Patent Description:
In many industrial processes, flotation is used to separate valuable or desired material from unwanted material. By way of example, in this process a mixture of water, valuable material, unwanted material, chemicals and air is placed into a flotation cell. The chemicals are used to make the desired material hydrophobic, as well as to aid the formation of bubbles and the stability of the froth, and the air is used to carry the material to the surface of the flotation cell. When the hydrophobic material and the air bubbles collide they become attached to each other. The bubble rises to the surface carrying the desired material with it.

The performance of the flotation cell is dependent on the bubble surface area flux in the collection zone of the cell. The bubble surface area flux is dependent on the size of the bubbles and the air injection rate. Controlling the bubble surface area flux has traditionally been very difficult. This is a multivariable control problem and there are no dependable real time feedback mechanisms to use for control. <CIT> discloses a process for separating at least one hydrophobic material from a mixture comprising this at least one hydrophobic material and at least one hydrophilic material, wherein the process uses a solid hydrophobic surface. <CIT> discloses removal of solid materials from a liquid, beneficiation of an ore, providing oil from bitumen, etc. using a flocculating agent comprising a 5polysaccharide that is cross-linked with a resin having azetidinium functional groups. <CIT> discloses a filter for filtering metallurgical pulps or slurries in order to remove solid particles from the liquid in which they are suspended. <CIT> and <CIT> are concerned with recovering bitumen from tar sand. Oil sand is mixed with steam and water into a slurry which is transferred to an 10inclined surface with apertures in a water bath, allowing the sand particles to drop through to the apertures to be discarded, while the bitumen moves to an oleophilic inclined surface where it adheres and is collected. <CIT> discloses a method for separating hydrocarbons from hydrocarbon bearing compositions by contacting buoyant beads having surfaces 15that are oleophilic with the composition. The hydrocarbons adhere to the oleophilic beads. <CIT> discloses the use of a water insoluble silicone fluid to separate ore in a froth flotation.

There is a need in the industry to provide a better way to separate valuable 20material from unwanted material, e.g., including in such a flotation cell, so as to eliminate problems associated with using air bubbles in such a separation process.

Subject-matter of this invention is an apparatus as claimed in independent claim <NUM> and a method as claimed in independent claim <NUM>. Embodiments of the invention are claimed in the respective dependent claim.

The present disclosure provides mineral separation techniques using functionalized polymer coated members.

The present disclosure consists of a new apparatus and process for recovering valuable materials or minerals from mineral rich pulp slurry. This slurry could be any type of slurry being air conveyed ground minerals or an aqueous mixture for example. This mineral rich slurry is put into contact with a functionalized polymer surface which has been engineered to attract or attach to the mineral of interest. The functionalized polymer surface may take the form of a synthetic bubble or bead, as well as a membrane or membrane structure that may take the form of an impeller, a conveyor belt, a filter assembly, or a flat plate.

The unwanted material may be washed away and only the desirable material or mineral is left on the functionalized polymer surface, or the membrane structure containing the functionalized polymer surface may be separated from the unwanted material. Such separation can take place via techniques related to flotation, size separation, gravimetric separation, and/or magnetic separation. The enriched surface is then treated so that the mineral is released and collected. The polymer surface can then be reused.

According to the present invention, the apparatus comprises a first processor and a second processor, and each processor may be configured with two chambers, tanks, cells or columns. One chamber, tank, cell or column has an environment conducive to attachment of a valuable material or mineral or particle of interest and the other chamber, tank, cell or column has an environment conducive for release of the valuable material or mineral or particle of interest. According to some embodiments of the present invention, an impeller is coated with a functionalized polymer and configured to rotate slowly inside the two chambers, tanks, cells or columns. As an impeller blade moves into an attachment zone in the one chamber, tank, cell or column, it collects the valuable material or mineral or particle of interest. As the enriched blade moves to a release zone in the other chamber, tank, cell or column, the valuable material or mineral or particle of interest are released.

According to some embodiments of the present invention, a functionalized polymer conveyor belt is configured to run between the two chambers, tanks, cells or columns, whereby it collects and releases the valuable material or mineral or particle of interest.

According to some embodiments of the present invention, a functionalized polymer collection filter is placed into each chamber, tank, cell or column to collect and release the valuable material or mineral or particle of interest. This is a batch type process.

In its broadest sense, the present invention takes the form of an apparatus comprising a functionalized polymer coated member, a first processor and a second processor,.

The first chamber, tank or column may be configured to receive a pulp slurry having water, the valuable material and the unwanted material in the attachment rich environment, which has a high pH (around <NUM> to <NUM>), conducive to attachment of the valuable material.

