Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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POLYMER COATING FOR SELECTIVE SEPARATION OF HYDROPHOBIC
PARTICLES IN AQUEOUS SLURRY
Cross-Reference to Related Patent Applications
The present application claims the benefit of U.S. Provisional Patent
Application
No. 62/416,314, filed 02 November 2016, entitled "Polymer coating for the
selective
separation of hydrophobic particles in aqueous slurry", which is incorporated
by
reference herein in its entirety.
The present application is also a continuation-in-part application of pending
application PCT/U512/39534, filed 25 May 2012 (Docket No. 712-002.359-1/CCS-
0087), entitled "Mineral separation using functionalized membrane", which
claims the
benefit of U.S. provisional application No. 61/489,893, filed 25 May 2011 and
U.S.
provisional application No. 61/533,544, filed 12 September 2011, which are all
incorporated by reference herein in their entirety.
This application is also related to a family of eight PCT applications, which
were
all concurrently filed on 25 May 2012, as follows:
PCT application no. PCT/US12/39528 (Atty docket no. 712-002.356-1), entitled
"Flotation separation using lightweight synthetic bubbles and beads;"
PCT application no. PCT/US12/39540 (Atty docket no. 712-002.359-2), entitled
"Mineral separation using sized, weighted and magnetized beads;"
PCT application no. PCT/US12/39576 (Atty docket no. 712-002.382), entitled
"Synthetic bubbles/beads functionalized with molecules for attracting or
attaching to
mineral particles of interest," which corresponds to U.S. Patent No.
9,352,335;
PCT application no. PCT/US12/39591 (Atty docket no. 712-002.383), entitled
"Method and system for releasing mineral from synthetic bubbles and beads;"
PCT application no. PCT/US/39596 (Atty docket no. 712-002.384), entitled
"Synthetic bubbles and beads having hydrophobic surface;"
PCT application no. PCT/US/39631 (Atty docket no. 712-002.385), entitled
"Mineral separation using functionalized filters and membranes," which
corresponds to
U.S. Patent No. 9,302,270;"
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PCT application no. PCT/US12/39655 (Atty docket no. 712-002.386), entitled
"Mineral recovery in tailings using functionalized polymers;" and
PCT application no. PCT/US12/39658 (Atty docket no. 712-002.387), entitled
"Techniques for transporting synthetic beads or bubbles In a flotation cell or
column," all
of which are incorporated by reference in their entirety.
This application also related to PCT application no. PCT/US2013/042202 (Atty
docket no. 712-002.389-1/CCS-0086), filed 22 May 2013, entitled "Charged
engineered
polymer beads/bubbles functionalized with molecules for attracting and
attaching to
mineral particles of interest for flotation separation," which claims the
benefit of U.S.
Provisional Patent Application No. 61/650,210, filed 22 May 2012, which is
incorporated
by reference herein in its entirety.
This application is also related to PCT/U52014/037823, filed 13 May 2014,
entitled "Polymer surfaces having a siloxane functional group," which claims
benefit to
U.S. Provisional Patent Application No. 61/822,679 (Atty docket no. 712-
002.395/CCS-
0123), filed 13 May 2013, which is incorporated by reference herein in its
entirety.
This application also related to PCT application no. PCT/US13/28303 (Atty
docket no. 712-002.377-1/CCS-0081/82), filed 28 February 2013, entitled
"Method and
system for flotation separation in a magnetically controllable and steerable
foam," which
is also hereby incorporated by reference in its entirety.
This application also related to PCT application no. PCT/US16/57334 (Atty
docket no. 712-002.424-1/CCS-0151), filed 17 October 2016, entitled
"Opportunities for
recovery augmentation process as applied to molybdenum production," which is
also
hereby incorporated by reference in its entirety.
This application also related to PCT application no. PCT/US16/37322 (Atty
docket no. 712-002.425-1/CCS-0152), filed 17 October 2016, entitled "Mineral
beneficiation utilizing engineered materials for mineral separation and coarse
particle
recovery," which is also hereby incorporated by reference in its entirety.
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Background of the Invention
1. Technical Field
This invention relates generally to a method and apparatus for separating
valuable material from unwanted material in an aqueous mixture, such as a pulp
slurry.
2. Description of Related Art
In many industrial processes, flotation is used to separate valuable or
desired
material from unwanted material. By way of example, in this process a mixture
of
water, valuable material, unwanted material, chemicals and air is placed into
a flotation
cell. The chemicals are used to make the desired material hydrophobic, as well
as to
aid the formation of bubbles and the stability of the froth, and the air is
used to carry the
material to the surface of the flotation cell. When the hydrophobic material
and the air
bubbles collide they become attached to each other. The bubble rises to the
surface
carrying the desired material with it.
The performance of the flotation cell is dependent on the bubble surface area
flux in the collection zone of the cell. The bubble surface area flux is
dependent on the
size of the bubbles and the air injection rate. Controlling the bubble surface
area flux
has traditionally been very difficult. This is a multivariable control problem
and there are
no dependable real time feedback mechanisms to use for control.
There is a need in the industry to provide a better way to separate valuable
material from unwanted material, e.g., including in such a flotation cell, so
as to
eliminate problems associated with using air bubbles in such a separation
process.
Summary of the Invention
The present invention provides a substrate for use in an aqueous slurry. The
substrate has a polymeric coating to provide a compliant and tacky surface.
The
polymeric coating also has a chemical to render the surface hydrophobic so as
to
attract hydrophobic or hydrophobized mineral particles in the slurry.
Thus, an aspect of the present invention is an apparatus, comprising:
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a substrate arranged to contact an aqueous slurry, the aqueous slurry
containing
minerals and unwanted materials, the minerals comprising hydrophobic or
hydrophobized mineral particles; and
a polymeric coating disposed on the substrate, the polymeric coating
comprising
a compliant and tacky surface, the polymer coating further comprising a
chemical to
render the compliant and tacky surface hydrophobic so as to attract the
hydrophobic or
hydrophobized mineral particles.
According to an embodiment of the present invention, the polymeric coating is
formed from a polymer selected from the group consisting of silicone;
acrylics; butyl
rubber; ethylene vinyl acetate; natural rubber; nitriles; styrene block
copolymers with
ethylene, propylene, and/or isoprene; polyurethanes; and polyvinyl ethers.
According to an embodiment of the present invention, the chemical comprises a
siloxane derivative.
According to an embodiment of the present invention, the polymeric coating
comprises a polymer modified with a material selected from the group
consisting of
tackifiers; plasticizers; crosslinking agents; chain transfer agents; chain
extenders;
adhesion promoters; aryl or alky copolymers; fluorinated copolymers and/or
additives;
hydrophobicizing agents such as hexamethyldisilazane; inorganic particles such
as
silica, hydrophobic silica, and/or fumed hydrophobic silica; MO resin; and /
or other
additives to control and modify the properties of the polymer.
