The transformation of kaolinite into metakaolinite by thermal activation to obtain highly active aluminosilicate is commonly known. In addition to kaolin, the high content of kaolinite in coal mining waste is another potential source for obtaining an aluminosilicate precursor, thereby protecting the environment and adding value to industrial wastes. In this paper, the kaolinite-based high ash slime (KAS) was calcined at temperatures ranging from 400 °C to 1000 °C under air, N₂, and CO₂ atmospheres, respectively. The thermal behaviors and structural evolution of each component in KAS were analyzed by thermal analysis (TG-DSC), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), and X-ray photoelectron spectroscopy (XPS). Moreover, the chemical reactivity of Al₂O₃ and SiO₂ in calcined KAS was evaluated by HCl and NaOH leaching methods. The results show that the applied KAS in this study primarily consisted of kaolinite and carbon, while the minor mineral phases included quartz, calcite, and pyrite. Additionally, the structural transformation of kaolinite during calcination included dehydroxylation, sintering, and the formation of mullite. Crystalline kaolinite completely decomposed into semicrystalline metakaolinite at 600–800 °C, accounting for the increase in chemical reactivity. The interlayer sintering of metakaolinite and the recrystallization of amorphous components led to the decrease in chemical reactivity after 800 °C. Furthermore, the thermal behaviors of carbon in KAS are greatly affected by the calcination atmosphere. The presence of carbon reduced the chemical reactivity of calcined KAS.

Floc structure plays an important role in the separation of coal wastewater. In this study, a camera-based method is used to evaluate quantitatively the structural characteristics of flocs generated by different coagulants and flocculants. The correlations between particle size, settlement velocity and effective density of coal tailings flocs are analysed. The results show that the statistical settling velocity increases linearly with floc size, while the effective density decreases with increase in floc size. Different flocculation mechanisms lead to diverse growth abilities of flocs. When the flocculant is used alone, the quality of the flocs generated by the flocculants, cationic polyacrylamide (CPAM) and non-ionic polyacrylamide (NPAM), is better than that generated by anionic polyacrylamide (APAM). However, the combination of trivalent cations and APAM yields a much better effect than that obtained using CPAM and NPAM. Flocs become larger and more compact when treated with a coagulant combined with a flocculant.

The cleaning process of coals is challenging due to the existence of clay minerals. The overall objective of this study is to investigate how the dewatering of coal slurry is impacted by the presence of clay minerals, i.e., kaolinite and montmorillonite. Filtration tests were first conducted to investigate the effect of kaolinite and montmorillonite on the dewatering efficiency of coal. Specifically, we measured the filtration velocity, moisture, average specific resistance, and porosity of filter cakes for six slurry samples, in which different amounts of kaolinite and montmorillonite were contained. Filtration tests show that a small amount of kaolinite and montmorillonite leads to a significant reduction in the filtration velocity and porosity, and a big increase in the average specific resistance and the moisture of the filter cake. We observe that most kaolinite existed in the top and middle layers of the filter cake, while most montmorillonite existed in the top layer; on the contrary, little montmorillonite is observed in the middle and bottom layers of the filter cake. Montmorillonite results in a much more deteriorative effect than kaolinite. Considering that the interactions between clay minerals and water may play a key role, we then further investigate the effect of such interactions using molecular simulations. Simulation results show that water molecules could hardly diffuse into kaolinite from the edge, while they could readily penetrate into the montmorillonite layers from the edge surface. This result can be explained by the hydrated cation in montmorillonite. The adsorption density of water on the octahedral surface of kaolinite is higher than that of water on the tetrahedral surface of kaolinite. Furthermore, the adsorption density of water on the double surfaces of kaolinite is higher than that of water on the montmorillonite surface. This research is expected to provide benefits or contributions to the dewatering of clay-rich coal tailings.