Abstract: The present invention provides carbonaceous fuels and processes for making them. Moreover, the invention also relates to processes using the carbonaceous fuels in the production of cement products. One embodiment of the invention is a carbonaceous fuel comprising (a) unconverted fines of a carbonaceous feedstock, the carbonaceous feedstock having an ash content of greater than 1%, the fines having an average particle size less than about 45 ?m; and (b) a char residue formed by catalytic gasification of the carbonaceous feedstock, the char residue having an ash content of greater than about 30%, wherein the ash includes at least one aluminum-containing compound or silicon-containing compound; and having a weight ratio of fines to char residue in the range of about 4:1 to about 1:4, and a total dry basis wt % of carbon of least about 40%.

Abstract: Processes are described for the extraction and recovery of alkali metal from the char that results from catalytic gasification of a carbonaceous material. Among other steps, the processes of the invention include a hydrothermal leaching step in which a slurry of insoluble particulate comprising insoluble alkali metal compounds is treated with carbon dioxide and steam at elevated temperatures and pressures to effect the conversion of insoluble alkali metal compounds to soluble alkali metal compounds. Further, processes are described for the catalytic gasification of a carbonaceous material where a substantial portion of alkali metal is extracted and recovered from the char that results from the catalytic gasification process.

Abstract: Processes for extracting and recycling alkali metal compounds present in the char produced from the catalytic gasification of carbonaceous materials are provided involving at least contacting the char with and alkali metal hydroxide followed by carbon dioxide. Both the alkali metal hydroxide and carbon dioxide treatments serve to convert at least a portion of the insoluble alkali metal compounds in the char into soluble species which can be recovered and recycled.

Abstract: Particulate compositions are described comprising an intimate mixture of a coal and a gasification catalyst in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons are formed. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.

Abstract: The present invention relates to catalyst-loaded coal compositions having a moisture content of less than about 6 wt %, a process for the preparation of catalyst-loaded coal compositions, and an integrated process for the gasification of the catalyst-loaded coal compositions. The catalyst-loaded coal compositions can be prepared by a diffusive catalyst loading process that provides for a highly dispersed catalyst that is predominantly associated with the coal matrix, such as by ion-exchange.

Abstract: A process for desulfurizing hydrocarbons such as gasoline and similar petroleum products to reduce the sulfur content to a range of from about 2 to 15 ppm sulfur without affecting the octane rating is described. The sulfur containing hydrocarbon is contacted at slightly elevated temperatures with an oxidizing/extracting solution of formic acid, a small amount of hydrogen peroxide, and no more than about 25 wt % water.

Abstract: A process for desulfurizing fuels such as diesel oil and similar petroleum products to reduce the sulfur content to a range of from about 2 to 15 ppm sulfur is described. The sulfur containing fuel is contacted at slightly elevated temperatures with an oxidizing/extracting solution of formic acid, a small amount of hydrogen peroxide, and no more than about 25 wt % water. A removal process for separating substituted dibenzothiophene oxidation products from tile fuel is also described.

Abstract: A process for desulfurizing hydrocarbons such as gasoline and similar petroleum products to reduce the sulfur content to a range of from about 2 to 15 ppm sulfur without affecting the octane rating is described. The sulfur containing hydrocarbon is contacted at slightly elevated temperatures with an oxidizing/extracting solution of formic acid, a small amount of hydrogen peroxide, and no more than about 25 wt % water.

Abstract: The present invention relates to a process for recovery of particulate calcium fluoride from a waste solution containing soluble fluoride. More specifically, the invention relates to a process for removal of soluble fluoride from and recovery of fluorspar-grade calcium fluoride from an aqueous waste solution using calcium sulfate to form the calcium fluoride.

Abstract: The invention relates to a process for separating extractable organic material from a composition comprising organic material intermixed with solids and water. The composition is contacted with a solvent and a dehydrating agent. The dehydrating agent removes water, improves the solvent extraction, and aids in later separation of the solids from the solvent. The process additionally provides a means for removing cyanide compounds from the composition and fixating the metals against leaching.

