The extraction process begins when the tar sand is sent through a crusher and reduced to ¾ inch crush. From there, the sand travels to a water/sand slurry where the catalyst solution is introduced and mixed with a pump specially designed for this process. Once mixed, the slurry travels to the first recovery tower where the tar is pulverized and individual grains of sand are exposed to the catalyst. Oil separates from the slurry and floats to the top while the slurry continues to the second recovery tower where the sand is pulverized and immersed in catalyst for a second time. The oil is captured and sent to the sales tank.
The sand that is produced and the solution containing the catalyst travel to a third tower while the soiled fluids are recycled to the clean water system. The clean water is then sent to the initial injection point in front of the crusher, where additional catalyst solution is added to bring it back to full strength. The sand passes over a shaker that removes most of the water and is then conveyed away and piled. That sand and clays can then be sold, returned to the open pit or mixed with the overburden. At this point the sand and clay are 98.22% by weight and the remaining 0.29% or less are hydrocarbons, based on independent laboratory tests.
Process Diagram
