Reduced grinding requirements for minerals beneficiation utilizing engineered materials for mineral separation and coarse particle recovery

Abstract

A mineral processing system for mineral separation and coarse particle recovery utilizing engineered media, features a first ore size reduction circuit and a second ore size reduction circuit. The first ore size reduction circuit includes a secondary crusher with a combination of a high pressure grinding roll crusher and a screen, and is configured to receive a primary crusher feed from a primary crusher, and provide a first ore size reduction circuit feed having first crushed ore with a first orebody feed size that is less than a primary orebody feed size of the primary crusher feed and in a range of about 6-8 mm. The second ore size reduction circuit is configured to receive the first ore size reduction circuit feed and provide a second ore size reduction circuit feed having second crushed ore with a second orebody feed size less than 1 mm.

Description

[0001] REDUCED GRINDING REQUIREMENTS

[0002] FOR MINERALS BENEFICIATION UTILIZING ENGINEERED MATERIALS FOR MINERAL SEPARATION AND COARSE PARTICLE RECOVERY

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] This application claims benefit to provisional patent application serial nos. 63 / 534,635 (WFMB no. 712-002.474 (CCS-0223)), filed 25 August 2023, and 63 / 561 ,485 (712-002.477 CCS-0226)), filed 5 March 2023, which are both incorporated by reference in its entirety.

[0005] BACKGROUND OF THE INVENTION

[0006] 1 . Field of Invention

[0007] This invention relates to a technique for reducing grinding requirements in a mineral processing system using engineered media for mineral separation and recovery of mineral particles of interest.

[0008] 2. Description of Related Art

[0009] The Assignee of the present invention has developed mineral extraction technology based upon using its engineered media, which has demonstrated the ability to selectively recover coarse particles (aka mineral particles of interest) from an orebody, e.g., by recovering particles with size distributions of 80 percent passing size (p80) of up to 3 millimeters (mm). In comparison, current mineral recovery techniques known in the art use froth flotation (e.g., hydrocyclones) that is most efficient for mineral recovery of particles in the 20 micron to 150 micron size range. Current mineral recovery by froth flotation also requires reducing the size of the ore from the mine down to size distributions with a p80 typically between 100 to 150 microns. This is generally done utilizing a two-stage grinding circuit comprising a SAG Mill and Ball Mill in a closed loop with hydrocyclones, e.g., as shown in Figure 1.

[0010] SUMMARY OF THE INVENTION

[0011] Since the Assignee's mineral extraction technology can recover coarse mineral particles up to 3mm, alternate size reduction technology can be used which replaces the need for the SAG / Ball mill grinding circuit like that shown in Figure 1 . In general, and according to the present invention, this alterative size reduction process includes crushing and screening technology alone or in combination with coarse stirred mill technology.

[0012] In particular, and according to some embodiments, the present invention may include, or take the form of, a mineral processing system for mineral separation and coarse particle recovery utilizing the Assignee's engineered media, featuring a first ore size reduction circuit and a second ore size reduction circuit.

[0013] The first ore size reduction circuit includes a secondary crusher with a combination of a high pressure grinding roll (HPGR) crusher and a screen that is configured to receive a primary crusher feed from a primary crusher, and provide a first ore size reduction circuit feed having first crushed ore with a first orebody feed size that is less than a primary orebody feed size of the primary crusher feed, e.g., the first orebody feed size being in a range of about 6 - 8 mm.

[0014] The second ore size reduction circuit is configured to receive the first ore size reduction circuit feed and provide a second ore size reduction circuit feed having second crushed ore with a second orebody feed size, e.g., that is less than 1 mm.

[0015] The present invention may also include one or more of the following features: The HPGR crusher and the screen may be configured in a HPGR crusher and screen feedback loop, e.g., where the HPGR crusher is configured to receive the primary crusher feed and provide a HPGR crusher feed; and the screen is configured to receive the HPGR crusher feed, and provide screened first crushed ore having the first orebody feed size and a feedback first crushed ore for further processing by the HPGR crusher.

