High Intensity Conditioning for Enhanced Mineral Separation

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Solution Overview

Problem

Traditional flotation methods for separating valuable mineral particles from unwanted material in pulp slurries face challenges in controlling air bubble surface area flux and size distribution, leading to inefficient separation processes.

Innovation Solution

The use of an enhanced mineral separation system incorporating a high intensity conditioning operation and a collection apparatus with functionalized polymers to attract mineral particles, eliminating the need for air bubbles by applying various forms of high intensity energy such as mechanical, acoustic, or ultrasonic energy before or after mineral separation processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional flotation methods using air bubbles are used for mineral separation, then the separation process can be performed, but the air bubble surface area flux and size distribution cannot be controlled reliably

Engineering Contradiction:

Improvemineral separation efficiencyVSAvoidair bubble surface area flux control

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces the air bubble-based flotation system with a magnetic field-based separation system. Instead of using air bubbles to carry mineral particles to the surface, the invention uses magnetic fields to selectively attract and separate magnetic mineral particles from the pulp slurry, eliminating the need to control air bubble surface area flux and size distribution.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental separation parameter from air bubble dynamics (surface area flux, size distribution) to magnetic field strength and particle magnetic susceptibility. This parameter transformation enables reliable control of the separation process through measurable and adjustable magnetic field parameters rather than difficult-to-control air bubble parameters.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high intensity conditioning is applied prior to mineral separation, then surface interactions and liberation of minerals are improved, but energy consumption increases

Engineering Contradiction:

Improvemineral recovery rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent applies high intensity conditioning as a preliminary treatment step before the main magnetic separation process. This conditioning step enhances surface interactions and mineral liberation to improve subsequent separation efficiency and recovery rates, justifying the energy input by producing better separation outcomes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The high intensity conditioning step involves changing physical parameters of the mineral particles and pulp slurry surface properties through energy input (mechanical, acoustic, ultrasonic, or thermal). These parameter changes enhance the magnetic susceptibility and surface characteristics of mineral particles, making them more responsive to the magnetic field and improving overall separation efficiency.

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

This approach enhances the recovery rate of valuable minerals, reduces energy and water requirements, and decreases capital costs by improving surface interactions and liberation of minerals without particle detachment, resulting in more efficient and cost-effective mineral separation.

Implementation Method 1

a collection surface configured with a functionalized polymer comprising a plurality of molecules having a functional group configured to attract the mineral particles of interest to the collection surface

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

The types of energy used may include any or all of the following: mechanical, acoustic, ultrasonic, hydrodynamic and/or pneumatic, cavitation, electrostatic, microwave, mechanical shear, mechanical abrasion, impact, mechanical agitation, thermal or electromagnetic.

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS11247214B2High intensity conditioning prior to enhanced mineral separation process

Publication Date: 2022.02.15 CIDRA CORP SERVICES INC

AI summary

A system for separating mineral particles of interest from an ore features mineral processing operations/stages/circuits configured to receive an ore, or mineral particles or concentrates formed by processing the ore, and provide processed mineral particles or concentrates, or a waste stream, for further enhanced mineral separation downstream processing; an enhanced mineral separation processor having a collection apparatus located therein, the collection apparatus having a collection surface configured with a functionalized polymer including molecules having a functional group configured to attract the mineral particles of interest to the collection surface, the enhanced mineral separation processor receive the processed mineral particles or concentrates, or the waste stream, and provide further enhanced downstream processed mineral particles or concentrates, or a further enhanced downstream processed waste stream; and a high intensity conditioning operation, stage or circuit configured to apply a high intensity form of energy to the processed mineral particles or concentrates, or the waste stream, prior to further enhanced mineral separation downstream processing by the enhanced mineral separation processor.