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Abstract

Bituminous froths, typically obtained from the known Hot Water Method of extraction treatment of oil sands, are processed to remove water and part of the coarse mineral solids contained in the froth. In the process, the froth feed stock from the Hot Water Method treatment is mixed with a naphtha diluent, preferably naphtha which is derived from upgrading or refining of separated bitumen, in preferably the minimum amount sufficient to effectively remove all water by azeotropic distillation, while providing a workable feed viscosity. The mixture of naphtha and froth is treated to remove coarse solids and part of the water in a settling device, heated to a temperature sufficient to cause vaporization of the naphtha and remaining water as an azeotrope and flashed to substantially separate all water and naphtha from the bitumen. The dry bitumen with remaining solids, is normally not suitable for passing to a refinery but rather is sent to upgrading at a typical oil sands mining upgrading complex. Naphtha is recovered and recycled. The naphtha, in addition to its azeotrope forming feature, makes the froth more homogenous, less viscous, easier to handle and less fouling in heat exchangers, facilitates separation of coarse solids, and eliminates severe foaming when the froth is heated.

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