[0016] The second ore size reduction circuit may include a second secondary crusher having a second combination of a second HPGR crusher and a second screen that is configured to receive the first ore size reduction circuit feed and provide the second ore size reduction circuit feed having the second crushed ore with the second orebody feed size, e.g. that is less than 1 mm.

[0017] The second HPGR crusher and the second screen may be configured in a second HPGR crusher-and screen feedback loop, e.g., where the second HPGR crusher is configured to receive the first ore size reduction circuit feed and provide a second HPGR crusher feed; and the second screen is configured to receive the second HPGR crusher feed, and provide second screened crushed ore having the first orebody feed size and a second feedback crushed ore for further processing by the second HPGR crusher.

[0018] Alternatively, the second ore size reduction circuit may include a coarse stirred mill that is configured to receive the first ore size reduction circuit feed and provide the second ore size reduction circuit feed having the second crushed ore with the second orebody feed size, e.g. that is less than 0.5 mm.

[0019] The coarse stirred mill may include ceramic media for grinding and milling the first ore size reduction circuit feed. The mineral processing system may include a mineral recovery circuit having the engineered media that is configured to receive the second ore size reduction circuit feed and provide a final product having loaded engineered media with mineral particle of interest attached thereto and also provide tailings for further processing.

[0020] The Method

[0021] The present invention may include, or take the form of, a method for mineral separation and coarse particle recovery utilizing engineered media in a mineral processing system, featuring configuring a first ore size reduction circuit having a secondary crusher with a combination of a high pressure grinding roll (HPGR) crusher and a screen to receive a primary crusher feed from a primary crusher and provide a first ore size reduction circuit feed having first crushed ore with a first orebody feed size that is less than a primary orebody feed size of the primary crusher feed, including the first orebody feed size being in a range of about 6 - 8 mm; and configuring a second ore size reduction circuit to receive the first ore size reduction circuit feed and provide a second ore size reduction circuit feed having second crushed ore with a second orebody feed size, including the second orebody feed size being less than 1 mm.

[0022] The method may include one or more other steps for implementing the other features disclosed herein. BRIEF DESCRIPTION OF THE DRAWING

[0023] The drawing includes Figures 1-3, which are not necessarily drawn to scale, as follows:

[0024] Figure 1 is a diagram of a traditional SAG, Ball Mill and flotation circuit that is known in the art.

[0025] Figure 2 is a diagram of a mineral processing system having a HPGR crusher, screening and a mineral recovery circuit using engineered media developed by the Assignee of the present invention, according to some embodiments of the present invention.

[0026] Figure 3 is a diagram of a mineral processing system having a HPGR crusher, coarse stirred milling and a mineral recovery circuit using engineered media developed by the Assignee of the present invention, according to some embodiments of the present invention.

[0027] DETAILED DESCRIPTION OF BEST MODE OF THE INVENTION

[0028] The Basic Invention

[0029] Since the Assignee's mineral extraction technology can recover coarse mineral particles up to 3mm, alternate size reduction technology can be used which replaces the need for a SAG / Ball mill grinding circuit like that shown in Figure 1 . By way of example, Figures 2-3 show the basic invention in the form of a mineral processing system for mineral separation and coarse particle recovery utilizing the Assignee's engineered media, featuring a first ore size reduction circuit and a second ore size reduction circuit .

[0030] The first ore size reduction circuit includes a secondary crusher with a combination of a HPGR crusher and a screen that is configured to receive a primary crusher feed from a primary crusher, and provide a first ore size reduction circuit feed having first crushed ore with a first orebody feed size that is less than a primary orebody feed size of the primary crusher feed, e.g. the first orebody feed size being in a range of about 6 - 8 mm.

