Carrier-Magnetic Separation for Mineral Processing
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Solution Overview
Problem
Current mineral processing methods, particularly carrier-magnetic-separation, face inefficiencies in concentrating desired particles, leading to high concentrations of undesired material, high energy consumption, and the use of toxic chemicals.
Innovation Solution
A process involving the addition of hydrophobic magnetic particles to a feedstock containing desired and undesired particles, followed by agglomeration, separation, desagglomeration, and further separation methods such as magnetic, electric, or gravity separation to isolate and recycle the magnetic particles, with optional re-introduction to enhance separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If carrier-magnetic-separation is used to concentrate desired particles, then separation is achieved, but high concentrations of undesired material remain in the product
Solution Approach 1:
The patent introduces a carrier particle as an intermediary that selectively binds to desired particles through hydrophobic interactions. The carrier particle acts as a mediator that transports desired particles through the magnetic separation process while leaving undesired material behind, thereby improving concentration precision without co-concentrating undesired material.
Solution Approach 2:
The patent segments the separation process into distinct stages: selective binding of desired particles to carrier particles, magnetic separation of carrier-particle complexes, and subsequent release of desired particles from carriers. This segmentation allows for precise control over which particles are concentrated, excluding undesired material.
2Manufacturing precision
If multiple separation steps are used to improve concentration, then desired particles are better separated, but energy consumption increases
Solution Approach 1:
The patent combines multiple separation functions into a single integrated process. The carrier particle enables simultaneous实现 of selective binding, magnetic responsiveness, and separation in one system, replacing what would traditionally require multiple separate separation steps, thereby reducing overall energy consumption while maintaining high separation efficiency.
Solution Approach 2:
The carrier particle serves multiple functions simultaneously: it selectively binds desired particles, provides magnetic responsiveness for separation, and facilitates particle release. This multi-functionality consolidates what would otherwise require multiple separate processes into one operation, reducing energy consumption.
3Manufacturing precision
If traditional separation methods are used, then separation is achieved, but toxic chemicals must be used
Solution Approach 1:
The patent replaces chemical-based separation methods with a mechanical/magnetic-based system. Instead of using toxic chemicals to differentiate and separate particles, the invention uses hydrophobic interactions for selective binding and magnetic fields for separation, eliminating the need for toxic chemical reagents while maintaining effective separation capability.
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
This process improves the efficiency of mineral processing by reducing undesired material concentration, lowering energy requirements, and minimizing the use of toxic chemicals, thereby enhancing the recovery of valuable minerals.
Implementation Method 1
adding hydrophobic magnetic particles to the feedstock which results in a loaded feedstock containing agglomerates of the magnetic particles and the desired particles or of the magnetic particles and the undesired material
Implementation Method 2
separating the agglomerates from the loaded feedstock by a separation method which results in isolated agglomerates, where the separation method is selected from sorting, electric separation, magnetic separation
Implementation Method 3
separating the magnetic particles from the suspension obtained in step d) by a separation method selected from sorting, electric separation, magnetic separation
Implementation Method 4
separating the agglomerates from the loaded feedstock by a separation method which results in isolated agglomerates, where the separation method is selected from sorting, electric separation, magnetic separation, screening, classification, gravity concentration
Implementation Method 5
separating the agglomerates from the loaded feedstock by a separation method which results in isolated agglomerates, where the separation method is selected from sorting, electric separation, magnetic separation, screening, classification, gravity concentration, and flotation
Data Source
AI summary
A process for concentrating desired particles containing a carrier-magnetic-separation with the following steps, providing a feedstock which contains the desired particles; adding hydrophobic magnetic particles to the feedstock which results in a loaded feedstock containing agglomerates of the magnetic particles and the desired particles or of the magnetic particles and the undesired material; separating the agglomerates from the loaded feedstock by a separation method which results in isolated agglomerates, breaking up the isolated agglomerates to obtain a suspension having magnetic particles in de-agglomerated form; and separating the magnetic particles from the suspension obtained in step d) by a separation method and provided that at least one separation method is a magnetic separation, and where the process has at least one further separation and where the further separation is s sorting, electric separation, screening, classification, gravity concentration, and flotation.