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 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>. As shown in <FIG>, pulp slurry <NUM> is processed through a plurality of flotation cells <NUM> and the tailings <NUM> are discarded in a tailings pond or dam <NUM>. If the processed slurry <NUM> can be further processed for mineral recovery, another flotation cell <NUM> may be used to repeat the process. When the processed slurry <NUM> is processed in the last flotation cell <NUM>, froth flotation is generally no longer an effective or viable process for mineral collection. Because of a number of other factors, as much as <NUM>% of the liberated minerals are not recovered and are discarded as gangue in the pond or dam <NUM>.

<CIT> relates to removing finely dispersed particulate matter from a fluid, using a particle functionalized by attachment of at least one activating group or amine functional group to modify the particle, so that the modified particle complexes with the particulate matter to form a removable complex.

<CIT> discloses a froth flotation process for beneficiation of fine coal, wherein a water-dispersible polyorganosiloxane is used as a collector. The collector renders the coal particles hydrophobic so that adhesion between the desired coal particles and the rising air bubbles in the froth flotation process is promoted.

<CIT> discloses the separation of hydrophobic metal compounds from a mixture of these hydrophobic metal compounds and hydrophilic metal oxides for the beneficiation of ores by means of a hydrophobic surface. A hydrophobic surface can be, for example, the surface of a plate or of a conveyor belt which has been rendered hydrophobic by a material such as dodecyltrichlorosilane.

There is a need in the industry to provide a better way to separate valuable material from unwanted material, from the discarded tailings.

The present invention satisfies this need by the methods having the features defined in independent claims <NUM>, <NUM> and <NUM>, and by the systems having the features defined in independent claims <NUM>, <NUM> and <NUM>. Embodiments of the invention are claimed in the respective dependent claims.

The present invention provides a method for separating mineral particles from unwanted material in tailings of a flotation process, the method comprising:.

The method comprises steps of providing collection apparatus functionalized with a synthetic material comprising a plurality of molecules having a functional group configured to collect mineral particles of interest to the surface of the collection apparatus; and causing the collection apparatus to contact with tailings having the mineral particles of interest, e.g., including the tailings from a flotation process. In the following, exemplary embodiments are described, but not all materials and material combinations, respectively, fall under the scope of the appended claims. Only the feature combinations defined in the claims are within the scope of the present invention.

According to the disclosure, the functional group may include an ion or charge species for bonding the mineral particles of interest to the molecules. The functional group may include, but not limited to, one or more ions in carboxylic, sulfates, sulfonates, xanthates, dithiophosphates, thionocarboamates, thioureas, xanthogens, monothiophosphates, hydroquinones and polyamines. 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, wherein none of these compounds fall under the scope of the claims. The list is not necessarily exhaustive.

According to the present invention, the functional group is configured to render the surface of the collection apparatus hydrophobic. By way of example, 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, and as regards synthetic materials according to this invention, reference is made to the appended claims. The list is not necessarily exhaustive. The mineral particles of interest may have one or more hydrophobic molecular segments attached thereon. The method may also further comprise providing collector molecules in the tailings, 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, including where the collector molecules is xanthates. The synthetic material may include a siloxane derivative, or polysiloxanates, or hydroxyl-terminated polydimethylsiloxanes, wherein only the hydroxyl-terminated polydimethylsiloxane falls under the scope of protection.

According to the disclosure, the method includes discharging the tailings to a discharge area, and causing the collection apparatus to contact with the tailings before or after the tailings are discharged.

According to the disclosure, the collection apparatus may comprise a plurality of passage ways in the collection area, wherein the passage ways comprise collection surfaces configured with the synthetic material, and the method may further include causing at least part of the tailings to move through the passage ways so as to allow the mineral particles of interest to contact with the molecules on the collection surfaces in the passage ways. By way of example, the passage ways may include a plurality of fibers for providing the collection surfaces.

According to the disclosure, the collection apparatus may include a collection plate having a collection surface configured with the synthetic material, and the method may further include causing at least part of the tailings to move over the collection plate so as to allow the mineral particles of interest to contact with the molecules on the collection surface.

According to the disclosure, the collection apparatus may include a plurality of solid-phase bodies (synthetic beads) for providing collection surfaces configured with the synthetic material.