[0031] The second ore size reduction circuit may be configured to receive the first ore size reduction circuit feed and provide a second ore size reduction circuit feed having second crushed ore with a second orebody feed size, e.g., less than 1 mm. According to the present invention, the second ore size reduction circuit may include, or take the form of, either a second HPGR crusher and a screen, or a coarse stirred mill grinder, e.g., as shown in Figures 2-3.

[0032] In effect, according to the present invention, this alterative size reduction process may include crushing and screening technology (Fig. 2) alone or in combination with coarse stirred mill technology (Fig. 3) .

[0033] The basic invention will now be described in further detail in relation to that shown in Figures 2-3, as follows:

[0034] Figure 2

[0035] Figure 2 shows a mineral processing system having HPGR crushers, screening and a mineral recovery circuit using the engineered media developed by the Assignee of the present invention, according to some embodiments of the present invention.

[0036] According to some embodiments of the present invention, this alterative size reduction process may include existing crushing and screening technology. By way of example, but not intended to be limited thereto, a new technique has been developed that utilizes HPGR crushers technology and screening technology to reduce ore from the primary crusher size down to <1mm, as shown in Figure 2. Utilizing this crushing and screening technology as shown in Figure 2 to reduce ore size down to <1mm reduces the operating costs and capital costs associated with the typical SAG / Ball mill grinding circuit shown in Figure 1 .

[0037] As shown in Figure 2, the HPGR crusher and the screen may be configured in a HPGR crusher and screen feedback loop, e.g., where the HPGR crusher is configured to receive the primary crusher feed and provide a HPGR crusher feed; and the screen is configured to receive the HPGR crusher feed, and provide screened first crushed ore having the first orebody feed size, as well as a feedback first crushed ore for further processing by the HPGR crusher.

[0038] Moreover, the second ore size reduction circuit may include a second secondary crusher having a second combination of a second HPGR crusher and a second screen that is configured to receive the first ore size reduction circuit feed and provide the second ore size reduction circuit feed having the second crushed ore with the second orebody feed size, e.g. that is less than 1 mm. The second HPGR crusher and the second screen may also be configured in a second HPGR crusher-and screen feedback loop, e.g., where the second HPGR crusher is configured to receive the first ore size reduction circuit feed and provide a second HPGR crusher feed; and the second screen is configured to receive the second HPGR crusher feed, and provide second screened crushed ore having the first orebody feed size and a second feedback crushed ore for further processing by the second HPGR crusher.

[0039] In Figure 2, the mineral recovery circuit using the Assignee's engineered media, e.g. that is configured to receive the second ore size reduction circuit feed from the second ore size reduction circuit and provide a final product having loaded engineered media with mineral particle of interest attached thereto and also provide tailings for further processing.

[0040] Figure 3

[0041] Figure 3 shows a mineral processing system having a HPGR crusher , screening, a coarse stirred mill and a mineral recovery circuit using engineered media developed by the Assignee of the present invention, according to some embodiments of the present invention.

[0042] According to some embodiments of the present invention, this alterative size reduction process may include existing crushing, coarse inert-media stirred milling and screening technology. By way of example, but not intended to be limited thereto, a new technique has been developed that utilizes HPGR crushers, coarse inert-media stirred milling technology and screening technology in a nondemanding (6-8mm) duty to reduce ore from the primary crusher down to <0.5mm, as shown in Figure 3. In effect, the coarse inert-media stirred milling in Figure 3 is utilized, e.g., instead of using the second secondary crusher having the second combination of the second HPGR crusher and the second screen shown in Figure 2. Utilizing this combined crushing, screening and milling technology shown in Figure 3 to reduce the ore size down to <0.5mm reduces the operating costs and capital costs associated with the typical tumbling SAG / Ball milling processes shown in Figure 1 . In addition, removing the tumbling milling processes eliminates the use of steel ball media typically required in SAG / Ball milling circuits shown in Figure 1 . Using steel media in tumbling milling processes often affects the physical and chemical properties of the mineral particles which complicates the mineral separation processes downstream. The present invention eliminates that problem because it uses inert (ceramic) media in the size reduction step as shown in Figure 3.

