Title of Invention

MODIFIED AMINE-ALDEHYDE RESINS AND USES THEREOF IN SEPARATION PROCESSES

Abstract Modified resins are disclosed for removing a wide variety of solids and/or ionic species from the liquids in which they are suspended and/or dissolved. These modified resins are especially useful as froth flotation depressants in the beneficiation of many types of materials (e.g., mineral and metal ores), including the beneficiation of impure coal comprising clay impurities, as well as in the separation of valuable bitumen from solid contaminants such as sand. The modified resins are also useful for treating aqueous liquid suspensions to remove solid particulates, as well as for removing metallic ions in the purification of water. The modified resins comprise a base resin that is modified with a coupling agent, which is highly selective for binding to solid contaminants and especially siliceous materials such as sand or clay.
Full Text CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority of U.S. Provisional Patent Application No.
60/638,143, filed December 23, 2004, and 60/713,339, filed September 2, 2005, each of which
is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0001] The present invention relates to modified resins for use in separation processes, and
especially the selective separation of solids and/or ionic species such as metallic cations from
aqueous media. Such processes include froth flotation (e.g., used in ore beneficiation), the
separation of drill cuttings from oil drilling fluids, clay and coal slurry dewatering, sewage
treatment, pulp and paper mill effluent processing, the removal of sand from bitumen, and the
purification of water to render it potable. The modified resins comprise a base resin that is the
reaction product of a primary or secondary amine and an aldehyde (e.g., a urea-formaldehyde
resin). The base resin is modified with a coupling agent (e.g., a substituted silane) during or
after its preparation.
BACKGROUND OF THE INVENTION
Froth Flotation
[0002] Industrially, processes for the purification of liquid suspensions or dispersions (and
especially aqueous suspensions or dispersions) to remove suspended solid particles are quite
prevalent. Froth flotation, for example, is a separation process based on differences in the
tendency of various materials to associate with rising air bubbles. Additives are often
incorporated into the froth flotation liquid (e.g., aqueous brine) to improve the selectivity of the
process. For example, "collectors" can be used to chemically and/or physically absorb onto
mineral(s) (e.g., those comprising value metals) to be floated, rendering them more hydrophobic.
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On the other hand, "depressants," typically used in conjunction with collectors, render other
materials (e.g., gangue minerals) less likely to associate with the air bubbles, and therefore less
likely to be carried into the froth concentrate.
[0003] In this manner, some materials (e.g., value minerals or metals) will, relative to others
(e.g., gangue materials), exhibit preferential affinity for air bubbles, causing them to rise to the
surface of the aqueous slurry, where they can be collected in a froth concentrate. A degree of
separation is thereby effected. In less common, so-called reverse froth flotations, it is the
gangue that is preferentially floated and concentrated at the surface, with the desired materials
removed in the bottoms. Gangue materials typically refer to quartz, sand and clay silicates, and
calcite, although other minerals (e.g., fluorite, barite, etc.,) may be included. In some cases, the
material to be purified comprises predominantly such materials, and the smaller amounts of
contaminants are preferentially floated. For example, in the beneficiation of kaolin clay, a
material having a number of industrially significant applications, iron and titanium oxides can be
separated by flotation from the impure, clay-containing ore, leaving a purified kaolin clay
bottoms product.
[0004] The manner in which known collectors and depressants achieve their effect is not
understood with complete certainty, and several theories have been proposed to date.
Depressants, for example may prevent the gangue minerals from adhering to the value materials
to be separated, or they may even prevent the collectors) from absorbing onto the gangue
minerals. Whatever the mechanism, the ability of a depressant to improve the selectivity in a
froth flotation process can very favorably impact its economics.
[0005] Overall, froth flotation is practiced in the beneficiation of a wide variety of value
materials (e.g., mineral and metal ores and even high molecular weight hydrocarbons such as
bitumen), in order to separate them from unwanted contaminants which are unavoidably co-
extracted from natural deposits. In the case of solid ore beneficiation, froth flotation generally
comprises grinding the crude ore into sufficiently small, discrete particles of a value mineral or
metal and then contacting an aqueous "pulp" of this ground ore with rising air bubbles, typically
while agitating the pulp. Prior to froth flotation, the crude ore may be subjected to any number
of preconditioning steps, including selective crushing, screening, desliming, gravity
concentration, electrical separation, low temperature roasting, and magnetic differentiation.
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[0006] Another particular froth flotation process of commercial significance involves the
separation of bitumen from sand and/or clay, which are ubiquitous in oil sand deposits, such as
those found in the vast Athabasca region of Alberta, Canada. Bitumen is recognized as a
valuable source of "semi-solid" petroleum or heavy hydrocarbon-containing crude oil, which
can be upgraded into many valuable end products including transportation fuels such as gasoline
or even petrochemicals. Alberta's oil sand deposits are estimated to contain 1.7 trillion barrels
of bitumen-containing crude oil, exceeding the reserves in all of Saudi Arabia. For this reason,
significant effort has been recently expended in developing economically feasible operations for
bitumen recovery, predominantly based on subjecting an aqueous slurry of extracted oil sand to
froth flotation. For example, the "Clark Process" involves recovering the bitumen in a froth
concentrate while depressing the sand and other solid impurities.
[0007] Various gangue depressants for improving froth flotation separations are known in the
art and include sodium silicate, starch, tannins, dextrins, lignosulphonic acids, carboxyl methyl
cellulose, cyanide salts and many others. More recently certain synthetic polymers have been
found advantageous in particular beneficiation processes. For example, U.S. Patent No. Re.
32,875 describes the separation of gangue from phosphate minerals (e.g., apatite) using as a
depressant a phenol-formaldehyde copolymer (e.g., a resol, a novolak) or a modified phenol
polymer (e.g., a melamine-modified novolak).
[0008] U.S. Patent No. 3,990,965 describes the separation of iron oxide from bauxite using as
a depressant a water soluble prepolymer of low chain length that adheres selectively to gangue
and that can be further polymerized to obtain a cross-linked, insoluble resin.
[0009] U.S. Patent No. 4,078,993 describes the separation of sulfide or oxidized sulfide ores
(e.g., pyrite, pyrrhotite, or sphalerite) from metal mineral ores (e.g., copper, zinc, lead, nickel)
using as a depressant a solution or dispersion of a low molecular weight condensation product of
an aldehyde with a compound containing 2-6 amine or amide groups.
[0010] U.S. Patent Nos. 4,128,475 and 4,208,487 describe the separation of gangue materials
from mineral ore using a conventional frothing agent (e.g., pine oils) combined with a
(preferably alkylated) amino-aldehyde resin that may have free methylol groups.
[0011] U.S. Patent No. 4,139,455 describes the separation of sulfide or oxidized sulfide ores
(eg., pyrite, pyrrhotite, or sphalerite) from metal mineral ores (e.g., copper, zinc, lead, nickel)
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using as a depressant an amine compound (e.g., a polyamine) in which at least .20% of the total
number of amine groups are tertiary amine groups and in which the number of quaternary amine
groups is from 0 to not more than 1/3 the number of tertiary amine groups.
[0012] U.S. Patent No. 5,047,144 describes the separation of siliceous materials (e.g.,
feldspar) from minerals (e.g., kaolinite) using as a depressant a cation-active condensation
product of aminoplast formers with formaldehyde, in combination with cation-active tensides
(e.g., organic alkylamines) or anion-active tensides (e.g.. long-chained alkyl sulfonates).
[0013] Russian Patent Nos. 427,737 and 276,845 describe the depression of clay slime using
carboxymethyl cellulose and urea-formaldehyde resins, optionally combined with methacrylic
acid-methacrylamide copolymers or starch ('845 patent).
[0014] Russian Patent Nos. 2,169,740; 2,165,798; and 724,203 describe the depression of clay
carbonate slimes from ores in the potassium industry, including sylvinite (KCl-NaCl) ores. The
depressant used is a urea/formaldehyde condensation product that is modified by
polyethylenepolyamine. Otherwise, a guanidine-formaldehyde resin is employed ('203 patent).
[0015] Markin, A.D., et. al., describe the use of urea-formaldehyde resins as carbonate clay
depressors in the flotation of potassium ores. Study of the Hydrophilizing Action of Urea-'
Formaldehyde Resins on Carbonate Clay Impurities in Potassium Ores, Inst. Obshch.
Neorg.Khim, USSR, Vestsi Akademii Navuk BSSR, Seryya Khimichnykh Navuk (1980); Effect
of Urea-Formaldehyde Resins on the Flotation of Potassium Ores, Khimicheskaya
Promyshlennost, Moscow, Russian Federation (1980); and Adsorption of Urea-Formaldehyde
Resins on Clay Minerals of Potassium Ores, Inst. Obshch Neorg. Khim., Minsk, USSR,
Doklady Akademii Nauk BSSR (1974).
[0016] As is recognized in the art, a great diversity cf materials can be subject to
beneficiation/refinement by froth flotation. Likewise, the nature of both the desired and the
unwanted components varies greatly. This is due to the differences in chemical composition of
these materials, as well as in the types of prior chemical treatment and processing steps used.
Consequently, the number and type of froth flotation depressants is correspondingly wide.
[0017] Also, the use of a given depressant in one service (e.g., raw potassium ore
beneficiation) is not a predictor of its utility in an application involving a significantly different
feedstock (e.g., bitumen-containing oil sand). This also applies to any expectation regarding the
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use of a depressant that is effective in froth flotation, in the any of the separations of solid
contaminants from aqueous liquid suspensions, described below (and vice versa). The
theoretical mechanisms by which froth flotation and aqueous liquid/solid separations occur are
significantly different, where the former process relies on differences in hydrophobicity and the
latter on several other possibilities (charge destabilization/neutralization, agglomeration, host-
guest theory (including podands), hard-soft acid base theory, dipole-dipole interactions, Highest
Occupied Molecular Orbital-Lowest unoccupied Molecular Orbital (HOMO-LUMO)
interactions, hydrogen bonding, Gibbs free energy of bonding, etc). Traditional depressants in
froth flotation for the benefication of metallic ores, such as guar gum, are not employed as
dewatering agents, or even as depressants in froth flotation for bitumen separation. Moreover, in
two of the applications described below (waste clay and coal dewatering), no agents are
currently used to improve the solid/liquid separation. Overall, despite the large offering of
flotation depressants and dewatering agents in the art, an adequate degree of refinement in many
cases remains difficult to achieve, even, in the case of froth flotation, when two or more
sequential "rougher" and "cleaner" flotations are employed. There is therefore a need in the art
for agents which can be effectively employed in a wide range of separation processes, including
both froth flotation and the separation of solid contaminants from liquid suspensions.
Other Separations
[0018] Other processes, in addition to froth flotation, for the separation of solid contaminants
from liquid suspensions can involve the use of additives that either destabilize these suspensions
or otherwise bind the contaminants into larger agglomerates. Coagulation, for example, refers to
the destabilization of suspended solid particles by neutralizing the electric charge that separates
them. Flocculation refers to the bridging or agglomeration of solid particles together into
clumps or floes, thereby facilitating their separation by settling or flotation, depending on the
density of the floes relative to the liquid. Otherwise, filtration may be employed as a means to
separate the larger floes.
[0019] The additives described above, and especially flocculants, are often employed, for
example, in the separation of solid particles of rock or drill cuttings from oil and gas well
drilling fluids. These drilling fluids (often referred to as "drilling muds") are important in the
drilling process for several reasons, including cooling and lubricating the drill bit, establishing a
fluid counterpressure to prevent high-pressure oil, gas, and/or water formation fluids from
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entering the well prematurely, and hindering the collapse of the uncased wellbore. Drilling
muds, whether water- or oil-based, also remove drill cuttings from the drilling area and transport
them to the surface. Flocculants such as acrylic polymers are commonly used to agglomerate
these cuttings at the surface of the circulating drilling mud, where they can be separated from the
drilling mud.
[0020] Other uses for flocculants in solid/liquid separations include the agglomeration of clays
which are suspended in the large waste slurry effluents from phosphate production facilities.
Flocculants such as anionic natural or synthetic polymers, which may be combined with a
fibrous material such as recycled newspaper, are often used for this purpose. The aqueous clay
slurries fonned in phosphate purification plants typically have a flow rate of over 100,000
gallons per minute and generally contain less than 5% solids by weight. The dewatering (or
settling) of this waste clay, which allows for recycle of the water, presents one of the most
difficult problems associated with reclamation. The settling ponds used for this dewatering
normally make up about half of the mined area, and dewatering time can be on the order of
several months to several years.
[0021] In the separation of solids from aqueous liquids, other specific applications of
industrial importance include the filtration of coal from water-containing slurries (i.e., coa!
slurry dewatering), the treatment of sewage to remove contaminants (e.g., sludge) via
sedimentation, and the processing of pulp and paper mill effluents to remove suspended
cellulosic solids. The dewatering of coal poses a significant problem industrially, as the BTU
value of coal decreases with increasing water content. Raw sewage, both industrial and
municipal, requires enormous treatment capacity, as wastes generated by the U.S. population,
for example, are collected into sewer systems and carried along by approximately 14 billion
gallons of water per day, Paper industry effluent streams likewise represent large volumes of
solid-containing aqueous liquids, as waste water generated from a typical paper plant often
exceeds 25 million gallons per day. The removal of sand from aqueous bitumen-containing
slurries generated in the extraction and subsequent processing of oil sands, as described
previously, poses another commercially significant challenge in the purification of aqueous
liquid suspensions. Also, the removal of suspended solid particulates is often an important
consideration in the purification of water, such as in the preparation of drinking (i.e., potable)
water. Synthetic polyacrylamides, as well as naturally-occurring hydrocolloidal polysaccharides
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such as alginates (copolymers of D-mannuronic and L-guluronic acids) and guar gum are
flocculants in this service.
[0022] The above applications therefore provide several specific examples relating to the
treatment of aqueous liquid suspensions to remove solid particulates. However, such
separations are common in a vast number of other processes in the mineral, chemical, industrial
and municipal waste, sewage treatment, and paper industries, as well as in a wide variety of
other water-consuming industries. Thus, there is a need in the art for additives that can
effectively promote selective separation of a wide variety of solid contaminants from liquid
suspensions. Advantageously, such agents should be selective in chemically interacting with the
solid contaminants, through coagulation, flocculation, or other mechanisms such that the
removal of these contaminants is easily effected. Especially desirable are additives that are also
able to complex unwanted ionic species such as metal cations to facilitate their removal as well.
SUMMARY OF THE INVENTION
All Uses
[0023] The present invention is directed to modified resins for removing, generally in a
selective fashion, a wide variety of solids and/or ionic species from the liquids in which they are
suspended and/or dissolved. These modified resins are especially useful as froth flotation
depressants in the beneficiation of many types of materials including mineral and metal ores,
such as in the beneficiation of kaolin clay. The modified resins are also useful for treating
aqueous liquid suspensions {e.g., aqueous suspensions containing sand, clay, coal, and/or other
solids, such as used drill cutting fluids, as well as process and effluent streams in phosphate and
coal production, sewage treatment, paper manufacturing, or bitumen recovery facilities) to
remove solid particulates and also potentially metallic cations {e.g., in the purification of
drinking water). The modified resins comprise a base resin that is modified with a coupling
agent. The coupling agent is highly selective for binding to solid contaminants and especially v
siliceous materials such as sand or clay.
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Froth Flotation
[0024] Without being bound by theory, the coupling agent is highly selective in froth flotation
separations for binding to either gangue or desired {e.g., kaolin clay) materials and especially
siliceous gangue materials such as sand or clay. Also, because the base resin has affinity for
water, the materials which interact and associate with the coupling agent, are effectively
sequestered in the aqueous phase in froth flotation processes. Consequently, the gangue
materials can be selectively separated from the value materials {e.g., minerals, metals, or
bitumen) or clay-containing ore impurities {e.g., iron and titanium oxides) that are isolated in the
froth concentrate.
[0025] Accordingly, in one embodiment, the present invention is a method for beneficiation of
an ore. The method comprises treating a slurry of ore particles with, a depressant comprising a
modified resin. The modified resin comprises a base resin that is the reaction product of a
primary or a secondary amine and an aldehyde, and the base resin is modified with a coupling
agent. The ore slurry treatment may occur before or during froth flotation. In one embodiment,
the ore comprises sand or clay impurities, and is typically an ore that is recovered in phosphate
or potassium mining. In another embodiment, the base resin is a urea-formaldehyde resin. In
another embodiment, the coupling agent is selected from the group consisting of a substituted
silane, a silicate, silica, a polysiloxane, and mixtures thereof.
[0026] In another embodiment, the present invention is a froth flotation depressant for
beneficiation of vaiue materials, including minerals or value metal ores. The depressant
comprises a modified resin in a solution or dispersion having a resin solids content from about
30% to about 90% by weight. The modified resin comprises a base resin that is the reaction
product of a primary or secondary amine and an aldehyde. The base resin is modified with a
coupling agent. The coupling agent is present in an amount representing from about 0.1% to
about 2.5% of the weight of the solution or dispersion, having a resin solids content from about
30% to about 90% by weight. In another embodiment, the base resin is a urea-formaldehyde
resin that is the reaction product of urea and formaldehyde at a formaldehyde : urea (F:U) molar
ratio from about 1.75:1 to about 3:1. In another embodiment, the coupling agent is a substituted
silane selected from the group consisting of a ureido substituted silane, an amino substituted
silane, a sulfur substituted silane, an epoxy substituted silane, a methacryl substituted silane, a
vinyl substituted silane, an alkyl substituted silane, and a haloalkyl substituted silane.
9

