Biodegradable Flotation Oil for Potash Recovery

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Solution Overview

Problem

Current flotation oils used in mineral recovery processes, such as potash production, face issues like high reagent costs, toxicity, and inefficiencies in extracting coarse minerals, leading to increased tailings and environmental concerns, while also being difficult to handle and transport safely.

Innovation Solution

A new formulation of flotation oil comprising hydrocracked, hydrotreated heavy oils, thermally or catalytically cracked waste oils, and intermediate streams from refineries, optimized for specific gravity, flash point, and resin content, which can be mixed with additives to enhance performance across varying operating conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional flotation oils are used, then mineral recovery can be achieved, but reagent costs are high and extraction efficiency for coarse minerals is low

Engineering Contradiction:

Improvemineral recovery efficiencyVSAvoidreagent cost

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent changes the chemical composition parameters of flotation oils by replacing conventional petroleum-based oils with biodegradable alternatives such as vegetable oils (canola, sunflower, soybean) and animal fats. This parameter change achieves both cost reduction and improved extraction efficiency while maintaining environmental sustainability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs inexpensive biodegradable oils that can be readily sourced from agricultural and animal waste products. These oils provide effective flotation performance at lower cost and can be easily replaced without environmental concern, functioning as disposable reagents that reduce both cost and environmental impact

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Productivity

If conventional flotation oils are used, then mineral extraction can proceed, but carcinogenic polyaromatic hydrocarbons are present causing environmental concerns

Engineering Contradiction:

Improvemineral extraction efficiencyVSAvoidcarcinogenic polyaromatic hydrocarbons

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts potentially harmful conventional oils into beneficial biodegradable alternatives by using waste vegetable oils and animal fats that would otherwise be discarded. This transformation eliminates carcinogenic polyaromatic hydrocarbons while maintaining flotation effectiveness, turning a harmful substance category into an environmentally beneficial solution

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent fundamentally changes the chemical composition parameters by eliminating aromatic hydrocarbon structures present in conventional oils and replacing them with aliphatic structures from biodegradable sources. This parameter change removes carcinogenic properties while preserving the essential flotation oil functions of reducing surface tension and promoting mineral attachment

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If conventional flotation oils are used, then flotation process can operate, but the oils are difficult to handle and transport safely

Engineering Contradiction:

Improvehandling and transport safetyVSAvoidoperational reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent uses biodegradable oils that pose minimal safety risks during handling and transport. These oils can be safely managed as disposable reagents without stringent safety protocols, improving ease of operation while maintaining sufficient operational reliability for mineral recovery processes

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Manufacturing precision

If flotation process recovers fine minerals effectively, then concentrate quality improves, but coarse minerals are lost increasing tailings

Engineering Contradiction:

Improveconcentrate qualityVSAvoidcoarse mineral loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent modifies the physical and chemical parameters of flotation oils to optimize performance across the full particle size range. By adjusting viscosity, surface tension, and chemical composition of biodegradable oils, the system achieves effective attachment to both fine and coarse minerals, improving concentrate quality while reducing coarse mineral losses to tailings

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The new flotation oil formulation significantly improves potash recovery, reduces tailings, decreases carcinogenic polyaromatic hydrocarbons, and is safer to handle and transport, offering improved efficiency and environmental sustainability in mineral extraction processes.

Implementation Method 1

A variety of chemicals may be added to the ore particles or pulp to assist in flotation... a frother chemical that can assist in generating a froth of air bubbles

Methodology Applied

Scientific EffectSurface tension reduction: Surfactant

Implementation Method 2

a collector chemical (e.g. amines) that can interact with the desired material... Minerals adhering to the froth are removed and further processed

Methodology Applied

Scientific EffectHydrophobic interaction: Hydrophobe

Data Source

PatentUS11554378B2Flotation oils, processes and uses thereof

Publication Date: 2023.01.17 ENVIROLLEA

AI summary

The present disclosure relates to flotation oils, processes for making such flotation oils, and uses thereof for example in the froth flotation of ores such as sylvinite ores to recover potassium chloride.