Water reuse is a common practice to alleviate water scarcity concerns and mitigate their environmental footprint in coal processing facilities. Nevertheless, water reuse leads to the accumulation of various organic and inorganic substances, including salt and residual reagents in the processing water, potentially leading to the retention of soluble impurities within the coal product. Residual impurities may result in a reduction in the quality of coal products. Salt and moisture retention has become a common issue on-site, but there lacks a proper solution currently. To resolve this industrial problem, investigations were carried out for the effects of washing on removing inorganic impurities from the cake during filtration. Filter cakes were prepared from flocculated metallurgical coal in process water. Two washing methods were trialled namely counter-current washing and displacement washing. Regarding washing efficiency, counter-current washing tended to produce cakes with higher specific resistance, which caused longer filtration time. Displacement washing, however, showed increased filtration time, though to a lesser extent. In addition, washing with different washing liquid ratios for multiple wash cycles showed that the filtration time, specific cake resistance, and medium resistance increased with the number of wash cycles. The analysis of the filtrate indicated that utilising a strategy of displacement washing with a washing ratio of 1:20 yielded the most effective removal of salt. The filter cakes were analysed using the μCT imaging technique to gain insights into the pore structure of the cake at a microscopic level. There was a significant change in the cake structure, where the pore profile was more evenly distributed and smaller when the cake was washed by displacement washing.
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