[0043] Since the coarse stirred milling technology operates in an open circuit, and because the product from the HPGR / Screen circuit is in a range of about 6-8mm, recirculation of material in the overall size reduction circuit will be minimal.

[0044] HPGR Crushing and Screening Technology

[0045] HPGR crushing and screening technology like that shown in Figures 2-3 is known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof either now known or later developed in the future.

[0046] Coarse Stirred Mill Technology

[0047] Coarse stirred mill or milling technology like that shown in Figure 3 is known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof either now known or later developed in the future.

[0048] The Mineral Recovery Circuit

[0049] The mineral recovery circuit that forms part of the mineral processing system shown in Figures 2 and 3 includes the Assignee's mineral recovery circuit / plant using the Assignee's engineered media, e.g. together with a flotation circuit having a regrind mill, a hydrocyclone, a cleaner flotation, etc., e.g., like that shown on the right side of Figure 1 but without any rougher flotation. The flotation circuit is configured for further processing concentrate and tailings received from the Assignee's mineral recovery circuit, so as to provide the final product and also provide tailings for further processing. The mineral recovery circuit that forms part of the mineral processing system shown in Figures 2 and 3 is known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof either now known or later developed in the future.

[0050] The Assignee's Mineral Recovery Plant and Technology

[0051] The Assignee's mineral recovery plant shown in Figures 2-3 includes the mineral recovery technology using engineered media developed by the Assignee of the present invention. By way of example, Applicant sets forth examples of the Assignee's mineral recovery technology, as follows:

[0052] This application is also related to a family of nine PCT applications, which were all concurrently filed on 25 May 2012, as follows:

[0053] PCT application no. PCT / US12 / 39528 (Atty docket no. 712-002.356-1 ), entitled "Flotation separation using lightweight synthetic bubbles and beads," which corresponds to US 10,357,782.

[0054] PCT application no. PCT / US12 / 39524 (Atty docket no. 712-002.359-1 ), entitled "Mineral separation using functionalized polymer membranes," which corresponds to US 1 1 ,731 ,143;

[0055] PCT application no. PCT / US12 / 39540 (Atty docket no. 712-002.359-2), entitled "Mineral separation using sized, weighted and magnetized beads," which corresponds to US 9,827,574;

[0056] PCT application no. PCT / US12 / 39576 (Atty 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; PCT application no. PCT / US12 / 39591 (Atty docket no. 712-002.383), entitled “Method and system for releasing mineral from synthetic bubbles and beads," which corresponds to US 9,981 ,271 and US 11 ,135,597;

[0057] PCT application no. PCT / US / 39596 (Atty docket no. 712-002.384), entitled "Synthetic bubbles and beads having hydrophobic surface," which corresponds to US 9,327,294;

[0058] PCT application no. PCT / US / 39631 (Atty docket no. 712-002.385), entitled "Mineral separation using functionalized filters and membranes," which corresponds to U.S. Patent No. 9,302,270;"

[0059] PCT application no. PCT / US12 / 39655 (Atty docket no. 712-002.386), entitled "Mineral recovery in tailings using functionalized polymers," which corresponds to US 9,943,860; and

[0060] PCT application no. PCT / US12 / 39658 (Atty docket no. 712-002.387), entitled "Techniques for transporting synthetic beads or bubbles In a flotation cell or column," which corresponds to US 9,981 ,272, all of which are incorporated by reference in their entirety.

