Coal-derived solid hydrocarbon particles

A process for obtaining particles of coal-derived solid hydrocarbon separated from particles of coal-derived mineral matter comprising:

• obtaining an aqueous slurry of coal-derived solids comprising:
• discrete particles of composite coal composed of a solid carbonaceous matter matrix and inherent mineral matter inherent in the carbonaceous matter matrix;
• discrete particles of coal-derived mineral matter;
• and
• a quantity of water, wherein the aqueous slurry contains greater than 25 wt. % solid particles comprising the discrete particles of composite coal and discrete particles of coal-derived mineral matter, and wherein the discrete particles of composite coal and discrete particles of coal-derived mineral matter have a particle size less than about 100 μm;
• separating the particles of composite coal from the particles of coal-derived mineral matter via a first froth flotation separation to yield a first coal-froth containing less than 8 wt. % coal-derived mineral matter on a dry basis;
• mechanically removing water from a portion of the first coal-froth to yield a wet filter cake;
• blending the wet filter cake and first coal-froth to form a mixture containing from 45 to 55 wt. % solids;
• adding a dispersant to the mixture to reduce particle agglomeration and enable subsequent froth flotation;
• milling the mixture to form discrete particles of coal-derived solid hydrocarbon and discrete particles of coal-derived mineral matter having an average particle size in the range from 1 μm to 10 μm;
• separating the particles of coal-derived solid hydrocarbon from the particles of coal-derived mineral matter in the milled mixture via a second froth flotation separation to yield a second coal-froth containing less than 1.5 wt. % coal-derived mineral matter on a dry basis;
• and
• mechanically removing water from the second coal-froth to yield a second wet filter cake comprising the particles of coal-derived solid hydrocarbon separated from the particles of coal-derived mineral matter.