[0027] In another embodiment, the present invention is a method for purifying clay from a
clay-containing ore comprising an impurity selected from a metal, a metal oxide, a mineral, and
mixtures thereof. The method comprises treating a slurry of the clay-containing ore with a
depressant comprising a modified resin and recovering, by froth flotation of the impurity either
after or during the treating step, a purified clay having a reduced amount at least one of the
impurities. The modified resin comprises a base resin that is the reaction product of a primary
or a secondary amine and an aldehyde. The base resin is modified with a coupling agent. In
another embodiment, the clay-containing ore comprises kaolin clay. In another embodiment, the
impurity comprises a mixture of iron oxide and titanium dioxide. In another embodiment, the
impurity comprises coal.
[0028] In another embodiment, the present invention is a method for purifying bitumen from a
bitumen-containing slurry comprising sand or clay. The method comprises treating the slurry
with a depressant comprising the modified resin described above and recovering, by froth
flotation either after or during the treating step, purified bitumen having a reduced amount of
sand or clay.
Other Separations
[0029] In another embodiment, the present invention is a method for purifying an aqueous
liquid suspension comprising a solid contaminant. The method comprises treating the liquid
suspension with a modified resin as described above and removing, either after or during the
treating step, (1) at least a portion of the solid contaminant in a contaminant-rich fraction and/or
(2) a purified liquid. In another embodiment, the treating step comprises flocculating the solid
contaminant (e.g., sand or clay). In another embodiment, the removing step is carried out by
sedimentation, flotation, or filtration. In another embodiment, the liquid suspension is an oil
well drilling fluid and the method comprises removing a purified drilling fluid for reuse in oil
well drilling. In another embodiment, the aqueous liquid suspension is a clay-containing
effluent slurry from a phosphate production facility and the method comprises removing purified
water for reuse in phosphate production. In another embodiment, the aqueous liquid suspension
is an aqueous coal-containing suspension and the method comprises removing a coal-rich
fraction by filtration. In another embodiment, the aqueous liquid suspension comprises sewage
and the method comprises removing purified water by sedimentation. In another embodiment,
the aqueous liquid suspension comprises a pulp or paper mill effluent, the solid contaminant
10

comprises a cellulosic material, and the method comprises removing purified water. In another
embodiment, the aqueous liquid suspension is a bitumen production process intermediate or
effluent slurry comprising sand or clay. In still another embodiment, the purified liquid is
potable water.
[0030] In another embodiment, the present invention is a method for purifying water
comprising a metallic cation. The method comprises treating the water with the modified resin
described above and removing at least a portion of the metallic cation by filtration to yield
purified water (e.g., potable water). In another embodiment, the removing step comprises
membrane filtration. In another embodiment, the metallic cation is selected from the group
consisting of As+5, Pb+2, Cd+2, Cu+2, Mn+2, Hg+2, and mixtures thereof. In yet another
embodiment, the base resin is further modified with an anionic functional group.
[0031] These and other embodiments are apparent from the following Detailed Description.
BRIEF DESCRIPTION'OF THE DRAWING
[0032] Fig. 1 illustrates the performance, in the flotation of a sample of ground potassium ore,
of silane coupling agent-modified urea-formaldehyde resins having a molecular weight within
the range of 400-1200 grams/mole. The performance is shown relative to unmodified resins
(i.e., without an added silane coupling agent) and also relative to a guar gum control sample.
DETAILED DESCRIPTION OF THE INVENTION
All Uses
[0033] The modified resin that is used in separation processes of the present invention
comprises a base resin that is the reaction product of a primary or secondary amine and an
aldehyde. The primary or secondary amine, by virtue of having a nitrogen atom that is not
completely substituted (i.e., that is not part of a tertiary or quaternary amine) is capable of
reacting with an aldehyde, to form an adduct. If formaldehyde is used as the aldehyde, for
example, the adduct is a methylolated adduct having reactive methylol functionalities.
Representative primary and secondary amines used to form the base resin include compounds
having at least two functional amine or amide groups, or amidine compounds having at least one
11

of each of these groups. Such compounds include ureas, guanidines, and melamines, which may
be substituted at their respective amine nitrogen atoms with aliphatic or aromatic radicals,
wherein at least two nitrogen atoms are not completely substituted. Primary amines are often
used. Representative of these is urea, which has a low cost and is extensively available
commercially. In the case of urea, if desired, at least a portion thereof can be replaced with
ammonia, primary alkylamines, alkanolamines, polyamines {e.g., alkyl primary diamines such
as ethylene diamine and alkyl primary triamines such as diethylene triamine),
polyalkanolamines, melamine or other amine-substituted triazines, dicyandiamide, substituted or
cyclic ureas {e.g., ethylene urea), primary amines, secondary amines and alkylamines, tertiary
amines and alkylamines, guanidine, and guanidine derivatives {e.g., cyanoguanidine and
acetoguanidine). Aluminum sulfate, cyclic phosphates and cyclic phosphate esters, formic acid
or other organic acids may also be used in conjunction with urea. The amount of any one of
these components (or if used in combination then their combined amount), if incoiporated into
the resin to replace part of the urea, typically will vary from about 0.05 to about 20% by weight
of the resin solids. These types of agents promote hydrolysis resistance, flexibility, reduced
aldehyde emissions and other characteristics, as is appreciated by those having skill in the art.
[0034] The aldehyde used to react with the primary or secondary amine as described above, to
form the base resin, may be formaldehyde, or other aliphatic aldehydes such as acetaldehyde and
propionaldehyde. Aldehydes also include aromatic aldehydes {e.g., benzylaldehyde and
furfural), and other aldehydes such as aldol, glyoxal, and crotonaldehyde. Mixtures of
aldehydes may also be used. Generally, due to its commercial availability and relatively low
cost, formaldehyde is used.
[0035] In forming the base resin, the initial formation of an adduct between the amine and the
aldehyde is well known in the art. The rate of the aldehyde addition reaction is generally highly
dependent on pH and the degree of substitution achieved. For example, the rate of addition of
formaldehyde to urea to form successively one, two, and three methylol groups has been
estimated to be in the ratio of 9 : 3 : 1, while tetramethylolurea is normally not produced in a
significant quantity. The adduct formation reaction typically proceeds at a favorable rate under
alkaline conditions and thus in the presence of a suitable alkaline catalyst {e.g., ammonia, alkali
metal hydroxides, or alkaline earth metal hydroxides). Sodium hydroxide is most widely used.
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[0036] At sufficiently high pH values, it is possible for the adduct formation reaction to
proceed essentially in the absence of condensation reactions that increase the resin molecular
weight by polymerization (i.e., that advance the resin). However, for the formation of low
molecular weight condensate resins from the further reaction of the amine-aldehyde adduct, the
reaction mixture is generally maintained at a pH of greater than about 5 and typically from about
5 to about 9. If desired, an acid such as acetic acid can be added to help control the pH and
therefore the rate of condensation and ultimately the molecular weight of the condensed resin.
The reaction temperature is normally in the range from about 30°C to about 120°C, typically less
than about 85°C, and often the reflux temperature is used. A reaction time from about from
about 15 minutes to about 3 hours, and typically from about 30 minutes to about 2 hours, is used
in preparing the low molecular weight amine-aldehyde condensate resin from the primary or
secondary amine and aldehyde starting materials.
[0037] Various additives may be incorporated, prior to or during the condensation reaction, in
order to impart desired properties into the final modified amine-aldehyde resin. For example,
guar gum; carboxymethylcellulose or other polysaccharides such as alginates; or polyols such as
polyvinyl alcohols, pentaerythitol, or Jeffol™ polyols (Hunstman Corporation, Salt Lake City,
Utah, USA) may be used to alter the viscosity and consistency of the amine-aldehyde resin
condensate, which when used to prepare the modified amine-aldehyde resin, can improve its
performance in froth flotation and other applications. Otherwise, quaternary ammonium salts
including diallyl dimethyl ammonium chloride (or analogs such as diallyl diethyl ammonium
chloride) or alkylating agents including epichlorohydrin (or analogs such as epibromohydrin)
may be used to increase the cationic charge of the amine-aldehyde resin condensate, which when
used to prepare the modified amine-aldehyde resin, can improve its performance in certain
solid/liquid separations (e.g., clay dewatering) discussed below. In this manner, such additives
may be more effectively reacted into the modified amine-aldehyde resin than merely blended
with the resin after its preparation.
[0038] Condensation reaction products of the amine-aldehyde, amide-aldehyde, and/or
amidine-aldehyde adducts described above include, for example those products resulting from
the formation of (i) methylene bridges between amido nitrogens by the reaction of alkylol and
amino groups, (ii) methylene ether linkages by the reaction of two alkylol groups, (iii)
methylene linkages from methylene ether linkages with the subsequent removal of
13

