Process and equipment assembly for beneficiation of coal discards

Abstract

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.

Claims

1. A continuous process for beneficiating coal particulates selectively to extract and increase yield of high calorific value carbon components from undesirable fractions of a raw coal feed, the process comprising the steps of: (a) pretreating wash water by delivering an amount of an amphipathic non-ionic surfactant to a wash water tank effective to shift the wash water to a reducing oxidation-reduction-potential such that the wash water has a pH in a range of from about 2.0 to 8.6 and an oxidation-reduction-potential of from about +200 mV to about +400 mV; (b) introducing the raw coal feed and pretreated wash water into a primary mixing tank and washing the coal particulates with the pretreated wash water so as selectively to alter surface electrostatic charges of the coal particulates and increase their hydrophobic mobilization; and (c) separating the high calorific value carbon particulates from the wash water.

2. The process according to claim 1, wherein the raw coal feed comprises raw coal particulates, coal fines and/or coal slurry.

3. The process according to claim 1, wherein the concentration of the non-ionic surfactant in the pretreated wash water is between 0.0007% and 0.0033% v/v or between 8.86 and 33.3 ppb (parts per billion).

4. The process according to claim 1, wherein the non-ionic surfactant is an emulsifier, wetting agent and lubricant.

5. The process according to claim 3, wherein the non-ionic surfactant a short-chained, ethoxylated and propoxylated alcohol base surfactant.

6. The process according to claim 5, wherein the alcohol base surfactant has a branched and linear carbon chain length of between 12 and 15 molecules.

7. The process according to claim 1, wherein the pretreated wash water is admixed with the raw coal particulate feed such that the coal-wash water slurry after addition of the pretreated wash water has a pH in a range of from about 2.0 to about 8.5 and an oxidation-reduction-potential of from about +500 mV to about +600 mV.

8. The process according to claim 1, wherein the pretreated wash water is admixed with the raw coal particulate feed so as to create a coal-wash water slurry mass percentage of approximately 4:1 and 6:1 solids to water ratio, and approximately 80% w/v to 86% w/v solids by weight.

9. The process according to claim 1, wherein the raw coal particulate feed is admixed with the pretreated wash water at a rate of between approximately 4:1 and 6:1, and volume supply of between approximately 20% w/v and 14% w/v.

10. The process according to claim 1, wherein the process includes the additional steps of: (i) vigorously agitating a coal-wash water slurry within the primary mixing tank; (ii) transferring the coal-wash water slurry to a primary gravitational separator for primary separation of high calorific value coal particulates of more than 100 micrometers from smaller particles low calorific value discards; and (iii) transferring the high calorific value coal particulates to a primary high frequency resonance screen having a mesh size of no more than 100 micrometers for further dehydrating and separating high calorific value coal particulates from any remaining pretreated wash water and particulates of less than 100 micrometers.

11. The process according to claim 10, wherein the coal-wash water slurry within the primary mixing tank is agitated at a frequency of approximately 900 RPM for a period of approximately 60 seconds to 90 seconds.

12. The process according to claim 10, wherein the coal-wash water slurry is introduced into the primary gravitational separator at a material feed rate of approximately 1 ton to 120 tons per hour.

13. The process according to claim 10, wherein the primary gravitational separator is a wet spiral separator having a cutter bar position set at approximately 100 micrometers and which is set to a separation specific gravity of 1.2 maximum.

14. The process according to claim 10, wherein the process provides assembling a number of primary spiral separators, either in series or parallel, for processing the pretreated water and coal slurry flow from the primary mixing tank across the primary high frequency resonance screen for separation of high calorific value coal particulates of more than 100 micrometers from smaller particles of low calorific value discards.

15. The process according to claim 10, wherein the process provides the additional steps of: (iv) introducing the high calorific value coal particulates that are collected from the primary high frequency resonance screen into a secondary mixing tank and washing the so-collected high calorific value coal particulates with pretreated or untreated wash water during a continuous secondary beneficiation stage; and (v) further separating the high calorific value carbon particulates from the wash water.

16. The process according to claim 15, wherein the process includes the additional steps of— (vi) vigorously agitating the high calorific value carbon particulates and pretreated or untreated wash water slurry within the secondary mixing tank; (vii) transferring the high calorific value carbon particulates and wash water slurry to a secondary gravitational separator for secondary separation of high calorific value coal particulates of more than 100 micrometers from smaller particles of low calorific value discards; and (viii) transferring the high calorific value coal particulates to a secondary high frequency resonance screen having a mesh size of no more than 100 micrometers for further dehydrating and separating high calorific value coal particulates from any remaining wash water and particulates of less than 100 micrometers.

