Abstract: Apparatus uses engineered collection media to recover mineral particles in a mineral extraction process, e.g., for processing a tailings stream at the end of a flotation separation process. The engineered collection media are added to slurry/tailings containing the mineral particles. The engineered collection media have collection surfaces coated with a chemical selected for attracting the mineral particles to the collection surfaces so the engineered collection media becomes mineral laden media in the slurry/tailings in a loading stage. The apparatus include three stages: removing unwanted material from mineral laden media; using a stripping agent to strip the mineral particles from the mineral laden media; and separating the engineered collection media from the mineral particles and the stripping agent. The stripping agent is reused for stripping, and the engineered collection media are returned to the loading stage. The engineered collection media can have a smooth or foam-like surface.

Abstract: A system for separating hydrocarbons from a solid source including a primary separation tank including a first hydrocarbon removing device to remove hydrocarbons from a slurry of water and solids. Further, the system including a transfer device between the primary separation tank and a secondary separation tank, wherein the transfer device is configured to transfer solids from the slurry to the secondary separation tank. Further still, the system including a second hydrocarbon removal device, a fine particle separation device to remove remaining solids in the secondary separation tank, and a product collection tank to receive hydrocarbons removed from the primary and secondary separation tanks.

Abstract: A bitumen recovery process is provided which includes the step of providing a bitumen froth or a component derived from the bitumen froth as a feed material, wherein the bitumen froth is produced in a primary separation process from a slurry comprising oil sand and water. Further, the process includes the step of subjecting the feed material to froth flotation in a column flotation cell in order to recover a bitumen product from the feed material. Preferably, the froth flotation cell includes an underwash zone, wherein a bitumen-rich fraction of the feed material is passed through the underwash zone as the bitumen-rich fraction rises within the column flotation cell.

Abstract: A method and apparatus for recovering bitumen as froth from a feed stream having solids, water and bitumen is provided using a separating vessel having mounted thereon a downpipe assembly, the downpipe assembly having at least one downpipe and a nozzle in fluid communication with each downpipe, for aerating a stream of middlings withdrawn from the separating vessel and reintroducing the aerated middlings back to the separating vessel.

Abstract: A system for separating hydrocarbons from a solid source including a primary separation tank including a first hydrocarbon removing device to remove hydrocarbons from a slurry of water and solids. Further, the system including a transfer device between the primary separation tank and a secondary separation tank, wherein the transfer device is configured to transfer solids from the slurry to the secondary separation tank. Further still, the system including a second hydrocarbon removal device, a fine particle separation device to remove remaining solids in the secondary separation tank, and a product collection tank to receive hydrocarbons removed from the primary and secondary separation tanks.

Abstract: A fluid level control apparatus for selectively controlling the movement of liquid flowing out of a flotation cell is described. The fluid level control apparatus is significantly reduced in size in comparison with the flotation cell or cells to which it is connected which enables less expensive construction and reduced operating costs in terms of both the equipment and the plant as a whole. The fluid level control apparatus comprises a vessel having a valve positioned therein which includes a valve body structured with a curved surface which provides selective and finite control of fluid flowing through the vessel of the control apparatus. In one embodiment at least one of the inlet and outlet of the control apparatus exhibit a cross-sectional area taken transverse to the intended fluid flow therethrough having a substantially horizontal dimension which is greater than a substantially vertical dimension.

Abstract: The present invention provides for a reactive oily bubble carrier comprising: (a) a gas bubble having an oil-coating; and (b) a collector dissolved within the oil-coating. The present invention also provides for the use a reactive oily bubble carrier in a flotation target particle separation process. The present invention also provides for a flotation target particle separation process using the reactive oily bubble carriers disclosed herein.

Abstract: The carbon and mineral components of fly ash are effectively separated by a continuous air agglomeration method, resulting in a substantially carboree mineral stream and a highly concentrated carbon product. The method involves mixing the fly ash comprised of carbon and inorganic mineral matter with a liquid hydrocarbon to form a slurry, contacting the slurry with an aqueous solution, dispersing the hydrocarbon slurry into small droplets within the aqueous solution by mechanical mixing and/or aeration, concentrating the inorganic mineral matter in the aqueous solution, agglomerating the carbon and hydrocarbon in the form of droplets, collecting the droplets, separating the hydrocarbon from the concentrated carbon product, and recycling the hydrocarbon.

