Patents by Inventor David R. Baughman
David R. Baughman has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 10640847Abstract: The present invention relates to the recovery of rare earths, scandium, niobium, tantalum, zirconium, hafnium, titanium, and the like from ores or concentrates containing fluorine. More specifically, the ores or concentrates are pretreated by carbochlorination to convert the rare earths and other metals into their chlorides and then subjected to dilute hydrochloric acid leaching to recover the valuable rare earths and other metals from the leachate. Niobium, tantalum, zirconium, hafnium, and titanium can be recovered as their chlorides or oxychlorides from the gaseous products of carbochlorination, or converted into their oxides while simultaneously regenerating chlorine.Type: GrantFiled: July 21, 2016Date of Patent: May 5, 2020Assignee: Hazen Research, Inc.Inventors: Kang Sun, David R. Baughman, Wayne W. Hazen
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Publication number: 20190177864Abstract: Various embodiments provide a process roasting a metal bearing material under oxidizing conditions to produce an oxidized metal bearing material, roasting the oxidized metal bearing material under reducing conditions to produce a roasted metal bearing material, and leaching the roasted metal bearing material in a basic medium to yield a pregnant leach solution.Type: ApplicationFiled: February 12, 2019Publication date: June 13, 2019Applicant: FREEPORT MINERALS CORPORATIONInventors: Joanna M. Robertson, Thomas R. Bolles, Wayne W. Hazen, Lawrence D. May, Jay C. Smith, David R. Baughman
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Patent number: 10246789Abstract: Various embodiments provide a process roasting a metal bearing material under oxidizing conditions to produce an oxidized metal bearing material, roasting the oxidized metal bearing material under reducing conditions to produce a roasted metal bearing material, and leaching the roasted metal bearing material in a basic medium to yield a pregnant leach solution.Type: GrantFiled: April 15, 2016Date of Patent: April 2, 2019Assignee: FREEPORT MINERALS CORPORATIONInventors: Joanna M Robertson, Thomas R Bolles, Wayne W Hazen, Lawrence D May, Jay C Smith, David R Baughman
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Publication number: 20180209015Abstract: The present invention relates to the recovery of rare earths, scandium, niobium, tantalum, zirconium, hafnium, titanium, and the like from ores or concentrates containing fluorine. More specifically, the ores or concentrates are pretreated by carbochlorination to convert the rare earths and other metals into their chlorides and then subjected to dilute hydrochloric acid leaching to recover the valuable rare earths and other metals from the leachate. Niobium, tantalum, zirconium, hafnium, and titanium can be recovered as their chlorides or oxychlorides from the gaseous products of carbochlorination, or converted into their oxides while simultaneously regenerating chlorine.Type: ApplicationFiled: July 21, 2016Publication date: July 26, 2018Inventors: Kang SUN, David R. BAUGHMAN, Wayne W. HAZEN
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Publication number: 20160230296Abstract: Various embodiments provide a process roasting a metal bearing material under oxidizing conditions to produce an oxidized metal bearing material, roasting the oxidized metal bearing material under reducing conditions to produce a roasted metal bearing material, and leaching the roasted metal bearing material in a basic medium to yield a pregnant leach solution.Type: ApplicationFiled: April 15, 2016Publication date: August 11, 2016Applicant: FREEPORT MINERALS CORPORATIONInventors: Joanna M. Robertson, Thomas R. Bolles, Wayne W. Hazen, Lawrence D. May, Jay C. Smith, David R. Baughman
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Patent number: 9340849Abstract: Various embodiments provide a process roasting a metal bearing material under oxidizing conditions to produce an oxidized metal bearing material, roasting the oxidized metal bearing material under reducing conditions to produce a roasted metal bearing material, and leaching the roasted metal bearing material in a basic medium to yield a pregnant leach solution.Type: GrantFiled: December 17, 2012Date of Patent: May 17, 2016Assignee: FREEPORT MINERALS CORPORATIONInventors: Joanna M Robertson, Thomas R Bolles, Wayne W Hazen, Lawrence D May, Jay C Smith, David R Baughman
