Abstract:
Disclosed is a system for processing oil sands to remove bitumen, the viscous petroleum product adhered to the sands, from the sands itself. The processing system is designed to be substantially air tight, preventing outside air from entering and volatile chemicals from escaping from the system. Mined oil sands are delivered to the system, which creates a slurry of oil sands and solvent in a slurry chamber. The slurry is transported to a dissolution chamber which conditions the slurry before the slurry is sent to an extraction chamber. A plurality of trays and scrapers further conditions the slurry to remove bitumen. The use of heavy, aromatic solvents and light, paraffinic solvents in sequence improves bitumen recovery while allowing environmentally safe processing of the sands to occur in a later step. The sands are dried and the solvent recovered for recycling and reuse in the system. Clean, dry sands are returned to the source of mined oil sands for reclamation.

Description:
PRIORITY CLAIM 
       [0001]    This non-provisional application claims the priority and the benefit of U.S. Provisional Patent Application 61/057,915 filed Jun. 2, 2008, which is incorporated herein for all purposes by this reference. 
     
    
     FIELD 
       [0002]    This invention relates to the processing of oil sands. Oil sands are typically mixed with clay, water, and bitumen. Bitumen is a form of heavy oil, typically with a specific gravity below 20° on the American Petroleum Institute (API) scale and a viscosity above 10,000 centipoise (cP) at 60° F., where centipoise is a centimeter-gram-second system unit equal to 1 mPa·s in the International System of Units (SI). Oil sands are typically found in deposits near the surface that are mined. The oil sands are then processed to remove the bitumen, which can be refined into commercially useful hydrocarbon products, and the sands cleaned so that it may be returned to the earth. 
       BACKGROUND 
       [0003]    Deposits of oil sands are found around the world, but most prominently in Canada, Venezuela, and the United States, most significantly in Utah. These oil sands contain significant deposits of heavy oil, typically referred to as bitumen. The bitumen from these oil sands may be extracted and refined into synthetic oil or directly into petroleum products. 
         [0004]    The difficulty with bitumen lies in that it typically is very viscous, sometimes to the point of being more solid than liquid. Thus, bitumen typically does not flow as less viscous, or lighter, crude oils do. 
         [0005]    Because of the viscous nature of bitumen, it cannot be produced from a well drilled into the oil sands as is the case with lighter crude oil. This is so because the bitumen simply does not flow without being first heated, diluted, or upgraded. 
         [0006]    Since normal oil drilling practices are inadequate to produce bitumen, several methods have been developed over several decades to extract and process oil sands to remove the bitumen. For shallow deposits of oil sands, a typical method includes surface extraction, or mining, followed by subsequent treatment of the oil sands to remove the bitumen. 
         [0007]    The development of surface extraction processes has occurred most extensively in the Athabasca field of Canada. In these processes, the oil sands are mined, typically through strip or open pit mining with draglines, bucket-wheel excavators, and, more recently, shovel and truck operations. The oil sands are then transported to a facility to process and remove the bitumen from the sands. These processes typically involve a solvent of some type, most often water or steam, although other solvents, such as hydrocarbon solvents, have been used. 
         [0008]    After excavation, a hot water extraction process is typically used in the Athabasca field in which the oil sands are mixed with water at temperatures ranging from approximately 110° F. to 180° F., with recent improvements lowering the temperature necessary to the lower portion of the range. A surfactant, such as sodium hydroxide (NaOH), or other surfactants, and air are also mixed with the oil sands. 
         [0009]    Adding the water and NaOH to the oil sands creates a slurry, which is then transported to an extraction plant, typically via a pipeline. Inside a separation vessel, the slurry is agitated and the water and NaOH releases the bitumen from the oil sands. Air entrained with the water and NaOH attaches to the bitumen, allowing it to float to the top of the slurry mixture and create a froth. The bitumen froth is further treated to remove residual water and fines, which are typically small sand and clay particles. The bitumen is then either stored for further treatment or immediately treated, either chemically or mixed with lighter petroleum products, and transported by pipeline for upgrading into synthetic crude oil. 
         [0010]    This process removes approximately 75% of the bitumen. Additional treatments applied to the oil sands may remove another 10% to 20% of the bitumen from the sands. The relatively clean sands (as compared to the oil sands) are then returned to the mine, typically in the form of tailing piles. Because some bitumen, NaOH, or other hazardous materials may remain on the relatively clean sands, the sands must be further treated or stored in tailings piles that have protections to prevent any of the hazardous materials from leaching into the ground or nearby water sources. 
         [0011]    Another method of extracting bitumen from oil sands includes a hydrocarbon-based solvent extraction process in which a solvent or mixture of solvents flows counter-current to a slurry of oil sand and solvent in a processor. The solvent helps separate the bitumen from the sand and the solvent-bitumen mixture is drawn off from the top of the processor while sands with any remaining bitumen and solvent exit from the bottom of the processor. 
         [0012]    While the known methods of extracting bitumen from oil sands work well with certain deposits of oil sands, those same processes often work poorly with deposits of oil sands that have different characteristics. For example, the processes that use water typically work poorly with oil sands that have a high concentration of clay mixed within the oil sands. The water may bind with the clay, causing the clay to swell and clog pipes, fittings, and other processing machinery. Further, a significant volume of water is required when used as a solvent, which may not always be available at a location because of permitting requirements or simply the arid nature of a region in which the oil sands are located. Large pits or basins to store water, both before and after use when the water is polluted with bitumen and other chemicals are often required. Air, water, and ground pollution concerns, not to mention the large space required, often make this unfeasible. In addition, any water used must be treated to remove impurities and other pollutants, which typically is an expensive process. 
         [0013]    Hydrocarbon-based solvent extraction processes may not always be suitable for a variety of reasons, too. First, air quality concerns often limit the use of hydrocarbon solvents because the evaporation of those solvents adversely affects air quality. In addition, solvent processes typically cost significantly more because of the cost and the large volume of solvent required. Pollution concerns often require special handling and disposal of these solvents, including those solvents that remain on the sand after processing, to prevent air, water, and ground pollution. 
         [0014]    Therefore, an environmentally sound method of extracting bitumen for oil sands is required that addresses the short comings in previous methods of processing oil sands. 
       SUMMARY 
       [0015]    Oil sands that include bitumen are first mined from an oil sand source. The oil sands, with larger clumps and pieces of oil sands and rock crushed into smaller pieces, are deposited into a slurry chamber and mixed with a liquid or liquids, which may include solvents, to form a slurry that can be pumped via pipe to other parts of a processing facility. The slurry chamber optionally is designed to minimize or prevent outside air from entering into the system and minimize or prevent any volatile chemicals within the system from escaping. 
         [0016]    The slurry optionally is pumped to a dissolution chamber in which the slurry is treated with a water- or hydrocarbon-based solvent to begin removing the bitumen from the oil sands, creating a froth of bitumen, solvent and fine solids. The slurry optionally passes through a screen and is further processed with an agitator to further reduce the oil sands and larger clumps into smaller pieces. 
         [0017]    From the dissolution chamber, the slurry is pumped to an extraction chamber in which the slurry and froth is treated with solvent. A light, paraffinic solvent such as hexane or a mixture of hexane with bitumen can be used to remove the bitumen from the oil sands. Alternatively, diesel can be used as a solvent. The slurry falls under the influence of gravity to a plurality of trays with openings therein. Scrapers push the slurry to the openings in a tray, causing the slurry to again descend under the influence of gravity to another tray with openings that are offset from the openings in the first tray. Another scraper pushes the slurry towards the openings in the second tray. The process removes the bitumen from the sands, with the less dense bitumen and solvent rising towards the top of the extraction chamber and forming what is typically referred to as a froth. The bitumen and solvent froth is extracted from the extraction chamber. The solvent-wetted sands exit the extraction chamber via a substantially air tight valve to a vacuum conveyor and dryer. 
         [0018]    Another embodiment of the extraction chamber uses a heavy, aromatic solvent that is injected in first extraction/rinsing section of the extraction chamber. The heavy solvent removes most of the bitumen from the oil sand and treats the froth and the slurry. The slurry is conditioned with a plurality of trays and scrapers as described above. 
         [0019]    The slurry descends under the influence of gravity and the action of the scrapers to a second extraction/rinsing section of the extraction chamber, into which a light, paraffinic solvent is injected. The light, paraffinic solvent has a lower distillation point than the heavy solvent and is therefore easier to vaporize during subsequent processing of the sands. The light, paraffinic solvent strips the heavy solvent from the sands. The light solvent-wetted sands exit the extraction chamber via a substantially air tight valve to a vacuum conveyor and dryer. 
         [0020]    The froth containing the heavy solvent and bitumen is extracted from proximate the top of the extraction chamber and sent to a solvent recovery system that separates recoverable solvent from the bitumen. A portion of the bitumen is used in the system while another portion is sent for processing into synthetic crude oil or to storage. 
         [0021]    The solvent-wetted sands are processed in a vacuum conveyor and a dryer to vaporize and substantially remove any remaining solvent from the sands. The vaporized solvent is recovered through a vapor solvent recovery system and an absorber to strip the light vapor solvent from a circulating inert gas. 
         [0022]    The clean, dry sands are stored for use as either backfill to reclaim the land disrupted during the mining of the oil sands, as construction material, as proppant in fracturing fluids used in the oil and gas industry, and other uses known in the art. 
         [0023]    As used herein, “at least one,” “one or more,” and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. 
         [0024]    Various embodiments of the present inventions are set forth in the attached figures and in the Detailed Description as provided herein and as embodied by the claims. It should be understood, however, that this Summary does not contain all of the aspects and embodiments of the one or more present inventions, is not meant to be limiting or restrictive in any manner, and that the invention(s) as disclosed herein is/are and will be understood by those of ordinary skill in the art to encompass obvious improvements and modifications thereto. 
         [0025]    Additional advantages of the present invention will become readily apparent from the following discussion, particularly when taken together with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]    To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
           [0027]      FIG. 1  depicts an embodiment of the system for processing oil sands in a block diagram; 
           [0028]      FIG. 2  depicts an embodiment of the system with embodiments of major subsystems identified; 
           [0029]      FIG. 3  depicts an embodiment of a slurry chamber used in an embodiment of the system; 
           [0030]      FIG. 4  depicts an embodiment of a dissolution chamber used in an embodiment of the system; 
           [0031]      FIG. 5  depicts an embodiment of an extraction chamber used in an embodiment of the system; 
           [0032]      FIG. 5A  depicts an embodiment of plurality of trays and scrapers used in an embodiment of the extraction chamber depicted in  FIG. 5 ; 
           [0033]      FIG. 6  depicts an embodiment of an absorber system used in an embodiment of the system; 
           [0034]      FIG. 7  depicts an embodiment of a vapor solvent recovery system used in an embodiment of the system; 
           [0035]      FIG. 8  depicts an embodiment of a solvent recovery system used in an embodiment of the system; 
           [0036]      FIG. 9  depicts an embodiment of a vacuum conveyor and a dryer used in an embodiment of the system; 
           [0037]      FIG. 10  an embodiment of a slurry chamber and a dissolution chamber used in an example of the system; 
           [0038]      FIG. 11  an embodiment of an extraction chamber used in an example of the system; 
           [0039]      FIG. 12  an embodiment of a vacuum conveyor used in an example of the system; 
           [0040]      FIG. 13  an embodiment of a dryer used in an example of the system; and, 
           [0041]      FIG. 14  an embodiment of a vapor recovery system and other components used in an example of the system. 
       