formaldehyde, and (iv) methylene linkages from alkylol groups with the subsequent removal of
water and formaldehyde.
[0039] Generally, in preparing the base resin, the molar ratio of aldehyde : primary or
secondary amine is from about 1.5:1 to about 4:1, which refers to the ratio of moles of all
aldehydes to moles of all amines, amides, and amidines reacted to prepare the base resin during
the course of the adduct formation and condensation reactions described above, whether
performed separately or simultaneously. The resin is normally prepared under ambient pressure.
The viscosity of the reaction mixture is often used as a convenient proxy for the resin molecular
weight. Therefore the condensation reaction can be stopped when a desired viscosity is
achieved after a sufficiently long time and at a sufficiently high temperature. At this point, the
reaction mixture can be cooled and neutralized. Water may be removed by vacuum distillation
to give a resin with a desired solids content. Any of a wide variety of conventional procedures
used for reacting primary and secondary amine and aldehyde components can be used, such as
staged monomer addition, staged catalyst addition, pH control, amine modification, etc., and the
present invention is not limited to any particular procedure.
[0040] A representative base resin for use in separation processes of the present invention is a
urea-formaldehdye resin. As described above, a portion of the urea may be replaced by other
reactive amine and/or amides and a portion of the formaldehyde may be replaced by other
aldehydes, to provide various desirable properties, without departing from the characterization
of the base resin as a urea-formaldehyde resin. Urea-formaldehyde resins, when used as the
base resin, can be prepared from urea and formaldehyde monomers or from precondensates in
manners well known to those skilled in the art. Generally, the urea and formaldehyde are
reacted at a molar ratio of formaldehyde to urea (F:U) in the range from about 1.75:1 to about
3:1, and typically at a formaldehyde : urea (F:U) mole ratio from about 2:1 to about 3:1, in order
to provide sufficient methylolated species for resin cross-linking (e.g., di- and tri-methylolated
ureas). Generally, the urea-formaldehyde resin is a highly water dilutable dispersion, if not an
aqueous solution.
[0041] In one embodiment, the condensation is allowed to proceed to an extent such that the
urea-formaldehyde base resin has a number average molecular weight (Mn), of greater than
about 300 grams/mole, and typically from about 400 to about 1200 grams/mole. As is known in
14


the art, the value of Mn of a polymer sample having a distribution of molecular weights is
defined as
[0042] where Nj is the number of polymer species having i repeat units and Mj is the
molecular weight of the polymer species having i repeat units. The number average molecular
weight is typically determined using gel permeation chromatography (GPC), using solvent.,
standards, and procedures well known to those skilled in the art.
[0043] A cyclic urea-formaldehyde resin may also be employed and prepared, for example,
according to procedures described in U.S. Patent No. 6,114,491. Urea, formaldehyde, and
ammonia reactants are used in a mole ratio of urea : formaldehyde : ammonia that may be about
0.1 to 1.0 : about 0.1 to 3.0 : about 0.1 to 1.0. These reactants are charged to a reaction vessel
while maintaining the temperature below about 70°C (160°F), often about 60°C (MOT). The
order of addition is not critical, but it is important to take care during the addition of ammonia to
formaldehyde (or formaldehyde to ammonia), due to the exothermic reaction. In fact, due to the
strong exotherm, it may be preferred to charge the formaldehyde and the urea first, followed by
the ammonia. This sequence of addition allows one to take advantage of the endotherm caused
by the addition of urea to water to increase the rate of ammonia addition. A base may be
required to maintain an alkaline condition throughout the cook.
[0044] Once all the reactants are in the reaction vessel, the resulting solution is heated at an
alkaline pH to between about 60 and 105°C (about 140 to about 220°F), often about 85 to 95°C
(about 185 to 205°F), for 30 minutes to 3 hours, depending on mole ratio and temperature, or
until the reaction is complete. Once the reaction is complete, the solution is cooled to room
temperature for storage. The resulting solution is storage stable for several months at ambient
conditions. The pH is between 5 and 11.
[0045] The yield is usually about 100%. The cyclic urea resins often contain at least 20%
triazone and substituted triazone compounds. The ratio of cyclic ureas to di- and tri- substituted
ureas and mono-substituted ureas varies with the mole ratio of the reactants. For example, a
cyclic urea resin having the mole ratio of 1.0:2.0:0.5 U:F:A resulted in a solution characterized
by CI3-NMR and containing approximately 42.1% cyclic ureas, 28.5% di/tri-substituted ureas,
15

24.5% mono-substituted ureas, and 4.9% free urea. A cyclic urea resin having the mole ratio of
1.0:1.2:0.5 U:F:A resulted in a solution characterized by CI3-NMR and containing
approximately 25.7% cyclic ureas, 7.2% di/tri-substituted ureas, 31.9% mono-substituted ureas,
and 35.2 free urea.
[0046] In addition, the cyclic urea-formaldehyde resin may be prepared by a method such as
described in U.S. Pat. No. 5,674,971. The cyclic urea resin is prepared by reacting urea and
formaldehyde in at least a two step and optionally a three-step process. In the first step,
conducted under alkaline reaction conditions, urea and formaldehyde are reacted in the presence
of ammonia, at an F/U mole ratio of between about 1.2:1 and 1.8:1. The ammonia is supplied in
an amount sufficient to yield an ammonia/urea mole ratio of between about 0.05:1 and 1.2:1. :
The mixture is reacted to form a cyclic triazone/triazine or cyclic urea resin.
[0047] Water soluble triazone compounds may also be prepared by reacting urea,
formaldehyde and a primary amine as described in U.S. Patent Nos. 2,641,584 and 4,778,510.
These patents also describe suitable primary amines such as, but are not limited to, alkyl amines
such as methyl amine, ethyl amine, and propyl amine, lower hydroxyamines such as
ethanolamine cycloalkylmonoamines such as cyclopentylamine, ethylenediamine,
hexamethylenediamine, and linear polyamines. The primary amine may be substituted or
unsubstituted.
[0048] In the case of a cyclic urea-formaldehyde or a urea-formaldehyde resin, skilled
practitioners recognize that the urea and formaldehyde reactants are commercially available in
many forms. Any form which is sufficiently reactive and which does not introduce extraneous
moieties deleterious to the desired reactions and reaction products can be used in the preparation
of urea-formaldehyde resins useful in the invention. For example, commonly used forms of
formaldehyde include paraform (solid, polymerized formaldehyde) and formalin solutions
(aqueous solutions of formaldehyde, sometimes with methanol, in 37 percent, 44 percent, or 50
percent formaldehyde concentrations). Formaldehyde also is available as a gas. Any of these
forms is suitable for use in preparing a urea-formaldehyde base resin. Typically, formalin
solutions are used as the formaldehyde source. To prepare the base resin of the present
invention, formaldehyde may be substituted in whole or in part with any of the aldehydes
described above (e.g., glyoxal).
16

[0049] Similarly, urea is commonly available in a variety of forms. Solid urea, such as prill,
and urea solutions, typically aqueous solutions, are commercially available. Any form of urea is
suitable for use in the practice of the invention. For example, many commercially prepared
urea-formaldehyde solutions may be used, including combined urea-formaldehyde products
such as Urea-Formaldehyde Concentrate (e.g., UFC 85) as disclosed in U.S. Patent Nos.
5,362,842 and 5,389,716.
[0050] Also, urea-formaldehyde resins such as the types sold by Georgia Pacific Resins, Inc.,
Borden Chemical Co., and Neste Resins Corporation may be used. These resins are prepared as
either low molecular weight condensates or as adducts which, as described above, contain
reactive methylol groups that can undergo condensation to form resin polymers, typically within
the number average molecular weight ranges described previously. The resins will generally
contain small amounts of unreacted (i.e., free) urea and formaldehyde, as well as cyclic ureas,
mono-methylolated urea, and di- and tri-methylolated ureas. The relative quantities of ihese
species can vary, depending on the preparation conditions (e.g., the molar formaldehyde : urea
ratio used). The balance of these resins is generally water, ammonia, and formaldehyde.
Various additives known in the art, including stabilizers, cure promoters, fillers, extenders, etc.,
may also be added to the base resin.
[0051] Modified resins of the present invention are prepared by modifying the base resin, as
described above, with a coupling agent that is highly selective for binding with unwanted solid
materials (e.g., sand or clay) and/or ionic species such as metallic cations to be separated in the
separation/purification processes of the present invention. Without being bound by theory, the
coupling agent is believed to improve the ability of the base resin, which, in one embodiment, is
generally cationic (i.e., carries more overall positive than negative charge) to attract most clay
surfaces, which are generally anionic (i.e., carry more overall negative than positive charge).
These differences in electronic characteristics between the base resin and clay can result in
mutual attraction at multiple sites and even the potential sharing of electrons to form covalent
bonds. The positive-negative charge interactions which cause clay particles to become attracted
to the base resin is potentially explained by several theories, such as host-guest theory (including
podands), hard-soft acid base theory, dipole-dipole interactions, and Highest Occupied
Molecular Orbital-Lowest unoccupied Molecular Orbital (H0M0-LUM0) interactions,
hydrogen bonding, Gibbs free energy of bonding, etc.
17

[0052] The coupling agent may be added before, during, or after the adduct-forming reaction,
as described above, between the primary or secondary amine and the aldehyde. For example,
the coupling agent may be added after an amine-aldehyde adduct is formed under alkaline
conditions, but prior to reducing the pH of the adduct (e.g., by addition of an acid) to effect
condensation reactions. Normally, the coupling agent is covalently bonded to the base resin by
reaction between a base resin-reactive functional group of the coupling agent and a moiety of the
base resin.
[0053] The coupling agent may also be added after the condensation reactions that yield a low
molecular weight polymer. For example, the coupling agent may be added after increasing the
pH of the condensate (e.g., by addition of a base) to halt condensation reactions.
Advantageously, it has been found that the base resin may be sufficiently modified by
introducing the coupling agent to the resin condensate at an alkaline pH (i.e., above pH 7),
without appreciably advancing the resin molecular weight. Typically, the resin condensate is in
the form of an aqueous solution or dispersion of the resin. When substituted silanes are used as
coupling agents, they can effectively modify the base resin under alkaline conditions and at
either ambient or elevated temperatures. Any temperature associated with adduct formation or
condensate formation during the preparation of the base resin, as described above, is suitable for
incorporation of the silane coupling agent to modify the base resin. Thus, the coupling agent
may be added to the amine-aldehyde mixture, adduct, or condensate at a temperature ranging
from ambient to about 100°C. Generally, an elevated temperature from about 35°C to about
45°C is used to achieve a desirable rate of reaction between the base resin-reactive group of the
substituted silane and the base resin itself. As with the resin condensation reactions described
previously, the extent of this reaction may be monitored by the increase in the viscosity of the
resin solution or dispersion over time.
[0054] Alternatively, in some cases the silane coupling agent may be added to the liquid that is
to be purified (e.g., the froth flotation slurry) and that contains the base resin, in order to modify
the base resin in situ.
[0055] Representative coupling agents that can modify the base resin of the present invention
and that also have the desired binding selectivity or affinity for impurities such as sand, clay,
and/or ionic species include substituted silanes, which posses both a base resin-reactive group
(e.g., an organorunctional group) and a second group (e.g., a trimethoxysilane group) that is
18

capable of adhering to, or interacting with, unwanted impurities (especially siliceous materials).
Without being bound by theory, the second group may effect the agglomeration of these
impurities into larger particles or floes (i.e., by flocculation), upon treatment with the modified
resin. This facilitates their removal. In the case of ore froth flotation separations, this second
group of the coupling agent promotes the sequestering of either gangue impurities or desired
materials (e.g., kaolin clay) in the aqueous phase, in which the base resin is soluble or for which
the base resin has a high affinity. This improves the separation of value materials from the
aqueous phase by flotation with a gas such as air.
[0056] Representative base resin-reactive groups of the silane coupling agents include, but are
not limited to, ureido-containing moieties (e.g., ureidoalkyl groups), amino-containing moieties
(e.g., aminoalkyl groups), sulfur-containing moieties (e.g., mercaptoalkyl groups), epoxy-
containing moieties (e.g., glycidoxyalkyl groups), methacryl-containing moieties (e.g.,
methacryloxyalkyl groups), vinyl-containing moieties (e.g., vinylbenzylamino groups), alkyl-
containing moieties (e.g., methyl groups), or haloalkyl-containing moieties (e.g., chloroalkyl
groups). Representative substituted silane coupling agents of the present invention therefore
include ureido substituted silanes, amino substituted silanes, sulfur substituted silanes, epoxy
substituted silanes, methacryl substituted silanes, vinyl substituted silanes, alkyl substituted
silanes, and haloalkyl substituted silanes.
[0057] It is also possible for the silane coupling agent to be substituted with more than one
base-resin reactive group. For example, the tetravalent silicon atom of the silane coupling agent
may be independently substituted with two or three of the base-resin reactive groups described
above. As an alternative to, or in addition to, substitution with multiple base-resin reactive
groups, the silane coupling agent may also have multiple silane functionalities, to improve the
strength or capacity of the coupling agent in bonding with either gangue impurities such as sand
or desired materials such as kaolin clay. The degree of silylation of the silane coupling agent
can be increased, for example, by incorporating additional silane groups into coupling agent or
by cross-linking the coupling agent with additional silane-containing moieties. The use of
multiple silane functionalities may even result in a different orientation between the coupling
agent and clay surface (e.g., affinity between the clay surface and multiple silane groups at the
"side" of the coupling agent, versus affinity between a single silane group at the "head" of the
coupling agent.
19

