Process Intensification and Operational Parameter Optimization of Oil Agglomeration for Coal Slime Separation

Coal slime, a byproduct of coal processing with high ash content, poses significant challenges in terms of its efficient separation and resource utilization due to its fine particle size and complex composition. This study aims to optimize the oil agglomeration process for coal slime separation through systematic parameter investigation and predictive modeling. Response surface methodology (RSM) was employed to analyze the individual and interactive effects of pulp density, oil dosage, and agitation rate on three key performance indicators: combustible recovery, efficiency index, and ash rejection. Meanwhile, an artificial neural network (ANN) was developed to establish a robust prediction model for the efficiency index. The novelty of this work lies in the integration of thermodynamic analysis, multi-objective optimization, and machine learning approaches. The key findings include the identification of dodecane as the optimal bridging liquid due to its intermediate carbon chain length that balances interfacial tension and wettability. Under optimized conditions (14% pulp density, 22% oil dosage, and 1600 r/min), the process achieved a combustible recovery of 91.49%, ash rejection of 61.58%, and efficiency index of 53.07%. The ANN model demonstrated superior predictive capability with an overall R2 of 0.9659 and RMSE of 1.12. This work provides comprehensive guidelines for the design, optimization, and scale-up of coal slime oil agglomeration processes in industrial applications.