According to the disclosure, the collection apparatus may be configured to contact the tailings over a period of time for providing an enriched collection surface containing the mineral particles, and the method may further include separating the collection apparatus from the tailings; and releasing the mineral particles of interest from the enriched collection surface. By way of example, the step for releasing may include contacting the enriched collection surface with a liquid having a pH value ranging from <NUM> to <NUM>, or at least partially submerging the enriched collection surface in a liquid and applying ultrasound waves in the liquid for providing ultrasonic agitation over the enriched collection surface.

The present invention provides a system suitable for separating mineral particles from unwanted material in tailings of a flotation process, the system comprising:.

According to the disclosure, the system features 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 comprising 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.

While in the following many exemplary embodiments are described, only the feature combinations indiciated in the appended claims are within the scope of the present invention.

According to the disclosure, the functional group may include an ionizing bond for bonding the mineral particles of interest to the molecules. By way of example, 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, wherein none of these compounds fall under the scope of the claims.

According to the disclosure, the functional group is configured to render the collection area hydrophobic. By way of example, 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, however, only the materials indicated in the claims fall under the scope of protection. Moreover, 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, or polysiloxanates, or hydroxyl-terminated polydimethylsiloxanates, from wich only the hydroxyl-terminated polydimethylsiloxanates fall under the scope of protection.

According to the disclosure, 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 further 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. By way of example, the release medium may include a liquid configured to contact with the enriched collection surface, the liquid having a pH value ranging from <NUM> to <NUM>. The release medium may also include a liquid configured to contact with the enriched collection surface, and the system may further 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.

The present disclosure provides mineral separation techniques using functionalized polymers. The present disclosure takes the form of a new machine and process for recovering valuable materials (minerals) from the tailings using such functionalized polymers. In particular, various functionalized polymers may be used to attract the valuable materials (mineral particles) of interest in the tailings, consistent with that disclosed in the claims. The tailings are put into contact with a functionalized polymer surface which has been engineered to attract the mineral of interest. The functionalized polymer surface may include, e.g., a synthetic bubble or bead, as well as membrane or membrane structure that may take the form of a conveyor belt, a filter assembly, or a flat plate.

The unwanted material may be washed away and only the desirable material (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, and/or gravimetric separation. The enriched surface is then treated so that the mineral is released and collected. The functionalized polymer surface can then be reused.

According to the disclosure, the functionalized polymer surface is provided on a functionalized polymer coated member. The functionalized polymer coated member may take the form of a functionalized polymer coated conveyor belt configured to run between a recovery processor and a release processor. The functionalized polymer coated conveyor belt may be made of a mesh material. In the recovery processor, the functionalized coated conveyor belt is configured to increase the contact between the tailings and the functionalized polymer.

The functionalized polymer coated member may take the form of a functionalized polymer coated collection filter configured to be placed in a recovery processor or to move in a recovery processor to increase the contact between the tailings and the functionalized polymer. The functionalized polymer coated member may take the form of a membrane or a thin soft pliable sheet or layer.

The functionalized polymer coated member may take the form of a functionalized polymer coated collection plate configured to be placed in a recovery processor or to move in a recovery processor to increase the contact between the tailings and the functionalized polymer. The functionalized polymer coated member may take the form of a pliable sheet or a rigid plate.

The functionalized polymer coated member may take the form of a functionalized polymer coated impeller blade (outside the scope of the claims) configured to be placed in a recovery processor or to move between a recovery zone and a release zone.

According to the disclosure, a plurality of synthetic beads provide the collection surfaces.

According to the disclosure, a part of the surface of the synthetic bubbles or beads may be configured to have the molecules attached thereto, wherein the molecules comprise collectors.

According to the disclosure, a part of the surface of the synthetic bubbles or beads may be configured to have the molecules attached thereto, wherein the molecules comprise collectors, and another part of the surface of the synthetic bubbles or beads may be configured to be hydrophobic.

According to the disclosure, a part of the surface of the synthetic bubbles or beads may be configured to be hydrophobic.

Referring now to the drawing, which are not necessarily drawn to scale, the foregoing and other features and advantages 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:.

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 the disclosure, 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 is 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 the disclosure, the functional group may include an ionizing bond for bonding the mineral particles to the molecules. The functional group renders 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>, after the tailings <NUM> is discharged from a last flotation cell <NUM> to a tailings pond or dam <NUM>, a functionalized polymer <NUM> may be placed in the tailings pond to collect the valuable material of interest in the pond.

