Patent Publication Number: US-11642679-B2

Title: Process configurations to prevent excess regrinding of scavengering concentrates

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Patent Application No. 62/464,505, filed 28 Feb. 2017, which is incorporated by reference herein in its entirety. 
     OTHER RELATED APPLICATIONS 
     This application is also related to a family of nine PCT applications, which were all concurrently filed on 25 May 2012, as follows:
         PCT application no. PCT/US12/39528, entitled “Flotation separation using lightweight synthetic bubbles and beads;”   PCT application no. PCT/US12/39524, entitled “Mineral separation using functionalized polymer membranes;”   PCT application no. PCT/US12/39540, entitled “Mineral separation using sized, weighted and magnetized beads;”   PCT application no. PCT/US12/39576, entitled “Synthetic bubbles/beads functionalized with molecules for attracting or attaching to mineral particles of interest,” which corresponds to U.S. Pat. No. 9,352,335;   PCT application no. PCT/US12/39591, entitled “Method and system for releasing mineral from synthetic bubbles and beads;”   PCT application no. PCT/US/39596, entitled “Synthetic bubbles and beads having hydrophobic surface;”   PCT application no. PCT/US/39631, entitled “Mineral separation using functionalized filters and membranes,” which corresponds to U.S. Pat. No. 9,302,270;”   PCT application no. PCT/US12/39655, entitled “Mineral recovery in tailings using functionalized polymers;” and   PCT application no. PCT/US12/39658, 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 is also related to other applications, as follows:
   PCT application no. PCT/US2013/042202, 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;   PCT/US2014/037823, 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, filed 13 May 2013, as well as U.S. patent application Ser. No. 14/118,984, filed 27 Jan. 2014, and is a continuation-in-part to PCT application no. PCT/US12/39631 (712-2.385//CCS-0092), filed 25 May 2012;   PCT application no. PCT/US13/28303, filed 28 Feb. 2013, entitled “Method and system for flotation separation in a magnetically controllable and steerable foam;”   PCT application no. PCT/US16/57334, filed 17 Oct. 2016, entitled “Opportunities for recovery augmentation process as applied to molybdenum production;” and   PCT application no. PCT/US16/37322, filed 17 Oct. 2016, entitled “Mineral beneficiation utilizing engineered materials for mineral separation and coarse particle recovery,”   PCT application no. PCT/US17/37322, filed 9 Jan. 2017, entitled “Recovery media for mineral processing, using open cell or reticulated foam having 3-dimensional functionalized open-network structure for selective separation of mineral particles in an aqueous system,”       

     which are all also hereby incorporated by reference in its entirety. 
     All of the aforementioned patent applications are assigned to and owned by the assignee of the instant application. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates generally to a method and apparatus for separating valuable material from unwanted material in a mixture, such tailings of a flotation process. 
     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 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. 
     Froth flotation is a process for selectively separating hydrophobic materials from hydrophilic. The process has been adapted and applied to a wide variety of materials to be separated, and additional collector agents, including surfactants and synthetic compounds have been adopted for various applications. The flotation process is used for the separation of a large range of sulfides, carbonates and oxides prior to further refinement. Phosphates and coal are also upgraded (purified) by flotation technology. Froth flotation commences by comminution (that is, crushing and grinding), which is used to increase the surface area of the ore for subsequent processing. The ore include the desired minerals and other unwanted materials, know a gangue. The process of grinding the ore into a fine power is known as liberation. The fine powder ore is then mixed with water to form pulp slurry. The desired mineral is rendered hydrophobic by the addition of a surfactant or collector chemical. The particular chemical depends on which mineral is being refined. This slurry (more properly called the pulp) of hydrophobic mineral particles and hydrophilic gangue particles is then placed in a flotation column or horizontal pipeline wherein the concentrated mineral is separated from the tailings containing the gangue. To be effective on a given ore slurry, the collectors are chosen based upon their selective wetting of the types of particles to be separated. A good collector will adsorb, physically or chemically, with one of the types of particles. In a flotation circuit for mineral concentration, various flotation reagents are added to a mixture of ore and water (called pulp) in a conditioning tank. The flow rate and tank size are designed to give the minerals enough time to be activated. The conditioner pulp is fed to a bank of rougher cells which remove most of the desired minerals as a concentrate. The rougher pulp passes to a bank of scavenger cells where additional reagents may be added. The scavenger cell froth is usually returned to the rougher cells for additional treatment, but in some cases may be sent to special cleaner cells. The scavenger pulp is usually barren enough to be discarded as tails. More complex flotation circuits have several sets of cleaner and re-cleaner cells, and intermediate re-grinding of pulp or concentrate. A typical slurry processing system is depicted in  FIG.  1   . As shown in  FIG.  1   , pulp slurry  8  is processed through a plurality of flotation cells  10  and the tailings  12  are discarded in a tailings pond or dam  100 . If the processed slurry  9  can be further processed for mineral recovery, another flotation cell  10  may be used to repeat the process. When the processed slurry  9  is processed in the last flotation cell  10 , froth flotation is generally no longer an effective or viable process for mineral collection. Because of a number of other factors, as much as 15% of the liberated minerals are not recovered and are discarded as gangue in the pond or dam  100 . 
     There is a need in the industry to provide a better way to separate valuable material from unwanted material, from the discarded tailings. 
     SUMMARY OF THE INVENTION 
     The Basic Invention 
     According to some embodiments, the present invention may take the form of a system having a collection processor configured to receive tailings of a flotation process, the tailings having mineral particles of interest; and at least one collection apparatus located in the collection processor. The collection apparatus may include a collection surface configured with a functionalized polymer having a plurality of molecules with a functional group configured to attract the mineral particles of interest to the collection surface. The flotation process may include one or more scavenger circuits configured to provide one or more scavenger circuit feeds having scavenger tails. 
     The system features one or more enhanced scavenger circuits having the at least one collection apparatus located in the collection processor and being configured to receive the one or more scavenger circuit feeds and provide enhanced scavenger circuit feeds having a first enhanced scavenger circuit feed with enhanced scavenger tails and a second enhanced scavenger circuit feed with enhanced scavenger concentrate for further processing by the system, based upon the at least one collection apparatus located in the collection processor. 
     The system according to the present invention may include one or more of the features, as follows: 
     Embodiments Using One Enhanced Scavenger Circuit (ESC) 
     The one or more scavenger circuits may include a scavenger circuit configured to provide a scavenger circuit feed; and the one or more enhanced scavenger circuits may include an enhanced scavenger circuit configured to receive the scavenger circuit feed and provide the first enhanced scavenger circuit feed as final tails and the second enhanced scavenger circuit feed for further processing by the system. 
     The flotation process may include a regrind mill configured to receive the second enhanced scavenger circuit feed, and provide a regrind mill feed for further processing by the system. 
     The flotation process may include a cyclone circuit configured to provide a cyclone U/F circuit feed; and the regrind mill may be configured to receive the cyclone U/F circuit feed, and provide the regrind mill feed for further processing by the system. 
     The regrind mill may be configured to provide the regrind mill feed to the cyclone circuit for further processing by the cyclone circuit. 
     The one or more scavenger circuits may include a cleaner scavenger circuit configured to provide a cleaner scavenger circuit feed; and the one or more enhanced scavenger circuits may include an enhanced scavenger circuit configured to receive the cleaner scavenger circuit feed and provide the first enhanced scavenger circuit feed and the second enhanced scavenger circuit feed for further processing by the system. 
     The flotation process may include a rougher circuit configured to receive the first enhanced scavenger circuit feed and provide a rougher circuit feed for further processing by the system. 
     The flotation process may include a second scavenger circuit configured to provide a second scavenger circuit feed; and the rougher circuit may be also configured to receive the second scavenger circuit feed and provide the rougher circuit feed for further processing by the system. 
     The flotation process may include a regrind mill configured to receive the second enhanced scavenger circuit feed, and provide a regrind mill feed for further processing by the system. 
     The flotation process includes a cyclone circuit configured to provide a cyclone U/F circuit feed; and the regrind mill may be configured to receive the cyclone U/F circuit feed, and provide the regrind mill feed for further processing by the system. 
     The regrind mill may be configured to provide the regrind mill feed to the cyclone circuit for further processing by the cyclone circuit. 
     The cyclone circuit may be configured to provide a cyclone O/F circuit feed; and the flotation process may include a cleaner column circuit configured to receive the cyclone O/F circuit feed, and provide a cleaner column circuit feed for further processing by the system. 
     The cleaner scavenger circuit may be configured to provide a second cleaner scavenger circuit feed; and the cleaner column may be configured to receive the second cleaner scavenger circuit feed and provide the cleaner column feed for further processing by the cleaner scavenger circuit. 
     The enhanced scavenger circuit may be configured to receive the cleaner scavenger circuit feed and provide the first enhanced scavenger circuit feed and the second enhanced scavenger circuit feed for further processing by the system. 
     Embodiments Using Two Enhanced Scavenger Circuit (ESCs) 
     The one or more scavenger circuits may include:
         a scavenger circuit configured to provide a scavenger circuit feed, and   a cleaner scavenger circuit configured to provide a cleaner scavenger circuit feed; and       

     the one or more enhanced scavenger circuits may include:
         a first enhanced scavenger circuit configured to receive the scavenger circuit feed and provide a corresponding first enhanced scavenger circuit feed with corresponding tails and a corresponding second enhanced scavenger circuit feed with corresponding concentrate for further processing by the system; and   a second enhanced scavenger circuit configured to receive the cleaner scavenger circuit feed and provide an associated first enhanced scavenger circuit feed with associated tails and an associate second enhanced scavenger circuit feed with associated concentrate for further processing by the system.       

     The flotation process may include a regrind mill configured to receive the corresponding concentrate, and the associate concentrate, and provide a regrind mill feed for further processing by the system. 
     The flotation process may include a cyclone circuit configured to provide a cyclone circuit feed; and the regrind mill may be configured to receive the cyclone circuit feed, and provide the regrind mill feed for further processing by the system. 
     The regrind mill may be configured to provide the regrind mill feed to the cyclone circuit for further processing by the cyclone circuit. 
     The flotation process may include a rougher circuit configured to receive the associated tails and provide a rougher circuit feed for further processing by the system. 
     The rougher circuit may be configured to receive a scavenger circuit feed from the scavenger circuit and provide the rougher circuit feed for further processing by the system. 
     The Screen Circuit Embodiment 
     The system may include a screen circuit configured to receive the corresponding concentrate and the associate concentrate, and provide screen circuit feeds having a screen circuit U/S feed with a final concentrate and a screen circuit O/S feed for further processing by the process flotation process. 
     The flotation process may include a regrind mill configured to receive the screen circuit O/S feed, and provide a regrind mill feed for further processing by the system. 
     The Collection Processor 
     The functional group may include an ionizing bond for bonding the mineral particles of interest to the molecules. 
     The synthetic material may be selected from a group consisting of polyamides, 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. 