17. The process according to claim 16, wherein the coal-wash water slurry within the secondary mixing tank is agitated for a period of approximately 90 seconds.

18. The process according to claim 16, wherein the coal-wash water slurry is introduced into the secondary gravitational separator at a material feed rate of a minimum of 1 ton per hour.

19. The process according to claim 16, wherein the secondary gravitational separator is a wet spiral separator having a cutter bar position set at approximately 100 micrometers and which is set to a separation specific gravity of 1.2 maximum.

20. The process according to claim 16, wherein the process provides assembling a number of secondary spiral separators, either in series or in parallel, and running an output of a first spiral separator through a second separator for further secondary separation of high calorific value coal particulates of more than 100 micrometers from smaller particles low calorific value discards.

21. The process according to claim 16, wherein the further step of transferring spent wash water to an underflow tailings tank; allowing the spent wash water to settle so as to separate fine coal particulates and ash from the wash water; and reintroducing the so-separated wash water back into the beneficiation process of the invention.

22. A batch process for beneficiating high calorific value coal particulates from undesirable fractions of a raw coal feed, the process comprising the steps of: (a) pretreating wash water by delivering an amount of an amphipathic non-ionic surfactant to a wash water tank effective to shift the wash water to a reducing oxidation-reduction-potential such that the wash water has a pH in a range of from about 2.0 to about 8.6 and an oxidation-reduction-potential of from about +200 mV to about +400 mV; (b) introducing the raw coal feed and pretreated wash water into a primary mixing tank and washing the coal particulates with the pretreated wash water so as selectively to alter surface electrostatic charges of the coal particulates and increase their hydrophobic mobilization; (c) transferring the coal-wash water slurry to a primary gravitational separator for primary separation of high calorific value coal particulates of more than 100 micrometers from smaller particles of low calorific value discards; (d) transferring the high calorific value coal particulates to a primary high frequency resonance screen having a mesh size of no more than 100 micrometers for further dehydrating and separating high calorific value coal particulates from any remaining pretreated wash water and particulates of less than 100 micrometers; (e) introducing the high calorific value coal particulates that are collected from the primary high frequency resonance screen back into the primary mixing tank and washing the so-collected high calorific value coal particulates with pretreated or untreated wash water during a secondary beneficiation stage; and (f) separating the high calorific value carbon particulates from the wash water through the primary gravitational separator and primary high frequency resonance screen.

23. A process for beneficiating high value particulates to selectively extract and increase yield of high value mineral components from undesirable fractions of a raw mineral feed, the process comprising the steps of: (a) pretreating wash water by delivering an amount of an amphipathic non-ionic surfactant to a wash water tank effective to shift the wash water to a reducing oxidation-reduction-potential such that the wash water has a pH in a range of from about 2.0 to about 8.6 and an oxidation-reduction-potential of from about +200 mV to about +400 mV; (b) introducing the raw mineral feed and pretreated wash water into a primary mixing tank and washing the mineral particulates with the pretreated wash water so as selectively to alter surface electrostatic charges of the mineral particulates and increase their hydrophobic mobilization; and (c) separating the high value mineral particulates from the wash water.

24. The process according to claim 23, wherein the raw mineral feed comprises high value non-calorific particulates selected from the group consisting gold, silver, platinum group metals (PGMs), zinc and chromium.

25. The process according to claim 23 wherein the process includes the additional steps of: (i) vigorously agitating a minerals-wash water slurry within the primary mixing tank; (ii) transferring the minerals-wash water slurry to a primary gravitational separator for primary separation of high value mineral particulates from smaller particles of low value discards; and (iii) transferring the high value mineral particulates to a primary high frequency resonance screen for further dehydrating and separating high value mineral particulates from any remaining wash water and undesirable small particulates.

26. The process according to claim 25, wherein the process includes pr vidcs the additional steps of: (iv) introducing the high value mineral particulates that are collected from the primary high frequency resonance screen into a secondary mixing tank and washing the so-collected high value mineral particulates with pretreated or untreated wash water during a secondary beneficiation stage; and (v) separating the high value mineral particulates from the wash water.