[0061] This application is also related to other applications, as follows:

[0062] PCT application no. PCT / US2013 / 042202 (Atty docket no. 712- 002.389-1 / CCS-0086), filed 22 May 2013, 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 22 May 2012, and which corresponds to US 9,839,919;

[0063] PCT / US2014 / 037823, filed 13 May 2014, entitled "Polymer surfaces having a siloxane functional group," which claims benefit to U.S. Provisional Patent Application No. 61 / 822,679 (Atty docket no. 712-002.395 / CCS-0123), filed 13 May 2013, as well as U.S. Patent Application No. 14 / 1 18,984 (Atty docket no. 712-002.385 / CCS-0092), filed 27 January 2014, and is a continuation-in-part to PCT application no. PCT / US12 / 39631 (712- 2.385 / / CCS-0092), filed 25 May 2012;

[0064] PCT application no. PCT / US13 / 28303 (Atty docket no. 712-002.377- 1 / CCS-0081 / 82), filed 28 February 2013, entitled "Method and system for flotation separation in a magnetically controllable and steerable foam," which corresponds to US 9,932,525;

[0065] PCT application no. PCT / US16 / 57334 (Atty docket no. 712-002.424- 1 / CCS-0151), filed 17 October 2016, entitled "Opportunities for recovery augmentation process as applied to molybdenum production," which corresponds to US 10,774,400:

[0066] PCT application no. PCT / US16 / 37322 (Atty docket no. 712-002.425- 1 / CCS-0152), filed 17 October 2016, entitled "Mineral beneficiation utilizing engineered materials for mineral separation and coarse particle recovery," which corresponds to US 10,981 ,181 ; and

[0067] PCT application no. PCT / US17 / 37322 (Atty docket no. 712-002.428- 1 / CCS-0158), filed 9 January 2017, entitled "Recovery media for mineral processing, using open cell or reticulated foam having 3-dimensional functionalized open-network structure for selective separation of mineral particles in an aqueous system," which corresponds to US 10,835,905; which are all also hereby incorporated by reference in its entirety. See also US 11 ,642,679, issued 9 May 2023 (WFMB no, 71 -002.442 (CCS- 0179)), including Figures 2a - 21 shown therein, which is all also hereby incorporated by reference in its entirety.

[0068] All of the aforementioned patent applications are assigned to and owned by the Assignee of the instant application.

[0069] Applications

[0070] By way of example, the present invention may be used in, or form part of, or used in conjunction with, industrial processes like a mineral extraction processing system for extracting or separating minerals in a fluidic medium that are either now known or later developed in the future, including any mineral process, such as those related to processing substances or compounds that result from inorganic processes of nature and / or that are mined from the ground, as well as including either other extraction processing systems or other industrial processes, where the extraction, or separating, or sorting, or classification, of product by size, or density, or some electrical characteristic, is critical to overall industrial process performance.

[0071] The Scope of the Invention

[0072] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, may modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed herein as the best mode contemplated for carrying out this invention.

Claims

WHAT IS CLAIMED IS:1 . A mineral processing system for mineral separation and coarse particle recovery utilizing engineered media, comprising: a first ore size reduction circuit having a secondary crusher with a combination of a high pressure grinding roll (HPGR) crusher and a screen, and being configured to receive a primary crusher feed from a primary crusher, and provide a first ore size reduction circuit feed having first crushed ore with a first orebody feed size that is less than a primary orebody feed size of the primary crusher feed, including the first orebody feed size being in a range of about 6 - 8 mm; and a second ore size reduction circuit configured to receive the first ore size reduction circuit feed and provide a second ore size reduction circuit feed having second crushed ore with a second orebody feed size, including the second orebody feed size being less than 1 mm.

2. A mineral processing system according to claim 1 , wherein the HPGR crusher and the screen are configured in a HPGR crusher and screen feedback loop; the HPGR crusher is configured to receive the primary crusher feed and provide a HPGR crusher feed; and the screen is configured to receive the HPGR crusher feed, and provide screened first crushed ore having the first orebody feed size and a feedback first crushed ore for further processing by the HPGR crusher.

