Functionalized open network structures of open or network foames for selective separation of

Abstract

An engineered collection medium for mineral separation is described herein. Engineered collection media have a solid phase body configured with a three-dimensional open-cell structure, such as foam or sponge, to provide a collection surface. The surface is functionalized with a hydrophobic chemical having molecules with functional groups for attaching mineral particles to the collection surface. The engineered collection medium may be a foam block, a filter or a conveyor belt placed in the slurry to collect mineral particles in the slurry. An engineered collection medium carrying mineral particles is provided to a release device, where the mineral particles can be released by using mechanical agitation, sonic agitation, or the like.

Description

[0001] This application is a divisional application of the Chinese patent application with application number 201780015513.1 and application date January 9, 2017, and the invention name is “Functionalized open network structure of open-pore or reticulated foam for selective separation of mineral particles in water systems”.

[0002] Cross-references to Related Patent Applications

[0003] This application claims the benefit of U.S. Provisional Application No. 62 / 276,051, filed January 7, 2016, entitled “Novel Recovery Media for Mineral Processing,” (712-2.428 (CCS-0158), and U.S. Provisional Application No. 62 / 405,569, filed October 7, 2016, entitled “Three Dimensional Functionalized Open-Network Structure for Selective Separation of Mineral Particles in an Aqueous System,” (712-2.439 (CCS-0175), both of which are incorporated herein by reference in their entirety. Technical Field

[0004] The present invention generally relates to techniques for separating valuable materials from undesirable materials in a mixture, such as a pulp slurry; more particularly, to a method and apparatus for separating valuable materials from undesirable materials in a mixture, such as a pulp slurry, using, for example, an engineered collection media. Background Art

[0005] In many industrial processes, flotation is used to separate valuable or desired materials from unwanted materials. For example, in this process, a mixture of water, valuable materials, unwanted materials, chemicals, and air is placed in a flotation cell. Chemicals are used to make the desired material hydrophobic, and air is used to carry the material to the surface of the flotation cell. When the hydrophobic material and air bubbles collide, they adhere to each other. The air bubbles then rise to the surface, carrying the desired material with them.

[0006] The performance of a flotation cell depends on the bubble surface area flux and the bubble size distribution in the collection zone of the device. The bubble surface area flux depends on the bubble size and the air injection rate. Controlling the bubble surface area flux has traditionally been very difficult. It is a multivariable control problem, and there is no reliable real-time feedback mechanism for control.

[0007] There is a need in the industry to provide a better way to separate valuable materials from undesirable materials, for example, including in such flotation cells, so as to eliminate the problems associated with the use of bubbles in such separation processes. Summary of the Invention

[0008] CCS-0158 and 0175

[0009] According to some embodiments, the present invention may include or take the form of an engineered collection medium characterized by a solid phase body and a plurality of molecules, wherein the solid phase body is configured with a three-dimensional open-cell structure to provide a plurality of collection surfaces; the plurality of molecules are disposed on the collection surface, the molecules including functional groups having chemical bonds for adsorbing one or more mineral particles in the aqueous mixture to the molecules so that the mineral particles are attached to the collection surface.

[0010] Engineered collection media may also include one or more of the following features:

[0011] The engineered collection media may include a coating configured with a hydrophobic chemical selected from the group consisting of polysiloxanes, poly(dimethylsiloxane), fluoroalkyl silanes, or pressure sensitive adhesives generally known to have low surface energy to provide molecules.

[0012] The solid phase body can be made of a material selected from polyurethane, polyester urethane, polyether urethane, reinforced polyurethane, polyurethane coated with PVC, silicone, polychloroprene, polyisocyanurate, polystyrene, polyolefin, polyvinyl chloride, epoxy resin, latex, fluoropolymer, polypropylene, phenolic resin, EPDM and nitrile.

[0013] The solid phase may include a coating or layer, such as a coating or layer modified with a tackifier, plasticizer, crosslinker, chain transfer agent, chain extender, adhesion promoter, aryl or alkyl copolymers, fluorinated copolymers, hexamethyldisilazane, silica, or hydrophobic silica.

[0014] The solid phase body may include a coating or layer made of a material selected from the group consisting of acrylic resins, butyl rubber, ethylene vinyl acetate, natural rubber, nitrile, styrene block copolymers with ethylene, propylene and isoprene, polyurethane and polyvinyl ether.

[0015] The engineered collection media can include a binder configured to promote adhesion between the solid body and the coating.

[0016] The solid phase body can be made of plastic, ceramic, carbon fiber or metal.

[0017] The three-dimensional open cell structure may include pores ranging from 10 to 200 pores per inch.

[0018] The solid phase may comprise or take the form of a reticulated foam block providing a three-dimensional open cell structure.

[0019] The solid phase body may include a filter providing a three-dimensional open-pored structure having pores to allow fluid in the aqueous mixture to flow through the filter.

[0020] The solid body may comprise a conveyor belt having a surface configured with a three-dimensional open-pore structure.

[0021] The engineered collection media may include different open cell foams having different specific surface areas that are mixed to recover a specific size distribution of mineral particles in the slurry.

[0022] Open-cell foam and its properties

[0023] The three-dimensional open-cell structure may take the form of an open-cell foam.

[0024] The open cell foam may be made of one or more materials selected from the group consisting of polyester urethane, polyether urethane, reinforced polyurethane, composite materials such as PU coated with PVC, non-polyurethane, as well as metals, ceramics, carbon fiber foams and rigid porous plastics to enhance mechanical durability.

[0025] The open-cell foam can be coated with polyvinyl chloride and then coated with a low surface energy compliant adhesive polymer to enhance chemical and mechanical durability.

[0026] Prior to applying the functionalized polymer coating, the open-cell foam may be primed with a high-energy primer to increase the adhesion of the functionalized polymer coating to the surface of the open-cell foam.

[0027] The surface of the open cell foam may be chemically or mechanically abraded to provide "grip points" on the surface to retain the functionalized polymer coating.

[0028] The surface of the open cell foam may be treated with a coating that covalently bonds to the surface to enhance adhesion between the functionalized polymer coating and the surface.

[0029] The surface of the open-cell foam can be coated with a functionalized polymer coating in the form of a compliant, adhesive polymer of low surface energy and having a thickness selected to capture certain mineral particles and collect certain particle sizes, including where a thin coating is selected to collect a proportionally smaller particle size fraction and a thick coating is selected to collect an additional large particle size fraction.

[0030] The specific surface area can be configured to have a specific number of pores per inch, determined for a specific size range of the mineral particles in the slurry.

[0031] Device

[0032] According to some embodiments, the present invention may take the form of a device featuring a processor and a release device.

[0033] The processor can be configured to receive one or more engineered collection media carrying mineral particles, each of the one or more engineered collection media including a solid phase body and a plurality of molecules, the solid phase body being configured with a three-dimensional open pore structure to provide a plurality of collection surfaces, and the plurality of molecules being attached to the collection surfaces, the molecules including functional groups having chemical bonds for adsorbing one or more mineral particles of the mineral particles in the aqueous mixture to the molecules so that the mineral particles are attached to the collection surfaces.

[0034] The release device may be configured to disrupt the chemical bonds of the functional groups, thereby removing the mineral particles from the collection surface.

[0035] The device may also include one or more of the following features:

[0036] The engineered collection media may include a coating configured with a hydrophobic chemical selected from the group consisting of polysiloxanes, poly(dimethylsiloxane), and fluoroalkyl silanes, or a pressure sensitive adhesive generally known to have low surface energy, to provide the molecules.

[0037] The releasing device may include a stirrer configured to provide mechanical agitation to break the chemical bonds of the functional groups.

[0038] The solid body may comprise a conveyor belt carrying the mineral particles, and the releasing means may comprise a brushing device configured to rub the conveyor belt, thereby breaking chemical bonds of the functional groups.

[0039] The device may also include one or more features described herein, including, for example, those set forth in connection with the engineered collection media described above.

[0040] method

[0041] According to some embodiments, the present invention may take the form of a method, characterized in that: a step for providing a processor, the processor being configured to receive one or more engineered collection media carrying mineral particles, each of the one or more engineered collection media comprising a solid body and a plurality of molecules, the solid body being configured with a three-dimensional open pore structure to provide a plurality of collection surfaces, and the plurality of molecules being attached to the collection surface, the molecules comprising functional groups having chemical bonds for adsorbing one or more mineral particles in the aqueous mixture to the molecules so that the mineral particles are attached to the collection surface; and interrupting the chemical bonds of the functional groups to remove the mineral particles from the collection surface.

[0042] The method may also include one or more of the following features:

[0043] The engineered collection media may include a coating configured with a hydrophobic chemical selected from the group consisting of polysiloxanes, poly(dimethylsiloxane), fluoroalkyl silanes, or pressure sensitive adhesives generally known to have low surface energy to provide molecules.

[0044] The method may further comprise the step of providing an agitator configured to provide mechanical agitation to facilitate said disruption, and wherein said disruption is performed in a surfactant.

[0045] The solid body may comprise a conveyor belt carrying the mineral particles, wherein the method further comprises the step of causing a brushing device to rub the conveyor belt to effect said interruption.

[0046] The method may further comprise the step of providing an acoustic wave source configured to provide ultrasonic waves to said disruption, wherein said disruption is performed in a liquid medium.

[0047] Parent application (CCS-0090 / 712-2.383-1)

[0048] The invention described herein may also be used in conjunction with various embodiments disclosed in the earlier parent application, U.S. Patent Application No. 14 / 117,912, filed on November 15, 2013, including, for example, using the engineered collection media disclosed herein, alone or in conjunction with the embodiments disclosed in the parent application. For example, as follows:

[0049] Method disclosed in the parent application

[0050] For example, according to some embodiments, the present invention may take the form of a method characterized by: steps for receiving a plurality of synthetic beads carrying mineral particles in a processor, each synthetic bead comprising a surface and a plurality of molecules attached to the surface, the molecules comprising functional groups having chemical bonds for adsorbing or attaching one or more mineral particles to the molecules such that the mineral particles are attached to the synthetic bead; and breaking the chemical bonds of the functional groups to remove the mineral particles from the synthetic beads. In this method, the plurality of synthetic beads may comprise or take the form of an engineered collection medium disclosed herein.

[0051] The method may also include one or more of the following features:

[0052] The synthetic beads carrying mineral particles may be received in a mixture having a first temperature, and the step of interrupting may include contacting the synthetic beads carrying mineral particles with a medium having a second temperature higher than the first temperature.

[0053] The synthetic beads carrying the mineral particles can be brought into contact with a liquid, and the interrupting step can include applying sonic agitation to the liquid to separate the mineral particles from the synthetic beads, or the interrupting step can include applying microwaves to the liquid to separate the mineral particles from the synthetic beads. The interrupting step can include providing an ultrasonic source to apply sonic agitation to the liquid, and / or arranging the ultrasonic source to generate an ultrasonic signal for sonic agitation, such as an ultrasonic signal in the range of 20 kHz to 300 kHz for sonic agitation. The interrupting step can include providing an ultrasonic signal selected at a resonant frequency of the beads to separate the mineral particles from the synthetic beads.

[0054] The synthetic beads carrying mineral particles can be received with a mixture having a first pH value, and the step of interrupting can include contacting the synthetic beads carrying mineral particles with a medium having a second pH value lower than the first pH value, including where the second pH value ranges from 0 to 7.

[0055] The interrupting step may comprise mechanically moving the synthetic beads relative to each other, including arranging a rotating device or apparatus to agitate the synthetic beads.

[0056] The synthetic beads may be made from a polymer having a glass transition temperature, and the second temperature may be substantially equal to or higher than the glass transition temperature.

[0057] The portion of the synthetic beads carrying the mineral particles may be made of a magnetic material, and the step of interrupting may comprise arranging a magnetic stirrer to stir the synthetic beads.

[0058] The synthetic beads carrying the mineral particles may be received with a mixture, wherein the disruption comprises two or more selected from the following disruption techniques: 1) lowering the pH of the mixture; 2) applying ultrasound to the mixture; 3) increasing the temperature of the mixture; and 4) mechanically agitating the mixture. The selected disruption techniques may be applied to the mixture simultaneously or sequentially.

[0059] In all of these embodiments, the plurality of synthetic beads may comprise or take the form of an engineered collection medium disclosed herein.

[0060] The device disclosed in the parent application

[0061] According to some embodiments, by way of another embodiment, the present invention can take the form of an apparatus characterized by: a processor configured to receive a plurality of synthetic beads carrying mineral particles, each synthetic bead comprising a surface and a plurality of molecules attached to the surface, the molecules comprising functional groups with chemical bonds for adsorbing or attaching one or more mineral particles to the molecules, thereby attaching the mineral particles to the synthetic bead; and a release device configured to interrupt the chemical bonds of the functional groups, thereby removing the mineral particles from the synthetic beads. In this apparatus, the plurality of synthetic beads can include or take the form of the engineered collection medium disclosed herein.

[0062] The device may also include one or more of the following features:

[0063] The release device may be configured to implement one or more of the features set forth herein.

[0064] The present invention can take the form of an apparatus characterized by: a processing compartment, synthetic beads and a controller, the processing compartment being used to receive a plurality of synthetic beads carrying mineral particles, each synthetic bead comprising a surface and a plurality of molecules attached to the surface, the molecules comprising functional groups having chemical bonds for adsorbing or attaching one or more mineral particles to the molecules so that the mineral particles are attached to the synthetic beads; the synthetic beads carrying the mineral particles, the mineral particles being received in a mixture having a pH value; and the controller being arranged to release an acidic material to lower the pH value of the mixture.

[0065] The present invention can take the form of a device characterized by: a processing compartment, synthetic beads and an acoustic wave source, the processing compartment is used to receive a plurality of synthetic beads carrying mineral particles, each synthetic bead includes a surface and a plurality of molecules attached to the surface, the molecules include functional groups with chemical bonds for adsorbing or attaching one or more mineral particles to the molecules so that the mineral particles are attached to the synthetic beads; the synthetic beads carry mineral particles, and the mineral particles are received in a mixture with physical conditions; the acoustic wave source is arranged to apply ultrasonic waves to the mixture.