In the embodiment as shown in <FIG>, a functionalized polymer <NUM> may be used in a recovery processor <NUM> located closed to the last flotation cell <NUM> to process the tailings <NUM> in order to collect the valuable material of interest in the recovery processor <NUM>. The processed tailings <NUM> are then transported to the pond or dam <NUM>.

In the embodiment as shown in <FIG>, the recovery processor <NUM> may be placed near the pond <NUM>. The recovery processor <NUM> may use the functionalized polymer <NUM> to process the tailings <NUM>. The processed tailings <NUM> may then be discharged into the pond or dam <NUM>.

In the embodiment as shown in <FIG>, the functionalized polymer <NUM> may be used to collect the mineral particle of interest in the recovery processor <NUM> and the functionalized polymer <NUM> may be used in the pond <NUM>.

A collection apparatus as defined in the claims supports the functionalized polymer, i.e. the functionalized polymer <NUM>, <NUM> may comprise functionalized polymer coated collection areas or surfaces as shown in <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, <FIG>.

The functionalized polymer <NUM> (<FIG>), 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. The collection apparatus may take the form of a conveyor belt, a filter or a collection plate. The functionalized polymer is selected from a polysiloxanate, an alkylsilane, a fluoroalkylsilane or a polydimethylsiloxane. In an embodiment, the collection areas comprise an irregular arrangement of fibers, the fibers are made of glass, ceramic, metal, nylon, cotton or another fabric material and coated with a polysiloxanate, an alkylsilane or a fluoroalkylsilane, or are made of polydimethylsiloxane. In an embodiment, the collection areas have a plurality of openings, the surfaces and edges around the openings are made of glass, ceramic, metal, nylon, cotton or another fabric material and coated with a polysiloxanate, an alkylsilane or a fluoroalkylsilane, or are made of polydimethylsiloxane. In an embodiment, the collection areas comprise a plane surface, the plane surface is made of glass, ceramic, metal, nylon, cotton or another fabric material and coated with a polysiloxanate, an alkylsilane, or a fluoroalkylsilane, or is made of polydimethylsiloxane.

In the embodiment as shown in <FIG>, one or both sides of the conveyor belt <NUM> are coated with, or made of, the functionalized polymer. As tailings <NUM> may be received into the recovery processor <NUM>, the tailings are caused to contact with the surfaces of the conveyor belt <NUM>, which is moving in a continuous loop between the recovery processor <NUM> and a release processor <NUM>. The valuable material or mineral particle of interest attached to the surfaces of the conveyor belt <NUM> in the recovery processor <NUM> will be released from the conveyor belt in the release processor <NUM> by means of a low pH environment and/or by means of ultrasonic agitation. As shown in <FIG>, one or more ultrasound sources <NUM> may be provided in the release processor <NUM> in order to apply ultrasonic agitation to the surfaces of the conveyor belt. The pH value in the release processor can be ranged from <NUM> to <NUM>. After being processed in the recovery processor <NUM>, the processed tailings <NUM> can be transported to a tailings pond or directly discharged into a tailings pond. Alternatively, the processed tailings <NUM> can be received into another recovery processor <NUM> for further processing.

In the embodiment as shown in <FIG>, a plurality of filters <NUM> is used in a group. Each of the filters <NUM> has a plurality of passage ways (see <FIG>) to allow the tailings <NUM> to move through. The passage ways are used to provide collection areas or surfaces (see <FIG>) configured to contact with the tailings as the tailings pass through the passage ways. The collection areas or surfaces in the passage ways are coated with, or made of, the functionalized polymer. As the tailings move from one end of the recovery processor <NUM> to the other end through the filters <NUM>, the molecules of the functionalized polymer are configured to attract the mineral particles of interest in the tailings. When the filters <NUM> have collected a certain amount of mineral particles of interest, one or some of the filters <NUM> can be removed from the recovery processor <NUM> at a time in order to release the mineral particles collected on the filters.

