Abstract: What is presented is a material processing system for processing tailings discharged from an ore processing system. The tailings comprise coarse waste rock, the fine waste rock, coarse valuable product, and the fine valuable product. The material processing system comprises a classification element, a coarse flotation element, and a fines flotation element arranged to separate the coarse valuable product, the coarse waste rock, the fine valuable product, and the fine waste rock. The classification element separates the coarse waste rock and/or the coarse valuable product from the fine waste rock and/or the fine valuable product. The coarse flotation element separates the coarse waste rock from the coarse valuable product, the fine waste rock, and/or the fine valuable product. The fines flotation element separates the fine valuable product from the coarse waste rock, the fine waste rock, and/or the coarse valuable product.

Abstract: A separation system is presented that partitions a slurry containing a plurality of particles that are influenced by a fluidization flow (which comprises teeter water and gas bubbles) and a fluidized bed. The separation system comprises a separation tank, a slurry feed distributor, a fluidization flow manifold and a gas introduction system. All of these components are arranged to create the fluidized bed in the separation tank by introducing the slurry through the slurry feed distributor and allowing the slurry to interact with the fluidization flow that enters the separation tank from the fluidization flow manifold. The gas introduction system is configured to optimize the gas bubble size distribution in the fluidization flow. The gas introduction system comprises a gas introduction conduit and a bypass conduit. The gas introduction system can be adjusted by modulating the flow of teeter water through the gas introduction conduit.

Abstract: A flotation separation system is provided for partitioning a slurry that includes a hydrophobic species which can adhere to gas bubbles formed in the slurry. The flotation separation system comprises a flotation separation cell that includes a sparger unit and a separation tank. The sparger unit has a slurry inlet for receiving slurry and a gas inlet to receive gas with at least enough pressure to allow bubbles to form in the slurry within the sparger unit. The sparger unit includes a sparging mechanism constructed to disperse gas bubbles within the slurry. The sparging mechanism sparges the gas bubbles to form a bubble dispersion so as to cause adhesion of the hydrophobic species to the gas bubbles substantially within the sparger unit while causing a pressure drop of about 10 psig or less across the sparging mechanism. The sparger unit includes a slurry outlet to discharge the slurry and the bubble dispersion into the separation tank.

Abstract: What is presented is a process for scrap metal processing for shredding and sorting recoverable material from a material stream that comprises a ferrous fraction, a non-ferrous fraction, a waste fraction and a less ferrous fraction that includes composite materials. The process comprises first shredding the material stream with a first shredder to a size that enables downstream processing. The shredded material stream is then conveyed to at least one drum separator to remove the non-ferrous fraction from the material stream and then conveyed to a first conveyor separator to further separate the ferrous fraction from the material stream. At the completion of these steps the remaining material stream to be handled by downstream processes represents 10% to 40% of the original material stream as compared to 70% to 75% of the material stream in the prior art.

Abstract: A magnetic drum separator for the separation of ferrous and non-ferrous materials from a material stream that comprises an outer shell that is rotatable by a drive mechanism. The outer shell has a tubular length, a circular cross-section, a traction plate is joined to the outer shell, the traction plate has a traction element. In another embodiment the outer shell has a tubular length, a circular cross-section, and a integral traction element. The traction elements could be a series of negative indentations, raised bumps, perforations, serrated teeth, protruding ridges, segmented protruding ridges, minor cleats, or segmented minor cleats.

Abstract: A magnetic drum separator, for separating ferrous and non-ferrous materials from a material stream. The magnetic drum separator comprising an outer shell that is rotatable around a central axis by a drive mechanism. The outer shell having a tubular length parallel to the central axis and a circular cross-section perpendicular to the central axis. An electromagnet pickup magnet positioned at a fixed location within the circular cross-section has a cross-section perpendicular to the central axis. The pickup magnet has a first end closest to the inner circumference of the outer shell and a second end located near the central axis. The pickup magnet comprises a core, with a backbar abutting it at the second end. The core comprises a plurality of blocks of different widths, in a cross-section perpendicular to the central axis, with the narrowest block at the first end and the widest block abutting the backbar.

Abstract: What is presented is a permanent magnet drum separator for removal of a ferrous fraction from a material stream comprising a pickup magnet that is a rare earth permanent magnet that can be moved within the drum separator. The drum separator comprises a rotatable outer shell having tubular shape with a circular cross section. The drum separator includes a carry magnet that is positioned at a fixed location within the rotatable outer shell near the inside circumference of the rotatable outer shell. The pickup magnet is positioned on a hinge plate within the rotatable outer shell. The hinge plate has a first end attached to a hinge and a second end attached to a movable element. The hinge is positioned at a fixed location within the rotatable outer shell near the inside circumference of said rotatable outer shell. The movable element is able to move the pickup magnet about the hinge to vary the distance between the pickup magnet and the inside circumference of the rotatable outer shell.

Abstract: A lifting electrode for a high-tension electrostatic separator. The high tension electrostatic separator having a rotating drum that is connected to ground and an ionizing electrode that generates a corona discharge of charged ions. The lifting electrode comprising a composite of a non-conductive polymer impregnated with conductive particles.

Abstract: A top feed, wet drum magnetic separator capable of treating, removing tramp metal from the full flow discharge of a grinding mill having a feed box which provides overflow capacity, velocity break to minimize turbulence, and spread the slurry evenly across the drum surface. A flow transition is provided to the rotating drum surface. A fixed magnet assembly is supported inside the drum. Barrier walls contain the flow and a cover confines the flow over the drum. A partitioned product hopper collects metallic fragments separately from the bulk slurry flow. A spray bar is provided to clean the drum.