Process for extracting and purifying naturally occuring 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 - 45 . (canceled)  
   
   
       46 . A process for extracting and purifying natural zeolite from zeolite ore comprising: 
 hydrating and mechanically dispersing a starting material to separate out highly hydrated clay content; and    separating a zeolite from contaminants having a higher mass to surface area ratio than said zeolite by use of one or more countercurrent flow separation columns in which the dispersing medium is demineralized water.    
   
   
       47 . The process of  claim 46 , wherein said starting material comprises a pre-processed feedstock.  
   
   
       48 . The process of  claim 47 , wherein the pre-processed feedstock is prepared by crushing, milling or grinding a feedstock to obtain a desired average or mean particle size.  
   
   
       49 . The process of  claim 47 , wherein the average or mean particle size of the pre-processed feedstock is about 10 to 40 microns.  
   
   
       50 . The process of  claim 46 , wherein the zeolite ore comprises one or more of clinoptilolite, mordenite or other naturally occurring zeolite minerals.  
   
   
       51 . A process for extracting and purifying natural zeolite from zeolite ore comprising: 
 pulverizing zeolite ore comprising clinoptilolite, mordenite, feldspar, clay, mica and quartz;    mixing the pulverized ore with demineralized water having less than about 50 ppm electrolytes to form a first slurry;    mixing the first slurry in a batch fashion at high speed;    allowing the first slurry to settle; and    decanting a clay liquid suspension from the settled first slurry to obtain a separated zeolite product.    
   
   
       52 . The process of  claim 51 , additionally comprising: 
 adding demineralized water having less than about 50 ppm electrolytes to said separated zeolite product;    mixing the demineralized water and the zeolite product to form a second slurry;    injecting said second slurry into the mid-section of a separation column;    delivering demineralized water having less than 50 ppm electrolytes to the lower section of said separation column;    providing a counterflow rate of demineralized water that is sufficient to suspend zeolite and to allow higher density components to settle; and    extracting the suspended zeolite from the settled higher density components.    
   
   
       53 . The process of  claim 51 , wherein the demineralized water has less than 10 ppm electrolytes.  
   
   
       54 - 93 . (canceled)