAFAC® SLF-18B-45 surfactant (BASF), PLURAFAC® L1220 surfactant (BASF), PLURONIC® 10R5 surfactant (BASF), PLURONIC® 17R2 ( BASF), PLURONIC® 17R4 (BASF), PLURONIC® 25R2 (BASF), PLURONIC® 25R4 (BASF), PLURONIC® 31R1 (BASF), poured solid surfactant PLURONIC® F108 (BASF), poured solid surfactant PLURONIC® F108 NF (BASF), surfactant in PLURONIC® F108 NF (BASF), surfactant in PLURONIC® F108 (BASF), solid surfactant PLURONIC® F127 (BASF) poured, surfactant in PLURONIC® F127 NF (BASF), poured solid surfactant PLURONIC® F127NF 500BHT (BASF), poured solid surfactant PLURONIC® F38 (BASF), pelleted PLURONIC® (BASF), pelleted PLURONIC® F68 LF surfactant (BASF), poured solid PLURONIC® F68 surfactant (BASF), poured solid PLURONIC® F77 surfactant (BASF), microplasticated PLURONIC® F-77 surfactant (BASF) PLURONIC® F87 solid surfactant (BASF), PLURONIC® F88 solid surfactant (BASF), PLURONIC® F98 solid surfactant poured, PLURONIC® L10 surfactant (BASF), PLURONIC® L101 surfactant (BASF), PLURONIC® L121 surfactant (BASF), PLURONIC® L31 surfactant (BASF), PLURONIC® L92 surfactant (BASF), PLURONIC® N-3 surfactant (BASF), PLURONIC® P103 surfactant (BASF), PLURONIC® P105 surfactant (BASF), PLURONIC® P123 surfactant (BASF), PLURONIC® P65 surfactant (BASF), PLURONIC® P84 surfactant (BASF), PLURONIC® P85 surfactant (BASF), microplasticized TETRONIC® 1107 surfactant (BASF), TETRONIC® 1107 surfactant (BASF) , TETRONIC® 1301 surfactant (BASF), TETRONIC® 1304 surfactant (BASF), TETRONIC® 1307 surfactant (BASF), TETRONIC® 1307 surfactant pelletized (BASF), TETRONIC® 150R1 surfactant (BASF), TETRONIC® 304 surfactant (BASF), TETRONIC® 701 surfactant (BASF), TETRONIC® 901 surfactant (BASF), TETRONIC® 904 surfactant (BASF), TETRONIC® 908 cast solid surfactant (BASF) and TETRONIC® 908 pelletized surfactant (BASF), as well as mixtures thereof.

[0012] Wetting agents may include one or more ethoxylated acetylene alcohols, such as, for example, 2,5,8,11-tetramethyl-6-dodecin-5,8-diol ethoxylate.