[0058] The silane coupling agents also comprise a second group, as described above, which
includes the silane portion of the molecule, that is typically substituted with one or more groups
selected from alkoxy (e.g., trimethoxy), acyloxy (e.g., acetoxy), alkoxyalkoxy (e.g.,
methoxyethoxy), aryloxy (e.g., phenoxy), aroyloxy (e.g., benzoyloxy), heteroaryloxy (e.g.,
furfuroxy), haloaryloxy (e.g., chlorophenoxy), heterocycloalkyloxy (e.g., tetrahydrofurfuroxy),
and the like. Representative silane coupling agents, having both base resin-reactive groups and
second groups (e.g., gangue-reactive groups) as described above, for use in modifying the base
resin, therefore include ureidopropyltrimethoxysilane, ureidopropyltriethoxysilane,
aminopropyltrimethoxysilane, aminopropyltriethoxysilane, aminopropylmethyldiethoxysilane,
aminopropylmethyldimethoxysilane, aminoethylaminopropyltrimethoxysilane,
aminoethylarninopropyltriethoxysilane, aminoethylarninopropylmethyldirnethoxysilane,
diethylenetriaminopropyltrimethoxysilane, diethylenetriaminopropyltriethoxysilane,
diethylenetriarninopropylmethyldimethoxysilane,
diethylenetriaminopropylmethyldiethoxysilane, cyclohexylaminopropyltrimethoxysilane,
hexanediaminomethyltriethoxysilane, anilinomethyltrimethoxysilane,
anilinomethyltriethoxysilane, diethylaroinomethyltriethoxysilane,
(diethylaminomethyl)methyldiethoxysilane, methylaminopropyltrimethoxysilane,
bis(triethoxysilylpropyl)tetrasulfide, bis(triethoxysilylpropyl)disulfide,
mercaptopropyltrimethoxysilane, mercaptopropyltriethoxysilane,
mercaptopropylmethyldimethoxysilane, 3-thiocyanatopropyltriethoxysilane, isocyanatopropyl
triethylsilane, glycidoxypropyltrimethoxysilane, glycidoxypropyltriethoxysilane,
glycidoxypropylmethyldiethoxysilane, glycidoxypropylmethyldimethoxysilane,
methacryloxypropyltrimethoxysilane, methacryloxypropyltriethoxysilane,
methacryloxypropylmethyldimethoxysilane, chloropropyltrimethoxysilane,
chloropropyltriethoxysilane, chloromethyltriethoxysilane, chloromethyltrimethoxysilane,
dichloromethyltriethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris(2-
methoxyethoxy)silane, vinyltriacetoxysilane, alkylmethyltrimethoxysilane,
vinylbenzylaminotrimethoxysilane, (3,4-epoxycyclohexyl)ethyltrimethoxysilane,
aminopropyltriphenoxysilane, aminopropyltribenzoyloxysilane, aminopropyltrifurfuroxysilane,
aminopropyltri(o-chlorophenoxy)silane, aminopropyltri(p-chlorophenoxy)silane,
aminopropyltri(tetrahydrofurfuroxy)silane, ureidosilane, mercaptoethyltriethoxysilane, and
vinyltrichlorosilane>methacryloxypropyltri(2-methoxyethoxy)silane.
20

[0059] Other representative silane coupling agents include oligomeric aminoalkylsilanes
having, as a base resin-reactive group, two or more repeating aminoalkyl or alkylamino groups
bonded in succession. An example of an oligomeric aminoalkylsilane is the solution Silane
A1106, available under the trade name Silquest (GE Silicones-OSi Specialties, Wilton, CT,
USA), which is believed to have the general formula (NH2CH2CH2SiO1.5),,, wherein n is
from 1 to about 3. Modified aminosilanes such as a triaminosilane solution (e.g., Silane A1128,
available under the same trade name and from the same supplier) may also be employed.
[0060] Other representative silane coupling agents are the ureido substituted and amino
substituted silanes as described above. Specific examples of these are
ureidopropyltrimethoxysilane, ureidopropyltriethoxysilane, aminopropyltrimethoxysilane, and
aminopropyltriethoxysilane.
[0061] Polysiloxanes and polysiloxane derivatives may also be used as coupling agents, as
described above, to enhance the performance of the modified base resin in solid/liquid
separations. Polysiloxane derivatives include those polyorganosiloxanes obtained from the
blending of organic resins with polysiloxane resins to incorporate various functionalities therein,
including urethane, acrylate, epoxy, vinyl, and alkyl functionalities.
[0062] Silica and/or silicates may be used in conjunction (e.g., added as a blending
component) with the modified resin of the present invention to potentially improve its affinity
for either gangue impurities or desired materials (e.g., kaolin clay), especially siliceous materials
including sand and clay. Other agents that may be used to improve the performance of modified
resins in the separation processes of the present invention include polysaccharides, polyvinyl
alcohol, polyacrylamide, as well as known flocculants (e.g., alginates). These agents can
likewise be used with modified urea-formaldehyde resins wherein, as described above, at least a
portion of the urea is replaced with ammonia or an amine as described above (e.g., primary
alkylamines, alkanolamines, polyamines, etc.). Otherwise, such agents can also be used with the
modified resins, which are further modified with anionic functional groups (e.g., sulfonate) or
stabilized by reaction with an alcohol (e.g., methanol), as described below.
[0063] Silica in the form of an aqueous silica sol, for example, is available from Akzo Nobel
under the Registered Trademark "Bindzil" or from DuPont under the Registered Trademark
"Ludox". Other grades of sol are available having various particle sizes of colloidal silica and
containing various stabilizers. The sol can be stabilized by alkali, for example sodium,
21

potassium, or lithium hydroxide or quaternary ammonium hydroxide, or by a water-soluble
organic amine such as alkanolamine.
[0064] Silicates, such as alkali and alkaline earth metal silicates {e.g., lithium silicate, sodium-
lithium silicate, potassium silicate, magnesium silicate, and calcium silicate), as well as
ammonium silicate or a quaternary ammonium silicate, may also be used in the preparation of a
modified resin. Additionally, stabilized colloidal silica-silicate blends or mixtures, as described
in U.S. Patent No. 4,902,442, are applicable.
[0065] In the separation processes of the present invention, particularly good performance has
been found when preparing the modified resin using an amount of coupling agent representing
from about 0.01% to about 5% of the weight of a solution or dispersion of the base resin, having
a solids content from about 30% to about 90%, typically from about 45% to about 70%. In
general, lower amounts of coupling agent addition do not achieve appreciable modification of
the base resin, while higher amounts do not improve performance enough to justify the cost of
the added coupling agent. When a mixture of coupling agents is used, the total weight of the
mixture is normally within this range. An especially desired amount of added coupling agent is
from about 0.1% to about 2.5% of the weight of a base resin solution or dispersion having a
. solids content within the range given above.
[0066] Alternatively, regardless of the solids content of the base resin solution or dispersion,
the coupling agent is generally employed in an amount from about 0.01% to about 17%, and
typically from about 0.1% to about 8.3%, of the weight of the base resin solids. These
representative ranges of added coupling agent, based on the weight of the base resin itself, apply
not only to resin solutions or dispersions, but also to "neat" forms of the modified base resin
having little or no added solvent or dispersing agent (e.g., water). These ranges also generally
apply when the basis is the combined weight of amine and aldehyde, as described previously,
that is reacted to form the base resin. Generally, at least about 90% by weight, and typically at
least about 95% by weight, of these amine and aldehyde components are reacted, in order to
reduce the amounts of free, unreacted amine and aldehyde components, thereby more efficiently
utilizing them in the production of the base resin polymer, and minimizing any deleterious
effects (e.g., vaporization into the environment) associated with these components in their free
form. As described previously, the modified resin may also be prepared by adding the coupling
agent to the reaction mixture of amine and aldehyde used to form the base resin. The optimal
22

amount of coupling agent is dependent on a number of factors, including the base resin solids
content, the type of base resin and the particular coupling agent, the purity of the raw ore slurry
to be beneficiated or liquid suspension to be purified, etc.
[0067] Modified amine-aldehyde resins for use in separation processes of the present
invention generally contain from about 40% to about 100% resin solids or non-volatiles, and
typically 55% to 75% non-volatiles. The non-volatiles content is measured by the weight loss
upon heating a small {e.g., 1-5 gram), sample of the composition at about 105°C for about 3
hours. When an essentially "neat" form of the modified resin, having few or no volatile
components, is employed, the pure resin may be added (e.g., as a viscous liquid, a gel, or a solid
form, such as a powder), to the froth flotation slurry or liquid dispersion to be purified, such that
an aqueous resin solution or dispersion is formed in situ. Neat forms of the modified amine-
aldehyde resins may be obtained from solutions or dispersions of these resins using conventional
drying techniques, for example spray drying.
[0068] Aqueous solutions or dispersions of the modified resins of the present invention will
generally be a clear liquid or a liquid having a white or yellow appearance. They will typically
have a Brookfield viscosity from about 75 to about 500 cps and a pH from about 6.5 to about
9.5. The free formaldehyde content and free urea content of urea-formaldehyde resin solutions
typically are each below 5%, and usually are each below 3%, and often are each below 1%. A
low content of formaldehyde is generally achieved due to health concerns associated with
exposure to formaldehyde emissions. If desired, conventional "formaldehyde scavengers" that
are known to react with free formaldehyde may be added to reduce the level of formaldehyde in
solution. Low amounts of free urea are also desirable, but for different reasons. Without being
bound by theory, while free urea may itself become modified by a coupling agent (e.g., it may
react with a substituted silane to improve its affinity for siliceous materials), free urea is not
believed to have the requisite molecular weight, (1) in froth flotation separations, to "blind"
either the gangue impurities or desired materials (e.g., kaolin clay) to their interaction with rising
air bubbles, (2) in the purification of liquid dispersions, to agglomerate a sufficiently large
number of solid contaminant particles into floes, or (3) in the removal of ionic species from
aqueous solutions, to bind these species to a molecule of sufficient size for retention by
filtration. In particular, it has been found that resin polymers having a number average
23

molecular weight of greater than about 300 grams/mole exhibit the mass needed to promote
efficient separations.
Froth Flotation
[0069] When used as depressants in froth flotation separations, modified resins of the present
invention, due to their high selectivity, provide good results at economical addition levels. For
example, when used as depressants in ore beneficiation, the modified resins are added in an
amount from about 100 to about 1000 grams, and typically from about 400 to about 600 grams,
based on resin solution or dispersion weight, per metric ton of material {e.g., clay-containing
ore) that is to be purified by froth flotation. In general, the optimal addition amount for a
particular separation can be readily ascertained by those of skill in the art and depends on
number of factors, including the type and amount of impurities.
[0070] Modified resins of the present invention can be applied in the froth flotation of a wide
variety of value materials (e.g., minerals or metals such as phosphates, potash, lime, sulfates,
gypsum, iron, platinum, gold, palladium, titanium, molybdenum, copper, uranium, chromium,
tungsten, manganese, magnesium, lead, zinc, clay, coal, and silver or high molecular weight
hydrocarbons such as bitumen). Often, the raw material to be purified and recovered contains
sand or clay, for which the modified resin depressants described herein are especially selective
[0071] Although clay is often considered an impurity in conventional metal or mineral ore
beneficiation, it may also be present in relatively large quantities, as the main component to be
recovered. Some clays, for example kaolin clay, are valuable minerals in a number of
applications, such as mineral fillers in the manufacture of paper and rubber. Thus, one froth
flotation process in which the modified resin of the present invention is employed involves the
separation of clay from a clay-containing ore. The impurities in such ores are generally metals
and their oxides, such as iron oxide and titanium dioxide, which are preferentially floated via
froth flotation. Other impurities of clay-containing ores include coal. Impurities originally
present in most Georgia kaolin, which are preferentially floated in the purification method of the
present invention, include iron-bearing titania and various minerals such as mica, ilmenite, or
tourmaline, which are generally also iron-containing.
[0072] Thus, the clay, which selectively associates with the modified resin of the present
invention, is separately recoverable from metals, metal oxides, and coal. In the purification of
24

clay, it is often advantageous to employ, in conjunction with the modified resin of the present
invention as a depressant, an anionic collector such as oleic acid, a flocculant such as
polyacrylamide, a clay dispersant such as a fatty acid or a rosin acid, and/or oils to control
frothing.
[0073] Other representative froth flotation processes of the present invention involve the
beneficiation of phosphate or potash, as well as other value metals and minerals discussed
above, in which the removal of siliceous gangue materials and other impurities is an important
factor in achieving favorable process economics. Potassium ores, for example, generally
comprise a mixture of minerals in addition to sylvite (KC1), which is desirably recovered in the
froth concentrate. These include halite (NaCl), clay, and carbonate minerals which are non-
soluble in water, such as aluminum silicates, calcite, dolomite, and anhydrite.
[0074] One approach, particularly in the refining of clay-containing ores, involves the further
modification of the base resin with an anionic functional group, as described in greater detail
below.
[0075] The modified resin of the present invention is also advantageously employed in the
separation of bitumen from sand and/or clay that are co-extracted from natural oil sand deposits.
Bitumen/sand mixtures that are removed from oil or tar sands within several hundred feet of the
earth's surface are generally first mixed with warm or hot water to create an aqueous slurry of
the oil sand, having a reduced viscosity that facilitates its transport (e.g., by pipeline) to
processing facilities. Steam and/or caustic solution may also be injected to condition the slurry
for froth flotation, as well as any number of other purification steps, described below. Aeration
of the bitumen-containing slurry, comprising sand or clay, results in the selective flotation of the
bitumen, which allows for its recovery as a purified product. This aeration may be effected by
merely agitating the slurry to release air bubbles and/or introducing a source of air into the
bottom of the separation cell. The optimal amount of air needed to float the desired bitumen,
without entraining excessive solid contaminants, is readily determined by one of ordinary skill
in the art.
[0076] Thus, the use of the modified resin depressant of the present invention advantageously
promotes the retention of the sand and/or clay impurities in an aqueous fraction, which is
removed from the bottom section of the froth flotation vessel. This bottoms fraction is enriched
(i.e., has a higher concentration of) the sand and/or clay impurities, relative to the initial bitumen
25