According to an embodiment of the present invention, the polymer is further
modified with a chemical selected from the group consisting of with alkyl,
aryl, and/or
fluorinated functionalities; silica-based additives and other inorganics such
as clays
and/or bentonite; low molecular weight and oligomeric plasticizers; degrees of
crosslinking density and branchedness (polymer structure); and / or FOSS
materials.
According to an embodiment of the present invention, the polymeric coating has
a thickness ranged from 0.2 mils to 5.0 mils.
According to an embodiment of the present invention, the compliant and tacky
surface has a tacky scale as measured by loop track against polished stainless
steel
using PSTC-16 Method A with loop tack in a range of 5 to 600 grams-force.
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According to an embodiment of the present invention, the polymeric coating is
reacted with additional functionality including oxyhydryl, sulfhydryl, or
cationic
functionality found in mineral collectors.
According to an embodiment of the present invention, the substrate comprises a
flat surface, a belt, a bead, a mesh, a filter, an open-cell foam or an
impeller.
According to an embodiment of the present invention, the substrate can be an
open-cell foam made from reticulated polyurethane.
According to an embodiment of the present invention, the substrate comprises
an open-cell foam made from a material selected from the group consisting of
silicone,
polychloroprene, polyisocyanurate, polystyrene, polyolefin, polyvinylchloride,
epoxy,
latex, fluoropolymer, phenolic, EPDM, and nitrile.
According to an embodiment of the present invention, the substrate comprises a
three-dimensional open cellular structure made of hard plastic.
According to an embodiment of the present invention, the substrate comprises a
solid, hollow, or network structure made of glass, metal, ceramic or polymer.
According to an embodiment of the present invention, the minerals comprise
sulfide-based materials such as copper, gold, lead, zinc, nickel and iron.
According to an embodiment of the present invention, the minerals are further
hydrophobized by addition of collector chemicals to the aqueous slurry, such
as
xanthate, dithiophosphate, dithiophosphinate, dithiocarbamate,
thionocarbamate,
hydroxamates, amine ethers, primary amines, fatty acids and their salts.
Brief Description of the Drawing
Figure 1 includes Figure la and Figure lb, where Figure la is a side partial
cutaway view in diagram form of a separation processor configured with two
chambers,
tanks or columns having a functionalized polymer coated impeller arranged
therein
according to some embodiments of the present invention, and Figure lb is a top
partial
cross-sectional view in diagram form of a functionalized polymer coated
impeller
moving in an attachment rich environment contained in an attachment chamber,
tank or
column and also moving in a release rich environment contained in a release
chamber,
tank or column according to some embodiments of the present invention.
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Figure 2 is diagram of a separation processor configured with two chambers,
tanks or columns having a functionalized polymer coated conveyor belt arranged
therein according to some embodiments of the present invention.
Figure 3 is diagram of a separation processor configured with a functionalized
polymer coated filter assembly for moving between two chambers, tanks or
columns in
a semi-continuous batch process according to some embodiments of the present
invention.
Figure 4a shows at least part of a generalized solid-phase body, e.g., a
functionalized polymer coated member, according to some embodiments of the
present
.. invention.
Figure 4b illustrates an enlarged portion of the functionalized polymer coated
member showing a molecule or molecular segment for attaching a function group
to the
surface of the functionalized polymer coated member, according to some
embodiments
of the present invention.
Figures 5a-5e illustrate a synthetic bead with different shapes and
structures.
Detailed Description of the Invention
The present invention provides an apparatus for use in an aqueous slurry
containing minerals and unwanted materials. The minerals include hydrophobic
or
hydrophobized mineral particles. The apparatus comprises a substrate arranged
to
contact with the aqueous slurry and a polymeric coating disposed on the
substrate. The
polymeric coating has a compliant and tacky surface. The polymeric coating
further
comprises a chemical to render the surface hydrophobic so as to attract the
hydrophobic or hydrophobized mineral particles.
According to an embodiment of the present invention, the polymeric coating
provides a compliant, tacky surface of low energy to enhance selective
collection of
hydrophobic and hydrophobized particles ranging widely in particle size when
distributed in an aqueous slurry. For example, the polymeric coating may be
mounted
on a substrate, such as a flat surface, belt, bead, mesh, filter, open cell
foam structure,
or other substrate.
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By way of example, beads and bubbles are disclosed in commonly owned,
copending U.S. Patent Application nos. 14/116,438, filed February 3, 2014;
14/117,209,
filed February 7, 2014, 12/039,631, filed May 25, 2012, 14/119,048, filed
February 14,
2014, and US Patent No. 9,352,335, which are all hereby incorporated by
reference in
their entirety.
By way of further example, open cell foam structures are disclosed in commonly
owned U.S. Provisional Application nos. 62/276,051, filed January 7, 2016 and
62/405,569, filed October 5, 2016, which are all also hereby incorporated by
reference
in their entirety.
By way of still further example, PDMS coating and other media coating
materials
are disclosed in commonly owned PCT application no. PCT/US2015/33485, filed
June
1, 2015, US Patent 9,352,335 and US Patent 9,731,221, which are all hereby
incorporated by reference in their entirety.
As disclosed in the above references, the substrate coated with the polymeric
coating may be disposed within the aqueous slurry for interaction with, and
selective
collection of, hydrophobic and hydrophobized particles. The aqueous slurry
contains
the hydrophobic and / or hydrophobized particles and may also contain unwanted
particles that are less hydrophobic or are hydrophilic. For example, in the
mining
industry, aqueous mining slurries contain a mixture of minerals and other
materials The
other materials in the slurry are typically referred to as "gangue materials,"
and include
various natural elements found in a mining deposit, such as sands, clays and
other
materials. Typically, the minerals and gangue material are ground to an
average
particle size. For example, depending on the mineral type, the average
particle size of
the mixture of minerals and gangue materials may range from fines of only
several
microns to coarse particles of greater than 800 microns. The ground minerals
and
gangue may be mixed with water to create the aqueous slurry. The minerals may
be
sulfide based minerals, such as copper, gold, lead, zinc, nickel, iron or
other mineral.
However, other minerals may be collected with the system of the present
invention.
Additionally, the minerals may be further hydrophobized by the addition of
collector
chemicals to the aqueous slurry, such as xanthate, dithiophosphate,
dithiophosphinate,
dithiocarbamate, thionocarbamate, hydroxamates, amine ethers, primary amines,
fatty
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acids and their salts, and petroleum based collector chemistries commonly
known in the
mining industry. Additionally, where there is a mixture of hydrophobic and
hydrophobized particles to be collected, together with other materials, such
as gangue,
within the slurry, depressants may be added to the aqueous slurry to reduce
the
hydrophobicity of the gangue materials or other materials that are not desired
to be
collected by the polymeric coating. Examples of common depressants include
cyanide,
zinc sulfate, sulfur dioxide, sodium hydrosulfide, sodium sulfide, Nokes
reagent,
phosphates, diethylenetriamine, triethylenetetramine, certain amphiphilic
polymers
often based on polyacrylamide, and natural products such as starch, dextrin,
CMC,
tannin, quebracho, and lignosulfonates.