The second chamber, tank or column may be configured to receive water in the release rich environment, which may have a low pH or receive ultrasonic waves conducive to release of the valuable material.

Although the invention is described as having a high pH in an attachment environment and a low pH in a release environment, the present invention will work equally as well where the pH of the attachment environment is selected to optimize the attachment of desired materials, such as a low, high or neutral pH, and the pH of the release environment is selected to be a different pH than the attachment environment and selected to optimize the release of the desired material.

The functionalized polymer coated member may take the form of a functionalized polymer coated impeller having at least one impeller blade configured to rotate slowly inside the first processor and the second processor. The first processor may be configured to receive the at least one impeller blade in an attachment zone, and provide at least one enriched impeller blade having the valuable material attached thereto in the attachment zone. The second processor may be configured to receive the at least one enriched impeller blade in a release zone and to provide the valuable material released from the at least one enriched impeller blade. The first processor may be configured with a first transition zone to provide drainage of tailings, and the second processor may be configured with a second transition zone to provide drainage of concentrate.

As used herein with respect to functionalized polymer, the term "enriched" is intended to refer to a functionalized material that has been exposed to a material of interest, and wherein the material of interest has been attached by the functionalized material prior to release.

The functionalized polymer coated member may take the form of a functionalized polymer coated conveyor belt configured to run between the first processor and the second processor. The first processor may be configured to receive the functionalized polymer coated conveyor belt and provide an enriched functionalized polymer coated conveyor belt having the valuable material attached thereto. The second processor may be configured to receive the enriched functionalized polymer coated conveyor belt and provide the valuable material released from the enriched functionalized polymer coated conveyor belt. The functionalized polymer coated conveyor belt may be made of a mesh material.

The functionalized polymer coated member may take the form of a functionalized polymer coated collection filter configured to move between the first processor and the second processor as part of a batch type process. The first processor may be configured to receive the functionalized polymer coated collection filter and to provide an enriched functionalized polymer coated collection filter having the valuable material attached thereto. The second processor device may be configured to receive the enriched functionalized polymer coated collection filter and provide the valuable material released from the enriched functionalized polymer coated collection filter.

The first processor may be configured to provide tailings containing the unwanted material, and the second processor may be configured to provide a concentrate containing the valuable material.

The functionalized polymer coated member may take the form of a membrane.

According to some embodiments of the present disclosure (not falling under the scope of protection), the apparatus may feature first means that may be configured to receive a mixture of fluid, valuable material and unwanted material and a functionalized polymer coated member configured to attach to the valuable material in an attachment rich environment, and provide an enriched functionalized polymer coated member having the valuable material attached thereto; and second means that may be configured to receive a fluid and the enriched functionalized polymer coated member in a release rich environment to release the valuable material, and provide the valuable material released from the enriched functionalized polymer coated member to the release rich environment.

According to some embodiments of the present disclosure, the first means may be configured to receive a pulp slurry having water, the valuable material and the unwanted material in the attachment rich environment, which has a high pH, conducive to attachment of the valuable material; and the second means may be configured to receive water in the release rich environment, which has a low pH or receives ultrasonic waves conducive to release of the valuable material.

According to some embodiments of the present disclosure, the functionalized polymer coated member may take the form of one of the following:.

The present invention also takes the form of a method comprising receiving in a first processor a mixture of fluid, valuable material and unwanted material and a functionalized polymer coated member, the functionalized polymer coated member configured to attach to the valuable material in an attachment rich environment, and providing from the first processor an enriched functionalized polymer coated member having the valuable material attached thereto; and.

The method may include being implemented consistent with one or more of the features set forth herein.

The Synthetic Functionalized Polymer Coated Member Chemistry.

According to the present invention, the functionalized polymer coated member is a solid-phase body comprising a surface coated with a hydroxyl-terminated polydimethylsiloxanate, so that the functionalized polymer coated member becomes hydrophobic. The functionalized polymer coated member may take the form of a solid-phase body comprising a surface in combination with a plurality of molecules attached to the surface, the molecules comprising a functional group selected for attracting or attaching to one or more mineral particles of interest to the molecules. The term "polymer" in this specification is understood to mean a large molecule made of many units of the same or similar structure linked together.

According to some embodiments of the present invention, the solid-phase body may be made of a synthetic material comprising the molecules.

According to some embodiments of the present invention, the solid-phase body may include an inner material and a shell providing the surface, the shell being made of a synthetic material comprising the molecules.

According to some embodiments of the present invention, the functional group may have an ionic group, which may be either anionic or cationic, for attracting or attaching the mineral particles to the surface.

