CA1106529A - Process for making high polymeric dispersants suitable for effecting separation of clays and other materials containing active hydroxyl groups on the surfaces present in ores and minerals - Google Patents

Process for making high polymeric dispersants suitable for effecting separation of clays and other materials containing active hydroxyl groups on the surfaces present in ores and minerals

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Publication number
CA1106529A
CA1106529A CA294,603A CA294603A CA1106529A CA 1106529 A CA1106529 A CA 1106529A CA 294603 A CA294603 A CA 294603A CA 1106529 A CA1106529 A CA 1106529A
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Canada
Prior art keywords
hours
temperature
sodium
reaction
reaction mixture
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA294,603A
Other languages
French (fr)
Inventor
Johnson P. Moyalan
Torun C. Saikia
Banshidhar Chattaraj
Gopalakrishna Thyagarajan
Samarendra N. Dutta
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Council of Scientific and Industrial Research CSIR
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Council of Scientific and Industrial Research CSIR
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Priority to CA294,603A priority Critical patent/CA1106529A/en
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Publication of CA1106529A publication Critical patent/CA1106529A/en
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Abstract

ABSTRACT OF THE DISCLOSURE

Described herein is a process for the preparation of high polymeric dispersants suitable for effecting the separation of clays and other materials containing active hydroxyl groups on the surface of ores and minerals wherein an alkali metal sulphite or metabisulphite and a lower aliphatic aldehyde are reacted by heating with a phenol, and the reaction product of this is in turn reacted with a water-soluble aliphatic aldehyde such as formaldehyde.

Description

This invention relates to 'A process for making high polymeric dispersants suitable for effecting separation of clays and other materials containing active hydroxyl groups on the surfaces present in ores and minerals'. More particularly, the present invention is directed to methods for synthesising a number of polymeric dispersants, using raw~
materials such as phenol, acetaldehyde, formaldehyde, paraformaldehyde, chloral hydrate, sodium sulphite, potassium sulphite, sodium and potassium metabisulphite, and the like.
In the mineral processing industries beneficiation of low-grade ores and minerals is an essential step to upgrade the same for effective commercial utilization. The technique adopted for beneficiation differs from material to material.
The conventional techniques are mainly:-1. Ma~netic separation, 2. Flotation, 3. Heavy media separation, 4~ El~ctrostatic separ~tion "
S. Elutriation and 6. Hydrocyclone.
No single technique is suitable for all kinds of minerals and ores. Concentration by a dispersion technique is yet another method being followed in clay beneficiation.
The common agents utilized for effecting dispersion are sodium carbonate, sodium pyrophosphate and modified polyacrylamide type polymers. While these are effective in dispersion in certain cases,in many others these are not suitable. For instance, beneficiation of Indian iron ore 7 fines needs removal of not only the clay materials associated as impurities but also alumina hydrate as well as alumina present in lateritic minerals. Indian iron ore fines are characterised by the presence of a higher percentage of alumina than silica. For utiliæation of the fines through a process of agglomeration it is of the utmost importance that in the final agglomerates the alumina:silica ratio should ~ - -preferably be 1 or less than 1. The polymeric dispersants prepared following the invented process as described hereinunder may be utilized more effectively for upgrading ores and minerals where impurities like clay and other aluminous materials create problems for their industrial utili~ation.
The present invention provides a process for the preparation of high polymeric dispersants suitable for effect-ing the separation of clays and other materials containing active hydroxy groups on the surface of ores and minerals which comprises the steps of (1) reacting a water-soluble aliphatic aldehyde with an equimolecular proportion o an alkali metal sulphite or metabisulfite, (2) then reacting with an equimolecular proportion of phenol or sodium or potassium phenate; and (3) reacting the product of step (2) with an equimolecular proportion of a water-soluble aliphatic aldehyde.
The present invention, more particularly, provides a method of preparing a number of polymeric dispersants as herein described which comprises reacting equimolecular proportions of water-soluble aliphatic aldehydes, for example ~ormaldehyde or acetaldehyde or chloral hydrate, with sodium or potassium sulphite; sodium or potassium metabisulphite and the like in water solution at room temperature and preferably between 30 and 50C and or a period of 1 2~ hours depending on the level of concentration of the reactants in solution; reacting further with equimolecular proportions of phenol or sodium phenate in the case where sodium or potassium metabisulphite is used, gradually added to the first step reaction product at ambient to room temperature, gradually raising the temperature to 95 + 2C. over a period of 4-24 hours and allowing the reaction mixture to stand for a further 2-4 hours at 95 + 2C; finally reacting with a .