Abstract: An improved process is described for agglomerating ground coal in which a bridging oil is used as the agglomerating vehicle. This bridging oil is a mixture of a heavy gas oil obtained from coal/oil coprocessing and a heavy hydrocarbon oil, such as bitumen or heavy oil, preferably mixed in the proportion of about 23-40% heavy hydrocarbon oil and 60-77% heavy gas oil. The agglomerated product is mixed with additional heavy oil or bitumen and it becomes the feedstock to a coal/oil coprocessor, with heavy gas oil being formed as one of the product streams. At least part of this heavy gas oil product stream is recycled to the agglomeration stage as the heavy gas oil component of the bridging oil. This agglomeration procedure has the advantage of providing an agglomerate of excellent quality, while carrying out the agglomeration in a short time at ambient temperature and using less than 10% by weight of bridging oil.

Abstract: An improved pretreatment method for preparing powdered catalysts with well controlled particle size distributions that are free of sub 1 micron particles comprising dispersion of the powdered catalyst in liquid comprised of either a) a hydrocarbon containing low levels of a surfactant or, b) a surfactant containing polar protic solvent, followed by decantation of the suspended finely divided sub 1 micron particles and repeating said sequence until essentially 90% of the sub 1 micron particles have been removed.

Abstract: Disclosed is a graded metal powder for metallic pigment, comprising a metal powder wherein the metal powder has a mean particle size of from about 2.5 to about 15.0 .mu.m, the content of particles having a particle size of not greater than 1 .mu.m is not larger than about 0.5% by volume, and the metal powder has a particle size distribution such that not smaller than 97% by volume of the particles of the metal powder fall within the range between half the mean particle size of the metal powder and double the mean particle size of the metal powder. Also is disclosed a process for producing a graded metal powder by classifying metal particles dispersed in a mineral oil containing a nonionic-anionic surfactant.

Abstract: A process is provided for removing pyritic sulfur and lowering ash content of bituminous coals by grinding the feed coal, subjecting it to micro-agglomeration with a bridging liquid containing heavy oil, separating the microagglomerates and separating them to a water wash to remove suspended pyritic sulfur. In one embodiment the coal is subjected to a second micro-agglomeration step.

Abstract: An improved process is described for agglomeration beneficiation of ground coal in which undiluted heavy oil or bitumen is used as the agglomerating vehicle. The ground cell, water and heavy oil or bitumen are mixed at an elevated temperature sufficient to lower the viscosity of the heavy oil or bitumen to a level permitting easy mixing and at an elevated pressure sufficiently high to prevent boiling of the water. This mixing causes agglomeration of the carbonaceous solids with the heavy oil or bitumen and the agglomerates obtained are separated from the tailings containing aqueous medium and inorganic solids. The separated agglomerates are preferably used with additional heavy oil or bitumen to form a slurry feedstock for a coprocessing unit. This provides a very efficient total process since the coal agglomeration beneficiation uses a portion of the same heavy oil or bitumen feedstock which is used for coprocessing and no additional hydrocarbon diluent is required.

Abstract: The present invention relates to a process for the separation of gold from particulate material containing gold, which comprises introducing a hydrophobic liquid, a non-gold particulate hydrophobic bulking material and particulate, gold containing material into an aqueous liquid so that the hydrophobic liquid becomes associated with the gold and, in conjunction with the non-gold particulate hydrophobic material, forms gold bearing agglomerates bonded by the hydrophobic liquid, and separating the gold bearing agglomerates from the aqueous liquid.

Abstract: A mixture containing oleophilic surfaced mineral particles and oleophobic gangue particles in an aqueous phase is separated by means of an apertured oleophilic endless sieve supported in a separation zone by a revolving cylindrical cage having apertured sidewalls and supported in a recovery zone by a support roller, each section of sieve surface alternately revolves through the separation zone and recovery zone. The aqueous mixture is introduced as a slurry into the rotating cage. The endless sieve partly covers the outside surface of the cylindrical cage sidewall. An oleophilic adhesive is placed on the sieve as a coating or added to the aqueous slurry in the cage or both. The mixture tumbles inside of the cage and passes through the cage sidewall apertures to the sieve surface. The oleophilic mineral particles of the mixture adhere to the oleophilic adhesive and are captured by the sieve upon contact and conveyed out of the separation zone into the recovery zone.

