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By M. Barsky, E. Barsky

A study was conducted to elucidate the relationship between the hovering velocity and the particle settling velocity. The experiments were carried out in a water medium on five materials ranging in density from 1.070 to 4.000 kg/m3. Analysis of the results with allowance for the distribution of stream velocities over the cross section of the pipe revealed that the final settling velocity of the particles was equal to their local hovering velocity (on the stream axis), and not to the average velocity of vertical flow as is generally believed. It therefore follows that the kinetic structure of the stream must be taken into account when constructing theoretical models of the process for purposes of computation. In addition, the optimal stream velocity is not always equal to the hovering velocity and in fact is governed by other factors as well. Illustration is provided by the results of a study conducted in a vertical cascade classifier comprising eleven identical stages. The feed material was introduced at each stage successively beginning with the topmost (i* = 1 ) and ending with the lowermost (i* = 11). First, the stream velocity that yields optimum separation conditions at each stage of the cascade (i.e. k=50%, k being the yield of a given size class in the fines for a single stage) was sought. Subsequently the conditions of optimal separation for the instrument as a whole were determined (i.e. F(x) = 50%, F(x) being the yield of a given size class for the entire instrument). The results of the study are presented in the table.

Jan 1, 2003

By A. C. Maffei, M. V. Lins Gonçalves

Ore concentration processes are a function of the respective particle size distribution; however, most of them do not use an efficient operational method to determine it. From a practical point of view, the surface area can be calculated for any size analysis. The physical principles for determining the size distribution in each method are different, for the results will not be compared directly. During the development of the research project of the sulfide ore flotation method using inert gas, different methods for calculating the specific surface area have been used, such as sieving, sedimentation/X-ray, laser diffraction and BET, i.e. specific techniques to determine the specific surface area of copper and gold ore concentrates. The statistical method of minimum squares was used to achieve practical correlation equations among them. Regarding these two ores, if one knows a specific surface area value using one of the methods above, one can predict the result of the others. Diminution of the reagent consumption was so controlled and it could be even decreased by using inert gas.

Jan 1, 2003

By Daniela Venter, Stephen Chryssoulis, Ken Stowe

"A sampling campaign was conducted at Kemess in order to identify and assess the chemical and physical factors, which control free gold flotation kinetics in the rougher and cleaner circuits. The rationale behind this approach was that accurate knowledge of the parameters affecting free gold flotation kinetics, can be used to determine how to accelerate free gold flotation. Collected samples were composites of 5-6 cuts over a four-hour period, at steady plant conditions.In the rougher circuit, coarser equidimensional gold particles floated ahead of the finer grained and the flaky gold. Sulphur followed by molybdenum and to a lesser extent silver enhanced gold flotation kinetics, while hydroxyl followed by carbonate ions induced depression."

Jan 1, 2003

By Takashi Furuyama, Sukeyuki Mori, Takafumi Okuma, Norio Hashiguchi

"In order to achieve a high recovery of particles finer than 10µm, three types of dry Tower Mill (VD-1, KD-1, KD-2 and KD-3) have been developed. These mills differ from each other in the size of the comminuting part, the inside diameter and shape of the classifying part and the system involved in the collecting process. The last version (KD-3) of tower mills in which the comminuting and classifying operations has been separated, can produce particles finer than 10µm from a limestone ore sizing from 420 to 3360µm. In this tower mill, products in comminuting section are blown up and transported into the classifying column, made of an inverted cone on top of a cylinder, before they agglomerate and settle down. Fine particles are deported and recovered in a cyclone with a central spiral ribbon.Previous studies on the grinding efficiency of the tower mill KD-3 have shown how the maximum size of collected products increased with the airflow velocity, disturbing in the same way a smooth regulation of the grinding operation with the tower mill KD-3. A complete knowledge of factors that influence the maximum size of collected products is needed, therefore, to increase the efficiency of the grindingclassifying operation and ensure a better control over the collected products. The present study deals with this issue and, assuming that the structure of the classifying column could be one of these factors, its internal structure was modified (insertion of vertical plates, cone or horizontal nets) before carrying out comminution tests that would establish a relationship between the inward shape of the column and the maximum size of collected products. It was found that the weight of products collected in the cyclone decreases when a cone or some horizontal nets are inserted inside the column. At the same time, the weight of products collected in the column increases. This is due to the fact that coarse particles blown up from the comminution section collide with the base of the cone or the nets and settle down the bottom of the classifying column. Therefore, the cone and some horizontal nets inserted inside a classifying column, have the particularity to stabilize the maximum size of particles (15.1-17.5µm and 8.4-11.3µm) in the cyclone even when the airflow velocity in duct increased. These tools could of great help in the production of particles of definite size to fit for instance the paper industries requirements (production of limestone material sizing - 10µm as paper filler)."

