RAFT Polymer-Based Surfactants for Minerals Recovery

Reagent consumption is an ongoing sustainability challenge for the mineral processing industry. There is a need to recover, regenerate, and reuse as many of the chemical inputs as possible. This study investigated the design and synthesis via reversible addition-fragmentation chain transfer (RAFT) polymerization of a novel polymer for use as a surfactant in a water-in-oil (w/o) emulsion system for ultrafine minerals recovery. The polymers were designed to hold a thermoresponsive moiety to allow for future recovery. The performance of the novel emulsion was tested for agglomeration of ultrafine talc mineral particles. A traditional emulsion containing sorbitan monooleate as the surfactant was used as a research benchmark to compare against the novel emulsion's stability and performance in minerals recovery. The novel RAFT polymer-based emulsions formed large and stable water droplets surrounded by a halo of smaller water droplets. Over time, the smaller droplets coalesced and a more uniform size distribution of droplets was formed, keeping the emulsion stable. Rheological testing of freshly made and aged emulsions showed both traditional and novel emulsions to have a high viscosity at a low shear rate. RAFT polymer B with a hydrophilic-lipophilic block ratio of 5:10 performed adequately as a surfactant replacement to stabilize w/o emulsions. The mineral recovery using the novel emulsion was on par with the traditional emulsions. The novel RAFT emulsion containing 2.5 wt % polymer B achieved 90% minerals recovery, a similar yield to the traditional emulsions. This study demonstrates that surfactants containing stimuli-responsive moieties can be synthesized via RAFT polymerization and successfully used in mineral processing applications to recover ultrafine particles. Work is ongoing to exploit the stimuli responsiveness to recover the polymer surfactant for reuse.