Abstract: A method for updating a concentrate of tar sands bitumen containing fine mineral matter and optionally coarse mineral matter in which solvent-diluted bitumen is contacted for a short time in a riser with hot attrition-resistant substantially catalytically inert acid-resistant fluidizable particles, causing a selective vaporization of the lighter high hydrogen content components of the bitumen. The preferred particles are composed of silica-alumina, most preferably a mixture of mullite and crystalline silica or mullite, crystalline silica and an acid-resistant form of alumina. A portion of the heavier asphaltenes and most of the components which contain metals, sulfur and nitrogen remain on the attrition-resistant fluidizable particles. Fine mineral matter in the bitumen feed also deposits on the fluidized particles instead of being carried over with the vaporized hydrocarbon product.

Abstract: A method for upgrading a concentrate of tar sands bitumen containing colloidal clay in which solvent-diluted bitumen is contacted for a short time in a riser with hot attrition-resistant substantially catalytically inert fluidizable microspheres, causing a selective vaporization of the lighter high hydrogen content components of the bitumen. A portion of the heavier asphaltenes and most of the components which contain metals, sulfur and nitrogen remain on the attrition-resistant microspheres. Colloidal clay in the bitumen feed also deposits on the microspheres instead of being carried over with the vaporized hydrocarbon product. The contact material, with deposit, is passed to a burner provided with high velocity air jets which attrites the colloidal clay away from the microspheres and the material removed by attrition is recovered. The heated microspheres are reintroduced into the riser for further contact with incoming diluted bitumen charge.

Abstract: A process for treating heavy hydrocarbon oil which contains metals and/or sulfur in the presence of a catalyst and recovering a hydrocarbon product having reduced metals and/or sulfur content by employing a metal impregnated mullite catalyst. The impreganted metals are selected from the group consisting of cobalt, nickel, molybdenum and tungsten. The mullite supporting bodies are prepared by calcining bodies of kaolin clay until the clay is converted to mullite and free silica, leaching the resulting bodies of mullite and silica with an alkaline aqueous solution to remove the silica, washing the leached clay bodies to remove alkali ions, and drying.

Abstract: A process which is especially useful for effecting magnetic separation of magnetically attractable impurities from an aqueous clay slurry or suspension includes passing the suspension through a porous, ferromagnetic matrix while applying a magnetic field to the matrix, on which impurities are collected, and thereafter regenerating the matrix by flushing collected impurities therefrom with a flush liquid, e.g., water. The improvement comprises, after discontinuing the passage of the suspension through the matrix, but before passing flush liquid therethrough, admitting a pressurized gas, e.g., compressed air, into the separator to displace suspension retained therein, and recovering the displaced suspension. In addition, flush liquid retained in the matrix after the flushing step may be displaced therefrom by the compressed air. By displacing the retained suspension from the matrix with, e.g., compressed air, instead of a flush liquid, e.g.

Abstract: A process for the wet processing of kaolin clay which includes a step for physically removing discrete particles of colored impurities by high gradient magnetic separation (HGMS) in which all processing steps including HGMS are carried out with the feed clay slurry at high solids, above 50%, and the magnetically purified clay slurry is also recovered at high solids, above 50%. A feature of the invention is that the HGMS unit is operated in a novel manner such as to avoid the dilution of the magnetically purified clay slurry with water during all stages of HGMS treatment without adverse effect on the yield of magnetically purified clay.

Abstract: Improved noncatalytic nonreactive alumina-silica solid for removing carbonaceous and metallic contaminants including nickel and vanadium from hydrocarbon feedstock by short term, high temperature contact comprises mullite and crystalline silica. In the decarbonizing and demetallizing process, impurities are deposited on the particles of the solid and the major portion of the feedstock is vaporized. After burning carbonaceous deposit from the particles, the hot particles containing nickel and vanadium are recycled into contact with incoming charges of contaminated feedstock. Periodically metals are removed from coke-depleted particles by extraction with a mineral acid at elevated temperature without dissolving or otherwise destroying the alumina-silica particles. The particles are then reintroduced into the system.