Jan 1, 2003

By Natalie J. Shackleton, Deryck de Vaux, Cyril T. O’Connor, Vratislav Malysiak

"The major losses of PGM and base metals in the beneficiation of platinum group deposits occur during the separation of gangue from the value minerals by selective flotation. A number of studies have shown that this negative impact on flotation is due to surface passivation, caused by various ions that may originate from the external water supply or, as is likely in the majority of cases, from the oxidation of the mineral surfaces and the grinding media. The objective of the study was to investigate the effect surface passivation and inadvertent activation have on flotation and how this can be managed so as to increase the separation of pentlandite and pyroxene. The aim was to minimise the percentage pyroxene reporting to the concentrate and simultaneously maximise the pentlandite recovery. The testwork incorporates the addition of an activator (copper sulphate), a complexing agent, such as DETA (diethylenetriamine) and a dispersant (polyphosphate) at pH 6 and pH 9 in an attempt to alleviate the surface passivation of pentlandite and inadvertent activation of pyroxene. Both synthetic minerals and plant ores were studied in order to determine the effect surface passivation and inadvertent activation have on mineral surface alteration and floatability. Zeta potential determinations, microflotation, ToF-SIMS (Time of Flight Secondary Ion Mass Spectrometry) analyses, laboratory batch flotation tests and continuous flotation testwork were used as tools to study the surface alteration and/or floatability.Zeta potential determinations and ToF-SIMS analyses showed that copper adsorption is non-selective. Both pentlandite and pyroxene become copper (II)-activated in the presence of copper sulphate and subsequently, in the presence of xanthate, adsorption of the collector will occur onto copper activated mineral surfaces. Zeta potential determinations also showed an alteration of the surface charge in the presence of polyphosphate, thereby inhibiting surface passivation of sulphides by slime coatings due to surface repulsion."

Jan 1, 2003

By K. A. Natarajan

Interaction with microorganisms results in significant surface chemical changes on minerals. For example, chemolithotrophs such as Thiobacillus ferrooxidans and Thiobacillus thiooxidans significantly alter the surface chemistry of several sulfide minerals such as pyrite, chalcopyrite, sphalerite and galena. Heterotrophic bacteria such as Bacillus sp. could alter the electrokinetic properties of oxide minerals such as hematite, alumina, silica, kaolinite and calcite. Microbe-mineral interactions could thus be beneficially utilised in mineral beneficiation as different from bioleaching. Microbially induced mineral beneficiation unlike bioleaching deals with interfacial phenomena at mineral-solution-bacteria interfaces and surface chemical changes are brought about at very rapid rates amounting to a few minutes resulting in mineral separations in an aqueous medium.