slurry. The overall purification of bitumen may rely on two or more stages of flotation
separation. For example, the middle section of a primary flotation separation vessel may contain
a significant amount of bitumen that can ultimately be recovered in a secondary flotation of this
"middlings" fraction.
[0077] Generally, in any froth flotation process according to the present invention, at least
70% of the value material (e.g., kaolin clay, phosphate, or bitumen) is recovered from the raw
material (e.g., the clay-containing ore), with a purity of at least 85% by weight. Also,
conventional known collectors may be used in conjunction with modified resins of the present
invention, when used as depressants. These collectors include, for example, fatty acids (e.g.,
oleic acid, sodium oleate, hydrocarbon oils), amines (e.g., dodecylamine, octadecylamine, a-
aminoarylphosphonic acid, and sodium sarcosinate), and xanthanate. Likewise, conventional
depressants known in the art can also be combined with the modified resin depressants.
Conventional depressants include guar gum and other hydrocolloidal polysaccharides, sodium
hexametaphosphate, etc. Conventional frothing agents that aid collection, (e.g.,
methylisobutylcarbinol, pine oil, and polypropylene oxides) may also be used, in accordance
with normal flotation practice, in conjunction with the modified resin depressants of the present
invention.
[0078] In froth flotation separations, the pH of the slurry to which the modified resins of the
present invention, when used as depressants, are added will vary according to the particular
material to be processed, as is appreciated by those skilled in the art. Commonly, the pH values
range from neutral (pH 7) to strongly alkaline (e.g., pH 12). It is recognized that in some
flotation systems, for example in copper sulfide flotations, high pH values (e.g., from about 8 to
about 12.5) give best results.
[0079] Typically in froth flotation for the beneficiation of solid materials such as mineral or
metal ores, the raw materials to be subjected to beneficiation are usually first ground to the
"liberation mesh" size where most of the value material-containing particles are either separate
mineral or metal particles or salt crystals, and the gangue (e.g., clay and/or sand) is mixed
between these particles. The solid material may be ground to produce, for example, one-eighth
inch average diameter particles prior to incorporation of the material into a brine solution to
yield an aqueous slurry. After crushing and slurrying the material, the slurry may be agitated or
stirred in a "scrubbing" process that breaks down clay into very fine particles that remain in the
26

brine as a muddy suspension. Some of this clay may be washed off the ore particles, into a clay-
containing aqueous suspension or brine, prior to froth flotation. Also, as is known in the art, any
conventional preconditioning steps including further crushing/screening, cycloning, and/or
hydro separation steps, may be employed, respectively, to further reduce/classify raw material
particle size, remove clay-containing brine, and/or recover smaller solid particles from the
muddy brine, prior to froth flotation.
[0080] Before or during froth flotation, the modified resin of the present invention, to be used
as a depressant, is added to the aqueous slurry, normally in a manner such that the depressant is
readily dispersed throughout. As stated above, conventional collectors may also be used to aid
in the flotation of the desired value materials. In the froth flotation process, the slurry, typically
having a solids content from about 10 to about 50% by weight, is transferred to one or more
froth flotation cells. Air is forced through the bottoms of these cells and a relatively
hydrophobic fraction of the material, having a selective affinity for the rising bubbles, floats to
the surface (i.e., the froth), where it is skimmed off and recovered. A bottoms product that is
hydrophilic relative to the froth concentrate may also be recovered. The process may be
accompanied by agitation. Commercially salable products can be prepared from the separate
fractions recovered in this manner, often after further conventional steps, including separation
(e.g., by centrifuge), drying (e.g., in a gas fired kiln), size classification (e.g., screening), and
refining (e.g., crystallization), are employed.
[0081] The froth flotation of the present invention may, though not always, involve flotation
in "rougher cells" followed by one or more "cleanings" of the rougher concentrate. Two or
more flotation steps may also be employed to first recover a bulk value material comprising
more than one component, followed by a selective flotation to separate these components.
Modified resins of the present invention, when used as depressants, can be used to advantage in
any of these steps to improve the selective recovery of desired materials via froth flotation.
When multiple stages of froth flotation are used, the modified resins may be added using a
single addition prior to multiple flotations or they may be added separately at each flotation
stage.
Other Separations
[0082] Because of their affinity for solid contaminants in liquid suspensions, the modified
resins of the present invention are applicable in a wide variety of separations, and especially
27

those involving the removal of siliceous contaminants such as sand and/or clay from aqueous
liquid suspensions or slurries of these contaminants. Such aqueous suspensions or slurries may
therefore be treated with modified resins of the present invention, allowing for the separation of
at least a portion of the contaminants, in a contaminant-rich fraction, from a purified liquid. A
"contaminant-rich" fraction refers to a part of the liquid suspension or slurry that is enriched in
solid contaminants (i.e., contains a higher percentage of solid contaminants than originally
present in the liquid suspension or slurry). Conversely, the purified liquid has a lower
percentage of solid contaminants than originally present in the liquid suspension or slurry.
[0083] The separation processes described herein are applicable to "suspensions" as well as to
"slurries" of solid particles. These terms are sometimes defined equivalently and sometimes are
distinguished based on the need for the input of at least some agitation or energy to maintain
homogeneity in the case of a "slurry." Because the methods of the present invention, described
herein, are applicable broadly to the separation of solid particles from aqueous media, the term
"suspension" is interchangeable with "slurry" (and vice versa) in the present specification and
appended claims.
[0084] The treatment step may involve adding a sufficient amount of the modified resin to
electronically interact with and either coagulate or flocculate the solid contaminants into larger
agglomerates. The necessary amount can be readily determined depending on a number of
variables (e.g., the type and concentration of contaminant), as is readily appreciated by those
having skill in the art. In other embodiments, the treatment may involve contacting the liquid
suspension continuously with a fixed bed of the modified resin, in solid form.
[0085] During or after the treatment of a liquid suspension with the modified resin, the
coagulated or flocculated solid contaminant (which may now be, for example, in the form of
larger, agglomerated particles or floes) is removed. Removal may be effected by flotation (with
or without the use of rising air bubbles as described previously with respect to froth flotation) or
sedimentation. The optimal approach for removal will depend on the relative density of the
floes and other factors. Increasing the quantity of modified resin that is used to treat the
suspension can in some cases increase the tendency of the floes to float rather than settle.
Filtration or straining may also be an effective means of removing the agglomerated floes of
solid particulates, regardless of whether they reside in a surface layer or in a sediment.
28

[0086] Examples of liquid suspensions that may be purified according to the present invention
include oil and gas well drilling fluids, which accumulate solid particles of rock (or drill
cuttings) in the normal course of their use. These drilling fluids (often referred to as "drilling
muds") are important in the drilling process for several reasons, including transporting these
drill cuttings from the drilling area to the surface, where their removal allows the drilling mud to
be recirculated. The addition of modified resins of the present invention to oil well drilling
fluids, and especially water-based (i.e., aqueous) drilling fluids, effectively coagulates or
flocculates solid particle contaminants into larger clumps (or floes), thereby facilitating their
separation by settling or flotation. The modified resins of the present invention may be used in
conjunction with known flocculants for this application such as polyacrylamides or
hydrocolloidal polysaccharides. Generally, in the case of suspensions of water-based oil or gas
well drilling fluids, the separation of the solid contaminants is sufficient to provide a purified
drilling fluid for reuse in drilling operations.
[0087] Other aqueous suspensions of practical interest include the clay-containing aqueous
suspensions or brines, which accompany ore refinement processes, including those described
above. The production of purified phosphate from mined calcium phosphate rock, for example,
generally relies on multiple separations of solid particulates from aqueous media, whereby such
separations can be improved using the modified resin of the present invention. In the overall
process, calcium phosphate is mined from deposits at an average depth of about 25 feet below
ground level. The phosphate rock is initially recovered in a matrix containing sand and clay
impurities. The matrix is first mixed with water to form a slurry, which, typically after
mechanical agitation, is screened to retain phosphate pebbles and to allow fine clay particles to
pass through as a clay slurry effluent with large amounts of water.
[0088] These clay-containing effluents generally have high flow rates and typically carry less
than 10% solids by weight and more often contain only from about 1% to about 5% solids by
weight. The dewatering (e.g., by settling or filtration) of this waste clay, which allows for
recycle of the water, poses a significant challenge for reclamation. The time required to dewater
the clay, however, can be decreased through treatment of the clay slurry effluent, obtained in the
production of phosphate, with the modified resin of the present invention. Reduction in the clay
settling time allows for efficient re-use of the purified water, obtained from clay dewatering, in
the phosphate production operation. In one embodiment of the purification method, wherein the
29

liquid suspension is a clay-containing effluent slurry from a phosphate production facility, the
purified liquid contains less than about 1% solids by weight after a settling or dewatering time of
less than about 1 month.
[0089] In addition to the phosphate pebbles that are retained by screening and the clay slurry
effluent described above, a mixture of sand and finer particles of phosphate is also obtained in
the initial processing of the mined phosphate matrix. The sand and phosphate in this stream are
separated by froth flotation which, as described earlier, can be improved using the modified
resin of-ihe present invention as a depressant for the sand.
[0090] In the area of slurry dewatering, another specific application of the modified resin is in
the filtration of coal from water-containing slurries. The dewatering of coal is important
commercially, since the BTU value and hence the quality of the coal decreases with increasing
water content. In one embodiment of the invention, therefore, the modified resin is used to treat
an aqueous coal-containing suspension or slurry prior to dewatering the coal by filtration.
[0091] Another significant application of the modified resin of the present invention is in the
area of sewage treatment, which refers to various processes that are undertaken to remove
contaminants from industrial and municipal waste water. Such processes thereby purify sewage
to provide both purified water that is suitable for disposal into the environment {e.g., rivers,
streams, and oceans) as well as a sludge. Sewage refers to any type of water-containing wastes
which are normally collected in sewer systems and conveyed to treatment facilities. Sewage
therefore includes municipal wastes from toilets (sometimes referred to as "foul waste") and
basins, baths, showers, and kitchens (sometimes referred to as "sullage water"). Sewage also
includes industrial and commercial waste water, (sometimes referred to as "trade waste"), as
well as stormwater runoff from hard-standing areas such as roofs and streets.
[0092] The conventional treatment of sewage often involves preliminary, primary, and
secondary treatment steps. Preliminary treatment refers to the filtration or screening of large
solids such as wood, paper, rags, etc., as well as coarse sand and grit, which would normally
damage pumps. The subsequent primary treatment is then employed to separate most of the
remaining solids by settling in large tanks, where a solids-rich sludge is recovered from the
bottom of these tanks and treated further. A purified water is also recovered and normally
subjected to secondary treatment by biological processes.
30

