Material processing systems and methods

A method of processing material includes positioning a transmitter to engage an ore sample with a sub-millisecond electromagnetic pulse, the ore sample including a conductive mineral particle and a volume of a gangue, specifying a characteristic of the electromagnetic pulse based on a desired energy deposition for the conductive mineral particle using a processing circuit, and selectively depositing energy with the electromagnetic pulse to at least one of melt and vaporize the conductive mineral particle by controlling the transmitter with the processing circuit.

BACKGROUND

Ore may be removed from a deposit for further processing as part of a mining operation. Further processing may include at least one of crushing and milling the ore from an initial size to a size that facilitates extracting the desirable minerals therein from the gangue (i.e., the surrounding material, the non-desirable materials, etc.). Traditional processing systems mechanically reduce the size of the ore. Such traditional processing is energy intensive. The energy required to reduce the size of the ore and the achieved size reduction may not be linearly related. By way of example, reducing the size of the ore from one centimeter to millimeter- or micron-sized particles may require significantly more energy than reducing the size of the ore from ten centimeters to one centimeter. The ore is thereafter traditionally exposed to a solution that facilitates extracting the desirable mineral. However, such solutions may present environmental concerns.

SUMMARY

One embodiment relates to a method of processing material that includes positioning a transmitter to engage an ore sample with a sub-millisecond electromagnetic pulse, the ore sample including a conductive mineral particle and a volume of gangue, specifying a characteristic of the electromagnetic pulse based on a desired energy deposition for the conductive mineral particle using a processing circuit, and selectively depositing energy with the electromagnetic pulse to at least one of melt and vaporize the conductive mineral particle by controlling the transmitter with the processing circuit.

Another embodiment relates to a method of processing material that includes transferring an ore sample from a first position to a second position through a first zone using a transporter, the ore sample including a conductive mineral particle and a volume of gangue, positioning a transmitter to engage the first zone with a sub-millisecond electromagnetic pulse, specifying a characteristic of the electromagnetic pulse based on a desired energy deposition for the conductive mineral particle using a processing circuit, and selectively depositing energy with the electromagnetic pulse to at least one of melt and vaporize the conductive mineral particle by controlling the transmitter with the processing circuit.

Still another embodiment relates to a material processing apparatus that includes a transmitter and a processing circuit. The transmitter is configured to irradiate an ore sample with a sub-millisecond microwave pulse in response to a command signal, the ore sample including a conductive mineral particle and a volume of gangue. The processing circuit is coupled to the transmitter and configured to specify the command signal for the transmitter, the command signal varying based on a characteristic of the microwave pulse, and provide the command signal to the transmitter such that the microwave pulse selectively deposits energy to at least one of melt and vaporize the conductive mineral particle of the ore sample.

Yet another embodiment relates to a material processing apparatus that includes a transmitter and a processing circuit. The transmitter is configured to irradiate an ore sample with a sub-millisecond radiofrequency pulse in response to a command signal, the ore sample including a conductive mineral particle and a volume of gangue. The processing circuit is coupled to the transmitter and configured to specify the command signal for the transmitter, the command signal varying based on a characteristic of the radiofrequency pulse, and provide the command signal to the transmitter such that the radiofrequency pulse selectively deposits energy to at least one of melt and vaporize the conductive mineral particle of the ore sample.

Another embodiment relates to a material processing apparatus that includes a transporter, a transmitter, and a processing circuit. The transporter is configured to transfer an ore sample from a first position to a second position through a first zone, the ore sample including a conductive mineral particle and a volume of gangue. The transmitter is positioned to irradiate the first zone with a sub-millisecond electromagnetic pulse in response to a command signal. The processing circuit is coupled to the transmitter and configured to specify the command signal for the transmitter, the command signal varying based on a characteristic of the electromagnetic pulse, and provide the command signal to the transmitter such that the electromagnetic pulse selectively deposits energy to at least one of melt and vaporize the conductive mineral particle of the ore sample.

