Patent Abstract:
One aspect is an ultrasonic crusher including a pipe system having at least one elutriator. A pump is configured to pump a slurry through the pipe system and the at least one elutriator. A first ultrasound sonotrode is configured proximate to the at least one elutriator.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/169,563 entitled “RECLAMATION SYSTEM,” having a filing date of Apr. 15, 2009 and is incorporated herein by reference. This patent application Ser. No. 12/761,362 is also related to Utility patent application filed on even date herewith, entitled “SYSTEM AND METHOD FOR RECOVERING MINERALS”. 
     BACKGROUND 
     One aspect relates to a system and method of separating or sorting and sizing iron ore and removing gangue. More specifically, in one embodiment the system and method separate and remove the silica components from an iron ore. 
     Throughout the world, there are quantities of minerals combined with other material. Often, attempts are made to separate materials. For example, ores are treated by mechanical, chemical, or thermal processes, or some combination thereof to liberate marketable minerals from waste minerals (called gangue). 
     In many mining districts enormous quantities of mineral resources are not utilized because mining and/or mineral processing to recover the marketable constituents is uneconomical. Additional quantities of desired minerals are locked to gangue minerals and are rejected during mining or mineral processing and are sent to stockpiles or tailing basins. 
     Billions of tons of unmined minerals, mined minerals disposed of in stockpiles and tailing basins, and other waste materials in landfills would be utilized if processing costs for separating gangue from valuable minerals were significantly reduced. 
     For these and other reasons, there is a need for the present embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawing is included to provide a further understanding of embodiments and is incorporated in and constitutes a part of this specification. The drawing illustrates embodiments and together with the description serve to explain principles of embodiments. Other embodiments and many of the intended advantages of embodiments will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawing are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts. 
         FIG. 1  illustrates a length-wise cross-sectional view of an ultrasonic crusher in accordance with one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     In the following Detailed Description, reference is made to the accompanying drawing, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the FIGURE(s) being described. Because components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. 
     It is to be understood that the features of the various exemplary embodiments described herein may be combined with each other, unless specifically noted otherwise. 
       FIG. 1  is an ultrasonic crusher  10  in accordance with one embodiment. In one exemplary embodiment, ultrasonic crusher  10  is used to sort and size iron ore and remove gangue. In another example, ultrasonic crusher  10  separates and removes silica components from an iron ore. In one embodiment, ultrasonic crusher  10  includes pump  12 , pipe system  14 , first and second ultrasound sonotrodes  16  and  18 , and first and second supplemental pipes  20  and  22 . 
     In one embodiment, ultrasonic crusher  10  is used to sort materials so that certain components can be removed. In one example, minerals such as iron ore mixed with gangue are sorted such that the gangue is removed. Iron ore is introduced into ultrasonic crusher  10  as a water-borne slurry through pump  12 . Pump  12  forces the ore and gangue mixture into a first pipe segment  14 A of pipe system  14  toward a first elbow section  26 . 
     In one embodiment, first pipe segment  14 A is substantially horizontally oriented toward first elbow section  26 . Pipe  14  has a first diameter in first pipe segment  14 A. In one embodiment, the first diameter is configured such that the cross-sectional area in first pipe segment  14 A is approximately 960 mm 2 . The slurry moves through first pipe segment  14 A toward first elbow section  26  in the direction marked with the adjacent arrow in  FIG. 1 . In one case, the slurry moves out of first elbow section  26  into second pipe segment  14 B of pipe system  14 . In one example, second pipe segment  14 B is substantially vertically oriented. 
     In one embodiment, pump  12  forcing the slurry through the combination of first pipe segment  14 A, first elbow section  26  and into second pipe segment  14 B, sets up a first stage elutriator, such that lighter particles are separated from heavier ones using the substantially vertically-directed stream of liquid in second pipe segment  14 B. In one example, separation of particles occurs by allowing particles to settle in a fluid. As such, in one embodiment, the coarser, heavier, and rounder grains settle faster than the finer, lighter, and more angular grains. The fluid is in motion, carrying away the slow-settling grains, while a sediment of fast-settling grains is developed. 
     In one embodiment, first ultrasound sonotrode  16  is configured adjacent first elbow section  26 . In one embodiment, sonotrode  16  is configured with 1,000 watts and 20 kHz. As the slurry moves upward from first elbow section  26  and first sonotrode  16 , the first stage of elutriation takes place as the slurry enters second pipe segment  14 B. In one embodiment, second pipe segment  14 B has a second diameter. In one embodiment, the second diameter is configured such that the cross-sectional area in second pipe segment  14 B is approximately 1,260 mm 2 , or approximately 1.3 times as large as the cross-section of first pipe segment  14 A. In one case, the cross-sectional area of second pipe segment  14 B is sized to permit the largest and densest particles in the slurry to settle down to first elbow section  26 , which houses first sonotrode  16 . Particles of lesser size and density will continue upward through second pipe segment  14 B in the direction indicated by the adjacent arrow in  FIG. 1 . 