The polymer of the polymeric coating may be comprised of a polysiloxane
derivative, such as, but not limited to, polydimethylsiloxane. The polymer may
be
modified with: tackifiers; plasticizers; crosslinking agents; chain transfer
agents; chain
extenders; adhesion promoters; aryl or alky copolymers; fluorinated copolymers
and/or
additives; hydrophobizing agents such as hexamethyldisilazane; inorganic
particles
such as silica, hydrophobic silica, and/or fumed hydrophobic silica; MO resin;
and / or
other additives to control and modify the properties of the polymer.
In another embodiment of the present invention, the coating may be comprised
of other materials typically known as pressure sensitive adhesives, including,
but not
limited to: acrylics; butyl rubber; ethylene vinyl acetate; natural rubber;
nitriles; styrene
block copolymers with ethylene, propylene, and/or isoprene; polyurethanes; and
polyvinyl ethers.
The materials listed above are formulated to be compliant and tacky with low
surface energy. All of these polymers may be mono-, bi-, or multi-modal, and
such
materials may be modified with alkyl, aryl, and/or fluorinated
functionalities; silica-based
additives and other inorganics such as clays and/or bentonite; low molecular
weight and
oligomeric plasticizers; degrees of crosslinking density and branchedness
(polymer
structure); and / or FOSS materials.
The modification in each case is to lower the surface energy and / or optimize
compliance and tack. Very effective coatings were prepared from various
modified
silicones, acrylics, and ethylene vinyl acetate; however, all of the
aforementioned
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polymers are effective if properly prepared to include the desired qualities
of lower
surface energy, compliance and tack.
The coating of the present invention has a hydrophobic surface with a contact
angle ec greater than 90 degrees. A contact angle ec is the angle,
conventionally
measured through a liquid droplet on the surface of the material being
measured,
where a liquid¨vapor interface meets the solid surface of the surface being
measured.
The contact angle ec quantifies the wettability of a solid surface by a liquid
(the ability of
a liquid to maintain contact with the solid surface) via the Young equation. A
given
system of solid, liquid, and vapor at a given temperature and pressure has a
unique
equilibrium contact angle. However, in practice contact angle hysteresis is
observed,
ranging from the so-called advancing (maximal) contact angle to the receding
(minimal)
contact angle. The equilibrium contact is within those values, and can be
calculated
from them. The equilibrium contact angle reflects the relative strength of the
liquid,
solid, and vapor molecular interaction.
The shape of a liquid¨vapor interface is determined by the Young¨Laplace
equation, with the contact angle playing the role of a boundary condition via
Young's
Equation. The theoretical description of contact arises from the consideration
of a
thermodynamic equilibrium between the three phases: the liquid phase (L), the
solid
phase (S), and the gas or vapor phase (G) (which could be a mixture of ambient
atmosphere and an equilibrium concentration of the liquid vapor). (The
"gaseous"
phase could be replaced by another immiscible liquid phase.) If the
solid¨vapor
interfacial energy is denoted by '(so, the solid¨liquid interfacial energy by
YSL, and the
liquid¨vapor interfacial energy (i.e. the surface tension) by YLG, then the
equilibrium
contact angle ec is determined from these quantities by Young's Equation:
YSG - YSL - YLG cos ec = 0
To maximize selective collection of desired hydrophobic or hydrophobized
particles
distributed in an aqueous slurry, the contact angle ec of a drop of water on
the surface
of the coating should be greater than 90 signifying a hydrophobic surface.
More
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preferably, the contact angle ec is between 1000 and 1400. Very effective
coatings
have been prepared with contact angles greater than 120 .
The compliance of the coating is a factor in determining the collection
efficiency
of the hydrophobic particles on the coating as well as the distribution of
particle sizes
collected on the coating. A fully non-compliant hardened coating will not
collect or only
have very limited collection of fines (small micron size particles) whereas an
extremely
soft coating, while collecting a large range of particles, lacks the cohesion
to durably
remain on its substrate in repeated use. A moderately compliant coating allows
particle
adhesion while also possessing the cohesion necessary to remain on the
substrate.
The cohesion of the coating is directly related to the durability of the
coating ¨ the
greater the cohesion of a particular coating, the greater the durability of
that coating.
Compliance is also affected by coating thickness; therefore, coating thickness
is also an
important parameter in hydrophobic particle collection efficiency. It is known
that upon
contact with a compliant surface, the compliance or "give" of the surface may
allow
greater surface to surface contact between the compliant surface and the
object that
comes in contact with the compliant surface. In contrast, a non-compliant, or
hard,
surface would not provide as much compliance, or give, when in contact with
another
object, providing less potential surface contact. The coating of the present
invention is
designed to include a compliant surface that provides increased surface area
contact
between the coating and a particle that comes in contact with the compliant
coating;
thereby enhancing adhesion forces. Coating thickness may be as low as 0.2 mils
and
greater than 5.0 mils, but is preferably greater than 0.75 mils (1 mils = 25.4
microns). In
general, coatings with low compliance preferentially collect smaller particle
sizes while
coatings with higher compliance collect a larger distribution of particle
sizes.
Hydrophobic, compliant coatings have been prepared with minimal tack that
exhibit particle collection; however, enhanced collection is generally
achieved when the
coating is tacky as measured by loop tack against polished stainless steel
using PSTC-
16 Method A. Loop tack is preferably greater than 5 grams-force, more
preferably
greater than 50 grams-force, and most preferably greater than 100 grams-force.
Very
effective coatings were prepared with loop tack of 300 ¨ 600 grams-force.
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The polymeric coating may be reacted with additional functionality allowing it
to
bond directly with a particle of interest. This functionality could include
oxyhydryl,
sulfhydryl, or cationic functionality found in mineral collectors.
The aforementioned coatings may be applied to any substrate effective in
slurry
processing. Substrates that may be coated include solid, hollow, or network
structures
made of glass, metal, ceramic, or polymer that may be smooth or have rough
surface
morphology to improve coating adhesion and/or to increase surface area. The
substrate may be comprised of open-cell foam comprised of reticulated
polyurethane or
another appropriate open-cell foam material such as silicone, polychloroprene,
polyisocyanurate, polystyrene, polyolefin, polyvinylchloride, epoxy, latex,
fluoropolymer,
phenolic, EPDM, nitrile, composite foams and such. The substrate may be
comprised
of other three-dimensional open cellular structures such as hard plastics,
ceramics,
carbon fiber, and metals may be used. Examples include Incofoam , Duocele,
metal
and ceramic foams produced by American Elements , and porous hard plastics
such
as polypropylene honeycombs and such. The three-dimensional, open cellular
structure may itself form a compliant, tacky surface of low energy by, for
example,
forming such a structure directly from the coating polymers as described
above.