Abstract: Amine-complexed zinc salts of organic diacids selected from the group consisting of (i) dicarboxylic acids, (ii) diphenols, and (iii) phthalic acids. Specifically disclosed compounds include C.sub.2 -C.sub.3 alkylene diamine-complexed zinc salts of thiodiphenol and sulfonyldiphenol, and ethylene diamine-complexed salts of phthalic, isophthalic and terephthalic acids. Such amine-complexed zinc salts have utility as corrosion inhibitors in coating compositions for metallic substrates, e.g., paints based on alkyds, latexes or linseed oil. Also disclosed are anticorrosion additives, comprising the aforementioned amine-complexed salts distended on mineral fillers such as kaolin, and a method of making same by reaction of zinc oxide, amine, and organic diacid, at elevated temperatures, in an aqueous slurry of the mineral filler. At least the dicarboxylic acid and diphenol derived salts also display utility as inhibitors of marine growth (algae and barnacles) on substrates.

Abstract: A heat stabilized slurry of bulked kaolin pigment is prepared by mixing a small but effective amount of a water-soluble cationic material such as a cationic polyelectrolyte flocculant with a kaolin clay pigment in the presence of water. The resultant bulked clay product is dispersed to form a high solids clay-water slurry useful in making aqueous coating colors suitable for manufacturing lightweight coated publication papers or the pigment can be used as a filler for paper webs. Slurries having stable viscosity during storage at elevated temperature and improved resistance to the formation of sediment are prepared by using as the dispersant a combination of an anionic lignosulfonate and an anionic naphthalene sulfonate formaldehyde complex in combination with a polyacrylate salt.

Abstract: A method for preparing a heat stable aqueous slurry of a bulking pigment suitable for use in coating or filling paper which comprises preparing a fluid aqueous suspension of particles of kaolin clay, adding thereto a water-soluble cationic polyelectrolyte, the amount of said cationic polyelectrolyte being sufficient to substantially thicken and flocculate said fluid suspension, acidifying the resulting flocculate clay suspension, bleaching the clay in said suspension with a hydrosulfite salt, filtering said acidified suspension to recover bulked clay, washing the filtered clay and adding minimal amounts of a sodium polyacrylate and a nonionic surfactant to the recovered bulked clay to provide a fluid suspension of bulked clay.

Abstract: A filled engineering plastic is provided with improved impact strength by pretreating the filler to provide separate coating deposits of a coupling agent and an impact modifier for the plastic matrix. For a nylon plastic composite, a kaolin filler coated with separate deposits of an amino functional silane coupling agent and a phenol or triethanolamine impact modifier has resulted in an improved impact strength without sacrificing tensile and elastic properties of the nylon.

Abstract: A highly bulked kaolin pigment is prepared by mixing a small but effective amount of a water-soluble cationic polyelectrolyte flocculant with a kaolin clay pigment in the presence of water to prepare a bulked clay pigment product. Upon dewatering, the resultant polyelectrolyte treated clay product can be dispersed to form high solids clay-water slurries useful in making aqueous coating colors suitable for manufacturing coating lightweight publication papers or the pigment can be used as a filler for paper webs.

Abstract: An improved heat balanced hydrocarbon conversion process is disclosed of the type employing circulating solids between a riser reactor (contactor) and regenerator (combustor). The ratio of circulating solid to hydrocarbon feed (C/O or cat-oil ratio) is increased by: directly cooling a portion of hot freshly regenerated contact material; passing a portion of hot regenerated material into the steam stripper; cooling hot regenerated contact material and charging it to the riser downstream of charging uncooled hot regenerated material which charging hydrocarbon feed to the base of the riser along with lift gas or steam; or lifting hot regenerated contact material by a carbonizable lift gas into the riser before contacting it with hydrocarbon feed which is injected higher in the riser.

Abstract: Materials containing vanadium values which are leachable by water are treated to reduce the leachability of vanadium to minimum practical values, thereby rendering the material suitable for disposal as landfill. Vanadium is insolubilized by adding a polyvalent metal salt which is capable of dissolving in water to form an acidic solution from which polyvalent metal cations are precipitated at a pH of 5, the polyvalent cations having a valence of +3 or higher or being a divalent metal that is oxidizable to a valence of +3 or higher. The salt-treated mixture is then neutralized by a base. The vanadium may be contained in a solid such as, for example, a spent cracking catalyst or a spent sorbent used in the upgrading of petroleum feedstock by selective vaporization or it may be contained in liquid material.

