Industrial methods which utilize microwave-based sensors to detect in real-time the total solids content of aqueous solid colloidal dispersions such as oil sands tailings streams are provided. Optionally, these microwave-based sensors may be utilized in combination with automatic cleaning systems or filters, which prevent sensor fouling and allow for extended sensor use without manual cleaning. The output signals from the microwave sensor are used to adjust desired process parameters, e.g., the dosage of chemical additives and/or to maintain total solids within specified limits.

Industrial methods which utilize microwave-based sensors to detect in real-time the total solids content of aqueous solid colloidal dispersions such as oil sands tailings streams are provided. Optionally, these microwave-based sensors may be utilized in combination with automatic cleaning systems or filters, which prevent sensor fouling and allow for extended sensor use without manual cleaning. The output signals from the microwave sensor are used to adjust desired process parameters, e.g., the dosage of chemical additives and/or to maintain total solids within specified limits.

Methods for preparing, converting, and/or transporting bitumen are provided. Asphaltene prills, prilling processes, and converted bitumen suitable for transport are disclosed. One method for preparing bitumen for transport comprises: separating asphaltene from the bitumen to generate a deasphalted oil and asphaltene; separating the asphaltene into a first asphaltene fraction and a second asphaltene fraction, the first asphaltene fraction being less soluble in deasphalted oil and the second asphaltene fraction being more soluble in deasphalted oil; and forming an asphaltene prill comprising an inner core comprising the second asphaltene fraction and an outer layer comprising the first asphaltene fraction. Asphaltene prills disclosed herein may comprise an inner core comprising an asphaltene fraction having more solubility in deasphalted oil, and an outer layer comprising an asphaltene fraction having less solubility in deasphalted oil. Methods for the transport of bitumen via a pipeline are disclosed.

A process to convert asphaltenes found in heavy hydrocarbon sources, remove the converted solid asphaltene portion from the hydrocarbon source at operating conditions and to prepare the separated solid asphaltenes for easier handling, storage or bulk transport, with a minimal amount of heavy hydrocarbon remaining with the asphaltenes to serve as an inherent binder for larger and robust formed solid asphaltene pieces.

A process to convert asphaltenes found in heavy hydrocarbon sources, remove the converted solid asphaltene portion from the hydrocarbon source at operating conditions and to prepare the separated solid asphaltenes for easier handling, storage or bulk transport, with a minimal amount of heavy hydrocarbon remaining with the asphaltenes to serve as an inherent binder for larger and robust formed solid asphaltene pieces.

Methods, processes, and apparatuses for preparing and transporting bitumen. Bitumen may be prilled such that a bitumen product comprising a prill core and a non-stick coating is produced. The non-stick coating may comprise asphaltenes and the prill core may comprise bitumen, deasphalted oil, or both bitumen and deasphalted oil. The resultant non-stick coated prills have reduced adhesion to transportation vessels and other non-stick coated prills at a temperature below an adhesion temperature, facilitating transport.

Methods, processes, and apparatuses for preparing and transporting bitumen. Bitumen may be prilled such that a bitumen product comprising a prill core and a non-stick coating is produced. The non-stick coating may comprise asphaltenes and the prill core may comprise bitumen, deasphalted oil, or both bitumen and deasphalted oil. The resultant non-stick coated prills have reduced adhesion to transportation vessels and other non-stick coated prills at a temperature below an adhesion temperature, facilitating transport.

A method for preparing a solid bitumen material at ambient temperature, said method comprising at least the steps of: a) preparing an emulsion of bitumen drops in a water phase; b) preparing a silica sol or silica gel from a silicon oxide precursor that has a pH of 4 to 8; c) bringing the emulsion of bitumen drops from step a) into contact with the silica sol or silica gel from step b); d) subjecting the bitumen suspension from step c) to an atomization treatment.

A method for preparing a solid bitumen material at ambient temperature, said method comprising at least the steps of: a) preparing an emulsion of bitumen drops in a water phase; b) preparing a silica sol or silica gel from a silicon oxide precursor that has a pH of 4 to 8; c) bringing the emulsion of bitumen drops from step a) into contact with the silica sol or silica gel from step b); d) subjecting the bitumen suspension from step c) to an atomization treatment.

A method for preparing a solid bitumen material at ambient temperature, the method comprising at least the steps of: a) preparing a stabilized emulsion of bitumen drops in a water phase that has a pH of 2 to 4; b) preparing a silica sol or silica gel from a first silicon oxide precursor that has a pH of 2 to 4; c) mineralizing the emulsion of bitumen drops from step a) with the silica sol or gel from step b); d) mineralizing the emulsion of bitumen drops from step c) having a maximum pH of 1 with a second silicon oxide precursor; e) separating the material from the water phase.