DETAILED DESCRIPTION

Ore samples may include gangue that at least partially surrounds a mineral particle. A material processing apparatus may facilitate removing the mineral particle from the gangue. The mineral particles may be conductive (e.g., a material having a reduced electrical resistance, etc.) while the gangue may be less-conductive (or non-conductive). The mineral particles may include metals that occur naturally in their metallic form, either as a pure material or as an alloy (i.e., the mineral particles may include native metals, etc.). By way of example, the mineral particles may include gold, silver, copper, platinum, or still other metals. In one embodiment, the material processing apparatus includes a transmitter configured to at least one of melt and vaporize the mineral with an electromagnetic pulse as part of a primary processing step. In one embodiment, the electromagnetic pulse facilitates directly collecting the mineral (e.g., where the melted mineral separates from the gangue, where the vaporized mineral separates from the gangue, etc.). In other embodiments, the material processing apparatus subjects the ore sample to a secondary processing step (e.g., crushing, milling, etc.). Interaction between the mineral and the gangue during the initial processing step may be used to reduce the energy required to perform the secondary processing step. By way of example, the processing apparatus may at least one of melt and vaporize the mineral during the initial processing step, the melted or vaporized mineral weakening the gangue (e.g., macroscopically fracturing, microcracking, etc.) to reduce the energy required to crush, mill, or otherwise secondarily process the ore sample. The material processing apparatus may thereafter extract the mineral from the ore sample.

According to the embodiment shown inFIG. 1, material processing apparatus10includes transmitter20. As shown inFIG. 1, transmitter20is configured to irradiate ore sample40with electromagnetic pulse30. Transmitter20may irradiate ore sample40in response to a command signal provided by processing circuit50.

In one embodiment, transmitter20includes a klystron. In one embodiment, transmitter20includes at least one of a two-cavity klystron, multi-cavity klystron, a reflex klystron, and an extended interaction klystron. In other embodiments, transmitter20includes at least one of a magnetron, a gyrotron, a traveling wave tube, a semiconductor microwave device, and a Gunn diode. Transmitter20may be configured to produce a microwave pulse, a radiofrequency pulse, or still another electromagnetic pulse. A frequency of the electromagnetic pulse may be greater than 10 MHz, greater than 100 MHz, greater than 1 GHz, greater than 10 GHz, or greater than 100 GHz. A frequency of the electromagnetic pulse may lie within the VHF band, the UHF band, the L band, the S band, the C band, the X band, the Ku band, the K band, or the Kα band. In other embodiments, transmitter20includes a Marx generator. In still other embodiments, transmitter20is configured to produce the sub-millisecond microwave pulse using a pulse compression (e.g., via a waveguide compressor, etc.) from an initially longer-duration microwave pulse.

As shown inFIGS. 1-4, ore sample40includes particle42and volume of gangue44. In some embodiments, ore sample40includes a plurality of particles42, which may have a variety of sizes and shapes. Particle42may be disposed within internal cavity46defined by gangue44or may be at least partially exposed to an outer surface of ore sample40. As shown inFIG. 2, internal cavity46defines a sidewall48along volume of gangue44. In one embodiment, particle42includes an at least partially conductive mineral while gangue44is non-conductive. By way of example, particle42may include a metal (e.g., gold, silver, copper, platinum, etc.). By way of another example, particle42may include a sulfide (e.g., pyrite, chalcopyrite, galena, etc.). By way of still another example, particle42may include an oxide (e.g., magnetite, etc.).

Referring again toFIG. 1, material processing apparatus10includes processing circuit50. Processing circuit50is coupled to (e.g., in communication with, etc.) transmitter20, according to the embodiment shown inFIG. 1. Processing circuit50may be physically disposed along or in proximity to transmitter20or may be remotely positioned and coupled to transmitter20(e.g., with a wired connection, with a wireless connection, etc.). In one embodiment, processing circuit50is coupled to a plurality of transmitters20. In other embodiments, a plurality of transmitters20are each coupled to a corresponding processing circuit50.