[0093] Thus, in one embodiment of the present invention, the settling or sedimentation of
sewage water may comprise treating the sewage with the modified resin of the present invention.
This treatment may be used to improve settling operation (either batch or continuous), for
example, by decreasing the residence time required to effect a given separation (e.g., based on
the purity of the purified water and/or the percent recovery of solids in the sludge). Otherwise,
the improvement may be manifested in the generation of a higher purity of the purified water
and/or a higher recovery of solids in the sludge, for a given settling time.
[0094] - After treatment of sewage with the modified resin of the present invention and
removing a purified water stream by sedimentation, it is also possible for the modified resin to
be subsequently used for, or introduced into, secondary treatment processes to further purify the
water. Secondary treatment normally relies on the action of naturally occurring microorganisms
to break down organic material. In particular, aerobic biological processes substantially degrade
the biological content of the purified water recovered from primary treatment. The
microorganisms (e.g., bacteria and protozoa) consume biodegradable soluble organic
contaminants (e.g., sugars, fats, and other organic molecules) and bind much of the less soluble
fractions into floes, thereby further facilitating the removal of organic material.
[0095] Secondary treatment relies on "feeding" the aerobic microorganisms oxygen and other
nutrients which allow them to survive and consume organic contaminants. Advantageously, the
modified resin of the present invention, which contains nitrogen, can serve as a "food" source
for microorganisms involved in secondary treatment, as well as potentially an additional
flocculant for organic materials. In one embodiment of the invention, therefore, the sewage
purification method further comprises, after removing purified water (in the primary treatment
step) by sedimentation, further treating the purified water in the presence of microorganisms and
the modified resin, and optionally with an additional amount of modified resin, to reduce the
biochemical oxygen demand (BOD) of the purified water. As is understood in the art, the BOD
is an important measure of water quality and represents the oxygen needed, in mg/1 (or ppm by
weight) by microorganisms to oxidize organic impurities over 5 days. The BOD of the purified
water after treatment with microorganisms and the modified resin, is generally less than 10 ppm,
typically less than 5 ppm, and often less than 1 ppm.
[0096] The modified resin of the present invention may also be applied to the purification of
pulp and paper mill effluents. These aqueous waste streams normally contain solid
31

contaminants in the form of cellulosic materials (e.g., waste paper; bark or other wood elements,
such as wood flakes, wood strands, wood fibers, or wood particles; or plant fibers such as wheat
straw fibers, rice fibers, switchgrass fibers, soybean stalk fibers, bagasse fibers, or cornstalk
fibers; and mixtures of these contaminants). In accordance with the method of the present
invention, the effluent stream comprising a cellulosic solid contaminant is treated with the
modified resin of the present invention, such that purified water may be removed via
sedimentation, flotation, or filtration.
[0097] In the separation of bitumen from sand and/or clay impurities as described previously,
various separation steps may be employed either before or after froth flotation of the bitumen-
containing slurry. These steps can include screening, filtration, and sedimentation, any of which
may benefit from treatment of the oil sand slurry with the modified resin of the present
invention, followed by removal of a portion of the sand and/or clay contaminants in a
contaminant-rich fraction {e.g., a bottoms fraction) or by removal of a purified bitumen fraction.
As described above with respect to phosphate ore processing water effluents, which generally
contain solid clay particles, the treating step can comprise flocculating these contaminants to
facilitate their removal {e.g., by filtration). Waste water effluents from bitumen processing
facilities will likewise contain sand and/or clay impurities and therefore benefit from treatment
with the modified resin of the present invention to dewater them and/or remove at least a portion
of these solid impurities in a contaminant-rich faction. A particular process stream of interest
that is generated during bitumen extraction is known as the "mature fine tails," which is an
aqueous suspension of fine solid particulates that can benefit from dewatering. Generally, in the
case of sand and/or clay containing suspensions from a bitumen production facility, separation
of the solid contaminants is sufficient to allow the recovery or removal of a purified liquid or
water stream that can be recycled to the bitumen process.
[0098] The treatment of various intermediate streams and effluents in bitumen production
processes with the modified resin of the present invention is not limited only to those processes
that rely at least partly on froth flotation of an aqueous bitumen-containing slurry. As is readily
appreciated by those of skill in the art, other techniques (e.g., centrifugation via the "Syncrude
Process") for bitumen purification will generate aqueous intermediate and byproduct streams
from which solid contaminant removal is desirable.
32

[0099] The modified resins of the present invention can be employed in the removal of
suspended solid particulates, such as sand and clay, in the purification of water, and particularly
for the purpose of rendering it potable.
[00100] Moreover, modified resins of the present invention have the additional ability to
complex metallic cations (e.g., lead and mercury cations) allowing these unwanted contaminants
to be removed in conjunction with solid particulates. Therefore, modified resins of the present
invention can be used to effectively treat impure water having both solid particulate
contaminants as well as metallic cation contaminants. Without being bound by theory, it is
believed that electronegative moieties, such as the carbonyl oxygen atom on the urea-
formaldehyde resin polymer backbone, complex with undesired cations to facilitate their
removal. Generally, this complexation occurs at a pH of the water that is greater than about 5
and typically in the range from about 7 to about 9.
[00101] Another possible mechanism for the removal of metallic cations is based on their
association with negatively charged solid particulates. Flocculation and removal of these
particulates will therefore also cause, at least to some extent, the removal of metallic cations.
Regardless of the mechanism, in one embodiment, the treatment and removal of both of these
contaminants can be carried out according to the present invention to yield potable water.
[00102] The removal of metallic cations may represent the predominant or even the sole
means of water purification that is effected by the modified resin, for example when the water to
be purified contains little or no solid particulates. Solid forms of the modified resin may be used
to remove cations in a continuous process whereby the impure water containing metallic cations
is continuously passed through a fixed bed of the resin. Alternatively, soluble forms of the
modified resin, generally having a lower molecular weight, may be added to the impure water in
order to treat it. The complexed cations in this case can be removed, for example, by
ultrafiltration through a porous membrane (e.g., polysulfone) having a molecular weight cutoff
that is less than the molecular weight of the modified resin. The water purification methods
described herein may also be used in conjunction with known methods including reverse
osmosis, UV irradiation, etc.
[00103] To increase the effectiveness of the modified resins in complexing with metallic
cations, it may be desirable to further modify the base resin as described above with one or more
anionic functional groups. Such modifications are known in the art and can involve the reaction
33

of the base resin or modified resin to incorporate the desired functional group (e.g., by
sulfonation with sodium metabisulfite). Alternatively, the further modification is achieved
during preparation of the base resin (e.g., during condensation) by incorporating an anionic co-
monomer, such as sodium acrylate, either into the base resin or into the coupling agent. For
example, as described above, organopolysiloxane derivatives used as coupling agents may be
prepared by incorporating further organic resin. functionalities, such as acrylate, into the
coupling agent. Representative additional functionalities with which the base resin or modified
resin, including a urea-formaldehyde resin, may be modified include the anionic functional
groups bisulfite, acrylate, acetate, carbonate, azide, amide, etc. Procedures for modifying the
base resin with additional functionalities are known to those having skill in the art. The
incorporation of anionic functional groups into the base resin may also be employed in
separations involving the purification of slurries containing solid clay particles (e.g., by froth
flotation, flocculation, etc), including those described above, such as in the purification of
kaolin clay ore. Without being bound by theory, sulfonation of the base resin or the
incorporation of other anionic functional groups can also increase hydrogen bonding between
the base resin and the surrounding aqueous phase to inhibit condensation of the base resin or
otherwise improve its stability.
[00104] As described above, therefore, the present invention, in one embodiment, is a method
for purifying water containing a metallic cation by treating the water with a modified resin as
described herein and which may be further modified with an anionic group. Removal of at least
a portion of the metallic cations may be effected by retaining them on a fixed bed of the
modified resin or otherwise by filtering them out. In the latter case, removal by filtration such as
membrane filtration is made possible by the'association of the metallic cations either directly
with the modified resin or indirectly with the modified resin via solid particulates, for which the
modified resin has affinity. In the case of indirect association, as described earlier, flocculation
of the solid particulates will also necessarily agglomerate at least a portion of the metallic
cations, which may therefore be removed by flotation or sedimentation of these particulates.
[00105] The modified resin of the present invention is therefore, advantageously used to treat
water for the removal of metallic cations such as arsenic, lead, cadmium, copper, and mercury
that are known to pose health risks when ingested. These cations thus include As+5, Pb+2, Cd+2,
Cu+2, Hg+2, and mixtures thereof. Generally, a degree of removal is effected such that the
34

purified water, after treatment, is essentially free of one or more of the above metallic cations.
By "essentially free" is meant that the concentration(s) of one or more metallic cation(s) of
interest is/are reduced to concentration(s) at or below those considered safe (e.g., by a regulatory
agency such as the U.S. Environmental Protection Agency). Therefore, in various representative
embodiments, the purified water will contain at most about 10 ppb of As+5, at most about 15 ppb
of Pb+2, at most about 5 ppb of Cd+2, at most about 1.3 ppm of Cu+2, and/or at most about 2 ppb
of Hg+2. That is, generally at least one, typically at least two, and often all, of the above-
mentioned cations are at or below these threshold concentration levels in the purified water.
[00106] In any of the applications described herein, it is possible to stabilize the modified
resin of the present invention by reaction with an alcohol (i.e., etherification). Without being
bound by theory, it is believed that etherification of pendant alkylol functionalities can inhibit
further condensation of the base resin (e.g., condensation of a urea-formaldehyde resin with
itself). This can ultimately hinder or prevent the precipitation of the base resin during long term
storage, such that, relative to their corresponding non-etherified resins, the etherified resins can
have increased molecular weight without an accompanying loss in stability
[00107] Etherification thus involves reacting the amine-aldehyde adducts or condensates, or
even the modified resins, as described above, with an alcohol. In one embodiment, a urea-
formaldehyde base resin is etherified with an alcohol having from 1 to 8 carbon atoms, prior its
modification with a coupling agent. Representative alcohols for use in the etherification include
methanol (e.g., to effect methylation), ethanol, n-propanol, isopropanol, n-butanol, and
isobutanol. In exemplary preparations of etherified base resins, the amine-aldehyde adduct or
condensate reaction product is heated to a temperature from about 70°C to about 120°C in the
presence of an alcohol until the etherification is complete. An acid such as sulfuric acid,
phosphoric acid, formic acid, acetic acid, nitric acid, alum, iron chloride, and other acids may be
added before or during the reaction with alcohol. Often, sulfuric acid or phosphoric acid is
employed.
[00108] All references cited hi this specification, including without limitation, all U.S.,
international, and foreign patents and patent applications, as well as all abstracts and papers
(e.g., journal articles, periodicals, etc.), are hereby incorporated by reference into this
specification in their entireties. The discussion of the references herein is intended merely to
summarize the assertions made by their authors and no admission is made that any reference
35

constitutes prior art. Applicants reserve fee right to challenge the accuracy and pertinence of the
cited references. In view of the above, it will be seen that several advantages of the invention
are achieved and other advantageous results obtained.
[00109] As various changes could be made in the above methods and compositions without
departing from the scope of the invention, it is intended that all matter contained in this
application, including all theoretical mechanisms and/or modes of interaction described above,
shall be interpreted as illustrative only and not limiting in any way the scope of the appended
claims.
[00110] The following examples are set forth as representative of the present invention.
These examples are not to be construed as limiting the scope of the invention as these and other
equivalent embodiments will be apparent in view of the present disclosure and appended claims.
Froth Flotation
EXAMPLE 1
[00111] Various urea-formaldehyde resins were prepared as low molecular weight condensate
resins, initially under alkaline conditions to form methylolated urea adducts, and then under
acidic conditions to form the condensate. The condensation reaction was stopped by raising the
pH of the condensation reaction mixture. Other preparation conditions were as described above.
These base resins are identified in Table 1 below with respect to their molecular weight (Mol.
Wt.) in grams/mole and their approximate normalized weight percentages of free urea, cyclic
urea species (cyclic urea), mono-methylolated urea (Mono), and combined di-/tri-methylolated
urea (Di/Tri). In each case, the base resins were in a solution having a resin solids content of 45-
70%, a viscosity of 500 cps or less, and a free formaldehyde content of less than 5% by weight.
36

Table 1—Urea-Formaldehyde Base Resins
ID Mol. Wt.a Free Urea Cyclic Urea Mono Di/Tri
Resin A 406 8 39 30 23
Resin B* 997 5 50 22 23
Resin C and C'** 500 6 46 25 23
Resin D and D'*** 131 43 21 30 6
Resin E 578 0 18 10 72
Resin F 1158 1 44 11 44
Resin G 619 0 26 3 71
* Resin B is a very stable urea-formaldehyde resin, having a high cyclic urea content. This
resin is described in U.S. Patent No. 6,114,491.
** Resin C was formed by adding, in addition to Silane #1 (described below), 2% by weight of
diethylenetriamine and 2% by weight dicyandiamide to the mixture of urea and
formaldehyde during resin preparation.
***Resin D' was formed by adding 0.75% by weight cyclic phosphate ester to the mixture of
urea and formaldehyde during resin preparation. The resin was a low molecular weight
formulation with a high content of free urea, essentially no free formaldehyde, and a high
content of non-volatiles (about 70% solids).
Number average molecular weight determined using gel permeation chromatography (GPC)
with appropriately sized PLgel™ columns (Polymer Laboratories, Inc., Amherst, MA,
USA), 0.5% glacial acetic acid/tetrahydrofuran mobile phase at 1500 psi, and polystyrene,
phenol, and bisphenol-A calibration standards.
[00112] The urea-formaldehyde resin solutions described above were modified by silane
coupling agents, in order to prepare resin depressants of the present invention. Silane coupling
agents #1, #2, and #3, all substituted silanes as identified in Table 2 below, were used in these
modified resin preparations.
Table 2—Silane Coupling Agents
ED Type Source
37

