US4802914A — Process for agglomerating mineral ore concentrate…

Claim 1

Independent Claim 38 words

A process of agglomerating a particulate material consisting essentially commingling said particulate material with a binding amount of water soluble polymer, wherein said polymer is applied to said particulate material as a dispersion in a non-aqueous dispersion medium.

Claim 2

Dependent Claim 38 words

A process of agglomerating a particulate material consisting essentially commingling said particulate material with a binding amount of water soluble polymer, wherein said polymer is applied to said particulate material as a dispersion in a non-aqueous dispersion medium.

Claim 3

Dependent Claim 19 words

The process of claim 1 in which the polymer is contained in the aqueous portion of a water-in-oil emulsion.

Claim 4

Dependent Claim 27 words

The process of claim 1 in which fine particles of the polymer are dispersed in an essentially non-aqueous dispersion medium which is a non-solvent for the polymer.

Claim 5

Dependent Claim 13 words

The process of claim 1 wherein said polymer is a poly(acrylamide) based polymer.

Claim 6

Dependent Claim 45 words

The process of claim 4 wherein said polymer contains repeating units of the following formula: ##STR16## wherein R 2 + is an alkali metal ion, f and g are from 5 to about 90 percent, f+g=100, and d is from about 1,000 to about 500,000.

Claim 7

Dependent Claim 18 words

The process of claim 5 wherein said polymer is derived from monomer units of acrylamide and sodium acrylate.

Claim 8

Dependent Claim 135 words

The process of claim 4 wherein said polymer contains repeating units of the following formula: ##STR17## wherein R, R 1 and R 3 are independently hydrogen or methyl, R 2 + is an alkali metal ion and R 4 is either (1) --OR 5 wherein R 5 is an alkyl group having up to 5 carbon atoms; (2) ##STR18## wherein R 6 is an alkyl group having up to up to 8 carbon atoms; (3) ##STR19## wherein R 7 is either metyl, or butyl; (4) phenyl; (5) substituted phenyl; (6) --CN; or (7) ##STR20## and hydrolyzed tetrapolymers thereof, wherein (a) is from about 5 to about 90 percent, (b) is from about 5 to about 90 percent, (c) is from 0 to about 20 percent, (a)+(b)+(c)=100, and (d) is from about 1,000 to about 500,000.

Claim 9

Dependent Claim 20 words

The process of claim 7 wherein said polymer is derived from monomer units of acrylamide, sodium acrylate, and vinyl acetate.

Claim 10

Dependent Claim 92 words

The process of claim 4 wherein said polymers are derived from at least one of the following groups of monomer units: acrylamide, methacrylamide and derivatives thereof of the formula: ##STR21## where R 13 is a hydrogen atom or a methyl group; R 14 is a hydrogen atom, a methyl group or an ethyl group; R 15 is a hydrogen atom, a methyl group, an ethyl group or --R 16 --SO 3 X, wherein R 16 is a divalent hydrocarbon group having 1 to 13 carbon atoms and X is a monovalent cation.

Claim 11

Dependent Claim 28 words

The process of claim 1 wherein said polymer is applied to said particulate material at an active polymer concentration between about 0.001 to about 0.3 percent by weight.

Claim 12

Dependent Claim 22 words

The process of claim 1, wherein an inorganic salt is commingled with said particulate material, said particulate material being mineral ore concentrate.

Claim 13

Dependent Claim 35 words

The process of claim 11 wherein said inorganic salt is an alkali metal or alkaline earth metal salt of carbonates, halides, or phosphates, or a mixture thereof, and said mineral ore concentrate is taconite concentrate.

Claim 14

Dependent Claim 32 words

The process of claim 11 wherein said inorganic salt is at least one member selected from the group consisting of sodium carbonate, calcium carbonate, dolomite, magnesium carbonate, sodium chloride, and sodium metaphosphate.

Claim 15

Dependent Claim 22 words

The process of claim 12 wherein said inorganic salt is applied to said mineral ore concentrate in an aqueous solution or slurry.

Claim 16

Dependent Claim 30 words

The process of claim 11 wherein said inorganic salt is applied to said mineral ore concentrate at a concentration between about 0.001 to about 0.5 percent by weight of concentrate.

