A two-stage classification circuit using 150 mm diameter gMax cyclones was installed and evaluated in a coal preparation plant in an effort to achieve a clean coal product without the use of froth flotation. Particle size separations of around 37 mu m were achieved while limiting ultrafine bypass to less than 10% in the circuit underflow stream. As a result, approximately 81% of the ash-bearing material in the circuit feed was rejected to the circuit overflow stream. The feed ash content was reduced from around 50% to values in the range of 22-30% in the circuit underflow stream with a mass recovery of about 30%. Further reductions in the coarse product ash content were limited due to the particle density effect and the remaining presence of a significant quantity of high-ash slime material in the coarse product. The typical D-50 for the coal particles was 40 mu m while the estimated value for mineral matter was 17 pm. Based on the findings of the study, the use of classification to recover a low-ash, coarse fraction in the feed of a fine coal circuit is limited by the density effect regardless of the ability to eliminate ultrafine bypass. (C) 2007 Elsevier Ltd. All rights reserved.