[0013] Suitable solubilizing agents may include, for example, one or more agents from the group consisting of TRITON® H-66 (Dow Chemical Company), TRITON® H-55 (Dow Chemical Company), TRITON® QS-44 (Dow Chemical Company ), TRITON® XQS-20 (Dow Chemical Company), TRITON® X-15 (Union Carbide Corporation), TRITON® X-35 (Union Carbide Corporation), TRITON® X-45 (Union Carbide Corporation), TRITON® X- 114 (Union Carbide Corporation), TRITON® X-100 (Union Carbide Corporation), active TRITON® X-165 (70%) (Union Carbide Corporation), active TRITON® X-305 (70%) (Union Carbide Corporation), active TRITON® X-405 (70%) (Union Carbide Corporation), non-ionic agent surfactant TRITON® BG (Union Carbide Corporation), TERGITOL® MinFoam 1X (Dow Chemical Company), TERGITOL® L-61 (Dow Chemical Company), TERGITOL® L-64 (Dow Chemical Company), TERGITOL® L-81 (Dow Chemical Company), TERGITOL® L-101 (Dow Chemical Company), TERGITOL® NP-4 (Dow Chemical Company), TERGITOL® NP-6 (Dow Chemical Company), TERGITOL® NP-7 (Dow Chemical Company), TERGITOL® NP-8 (Dow Chemical Company), TERGITOL® NP-9 (Dow Chemical Company), TERGITOL® NP-11 ( Dow Chemical Company), TERGITOL® NP-12 (Dow Chemical Company), TERGITOL® NP-13 (Dow Chemical Company), TERGITOL® NP-15 (Dow Chemical Company), TERGITOL® NP-30 (Dow Chemical Company), TERGITOL ® NP-40 (Dow Chemical Company), SURFYNOL® 420 (Air Products and Chemicals, Inc.), SURFYNOL® 440 (Air Products and Chemicals, Inc.), SURFYNOL® 465 (Air Products and Chemicals, Inc.), SURFYNOL® 485 (Air Products and Chemicals, Inc.), MAPHOS® 58 ESTER (BASF), surfactant MAPHOS® 60 A (BASF), MAPHOS® 66 H ester (BASF), MAPHOS® 8135 (BASF) ester, MAPHOS® M-60 ESTER (BASF), solubilizing salt of phosphate ester 6660 K (Burlington Chemical), Burofac aromatic phosphate ester 7580 (Burlington Chemical) and Burofac 9125 (Burlington Chemical) and mixtures thereof.

[0014] The solubilizing agent may be one or more aromatic phosphate esters, such as, for example, an aromatic phosphate ester of formula:

<img file="PL2069467T3_D0003.tif" />

₁ in which R¹ is a C1-C5 linear or branched alkyl group and n = 1 to 8.

[0015] Suitable dispersants with flocculating properties may include, for example, one or more of sodium acid pyrophosphate, tetrapotassium pyrophosphate and mixtures thereof.

[0016] The dispersant with flocculating properties may include one or more pyrophosphate salts, including, for example, one or more salts of sodium acid pyrophosphate and tetrapotassium pyrophosphate.

[0017] In one embodiment, the solubilizing agent may be present in an amount of from 0.1% to 4.0% by weight of the separation composition. The dispersant with flocculating properties may be present in an amount of from 0.25% to 4.5% by weight of the separating composition.

[0018] In one embodiment, the release composition may further comprise a strong base, such as, for example, alkali metal and alkaline earth metal hydroxides, such as, for example, NaOH, KOH, Ba (OH) 2, CsOH, SrOH, Ca (OH) ) 2, LiOH, RbOH, NaH, LDA and NaNH2. As used herein, a "strong base" is an opH chemical greater than about 13. The strong base may be present in an amount of from 2% to 9.5% by weight of the separating composition.

[0019] In one embodiment, the release composition may further comprise heavy acid, such as, for example, phosphoric acid, nitric acid, sulfuric acid, hydrochloric acid, hydrobromic acid, perchloric acid, hydrofluoric acid, magical acid (FSO3HSbF5), carboranic superacid [H (CHB11Cl11)], trifluoroacetic acid, ethane acid and acetylsalicylic acid. As used herein, "heavy" means an acid with a density greater than 1.5. Heavy acid may be present in an amount of 1.7% to 8.6% by weight of the precipitation composition.

[0020] In one embodiment, the pH of the release composition may be above 7.5. The pH of the secretion composition may further be from 7.0 to 8.5. The pH of the release composition may also be from 7.6 to 7.8. [0021] In another embodiment, the composition may be substantially free of organic solvent. As used herein, the term "organic solvent" refers to solvents that are organic compounds and contain carbon atoms, such as, for example, naphtha, [0022] In addition to the release composition, the composition may also contain hydrocarbon-containing materials such as sands oil, waste and the like. The ratio of the separating composition to materials containing hydrocarbons can be from 2: 3 to 3: 2.

