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.

Provided is a system to upgrade an input stream of a straight run vacuum residue or a cracked feedstock that includes a vacuum column, a hydrocracking unit, a high lift solvent deasphalting unit, a low lift solvent deasphalting unit, and a bitumen blowing unit or a pitch pelletizing unit, and optionally a hydrotreating reactor. The system and components thereof may pass a distillate and naphtha product, a light ends product, an asphaltene-lean heavy deasphalted oil stream, an asphaltene-rich pitch stream, a light deasphalted oil that is a lube base feed stock, a heavy oil stream, a bitumen and asphalt stream or a solid fuel. Further provided is a process, including introducing a straight run vacuum residue or a cracked feed stock into a system, and operating the system including a step of fractionating, a step of solvent stage deasphalting, and a step of hydrocracking.

Provided is a system to upgrade an input stream of a straight run vacuum residue or a cracked feedstock that includes a vacuum column, a hydrocracking unit, a high lift solvent deasphalting unit, a low lift solvent deasphalting unit, and a bitumen blowing unit or a pitch pelletizing unit, and optionally a hydrotreating reactor. The system and components thereof may pass a distillate and naphtha product, a light ends product, an asphaltene-lean heavy deasphalted oil stream, an asphaltene-rich pitch stream, a light deasphalted oil that is a lube base feed stock, a heavy oil stream, a bitumen and asphalt stream or a solid fuel. Further provided is a process, including introducing a straight run vacuum residue or a cracked feed stock into a system, and operating the system including a step of fractionating, a step of solvent stage deasphalting, and a step of hydrocracking.

A substantially solid brick of non-volatile bituminous material has a shape that is defined by an irregular outer surface to minimize surface contact with nearby bricks when shipped in bulk. The overall shape is preferably that of a modified tetrahedron having three non-planar face surfaces, a top surface, and a surface or point. Both the top and bottom surfaces are preferably modified domed shapes comprised of several sections. The face sections are preferably modified concave surfaces comprised of several triangular sections that can be planar, concave, or convex. Curved edges connect the face sections to each other and can include several planar edge sections. The bituminous material can include additives, and the brick can further include a skeleton distributed throughout. The skeleton can be a customizable matrix, framework of fiber groups, or other structure and can include customizable buoyant features such as air pockets or capsules.

A substantially solid brick of non-volatile bituminous material has a shape that is defined by an irregular outer surface to minimize surface contact with nearby bricks when shipped in bulk. The overall shape is preferably that of a modified tetrahedron having three non-planar face surfaces, a top surface, and a surface or point. Both the top and bottom surfaces are preferably modified domed shapes comprised of several sections. The face sections are preferably modified concave surfaces comprised of several triangular sections that can be planar, concave, or convex. Curved edges connect the face sections to each other and can include several planar edge sections. The bituminous material can include additives, and the brick can further include a skeleton distributed throughout. The skeleton can be a customizable matrix, framework of fiber groups, or other structure and can include customizable buoyant features such as air pockets or capsules.

Pitch particles may be produced by a grinding process, in which pitch fines may be recovered and recycled to a grinding apparatus as a pitch melt. Such methods may comprise: providing a petroleum pitch having a first softening temperature; grinding the petroleum pitch in a grinding apparatus below the first softening temperature to produce a plurality of pitch particles and a plurality of pitch fines; separating the pitch particles from the pitch fines; heating the pitch fines at a temperature above the first softening temperature to produce a pitch melt; and combining the pitch melt with the petroleum pitch in the grinding apparatus. The pitch melt hardens in the grinding apparatus and is reground. The pitch particles may be further stabilized by heating at a treatment temperature below the first softening temperature in an environment comprising about 1 mol % to about 20 mol % oxygen to form stabilized pitch particles.

Pitch particles may be produced by a grinding process, in which pitch fines may be recovered and recycled to a grinding apparatus as a pitch melt. Such methods may comprise: providing a petroleum pitch having a first softening temperature; grinding the petroleum pitch in a grinding apparatus below the first softening temperature to produce a plurality of pitch particles and a plurality of pitch fines; separating the pitch particles from the pitch fines; heating the pitch fines at a temperature above the first softening temperature to produce a pitch melt; and combining the pitch melt with the petroleum pitch in the grinding apparatus. The pitch melt hardens in the grinding apparatus and is reground. The pitch particles may be further stabilized by heating at a treatment temperature below the first softening temperature in an environment comprising about 1 mol % to about 20 mol % oxygen to form stabilized pitch particles.