    
    
       [0042]    The drawings are not necessarily to scale. 
       DETAILED DESCRIPTION 
       [0043]    “Oil sands” or “tar sands” are the common terms for what are formally known as “bituminous sands.” Oil sands are naturally occurring mixtures of sand and a viscous form of petroleum called bitumen. Oil sands often include clay, silt, water, and other minerals and liquids. Oil sands are a major source of what is referred to as non-conventional oil. Non-conventional oil is termed as such because it typically cannot be extracted through the use of oil wells as is the case with conventional oil reservoirs. 
         [0044]    Illustrated in  FIG. 1  is a block outline of an embodiment of the processing system  10  of the invention;  FIG. 2  depicts various embodiments of subsystems of  FIG. 1  in greater detail as outlined in the dotted boxes. (The subsystems are illustrated in greater detail in  FIGS. 3 through 9 , which are discussed below.) To be useful as a source of petroleum, the bitumen must first be removed from the oil sands to which it is attached. In ex situ methods of extracting the bitumen, the oil sands are typically excavated or mined from shallow deposits and delivered to a processing facility near the deposits of oil sands, depicted at  15 . The method of mining and transporting  20  the oil sands to the processing site vary, but are not germane to the invention. 
         [0045]    Once mined, the oil sands are optionally delivered to a slurry chamber  25  where the oil sands are mixed with a solvent or solvents and treated mechanically to form a slurry that can be pumped through the processing system  10 . The solvent, which can include one or more solvents, such as water (including fresh water, brine, salt water, recycled or reclaimed water, and/or water with various additives and/or solids therein), one or more heavy distillates (i.e. having a higher distillation point or temperature than hexane) or heavy petroleum products, other known solvents, and/or mixtures thereof, is injected into the slurry chamber  25  through line  155 . Non-limiting examples of the heavy distillate solvents include diesel, heavy fuel oil, mixtures of bitumen and other solvents, and others. A physical characteristic that these examples of the heavy distillate solvents share is a low volatility, which means that the solvent does not vaporize at low temperatures easily. 
         [0046]    Optionally, the slurry is fed via line  30  to a dissolution chamber  35 , in which additional solvent such as those described above is added through line  76  to the slurry. The slurry is further treated mechanically to reduce the size of the sand and other particulates within the slurry. (The connection lines, such as line  30  are idealized representations of physical structure, typically industrial piping of some sort, but also including conveyors, valves and other connections, as one having ordinary skill in the art understands.) The solvent (such as those described above) applied in the dissolution chamber begins the process of removing the bitumen from the oil sands to create a froth of bitumen, solvent, and, typically, some fine solids. (While some dissolution of the bitumen from the oil sands occurs in the slurry chamber as the water and/or heavy distillate solvent is added, significantly more dissolution occurs in the dissolution chamber.) Non-limiting examples of the solvent include water, heavy solvents such as bitumen extracted from the oil sands in other systems of the process, and other hydrocarbons, such as diesel, heavy fuel oil, and mixtures of these and other hydrocarbons as described above. 
         [0047]    From the slurry chamber  25  or, if optionally passed through the dissolution chamber  35 , the slurry is pumped via a line  40 , typically a pipe configured to pump highly erosive slurry, to an extraction system  43 , which includes an extraction chamber, or vessel,  45 . The extraction chamber, or vessel,  45  includes a plurality of sections, although it is understood that these sections do not necessarily have discrete boundaries and are merely identified as such for clarity. The embodiment illustrated includes three sections, although more or fewer sections may be present. Further, while the embodiment of the extraction chamber  45  is illustrated with various subsystems both before and after the extraction chamber  45 , one having skill in the art would understand that the extraction chamber  45  is capable of being used with other subsystems and combinations, both before and after, to treat the bitumen froth and the slurry. 
         [0048]    The first section is a settling section  50  near the upper portion of the extraction chamber, or vessel,  45 . The settling section  50  is where the slurry settles to a degree, which means that a portion of the bitumen, solvents, and other liquids rise towards the top of the extraction chamber or vessel,  45  as a froth while the sand and other solids settle or descend under the influence of gravity towards the bottom of the extraction chamber, or vessel,  45 . 
         [0049]    The second section is the first extracting/rinsing section  55  and lies below the settling section  50  in the extraction chamber, or vessel,  45 . Heavy solvents, such as aromatics (i.e., those solvents whose chemical formula includes a benzene ring) are injected through line  70  into the first extracting/rinsing section  55 . The heavy solvent mixes with the oil sands in the slurry in the first extracting/rinsing section  55  and removes a substantial portion of the bitumen from the oil sands and dilutes the bitumen. As the sands from which most of the bitumen has been removed descends in the extraction chamber  45  under the force of gravity, bitumen and the heavy solvent rises towards the top as a froth. The descending sands are now wetted with the heavy solvent (and some bitumen) and referred to as heavy solvent-wetted sands and descend under the force of gravity in the first extraction/rinsing section  55 . 
         [0050]    A second extracting/rinsing section  60  lies below the first extracting/rinsing section  55 . Light solvents are injected through line  68  into the second extracting/rinsing section  60 . These light solvents are lighter than the heavy solvents injected into the first extracting/rinsing section  55 . Light solvents include paraffinic solvents, i.e., those solvents whose chemical formula includes a single-bond carbon chain. The light solvents also have a higher vapor pressure than the heavy solvents. That is the light solvents have a lower distillation point than the heavy solvents and therefore vaporize at a lower temperature than the heavy solvents. The light solvents remove substantially all of the heavy solvent and any bitumen remaining on the heavy solvent-wetted sands. The remaining heavy solvent and bitumen rises towards the top of the extraction chamber, or vessel,  45  as a froth. The sands are now substantially free of heavy solvent and bitumen and are wetted only with the light solvent and are referred to as light solvent-wetted sands. 
         [0051]    The froth of heavy solvent and bitumen that rises to the top of the extraction chamber, or vessel,  45  is drawn off via line  75 , such as a conduit, valve, passage, pipe, or other connection through which the heavy solvent and bitumen can flow. A portion of the froth of the heavy solvent and bitumen is sent via line  76  to the dissolution chamber  35  and another portion is sent via line  76  through a filter configured to remove fine (i.e., small diameter) silt, sand, and other solids from the froth of heavy solvent and bitumen before being sent via line  78  and  130  to a solvent recovery system  135 . 
         [0052]    Returning to the extraction chamber, or vessel,  45 , the light solvent-wetted oil sands are removed from the lower portion of the extraction chamber, or vessel,  45  and the second extracting/rinsing section  60  via a valve (discussed in more detail below) and through line  80  to the clean sand drying system  83 , which includes a vacuum conveyer  85  and a rotary dryer  95 . 
         [0053]    Line  80  first delivers the light solvent-wetted sands to the vacuum conveyer  85 . A vacuum draws off a portion of the light solvent from the light solvent-wetted sands and delivers a portion of the light solvent via line  66  to line  68 , where the light solvent is reinjected into the second extracting/rinsing section  60  as discussed above. 
         [0054]    The vacuum conveyor  85  delivers the remaining light solvent-wetted sands via line  90  to the rotary dryer  95 . The rotary dryer  95  applies heat to the light solvent-wetted oil sands to vaporize any light solvent remaining on the sands. Before the clean sands exits the rotary dryer  95 , inert gas is optionally injected via line  115  into the rotary dryer  95 . The inert gas acts to strip any remaining light solvent adhered to the sands. The vaporized light solvent and circulating inert gas is removed from the rotary dryer  95  via line  100  and sent to a vapor solvent recovery system  105 . Clean dry sands  175  exit the rotary dryer via line  102 . 