Jan 1, 2003

By Francesco Vegliò, Luigi Toro, Francesca Beolchini, Francesca Pagnanelli, Stefano Ubaldini

"Biosorption is an innovative technology used to remove heavy metals from aqueous solutions from mining waters and other industrial wastes. A wider application of this alternative process is strictly dependent on the understanding of the chemico-physical aspects involved, in order to optimize the operating conditions. Mechanistic models are the most useful tools used for understanding purposes, even if the empirical models are still widely applied for their simplicity.In this paper especially propagated biomasses of Sphaerotilus natans, calcium alginate and some waste materials were tested as adsorbents for single and binary solutions containing heavy metals at different pH. The equilibrium experimental results were fitted according to empirical and physical models with growing complexity outlining the inadequacy of the predictive models; in fact, the non-ideal interactions among metals require the insertion of additional correction parameters."

Jan 1, 2003

By Rhulani F. Maluleke, Francis W. Petersen, John H. Marsh, Johann de T. Steyl, Allan Nesbitt

"Pressure leaching of chalcopyrite and nickeliferrous pyrrotite at temperatures between 105 and 200 ºC has been proposed as a potentially viable route for the extraction of mineral elements from sulphide concentrates. In general, these concentrates contain iron, and the economic success of the processes is partially dependent on the choice of the environmentally acceptable iron-removal technique. One of the most widely used methods for the removal of iron from sulphate liquors is precipitation as hematite, goethite, or jarosite. The nature of the iron precipitate formed, dictates downstream dewatering and residue treatment and disposal options. However, a better understanding of iron precipitation under the defined process conditions would consequently be of benefit in process design and optimization.This study investigated the precipitation of iron in the autoclave at temperatures between 105 and 200 ºC. The effects of temperature, acid concentration, iron concentration, and the presence of other metal cations on the nature and composition of the precipitates were determined."

Jan 1, 2003

By Yongfu Yu, Xiaotie Wang, Fuguang Zhang, Liping Che

"Rare Earth water dregs is the drained waste dregs, which contains over 0.2 percent thorium dioxide and about 6-10 percent di-Rare Earth trioxide, which is beyond the standard of draining off that China governments set, so that the Rare Earth water leach dregs must be sacked and laid down in storehouse, which costs lots of money. It is a pity that the RE and thorium compounds very useful elements in industry are discarded. A lot of work must be carried out so that this resource was fully developed.In this paper, four separation techniques of recovery Rare Earth minerals and enrichment thorium element and reduction thorium content of drained dreg for the different test samples of Rare Earth water leach dregs which is radioactive waste dregs got from diverse locus are studied, respectively, and the separation characteristic and the separation process are described, using several combination processes of classification and gravity and flotation separation which were prepared according to the characteristic of test samples and technology. The test results show that the combination processes are the more remarkable separation techniques and the flotation reagents used in test can be applied to utilizing synthetically radioactive waste dregs. Through the combined technique process, three parts of products were obtained, namely, Rare Earth concentrate collected, the thorium product enriched and a large amount of the waste dregs product that can be directly drained and the total quantity is 50%-60%. In order to determine optimum technical condition, the effect factors of separation process were investigated in the test."

Jan 1, 2003

By Leon Lorenzen, Charlene Gokhale

"In excess of 24 x 106 tons (Eskom, 1997) of coal-derived fly ash is produced annually in South Africa for the production of electric power. A large quantity of this ash is disposed of as a solid waste in landfills, thus posing a serious environmental problem. Due to the shortage of landfill sites, new ways of utilising fly ash are needed. Recently several authors have shown that various combustion fly ashes can be converted into zeolites to obtain industrial products with applicability in environmental management. Geopolymerisation has emerged during the last few years as a possible solution to some waste stabilisation and solidification problems. henolic compounds have been shown to be toxic to soil microorganisms at the parts-per-million level. Indeed several of the organic compounds classified by the U.S. Environmental Protection Agency as priority pollutants, are phenols. Immobilisation of phenols by adsorption on zeolites and encapsulation in a geopolymer appears to be a promising solution to this problem.This paper reports a technique for the production of a low-silica sodium zeolitic material from fly ash (zeolite NaP1), and its application for the stabilisation of phenols by adsorption and subsequent encapsulation in a geopolymer matrix. A commercial zeolite, clinoptilolite was also utilised as an adsorbent. Due to their uniform pore sizes and large surface areas, zeolitic materials are suitable for ion exchange and adsorption of certain organic substances. Adsorption data show that the commercial zeolite, clinoptilolite was an effective adsorbent for organics. Adsorption data showed that between 51.2 ppm and 74.3 ppm of chlorophenol or between 15.4 ppm and 32.5 ppm of phenol could be adsorbed. Physical encapsulation of the coated zeolite loaded with organic within a geopolymeric matrix increased the compressive strength of the matrix from 28.80 kN to 40.79 kN. Leaching data for the various geopolymer matrices with encapsulated and loaded zeolites show no organics being leached from the system at a detection level of 2ppm. According to the SABS these would have been acceptable organic concentrations within a waste water stream."