27. The process according to claim 26, wherein the process includes the additional steps of: (vi) vigorously agitating the high value mineral particulates and wash water slurry within the secondary mixing tank; (vii) transferring the high value mineral particulates and wash water slurry to a secondary gravitational separator for secondary separation of high value mineral particulates from smaller particles low value discards; and (viii) transferring the high value mineral particulates to a secondary high frequency resonance screen [30] for further dehydrating and separating high value mineral particulates from any remaining wash water and smaller particulates.

28. A beneficiation equipment assembly suitable for use in a process for beneficiating coal particulates to selectively extract and increase yield of high calorific value carbon components from undesirable fractions of a raw coal feed, the equipment assembly comprising: a pretreatment wash water tank for pretreating wash water; a primary mixing tank arranged in flow communication with the pretreatment wash water tank and configured for receiving the raw coal feed and pretreated wash water; an agitator operatively associated with the primary mixing tank and configured for washing the coal particulates with the pretreated wash water so as selectively to alter surface electrostatic charges of the coal particulates and increase their hydrophobic mobilization; a primary gravitational separator arranged in flow communication with the primary mixing tank for primary separation of high calorific value coal particulates of more than 100 micrometers from smaller particle low calorific value discards; a primary high frequency resonance screen arranged in flow communication with the primary gravitational separator and having a mesh size of no more than 100 micrometers for further dehydrating and separating high calorific value coal particulates from any remaining wash water and particulates of less than 100 micrometers; and an underflow tailings tank arranged in flow communication with the primary gravitational separator and primary high frequency resonance screen for receiving spent wash water.

29. The equipment assembly according to claim 28, wherein the primary gravitational separator is a wet spiral separator having a cutter bar position set at approximately 100 micrometers and which is set to a separation specific gravity of 1.2 maximum.

30. The equipment assembly according to claim 28, wherein the assembly includes a number of primary spiral separators such that an output of a first spiral separator is run through a second separator for further primary separation of high calorific value coal particulates of more than 100 micrometers from smaller particles low calorific value discards.

31. The equipment assembly according to claim 28, wherein the assembly further comprises: a secondary wash water tank containing either pretreated or untreated wash water; a secondary mixing tank arranged in flow communication with the secondary wash water tank and the primary high frequency resonance screen and configured for receiving the high calorific value coal particulates that are collected from the primary high frequency resonance screen into the secondary mixing tank; an agitator operatively associated with the secondary mixing tank and configured for washing the collected high calorific value coal particulates with pretreated or untreated wash water; a secondary gravitational separator arranged in flow communication with the secondary mixing tank for secondary separation of high calorific value coal particulates of more than 100 micrometers from smaller particles low calorific value discards; a secondary high frequency resonance screen arranged in flow communication with the secondary gravitational separator and having a mesh size of no more than 100 micrometers for further dehydrating and separating high calorific value coal particulates from any remaining wash water and particulates of less than 100 micrometers; and an underflow tailings tank arranged in flow communication with the secondary gravitational separator and secondary high frequency resonance screen for receiving spent wash water.

32. The equipment assembly according to claim 28, wherein the equipment assembly is in the form of a mobile rig.

33. Pretreated wash water adapted for use in a process for beneficiating coal particulates from a raw coal feed, the pretreated wash water including an amount of an amphipathic non-ionic surfactant effective to shift the wash water to a reducing oxidation-reduction-potential such that the wash water has a pH in a range of from about 2.0 to about 8.6 and an oxidation-reduction-potential of from about +200 mV to about +400 mV.

34. The pretreated wash water according to claim 33, wherein the non-ionic surfactant is an emulsifier, wetting agent and lubricant.

35. The pretreated wash water according to claim 34, wherein the non-ionic surfactant a short-chained, ethoxylated and propoxylated alcohol base surfactant.

36. The pretreated wash water according to claim 35, wherein the alcohol base surfactant has a branched and linear carbon chain length of between 12 and 15 molecules.

37. The pretreated wash water according to claim 33, wherein the concentration of the non-ionic surfactant in the pretreated wash water is between 0.0007% and 0.0033% v/v or between 8.86 and 33.3 ppb (parts per billion).

38. A high calorific value carbonaceous fuel comprising high calorific value carbon particulates extracted from a raw coal feed according to the process of claim 1.