     The functional group may be configured to render the collection area hydrophobic. 
     The synthetic material may be selected from a group consisting of polystyrene, poly(d,l-lactide), poly(dimethylsiloxane), polypropylene, polyacrylic, polyethylene, hydrophobically-modified ethyl hydroxyethyl cellulose polysiloxanates, alkylsilane and fluoroalkylsilane. 
     The mineral particles of interest may have one or more hydrophobic molecular segments attached thereon, and the tailings have a plurality of molecules, each collector molecule comprising a first end and a second end, the first end comprising the functional group configured to attach to the mineral particles of interest, the second end comprising a hydrophobic molecular segment. 
     The synthetic material may include a siloxane derivative. 
     The synthetic material may comprise polysiloxanates or hydroxyl-terminated polydimethylsiloxanes. 
     The collection surface may be configured to contact the tailings over a period of time for providing an enriched collection surface in the collection apparatus, containing the mineral particles of interest, and the system may also include a release processor configured to receive the collection apparatus having the enriched collection surface, the release processor further configured to provide a release medium for releasing the mineral particles of interest from the enriched collection surface. 
     The release medium may include a liquid configured to contact with the enriched collection surface, the liquid having a pH value ranging from 0 to 7. 
     The release medium may include a liquid configured to contact with the enriched collection surface, and the system may also include an ultrasound source configured to apply ultrasound waves to the enriched collection area for releasing the mineral particles of interest from the enriched collection surface. 
     A part of the collection surface may be configured to have the molecules attached thereto, wherein the molecules comprise collectors. Another part of the collection surface may be configured to be hydrophobic. 
     A part of the collection surface is configured to be hydrophobic. 
     Reticulated Foam and/or Foam Block 
     The at least one collection apparatus may include reticulated foam and/or a reticulated foam block providing the three-dimensional open-cell structure. 
     The three-dimensional open-cell structure reticulated foam an open cell foam. 
     The open cell foam may be made from a material or materials selected from a group that includes polyester urethanes, polyether urethanes, reinforced urethanes, composites like PVC coated PU, non-urethanes, as well as metal, ceramic, and carbon fiber foams and hard, porous plastics, in order to enhance mechanical durability. 
     The open cell foam may be coated with polyvinylchloride, and then coated with a compliant, tacky polymer of low surface energy in order to enhance chemical durability. 
     The open cell foam may be primed with a high energy primer prior to application of a functionalized polymer coating to increase the adhesion of the functionalized polymer coating to the surface of the open cell foam. 
     The surface of the open cell foam may be chemically or mechanically abraded to provide “grip points” on the surface for retention of the functionalized polymer coating. 
     The surface of the open cell foam may be coated with a functionalized polymer coating that covalently bonds to the surface to enhance the adhesion between the functionalized polymer coating and the surface. 
     The surface of the open cell foam may be coated with a functionalized polymer coating in the form of a compliant, tacky polymer of low surface energy and a thickness selected for capturing certain mineral particles and collecting certain particle sizes, including where thin coatings are selected for collecting proportionally smaller particle size fractions and thick coatings are selected for collecting additional large particle size fractions. 
     The specific surface area may be configured with a specific number of pores per inch that is determined to target a specific size range of mineral particles in the slurry. 
     The the at least one collection apparatus may include different open cell foams having different specific surface areas that are blended to recover a specific size distribution of mineral particles in the slurry. 
     The Method 
     According to some embodiments, the present invention may include, or take the form of a method for implementing a system having a collection processor configured to receive tailings of a flotation process, the tailings having mineral particles of interest; and at least one collection apparatus located in the collection processor, the collection apparatus having a collection surface configured with a functionalized polymer comprising a plurality of molecules having a functional group configured to attract the mineral particles of interest to the collection surface, the flotation process having one or more scavenger circuits configured to provide one or more scavenger circuit feeds having scavenger tails, 
     wherein the method comprises configuring the system with one or more enhanced scavenger circuits having the at least one collection apparatus located in the collection processor and configured to receive the one or more scavenger circuit feeds and provide enhanced scavenger circuit feeds having a first enhanced scavenger circuit feed with enhanced scavenger tails and a second enhanced scavenger circuit feed with enhanced scavenger concentrate for further processing by the system, based upon the at least one collection apparatus located in the collection processor. 
     The method may include steps for implementing one or more of the additional features set forth herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       Referring now to the drawing, which are not necessarily drawn to scale, the foregoing and other features and advantages of the present invention will be more fully understood from the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawing in which like elements are numbered alike: 
         FIG.  1    is a diagram of a prior art slurry processing system. 
         FIGS.  2   a - 2   d    are diagrams of an overall scheme for tailings processing, according to some embodiments of the present invention. 
         FIG.  3   a    is a diagram of a recovery processor configured with a functionalized polymer coated conveyor belt operated in conjunction with a releasing processor, according to some embodiments of the present invention. 
         FIG.  3   b    is a diagram of a recovery processor configured with a plurality of filters having functionalized polymer surfaces for collecting valuable material in a batch process, according to some embodiments of the present invention. 
         FIG.  3   c    is a diagram of a recovery processor configured with a plurality of collection plates having functionalized polymer surfaces for collecting valuable material in a batch process, according to some embodiments of the present invention. 
         FIG.  4    is a diagram of a releasing processor, according to some embodiments of the present invention. 
         FIG.  5   a    is an illustration of a section of a conveyor belt, according to some embodiments of the present invention. 
         FIG.  5   b    is an illustration of a filter, according to some embodiments of the present invention. 
         FIG.  5   c    is an illustration of a collection plate, according to some embodiments of the present invention. 
         FIGS.  6   a - 6   d    illustrate various surface features of the collection plate, according to some embodiments of the present invention. 
         FIGS.  7   a - 7   f    illustrate various surface features of the filter and the conveyor belt, according to some embodiments of the present invention. 
         FIG.  8   a    illustrates a plurality of functional groups attached to a fiber for attracting mineral particles, according to some embodiments of the present invention. 
         FIG.  8   b    illustrates a plurality of hydrophobic molecules attached to a fiber for attracting mineral particles, according to some embodiments of the present invention. 
         FIG.  8   c    illustrates a plurality of hydrophobic molecules attached to a fiber for attracting non-mineral particles, according to some embodiments of the present invention. 
         FIG.  9   a    illustrates a plurality of functional groups attached to edges or surfaces for attracting mineral particles, according to some embodiments of the present invention. 
         FIG.  9   b    illustrates a plurality of hydrophobic molecules attached to edges or surfaces for attracting mineral particles, according to some embodiments of the present invention. 
         FIG.  9   c    illustrates a plurality of hydrophobic molecules attached to edges or surfaces for attracting non-mineral particles, according to some embodiments of the present invention. 
         FIG.  10   a    illustrates a filter using a plurality of synthetic beads or bubbles for collecting valuable material in tailings of a flotation process, according to some embodiments of the present invention. 
         FIG.  10   b    illustrates a collection plate using a plurality of synthetic beads or bubbles for collecting valuable material in tailings of a flotation process, according to some embodiments of the present invention. 
         FIG.  10   c    illustrates a sack of synthetic beads which can be used as a filter to collect valuable material in tailings of a flotation process, according to some embodiments of the present invention. 
         FIG.  11   a    illustrates a synthetic bead functionalized to attract hydrophobic particles, according to some embodiments of the present invention. 
         FIG.  11   b    is an enlarged surface portion of the synthetic bead functionalized to attract wetted mineral particles, according to some embodiments of the present invention. 
         FIG.  11   c    is an enlarged surface portion of the synthetic bead functionalized to attract non-mineral hydrophobic particles, according to some embodiments of the present invention. 
         FIG.  12   a    illustrates a synthetic bead having a functional group to attract mineral particles, according to some embodiments of the present invention. 
         FIG.  12   b    is an enlarged surface portion of the synthetic bead functionalized to attract mineral particles, according to some embodiments of the present invention. 
         FIG.  13    illustrates a tailings pond wherein a plurality of functionalized polymer coated surfaces configured to attract the valuable material in the pond, according to some embodiments of the present invention. 
         FIG.  14    includes  FIG.  14   a    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 includes  FIG.  14   b    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. 
         FIG.  15    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. 
         FIG.  16    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. 
         FIG.  17   a    shows a large mineral particle is attracted to a plurality of functional groups provided on a surface of a filter, according to some embodiments of the present invention. 
         FIG.  17   b    shows a large mineral particle is attracted to a plurality of functional groups provided on a backbone of a molecule, according to some embodiments of the present invention. 
         FIG.  17   c    shows a large, wetted mineral particle is attracted to a plurality of hydrophobic molecules on a surface of a filter, according to some embodiments of the present invention. 
         FIG.  18   a    illustrates a mineral particle being attached to a number of much smaller synthetic beads at the same time, according to some embodiments of the present invention. 
         FIG.  18   b    illustrates a mineral particle being attached to a number of slightly larger synthetic beads at the same time, according to some embodiments of the present invention. 
         FIG.  19   a    illustrates a wetted mineral particle being attached to a number of much smaller hydrophobic synthetic beads at the same time, according to some embodiments of the present invention. 
         FIG.  19   b    illustrates a wetted mineral particle being attached to a number of slightly larger hydrophobic synthetic beads at the same time, according to some embodiments of the present invention. 
         FIG.  20   a    illustrates a collection media taking the form of an open-cell foam in a cubic shape. 
         FIG.  20   b    illustrates a filter according to some embodiments of the present invention. 
         FIG.  20   c    illustrates a section of a membrane or conveyor belt according to an embodiment of the present invention. 
         FIG.  20   d    illustrates a section of a membrane or conveyor belt according to another embodiment of the present invention. 
         FIG.  21    is a picture showing reticulated foam with Cu Mineral entrained throughout the structure. 
         FIG.  22    shows an example of a flotation circuit that is known in the art. 
         FIG.  23    shows the flotation circuit in  FIG.  22    having enhanced scavenger circuits included therein, according to some embodiments of the present invention. 
         FIG.  24    shows the flotation circuit in  FIG.  23    having enhanced scavenger circuits included therein, according to some embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIGS.  22 - 24   
     This application builds and improves on technology disclosed in the aforementioned PCT application no. PCT/US12/39655, which corresponds to U.S. patent application Ser. No. 14/119,013, filed 23 Mar. 2015, as well as PCT application no. PCT/US17/37322, which corresponds to U.S. patent application Ser. No. 15/401,755, filed 9 Jan. 2017, which are all incorporated by reference in their entirety. 
       FIGS.  1 - 19     b  form part of the aforementioned PCT application no. PCT/US12/39655,  FIGS.  20   a    thru  20   d  and  21  form part of PCT application no. PCT/US17/37322, and  FIGS.  22 - 24    form part of the improvement to the aforementioned technology. 
     In summary, the present invention sets forth an improvement to the use of the assignee&#39;s polymer separation technology in a scavenging application to concentrate valuable mineral particles from a stream that would otherwise be discarded or recirculated. 