         [0055]    The vapor solvent recovery system  105  condenses the light solvent for reuse within the entire process. The light vapor solvent recovered as liquid is sent via line  67  to intersect with the light solvent in line  66 , which is delivered via line  68  to the second extracting/rinsing section  60 . The light vapor solvent unrecovered is sent via line  108  to line  110 , which delivers the solvent to an absorber system  120 . 
         [0056]    The absorber system  120  strips the light vapor solvent delivered via line  110  from the vapor solvent recovery system  105  from any circulating inert gas. Excess inert gases optionally are flared, or vented to the atmosphere, at  170 . Heavy distillate arrives at the absorber system  120  from the solvent recovery system  135  via line  160 . The heavy distillate removes the light solvent that arrives via line  110 , with the heavy distillate and light solvent being sent via line  125  to intersect with the bitumen and heavy solvent from the filter  77  via line  78 . The combined bitumen/heavy solvent and heavy distillate/light solvent is then sent to the solvent recovery system  135 . 
         [0057]    The solvent recovery system  135  is configured to separate the bitumen from the heavy and light solvents that it receives via line  130 . The solvent recovery system  135  delivers heavy solvents and aromatics via line  70  to the first extracting/rinsing section  55  of the extraction chamber, or vessel,  45 . The solvent recovery system  135  also delivers light solvents and paraffinics via line  65  to the second extraction/rinsing section  60  of the extraction chamber, or vessel,  45 . Heavy distillates are sent from the solvent recovery system  135  via line  150 , which branches into line  155 , via which heavy distillates optionally are delivered to the slurry chamber  25 , and line  160 , which delivers heavy distillates to the absorber system  120 . The solvent recovery system  135  also delivers the separated bitumen  145  to storage via line  140 . 
         [0058]      FIG. 3  depicts an enlarged view of an embodiment of the optional slurry chamber  25  from  FIGS. 1 and 2 . Mined oil sands  15  are delivered to the slurry chamber  25 . The sands can be delivered directly via truck, conveyor, pipeline (if previously formed into a slurry) and other methods known in the art. The oil sands  15  optionally enter through a feeder-breaker  310  that crushes and breaks the incoming oil sands  15  into smaller pieces and optionally prevents any significant amount of ambient (outside) air from entering into the slurry chamber  25 . While it is not necessary to prevent air from entering into the slurry chamber  25 , it is preferred to minimize or prevent air from entering into the slurry chamber  25  (and the system beyond) because it reduces or removes the presence of oxygen that could be consumed should any of the inflammable gases and liquids in the processing system  10  ignite. Additionally, while a feeder-breaker  310  prevents outside air from entering, it also reduces or eliminates the release of any solvents, volatile hydrocarbons, and other vapors into the air. Not only is reducing or eliminating the amount of solvents, volatile hydrocarbons, and other vapors that escape one consideration as part of reducing the economic cost of operating the system  10 —any solvent lost to the atmosphere cannot be recycled and reused in the system, but has to be purchased and added—it also reduces the environmental impact and air pollution. The latter reason is a consideration not only for protecting the air quality near the processing facility and the environment nearby, but it also may be a necessary requirement to receive operating permits under various regulatory schemes. The feeder-breaker  310  includes a valve depicted in  FIG. 3  that is a rotary-type valve, as known in the art, but it will be appreciated that valves of other types fall within the scope of the disclosure. 
         [0059]    A conveyor  315  optionally transports deposited oil sands  15  to the feeder-breaker  310 . While  FIG. 3  depicts a horizontal arrangement, it is understood that the slurry chamber  25  can be configured vertically in a bin arrangement (not illustrated) in which the oil sands  15  are deposited in a bin and descend vertically under the force of gravity to a feeder-breaker  310  at the bottom of the bin, which allows the oil sands to pass through the feeder-breaker  310  and into the slurry chamber  25 . 
         [0060]    In either arrangement, it is preferable, although not necessary, to provide a sufficient volume of oil sands at the feeder-breaker  310  and conveyor  315  such that the oil sands provides a partial, mechanical barrier to the entrance of outside air and the escape of vapors and solvents from within the slurry chamber  25 . 
         [0061]    Once entering the slurry chamber  25 , the oil sands  15  optionally pass through an inert gas or gases injected at a first sprayer or sparger  320 . The inert gas, typically nitrogen, carbon dioxide, a mixture thereof, or other inert gases, acts to strip oxygen and other ambient air that entered with the oil sands  15  through the feeder-breaker  310 . The inert gas and ambient air can be removed via a flare or vent  305  and vented directly to the atmosphere or it can be sent to be recycled, treated, scrubbed, or handled in other known ways to reduce pollution and cost. 
         [0062]    The oil sands  15  optionally are treated with a solvent, such as water (hot or cold, in terms of temperature, and of the several types of water described above) or hydrocarbon-based solvents as described above. For example, the solvent can include a heavy distillate in the slurry chamber  25  as discussed above. The heavy distillate is delivered into the slurry chamber  25  via a second sprayer or sparger  325 . The heavy distillate arrives at the slurry chamber  25  via line  155  from the solvent recovery system  135 . The heavy distillate (or water, in the case of a water based conditioning program or process is employed) begins the process of conditioning the oil sand  15  and, possibly, removing some bitumen from the oil sands, but, more importantly, it provides a sufficient liquid base to form a slurry of the solvent, oil sand  15 , and other materials so that it may be transported throughout the processing system  10 . 
         [0063]    The slurry of oil sands and solvent optionally are transported via a screw conveyor  330  that is operably connected to a motor  340  that provides the motive force to turn the screw conveyor  330 . The motor  340  is typically an electric motor as known in the art, but hydraulic motors and other types of motors known fall within the scope of the disclosure. (All of the motors described within this specification are typically electric motors, but any type of motor, such as hydraulic motors, may be used. Thus, this reference refers to all motors further discussed within this specification.) The screw conveyor breaks larger agglomerations and clumps of the oil sands into smaller pieces, further conditioning and exposing the oil sand to the solvent, such as water and/or the heavy distillate introduced at the sprayer  325 . While the slurry chamber depicted illustrates a screw conveyor  330 , one having skill in the art understands that other known methods of conditioning and transporting slurries of oil sands and distillates can be used. 
         [0064]    The partially conditioned slurry optionally is delivered to the dissolution chamber  35 .  FIG. 3  illustrates this at line  30 , but it is understood that line  30  represents a physical connection between the slurry chamber  25  and the dissolution chamber  35 , such as a pipeline, open chute, or other physical connections known. It is also understood that the connection between the slurry chamber  25  and the dissolution chamber  35  typically is air tight or nearly air tight, which means that outside air is prevented or limited from entering into the processing system  10  and vapors, solvents and other volatiles are prevented or limited from escaping from the processing system  10 . 
         [0065]    An embodiment of the dissolution chamber  35  is illustrated in  FIG. 4 . The slurry of oil sands and solvent, such as water or heavy distillate, is delivered from the slurry chamber  25  via line  30 , as discussed above. The slurry is further treated with a second solvent delivered into the dissolution chamber  35  via third sprayer  405  and fourth sprayer  410 . While  FIG. 4  illustrates sprayers  405  and  410 , it is understood that either fewer or more sprayers can be used. The solvent can be water, either hot or cold and/or with a mixture of various chemical additives or treatments included, a mixture of bitumen and heavy solvent, referred to as “bitumen oil,” or other hydrocarbon based solvent, that is optionally delivered via line  76  from the extraction chamber, or vessel,  45 . While a ratio of bitumen to solvent typically ranges from 60/40 to 40/60, it is understood that the solvent can range from entirely bitumen to entirely solvent. 