Processing circuit50may be configured to evaluate the command signal for transmitter20. In one embodiment the command signal varies based on a characteristic associated with electromagnetic pulse30. By way of example, the command signal may itself vary (e.g., in amplitude, in frequency, in pulse length, in wave form, etc.) based on the characteristic associated with electromagnetic pulse30, among other alternatives.

Processing circuit50may be implemented as a general-purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a digital-signal-processor (DSP), circuits containing one or more processing components, circuitry for supporting a microprocessor, a group of processing components, or other suitable electronic processing components. According to the embodiment shown inFIG. 1, processing circuit50includes processor52and memory54. Processor52may include an ASIC, one or more FPGAs, a DSP, circuits containing one or more processing components, circuitry for supporting a microprocessor, a group of processing components, or other suitable electronic processing components.

In some embodiments, processor52is configured to execute computer code stored in memory54to facilitate the activities described herein. Memory54may be any volatile or non-volatile computer-readable storage medium capable of storing data or computer code relating to the activities described herein. In one embodiment, memory54has computer code modules (e.g., executable code, object code, source code, script code, machine code, etc.) configured for execution by processor52. In some embodiments, processing circuit50represents a collection of processing devices (e.g., servers, data centers, etc.). In such cases, processor52represents the collective processors of the devices, and memory54represents the collective storage devices of the devices.

In one embodiment, processing circuit50retrieves the command signal from a database stored within memory54. In another embodiment, processing circuit50generates the command signal. By way of example, processing circuit50may generate the command signal based on information associated with at least one of particle42(e.g., size, density, conductivity, composition, position relative to an outer surface of gangue44, etc.) and gangue44(e.g., conductivity, thickness, etc.).

According to one embodiment, processing circuit50is configured to provide the command signal to transmitter20. In response to receiving the command signal (e.g., after a preset time delay, immediately, etc.), transmitter20produces electromagnetic pulse30. Electromagnetic pulse30selectively deposits energy into particle42, according to one embodiment. The selective deposition of energy may at least one of melt and vaporize particle42. According to one embodiment, electromagnetic pulse30includes a microwave pulse. According to another embodiment, electromagnetic pulse30includes a radiofrequency pulse.

Electromagnetic pulse30selectively deposits energy into particle42without selectively depositing energy into gangue44, according to one embodiment. By way of example, particle42may be more conductive than gangue44, and thereby absorb more energy. By way of example, gangue44may be non-conductive and thereby not absorb energy from electromagnetic pulse30. Material processing apparatus10that irradiates ore sample40with electromagnetic pulse30has a reduced energy consumption relative to devices that subject samples to continuous wave fields. Material processing apparatus10reduces energy consumption by reducing conductive heat transfer from particle42to gangue44, according to one embodiment. Transmitter20may be configured to at least one of melt and vaporize particle42before a significant portion of the energy absorbed by particle42is transferred to gangue44.

As shown inFIG. 3, particle42is melted by electromagnetic pulse30to produce a mineral liquid. Such liquification may reduce the density of particle42(e.g., by two grams per cubic centimeter, etc.). The drop in density, and the associated increase in volume, performs work and thereby weakens gangue44(e.g., macroscopically fracturing, microcracking, etc.). Weakening gangue44may be facilitated by a transfer of thermal energy from particle42into the surrounding material. During or after irradiation, particle42or the mineral liquid may have a temperature that is much greater than the temperature of gangue44, and a rapid heat transfer from particle42or the mineral liquid into gangue44may produce a rapid increase in temperature and expansion of gangue44to facilitate weakening. By way of another example, the mineral liquid may have a reduced volume and non-uniformly transfer energy to sidewall48of internal cavity46, thereby weakening gangue44.

As shown inFIG. 4, particle42is vaporized by electromagnetic pulse30to produce a mineral vapor. Such vaporization reduces the density of particle42. The drop in density, and the associated increase in volume, performs work and thereby weakens gangue44(e.g., macroscopically fracturing, microcracking, etc.). Weakening gangue44may be facilitated by a transfer of thermal energy from particle42into the surrounding material. During or after irradiation, particle42or the mineral vapor may have a temperature that is much greater than the temperature of gangue44, and a rapid heat transfer from particle42or the mineral vapor into gangue44may produce a rapid increase in temperature and expansion of gangue44to facilitate weakening. By way of another example, the mineral vapor may have an elevated pressure that applies a force outward on sidewall48of internal cavity46, thereby weakening gangue44.