i5 ~9 further amount of formaldehyde,at ambient to room temperature, gradually raised to 95 + 2C. and maintained at that temperature for a period up to 47 hours or until such time as the reaction resulting in the formation of the polymeric dispersant is complete.
In accordance with the present invention there is also provided a method as herein described wherein all the three step reactions as described earlier can be carried out in a single operation using the same reactants except for the formaldeh~de solution and maintaining the same ingredient molar proportions but mixing the ingredients in dry condition and ~
adding a molar proportion of water, and warming to initiate ?
the reaction.
In another embodiment the invention is directed to a process of synthesising polymeric dispersants using the same reactants and in molar proportions as described earlier, excepting that in the inal step o the reaction the formaLdehyde molar ratio was increased up to three mole~ per mole of phenol, thus resulting in the formation of polymeric dispersants with better compatibility towards electrolytes concentration in efecting a stable dispersion.
The first step of the present process comprises dissolution of sodium or potassium sulphite or metabisulphite in water, preerably a saturated solution under conditions of substantially atmospheric pressure and at room temperature ~
and adding gradually an equimolecular proportion of the ~'' aldehyde in water solution with constant agitation. ~he duration of reaction is dependent on the concentration of ~' the reactants in solution and may extend from instantaneous ' reaction to several hours. The reaction rate is also dependent on the temperature employed. ~;

~''&
~,.,."'~ .

In the second step of the process phenol or sodium phenate in e~uimolecular proportion to sodium or potassium sulphite or metabisulphite is gradually added to the product of the first step reaction with constant agitation. The reaction between phenol and the ~irst step reaction product leading to the formation of monomer is dependent largely on the temperature employed and may extend from about 4 h~s. at 95 + 2C. to more than 24 hours at ~0C.
In the third step reaction the monomer from the second step is cooled to below 50C., and an equimolecular proportion or more of formaldehyde solution is gradually added, depending upon the el~ctrolyte compatibility level to be achieved by the polymeric dispersant~ with constant stirring. The rate of reaction leading to the formation of polymeric dispersant is again dependent on the concentration of the reactant in solution and to the temperature during reaction. For a particular reactant concentration the rate of reaction is a function of temperature. Using reactants in the solid state, all the three steps of the reaction leading to the formation of polymeric dispersant can be merged into a single step and can be completed in 10 minutes.
The following examples will serve to illustrate the method of this invention, without limitin~ it.
Example 1 To a solution of 66.3 gms. of sodium sulphite in 220 ml water, 25.7 ml of acetaldehyde was added with stirring at room temperature. A~ter allowing the reaction to continue for two hours 65.2 ml of phenol was added. Gradually the temperature was raised to 95 + 2C. and stirred at that temperature for 3-4 hrs. At the end the contents were cooled to below 50C and 45.2 ml formaldehyde solution was added.
The temperature of the reaction mixture was raised to 95 + 2C.
and maintalned at that temperature for a period of 32 hrs. to obtain the polymeric dispersant.
~`' - 4 -i; , iS2~
Example 2 The product oE this example was made in essentially the same manner as in Example 1 except tha~ the proportioned amount of phenol was added simultaneously along with sodium sulphite and ace-taldehyde at room temperature.
Example 3 The product of this example was made in essentially the same manner as in Example 1 except that instead of sodium sulphite an equimolecular amount of potassium sulphite was used~
Example 4 . .
The product of the Example was made essentially in the same manner as in Example 1 except that an equivalent amount of potassium metabisulphite, formaldehyde solution and sodium phenate were used at the appropriate stages instead of sodium sulphite, formaldehyde and phenol and also the reaction was carried out for 38 hours ater the second addition of formaldehyde solution.
Example 5 .
The product of this example was made essentially in the same manner as in Example 4 except that the final reaction was prolonged to 100 hours after the second addition of formaldehyde solution with successive addition of a half molecular proportion of formaldehyde every 24 hours.
Example 6 : :
The product of this example was made essentially in the same manner as in Example 1 except that an equimolecular amount of sodium metabisulphite was used and the reaction was prolonged to 47 hours at 9S + 2C. after the second addition of formaldehyde solution.
Example 7 The products of this example were made essentially in the same manner as in Example 1 except that sodium sulphite _ 5 '~ .