[0023] In yet another embodiment, there is provided an isolating composition comprising from 0.001% to 2.5% by weight of a wetting agent; from 0.1% to 4.0% by weight of a solubilizing agent; and from 0.25% to 4.5% by weight of a dispersant with flocculating properties. The pH of the secretion composition may be above 7.5; from 7.0 to 8.5; or 7.6 to 7.8. The wetting agent may be, for example, 2,5,8,11-tetramethyl-6-dodecin-5,8-diol ethoxylate. The solubilizing agent may be, for example, the MAPHOS® 66H aromatic phosphate ester. The dispersant with flocculating properties can be, for example, one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.

[0024] The release composition may further contain a strong base, which may be, for example, sodium hydroxide. A strong base may be present in an amount of from 2% to 9.5% by weight of the separating composition. The release composition may further comprise a heavy acid, which may be, for example, phosphoric acid. Heavy acid may be present in an amount of 1.7% to 8.6% by weight of the precipitation composition. The release composition may be essentially free of organic solvent.

[0025] In one embodiment, a separation composition is provided for separating bitumen from oil sands or waste, comprising from 0.001% to 2.5% by weight 2,5,8,11-tetramethyl-6-dodecin-5,8-diol ethoxylate; from 0.1% to 4.0% by weight of an aromatic phosphate ester having the formula:

<img file="PL2069467T3_D0004.tif" />

₁ in which R¹ is a C1-C5 linear or branched alkyl group an = 1 to 8; from 0% to 4.5% by weight sodium pyrophosphate; from 0% to 4.5% by weight tetrapotassium pyrophosphate; from 2.0% to 9.5% by weight of sodium hydroxide; and from 1.7% to 8.6% by weight of phosphoric acid. The pH of the release composition may be from 7.0 to 8.5. The release composition may also be substantially free of organic solvent.

[0026] In one embodiment, a method for separating bitumen from oil sands is provided, comprising contacting the separating composition containing wetting agent, solubilizing agent and dispersant with flocculating properties with oil sands containing bitumen and sand; heating the separating composition and oil sands; mixing the precipitation composition and oil sands; and obtaining7 bitumen and sands as separate products. The pH of the secretion composition may be over

7.5; from 7.0 to 8.5; or from 7.6 to 7.8.

[0027] In one embodiment, the release composition used in the exemplary method may comprise from

0.001% to 2.5% by weight of wetting agent; from 0.1% to 4.0% by weight of a solubilizing agent; and from 0.25% to 4.5% by weight of a dispersant with flocculating properties.

[0028] In another embodiment, the isolating composition used in the exemplary method may contain from 0.001% to 2.5% by weight 2,5,8,11-tetramethyl-6-dodecin-5,8-diol ethoxylate; from 0.1% to 4.0% by weight of an aromatic phosphate ester having the formula:

<img file="PL2069467T3_D0005.tif" />

₁ in which R¹ is a C1-C5 linear or branched alkyl group an = 1 to 8; from 0% to 4.5% by weight sodium pyrophosphate; from 0% to 4.5% by weight tetrapotassium pyrophosphate; from 2% to 9.5% by weight of sodium hydroxide; and from 1.7% to 8.6% by weight of phosphoric acid.

[0029] With respect to the process conditions under which the exemplary method can be carried out, the release composition and oil sands can be heated to a temperature above 25 ° C; from 32 ° C to 72 ° C; or from 54 ° C to 60 ° C. Any heat source known to those skilled in the art can be used. Similarly, any device capable of providing sufficient mixing may be used to mix the release composition and oil sands, including, for example, high shear mixer, high speed blower, high speed dispersing devices, fluidized beds and the like, or any other device capable of providing sufficient mixing known to those skilled in the art.

[0030] In one embodiment, the ratio of the separating composition to oil sands may be from 2: 3 to 3: 2. In another embodiment, the ratio of the separating composition to oil sands may be 1: 1. [0031] The recovered bitumen may be substantially emulsion-free. The exemplary method can be carried out without adding an organic solvent.

