Ultra-Fine Falcon Concentration for Bastnaesite-Calcite Separation
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Solution Overview
Problem
Existing methods struggle to efficiently separate carbonate gangue from bastnaesite in rare earth element ores, particularly when the mineralogy is ultra-fine, leading to challenges in achieving high recovery and grade without significant losses.
Innovation Solution
The use of Ultra-Fine Falcon centrifugal concentrators, which are designed to handle fine particle sizes and high G-forces, allows for selective separation of bastnaesite from calcite by achieving up to 90% REO recovery and 30% calcite rejection through optimized parameters such as pulp density and RPM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional gravity separation methods are used to separate bastnaesite from carbonate gangue, then the process is simple and equipment is readily available, but the recovery and grade are insufficient for ultra-fine mineralogy
Solution Approach 1:
The patent applies parameter changes by modifying the operating conditions of the centrifugal concentrator, specifically using high G-forces (up to 600g) and optimized pulp densities (15-20% solids) to achieve effective separation of ultra-fine bastnaesite particles from carbonate gangue, thereby resolving the contradiction between recovery and separation efficiency
Solution Approach 2:
The patent replaces traditional gravity separation mechanics with centrifugal separation mechanics, using a spinning bowl that generates high G-forces to enhance the separation capability for ultra-fine particles, thus improving both productivity and manufacturing precision simultaneously
2Productivity
If flotation circuits are used to separate bastnaesite from gangue, then recovery can be improved, but carbonate gangue rejection remains challenging and losses occur
Solution Approach 1:
The patent merges flotation circuits with centrifugal concentration to create a hybrid separation system, where flotation provides initial recovery enhancement and centrifugal concentration delivers precise gangue rejection, thereby simultaneously improving REO recovery while minimizing gangue losses
Solution Approach 2:
The centrifugal concentrator acts as an intermediary between flotation and final product recovery, taking flotation concentrate as input and delivering high-grade, low-gangue final concentrate, thus resolving the contradiction between recovery improvement and gangue rejection
3Manufacturing precision
If ultra-fine particle sizes are processed to improve liberation, then grade can be enhanced, but separation becomes more difficult and losses increase
Solution Approach 1:
The patent applies parameter changes by using high G-forces (up to 600g) in the centrifugal concentrator, which enables effective separation of ultra-fine liberated particles that would be too fine for traditional gravity methods, thus achieving both high grade and high recovery simultaneously
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 Ultra-Fine Falcon concentrator effectively achieves high REO recovery while rejecting calcite, demonstrating a significant improvement over traditional methods, making it suitable for use in conjunction with flotation circuits.
Implementation Method 1
The use of Ultra-Fine Falcon centrifugal concentrators, which are designed to handle fine particle sizes and high G-forces, allows for selective separation of bastnaesite from calcite
Implementation Method 2
designed to handle fine particle sizes and high G-forces
Data Source
AI summary
Disclosed herein are methods, devices, and systems for effectively separating carbonate gangue from bastnaesite without sacrificing significant REO grade or recovery. In some embodiments, centrifugal concentrators may beneficiate Ultra-Fine (UF) bastnaesite and calcite bearing flotation concentrates. The disclosed methods, devices, and systems can achieve initial gravity REO recoveries exceeding 90% while rejecting on the order of 25% to 35% of the total calcium from an assortment of rougher and cleaner flotation concentrates. Addition of stages of cleaner UF Falcon gravity separation may be operated in an open circuit configuration, from an original fine feed of 35 microns containing 50.5% REO and 5.5% Ca, to upgrade up to approximately 59% REO and 2.0% calcium. The disclosed methods, devices, and systems may comprise UF gravity concentration that may provide for recovery of rare earth oxides at levels of greater than 70%, 80% and 90%, while also rejecting more than 15%, 20%, 25%, 30, or 35% of the total calcium. Also described are benefication of fine feed of 35 microns containing 50.5% REO and 5.5% Ca, to approximately 59% REO and 2.0% calcium. In some embodiments, the disclosed methods, compounds, and systems may be used to complement existing or modified flotation systems.