39. A high calorific value carbonaceous fuel comprising high calorific value carbon particulates extracted from a raw coal feed through use of the equipment assembly according to claim 28.

40. A high calorific value carbonaceous fuel comprising high calorific value carbon particulates extracted from a raw coal feed through use of pretreated wash water according to claim 33.

Description

SPECIFIC EMBODIMENTS OF THE INVENTION

(1) Without limiting the scope thereof, the invention will now further be described and exemplified with reference to the accompanying examples and drawings in which—

(2) FIG. 1 is a process flow chart representing a first stage for the beneficiation of coal discards according to the invention;

(3) FIG. 2 is a process flow chart representing a second stage for the beneficiation of coal discards according to the invention.

(4) The present invention provides a dedicated equipment design, customized process and pre-processing capacitation of the physicochemical characteristics of an aqueous phase of a washing process for the beneficiation of coal discards and have been designed to optimize reclamation of high calorific value carbonaceous particulates from a raw coal feed, while retaining all discards for further processing or validation of mass balance yield parameters. The process flow and mechanical configuration of FIGS. 1 and 2 describes a two-phase approach which is continuous and mutually inclusive.

(5) The first process phase [10] of FIG. 1 comprises of a raw coal feed [12] fed into a primary mixing tank [16] including a motorized mixing paddle to agitate the coal discards, fines and/or slurry. Pretreated wash water is added to the primary mixing tank [16] from a wash water pretreatment tank [14]. The pre-treatment compound that is used for capacitation of the phase one wash water during particulate dispersion and hydrophobic mobilization comprises of a short chained, ethoxylated and propoxylated alcohol base which acts as an amphipathic, non-ionic surfactant, emulsifier, wetting agent and lubricant. From the primary mixing tank [16], the suspended coal-wash water slurry is pumped into a primary spiral separator [18]. The primary spiral separator [18] is preset to a separation specific gravity of 1.2 maximum to gravitationally separate impurities and water from the coal slurry.

(6) The pro-active inclusion of the pre-treatment compound serves to manipulate the properties of the aqueous phase of the slurry mixture in the primary mixing tank [16] so as to potentiate the mechanical separation of the different particulate fractions within the primary spiral separator [18]. Further enhancement of particulate partitioning and selective extraction of high calorific value coal may be achieved with further integration of the pretreated water throughout the entire washing process.

(7) Overflow from the primary spiral separator [18] is pumped to a high frequency resonance screen [20] with a mesh size of 100 micrometres. The resonance screen [20] further separates water and wastes from the coal slurry. All discards or underflow water [22] is harvested in tailings tanks (not shown) for settling of low calorific ash, clay rich fractions coal and water for subsequent re-use.

(8) The second process phase [24] of FIG. 2 is directly coupled to the infrastructure of the first phase [10], FIG. 1, components and is directly dependent on the outputs of the first phase [10], FIG. 1, to further refine the beneficiated product by processing through the second phase [24] structures. The second phase [24] comprises a secondary mixing tank [26] for receiving the beneficiated coal slurry of the first phase [10]. Treated or untreated wash water is added from a secondary wash water tank [27] to the secondary mixing tank [26] and the coal slurry is further agitated and washed.

(9) From the secondary mixing tank [26], the coal slurry is pumped into a secondary spiral separator [28] preset to a separation specific gravity of 1.2 maximum, for another round of waste and coal slurry separation. Overflow from the secondary spiral separator [28] is pumped to a secondary high frequency resonance screen [30] with a mesh size of 100 micrometres to dehydrate the post spiral slurry mix. The final beneficiated coal product [32] is harvested from the secondary resonance screen [30]. All discards and spent underflow wash water [22; 34] are harvested in collection sumps (not shown) to reclaim wash water for re-use.

(10) The applicant has found that a combination of pretreatment of the wash water to be used in the aqueous phase washing of the raw coal with the surfactant, the vigorous mechanical agitation of the raw coal and the pretreated wash water, and the mechanical process flow through the two phases of the process design provide consistently repeatable results in terms of the beneficiated coal. The enhanced beneficiation resulting from the process of the invention, suggests that pretreatment of the aqueous washing phase potentiates selective partitioning of different aspects of the raw coal feed product. It is universally acknowledged and has reliably been shown that selective removal of unwanted elements from the fine raw coal material, specifically Sulphur and Sulphur-based compounds, may adversely impact upon suitability of reclaimed wash water to be re-used during further ongoing washing and beneficiation processes. Progressive increases in acidity and a lowering of pH values traditionally render coal wash water unusable and may pose a significant environmental risk if allowed to discharge into natural water courses. By contrast, the technology and process of the invention have been shown to reduce Sulphur content of the final washed product, without an adverse impact on the quality of the reclaimed wash water. Within minor limits, this allows the bulk of the reclaimed water to be re-used for further raw material washing without hindrance to the extraction performance of the combined mechano-chemical beneficiation process.

