A process for extracting bitumen from weathered oil sand ore is provided, comprising mixing the weathered oil sand ore with heated water and sodium triphosphate to form a weathered oil sand slurry; adding sodium triphosphate to either the weathered oil sand ore, the heated water, or to the weathered oil sand slurry; conditioning the weathered oil sand slurry at a temperature of at least 50 C. to form a conditioned weathered oil sand slurry; and subjecting the conditioned weathered oil sand slurry to gravity separation at a temperature of at least 50 C. to form a bitumen froth product.

A method of extracting bitumen from oil sands having a transition temperature at which the oil sands solidify includes forming formable oil sands into pellets and cooling at least a surface of the pellets sufficiently to prevent the pellets from aggregating; cooling the pellets to below the transition temperature; fracturing the pellets to release the bitumen from the oil sands while maintaining the temperature of the pellets below the transition temperature; and separating the bitumen from the oil sands in a separator.

A method of extracting bitumen from oil sands having a transition temperature at which the oil sands solidify includes forming formable oil sands into pellets and cooling at least a surface of the pellets sufficiently to prevent the pellets from aggregating; cooling the pellets to below the transition temperature; fracturing the pellets to release the bitumen from the oil sands while maintaining the temperature of the pellets below the transition temperature; and separating the bitumen from the oil sands in a separator.

A water-based extraction process for extracting bitumen from mined oil is provided comprising providing a water-based mixture containing bitumen; and introducing nanobubbles to the mixture to attach to bitumen and, thereby, extract the bitumen from the water-based mixture, wherein a nanobubble has a diameter of less than 5,000 nm.

A water-based extraction process for extracting bitumen from mined oil is provided comprising providing a water-based mixture containing bitumen; and introducing nanobubbles to the mixture to attach to bitumen and, thereby, extract the bitumen from the water-based mixture, wherein a nanobubble has a diameter of less than 5,000 nm.

A single solvent method and machine for separating bitumen from oil sand ore are disclosed. The method includes the use of a single light paraffinic solvent, such as propane or butane as the agent to separate the bitumen from mined oil sand ore. Since light paraffinic solvents are vapors at atmospheric pressure and temperatures, the ore is placed in a pressurized container so that the solvent remains in a liquid state. When the container is pressurized, by the addition of the solvent itself, the liquid solvent is mixed with the ore to effect separation. The proposed machine settles more than 80% of the solids out under gravity in a modest period of time. The solvent-bitumen mixture is drained after the cleaning cycle, the container is depressured to a vapor recovery system and the remaining solids dumped out. The fine solids, drained with the liquids, are separated from the liquid mixture with relative ease by the use of current technology in other downstream equipment.

A single solvent method and machine for separating bitumen from oil sand ore are disclosed. The method includes the use of a single light paraffinic solvent, such as propane or butane as the agent to separate the bitumen from mined oil sand ore. Since light paraffinic solvents are vapors at atmospheric pressure and temperatures, the ore is placed in a pressurized container so that the solvent remains in a liquid state. When the container is pressurized, by the addition of the solvent itself, the liquid solvent is mixed with the ore to effect separation. The proposed machine settles more than 80% of the solids out under gravity in a modest period of time. The solvent-bitumen mixture is drained after the cleaning cycle, the container is depressured to a vapor recovery system and the remaining solids dumped out. The fine solids, drained with the liquids, are separated from the liquid mixture with relative ease by the use of current technology in other downstream equipment.

A process for refining sand for use as frac sand includes the steps of passing the sand through a first fines separation stage to remove fine particles of contaminant from the sand, reducing the water content of the sand (such as to less than 20%), passing the sand into an attrition scrubber unit containing moving blades to delaminate clay and other contaminants from the sand grains, passing the sand from the attrition scrubber unit through a second fines separation stage to separate fine contaminants from the sand, and dewatering the resulting sand product in a further dewatering stage.

A process for refining sand for use as frac sand includes the steps of passing the sand through a first fines separation stage to remove fine particles of contaminant from the sand, reducing the water content of the sand (such as to less than 20%), passing the sand into an attrition scrubber unit containing moving blades to delaminate clay and other contaminants from the sand grains, passing the sand from the attrition scrubber unit through a second fines separation stage to separate fine contaminants from the sand, and dewatering the resulting sand product in a further dewatering stage.

One or two continuous recirculation loops are utilized for the well-site equipment that separates produced fluids into sand, liquid, and gas during drill out and flow back that occurs after fracturing a subterranean formation. When one recirculation loop is utilized, the recirculation loop continuously recirculates fluid between the recirculation chamber of the disclosed sand removal apparatus and a shaker device. When two recirculation loops are utilized, the first recirculation loop continuously recirculates fluid between a recirculation chamber of the disclosed sand removal apparatus and a shaker device, and the second recirculation loop continuously recirculates fluid between the recirculation chamber and a gas separator.