In the embodiment as shown in <FIG>, a plurality of collection plates <NUM> are arranged in a certain pattern to increase the contact between the tailings in the recovery processor <NUM> and the collection plates <NUM>. Each of the collection plates <NUM> is coated with, or made of, the functionalized polymer. As the tailings move from one end of the recovery processor <NUM> to the other end through the collection plates <NUM>, the molecules of the functionalized polymer are configured to attract the mineral particles of interest in the tailings. When the collection plates <NUM> have collected a certain amount of mineral particles, one or some of the collection plates <NUM> can be removed from the recovery processor <NUM> at a time in order to release the mineral particles collected on the collection plate. The mineral particles attached to the filters <NUM> or the collection plates <NUM> 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 <NUM> or collection plate <NUM> with collected mineral particles can be taken to a release station <NUM> as shown in <FIG>. The filter <NUM> or collection plate may be placed in a release apparatus <NUM> to be washed with a mixture of acid and water provided by water container <NUM> and acid container <NUM>. One or more ultrasonic sources <NUM> may be used to shake loose the attached mineral particles from the filter <NUM> or collection plate <NUM>. The reclaimed water <NUM> can be channeled back for reuse. The concentrated mineral <NUM> can be taken out of the releasing apparatus <NUM>.

The conveyor belt <NUM> (<FIG>) is configured with a collection area <NUM> to support the functionalized polymer (<FIG>). The filter <NUM> (<FIG>) is configured with a collection area <NUM> to support the functional polymer (<FIG>). The collection plate <NUM> (<FIG>) is configured with a collection area <NUM> to support the functionalized polymer (<FIG>). The collection area <NUM>, <NUM> and <NUM> can take many forms and have various surface features (<FIG>) to collect the mineral particles of interest, when the conveyor belt <NUM>, the filter <NUM> and the collection plate <NUM> are made to contact with the tailings, whether in a tailings pond <NUM> (<FIG>) or in recovery processor <NUM> (<FIG>, <FIG>).

The collection area <NUM> of the collection plate <NUM> can take many different forms. For example, the collection area <NUM> on one or both of sides of the collection plate <NUM> can be a smooth surface, as shown in <FIG>. The collection area <NUM> on one or both of sides of the collection plate <NUM> can be a rough surface of irregular height and pattern, as shown in <FIG>. The collection area <NUM> on one or both of sides of the collection plate <NUM> can have grooves and dents, as shown in <FIG>. The collection area <NUM> on one or both of sides of the collection plate <NUM> can have hair-like structure as shown in <FIG>. The collection area is coated with, or made of, functionalized polymer to attract mineral particles of interest. The surface structures on <FIG> may be configured to increase the contact between the functionalized polymer on the collection area and the tailings.

By way of example, each of the collection areas <NUM>, <NUM> and <NUM> (<FIG>) may have a plurality of openings to allow the tailings <NUM> (<FIG>) 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 are 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 <NUM>, <NUM> and <NUM> can take the form of holes or cylindrical passage ways <NUM> as shown in <FIG>. The openings on the collection areas <NUM>, <NUM> and <NUM> can take the form of hexagonal passage ways <NUM> arranged like honeycomb, as shown in <FIG>. The collection areas <NUM>, <NUM> and <NUM> can have a rectangular grid <NUM>, as shown in <FIG>. The collection areas <NUM>, <NUM> and <NUM> may comprise a stack of wavy sheets <NUM> as shown in <FIG>. The collection areas <NUM>, <NUM> and <NUM> may comprise an irregular arrangement of fiber-like structures <NUM> as shown in <FIG>. The collection areas <NUM> and <NUM> may comprise a plain surface <NUM> as shown in <FIG>. The plain surface <NUM> may be a smooth surface, a paper-like surface or matted surface, without larger structures. The collection area <NUM>, <NUM> and <NUM> can be made of a synthetic material, i.e. 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 <NUM>, the filter <NUM> and the collection plate <NUM> may be made of metal, ceramic, glass or a different polymer, with only the materials and material combinations defined in the claims being within the scope of the invention.

By way of example, the fiber-like structures <NUM> (<FIG>) can be functionalized so that they become attached to molecules <NUM> (<FIG>). The fiber-like structures <NUM> as shown in <FIG> can be made of individual fibers <NUM>, <NUM>' as shown in <FIG>. In one embodiment of the present disclosure, the fiber <NUM> (<FIG>) can be made of a polymer that has a plurality of molecules <NUM> to provide the functional group <NUM> and the attaching molecular segment <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 fiber <NUM>. A functional group <NUM> is also known as a collector that is either ionic or non-ionic bonding to mineral particles <NUM>. 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 <NUM> include thionocarboamates, thioureas, xanthogens, monothiophosphates, hydroquinones and polyamines. In another embodiment of the present invention, the fiber <NUM> is coated with polymer that has the molecules <NUM> to provide the functional group <NUM> and the attaching molecular segment <NUM>. With such a coating, the fiber <NUM> can be made of glass, ceramic, metal, nylon, cotton or a different polymer. A diagram of the fiber <NUM> and the attached molecules <NUM> is shown in <FIG>.