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Patent number: 8920773Abstract: Various embodiments provide a process roasting a metal bearing material under oxidizing conditions to produce an oxidized metal bearing material, roasting the oxidized metal bearing material under reducing conditions to produce a roasted metal bearing material, leaching the roasted metal hearing material in a basic medium to yield a pregnant leach solution, conditioning the pregnant leach solution to thrill a preprocessed metal bearing material; and leaching the preprocessed metal bearing material in acid medium.Type: GrantFiled: December 17, 2012Date of Patent: December 30, 2014Assignee: Freeport Minerals CorporationInventors: Joanna M. Robertson, Thomas R. Bolles, Wayne W. Hazen, Lawrence D. May, Jay C. Smith, David R. Baughman
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Patent number: 8506673Abstract: The present invention relates generally to a process for removing dissolved or colloidal silica from a pregnant leach solution (“PLS”). More particularly, an exemplary embodiment of the present invention relates to a, process which mixes PLS with an acid source, preferably lean electrolyte, to induce formation of colloidal silica that can then be collected and removed. Additionally, in an exemplary embodiment of the present invention, at least one silica seeding agent is added to induce formation of colloidal silica, at least one flocculant is added to induce aggregation of the colloidal silica, and a solid-liquid separation process is utilized to remove advantageous amounts or substantially all of the colloidal silica, thereby providing relief from supersaturation of dissolved silica in the metal recovery processes.Type: GrantFiled: January 30, 2012Date of Patent: August 13, 2013Assignee: Freeport-McMoran CorporationInventors: James D Gillaspie, David R Baughman, Dennis D Gertenbach, Wayne W Hazen, George Owusu, John C Wilmot
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Publication number: 20120125160Abstract: The present invention relates generally to a process for removing dissolved or colloidal silica from a pregnant leach solution (“PLS”). More particularly, an exemplary embodiment of the present invention relates to a, process which mixes PLS with an acid source, preferably lean electrolyte, to induce formation of colloidal silica that can then be collected and removed. Additionally, in an exemplary embodiment of the present invention, at least one silica seeding agent is added to induce formation of colloidal silica, at least one flocculant is added to induce aggregation of the colloidal silica, and a solid-liquid separation process is utilized to remove advantageous amounts or substantially all of the colloidal silica, thereby providing relief from supersaturation of dissolved silica in the metal recovery processes.Type: ApplicationFiled: January 30, 2012Publication date: May 24, 2012Applicant: FREEPORT-MCMORAN CORPORATIONInventors: James D Gillaspie, David R. Baughman, Dennis D. Gertenbach, Wayne W. Hazen, George Owusu, John C Wilmot
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Patent number: 8114365Abstract: The present invention relates generally to a process for removing dissolved or colloidal silica from a pregnant leach solution (“PLS”). More particularly, an exemplary embodiment of the present invention relates to a process which mixes PLS with an acid source, preferably lean electrolyte, to induce formation of colloidal silica that can then be collected and removed. Additionally, in an exemplary embodiment of the present invention, at least one silica seeding agent is added to induce formation of colloidal silica, at least one flocculant is added to induce aggregation of the colloidal silica, and a solid-liquid separation process is utilized to remove advantageous amounts or substantially all of the colloidal silica, thereby providing relief from supersaturation of dissolved silica in the metal recovery processes.Type: GrantFiled: March 5, 2010Date of Patent: February 14, 2012Assignee: Freepoint-McMoran CorporationInventors: James D. Gillaspie, David R. Baughman, Dennis D. Gertenbach, Wayne W. Hazen, George Owusu, John C. Wilmot
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Patent number: 8012318Abstract: A system and process for recovering copper from a copper-containing ore, concentrate, or other copper-bearing material to produce high quality cathode copper from a leach solution without the use of copper solvent/solution extraction techniques or apparatus. A process for recovering copper from a copper-containing ore generally includes the steps of providing a feed stream containing comminuted copper-containing ore, concentrate, or other copper-bearing material, leaching the feed stream to yield a copper-containing solution, conditioning the copper-containing solution through one or more physical or chemical conditioning steps, and electrowinning copper directly from the copper-containing solution in multiple electrowinning stages, without subjecting the copper-containing solution to solvent/solution extraction prior to electrowinning.Type: GrantFiled: April 29, 2010Date of Patent: September 6, 2011Assignee: Freeport-McMoran CorporationInventors: John O Marsden, Robert E Brewer, Susan R Brewer, Joanna M Robertson, David R Baughman, Philip Thompson, Wayne W Hazen, Christel M. A. Bemelmans