~ .:

solutions of 33~, 50~ and 100~ concentrations were used and were reacted with an equimolecular amount of formaldehyde solution, and the reaction was prolonged to 26-30 hours ater the second addition of formaldehyde solution.
Example 8 The products of this example was made essentially in the same manner as in Example 1 except that all the ingredients, namely sodium or potassiunl sulphite, para-formaldehyde and phenol in equimolecular amount in the dry state were added together, and equimolecular quantity of water was then added, the mixture was warmed to initiate the reaction which was completed in about 5-10 minutes.
Example 9 The product o this example was made essentially in the same manner as in Example 1 except that sodium or potassium metabisulphite was used and the reaction was carried out exactly in the same manner as described under Example 8 after the addition of the requisite amount of sodium hydroxide to neutralise the acidity due to phenol.
Example 10 The produc-t of this example was made essentially in the same manner as in Example 1 except that chloral hydrate and sodium phenate were used in equivalent amount. The addition of sodium sulphite solution was made slowly to chloral hydrate solution with stirring and the reaction was prolonged after the addition of chloral hydrate to 24 hours.
After standing for a while the top layer was separated and used for the final reaction. The bottom layer was discarded.
Final reaction was carried out for 9 hours with an equimolecular amount of formaldehyde solution and sodium hydroxide in an amount sufficient to raise the pH to 8 9.

. i ,-,

Claims (10)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A process for the preparation of high polymeric dispersants suitable for effecting the separation of clays and other materials containing active hydroxy groups on the surface of ores and minerals which comprises the steps of (1) reacting a water-soluble aliphatic aldehyde with an equimolecular proportion of an alkali metal sulphite or metabisulfite, (2) then reacting with an equimolecular proportion of phenol or sodium or potassium phenate; and (3) reacting the product of step (2) with an equimolecular proportion of a water-soluble aliphatic aldehyde.
2. A process as claimed in claim 1 wherein the alkali metal sulphite or metabisulphite is selected from the group consisting of sodium sulphite, potassium sulphite, sodium metabisulphite or potassium metabisulphite.
3. A process as claimed in claim 1 where the water soluble aliphatic aldehyde is selected from the group consisting of acetaldehyde, paraformaldehyde, formaldehyde and chloral hydrate.
4. A process as claimed in claim 1 wherein the reactants in equivalent quantities are mixed all at one time and then reacted by heating.
5. A process as claimed in claim 1 wherein the operating temperature of the reactions ranges from room temperature to 100°C.
6. A process as claimed in claim 1 wherein the reaction time between the ingredients ranges from 10 minutes to 100 hours.
7. A process as claimed in claim 1 wherein the reactants in equivalent amount are mixed all at one time in a dry state and then reacted.
8. A process as claimed in claim 1 wherein the final step of the reaction is carried out using in excess of a stoichiometric amount of the water soluble aliphatic aldehyde.
9. A process according to claim 1 wherein step (1) is carried out at a temperature ranging from room temperature to about 50°C. and for a period of from 1 to 24 hours.
10. A process according to claim 1 wherein the phenol or sodium or potassium phenate is gradually added to the first step reaction product at ambient to room temperature, the temperature is gradually raised to 95° ? 2°C.
over a period of from 4 to 25 hours, and the reaction mixture is allowed to stand at said temperature of 95° ? 2°C. for a further period of from 2 to 4 hours.
11. A process according to claim 1 or claim 10 wherein step (3) is initially carried out at ambient to room temperature, and then the temperature is gradually raised to 95° ? 2°C. and the reaction mixture is maintained at said temperature of 95° ? 2°C. until the reaction resulting in the formation of the polymeric dispersant is complete.
12. A process according to claim 1 wherein the acetaldehyde is reacted with sodium sulphite in the first step for a period of about 2 hours, then phenol is added to the reaction mixture, and the mixture is heated to about 95°C. and maintained at this temperature for 2-4 hours, the mixture is then cooled to below 50°C., formaldehyde is then added, the temperature of the reaction mixture is then raised to about 95°C., and the reaction mixture is maintained at said temperature of about 95°C. for about 32 hours.

