Process for extracting and purifying naturally occurring zeolite

Abstract

A process for extracting and purifying naturally occurring zeolite from ores in the presence of other mineral phases by using mechanical dispersion and differential suspension to remove a majority of the clay content of the ore. The process continues by removal of contaminants with a higher mass to surface area ratio than that of the desired zeolite product by employing the properties of demineralized water in combination with a countercurrent flow separation column. No chemical flocculating or flotation agents need be employed in the process.

1 - 89 . (canceled)  
   
   
       90 . A method for separation of mineral phases from a natural mineral ore composition, said mineral phases having inherent variations in hydration properties, and resulting in differential suspension in a aqueous slurry or suspension, comprising: 
 crushing, grinding, or milling said natural ore to substantially liberate said mineral phases;    preparing an aqueous slurry or suspension in demineralized water wherein the low electrolyte content sustains a maximum electrical double layer to aid dispersal and separation of said mineral phases according to extent of hydration; and    separating said mineral phases by integrating the effect of differential suspension and physical separation principles.    
   
   
       91 . A composition prepared by a process comprising: 
 preparing an aqueous slurry of said particulate mineral compound, said aqueous slurry having a slurry density of 5% to 40%;    introducing said slurry into a countercurrent classifying column, said classifying column having one or more stages, a feed injection port at about the midpoint of said classifying column, a demineralized water injection port below said feed injection port, a cap at such column's topmost edge, and an overflow port below said cap;    introducing demineralized water into said countercurrent classifying column at said demineralized water injection port to form an ascending demineralized water stream;    separating said particulate compound using the separation effect of said electrical double layer; and    extracting an overflow stream through said overflow port.    
   
   
       92 . A composition prepared by a process comprising: 
 preparing a slurry consisting of demineralized water and zeolite ore having a mean particle size ranging from about 10 to 40 microns, said slurry having a density of about 5% to 40%, said slurry having a demineralized water to zeolite ore mass ratio sufficient to substantially suspend;    subjecting said slurry to mechanical dispersion having a demineralized water to zeolite ore mass ratio to substantially suspend any clay fraction of said zeolite ore;    allowing said zeolite to settle from said slurry resulting in an upper aqueous fraction and a settled zeolite fraction;    separating said settled zeolite fraction and said upper aqueous fraction; and    mixing said settled zeolite fraction with demineralized water to produce a slurried process stream.    
   
   
       93 . A composition prepared by a process comprising: 
 crushing, grinding, or milling a natural mineral ore to liberate mineral phases that have inherent variations in hydration properties;    preparing an aqueous slurry or suspension of the natural mineral ore in demineralized water wherein the low electrolyte content sustains a maximum electrical double layer to aid dispersal and separation of mineral phases in the natural mineral ore according to extent of hydration; and    separating said mineral phases by integrating the effect of differential suspension and physical separation principles.