Patent ID: 8460407

Claim:
An improved form of coal particles made by a process comprising: a) providing coal solids having a maximum diameter of approximately 3 inches or less; b) optionally adjusting the moisture content of the coal solids as provided before further comminution; c) optionally removing air from the coal 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 coal 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 coal by A) removing steam and condensed water by direct evaporation from the comminuted particles, or B) 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 C) removing essentially all of the water from the comminuted particles and then rehydrating them by means of liquid water or a humid gaseous medium.