According to some embodiments of the present invention, the functional group may take the form of a collector having a non-ionizing bond having a neutral or ionic functional group, or having an ionizing bond.

According to some embodiments of the present invention, the ionizing bond may be an anionic bond or a cationic bond. The anionic functional group may be comprised of an oxyhydryl, including carboxylic, sulfates and sulfonates, and sulfhydral bond.

According to some embodiments of the present invention, the surface of the functionalized polymer coated member is functionalized to be hydrophobic so as to provide a bonding between the surface and a mineral particle associated with one or more hydrophobic molecules.

Furthermore, the polymer can be naturally hydrophobic or functionalized to be hydrophobic. Some polymers having a long hydrocarbon chain or silicon-oxygen backbone, for example, tend to be hydrophobic. Hydrophobic polymers include polystyrene, poly(d,l-lactide), poly(dimethylsiloxane), polypropylene, polyacrylic, polyethylene, etc. The mineral particle of interest or the valuable material associated with one or more hydrophobic molecules is referred to as a wetted mineral particle. When the pulp slurry contains a plurality of collectors or collector molecules, some of the mineral particles will become wetted mineral particles if the collectors are attached to mineral particles. Xanthates can be used in the pulp slurry as the collectors.

According to some embodiments of the present invention, a part of the surface of the functionalized polymer coated member may be configured to have the molecules attached thereto, wherein the molecules comprise collectors.

According to some embodiments of the present invention, a part of the surface of the functionalized polymer coated member may be configured to have the molecules attached thereto, wherein the molecules comprise collectors, and another part of the surface of the functionalized polymer coated member is configured to be hydrophobic.

According to some embodiments of the present invention, only a part of the surface of the functionalized polymer coated member is configured to be hydrophobic.

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 drawings:.

By way of example, <FIG> shows an apparatus <NUM>, for separating valuable material from unwanted material in a mixture <NUM>, such as a pulp slurry, using a first processor <NUM> and a second processor <NUM> and a functionalized polymer coated impeller. The first processor <NUM> and the second processor <NUM> are configured with a functionalized polymer coated member that is a functionalized polymer coated impeller <NUM> (<FIG>), <NUM>' (<FIG>). In operation, the impeller <NUM>, <NUM>' slowly rotates in relation to the first processor <NUM> and the second processor <NUM>, the impeller blades slowly pass through the attachment rich environment <NUM> in the first processor <NUM> where the valuable material is attached to the blades, and through the release rich environment <NUM> in the second processor <NUM> where the valuable material is released from the blades. By way of example, the impeller <NUM> 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 <NUM> (<FIG>), <NUM>' (<FIG>) is arranged, mounted, or configured in relation to the first processor <NUM> and the second processor <NUM>.

In the embodiment shown in <FIG>, the first processor <NUM> takes the form of a first chamber, tank, cell or column that contains an attachment rich environment generally indicated as <NUM>. The first chamber, tank or column <NUM> is configured to receive via piping <NUM> the mixture or pulp slurry <NUM> in the form of fluid (e.g., water), the valuable material and the unwanted material in the attachment rich environment <NUM>, e.g., which has a high pH, conducive to attachment of the valuable material. The second processor <NUM> takes the form of a second chamber, tank, cell or column that contains a release rich environment generally indicated as <NUM>. The second chamber, tank, cell or column <NUM> is configured to receive via piping <NUM>, e.g., water <NUM> in the release rich environment <NUM>, 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 <NUM> conducive to the attachment of a valuable material of interest and release rich environments like that forming part of environment <NUM> 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 Moreover, a person skilled in the art would be able to formulate an attachment rich environment like environment <NUM> and a corresponding release rich environment like environment <NUM> based on the separation technology disclosed herein for any particular valuable mineral of interest, e.g., copper, forming part of any particular mixture or slurry pulp.

Although the invention is described as having a high pH in an attachment environment and a low pH in a release environment, embodiments are envisioned in which the invention will work equally as well where the pH of the attachment environment is selected to optimize the attachment of desired materials, such as a low, high or neutral pH, and the pH of the release environment is selected to be a different pH than the attachment environment and selected to optimize the release of the desired material.