         [0066]    The slurry with additional solvent descends under gravity in the dissolution chamber  35  through an optional screen, or screens,  415 . While any type of screen  415  can be used, the embodiment depicted uses a trough-type screen. The size (mesh) of the screen is selected to vary with the size and condition of the oil sands and is configured to further reduce any agglomerations or clumps of oil sands into yet smaller pieces, thereby further exposing all or nearly all parts of the oil sands to the solvents that act to remove the bitumen from the oil sands. The screens can be configured such that the uppermost screen has the largest spaces (or least fine mesh, i.e., has a small mesh number) such that larger agglomerations are broken up slightly. Additional screens, if used, might have a successively larger mesh number (i.e., it is a finer mesh allowing only small agglomerations to pass) such that the size of the agglomerations and clumps of oil sands become progressively smaller as they descend in the dissolution chamber  35 . This ensures that the oil sands become further exposed to the solvent and thereby conditioned to increase the amount of bitumen removed from the oil sands. The screens are configured to be removed and replaced as needed for maintenance. 
         [0067]    Once the slurry passes through the screen  415 , it descends under the influence of gravity towards the bottom of the dissolution chamber  45 . An optional agitator  420  is operably connected and configured to rotate under the motive power provided by a motor  425 . The agitator  420  further conditions and mixes the slurry to ensure that the oil sands in the slurry are well mixed with the solvent, thereby creating in large measure froth of bitumen with solvent. 
         [0068]    The dissolution chamber  35  typically operates at or within several pounds of atmospheric pressure. The time during which the slurry within the dissolution chamber  35  is conditioned is optimized to maximize the amount of bitumen produced against the cost of operating the processing system  10 . In addition, the interior temperature at which the dissolution chamber  35  operates is also optimized to maximize the amount of bitumen produced against the cost of operating the processing system  10 . 
         [0069]    The conditioned slurry and froth is drawn off from near the bottom of the dissolution chamber  35  via line  428 . Pump  430  urges the slurry through line  40  to the extraction chamber, or vessel,  45 . The pump  430  can be of any type of pump configured to pump slurries and other dense fluids, including duplex, triplex and other types piston-style pumps, centrifugal pumps, and others known to one having skill in the art. 
         [0070]    The slurry and froth delivered from the dissolution chamber  35  to the extraction chamber, or vessel,  45  arrives via line  40  typically, although not necessarily, near an upper third portion of the extraction chamber, or vessel,  45 , as illustrated in  FIG. 5 . This upper third portion of the extraction chamber, or vessel,  45  is referred to as the settling section  50  for convenience. While the settling section  50  is referred to as part of the upper third of the extraction chamber, or vessel,  45 , it is understood that the boundary between the settling section  50  and the first extraction/rinsing section  55  and the second extraction/rinsing section  60  is one more of function than a precise geographical landmark of the extraction chamber, or vessel,  45  and is defined as such for convenience. 
         [0071]    Typically, the slurry enters into the settling section  50  through a port connected with line or conduit  40  with an angular momentum relative to a center line (one that follows the shaft  515 , which is discussed in further detail below). In other words, the port is typically, although not necessarily, configured to enter the settling section  50  at an angle to impart the slurry with an angular momentum. The angular momentum of the slurry propels the heavier sands and other sediments towards the outer portion (i.e., furthest from the center line along shaft  515 ), while the lighter fluids remain closer to the center line, helping to separate the bitumen and fluids from the sands. 
         [0072]    The sands, some of which still having bitumen adhered thereto, and other sediments descend under the influence of gravity in the settling section  50 , and settle, to a degree, as depicted at  520 . These bitumen and solvent-wetted sands  520  settle into the first extraction/rinsing section  55 . 
         [0073]    The first extraction/rinsing section  55  is configured to further condition the oil sands and expose any sands with bitumen remaining thereon to additional solvent, typically a heavy solvent, although water may be used, to remove any remaining bitumen and dilute the froth. The first reaction/rinsing section  55  includes one or more tray-scrapers  530 , as seen in  FIG. 5  and enlarged in  FIG. 5A . The oil sands fall under the influence of gravity onto a tray  540 . The tray  540  includes one or more openings  535  within the tray through which the oil sands can pass under the influence of gravity to another tray  541  or towards the bottom of the extraction chamber, or vessel,  45 . The tray  541  also includes openings  536 , but the openings  536  of the another tray  541  are offset from the openings  535  of tray  540 . Offsetting the openings  535  and  536  aids in conditioning the oil sands because it prevents oil sands from descending through any openings that could otherwise be aligned and thus allow some oil sands to descend to the bottom of the extraction chamber, or vessel,  45  without encountering a tray  540  or  541 . 
         [0074]    Associated with tray  540  is a scraper  545  and with tray  541  is scraper  546 . The scrapers  545  and  546  rotate relative to the respective tray to which it is associated. That is, the tray  540 ,  541  may rotate relative to a fixed scraper  545 ,  546 ; the scraper  545 ,  546  may rotate relative to the fixed tray  540 ,  541 ; or, both the tray  540 , 541  and the scraper  545 ,  546  both rotate relative to each other. Regardless, a shaft  515  operably connected to a motor  510  is configured to impart the rotation to the tray  540 ,  541 , the scraper  545 ,  546 , or both. 
         [0075]    The openings  535 ,  536  of the trays  540 ,  541  are illustrated to be 90° segments of the round tray  540 ,  541  with each opening 180° apart on a selected tray, as illustrated in  FIG. 5A . The opening  536  of tray  541  is also offset by 90° from the opening  535  in the tray  540  that lies above. One having skill in the art would understand that the size of the opening can be adjusted from 90° to larger or smaller opening as desired. In addition, the size of the opening  536  can be adjusted to be different from that of opening  535 . For example, opening  535  can be adjusted to 110° while opening  536  remains at 90°. In addition, the number of openings in each tray can be adjusted to include more or fewer openings, and the number of openings between trays can also vary. Finally, the degree of offset between the openings of successive trays can be adjusted as desired. 
         [0076]      FIG. 5  illustrates that the first extraction/rinsing section  50  includes three tray-scrapers  530 , but one having skill in the art understands that either more or fewer tray scrapers  530  can be used. 
         [0077]    The first extraction/rinsing section  50  includes a sprayer or sparger  550  that injects a solvent, typically a heavy solvent such as an aromatic (i.e., having a chemical formula that includes a benzene ring) typically, although not necessarily, below the first series of tray-scrapers  530 . The heavy solvent typically arrives via line  65  from the solvent recovery system  135 , although provision for injecting new (i.e., unrecovered) solvent can be made. The solvent acts on any bitumen remaining on the oil sands as the oil sands are conditioned as it moves through the tray-scrapers  530  and dilutes the bitumen in the froth. This arrangement further removes any bitumen remaining on the sands. The heavy solvent typically removes the bitumen while minimizing the amount of any asphaltene present in the bitumen from precipitating out of solution. The less dense bitumen (as compared to the sands and any sediment) and any heavy solvent that does not adhere to the sands ascend towards the top of the extraction chamber, or vessel,  45 . Thus, the sands towards the bottom of the first extraction/rinsing section  50  are substantially free of bitumen. Instead, the sands at the bottom of the first extraction/rinsing section  50  is therefore substantially wetted with heavy solvent, or heavy solvent-wetted sands. 