[0032] In some cases, it may be desirable to subject the separated, recovered bitumen to a second or subsequent portion of the separating composition. In this case, the exemplary method further includes contacting the separated, recovered bitumen with a second or subsequent portion of the fresh release composition; heating the fresh bitumen separating composition; mixing fresh separation composition and recovered bitumen; and recovering the obtained bitumen. This "rinsing" cycle can be repeated until the bitumen is substantially free of any sand or other particulate components.

[0033] In another embodiment, the release composition may be recyclable. Thus, an exemplary method further includes recovering the separation composition; contacting the recovered release composition with a second or subsequent portion of oil sands containing bitumen and sand; heating the recovered separating composition and the second or subsequent portion of the oil sands; mixing the recovered secretion composition with a second or subsequent portion of the oil sands; and recovery of bitumen and sand as separate products.

[0034] In another embodiment, a method for treating existing waste is disclosed, both to collect residual bitumen and to allow re-deposition of substantially bitumen-free sand. The method may include contacting the release composition comprising a wetting agent, solubilizing agent and dispersant having flocculating properties with the bitumen and sand containing waste; heating the separating composition and waste; mixing the precipitation composition and waste; and recovery of bitumen and sand as separate products. The pH of the secretion composition may be above 7.5; from 7.0 to 8.5; or from 7.6 to 7.8.

[0035] In one embodiment, the separating composition used in the exemplary waste treatment method may contain from 0.001% to 2.5% by weight of a wetting agent; from 0.1% to 4.0% by weight of a solubilizing agent; and from 0.25% to 4.5% by weight of a dispersant with flocculating properties.

[0036] In another embodiment, the separating composition used in the exemplary waste treatment method may contain from 0.001% to 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecin-5,8-diol ethoxylate; from 0.1% to 4.0% by weight of an aromatic phosphate ester having the formula:

<img file="PL2069467T3_D0006.tif" />

₁ in which R¹ is a C1-C5 linear or branched alkyl group an = 1 to 8; from 0% to 4.5% by weight sodium pyrophosphate; from 0% to 4.5% by weight tetrapotassium pyrophosphate; from 2% to 9.5% by weight of sodium hydroxide; and from 1.7% to 8.6% by weight of phosphoric acid.

[0037] With respect to the process conditions under which an exemplary method of processing existing waste can be carried out, the separating composition and waste can be heated to a temperature above 25 ° C; from 32 ° C to 72 ° C; or from 54 ° C to 60 ° C. Any heat source known to those skilled in the art can be used. Similarly, any device capable of providing sufficient mixing may be used to mix the release composition and waste, including, for example, high shear mixer, high speed blower, high speed dispersing devices, fluidized beds and the like, or any other device capable of providing sufficient mixing known specialists in this field.

[0038] In one embodiment, the ratio of the separating composition to waste may be from 2: 3 to 3: 2. In another embodiment, the ratio of the separating composition to waste may be 1: 1.

[0039] The recovered bitumen may be substantially free of emulsion. The exemplary method can be carried out without adding an organic solvent.

[0040] In some cases it may be desirable to subject the separated, recovered bitumen from the waste to a second or subsequent portion of the separating composition. In this case, an exemplary method involves contacting the separated, recovered bitumen with a second or subsequent portion of a fresh release composition; heating the fresh separation composition and bitumen; mixing fresh separation composition and recovered bitumen; and recovering the obtained bitumen. This "rinsing" cycle can be repeated until the bitumen is substantially free of any sand or other particulate components.

[0041] In another embodiment, the release composition may be recyclable. Thus, an exemplary method of treating existing waste could further include recovering the separating composition;

contacting the recovered separating composition with a second or subsequent portion of waste containing bitumen and sand; heating the recovered separating composition and the second or subsequent batch of waste; mixing the recovered separating composition and the second or subsequent portion of waste; and recovery of bitumen and sand as separate products.