     FIG.  22   
     By way of example,  FIG.  22    shows a common process configuration for base metal sulfide processing that is known in the art. In summary, and consistent with that shown in  FIG.  22   , a flotation circuit receives a fresh feed and water and provides final tails and a final concentrate, as follows:
         A semi-autogenous grinding (SAG) mill is configured to receive a fresh feed, fresh water and an overscreen (O/S) screen feed back from a screen, and provide a SAG mill feed e.g., after further SAG milling the O/S screen feed received from the screen.   The screen is configured to receive the SAG mill feed, and provide the O/S screen feed back to the SAG mill and an underscreen (U/S) screen feed.   A cyclone is configured to receive the U/S screen feed and a ball mill feed from a ball mill, and provide an overflow (O/F) cyclone feed and an underflow (U/F) cyclone feed back to the ball mill.   The ball mill is configured to receive the U/F feed from the cyclone, and provide the ball mill feed back to the cyclone, e.g., after further ball milling the U/F feed received from the cyclone.   A rougher is configured to receive the O/F feed from the cyclone, a first scavenger feed from a scavenger and a first cleaner scavenger feed from a cleaner scavenger, and provide one rougher feed to the scavenger and another rougher feed to another cyclone.   The scavenger is configured to receive the one rougher feed from the rougher, and provide the first scavenger feed back to the rougher for further roughening, and a second scavenger feed as final tails.   The other cyclone is configured to receive the other rougher feed from the rougher and a regrind mill feed from a regrind mill, and provide an overflow (O/F) cyclone feed and an underflow (U/F) cyclone feed back to the regrind mill.   The regrind mill is configured to receive the U/F cyclone feed from the other cyclone and provide the regrind mill feed back to the other cyclone.   A cleaner column is configured to receive the O/F cyclone feed from the other cyclone and a second cleaner scavenger feed from the cleaner scavenger, and provide one cleaner column feed as final concentrate and another column cleaner feed back to the cleaner scavenger.   The cleaner scavenger is configured to receive the other column cleaner feed back from the cleaner column, and provide the first cleaner scavenger feed to the rougher and the second cleaner scavenger feed back to the cleaner column.       

     In this process shown in  FIG.  22   , the incoming raw materials undergo multiple stages of size reduction along with multiple stages of separation in order to produce a final product of suitable purity. It should be understood that the configuration shown here in  FIG.  22    is only exemplary and the present invention should be suitable for any similar process in which the size reduction steps can consist of one or more of the following: crushers; rod mills; ball mills; semi-autogenous grinding mills; autogenous grinding mills; high pressure grinding rolls; vertically stirred mills; horizontal fine grinding mills; or any other similar size reduction technology. Similarly the separation steps/stages shown in  FIG.  20    may consist of one or more of the following: mechanical flotation; column cell flotation; impinging jet flotation systems (contact cell, Jameson cell, microcell); permanent magnetic separators; electromagnetic separators; gravity separation equipment; enhanced gravity separators (See works related to continuous concentrators and mineral separation systems related to Falcon, Knelson, MGS, Kelsey, Jig, etc.); electrostatic separators; or any other similar mineral separation equipment. Finally it should also be understood that screening or cyclone stages shown in  FIG.  22    are exemplary of classification processes and may consist of one or more of the following: hydrocylones; wet screens; dry screens; or any other similar classification technology for minerals. 
     The new technology according to the present invention is able to selectively concentrate value mineral particles from tailings streams in mineral processing plants which would otherwise be unrecoverable due to issues with particle size, mineral associations, mineral liberation or mineral surface exposure. Details of this application of the scavenger technology have been disclosed previously (See the aforementioned PCT application no. PCT/US12/39655, set forth in the family of the assignee&#39;s cases herein). A key process step in many beneficiation processes is the regrind stage ( FIG.  22   ) where particles containing value minerals which are initially recovered by a given separation technology undergo further size reduction to improve the liberation and surface exposure of the value minerals. The products of regrinding stages can then be more selectively upgraded (e.g. the cleaner column stage in  FIG.  22   ) to produce final products with acceptably high concentrations of value minerals. 
     Regrinding steps may also be used for the products of scavenging separation stages ( FIG.  22   ) whose goal is to prevent recoverable value mineral particles from exiting the plant in final waste streams. Particles recovered in these scavenging steps often possess non-optimal particle characteristics (particle size/liberation/surface exposure) for recovery. Therefore, simply recirculating these particles from scavenging stages to rougher separation stages without the possibility of further size reduction would only serve to generate undesirable circulating loads in separation circuits. It is for this reason that particles recovered from scavenging stages will be fed directly or indirectly to a regrinding step. 
     In the case of the new tailings scavenging technology, examples of embodiments/applications according to the present invention are shown in  FIG.  23    as added processes to the flotation circuit in the flowsheet shown in  FIG.  22   . 
     FIG.  23   
     In particular, according to some embodiments of the present invention, the flotation circuit in  FIG.  23    may be configured with a first enhanced scavenger circuit ESC 1  after the scavenger circuit for further processing scavenger tails or tailings. The ESC 1  may be configured to receive the second scavenger feed, and provide a first ESC 1  feed (tails) as the final tails and a second ESC 1  feed (conc) as ESC 1  concentrate back to the regrind mill for further regrinding. Moreover, according to some embodiments of the present invention, the flotation circuit in  FIG.  23    may also be configured with a second enhanced scavenger circuit ESC 2  after the cleaner scavenger circuit for further processing cleaner scavenger tailings. The ESC 2  may be configured to receive the first cleaner scavenger feed, provide a first ESC 2  feed (tails) as the tails back to the rougher for further processing, and also provide a second ESCs feed (conc) as ESC 2  concentrate back to the regrind mill for further regrinding. In this case, the rougher may be configured to receive the O/F feed from the cyclone, the first scavenger feed from the scavenger and the first ESC 2  feed (tails) as the tails from the ESC 2 , and provide the one rougher feed to the scavenger and the other rougher feed to the other cyclone. In addition, in this case, the regrind mill may be configured to receive the U/F cyclone feed from the other cyclone, the second ESC 1  feed (conc) as the ESC 1  concentrate and the second ESC 2  feed (conc) as the ESC 2  concentrate, and provide the regrind mill feed back to the other cyclone for further processing. 
     In  FIG.  23   , the ESC 1  and ESC  2  may be configured to further treat and process the tailings of rougher-scavenger flotation as well as the tailings of the cleaner-scavenger flotation.  FIG.  23    shows the concentrates produced from the ESC 1  and ESC 2  as being fed directly to the regrinding step. This would be expected to ultimately lead to increased value mineral recovery in the final concentrate from the cleaner column in  FIG.  23    and therefore have a positive economic benefit for the overall plant. 
     However, one negative aspect of the flotation circuit shown in  FIG.  23    is that well-liberated, finely sized value mineral particles in the ESC-produced concentrate (likely not recovered by the existing separation circuits because of particle size effects rather than liberation/locking issues) may not likely benefit from regrinding. This process step would reasonably be expected to either reduce the particle size needlessly, or may have no effect as fine sized particles recirculated to a regrind mill&#39;s cyclone feed would likely report to the cyclone underflow and effectively short-circuit the regrinding step entirely. This may be undesirable as the regrinding of the fine particles in the ESC concentrate would not result in an increased probability of these particles reporting to the plant&#39;s final concentrate (cleaner column concentrate in  FIG.  23   ). 
     FIG.  24   
     In view of this, some embodiments of the present invention may be geared towards addressing this issue, e.g., by employing additional classification steps for the ESC-produced concentrates as shown in  FIG.  24   . 
     In particular, according to some embodiments of the present invention, the flotation circuit shown in  FIG.  23    may also be configured with a second screen as shown in  FIG.  24   . In this case, the second screen may be configured to receive the second ESC 1  feed (conc) as the ESC 1  concentrate and also receive the second ESC 2  feed (conc) as the ESC 2  concentrate, and provide a second screen U/S feed as a final concentrate (final conc), and also provide a second screen O/S feed back to the regrind mill for further processing. In this embodiment, the flotation circuit in  FIG.  24    is configured so that the second ESC 1  feed (conc) as the ESC 1  concentrate and the second ESC 2  feed (conc) as the ESC 2  concentrate are not provided directly back to the regrind mill, but instead are provided to the second screen. In this case, the regrind mill may be configured to receive the U/F cyclone feed from the other cyclone and the second screen O/S feed from the second screen, and provide the regrind mill feed back to the other cyclone for further processing. 
     Many valuable minerals show preferential deportment to finer size classes relative to common gangue minerals (often silicates) so it is reasonable to expect a significant amount of the valuable minerals in the assignee&#39;s circuit feeds ( FIG.  24   ) to be in very fine size classes. The classification stage shown in  FIG.  24    may therefore be able to produce a secondary concentrate that could be fed to downstream refining processes or blended with the main plant concentrate product. This process configuration would minimize the contribution of the ESC 1 / 2 &#39;s concentrates to regrind stage feed rates and therefore minimize plant disruptions due to the introduction of the assignee&#39;s mineral separation technology in an operating mineral processing plant. 
     The Implementation of the ESC 1  and ESC 2   
     Consistent with that disclosed in the aforementioned PCT application no. PCT/US12/39655, the ESC 1  and ESC 2  according to the present invention may be implement using one or more of the combinations of technology disclosed in relation to  FIGS.  2   a  through  19   b   , as follows: 
     FIG.  2   a - 2   d : Tailings Processing 
     By way of example, tailings from a flotation process can be processed in a tailings pond or in a location between the end of the flotation process and the tailings pond. According to some embodiments of the present invention, a method or technique is provided to recover a valuable material or mineral particle of interest in, or that form part of, the tailings, using collection apparatus that may be functionalized with a synthetic material comprising a plurality of molecules having a functional group configured to attract the mineral particles of interest to the surface of the collection apparatus. The method or technique includes causing the collection apparatus to contact with the tailings having the mineral particles of interest, including the tailings from a flotation process. Numerous techniques or ways are set forth herein for causing the collection apparatus to contact with the tailings. 
     According to some embodiments of the present invention, the functional group may include an ionizing bond for bonding the mineral particles to the molecules. According to some embodiments of the present invention, the functional group may render the collection area or surface hydrophobic in order to attract hydrophobic mineral particles of interest. In the specification, the terms “functionalized synthetic material”, “synthetic material” and “functionalized polymer” are used interchangeably. The terms “valuable material”, “valuable mineral” and “mineral particles of interest” are also used interchangeably. The term “polymer” means a large molecule made of many units of the same or similar structure linked together. 
     In the embodiment as shown in  FIG.  2   a   , after the tailings  12  is discharged from a last flotation cell  10  to a tailings pond or dam  100 , a functionalized polymer  20  may be placed in the tailings pond to collect the valuable material of interest in the pond. 