[0066] In practice, the present invention provides a mineral separation technology using synthetic beads or bubbles, including polymer bubbles or beads based on size, weight, density and magnetic properties.The term "polymer" in this specification refers to a macromolecule composed of many units of the same or similar structure linked together.

[0067] The present invention can include replacing or supplementing the bubbles in the flotation cells currently used in the prior art with similar density materials having very controllable size characteristics. By controlling the size and injection rate, very precise surface area flux can be achieved. This type of control will enable the bead or bubble size to be adjusted or selected to a target particle size to better separate valuable or desired materials from unwanted materials in the mixture. In addition, the buoyancy of the bubbles or beads can be selected to provide a desired rise rate within the flotation cell to optimize adsorption and attachment to the target mineral particles. For example, the material or medium can be a polymer or polymer-based bubbles or beads. These polymers or polymer-based bubbles or beads are very inexpensive to manufacture and have very low density. They can function very similarly to foam, but are not commonly used.

[0068] Because the lifting media size is independent of the flotation cell chemistry, the chemistry can be tailored to optimize hydrophobicity. Frother performance does not need to be compromised to produce the desired bubble size. The controlled media size distribution can be tailored to maximize recovery of different feed substrates to flotation as ore quality changes.

[0069] There may be a mixture of air and lightweight beads or bubbles. The lightweight beads or bubbles can be used to lift the valuable material and the air can be used to create the required foam layer to achieve the desired material grade.

[0070] Bead or bubble chemistries have also been developed to maximize the adhesion of the lightweight beads or bubbles to the valuable material.

[0071] A bead recovery process has also been developed to enable the reuse of lightweight beads or bubbles in a closed-loop process. This process can consist of a scrubbing station whereby valuable minerals are removed from the lightweight beads or bubbles mechanically, chemically, thermally, or electromagnetically. Specifically, the removal process can be performed by controlling the pH of the medium in which the enriched polymer beads or bubbles are embedded, controlling the temperature of the medium, applying mechanical or sonic agitation to the medium, irradiating the enriched polymer with light of a certain frequency, or applying electromagnetic waves to the enriched polymer beads to weaken or disrupt the binding of the valuable material to the polymer bead or bubble surface.

[0072] In all of these embodiments, the plurality of synthetic beads may comprise or take the form of an engineered collection medium disclosed herein.

[0073] Separation process or processor disclosed in the parent application

[0074] According to some embodiments of the present invention, and by way of example, the separation process can utilize existing mining industry equipment, including conventional column units and thickeners. Lightweight synthetic bubbles or beads can be provided, for example, to the middle of a column. Such conventional columns or units have an environment that promotes the release of mineral particles. The mineral particles fall to the bottom and the synthetic bubbles or beads float or come to the surface. The synthetic bubbles or beads can be recovered and then returned through the process that occurs in the first conventional column or unit. The thickener can be used to recycle process water at both stages of the process. In this embodiment, the plurality of synthetic beads can include or take the form of an engineered collection medium disclosed herein.

[0075] Flotation recovery of coarse ore particles in mining disclosed in the parent application

[0076] According to some embodiments, the present invention may be used for flotation recovery of coarse ore particles in mining.

[0077] For example, the concept may take the form of generating lightweight synthetic beads or bubbles in flotation recovery to lift particles larger than, for example, 150 microns to the surface in a flotation cell or column.

[0078] The basic concept is to create shells or "semi-porous" structured beads or bubbles of predetermined size and use them as "engineered" bubbles to improve flotation recovery of coarse ore particles in, for example, mining.

[0079] Flotation recovery can be implemented in multiple stages, for example, the first stage works well in recovering ground ore of the correct size (<150 microns), but ore particles are either too small or too large to pass to later stages and are more difficult to recover.

[0080] The invention involves creating "bubbles" and designing them to carry ore to the surface using, for example, a polymer shell or structure, suitably chemically activated to adsorb or attach to the ore.

[0081] Depending on the method of "engineering" the bubbles, at or near the surface, the shell can dissolve (time activated) and release agents that further promote foaming.

[0082] In these embodiments, the plurality of synthetic beads may comprise or take the form of an engineered collection medium disclosed herein.

[0083] Polymer blocks with bound air or lightweight materials

[0084] According to some embodiments, the present invention may take the form of synthetic flotation bubbles, using concepts such as incorporating bubbles into polymer blocks that are designed to attract or attach mineral-rich ore to their surface, which then floats to the top of the flotation cell. Lightweight materials such as polystyrene foam may also be incorporated into the polymer blocks to aid buoyancy.

[0085] Benefits of this approach include “engineered bubbles” in the polymer that enable a wider range of ore particles to be lifted to the surface, improving recovery efficiency.

[0086] According to some embodiments, optimally sized polymer blocks with a high percentage of air can be produced with appropriate collector chemicals and can also be encapsulated in polymers.

[0087] Once the mass is in a mixture such as a slurry, the collector chemical can be released to initially adsorb or attach to the mineral-rich ore particles and then rise to the surface.

[0088] For example, in these embodiments, polymeric blocks, including Styrofoam, can include or take the form of the engineered collection media disclosed herein.

[0089] The device disclosed in the parent application is in the form of a cell or column

[0090] According to some embodiments, the present invention can take the form of an apparatus characterized by: a tank or column configured to receive a fluid (e.g., water) and a mixture of valuable materials and undesirable materials; receiving synthetic bubbles or beads configured to float when immersed in the mixture and functionalized to control the chemistry of a process conducted in the tank or column; and providing enriched synthetic bubbles or beads having valuable substances thereon.

[0091] The synthetic bubbles or beads may be made of polymer or polymer-based materials, or silica or silica-based materials, or glass or glass-based materials.

[0092] The cell or column may take the form of a flotation cell or column and the synthetic bubbles or beads may be functionalised to attach to valuable materials in the mixture which form part of the flotation separation process carried out in the flotation cell or column.

[0093] The synthetic bubbles or beads can be functionalized to release chemicals to control the chemistry of the flotation separation process.

[0094] The synthetic bubbles or beads may be configured with a solid outer shell that is functionalized with chemicals to attach to valuable materials in the mixture. Alternatively, the synthetic bubbles or beads may include chemicals that can be released to attach to valuable materials in the mixture.

[0095] The synthetic bubbles or beads can be configured with a solid outer shell configured to contain a gas, including air, to increase buoyancy when immersed in a mixture. Alternatively, the synthetic bubbles or beads can be made of a low-density material so as to be buoyant when immersed in a mixture, including the synthetic bubbles being configured as solids without an inner cavity.

[0096] Synthetic bubble or bead can comprise a plurality of hollow objects, main body, element or structure, and each is configured with corresponding cavity, unfilled space or hole to capture and keep inner bubble.Hollow object, main body, element or structure can comprise hollow cylinder, sphere or bead or capillary or some combination thereof.Each hollow object, main body, element or structure can be configured with size, so that do not absorb the liquid that comprises water, wherein size is in the approximately 20-30 micron scope.A plurality of hollow objects, main body, element or structure can be configured with chemicals, for preventing liquid from migrating in the corresponding cavity, wherein chemical is a hydrophobic chemical.Synthetic bubble or bead made by silicon dioxide or silicon dioxide based material or glass or glass based material can adopt the form of the hollow glass cylinder that uses stretching and cutting process to make.

[0097] It is not intended that the scope of the present invention be limited to the size or shape of the synthetic beads or bubbles to enhance their rise or fall in the mixture.

[0098] The scope of the present invention is also intended to include other types or kinds of ways of configuring and functionalizing synthetic bubbles or beads, now known or developed in the future, so as to perform the above-mentioned function of floating when immersed in a mixture and attaching to valuable substances in the mixture.

[0099] The mixture may take the form of a slurry containing, for example, water and the desired valuable materials.

[0100] In these embodiments, the synthetic bubbles or beads may comprise or take the form of the engineered collection media disclosed herein.

[0101] Implementation method of flotation separation equipment disclosed in the parent application

[0102] The present invention may also take the form of a method, for example, for implementation in a flotation separation apparatus having a flotation cell or column. The method may include the steps of receiving a mixture of a fluid and a valuable material in the flotation cell or column; receiving synthetic bubbles or beads in the flotation cell or column, configured to float when immersed in the mixture and functionalized to attach to the valuable material in the mixture; and providing enriched synthetic bubbles or beads from the flotation cell or column with the valuable material attached thereto. The method may include implementation consistent with one or more features set forth herein.

[0103] In these embodiments, the synthetic bubbles or beads may comprise or take the form of the engineered collection media disclosed herein.

[0104] The device disclosed in the parent application is in the form of a flotation separation device

[0105] According to some embodiments, the present invention may take the form of an apparatus, such as a flotation separation device, comprising a flotation cell or column configured to receive a mixture of water, valuable material, and undesirable material; receive a polymer or polymer-based material, including polymer or polymer bubbles or beads, configured to attach to the valuable material in the mixture; and provide an enriched polymer or polymer-based material, including enriched polymer or polymer-based bubbles or beads, to which the valuable material is attached. According to some embodiments, the polymer or polymer-based material may be configured to have a surface area flux by controlling some combination of the size of the polymer or polymer-based material and / or the injection rate of the received mixture in the flotation cell; alternatively, the polymer or polymer-based material may be configured to have a low density so as to behave like bubbles; alternatively, the polymer or polymer-based material may be configured with a controlled media size distribution that can be tailored to maximize recovery of different feed substrates as the quality of the valuable material varies, including as the quality of the ore varies; or some combination thereof.

[0106] The present invention may take the form of an apparatus for use in or forming part of a separation process implemented in separation processor technology, the apparatus being characterized by synthetic bubbles or beads configured with a polymer or polymer-based material, functionalized to attach to a valuable material in a mixture so as to form enriched synthetic bubbles or beads having the valuable material attached thereto, and further configured to be separated from the mixture based at least in part on a difference in physical properties between the enriched synthetic bubbles or beads having the valuable material attached thereto and the mixture.

[0107] The separation process can be implemented in a separation processor technology that combines synthetic bubbles or beads with a mixture and provides enriched synthetic bubbles or beads having valuable materials attached thereto that are separated from the mixture based at least in part on a difference in physical properties between the enriched synthetic bubbles or beads having valuable materials attached thereto and the mixture.

[0108] In these embodiments, the synthetic bubbles or beads may comprise or take the form of the engineered collection media disclosed herein.

[0109] Size-based separation disclosed in the parent application

[0110] The separation process can be implemented using size-based separation, where the synthetic bubbles or beads can be configured to be separated from the mixture based at least in part on the difference between the size of the synthetic bubbles or beads enriched with valuable material attached thereto and the size of unwanted substances in the mixture.

[0111] The synthetic bubbles or beads may be arranged such that the size of the synthetic bubbles or beads is larger than the largest ground ore particle size in the mixture, or such that the size of the synthetic bubbles or beads is smaller than the smallest ground ore particle size in the mixture.

[0112] The synthetic bubbles or beads may be configured as solid polymer bubbles or beads.

[0113] The synthetic bubbles or beads may be configured with a core material of sand, silica or other suitable material, and further configured with a polymer encapsulation.

[0114] In these embodiments, the synthetic bubbles or beads may comprise or take the form of the engineered collection media disclosed herein.

[0115] Weight-based separation disclosed in the parent application

[0116] The separation process can be implemented using weight-based separation, where the synthetic bubbles or beads can be configured to separate from the mixture based at least in part on the difference between the weight of the synthetic bubbles or beads enriched with valuable material attached thereto and the weight of unwanted substances in the mixture.

[0117] The synthetic bubbles or beads may be arranged such that the weight of the synthetic bubbles or beads is greater than the weight of the largest ground ore particle in the mixture, or such that the weight of the synthetic bubbles or beads is less than the weight of the smallest ground ore particle in the mixture.

[0118] The synthetic bubbles or beads may be configured as solid polymer bubbles or beads.

[0119] The synthetic bubbles or beads may be configured with a core material of magnetite, air, or other suitable material, and also with a polymer encapsulation.

[0120] In these embodiments, the synthetic bubbles or beads may comprise or take the form of the engineered collection media disclosed herein.

[0121] Magnetic-based separation

[0122] The separation process can be implemented using magnetic-based separation, where the synthetic bubbles or beads can be configured to be separated from the mixture based at least in part on the difference between the magnetic, ferrimagnetic, or ferromagnetic properties of the enriched synthetic bubbles or beads having valuable material attached thereto and the magnetic, ferrimagnetic, or ferromagnetic properties of unwanted substances in the mixture.

[0123] The synthetic bubbles or beads may be configured such that the paramagnetic, ferrimagnetic or ferromagnetic properties of the synthetic bubbles or beads are greater than the paramagnetic, ferrimagnetic or ferromagnetic properties of the unwanted ground ore particles in the mixture.

[0124] The synthetic bubbles or beads can be configured with a ferromagnetic or ferrimagnetic core adsorbed to a paramagnetic surface and also configured with a polymer encapsulation.

[0125] In these embodiments, the synthetic bubbles or beads may comprise or take the form of the engineered collection media disclosed herein.

[0126] Density-based separation disclosed in the parent application

[0127] The separation process can be implemented using density-based separation, wherein the synthetic bubbles or beads can be configured to separate from the mixture based at least in part on the difference between the density of the enriched synthetic bubbles or beads having valuable material attached thereto and the density of the mixture, which is similar to PCT application No. PCT / US12 / 39528 (Agent Docket No. 712-002.356-1), filed on May 25, 2012, entitled “Flotation separation using lightweight synthetic bubbles and beads,” the entire contents of which are incorporated herein by reference.

[0128] In these embodiments, the synthetic bubbles or beads may comprise or take the form of the engineered collection media disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0129] The foregoing and other features and advantages of the present invention will be more fully understood from the following detailed description of illustrative embodiments taken in conjunction with the accompanying drawings, which are not necessarily drawn to scale and in which like elements are numbered alike:

[0130] Figure 1 is a diagram of a flotation system, process, or apparatus according to some embodiments of the present invention.