3. A mineral processing system according to claim 1 , wherein the second ore size reduction circuit comprises a second secondary crusher having a second combination of a second HPGR crusher and a second screen, and being configured to receive the first ore size reduction circuit feed and provide the second ore size reduction circuit feed having the second crushed ore with the second orebody feed size that is less than 1 mm.

4. A mineral processing system according to claim 3, wherein the second HPGR crusher and the second screen are configured in a second HPGR crusher-and screen feedback loop; the second HPGR crusher is configured to receive the first ore size reduction circuit feed and provide a second HPGR crusher feed; and the second screen is configured to receive the second HPGR crusher feed, and provide second screened crushed ore having the first orebody feed size and a second feedback crushed ore for further processing by the second HPGR crusher.

5. A mineral processing system according to claim 1 , wherein the second ore size reduction circuit comprises a coarse stirred mill being configured to receive the first ore size reduction circuit feed and provide the second ore size reduction circuit feed having the second crushed ore with the second orebody feed size that is less than 0.5 mm.

6. A mineral processing system according to claim 5, wherein the coarse stirred mill comprises ceramic media for grinding and milling the first ore size reduction circuit feed.

7. A mineral processing system according to claim 1 , wherein the mineral processing system comprises a mineral recovery circuit having engineered media, and being configured to receive the second ore size reduction circuit feed and provide a final product having loaded engineered media with mineral particle of interest attached thereto and also provide tailings for further processing.

8. A method for mineral separation and coarse particle recovery utilizing engineered media in a mineral processing system, comprising: configuring a first ore size reduction circuit having a secondary crusher with a combination of a high pressure grinding roll (HPGR) crusher and a screen to receive a primary crusher feed from a primary crusher and provide a first ore size reduction circuit feed having first crushed ore with a first orebody feed size that is less than a primary orebody feed size of the primary crusher feed, including the first orebody feed size being in a range of about 6 - 8 mm; and configuring a second ore size reduction circuit to receive the first ore size reduction circuit feed and provide a second ore size reduction circuit feed having second crushed ore with a second orebody feed size, including the second orebody feed size being less than 1 mm.

9. A method according to claim 8, wherein the method further comprises: configuring the HPGR crusher and the screen in a HPGR crusher and screen feedback loop; receiving in the HPGR crusher the primary crusher feed and providing a HPGR crusher feed; and receiving with the screen the HPGR crusher feed, and providing screened first crushed ore having the first orebody feed size and a feedback first crushed ore for further processing by the HPGR crusher.

10. A method according to claim 8, wherein the method further comprises: configuring the second ore size reduction circuit with a second secondary crusher having a second combination of a second HPGR crusher and a second screen; and receiving with the second combination the first ore size reduction circuit feed and providing the second ore size reduction circuit feed having the second crushed ore with the second orebody feed size that is less than 1 mm.11 . A method according to claim 10, wherein the method further comprises: configuring the second HPGR crusher and the second screen in a secondHPGR crusher-and screen feedback loop; receiving with the second HPGR crusher the first ore size reduction circuit feed and providing a second HPGR crusher feed; and receiving with the second screen the second HPGR crusher feed, and providing second screened crushed ore having the first orebody feed size and a second feedback crushed ore for further processing by the second HPGR crusher.

12. A method according to claim 8, wherein the method further comprises: configuring the second ore size reduction circuit with a coarse stirred mill; and receiving with the coarse stirred mill the first ore size reduction circuit feed and providing the second ore size reduction circuit feed having the second crushed ore with the second orebody feed size that is less than 0.5 mm.

13. A method according to claim 12, wherein the method further comprises configuring the coarse stirred mill with ceramic media for grinding and milling the first ore size reduction circuit feed.

14. A method according to claim 1 , wherein the method further comprises: configuring a mineral recovery circuit with engineered media; and receiving with the mineral recovery circuit the second ore size reduction circuit feed and providing a final product having loaded engineered media with mineral particle of interest attached thereto and also provide tailings for further processing.

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