Abstract
This study is the first of two companion papers using hyperspectral data to generate predictive models of oil sand ore and froth characteristics as a potential new means for process control. In Alberta, Canada, shallow oil sands deposits are accessed by surface mining and crushed ore is transported to a processing plant for extraction of bitumen using flotation processes. The ore displays considerable variability in clay, bitumen, and fines which affects their behavior in flotation units. Using oil sand ore spanning a range of bitumen and fines characteristics, flotation experiments were performed to generate froth in a batch extractor to determine ore processability (e.g., separation performance) and froth characteristics (color, bitumen, solids). From hyperspectral observations of ore, models can predict the %bitumen content and %fines (particle passing at 44 and 3.9 µm) of ore but the models with highest r2 (>0.96) predict the solids/bitumen of froth and the processability of ore. Spectral observations collected on ore upstream of the separation vessels could therefore offer a first order assessment of froth quality for an ore blend before the ore enters the plant. These models could also potentially be used to monitor and control the performance of the blending process as another means to control the performance of the flotation process.
Highlights
Oil sands are comprised of bitumen, solid particles, and water [1,2,3]
Solids in some samples (e.g., Sp#4, Sp#5, and Sp#6) had a very slow settling rate and the water layer remained muddy after several hours and much of the solids remained agglomerated with the floating bitumen in an emulsified state resulting in a brown froth color (Figure 2, Sp#4 and Sp#6)
It is worth noting that each model is based on distinct spectral phenomena, the solids/bitumen model resting on information related to bitumen and clay while the processability model rests on information related to water and clay
Summary
Oil sands are comprised of bitumen, solid particles, and water [1,2,3]. In Alberta, Canada, shallow oil sands deposits are accessed by surface mining and crushed ore is transported to a processing plant for extraction of aerated bitumen from water and oil sands slurry using flotation processes [2,4,5].The Clark hot water extraction process, which involves conditioning, multistage separation, and froth treatment, is the common method for extracting bitumen from the oil sands and water slurry [3,6].The conditioning stage allows the oil sand matrix to disintegrate, releasing bitumen into the water phase, where bitumen droplets coalescence and bitumen–air attachment occurs in favorable interfacial conditions. Oil sands are comprised of bitumen, solid particles, and water [1,2,3]. In Alberta, Canada, shallow oil sands deposits are accessed by surface mining and crushed ore is transported to a processing plant for extraction of aerated bitumen from water and oil sands slurry using flotation processes [2,4,5]. The Clark hot water extraction process, which involves conditioning, multistage separation, and froth treatment, is the common method for extracting bitumen from the oil sands and water slurry [3,6]. The aerated slurry enters a separation unit where bitumen floats to the top of the separation unit in the froth layer. The underflow stream contains waste materials including solid particles
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