Claim 17

Dependent Claim 33 words

The process of claim 2 wherein said water-in-oil emulsion has an oil phase selected from the group consisting of benzene, xylene, toluene, mineral oils, kerosenes, paraffinic hydrocarbons, petroleum, Isopar® M, and mixtures thereof.

Claim 18

Dependent Claim 12 words

The process of claim 2 wherein said emulsion contains an inverting surfactant.

Claim 19

Dependent Claim 8 words

A product of the process of claim 1.

Claim 20

Dependent Claim 36 words

The process of claim 1 wherein green pellets of mineral ore are obtained by agglomerating said particulate material and said green pellets are then fired by a means for applying heat sufficient to indurate said ore.

Claim 21

Dependent Claim 19 words

The process of claim 19 wherein said sufficient heat to indurate said pellets is at least about 1800° F.

Claim 22

Dependent Claim 19 words

The process of claim 20 wherein said sufficient heat to indurate said pellets is at least about 2800° F.

Claim 23

Dependent Claim 8 words

A product of the process of claim 19.

Claim 24

Dependent Claim 56 words

A process of producing pellets consisting essentially of: (a) selecting a water soluble polymer dispersed in a non aqueous dispersion medium; (b) mixing a binding quantity of said polymer with a taconite concentrate; (c) pelletizing in a balling apparatus the mixture of step (b) to form green pellets; and (d) indurating said green pellets with heat.

Claim 25

Dependent Claim 56 words

A process of producing pellets consisting essentially of: (a) selecting a water soluble polymer dispersed in a non aqueous dispersion medium; (b) mixing a binding quantity of said polymer with a taconite concentrate; (c) pelletizing in a balling apparatus the mixture of step (b) to form green pellets; and (d) indurating said green pellets with heat.

Claim 26

Dependent Claim 19 words

The process of claim 23 in which the polymer is contained in the aqueous portion of a water-in-oil emulsion.

Claim 27

Dependent Claim 27 words

The process of claim 23 in which fine particles of the polymer are dispersed in an essentially non-aqueous dispersion medium which is a non-solvent for the polymer.

Claim 28

Dependent Claim 123 words

The process of claim 23 wherein said polymer contains repeating units selected from the group consisting of units of the formula: ##STR22## wherein R 13 is a hydrogen atom or a methyl group; R 14 is a hydrogen atom, a methyl group or an ethyl group; R 15 is a hydrogen atom, a methyl group, an ethyl group or --R 16 --SO 3 X, wherein R 16 is a divalent hydrocarbon group having 1 to 13 carbon atoms and X is a monovalent cation; units of the formula: ##STR23## wherein R 2 + is an alkali metal ion, f and g are from 5 to about 90 percent, f+g=100, and d is from about 1,000 to about 500,000; and mixtures of such units.

Claim 29

Dependent Claim 37 words

The process of claim 23 wherein an inorganic salt is also mixed with the concentrate, said inorganic salt being an alkali metal or an alkaline earth metal salt of carbonates, halides, or phosphates, or a combination thereof.

Claim 30

Dependent Claim 53 words

The process of claim 27 wherein said inorganic salt is applied to said mineral ore concentrate in a concentration between about 0.001 to about 0.5 percent by weight and wherein said polymer is applied to said mineral ore concentrate at an active polymer concentration between about 0.001 to about 0.3 percent by weight.

Claim 31

Dependent Claim 8 words

A product of the process of claim 28.

Claim 32

Dependent Claim 32 words

A process of agglomerating a particulate material, comprising: commingling said particulate material with a water soluble poly(acrylamide) based polymer, wherein said polymer is applied to said particulate material as a dry powder.

Claim 33

Dependent Claim 32 words

A process of agglomerating a particulate material, comprising: commingling said particulate material with a water soluble poly(acrylamide) based polymer, wherein said polymer is applied to said particulate material as a dry powder.

Claim 34

Dependent Claim 45 words

The process of claim 30 wherein said polymer contains repeating units of the following formula: ##STR24## wherein R 2 + is an alkali metal ion, f and g are from 5 to about 90 percent, f+g=100, and d is from about 1,000 to abotu 500,000.