(11) Pretreatment of the aqueous phase of the wash water according to the invention selectively manipulates the physicochemical and electrodynamic properties of the suspended coal particulates, in that the surfactant formulation partitions and separates different components of the suspended raw coal particulates discard solution to promote extraction of commercially viable, high calorific value carbon elements to the exclusion of inorganic contaminants lacking in combustible capacity.

(12) Based on the inclusive actions of the specific spiral design specifications and configuration, sieve porosity and agitation frequency, preconditioned slurry admixture rate as well as the rate and volume of the raw coal supply, the selective and predictable partitioning of the high commercial value carbon fraction from ash and non-combustible components of the raw slurry feed after dewatering through a specific micron porosity sieve and agitator/vibrator consistently results in attainment of the following washed coal quality objectives: Increased Calorific Value (CV) per unit mass Increased Fixed Carbon content per unit mass Increased combustible fraction (yield) per initial unit mass Reduced ash content per unit mass Reduced Sulphur content per unit mass

(13) The invention extends to the use of a coal fine and slurry beneficiating technology for application across a diverse array of coal types, inorganic compounds, moisture and diverse soil and clay contents. In addition, the same approach can be applied for the selective extraction and beneficiation of other unrelated and valuable fine minerals from unwanted impurities and contaminants.

(14) A further advantage of this invention is that discard coal meets the CV requirements of Pulverised Fuel power station requirements and an additional benefit is that minimal milling is required to get the specified fineness for commercial suitability of the resource.

Example 1

(15) A comparative test was conducted to evaluate capacity of the process configuration in combination with a pretreated aqueous wash solution to selectively extract high calorific value coal residues from a low-grade slurry mixture. Changes to the profile of commercially relevant parameters were recorded at each stage of the process and the sampling site can be correlated with the Process Flow Diagram detailed in FIG. 1. Samples were processed in accordance with a standard protocol which was adapted and refined relative to the specifications and quantities of the Raw Feed material.

(16) TABLE-US-00001 Inherent Ash Volatile Fixed Calorific Calorific Total Total Moisture Content Matter Carbon Value Value Sulphur Moisture Sample Identity % % % % MJ/Kg Kcal/Kg % % RAW FEED 3.4 40.7 19.7 36.2 16.85 4024.55 0.81 9.1 GGV/MRF-DRY-RAW FEED Jun. 10, 2016 SCREEN 1 UNDERFLOW 2.3 44.7 18.6 34.5 15.91 3800.04 0.98 33.1 GGV/MRF-DRY-B SCR(1) Jun. 10, 2016 SCREEN 2 UNDERFLOW 2.1 34.4 20.1 43.4 19.76 4719.59 0.64 34.9 GGV/MRF-DRY-B SCR(2) Jun. 10, 2016 SPIRAL 1 UNDERFLOW 0.9 68.3 13.7 17.2 5.77 1378.14 1.56 24.0 TAILINGS GGV/MRF-DRY-B Spiral(1) Jun. 10, 2016 SPIRAL 2 UNDERFLOW 1.4 55.1 16.1 27.5 11.88 2837.49 0.73 28.4 TAILINGS GGV/MRF-DRY-B Spiral(2) Jun. 10, 2016 FINAL SCREENED PRODUCT 1.9 20.7 24.3 53.2 24.96 5961.59 0.46 28.0 GGV/MRF-DRY-B After Clean Coal

(17) The technology and process protocol detailed a consistent increase in volatile matter, Fixed Carbon and calorific value between the raw and final screened product. At the same time, the technology consistently reduced inherent moisture, ash content and total sulphur contents.