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Publication number: 20110000337Abstract: The present invention relates generally to a process for removing dissolved or colloidal silica from a pregnant leach solution (“PLS”). More particularly, an exemplary embodiment of the present invention relates to a process which mixes PLS with an acid source, preferably lean electrolyte, to induce formation of colloidal silica that can then be collected and removed. Additionally, in an exemplary embodiment of the present invention, at least one silica seeding agent is added to induce formation of colloidal silica, at least one flocculant is added to induce aggregation of the colloidal silica, and a solid-liquid separation process is utilized to remove advantageous amounts or substantially all of the colloidal silica, thereby providing relief from supersaturation of dissolved silica in the metal recovery processes.Type: ApplicationFiled: March 5, 2010Publication date: January 6, 2011Applicant: FREEPORT-MCMORAN CORPORATIONInventors: James D. Gillaspie, David R. Baughman, Dennis D. Gertenbach, Wayne W. Hazen, George Owusu, John C. Wilmot
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Publication number: 20100206741Abstract: A system and process for recovering copper from a copper-containing ore, concentrate, or other copper-bearing material to produce high quality cathode copper from a leach solution without the use of copper solvent/solution extraction techniques or apparatus. A process for recovering copper from a copper-containing ore generally includes the steps of providing a feed stream containing comminuted copper-containing ore, concentrate, or other copper-bearing material, leaching the feed stream to yield a copper-containing solution, conditioning the copper-containing solution through one or more physical or chemical conditioning steps, and electrowinning copper directly from the copper-containing solution in multiple electrowinning stages, without subjecting the copper-containing solution to solvent/solution extraction prior to electrowinning.Type: ApplicationFiled: April 29, 2010Publication date: August 19, 2010Applicant: FREEPORT-MCMORAN CORPORATIONInventors: John O. Marsden, Robert E. Brewer, Susan R. Brewer, Joanna M. Robertson, David R. Baughman, Philip Thompson, Wayne W. Hazen, Christel M.A. Bemelmans
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Patent number: 7736487Abstract: The present invention relates generally to a process for recovering copper and/or other metal values from a metal-bearing ore, concentrate, or other metal-bearing material using pressure leaching and direct electrowinning. More particularly, the present invention relates to a substantially acid-autogenous process for recovering copper from chalcopyrite-containing ore using pressure leaching and direct electrowinning in combination with a leaching, solvent/solution extraction and electrowinning operation. In accordance with one aspect of the process, at least a portion of the residue from the pressure leaching operation is directed to a heap, stockpile or other leaching operation.Type: GrantFiled: May 1, 2007Date of Patent: June 15, 2010Assignee: Freeport-McMoran CorporationInventors: John O. Marsden, John C. Wilmot, Christy Green, Wayne W. Hazen, David R. Baughman
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Patent number: 7736488Abstract: The present invention relates generally to a process for recovering copper and/or other metal values from a metal-bearing ore, concentrate, or other metal-bearing material using pressure leaching and direct electrowinning. More particularly, the present invention relates to a substantially acid-autogenous process for recovering copper from chalcopyrite-containing ore using pressure leaching and direct electrowinning in combination with a leaching, solvent/solution extraction and electrowinning operation.Type: GrantFiled: December 29, 2008Date of Patent: June 15, 2010Assignee: Freeport-McMoran CorporationInventors: John O Marsden, Robert E Brewer, Susan R Brewer, Joanna M Robertson, David R Baughman, Philip Thompson, Wayne W Hazen, Christel M. A. Bemelmans