13. A process according to claim 1 wherein acetaldehyde, sodium sulphite, and phenol in stoichiometric proportions are added simultaneously at room temperature.
14. A process according to claim 1 wherein formaldehyde solution is reacted with potassium metabisulfite in the first step for a period of about 2 hours, then sodium phenate is added to the reaction mixture, and the mixture is heated to about 95°C. and maintained at this temperature for 2-4 hours, the mixture is then cooled to below 50°C., formaldehyde is then added, the temperature of the reaction mixture is then raised to about 95°C., and the reaction mixture is maintained at said temperature of about 95°C. for about 38 hours.
15. A process as in claim 12, except that an equimolecular amount of potassium sulfite is used in place of sodium sulfite in the first step.
16. A process as in claim 12, with the exception that equivalent amounts of chloral hydrate and sodium phenate are used in place of the acetaldehyde and phenol, respectively, and the first step is carried out for a period of about 24 hours, and the final step is carried out for a period of about 9 hours.
17. High polymeric dispersants suitable for effecting the separation of clays and other materials containing active hydroxy groups on the surface of ores and minerals, said dispersants having been prepared by the process of claim 1 or
claim 10.
CA294,603A 1978-01-09 1978-01-09 Process for making high polymeric dispersants suitable for effecting separation of clays and other materials containing active hydroxyl groups on the surfaces present in ores and minerals Expired CA1106529A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA294,603A CA1106529A (en) 1978-01-09 1978-01-09 Process for making high polymeric dispersants suitable for effecting separation of clays and other materials containing active hydroxyl groups on the surfaces present in ores and minerals

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA294,603A CA1106529A (en) 1978-01-09 1978-01-09 Process for making high polymeric dispersants suitable for effecting separation of clays and other materials containing active hydroxyl groups on the surfaces present in ores and minerals

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CA1106529A true CA1106529A (en) 1981-08-04

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6041941A (en) * 1997-06-26 2000-03-28 Boc Gases Australia Limited Reagent consumption in mineral separation circuits
US9346062B2 (en) 2009-12-04 2016-05-24 Barrick Gold Corporation Separation of copper minerals from pyrite using air-metabisulfite treatment

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6041941A (en) * 1997-06-26 2000-03-28 Boc Gases Australia Limited Reagent consumption in mineral separation circuits
US9346062B2 (en) 2009-12-04 2016-05-24 Barrick Gold Corporation Separation of copper minerals from pyrite using air-metabisulfite treatment
US10258996B2 (en) 2009-12-04 2019-04-16 Barrick Gold Corporation Separation of copper minerals from pyrite using air-metabisulfite treatment

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