[0042] Current implementations have been described mainly in the context of laboratory scale results. However, it should be understood that the results described are intended to cover the entire process in which oil sands are obtained, bitumen extraction from oil sands and further processing of the extracted bitumen. For example, mining excavators extract oil deposits for trucks or other means of transport. Trucks transport oil sands to crushers in which oil sands are crushed. The shredded oil sands are added to the mixing tank and contacted with the release composition as described. The separated bitumen is conveyed by means of a screw conveyor and pumped to the depot, and then subjected to further refining to produce synthetic crude oil suitable for use as a raw material for the production of liquid motor fuels, heating oil and petrochemical products.

[0043] The following examples are given to illustrate the various forms and should not be considered as limiting the scope.

EXAMPLE 1 - Isolation of bitumen from the Athabasca oil sands [0044] 300 g of the following precipitation composition with a pH of about 7.8 was prepared and placed in a 1-liter beaker:

<td>265.197 g</td><td>H₂ABOUT</td>

<td>13.5 g</td><td>75% phosphoric acid</td>

<td>0.75 g</td><td>Acid sodium pyrophosphate</td>

<td>15 g</td><td>Caustic soda 50%</td>

<td>4.8 g</td><td>Tetrapotassium pyrophosphate 60%</td>

<td>0.75 g</td><td>MAPHOS® 66 H ester</td>

<td>0.003 g</td><td>DYNOL® 607 surfactant</td>

[0045] 300 g of Athabasca oil sands were added to the beaker containing the release composition. The resulting suspension was heated to a temperature between 54 ° C and 60 ° C. A high-shear laboratory stirrer was lowered into the beaker and the suspension was mixed at 3500 rpm for 3 minutes. The stirrer was removed from the beaker. Over the next 5-30 minutes, complete phase separation occurred in the beaker. Four separate phases were observed. The first top layer contained bitumen. The second layer contained the release composition. The third layer contained clay. The bottom fourth layer contained sand and other particulate material.

[0046] The contents of the beaker were allowed to cool, after which the bitumen was removed from the beaker. It was determined that bi10 tum was over 99% free of impurities, including sand and clay. About 45 g of bitumen was recovered, which accounted for over 99% of all available bitumen in the sample of oil sands.

[0047] Sand was also recovered and found to be more than 99% free of bitumen. The sand was placed in an oven at 72 ° C for 8 hours and after cooling to room temperature it could be sieved through a 20-25 mesh screen.

[0048] To accurately determine the amount of bitumen remaining in the sand, 100.00 g of dried sand was placed in a beaker. 100 g toluene was added to the sand. The resulting suspension was mixed and allowed to stand. Toluene was decanted from the sand. Decantant toluene was examined and found clear. The sand was dried again at 72 ° C for 8 hours to evaporate any residual toluene. Then the sand was weighed. 99.86 g of sand remained.

[0049] A fresh portion of 300 g of release composition was placed in a separate 1 liter beaker. 45 g of separated, recovered bitumen was added to the fresh release composition. The separating composition and bitumen were heated to 72 ° C and mixed at 2000 rpm for 3 minutes. The contents of the beaker were allowed to cool and separated as described above. The obtained bitumen was essentially completely free of impurities.

[0050] The original separating composition was removed from the 1 liter beaker after the bitumen was removed. 275 g of this isolation composition was added to a 1 liter beaker. 275 g of a new portion of Athabasca oil sands was added to the beaker. The suspension was heated to 72 ° C and stirred at 3000 rpm for 3 minutes. [0051] The contents of the beaker were allowed to cool, after which the bitumen was removed from the beaker. It was determined that the bitumen was more than 99% free of impurities, including sand and clay. About 41 g of bitumen was recovered, which is more than 99% of the total available bitumen in the sample of oil sands.

[0052] Sand was also recovered and found to be more than 99% free of bitumen. The sand was placed in an oven at 72 ° C for 8 hours and after cooling to room temperature it could be sieved through a 20-25 mesh screen.