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Patent number: 7722756Abstract: A system and process for recovering copper from a copper-containing ore, concentrate, or other copper-bearing material to produce high quality cathode copper from a leach solution without the use of copper solvent/solution extraction techniques or apparatus. A process for recovering copper from a copper-containing ore generally includes the steps of providing a feed stream containing comminuted copper-containing ore, concentrate, or other copper-bearing material, leaching the feed stream to yield a copper-containing solution, conditioning the copper-containing solution through one or more physical or chemical conditioning steps, and electrowinning copper directly from the copper-containing solution in multiple electrowinning stages, without subjecting the copper-containing solution to solvent/solution extraction prior to electrowinning.Type: GrantFiled: November 19, 2008Date of Patent: May 25, 2010Assignee: Freeport-McMoran CorporationInventors: John O Marsden, Joanna M Robertson, Robert E Brewer, Susan R. Brewer, legal representative, David R Baughman, Philip Thompson, Wayne W Hazen, Christel M. A. Bemelmans
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Patent number: 7691347Abstract: The present invention relates generally to a process for removing dissolved or colloidal silica from a pregnant leach solution (“PLS”). More particularly, an exemplary embodiment of the present invention relates to a process which mixes PLS with an acid source, preferably lean electrolyte, to induce formation of colloidal silica that can then be collected and removed. Additionally, in an exemplary embodiment of the present invention, at least one silica seeding agent is added to induce formation of colloidal silica, at least one flocculant is added to induce aggregation of the colloidal silica, and a solid-liquid separation process is utilized to remove advantageous amounts or substantially all of the colloidal silica, thereby providing relief from supersaturation of dissolved silica in the metal recovery processes.Type: GrantFiled: September 19, 2007Date of Patent: April 6, 2010Assignee: Freeport-McMoran CorporationInventors: James D. Gillaspie, David R. Baughman, Dennis D. Gertenbach, Wayne W. Hazen, George Owusu, John C. Wilmot
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Patent number: 7666371Abstract: The present invention relates generally to a process for recovering copper and other metal values from metal-containing materials through pressure leaching operations. In accordance with the various aspects of the present invention, metal-containing pregnant leach solutions from pressure leaching operations need not be significantly diluted to facilitate effective metal recovery using solvent extraction and electrowinning.Type: GrantFiled: December 7, 2007Date of Patent: February 23, 2010Assignee: Freeport-McMoran CorporationInventors: John O Marsden, Robert E Brewer, Joanna M Robertson, Wayne W Hazen, Philip Thompson, David R Baughman
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Publication number: 20090101518Abstract: The present invention relates generally to a process for recovering copper and/or other metal values from a metal-bearing ore, concentrate, or other metal-bearing material using pressure leaching and direct electrowinning. More particularly, the present invention relates to a substantially acid-autogenous process for recovering copper from chalcopyrite-containing ore using pressure leaching and direct electrowinning in combination with a leaching, solvent/solution extraction and electrowinning operation.Type: ApplicationFiled: December 29, 2008Publication date: April 23, 2009Applicant: PHELPS DODGE CORPORATIONInventors: John O. Marsden, Robert E. Brewer, Susan R. Brewer, Joanna M. Robertson, David R. Baughman, Philip Thompson, Wayne W. Hazen, Christel M.A. Bemelmans
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Patent number: 7517384Abstract: The present invention is directed to a system for recovering metal values from metal-bearing materials. During a reactive process, a seeding agent is introduced to provide a nucleation site for the crystallization and/or growth of solid species which otherwise tend to passivate the reactive process or otherwise encapsulate the metal value, thereby reducing the amount of desired metal values partially or completely encapsulated by such material. The seeding agent may be generated in a number of ways, including the recycling of residue or the introduction of foreign substances. Systems embodying aspects of the present invention may be beneficial for recovering a variety of metals such as copper, gold, silver, nickel, cobalt, molybdenum, zinc, rhenium, uranium, rare earth metals, and platinum group metals from any metal-bearing material, such as ores and concentrates.Type: GrantFiled: October 23, 2006Date of Patent: April 14, 2009Assignee: Phelps Dodge CorporationInventors: John O. Marsden, Robert E. Brewer, Joanna M. Robertson, David R. Baughman, Philip Thompson, Wayne W. Hazen, Roland Schmidt