         [0078]    The heavy solvent-wetted sands descend under the influence of gravity to the second extraction/rinsing section  60  of the extraction chamber, or vessel,  45 . The heavy solvent-wetted sands descends through one or more tray-scrapers  530  similar to those described in detail above in the first extraction/rinsing section  55 . In the second extraction/rinsing section  60 , light solvent, typically a paraffinic (i.e., a hydrocarbon solvent whose chemical formula includes a single bond chain of carbon to which hydrogen bonds) with a lower distillation point than the heavy solvent (i.e., the paraffinic vaporizes at a lower temperature) is injected into the second extraction/rinsing section  60  via sprayer or sparger  555  typically positioned below the heavy solvent sprayer or sparger  550 . The light solvent typically is delivered to the sprayer  555  via line  70  from the solvent recovery system  135 , although provision can be made for injecting new light solvent into the second extraction/rinsing section  60 . 
         [0079]    As the light solvent rises in the second extraction/rinsing section  60 , it interacts with the heavy solvent-wetted sands, as aided through the mechanical agitation of the heavy solvent-wetted sands with the tray-scrapers  530  in the second extraction/rinsing section  60 . The light solvent, typically hexane, although other, similar solvents can be used, removes most, if not all, of any bitumen that remains adhered to the sands. The light solvent has a greater likelihood of causing any asphaltene present in the bitumen to precipitate out of solution, which could cause problems such as clogging with the processing system  10 . Thus, it is preferred to inject the light solvent after the heavy solvent has removed the majority of the bitumen from the oil sands. In addition, the light solvent displaces the heavy solvent adhered to the heavy solvent-wetted sands. Thus, after treatment in the second extraction/rinsing section  60  the sands have light solvent adhered thereto to form light solvent-wetted sands  558 . The light solvent, having a higher vapor pressure (or lower distillation point) than the heavy solvent, is easier to remove from the sands during subsequent processing, as will be discussed below. 
         [0080]    The removed heavy solvent rises towards the top of the extraction chamber, or vessel,  45  for removal as will be discussed below. The now light solvent-wetted sands  558  descend under the influence of gravity towards the bottom of the extraction chamber, or vessel,  45 . The light solvent-wetted sands are depicted at  558  in  FIG. 5 . 
         [0081]    The extraction chamber, or vessel,  45  typically operates at an elevated temperature as compared to ambient temperature. The elevated temperature, typically in the range of about 20° C. to about 100° C. and, more preferably, about 40° C. to about 80° C., and more preferably still, about 50° C. to about 70° C., improves the ability of the heavy and light solvents to remove the bitumen from the oil sands. In addition, the extraction chamber typically operates at an elevated internal pressure relative to ambient (i.e., 1 atmosphere, or 14.7 pounds per square inch). This is done to prevent the light solvent, which has a relatively lower distillation point than the heavy solvent, from vaporizing within the extraction chamber, or vessel,  45 . In other words, the elevated pressure within the extraction chamber, or vessel,  45  keeps the light solvent in a substantially liquid phase. Typically, the pressure within the extraction chamber, or vessel,  45  is in a range of about 1 ½ to about 5 times ambient pressure and, more preferably, about 2 to about 4 times ambient pressure, although other pressures can be used. 
         [0082]    The light solvent-wetted sands  558  exits the extraction chamber, or vessel,  45  via a valve  565  typically proximate the bottom of the extraction chamber, or vessel,  45  that is operably connected to and configured to be powered by a motor  560 . The valve  565  in the embodiment depicted in  FIG. 5  is a rotary-valve type, although valves of other types can be used. 
         [0083]    The light solvent-wetted sands  558  are delivered via line  80  to the vacuum conveyor  85 . Line  80 , as is understood, is a figurative representation of the connection between the extraction chamber, or vessel,  45  and the vacuum conveyor  85 . The connection between the extraction chamber, or vessel,  45  and the vacuum conveyor  85  optionally is substantially air tight to prevent outside air from entering (or to minimize the amount of air entering) into the processing system  10  and to prevent or minimize the amount of any volatile hydrocarbons, solvents, vapors, or other potentially harmful pollutants from escaping the system. 
         [0084]    At the top of the extraction chamber, or vessel,  45 , the froth of bitumen released from the oil sands and any solvent, primarily heavy solvent released from the heavy solvent-wetted sands through the action of the light solvent, is drawn off via line or conduit  75  typically, although not necessarily, positioned proximate a top of the extraction chamber, or vessel,  45 . A valve (not shown) can be used to connect the extraction chamber, or vessel,  45  to the line  75 , as known in the art. The bitumen and solvent (typically bitumen oil, as discussed above) is sent via line  76  through a heat exchanger  505  to the dissolution chamber  35  as discussed above. In addition, line  76  delivers bitumen oil to the filter  77 , which is configured to remove fine particulates and sediment entrained with the froth of bitumen and solvent drawn off from the extraction chamber, or vessel,  45 . After passing through the filter  77 , the froth of bitumen and solvent is delivered via line  78  to the solvent recovery system  135 , which is configured to separate the bitumen from the solvent as will be discussed below. 
         [0085]    The light solvent-wetted sand  558  optionally arrives from the extraction chamber, or vessel,  45  into the vacuum conveyor  85  via line  80 , as illustrated in  FIG. 9 , upon which the light solvent-wetted sands  558  is deposited upon the conveyor  955 . The conveyor  955  includes the normal items necessary for a conveyor as known in the art. 
         [0086]    An optional vacuum system  945  creates a vacuum in the vacuum conveyor  85  via line  950 , drawing off a portion of the light solvent from the light solvent-wetted sands. Pump  935  draws off the light solvent via line  940 , sending the light solvent  925  via line  930  to be recycled and reused in the processing system  10 . Pump  915  draws the vacuum gas  905  via line  920  and sends the vacuum gas via line  910  to the vapor recovery solvent system  105 . 
         [0087]    The conveyor  955  transports and deposits the remaining light solvent-wetted sands into a rotary dryer  95 . A source of hot heating oil  980  optionally jackets the rotary dryer  95  to provide heat to the rotary dryer  95 . The heating oil  980  can be from an outside source or can be hot liquids from other parts of the processing system  10  routed to the rotary dryer  95 . The temperature of the heating oil is typically in the range of 200° to 250° C., although other temperatures fall within the scope of the disclosure. 
         [0088]    The rotary dryer  95  further applies heat to the light solvent-wetted sands and rotates the sands within, typically around several fins or paddles to ensure even drying. As the light solvent is vaporized (and circulating inert gas entrained therein; the source of the inert gas is discussed below), it is drawn off from the rotary dryer  95  via line  100  and sent to the vapor solvent recovery system  105 . 
         [0089]    The rotary dryer  95  is configured such that as the light solvent is vaporized from the light solvent-wetted sands, the dry sands move towards a valve  970  from which the substantially clean, dry sands exits the rotary dryer  95 . The valve  970  may be of any type known in the art, but in this particular embodiment it is a rotary valve operably coupled to a motor  965  that provides the motive force to turn the rotary valve  970 . Above the rotary valve  970 , a source of inert gas  963  optionally supplies inert gas via line  962  to sprayer or sparger  960 . Optionally, inert gas is also injected directly into the rotary dryer  95  via line  964 . The inert gas is typically nitrogen, carbon dioxide, a mixture thereof, and other types of inert gas fall within the scope of the embodiment. The inert gas strips any light solvent that remains adhered to the sands and purges any vaporized light solvent from the area of the rotary valve  970 , minimizing or preventing any light solvent from escaping the rotary dryer  95  and, thereby, reducing cost and minimizing air pollution. 
         [0090]    Any excess inert gas injected into the rotary dryer  95  is optionally drawn off from the rotary dryer  95  via line  985  and flared to ambient, or outside, air. 