     At first elbow section  26  where first sonotrode  16  is installed, particles that are too large and/or too dense to move upward through second pipe segment  14 B, fall back to first elbow section  26  above first sonotrode  16 . In one embodiment, this settled or sediment material is milled, crushed, and ground by ultrasound energy generated by first sonotrode  16  until the particles are small enough to move upward with the bulk of the slurry. 
     In one embodiment, first supplemental pipe  20  is used to draw off or to add slurry components to modify slurry properties in pipe system  14 , and to allow sampling of the slurry materials. Ore particles in the slurry that are of the desired density and size can be removed or added, and fluids, or reagents, can also be introduced to the system to adjust the slurry chemistry, density, and rate of particle settling. 
     In one embodiment, slurry from second pipe segment  14 B moves into third pipe segment  14 C. In one example, third pipe segment  14 C is substantially horizontally oriented toward second elbow section  28 . Pipe  14  has a third diameter in third pipe segment  14 C. In one embodiment, the third diameter is configured such that the cross-sectional area in third pipe segment  14 C is approximately 1,260 mm 2 , or approximately the same as the cross-section of second pipe segment  14 B. The slurry moves through third pipe segment  14 C toward second elbow section  28  in the direction marked with the adjacent arrow in  FIG. 1 . In one case, the slurry moves out of second elbow section  28  into fourth pipe segment  14 D of pipe system  14 . In one example, fourth pipe segment  14 D is substantially vertically oriented. 
     In one embodiment, pump  12  forcing the slurry through the combination of third pipe segment  14 C, second elbow section  28 , and into fourth pipe segment  14 D, sets up a second stage elutriator, which very similarly to the first stage elutriator, allows lighter particles to be separated from heavier ones using the substantially vertically-directed stream of liquid in fourth pipe segment  14 D. 
     In one embodiment, second ultrasound sonotrode  18  is configured adjacent second elbow section  28 . In one embodiment, second sonotrode  18  is configured with 1,000 watts and 20 kHz. As the slurry moves upward from second elbow section  28  and second sonotrode  18 , the second stage of elutriation takes place as the slurry enters fourth pipe segment  14 D. In one embodiment, fourth pipe segment  14 D has a fourth diameter. In one embodiment, the fourth diameter is configured such that the cross-sectional area in fourth pipe segment  14 D is approximately 1,590 mm 2 , or approximately 1.6 times as large as the cross-section of first pipe segment  14 A. In one case, the cross-sectional area of fourth pipe segment  14 D is sized to permit the largest and densest particles in the slurry to settle down to second elbow section  28 , which houses second sonotrode  18 . Particles of lesser size and density will continue upward through fourth pipe segment  14 D in the direction indicated by the adjacent arrow in  FIG. 1 . 
     As was the case at the first stage elutriator, at second elbow section  28  where second sonotrode  18  is installed, particles that are too large or too dense to move upward through fourth pipe segment  14 D, fall back to second elbow section  28  above second sonotrode  18 . In one embodiment, this settled or sediment material is milled, crushed, and ground by ultrasound energy generated by second sonotrode  18  until the particles are small enough to move upward with the bulk of the slurry. 
     In one embodiment, second supplemental pipe  22  is used to draw off or to add slurry components to modify slurry properties in pipe system  14 , and to allow sampling of the slurry materials. Ore particles that are of the desired density and size can be removed or added and fluids, or reagents, can also be introduced to the system to adjust the slurry chemistry, density, and rate of particle settling. 
     One skilled in the art will observe that additional stages of elutriation can be added with combinations of pipe segments and elbow sections, along with adjacent sonotrodes, such that further sorting and separation occurs. Additionally, adjacent supplemental pipes can be used to add and remove material at the stages. 
     Mechanical characteristics, such as elutriator tube cross-sectional area, shape, and length can be varied as required and along with slurry properties such as flow rate, slurry density, and fluid chemistry controlled in the initial slurry composition and/or via the supplemental pipes, such as  20  and  22  illustrated, act in concert with the ultrasound energy to produce the desired separations of ores and wastes. 
     In one embodiment, ultrasonic crusher  10  is used to separate particles on the order of −20 to +300 mesh (833 to 50 microns). In one embodiment, larger sizes are sorted when heavy media is introduced, or when extreme hindered settling conditions are produced. 