The coated substrate must contact the aqueous slurry, be removed from the
slurry, and then the hydrophobic particles removed from the coated substrate
to recover
.. the valuable particles. This contact could occur within a flotation cell,
an agitated tank,
a tumbler or some other such known method of contact. The particle-rich coated
substrate is then removed from the contactor and washed and/or blown to remove
unwanted, unadhered gangue materials. Once any gangue material is removed, the
hydrophobic particle laden substrate may be further processed to collect the
attached
materials, such as attached minerals, for further processing.
Hydrophobic mineral particles of interest may include but not be limited to
hydrophobic and/or hydrophobized metallic or nonmetallic mineral particles,
coal
particles, diamond particles, or any hydrophobic particles of value.
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Embodiment of Mineral Separation Apparatus
In its broadest sense, the present invention may take the form of a machine,
system or apparatus featuring a first processor and a second processor. The
first
processor may be configured to receive a mixture of fluid, valuable material
and
unwanted material and a functionalized polymer coated member configured to
attach to
the valuable material in an attachment rich environment, and provide an
enriched
functionalized polymer coated member having the valuable material attached
thereto.
The second processor may be configured to receive a fluid and the enriched
functionalized polymer coated member in a release rich environment to release
the
valuable material, and provide the valuable material released from the
enriched
functionalized polymer coated member to the release rich environment.
The apparatus may be configured to include one or more of the following
features:
The first processor may take the form of a first chamber, tank, cell or
column,
and the second processor may take the form of a second chamber, tank, cell or
column.
The first chamber, tank or column may be configured to receive a pulp slurry
having water, the valuable material and the unwanted material in the
attachment rich
environment, which has a high pH, conducive to attachment of the valuable
material.
The second chamber, tank or column may be configured to receive water in the
release rich environment, which may have a low pH or receive ultrasonic waves
conducive to release of the valuable material.
Although the invention is described as having a high pH in an attachment
environment and a low pH in a release environment, the present invention will
work
equally as well where the pH of the attachment environment is selected to
optimize the
attachment of desired materials, such as a low, high or neutral pH, and the pH
of the
release environment is selected to be a different pH than the attachment
environment
and selected to optimize the release of the desired material.
The functionalized polymer coated member may take the form of a functionalized
polymer coated impeller having at least one impeller blade configured to
rotate slowly
inside the first processor and the second processor. The first processor may
be
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configured to receive the at least one impeller blade in an attachment zone,
and provide
at least one enriched impeller blade having the valuable material attached
thereto in the
attachment zone. The second processor may be configured to receive the at
least one
enriched impeller blade in a release zone and to provide the valuable material
released
from the at least one enriched impeller blade. The first processor may be
configured
with a first transition zone to provide drainage of tailings, and the second
processor may
be configured with a second transition zone to provide drainage of
concentrate.
As used herein with respect to functionalized polymer, the term "enriched" is
intended to refer to a functionalized material that has been exposed to a
material of
interest, and wherein the material of interest has been attached, attracted,
connected or
otherwise collected by the functionalized material prior to release.
The functionalized polymer coated member may take the form of a functionalized
polymer coated conveyor belt configured to run between the first processor and
the
second processor. The first processor may be configured to receive the
functionalized
polymer coated conveyor belt and provide an enriched functionalized polymer
coated
conveyor belt having the valuable material attached thereto. The second
processor
may be configured to receive the enriched functionalized polymer coated
conveyor belt
and provide the valuable material released from the enriched functionalized
polymer
coated conveyor belt. The functionalized polymer coated conveyor belt may be
made
of a mesh material.
The functionalized polymer coated member may take the form of a functionalized
polymer coated collection filter configured to move between the first
processor and the
second processor as part of a batch type process. The first processor may be
configured to receive the functionalized polymer coated collection filter and
to provide
an enriched functionalized polymer coated collection filter having the
valuable material
attached thereto. The second processor device may be configured to receive the
enriched functionalized polymer coated collection filter and provide the
valuable
material released from the enriched functionalized polymer coated collection
filter.
The first processor may be configured to provide tailings containing the
unwanted material, and the second processor may be configured to provide a
concentrate containing the valuable material.
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The functionalized polymer coated member may take the form of a membrane or
a thin soft pliable sheet or layer.
According to some embodiment, the present invention may also take the form of
apparatus featuring first means that may be configured to receive a mixture of
fluid,
valuable material and unwanted material and a functionalized polymer coated
member
configured to attach to the valuable material in an attachment rich
environment, and
provide an enriched functionalized polymer coated member having the valuable
material attached thereto; and second means that may be configured to receive
a fluid
and the enriched functionalized polymer coated member in a release rich
environment
to release the valuable material, and provide the valuable material released
from the
enriched functionalized polymer coated member to the release rich environment.
According to some embodiments of the present invention, the first means may
be configured to receive a pulp slurry having water, the valuable material and
the
unwanted material in the attachment rich environment, which has a high pH,
conducive
to attachment of the valuable material; and the second means may be configured
to
receive water in the release rich environment, which has a low pH or receives
ultrasonic
waves conducive to release of the valuable material.
According to some embodiments of the present invention, the functionalized
polymer coated member may take the form of one of the following:
a functionalized polymer coated impeller having at least one impeller blade
configured to rotate slowly inside the first means and the second means;
a functionalized polymer coated conveyor belt configured to run between the
first
means and the second means; or
a functionalized polymer coated collection filter configured to move between
the
first means and the second means as part of a batch type process.
Embodiments of Mineral Separation Processes or Methods
According to some embodiment, the present invention may also take the form of
a process or method featuring receiving in a first processor a mixture of
fluid, valuable
material and unwanted material and a functionalized polymer coated member
configured to attach to the valuable material in an attachment rich
environment, and
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providing from the first processor an enriched functionalized polymer coated
member
having the valuable material attached thereto; and receiving in a second
processor a
fluid and the enriched functionalized polymer coated member in a release rich
environment to release the valuable material, and providing the valuable
material
released from the enriched functionalized polymer coated member to the release
rich
environment.
According to some embodiments of the present invention, the method may
include being implemented consistent with one or more of the features set
forth herein.
The Synthetic Functionalized Polymer Coated Member Chemistry
According to some embodiments of the present invention, the functionalized
polymer coated member may take the form of a solid-phase body comprising a
surface
in combination with a plurality of molecules attached to the surface, the
molecules
comprising a functional group selected for attracting or attaching to one or
more mineral
particles of interest to the molecules. The term "polymer" in this
specification is
understood to mean a large molecule made of many units of the same or similar
structure linked together.
According to some embodiments of the present invention, the solid-phase body
may be made of a synthetic material comprising the molecules. By way of
example, the
synthetic material may be selected from a group consisting of, but not limited
to,
polyamides (nylon), polyesters, polyurethanes, phenol-formaldehyde, urea-
formaldehyde, melamine-formaldehyde, polyacetal, polyethylene,
polyisobutylene,
polyacrylonitrile, poly(vinyl chloride), polystyrene, poly(methyl
methacrylates), poly(vinyl
acetate), poly(vinylidene chloride), polyisoprene, polybutadiene,
polyacrylates,
poly(carbonate), phenolic resin and polydimethylsiloxane.