In operation, the first processor <NUM> is configured to receive the mixture or pulp slurry <NUM> 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 <NUM>. In <FIG>, the functionalized polymer coated member is shown as the functionalized polymer coated impeller <NUM> (<FIG>), <NUM>' (<FIG>). In <FIG>, the functionalized polymer coated impeller <NUM> has a shaft <NUM> and at least one impeller blade 20a, 20b, 20c, 20d, 2e, 20f, <NUM> and is configured to rotate slowly inside the first processor <NUM> and the second processor <NUM>. In <FIG>, the functionalized polymer coated impeller <NUM>' has a shaft <NUM>' and impeller blades 20a', 20b', 20c', 20d', 2e', 20f', <NUM>' and <NUM>'. Each impeller blade in <FIG> is understood to be configured and functionalized with a polymer coating to attach to the valuable material in the attachment rich environment <NUM>. (The scope of the invention is not intended to be limited to the number of blades on the impeller <NUM>, <NUM>' and the embodiment in <FIG> is shown with impellers <NUM>, <NUM>' having a different number of blades.

In <FIG>, the first processor <NUM> is configured to receive at least one impeller blade of the functionalized polymer coated impeller <NUM> (<FIG>), <NUM>' (<FIG>). In <FIG>, the at least one impeller blade is shown as impeller blade <NUM>' being received in an attachment zone <NUM> that forms part of the attachment rich environment <NUM> defined by walls 30a, 30b. The first processor <NUM> may also be configured with a first transition zone generally indicated as <NUM> to provide drainage from piping <NUM> of, e.g., tailings <NUM> as shown in <FIG>.

The first processor <NUM> is also configured to provide at least one enriched impeller blade having the valuable material attached thereto, after passing through the attachment rich environment <NUM>. In <FIG>, the at least one enriched impeller blade is shown as the at least one enriched impeller blade 20c' being provisioned from the attachment rich environment <NUM> in the first processor <NUM> to the release rich environment <NUM> in the second processor <NUM>.

The second processor <NUM> is configured to receive e.g. via the piping <NUM> the fluid <NUM> (e.g. water) and the enriched functionalized polymer coated member to release the valuable material in the release rich environment <NUM>. In <FIG>, the second processor <NUM> is shown receiving the enriched impeller blade 20c' in a release zone <NUM>, e.g., that forms part of the release rich environment <NUM> and is defined, e.g., by walls 30c and 30d.

The second processor <NUM> is also configured to provide the valuable material that is released from the enriched functionalized polymer coated member into the release rich environment <NUM>. For example, in <FIG> the second processor <NUM> is shown configured with a second transition zone <NUM> defined by walls 30a and 30d to provide via piping <NUM> drainage of the valuable material in the form of a concentrate <NUM> (<FIG>).

By way of example, <FIG> shows an apparatus <NUM>, for separating valuable material from unwanted material in a mixture <NUM>, such as a pulp slurry, using a first processor <NUM> and a second processor <NUM> and a functionalized polymer coated conveyor belt. The first processor <NUM> and the second processor <NUM> are configured with a functionalized polymer coated member that is a functionalized polymer coated conveyor belt <NUM> that runs between the first processor <NUM> and the second processor <NUM>. The arrows A1, A2, A3 indicate the movement of the functionalized polymer coated conveyor belt <NUM>. Techniques, including motors, gearing, etc., for running a conveyor belt like element <NUM> between two processors like elements <NUM> and <NUM> are known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof. According to some embodiments of the present invention, the functionalized polymer coated conveyor belt <NUM> may be made of a mesh material.

In the embodiment shown in <FIG>, the first processor <NUM> takes the form of a first chamber, tank, cell or column that contains an attachment rich environment generally indicated as <NUM>. The first chamber, tank or column <NUM> is configured to receive the mixture or pulp slurry <NUM> in the form of fluid (e.g., water), the valuable material and the unwanted material in the attachment rich environment <NUM>, e.g., which has a high pH, conducive to attachment of the valuable material. The second processor <NUM> takes the form of a second chamber, tank, cell or column that contains a release rich environment generally indicated as <NUM>. The second chamber, tank, cell or column <NUM> is configured to receive, e.g., water <NUM> in the release rich environment <NUM>, 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 <NUM> conducive to the attachment of a valuable material of interest and release rich environments like that forming part of environment <NUM> 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. Moreover, a person skilled in the art would be able to formulate an attachment rich environment like environment <NUM> and a corresponding release rich environment like environment <NUM> based on the separation technology disclosed herein for any particular valuable mineral of interest, e.g., copper, forming part of any particular mixture or slurry pulp.

In operation, the first processor <NUM> is configured to receive the mixture or pulp slurry <NUM> of water, valuable material and unwanted material and the functionalized polymer coated conveyor belt <NUM> that is configured to attach to the valuable material in the attachment rich environment <NUM>. In <FIG>, the belt <NUM> is understood to be configured and functionalized with a polymer coating to attach to the valuable material in the attachment rich environment <NUM>.