[0053] To accurately determine the amount of bitumen remaining in the sand, 100.00 g of dried sand was placed in a beaker. 100 g toluene was added to the sand. The resulting suspension was mixed and allowed to stand. Toluene was decanted from the sand. Decantant toluene was examined and found clear. The sand was dried again at 72 ° C for 8 hours to evaporate residual toluene. Then the sand was weighed. 99.83 g of sand remained.

EXAMPLE 2 - Separation of bitumen from the Athabasca waste basin [0054] 200 g of the separating composition was prepared as described in Example 1. The separating composition was placed in a 1 liter beaker. 300 g of waste from the Athabasca waste basin was added to the beaker. The suspension was heated to 72 ° C and stirred at 3000 rpm for 2 minutes. The stirrer was removed from the beaker. Over the next 5-30 minutes, complete phase separation occurred in the beaker. Four separate phases were observed. The first top layer contained bitumen. The second layer contained the release composition. The third layer contained clay. The bottom fourth layer contained sand and other particulate material.

[0055] The contents of the beaker were allowed to cool, after which the bitumen was removed from the beaker. It was determined that the bitumen was more than 99% free of impurities, including sand and clay. About 12 g of bitumen was recovered, representing more than 99% of the total available bitumen in the waste sample.

[0056] Sand was also recovered and found to be more than 99% free of bitumen. The sand was placed in an oven at 72 ° C for 8 hours and after cooling to room temperature it could be sieved through a 20-25 mesh screen.

[0057] To accurately determine the amount of bitumen remaining in the sand, 100.00 g of dried sand was placed in a beaker. 100 g toluene was added to the sand. The resulting suspension was mixed and allowed to stand. Toluene was decanted from the sand. Decantant toluene was examined and found clear. The sand was dried again at 72 ° C for 8 hours to evaporate any residual toluene. Then the sand was weighed. 99.76 g of sand remained.

EXAMPLE 3 - Separation of bitumen from oil sands of Utah [0058] 300 g of the separating composition were prepared as described in Example 1 and placed in a 1 liter beaker. 300 g of Utah oil sands were added to the beaker containing the release composition. The resulting mixture was heated to a temperature between 54 ° C and 60 ° C. A high-shear laboratory stirrer was lowered into the beaker and the suspension was mixed at 3500 rpm for 3 minutes. The stirrer was removed from the beaker. Over the next 5-30 minutes, complete phase separation occurred in the beaker. Four separate phases were observed. The first top layer contained bitumen. The second layer contained the release composition. The third layer contained clay. The bottom fourth layer contained sand and other particulate material.

[0059] The contents of the beaker were allowed to cool, after which the bitumen was removed from the beaker. It was determined that the bitumen was more than 99% free of impurities, including sand and clay. About 40 g of bitumen was recovered, which accounted for over 99% of the total available bitumen in the sample of oil sands. The sand was also recovered and found to be over 99% free of bitumen. The sand was placed in an oven at 72 ° C for 8 hours and after cooling to room temperature it could be sieved through a 20-25 mesh screen.

[0061] A fresh portion of 300 g of separation composition was placed in a separate 1 liter beaker. 40 g of separated, recovered bitumen was added to the fresh release composition. The separating composition and bitumen were heated to 72 ° C and mixed at 2000 rpm for 3 minutes. The contents of the beaker were allowed to cool and separated as described above. The obtained bitumen was essentially completely free of impurities.

[0062] The original separating composition was removed from the 1 liter beaker after the bitumen was removed. 275 g of this isolation composition was added to a 1 liter beaker. 275 g of a new portion of Utah sands were added to the beaker. The suspension was heated to 72 ° C and stirred at 3000 rpm for 3 minutes. The stirrer was removed from the beaker. Over the next 5-30 minutes, complete phase separation occurred in the beaker. Four separate phases were observed. The first top layer contained bitumen. The second layer contained the release composition. The third layer contained clay. The bottom fourth layer contained sand and other particulate material.

[0063] The contents of the beaker were allowed to cool, after which the bitumen was removed from the beaker. It was determined that the bitumen was more than 99% free of impurities, including sand and clay. About 44 g of bitumen was recovered, which accounted for over 99% of all available bitumen in the sample of oil sands.