According to some embodiments of the present invention, the solid-phase body
may include an inner material and a shell providing the surface, the shell
being made of
a synthetic material comprising the molecules.
According to some embodiments of the present invention, the functional group
may have an ionic group, which may be either anionic or cationic, for
attracting or
attaching the mineral particles to the surface.
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According to some embodiments of the present invention, the functional group
may take the form of a collector having a non-ionizing bond having a neutral
or ionic
functional group, or having an ionizing bond.
According to some embodiments of the present invention, the ionizing bond may
be an anionic bond or a cationic bond. The anionic functional group may be
comprised
of an oxyhydryl, including carboxylic, sulfates and sultanates, and sulfhydral
bond.
Hydrophobicity
According to some embodiments of the present invention, the surface of the
.. polymer coated member may be functionalized to be hydrophobic so as to
provide a
bonding between the surface and a mineral particle associated with one or more
hydrophobic molecules.
Furthermore, the polymer can be naturally hydrophobic or functionalized to be
hydrophobic. Some polymers having a long hydrocarbon chain or silicon-oxygen
backbone, for example, tend to be hydrophobic. Hydrophobic polymers include
polystyrene, poly(d,l-lactide), poly(dimethylsilaxane), polypropylene,
polyacrylic,
polyethylene, etc. The mineral particle of interest or the valuable material
associated
with one or more hydrophobic molecules is referred to as a wetted mineral
particle.
When the pulp slurry contains a plurality of collectors or collector
molecules, some of
the mineral particles will become wetted mineral particles if the collectors
are attached
to mineral particles. Xanthates can be used in the pulp slurry as the
collectors. The
functionalized polymer coated member can be coated with hydrophobic silicone
polymer including polysiloxanates so that the functionalized polymer coated
member
become hydrophobic. The functionalized polymer coated member can be made of
hydrophobic polymers, such as polystyrene and polypropylene to provide the
desired
hydrophobicity.
Combined Collector/Hydrophobic Functionalized Polymer Coated Member
According to some embodiments of the present invention, only a part of the
surface of the functionalized polymer coated member may be configured to have
the
molecules attached thereto, wherein the molecules comprise collectors.
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According to some embodiments of the present invention, a part of the surface
of the functionalized polymer coated member may be configured to have the
molecules
attached thereto, wherein the molecules comprise collectors, and another part
of the
surface of the functionalized polymer coated member may be configured to be
hydrophobic.
According to some embodiments of the present invention, a part of the surface
of the functionalized polymer coated member may be configured to be
hydrophobic.
Release of minerals from compliant, tacky surface
The compliant, tacky surface, according to the present invention, has a
polymeric
coating to render the surface hydrophobic so as to attract mineral particles
in the slurry.
To collect the mineral particles, a surfactant can be used to lower the
surface tension of
the polymeric coating so as to release the minerals from the surface. Suitable
surfactants can include alcohols, liquid silicones, various emulsions
containing
combinations of alcohols and silicones, or other suitable surfactants or other
suitable
materials. Along with the surfactant, rotating impellers can be used to stir
the container
having the surfactant and the mineral laden surface to aid the release.
Alternatively, the attached mineral particles can be washed off (with the
release
being chemically triggered ¨ e.g., a low pH environment), mechanically
released (e.g.,
ultrasonic agitation, brushes, squeegee contact), thermally, or
electromagnetically
released.
Figures 1, la, lb
By way of example, Figure 1 shows the present invention is the form of a
machine, device, system or apparatus 10, e.g., for separating valuable
material from
unwanted material in a mixture 11, such as a pulp slurry, using a first
processor 12 and
a second processor 14. Figure 1 includes Figure la and Figure lb, where Figure
la is
a side partial cutaway view in diagram form of a separation processor
configured with
two chambers, tanks or columns having a functionalized polymer coated impeller
arranged therein according to some embodiments of the present invention, and
Figure
lb is a top partial cross-sectional view in diagram form of a functionalized
polymer
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coated impeller moving in an attachment rich environment contained in an
attachment
chamber, tank or column and also moving in a release rich environment
contained in a
release chamber, tank or column. The first processor 12 and the second
processor 14
are configured with a functionalized polymer coated member that is shown,
e.g., as a
functionalized polymer coated impeller 20 (Fig. la), 20' (Fig. 1b), according
to some
embodiments of the present invention. In operation, the impeller 20, 20'
slowly rotates
in relation to the first processor 12 and the second processor 14, the
impeller blades
slowly pass through the attachment rich environment 16 in the first processor
12 where
the valuable material is attached to the blades and through the release rich
environment 18 in the second processor 14 is released from the blades. By way
of
example, the impeller 20 is shown rotating in a counterclockwise direction as
indicated
by arrow a, although the scope of the invention is not intended to be limited
to the
direction of the impeller rotation, or the manner in which the functionalized
polymer
coated impeller 20 (Fig. la), 20' (Fig. 1b) is arranged, mounted, or
configured in relation
to the first processor 12 and the second processor 14.
The first processor 12 may take the form of a first chamber, tank, cell or
column
that contains an attachment rich environment generally indicated as 16. The
first
chamber, tank or column 12 may be configured to receive via piping 13 the
mixture or
pulp slurry 11 in the form of fluid (e.g., water), the valuable material and
the unwanted
material in the attachment rich environment 16, e.g., which has a high pH,
conducive to
attachment of the valuable material. The second processor 14 may take the form
of a
second chamber, tank, cell or column that contains a release rich environment
generally indicated as 18. The second chamber, tank, cell or column 14 may be
configured to receive via piping 15, e.g., water 22 in the release rich
environment 18,
e.g., which may have a low pH or receive ultrasonic waves conducive to release
of the
valuable material. Attachment rich environments like that forming part of
element
environment 16 conducive to the attachment of a valuable material of interest
and
release rich environments like that forming part of environment 18 conducive
to the
release of the valuable material of interest are known in the art, and the
scope of the
invention is not intended to be limited to any particular type or kind thereof
either now
known or later developed in the future. Moreover, a person skilled in the art
would be
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able to formulate an attachment rich environment like environment 16 and a
corresponding release rich environment like environment 18 based on the
separation
technology disclosed herein for any particular valuable mineral of interest,
e.g., copper,
forming part of any particular mixture or slurry pulp.
Although the invention is described as having a high pH in an attachment
environment and a low pH in a release environment, embodiments are envisioned
in
which the invention will work equally as well where the pH of the attachment
environment is selected to optimize the attachment of desired materials, such
as a low,
high or neutral pH, and the pH of the release environment is selected to be a
different
pH than the attachment environment and selected to optimize the release of the
desired
material.
In operation, the first processor 12 may be configured to receive the mixture
or
pulp slurry 11 of water, valuable material and unwanted material and the
functionalized
polymer coated member that is configured to attach to the valuable material in
the
attachment rich environment 16. In Figure 1, the functionalized polymer coated
member is shown as the functionalized polymer coated impeller 20 (Fig. la),
20' (Fig.