The first processor <NUM> may also be configured to provide drainage from piping <NUM> of, e.g., tailings <NUM> as shown in <FIG>.

The first processor <NUM> is also configured to provide an enriched functionalized polymer coated conveyor belt having the valuable material attached thereto, after passing through the attachment rich environment <NUM>. In <FIG>, the enriched functionalized polymer coated conveyor belt is shownas that portion or part 120a of the belt <NUM> being provisioned from the attachment rich environment <NUM> in the first processor <NUM> to the release rich environment <NUM> in the second processor <NUM>. It is understood that some other portions or parts of the belt <NUM> may be enriched, including the portion or part immediately leaving the attachment rich environment <NUM>, as well as the portion or part immediately entering the release rich environment <NUM>.

The second processor <NUM> is configured to receive the fluid <NUM> (e.g. water) and the portion 120a of the enriched functionalized polymer coated conveyor belt <NUM> to release the valuable material in the release rich environment <NUM>.

The second processor <NUM> is also configured to provide the valuable material that is released from the enriched functionalized polymer coated member into the release rich environment <NUM>. For example, in <FIG> the second processor <NUM> is shown configured to provide via piping <NUM> drainage of the valuable material in the form of a concentrate <NUM>.

In <FIG>, the first processor <NUM> is configured with the functionalized polymer coated conveyor belt <NUM> passing through with only two turns inside the attachment rich environment <NUM>. However, embodiments are envisioned in which the first processor <NUM> may be configured to process the functionalized polymer coated conveyor belt <NUM> using a serpentine technique for winding or turning the belt <NUM> one way and another way, back and forth, inside the first processor to maximize surface area of the belt inside the processor <NUM> and exposure of the belt <NUM> to the attachment rich environment <NUM>.

By way of example, <FIG> shows an apparatus <NUM>, for separating valuable material from unwanted material in a mixture <NUM>, such as a pulp slurry, using a first processor <NUM>, <NUM>' and a second processor <NUM>, <NUM>' and a functionalized polymer coated collection filter. The first processor <NUM> and the second processor <NUM> are configured to process a functionalized polymer coated member that is a functionalized polymer coated collection filter <NUM> configured to be moved between the first processor <NUM> and the second processor <NUM>' as shown in <FIG> as part of a batch type process. In <FIG>, by way of example the batch type process is shown as having two first processors <NUM>, <NUM>' and two second processors <NUM>, <NUM>, although the scope of the invention is not intended to be limited to the number of first or second processors. Moreover, embodiments are envisioned using a different number of first and second processors, as well as different types or kinds of processors. According to the present invention, the functionalized polymer coated collection filter <NUM> may take the form of a membrane or a thin soft pliable sheet or layer. The arrow B1 indicates the movement of the functionalized polymer coated filter <NUM> from the first processor <NUM>, and the arrow B2 indicates the movement of the functionalized polymer coated collection filter <NUM> into the second processor <NUM>'. Techniques, including motors, gearing, etc., for moving a filter like element <NUM> from one processor to another processor like elements <NUM> and <NUM> are known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof.

In operation, the first processor <NUM> is configured to receive the mixture or pulp slurry <NUM> of water, valuable material and unwanted material and the functionalized polymer coated collection filter <NUM> that is configured to attach to the valuable material in the attachment rich environment <NUM>. In <FIG>, the functionalized polymer coated collection filter <NUM> is understood to be configured and functionalized with a polymer coating to attach to the valuable material in the attachment rich environment <NUM>.

The first processor <NUM> is also configured to provide an enriched functionalized polymer coated collection filter having the valuable material attached thereto, after soaking in the attachment rich environment <NUM>. In <FIG>, the enriched functionalized polymer coated collection filter <NUM> is shown, being provisioned from the attachment rich environment <NUM> in the first processor <NUM> to the release rich environment <NUM> in the second processor <NUM>.

The second processor <NUM> is configured to receive the fluid <NUM> (e.g. water) and the enriched functionalized polymer coated collection filter <NUM> to release the valuable material in the release rich environment <NUM>.

The second processor <NUM> is also configured to provide the valuable material that is released from the enriched functionalized polymer coated collection filter <NUM> into the release rich environment <NUM>. For example, in <FIG> the second processor <NUM> is shown configured to provide via piping <NUM> drainage of the valuable material in the form of a concentrate <NUM>.

The first processor <NUM>' may also be configured with piping <NUM> and pumping <NUM> to recirculate the tailings <NUM> back into the first processor <NUM>'. The scope of the invention is also intended to include the second processor <NUM>' being configured with corresponding piping and pumping to recirculate the concentrate <NUM> back into the second processor <NUM>'. Similar recirculation techniques may be implemented for the embodiments disclosed in relation to <FIG> above.

