A method and apparatus are provided for processing hydrocarbon coal slurry feeds. The method and apparatus enhance the conversion of the coal feeds into useful conversion products, such as high melting and high carbon containing pitch products. In particular, the present techniques utilize a specially designed self-cleaning and wall-catalyzed preheater-reactor systems.

A method of transporting non-volatile bituminous materials from a first location to a second location involves carrying a plurality of irregular bricks formed by the bituminous material in transport chambers carried by vehicles. Bricks are defined by a plurality of non-planar surface, which create gaps between adjacent bricks, and can further include polymer skeletons and other features that help them float. The bricks can travel by land, sea, air, or rail and need not be heated while in transit. Transport chambers have active or preferably passive environmental control systems to circulate cooling air, water, or other substances through the transport chamber and the gaps between adjacent bricks. In a preferred embodiment, ambient air circulates among the bricks during travel by land and ambient water circulates among the bricks during marine travel. The vehicles carrying the transport chambers can be low-emissions or zero-emission vehicles including fuel-cell powered trains and ships.

Processes are described for producing mesophase pitch. The processes generally comprise providing a feedstock having a T5 400 F. (204 C.) and a T95 1,400 F. (760 C.) and heating the feedstock at a temperature ranging from about 420 C. to about 520 C. to produce a heat treated product including isotropic pitch. Generally, the heating is conducted under conditions sufficient to satisfy the relationship [X*Y]20,000 seconds, wherein X is the equivalent reaction time of the heating, and wherein Y is the bromine number of the feedstock as measured in accordance with ASTM D1159. The processes generally further comprise contacting the isotropic pitch with a solvent having a Solubility Blending number (S.sub.BN) of at least about 10 SU under conditions sufficient to produce a solvent fraction comprising the solvent and an insoluble fraction comprising mesophase pitch, and recovering the mesophase pitch.

A process and apparatus for the continuous conversion of isotropic carbonaceous materials into anisotropic mesophase pitch is disclosed. The invention disclosed herein addresses the need for lower production costs compared with traditional batch mesophase conversion of isotropic pitch. A unique thermal processing and in-process separation of reacted mesophase from the continuous matrix of fresh or partially reacted isotropic pitch is provided. Potential uses are for further continuous processing into carbon fibers or carbon form densification.

Processes are described for the production of a pitch for use in the manufacture of carbon composite materials. The process comprises the steps of providing a purified coal product (PCP), wherein the PCP is in particulate form, and wherein at least about 90% by volume (% v) of the particles are no greater than about 25 ?m in diameter; wherein the PCP has an ash content of less than about 10% m; and combining the PCP with a feedstock for pitch to create a combined blended mixture suitable for thermal reaction followed by distillation to create a resultant pitch. The combined blended mixture comprises at least around 0.1% m and at most around 90% m PCP. Composite materials that find utility as carbon electrodes, particularly electrolytic baked carbon anodes, can be made from combining the pitch and PCP with a filler material, such as a pet coke.

Systems and methods of production for consistently sized and shaped optically anisotropic mesophase pitch from vacuum residue, one method including supplying processed vacuum residue to an extruder; heating the processed vacuum residue throughout a horizontal profile of the extruder from an inlet to an outlet of the extruder; venting hydrocarbon off-gases from the extruder along the horizontal profile of the extruder from the inlet to the outlet of the extruder; and physically shaping the consistently sized and shaped mesophase pitch at the outlet of the extruder for production of carbon fibers.

The use of recycled materials can have significant economic value. With the increasing quantity of recycled material used in viscoelastic materials, especially asphalt mixture, understanding how they interact with original materials to produce a mixture that performs successfully, becomes critical. Currently, the technology to determine the effect of additives on the performance of asphalt mixture is lacking. The present invention relates to a new unified methodology for mechanical testing of asphalt mixture and other viscoelastic materials that improves the current practice in speed, convenience, and accuracy. A new improved specimen mounting method on Dynamic Shear Rheometer (DSR), a new recovery method for fine portion of asphalt mixture, and three new tests for the performance of recovered material using DSR is disclosed. The new methods provide performance grading of asphalt mixtures that is new to the industry and provide necessary tools for determining the effect of recycled materials on performance.

In one aspect, the disclosure relates to processes for preparation of a carbon foam material, the process comprising devolatization of coal-derived pitches or extracts at atmospheric pressure near green coke temperatures, thereby forming a solid coke-like material. In a further aspect, the process can further comprise grinding the solid coke-like material to a powder, providing the ground powder to a mold, and then reheating above green coking temperature (e.g., >600 C.) to further devolatize the material and form a porous solid foam material. The process further provides carbon materials such as carbon composite materials and sp2-hybridized carbon in the form of graphene oxide or graphene. In various aspects, the disclosure relates to the carbon foam and other materials prepared using the disclosed processes. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

The use of recycled materials can have significant economic value. With the increasing quantity of recycled material used in viscoelastic materials, especially asphalt mixture, understanding how they interact with original materials to produce a mixture that performs successfully, becomes critical. Currently, the technology to determine the effect of additives on the performance of asphalt mixture is lacking. The present invention relates to a new unified methodology for mechanical testing of asphalt mixture and other viscoelastic materials that improves the current practice in speed, convenience, and accuracy. A new improved specimen mounting method on Dynamic Shear Rheometer (DSR), a new recovery method for fine portion of asphalt mixture, and three new tests for the performance of recovered material using DSR is disclosed. The new methods provide performance grading of asphalt mixtures that is new to the industry and provide necessary tools for determining the effect of recycled materials on performance.

A method of producing advanced carbon materials can include extracting a coal sample from a location, performing a spectral analysis on the coal sample, determining one or more desired advanced carbon materials based at least in part on spectral analysis, extracting an amount of coal from the location, beneficiating the amount of coal, and processing the beneficiated amount of coal to produce the one or more desired advanced carbon materials from at least some of the amount of coal.