1b). In Figure la, the functionalized polymer coated impeller 20 has a shaft
21 and at
least one impeller blade 20a, 20b, 20c, 20d, 2e, 20f, 20g and is configured to
rotate
slowly inside the first processor 12 and the second processor 14. In Figure
lb, the
.. functionalized polymer coated impeller 20' has a shaft 21' and impeller
blades 20a',
20b', 20c', 20d', 2e', 20f', 20g' and 20h'. Each impeller blade in Figures 1
is understood
to be configured and functionalized with a polymer coating to attach to the
valuable
material in the attachment rich environment 16. (The scope of the invention is
not
intended to be limited to the number of blades on the impeller 20, 20' and the
embodiment in Figures la and lb is shown with impellers 21, 21' having a
different
number of blades.)
In Figure 1, the first processor 12 is configured to receive at least one
impeller
blade of the functionalized polymer coated impeller 20 (Fig. la), 20' (Fig.
1b). In Figure
lb, the at least one impeller blade is shown as impeller blade 20g' being
received in an
attachment zone 30 that forms part of the attachment rich environment 16
defined by
walls 30a, 30b. The first processor 12 may also be configured with a first
transition
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zone generally indicated as 40 to provide drainage from piping 41 of, e.g.,
tailings 42 as
shown in Figure la.
The first processor 12 may also be configured to provide at least one enriched
impeller blade having the valuable material attached thereto, after passing
through the
attachment rich environment 16. In Figure lb, the at least one enriched
impeller blade
is shown as the at least one enriched impeller blade 20c' being provisioned
from the
attachment rich environment 16 in the first processor 12 to the release rich
environment
18 in the second processor 14.
The second processor 14 may be configured to receive via the piping 15 the
fluid
22 (e.g. water) and the enriched functionalized polymer coated member to
release the
valuable material in the release rich environment 18. In Figure lb, the second
processor 14 is shown receiving the enriched impeller blade 20c' in a release
zone 50,
e.g., that forms part of the release rich environment 18 and is defined, e.g.,
by walls 30c
and 30d.
The second processor 14 may also be configured to provide the valuable
material that is released from the enriched functionalized polymer coated
member into
the release rich environment 18. For example, in Figure lb the second
processor 14 is
shown configured with a second transition zone 60 defined by walls 30a and 30d
to
provide via piping 61 drainage of the valuable material in the form of a
concentrate 62
(Fig. la).
Figure 2: The Functionalized Polymer Coated Conveyor Belt
By way of example, Figure 2 shows the present invention is the form of a
machine, device, system or apparatus 100, e.g., for separating valuable
material from
unwanted material in a mixture 101, such as a pulp slurry, using a first
processor 102
and a second processor 104. The first processor 102 and the second processor
104
are configured with a functionalized polymer coated member that is shown,
e.g., as a
functionalized polymer coated conveyor belt 120 that runs between the first
processor
102 and the second processor 104, according to some embodiments of the present
invention. The arrows Al, A2, A3 indicate the movement of the functionalized
polymer
coated conveyor belt 120. Techniques, including motors, gearing, etc., for
running a
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conveyor belt like element 120 between two processors, such as elements 102
and 104
are known in the art, and the scope of the invention is not intended to be
limited to any
particular type or kind thereof either now known or later developed in the
future.
According to some embodiments of the present invention, the functionalized
polymer
.. coated conveyor belt 120 may be made of a mesh material.
The first processor 102 may take the form of a first chamber, tank, cell or
column
that contains an attachment rich environment generally indicated as 106. The
first
chamber, tank or column 102 may be configured to receive the mixture or pulp
slurry
101 in the form of fluid (e.g., water), the valuable material and the unwanted
material in
.. the attachment rich environment 106, e.g., which has a high pH, conducive
to
attachment of the valuable material. The second processor 104 may take the
form of a
second chamber, tank, cell or column that contains a release rich environment
generally indicated as 108. The second chamber, tank, cell or column 104 may
be
configured to receive, e.g., water 122 in the release rich environment 108,
e.g., which
.. may have a low pH or receive ultrasonic waves conducive to release of the
valuable
material. Consistent with that stated above, attachment rich environments like
that
forming part of element environment 106 conducive to the attachment of a
valuable
material of interest and release rich environments like that forming part of
environment
108 conducive to the release of the valuable material of interest are known in
the art,
.. and the scope of the invention is not intended to be limited to any
particular type or kind
thereof either now known or later developed in the future. Moreover, a person
skilled in
the art would be able to formulate an attachment rich environment like
environment 106
and a corresponding release rich environment like environment 108 based on the
separation technology disclosed herein for any particular valuable mineral of
interest,
.. e.g., copper, forming part of any particular mixture or slurry pulp.
In operation, the first processor 102 may be configured to receive the mixture
or
pulp slurry 101 of water, valuable material and unwanted material and the
functionalized polymer coated conveyor belt 120 that is configured to attach
to the
valuable material in the attachment rich environment 106. In Figure 2, the
belt 120 is
understood to be configured and functionalized with a polymer coating to
attach to the
valuable material in the attachment rich environment 106.
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The first processor 102 may also be configured to provide drainage from piping
141 of, e.g., tailings 142 as shown in Figure 2.
The first processor 102 may also be configured to provide an enriched
functionalized polymer coated conveyor belt having the valuable material
attached
thereto, after passing through the attachment rich environment 106. In Figure
2, the
enriched functionalized polymer coated conveyor belt is shown, e.g., as that
portion or
part 120a of the belt 120 being provisioned from the attachment rich
environment 106 in
the first processor 102 to the release rich environment 108 in the second
processor
104. It is understood that some other portions or parts of the belt 120 may be
enriched,
including the portion or part immediately leaving the attachment rich
environment 106,
as well as the portion or part immediately entering the release rich
environment 108.
The second processor 14 may be configured to receive the fluid 122 (e.g.
water)
and the portion 120a of the enriched functionalized polymer coated conveyor
belt 120
to release the valuable material in the release rich environment 108.
The second processor 104 may also be configured to provide the valuable
material that is released from the enriched functionalized polymer coated
member into
the release rich environment 108. For example, in Figure 2 the second
processor 104
is shown configured to provide via piping 161 drainage of the valuable
material in the
form of a concentrate 162.
In Figure 2, the first processor 102 is configured with the functionalized
polymer
coated conveyor belt 120 passing through with only two turns inside the
attachment rich
environment 106. However, embodiments are envisioned in which the first
processor
102 may be configured to process the functionalized polymer coated conveyor
belt 120
using a serpentine technique for winding or turning the belt 120 one way and
another
way, back and forth, inside the first processor to maximize surface area of
the belt
inside the processor 102 and exposure of the belt 120 to the attachment rich
environment 106.