The disclosure 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 <NUM>, <NUM> being configured to process the enriched functionalized polymer coated collection filter <NUM> in relation to one type or kind of valuable material, and the first and second processors <NUM>', <NUM>' being configured to process the enriched functionalized polymer coated collection filter <NUM> in relation to either the same type or kind of valuable material, or a different type or kind of valuable material.

A synthetic bead is an example of a functionalized polymer coated member. For aiding a person of ordinary skill in the art in understanding various embodiments of the present disclosure, <FIG> shows at least part of a generalized functionalized polymer coated member having a solid-phase body, and <FIG> shows an enlarged portion of the surface. As shown in <FIG>, the functionalized polymer coated member <NUM> has a body to provide a surface <NUM>. At least the outside part of the body is made of a synthetic material, such as polymer, so as to provide a plurality of molecules or molecular segments <NUM> on the surface <NUM>. The molecule <NUM> is used to attach a chemical functional group <NUM> to the surface <NUM>. In general, the molecule <NUM> can be a hydrocarbon chain, for example, and the functional group <NUM> can have an anionic bond for attracting or attaching a mineral particle of interest, such as copper to the surface <NUM>. A xanthate, for example, has both the functional group <NUM> and the molecular segment <NUM> to be incorporated into the polymer that is used to make the synthetic bead <NUM>, or the surface thereof. The functional group <NUM> is also known as a collector that can have a neutral or charged functional group for attachment to the desired mineral, e.g., via a non-ionizing or ionizing bond. The charged functional group may include an ionizing bond that is anionic or cationic. An anionic bond or groups may include an oxyhydryl, such as carboxylic, sulfates and sulfonates, and sulfhydral, such as xanthates and dithiophosphates. Other molecules or compounds that can be used to provide the function group <NUM> include thionocarboamates, thioureas, xanthogens, monothiophosphates, hydroquinones and polyamines.

Similarly, a chelating agent can be incorporated into the polymer as a collector site for attracting a mineral, such as copper. As shown in <FIG>, a mineral particle <NUM> is attached to the functional group <NUM> on the molecule <NUM>. In general, the mineral particle <NUM> is much smaller than the synthetic bead <NUM>. Many mineral particles <NUM> can be attracted to or attached to the surface <NUM> of a functionalized polymer coated member <NUM>.

In some embodiments, a functionalized polymer coated member takes the form of a solid-phase body made of a synthetic material, such as polymer. (By way of example, the term "solid-phase body" is understood herein to be a body having a cohesive force of matter that is strong enough to keep the molecules or atoms in the given positions, restraining the thermal mobility. ) The polymer can be rigid or elastomeric. An elastomeric polymer can be a bisoxazolone-based polymer, for example. The body has a surface comprising a plurality of molecules with one or more functional groups for attracting mineral particles of interest to the surface. A polymer having a functional group to attract or collect mineral particles is referred to as a functionalized polymer. By way of example, the entire body of the functionalized polymer coated member may be made of the same functionalized material, or the body may be a shell, which can be formed around an inner material.

It should be understood that the surface of a functionalized polymer coated member, according to the present invention, is not limited to an overall smoothness of its surface as shown in <FIG>. In some embodiments, the surface can be irregular and rough. For example, the surface can have some physical structures like grooves or rods, or holes or dents. The surface can have some hair-like physical structures. In addition to the functional groups on the functionalized polymer coated member that attract mineral particles of interest to the surface, the physical structures can help trapping the mineral particles on the surface. The surface can be configured to be a honeycomb surface or a sponge-like surface for trapping the mineral particles and/or increasing the contacting surface. In effect, the scope of the invention is not intended to be limited to any particular type or kind of surface of the synthetic bead.

It should be noted that a functionalized polymer coated member can be realized by a different way to achieve the same goal. Namely, it is possible to use a different means to attract the mineral particles of interest to the surface of the functionalized polymer coated member. For example, the surface of the polymer coated member can be functionalized with a hydrophobic chemical molecule or compound, as discussed below. Alternatively, according to the invention, the surface of the functionalized polymer coated member is coated with a hydroxyl-terminated polydimethylsiloxane.

In the pulp slurry, xanthate and hydroxamate collectors can also be added therein for collecting the mineral particles and making the mineral particles hydrophobic. When the functionalized polymer coated member are used to collect the mineral particles in the pulp slurry having a pH value around <NUM>-<NUM>, it is possible to release the mineral particles on the enriched synthetic beads from the surface of the functionalized polymer coated member in an acidic solution, such as a sulfuric acid solution. According to some embodiments, it is also possible to release the mineral particles carried with the enriched functionalized polymer coated member by sonic agitation, such as ultrasonic waves, or simply by washing it with water.

