Hydrolyzed Starch Grinding Aids for Mineral Ore Slurry Rheology
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Solution Overview
Problem
The mineral processing industry faces inefficiencies and high energy consumption in grinding mineral ore, with existing grinding aids not fully addressing the need for reduced energy use and environmental impact, particularly in the comminution process.
Innovation Solution
The use of hydrolyzed starch as a grinding aid, specifically non-ionic low molecular weight species like dextrin, maltodextrin, and corn syrup solids, added to mineral ore slurry to reduce stickiness, energy consumption, and viscosity, enhancing flowability and throughput during the grinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional grinding aids are used to facilitate ore grinding, then grinding efficiency is improved, but energy consumption increases and environmental harm occurs
Solution Approach 1:
The patent changes the chemical parameters of grinding aids by using hydrolyzed starch with specific molecular weights (10,000-100,000 g/mol) and degrees of substitution (0.3-1.7), optimizing the balance between grinding efficiency and energy consumption. This parameter optimization allows effective grinding while reducing overall energy requirements compared to conventional additives.
Solution Approach 2:
The patent employs composite starch molecules with specific structural characteristics (hydrolyzed starch containing both crystalline and amorphous regions) to achieve multiple functions simultaneously: facilitating grinding, reducing energy consumption, and minimizing environmental impact. The composite nature of the modified starch provides synergistic effects that resolve the contradiction between efficiency and energy use.
2Productivity
If conventional grinding aids are used to facilitate ore grinding, then grinding efficiency is improved, but environmental harm increases
Solution Approach 1:
The patent uses biodegradable hydrolyzed starch as a temporary grinding aid that performs its function during the grinding process and then decomposes naturally without persisting in the environment. This approach allows effective grinding while eliminating long-term environmental contamination, as the starch-based additive breaks down into harmless substances after use.
Solution Approach 2:
The patent modifies the chemical structure of starch through controlled hydrolysis and substitution to create an additive that is both effective for grinding and environmentally benign. By adjusting parameters such as molecular weight, degree of substitution, and hydrolysis level, the patent achieves optimal performance while ensuring the additive degrades safely in the environment, resolving the contradiction between efficiency and environmental harm.
3Productivity
If hydrolyzed starch is added to reduce slurry viscosity and improve flowability, then throughput increases, but additive consumption increases
Solution Approach 1:
The patent optimizes the concentration and molecular weight parameters of hydrolyzed starch to achieve maximum flowability improvement at minimum additive levels. By carefully controlling the degree of hydrolysis and substitution, the patent enhances slurry flow properties with lower additive dosages, reducing consumption while maintaining high throughput.
Solution Approach 2:
The patent uses composite hydrolyzed starch structures with specific molecular weight distributions and substitution patterns that provide superior flow modification efficiency per unit of additive. The composite nature of the modified starch allows it to interact more effectively with slurry components, achieving better flowability with reduced quantities compared to conventional additives.
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
Hydrolyzed starch compositions decrease the energy required for grinding, improve slurry flowability, and increase throughput, reducing downtime and energy costs while minimizing environmental impact by preventing agglomeration and improving ore recovery efficiency.
Implementation Method 1
use of a composition comprising a hydrolyzed starch for reducing the stickiness, energy of grinding, yield stress and/or the viscosity of an aqueous mineral ore slurry
Implementation Method 2
hydrolyzed starch compositions decrease the energy required for grinding
Implementation Method 3
minimizing environmental impact by preventing agglomeration and improving ore recovery efficiency
Data Source
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AI summary
Grinding aid compositions comprising hydrolyzed starches, such as dextrin, maltodextrin or corn syrup solids. The grinding aid compositions are typically added to various mineral ore slurries prior to grinding operations to affect the rheology characteristics of the mineral ore slurries.