[0131] Figure 2 is a diagram of an alternative flotation cell or column that may be used instead of forming a flotation cell according to some embodiments of the present invention. Figure 1 A flotation cell or column as a portion of a flotation system, process or apparatus as shown in FIG.

[0132] Figure 3a Shown are generic synthetic beads according to some embodiments of the present invention, which can be size-based beads or bubbles, weight-based polymer beads and bubbles, and magnetic-based beads and bubbles.

[0133] Figure 3b An enlarged portion of a synthetic bead showing molecules or molecular segments used to attach functional groups to the surface of the synthetic bead is shown according to some embodiments of the present invention.

[0134] Figure 4a Synthetic beads having a body made of a synthetic material are shown according to some embodiments of the present invention.

[0135] Figure 4b Synthetic beads with synthetic shells according to some embodiments of the present invention are shown.

[0136] Figure 4c Synthetic beads with synthetic coatings according to some embodiments of the present invention are shown.

[0137] Figure 4d Synthetic beads in the form of porous blocks, sponges, or foams are shown according to some embodiments of the present invention.

[0138] Figure 5a Surfaces of synthetic beads having recesses and / or stems are shown according to some embodiments of the present invention.

[0139] Figure 5b Shown are surfaces of synthetic beads having indentations and / or pores according to some embodiments of the present invention.

[0140] Figure 5c Shown is a surface of a synthetic bead with stacked beads according to some embodiments of the present invention.

[0141] Figure 5d The surface of a synthetic bead having a hair-like physical structure according to some embodiments of the present invention is shown.

[0142] Figure 6 is a diagram of a bead recovery processor according to some embodiments of the present invention, in which valuable materials are thermally removed from polymer bubbles or beads.

[0143] Figure 7 is a diagram of a bead recovery processor according to some embodiments of the present invention, in which valuable materials are sonically removed from polymer bubbles or beads.

[0144] Figure 8 is a diagram of a bead recovery processor according to some embodiments of the present invention, in which valuable materials are chemically removed from polymer bubbles or beads.

[0145] Figure 9is a diagram of a bead recovery processor according to some embodiments of the present invention, in which valuable materials are electromagnetically removed from polymer bubbles or beads.

[0146] Figure 10 is a diagram of a bead recovery processor according to some embodiments of the present invention, in which valuable materials are mechanically removed from polymer bubbles or beads.

[0147] Figure 11 is a diagram of a bead recovery processor according to some embodiments of the present invention, in which valuable materials are removed from polymer bubbles or beads in two or more stages.

[0148] Figure 12 is a diagram of an apparatus for mineral separation using countercurrent flow to separate bubbles or beads based on size from a mixture, according to some embodiments of the present invention.

[0149] Figure 13a Shown are general synthetic beads functionalized to be hydrophobic, according to some embodiments of the present invention, where the beads can be size-based beads or bubbles, weight-based polymer beads and bubbles, and magnetic-based beads and bubbles.

[0150] Figure 13b An enlarged portion of a hydrophobic synthetic bead is shown, showing wetted mineral particles attached to the hydrophobic surface of the synthetic bead.

[0151] Figure 13c An enlarged portion of a hydrophobic synthetic bead is shown, showing the hydrophobic non-mineral particles attached to the hydrophobic surface of the synthetic bead.

[0152] Figure 14a The mineral particles are shown attached simultaneously to many very small synthetic beads.

[0153] Figure 14b The mineral particles are shown attached simultaneously to a number of slightly larger synthetic beads.

[0154] Figure 15a The wetted mineral particles are shown to be simultaneously attached to many small hydrophobic synthetic beads.

[0155] Figure 15b The wetted mineral particles are shown being simultaneously attached to many slightly larger hydrophobic synthetic beads.

[0156] Figure 16a and 16b Some embodiments of the invention are shown in which a portion of the synthetic beads or bubbles is functionalized to have collector molecules, while another portion is functionalized to be hydrophobic.

[0157] Figure 17aA collection medium in the form of an open-cell foam in the shape of a cube is shown.

[0158] Figure 17b Filters according to some embodiments of the present invention are shown.

[0159] Figure 17c Shown is a cross section of a film or conveyor belt according to an embodiment of the invention.

[0160] Figure 17d A cross section of a film or conveyor belt according to another embodiment of the invention is shown.

[0161] Figure 18 A separation processor is shown having a functionalized polymer-coated conveyor belt disposed therein, according to some embodiments of the present invention.

[0162] Figure 19 A separation processor configured with a filter assembly coated with a functionalized polymer according to some embodiments of the present invention is shown.

[0163] Figure 20 A co-current drum unit according to some embodiments of the present invention is shown that is configured to enhance contact between the collection medium and the mineral particles in the slurry.

[0164] Figure 21 A cross-current drum unit according to some embodiments of the present invention is shown, which is configured to enhance contact between the collection medium and the mineral particles in the slurry.

[0165] Figure 22 is a photograph showing a reticulated foam with Cu minerals entrapped throughout the structure. DETAILED DESCRIPTION

[0166] CIP application

[0167] The CIP application includes Figures 1 to 22 , such as including a reference showing subject matter from an earlier filed parent application Figures 1 to 16b and showing the subject matter forming the basis of this CIP application Figures 17a to 22 .

[0168] The CIP application is about Figures 17a to 22 Various inventions related to the use of engineered collection media in the form of foam, Styrofoam, etc. are further expanded and developed in detail and are described below.

[0169] Figures 17a to 17d

[0170] As above combined Figure 4dIn some embodiments, the synthetic beads 70 can be porous blocks or can be in the form of sponges or foams with a plurality of separated aeration chambers. According to some embodiments of the present invention, foam or sponge can be in the form of filters, membranes or conveyor belts, as disclosed in PCT Application No. PCT / US12 / 39534 (agent roll number 712-002.359-1), filed May 21, 2012, entitled "Mineral separation using functionalized membranes," which is incorporated herein by reference in its entirety. Therefore, the synthetic beads described herein can be summarized as engineered collection media. Equally, porous materials, foam or sponges can be summarized as materials, open-cell foams or reticulated foams with three-dimensional open-cell structures, which can be made of soft polymers, hard plastics, ceramics, carbon fibers, glass and / or metals, and can include hydrophobic chemicals with molecules to adsorb and adhere to the surface of engineered collection media with mineral particles.

[0171] Open-cell or reticulated foams offer advantages over non-open-cell materials by having a higher surface area to volume ratio. Using a functionalized polymer coating to promote attachment of minerals to the foam "network" can improve mineral recovery and also improve the recovery of minerals that are less likely to be released than with traditional processes. For example, the open cells in an engineered foam block allow fluids and particles smaller than the pore size to pass through, but trap mineral particles that come into contact with the functionalized polymer coating on the open cells. This also allows the cell size to be selected based on the slurry properties and application.

[0172] According to some embodiments of the present invention, the engineered collection medium is used as Figure 17a The collection medium may be in the form of an open cell foam / structure in the shape of a rectangular block or cube 70a as shown. Depending on the material used to make the collection medium, the specific gravity of the collection medium may be less than, equal to, or greater than the slurry. Therefore, when the collection medium is mixed with the slurry for mineral recovery, the use of a Figure 20 and Figure 21 The tumbler units shown are advantageous. These tumbler units are disclosed in PCT Application No. PCT / US16US / 68843, filed December 28, 2016, entitled “Tumbler cellform mineral recovery using engineered media” (Attorney Docket No. 712-002.427-1 / CCS-0157), which claims the benefit of Provisional Application No. 62 / 272,026, filed December 28, 2015, both of which are incorporated herein by reference in their entireties.

[0173] According to some embodiments of the present invention, the engineered collection medium can be used as follows Figure 17bThe filter 70b shown has a three-dimensional open pore structure. For example, the filter 70b can be used in Figure 19 In the filter assembly shown.

[0174] According to some embodiments of the present invention, the engineered collection medium may take the form of a membrane 70c, a portion of which is shown in FIG. Figure 17c In. Figure 17c As shown, membrane 70c can have an open-cell foam layer attached to a substrate or base. The substrate can be made of a material that is less porous than the open-cell foam layer. For example, the substrate can be a flexible polymer sheet to enhance the durability of the membrane. For example, membrane 70c can be used as a conveyor belt, such as Figure 18 shown.

[0175] According to some embodiments of the present invention, the engineered collection medium may take the form of a membrane 70d, a portion of which is Figure 17d As shown in Figure 17d As shown, membrane 70d can have two open-cell foam layers connected to both sides of a substrate or base. The substrate can be made of a material that is less porous than the open-cell foam layers. For example, membrane 70d can also be used as Figure 18 Conveyor belt shown.

[0176] In various embodiments of the present invention, Figures 17a to 17d The engineered collection medium shown in may include or take the form of a solid body configured with a three-dimensional open pore structure to provide multiple collection surfaces; and the coating may be configured to provide multiple molecules on the collection surface, the molecules including functional groups with chemical bonds for adsorbing one or more mineral particles in the aqueous mixture to the molecules, which causes the mineral particles to be attached to the collection surface.

[0177] In some embodiments of the present invention, the open-cell structure or foam may include a coating attached thereto to provide a plurality of molecules to adsorb mineral particles, the coating comprising a hydrophobic chemical selected from polysiloxanes, poly(dimethylsiloxanes), fluoroalkyl silanes, or substances generally known as pressure-sensitive adhesives having low surface energy.

[0178] In some embodiments of the present invention, the solid phase body can be made of a material selected from polyurethane, polyester urethane, polyether urethane, reinforced polyurethane, PU coated with PVC, silicone resin, polychloroprene, polyisocyanurate, polystyrene, polyolefin, polyvinyl chloride, epoxy resin, latex, fluoropolymer, polypropylene, phenolic resin, EPDM and nitrile.

[0179] In some embodiments of the present invention, the solid phase body may include a coating or layer, such as a coating or layer modified with a tackifier, a plasticizer, a crosslinker, a chain transfer agent, a chain extender, an adhesion promoter, an aromatic or alkyl copolymer, a fluorinated copolymer, hexamethyldisilazane, silica, or hydrophobic silica.

[0180] In some embodiments of the present invention, the solid phase body may include a coating or layer, for example, made of a material selected from acrylic resin, butyl rubber, ethylene vinyl acetate, natural rubber, nitrile, styrene block copolymers with ethylene, propylene and isoprene, polyurethane and polyethylene ether.

[0181] In some embodiments of the present invention, an adhesive may be provided between the solid body and the coating to promote adhesion between the solid body and the coating.

[0182] In some embodiments of the present invention, the solid phase body can be made of plastic, ceramic, carbon fiber or metal.

[0183] In some embodiments of the present invention, the three-dimensional open cell structure may include pores ranging from 10 to 200 pores per inch.

[0184] In some embodiments of the present invention, the engineered collection media may be encapsulated in a cage structure that allows a mineral-containing slurry to pass through the cage structure to promote contact between the mineral particles in the slurry and the engineered collection media.

[0185] In some embodiments of the present invention, the cage structures or filters carrying mineral particles can be removed from the processor so that they can be stripped of mineral particles, cleaned, and reused.

[0186] Figure 18 : Conveyor belts coated with functionalized polymers

[0187] For example, Figure 18The invention is shown in the form of a machine, device, system or apparatus 400, for example, for separating valuable materials from unwanted materials in a mixture 401 (e.g., a liquid slurry) using a first processor 402 and a second processor 404. According to some embodiments of the present invention, the first processor 402 and the second processor 404 may be configured with a member coated with a functionalized polymer, which is shown as, for example, a conveyor belt 420 coated with the functionalized polymer extending between the first processor 402 and the second processor 404. Arrows A1, A2, A3 represent the movement of the conveyor belt 420 coated with the functionalized polymer. Technology for causing the conveyor belt-like element 420 to operate between two processors such as element 402 and element 404, including motors, transmissions, etc., is known in the art, and the scope of the present invention is not intended to be limited to any particular type or kind now known or later developed in the future. According to some embodiments of the present invention, the conveyor belt 420 coated with the functionalized polymer may include, for example, a plurality of conveyor belts 420 coated with a plurality of functionalized polymers. Figure 17c Or the layer structure shown in 17d.

[0188] The first processor 402 may take the form of a first chamber, tank, trough, or column containing an attachment-rich environment, generally designated 406. The first chamber, tank, or column 402 may be configured to receive a mixture or liquid slurry 401 in the form of a fluid (e.g., water), a valuable material, and an undesirable material, which is present in an attachment-rich environment 406, for example, having a high pH value, which facilitates the attachment of the valuable material. The second processor 404 may take the form of a second chamber, tank, trough, or column containing a release-rich environment, generally designated 408. The second chamber, tank, trough, or column 404 may be configured to receive, for example, water 422 (which may have a low pH value) present in the release-rich environment 408, or to receive ultrasonic waves that facilitate the release of the valuable material. Alternatively, for example, a surfactant may be used in the release-rich environment 408 to separate the valuable material from the conveyor belt 420 under mechanical agitation or sonic agitation. Sonic agitation may be achieved by, for example, Figure 7 Mechanical agitation can be achieved by, for example, an ultrasonic generator 164. Figure 10 This may be accomplished by an agitation device such as the agitator 188 shown, or by a brush (not shown) rubbing the surface of the conveyor belt 420 as it moves through the release-rich environment.

[0189] In operation, the first processor 402 can be configured to receive a mixture or liquid slurry 401 of water, valuable materials, and undesirable materials and a conveyor belt 420 coated with a functionalized polymer that can be configured to adhere to the valuable materials in an adherent-rich environment. Figure 18 In FIG. 4 , the tape 420 is understood to be configured and functionalized with a polymer coating to attach to the valuable material in the attachment-rich environment 406 .

[0190] The first processor 402 may also be configured to receive data from, for example, Figure 18 The tailings 442 are shown as being discharged from a pipe 441. The second processor 404 can also be configured to provide valuable materials released from the enriched functionalized polymer coated component into a rich release environment 408. For example, in Figure 18 , second processor 404 is shown as being configured to discharge valuable material in the form of concentrate 462 via conduit 461 .