     In one embodiment, dilution of the slurry in ultrasonic crusher  10  is 3%-35% solids by weight (finer particles to coarser particles). Sorting is done at as high a fluid density as possible, typically 40%-70% solids by weight. 
     In one embodiment, ultrasonic crusher  10  is used to crush and/or separate ores such as Oolitic Iron ore, Ferruginous Chert (Silicified hematite/magnetite mix), Banded Iron Formation (Silicified hematite/magnetite mix), Cretaceous Pebbles (Silicified hematite/magnetite mix), Taconite (Magnetite, hematite, and SiO 2 ), Natural Iron Ore (hematite), Dunka Pit type (Fe sulfides, hematite, magnetite), and Gold bearing Quartz (Au, Ag in SiO 2  matrix). 
     In one embodiment, ultrasonic crusher  10  is used to crush and/or separate minerals such as Bauxite (Al hydroxides), Kaolinite (Al 2 Si 2 O 5 (OH) 4 ), Kyanite (Al 2 SiO 5 ), Andalusite (Al 2 SiO 5 ), Topaz (Al 2 SiO 4 (F,OH) 2 ), Sillimanite (Al 2 SiO 5 ), Corundum (Al 2 O 3 ), Orpiment (As 2 S 3 ), Realgar (AsS), Barite (BaSO 4 ), Witherite (BaCO 3 ), Borax (Na 2 B 4 O 5 (OH) 4 -8H 2 O), Tourmaline (B(Na—Ca—Al—Mg—Fe—Mn) silicate), Beryl (Be 3 Al 2 (Si 6 O 18 )), Calcite (CaCO 3 ), Gypsum (CaSO 4 -2H 2 O), Dolomite (CaMg(CO 3 ) 2 ), Anhydrite (CaSO 4 ), Stilbite (CaAl 2 Si 7 O 18 -7H 2 O), Aragonite (CaCO 3 ), Apatite (Ca 5 (PO 4 ) 3 (F,Cl,OH)), Epidote (Ca 2 (Al, Fe)Al 2 O(SiO 4 )—(Si 2 O 7 )(OH)), Malachite (Cu 2 CO 3 (OH) 2 ), Chrysocolla (Cu 4 H 4 Si 4 O 10 (OH) 8 ), Bornite (Cu 5 FeS 4 ), Chalcopyrite (CuFeS 2 ), Pyrrhotite (Fe 1−x S), Magnetite (Fe 3 O 4 ), Hematite (Fe 2 O 3 ), Arsenopyrite (FeAsS), Siderite (FeCO 3 ), Chromite (FeCr 2 O 4 ), Pyrite (FeS 2 ), Marcasite (FeS 2 ), Ilmenite (FeTiO 3 ), Wolframite ((Fe,Mn)WO 4 ), Goethite (aFeO(OH)), Limonite (Fe—OH nH 2 O), Staurolite (Fe 2 A 19 O 6 (SiO 4 ) 4 —(O,OH) 2 ), Cinnabar (HgS), Muscovite (KAl hydrated silicate), Biotite (KMg hydrated silicate), Talc (Mg hydrate), Chlorite (MgFe hydrate), Serpentine (Mg 3 Si 2 O 5 (OH) 4 ), Magnesite (MgCO 3 ), Spinel (MgAl 2 O 4 ), Manganite (MnO(OH), Pyrolusite (MnO 2 ), Molybdenite (MoS 2 ), Halite (NaCl), Natrolite (Na 2 Al 2 Si 3 O 10  2H 2 O), Galena (PbS), Anglesite (PbSO 4 ), Cerussite (PbCO 3 ), Stibnite (Sb 2 S 3 ), Quartz (SiO 2 ), Opal (SiO 2 -nH 2 O), Cassiterite (SnO 2 ), Celestite (SrSO 4 ), Strontianite (SrCO 3 ), Rutile (TiO 2 ), Sphalerite (ZnS), Hemimorphite (Zn 4 (Si 2 O 7 )(OH) 2 —H 2 O), Smithsonite (ZnCO 3 ), and Zircon (ZrSiO 4 ). 
     In one embodiment, ultrasonic crusher  10  is used to crush igneous rock such as granite, gabbro, basalt; sedimentary rock such as conglomerate, sandstone, shale, limestone, iron formation; metamorphic rock such as slate, marble, gneiss, quartzite; and various other rocks. 
     In one embodiment, ultrasonic crusher  10  is configured as a portable system. In one example, each of the components ultrasonic crusher  10  is configured compact enough to be carried on rail cars, such as one or more cars of a train, such that ultrasonic crusher  10  can be rolled over a rail directly to a waste stockpile for processing thereof. 
     Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.

Technology Classification (CPC): 8