In a different embodiment of the present disclosure, the fiber <NUM>' (<FIG>) can be made of a polymer that has a plurality of molecules <NUM> to render the fiber <NUM>' (and thus the collection areas <NUM>, <NUM> and <NUM> of <FIG>) 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. According to the present disclosure, the fiber is made of polydimethylsiloxane, or the fiber <NUM>' is made of glass, ceramic, metal, nylon, cotton or other fabric materials and coated with hydrophobic molecules, i.e. with a polysiloxanate, an alkylsilane or a fluoroalkylsilane. The molecules <NUM> cause the fiber <NUM>' to become hydrophobic. As such, a hydrophobically-modified mineral particle <NUM>' can be attracted to the hydrophobic fiber <NUM>'. The hydrophobically-modified, or wetted, mineral particle <NUM>' may include a mineral particle <NUM> and one or more molecules <NUM> attached thereon. The molecule <NUM>, or collector, may have a functional group <NUM> attached to the mineral particle <NUM> and a hydrophobic chain or molecular segment <NUM>. A diagram showing the attraction between the hydrophobic chain or molecular segments <NUM> and the hydrophobic fiber <NUM>' is shown in <FIG>. It should be understood that the particles <NUM>' may be non-mineral and can be some harmful particles in a body of water. Attracting non-mineral particles is outside the scope of the invention. Furthermore, the hydrophobic fiber <NUM>' can also be used to attract non-mineral particles (outside the scope of the invention). For example, if a non-mineral particle <NUM>' has one or more hydrophobic chains or molecular segments <NUM>, the non-mineral particle <NUM>' may also attracted to the hydrophobic fiber <NUM>'. A diagram showing the attraction between non-mineral particles <NUM>' and the hydrophobic fiber <NUM>' is shown in <FIG>. Thus, the hydrophobic fiber <NUM>' can be used in a filter, impeller or conveyor belt (similar to those shown in <FIG>) for water-pollution control, water purification, etc. (outside the scope of the invention).

The surfaces and edges around the openings or surface structures <NUM>, <NUM>, <NUM>, <NUM> (<FIG>) can be functionalized to provide the molecules <NUM> (<FIG>). Materials and material combinations of the surfaces and edges around the openings are defined in the claims, and different materials and material combinations are outside the scope of this invention. The exposed surfaces and edges around the openings or surface structures <NUM>, <NUM>, <NUM>, <NUM> are represented by surface portions <NUM>, <NUM>' as shown in <FIG>. The length L of the surface portions <NUM>, <NUM>' can be equal to the thickness of the conveyor belt <NUM>, the filter <NUM> and the collection plate <NUM> (<FIG>). As with the fiber <NUM> as shown in <FIG>, the surface portion <NUM> can be made of a polymer that has a plurality of molecules <NUM> to provide the functional group <NUM> and the attaching molecular segment <NUM>. In a different embodiment, the surface portion <NUM> may be coated with polymer that has the molecules <NUM> to provide the functional group <NUM> and the attaching molecular segment <NUM>. The surface portion <NUM> can be made of glass, ceramic, metal, nylon, cotton or a different polymer. The functional group <NUM> may be used to attract mineral particles of interest <NUM>. A diagram of the surface portion <NUM> and the attached molecules <NUM> is shown in <FIG>.