Material processing apparatus10may weaken gangue44to facilitate extracting the mineral of particle42from ore sample40using a separation system. In one embodiment, the separation system includes a solution that is configured to facilitate extracting the mineral of particle42. By way of example, the separation system may employ cyanidation and the solution may include at least one of sodium cyanide, potassium cyanide, and calcium cyanide. In other embodiments, the solution includes still another element or compound. The solution may convert the mineral of particle42(e.g., gold, silver, copper, platinum, etc.) into a water soluble coordination complex, which may be thereafter treated to extract the mineral itself.

According to the embodiment shown inFIG. 5, mineral processing apparatus10includes a recovery system, shown as recovery system60. Transmitter20may be configured to selectively deposit energy to at least partially vaporize particle42using electromagnetic pulse30, thereby producing a mineral vapor. In one embodiment, recovery system60includes a vapor recovery system positioned to collect at least a portion of the mineral vapor. By way of example, recovery system60may be disposed above ore sample40such that mineral vapor produced during irradiation by transmitter20travels upward into recovery system60. The mineral vapor may travel upward due to a density differential between the mineral vapor and an ambient environment. In other embodiments, recovery system60includes a vent configured to generate a pressure or flow gradient to draw the mineral vapor away from ore sample40. Recovery system60including a vent may be disposed above, below, or to the side of ore sample40.

According to another embodiment, transmitter20is configured to selectively deposit energy to at least partially melt particle42using electromagnetic pulse30, thereby producing a mineral liquid. In one embodiment, recovery system60includes a liquid recovery system positioned to collect at least a portion of the mineral liquid. By way of example, recovery system60may be disposed below ore sample40such that mineral liquid produced during irradiation flows (e.g., due to gravity, due to surface tension, etc.) into recovery system60. In other embodiments, recovery system60includes a vacuum line configured to engage ore sample40and extract the liquid mineral.

In one embodiment, transmitter20irradiates ore sample40with a single electromagnetic pulse30. In other embodiments, transmitter20irradiates ore sample40with a plurality of electromagnetic pulses. The plurality of electromagnetic pulses may be successively provided by transmitter20. In one embodiment, the plurality of electromagnetic pulses may repeatedly shock and weaken (e.g., fracture, etc.) ore sample40. In other embodiments, the plurality of electromagnetic pulses facilitates a migration of the material of particle42from gangue44due to at least one of repetitive melting and repetitive vaporization (e.g., repeated melting due to selective deposition of energy from electromagnetic pulse30, repeated vaporization due to selective deposition of energy from electromagnetic pulse30, etc.). The plurality of electromagnetic pulses may have similar characteristics or may have different characteristics, according to various embodiments. By way of example, transmitter20may produce a first electromagnetic pulse30having a first set of characteristics and a second electromagnetic pulse30having a second set of characteristics. The first and second electromagnetic pulses30may be produced sequentially or in parallel (e.g., using a pair of electromagnetic sources, etc.).

According to one embodiment, the first set of characteristics associated with first electromagnetic pulse30facilitates selectively depositing energy to at least one of melt and vaporize a first set of particles42(e.g., a group of particles42having a first size or within a first size range, etc.) while the second set of characteristics associated with second electromagnetic pulse30may facilitate selectively depositing energy to at least one of melt and vaporize a second set of particles42(e.g., a group of particles42having a second size or within a second size range, etc.). In one embodiment, first electromagnetic pulse30has a power level configured to only heat larger particles42while melting smaller particles42. Second electromagnetic pulse30may have a power level that, when added to the energy deposition from first electromagnetic pulse30, melts larger particles42without vaporizing smaller particles42. Accordingly, transmitter20may be configured to irradiate ore sample40with first and second electromagnetic pulses30to melt differently sized particles42without risking vaporization of particles42.