<FIG> shows at least part of a generalized functionalized polymer coated member having some particles attached to the surface. <FIG> illustrates an enlarged portion of the functionalized polymer coated member showing a wetted mineral particle attached to the hydrophobic surface of the functionalized polymer coated member. <FIG> illustrates an enlarged portion of the functionalized polymer coated member showing a hydrophobic particle attached to the hydrophobic surface of the functionalized polymer coated member.

The hydrophobic particle can be mineral related or non-mineral related. Non-mineral related particles do not fall under the scope of protection.

As shown in <FIG>, the functionalized polymer coated member <NUM> has a body to provide a surface <NUM>. At least the outside part of the body is made of a coating of a hydrophobic chemical, i.e. a hydrophobic silicone polymer. As such, hydrophobic particles <NUM>, <NUM>' are attracted to the surface <NUM> to form an enriched functionalized polymer coated member <NUM>. As shown in <FIG>, the surface <NUM> of the functionalized polymer coated member comprises a plurality of molecules <NUM> which renders the surface <NUM> hydrophobic. Polysiloxanates, such as hydroxyl-terminated polydimethysiloxanes, have a silicon-oxygen chain to provide the hydrophobic molecules <NUM>. The hydrophobic particle <NUM>', as shown in <FIG>, can be a mineral particle <NUM>' having one or more collectors <NUM> attached thereto. One end <NUM> of the collector <NUM> has an ionic bond or ionic group attached to the mineral particle of interest <NUM>'. The other end of the collector <NUM> has a hydrophobic chain <NUM> which tends to move into the hydrophobic molecules <NUM>. Thus, the hydrophobic particle <NUM>' can be a wetted mineral particle. A collector, such as xanthate, has both the functional group <NUM> and the molecule <NUM>. A xanthate, for example, has both the functional group <NUM> and the molecular segment <NUM> to be incorporated into the polymer that is used to make the functionalized polymer coated member <NUM>. A functional group <NUM> is also known as a collector that can have a non-ionizing or ionizing bond. The ionizing bond or group can be anionic or cationic. An anionic bond or group may include an oxyhydryl, such as carboxylic, sulfates and sulfonates, and sulfhydral, such as xanthates and dithiophosphates. Other molecules or compounds that can be used to provide the function group <NUM> include thionocarboamates, thioureas, xanthogens, monothiophosphates, hydroquinones and polyamines.

The hydrophobic particle <NUM>, as shown in <FIG>, can be a particle that has a hydrophobic chain <NUM>. Such particle can be non-mineral related, but while the present invention can be used in non-mining applications, such as water-pollution control and water purification, such non-mineral particle related applications are not within the scope of the invention as claimed.

In many releasing environments, the pH value is lower than the pH value for mineral attachment. It should be noted that, however, when the valuable material is copper, for example, it is possible to provide a lower pH environment for the attachment of mineral particles and to provide a higher pH environment for the releasing of the mineral particles from the synthetic beads or bubbles. In general, the pH value is chosen to facilitate the strongest attachment, and a different pH value is chosen to facilitate release. Thus, according to some embodiments of the present invention, one pH value is chosen for mineral attachment, and a different pH value is chosen for mineral releasing. The different pH could be higher or lower, depending on the specific mineral and collector.

The synthetic beads can be made with different sizes in order to attract mineral particles of different sizes. For example, unlike air bubbles, the synthetic beads of a larger size can be used to attract mineral particles larger than, say, <NUM>. Thus, the grinding of the blasted ore can be separated into different stages. In the first stage, the rock is crushed into particles in the order of <NUM>. After the separation process using the larger synthetic beads in the slurry containing these crude particles, the remaining slurry can be subjected to a finer grinding stage where the crushed rock is further crushed into particles in the order of <NUM>. With the slurry containing the finer mineral particles, synthetic beads with a smaller size may be more effective in interacting with the finer mineral particles. In a flotation cell application, the bead size can be smaller than <NUM>. In a tailings pond application, the bead size can be <NUM> to <NUM> or larger. However, large beads would reduce the functionalized surfaces where the mineral particles can attach to the synthetic beads. Thus, according to some embodiments of the present invention, the synthetic beads are configured with a size less than <NUM> for attracting to mineral particles having a substantially similar size, including in applications related to flotation cells; the synthetic beads are configured with a size of about <NUM> for attracting or attaching to mineral particles having a substantially similar size, smaller size or larger size; the synthetic beads are configured with a size in a range of about <NUM>-<NUM> for attracting or attaching to mineral particles having a substantially similar size, smaller size or larger size; the synthetic beads are configured with a size about <NUM> for attracting to mineral particles having a substantially similar size; the synthetic beads are configured with a size in a range of about <NUM> to <NUM>, including in applications related to a tailings pond. In general, the synthetic beads are configured with a size in a range of about <NUM> to <NUM>. But the beads can be smaller than <NUM> and larger than <NUM>.

