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Abstract The contemporary research article is central to understanding coal structure evaluation and the morphological development impacting its utilization in different applications. Through Mineral Liberation Analysis (MLA) designs high content phyllosilicates minerals and swelling clay minerals were rationalized to provides a novel insight into enhanced coal beneficiation and the benefits of coal by-product re-utilization progressions that encourage safer environments and economic sustainability. This work commences with collection of five (5) different coal samples from the central district region in Botswana, sample characterization deploying Thermogravimetric coal analysis (TGA), x-ray fluorescence spectroscopy (XRF), x-ray diffraction (XRD), scanning electron microscopy (SEM) and the Hardgrove Grindability Index (HGI) test that was directed to quantification of the coal hardness and fracture toughness during milling. The cumulative objective was to understand the correlation that exists between the natural composition of the coal sample and their adaptation and application in various carbonaceous products. A solid connection was thus identified in the sulfur and phosphorus weight percentage inclusions in all the coal materials hence higher significance in sphalerite mineral phases (Zn, Fe) S critically increased the fracture toughness and hardness properties. Moreover, mineral amalgams intrinsic to the coal maceral such as aluminum oxides (Al2O3), silicate (SiO2), calcites (CaO), Iron oxide (Fe2O3), potassium feldspars (K − AlSi3O8), albite (Na − AlSi3O8), and anorthite (Ca − Al2Si2O8) compounds in alkali feldspars were detected in larger quantities. The coal industry has attracted much industrial attention to manufacturing foundations producing cement, ceramic tiles, paving bricks, and material synthesis and will continue to supply other economic sectors in the conceivable future. Graphical Abstract