Processes for upgrading of a coal product and preparing of a purified coal product are provided. The process comprises the steps of: (i) providing a purified coal composition, wherein the composition is in the form of solid particles, and wherein at least about 90% by volume (% vol) of the solid particles are no greater than about 500 ?m in diameter; and (ii) combining the purified coal composition with a solid coal feedstock, in order to create a combined solid-solid blend upgraded coal product.

A method of removing metal particles from a contaminated metalworking fluid comprising emulsion droplets and metal particles includes pressurizing a first clean metalworking fluid with gas to provide an aerated metalworking fluid; releasing the pressure of the aerated metalworking fluid to form a plurality of bubbles; applying a shear force to the contaminated metalworking fluid to separate the emulsion droplets from the metal particles; flowing the contaminated metalworking fluid with the aerated metalworking fluid in a laminar flow to form a combined fluid, wherein the flowing occurs during the formation of the plurality of bubbles and while the emulsion droplets are separated from the metal particles, and wherein the laminar flow lasts for a time sufficient for the plurality of bubbles to attach to the metal particles; releasing the combined fluid into a flotation tank; and removing the metal particles to form a second clean metalworking fluid.

What is presented is a material processing system for processing tailings discharged from an ore processing system. The tailings comprise coarse waste rock, the fine waste rock, coarse valuable product, and the fine valuable product. The material processing system comprises a classification element, a coarse flotation element, and a fines flotation element arranged to separate the coarse valuable product, the coarse waste rock, the fine valuable product, and the fine waste rock. The classification element separates the coarse waste rock and/or the coarse valuable product from the fine waste rock and/or the fine valuable product. The coarse flotation element separates the coarse waste rock from the coarse valuable product, the fine waste rock, and/or the fine valuable product. The fines flotation element separates the fine valuable product from the coarse waste rock, the fine waste rock, and/or the coarse valuable product.

A method of recovering gold and copper from a sulfide ore includes (a) removing valuable fines from a product stream from a comminution circuit, such as a crushing and milling circuit, for run of mine ore and producing a valuable fines concentrate stream and (b) processing the remaining comminution product stream after valuable fines removal and producing a valuable coarse concentrate stream.

The coal-derived solid hydrocarbon particles are discrete particles of coal-derived carbonaceous matter having a particle size less than about 10 m that are substantially free of inherent or entrained mineral matter. The particles of have an average particle size in the range from 1 m to 8 m. The particles of coal-derived carbonaceous matter are milled to a size approximately the same as a size of coal-derived mineral matter inherent in the coal source to release inherent coal-derived mineral matter particles such that the particles of carbonaceous matter and the particles of mineral matter are discrete and separable solid particles. Following separation, less than 1.5 wt. % discrete coal-derived mineral matter particles are associated with the discrete particles of coal-derived carbonaceous matter. Particles of coal-derived solid hydrocarbon matter are blended with a gaseous or liquid hydrocarbon fuel to form a two-phase hydrocarbon fuel feedstock.

Various examples are provided in relation to improved recovery and throughput of both fine and coarse particulate materials. In one example, a method includes injecting an aqueous suspension of a cloud of small air bubbles into an aqueous phase including fine particulate materials, wherein the fine particulate material is selectively hydrophobized and collected by small air bubbles; allowing the bubbles to rise in the aqueous phase; and collecting the air bubbles to obtain a concentrate of the fine particulate materials. In another example, a method includes adding a hydrophobizing agent to an aqueous phase to render coarse particulate material selectively hydrophobic; allowing air bubbles to attach to the coarse particulate material and changing the apparent specific gravity of the coarse particulate materials so a layer of one type of coarse particle is formed on top; allowing the one type of coarse particles to float and enter the forth phase.

Coal fines are processed by flotation separation to separate coal particles from ash-forming mineral content particles. Coal fines are mixed water under high shear mixing conditions to form an aqueous slurry of coal fines containing between 15 wt. % and 55 wt. % coal fines. The aqueous slurry is introduced into a coal flotation cell to separate coal particles from ash-forming mineral content particles by flotation separation, wherein the coal fines have a particle size less than 100 m, and more preferably less than 50 m. Bubbles are generated in the coal flotation cell having a bubble size and bubble quantity selected to float the coal particles and to form a coal-froth containing at least 15 wt. % solid particles. The solid particles include coal particles and ash-forming mineral content particles. The coal-froth is collected for further processing.

The invention provides methods and compositions for improving a froth flotation type separation. The method uses a microemulsion to improve the effectiveness of a frother. The improvement allows for low dosages of frother to work as well as much greater amounts of non-microemulsified frother.

A method of recovering particles from a liquid, a froth flotation apparatus, and a method of recovering particles in a flotation cell are disclosed. In an embodiment, the method comprises a technique of exposing the particles to first-size bubbles having a first predetermined size; the first-size bubbles adhering to the particles; and exposing the particles in a liquid, with the first-size bubbles adhering to the particles, to second-size bubbles having a second predetermined size, the second predetermined size being at least approximately ten times larger than the first predetermined size. The method further comprises the second-size bubbles adhering to the particles and engulfing the first-size bubbles on the particles; and using the second-size bubbles adhering to the particles to recover the particles from the liquid. In one embodiment a first surfactant is used to form the first-size bubbles, and a second surfactant is used to form the second-size bubbles.

Disclosed is a vortex mineralization-static separation flotation device and a flotation method. The device comprises: a static separator provided with a separation chamber and a vortex mineralizer provided with a mineralization cylinder. The separation chamber includes a raw ore treatment pipeline and an intermediate ore treatment pipeline. The mineralization cylinder includes a vortex mineralization pipeline. The method comprises: the mineralization cylinder being full of a raw ore slurry and the raw ore slurry in the separation chamber reaching a set level, turning on air conduits and an agitation device to make air enter the mineralization cylinder and form tiny bubbles to collide with first mineral particles and mineralize to form an aerated intermediate ore slurry; the aerated intermediate ore slurry entering the separation chamber and performing collision and mineralization with second mineral particles and the raw ore slurry, and concentrate froth being formed at a top of the separation chamber to be collected.