(18) TABLE-US-00002 Particle Size Analysis Sample Identity % % % % % RAW FEED +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm GGV/MRF-DRY-RAW FEED 0.0 23.4 32.8 13.6 30.1 Jun. 10, 2016 SCREEN 1 UNDERFLOW +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm GGV/MRF-DRY-B SCR(1) 0.0 1.9 15.9 41.7 40.51 Jun. 10, 2016 SCREEN 2 UNDERFLOW +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm GGV/MRF-DRY-B SCR(2) 0.0 0.6 31.0 30.3 38.10 Jun. 10, 2016 SPIRAL 1 UNDERFLOW +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TAILINGS GGV/MRF-DRY-B 0.0 10.9 70.3 11.3 7.50 Spiral(1) Jun. 10, 2016 SPIRAL 2 UNDERFLOW +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TAILINGS GGV/MRF-DRY-B 0.0 17.5 78.5 3.5 0.50 Spiral(2) Jun. 10, 2016 FINAL SCREENED +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm PRODUCT GGV/MRF-DRY-B 0.0 43.5 55.0 1.0 0.50 After Clean Coal

(19) The Particle Size Distribution (PSD) for the raw coal shifted from a greater than 100 μm percentage of 56% to a final screened product of 98% confirming improved handling capacity.

Example 2

(20) An equivalent study to that described in Example 1 was performed at a geographically distant mine with a substantially different coal quality. The protocol was again refined to address the specific attributes of the coal discards to be processed.

(21) TABLE-US-00003 Inherent Ash Volatile Fixed Calorific Calorific Total Total Moisture Content Matter Carbon Value Value Sulphur Moisture Sample Identity % % % % M J/Kg Kcal/Kg % % RAW FEED 238.85 TWFN/MRF-Wet-Raw Feed 2.7 33.2 20.1 44.0 19.84 4738.78 1.11 37.8 SCREEN 1 UNDERFLOW 3.4 33.3 19.5 43.8 19.51 4659.96 0.82 46.6 TWFN/MRF-Wet-B/line Scr1 SCREEN 2 UNDERFLOW 2.9 20.0 23.0 54.1 24.81 5925.87 0.49 16.1 TWFN/MRF-Wet-B/line Scr2 SPIRAL 1 UNDERFLOW TAILINGS 2.0 39.7 19.5 38.9 17.63 4210.93 1.19 34.8 TWFN/MRF-Wet-B/line Spiral1 SPIRAL 2 UNDERFLOW TAILINGS 2.6 45.9 17.4 34.1 14.66 3501.54 0.93 35.8 TWFN/MRF-Wet-B/line Spiral2 FINAL SCREENED PRODUCT 2.8 18.4 22.6 56.2 25.61 6116.95 0.48 34.0 TWFN/MRF-Wet-B/line After C/Coal

(22) The technology was able to reduce ash content and sulphur (moisture relatively unchanged). At the same time, it substantially increased the values of volatile matter, fixed carbon and calorific value relative to the raw sample.

(23) TABLE-US-00004 Particle Size Analysis Sample Identity % % % % % RAW FEED +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TWFN/MRF-Wet-Raw Feed 0.0 7.5 28.1 18.0 46.37 SCREEN 1 UNDERFLOW +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TWFN/MRF-Wet-B/line Scr1 0.0 0.8 5.7 26.1 67.51 SCREEN 2 UNDERFLOW +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TWFN/MRF-Wet-B/line Scr2 0.0 0.3 58.4 30.2 11.00 SPIRAL 1 UNDERFLOW TAILINGS +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TWFN/MRF-Wet-B/line Spiral1 0.0 4.8 40.6 21.4 33.24 SPIRAL 2 UNDERFLOW TAILINGS +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TWFN/MRF-Wet-B/line Spiral2 0.0 13.9 80.7 4.7 0.68 FINAL SCREENED PRODUCT +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm TWFN/MRF-Wet-B/line 0.2 31.9 66.4 1.5 0.09 After C/Coal

(24) The PSD for the raw coal shifted from a greater than 100 μm percentage of 35.6% to a final screened product of 98.3%, again confirming improved handling capacity.

Example 3

(25) Thermal discard coal samples derived from a long-term dump were processed in accordance with an established protocol. This protocol comprised of various permutations, including different concentrations of water treatment compound (surfactant), to establish inclusion rate relative to the mass of coal discard to be processed, as well as relative to the Particle Size Distribution (PSD) profile of the sample in question. The results reflect the standardized dose and inclusion rate of the water treatment compound with the raw product in the mixing tanks.