         [0091]    The clean dry sands pass through the rotary valve  970  and can be stored at  175  for later use as backfill in the oil sands mining pit, as a proppant in fracturing fluids used in the petroleum exploration industry, as construction sands, and other uses. Before reaching the clean sands storage  175 , the hot sands that exits the rotary dryer  95  optionally passes through a heat exchanger (not shown) through which the heat from the hot sands is captured to heat fluids and the like that are used in the processing system  10 , thereby increasing the energy efficiency of the system  10  as a whole. 
         [0092]    An embodiment of a vapor solvent recovery system  105  is depicted in  FIG. 7 . Vaporized light solvent (and any circulating inert gas) arrives from the dryer  95  via line  100 , optionally passing through a cyclonic separator  705 . The cyclonic separator  705  is configured to remove sand that is entrained with the vaporized light solvent drawn off from the rotary dryer  95 . The cyclonic separator  705  delivers dry sands  745  via line  740 . The vaporized light solvent travels via line  707  through a cooler  710 , which reduces the heat of the vaporized solvent. A receiver  730  draws the vaporized solvent via line  715 , sending condensed, liquid, light solvent  755  via line  735  for reuse. Still vaporized light solvent (and any circulating inert gas) is sent from the receiver  730  through line  720  to a blower  725 . The blower  725  urges the vaporized light solvent via line  110  to the absorber system  120 . 
         [0093]    An embodiment of an absorber system  120  is depicted in  FIG. 6  in which vaporized light solvent (and any circulating inert gas) arrives from the vapor solvent recovery system  105 . The vaporized light solvent is injected into the absorber system  120  via a sprayer or sparger  615 . A heavy distillate, such as diesel, is injected via  610  at the top of the absorber system  120 . The heavy distillate typically arrives via line  160  from the solvent recovery system  135 . Optionally, the heavy distillate arrives via another source of heavy distillate (not shown). The heavy distillate strips the vaporized light solvent from the stream, and the heavy distillate and absorbed light vapor solvent are sent via line  125  to the solvent recovery system  135 . Any inert gas that remains is flared  170  to the atmosphere via line  165 , as is any inert gas sent via line  985  from the rotary dryer  95 . 
         [0094]    An embodiment of a solvent recovery system  135  is depicted in  FIG. 8 . The solvent recovery system  135  includes distillation column  810 . The distillation column  810  is of a type known in the art and typically includes two or more trays. Bitumen and heavy solvent arrives to the distillation column  810  via line  130 . Heavy distillates are drawn off from the distillation column  810  via line  150 , which are then optionally sent via line  160  to the absorber system  120  and via line  155  to the slurry chamber  25  after passing through a cooler  805 . 
         [0095]    Heavy solvents are drawn off from the distillation column  810  via line  70  and optionally sent to the extraction chamber, or vessel,  45  via line  70 . 
         [0096]    Light solvents are drawn from the top of the distillation column  810  via line  65  and optionally sent to the extraction chamber, or vessel,  45 . 
         [0097]    Separated bitumen oil is separated from near the bottom of the distillation column  810  and sent via line  140  to bitumen storage  145 . 
       EXAMPLE 1 
       [0098]    An example of an embodiment of the processing system  10  is depicted in  FIGS. 10 through 14 ; Table 1 provides information as to the temperature, pressure, and composition of various streams of material throughout the processing system  10  and provides context for such terms as substantially, about, proximate, and other terms of degree. The identical figure numbers in  FIGS. 10 through 14  denote the same element as those figure numbers in  FIGS. 1 through 9 , for which a more detailed explanation can be found above. 
         [0099]    A slurry chamber  25  and dissolution chamber  35  are depicted in  FIG. 10 . Oil sands  15  are mined and delivered via line  20  to the slurry chamber as stream  1000 . The stream  1000  enters into the slurry chamber  25  via feeder-breaker  310 . An inert gas stream  1005 , in this instance carbon dioxide and nitrogen, is delivered via line  1090  to a sprayer or sparger  320 . The inert gas prevents or minimizes the amount of external air entering into the processing system  10 . 
         [0100]    A stream  1010  of bitumen oil, a mixture of bitumen and solvent, typically a heavy distillate such as diesel that has a high vapor pressure, arrives to the slurry chamber  25  via line  155  and is injected into the slurry chamber  25  via sprayer  325 . (As discussed above, water and/or other solvents may be used, but this example discusses the use of bitumen oil as the solvent.) The bitumen oil mixes with the oil sands to form a slurry stream  1015  that the screw conveyor  330  conditions as it transports the slurry  1015  to the dissolution chamber  35 . 
         [0101]    Excess nitrogen and any solvent that vaporizes in the slurry chamber  25  is drawn off as stream  1020  from the slurry chamber  25  via line  1085  and sent to the vapor solvent recovery system  105 . 
         [0102]    Line  30  delivers the slurry stream  1015  to the dissolution chamber  35 . The slurry stream  1015  is exposed to stream  1030  of bitumen oil, a mixture of bitumen and solvent, sent via line  76  through sprayer  405 . Line  76  also delivers stream  1030  of bitumen oil to sprayer  410  within the dissolution chamber  35 . The stream  1030  is heated through a steam heat exchanger  1055  that has hot steam  1045  enter the heat exchanger  1055  via line  1050  and condensate  1065  leave the heat exchanger  1055  via line  1060 . The cooler stream  1035  of bitumen oil enters the heat exchanger  1055  via line  1070 . 
         [0103]    Vaporized solvent in stream  1025  is drawn off proximate the top of the dissolution chamber  35  via line  1080  and sent to the vapor solvent recovery system  105 . 
         [0104]    The slurry within the dissolution chamber  35  passes through one or more screens  415  to reduce the size of the solids entrained within the slurry. The screen  415  in this embodiment is a trough-type screen, although other types of screens are contemplated. 
         [0105]    An agitator  420  operably connected to motor  425  is configured to condition the slurry to provide a relatively homogenous slurry in terms of particle size of the solids and the degree to which the oil sands are exposed to the solvent in the slurry. 
         [0106]    The slurry is drawn from proximate the bottom of the slurry chamber. In the embodiment depicted in  FIG. 10 , two separate lines  428  draw off the slurry and pumps  430  urges the slurry as stream  1040  towards the extraction chamber, or vessel,  45  via line  40 . 
         [0107]    Another embodiment of an extraction chamber, or vessel,  45  is depicted in  FIG. 11 . The slurry stream  1040  from the dissolution chamber  35  enters the upper portion of the extraction chamber, or vessel,  45  in the settling section  50 . The slurry stream descends under the influence of gravity downward in the settling section to the first extraction/rinsing section  55 . In this particular embodiment, the extraction chamber, or vessel,  45  has a plurality of trays-scrapers  530  in only the first extraction/rinsing section  55 , unlike the embodiment discussed above which also has trays-scrapers  530  in a second extraction/rinsing section  60 . The slurry encounters the plurality of tray-scrapers  530  similar to those described above in  FIGS. 5 and 5A . The plurality of tray-scrapers  530  are operably connected shaft  515  which in turn is operably connected to motor  510 , which urges the tray-scrapers  530  to rotate as described above. 
         [0108]    Solvent stream  1115  enters the second extraction/rinsing section  60  via sprayer  555  and line  1185  proximate the lower third of the extraction chamber, or vessel,  45 . Solvent arrives via line  70  and passes through a heat exchanger  1180  to heat the solvent stream. Steam  1140  enters into the heat exchanger via line  1135  and exits as condensate  1125  via line  1130 . 
         [0109]    Solvent stream  1115  also enters via sprayer  1165  and, optionally, at valves  1170  and  1   175 . The solvent stream  1115  that enters via sprayer  1165  and valves  1170  and  1175  add additional solvent, if necessary to the light solvent-wetted sands to ensure that the sands flow sufficiently easy through the rotary valve  565  into line  80  (as stream  1120 ) going to the vacuum conveyor  85 . 
         [0110]    Hot oil  1145  is sent via line  1150  to jacket the extraction chamber, or vessel,  45  to elevate the temperature within the extraction chamber, or vessel,  45 . The cooled oil  1160  leaves via line  1155 . Operating the extraction chamber at an elevated temperature improves the efficiency with which the bitumen is removed from the oil sands, as discussed above. 
         [0000]    
       