[0191] Figure 19 : Filters coated with functionalized polymers

[0192] For example, Figure 19 The present invention is shown in the form of a machine, device, system or apparatus 500, for example, for separating valuable materials from unwanted materials in a mixture 501 (e.g., a liquid slurry) using a first processor 502, 502' and a second processor 504, 504'. According to some embodiments of the present invention, the first processor 502 and the second processor 504 can be configured to process a component coated with a functionalized polymer, which is shown as being configured, for example, in a manner such as Figure 19 A collection filter 520 coated with a functionalized polymer is shown moving between a first processor 502 and a second processor 504' as part of a batch type process. Figure 19 In the embodiment of the present invention, and as an example, a batch type process is shown as having two first processors 502, 502' and two second processors 504, 504, but the scope of the present invention is not intended to be limited to the number of first or second processors. According to some embodiments of the present invention, the collection filter 520 coated with the functionalized polymer can take the form of an engineered collection medium having an open pore structure or made of a foam block, such as Figure 17b Arrow B1 represents the movement of the filter 520 coated with the functionalized polymer from the first processor 502, and arrow B2 represents the movement of the collection filter 520 coated with the functionalized polymer into the second processor 502. Technology (including motors, transmissions, etc.) for moving elements 520 such as filters from one processor, such as elements 502 and 504, to another processor is known in the art, and the scope of the present invention is not intended to be limited to any particular type or types now known or later developed in the future.

[0193] The first processor 502 can take the form of a first chamber, tank, trough, or column that contains a high pH, ​​which is an attachment-rich environment that facilitates the attachment of valuable materials. The second processor 504 can take the form of a second chamber, tank, trough, or column that contains a release-rich environment that can have a low pH or receive ultrasound, which facilitates the release of valuable materials. Alternatively, the second processor 504 can be configured as a stripping tank, in which a surfactant is used to release valuable materials from the filter 522 under mechanical or sonic agitation.

[0194] The first processor 502 may also be configured to receive data from, for example, Figure 19 The tailings 542 are shown as being discharged through a pipe 541. The second processor 504 can be configured to receive a fluid 522 (e.g., water) and an enriched collection filter 520 coated with a functionalized polymer to release valuable materials in a rich release environment. For example, in Figure 19 , second processor 504 is shown as being configured to discharge valuable material in the form of concentrate 562 via conduit 561 .

[0195] The first processor 502' may also be configured with piping 580 and pumps 280 to recirculate tailings 542 back to the first processor 502'. The scope of the present invention is also intended to include a second processor 504' configured with corresponding piping and pumps to recirculate concentrate 562 back to the second processor 504'.

[0196] Figure 20 and 21 :Drum unit

[0197] According to some embodiments of the present invention, Figure 17a The engineered collection media shown can be used as Figure 20 Mineral recovery in a co-current unit is shown. Figure 20 A co-current rotating drum unit configured to enhance contact between an engineered collection media and mineral particles in a slurry is shown.

[0198] like Figure 20 As shown, the drum unit 600 may include a container 602 configured to hold a mixture comprising the engineered collection media 70a and a liquid slurry or slurry 677. The slurry 677 may contain mineral particles (see Figure 3a and 3b). The vessel 602 may include a first input 614 configured to receive the engineered collection medium 70a and a second input 618 configured to receive the slurry 677. On the other side of the vessel 602, an output 620 may be provided to discharge at least a portion of the mixture 681 from the vessel 602 after allowing the engineered collection medium 70a to interact with the mineral particles in the slurry 677 in the vessel. The mixture 681 may include a mineral loading medium or loading medium and an ore residue or tailings 679. Figure 20 The arrangement of inputs and outputs on the container 602 shown is referred to as a co-current configuration. The engineered collection medium 70a may include a collection surface functionalized with a chemical having molecules that adsorb mineral particles to the collection surface to form a mineral-loaded medium. Typically, if the engineered collection medium 70a has a smaller specific gravity than the slurry 677, a large amount of the engineered collection medium 70a in the container 602 may float on top of the slurry 677. If the collection medium 70a has a larger specific gravity than the slurry 677, a large amount of the engineered collection medium 70a may sink to the bottom of the container 602. Thus, the interaction between the engineered collection medium 70a and the mineral particles in the slurry 677 may not be efficient for forming a mineral-loaded medium. To increase or enhance the contact between the engineered collection medium 70a and the mineral particles in the slurry 677, the container 602 may be rotated, for example, so that at least some of the mixture in the upper portion of the container can interact with at least some of the mixture in the lower portion of the container 602. After being discharged from the container 602, the mixture 681 having the mineral-loaded medium and the ore residue can be processed through a separation device such as a screen so that the mineral-loaded medium and the ore residue can be separated. For example, the container 602 can be a horizontal tube or a cylindrical drum configured to rotate along a horizontal axis, as shown by reference numeral 610.

[0199] Figure 21 A cross-flow drum unit according to some embodiments of the present invention is shown, which is configured to enhance contact between the collection medium and the mineral particles in the slurry. Figure 21As can be seen, the drum unit 600' has a container 602, a first input 614, a second input 618, a first output 622, and a second output 624. The first input 614 can be arranged to receive the engineered collection medium 70a and the second output 624 can be arranged to discharge ore residue 679. The second input 618 can be arranged to receive the slurry 677 and the first output 622 can be arranged to discharge the mineral-laden medium 670. The arrangement of the inputs and outputs on the container 602 is referred to as a counter-current configuration. In a counter-current configuration, an internal separation device such as a screen can be used to prevent the medium laden with the medium and the engineered collection medium 70a in the container 602 from being discharged through the second output 624. Thus, what is discharged through the second output 624 is the ore residue or tailings 679. By rotating the container 602 along the rotation axis 691 , at least some of the mixture in the upper portion of the container 602 can be caused to interact with at least some of the mixture in the lower portion of the container 602 to increase or enhance contact between the engineered collection media 70a and the mineral particles in the slurry 677 .

[0200] Three-dimensional functionalized open network structure

[0201] Surface area is an important characteristic in the mineral recovery process because it defines the mass that can be captured and recovered. A high surface area to volume ratio allows for higher recovery rates per unit volume of media added to the tank. Figures 17a to 17d As shown, the engineered collection media is shown to have an open cell structure. Open cell or reticulated foams offer advantages over other media shapes (e.g., spheres) by having a higher surface area to volume ratio. The application of a functionalized polymer coating that promotes attachment of minerals to the foam "network" can achieve higher recoveries and improved recovery of less released minerals compared to conventional processes. For example, the open cells allow fluids and unadsorbed particles smaller than the cell size to pass through, but capture mineral-containing particles that come into contact with the functionalized polymer coating. The choice of cell size depends on the slurry properties and the application.

[0202] Coated foam can be cut into a variety of shapes and forms. For example, a strip of polymer-coated foam can be moved through the slurry to collect the desired minerals, then cleaned to remove the collected desired minerals. The cleaned foam strip can be reintroduced into the slurry. Strips, blocks, and / or sheets of coated foam of varying sizes can also be used where they are randomly mixed with the slurry in the mixing chamber. The thickness and cell size of the foam can be tailored to function as a cartridge filter that can be removed, cleaned of recovered minerals, and reused.

[0203] As previously mentioned, open-cell or reticulated foams offer advantages over other media shapes (such as spheres) by having a higher surface area to volume ratio when coated or impregnated with hydrophobic chemicals. Surface area is an important property in the mineral recovery process because it defines the mass that can be captured and recovered. A high surface area to volume ratio allows for higher recovery rates per unit volume of media added to the tank.

[0204] Open-cell or reticulated foams offer a functionalized, three-dimensional open network structure with high surface area, extensive internal surfaces, and tortuous paths, preventing abrasion and premature release of attached mineral particles. This provides enhanced collection and increased functional durability. Spherical recovery media, such as beads, belts, and filters, have a poor surface area to volume ratio—these media do not provide the high surface area necessary for maximum mineral collection. Furthermore, certain media, such as beads, belts, and filters, may experience rapid degradation of function.

[0205] The application of a functionalized polymer coating that promotes mineral attachment to the foam "network" enables higher recovery rates and improved recovery of less released minerals compared to conventional processes. The foam is open-celled, allowing fluids and unadsorbed particles smaller than the cell size to pass through, but traps mineral-bearing particles that come into contact with the functionalized polymer coating. The choice of cell size depends on the slurry properties and the application.

[0206] The three-dimensional open-cell structure is optimized to provide the compliance, the sticky surface of low energy, has strengthened the collection of hydrophobicity or hydrophobized mineral particles, and its particle size range is extensive.This structure can comprise or adopt the form of open-cell foam, and it is coated with the compliance, the sticky polymer of low surface energy.Foam can comprise or take the form of reticulated polyurethane or other suitable open-cell foam materials, for example silicone resin, polychloroprene, polyisocyanurate, polystyrene, polyolefin, polyvinyl chloride, epoxy resin, latex, fluoropolymer, phenolic resin, EPDM, nitrile, composite foam or the like.Coating can be a polysiloxane derivative, for example polydimethylsiloxane, and can use tackifier, plasticizer, crosslinking agent, chain transfer agent, chain extender, adhesion promoter, aryl or alkyl copolymer, fluorinated copolymer, as the hydrophobizing agent of hexamethyldisilazane and / or as the inorganic particle modification of silicon-dioxide or hydrophobic silicon dioxide. Alternatively, the coating may include or take the form of materials commonly known as pressure sensitive adhesives, such as acrylics, butyl rubber, ethylene vinyl acetate, natural rubber, nitriles, styrene block copolymers with ethylene, propylene and isoprene, polyurethanes and polyethylene ethers, so long as they are formulated to be compliant and adhesive with low surface energy.

[0207] The three-dimensional open cell structure may be coated with a primer or other adhesive to promote adhesion of the outer collection coating to the underlying structure.

[0208] In addition to soft polymer foams, other three-dimensional open-cell structures can be used, such as hard plastics, ceramics, carbon fibers, and metals. Examples include And including American Produced metal and ceramic foams, as well as porous hard plastics such as polypropylene honeycomb, etc. These structures must be similarly optimized to provide a compliant, adhesive, low-energy surface provided by the coatings described above.

[0209] The above three-dimensional open-porous structure can be coated or can be directly reacted to form a low-energy compliant, adhesive surface.

[0210] The three-dimensional open cell structure itself can be formed into a compliant, low-tack, low-energy surface by, for example, forming the structure directly from a coating polymer as described above. This is achieved by methods known in the art for forming open cell polymer foams.

[0211] The structures can be in the form of sheets, cubes, spheres, or other shapes and densities (described by pores per inch and pore size distribution), as well as levels of tortuosity that optimize surface access, surface area, mineral attachment / detachment kinetics, and durability. These structures can also be optimized to achieve smaller particle sizes for certain mineral particle size ranges, with denser structures. Typically, the cell density can be from 10 to 200 pores per inch, more preferably from 30 to 90 pores per inch, and most preferably from 30 to 60 pores per inch.

[0212] The specific shape or form of the structure can be selected for optimal performance for a particular application. For example, the structure (e.g., coated foam) can be cut into various shapes and forms. For example, a strip of foam coated with a polymer can be moved through the slurry, removing the desired mineral, thereby cleaning it and reintroducing it into the slurry. Strips, blocks, and / or sheets of foam coated with different sizes can also be used where they are randomly mixed with the slurry in a mixing chamber. Alternatively, according to the present invention, a conveyor structure can be formed in which the foam is enclosed in a cage-like structure that allows the mineral-containing slurry to pass through the cage-like structure to be introduced into the foam structure below, where the mineral can react with the foam and then be further processed. The thickness and pore size can be changed to form a filter-like box so that the filter is removed, the recovered mineral is removed, and reused. Figure 22 An example of a portion of a polymer-coated reticulated foam used to recover chalcopyrite mineral. Mineral particles captured from a copper ore slurry can be seen throughout the foam network.

[0213] There are many characteristics of foam that may be important and should also be considered, including the following:

[0214] Mechanical durability: Ideally, the foam will be durable during the mineral separation process. For example, a lifespan exceeding 30,000 cycles in a plant system would be beneficial. As mentioned above, there are many foam structures that can provide the required durability, including polyester urethanes, polyether urethanes, reinforced polyurethanes, more durable shapes (spheres and cylinders), composites such as PU coated with PVC, and non-polyurethanes. Other potential mechanically durable foam candidates include metal, ceramic, and carbon fiber foams, as well as rigid porous plastics.

[0215] Chemical durability: Mineral separation processes can involve high pH environments (up to 12.5), water, and abrasives. Urethanes undergo hydrolytic degradation, especially at extreme pH values. While functionalized polymer coatings provide protection for the underlying foam, ideally, the foam carrier system should resist the chemical environment to which it is exposed.

[0216] Adhesion to Coatings: If the foam surface energy is too low, the functionalized polymer coating will have difficulty adhering to the foam and may wear off. However, as mentioned above, low-surface-energy foams can be primed with a high-energy primer before applying the functionalized polymer coating to improve the coating's adhesion to the foam carrier. Alternatively, the surface of the foam carrier can be chemically abraded to provide "gripping points" on the surface to hold the polymer coating, or a higher-surface-energy foam material can be used. Furthermore, the functionalized polymer coating can be modified to improve its adhesion to lower-surface-energy foams. Alternatively, the functionalized polymer coating can be covalently bonded to the foam.

[0217] Surface Area: Higher surface area provides more sites for minerals to bind to the functionalized polymer coating carried by the foam substrate. There is a trade-off between a larger surface area (e.g., using a small-cell foam) and the ability of the coated foam structure to capture minerals while allowing gangue materials to pass through rather than being captured, e.g., due to the small cell size that will effectively retain gangue materials. The foam size is selected to optimize the capture of the desired minerals and minimize the mechanical entrainment of undesirable gangue materials.

