Selective Recirculation Circuit for Mineral Processing
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Solution Overview
Problem
Conventional mineral processing for base metals, particularly copper sulfide beneficiation, is energy-intensive due to the need for fine grinding, which increases energy requirements exponentially and compromises recovery in downstream froth flotation processes, leading to high operational costs and water usage.
Innovation Solution
The implementation of a selective recirculation circuit with polymer-coated media that allows for higher sulfide mineral recovery without particle detachment, operating at higher pulp percent solids, reducing water and energy requirements, and optimizing comminution processes by recycling only particles with exposed hydrophobic faces back to grinding stages, thereby reducing the amount of work needed in comminution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine grinding is performed to expose sulfide mineral crystals, then mineral liberation is improved, but energy consumption increases exponentially
Solution Approach 1:
The patent applies preliminary classification before grinding to separate already-liberated particles from those requiring further size reduction. By using a classifier to identify and remove liberated particles before they enter the grinding circuit, the system performs size reduction only on particles that need it, avoiding unnecessary energy consumption on already-sufficiently-liberated particles while maintaining high overall mineral liberation efficiency
Solution Approach 2:
The patent implements a closed-loop feedback system where classified particles are analyzed and information about their liberation state is used to control the grinding process. The classifier provides feedback on particle size and liberation status, allowing the system to dynamically adjust grinding parameters and recirculate only those particles that require further size reduction, thereby optimizing energy utilization while achieving target liberation levels
2Productivity
If particle size is reduced to improve flotation recovery, then mineral recovery is improved, but water consumption increases due to thickening requirements
Solution Approach 1:
The patent extracts and removes already-liberated particles from the grinding circuit through preliminary classification before flotation. By separating these particles and directing them straight to flotation without requiring them to pass through the thickening stage, the system eliminates the water consumption associated with thickening these specific particles while maintaining their contribution to overall flotation recovery
Solution Approach 2:
The patent performs preliminary classification and separation of liberated particles before the flotation stage. This preliminary action identifies and isolates particles that have achieved sufficient liberation, allowing them to bypass subsequent water-intensive processing stages like thickening, thereby reducing overall water consumption while preserving flotation recovery efficiency
3Productivity
If recirculation of all ground material is performed to maximize recovery, then mineral recovery is improved, but energy consumption increases due to redundant grinding
Solution Approach 1:
The patent uses feedback from the classification stage to control recirculation. The classifier provides real-time information about which particles have achieved sufficient liberation, and this feedback is used to selectively recirculate only those particles that require further size reduction. This feedback-controlled approach maintains high mineral recovery by ensuring all potentially recoverable particles are processed, while eliminating redundant energy consumption by avoiding recirculation of already-sufficiently-liberated particles
Solution Approach 2:
The patent applies partial recirculation rather than recirculating all ground material. By using the classifier to identify and separate particles that have achieved adequate liberation, the system performs recirculation action only on the necessary subset of particles that require further size reduction, avoiding excessive energy consumption on particles that have already met liberation requirements while maintaining overall recovery efficiency
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 capital and operating costs, energy consumption, and water requirements while maintaining high sulfide mineral recovery rates by optimizing the comminution and flotation processes, allowing for more efficient mineral processing.
Implementation Method 1
a plurality of polymer-coated media having hydrophobic surfaces to attract mineral particles in a slurry
Implementation Method 2
a connected pipe manifold configured to extend a path of the flow from the loading compartment to the separation compartment so as to enhance loading of the polymer-coated media with the mineral particles
Data Source
Figure 1
Figure 2~2a
Figure 3
AI summary
A modified selective recirculation circuit has a loading stage, a stripping stage and a filtering stage for use in processing a feed stream or slurry containing mineral particles. The stripping stage forms a first loop with the loading stage, a second loop with the filtering stage. The loading stage has a loading mixer and 5 a loading washing screen. The stripping stage has a stripping mixer and a stripping washing screen. The loading mixer receives the slurry and causes barren media in the circuit to contact with the slurry so that the mineral particles in the slurry are loaded onto the barren media. The media is directed to the stripping stage where the mineral particles are removed 10 from the media. The barren media is recycled to the loading stage. The stripping solution recovered from the filtering stage is returned to the stripping stage and the mineral particles are discharged as concentrate.