Effect of process water chemistry and particulate mineralogy on model oilsands separation using a warm slurry extraction process simulation

Variability in ore composition and process parameters is known to affect bitumen recovery from natural oilsands. In this work, we extend our earlier investigations with model oilsands systems (MOS) to determine the effects of calcium, magnesium and bicarbonate ion concentrations in the process water and their interactions with ‘active’ solids such as: kaolinite, montmorillonite and ultra-fine silica. Our results demonstrate that solids mineralogy and decreasing particle size produce negative outcomes on bitumen recovery related to concomitant effects on bitumen droplet size during flotation. In some cases, certain process water chemistries were found to restore recovery, but clay concentration was the key factor.Naturally acidic oilsands are known to give poor bitumen recoveries. An MOS prepared with connate water at pH 2 responded in the same way. Comparison with a typical oilsands showed no significant differences in middlings pH and the large, negative effect on bitumen recovery was not reversed by higher caustic loading during separation. This result may be caused by irreversible co-flocculation of bitumen and mineral particles during preparation of the MOS and may reflect similar behavior in comparable natural samples.