[0218] Cell size distribution: The cell diameter needs to be large enough to allow gangue and minerals to be removed, but small enough to provide a high surface area. There should be an optimal cell diameter distribution for the capture and removal of a specific mineral particle size.

[0219] Tortuosity: A perfectly straight cylinder has very low tortuosity. Cells that twist and turn throughout the foam have a "tortuous path" and produce a foam with high tortuosity. Tortuosity can be selected to optimize the potential interaction of the mineral particles with the coated portion of the foam substrate, while being so tortuous that unwanted gangue material is trapped by the foam substrate.

[0220] Functionalized Foams: Functional chemical groups can be covalently bonded to the foam surface. This can include covalently bonding a functionalized polymer coating to the foam or bonding small molecules to functional groups on the foam surface to make the mineral bond more durable.

[0221] The cell size (pores per inch (PPI)) of the foam is an important property that can be used to improve mineral recovery and / or target minerals in a specific size range. As the PPI increases, the specific surface area (SSA) of the foam also increases. The high SSA provided to the process increases the probability of particle contact, which leads to a reduction in the required residence time. This in turn can lead to smaller reactor sizes. At the same time, the higher PPI foam acts as a filter due to the smaller pore size and only allows particles smaller than the pores to enter its core. This makes it possible to target mineral fines for, for example, coarse particles, or opens the possibility of mixing combinations of foams with different PPIs to optimize recovery performance across a specific size distribution.

[0222] Parent case application Figures 1 to 16b

[0223] Parent case application Figures 1 to 16b The description is as follows:

[0224] Figure 1

[0225] For example, Figure 1 The invention is shown in the form of an apparatus 10 having a flotation cell or column 12 configured to receive a mixture of a fluid (e.g., water), valuable material, and undesirable material (e.g., a liquid slurry 14); receive synthetic bubbles or beads 70 ( Figures 3a to 5d ), which are configured to float when immersed in a liquid slurry or mixture 14 and are functionalized to control the chemistry of the process carried out in the flotation cell or column, including attaching to valuable materials in the liquid slurry or mixture 14; and providing enriched synthetic bubbles or beads 18 to which valuable materials are attached. The terms "synthetic bubbles or beads" and "polymer bubbles or beads" are used interchangeably in this disclosure. The terms "valuable material", "valuable mineral" and "mineral particles" are also used interchangeably. For example, the synthetic bubbles or beads 70 can be made of a polymer or polymer-based material, or silica or silica-based material, or glass or glass-based material, although the scope of the present invention is intended to include other types or kinds of materials either now known or later developed in the future. To describe one example of the present invention, in Figure 1, synthetic bubbles or beads 70 and enriched synthetic bubbles or beads 18 are shown as enriched polymer or polymer-based bubbles designated 18. The flotation cell or column 12 is configured with a top or conduit 20 to provide the enriched polymer or polymer-based bubbles 18 from the flotation cell or column 12 for further processing consistent with the bubbles described herein.

[0226] The flotation cell or column 12 can be configured with a top portion or conduit 22, for example, having a valve 22a, to receive the liquid slurry or mixture 14, and also with a bottom portion or conduit 24 to receive the synthetic bubbles or beads 70. In operation, the buoyancy of the synthetic bubbles or beads 70 causes them to float upward through the liquid slurry or mixture 14 in the flotation cell or column 12 from the bottom toward the top of the flotation cell or column 12, thereby colliding with water, valuable materials, and undesirable materials in the liquid slurry or mixture 14. The functionalization of the synthetic bubbles or beads 70 causes them to attach to the valuable materials in the liquid slurry or mixture 14. As used herein, the term "functionalization" refers to the selection (based on material selection) or alteration during manufacture and during production of the materials comprising the synthetic bubbles or beads 70 to "adsorb" to the valuable materials, so that a bond is formed between the synthetic bubbles or beads 70 and the valuable materials, such that the valuable materials are lifted through the flotation cell or column 12 due to the buoyancy of the synthetic bubbles or beads 70. For example, the surface of the synthetic bubbles or beads has functional groups for collecting valuable materials. Alternatively, the synthetic bubbles or beads are functionalized to be hydrophobic so as to adsorb wetted mineral particles - those mineral particles to which the collection molecules attach. Due to the collisions between the synthetic bubbles or beads 70 and the water, valuable materials and unwanted materials in the liquid slurry or mixture 14, and the attachment of the synthetic bubbles or beads 70 to the valuable materials in the liquid slurry or mixture 14, the enriched polymer or polymer-based bubbles 18 having the valuable materials attached thereto will float to the top of the flotation cell 12 and form part of the froth formed at the top of the flotation cell 12. The flotation cell 12 may include a top or conduit 20 configured to provide the enriched polymer or polymer-based bubbles 18 having the valuable materials attached thereto, which can be further processed, consistent with what is described herein. In practice, the enriched polymer or polymer-based bubbles 18 can be removed from the top of the flotation cell 12 or can be discharged through the top or conduit 20.

[0227] The flotation cell or column 12 can be configured to contain a sediment-rich environment, including one having a high pH, ​​to facilitate a flotation recovery process therein. The flotation recovery process can include recovering ore particles, including copper, from mining. The scope of the present invention is not limited to any particular type or kind of flotation recovery process, now known or later developed. The scope of the present invention is also not limited to any particular type or kind of target mineral that may form part of a flotation recovery process, now known or later developed.

[0228] According to some embodiments of the present invention, the synthetic bubbles or beads 70 can be configured with a surface area flux by controlling some combination of the size of the polymer or polymer-based bubbles and / or the injection rate of the liquid slurry or mixture received in the flotation cell or column 12. The synthetic bubbles or beads 70 can also be configured to be low in density so as to behave like bubbles. The synthetic bubbles or beads 70 can also be configured with a controlled media size distribution that can be tailored to maximize the recovery of different feed matrices to flotation as the quality of the valuable material varies, including as the quality of the ore varies.

[0229] According to some embodiments of the present invention, the flotation cell or column 12 can be configured to receive synthetic bubbles or beads 70 along with air, where the air is used to create a desired froth layer in the mixture in the flotation cell or column 12 in order to obtain a desired grade of valuable material. The synthetic bubbles or beads 70 can be configured to lift the valuable material to the surface of the mixture in the flotation cell or column.

[0230] Thickener 28

[0231] The apparatus 10 may also include a conduit 26 having a valve 26a for providing tailings to a thickener 28 configured to receive tailings from the flotation tank or column 12. The thickener 28 includes a conduit 30 having a valve 30a for providing thickened tailings. The thickener 28 also includes a suitable conduit 32 for providing recovered water back to the flotation tank or column 12 for reuse in the process. Components similar to thickeners 28 are known in the art, and the scope of the present invention is not intended to be limited to any particular type or kind now known or later developed.

[0232] Bead recovery process or processor 50

[0233] According to some embodiments of the present invention, the apparatus 10 may further include a bead recovery process or processor, generally designated 50, configured to receive the enriched polymer or polymer-based bubbles 18 and provide recovered polymer or polymer-based bubbles 52 free of valuable materials attached thereto, so as to enable reuse of the polymer or polymer-based bubbles 52 in a closed-loop process. For example, the bead recovery process or processor 50 may take the form of a scrubbing station, whereby valuable minerals are mechanically, chemically, or electrostatically removed from the polymer or polymer-based bubbles 18.

[0234] The bead recovery process or processor 50 can include a release device in the form of a second flotation cell or column 54 having a conduit 56 with a valve 56a configured to receive the enriched polymer bubbles or beads 18, substantially release valuable materials from the polymer bubbles or beads 18, and further having a top portion or conduit 57 configured to provide recovered polymer bubbles or beads 52 substantially free of valuable materials attached thereto. The second flotation cell or column 54 can be configured to contain a rich release environment, including one having a low pH, or one in which the rich release environment is generated by ultrasonic waves pulsed into the second flotation cell or column 54.

[0235] The bead recovery process or processor 50 may also include a conduit 58 having a valve 56a for providing concentrated mineral to a thickener 60 configured to receive concentrated mineral from the flotation cell or column 54. The thickener 60 includes a conduit 62 having a valve 62a for providing thickened concentrate. The thickener 60 also includes a suitable conduit 64 for providing recovered water back to the second flotation cell or column 54 for reuse in the process. Components similar to thickeners 60 are known in the art, and the scope of the present invention is not intended to be limited to any particular type or kind now known or later developed.

[0236] Also contemplated are embodiments in which the enriched synthetic beads or bubbles are placed in a chemical solution to dissolve away valuable materials, or are sent to a smelter for valuable materials, including subsequent reuse of the synthetic beads or bubbles.

[0237] Dosage control

[0238] According to some embodiments of the present invention, the synthetic beads or bubbles 70 may be functionalized to control the chemistry of a process carried out in a cell or column, for example, to release chemicals to control the chemistry of a flotation separation process.

[0239] In particular, Figure 1 The flotation cell or column 12 can be configured to receive polymer-based blocks, such as synthetic beads, containing one or more chemicals used in the flotation separation of valuable materials, including mining ores, which are encapsulated in the polymer to provide a slow or targeted release of the chemicals once released into the flotation cell or column 12. For example, the one or more chemicals may include chemical mixtures now known or later developed, including typical frothers, collectors and other additives used in flotation separations. The scope of the present invention is not limited to the types or kinds of chemicals or chemical mixtures that can be released into the flotation cell or column 12 using synthetic bubbles according to the present invention.

[0240] The scope of the present invention is intended to include other types or kinds of functionalization of synthetic beads or bubbles to provide other types or kinds of control over the chemistry of the process carried out in the cell or column, including functionalizations and controls now known and those later developed in the future. For example, the synthetic beads or bubbles can be functionalized to control the pH of a mixture forming part of a flotation separation process carried out in a flotation cell or column.

[0241] Figure 2 : Collision Technology

[0242] Figure 2 An alternative apparatus according to some embodiments of the present invention is shown, generally indicated at 200 in the form of an alternative flotation cell 201 that is based, at least in part, on a collision technique between a mixture and synthetic bubbles or beads. A mixture 202, such as a liquid slurry, may be contained in a top portion or conduit 204 and synthetic bubbles or beads 206 may be contained in a bottom portion or conduit 208. The flotation cell 201 may be configured to include a first device 210 for receiving the mixture 202 and may also be configured to include a second device 212 for receiving a polymer-based material. The first device 210 and the second device 212 are configured to face each other so as to provide the mixture 202 and the synthetic bubbles or beads 206, such as a polymer or polymer-based material, using a collision technique. In Figure 2 In FIG. 2 , arrows 210 a represent the ejected mixture and arrows 212 a represent the synthetic bubbles or beads 206 ejected toward each other in the flotation cell 201 .

[0243] In operation, the collision technique uses enough energy to induce turbulence and collisions to increase the likelihood of contact between the polymer or polymer-based material 206 and the valuable materials in the mixture 202, but not enough energy to break the bonds formed between the polymer or polymer-based material 206 and the valuable materials in the mixture. A pump (not shown) may be used to provide the appropriate pressure to the mixture 202 and the synthetic bubbles or beads 206 to implement the collision technique.

[0244] For example, the first device 210 and the second device 212 can take the form of a showerhead-like device having a perforated nozzle with a plurality of holes for spraying the mixture and the synthetic bubbles or beads toward each other. Showerhead-like devices are known in the art, and the scope of the present invention is not intended to be limited to any particular type or kind now known or later developed. Moreover, based on the disclosure in this patent application, one skilled in the art will be able to determine, without undue experimentation, the number and size of holes for spraying the mixture 202 and the synthetic bubbles or beads 206 toward each other, as well as determining an appropriate pumping pressure to provide sufficient energy to increase the likelihood of the polymer or polymer-based material 206 coming into contact with the valuable materials in the mixture 202, but not too much energy to break the bonds formed between the polymer or polymer-based material 206 and the valuable materials in the mixture 202.

[0245] Due to collisions between the synthetic bubbles or beads 206 and the mixture, the enriched synthetic bubbles or beads having valuable material attached thereto will float to the top and form part of the froth in the flotation cell 201. The flotation cell 201 may include a top or conduit 214 configured to provide enriched synthetic bubbles or beads 216, such as enriched polymer bubbles as shown, having valuable material attached thereto, which may be further processed consistent with what is described herein.

[0246] The replacement device 200 can be used to replace a flotation column or cell and inserted into Figure 1 The apparatus or system shown may prove more efficient than using flotation columns or cells.

[0247] Figures 3a to 5d : Synthetic bubbles or beads

[0248] The bubbles or beads used for mineral separation are referred to as synthetic bubbles or beads in this article. At least the surface of the synthetic bubbles or beads has a polymer layer, which is functionalized to adsorb or adhere to valuable materials or mineral particles in the mixture. The terms "polymer bubbles or beads" and "synthetic bubbles or beads" are used interchangeably. The term "polymer" in this specification refers to a macromolecule made from units of many identical or similar structures connected together. The unit can be a monomer or oligomer, which forms the basis of, for example, polyamide (nylon), polyester, polyurethane, phenol-formaldehyde, urea-formaldehyde, melamine-formaldehyde, polyacetal, polyethylene, polyisobutylene, polyacrylonitrile, poly(vinyl), polystyrene, poly(methyl methacrylate), poly(vinyl acetate), poly(vinylidene chloride), polyisoprene, polybutadiene, polyacrylate, poly(carbonate), phenolic resin, polydimethylsiloxane and other organic or inorganic polymers. This list is not necessarily exhaustive. Therefore, synthetic materials can be hard or rigid like plastics, or soft and flexible like elastomers. While the physical properties of the synthetic beads can vary, the surfaces of the synthetic beads are chemically functionalized to provide a plurality of functional groups for adsorption or attachment to the mineral particles. (For example, the term "functional group" may be understood as a group of atoms responsible for the characteristic reactions of a particular compound, including those atoms that define the structure of a family of compounds and determine their properties.)

