Patent ID: 8202399

Claim:
A process for modification of fuel solids, comprising: a) providing fuel solids having a maximum diameter of approximately 3 inches or less; b) optionally adjusting the moisture content of the fuel solids as provided; c) optionally removing air from the fuel solids; d) optionally providing a grinding aid; e) providing steam at a temperature of at least 350° F. at a velocity of at least 1340 ft/s; f) directing the steam from a plurality of nozzles within an interior chamber defined by a housing to form a shear field and vortexes; g) entraining the fuel solids and if present the grinding aid within the steam that forms the shear field and vortexes; h) allowing the solids to remain in the shear field and vortexes until they are comminuted to particles having a maximum diameter of 40 microns or less; and i) removing all but 0.05-7.0 mass % water by weight relative to the fuel by i) removing steam and condensed water by direct evaporation from the comminuted particles, or ii) cooling or heating the steam or particles until the temperature of the steam is at a level that provides a desired level of particle hydration after evaporation of the steam upon venting is complete, or iii) removing essentially all of the water from the comminuted particles and then rehydrating them by means of liquid water or a humid gaseous medium.