In another embodiment, the first set of particles42at least one of melted and vaporized by first electromagnetic pulse30includes a first material (e.g., gold, etc.), while the second set of particles42at least one of melted and vaporized by second electromagnetic pulse30includes a second material (e.g., silver, etc.). Transmitter20may be configured to selectively irradiate ore sample40with first electromagnetic pulse30and second electromagnetic pulse30to facilitate selective extraction of the first material and the second material from ore sample40, according to one embodiment.

Transmitter20may produce the first electromagnetic pulse30to selectively deposit energy and at least one of melt and vaporize particle42, thereby weakening gangue44. Transmitter20may produce the second electromagnetic pulse30to selectively deposit energy and at least one of the melt and vaporize particle42, thereby further weakening gangue44or facilitating recovery of the mineral vapor with recovery system60. According to one embodiment, transmitter20produces the second electromagnetic pulse30after a time delay. By way of example, the time delay may allow the at least one of melted and vaporized particle42to weaken gangue44before additional energy is deposited by the second electromagnetic pulse30.

In one embodiment, the command signal provided by processing circuit50to transmitter20varies based on a characteristic associated with electromagnetic pulse30. Electromagnetic pulse30may have an internal alternating current variation or may vary in time, according to various embodiments. In embodiments where transmitter20is configured to provide a plurality of electromagnetic pulses30having the same or different characteristics, processing circuit50may be configured to provide a plurality of identical or different command signals, respectively. The command signal may encode data that is read and used by transmitter20in producing electromagnetic pulse30.

According to one embodiment, the characteristic includes a frequency of electromagnetic pulse30. Electromagnetic pulse30may interact with particle42to a skin depth. By way of example, the skin depth may include a distance from a surface of particle42into which energy is directly deposited by electromagnetic pulse30. The skin depth is related to the conductivity of particle42, the permeability of particle42, and the frequency of electromagnetic pulse30, according to one embodiment. In one embodiment, the skin depth can be approximated as scaling with the inverse square root of the product of frequency, permeability, and conductivity of particle42. The frequency of electromagnetic pulse30may be selected such that skin depth is equal or similar to a thickness of particle42thereby directly depositing energy into the majority, or the entirety, of particle42. In some embodiments, electromagnetic pulse30preferentially has a high frequency (e.g., GHz-level, etc.). By way of example, electromagnetic pulse30may have a high frequency where the size of particle42is sufficiently small (e.g., micron-level, etc.). In other embodiments, the frequency of electromagnetic pulse30is selected to avoid heating other residents within ore sample40(e.g., materials or gangue that are preferentially heated by a particular frequency, etc.).

The frequency of electromagnetic pulse30may be varied based on the material of particle42. By way of example, processing circuit50may vary the command signal provided to transmitter20based on the material of particle42. Different materials (e.g., gold, silver, copper, platinum, etc.) may have different electrical conductivities. In one embodiment, the frequency of electromagnetic pulse30varies based on the electrical conductivity of particle42. Processing circuit50may receive user input or sensor input relating to the electrical conductivity of particle42or may receive user input or sensor input relating to the material of particle42, according to various embodiments. In one embodiment, processor52of processing circuit50may use the material of particle42to retrieve data relating to the electrical conductivity of particle42from a lookup table stored within memory54.

According to another embodiment, the characteristic includes a pulse length of the electromagnetic pulse30. The pulse length may be related to a shape of a waveform associated with electromagnetic pulse30. The pulse length may also vary the total amount of energy deposited into particle42by electromagnetic pulse30.

The pulse length may be defined between the points where electromagnetic pulse30has a non-zero amplitude (e.g., for a pulse having a step shape, etc.) or between an initial point and a point where the amplitude of electromagnetic pulse30falls below a threshold value. The threshold value may include a constant or may be a fraction of a maximum amplitude, among other alternatives. In one embodiment, the pulse length is specified based on the energy deposition required to at least one of melt and vaporize particle42. In embodiments where transmitter20is configured to reduce the energy loss associated with heat transfer out of particle42before its melting or vaporization, a shorter pulse length may be specified for electromagnetic pulse30where particle42has a smaller size, compared to the pulse length sufficient for larger particle sizes.