     In the embodiment as shown in  FIG.  2   b   , a functionalized polymer  30  may be used in a recovery processor  50  located closed to the last flotation cell  10  to process the tailings  12  in order to collect the valuable material of interest in the recovery processor  50 . The processed tailings  14  are then transported to the pond or dam  100 . 
     In the embodiment as shown in  FIG.  2   c   , the recovery processor  50  may be placed near the pond  100 . The recovery processor  50  may use the functionalized polymer  30  to process the tailings  12 . The processed tailings  14  may then be discharged into the pond or dam  100 . 
     In the embodiment as shown in  FIG.  2   d   , the functionalized polymer  30  may be used to collect the mineral particle of interest in the recovery processor  50  and the functionalized polymer  20  may be used in the pond  100 . 
     By way of example, the functionalized polymer  20 ,  30  may comprise functionalized polymer coated collection areas or surfaces as shown in  FIGS.  3   a - 3   c ,  5   a - 5   c ,  6   a - 6   d ,  7   a - 7   f ,  8   a - 9   c ,  11   a   ,  12   a.    
     FIGS.  3   a - 3   c : Functionalized Polymer in Recovery Processor 
     By way of example, the functionalized polymer  30  ( FIGS.  2   c - 2   d   ), according to some embodiments, may be provided on a collection apparatus in the recovery processor. The collection apparatus may include a collection area or surface coated with the functionalized polymer. The collection apparatus can take many different forms, 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. For example, the collection apparatus can take the form of a conveyor belt, a filter and a collection plate. 
     In the embodiment as shown in  FIG.  3   a   , one or both sides of the conveyor belt  120  may be coated with, or made of, the functionalized polymer. As tailings  12  may be received into the recovery processor  50 , the tailings are caused to contact with the surfaces of the conveyor belt  120 , which is moving in a continuous loop between the recovery processor  50  and a release processor  70 . The valuable material or mineral particle of interest attached to the surfaces of the conveyor belt  120  in the recovery processor  50  will be released from the conveyor belt in the release processor  70  by means of a low pH environment and/or by means of ultrasonic agitation. As shown in  FIG.  3   a   , one or more ultrasound sources  72  may be provided in the release processor  70  in order to apply ultrasonic agitation to the surfaces of the conveyor belt. The pH value in the release processor can be ranged from 0 to 7. After being processed in the recovery processor  50 , the processed tailings  14  can be transported to a tailings pond or directly discharged into a tailings pond. Alternatively, the processed tailings  14  can be received into another recovery processor  50  for further processing. 
     In the embodiment as shown in  FIG.  3   b   , a plurality of filters  220  may be used in a group. Each of the filters  220  may have a plurality of passage ways (see  FIGS.  7   a - 7   e   ) to allow the tailings  12  to move through. The passage ways may be used to provide collection areas or surfaces (see  FIGS.  8   a - 9   c   ) configured to contact with the tailings as the tailings pass through the passage ways. The collection areas or surfaces in the passage ways may be coated with, or made of, the functionalized polymer. As the tailings move from one end of the recovery processor  50  to the other end through the filters  220 , the molecules of the functionalized polymer are configured to attract the mineral particles of interest in the tailings. When the filters  220  have collected a certain amount of mineral particles of interest, one or some of the filters  220  can be removed from the recovery processor  50  at a time in order to release the mineral particles collected on the filters. 
     In the embodiment as shown in  FIG.  3   c   , a plurality of collection plates  320  may be arranged in a certain pattern to increase the contact between the tailings in the recovery processor  50  and the collection plates  320 . Each of the collection plate  320  may be coated with, or made of, the functionalized polymer. As the tailings move from one end of the recovery processor  50  to the other end through the collection plates  320 , the molecules of the functionalized polymer are configured to attract the mineral particles of interest in the tailings. When the collection plates  320  have collected a certain amount of mineral particles, one or some of the collection plates  320  can be removed from the recovery processor  50  at a time in order to release the mineral particles collected on the collection plate. The mineral particles attached to the filters  220  or the collection plates  320  can be released in many different ways. For example, they can be released in a low pH environment, by ultrasonic agitation, by microwaves, by ultraviolet light illumination or thermally. By way of example, a filter  220  or collection plate  320  with collected mineral particles can be taken to a release station  400  as shown in  FIG.  4   . The filter  200  or collection plate may be placed in a release apparatus  410  to be washed with a mixture of acid and water provided by water container  424  and acid container  422 . One or more ultrasonic sources  432  may be used to shake loose the attached mineral particles from the filter  220  or collection plate  230 . The reclaimed water  427  can be channeled back for reuse. The concentrated mineral  440  can be taken out of the releasing apparatus  410 . 
     FIGS.  5   a ,  5   b  and  5   c : Conveyor Belts, Filters and Collection Plates 
     By way of example, the conveyor belt  120  ( FIG.  3   a   ) may be configured with a collection area  123  to support the functionalized polymer ( FIG.  5   a   ). The filter  220  ( FIG.  3   b   ) may be configured with a collection area  223  to support the functional polymer ( FIG.  5   b   ). The collection plate  320  ( FIG.  3   c   ) may be configured with a collection area  323  to support the functionalized polymer ( FIG.  5   c   ). The collection area  123 ,  223  and  323  can take many forms and have various surface features (FIGS.  7   a - 7   f ) to collect the mineral particles of interest, when the conveyor belt  120 , the filter  220  and the collection plate  320  are made to contact with the tailings, whether in a tailings pond  100  ( FIGS.  2   a - 2   d   ) or in recovery processor  50  ( FIGS.  2   b - 2   d ,  3   a - 3   c   ). 
     FIGS.  6   a - 6   d : Surface Structures 
     The collection area  323  of the collection plate  320  can take many different forms. For example, the collection area  323  on one or both of sides of the collection plate  323  can be a smooth surface, as shown in  FIG.  6   a   . The collection area  323  on one or both of sides of the collection plate  323  can be a rough surface of irregular height and pattern, as shown in  FIG.  6   b   . The collection area  323  on one or both of sides of the collection plate  323  can have grooves and dents, as shown in  FIG.  6   c   . The collection area  323  on one or both of sides of the collection plate  323  can have hair-like structure as shown in  FIG.  6   d   . The collection area may be coated with, or made of, functionalized polymer to attract mineral particles of interest. The surface structures on  FIGS.  6   b - 6   d    may be configured to increase the contact between the functionalized polymer on the collection area and the tailings. 
     FIGS.  7   a - 7   f : Surface Features 
     By way of example, each of the collection areas  123 ,  223  and  323  ( FIGS.  5   a - 5   c   ) may have a plurality of openings to allow the tailings  12  ( FIGS.  3   a - 3   c   ) to pass through while collecting at least part of the valuable material or mineral particles of interest in the tailings. The surface inside an opening and the surfaces or edges around the opening may be provided with the molecules of the functionalized polymer to attract the mineral particles. Those surfaces are referred to as collection surfaces. For example, the openings on the collection areas  123 ,  223  and  323  can take the form of holes or cylindrical passage ways  701  as shown in  FIG.  7   a   . The openings on the collection areas  123 ,  223  and  323  can take the form of hexagonal passage ways  702  arranged like honeycomb, as shown in  FIG.  7   b   . The collection areas  123 ,  223  and  323  can have a rectangular grid  703 , as shown in  FIG.  7   c   . The collection areas  123 ,  223  and  323  may comprise a stack of wavy sheets  704  a shown in  FIG.  7   d   . The collection areas  123 ,  223  and  323  may comprise an irregular arrangement of fiber-like structures  705  as shown in  FIG.  7   e   . The collection areas  123  and  323  may comprise a plain surface  706  as shown in  FIG.  7   f   . The plain surface  706  may be a smooth surface, a paper-like surface or matted surface, without larger structures. The collection area  23 ,  123  and  223  can be made of a synthetic material, such as a polymer functionalized for attracting the mineral particles. Alternatively, only the collection surfaces may be coated with such a functionalized polymer while most part of the conveyor belt  120 , the filter  220  and the collection plate  320  may be made of metal, ceramic, glass or a different polymer. 
     FIGS.  8   a - 9   c : Surface Molecules 
     By way of example, the fiber-like structures  705  ( FIG.  7   e   ) can be functionalized so that they become attached to molecules  73  ( FIGS.  8   a ,  8   b   ). The fiber-like structures  705  as shown in  FIG.  7   e    can be made of individual fibers  401 ,  401 ′ as shown in  FIG.  8   a - 8   c   . In one embodiment of the present invention, the fiber  401  ( FIG.  8   a   ) can be made of a polymer that has a plurality of molecules  73  to provide the functional group  78  and the attaching molecular segment  76 . 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 the fiber  401 . A functional group  78  is also known as a collector that is either ionic or non-ionic bonding to mineral particles  72 . The ion can be anionic or cationic. An anion includes, but not limited to, 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. In another embodiment of the present invention, the fiber  401  is coated with polymer that has the molecules  73  to provide the functional group  78  and the attaching molecular segment  76 . With such a coating, the fiber  401  can be made of glass, ceramic, metal, nylon, cotton or a different polymer. A diagram of the fiber  401  and the attached molecules  73  is shown in  FIG.  8     a.    
     In a different embodiment of the present invention, the fiber  401 ′ ( FIG.  8   b   ) can be made of a polymer that has a plurality of molecules  79  to render the fiber  401 ′ (and thus the collection areas  123 ,  223  and  323  of  FIGS.  5   a - 5   c   ) hydrophobic. The polymer can be a hydrophobic material such as polystyrene, poly(d,l-lactide), poly(dimethylsiloxane), polypropylene, polyacrylic, polyethylene, etc. The polymer can also be a hydrophobically-modified polymer, such as hydrophobically-modified ethyl hydroxyethyl cellulose. Alternatively, the fiber  401 ′ can be made of glass, ceramic, metal, nylon, cotton or other fabric materials and coated with hydrophobic molecules, such as polysiloxanates, alkylsilane and fluoroalkylsilane. The molecules  79  cause the fiber  401 ′ to become hydrophobic. As such, a hydrophobically-modified mineral particle  72 ′ can be attracted to the hydrophobic fiber  401 ′. The hydrophobically-modified, or wetted, mineral particle  72 ′ may include a mineral particle  71  and one or more molecules  73  attached thereon. The molecule  73 , or collector, may have a functional group  78  attached to the mineral particle  71  and a hydrophobic chain or molecular segment  76 . A diagram showing the attraction between the hydrophobic chain or molecular segments  76  and the hydrophobic fiber  401 ′ is shown in  FIG.  8   b   . It should be understood that the particles  72 ′ may be non-mineral and can be some harmful particles in a body of water. Furthermore, the hydrophobic fiber  401 ′ can also be used to attract non-mineral particles. For example, if a non-mineral particle  71 ′ has one or more hydrophobic chains or molecular segments  76 , the non-mineral particle  71 ′ may also attracted to the hydrophobic fiber  401 ′. A diagram showing the attraction between non-mineral particles  71 ′ and the hydrophobic fiber  401 ′ is shown in  FIG.  8   c   . Thus, the hydrophobic fiber  401 ′ can be used in a filter, impeller or conveyor belt (similar to those shown in  FIGS.  4 - 6   ) for water-pollution control, water purification, etc. 