Abstract: A process for the treatment of flue dust from copper and lead smelters includes the steps of subjecting a slurry (10) of water and flue dust to a first caustic leach (12) to form a first liquids soluble sulfate solution (14) and a first solids portion (15), subjecting the solids portion to a second caustic leach (16) to solubilize lead and arsenic in a second liquid portion (22) and, selectively extracting the arsenic from the second liquid portion by precipitation (23).

Abstract: The selective leaching of metal ions from various iron oxide and manganese oxide containing ores employs intermediary solutions. The leaching processes are based upon a redox acid leach step employing stabilized cuprous ions and, in one instance, a combination thereof with ferrous ions. Leaching is conducted at low temperatures, up to about 90.degree. C. and low pressures, up to about 1.5 MPa and at a pH of about 1.5 to 2.5. Nickel and cobalt recoveries from the ores, employing these processes, will usually equal or exceed 90 percent. The intermediary solutions comprise stabilized acidic cuprous ions Cu.sup.+ L wherein L is a stabilizing ligand selected from the group consisting of CO, XRCN and Cl.sup.-, X being --H or --OH and R being aliphatic having from one to about four carbon atoms. In at least one process, ferrous ions are introduced for a separate leaching step.

Abstract: A pregnant liquor is mixed with an organic mixture comprised of an organic extracting agent and iso-butyl-heptyl ketone. Metallic values are absorbed from the pregnant liquor by the organic mixture. The metal-bearing organic mixture is then separated from the liquor and stripped of its metallic values.

Abstract: Alloy scrap containing refractory metals such as chromium, molybdenum, tungsten, vanadium, niobium and tantalum and base metals such as nickel, cobalt, copper and iron are treated to partition the refractory metal values from the base metal values without an energy intensive remelting step. The scrap in finely divided form is calcined in the presence of an oxygen containing gas and a member of a certain group of alkali metal salts at a temperature in the range of 800.degree. C. to 1150.degree. C. for 1/4 hour to four hours. This treatment converts the refractory metals to alkali metal molybdates, tungstates, chromates, vanadates, niobates and tantalates and the base metals to oxides. The calcined product may then be water leached to produce a substantially base metal-free liquor rich in refractory metal values. Both the refractory and the base metal values may be subsequently recovered by conventional hydrometallurgical techniques.

Abstract: Disclosed is a process for recovering chromium, vanadium, molybdenum, and tungsten from secondary resources such as alloy scrap comprising a refractory metal and base metals such as cobalt nickel, iron, and copper. The scrap is calcined with sodium carbonate in air to convert the refractory metal values to MoO.sub.4.sup..dbd., VO.sub.4.sup..tbd., WO.sub.4.sup..dbd., CrO.sub.4.sup..dbd., and the base metals to water insoluble oxides. A leach of the calcined materials produces a pregnant liquor rich in refractory metals which, after separation of the vanadium, molybdenum and tungsten values, is treated with CO, CHOO.sup.-, CH.sub.3 OH, or HCHO to reduce Cr.sup.+6 to Cr.sup.+3. The carbonate and bicarbonate salts produced as a byproduct of the reduction are recycled to the calcination stage.As a result of the V, W, and Mo partition, a mixed solid comprising CaO.multidot.nV.sub.2 O.sub.5, CaMoO.sub.4, and CaWO.sub.4 is produced.

Abstract: Disclosed is a process for recovering chromium, vanadium, molybdenum, and tungsten from secondary resources such as alloy scrap comprising a refractory metal and base metals such as cobalt, nickel, iron, and copper. The scrap is calcined with sodium carbonate in air to convert the refractory metal values to MoO.sub.4.sup.=, VO.sub.4.sup..ident., WO.sub.4.sup.=, and CrO.sub.4.sup.= and the base metals to water insoluble oxides. A leach of the calcined materials produces a pregnant liquor rich in refractory metals which, after separation of the vanadium, molybdenum and tungsten values, is treated with CO, CHOO.sup.- CH.sub.3 OH, or HCHO to reduce Cr.sup.+6 to CR.sup.+3. The carbonate and bicarbonate salts produced as a byproduct of the reduction are recycled to the calcination stage.As a result of the V, W, and Mo partition, a mixed solid comprising CaO.nV.sub.2 O.sub.5, CaMoO.sub.4, and CaWO.sub.4 is produced.