In another embodiment, the pulse length varies based a thermal diffusivity of gangue44. A greater thermal diffusivity produces a more rapid transfer of energy from particle42to gangue44. In embodiments where transmitter20is configured to reduce the energy loss associated with heat transfer into gangue44during the melting or vaporization of particle42, a shorter pulse length may be specified for electromagnetic pulse30where gangue44has a larger thermal diffusivity. In other embodiments, the pulse length used for electromagnetic pulse30varies based on a thermal diffusion rate associated with the transfer of energy from particle42into gangue44. By way of example, a shorter pulse length may be used for electromagnetic pulse30where the thermal diffusion rate from particle42into gangue44is larger. The pulse length for electromagnetic pulse30may be between one nanosecond and five hundred nanoseconds. In one embodiment, the pulse length is about ten nanoseconds.

The characteristic associated with electromagnetic pulse30may vary an energy deposition into particle42. In one embodiment, the characteristic produces an energy deposition into particle42at a rate that is greater than the thermal diffusion rate from particle42into gangue44. In embodiments where the pulse energy is specified, reducing the pulse length increases the energy deposition rate and may therefore decrease the amount of deposited energy that is thermally conducted into the gangue, thereby increasing the energy efficiency of melting or vaporizing particle42. The differential between the rate that energy is deposited into particle42and the thermal diffusion rate impacts the efficiency with which particle42is at least one of melted and vaporized. In one embodiment, the rate of the energy deposition melts particle42. Such an energy deposition may be associated with a heat capacity and a phase change of particle42. By way of example, the energy deposition may be used to heat particle42from an initial condition (e.g., an ambient temperature, etc.) to a melting point and provide the latent heat of fusion needed to complete a solid-to-liquid phase change (i.e., the energy deposition is associated with a heat capacity and a phase change of particle42). In another embodiment, the energy deposition may be used to heat particle42from an initial condition (e.g., an ambient temperature, etc.) to a melting point, provide the latent heat of fusion needed to complete a solid-to-liquid phase change, heat particle42to vaporization temperature, and provide the latent heat of vaporization needed to complete a liquid-to-vapor phase change (i.e., the energy deposition is associated with a heat capacity, a melting phase change, and a vaporization phase change of the particle42). By way of example, the pulse length may be specified such that prior to vaporizing or melting particle42, less than a designated fraction (e.g., less than half, etc.) of the electromagnetic pulse energy deposited into particle42may be transferred (e.g., by thermal diffusion, etc.) into gangue44. By way of another example, the pulse length may be specified such that prior to vaporizing or melting particle42, more than a designated amount (e.g., more than half, etc.) of the absorbed electromagnetic pulse energy is in one or more particles42rather than being in gangue44. By way of yet another example, the pulse length may be specified based on energy efficiency, such that more than a designated amount (e.g., 10%, 50%, 90%, etc.) of the absorbed electromagnetic pulse energy is used to melt or vaporize one or more particles42(e.g., used to heat the one or more particles42to a phase change temperature and then supply a latent heat associated with the phase change, etc.).

According to one embodiment, transmitter20is configured to irradiate ore sample40in-situ. By way of example, transmitter20may be used to irradiate ore sample40within a deposit (e.g., an underground deposit, a surface deposit exposed to an ambient environment, etc.). Irradiating ore sample40in-situ within a deposit may facilitate a mining operation where the selective deposition of energy into particle42weakens gangue44. Weakening gangue44may facilitate direct recovery of the mineral within particle42or may increase the efficiency of a secondary processing step used to remove ore sample40from the deposit (e.g., blasting, hammering, sawing, another mechanical process, etc.).

According to the embodiment shown inFIG. 6, a material processing apparatus, shown as material processing apparatus100, is configured to selectively deposit energy into particles (e.g., conductive metallic particles, conductive sulfide particles, conductive oxide particles, still other conductive particles, etc.) of ore samples110. In one embodiment, ore samples110have a size of about one centimeter. As shown inFIG. 6, material processing apparatus100performs at least a portion of a comminution operation.