     The surfaces and edges around the openings or surface structures  701 ,  702 ,  703 ,  704  ( FIGS.  7   a - 7   d   ) can be functionalized to provide the molecules  73  ( FIGS.  9   a ,  9   b   ). The exposed surfaces and edges around the openings or surface structures  701 ,  702 ,  703 ,  704  are represented by surface portions  403 ,  403 ′ as shown in  FIGS.  9   a - 9   c   . The length L of the surface portions  403 ,  403 ′ can be equal to the thickness of the conveyor belt  120 , the filter  220  and the collection plate  320  ( FIGS.  5   a - 5   c   ). As with the fiber  401  as shown in  FIG.  8   a   , the surface portion  403  can be made of a polymer that has a plurality of molecules  73  to provide the functional group  78  and the attaching molecular segment  76 . In a different embodiment, the surface portion  403  may be coated with polymer that has the molecules  73  to provide the functional group  78  and the attaching molecular segment  76 . The surface portion  403  can be made of glass, ceramic, metal, nylon, cotton or a different polymer. The functional group  78  may be used to attract mineral particles of interest  72 . A diagram of the surface portion  403  and the attached molecules  73  is shown in  FIG.  9     a.    
     In a different embodiment of the present invention, the surface portion  403 ′ can be made of a polymer having a plurality of molecules  79  that render the surface portion  403 ′ (and thus the collection areas  123 ,  223  and  323  of  FIGS.  5   a - 5   c   ) hydrophobic. As with the hydrophobic fiber  401 ′ as shown in  FIGS.  8   b  and  8   c   , the polymer can be a hydrophobic material such as polystyrene, poly(d,l-lactide), poly(dimethylsiloxane), polypropylene, polyacrylic, polyethylene, etc. The polymer can also be a hydrophobically-modified polymer, such as hydrophobically-modified ethyl hydroxyethyl cellulose. Alternatively, the surface portion  403 ′ can be made of glass, ceramic, metal, nylon, cotton or other fabric materials and coated with hydrophobic molecules, such as polysiloxanates, alkylsilane and fluoroalkylsilane. The molecules  79  cause the surface portion  403 ′ to become hydrophobic. As such, a hydrophobically-modified mineral particle  72 ′ is attracted to the hydrophobic surface portion  403 ′. A diagram showing the attraction between the molecular segments  76  and the hydrophobic surface portion  403 ′ is shown in  FIG.  9   b   . It should be understood that the particles  72 ′ may be non-mineral and can be some harmful particles in a body of water. Furthermore, the hydrophobic surface portion  403 ′ can also be used to attract non-mineral particles. For example, if a non-mineral particle  71 ′ has one or more hydrophobic chains or molecular segments  76 , the non-mineral particle  71 ′ may also be attracted to the hydrophobic surface portion  403 ′. A diagram showing the attraction between the non-mineral particles  71 ′ and the hydrophobic surface portion  403 ′ is shown in  FIG.  9   c   . Thus, a filter, collection plate or conveyor belt (similar to those shown in  FIGS.  5   a - 5   c   ) that has hydrophobic surface portions  403 ′ can also be used for water-pollution control, water purification, etc. to rid of hydrophobically-modified particles  72 ′ which may not be a mineral of interest, but some metal or other material or chemical harmful to the environment. 
     The treatment of plain surface  706  ( FIG.  7   f   ) can be made similar to the surface portions  403 ,  403 ′ as shown in  FIGS.  9   a - 9   c   . That is, the plain surface  706  can be functionalized to provide a functional group  78  as shown in  FIG.  9   a   . The plain surface  706  can also be functionalized to be hydrophobic, as shown in  FIGS.  9   b    and  9   c.    
     It should be understood that, when the collection area or surface  123  of the conveyor belt  120  ( FIG.  5   a   ), the collection area or surface  223  of the filter  220  ( FIG.  5   b   ) and the collection area  323  of the collection plate  320  ( FIG.  5   c   ) are functionalized to be hydrophobic, the tailings  12  in the recovery processor  50  ( FIGS.  2   b - 2   d ,  3   a - 3   c   ) and the tailings in the pond  100  ( FIGS.  2   a  and  2   d   ) must be mixed with collector molecules such as xanthates so that the mineral particles  71  ( FIGS.  8   b  and  9   b   ) in the tailings may be hydrophobically modified with the collector molecules  73  to become wetted mineral particles  72 ′. 
     FIGS.  10   a - 10   c : Different Embodiments 
     In different embodiments of the present invention, the functionalized synthetic material can be used to provide those particular molecules on beads or bubbles, or to make the beads or bubbles (see  FIGS.  11   a - 12   b   ). The bubbles or beads that have the particular molecules having a functional group configured to attract mineral particles of interest are herein referred to as synthetic bubbles or beads. By way of example, the synthetic beads or bubbles  170  may be used in a filter  220  to collect mineral particles  72 ,  72 ′ (see  FIGS.  8   a - 9   b ,  11   a - 12   b   ). As shown in  FIG.  10   a   , the filter may use a cage or the like to contain a plurality of synthetic beads to provide the collection surfaces in the collection area  223 . As shown in  FIG.  10   b   , the collection plate uses a cage or the like to contain a plurality of synthetic beads  170  to provide the collection surfaces in the collection area  323 . When the synthetic beads or bubbles  170  are used to collect valuable material in a tailings pond  100  ( FIG.  13   ), they can be put in a sack  420  as shown in  FIG.  10   c   . As with the synthetic material that is used on the collection surfaces  403 ,  403 ′ ( FIGS.  9   a - 9   c   ), the synthetic material to be used on the synthetic beads or bubbles  170  may have the functional groups  78  to attract the mineral particles  72 , or may have the hydrophobic molecules  79 . 
       FIG.  11   a    illustrates a synthetic bead functionalized to attract hydrophobic particles. As shown in  FIG.  11   a   , the synthetic bubble or bead  170  has a solid-phase bead body to provide a bead surface  174 . At least the outside part of the bead body is made of a synthetic material, such as a hydrophobic polymer, or a coating of a hydrophobic chemical. As shown in  FIGS.  11   a  and  11   b   , the surface  174  of the synthetic bubble or bead comprises a plurality of molecules  79  which renders the surface  174  hydrophobic. For example, the surface  174  may be a glass surface coated with polysiloxanates which can bind to the hydroxyl group of the glass surface. Polysiloxanates, such as hydroxyl-terminated polydimethysiloxanes, have a silicon-oxygen chain to provide the hydrophobic molecules  79 . The hydrophobic particle  72 ′, as shown in  FIG.  11   b   , can be a mineral particle  71  having one or more collectors  73  attached thereto. One end ( 78 ) of the collector  73  has an ionizing bond attached to the mineral particle  71 . The other end of the collector  73  has a hydrophobic chain  76  which tends to move into the hydrophobic molecules  79 . Thus, the hydrophobic particle  72 ′ can be a wetted mineral particle. A collector, such as xanthate, has both the functional group  78  and the molecule  76 . The hydrophobic particle  72 , as shown in  FIG.  11   c   , can be a particle  71 ′ that has a hydrophobic chain  76 . Such particle can be non-mineral related, but it can be arranged to contact with the hydrophobic synthetic bubbles or beads  170  of the present inventions. Likewise, the particle  71  may be non-mineral and can be harmful to the environment. Thus the hydrophobic bubbles or beads  170 , according to the present invention, can be used in non-mining applications, such as water-pollution control. The size of the synthetic bead can be smaller than the minimum size of the mineral particles which is about 150 μm, and can be larger than the maximum size of the mineral particles. In certain applications, the size of the synthetic bead can be 1 cm or larger. 
       FIG.  12   a    illustrates a synthetic bead having a functional group to attract mineral particles of interest. The synthetic bead  170  has a bead body to provide a bead surface  174  to attract mineral particles of interest  72 .  FIG.  12   b    is an enlarged surface of the synthetic bead functionalized to attract mineral particles of interest. At least the outside part of the bead 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  174 . The molecule  76  may be used to attach a chemical functional group  78  to the surface  174 . In general, the molecule  76  can be a hydrocarbon chain, for example, and the functional group  78  can have an anionic bond for attracting a mineral, such as copper to the surface  174 . 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 the synthetic bead  70 . The functional group  78  is also known as a collector that is either ionic or non-ionic for bonding to the mineral particles  72 . Similarly, a chelating agent can be incorporated into or onto the polymer as a collector site for attracting a mineral, such as copper. 
     The releasing of the mineral particles from the synthetic beads can be similar to the releasing of the mineral particles from the collection plate, conveyor belt or the filter. For example, after the synthetic beads  170  in the collection area  223  or  323  or in the sack  320  ( FIGS.  10   a - 10   c   ) have collected a certain amount of mineral particles, the synthetic beads  170  can be made contact with a low pH solution and/or subjected to ultrasonic agitation (e.g.,  FIG.  4   ) in order to release the mineral particles. 
       FIG.  13    illustrates a tailings pond wherein a plurality of functionalized polymer coated surfaces may be configured to attract the valuable material of interest in the pond. As shown in  FIG.  13   , tailings  12  ( FIG.  2   a   ) or processed tailings ( FIGS.  2   b - 3   c   ) may be discharged into the tailings pond  100  at a discharge point  16 . A plurality of filters  220  can be placed near the discharge point  16  to collect the valuable material of interest in the tailings  12  or processed tailings  14  in the pond. It is also possible to place a plurality of collection plates  320  and a plurality of sacks  420  in the pond to collect the valuable material therein. The filters  220 , the collection plates  320  and the sacks  420  may be moved around in order to increase the contact between the valuable material and the functionalized polymer provided in the filters  220 , collection plates  320  and sacks  420 . 
     FIGS.  14 ,  14   a ,  14   b    
     By way of example,  FIG.  14    shows the present invention is the form of a machine, device, system or apparatus  610 , e.g., for separating valuable material from unwanted material in a mixture  611 , such as tailings, using a first processor  612  and a second processor  614 . The first processor  612  and the second processor  614  may be configured with a functionalized polymer coated member that is shown, e.g., as a functionalized polymer coated impeller  620  ( FIG.  14   a   ),  620 ′ ( FIG.  14   b   ), according to some embodiments of the present invention. In operation, the impeller  620 ,  620 ′ slowly rotates in relation to the first processor  612  and the second processor  614 , the impeller blades slowly pass through the attachment rich environment  616  in the first processor  612  where the valuable material is attached to the blades and through the release rich environment  618  in the second processor  614 . is released from the blades. By way of example, the impeller  620  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  620  ( FIG.  14   a   ),  620 ′ ( FIG.  14   b   ) is arranged, mounted, or configured in relation to the first processor  612  and the second processor  614 . 