         
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Stream Composition, Temperature, and Pressure 
               
             
          
           
               
                 Stream 
                   
                   
                   
                 Press 
                   
                   
                   
                   
                   
                   
                   
               
               
                 Fluid 
                 Fluid 
                 Fluid 
                 Temp 
                 ATM 
                 Sand 
                 Bitumen 
                 Solvent 
                 CO 2   
                 O 2   
                 N 2   
                 H 2 O 
               
               
                 No. 
                 Name 
                 State 
                 ° C. 
                 (kg/cm 2 ) 
                 (kg/hr) 
                 (kg/hr) 
                 (kg/hr) 
                 (kg/hr) 
                 (kg/hr) 
                 (kg/hr) 
                 (kg/hr) 
               
               
                   
               
             
          
           
               
                 1000 
                 Sands 
                 Sands 
                 20 
                 ATM 
                 37,648 
                 3,219 
                 — 
                 — 
                 — 
                 — 
                 800 
               
               
                 1015 
                 Slurry 
                 Slurry 
                 60 
                 ATM 
                 37,648 
                 6,438 
                 1,812.7 
                 — 
                 — 
                 — 
                 800 
               
               
                 1040 
                 Slurry 
                 Slurry 
                 60 
                 3 
                 37,648 
                 19,314 
                 9,800.6 
                 — 
                 — 
                 — 
                 800 
               
               
                 1110 
                 Bit. Oil 
                 Liquid 
                 60 
                 2 
                 — 
                 19,314 
                 13,116 
                 — 
                 — 
                 — 
                 — 
               
               
                 1100 
                 Bit. Oil 
                 Liquid 
                 60 
                 3 
                 — 
                 16,095 
                 10,930 
                 — 
                 — 
                 — 
                 — 
               
               
                 1105 
                 Bit. Oil 
                 Liquid 
                 60 
                 3 
                 — 
                 3,219 
                 2,186 
                 — 
                 — 
                 — 
                 — 
               
               
                 1030 
                 Bit. Oil 
                 Liquid 
                 90 
                 3 
                 — 
                 12,876 
                 8,744 
                 — 
                 — 
                 — 
                 — 
               
               
                 1250 
                 H 2 O 
                 Liquid 
                 38 
                 390 mm Hg 
                 — 
                 — 
                 ~0 
                 1 
                 ~0 
                 0.3 
                 769.8 
               
               
                 1005 
                 CO 2  &amp; 
                 Vapor 
                 90 
                 760 mm Hg 
                 — 
                 — 
                 — 
                 27.6 
                 1.7 
                 80.4 
                 — 
               
               
                   
                 N 2   
               
               
                 1115 
                 Sol. 
                 Liquid 
                 60 
                 3 
                 — 
                 — 
                 9,515.4 
                 — 
                 — 
                 — 
                 — 
               
               
                 1120 
                 Sands &amp; 
                 Slurry 
                 60 
                 780 mm Hg 
                 37,648 
                 — 
                 6,200 
                 — 
                 — 
                 — 
                 800 
               
               
                   
                 Sol 
               
               
                 1240 
                 H 2 O 
                 Liquid &amp; 
                 38 
                 400 mm Hg 
                 — 
                 — 
                 3,668.9 
                 93.1 
                 7.2 
                 341.7 
                 800.1 
               
               
                   
                 and Sol. 
                 Vapor 
               
               
                 1200 
                 Sands &amp; 
                 Slurry &amp; 
                 60 
                 775 mm Hg 
                 37,648 
                 — 
                 2,629 
                 — 
                 — 
                 — 
                 — 
               
               
                   
                 Sol. 
                 Liquid 
               
               
                 1300 
                 CO 2  &amp; 
                 Vapor 
                 90 
                 775.5 mm Hg   
                 — 
                 — 
                 257.3 
                 243.1 
                 19 
                 898.7 
                 0.2 
               
               
                   
                 Sol. 
               
               
                   
                 CO 2  &amp; 
                 Vapor 
                 10 
                 780 mm Hg 
                 — 
                 — 
                 22 
                 20.8 
                 1.6 
                 76.8 
                 ~0 
               
               
                   
                 Sol. 
               
               
                 1245 
                 CO 2  &amp; 
                 Liquid 
                 38 
                 390 mm Hg 
                 — 
                 — 
                 3,067.5 
                 0.9 
                 ~0 
                 0.2 
                 1.3 
               
               
                   
                 Sol. 
               
               
                 1205 
                 N 2  &amp; 
                 Vapor 
                 38 
                 390 mm Hg 
                 — 
                 — 
                 601.4 
                 91.2 
                 7.2 
                 341.1 
                 29 
               
               
                   
                 Sol. 
               
               
                 1235 
                 N 2  &amp; 
                 Vapor 
                 75 
                 760 mm Hg 
                 — 
                 — 
                 601.4 
                 91.2 
                 7.2 
                 341.1 
                 29 
               
               
                   
                 Sol. 
               
               
                 1305 
                 N 2  &amp; 
                 Vapor 
                 90 
                 775 mm Hg 
                 — 
                 — 
                 2,885.4 
                 245.2 
                 19 
                 897.5 
                 0.2 
               
               
                   
                 Sol. 
               
               
                 1310 
                 Sands 
                 Sands 
                   
                 ATM 
                 37,648 
                 — 
                 — 
                 — 
                 — 
                 — 
                 — 
               
               
                 1315 
                 CO 2   
                 Vapor 
                 90 
                 Including 
                 — 
                 — 
                 — 
                   
                 — 
                 — 
                 — 
               
               
                 1420 
                 N 2  &amp; 
                 Vapor 
                 82 
                 755 mm Hg 
                 — 
                 — 
                 4,616.2 
                 364 
                 28 
                 1,319 
                 29.1 
               
               
                   
                 Sol. 
               
               
                 1430 
                 N 2  &amp; 
                 Vapor 
                 55 
                 728.1 mm Hg   
                 — 
                 — 
                 4,616.2 
                 364 
                 28 
                 1,319 
                 29.1 
               
               
                   
                 Sol. 
               
               
                 1440 
                 N 2  &amp; 
                 Liquid &amp; 
                 0 
                 726.5 mm Hg   
                 — 
                 — 
                 4,616.2 
                 364 
                 28 
                 1,319 
                 29.1 
               
               
                   
                 Sol. 
                 Vapor 
               
               
                 1450 
                 N 2  &amp; 
                 Vapor 
                 4 
                 726.5 mm Hg   
                 — 
                 — 
                 377.2 
                 356.4 
                 27.9 
                 1,317.7 
                 0.3 
               
               
                   
                 Sol. 
               
               
                 1400 
                 N 2  &amp; 
                 Vapor 
                 10 
                 780 mm Hg 
                 — 
                 — 
                 257.3 
                 243.1 
                 19 
                 898.7 
                 0.2 
               
               
                   
                 Sol. 
               
               
                 1025 
                 Sol. 
                 Vapor 
                 77 
                 755 mm Hg 
                 — 
                 — 
                 756.1 
                 — 
                 — 
                 — 
                 — 
               
               
                 1470 
                 Sol. 
                 Liquid 
                 4 
                 726.5 mm Hg   
                 — 
                 — 
                 4,239 
                 7.4 
                 ~0 
                 1.3 
                 1.2 
               
               
                 1485 
                 H 2 O 
                 Liquid 
                 4 
                 726.5 mm Hg   
                 — 
                 — 
                 ~0 
                 0.2 
                 ~0 
                 ~0 
                 27.6 
               
               
                 1020 
                 N 2  &amp; 
                 Liquid &amp; 
                 50 
                 755 mm Hg 
                 — 
                 — 
                 373.1 
                 27.6 
                 1.7 
                 80.4 
               
               
                   
                 Sol. 
                 Vapor 
               
               
                 1010 
                 Bit. Oil 
                 Liquid 
                 60 
                 3 
                 — 
                 3,219 
                 2,186 
                 — 
                 — 
                 — 
                 — 
               
               
                 1035 
                 Bit. Oil 
                 Liquid 
                 60 
                 3 
                 — 
                 12,876 
                 8,744 
                 — 
                 — 
                 — 
                 — 
               
               
                 1300 
                 N 2  &amp; 
                 Vapor 
                 90 
                 775.5 mm Hg   
                 — 
                 — 
                 256.4 
                 245.2 
                 19 
                 897.5 
                 0.2 
               
               
                   
                 Sol. 
               