In a different embodiment of the present disclosure, the surface portion <NUM>' can be made of a polymer having a plurality of molecules <NUM> that render the surface portion <NUM>' (and thus the collection areas <NUM>, <NUM> and <NUM> of <FIG>) hydrophobic. As with the hydrophobic fiber <NUM>' as shown in <FIG>, 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. According to the disclosure, the surface portion is made of polydimethylsiloxane, or the surface portion <NUM>' is made of glass, ceramic, metal, nylon, cotton or other fabric materials and coated with hydrophobic molecules, i.e. with a polysiloxanate, an alkylsilane or a fluoroalkylsilane. The molecules <NUM> cause the surface portion <NUM>' to become hydrophobic. As such, a hydrophobically-modified mineral particle <NUM>' is attracted to the hydrophobic surface portion <NUM>'. A diagram showing the attraction between the molecular segments <NUM> and the hydrophobic surface portion <NUM>' is shown in <FIG>. It should be understood that the particles <NUM>' may be non-mineral and can be some harmful particles in a body of water. Furthermore, the hydrophobic surface portion <NUM>' can also be used to attract non-mineral particles (outside the scope of the invention). For example, if a non-mineral particle <NUM>' has one or more hydrophobic chains or molecular segments <NUM>, the non-mineral particle <NUM>' may also be attracted to the hydrophobic surface portion <NUM>'. A diagram showing the attraction between the non-mineral particles <NUM>' and the hydrophobic surface portion <NUM>' is shown in <FIG>. Thus, a filter, collection plate or conveyor belt (similar to those shown in <FIG>) that has hydrophobic surface portions <NUM>'can also be used for water-pollution control, water purification, etc. to rid of hydrophobically-modified particles <NUM>' which may not be a mineral of interest, but some metal or other material or chemical harmful to the environment (outside the scope of the invention).

The treatment of plain surface <NUM> (<FIG>) can be made similar to the surface portions <NUM>, <NUM>' as shown in <FIG>. That is, the plain surface <NUM> can be functionalized to provide a functional group <NUM> as shown in <FIG>. The plain surface <NUM> can also be functionalized to be hydrophobic, as shown in <FIG>, with only the materials and material combinations defined in the claims being within the scope of this invention.

It should be understood that, when the collection area or surface <NUM> of the conveyor belt <NUM> (<FIG>), the collection area or surface <NUM> of the filter <NUM> (<FIG>) and the collection area <NUM> of the collection plate <NUM> (<FIG>) are functionalized to be hydrophobic, the tailings <NUM> in the recovery processor <NUM> (<FIG>, <FIG>) and the tailings in the pond <NUM> (<FIG> and <FIG>) must be mixed with collector molecules such as xanthates so that the mineral particles <NUM> (<FIG> and <FIG>) in the tailings may be hydrophobically modified with the collector molecules <NUM> to become wetted mineral particles <NUM>'.

In different embodiments of the disclosure, the collection surfaces may be provided by synthetic beads, i.e. the functionalized synthetic material can be used to provide those particular molecules on beads or bubbles, or to make the beads or bubbles (see <FIG>). 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 <NUM> may be used in a filter <NUM> to collect mineral particles <NUM>, <NUM>' (see <FIG>, <FIG>). As shown in <FIG>, 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 <NUM>. As shown in <FIG>, the collection plate uses a cage or the like to contain a plurality of synthetic beads <NUM> to provide the collection surfaces in the collection area <NUM>. When the synthetic beads or bubbles <NUM> are used to collect valuable material in a tailings pond <NUM> (<FIG>), they can be put in a sack <NUM> as shown in <FIG>. As with the synthetic material that is used on the collection surfaces <NUM>, <NUM>' (<FIG>), the synthetic material to be used on the synthetic beads or bubbles <NUM> may have the functional groups <NUM> to attract the mineral particles <NUM>, or may have the hydrophobic molecules <NUM>.

<FIG> illustrates a synthetic bead functionalized to attract hydrophobic particles. As shown in <FIG>, the synthetic bubble or bead <NUM> has a solid-phase bead body to provide a bead surface <NUM>. 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 <FIG>, the surface <NUM> of the synthetic bubble or bead comprises a plurality of molecules <NUM> which renders the surface <NUM> hydrophobic. For example, the surface <NUM> 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 <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 ionizing bond attached to the mineral particle <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>. The hydrophobic particle <NUM>, as shown in <FIG>, can be a particle <NUM>' that has a hydrophobic chain <NUM>. Such particle can be non-mineral related (outside the scope of the invention), but it can be arranged to contact with the hydrophobic synthetic bubbles or beads <NUM> of the disclosure. Likewise, the particle <NUM> may be non-mineral and can be harmful to the environment (outside the scope of the invention).

Thus the hydrophobic bubbles or beads <NUM> can be used in non-mining applications, such as water-pollution control, with non-mining applications being outside the scope of the invention. The size of the synthetic bead can be smaller than the minimum size of the mineral particles which is about <NUM>, and can be larger than the maximum size of the mineral particles. In certain applications, the size of the synthetic bead can be <NUM> or larger.