(26) The pre-wash “raw feed” coal profile description of the discard sample was confirmed before processing and the “washed coal” qualities of the washed and processed coal are detailed below:

(27) TABLE-US-00005 Raw Coal Washed Coal Parameter Value Before Value After % Change SAMPLE 1 CV (Mj/Kg) 23.54 30.74 +31 Ash (%) 31.3 12.9 −59 Volatiles (%) 18.3 20.6 +13 Fixed Carbon (%) 49.6 65.5 +32 Sulphur (%) 1.9 1.25 −34 SAMPLE 2 CV (Mj/Kg) 26.29 31.45 +20 Ash (%) 24.1 10.5 −57 Volatiles (%) 19.2 22.6 +18 Fixed Carbon (%) 55.8 64.8 +18 Sulphur (%) 1.51 1.19 −21 SAMPLE 3 CV (Mj/Kg) 16.85 25.96 +54 Ash (%) 40.7 18.0 −53 Volatiles (%) 19.7 24.5 +23 Fixed Carbon (%) 36.2 55.4 +23 Sulphur (%) 0.81 0.46 −43 SAMPLE 4 CV (Mj/Kg) 19.8 26.2 +32 Ash (%) 33.2 16.4 −50 Volatiles (%) 20.1 23.9 +19 Fixed Carbon (%) 44.0 56.4 +29 Sulphur (%) 1.11 0.48 −58

(28) The samples were processed through the washing system and the non-viable fractions were collected as discards at the different stages of the washing process. The final “washed coal” fraction was collected after discharge from the processing system and submitted for independent measurement of commercially relevant criteria. The technology consistently increased the Calorific Value (CV), Volatiles and Fixed carbon percentages, while reducing the Ash and Sulphur contents.

Example 4

(29) Anthracite coal discard samples were derived from a dedicated slurry pond containing suspended coal and ash particles after having been flushed from a washing plant. The features of the preprocessed “Raw Feed” ‘wet coal discards’ and the processed “washed coal” had the following qualities and features:

(30) TABLE-US-00006 Raw Anthracite Washed anthracite Parameter Before After % Change SAMPLE 1 Ash (%) 44.2 12.3 −72.0 Volatiles (%) 8.9 5.1 −42.6 Fixed Carbon (%) 42.6 79.3 +46.2 Sulphur (%) 1.7 0.8 −52.94 SAMPLE 2 Ash (%) 36.5 14.0 −61 Volatiles (%) 7.6 5.0 −34.2 Fixed Carbon (%) 54.1 75.8 +28.6 Sulphur (%) 1.9 0.8 −57.8 SAMPLE 3 Ash (%) 42.3 18.9 −55 Volatiles (%) 7.46 6.3 −14.6 Fixed Carbon (%) 44.4 72.3 +63 Sulphur (%) 2.59 1.02 −59

(31) The sample was prepared in accordance with the standard processing protocol and processed through the washing and separation system. The technology consistently reduced ash, volatiles and Sulphur while increasing fixed or combustible carbon percentiles.

Example 5

(32) A semi-bituminous sample drawn from a ‘Run of Mine’ (ROM) stream was collected and processed through the dedicated wash and separation process using the standard processing protocols. The features of the preprocessed ROM “Raw Feed” and the arriving processed “washed coal” had the following qualities and features:

(33) TABLE-US-00007 Raw Coal Washed coal Parameter Value Before Value After Difference % Change SAMPLE 1 CV (Mj/kg) 26.35 31.15 +4.8 +18 Ash (%) 24.9 10.0 −14.9 −60 Volatiles (%) 20.4 21.9 +1.5 +7 Fixed Carbon (%) 54.7 66.7 +12 +22 Sulphur (%) 2.92 1.44 −1.48 −51

(34) The Particle size distribution of the ROM sample and the washed sample are detailed below:

(35) TABLE-US-00008 Particle Size Analysis % % % % % ROM +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm Sample 0.5 63.6 21.2 5.0 9.7 Washed +3 mm +0.5 mm +0.100 um +0.045 mm −0.045 mm sample 0.7 75.1 23.6 0.5 0.10

(36) Aside from reducing impurities and enhancing combustibility, the technology also washed out the ultrafine particles, thereby improving the handling and further processing properties of the washed product.

(37) While the presently preferred embodiments have been described for purposes of this disclosure, changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within this invention as defined by the claims.