A NEW PROCESS FOR TAR SAND RECOVERY

An extraction process for bitumen recovery from tar sand has been developed using an alkaline solution (c.g., NaOH, Na2SiO3) and sonication at a low temperature and ambient atmosphere. The bitumen recovered thus far is extraordinarily low in ash content and virtually free of metal and asphaltene, with an average gravity of 15-degrees API for 95% cumulative recovery (based on carbon content) in a continuous operation. The heavier components, asphaltene and preasphaltene, were separated as solids, which contained many highly-enriched strategic metals. Clean sand and intact clay can be recovered simultaneously, easily, and essentially in full. It is demonstrated here that (1) the addition of radicals (H2O2, benzoyl peroxide, AIBN) reduces the reaction time from hours to minutes, and (2) hydroquinone (radical inhibitor) slows the reaction rate tremendously. This process utilizes the principle of membrane-mimetic chemistry. By applying sonication simultaneously, the multi-lamellar vesicles dissociate into individual micelles that can be reorganized into the oil phase. In this manner, the lighter portions of the bitumen (hydrocarbons) can be separated from the heavy residua (asphaltics). In addition, the surfactants formed (spent solution) can be used to extract more bitumen from new batches of tar sand.