Method and Apparatus for Separating Metal Values

Abstract

Methods and apparatuses for separating metal values, such as nickel and nickel compounds, from mineral ores, including lateritic ores are disclosed. The method includes providing a mixture of particles (e.g., crushed and sized ore) that is composed of at least a first group of particles and a second group of particles. Group members have similar chemical composition, while particles belonging to different groups have dissimilar chemical compositions. The mixture of particles is concurrently, or generally concurrently, heated (using microwave/millimeter wave energy) and exposed to a reactant. The wave energy and the reactant act to increase the difference in either the magnetic susceptibility or other separation properties between the first and second group of particles. The mixture of particles is then passed through an appropriate separator to separate the particles of interest. Optional steps are disclosed for purifying selected particles. The reactant includes sulfur, sulfur compounds, halogens, or halogen compounds.

1 - 37 . (canceled) 
     
     
         38 . An apparatus that separates a mixture of particles, the mixture comprised of at least a first group of particles and a second group of particles, the first group of particles having a different chemical composition than the second group of particles, wherein the mixture of particles is a lateritic ore, the apparatus comprising:
 a wave energy generator that exposes the mixture of particles to millimeter wave energy in order to difference heat the first and second group of particles, thereby increasing the difference in magnetic susceptibility between the first and second group of particles; and   a magnetic separator that exposes the mixture of particles to a magnetic field gradient, the magnetic field gradient causing the particles to separate into first and second fractions, the first fraction having a greater percentage of the first group of particles than the mixture, and the second fraction having a greater percentage of the second group of particles than the mixture.   
     
     
         39 . The apparatus of  claim 38 , wherein the first group of particles includes one or more metal values. 
     
     
         40 . The apparatus of  claim 39 , further comprising:
 a heating device, wherein after exposing the mixture of particles to the millimeter wave energy with the wave energy generator, the heating device heats at least a portion of the first group of particles to approximately the Néel temperature of one of the metal values.   
     
     
         41 . The apparatus of  claim 39 , wherein the first group of particles includes one or more nickel values. 
     
     
         42 . The apparatus of  claim 38 , further comprising a third group of particles that includes one or more cobalt values. 
     
     
         43 . The apparatus of  claim 38 , further comprising:
 a gas generator that contacts the mixture of particles with a gas.   
     
     
         44 . The apparatus of  claim 38 , wherein the mixture of particles is lateritic ore. 
     
     
         45 . A method for separating components of a mixture of particles, the method comprising the steps of:
 containing the mixture of particles within a vessel,   directly exposing the mixture of particles within the vessel to microwave/millimeter wave energy,   exposing the mixture of particles to a reactant,   separating the mixture of particles by:
 diverting magnetic particles away from non-magnetic particles, and 
 separating the magnetic particles into a first group of particles and a second group of particles. 
   
     
     
         46 . The method of  claim 45 , further comprising the step of:
 utilizing a gas distributor for contacting the mixture of particles with said reactant.   
     
     
         47 . The method of  claim 45 , further comprising the step of:
 utilizing a gas distributor for distributing said reactant while simultaneously fluidizing the mixture of particles using said reactant.   
     
     
         48 . The method of  claim 45 , further comprising the step of:
 utilizing a gyrotron or a millimeter wave source for exposing the mixture of particles within the vessel to microwave/millimeter wave energy.   
     
     
         49 . The method of  claim 45 , further comprising the step of:
 utilizing a reactant system for exposing the mixture of particles to the reactant, wherein the reactant system includes a source of at least one of: a sulfur,   a compound containing sulfur, a halogen containing chlorine or fluorine, a compound containing halogen, or a hydrogen gas.   
     
     
         50 . The method of  claim 45 , further comprising the step of:
 arranging the vessel as being open to atmospheric pressure.   
     
     
         51 . The method of  claim 45 , further comprising the steps of:
 arranging the vessel as being closed to atmospheric pressure, and   operating said vessel at a pressure that is greater than atmospheric pressure.   
     
     
         52 . The method of  claim 45 , further comprising the steps of:
 providing a conduit having a first end and a second end,   connecting the first end of the conduit to the vessel,   providing a dust separator,   connecting the second end of the conduit to the duster separator,   utilizing the conduit for channeling a gas stream from within the vessel into the dust separator, and   utilizing the dust separator for removing entrained solids from the gas stream.   
     
     
         53 . The method of  claim 45 , further comprising the steps of:
 providing a separator for separating the mixture of particles, wherein the separator includes
 a first portion, and 
 a second portion. 
   
     
     
         54 . The method of  claim 53 , wherein the first portion includes a magnetic separator, wherein the method further comprises the step of:
 utilizing the magnetic separator for diverting magnetic particles away from non-magnetic particles.   
     
     
         55 . The method of  claim 54 , wherein the second portion includes a first exterior separator portion and a second exterior separator portion, wherein the first exterior separator portion includes a leach cycle, wherein the second exterior separator portion includes a flotation separator, wherein the method includes the steps of:
 utilizing the flotation separator for separating the magnetic particles into a first group of particles and a second group of particles,   passing the first group of particles to a first leach cycle of the second exterior portion, and   passing the second group of particles to a second leach cycle of the second exterior portion.   
     
     
         56 . The method of  claim 45 , wherein the particles in said containing the mixture of particles step further includes lateritic ore particles.