Abstract: A pigment comprising particles of uncalcined kaolin clay combined in the absence of a binder with an amount of an added source of zirconium ion, such as ammonium zirconium carbonate, at least sufficient to enhance optical character of a dried composition containing the pigment. In application, the pigment may be utilized in a coating for paper or other fibrous web substrate to produce sheet materials of enhanced opacity. Alternatively, the pigment may be employed as a filler in a fibrous web substrate to provide improved optical character of the material. Also disclosed is a method preparing a pigment, including preparing a dispersed slurry of clay particles in an aqueous medium, wherein the improvement comprises utilizing an uncalcined kaolin clay and introducing into the slurry in the absence of a binder the source of zirconium ion in an amount at least sufficient to enhance the optical character afforded by the pigment.

Abstract: The useful storage life of a clear solution of seeds used to initiate the crystallization of zeolite in porous microspheres of calcined clay is increased by adding sodium silicate solution to a matured seed solution.

Abstract: Clay convertible by thermal treatment into crystalline mullite and silica is formed into green coherent bodies of desired size and shape such as, for example, microspheres, pellets or honeycombs. The bodies are then calcined to convert the clay into a mixture of crystalline mullite and silica, thereby also hardening the bodies. Without destroying the form of the bodies, e.g., without grinding and without causing the bodies to decrepitate, pores in the size range of about 150 to 350 A are formed by selectively leaching silica from the bodies. The porous mullite bodies retain porosity at elevated temperatures and are useful, for example, as catalyst supports and contact materials. Pore structure in the meso- (100-600 A diameter) and macro- (600-20,000 A diameter) size ranges may be controlled.

Abstract: Amine-complexed zinc salts of organic diacids selected from the group consisting of (i) dicarboxylic acids, (ii) diphenols, and (iii) phthalic acids. Specifically disclosed compounds include C.sub.2 -C.sub.3 alkylene diamine-complexed zinc salts of thiodiphenol and sulfonyldiphenol, and ethylene diamine-complexed salts of phthalic, isophthalic and terephthalic acids. Such amine-complexed zinc salts have utility as corrosion inhibitors in coating compositions for metallic substrates, e.g., paints based on alkyds, latexes or linseed oil. Also disclosed are anticorrosion additives, comprising the aforementioned amine-complexed salts distended on mineral fillers such as kaolin, and a method of making same by reaction of zinc oxide, amine, and organic diacid, at elevated temperatures, in an aqueous slurry of the mineral filler. At least the dicarboxylic acid and diphenol derived salts also display utility as inhibitors of marine growth (algae and barnacles) on substrates.

Abstract: The present invention provides novel catalyst products for promoting the combustion of carbon monoxide, particularly in catalytic cracking units, especially FCC units. The improved products of the invention comprise one or more catalytically active metals selected from the group consisting of palladium or mixtures of palladium and at least one other precious metal on a porous silica-alumina support obtained by leaching sufficient silica from shaped particles of calcined clay with caustic solution to impart porosity to the particles. The calcined clay from which silica is leached to impart porosity is preferably kaolin clay that has been calcined at a temperature and for a time sufficient to substantially convert the clay into mullite and silica, whereby the support particles consist essentially of mullite crystals.

Abstract: A palladium alloy for use in making porcelain jacketed dental restorations having the following composition: 60-85 percent by weight palladium, 5-20 percent by weight copper, 3-15 percent by weight gallium, and a modifier metal selected from gold, indium, ruthenium, tin, nickel and mixtures thereof, the sum of the concentrations of the modifier metal percent in the alloy being greater than 5.5 percent by weight.

Abstract: The present invention is directed to a fluid catalytic cracking catalyst comprising a blend of a catalytically active first component and a second component for reducing the emissions of oxides of sulfur from the regenerator of a catalytic cracking unit and the use of that catalyst to crack sulfur containing petroleum feedstocks. The catalytically active first component contains Y-faujasite zeolite and comprises about 10-70% by weight, preferably about 25-50% by weight, of the catalyst. The second component of the catalyst comprises about 30-90% by weight, preferably about 50-75% by weight, of the catalyst. The second component comprises fluidizable particles containing at least about 70% by weight, preferably at least about 90% by weight, alumina and having an equilibrium surface area in the range of about 40-100 m.sup.2 /g., preferably in the range of about 50-90 m.sup.2 /g.