Grain Size Analysis for Real-Time Mineral Content
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Solution Overview
Problem
Current methods for real-time measurement of particle and mineral contents in mineral separation processes, especially for light-weight elements and minerals, face challenges such as limited precision, high costs, and complexity in wet and dry processes, particularly in controlling separation processes like flotation, gravity separation, and electrostatic separation.
Innovation Solution
A method utilizing grain size analysis to calculate element and mineral content by defining grain size distribution through techniques like X-Ray diffraction, ultrasonic absorption, or optical image analysis, allowing for real-time process control in mineral separation processes, where a representative sample is analyzed to determine the cumulative grain size distribution and then mathematically calculate the content using calibration models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If X-Ray fluorescence is used to measure element contents in mineral processes, then measurement can be carried out directly from mineral slurry, but measurement precision is limited and only works reliably for elements heavier than silicon in dry processes
Solution Approach 1:
The patent replaces X-Ray fluorescence measurement with grain size analysis using laser diffraction or optical image analysis. This substitution enables accurate measurement of light-weight elements and minerals that XRF cannot detect, while maintaining direct online measurement capability from slurry without requiring sample processing.
Solution Approach 2:
The patent changes the measurement parameter from element-specific X-Ray fluorescence signals to grain size distribution parameters. By measuring grain size distribution and using calibration models, the system can determine content of various elements and minerals including light-weight ones, overcoming the elemental mass limit of XRF.
2Quantity of substance
If Prompt Gamma Neutron Activation Analysis is used to measure light-weight elements directly from slurry, then measurement can be performed on large sample volumes, but measurement duration becomes immoderately long and equipment becomes expensive and difficult to maintain
Solution Approach 1:
The patent replaces PGNAA with laser diffraction or optical image analysis for grain size measurement. This substitution dramatically reduces measurement time from minutes to seconds while maintaining the ability to measure light-weight elements, and eliminates the need for complex radiation safety infrastructure.
Solution Approach 2:
The patent uses inexpensive laser diffraction or optical imaging equipment instead of expensive PGNAA systems. The measurement apparatus is simpler, cheaper to buy and maintain, and can be easily replaced if needed, while providing faster and sufficiently accurate measurements.
3Adaptability or versatility
If X-Ray diffraction is used for online measurement of element and mineral contents, then analysis can be made directly from slurry or dry matter, but measurement speed is slow and analytic accuracy is poor
Solution Approach 1:
The patent replaces X-Ray diffraction with laser diffraction or optical image analysis. These alternative methods provide faster measurement speeds suitable for real-time process control while maintaining the ability to analyze both slurry and dry matter directly, and improve analytic accuracy for grain size distribution.
4Measurement precision
If optical spectroscopy methods are used for content measurement, then high expenses are incurred, but measurement repeatability is poor
Solution Approach 1:
The patent replaces optical spectroscopy with laser diffraction or optical image analysis. These methods provide consistent, repeatable measurements of grain size distribution that can be performed rapidly and reliably in an online setting, eliminating the poor repeatability issues of optical spectroscopy while maintaining measurement precision.
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
Enables accurate and cost-effective real-time monitoring of particle and mineral contents, improving process control by providing immediate data for optimizing feed, product, and side product compositions in mineral separation processes, thereby enhancing yield and quality.
Implementation Method 1
grain size distribution is defined by methods based on X-Ray diffraction
Implementation Method 2
grain size distribution is defined by methods based on ultrasonic absorption
Implementation Method 3
content measurement methods based on optical spectroscopy
Implementation Method 4
Prompt Gamma Neutron Activation_analysis_(PGNAA)
Data Source
AI summary
The invention relates to a method for defining particle and/or mineral content in real time in a mineral separation process from finely divided particle material flowing either in solid or slurry-like form, so that from the particle material, there is extracted a representative sample, which sample is then subjected to grain size analysis, on the basis of which there is calculated the element and/or mineral content of the particle material.