Jan 1, 2003

By Ralph J. Holmes, Victor Sharp, Steven J. Spencer, CSIRO Minerals, Kevin J. Davey, Jonathan J. Campbell, Peter L. Phillips

"Improved measurement tools for monitoring and control of AG/SAG mill performance have a high level of interest in industry. Historically, acoustic emission monitoring has been widely used on SAG/AG/ball mills and hydrocyclones to provide new information on the conditions inside these devices affecting their performance. The current work was focused on a new technique using surface vibration monitoring of a number of pilot-scale and production-scale AG/SAG mills to yield insights into the events occurring in the mills. The development of relationships between signal analysis outputs and mill operating conditions can be used for soft-sensor measurement of mill process variables. The technique used an array of accelerometers mounted on the mill lifter bolts linked to a fast data acquisition system which monitored the surface waves generated during operation. Details of the system are presented. Mill operating variables were adjusted systematically to provide a wide range of operating conditions for surface vibration signal collection. The experimental approach is discussed.The signals acquired during the experiments were analysed using a range of techniques. The results show that strong relationships exist between measured vibration power (both total power and within certain frequency bands) and mill load level/power and mill speed. A new method for extraction of power spectral density and band power information on features of interest in a mill rotation cycle is also presented."

Jan 1, 2003

By Jurgens J. Louw, Vincent C. Smith, Gareth C. Smith, Agit Singh, Dave G. Hulbert

"During 2000 Mintek Developed the PlantStar plant wide control platform for the minerals processing industry. The flexibility of the PlantStar control platform has enabled Mintek to investigate and easily develop new control strategies for both milling and flotation. This includes a Solids Feed Controller, a Safety Limit Controller, Mill Power Optimiser and Flotation Optimiser, amongst others.Processes with long dead times, like a feed belt to a mill, are difficult to control. The solids feed controller was developed for minerals processing plants using a specialised time delay compensator. Using conventional time delay compensators that are purely model based, results in robustness problems due to model uncertainties. The Mintek Solid Feeds Controller makes use of a plant model, but compensates for model inaccuracies, giving more controller stability and a more robust delay compensation algorithm.Often there are more variables on a plant that need to be controlled (process variables) than there are variables to control them with (manipulated variables). Process constraints are often reached and violated. Safety control loops are necessary to prevent constraints being reached. The safety limit controller has been developed to switch smoothly between normal and safety control loops without bumping the process. The safety loop output is chosen in accordance with a predefined list of priorities and whether the respective constraint boundaries are exceeded.The Mill Power Optimiser helps to find the power peak on the mill power curve. It continuously perturb the solids feed rate to learn ‘where’ on the curve the mill ‘was’ and then to drive it continuously toward the middle, maximum power drawn. This insures maximum grind with maximum throughput. It also prevents power dips due to mill overloads by cutting the solids feed to a minimum if the power drop below a specified threshold. Once the power rises above the threshold the solids feed is increased again to an intermediate value from where it start the perturbations again to find the maximum. This makes the milling circuit easier to operate."