<FIG> illustrates a synthetic bead having a functional group to attract mineral particles of interest. The synthetic bead <NUM> has a bead body to provide a bead surface <NUM> to attract mineral particles of interest <NUM>. <FIG> 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, i.e. a particular polymer, so as to provide a plurality of molecules or molecular segments <NUM> on the surface <NUM>. The molecule <NUM> may be 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 a mineral, 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>. The functional group <NUM> is also known as a collector that is either ionic or non-ionic for bonding to the mineral particles <NUM>. 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 <NUM> in the collection area <NUM> or <NUM> or in the sack <NUM> (<FIG>) have collected a certain amount of mineral particles, the synthetic beads <NUM> can be made contact with a low pH solution and/or subjected to ultrasonic agitation (e.g., <FIG>) in order to release the mineral particles.

<FIG> 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>, tailings <NUM> (<FIG>) or processed tailings (<FIG>) may be discharged into the tailings pond <NUM> at a discharge point <NUM>. A plurality of filters <NUM> can be placed near the discharge point <NUM> to collect the valuable material of interest in the tailings <NUM> or processed tailings <NUM> in the pond. It is also possible to place a plurality of collection plates <NUM> and a plurality of sacks <NUM> in the pond to collect the valuable material therein. The filters <NUM>, the collection plates <NUM> and the sacks <NUM> may be moved around in order to increase the contact between the valuable material and the functionalized polymer provided in the filters <NUM>, collection plates <NUM> and sacks <NUM>.

By way of example, <FIG> shows the form of a system610 for separating valuable material from unwanted material in a mixture <NUM>(tailings), using a first processor <NUM> and a second processor <NUM>. The first processor <NUM> and the second processor <NUM> may be configured with a functionalized polymer coated member that is shown, e.g., as a functionalized polymer coated impeller <NUM> (<FIG>), <NUM>' (<FIG>), with impellers being outside the scope of the claimed invention. 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> is released from the blades. By way of example, the impeller <NUM> is shown rotating in a counterclockwise direction as indicated by arrow a.

The first processor <NUM> may take 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> may be configured to receive via piping <NUM> the tailings <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> may take 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> may be 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. 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 tailings.

In operation, the first processor <NUM> may be configured to receive the tailings <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 620a, 620b, 620c, 620d, 620e, 620f, <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 620a', 620b', 620c', 620d', 620e', 620f', <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>.

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 Figure 1b, 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., processed tailings <NUM> as shown in <FIG>.

The first processor <NUM> 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 <NUM>. In <FIG>, the at least one enriched impeller blade is shown as the at least one enriched impeller blade 620c' 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> may be configured to receive 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 620c' in a release zone <NUM>, e.g., that forms part of the release rich environment <NUM> and is defined, e.g., by walls 630c and 630d.

The second processor <NUM> may also be 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 630a and 630d to provide via piping <NUM> drainage of the valuable material in the form of a concentrate <NUM> (<FIG>).

By way of example, <FIG> shows a system <NUM> for separating valuable material from unwanted material in a mixture <NUM>, i.e. tailings, using a first processor <NUM> and a second processor <NUM>. The first processor <NUM> and the second processor <NUM> are configured with a functionalized polymer coated member that is shown as a functionalized polymer coated conveyor belt <NUM> that runs between the first processor <NUM> and the second processor <NUM>, according to some embodiments. 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.

The first processor <NUM> may take 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> may be configured to receive the mixture (tailings) <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> may take 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> may be 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 tailings.

In operation, the first processor <NUM> may be configured to receive the mixture, i.e. tailings <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 polymers are defined in the claims.

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

The first processor <NUM> 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 <NUM>. In <FIG>, the enriched functionalized polymer coated conveyor belt is shown, e.g., as that portion or part 720a 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> may be configured to receive the fluid <NUM> (e.g. water) and the portion 720a of the enriched functionalized polymer coated conveyor belt <NUM> to release the valuable material in the release rich environment <NUM>.

The second processor <NUM> may also be 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 a system <NUM> for separating valuable material from unwanted material in a mixture <NUM>, i.e. tailings, using a first processor <NUM>, <NUM>' and a second processor <NUM>, <NUM>'. The first processor <NUM> and the second processor <NUM> are configured to process a functionalized polymer coated member that is shown as 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, according to some embodiments. In <FIG>, by way of example the batch type process is shown as having two first processor <NUM>, <NUM>' and second processor <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 processor, different types or kinds of processors, as well as different types or kinds of processors. According to some embodiments, 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.