Figure 3: The Functionalized Polymer Coated Filter
By way of example, Figure 3 shows the present invention is the form of a
machine, device, system or apparatus 200, e.g., for separating valuable
material from
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unwanted material in a mixture 201, such as a pulp slurry, using a first
processor 202,
202' and a second processor 204, 204'. The first processor 202 and the second
processor 204 are configured to process a functionalized polymer coated member
that
is shown, e.g., as a functionalized polymer coated collection filter 220
configured to be
moved between the first processor 202 and the second processor 204' as shown
in
Figure 3 as part of a batch type process, according to some embodiments of the
present invention. In Figure 3, by way of example the batch type process is
shown as
having two first processors 202, 202' and second processors 204, 204, although
the
scope of the invention is not intended to be limited to the number of first or
second
processors. Moreover, embodiments are envisioned using a different number of
first
and second processors, different types or kinds of processors, as well as
different types
or kinds of processors both now known or later developed in the future.
According to
some embodiments of the present invention, the functionalized polymer coated
collection filter 220 may take the form of a membrane or a thin soft pliable
sheet or
.. layer. The arrow B1 indicates the movement of the functionalized polymer
coated filter
220 from the first processor 202, and the arrow B2 indicates the movement of
the
functionalized polymer coated collection filter 220 into the second processor
202.
Techniques, including motors, gearing, etc., for moving a filter like element
220 from
one processor to another processor like elements 202 and 204 are known in the
art,
and the scope of the invention is not intended to be limited to any particular
type or kind
thereof either now known or later developed in the future.
The first processor 202 may take the form of a first chamber, tank, cell or
column
that contains an attachment rich environment generally indicated as 206. The
first
chamber, tank or column 102 may be configured to receive the mixture or pulp
slurry
.. 201 in the form of fluid (e.g., water), the valuable material and the
unwanted material in
the attachment rich environment 206, e.g., which has a high pH, conducive to
attachment of the valuable material. The second processor 204 may take the
form of a
second chamber, tank, cell or column that contains a release rich environment
generally indicated as 208. The second chamber, tank, cell or column 204 may
be
configured to receive, e.g., water 222 in the release rich environment 208,
e.g., which
may have a low pH or receive ultrasonic waves conducive to release of the
valuable
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material. Consistent with that stated above, attachment rich environments like
that
forming part of element environment 206 conducive to the attachment of a
valuable
material of interest and release rich environments like that forming part of
environment
208 conducive to the release of the valuable material of interest are known in
the art,
and the scope of the invention is not intended to be limited to any particular
type or kind
thereof either now known or later developed in the future. Moreover, a person
skilled in
the art would be able to formulate an attachment rich environment like
environment 206
and a corresponding release rich environment like environment 208 based on the
separation technology disclosed herein for any particular valuable mineral of
interest,
.. e.g., copper, forming part of any particular mixture or slurry pulp.
In operation, the first processor 202 may be configured to receive the mixture
or
pulp slurry 101 of water, valuable material and unwanted material and the
functionalized polymer coated collection filter 220 that is configured to
attach to the
valuable material in the attachment rich environment 206. In Figure 3, the
functionalized polymer coated collection filter 220 is understood to be
configured and
functionalized with a polymer coating to attach to the valuable material in
the
attachment rich environment 106.
The first processor 202 may also be configured to provide drainage from piping
241 of, e.g., tailings 242 as shown in Figure 3.
The first processor 202 may also be configured to provide an enriched
functionalized polymer coated collection filter having the valuable material
attached
thereto, after soaking in the attachment rich environment 106. In Figure 3,
the
enriched functionalized polymer coated collection filter 220 is shown, e.g.,
being
provisioned from the attachment rich environment 206 in the first processor
202 to the
.. release rich environment 208 in the second processor 204.
The second processor 204 may be configured to receive the fluid 222 (e.g.
water) and the enriched functionalized polymer coated collection filter 220 to
release
the valuable material in the release rich environment 208.
The second processor 204 may also be configured to provide the valuable
material that is released from the enriched functionalized polymer coated
collection filter
220 into the release rich environment 208. For example, in Figure 3 the second
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processor 204 is shown configured to provide via piping 261 drainage of the
valuable
material in the form of a concentrate 262.
The first processor 202' may also be configured with piping 280 and pumping
280 to recirculate the tailings 242 back into the first processor 202'. The
scope of the
invention is also intended to include the second processor 204' being
configured with
corresponding piping and pumping to recirculate the concentrate 262 back into
the
second processor 204'. Similar recirculation techniques may be implemented for
the
embodiments disclosed in relation to Figures 1-2 above.
The scope of the invention is not intended to be limited to the type or kind
of
batch process being implemented. For example, embodiments are envisioned in
which
the batch process may include the first and second processors 202, 204 being
configured to process the enriched functionalized polymer coated collection
filter 220 in
relation to one type or kind of valuable material, and the first and second
processors
202', 204' being configured to process the enriched functionalized polymer
coated
collection filter 220 in relation to either the same type or kind of valuable
material, or a
different type or kind of valuable material. Moreover, the scope of the
invention is
intended to include batch processes both now known and later developed in the
future.
Figures 4a, 4b: The Synthetic Bead Chemistry
For aiding a person of ordinary skill in the art in understanding various
embodiments of the present invention, Figure 4a shows at least part of a
generalized
solid-phase body, e.g., a functionalized polymer coated member, and Figure 4b
shows
an enlarged portion of the surface. As shown in Figures 4a and 4b, the
functionalized
polymer coated member 70 has a body to provide a surface 74. At least the
outside
part of the body may be made of a synthetic material, such as polymer, so as
to provide
a plurality of molecules or molecular segments 76 on the surface 74. The
molecule 76
is used to attach a chemical functional group 78 to the surface 74. In
general, the
molecule 76 can be a hydrocarbon chain, for example, and the functional group
78 can
have an anionic bond for attracting or attaching a mineral particle of
interest, such as
copper to the surface 74. A xanthate, for example, has both the functional
group 78
and the molecular segment 76 to be incorporated into the polymer that is used
to make
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the synthetic bead 70, or the surface thereof. The functional group 78 is also
known as
a collector that can have a neutral or charged functional group for attachment
to the
desired mineral, e.g., via a non-ionizing or ionizing bond. The charged
functional group
may include an ionizing bond that is anionic or cationic. An anionic bond or
groups may
include an oxyhydryl, such as carboxylic, sulfates and sulfonates, and
sulfhydral, such
as xanthates and dithiophosphates. Other molecules or compounds that can be
used
to provide the function group 78 include thionocarboamates, thioureas,
xanthogens,
monothiophosphates, hydroquinones and polyamines.
Similarly, a chelating agent can be incorporated into the polymer as a
collector
site for attracting a mineral, such as copper. As shown in Figure 4b, a
mineral particle
72 is attached to the functional group 78 on the molecule 76. In general, the
mineral
particle 72 is much smaller than the synthetic bead 70. Many mineral particles
72 can
be attracted to or attached to the surface 74 of a functionalized polymer
coated
member 70.