Material processing apparatus100includes transporter120, according to the embodiment shown inFIG. 6. Transporter120is configured to transfer ore samples110from first position132to second position134through treatment zone136. As shown inFIG. 6, transporter120includes a conveyor system. The conveyor system includes plurality of rollers122and belt124. In other embodiments, transporter120includes another device configured to move ore samples110through treatment zone136. By way of example, transporter120may include a vibratory table (e.g., an inclined table that vibrates to move ore samples110along a sloped surface, etc.) or a mechanized container assembly (e.g., a plurality of containers that are moved by a motor and chain system or another actuator mechanism, etc.), among other alternatives. In other embodiments, material processing apparatus100does not include transporter120(e.g., where material processing apparatus100facilitates extracting particles from in-situ ore samples110disposed within a deposit, etc.).

According to one embodiment, material processing apparatus100includes transmitter140. Transmitter140is positioned to irradiate treatment zone136with electromagnetic pulse142. In one embodiment, transmitter140is positioned to irradiate ore samples110that are transferred through treatment zone136by transporter120. Transmitter140may be configured to emit electromagnetic pulse142in response to a command signal. Processing circuit150is coupled to transmitter140and configured to evaluate the command signal for transmitter140, which may vary based on a characteristic associated with electromagnetic pulse142. In one embodiment, processing circuit150is also configured to provide the command signal to transmitter140such that electromagnetic pulse142selectively deposits energy to at least one of melt and vaporize conductive particles within ore samples110.

Transmitter140is configured to selectively vaporize at least a portion of the conductive particles within ore samples110, according to the embodiment shown inFIG. 6, to produce mineral vapor112that separates from ore samples110. Interaction between mineral vapor112and ore samples110may at least partially weaken the gangue of ore samples110to produce treated ore samples114. As shown inFIG. 6, material processing apparatus100includes recovery system160that is configured to collect at least a portion of mineral vapor112within collection zone162. Treated ore samples114may include additional conductive particles (e.g., solid conductive particles, melted conductive particles, vaporized conductive particles, etc.) that did not separate from ore samples110as mineral vapor112. By way of example, treated ore samples114may include conductive particles that did not receive the requisite energy deposition for vaporization (e.g., due to their size, due to a differential electrical conductivity, etc.). In other embodiments, transmitter140is configured to selectively melt at least a portion of the conductive particles within ore samples110, and recovery system160includes a liquid recovery device configured to collect at least a portion of the liquefied mineral.

In still other embodiments, material processing apparatus does not include recovery system160. Transmitter140may be configured to selectively deposit energy and only melt the conductive particles within ore samples110, and the melted mineral may not separate from ore samples110. By way of another example, transmitter140may be configured to selectively deposit energy and vaporize the conductive particles within ore samples110, but the vapor may not separate from ore samples110(e.g., the vapor may condense along the wall of a crack within the gangue of ore samples110due to a drop in conductivity associated with the continued decrease in density, the vapor may condense within a cavity within which the conductive particle resided prior to irradiation, etc.). Where mineral vapor or the mineral liquid does not separate from ore samples110or the mineral liquid, interaction between the gangue of ore samples110and the at least one of melted and vaporized conductive particles may nonetheless weaken gangue of ore samples110to produce treated ore sample114.