     The first processor  612  may take the form of a first chamber, tank, cell or column that contains an attachment rich environment generally indicated as  616 . The first chamber, tank or column  612  may be configured to receive via piping  613  the mixture or tailings  611  in the form of fluid (e.g., water), the valuable material and the unwanted material in the attachment rich environment  616 , e.g., which has a high pH, conducive to attachment of the valuable material. The second processor  614  may take the form of a second chamber, tank, cell or column that contains a release rich environment generally indicated as  618 . The second chamber, tank, cell or column  614  may be configured to receive via piping  615 , e.g., water  622  in the release rich environment  618 , 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  616  conducive to the attachment of a valuable material of interest and release rich environments like that forming part of environment  618  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  616  and a corresponding release rich environment like environment  618  based on the separation technology disclosed herein for any particular valuable mineral of interest, e.g., copper, forming part of any particular mixture or tailings. 
     In operation, the first processor  612  may be configured to receive the mixture or tailings  611  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  616 . In  FIG.  14   , the functionalized polymer coated member is shown as the functionalized polymer coated impeller  620  ( FIG.  14   a   ),  620 ′ ( FIG.  14   b   ). In  FIG.  14   a   , the functionalized polymer coated impeller  620  has a shaft  621  and at least one impeller blade  620   a ,  620   b ,  620   c ,  620   d ,  620   e ,  620   f ,  620   g  and is configured to rotate slowly inside the first processor  612  and the second processor  614 . In  FIG.  14   b   , the functionalized polymer coated impeller  620 ′ has a shaft  621 ′ and impeller blades  620   a ′,  620   b ′,  620   c ′,  620   d ′,  620   e ′,  620   f ′,  620   g ′ and  620   h ′. Each impeller blade in  FIG.  14    is understood to be configured and functionalized with a polymer coating to attach to the valuable material in the attachment rich environment  616 . (The scope of the invention is not intended to be limited to the number of blades on the impeller  620 ,  620 ′ and the embodiment in  FIGS.  14   a  and  14   b    is shown with impellers  621 ,  621 ′ having a different number of blades.) 
     In  FIG.  14   , the first processor  612  is configured to receive at least one impeller blade of the functionalized polymer coated impeller  620  ( FIG.  14   a   ),  620 ′ ( FIG.  14   b   ). In  FIG.  1   b   , the at least one impeller blade is shown as impeller blade  620   g ′ being received in an attachment zone  630  that forms part of the attachment rich environment  616  defined by walls  30   a ,  30   b . The first processor  612  may also be configured with a first transition zone generally indicated as  640  to provide drainage from piping  641  of, e.g., processed tailings  642  as shown in  FIG.  14     a.    
     The first processor  612  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  616 . In  FIG.  14   b   , the at least one enriched impeller blade is shown as the at least one enriched impeller blade  620   c ′ being provisioned from the attachment rich environment  616  in the first processor  612  to the release rich environment  618  in the second processor  614 . 
     The second processor  614  may be configured to receive via the piping  615  the fluid  622  (e.g. water) and the enriched functionalized polymer coated member to release the valuable material in the release rich environment  618 . In  FIG.  14   b   , the second processor  614  is shown receiving the enriched impeller blade  620   c ′ in a release zone  650 , e.g., that forms part of the release rich environment  618  and is defined, e.g., by walls  630   c  and  630   d.    
     The second processor  614  may also be configured to provide the valuable material that is released from the enriched functionalized polymer coated member into the release rich environment  618 . For example, in  FIG.  14   b    the second processor  614  is shown configured with a second transition zone  660  defined by walls  630   a  and  630   d  to provide via piping  661  drainage of the valuable material in the form of a concentrate  662  ( FIG.  14   a   ). 
     FIG.  15 : The Functionalized Polymer Coated Conveyor Belt 
     By way of example,  FIG.  15    shows the present invention is the form of a machine, device, system or apparatus  700 , e.g., for separating valuable material from unwanted material in a mixture  701 , such as a tailings, using a first processor  702  and a second processor  704 . The first processor  702  and the second processor  704  are configured with a functionalized polymer coated member that is shown, e.g., as a functionalized polymer coated conveyor belt  720  that runs between the first processor  702  and the second processor  704 , according to some embodiments of the present invention. The arrows A 1 , A 2 , A 3  indicate the movement of the functionalized polymer coated conveyor belt  720 . Techniques, including motors, gearing, etc., for running a conveyor belt like element  720  between two processors like elements  702  and  704  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 know or later developed in the future. According to some embodiments of the present invention, the functionalized polymer coated conveyor belt  720  may be made of a mesh material. 
     The first processor  702  may take the form of a first chamber, tank, cell or column that contains an attachment rich environment generally indicated as  706 . The first chamber, tank or column  702  may be configured to receive the mixture or tailings  701  in the form of fluid (e.g., water), the valuable material and the unwanted material in the attachment rich environment  706 , e.g., which has a high pH, conducive to attachment of the valuable material. The second processor  704  may take the form of a second chamber, tank, cell or column that contains a release rich environment generally indicated as  708 . The second chamber, tank, cell or column  704  may be configured to receive, e.g., water  722  in the release rich environment  708 , 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  706  conducive to the attachment of a valuable material of interest and release rich environments like that forming part of environment  708  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  708  based on the separation technology disclosed herein for any particular valuable mineral of interest, e.g., copper, forming part of any particular mixture or tailings. 
     In operation, the first processor  702  may be configured to receive the mixture or tailings  701  of water, valuable material and unwanted material and the functionalized polymer coated conveyor belt  720  that is configured to attach to the valuable material in the attachment rich environment  706 . In  FIG.  15   , the belt  720  is understood to be configured and functionalized with a polymer coating to attach to the valuable material in the attachment rich environment  706 . 
     The first processor  702  may also be configured to provide drainage from piping  741  of, e.g., processed tailings  742  as shown in  FIG.  15   . 
     The first processor  702  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  706 . In  FIG.  15   , the enriched functionalized polymer coated conveyor belt is shown, e.g., as that portion or part  720   a  of the belt  720  being provisioned from the attachment rich environment  106  in the first processor  702  to the release rich environment  708  in the second processor  704 . It is understood that some other portions or parts of the belt  720  may be enriched, including the portion or part immediately leaving the attachment rich environment  706 , as well as the portion or part immediately entering the release rich environment  708 . 
     The second processor  704  may be configured to receive the fluid  722  (e.g. water) and the portion  720   a  of the enriched functionalized polymer coated conveyor belt  720  to release the valuable material in the release rich environment  708 . 
     The second processor  704  may also be configured to provide the valuable material that is released from the enriched functionalized polymer coated member into the release rich environment  708 . For example, in  FIG.  15    the second processor  704  is shown configured to provide via piping  761  drainage of the valuable material in the form of a concentrate  762 . 
     In  FIG.  15   , the first processor  702  is configured with the functionalized polymer coated conveyor belt  720  passing through with only two turns inside the attachment rich environment  706 . However, embodiments are envisioned in which the first processor  702  may be configured to process the functionalized polymer coated conveyor belt  720  using a serpentine technique for winding or turning the belt  720  one way and another way, back and forth, inside the first processor to maximize surface area of the belt inside the processor  702  and exposure of the belt  720  to the attachment rich environment  706 . 
     FIG.  16 : The Functionalized Polymer Coated Filter 
     By way of example,  FIG.  16    shows the present invention is the form of a machine, device, system or apparatus  800 , e.g., for separating valuable material from unwanted material in a mixture  801 , such as tailings, using a first processor  802 ,  802 ′ and a second processor  804 ,  804 ′. The first processor  802  and the second processor  804  are configured to process a functionalized polymer coated member that is shown, e.g., as a functionalized polymer coated collection filter  820  configured to be moved between the first processor  802  and the second processor  804 ′ as shown in  FIG.  16    as part of a batch type process, according to some embodiments of the present invention. In  FIG.  16   , by way of example the batch type process is shown as having two first processor  802 ,  802 ′ and second processor  804 ,  804 , 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 processor, 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  820  may take the form of a membrane or a thin soft pliable sheet or layer. The arrow B 1  indicates the movement of the functionalized polymer coated filter  820  from the first processor  202 , and the arrow B 2  indicates the movement of the functionalized polymer coated collection filter  820  into the second processor  802 . Techniques, including motors, gearing, etc., for moving a filter like element  820  from one processor to another processor like elements  802  and  804  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 know or later developed in the future. 
     The first processor  802  may take the form of a first chamber, tank, cell or column that contains an attachment rich environment generally indicated as  806 . The first chamber, tank or column  802  may be configured to receive the mixture or tailings  801  in the form of fluid (e.g., water), the valuable material and the unwanted material in the attachment rich environment  806 , e.g., which has a high pH, conducive to attachment of the valuable material. The second processor  804  may take the form of a second chamber, tank, cell or column that contains a release rich environment generally indicated as  808 . The second chamber, tank, cell or column  804  may be configured to receive, e.g., water  822  in the release rich environment  808 , 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  806  conducive to the attachment of a valuable material of interest and release rich environments like that forming part of environment  808  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  806  and a corresponding release rich environment like environment  808  based on the separation technology disclosed herein for any particular valuable mineral of interest, e.g., copper, forming part of any particular mixture or tailings. 
     In operation, the first processor  802  may be configured to receive the mixture or tailings  101  of water, valuable material and unwanted material and the functionalized polymer coated collection filter  820  that is configured to attach to the valuable material in the attachment rich environment  806 . In  FIG.  16   , the functionalized polymer coated collection filter  620  is understood to be configured and functionalized with a polymer coating to attach to the valuable material in the attachment rich environment. 
     The first processor  802  may also be configured to provide drainage from piping  841  of, e.g., processed tailings  842  as shown in  FIG.  16   . 
     The first processor  802  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. In  FIG.  16   , the enriched functionalized polymer coated collection filter  820  is shown, e.g., being provisioned from the attachment rich environment  806  in the first processor  202  to the release rich environment  808  in the second processor  204 . 
     The second processor  804  may be configured to receive the fluid  822  (e.g. water) and the enriched functionalized polymer coated collection filter  820  to release the valuable material in the release rich environment  808 . 
     The second processor  804  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  808 . For example, in  FIG.  16    the second processor  804  is shown configured to provide via piping  861  drainage of the valuable material in the form of a concentrate  862 . 
     The first processor  802 ′ may also be configured with piping  880  and pumping  880  to recirculate the tailings  842  back into the first processor  802 ′. The scope of the invention is also intended to include the second processor  804 ′ being configured with corresponding piping and pumping to recirculate the concentrate  862  back into the second processor  804 ′. Similar recirculation techniques may be implemented for the embodiments disclosed in relation to  FIGS.  14 - 15    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  802 ,  804  being configured to process the enriched functionalized polymer coated collection filter  820  in relation to one type or kind of valuable material, and the first and second processors  802 ′, 804 ′ being configured to process the enriched functionalized polymer coated collection filter  820  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. 
