Sensor-Based Trona Ore Sorting for High-Purity Products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing trona ore processing methods struggle to efficiently separate high-grade and ultra-high-grade trona ore from impurities, leading to reduced economic value and increased processing costs.
Innovation Solution
Employing sensor-based sorting systems, including laser scanners and X-ray transmission, to analyze trona ore particles for absorption, fluorescence, and reflectance characteristics, and using high-pressure air jets to separate high-grade and ultra-high-grade ore from gangue material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional ore processing methods are used to separate trona ore from impurities, then the processing cost increases and economic value decreases, but the separation efficiency and purity achievement are insufficient
Solution Approach 1:
The system performs preliminary classification of ore particles before full processing by using sensors to identify high-grade vs low-grade ore, directing only high-grade material through the complex separation system while sending low-grade material to standard processing, thus reducing overall system complexity requirements
Solution Approach 2:
The patent replaces traditional mechanical separation methods with sensor-based identification systems (X-ray transmission, laser scanning, optical sensors) that use electromagnetic radiation and optical properties to detect ore composition and grade, achieving higher measurement precision without proportionally increasing mechanical system complexity
2Manufacturing precision
If sensor-based sorting systems are implemented to separate high-grade and ultra-high-grade trona ore, then the purity increases and economic value increases, but the equipment complexity and initial investment increase
Solution Approach 1:
The sorting system is divided into multiple independent sensor modules (X-ray transmission sensors, laser scanners, optical sensors) that each perform specific detection functions, allowing the complex separation task to be distributed across simpler, specialized components rather than requiring one monolithic complex system
Solution Approach 2:
The system achieves high purity separation by measuring and utilizing multiple physical parameters of the ore particles simultaneously (X-ray absorption characteristics, laser reflectance, optical properties), allowing differentiation of ore grades based on composite parameter analysis rather than relying on a single complex measurement system
3Productivity
If high-pressure air jets are used to separate ore particles, then the separation speed increases and productivity improves, but the energy consumption increases
Solution Approach 1:
The system applies high-pressure air jets only to particles identified as requiring separation (low-grade or contaminated ore), rather than applying energy-intensive separation to all particles uniformly, thus achieving high productivity for the fraction that needs it while reducing overall energy consumption
Solution Approach 2:
The patent utilizes pneumatic ejection systems (high-pressure air jets) as the separation mechanism, leveraging gas pressure to physically separate and eject identified particles from the processing stream, enabling rapid separation without mechanical contact and maintaining high processing speeds
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
Achieves high-purity trona ore with greater than 98% purity, reducing waste and increasing the economic value of the ore by effectively removing impurities, thereby enhancing the efficiency and profitability of trona processing.
Implementation Method 1
analyze trona ore particles for absorption, fluorescence, and reflectance characteristics
Implementation Method 2
analyze trona ore particles for absorption, fluorescence, and reflectance characteristics
Implementation Method 3
analyze trona ore particles for absorption, fluorescence, and reflectance characteristics
Implementation Method 4
Employing sensor-based sorting systems, including laser scanners and X-ray transmission
Implementation Method 5
analyze trona ore particles for absorption, fluorescence, and reflectance characteristics
Implementation Method 6
using high-pressure air jets to separate high-grade and ultra-high-grade ore from gangue material
Data Source
AI summary
An ore-sorting system includes a trona ore screen system, the trona ore screen system including an ore crusher and a filter. The screen system is configured to produce an ore feed comprising ore particles having a predetermined size. The ore sorting system further includes a beneficiation system that receives the ore particles having a predetermined size, the beneficiation system configured to increase an economic value of the trona ore by removing gangue material, resulting in a high-grade ore product. The beneficiation system includes a laser scanner. The ore sorting system also includes a sorter configured to separate the high-grade ore product from the gangue material. The sorter includes an identification system configured to accept or reject ore. The accepted ore is deposited in a bin and rejected ore is ejected with a high-pressure air jet.