Abstract: Disclosed is a process for recovering chromium, vanadium, molybdenum, and tungsten from secondary resources such as alloy scrap comprising a refractory metal and base metals such as cobalt, nickel, iron, and copper. The scrap is calcined with sodium carbonate in air to convert the refractory metal values to MoO.sub.4.sup.=, VO.sub.4.sup..ident., WO.sub.4.sup.=, and CrO.sub.4.sup.= and the base metals to water insoluble oxides. A leach of the calcined materials produces a pregnant liquor rich in refractory metals which, after separation of the vanadium, molybdenum and tungsten values, is treated with CO, CHOO.sup.-, CH.sub.3 OH, or HCHO to reduce Cr.sup.+6 to Cr.sup.+3. The carbonate and bicarbonate salts produced as a byproduct of the reduction are recycled to the calcination stage.As a result of the V, W, and Mo partition, a mixed solid comprising CaO.nV.sub.2 O.sub.5, CaMoO.sub.4, and CaWO.sub.4 is produced.

Abstract: Disclosed is a process for recovering chromium, vanadium, molybdenum, and tungsten from secondary resources such as alloy scrap comprising a refractory metal and base metals such as cobalt, nickel, iron, and copper. The scrap is calcined with sodium carbonate in air to convert the refractory metal values to MoO.sub.4.sup..dbd., VO.sub.4.sup..tbd., WO.sub.4.sup..dbd., and CrO.sub.4.sup..dbd. and the base metals to water insoluble oxides. A leach of the calcined materials produces a pregnant liquor rich in refractory metals which, after separation of the vanadium, molybdenum and tungsten values, is treated with CO, CHOO.sup.-, CH.sub.3 OH, or HCHO to reduce Cr.sup.+6 to Cr.sup.+3. The carbonate and bicarbonate salts produced as a byproduct of the reduction are recycled to the calcination stage.As a result of the V, W, and Mo partition, a mixed solid comprising CaO.nV.sub.2 O.sub.5, CaMoO.sub.4, and CaWO.sub.4 is produced.

Abstract: A novel class of extractants and a method of using the extractants in the hydrometallurgical recovery of nickel and cobalt metal. The extractants comprise a water immiscible organic solvent system containing solubilized mercaptide anions. In an important embodiment of the invention, the mercaptide anions are generated by solubilizing an alkali metal mercaptide in a polar organic solvent capable of solvating alkali metal ions. Alternatively, an organic solution of a mercaptan is exposed to an aqueous solution of NaOH or KOH to produce the mercaptide anion.The extractants are used by being contacted with cobalt, nickel, or cobalt and nickel pregnant aqueous solutions. On mixing, the cobalt and/or nickel values are taken up by the organic as cobalt or nickel mercaptides. These may then be stripped of cobalt and nickel by treatment with an aqueous alkaline solution and carbon monoxide.

Abstract: A novel class of extractants and a method of using the extractants in the hydrometallurgical recovery of nickel and cobalt metal. The extractants comprise a water immiscible organic solvent system containing solubilized mercaptide anion. In an important embodiment of the invention, the mercaptide anions are generated by adding compounds containing both a thiol group and an amine group such as aminoethanethiols or amides of thioglycolic acids to water immiscible organic solvents, preferably of polar character. These systems generate the required mercaptide anions by undergoing an internal acid dissociation.The extractants are used by being contacted with cobalt, nickel, or cobalt and nickel pregnant aqueous solutions. On mixing, the cobalt and/or nickel values are taken up by the organic as cobalt and nickel mercaptides. These may then be stripped of cobalt and nickel by treatment with an aqueous alkaline solution and carbon monoxide.