     Polymer Surface Having Functional Groups 
     The term “polymer” in this disclosure means a large molecule made of many units of the same or similar structure linked together. In some embodiments of the present invention, the polymer surface on a filter has a plurality of molecules  73  ( FIGS.  8   a ,  9   a   ) having a functional group  78  ( FIGS.  8   a ,  8   b   ) to attract mineral particles  72  ( FIGS.  8   a ,  9   a   ). In these embodiments, the unit can be a monomer or an oligomer which forms the basis of, for example, 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, polydimethylsiloxane and other organic or inorganic polymers. Thus, the synthetic material can be hard or rigid like plastic or soft and flexible like an elastomer. While the physical properties of the synthetic beads can vary, the surface of the synthetic beads is chemically functionalized to provide a plurality of functional groups to attract mineral particles. The terms “valuable material” and “mineral particle” are used herein interchangeably. It is possible to use a molecule or molecular segment  76  ( FIG.  8   a ,  9   a   ) to attach a function group  78  to the polymer surface. In general, the molecule  76  can be a hydrocarbon chain, for example, and the functional group  78  can be an ion or charge species for bonding to a mineral, 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 the synthetic bead  70 . A functional group  78  is also known as a collector that is either ionic or non-ionic. The ion can be anionic or cationic. An anion includes, but not limited to, 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. A surface having a functionalized polymer is also referred herein as synthetic surface. 
     Polymer Having Molecules to Render a Surface Hydrophobic 
     In some embodiments of the present invention, at least the surface of a filter surface is functionalized so that the surface is hydrophobic. It is possible to functionalize a polymer surface to have a plurality of molecules  79  ( FIGS.  8   b ,  8   c ,  9   b ,  9   c   ) to render the surface hydrophobic. A hydrophobic surface tends to attract hydrophobic molecules. 
     In chemistry, hydrophobicity is the physical property of a molecule (known as a hydrophobe) that is repelled from a mass of water. Hydrophobic molecules tend to be non-polar and, thus, prefer other neutral molecules and non-polar solvents. Hydrophobic molecules in water often cluster together. According to thermodynamics, matter seeks to be in a low-energy state, and bonding reduces chemical energy. Water is electrically polarized, and is able to form hydrogen bonds internally, which gives it many of its unique physical properties. But, since hydrophobes are not electrically polarized, and because they are unable to form hydrogen bonds, water repels hydrophobes, in favor of bonding with itself. It is this effect that causes the hydrophobic interaction. 
     The hydrophobic effect is the observed tendency of nonpolar substances to aggregate in aqueous solution and exclude water molecules. It can be observed as the segregation and apparent repulsion between water and non-polar substances. The hydrophobic interaction is mostly an entropic effect originating from the disruption of highly dynamic hydrogen bonds between molecules of liquid water by the non-polar solute. A hydrocarbon chain or a similar non-polar region or a big molecule is incapable of forming hydrogen bonds with water. The introduction of such a non-hydrogen bonding surface into water causes disruption of the hydrogen bonding network between water molecules. The hydrogen bonds are reoriented tangential to such a surface to minimize disruption of the hydrogen bonded 3D network of water molecules and thus leads to a structured water “cage” around the nonpolar surface. The water molecules that form the “cage” (or solvation shell) have restricted mobilities. For example, in the case of larger non-polar molecules the reorientational and translational motion of the water molecules in the solvation shell may be restricted by a factor of two to four. Generally, this leads to significant losses in translational and rotational entropy of water molecules and makes the process unfavorable in terms of free energy of the system. By aggregating together, nonpolar molecules reduce the surface area exposed to water and minimize their disruptive effect. 
     The desired mineral is rendered hydrophobic by the addition of a surfactant or collector chemical. To be effective on tailings, the collectors are chosen based upon their selective wetting of the types of particles to be separated. A good collector will adsorb, physically or chemically, with one of the types of particles. 
     Collectors 
     Collectors either chemically bond (chemisorption) on a hydrophobic mineral surface, or adsorb onto the surface in the case of, for example, coal flotation through physisorption. Collectors increase the hydrophobicity of the surface, increasing the separability of the hydrophobic and hydrophilic particles. The hydrophobic particles of interest, according to the present invention, are depicted as particles  71 ′, 72 ′ in  FIGS.  8   b ,  8   c ,  9   b    and  9   c.    
     FIGS.  17   a - 17   c : Large Mineral Particles 
     It should be noted that the mineral particles in the tailings can be relatively large as compared to the mineral particles recovered in the flotation process. Some mineral particles may be larger than  200 μm, for example. It is likely that a large mineral particle requires more bonding forces so that it can be attached to a functionalized surface. As shown in  FIG.  17   a   , the mineral particle  72  is attached to the filter surface  403  by the attraction of many function groups  78 . In order to increase the bonding forces between the filter surface  403  and the mineral particle  72 , it is possible to functionalize the surface  403  with molecules  67  comprising a plurality of functional groups  78  attached to a flexible backbone or chain  69 . As such, many more functional groups  78  can be drawn to the surface of the mineral particle  72 , as shown in  FIG.  17   b   .  FIG.  17   c    shows a large wetted mineral particle  72 ′ is attracted or attached to the filter surface  403  which is render hydrophobic by molecules  79 . 
       FIG.  18   a    illustrates a scenario where a mineral particle  72  is attached to a number of synthetic beads  74  at the same time. Thus, although the synthetic beads  74  are much smaller in size than the mineral particle  72 , a number of synthetic beads  74  may be able to lift the mineral particle  72  upward in a flotation cell. Likewise, a smaller mineral particle  72  can also be lifted upward by a number of synthetic beads  74  as shown in  FIG.  18   b   . In order to increase the likelihood for this “cooperative” lifting to occur, a large number of synthetic beads  74  can be mixed into the slurry. Unlike air bubbles, the density of the synthetic beads can be chosen such that the synthetic beads may stay along in the slurry before they rise to surface in a flotation cell. 
       FIGS.  19   a  and  19   b    illustrate a similar scenario. As shown, a wetted mineral particle  172  is attached to a number of hydrophobic synthetic beads  174  at the same time. 
     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 are used to scavenge the unrecovered minerals from a tailings stream. 
     Tailings cleaning cell is 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. 
     It should be understood that the synthetic beads according to the present invention, whether functionalized to have a collector or functionalized to be hydrophobic, are also configured for use in oilsands separation—to separate bitumen from sand and water in the recovery of bitumen in an oilsands mining operation. Likewise, the functionalized filters and membranes, according to some embodiments of the present invention, are also configured for oilsands separation. 
     According to some embodiments of the present invention, the surface of a synthetic bead can be functionalized to have a collector molecule. The collector has a functional group with an ion capable of forming a chemical bond with a mineral particle. A mineral particle associated with one or more collector molecules is referred to as a wetted mineral particle. According to some embodiments of the present invention, the synthetic bead can be functionalized to be hydrophobic in order to collect one or more wetted mineral particles. 
     Other types or kinds of valuable material or minerals of interest, include 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. 
     FIGS.  20   a  Thru  20   d    
     According to a different embodiment of the present invention, the synthetic bead can be a porous block or take the form of a sponge or foam with multiple segregated gas filled chambers. This application expands upon and develops out in further detail various inventions related to the use of engineered collection media in the form of foam, Styrofoam, etc. in relation to  FIGS.  20   a  through  20   d   , which are described as follows 
     By way of example, the synthetic bead can be a porous block or take the form of a sponge or foam with multiple segregated gas filled chamber. According to some embodiments of the present invention, the foam or sponge can take the form of a filter, a membrane or a conveyor belt as described in PCT application no. PCT/US12/39534, entitled “Mineral separation using functionalized membranes;” filed 21 May 2012, which is hereby incorporated by reference in its entirety. Therefore, the synthetic beads described herein are generalized as engineered collection media. Likewise, a porous material, foam or sponge may be generalized as a material with three-dimensional open-cellular structure, an open-cell foam or reticulated foam, which can be made from soft polymers, hard plastics, ceramics, carbon fibers, glass and/or metals, and may include a hydrophobic chemical having molecules to attract and attach mineral particles to the surfaces of the engineered collection media. 
     Open-cell foam or reticulated foam offers an advantage over non-open cell materials by having higher surface area to volume ratio. Applying a functionalized polymer coating that promotes attachment of mineral to the foam “network” enables higher mineral recovery rates and also improves recovery of less liberated mineral than conventional process. For example, the open cells in an engineered foam block allow passage of fluid and particles smaller than the cell size but captures mineral particles that come in contact with the functionalized polymer coating on the open cells. This also allows the selection of cell size dependent upon slurry properties and application. 
     According to some embodiments of the present invention, the engineered collection media take the form of an open-cell foam/structure in a rectangular block or a cubic shape  70   a  as illustrated in  FIG.  20   a   . Dependent upon the material that is used to make the collection media, the specific gravity of the collection media can be smaller than, equal to or greater than the slurry. Thus, when the collection media are mixed with the slurry for mineral recovery, it is advantageous to use the tumbler cells, e.g., that are disclosed in PCT application serial no. PCT/US16US/68843, entitled “Tumbler cell form mineral recovery using engineered media,” filed 28 Dec. 2016, which claims benefit to Provisional Application No. 62/272,026, filed 28 Dec. 2015, which are both incorporated by reference herein in their entirety. 
     According to some embodiments of the present invention, the engineered collection media may take the form of a filter  70   b  with a three-dimensional open-cell structure as shown in  FIG.  20   b   . The filter  70   b  can be used in a filtering assembly as disclosed herein. 
     According some embodiments of the present invention, the engineered collection media may take the form of a membrane  70   c , a section of which is shown in  FIG.  20   c   . As seen in  FIG.  20   c   , the membrane  70   c  can have an open-cell foam layer attached to a substrate or base. The substrate can be made from a material which is less porous than the open-cell foam layer. For example, the substrate can be a sheet of pliable polymer to enhance the durability of the membrane. The membrane  70   c  can be used as a conveyor belt as disclosed herein. 
     According some embodiments of the present invention, the engineered collection media may take the form of a membrane  70   d , a section of which is shown in  FIG.  20   d   . As seen in  FIG.  20   d   , the membrane  70   d  can have two open-cell foam layers attached to two sides of a substrate or base. The substrate can made of a material which is less porous than the open-cell foam layer. The membrane  70   d  can also be used as a conveyor belt as disclosed herein. 
     In various embodiments of the present invention, the engineered collection media as shown in  FIGS.  20   a - 20   d    may include, or take the form of, a solid-phase body configured with a three-dimensional open-cell structure to provide a plurality of collection surfaces; and a coating may be configured to provide on the collection surfaces a plurality of molecules comprising a functional group having a chemical bond for attracting one or more mineral particles in an aqueous mixture to the molecules, causing the mineral particles to attached to the collection surfaces. 