               
                 1275 
                 CO 2  &amp; 
                 Vapor 
                 10 
                 760 mm Hg 
                 — 
                 — 
                 97.9 
                 93.1 
                 7.2 
                 341.7 
                 0.2 
               
               
                   
                 N 2   
               
               
                 1275 
                 CO 2  &amp; 
                 Vapor 
                 10 
                 780 mm Hg 
                 — 
                 — 
                 98 
                 92.6 
                 7.2 
                 342.2 
                 ~0 
               
               
                   
                 N 2   
               
               
                 1495 
                 Bit. Oil 
               
               
                   
               
             
          
         
       
     
         [0111]    Bitumen and solvent is drawn off from proximate the top of the extraction chamber, or vessel,  45  in stream  1110  via line  1185 . Line  1185  branches into line  1075 , which sends stream  1100  towards the dissolution chamber  35 . Line  1185  also branches into line  76 , which sends stream  1105  to filter  77 . 
         [0112]    An embodiment of a vacuum conveyor  85  is depicted in  FIG. 12 . Light solvent-wetted sands in stream  1120  are sent via line  80  to the vacuum conveyor  85 . Stream  1120  is deposited upon conveyor  955 . As discussed above, line  80  is configured to provide a substantially air tight connection between the extraction chamber, or vessel,  45  and the vacuum conveyor  85 , by which it is meant that outside air is prevented (or the amount minimized) from entering into the vacuum conveyor  85  and vaporized solvent is prevented (or the amount minimized) from escaping the vacuum conveyor  85 . 
         [0113]    Inert gas, in this example carbon dioxide and nitrogen, in stream  1275  arrives via line  1270  from heat exchanger  1290  and is injected into the vacuum conveyor  85 . A portion of stream  1275  passes through compressor  1265  and also enters vacuum conveyor  85  via line  1285 . The inert gas stream  1275  further prevents the entrance of any outside air from entering into the vacuum conveyor  85 . 
         [0114]    Vacuum drum  945  draws off any water and solvent in stream  1240  via line  950  from the light-solvent wetted sands in stream  1120 . 
         [0115]    Line  1215  carries stream  1205  of nitrogen and solvent to vacuum pump  1220 . The vacuum pump  1220  urges stream  1235  via line  1230  to the vapor solvent recovery system  105 . 
         [0116]    Lines  940  carries stream  1245  of carbon dioxide and solvent to pumps  935 , which urge stream  1245  via line  930  to a solvent storage  1255 , for example, or optionally the solvent recovery system  135 . 
         [0117]    Line  1298  carries waste water stream  1250  away from vacuum drum  945  and to pump  1280 , which urges stream  1250  to a waste water storage and treatment  1260  and for optional reuse in the process. 
         [0118]    The remaining light solvent-wetted sands in stream  1200  are removed via line  1210  from conveyor  85  and sent to the rotary dryer  95 . 
         [0119]    An embodiment of a rotary dryer  95  is depicted in  FIG. 13 . In this embodiment, two rotary dryers  95  are employed. Light solvent-wetted sands in stream  1200  are delivered from the vacuum conveyor  85  via line  1210  to the rotary dryers  95 . As discussed previously, the connection between the rotary dryer  95  and the vacuum conveyor  85  are substantially air tight. 
         [0120]    A source of fresh inert gas  963 , such as carbon dioxide, is delivered in stream  1315  via line  962  into the rotary dryers  95 . The inert gas aids in stripping the light solvent from the light solvent-wetted sands in the rotary dryers  95 . In addition, the inert gas in stream  1315  helps prevent outside air from entering through the rotary valve  970  as it operates to permit clean, dry sands in stream  1310  to exit from the rotary dryers  95 . 
         [0121]    A source of hot oil  980  delivered via line  981  to the rotary dryers  95  jackets the rotary dryers  95  and provides a source of heat to raise the temperature within the rotary dyers  95  and thereby vaporize the light solvent on the light solvent-wetted sands. The temperature of the rotary dryers is raised to 200° to 250° C. 
         [0122]    Carbon dioxide and solvent in stream  1300  is sent via line  1320  to the rotary dryers from the heat exchanger  1290 . 
         [0123]    Nitrogen and vaporized solvent in stream  1305  is drawn from the rotary dryers  95  via line  100  and sent to the vapor solvent recovery system  105 . 
         [0124]    Clean, dry sands exit the rotary dryers  95  via rotary valves  970  operably connected to the motor  965 . The clean, dry sands in stream  1310  are sent via line  102  to sands storage or, optionally, to a heat exchanger (not shown) that captures the heat of the sands to heat other fluids in the processing system  10  and, thereby, increase the energy efficiency of the processing system  10 . 
         [0125]    An embodiment of the vapor solvent recovery system  105  is depicted in  FIG. 14 . Stream  1305  of nitrogen and solvent is sent via line  1305  from the rotary dryer  95  to the cyclonic separator  705 . The cyclonic separator  705  removes sand and other sediment entrained in stream  1305 , with the dry sand  745  exiting the cyclonic separator via line  740 . 
         [0126]    Stream  1305  is joined with stream  1235  sent via line  1230  from vacuum conveyor  85 ; line  1295  from vacuum conveyor  85 ; stream  1025  via line  1080  from dissolution chamber  35 ; and, stream  1020  via line  1085  from slurry chamber  25 . Together, the aforementioned streams combine to form stream  1420  in line  1415 . 
         [0127]    Stream  1420  enters a cooler  710  that includes motors and fans to cool stream  1420 . 
         [0128]    Stream  1430  exits from the cooler  710  via line  1425 , which intersects line  1435  in which stream  1440  is sent to receiver  730 . 
         [0129]    From receiver  730 , waste water stream  1485  is drawn off via drum  1475  and delivered via line  1480  to storage or further treatment. 
         [0130]    Stream  1470  is drawn off from receiver  730  via line  735 . Pump  1460  urges stream  1470  via line  1465  to solvent storage  755  or, optionally, to the solvent recovery system  735 . 
         [0131]    Nitrogen and solvent in stream  1450  is drawn off from receiver  730  via line  1445 . Stream  1450  is compressed in compressor  1455  and sent via line  110  to the solvent absorber system  120 . 
         [0132]    Also illustrated within  FIG. 14 , although not part of the vapor solvent recovery system  105 , is the heat exchanger  1290 , previously discussed in  FIG. 12 . Inert gas, such as nitrogen, from source  963 , enters the heat exchanger  1290  via line  1410 . Line  1270  carries stream  1275 , as urged by pump  1405 , to the vacuum conveyor  85 . Line  1320  carries stream  1300  to the rotary dryer  95 . Finally, steam enters the heat exchanger  1290  via line  1498  while condensate leaves the heat exchanger  1290  via line  1499 . 
         [0133]    Also depicted in  FIG. 14 , but also not part of the vapor solvent recovery system  105 , is the filter  77 . Line  76  delivers stream  1105  from the extraction chamber, or vessel,  45 . After passing through the filter  77 , bitumen in stream  1495  leaves via line  1490  for storage or further processing, while some bitumen leaves via line  1497  to the dissolution chamber  35 . 
         [0134]    Additionally, a method of processing oil sands in an extraction chamber or vessel is disclosed as an embodiment of the invention. The method includes preparing a slurry of bitumen rich oil sands and solvent, which can be water (hot or cold) and/or hydrocarbon based, mixtures thereof, or other solvents, in a slurry chamber and/or dissolution chamber as discussed above. An extraction chamber or vessel is provided into which a slurry of bitumen rich oil sands and solvents is injected into the upper portion of the chamber, typically, but not necessarily, the top third. The extraction chamber is provided with a plurality of trays and scrapers in a stacked, vertical arrangement. Each tray has an associated scraper adjacent thereto. 
         [0135]    A motor is provided that is coupled to at least one of the trays and the scrapers and provides a relative rotation between each tray and its associated scraper. The trays have one or more openings, with the relative rotation of each tray and its associated scraper urging the slurry towards the opening through which the slurry falls under the force of gravity to the next lower tray in the vertical stack. 
         [0136]    One or more sprayers or spargers are provided, through which additional solvent is injected into the extraction chamber as described above. Typically, the solvent is water and/or a hydrocarbon based solvent. In one embodiment, a first sprayer injects a heavy solvent, such as an aromatic, into the extraction chamber, which is further mixed through the slurry through the action of the relative rotation of the trays and scrapers. 
         [0137]    Optionally a second sprayer or sparger is provided, through which additional solvent of the same type or different type as the type that is injected in the first sprayer is injected into the extraction chamber. In one embodiment, a light solvent, such as a paraffinic solvent is injected through the second sprayer. 
         [0138]    Bitumen released from the formerly bitumen rich sands rises upward through the extraction chamber, along with the heavy solvent, in a froth that is drawn off through a provided line or conduit proximate the top of the extraction chamber. 
         [0139]    Sands, typically solvent wetted and, more typically, light solvent-wetted sands pass through a provided valve proximate the bottom of the extraction chamber. The valve is selectively operable and configured to pass the light solvent-wetted sands from the extraction chamber to a dryer without substantially admitting ambient air and/or substantially allowing hydrocarbons and vapors to escape to the external environment. 
         [0140]    The one or more present inventions, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. 
         [0141]    The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation. 
         [0142]    The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention. 
         [0143]    Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.