Referring again to the embodiment shown inFIG. 6, material processing apparatus100includes reducer170. In one embodiment, reducer170is configured to decrease the size of treated ore samples114within a reduction zone172to produce reduced ore material116. Reducer170may include a crusher (e.g., a jaw crusher, a cone crusher, etc.), a grinding mill (e.g., a ball mill, a rod mill, an autogenous mill, etc.), or still another device configured to decrease the size of treated ore samples114. According to one embodiment, material processing apparatus100is configured to weaken ore samples110by depositing energy into conductive particles therein with electromagnetic pulse142and thereafter subject treated ore samples114to reducer170. Weakening ore samples110(e.g., the gangue of ore samples110, etc.) prior to subjecting the material to reducer170decreases the energy required to crush, mill, or otherwise reduce ore samples110(e.g., into smaller pieces that are more efficiently processed to extract minerals from the gangue, etc.). In one embodiment, weakening ore samples110using electromagnetic pulse142reduces the energy consumption associated with melting or vaporizing the conductive particles (e.g., by reducing pre-melt or pre-vaporization heat transfer into the gangue). Such processes may reduce the total energy required to extract the minerals from the gangue (e.g., by facilitating direct collection of the mineral using recovery system160, by reducing the energy needed to power reducer170by a level that is greater than the energy required to power transmitter140, etc.). In some embodiments, a portion of ore samples110may not have been sufficiently reduced in size by reducer170(e.g., were not sufficiently weakened by irradiation within treatment zone136, etc.). In one embodiment, the size of ore samples is monitored, and those having a size above a specified threshold are returned to treatment zone136for further irradiation.

As shown inFIG. 6, material processing apparatus100includes separation system180. Separation system180may extract minerals from reduced ore material116within separation zone182. In one embodiment, separation system180includes a solution (e.g., sodium cyanide, potassium cyanide, calcium cyanide, etc.) that converts the desirable minerals within reduced ore material116into coordination complex184, thereby separating the mineral from gangue186. By way of example, separation system180may include a trough or other container within which the solution is disposed. Reduced ore material116may be introduced into the trough or other container for exposure to the solution. In other embodiments, separation system180includes a nozzle, and the solution is topically applied to reduced ore material116. Coordination complex184may be treated to thereafter extract the mineral itself.

In one embodiment, the ore samples travel along a linear path through material processing apparatus100. In other embodiments, the ore samples travel non-linearly through material processing apparatus100. By way of example, treated ore samples114may enter a top portion of reducer170and fall from a bottom portion of reducer170. Reduced ore material116may fall into, may be linearly conveyed, or may be otherwise transported to separation system180.

As shown inFIG. 6, treatment zone136, collection zone162, and separation zone182are sequentially disposed. In other embodiments, at least one of treatment zone136, collection zone162, and separation zone182at least partially overlap. By way of example, collection zone162may overlap treatment zone136such that mineral vapor112or mineral liquid produced during irradiation may be collected. By way of another example, collection zone162may overlap treatment zone136where material processing apparatus100facilitates extracting particles from in-situ ore samples110disposed within a deposit.

Referring next to the embodiment shown inFIG. 7, material is processed according to method200. As shown inFIG. 7, method200includes positioning a transmitter to engage an ore sample with an electromagnetic pulse (210). The ore sample may include a conductive mineral particle and a volume of a gangue. Method200also includes specifying a characteristic of the electromagnetic pulse using a processing circuit (220) and selectively depositing energy with the electromagnetic pulse (230), according to the embodiment shown inFIG. 7. The characteristic may be specified based on a desired energy deposition for the conductive mineral particle. In one embodiment, selectively depositing energy with the electromagnetic pulse includes at least one of melting and vaporizing the conductive mineral particle by controlling the transmitter with the processing circuit.

Referring next to the embodiment shown inFIG. 8, material is processed according to method300. As shown inFIG. 8, method300includes transferring an ore sample from a first position to a second position through a first zone using a transporter (310). The ore sample may include a conductive mineral particle and a volume of a gangue. Method300also includes positioning a transmitter to engage the first zone with an electromagnetic pulse (320), specifying a characteristic of the electromagnetic pulse using a processing circuit (330), and selectively depositing energy with the electromagnetic pulse (340), according to the embodiment shown inFIG. 8. The characteristic may be specified based on a desired energy deposition for the conductive mineral particle. In one embodiment, selectively depositing energy with the electromagnetic pulse includes at least one of melting and vaporizing the conductive mineral particle by controlling the transmitter with the processing circuit.

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. For example, elements shown as integrally formed may be constructed of multiple parts or elements. It should be noted that the elements and/or assemblies of the enclosure may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present inventions. The order or sequence of any process or method steps may be varied or re-sequenced according to other embodiments. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.