Silane #1 Ureidopropyltrimethoxysilane Silane Al 160*
Si1ane#2 Oligomeric aminoalkylsilane Silane Al 106*
Silane #3 Aminopropyltriethoxysilane Silane A1100*
r Available under the trade name Silquest (GE Silicones-OSi Specialties, Wilton, CT, USA)
EXAMPLE 2
[00113] The above urea-formaldehyde base resins described in Table 1 were modified by the
silane coupling agents #1, #2, and #3, as described in Table 2, according to procedures described
previously. Namely, the silane coupling agent was added to the base resin solution in an amount
of about 0.1-2.5% based on the weight of the resin solution, after formation of a low molecular
weight condensate and the subsequent addition of a base to increase the solution pH and halt the
condensation reactions, as described above. The alkaline mixture of the base resin and silane
coupling agent was then heated to a temperature of about 35-45°C for about 0.5-4 hours, until a
viscosity of about 350-450 cps was achieved.
EXAMPLE 3
[00114] Various urea-formaldehyde resin samples, representing both un-modified resins or
resins modified with silane coupling agents as noted above, along with a control depressant,
were tested for their selectivity in removing siliceous sand and clay impurities from potash ore
by froth flotation, in a laboratory-scale beneficiation study. In each test, the amount of
depressant employed per unit weight of ore to be beneficiated, the solids content of the ore
slurry, the pH of the slurry, the volumetric air flow rate per unit volume of the slurry, the
phosphate purity of the ore prior to beneficiation, and other conditions were representative of a
commercial operation. In each test, the ore recovered by flotation was at least 90% by weight
pure phosphate material. A commercially available guar gum was used as a depressant control
sample.
[00115] In these experiments, the performance of each depressant was measured based on the
quantity of potash that could be recovered (i.e., floated) at a specified purity. This quantity
provided the measure of each depressant's selectively in binding to unwanted gangue materials.
In other words, the higher the selectivity of a depressant, the greater the quantity of 90% pure
phosphate that could be floated. The following data was obtained, as shown in Table 3 below.
38

Table 3—Performance of Depressants in Phosphate Recovery
Depressant Grams of >90% Potassium
Floated
Control 1—Guar Gum 212
Resin A, Modified by Silane #1 230
Resin A, Unmodified 85
Resin B, Modified by Silane #1 226
Resin B, Unmodified 97
Resin C, Modified by Silane #1 172
Resin C, Modified by Silane #1 158
Resin D, Modified by Silane #1 82 (avg. of 2 tests)
Resin D', Unmodified 100
Resin E, Modified by Silane #1 215
Resin E, Modified by Silane #2 232 (avg. of 2 tests)
Resin E, Modified by Silane #3 226 (avg. of 2 tests)
Resin F, Modified by Silane #1 229
Resin F, Modified by Silane #2 231
Resin F, Modified by Silane #3 225
Resin G, Modified by Silane #1 223
Resin G, Modified by Silane #2 228
Resin G, Modified by Silane #3 224
[00116] Based on the above results, the use of a silane coupling agent to modify a urea-
formaldehyde base resin, preferably via a covalent link, can dramatically improve the resin
performance as a depressant in froth flotation. Also, the performance advantage associated with
the use of a silane coupling agent becomes more evident as the molecular weight of the base
resin is increased. Especially good performance is obtained for base resins having a molecular
39

weight above about 300 grams/mole, before modification. This is illustrated in Figure 1,
showing the performance of silane coupling agent-modified resins compared to unmodified
resins, for resins having a molecular weight from about 400 to about 1200 grams/mole.
Moreover, the performance of urea-formaldehyde resins within this molecular weight range is
not appreciably affected by the use of additional resin modifiers (e.g., diethylenetriamine,
dicyandiamide, phosphate esters, etc.) of the base resin.
[00117] Figure 1 also illustrates that silane coupling agent-modified resins having a molecular
weight from about 400 to about 1200 grams/mole perform superior to their unmodified
counterpart and generally perform superior to guar gum, which is known in the art to bind clay
and talc, but is considerably more expensive. Furthermore, in contrast to guar gum, the
depressants of the present invention showed substantially higher selectivity for the flotation of
coarse phosphate particles. The comparatively greater amount of fines material in the purified
phosphate that was floated in the test with guar gum would add significantly to the expense
associated with downstream drying and screening operations to yield a salable product.
EXAMPLE 4
[00118] A sample of a modified resin depressant of the present invention was tested for its
performance in a potash beneficiation plant, relative to guar gum, which is currently employed at
the plant as a commercial depressant of gangue materials. The depressant of the present
invention used for this test was Resin F, Modified by Silane #2, as described in Examples 1-3
above.
[00119] For the comparative tests, the amount of depressant employed per unit weight of ore
to be beneficiated, the solids content of the ore slurry, the pH of the slurry, the volumetric air
flow rate per unit volume of the slurry, the potassium mineral purity of the ore prior to
beneficiation, and other conditions were representative of a commercial operation. The
performance of each depressant was measured based on the quantity of phosphate that could be
recovered (i.e., floated) at a specified purity. This quantity provided the measure of each
depressant's selectively in binding to unwanted gangue materials. In other words, the higher the
selectivity of a depressant, the greater the quantity of potash that could be floated at a specified
purity.
40

[00120] Relative to guar gum, the depressant of the present invention provided an increase in
the yield of purified potash of about 19%. Furthermore, the yield of coarse particles of the
desired potash (potassium chloride) mineral was substantially higher using the urea-
formaldehyde resin, modified with a silane coupling agent. For the reasons explained above,
this improvement in the yield of coarse material reduces costs associated with drier energy
requirements and other downstream operations, as well as the overall processing time needed for
further refinement, prior to sale.
EXAMPLE 5
[00121] A urea-formaldehyde (UF) resin, modified with a silane coupling agent as described
above, was tested for its ability to reduce the dewatering time, by filtration, of various solid
contaminants suspended in aqueous slurries. In each experiment, a 25 gram sample of solid
contaminant was uniformly slurried with 100 grams of 0.01 molar KNO3. The pH of the slurry
was measured. The slurry was then subjected to vacuum filtration using a standard 12.7 cm
diameter Buchner funnel apparatus and 11.0 cm diameter Whatman qualitative #1 filter paper.
The dewatering time in each case was the time required to recover 100 ml of filtrate through the
filter paper.
[00122] For each solid contaminant tested, a control experiment as run, followed by an
identical experiment, differing only in (1) the addition of 0.5-1 grams of silane modified UF
resin to the slurry and (2) mixing of the slurry for one additional minute, after a uniform slurry
was obtained upon stirring. Results are shown below in Table 4.
Table 4—Dewatering Time for Aqueous Slurries
(25 grams Solid Contaminant in 100 grams 0.01 M KN03)

Solid Control Control+ 0.5-1 grams
Silane-Modified UF Resin
Geltone* 13.1 seconds 8.2
(slurry pH) (8.1) (8.5)
Bentonite 5.3 2.3
(slurry pH) (8.8) (8.8)
41

Graphite 8.1 5.2
(slurry pH) (4.4) (4.5)
Kaolin(slurry pH) 10.5(3-3) 5.4(3.7)
Talc ( *brand name for montmorillonite clay
[00123] The above results demonstrate the ability of si lane-modified UF resins, even when
used in small quantities, to significantly decrease the dewatering time for a number of solid
particles.
42

WE CLAIM:
1. A method for purifying clay from a clay-containing ore, comprising:
a. providing a clay-containing ore comprising clay and one or more organic or inorganic
impurities;
b. contacting an aqueous slurry of the clay-containing ore with an amine-aldehyde resin
comprising a silane coupling agent, and
c. during or after the contacting step, separating the purified clay from the clay-
containing ore by froth flotation of at least one organic or inorganic impurity.
2. The method of claim 1, wherein the one or more organic or inorganic impurities are
selected from a metal, a metal oxide, a mineral, coal, bitumen, or any combination thereof.
3. The method of claim 1, wherein the clay-containing ore comprises kaolin clay, and
wherein the one or more organic or inorganic impurities are selected from iron oxide, titanium
dioxide, or a combination thereof.
4. A method for purifying bitumen, comprising:
a. providing an aqueous slurry comprising bitumen and one or more soluble or insoluble
impurities;
b. contacting the aqueous slurry with an amine-aldehyde resin comprising a silane
coupling agent, and
c. during or after the treating step, separating the bitumen from the aqueous slurry by
froth flotation;
wherein the froth comprises a lower concentration of at least one or more soluble or
insoluble impurities relative to the aqueous slurry.
5. The method of claim 4, wherein the one or more soluble or insoluble impurities
comprises sand or clay.
6. A method for purifying water, comprising:
43

a. providing an aqueous composition comprising water and one or more soluble or
insoluble impurities;
b. contacting the aqueous composition with an amine-aldehyde resin comprising a silane
coupling agent to form a resin-impurity complex, and
c. during or after the treating step, separating the resin-impurity complex from the
aqueous composition to provide purified water.
7. The method of claim 6, wherein the separating step c) comprises sedimentation, flotation,
filtration, membrane filtration, or any combination thereof.
8. The method of claim 6, wherein the one or more soluble or insoluble impurities is
selected from compounds of As+5, Pb+2, Cd+2, Cu+2, Mn+2, Hg+2, Zn+2, Fe+2, or any combination
thereof.
9. The method of claim 6, wherein the aqueous composition comprising one or more soluble
or insoluble impurities is a water-based oil well drilling fluid, a clay-containing effluent slurry
from a phosphate production facility, a coal-containing suspension, sewage, pulp or paper mill
effluent, a bitumen production process intermediate, or bitumen production process effluent
slurry comprising clay or sand.
10. The method of claim 6, wherein separating the resin-impurity complex from the aqueous
composition comprises removing purified water for reuse in phosphate production.
11. The method of claim 6, wherein the method further comprises step d) of treating the
purified water in the presence of microorganisms and the amine-aldehyde resin to reduce the
biochemical oxygen demand of the purified water.
12. The method of claim 6, wherein the aqueous composition is a water-based oil well
drilling fluid, and wherein separating the resin-impurity complex from the aqueous composition
comprising removing a purified drilling fluid for reuse in oil well drilling.
44

13. The method of claim 6, wherein the aqueous composition is a coal-containing suspension,
and wherein separating the resin-impurity complex from the aqueous composition comprising
removing a coal-rich fraction by filtration.
14. The method of claim 6, wherein the one or more soluble or insoluble impurities is clay,
sand, or a cellulosic material.
15. A method of beneficiation of an ore. comprising
a. providing an ore comprising a value mineral and one or more impurities;
b. treating an aqueous slurry of the ore with an amine-aldehyde resin comprising a
silane coupling agent, and
c. during or after the treating step, separating the value material from the aqueous slurry
by froth flotation.
16. The method of claim 15, wherein the value material is selected from phosphate, potash,
lime, sulfate, gypsum, iron, platinum, gold, palladium, titanium, molybdenum, copper, uranium,
chromium, tungsten, manganese, magnesium, lead, zinc, silver, coal, or any combination thereof.
17. The method of claim 15, wherein the one or more impurities is selected from sand, clay,
an iron oxide, a titanium oxide, iron-bearing titania, mica, ilmenite, tourmaline, an aluminum
silicate, calcite, dolomite, anhydrite, or any combination thereof.
18. The method of claim 15, wherein the amine-aldehyde resin is the reaction product of a
primary amine and formaldehyde.
19. The method of claim 15, wherein the amine-aldehyde resin comprises a solution or a
dispersion having a resin solids content from about 30% to about 90% by weight, and wherein
the silane coupling agent is present in an amount from about 0.01% to about 5% of the weight of
the amine-aldehyde resin solution or dispersion.
45

20. The method of claim 15, wherein the slurry of the ore is treated with the amine-aldehyde
resin in an amount ranging from about 100 to about 1000 grams of the amine-aldehyde resin per
metric ton of the ore.
21. The method of claim 15, wherein the method recovers at least 70% by weight of the
value material from the ore, and wherein the value material has a purity of at least 85% by
weight.
22. The method of claim 15, wherein the amine-aldehyde resin has a solids content from
about 40% to about 100%.
23. The method of claim 15, wherein the amine-aldehyde resin is essentially neat and is a
viscous liquid, a gel, or a solid powder.
24. The method of any one of claims 1-23, wherein the amine-aldehyde resin is the reaction
product of a primary or a secondary amine and an aldehyde, and wherein the silane coupling
agent is selected from a substituted silane, silica, a silicate, a polysiloxane, or any combination
thereof.
25. The method of any one of claims 1-23, wherein the amine-aldehyde resin comprises a ,
urea-formaldehyde resin, and wherein the silane coupling agent comprises a substituted silane.
26. The method of any one of claims 1-23, wherein the amine-aldehyde resin is the reaction
product of an aldehyde and an amine in a molar ratio from about 1.5:1 to about 2.5:1,
respectively.
27. The method of any one of claims 1-23, wherein the amine-aldehyde resin comprises a
urea-formaldehyde resin that is a reaction product of formaldehyde and urea in a molar ratio
from about 1.75:1 to about 3:1, respectively.
46