[0249] In order to help those skilled in the art understand the various embodiments of the present invention, Figure 3a shows a generic synthetic bead, Figure 3b An enlarged portion of the surface is shown. The synthetic beads can be size-based beads or bubbles, weight-based polymer beads and bubbles, and / or magnetic-based beads and bubbles. Figure 3a and Figure 3b As shown, synthetic beads 70 have a bead body to provide a bead surface 74. At least the outer portion of the bead body is made of a synthetic material, such as a polymer, so as to provide a plurality of molecules or molecular segments 76 on the surface 74. The molecules 76 are used to attach chemical functional groups 78 to the surface 74. Typically, the molecules 76 can be, for example, hydrocarbon chains, and the functional groups 78 can have anionic bonds for adsorbing or attaching minerals, such as copper, to the surface 74. For example, xanthate has functional groups 78 and molecular segments 76 to be incorporated into the polymer used to make the synthetic beads 70. Functional groups 78 are also referred to as ionic or non-ionic collectors. The ions can be anions or cations. Anions include hydroxyls, such as carboxyls, sulfates, and sulfonates, and sulfhydryls, such as xanthates and dithiophosphates. Other molecules or compounds that can be used to provide functional groups 78 include, but are not limited to, thiocarbamates, thioureas, xanthan gum, monothiophosphates, hydroquinones, and polyamines. Similarly, chelating agents can be incorporated into or onto polymers to act as collector sites for minerals such as copper. Figure 3bAs shown, mineral particles 72 are attached to functional groups 78 on molecules 76. Typically, the mineral particles 72 are much smaller than the synthetic beads 70. Many of the mineral particles 72 may be adsorbed or attached to the surface 74 of the synthetic beads 70.

[0250] In some embodiments of the present invention, the synthetic bead has a solid phase made of a synthetic material, such as a polymer. The polymer can be rigid or elastic. The elastomeric polymer can be, for example, polyisoprene or polybutadiene. The synthetic bead 70 has a bead body 80 having a surface comprising a plurality of molecules having one or more functional groups for adsorbing mineral particles to the surface. Polymers having functional groups for collecting mineral particles are referred to as functionalized polymers. In one embodiment, the entire interior portion 82 of the synthetic bead 80 is made of the same functionalized material, such as Figure 4a As shown. In another embodiment, the bead 80 includes a shell 84. The shell 84 can be formed by expansion, such as thermal expansion or decompression. The shell 84 can be a micro bubble or a balloon. Figure 4b In, a shell 84 made of a functionalized material has an interior portion 86. For example, the interior portion 86 can be filled with air or a gas to assist buoyancy. The interior portion 86 can be used to contain a liquid to be released during the mineral separation process. The encapsulated liquid can be, for example, a polar liquid or a non-polar liquid. For example, the encapsulated liquid can contain a depressant composition for enhancing the separation of copper, nickel, zinc, lead from sulfide ores during the flotation stage. For example, the shell 84 can be used to encapsulate a powder, which can be magnetic, thereby making the synthetic beads magnetic. The encapsulated liquid or powder can contain monomers, oligomers, or short polymer chain segments for wetting the surface of the mineral particles when released from the beads. For example, each monomer or oligomer can contain a functional group for attaching to the mineral particles and an ion for attaching the wetted mineral particles to the synthetic beads. For example, the shell 84 can be used to encapsulate a solid core, such as polystyrene foam, to assist buoyancy. In another embodiment, only the coating of the beads is made of a functionalized polymer. As Figure 4c As shown, the synthetic beads have a core 90 made of ceramic, glass or metal, and only the surface of the core 90 has a coating 88 made of a functionalized polymer. Depending on the application, the core 90 can be a hollow core or a filled core. The core 90 can be a microbubble, a sphere or a balloon. For example, a filled core made of metal allows the density of the synthetic beads to be higher than the density of, for example, a liquid slurry. The core 90 can be made of a magnetic material so that the magnetic, ferrimagnetic, and ferromagnetic properties of the synthetic beads are greater than the magnetic, ferrimagnetic, and ferromagnetic properties of the unwanted ground ore particles in the mixture. In different embodiments, the synthetic beads can be configured with a ferromagnetic or ferrimagnetic core that is adsorbed to a paramagnetic surface. The core 90 made of glass or ceramic can be used to make the density of the synthetic beads substantially equal to the density of the liquid slurry so that when the synthetic beads are mixed into the liquid slurry for mineral collection, the beads can be in a suspended state.

[0251] According to various embodiments of the present invention, the synthetic beads 70 may be a porous block or in the form of a sponge or foam having a plurality of separate air-filled chambers, such as Figure 4d A combination of air and synthetic beads or bubbles 70 can be added to a conventional naturally aspirated flotation cell.

[0252] It should be understood that the term "bead" does not limit the shape of the synthetic beads of the present invention to the spherical shape shown in Figure 3. In some embodiments of the present invention, the synthetic beads 70 may have an elliptical shape, a cylindrical shape, or a block shape. In addition, the synthetic beads may have an irregular shape.

[0253] It should also be understood that the surface of the synthetic beads according to the present invention is not limited to an overall smooth surface, such as Figure 3a In some embodiments of the present invention, the surface may be irregular and rough. For example, the surface 74 may have some physical structures 92 such as recesses or rods, such as Figure 5a The surface 74 may have some physical structure 94 such as holes or indentations, such as Figure 5b The surface 74 may have some physical structure 96 formed by stacked beads, such as Figure 5c The surface 74 may have some hair-like physical structures 98, such as Figure 5d In addition to the functional groups on the synthetic beads that adsorb mineral particles to the bead surface, the physical structure can help capture mineral particles on the bead surface. The surface 74 can be configured as a honeycomb surface or a sponge-like surface for capturing mineral particles and / or increasing the contact surface.

[0254] It should also be noted that the synthetic beads of the present invention can be implemented in different ways to achieve the same purpose. That is, it is possible to use different methods to adsorb mineral particles to the surface of the synthetic beads. For example, the surface of the polymer beads, shells can be functionalized with hydrophobic chemical molecules or compounds. Alternatively, the surface of beads made of glass, ceramics and metals can be coated with hydrophobic chemical molecules or compounds. Using the coating of glass beads as an example, polysilicone salts can be used to functionalize glass beads to prepare synthetic beads. In the liquid slurry, xanthate and isohydroxamate collectors can also be added to collect mineral particles and make the mineral particles hydrophobic. When the synthetic beads are used to collect mineral particles in a liquid slurry with a pH value of about 8-9, the mineral particles on the enriched synthetic beads can be released from the surface of the synthetic beads in an acidic solution such as a sulfuric acid solution. The mineral particles carrying the enriched synthetic beads can also be released by sonic agitation, such as ultrasound.

[0255] A plurality of hollow objects, main bodies, elements or structures can comprise hollow cylinders or spheres, and capillaries, or some combinations thereof. Scope of the present invention is not limited to the uniformity of the type, kind or geometrical shape or its mixture of hollow objects, main bodies, elements or structures. Each hollow object, main body, element or structure can be configured with size, so that the liquid comprising water is not absorbed, wherein the size is in the range of about 20-30 microns. Each hollow object, main body, element or structure can be made of glass or glassy material and some other suitable materials known now or developed in the future.

[0256] For example, a plurality of hollow objects, bodies, elements, or structures received in a mixture may include several thousand bubbles or beads per cubic foot of mixture, although the scope of the present invention is not inherently limited to a particular number of bubbles. For example, approximately three thousand cubic feet of mixture may include several million bubbles or beads, e.g., approximately 1 mm in size, within the three thousand cubic feet of mixture.

[0257] The plurality of hollow objects, bodies, elements or structures may be configured with a chemical to prevent liquid from migrating into the corresponding cavities, unfilled spaces or pores prior to the wet concrete mix curing, wherein the chemical is a hydrophobic chemical.

[0258] The one or more bubbles may take the form of small amounts of gas, including air, that are trapped or held within cavities, unfilled spaces, or pores of the plurality of hollow objects, bodies, components, or structures.

[0259] The scope of the present invention is intended to include synthetic bubbles or beads as described herein that are made from polymers or polymer-based materials, or silica or silica-based materials, or glass or glass-based materials.

[0260] Figures 6 to 11 : Release mechanism

[0261] The various embodiments of the present invention are envisioned as examples to show that valuable minerals can be removed or released from enriched synthetic beads or bubbles mechanically, chemically, thermally, optically, or electromagnetically.

[0262] For example, if Figure 1 The bead recovery process or processor 50 shown in FIG can be adapted to remove valuable minerals from the concentrated synthetic beads or bubbles in different ways. The release device can include or take the form of a heater 150 ( Figure 6 ), the heater 150 is configured to provide heat for the removal of valuable minerals from the concentrated synthetic beads or bubbles; the ultrasonic generator 164 ( Figure 7 ) is configured to provide ultrasonic waves for the removal of valuable minerals from the concentrated synthetic beads or bubbles, the vessel 168 ( Figure 8) is configured to provide an acid or acidic solution 170 for removal of valuable minerals from the concentrated synthetic beads or bubbles; a microwave source 172 ( Figure 9 ) is configured to provide microwaves for the removal of valuable minerals from the concentrated synthetic beads or bubbles, a motor 186 and a stirrer 188 ( Figure 10 ) configured to agitate the enriched synthetic beads or bubbles for removal of valuable minerals from the enriched synthetic beads or bubbles; and a plurality of release or recovery processors ( Figure 11 ), configured to use a variety of release or recovery techniques for the removal of valuable minerals from the concentrated synthetic beads or bubbles. According to some embodiments of the present invention, the aforementioned release device can respond to signals from, for example, a controller or control processor. In view of the foregoing, and as an example, the release techniques are detailed below:

[0263] Thermal release of valuable materials

[0264] like Figures 3a to 5c As shown, the synthetic beads or bubbles 70 can be made of a polymer that softens when subjected to high temperatures. It is known that polymers can become rubbery above a certain temperature. This is due to the polymer-glass transition at the glass transition temperature Tg. In general, the physical properties of polymers depend on the size or length of the polymer chains. In polymers above a certain molecular weight, increased chain length tends to increase the glass transition temperature Tg. This is a result of increased chain interactions, such as van der Waals attractions and entanglements that may occur with increasing chain length. Polymers such as polyvinyl chloride (PVC) have a glass transition temperature of about 83 degrees Celsius. If the polymer bubble or bead 70 has a hair-like surface structure 98 (see Figure 5d ) to capture mineral particles 72 (see Figure 3b ), the hair-like surface structure 98 may become soft. Therefore, in a certain polymer in a rubbery state, the hair-like surface structure 98 may lose the ability to hold mineral particles. Figure 1 and Figure 2 The separation process shown may be performed at room temperature or about 23 degrees Celsius. Any temperature, for example above 50 degrees Celsius, may soften the hair-like surface structure 98 (see Figure 5d For synthetic bubbles or beads 70 made of PVC, a temperature of about or above 83 degrees Celsius may be used to remove mineral particles from the surface structure of the synthetic bubbles or beads. Figure 1 The bead recovery process or processor 50 shown in FIG can be adapted to remove mineral particles from the enriched polymer bubbles 18. For example, as the recovered water exits the thickener 60 through the conduit 64, the heater 150 can be used to heat the recovered water, such as Figure 6As shown. Thus, the heated withdrawn water 152 can be arranged to clean the enriched polymer bubbles 18 within the flotation column 54, thereby releasing at least some of the valuable materials or mineral particles attached to the enriched polymer bubbles 18 into the pipe 58. The withdrawn water can be heated to or above the glass transition temperature of the polymer used to make the polymer bubbles. The elevated temperature of the heated withdrawn water 152 also weakens the bonds between the collector 78 and the mineral particles 72 (see Figure 3b ). A heater may be used to boil water into steam and apply the steam to the accumulated polymer bubbles. Superheated steam may also be generated under pressure and applied to the accumulated polymer bubbles.

[0265] Sound waves release valuable materials

[0266] When ultrasound is applied to a solution or mixture containing enriched polymer bubbles or beads, at least two possible effects can occur in disrupting the attachment of valuable materials to the surface of the polymer bubbles or beads. The sound waves can cause the attached mineral particles to move rapidly in the opposite direction (against) of the surface of the polymer bubbles or beads, thereby shaking the mineral particles loose from the surface. The sound waves can also cause the shape of the synthetic bubbles to change, affecting the physical structure on the surface of the synthetic bubbles. It is well known that ultrasound is a cyclic sound pressure with a frequency greater than the upper limit of human hearing. Therefore, typically, ultrasound ranges from just over 20 kilohertz (KHz) to about 300KHz. In ultrasonic cleaners, low frequency ultrasonic cleaners have a tendency to remove larger particle sizes more effectively than higher operating frequencies. However, higher operating frequencies tend to produce a more penetrating scrubbing action and are more effective in removing smaller sized particles. In mineral release applications involving mineral particles less than 100μm to 1mm or larger, according to some embodiments of the present invention, the ultrasound frequency range is 10Hz to 10MHz. For example, if Figure 1 The illustrated bead recovery process or processor 50 may be adapted to remove mineral particles from the enriched polymer bubbles 18 by applying ultrasound to the solution in the flotation column 54. For example, as the withdrawn water from the line 64 is used to wash the enriched polymer bubbles 18 within the flotation column 54, ultrasound waves 166 may be applied using an ultrasound generator 164 to release valuable materials (mineral particles 72, Figure 3b ). Figure 7 A schematic diagram of ultrasound application is shown. According to some embodiments of the present application, an ultrasound frequency is selected for mineral release application as the resonant frequency of the synthetic beads or bubbles.