Claim 35

Dependent Claim 18 words

The process of claim 31 wherein said polymer is derived from monomer units of acrylamide and sodium acrylate.

Claim 36

Dependent Claim 134 words

The process of claim 30 wherein said polymer contains repeating units of the following formula: ##STR25## wherein R, R 1 , and R 3 are independently hydrogen or methyl, R 2 + is an alkali metal ion, R 4 is either (1) --OR 5 wherein R 5 is an alkyl group having up to 5 carbon atoms; (2) ##STR26## wherein R 6 is an alkyl group having up to up to 8 carbon atoms; (3) ##STR27## wherein R 7 is either methyl, or butyl; (4) phenyl; (5) substituted phenyl; (6) --CN; or (7) ##STR28## and hydrolized tetrapolymers thereof, wherein (a) is from about 5 to about 90 percent, (b) is from about 5 to about 90 percent, (c) is from 0 to about percent, (a)+(b)+(c)=100, and (d) is from about 1,000 to about 500,000.

Claim 37

Dependent Claim 20 words

The process of claim 33 wherein said polymer is derived from monomer units of acrylamide, sodium acrylate, and vinyl acetate.

Claim 38

Dependent Claim 92 words

The process of claim 30 wherein said polymers are derived from at least one of the following roups of monomer units: acrylamide, methacrylamide and derivatives thereof of the formula: ##STR29## where R 13 is a hydrogen atom or a methyl group; R 14 is a hydrogen atom, a methyl group or an ethyl group; R 15 is a hydrogen atom, a methyl group, an ethyl group or --R 16 --SO 3 X, wherein R 16 is a divalent hydrocarbon group having 1 to 13 carbon atoms and X is a monovalent cation.

Claim 39

Dependent Claim 28 words

The process of claim 30 wherein said polymer is applied to said particulate material at an active polymer concentration between about 0.001 to about 0.3 percent by weight.

Claim 40

Dependent Claim 23 words

The process of claim 30 wherein an inorganic salt is commingled with said particulate material, said particulate material being a mineral ore concentrate.

Claim 41

Dependent Claim 35 words

The process of claim 37 wherein said inorganic salt is an alkali metal or alkaline earth metal salt of carbonates, halides, or phosphates, or a mixture thereof, and said mineral ore concentrate is taconite concentrate.

Claim 42

Dependent Claim 32 words

The process of claim 37 wherein said inorganic salt is at least one member selected from the group consisting of sodium carbonate, calcium carbonate, dolomite, magnesium carbonate, sodium chloride, and sodium metaphosphate.

Claim 43

Dependent Claim 22 words

The process of claim 38 wherein said inorganic salt is applied to said mineral ore concentrate in an aqueous solution or slurry.

Claim 44

Dependent Claim 32 words

The process of claim 39 wherein said inorganic salt is applied to said mineral ore concentrate at a concentration on said concentrate between about 0.001 to 0.5 percent by weight of concentrate.

Claim 45

Dependent Claim 8 words

A product of the process of claim 30.

Claim 46

Dependent Claim 40 words

The process of claim 30 wherein green pellets of mineral ore are obtained by agglomerating said particulate material and said green pellets are fired by a means for applying heat sufficient to indurate said ore, said particulate material being taconite.

Claim 47

Dependent Claim 22 words

The process of claim 43 wherein said sufficient heat to indurate said pellets is of a temperature of at least 1800° F.

Claim 48

Dependent Claim 21 words

The process of claim 44 wherein said sufficient heat to indurate said pellets is of a temperature of about 2800° F.

Claim 49

Dependent Claim 8 words

A product of the process of claim 43.

Claim 50

Dependent Claim 59 words

A process of producing pellets comprising: (a) selecting a water soluble poly(acrylamide) based polymer, said polymer being in the form of a dry powder; (b) mixing a binding quantity of said polymer with a taconite concentrate; (c) pelletizing in a balling apparatus the mixture of step (b) to form green pellets; and (d) indurating said green pellets with heat.

