Design and construction of a continuous pilot flotation facility: A case study for water-based oil sand extraction

Abstract

In this work, the design and construction of a continuous and pilot-scale flotation facility are demonstrated. The performance of the new facility was evaluated from series of pilot flotation tests, carried out using oil sands slurry to extract bitumen—an extra-heavy form of petroleum. Results indicated that bitumen recoveries of the new pilot plant for an identical ore and water chemistry were largely dependent on air injection method, slurry conditioning time, flotation residence time, and slurry temperature. Importantly, when compared with those of bitumen extraction tests using a bench-scale Batch Extraction Unit (BEU) operated at the most optimal conditions, it was suggested that the new pilot plant produced flotation recoveries of bitumen and froth qualities at a level as good as, or even higher than, the level accomplished using the BEU at an identical ore, water chemistry and operating temperature. This continuous, pilot flotation plant could potentially serve as a pre-commercial production system that verifies a new processing aid, or as an alternative extraction technology for oil sand, coal, and mineral processing.