[0267] Chemical release of valuable materials

[0268] In physical adsorption, valuable minerals are reversibly bound to synthetic bubbles or beads, attached due to electrostatic adsorption and / or van der Waals bonding and / or hydrophobic adsorption and / or adhesive attachment. If the pH of the solution changes, the physically adsorbed mineral particles can be desorbed or released from the surface of the synthetic bubbles or beads. In addition, the surface chemistry of most minerals is affected by pH. Some minerals develop a positive surface charge under acidic conditions and a negative charge under alkaline conditions. The effect of pH changes generally depends on the collector and the mineral being collected. For example, chalcopyrite desorbs at a higher pH than galena, and galena desorbs at a higher pH than pyrite. If the valuable mineral is collected at a pH of 8 to 11, the binding between the valuable mineral and the surface of the polymer bubbles or beads can be weakened by lowering the pH to 7 and lower. However, acidic solutions with a pH of 5 or lower are more efficient in releasing valuable minerals from enriched polymer bubbles or beads. According to one embodiment of the present invention, as Figure 1 The bead recovery process or processor 50 shown can be adapted to remove mineral particles from the enriched polymer bubbles 18 by changing the pH of the solution in the flotation column 54. For example, when the withdrawn water from the pipe 64 is used to wash the enriched polymer bubbles 18 in the flotation column 54, the acid or acidic solution 170 can be released into the withdrawn water using the container 168, as shown. Figure 8 As shown. There are many acids that can easily change pH. For example, sulfuric acid (HCl), hydrochloric acid (H2SO4), nitric acid (HNO3), perchloric acid (HClO4), hydrobromic acid (HBr), and hydroiodic acid (HI) are strong acids that completely dissociate in water. However, sulfuric acid and hydrochloric acid can provide a greater pH change at the lowest cost. The pH range for mineral release is 7 to 0. Using very low pH may cause degradation of the polymer beads. However, it should be noted that when the valuable material is, for example, copper, a lower pH environment can be provided for the attachment of mineral particles and a higher pH environment can be provided for the release of mineral particles from the synthetic beads or bubbles.

[0269] Typically, a pH value is selected to promote the strongest attachment, and a different pH value is selected to promote release. Thus, according to some embodiments of the present invention, a pH value is selected for mineral attachment, and a different pH value is selected for mineral release. The different pH values ​​can be higher or lower, depending on the specific mineral and collector.

[0270] Physically adsorbed mineral particles can be desorbed or released from the surface of the synthetic bubbles or beads if a surfactant is introduced to disrupt the adhesive bond between the particles and the surface. In one embodiment, the particles are readily detached from the surface when the surfactant is combined with mechanical energy.

[0271] Electromagnetic release of valuable materials

[0272] More than one method can be used to electromagnetically disrupt the bond between the mineral particles and the synthetic bubbles or beads. For example, microwaves can be used to heat the concentrated synthetic bubbles or beads and the water in the flotation column. Laser beams can also be used to weaken the bonds between the functional groups and the polymer surface itself. Thus, a microwave source or a laser light source can be provided, wherein the concentrated synthetic bubbles or beads are treated. For example, Figure 1 The illustrated bead recovery process or processor 50 can be adapted to remove mineral particles from the enriched polymer bubbles 18 by using an electromagnetic source to provide electromagnetic waves to the solution or mixture in the flotation column 54. For example, while withdrawn water from the pipe 64 is used to scrub the enriched polymer bubbles 18 within the flotation column 54, a microwave source 172 can be used to apply a microwave beam 174 to release valuable materials (mineral particles 72, Figure 3b ). A diagram showing the application of ultrasound is shown in Figure 9 middle.

[0273] Mechanical release of valuable materials

[0274] When the concentrated synthetic bubbles or beads are densely packed so that they are very close to each other, the friction between the adjacent synthetic bubbles or beads may cause the mineral particles attached to the concentrated synthetic bubbles or beads to be separated. Figure 1 The bead recovery process or processor 50 shown in FIG can be adapted to mechanically remove mineral particles from the concentrated polymer bubbles 18. For example, a motor 186 and an agitator 188 are used to move the concentrated polymer bubbles around so that the concentrated polymer bubbles or beads 18 within the flotation column 54 rub against each other. If the synthetic bubbles or beads are magnetic, the agitator 188 can be a magnetic agitator. A diagram of the mechanical release of valuable materials is shown in FIG. Figure 10 middle.

[0275] Other types or kinds of release techniques

[0276] A heater similar to element 150 ( Figure 6 ), an ultrasonic generator similar to element 164 ( Figure 7 ), a container similar to element 168 ( Figure 8 ), a microwave source similar to element 172 ( Figure 9 ), motors and agitators similar to elements 186, 188 ( Figure 10 ) are known in the art, and the scope of the present invention is not intended to be limited to any particular type or kind now known or later developed in the future.

[0277] The scope of the present invention is also intended to include other types or kinds of release devices that are consistent with the spirit of the present invention now known or later developed in the future.

[0278] Multi-stage removal of valuable materials

[0279] More than one method for releasing valuable materials from the enriched synthetic bubbles or beads can be used simultaneously in the same bead recovery process or processor. For example, when the enriched synthetic bubbles or beads 18 are subjected to ultrasonic agitation (see Figure 7 ), the recovered water can also be heated by a water heater, e.g. Figure 6 In addition, an acidic solution can also be added to the water to reduce the pH value in the flotation column 54. In another embodiment of the present invention, the same or different release methods are used in different stages. For example, the release method from the separation device 200 (see Figure 2 ) of the enriched polymer bubbles 216 can be obtained in the following manner: Figure 11 The polymer bubbles 216 are treated in a multi-stage treatment process 203. Apparatus 200 includes a first recovery process 218, in which an acidic solution is used to at least partially release valuable materials from the enriched polymer bubbles 216. A filter 219 is used to separate the released minerals 226 from the polymer bubbles 220. At a second recovery process 222, an ultrasonic source is used to apply ultrasonic agitation to the polymer bubbles 220 to release any remaining valuable materials, if any, from the polymer bubbles. A filter 223 is used to separate the released minerals 226 from the recovered polymer bubbles 224. It should be understood that more than two treatment stages may be performed, and that different combinations of release methods are possible.

[0280] Figure 12 : Horizontal pipeline

[0281] According to some embodiments of the present invention, the separation process can be performed as follows: Figure 12 It is carried out in the horizontal pipeline shown in the figure. Figure 12 As shown, the synthetic bubbles or beads 308 may be used for, or form part of, a size-based separation process using countercurrent flow along with mixing implemented in an apparatus generally designated 300 such as a horizontal pipe. Figure 12, a horizontal conduit 310 is configured with a screen 311 to separate enriched synthetic bubbles or beads 302 having valuable material attached thereto from a mixture based at least in part on size differences. The horizontal conduit 310 can be configured to use countercurrent flow along with mixing to separate the enriched synthetic bubbles or beads 302 having valuable material attached thereto from the mixture, such that a slurry 304 flowing in a first direction A is received in the horizontal conduit 310, synthetic bubbles or beads 308 flowing in a second direction B opposite to the first direction A is received in the horizontal conduit 300, enriched synthetic bubbles or beads 302 having valuable material attached thereto and flowing in the second direction B is provided from the horizontal conduit 308, and waste or tailings 306 separated from the mixture using the screen 311 and flowing in the second direction B is provided from the horizontal conduit 310. In the horizontal conduit 310, the synthetic beads or bubbles 308 do not need to be lighter than the slurry 304. The density of the synthetic beads or bubbles 308 can be substantially equal to the density of the slurry 304 so that the synthetic beads or bubbles can be in suspension when mixed with the slurry 304 in the horizontal conduit 310.

[0282] It should be understood that, if combined with Figures 3a to 5d The size-based beads or bubbles, weight-based beads or bubbles, and magnetic-based beads or bubbles can be functionalized to be hydrophobic in order to adsorb mineral particles. Figure 13a shows generalized hydrophobic synthetic beads, Figure 13b A magnified section of the bead surface and mineral grains is shown. Figure 13b A magnified portion of the bead surface and non-mineral particles is shown. Figure 13a As shown, a hydrophobic synthetic bead 170 has a polymer surface 174 and a plurality of particles 172 , 172 ′ attached to the polymer surface 174 . Figure 13b An enlarged portion of a polymer surface 174 is shown, with a plurality of molecules 179 thereon rendering the polymer surface 174 hydrophobic.

[0283] Mineral particles 171 in the slurry become wetted mineral particles 172 after bonding with one or more collector molecules 73. Collector molecules 73 have functional groups 78 that attach to mineral particles 171 and hydrophobic ends or molecular segments 76. Hydrophobic ends or molecular segments 76 are adsorbed to hydrophobic molecules 179 on polymer surfaces 174. Figure 13cAn enlarged portion of a polymer surface 174 is shown, which has a plurality of hydrophobic molecules 179 for adsorbing non-mineral particles 172'. Non-mineral particles 172' have a particle body 171' to which one or more hydrophobic molecular segments 76 are attached. The hydrophobic ends or molecular segments 76 are adsorbed to the hydrophobic molecules 179 on the polymer surface 174. The term "polymer" as used herein refers to a macromolecule composed of many units of the same or similar structure linked together. In addition, Figures 13a to 13c The polymers involved can be naturally hydrophobic or functionalized to be hydrophobic. For example, some polymers with long hydrocarbon chains or siloxane backbones tend to be hydrophobic. Hydrophobic polymers include polystyrene, poly(d,l-lactide), poly(dimethylsiloxane), polypropylene, polyacrylic acid, polyethylene, etc. For example, the bubbles or beads of the synthetic beads 170 can be made of glass to be coated with a hydrophobic siloxane polymer including a polysiloxane salt, which makes the bubbles or beads hydrophobic. For example, the bubbles or beads can be made of metal to be coated with an organosilicon alkyd copolymer to make the bubbles or beads hydrophobic. For example, the bubbles or beads can be made of ceramic to be coated with a fluoroalkyl silane to make the bubbles and beads hydrophobic. The bubbles or beads can be made of hydrophobic polymers, such as polystyrene and polypropylene, to provide a hydrophobic surface. The wetting mineral particles attached to the hydrophobic synthetic bubbles or beads can be released thermally, ultrasonically, electromagnetically, mechanically, or in a low pH environment.

[0284] Figure 14a The case where the mineral particles 72 are simultaneously attached to a plurality of synthetic beads 74 is shown. Thus, although the synthetic beads 74 are much smaller in size than the mineral particles 72, many synthetic beads 74 may be able to lift the mineral particles 72 upward in the flotation cell. Likewise, smaller mineral particles 72 may also be lifted upward by many synthetic beads 74, such as Figure 14b To increase the likelihood of this "synergistic" lifting occurring, a large number of synthetic beads 74 can be mixed into the slurry. Unlike air bubbles, the density of the synthetic beads can be selected so that the synthetic beads can remain in the slurry before they rise to the surface in the flotation cell.

[0285] Figure 15a and Figure 15b A similar situation is shown in FIG. 1 , where wetted mineral particles 172 are attached to a plurality of hydrophobic synthetic beads 174 simultaneously.

[0286] According to some embodiments of the present invention, only a portion of the surface of the synthetic beads is functionalized to be hydrophobic. This has the following benefits:

[0287] 1. Keep too many beads from clumping together - or limit the clumping of beads,

[0288] 2. Once the mineral is attached, the weight of the mineral may force the beads to rotate, allowing the mineral to lie beneath the beads as they rise through the flotation cell;

[0289] a. Better cleaning because it allows the gangue to pass through

[0290] b. protect the attached mineral particle or particles from being knocked off, and

[0291] c. Provides a smoother rise to the top collection area in the flotation cell.

[0292] According to some embodiments of the present invention, only a portion of the surface of the synthetic beads is functionalized with a collector. This also has the advantage that:

[0293] 1. Once the mineral is attached, the weight of the mineral may force the beads to rotate, allowing the beads to lie beneath the beads as they rise through the flotation cell;

[0294] a. Better cleaning because it allows the gangue to pass through

[0295] b. protect the attached mineral particle or particles from being knocked off, and

[0296] c. Provides a smoother rise to the top collection area in the flotation cell.

[0297] According to some embodiments of the present invention, a portion of the synthetic beads is functionalized with a collector, while another portion of the same synthetic beads is functionalized to be hydrophobic, e.g. Figure 16a and Figure 16b As shown. Figure 16a As shown, synthetic beads 74 have a surface portion where the polymer is functionalized to have collector molecules 73 with functional groups 78 and molecular segments 76 attached to the surface of the beads 74. Synthetic beads 74 also have a different surface portion where the polymer is functionalized to have hydrophobic molecules 179. Figure 16b In the embodiment shown, the entire surface of the synthetic bead 74 may be functionalized with collector molecules 73, but a portion of the surface is functionalized so that the hydrophobic molecules 179 render it hydrophobic.

[0298] These "hybrid" synthetic beads can capture both wetting and non-wetting mineral particles.

[0299] application

[0300] The scope of the present invention has been described with respect to mineral separations, including the separation of copper from ores. It should be understood that the synthetic beads according to the present invention, whether functionalized to have collectors or functionalized to be hydrophobic, are also configured for oil sands separation - separating bitumen from sand and water in bitumen recovery in oil sands mining operations. Likewise, according to some embodiments of the present invention, functionalized filters and membranes are also configured for oil sands separation. According to some embodiments of the present invention, the surface of the synthetic beads can be functionalized to have collector molecules. The collector has functional groups that have ions that are capable of forming chemical bonds with mineral particles. Mineral particles associated with one or more collector molecules are referred to as wetted mineral particles. According to some embodiments of the present invention, the synthetic beads can be functionalized to be hydrophobic so as to collect one or more wetted mineral particles.

[0301] The scope of the invention is intended to include other types or kinds of applications now known or later developed in the future, including, for example, flotation circuits, leaching, smelting, gravity circuits, magnetic circuits, or water pollution control.

