According to the invention, there is provided a process for the beneficiation of coal discards by increasing calorific value and carbon content while removing inert mineral matter and sulphur compounds. The process involves the pretreatment of wash water with a non-ionic kinetically energized surface-active agent and the admixture with a fixed mass of raw coal discard to enhance hydrophobicity and carboniferous particle agglomeration. Processing of the resulting suspension though a dedicated series of spiral separators and high frequency, resonance sieves reliably reduces excessive levels of mineral ash and sulphur compounds.

A process of aggregating coal fines in a coal flotation concentrate includes dewatering the coal flotation concentrate to reduce moisture content and provide a dewatered flotation concentrate, mixing the dewatered flotation concentrate with a binder to provide a mixture, compacting the mixture under pressure to provide a green body of aggregated coal fines, having a sufficient strength for handling utilizing typical commercial methods of conveying and shipping.

A process of aggregating coal fines in a coal flotation concentrate includes dewatering the coal flotation concentrate to reduce moisture content and provide a dewatered flotation concentrate, mixing the dewatered flotation concentrate with a binder to provide a mixture, compacting the mixture under pressure to provide a green body of aggregated coal fines, having a sufficient strength for handling utilizing typical commercial methods of conveying and shipping.

A fuel pellet includes a pellet body made from a mixture of (a) hemp byproduct, kenaf byproduct or hemp and kenaf byproduct, (b) sawdust and, optionally, (c) coal fines. The fuel pellet may be made without adding a binder. A method of making the binderless fuel pellet is also described.

A method of preparing a fuel composition includes placing coal having a heat content between about 3,000 BTU/lb and about 9,000 BTU/lb and a moisture content between about 20 wt % and about 60 wt % in a vessel. The coal is exposed to heat and a pressure less than atmospheric pressure within the vessel, thereby reducing the coal, such that an average primary particle size of the coal is less than 1 millimeter. A binder is introduced to the vessel, such that the coal combines with the binder to yield a mixture. The mixture is shaped to yield a fuel composition.

A method of preparing a fuel composition includes placing coal having a heat content between about 3,000 BTU/lb and about 9,000 BTU/lb and a moisture content between about 20 wt % and about 60 wt % in a vessel. The coal is exposed to heat and a pressure less than atmospheric pressure within the vessel, thereby reducing the coal, such that an average primary particle size of the coal is less than 1 millimeter. A binder is introduced to the vessel, such that the coal combines with the binder to yield a mixture. The mixture is shaped to yield a fuel composition.

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.

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 method of preparing non-volatile bituminous material in solid form includes first accessing molds having mold cavities defining an irregularly shaped brick having a plurality of non-planar surfaces and preparing the bituminous material for casting by heating it until it is suitably viscous for casting and optionally blending it with an additive. Then, the molds can be filled with the bituminous materials, preferably using a retractable conduit that progressively fills each mold cavity from its bottom to its top. Next, the bituminous material in the molds is solidified until substantially solid bricks are formed. Optionally, a skeleton with optional additional buoyant features can be placed in each mold cavity prior to casting so that the resulting brick has increased buoyancy throughout, and the skeleton and any buoyant features can be customized according to the needs of the customer. The resulting bricks can be removed for transport.

In the interest of making an existing consumer product, the fire starter log, better. Coming up with a new mixture came to mind. Many materials are being thrown away or wasted. The goal is to use these materials to create a natural burning alternative. By combining chipped hemp stalk, dried orange peel, and beeswax the use of less environmentally friendly materials used in other fire starters can be decreased. This product also creates value opportunity for producers of beeswax, oranges and hemp. Consumers of this product support a shift towards sustainable biomaterials.