Claim 51

Dependent Claim 59 words

A process of producing pellets comprising: (a) selecting a water soluble poly(acrylamide) based polymer, said polymer being in the form of a dry powder; (b) mixing a binding quantity of said polymer with a taconite concentrate; (c) pelletizing in a balling apparatus the mixture of step (b) to form green pellets; and (d) indurating said green pellets with heat.

Claim 52

Dependent Claim 117 words

The process of claim 47 wherein said polymer contains repeating units selected from the group consisting of units of the formula: ##STR30## wherein R 13 is a hydrogen atom or a methyl group; R 14 is a hydrogen atom, a methyl group or an ethyl group; R 15 is a hydrogen atom, a methyl group, an ethyl group or --R 16 --SO 3 X, wherein R 16 is a divalent hydrocarbon group having 1 to 13 carbon atoms and X is a monovalent cation; units of the formula: ##STR31## wherein R 2 + is an alkali metal ion, f and g are from 5 to about 90 percent, f+g=100, and d s from about 1,000 to 500,000.

Claim 53

Dependent Claim 37 words

The process of claim 47 wherein an inorganic salt is also mixed with the concentrate, said inorganic salt being an alkali metal or an alkaline earth metal salt of carbonates, halides, or phosphates, or a combination thereof.

Claim 54

Dependent Claim 51 words

The process of claim 49 wherein said inorganic salt is applied to said taconite concentrate in a concentration between about 0.001 to about 0.5 percent by weight and wherein said polymer is applied to said taconite concentrate at an active polymer concentration between about 0.001 to about 0.3 percent by weight.

Claim 55

Dependent Claim 8 words

A product of the process of claim 47.

Claim 56

Dependent Claim 35 words

The process of claim 12 wherein said inorganic salt is a mixture of a water soluble inorganic salt and at least one member selected from the group consisting of dolomite, maqnesium carbonate, and calcium carbonate.

Claim 57

Dependent Claim 48 words

The process of claim 12 wherein said inorganic salt is a mixture of Na 2 CO 3 , used at less than 1.2 lb/tonne of added Na 2 CO 3 , plus at least one member selected from the group consisting of dolomite, magnesium carbonate, and calcium carbonate.

Claim 58

Dependent Claim 18 words

The process of claim 52 wherein the water soluble inorganic salt is used in making a flux pellet.

Claim 59

Dependent Claim 17 words

The process of claim 54 wherein the water soluble inorganic salt is Na 2 CO 3 .

Claim 60

Dependent Claim 35 words

The process of claim 38 wherein said inorganic salt is a mixture of a water soluble inorganic salt and at least one member selected from the group consisting of dolomite, magnesium carbonate, and calcium carbonate.

Claim 61

Dependent Claim 48 words

The process of claim 38 wherein said inorganic salt is a mixture of Na 2 CO 3 , used at less than 1.2 lb/tonne of added Na 2 CO 3 , plus at least one member selected from the group consisting of dolomite, magnesium carbonate, and calcium carbonate.

Claim 62

Dependent Claim 18 words

The process of claim 56 wherein the water soluble inorganic salt is used in making a flux pellet.

Claim 63

Dependent Claim 17 words

The process of claim 58 wherein the water soluble inorganic salt is Na 2 CO 3 .

Claim 64

Dependent Claim 41 words

The process of claim 23 including the additonal steps of selecting an inorganic material that tends to reduce the acidity of taconite concentrate and adding that material to the taconite concentrate in an amount sufficient to result in a flux pellet.

Claim 65

Dependent Claim 20 words

The process of claim 60 wherein sodium carbonate is commingled with said inorganic material selected to create the flux pellet.

Claim 66

Dependent Claim 41 words

The process of claim 47 including the additonal steps of selecting an inorganic material that tends to reduce the acidity of taconite concentrate and adding that material to the taconite concentrate in an amount sufficient to result in a flux pellet.

Claim 67

Dependent Claim 20 words

The process of claim 62 wherein sodium carbonate is commingled with said inorganic material selected to create the flux pellet.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1992-02-07	1992-08-08	1993-02-07	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1996-02-07	1996-08-08	1997-02-07	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2000-02-07	2000-08-08	2001-02-07	$7700.00	Window Closed / Lapsed

Process for agglomerating mineral ore concentrate utilizing dispersions of polymer binders or dry polymer binders

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