Abstract: A process for purifying graphite comprising:(1) comminuting graphite containing mineral matter to liberate at least a portion of the graphite particles from the mineral matter;(2) mixing the comminuted graphite particles containing mineral matter with water and hydrocarbon oil to form a fluid slurry;(3) separating a water phase containing mineral matter and a hydrocarbon oil phase containing graphite particles; and(4) separating the graphite particles from the hydrocarbon oil to obtain graphite particles reduced in mineral matter.Depending upon the purity of the graphite desired, steps of the process can be repeated one or more times to provide a progressively purer graphite.

Abstract: A method is proposed for processing high-ash coal sludges by flotation of a slurry in the cells of flotation units, particularly for processing gas coal and open burning coal which are difficult to float, in which the coal slurry to be processed flows through the cells of the flotation unit pre-conditioned and controllably, particularly with control of the dwell time. In a preferred embodiment, the control of the dwell time occurs by a controlled distribution of the slurry to cells of the flotation unit which operate in parallel. For the purpose of controlling the dwell time of the slurry in a flotation unit, cells which are traversed in parallel are additionally connected or disconnected as a function of operating parameters, such as slurry density or solids content or solids distribution.

Abstract: Mineral impurities can be effectively removed from coal by introducing oil droplets into an aqueous slurry of pulverized coal. Coal, which is lipophilic, attaches to the surface of the oil droplets and floats upwardly along with the oil droplets utilizing their buoyancy. On the other hand, mineral impurities, which are hydrophilic, are left in the aqueous slurry.

Abstract: A method of separating fine coal particles from refuse particles comprising the step of:(a) providing a coal filter cake(b) forming a slurry of fine coal particles, refuse particles in a liquid mixture comprising water and organic liquid,(c) contacting said coal filter cake with said slurry,whereby a major portion of said water and a major portion of said refuse pass through said filter cake and a major portion of said organic liquid and a major portion of said fine coal particles pass across the top of said filter cake.

Abstract: An improved process for the beneficiation of coal and the separation of impurities therefrom comprising subjecting coal to surface treatment by contact with an aqueous medium comprising polymerizable monomer, polymerization catalyst and liquid organic carrier, thereby rendering said coal hydrophobic and oleophilic, the improvement comprising the high shear intermixing of the surface treated coal with at least one water wash medium thereby providing for the removal of further hydrophilic impurities, such as mineral ash from the coal. Apparatus for carrying out the process and the products prepared therefrom are also provided.

Abstract: There is described a process for separating from a mixture of mineral components at least one of the components. The process comprises the steps of (a) dispersing the mixture of mineral components in water so as to form an aqueous suspension containing said mixture of mineral components, (b) mixing together said aqueous suspension and a non-polar organic liquid in which there has been dissolved or suspended an anionic collector for at least one of the components of the mixture of mineral components, the volume ratio of said aqueous suspension to non-polar organic liquid being controlled and the conditions under which said aqueous suspension and non-polar organic liquid are mixed together being such that only a small amount of energy is dissipated therein in a short time in order to effect the mixing together thereof and one liquid is uniformly dispersed in the other but a stable emulsion is not formed and (c) thereafter separating, or allowing to separate, the two liquid phases.

Abstract: The present invention is directed to silicon carbide whisker recovery from a mixture of silicon carbide whiskers and carbonaceous silicon carbide particles. The invention involves shredding the mixture down to a specified size, dispersing the mixture in water to form an aqueous mixture, agitating the aqueous mixture, mixing the aqueous mixture with an immiscible organic solvent which is lighter than water, agitating the resulting water-organic solvent mixture, allowing the organic solvent and its contents to rise above the water and its contents, separating the two liquid phases into an organic solvent phase and an aqueous phase and, lastly, performing a solid-liquid separation on each of the two phases, thereby obtaining from the aqueous solution the desired silicon carbide whiskers and obtaining from the organic solvent solution a carbonaceous silicon carbide particle product.

Abstract: A method for deinking printed wastepapers in a system of separators through which printed wastepapers, previously impregnated with surface-active agents and alkalis, and repulped in the presence of an organic hydrocarbon compound and high-adsorptive flakes obtained by precipitating solutions of metal soaps of fatty or bituminous acids with solutions of salts of alkaline earths, are forced. The adsorptive flakes containing printing ink are separated from the repulped paper stock by latent vortex action.