[0064] Sand was also recovered and found to be more than 99% free of bitumen. The sand was placed in an oven at 72 ° C for 8 hours and after cooling to room temperature it could be sieved through a 20-25 mesh screen.

[0065] To accurately determine the amount of bitumen remaining in the sand, 100.00 g of dried sand was placed in a beaker. 100 g toluene was added to the sand. The resulting suspension was mixed and allowed to stand. Toluene was decanted from the sand. Decantant toluene was visually examined and found to be clear. The sand was dried again at 72 ° C for 8 hours to evaporate any residual toluene. Then the sand was weighed. 99.85 g of sand remained.

EXAMPLE 4 - Separation of bitumen from the Utah waste basin [0066] 300 g of the separating composition were prepared as described in Example 1. The separating composition was placed in a 1 liter beaker. 300 g of waste from the Utah waste basin was added to the beaker. The suspension was heated to 72 ° C and stirred at 3000 rpm for 3 minutes. The stirrer was removed from the beaker. Over the next 5-30 minutes, complete phase separation occurred in the beaker. Four separate phases were observed. The first top layer contained bitumen. The second layer contained the release composition. The third layer contained clay. The bottom fourth layer contained sand and other particulate material.

[0067] The contents of the beaker were allowed to cool, after which the bitumen was removed from the beaker. It was determined that the bitumen was more than 99% free of impurities, including sand and clay. About 4 g of bitumen was recovered, which accounted for over 99% of the total available bitumen in the waste sample.

[0068] Sand was also recovered and found to be more than 99% free of bitumen. The sand was placed in an oven at 72 ° C for 8 hours and after cooling to room temperature it could be sieved through a 20-25 mesh sieve.

[0069] To accurately determine the amount of bitumen remaining in the sand, 100.00 g of dried sand was placed in a beaker. 100 g toluene was added to the sand. The resulting suspension was mixed and allowed to stand. Toluene was decanted from the sand. Decantant toluene was examined and found clear. The sand was dried again at 72 ° C for 8 hours to evaporate any residual toluene. Then the sand was weighed. 99.77 g of sand remained.

[0070] Although the numerical ranges and parameters representing the broad scope of the invention are approximate, the numerical values ​​shown in the specific examples are given as accurately as possible. However, any numerical value inherently contains some errors inevitably resulting from the standard deviation found in their respective measurements during the test.

[0071] Furthermore, although the systems, methods and similar elements have been illustrated by describing the examples, and although the examples have been described in significant detail, it is not intended by the applicant to limit or otherwise narrow the scope of the appended claims to such details. It is of course not possible to describe every possible combination of ingredients or methodologies to describe systems, methods and similar elements given in the description. Additional advantages and modifications will be easily noticed by specialists in this field. Accordingly, the invention, in its broadest aspects, is not limited to the particular details presented and described and illustrative examples. Therefore, deviations from such details may occur without deviating from the nature or scope of the inventor's overall inventive concept. Therefore, the application is intended to cover changes, modifications and changes falling within the scope of the appended claims. The preceding description is not intended to limit the scope of the invention. Rather, the scope of the invention is defined by the appended claims and their equivalents.

[0072] Finally, the extent to which the term "includes" or "including" is used in the detailed description or the claims is intended to connect, in a manner similar to the term "comprising," as the term is interpreted when it is used in the claims as a connecting word. In addition, to the extent that the word "or" is used in the claims (e.g. A or B) is intended to mean "A or B or both." Where applicants intend to indicate "only A or B, but not both," the term "only A or B, but not both" will be used. Similarly, if applicants intend to indicate "one and only one" among A, B or C, applicants will use the term "one and only one." Therefore, in the sense used in the description, the word "or" has an inclusive, not an exclusive meaning. See Bryan A. Gamer, A Dictionary of Modern Legal Usage 624 (2nd edition 1995).