According to some embodiments, the synthetic beads are configured to be larger than the mineral particles. As such, a plurality of mineral particles may attach to one synthetic bead. The synthetic beads are configured to be smaller than the mineral particles. As such, a plurality of synthetic beads may attach to one mineral particle. The size of the synthetic beads can also be about the same as the size of the mineral particle.

It should be understood that the synthetic beads according to the present disclosure, whether functionalized to have a collector or functionalized to be hydrophobic, are also configured for use in oilsands separation (not according to the invention) - 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 disclosure, are also configured for oilsands separation (not according to the invention).

According to some embodiments, only a portion of the surface of the synthetic bead is functionalized to be hydrophobic. This has the benefits as follows:.

According to some embodiments, only a portion of the surface of the synthetic bead is functionalized with collectors. This also has the benefits of.

According to some embodiments, one part of the synthetic bead is functionalized with collectors while another part of same synthetic bead is functionalized to be hydrophobic as shown in <FIG>. As shown in <FIG>, a synthetic bead <NUM> has a surface portion where polymer is functionalized to have collector molecules <NUM> with functional group <NUM> and molecular segment <NUM> attached to the surface of the bead <NUM>. The synthetic bead <NUM> also has a different surface portion where polymer is functionalized to have hydrophobic molecules <NUM> (or <NUM>). In the embodiment as shown in <FIG>, the entire surface of the synthetic bead <NUM> can be functionalized to have collector molecules <NUM>, but a portion of the surface is functionalized to have hydrophobic molecules <NUM> (or <NUM>) render it hydrophobic.

According to some embodiments, one part of the synthetic bead is functionalized with collectors while another part of same synthetic bead is functionalized to be hydrophobic and this "hybrid" synthetic bead is configured for use in a traditional flotation cell as well. The "hybrid" synthetic bead (see <FIG>) has a hydrophobic portion and a separate collector portion. When the "hybrid" beads are mixed with air in the flotation cell, some of them will attach to the air bubbles because of the hydrophobic portion. As the "hybrid" synthetic bead is attached to an air bubble, the collector portion of the attached bead can collect mineral particles with the functional groups. Thus, the synthetic beads, according to some embodiments, can be used to replace the air bubbles, or to work together with the air bubbles in a flotation process.

According to some embodiments, 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. The synthetic bead is functionalized to be hydrophobic in order to collect one or more wetted mineral particles.

The scope of the invention is described in relation to mineral separation, including the separation of copper from ore.

By way of example, applications are envisioned to include.

Rougher, scavenger, cleaner and rougher/scavenger separation cells in the production stream, replacing the traditional flotation machines.

Tailings scavenger cells used to scavenge the unrecovered minerals from a tailings stream.

Tailings cleaning cell use to clean unwanted material from the tailings stream before it is sent to the disposal pond.

Tailings reclamation machine that is placed in the tailings pond to recover valuable mineral that has been sent to the tailings pond.

Other types or kinds of valuable material or minerals of interest, including gold, molybdenum, etc..

Claim 1:
Apparatus comprising a functionalized polymer coated member, a first pro - cessor and a second processor,
the first processor configured to receive a mixture of fluid, valuable material and unwanted material and the functionalized polymer coated member, the functionalized polymer coated member configured to attach to the valuable material in an attachment rich environment, and configured to provide an en - riched functionalized polymer coated member having the valuable material at - tached thereto; and
the second processor configured to receive a fluid and the enriched function - alized polymer coated member in a release rich environment to release the valuable material, and provide the valuable material released from the en - riched functionalized polymer coated member to the release rich environment, wherein an attachment rich environment is an environment conducive to the attachment of the valuable material to the functionalized polymer coated member, and a release rich environment is an environment conducive to the release of the valuable material from the enriched functionalized polymer coated member, and further
wherein the valuable material comprises mineral particles, and the functional - ized polymer coated member is a solid-phase body comprising a surface coated with a hydroxyl-terminated polydimethylsiloxanes, so that the function - alized polymer coated member becomes hydrophobic.