Jan 1, 2003

By Atsushi Shibayama, Toyohisa Fujita, Luo Lin, Toshio Miyazaki

A novel process is developed in this study for separation of tungsten and vanadium from a leach solution of tungsten alloy scraps. Specifically, a magnesium salt combined ammonium solution is employed to precipitate vanadium and impurities in the purification of the leach solution. This separates vanadium from tungsten by rejecting tungsten in aqueous solution. Finally, tungsten is recovered as the form of ammonium para-tungstate (APT). Vanadium is recovered as the form of ammonium meta-vanadate(AMV).

Jan 1, 2003

By Kang N. Zhong, Hui H. Luo, Yunan Phosphate Chemical Co., Yi H. Wei, Yao J. Li, Yu L. Wang

"The three kinds of phosphate ores (igneous, metasedimentary and sedimentary) found in China have great differences in flotation flowsheets and reagents suite because of their crystal structure and mineral composition. The igneous and metasedimentary apatites have good floatability with fatty acid as collector and waterglass, sodium hydroxide or sodium carbonate as conditioners. The sedimentary phosphate is very difficult to beneficiate by direct flotation because of their poor floatabilities and relatively high content of MgO and SiO2, even though the dolomite depressants are used sometimes.The differences in floatability of apatites in China are closely related to their differences in specific surface area. The amount of collector to float apatite increases with the specific surface area. Apatite with lower specific surface area showed good floatability at lower collector concentration. Apatite with a higher specific surface area needed a higher concentration of collector. The content of CO3 2- will affect the specific surface area of apatite by distortion of its crystal structure and consequently affect its floatability.Dolomite can be easily rejected from apatite in a weak acidic medium (pH=5), especially in phosphoric acid medium by reverse flotation. Quartz and siliceous gangue in sedimentary apatite can be removed by direct flotation using fatty acid or by reverse flotation using amine. Amine is not practically applied because sedimentary apatite in China is usually very fine and needs fine grinding, which always results in excessive, very fine, stable and non-flowable foam.Based on the floatability of phosphate ore in China, a two-stage flotation process, direct and reverse flotation (D+R), was developed to beneficiate sedimentary ore. For the Haikou phosphate ore containing 25.11% P2O5, 3.46% MgO and 16.5% SiO2, a concentrate containing 31.84% P2O5, 0.48% MgO and 14.8% SiO2 can be obtained through a continuous D+R test at a recovery of 89%."

Jan 1, 2003

By Jan J. Cilliers, Nicolas Barbian, Esther Ventura-Medina

"Froth structure and stability are known to play an important role in determining flotation recovery and selectivity. An industrial sampling campaign was performed to develop a clearer understanding of the effect of flotation variables on froth stability and the role played by the resulting stability on flotation performance.Froth stability was estimated as the fraction of bubbles bursting on the surface of the froth through image analysis and the solids loading on the bubbles at the top surface. The image processing was performed using the Smartfroth software on the top surface of the froth. The system gives measurements of bubble size distribution, average bubble size and froth velocity. The froth velocity was used to estimate the volume of bubbles overflowing the weir yielding to the fraction of air overflowing the cell. This measurement is the complement of the rate of bubble bursting on the top surface. Also samples of the lamellae were taken by touching the top surface of the bubbles with a glass slide. Then, the amount of solids and liquid per unit area in the bubble lamellae was estimated gravimetrically. Both measurements were used to establish stability criteria.It was generally found that high air flowrates resulted in a drop of froth stability showed by a drop in the fraction of air overflowing and a decrease in the solids loading and simultaneously produced low copper recoveries and low concentrate grades. Deep froths only allowed a small fraction of air to overflow and consequently produced low recoveries. An increase to high frother dosage did not result in an improved fraction of air overflowing, hence producing low recoveries. Likewise, low frother addition only allows low recoveries because the resulting unstable froth cannot support itself. Low aeration was found to be preferential as it allowed high particle loading, therefore high bubble stabilisation, and low gangue entrainment, resulting in the highest flotation performance."

