Molybdenum Separation Using Polymeric Media Without Air
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Solution Overview
Problem
The existing molybdenum flotation process is inefficient due to the requirement of air, which oxidizes sodium hydrosulfide, leading to higher pH levels, slower kinetics, and increased separation costs, as well as issues with hydraulic entrainment and froth handling, resulting in complex and costly operations.
Innovation Solution
A copper/molybdenum separation processor using engineered polymeric hydrophobic media, such as beads or bubbles, to separate molybdenite from copper and other minerals without the need for air, reducing entrainment and simplifying materials handling by eliminating the froth phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If air is used in the flotation process, then oxygen is supplied for oxidation reactions, but sodium hydrosulfide is oxidized leading to higher pH levels, slower kinetics, and increased separation costs
Solution Approach 1:
The patent replaces air (oxidizing atmosphere) with an inert atmosphere using nitrogen gas. This prevents the oxidation of sodium hydrosulfide while maintaining the flotation process, thereby avoiding pH increases and kinetic slowdowns. The inert environment eliminates harmful oxidation reactions that occur with air, directly resolving the contradiction between providing oxidation capability and maintaining productivity.
2Manufacturing precision
If traditional flotation methods are used, then separation can be achieved, but hydraulic entrainment occurs and froth handling becomes complex and costly
Solution Approach 1:
The patent extracts and eliminates the froth phase from the flotation process by using a different separation mechanism that does not rely on air bubbles and froth formation. This removes the source of hydraulic entrainment and simplifies materials handling, as the separation occurs without the complex froth phase that requires specialized handling equipment and procedures.
3Quantity of substance
If byproduct molybdenum concentrates are used, then production costs are reduced, but contaminant levels (especially copper) are higher requiring more stringent purification
Solution Approach 1:
The patent changes the chemical parameters of the flotation process by using an inert atmosphere and modified reagent chemistry. This alters the selectivity of the separation process, enabling it to achieve higher purity concentrations even from byproduct feeds with high copper content. The parameter changes in the flotation chemistry allow for better discrimination between molybdenite and copper minerals, resolving the contradiction between cost efficiency and purity requirements.
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 significantly reduces sodium hydrosulfide consumption, increases process selectivity, simplifies materials handling, eliminates the need for redundant thickening stages, and allows for higher percent solids processing, thereby improving molybdenum recovery efficiency and reducing operational costs.
Implementation Method 1
engineered polymeric hydrophobic media, such as beads or bubbles, to separate molybdenite from copper and other minerals without the need for air
Data Source
AI summary
A copper/molybdenum separation processor is provide featuring a slurry/media mixture stage configured to receive a conditioned pulp containing hydrophobic molybdenite and hydrophilic copper, iron and other minerals that is conditioned with sodium hydrosulfide together with an engineered polymeric hydrophobic media, and provide a slurry/media mixture; and a slurry/media separation stage configured to receive the slurry/media mixture, and provide a slurry product having a copper concentrate and a polymerized hydrophobic media product having a molybdenum concentrate that are separately directed for further processing. The slurry/media mixture stage include a molybdenum loading stage configured to contact the conditioned pulp with the engineered polymeric hydrophobic media in an agitated reaction chamber, and load the hydrophobic molybdenite on the engineered polymeric hydrophobic media.