Recovery of extra-heavy oil and minerals from carbonate asphalt rocks by reactive extraction

Quite different from the Canadian oil sands, the Indonesian asphalt rocks proved to be carbonate unconventional oil ores. The strong interactions between asphalt and minerals make water-based extraction work poorly in separating this kind of ore. Herein, a reactive extraction process has been proposed to separate asphalt and mineral solids from the ores through dissolving the mineral solids (i.e., carbonate minerals, metal oxides, etc.) by acids (formic acid). It is evidenced that most of the asphalt could be recovered and collected on the top of the solution by generated CO(2). What's more, the unreacted formic acid could be recycled in this process. The dissolved metal ions could be efficiently recovered to obtain different by-products by chemical settling and crystallization. The amount of residual solids settled at the bottom of the reactor is very small. Further tests show that the reaction efficiency is highly dependent on the operational conditions, including temperature, stirring rate, acid dosage, concentration of acid, etc. It is also found that the reaction could allow minerals to be redistributed in different phases. Although some metal elements could be dissolved into solution, elements such as Fe, Al, S, Si, and Ti are observed to accumulate in asphalt froth. In addition to reacting with minerals, formic acid is also found to reduce asphalt viscosity. This reduction improves the reaction efficiency. Based on primary evaluations, the above findings suggest that the reactive extraction would be a potential process to exploit the Indonesian asphalt rocks (or other similar ores) due to its full recovery to all materials.