Jan 1, 2003

By Matti Kongas, Kari Saloheimo, Antti Remes

"The paper studies the control performance of the flotation process as a function of the measurement accuracy and sampling frequency of an on-stream XRF analyzer, using a simple dynamic model. An additional aim is to assess how the economical result of a mineral flotation process depends on the quality of process control based on the on-line elemental assays.An on-stream XRF analyzer measures the concentrations of slurry lines in a continuous cycle from several process points. The control performance depends on the analytical accuracy and sampling frequency of the concentration measurement. With a long cycle time, the state of the process changes before a new measurement becomes available. With short measurement times the statistical variance of the counted Xray pulses increases, increasing the random error in the analysis. In addition, the measurement accuracy depends on the concentration of the component to be measured from the slurry.To quantify the effect of analysis error and frequency to process control, a simple dynamic process model is created in the Matlab environment. Data from a copper flotation circuit is used as a test case. The process model comprises a first order reaction equation and the grade-recovery -relationship estimated from process data. The control was modeled using the control strategies implemented into a rule based advanced control system. The economical performance of the control was studied by calculating the overall net smelter return at various analyzer parameter combinations."

Jan 1, 2003

By Z. S. Abisheva

Rare and rare earth metals use quite often is an indicator of national economy development. The world structure of the rare-earth metals manufacturing countries in 2015 was presented as follows: China – 94.2%, India – 2.0%, Russia – 1.8%, the USA – 1.2%, Brazil – 0.5%, Malaysia – 0.3%. In Russia, large reserves of rare-earth metals, which reach nearly 28 million tons, are revealed. Kazakhstan, possessing a raw materials source of rare-earth metals, has all prerequisites for development of branch. Rare metals are manufactured in Kazakhstan incidentally by non-ferrous metals production. The production of indium, thallium, cadmium, selenium, tellurium, bismuth is made at the Ust-Kamenogorsk lead plant; tantalum, beryllium, niobium and molybdenum – at the enterprises of “National Atomic Company Kazatomprom” JSC. Production of a titanium, magnesium and vanadium is adjusted on “Ust-Kamenogorsk Titanium-magnesium Plant” JSC. Capacities for beryllic production yield are available on “Ulba Metallurgical Plant” JSC. The main producer of perrhenic production and osmium-187 is "Zhezkazganredmet" RSE. The single producer of gallium in Kazakhstan is “Aluminium of Kazakhstan” JSC; the capacity of enterprise is 25 t a year. In Kazakhstan innovative technologies for rare and rare earths mineral raw materials processing are created. The technology has been developed and a vacuum distillation apparatus has been created to purify crude selenium, which makes it possible to obtain a metal with a main component content of 99.9-99.99%. Technologies for processing of technogenic wastes and byproducts of the copper industry are developed. Implementation of technologies allow to obtain ammonium perrhenate, perrhenic acid, osmium isotope -187, tribasic lead sulphate, silver-concentrate. The technology of complex processing of black shales of Balasauskandyk deposit with the production of gold, vanadium, rare earth elements, uranium and ferrosilicon has been proposed. The processing was carried out using methods of autoclave leaching, sorption, extraction, precipitation. A highly profitable sorption technology for recovery of rhenium from solutions of underground leaching of uranium ores containing 0.2-0.4 mg/L of Re has been created. The organization of ammonium perrhenate production from solutions of uranium ore will significantly increase the volume of its production in Kazakhstan.