The first processor <NUM> may take 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> may be configured to receive the mixture, i.e. tailings <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> may take 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> may be 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 (tailings).

In operation, the first processor <NUM> may be configured to receive the mixture (tailings) <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.

The first processor <NUM> 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>, the enriched functionalized polymer coated collection filter <NUM> is shown, e.g., 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> may be 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> may also be 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.

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.

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, the polymer surface on a filter has a plurality of molecules <NUM> (<FIG>, <FIG>) having a functional group <NUM> (<FIG>) to attract mineral particles <NUM> (<FIG>, <FIG>). 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, none of these compounds fall within the scope of the claimed invention. 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 <NUM> (<FIG>, <FIG>) to attach a function group <NUM> to the polymer surface. In general, the molecule <NUM> can be a hydrocarbon chain, for example, and the functional group <NUM> can be an ion or charge species for bonding to a mineral, 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>. A functional group <NUM> 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 <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. A surface having a functionalized polymer is also referred herein as synthetic surface.

In some embodiments, 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 <NUM> (<FIG>, <FIG>) 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 either chemically bond (chemisorption) on a hydrophobic mineral surface, or adsorb onto the surface in the case of, for example, coal flotation through physisorption. Coal flotation is outside the scope of the present invention). Collectors increase the hydrophobicity of the surface, increasing the separability of the hydrophobic and hydrophilic particles. The hydrophobic particles of interest, i.e. mineral particles according to the present invention, are depicted as particles <NUM>' in <FIG> and <FIG>.

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 <NUM>, 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>, the mineral particle <NUM> is attached to the filter surface <NUM> by the attraction of many function groups <NUM>. In order to increase the bonding forces between the filter surface <NUM> and the mineral particle <NUM>, it is possible to functionalize the surface <NUM> with molecules <NUM> comprising a plurality of functional groups <NUM> attached to a flexible backbone or chain <NUM>. As such, many more functional groups <NUM> can be drawn to the surface of the mineral particle <NUM>, as shown in <FIG>. <FIG> shows a large wetted mineral particle <NUM>' is attracted or attached to the filter surface <NUM> which is render hydrophobic by molecules <NUM>.

<FIG> illustrates a scenario where a mineral particle <NUM> is attached to a number of synthetic beads <NUM> at the same time. Thus, although the synthetic beads <NUM> are much smaller in size than the mineral particle <NUM>, a number of synthetic beads <NUM> may be able to lift the mineral particle <NUM> upward in a flotation cell. Likewise, a smaller mineral particle <NUM> can also be lifted upward by a number of synthetic beads <NUM> as shown in <FIG>. In order to increase the likelihood for this "cooperative" lifting to occur, a large number of synthetic beads <NUM> 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.

<FIG> illustrate a similar scenario. As shown, a wetted mineral particle <NUM> is attached to a number of hydrophobic synthetic beads <NUM> at the same time.

In any case, the collection surfaces are configured with the functionalized polymer defined in the attached claims.

The disclosure relates 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.

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 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..

Claim 1:
A method for separating mineral particles (<NUM>, <NUM>') from unwanted material in tailings (<NUM>, <NUM>, <NUM>, <NUM>) of a flotation process, the method comprising:
providing collection apparatus (<NUM>) functionalized with a synthetic material (<NUM>) comprising a plurality of molecules (<NUM>, <NUM>) having a functional group configured to render the surface of the collection apparatus hydrophobic to collect mineral particles (<NUM>, <NUM>') of interest to the surface (<NUM>, <NUM>, <NUM>) of the collection apparatus; and
causing the collection apparatus to contact with tailings having the mineral particles of interest, including the tailings from a flotation process, characterized in that
the collection apparatus is a conveyor belt (<NUM>) configured with a collection area (<NUM>) to support the functionalized polymer being hydroxyl-terminated polydimethysiloxanes,
wherein said collection area (<NUM>)
comprise an irregular arrangement of fibers, or
comprise a plain surface (<NUM>),
and further wherein
the fibers (<NUM>), or the plain surfaces (<NUM>), respectively are made of glass, ceramic, metal, nylon, cotton or another fabric material and coated with hydroxyl-terminated polydimethysiloxanes.