In some embodiments of the present invention, a functionalized polymer coated
member may take the form of a solid-phase body made of a synthetic material,
such as
polymer. (By way of example, the term "solid-phase body" is understood herein
to be a
body having a cohesive force of matter that is strong enough to keep the
molecules or
atoms in the given positions, restraining the thermal mobility.) The polymer
can be rigid
or elastomeric. An elastomeric polymer can be a bisoxazolone-based polymer,
for
example. The body has a surface comprising a plurality of molecules with one
or more
functional groups for attracting mineral particles of interest to the surface.
A polymer
having a functional group to attract or collect mineral particles is referred
to as a
functionalized polymer. By way of example, the entire body of the
functionalized
polymer coated member may be made of the same functionalized material, or the
body
may be a shell, which can be formed around an inner material.
It should be understood that the surface of a functionalized polymer coated
member, according to the present invention, is not limited to an overall
smoothness of
its surface as shown in Figure 4a. In some embodiments of the present
invention, the
surface can be irregular and rough. For example, the surface can have some
physical
structures like grooves or rods, or holes or dents. The surface can have some
hair-like
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physical structures. In addition to the functional groups on the
functionalized polymer
coated member that attract mineral particles of interest to the surface, the
physical
structures can help trapping the mineral particles on the surface. The surface
can be
configured to be a honeycomb surface or a sponge-like surface for trapping the
mineral
particles and/or increasing the contacting surface. In effect, the scope of
the invention
is not intended to be limited to any particular type or kind of surface of the
synthetic
bead.
It should be noted that the functionalized polymer coated member of the
present
invention can be realized by a different way to achieve the same goal. Namely,
it is
possible to use a different means to attract the mineral particles of interest
to the
surface of the functionalized polymer coated member. For example, the surface
of the
polymer coated member can be functionalized with a hydrophobic chemical
molecule or
compound, as discussed below. Alternatively, the surface of the functionalized
polymer
coated member can be coated with hydrophobic chemical molecules or compounds.
In
.. the pulp slurry, xanthate and hydroxamate collectors can also be added
therein for
collecting the mineral particles and making the mineral particles hydrophobic.
When
the functionalized polymer coated member is used to collect the mineral
particles in the
pulp slurry having a pH value around 8-9, it is possible to release the
mineral particles
on the enriched synthetic beads from the surface of the functionalized polymer
coated
member in an acidic solution, such as a sulfuric acid solution. According to
some
embodiment, it may also be possible to release the mineral particles carried
with the
enriched functionalized polymer coated member by sonic agitation, such as
ultrasonic
waves, or simply by washing it with water.
Figures 5a-5e
In some embodiments of the present invention, a synthetic bead has a solid-
phase body made of a synthetic material, such as polymer. The polymer can be
rigid or
elastomeric. An elastomeric polymer can be polyisoprene or polybutadiene, for
example. The synthetic bead 170 has a bead body 180 having a surface
comprising a
plurality of molecules with one or more functional groups for attracting
mineral particles
to the surface. A polymer having a functional group to collect mineral
particles is
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referred to as a functionalized polymer. In one embodiment, the entire
interior part 182
of the synthetic bead 180 is made of the same functionalized material, as
shown in
Figure 5a. In another embodiment, the bead body 180 comprises a shell 184. The
shell 184 can be formed by way of expansion, such as thermal expansion or
pressure
reduction. The shell 184 can be a micro-bubble or a balloon. In Figure 5b, the
shell
184, which is made of functionalized material, has an interior part 186. The
interior part
186 can be filled with air or gas to aid buoyancy, for example. The interior
part 186 can
be used to contain a liquid to be released during the mineral separation
process. The
encapsulated liquid can be a polar liquid or a non-polar liquid, for example.
The
encapsulated liquid can contain a depressant composition for the enhanced
separation
of copper, nickel, zinc, lead in sulfide ores in the flotation stage, for
example. The shell
184 can be used to encapsulate a powder which can have a magnetic property so
as to
cause the synthetic bead to be magnetic, for example. The encapsulated liquid
or
powder may contain monomers, oligomers or short polymer segments for wetting
the
surface of mineral particles when released from the beads. For example, each
of the
monomers or oligomers may contain one functional group for attaching to a
mineral
particle and an ion for attaching the wetted mineral particle to the synthetic
bead. The
shell 184 can be used to encapsulate a solid core, such as Styrofoam to aid
buoyancy,
for example. In yet another embodiment, only the coating of the bead body is
made of
functionalized polymer. As shown in Figure 5c, the synthetic bead has a core
190
made of ceramic, glass or metal and only the surface of core 190 has a coating
188
made of functionalized polymer. The core 190 can be a hollow core or a filled
core
depending on the application. The core 190 can be a micro-bubble, a sphere or
balloon. For example, a filled core made of metal makes the density of the
synthetic
bead to be higher than the density of the pulp slurry, for example. The core
190 can be
made of a magnetic material so that the para-, fern-, ferro-magnetism of the
synthetic
bead is greater than the para-, fern-, ferro-magnetism of the unwanted ground
ore
particle in the mixture. In a different embodiment, the synthetic bead can be
configured
with a ferro-magnetic or fern-magnetic core that attract to paramagnetic
surfaces. A
core 90 made of glass or ceramic can be used to make the density of the
synthetic
bead substantially equal to the density of the pulp slurry so that when the
synthetic
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beads are mixed into the pulp slurry for mineral collection, the beads can be
in a
suspension state.
According to a different embodiment of the present invention, the synthetic
bead
170 can be a porous block or take the form of a sponge or foam with multiple
segregated gas filled chambers as shown in Figures 5d and 5e. A foam is an
example
of an open-cell structure. An open-cell foam can be made from reticulated
polyurethane.
Applications
The scope of the invention is described in relation to mineral separation,
including the separation of copper from ore.
By way of example, applications are envisioned to include
Rougher, scavenger, cleaner and rougher/scavenger separation cells in the
production stream, replacing the traditional flotation machines.
Tailings scavenger cells used to scavenge the unrecovered minerals from a
tailings stream.
Tailings cleaning cell used to clean unwanted material from the tailings
stream
before it is sent to the disposal pond.
Tailings reclamation machine that is placed in the tailings pond to recover
valuable mineral that has been sent to the tailings pond.
Other types or kinds of valuable material or minerals of interest, including
gold,
molybdenum, etc.
However, the scope of the invention is intended to include other types or
kinds of
applications either now known or later developed in the future, including
applications
related to oilsands separation that includes separating bitumen from sand and
water in
the recovery of bitumen in an oilsands mining operation.
The Scope of the Invention
It should be further appreciated that any of the features, characteristics,
.. alternatives or modifications described regarding a particular embodiment
herein may
also be applied, used, or incorporated with any other embodiment described
herein.
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Although the invention has been described and illustrated with respect to
exemplary
embodiments thereof, the foregoing and various other additions and omissions
may be
made therein and thereto without departing from the scope of the present
invention.
