Low Grade Uranium Ore Beneficiation via Size-Based Segmentation
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Solution Overview
Problem
Current methods for processing low-grade uranium ores are economically sub-viable due to high capital and operating costs associated with downstream processing, as they require large volumes of low-concentration feedstock, which is inefficient and costly, especially for ores with restricted mineral phase liberation at selected particle sizes.
Innovation Solution
A two-stage beneficiation process involving wet scrubbing to separate low-grade uranium ore into fine and coarse fractions, followed by size separation to produce an intermediate concentrate, which is then further processed to achieve a high-grade concentrate, significantly reducing the mass and volume of material for downstream leaching, thereby enhancing economic viability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional froth flotation procedures are used to process low-grade uranium ores, then uranium concentrate can be recovered, but the process complexity and capital costs increase significantly
Solution Approach 1:
The patent divides the beneficiation process into distinct size-based separation stages: coarse fraction (>0.5mm) processed by heavy media separation, intermediate fraction (0.25-0.5mm) processed by flotation, and fine fraction (<0.25mm) processed by hydrocyclones. This segmentation allows each stage to be optimized for its specific particle size range, reducing overall process complexity while maintaining uranium recovery efficiency
Solution Approach 2:
The patent applies preliminary size classification before the main separation processes. By using screens and hydrocyclones to pre-sort particles by size, the material is prepared in advance for the appropriate separation method, reducing the complexity of the subsequent flotation and heavy media separation circuits
2Quantity of substance
If large volumes of low-grade ore are processed to achieve sufficient uranium recovery, then uranium mass can be recovered, but capital and operating costs increase
Solution Approach 1:
The patent changes the physical parameters of the feed material by size classification, directing different size fractions to different separation processes optimized for their specific characteristics. This parameter-based routing improves the efficiency of uranium recovery per tonne of ore processed, reducing the overall volume of material that needs to be handled and the associated capital and operating costs
3Quantity of substance
If heavy media separation and flotation are combined to process low-grade ores, then uranium concentration can be improved, but the process becomes sub-economic
Solution Approach 1:
The patent applies different separation methods tailored to the local characteristics of each particle size fraction. Coarse particles (>0.5mm) are directed to heavy media separation where density differences are most effective, while fine particles (<0.25mm) are directed to hydrocyclones where size-based separation is more efficient. This localized optimization of separation methods for each fraction improves overall uranium concentration while maintaining economic viability
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
The process effectively upgrades uranium concentration, reducing the mass and volume of material processed, leading to lower capital and operating costs, improved efficiency, and increased uranium recovery, making the extraction of uranium from low-grade ores commercially viable.
Implementation Method 1
wet scrubbing the low grade uranium ore to separate the low grade ore into a fine fraction and a coarse fraction
Implementation Method 2
screening the fine fraction according to a size separation parameter to provide an undersize fraction and an oversize fraction
Data Source
AI summary
The disclosure relates to a beneficiation process for low grade uranium ore, wherein the process comprises a primary beneficiation stage comprising: wet scrubbing the low grade uranium ore to separate the low grade ore into a fine fraction and a coarse fraction; screening the fine fraction according to a size separation parameter to provide an undersize fraction and an oversize fraction, wherein the uranium predominantly reports to the undersize fraction; and separating the undersize fraction to produce an intermediate uranium concentrate. The intermediate uranium concentrate may be further processed in a secondary beneficiation stage to produce a high grade uranium concentrate.