[0302] Related family

[0303] This application is also related to nine PCT family applications, all of which were filed simultaneously on May 25, 2012, as follows:

[0304] PCT Application No. PCT / US12 / 39528 (Attorney Docket No. 712-002.356-1), entitled “Flotation separation using lightweight synthetic bubbles and beads”;

[0305] PCT Application No. PCT / US12 / 39524 (Attorney Docket No. 712-002.359-1), entitled “Mineral separation using functionalized polymer membranes”;

[0306] PCT Application No. PCT / US12 / 39540 (Attorney Docket No. 712-002.359-2), entitled “Mineral separation using sized, weighted and magnetized beads”;

[0307] PCT Application No. PCT / US12 / 39576 (Attorney Docket No. 712-002.382), entitled “Synthetic bubbles / beads functionalized with molecules for attracting or attaching to mineral particles of interest,” which corresponds to U.S. Patent No. 9,352,335;

[0308] PCT Application Serial No. PCT / US12 / 39591 (712-2.383-1 / CCS-0090), entitled “Method and system for releasing mineral from synthetic bubbles and beads,” filed May 25, 2012, which itself claims the benefit of U.S. Provisional Patent Application No. 61 / 489,893, filed May 25, 2011, and U.S. Provisional Patent Application No. 61 / 533,544, filed September 12, 2011. U.S. Provisional Patent Application No. 61 / 533,544 corresponds to co-pending U.S. Patent Application No. 14 / 117,912, filed November 15, 2013;

[0309] PCT Application No. PCT / US / 39596 (Attorney Docket No. 712-002.384), entitled “Synthetic bubbles and beads having a hydrophobic surface”;

[0310] PCT Application No. PCT / US / 39631 (Attorney Docket No. 712-002.385), entitled “Mineral separation using functionalized filters and membranes,” which corresponds to U.S. Patent No. 9,302,270;

[0311] PCT Application No. PCT / US12 / 39655 (Attorney Docket No. 712-002.386), entitled “Mineral recovery in tailings using functionalized polymers”; and

[0312] PCT Application No. PCT / US12 / 39658 (Attorney Docket No. 712-002.387), entitled "Techniques for Transporting Synthetic Beads or Bubbles in a Flotation Cell or Column," all of which are incorporated herein by reference in their entirety.

[0313] This application is also related to PCT application no. PCT / US2013 / 042202 filed on May 22, 2013 (attorney docket no. 712-002.389-1 / CCS-0086), entitled “Charged engineered polymer beads / bubbles functionalized with molecules for attracting and attaching to mineral particles of interest for flotation separation,” which claims the benefit of U.S. Provisional Patent Application No. 61 / 650,210 filed on May 22, 2012, which is incorporated herein by reference in its entirety.

[0314] This application also relates to PCT / US2014 / 037823, filed May 13, 2014, entitled “Polymer surfaces having asiloxane functional group,” which claims the benefit of U.S. Provisional Patent Application No. 61 / 822,679, filed May 13, 2013 (Attorney Docket No. 712-002.395 / CCS-0123), and U.S. Patent Application No. 14 / 118,984, filed January 27, 2014 (Attorney Docket No. 712-002.385 / CCS-0092), and is a continuation-in-part of PCT Application No. PCT / US12 / 39631, filed May 25, 2012 (712-2.385 / / CCS-0092), which is incorporated herein by reference in its entirety.

[0315] This application is also related to PCT application no. PCT / US13 / 28303 filed on February 28, 2013 (Attorney Docket No. 712-002.377-1 / CCS-0081 / 82), entitled “Method and system for flotation separation in a magnetically controllable and steerable foam,” which is also incorporated herein by reference in its entirety.

[0316] This application is also related to PCT application no. PCT / US16 / 57334 filed on October 17, 2016 (attorney docket number 712-002.424-1 / CCS-0151), entitled “Opportunities for recovery augmentation process as applied to molybdenum production,” which is also incorporated herein by reference in its entirety.

[0317] This application is also related to PCT application no. PCT / US16 / 37322 filed on October 17, 2016 (attorney docket number 712-002.425-1 / CCS-0152), entitled “Mineral beneficiation utilizing engineered materials for mineral separation and coarse particle recovery,” which is also incorporated herein by reference in its entirety.

[0318] This application is also related to PCT application no. PCT / US16 / 62242 filed on November 16, 2016 (attorney docket number 712-002.426-1 / CCS-0154), entitled “Utilizing engineered media for recovery of minerals in tailings stream at the end of a flotation separation process,” which is also incorporated herein by reference in its entirety.

[0319] This application is related to PCT application serial number PCT / US16US / 68843 filed on December 28, 2016 (attorney docket number 712-002.427-1 / CCS-0157), entitled “Tumbler cell form mineral recovery using engineered media,” which claims the benefit of provisional application no. 62 / 272,026 filed on December 28, 2015, entitled “Tumbler Cell Design for Mineral Recovery Using Engineered Media,” both of which are incorporated herein by reference in their entirety.

[0320] Scope of the Invention

[0321] It should be further understood that any features, characteristics, substitutions or modifications described with respect to a particular embodiment herein may also be applied, used or incorporated into any other embodiment described herein. Figure 17a The open-pore structured engineered collection media shown can be made of a material having a specific gravity less than, equal to, or greater than the specific gravity of the slurry. The engineered collection media can be made of a magnetic polymer or have a magnetic core such that the anti-magnetic, ferrimagnetic, and ferromagnetic properties of the engineered collection media are greater than the anti-magnetic, ferrimagnetic, and ferromagnetic properties of the unwanted ground ore particles in the slurry. Thus, while the present invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein without departing from the spirit and scope of the invention.

Claims

1. An engineered collection medium comprising a solid body configured with a three-dimensional open pore structure to provide a plurality of collection surfaces; and a plurality of molecules disposed on the collection surface, the molecules comprising functional groups having chemical bonds for adsorbing one or more mineral particles in the aqueous mixture to the molecules so that the mineral particles adhere to the collection surface; wherein the solid phase comprises a coating or layer, the coating or layer being configured with a hydrophobic chemical selected from polysiloxane derivatives, and wherein the coating or layer is modified with a tackifier, a plasticizer, a crosslinker, a chain transfer agent, a chain extender, an adhesion promoter, an aryl or alkyl copolymer, a fluorinated copolymer, hexamethyldisilazane, silica or hydrophobic silica, wherein the polysiloxane derivative is poly(dimethylsiloxane), The engineered collection media takes the form of a membrane having an open-cell foam layer attached to a substrate or base, with the substrate being made of a less porous material than the open-cell foam layer.

2. The engineered collection medium of claim 1, wherein the solid phase body is made of polyurethane.

3. The engineered collection medium of claim 1 , wherein the solid phase body has a coating or layer made of a material selected from the group consisting of acrylic resin, butyl rubber, ethylene vinyl acetate, natural rubber, nitrile, styrene block copolymers with ethylene, propylene and isoprene, polyurethane and polyethylene ether.

4. The engineered collection medium of claim 1, further comprising a binder configured to promote adhesion between the solid body and the coating or layer.

5. The engineered collection medium of claim 1, wherein the solid phase body is made of plastic, ceramic, carbon fiber or metal.

6. The engineered collection media of claim 1, wherein the three-dimensional open pore structure comprises pores ranging from 10 to 200 pores per inch.

7. The engineered collection media of claim 1, wherein the solid phase body comprises a reticulated foam block that provides the three-dimensional open-cell structure.

8. The engineered collection medium of claim 1, wherein the solid phase body comprises a filter providing the three-dimensional open-pored structure, the structure having pores to allow fluid in the aqueous mixture to flow through the filter.

9. The engineered collection medium of claim 1, wherein the solid body comprises a conveyor belt having a surface configured with the three-dimensional open-pore structure.

10. The engineered collection media of claim 1, wherein the three-dimensional open-cell structure comprises an open-cell foam.

11. An engineered collection media according to claim 10, wherein the open-cell foam is made of one or more materials selected from the group consisting of polyester urethane, polyether urethane, reinforced polyurethane, composite materials such as PU coated with PVC, non-polyurethane, and metal, ceramic and carbon fiber foams and rigid porous plastics to enhance mechanical durability.

12. The engineered collection media of claim 10, wherein the open cell foam is coated with polyvinyl chloride and subsequently coated with a low surface energy compliant adhesive polymer to enhance chemical durability.

13. The engineered collection media of claim 10, wherein the open cell foam is primed with a high energy primer prior to applying the functionalized polymer coating to increase adhesion of the functionalized polymer coating to the surface of the open cell foam.

14. The engineered collection media of claim 13, wherein the surface of the open-cell foam is chemically or mechanically abraded to provide "gripping points" on the surface to retain the functionalized polymer coating.

15. The engineered collection media of claim 10, wherein the surface of the open-cell foam is coated with a functionalized polymer coating that is covalently bonded to the surface to enhance adhesion between the functionalized polymer coating and the surface.

16. An engineered collection media according to claim 10, wherein the surface of the open-cell foam is coated with a functionalized polymer coating, the functionalized polymer coating being in the form of a compliant, adhesive polymer with low surface energy and having a thickness selected to capture certain mineral particles and collect certain particle sizes, including wherein a thin coating is selected to collect a proportionally smaller particle size fraction and a thick coating is selected to collect an additional large particle size fraction.

17. The engineered collection media of claim 1, wherein the specific surface area is configured to have a specific number of pores per inch, the number determined for a specific size range of mineral particles in the slurry.

18. The engineered collecting media of claim 1, wherein the engineered collecting media comprises different open cell foams having different specific surface areas that are mixed to recover a specific size distribution of mineral particles in the slurry.

19. The engineered collection media of claim 1, wherein the three-dimensional open-pored structure comprises a low-energy, compliant, adhesive surface to provide the molecules.

20. An engineered collection medium according to claim 19, wherein the low energy, compliant adhesive surface is made of a material selected from the group consisting of polyurethane, reticulated polyurethane, polyester urethane, polyether urethane, reinforced polyurethane, PV coated with PVC, silicone, polychloroprene, polyisocyanurate, polystyrene, polyolefin, polyvinyl chloride, epoxy resin, latex, fluoropolymer, polypropylene, phenolic resin, EPDM and nitrile.

21. The engineered collection media of claim 1, wherein the three-dimensional open-porous structure is reacted to form a low-energy, compliant, adhesive surface.

22. An engineered collection medium according to claim 19, wherein the three-dimensional open pore structure is made of a material selected from the group consisting of polyamide (nylon), polyester, polyurethane, phenol-formaldehyde, urea-formaldehyde, melamine-formaldehyde, polyacetal, polyethylene, polyisobutylene, polyacrylonitrile, poly(vinyl), polystyrene, poly(methyl methacrylate), poly(vinyl acetate), poly(vinylidene chloride), polyisoprene, polybutadiene, polyacrylate, poly(carbonate), phenolic resin, silicone acid copolymer, fluoroalkyl silane, polysiloxane salt and polydimethylsiloxane.

23. The engineered collection media of claim 4, wherein the layer comprises the three-dimensional open pore structure.

24. The engineered collection medium of claim 22, wherein the three-dimensional open pore structure is modified with a tackifier, a plasticizer, a cross-linker, a chain transfer agent, a chain extender, an adhesion promoter, an aromatic or alkyl copolymer, a fluorinated copolymer, hexamethyldisilazane, silica, or hydrophobic silica.

25. The engineered collection medium of claim 1, wherein the polysiloxane derivative is selected from the group consisting of polysiloxane salts, poly(dimethylsiloxane), fluoroalkyl silanes.

26. The engineered collection medium of claim 1, wherein the solid phase body is made of a material selected from the group consisting of polyester urethane, polyether urethane, reinforced polyurethane, PV coated with PVC, silicone, polychloroprene, polyisocyanurate, polystyrene, polyolefin, polyvinyl chloride, epoxy, latex, fluoropolymer, polypropylene, phenolic resin, EPDM and nitrile.

27. The engineered collection media of claim 4, wherein the adhesive comprises a pressure sensitive adhesive having a low surface energy.

28. An apparatus comprising: a processor configured to receive one or more engineered collection media carrying mineral particles, each of the one or more engineered collection media comprising a solid body and a plurality of molecules, the solid body being configured with a three-dimensional open pore structure to provide a plurality of collection surfaces, the plurality of molecules being attached to the collection surfaces, the molecules comprising functional groups having chemical bonds for adsorbing one or more of the mineral particles in the aqueous mixture to the molecules such that the mineral particles attach to the collection surfaces, wherein the solid body comprises a coating or layer, the coating or layer being configured with a hydrophobic chemical selected from the group consisting of polysiloxane derivatives, and wherein the coating or layer is modified with a tackifier, a plasticizer, a crosslinker, a chain transfer agent, a chain extender, an adhesion promoter, an aryl or alkyl copolymer, a fluorinated copolymer, hexamethyldisilazane, silica, or hydrophobic silica, wherein the polysiloxane derivative is poly(dimethylsiloxane); and a release device configured to break the chemical bonds of the functional groups, thereby removing the mineral particles from the collection surface, The engineered collection media takes the form of a membrane having an open-cell foam layer attached to a substrate or base, with the substrate being made of a less porous material than the open-cell foam layer.

29. The device of claim 28, wherein the engineered collection medium further comprises a coating configured with a hydrophobic chemical selected from the group consisting of polysiloxanes, poly(dimethylsiloxane), fluoroalkyl silanes, and / or pressure sensitive adhesives with low surface energy to provide the molecules.

30. A method for mineral recovery, comprising providing a processor configured to receive one or more engineered collection media carrying mineral particles, each of the one or more engineered collection media comprising a solid body and a plurality of molecules, the solid body being configured with a three-dimensional open pore structure to provide a plurality of collection surfaces, the plurality of molecules being attached to the collection surfaces, the molecules comprising functional groups having chemical bonds for adsorbing one or more of the mineral particles in the aqueous mixture to the molecules such that the mineral particles attach to the collection surfaces, wherein the solid body comprises a coating or layer, the coating or layer being configured with a hydrophobic chemical selected from a polysiloxane derivative, and wherein the coating or layer is modified with a tackifier, a plasticizer, a crosslinker, a chain transfer agent, a chain extender, an adhesion promoter, an aryl or alkyl copolymer, a fluorinated copolymer, hexamethyldisilazane, silica, or hydrophobic silica, wherein the polysiloxane derivative is poly(dimethylsiloxane); and breaking the chemical bonds of the functional groups, thereby removing the mineral particles from the collection surface, The engineered collection media takes the form of a membrane having an open-cell foam layer attached to a substrate or base, with the substrate being made of a less porous material than the open-cell foam layer.

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