Interaction forces in bitumen extraction from oil sands

Water-based extraction process (WBEP) has been successfully applied to bitumen recovery from Athabasca oil sand ore deposits in Alberta. In this process, two essential steps are involved. The bitumen first needs to be “liberated” from sand grains, followed by “aeration” with air bubbles. Bitumen “liberation” from the sand grains is controlled by the interaction between the bitumen and sand grains. Bitumen “aeration” is dependent, among other mechanical and hydrodynamic variables, on the hydrophobicity of the bitumen surface, which is controlled by water chemistry and interactions between bitumen and fine solids. In this paper, the interaction force measured with an atomic force microscope (AFM) between bitumen-bitumen, bitumen-silica, bitumen-clays and bitumen-fines is summarized. The measured interaction force barrier coupled with the contacted adhesion force allows us to predict the coagulative state of colloidal systems. Zeta potential distribution measurements, in terms of heterocoagulation, confirmed the prediction of the measured force profiles using AFM. The results show that solution pH and calcium addition can significantly affect the colloidal interactions of various components in oil sand extraction systems. The strong attachment of fines from a poor processing ore on bitumen is responsible for the corresponding low bitumen flotation recovery. The identification of the dominant non-contact forces by fitting with the classical DLVO or extended DLVO theory provides guidance for controlling the interaction behavior of the oil sand components through monitoring the factors that could affect the non-contact forces. The findings provide insights into megascale industrial operations of oil sand extraction.