Jan 1, 2018

By Pradip, Beena Rai

A molecular modeling study was carried out on an adsorbed oleate monolayer on the surfaces of three calcium minerals, fluorite, calcite and fluorapatite using Universal Force Field (UFF) potentials. The cleavage plane of calcite {104} was the best template for oleate monolayer adsorbed since the surface structure enabled all the calcium sites available on the surface to be occupied by oleate anions. The area occupied per chain of oleate in this well packed monolayer was computed to be 20.2 Å, which exactly matches the value calculated to be the parking area per oleate molecule for a fully packed monolayer based on strictly geometric calculations. On the other hand, the precentage of calcium sites occupied by oleate to achieve a fully packed monolayer in case of fluroite and and fluorapatite was found to be 67% and 75% respectively. The results of this theoretical study suggest that while all the three adsorption conformations, that is unidentate, bidentate and bridging type are equally likely on fluorite and fluorapatite, bridging is most likely on calcite. Interestingly, all the conformations are observed experimentally for calcite-oleate system also. The reasons for this discrepancy between the theoretical predictions and experimental observations are not clear. More work is required to resolve this discrepancy, in particular simulation studies in presence of solvent water molecules on the surface.

Jan 1, 2003

By Richard K. Komarek, Antonios Zavaliangos, Roman T. Dec

"The work in the paper introduces a 2-dimensional finite element model for analyzing particular material processing in a roller press. Two basic roller geometries are considered: (a) smooth rolls (used for milling and compaction) and (b) rolls with cavities, commonly used for briquetting. A model is presented that is suitable to analyze material behavior through all stages of the rolling process: feeding zone, nip region, neutral plane and release section. It can predict pressure, shear stress, slip of the material over the roller surface, material velocity field, failure of the compact during release and the course of other important process variables.MODEL, RESULTS AND CONCLUSIONSAn associated Gurson model was employed as a constitutive model for the material. The calibration of the model was based on experimental results from an instrumented compaction die. Coulomb friction law was used to describe phenomena on the material/roller surface interface. Powder River Basin sub bituminous coal fines with moisture content 9% was used as a model material.Two finite element models have been set up, one for the briquetting roll and one for the “equivalent” flat roll. Approximately 3200 plain strain continuum elements with reduced integration (CPE4R) were used. Lagrangian-Eulerian (ALE) approach in conjunction with judiciously applied remeshing was employed with the commercially-available, dynamic explicit version of ABAQUS finite element code.Comparison of model predictions with experiment shows that there is an agreement in terms of the general trends of experimental values recorded on laboratory roller presses. Gurson model overpredicts stresses at low densities and, as a consequence, overpredicts roll force and roll torque."

Jan 1, 2003

By Kal Sastry, Anshuman Prasad

"Agglomeration of fine iron ore concentrates is carried out in two steps:Balling, which refers to the production of green pellets by tumbling moist fines powders in drums, discs, or cones, and Induration, which refers to the subsequent thermal treatment of the green pellets in straight grate or grate-kiln systems.This paper addresses computer simulation of balling or green pelletization step. The process of agglomeration from a mechanistic point of view can be described as the transformation of moist feed to well-formed species or pellets. The moist feed is composed of fines of infinitesimal size while well-formed species are of finite size and number. These well-formed species undergo changes in their size and number through different mechanisms of agglomerate formation and growth. Nucleation, coalescence and layering are the three main mechanisms that describe the formation and growth of granules during an agglomeration process. A population balance equation enables quantitative description of the evolution of agglomerate size distribution due to the occurrence of each of the mechanisms.A numerical solution for the population balance model is necessary and is obtained by the use of a sizediscretization approach. The numerical solutions provide a suitable basis for the analysis of the agglomeration process. Also a coalescence kernel has been introduced that is capable of describing the simultaneous occurrence of nucleation, coalescence and layering mechanisms. The effect of feed moisture has been described using a moisture factor with an exponential functional dependence on the moisture content. The effect of the feed to seed ratio is modelled by the introduction of a crowding factor. It was assumed that only the feed particles which are much more in number experience a crowding or restricted in space interactions effect. A computer simulation program has been developed with MATLAB as the simulation language."

Jan 1, 2003