A deterministic lateral displacement array that includes a channel, within a substrate, having a first sidewall, a second sidewall, and a channel length. A condenser portion that includes an entry port and an exit port. A first array of pillars is disposed between the entry port and the exit port of the condenser portion along the channel length, the first array of pillars operative to drive a first material particle and a second material particle towards the first sidewall of the channel. A separator portion that includes an entry port and an exit port, and a second array of pillars disposed between the entry port and the exit port of the separator portion along the channel length, the pillars operative to drive the first material particle towards the second sidewall of the channel.

A technique related to sorting entities is provided. An inlet is configured to receive a fluid, and an outlet is configured to exit the fluid. A nanopillar array, connected to the inlet and the outlet, is configured to allow the fluid to flow from the inlet to the outlet. The nanopillar array includes nanopillars arranged to separate entities by size. The nanopillars are arranged to have a gap separating one nanopillar from another nanopillar. The gap is constructed to be in a nanoscale range.

A technique related to sorting entities is provided. An inlet is configured to receive a fluid, and an outlet is configured to exit the fluid. A nanopillar array, connected to the inlet and the outlet, is configured to allow the fluid to flow from the inlet to the outlet. The nanopillar array includes nanopillars arranged to separate entities by size. The nanopillars are arranged to have a gap separating one nanopillar from another nanopillar. The gap is constructed to be in a nanoscale range.

A method is provided for removing ultrafine particles from an atomized powder. The method includes contacting the atomized powder with a removal liquid, the atomized powder comprising fine particles and ultrafine particles, wherein contacting the atomized powder with the removal liquid comprises adding energy to a mixture of the atomized powder and the removal liquid to detach the ultrafine particles from the fine particles; and separating the removal liquid and ultrafine particles from the fine particles.

A method is provided for removing ultrafine particles from an atomized powder. The method includes contacting the atomized powder with a removal liquid, the atomized powder comprising fine particles and ultrafine particles, wherein contacting the atomized powder with the removal liquid comprises adding energy to a mixture of the atomized powder and the removal liquid to detach the ultrafine particles from the fine particles; and separating the removal liquid and ultrafine particles from the fine particles.

Static screening apparatuses that provide improved efficiency in the removal of undersized particles from oversized particles. In an embodiment, a static screening apparatus incorporates two or more (e.g., multiple) stacked screening modules allowing for adding additional screening capacity without significantly increasing space requirements for the multiple screening apparatuses. In some embodiments, a static screening apparatus utilizes specialized synthetic screening surfaces having an increased open area in relation to convention wire and wedge wire screens. The increased open area of such synthetic screen surfaces provides more efficient separation of oversized materials from undersized materials in sieve or static screen assemblies. In further embodiments, a stacked static screening apparatus may incorporate synthetic screening surfaces.

Static screening apparatuses that provide improved efficiency in the removal of undersized particles from oversized particles. In an embodiment, a static screening apparatus incorporates two or more (e.g., multiple) stacked screening modules allowing for adding additional screening capacity without significantly increasing space requirements for the multiple screening apparatuses. In some embodiments, a static screening apparatus utilizes specialized synthetic screening surfaces having an increased open area in relation to convention wire and wedge wire screens. The increased open area of such synthetic screen surfaces provides more efficient separation of oversized materials from undersized materials in sieve or static screen assemblies. In further embodiments, a stacked static screening apparatus may incorporate synthetic screening surfaces.

The value-minerals are captured by gravity-separation, from a low-grade slurry. The ratio of liquids-to-solids in the slurry affects the efficiency of capture, and an ideal liquids/solids ratio is the ratio at which the efficiency of capture is at a maximum. The ideal ratio is different for different particle-sizes. The procedure includes dewatering the slurry, dividing the dry particles by particle-size, and feeding the several size-divided dry-streams into respective capture-stations. Prior to each dry-stream entering its respective capture-station, make-up water is added to the dry-stream in such quantity as to bring the liquids/solids ratio up to the ideal, for that particle-size. The procedure makes it simple to provide accurate measurement of, and accurate control of, the liquids/solids ratio.

A process for refining sand for use as frac sand includes the steps of passing the sand through a first fines separation stage to remove fine particles of contaminant from the sand, reducing the water content of the sand (such as to less than 20%), passing the sand into an attrition scrubber unit containing moving blades to delaminate clay and other contaminants from the sand grains, passing the sand from the attrition scrubber unit through a second fines separation stage to separate fine contaminants from the sand, and dewatering the resulting sand product in a further dewatering stage.

A process for refining sand for use as frac sand includes the steps of passing the sand through a first fines separation stage to remove fine particles of contaminant from the sand, reducing the water content of the sand (such as to less than 20%), passing the sand into an attrition scrubber unit containing moving blades to delaminate clay and other contaminants from the sand grains, passing the sand from the attrition scrubber unit through a second fines separation stage to separate fine contaminants from the sand, and dewatering the resulting sand product in a further dewatering stage.