Abstract: In the present invention, iron sulfate is added in the form of an aqueous wash solution to coal agglomerates after separation of ash from the agglomerated coal. As the agglomerates remain in a continuous water phase, a good dispersion of the iron sulfate solution throughout the agglomerate matrix occurs. At this stage an unexpectedly strong adsorption of Fe ions onto the coal surfaces occurs without any adverse effects on agglomerate integrity and the ability to separate it selectively by floatation. Furthermore, this good dispersion also results in over 94% of the iron sulfate in the wash solution being transferred to the agglomerates. This manner of addition of iron sulphate to coal has been shown to elevate advantageously the lowest temperature at which coke formation occurs during coprocessing.

Abstract: A process is described for removing mineral or ash constituents from heavy hydrocarbon residues, such as those resulting from coal-oil coprocessing, residue hydrocracking or coal liquifaction. The process comprises the steps of: (a) intimately mixing the ash-containing heavy hydrocarbon oil residue with a surfactant and a pH-conditioned aqueous solution under high shear mixing conditions to disperse the ash-containing residue in the aqueous phase thereby creating a fine oil-in-water emulsion, (b) adding a strong oxidizing agent to the emulsion to thereby break the emulsion and release the ash into the aqueous phase and (c) separating the ash-containing aqueous phase from the oil phase. The HLB method for characterizing the emulsion forming activity of a surface active material is described in M. J. Rosen, Surfactants and Interfacial Phenomena, John Wiley & Sons, New York (1989), incorporated herein by reference.

Abstract: A process is described for the flash pyrolysis of a high rank caking coal in a pyrolysis chamber in which the coal passes through a tacky state during flash pyrolysis. According to the novel feature, before entering the pyrolysis chamber, the particles of high rank caking coal are blended with a diluent comprising a finely ground non-caking coal, whereby agglomeration and caking of the high rank coal is prevented during flash pyrolysis.

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: A corrosive liquid such as sulphuric acid is concentrated by boiling in an evaporator vessel having a thermosyphon loop connected to the bottom of the vessel. Electrodes of carbon which is essentially free of any organic binders are located in one leg of the thermosyphon loop to heat the liquid by current conducted through the liquid. The electrodes are located well below the liquid surface so that boiling occurs only above the electrode level, reducing erosion of the electrodes. The electrodes are blanketed with air which flows through the porous carbon into the liquid, thereby protecting the seals and electrode connections and also introducing air into the thermosyphon loop to promote circulation of the liquid in the loop.