28. The method of any one of claims 1-23, wherein the silane coupling agent comprises a
ureido substituted silane, an amino substituted silane, a sulfur substituted silane, an epoxy
substituted silane, a methacryl substituted silane, a vinyl substituted silane, an alkyl substituted
silane, a haloalkyl substituted silane, or any combination thereof.
29. The method of any one of claims 1-23, wherein the silane coupling agent is selected from
a ureidoalkyltrialkoxysilane, an aminoalkyltrialkoxysilane, an oligomeric aminoalkylsilane, or
any combination thereof.
30. The method of any one of claims 1-23, wherein the silane coupling agent is selected
fromureidopropyltrimethoxysilane, ureidopropyltriethoxysilane, aminopropyltrimethoxysilane,
aminopropyltriethoxysilane, aminopropylmethyldiethoxysilane,
aminopropylmethyldimethoxysilane, aminoethylaminopropyltrimethoxysilane,
aminoethylaminopropyltriethoxysilane, aminoethylaminopropylmethyldimethoxysilane,
diethylenetriaminopropyltrimethoxysilane, diethylenetriaminopropyltriethoxysilane,
dethylenetriaminopropylmethyldimethoxysilane,
diethylenetriaminopropylmethyldiethoxysilane, cyclohexylaminopropyltrimethoxysilane,
hexanediaminomethyltriethoxysilane, anilinomethyltrimethoxysilane,
anilinomethyltriethoxysilane, diethylaminomethyltriethoxysilane,
(diethylaminomethyl)methyldiethoxysilane, methylaminopropyltrimethoxysilane,
bis(triethoxysilylpropyl)tetrasulfide, bis(triethoxysilylpropyl)disulflde,
mercaptopropyltrimethoxysilane, mercaptopropyltriethoxysilane,
mercaptopropylmethyldimethoxysilane, 3 -thiocyanatopropyltriethoxysilane, isocyanatopropyl
triethylsilane, glycidoxypropyltrimethoxysilane, glycidoxypropyltriethoxysilane,
glycidoxypropylmethyldiethoxysilane, glycidoxypropylmethyldimethoxysilane,
methacryloxypropyltrimethoxysilane, methacryloxypropyltriethoxysilane,
methacryloxypropylmethyldimethoxysilane, chloropropyltrimethoxysilane,
chloropropyltriethoxysilane, chloromethyltriethoxysilane, chloromethyltrimethoxysilane,
dichloromethyltriethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris(2-
methoxyethoxy)silane, vinyltriacetoxysilane, alkylmethyltrimethoxysilane,
vinylbenzylaminotrimethoxysilane, (3,4-epoxycyclohexyl)ethyltrimethoxysilane,
47

aminopropyltriphenoxysilane, aminopropyltribenzoyloxysilane, aminopropyltrifurfuroxysilane,
aminopropyltri(o-chlorophenoxy)silane, aminopropyltri(p-chlorophenoxy)silane,
aminopropyltxi(tetrahydrofurfuroxy)silane, ureidosilane, mercaptoethyltriethoxysilane, and
vinyltrichlorosilane, methacryloxypropyltri(2-methoxyethoxy)silane, or any combination thereof.
31. The method of any one of claims 1 -23, wherein the amine-aldehyde resin further
comprises an anionic functional group.
32. The method of any one of claims 1-23, wherein the amine-aldehyde resin further
comprises a chelating agent.
33. The method of any one of claims 1-23, wherein the amine-aldehyde resin has a free
formaldehyde concentration to less than about 5%.
34. The method of any one of claims 1-23, wherein the amine-aldehyde resin has a number
average molecular weight (Mn) of greater than about 300 grams/mole.
35. The method of any one of claims 1-23, wherein the treating step further comprises
treating with silica, a silicate, a polysiloxane, a polysaccharide, a polyvinyl alcohol, a
polyacrylamide, a flocculant, or any combination thereof.
36. An amine-aldehyde resin comprising a silane coupling agent.
37. The amine-aldehyde resin of claim 36, wherein the amine-aldehyde resin comprises a
urea-formaldehyde resin having a number average molecular weight (Mn) of greater than about
300 grams/mole.
38. The amine-aldehyde resin of claim 36, wherein the amine-aldehyde resin comprises a
urea-formaldehyde resin having a free formaldehyde concentration of less than about 5%.
48

39. The amine-aldehyde resin of claim 36, wherein the amine-aldehyde resin comprises a
urea-formaldehyde resin, and wherein the silane coupling agent comprises a substituted silane.
40. The amine-aldehyde resin of claim 36, wherein the amine-aldehyde resin is the reaction
product of an aldehyde and an amine in a molar ratio from about 1.5:1 to about 2.5:1,
respectively.
41. The amine-aldehyde resin of claim 36, wherein the amine-aldehyde resin comprises a
urea-formaldehyde resin that is a reaction product of formaldehyde and urea in a molar ratio
from about 1.75:1 to about 3:1, respectively.
42. The amine-aldehyde resin of claim 36, wherein the silane coupling agent comprises a
ureido substituted silane, an amino substituted silane, a sulfur substituted silane, an epoxy
substituted silane, a methacryl substituted silane, a vinyl substituted silane, an alkyl substituted
silane, a haloalkyl substituted silane, or any combination thereof.
43. The amine-aldehyde resin of claim 36, wherein the silane coupling agent is selected from
a ureidoalkyltrialkoxysilane, an aminoalkyltrialkoxysilane, an oligomeric aminoalkylsilane, or
any combination thereof.
44. The amine-aldehyde resin of claim 36, wherein the silane coupling agent is selected from
ureidopropyltrimethoxysilane, ureidopropyltriethoxysilane, aminopropyltrimethoxysilane,
aminopropyltriethoxysilane, aminopropylmethyldiethoxysilane,
aminopropylmethyldimethoxysilane, aminoethylaminopropyltrimethoxysilane,
aminoethylaminopropyltriethoxysilane, aminoethylaminopropylmethyldimethoxysilane,
diethylenetriaminopropyltrimethoxysilane, diethylenetriaminopropyltriethoxysilane,
diethylenetriaminopropylmethyldimethoxysilane,
diethylenetriaminopropylmethyldiethoxysilane, cyclohexylaminopropyltrimethoxysilane,
hexanediaminomethyltriethoxysilane, anilinomethyltrimethoxysilane,
anilinomethyltriethoxysilane, diethylaminomethyltriethoxysilane,
(diethylaminomethyl)methyldiethoxysilane, methylaminopropyltrimethoxysilane,
49

bis(triethoxysilylpropyl)tetrasulfide, bis(triethoxysilylpropyl)disulfide,
mercaptopropyltrimethoxysilane, mercaptopropyltriethoxysilane,
mercaptopropylmethyldimethoxysilane, 3 -thiocyanatopropyltriethoxysilane, isocyanatopropyl
triethylsilane, glycidoxypropyltrimethoxysilane, glycidoxypropyltriethoxysilane,
glycidoxypropylmethyldiethoxysilane, glycidoxypropylmethyldimethoxysilane,
methacryloxypropyltrimethoxysilane, methacryloxypropyltriethoxysilane,
methacryloxypropylmethyldimethoxysilane, chloropropyltrimethoxysilane,
chloropropyltriethoxysilane, chloromethyltriethoxysilane, chloromethyltrimethoxysilane,
dichloromethyltriethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilsne, vinyltris(2-
methoxyethoxy)silane, vinyltriacetoxysilane, alkylmethyltrimethoxysilane,
vinylbenzylaminotrimethoxysilane, (3,4-epoxycyclohexyl)ethyltrimethoxysilane,
aminopropyltriphenoxysilane, aminopropyltribenzoyloxysilane, aminopropyltrifurfuroxysilane,
aminopropyltri(o-chlorophenoxy)silane, aminopropyltri(p-chlorophenoxy)silane,
aminopropyltri(tetrahydrofurfuroxy)silane, ureidosilane, mercaptoethyltriethoxysilane, and
vinyltrichlorosilane, methacryloxypropyltri(2-methoxyethoxy)silane, or any combination thereof.


Dated this 9th day of July 2007

50

Modified resins are disclosed for removing a wide variety of solids and/or ionic species from the
liquids in which they are suspended and/or dissolved. These modified resins are especially useful
as froth flotation depressants in the beneficiation of many types of materials (e.g., mineral and
metal ores), including the beneficiation of impure coal comprising clay impurities, as well as in
the separation of valuable bitumen from solid contaminants such as sand. The modified resins
are also useful for treating aqueous liquid suspensions to remove solid particulates, as well as for
removing metallic ions in the purification of water. The modified resins comprise a base resin
that is modified with a coupling agent, which is highly selective for binding to solid
contaminants and especially siliceous materials such as sand or clay.

Documents:

02541-kolnp-2007-abstract.pdf

02541-kolnp-2007-claims 1.0.pdf

02541-kolnp-2007-claims 1.1.pdf

02541-kolnp-2007-correspondence others 1.1.pdf

02541-kolnp-2007-correspondence others 1.2.pdf

02541-kolnp-2007-correspondence others.pdf

02541-kolnp-2007-description complete.pdf

02541-kolnp-2007-drawings.pdf

02541-kolnp-2007-form 1 1.1.pdf

02541-kolnp-2007-form 1.pdf

02541-kolnp-2007-form 2.pdf

02541-kolnp-2007-form 3.pdf

02541-kolnp-2007-form 5.pdf

02541-kolnp-2007-international publication.pdf

02541-kolnp-2007-international search report.pdf

02541-kolnp-2007-pa.pdf

02541-kolnp-2007-pct request form.pdf

02541-kolnp-2007-priority document.pdf

2541-KOLNP-2007-(01-07-2013)-FORM-13.pdf

2541-KOLNP-2007-(10-07-2012)-CORRESPONDENCE.pdf

2541-KOLNP-2007-(16-05-2012)-ABSTRACT.pdf

2541-KOLNP-2007-(16-05-2012)-AMANDED CLAIMS.pdf

2541-KOLNP-2007-(16-05-2012)-ASSIGNMENT.pdf

2541-KOLNP-2007-(16-05-2012)-CERTIFIED COPIES(OTHER COUNTRIES).pdf

2541-KOLNP-2007-(16-05-2012)-DESCRIPTION (COMPLETE).pdf

2541-KOLNP-2007-(16-05-2012)-DRAWINGS.pdf

2541-KOLNP-2007-(16-05-2012)-EXAMINATION REPORT REPLY RECEIVED.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-1.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-13-1.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-13-2.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-13-3.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-13.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-2.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-3.pdf

2541-KOLNP-2007-(16-05-2012)-FORM-5.pdf

2541-KOLNP-2007-(16-05-2012)-OTHERS.pdf

2541-KOLNP-2007-(16-05-2012)-PETITION UNDER RULE 137-1.pdf

2541-KOLNP-2007-(16-05-2012)-PETITION UNDER RULE 137-2.pdf

2541-KOLNP-2007-(16-05-2012)-PETITION UNDER RULE 137.pdf

2541-KOLNP-2007-ASSIGNMENT.pdf

2541-KOLNP-2007-CANCELLED PAGES.pdf

2541-KOLNP-2007-CORRESPONDENCE 1.1.pdf

2541-KOLNP-2007-CORRESPONDENCE.pdf

2541-KOLNP-2007-EXAMINATION REPORT.pdf

2541-KOLNP-2007-FORM 1.1.1.pdf

2541-KOLNP-2007-FORM 1.pdf

2541-KOLNP-2007-FORM 13.pdf

2541-KOLNP-2007-FORM 18.pdf

2541-kolnp-2007-form-18.pdf

2541-KOLNP-2007-GRANTED-ABSTRACT.pdf

2541-KOLNP-2007-GRANTED-CLAIMS.pdf

2541-KOLNP-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

2541-KOLNP-2007-GRANTED-DRAWINGS.pdf

2541-KOLNP-2007-GRANTED-FORM 1.pdf

2541-KOLNP-2007-GRANTED-FORM 2.pdf

2541-KOLNP-2007-GRANTED-FORM 3.pdf

2541-KOLNP-2007-GRANTED-FORM 5.pdf

2541-KOLNP-2007-GRANTED-SPECIFICATION-COMPLETE.pdf

2541-KOLNP-2007-INTERNATIONAL PUBLICATION.pdf

2541-KOLNP-2007-INTERNATIONAL SEARCH REPORT & OTHERS.pdf

2541-KOLNP-2007-OTHERS.pdf

2541-KOLNP-2007-PA.pdf

2541-KOLNP-2007-PETITION UNDER RULE 137.pdf

2541-KOLNP-2007-REPLY TO EXAMINATION REPORT.pdf

abstract-02541-kolnp-2007.jpg


Patent Number 257087
Indian Patent Application Number 2541/KOLNP/2007
PG Journal Number 36/2013
Publication Date 06-Sep-2013
Grant Date 02-Sep-2013
Date of Filing 09-Jul-2007
Name of Patentee GEORGIA-PACIFIC CHEMICALS LLC.
Applicant Address 133 PEACHTREE STREET N.E., ATLANTA, GEORGIA
Inventors:
# Inventor's Name Inventor's Address
1 WRIGHT, JAMES 23 HOWELL STREET,NE,ATLANTA,GEORGIA 30312
2 GABRIELSON, KURT 1710 LAKE LUCERNE ROAD, LILBURN GEORGIA 30047
3 HINES, JOHN, B 1092 COLQUITT AVENUE, ATLANTA, GEORGIA 30307
4 ARTHUR, LISA, M 3813 MARTINGALE DRIVE SE, CONYERS, GEORGIA 30094
5 PHILLIP W. HURD 1881 LANCASTER DRIVE, CONYERS,GEORGIA 30013
6 PAUL HART 356 EAST BROWN STREET, EAST STROUDSBURG,PENNSYLVANIA 18301
7 RICHARD REDIGER 2117 FLAT SHOALS ROAD, CONYERS, GEORGIA 30094
8 ROBBIE D. KELLY 395 WEEPING WILLOW WAY,TYRONE, GEORGIA 30290
9 WHITE, CARL R 1728 BRANDY WOODS DRIVE, CONYERS, GEORGIA 30013
PCT International Classification Number B03D 1/02, C09C 1/42
PCT International Application Number PCT/US2005/046364
PCT International Filing date 2005-12-21
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/713,339 2005-09-02 U.S.A.
2 60/638,143 2004-12-23 U.S.A.