     In some embodiments of the present invention, the open-cell structure or foam may include a coating attached thereto to provide a plurality of molecules to attract mineral particles, the coating including a hydrophobic chemical selected from a group consisting of polysiloxanates, poly(dimethylsiloxane) and fluoroalkylsilane, or what are commonly known as pressure sensitive adhesives with low surface energy. 
     In some embodiments of the present invention, the solid phase body may be made from a material selected from polyurethane, polyester urethane, polyether urethane, reinforced urethanes, PVC coated PV, silicone, polychloroprene, polyisocyanurate, polystyrene, polyolefin, polyvinylchloride, epoxy, latex, fluoropolymer, polypropylene, phenolic, EPDM, and nitrile. 
     In some embodiments of the present invention, the solid phase body may including a coating or layer, e.g., that may be modified with tackifiers, plasticizers, crosslinking agents, chain transfer agents, chain extenders, adhesion promoters, aryl or alky copolymers, fluorinated copolymers, hexamethyldisilazane, silica or hydrophobic silica. 
     In some embodiments of the present invention, the solid phase body may include a coating or layer, e.g., made of a material selected from acrylics, butyl rubber, ethylene vinyl acetate, natural rubber, nitriles; styrene block copolymers with ethylene, propylene, and isoprene; polyurethanes, and polyvinyl ethers. 
     In some embodiments of the present invention, an adhesion agent may be provided between the solid phase body and the coating so as to promote adhesion between the solid phase body and the coating. 
     In some embodiments of the present invention, the solid phase body may be made of plastic, ceramic, carbon fiber or metal. 
     In some embodiments of the present invention, the three-dimensional open-cell structure may include pores ranging from 10-200 pores per inch. 
     In some embodiments of the present inventions, the engineered collection media may be encased in a cage structure that allows a mineral-containing slurry to pass through the cage structure so as to facilitate the contact between the mineral particles in slurry and the engineered collection media. 
     In some embodiments of the present invention, the cage structures or the filters carrying mineral particles may be removed from the processor so that they can be stripped of the mineral particles, cleaned and reused. 
     Three Dimensional Functionalized Open-Network Structure 
     Surface area is an important property in the mineral recovery process because it defines the amount of mass that can be captured and recovered. High surface area to volume ratios allows higher recovery per unit volume of media added to a cell. As illustrated in  FIGS.  20   a  to  20   d   , the engineered collection media are shown as having an open-cell structure. Open cell or reticulated foam offers an advantage over other media shapes such as the sphere by having higher surface area to volume ratio. Applying a functionalized polymer coating that promotes attachment of mineral to the foam “network” enables higher recovery rates and improved recovery of less liberated mineral when compared to the conventional process. For example, open cells allow passage of fluid and unattracted particles smaller than the cell size but capture mineral bearing particles that come in contact with the functionalized polymer coating. Selection of cell size is dependent upon slurry properties and application. 
     The coated foam may be cut in a variety of shapes and forms. For example, a polymer coated foam belt can be moved through the slurry to collect the desired minerals and then cleaned to remove the collected desired minerals. The cleaned foam belt can be reintroduced into the slurry. Strips, blocks, and/or sheets of coated foam of varying size can also be used where they are randomly mixed along with the slurry in a mixing cell. The thickness and cell size of a foam can be dimensioned to be used as a cartridge-like filter which can be removed, cleaned of recovered mineral, and reused. 
     As mentioned earlier, the open cell or reticulated foam, when coated or soaked with hydrophobic chemical, offers an advantage over other media shapes such as sphere by having higher surface area to volume ratio. Surface area is an important property in the mineral recovery process because it defines the amount of mass that can be captured and recovered. High surface area to volume ratios allows higher recovery per unit volume of media added to a cell. 
     The open cell or reticulated foam provides functionalized three dimensional open network structures having high surface area with extensive interior surfaces and tortuous paths protected from abrasion and premature release of attached mineral particles. This provides for enhanced collection and increased functional durability. Spherical shaped recovery media, such as beads, and also of belts, and filters, is poor surface area to volume ratio—these media do not provide high surface area for maximum collection of mineral. Furthermore, certain media such as beads, belts and filters may be subject to rapid degradation of functionality. 
     Applying a functionalized polymer coating that promotes attachment of mineral to the foam “network” enables higher recovery rates and improved recovery of less liberated mineral when compared to the conventional process. This foam is open cell so it allows passage of fluid and unattracted particles smaller than the cell size but captures mineral bearing particles the come in contact with the functionalized polymer coating. Selection of cell size is dependent upon slurry properties and application. 
     A three-dimensional open cellular structure optimized to provide a compliant, tacky surface of low energy enhances collection of hydrophobic or hydrophobized mineral particles ranging widely in particle size. This structure may include, or take the form of, open-cell foam coated with a compliant, tacky polymer of low surface energy. The foam may include, or take the form 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 coating may be a polysiloxane derivative such as polydimethylsiloxane and may be modified with tackifiers, plasticizers, crosslinking agents, chain transfer agents, chain extenders, adhesion promoters, aryl or alky copolymers, fluorinated copolymers, hydrophobizing agents such as hexamethyldisilazane, and/or inorganic particles such as silica or hydrophobic silica. Alternatively, the coating may include, or take the form of, materials typically known as pressure sensitive adhesives, e.g. acrylics, butyl rubber, ethylene vinyl acetate, natural rubber, nitriles; styrene block copolymers with ethylene, propylene, and isoprene; polyurethanes, and polyvinyl ethers as long as they are formulated to be compliant and tacky with low surface energy. 
     The three-dimensional open cellular structure may be coated with a primer or other adhesion agent to promote adhesion of the outer collection coating to the underlying structure. 
     In addition to soft polymeric foams, other three-dimensional open cellular structures such as hard plastics, ceramics, carbon fiber, and metals may be used. Examples include Incofoam®, Duocel®, metal and ceramic foams produced by American Elements®, and porous hard plastics such as polypropylene honeycombs and such. These structures must be similarly optimized to provide a compliant, tacky surface of low energy by coating as above. 
     The three-dimensional, open cellular structures above may be coated or may be directly reacted to form a compliant, tacky surface of low energy. 
     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. This is accomplished through methods of forming open-cell polymeric foams known to the art. 
     The structure may be in the form of sheets, cubes, spheres, or other shapes as well as densities (described by pores per inch and pore size distribution), and levels of tortuosity that optimize surface access, surface area, mineral attachment/detachment kinetics, and durability. These structures may be additionally optimized to target certain mineral particle size ranges, with denser structures acquiring smaller particle sizes. In general, cellular densities may range from 10-200 pores per inch, more preferably 30-90 pores per inch, and most preferably 30-60 pores per inch. 
     The specific shape or form of the structure may be selected for optimum performance for a specific application. For example, the structure (coated foam for example) may be cut in a variety of shapes and forms. For example, a polymer coated foam belt could be moved through the slurry removing the desired mineral whereby it is cleaned and reintroduced into the slurry. Strips, blocks, and/or sheets of coated foam of varying size could also be used where they are randomly mixed along with the slurry in a mixing cell. Alternatively, a conveyor structure may be formed where the foam is encased in a cage structure that allows a mineral-containing slurry to pass through the cage structure to be introduced to the underlying foam structure where the mineral can react with the foam and thereafter be further processed in accordance with the present invention. The thickness and cell size could be changed to a form cartridge like filter whereby the filter is removed, cleaned of recovered mineral, and reused.  FIG.  22    is an example a section of polymer coated reticulated foam that was used to recovery Chalcopyrite mineral. Mineral particles captured from copper ore slurry can be seen throughout the foam network. 
     There are numerous characteristics of the foam that may be important and should also be considered, as follows: 
     Mechanical durability: Ideally, the foam will be durable in the mineral separation process. For example, a life of over 30,000 cycles in a plant system would be beneficial. As discussed above, there are numerous foam structures that can provide the desired durability, including polyester urethanes, polyether urethanes, reinforced urethanes, more durable shapes (spheres &amp; cylinders), composites like PVC coated PU, and non-urethanes. Other potential mechanically durable foam candidate includes metal, ceramic, and carbon fiber foams and hard, porous plastics. 
     Chemical durability: The mineral separation process can involve a high pH environment (up to 12.5), aqueous, and abrasive. Urethanes are subject to hydrolytic degradation, especially at pH extremes. While the functionalized polymer coating provides protection for the underlying foam, ideally, the foam carrier system is resistant to the chemical environment in the event that it is exposed. 
     Adhesion to the coating: If the foam surface energy is too low, adhesion of the functionalized polymer coating to the foam will be very difficult and it could abrade off. However, as discussed above, a low surface energy foam may be primed with a high energy primer prior to application of the functionalized polymer coating to improve adhesion of the coating to the foam carrier. Alternatively, the surface of the foam carrier may be chemically abraded to provide “grip points” on the surface for retention of the polymer coating, or a higher surface energy foam material may be utilized. Also, the functionalized polymer coating may be modified to improve its adherence to a lower surface energy foam. Alternatively, the functionalized polymer coating could be made to covalently bond to the foam. 
     Surface area: Higher surface area provides more sites for the mineral to bond to the functionalized polymer coating carried by the foam substrate. There is a tradeoff between larger surface area (for example using small pore cell foam) and ability of the coated foam structure to capture mineral while allowing gangue material to pass through and not be capture, for example due to a small cell size that would effectively entrap gangue material. The foam size is selected to optimize capture of the desired mineral and minimize mechanical entrainment of undesired gangue material. 
     Cell size distribution: Cell diameter needs to be large enough to allow gangue and mineral to be removed but small enough to provide high surface area. There should be an optimal cell diameter distribution for the capture and removal of specific mineral particle sizes. 
     Tortuosity: Cells that are perfectly straight cylinders have very low tortuosity. Cells that twist and turn throughout the foam have “tortuous paths” and yield foam of high tortuosity. The degree of tortuosity may be selected to optimize the potential interaction of a mineral particle with a coated section of the foam substrate, while not be too tortuous that undesirable gangue material in entrapped by the foam substrate. 
     Functionalized foam: It may be possible to covalently bond functional chemical groups to the foam surface. This could include covalently bonding the functionalized polymer coating to the foam or bonding small molecules to functional groups on the surface of the foam, thereby making the mineral-adhering functionality more durable. 
     The pore size (pores per inch (PPI)) of the foam is an important characteristic which can be leveraged to improved mineral recovery and/or target a specific size range of mineral. As the PPI increases the specific surface area (SSA) of the foam also increases. A high SSA presented to the process increases the probability of particle contact which results in a decrease in required residence time. This in turn, can lead to smaller size reactors. At the same time, higher PPI foam acts as a filter due to the smaller pore size and allows only particles smaller than the pores to enter into its core. This enables the ability to target, for example, mineral fines over coarse particles or opens the possibility of blending a combination of different PPI foam to optimize recovery performance across a specific size distribution. 
     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. In addition, it is contemplated that, while the embodiments described herein are useful for homogeneous flows, the embodiments described herein can also be used for dispersive flows having dispersive properties (e.g., stratified flow). 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 spirit and scope of the present invention.