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Rotor speed is one of the key hydrodynamic parameters in froth-flotation and it plays an important role in bubble-particle attachment. Laboratory scale studies for optimizing the rotor speed to achieve maximum flotation rate constant (K) of quartz, ground by ball mill, are. Purity of quartz was 99.4 percent and d80 of ball mill product was 230 µm. Each size fraction was separately subjected to flotation at three different rotor speeds, namely, 1200, 1000 and 800 rpm, and the flotation rate constant was calculated. The results showed that the flotation rate constant was high at the rotor speed of 1200 rpm. The flotation rate constants achieved at 1200 rpm were 8.676, 8.232, 7.818, 7.248, 7.068 and 6.984 min-1forthesize fractions of +300, -300+250, -250+212, -180+150, -150+125 and -125+106 µm, respectively. Keywords: froth flotation, rotor speed, flotation rate constant, ball mill, quartz

Sep 1, 2012

By X. Q. Wu

Magnetization in slurry (MIS) of weakly magnetic minerals by iron ions was investigated. The magnetic seeds (strongly magnetic particles) were synthesized by ferruginous chlorides directly in slurry instead of previous preparations of magnetic seeds by finely grinding mineral magnetite or specially synthesizing them separately in an aqueous solution. In this way, the growth of the seeds and their adsorption on the minerals simultaneously take place in the same slurry. That after MIS the recovery of weakly magnetic mineral limonite in a magnetic separator increased means the formation and adsorption of magnetic seeds on the surface of iron mineral limonite. The magnetization effect was evaluated by limonite recovery at a magnetic strength of 3.500 Gs in a magnetic separator. Mineral limonite was properly magnetized in the following slurry condition: molar ratio of Fe3+ to Fe2+1:3, slurry temperature of 45 °C and pH 10.5. The selectivity of the magnetization between minerals limonite and quartz was improved by adding surfactant sodium oleate.

Jan 1, 2014

By Yuriy V. Gulyaev, Galina V. Sedelnikova, Valeriy D. Lunin, Valentin A. Chanturiya, Igor J. Bunin

"Probable mechanisms of disintegration of mineral particles in gold-containing sulphides and benefication products exposed to high-power electromagnetic pulses are discussed. Experimental data are presented to confirm the formation of breakdown channels and selective disintegration of mineral complexes as a result of pulse irradiation, which makes for efficient access of lixiviant solutions to precious metal grains and enhanced precious metal recovery into lixivia during leaching. Experiments with different gold-containing products revealed a synergetic effect of high-power electromagnetic pulses with widely varying parameters and moisture in mineral pores on breaking-up and gold extraction processes for various resistant goldcontaining mineral products.Several series of tests performed in IPKON RAS, IRE RAS and TsNIGRI yielded an absolute gain in precious metal recovery, up to 30-80 % for gold and 20-47 % for silver, with resultant gold recovery as high as 90 %. An essentially new, environmentally safe and energy-saving breaking-up technology has been developed for resistant gold-containing products. This new method would shorten the way from raw minerals to final products and help significantly reduce the cost of these products as it obviates the necessity for using the expensive procedures of energy-intensive and environmentally hazardous oxidative roasting and autoclave breaking-up for ore concentrates."

Jan 1, 2003

By W. Yao, M. L. Li, R. Cui

"The purpose of this research is providing a flotation process for recovery of lead in lead silver residues from a zinc smelting plant with a new hydroximic acid collector (HOC). The collecting ability and reaction mechanisms of HOC were investigated based on pure mineral flotation tests and analysis of zeta potential. The pure anglesite flotation tests showed that HOC has a good collecting ability for anglesite. Zeta potential measurements proved that HOC adsorbed on anglesite surface physically and chemically. The lead-silver residues in a zinc smelting plant with lead grade about 17.5% was used as raw material for flotation tests. The results showed that under the conditions of pH adjusting agent lime 500g/t, inhibitors sodium silicate 2000g/t, collector HOC 1500g/t, frother alcohol oil 75g/t, the grade of the lead concentrate can be reach 47.18% and the recovery was 76.39% by one roughing-one scavenging-three cleaning and middles back to the flow-sheet in turn after the lead-silver residues were washed by two stages of cleaning-filtration.INTRODUCTION Nowadays, with the increasing exploitation of natural mineral resources, more and more secondary resources should be researched and used for the valuable metals. Hydrometallurgical zinc leaching residues, which contain a considerable amount of zinc, lead, silver and other minor valuable constituents, is a typical and abundant secondary resources (Zhang et al., 2011). A huge quantity of zinc leaching residues (ZLR) had been produced per year (Jiang et al., 2017).This residues not only occupy precious land but also threaten the environment because of the dissolved heavy metals especially in rainy days (Han et al., 2014). Consequently, it is urgent to develop an effective and clean method to dispose this residues which can benefit not only in economical but also in environmental (Jha et al., 2001)."

Jan 1, 2018

By J. Langwaldt

Ammonium-nitrate is a main component in blasting agents and dissolved ammonium residues may be discharged with mine water. The European Union aims to reach a good state of the water quality and recommends ammonium content below 0.5 mg/L for drinking water. Natural zeolites adsorb ammonium from water. In this work, the removal of low-concentration ammonium by commercial natural zeolites was studied in continuous tests. Natural zeolites made up between 83% and 95% of the mineral composition. The major zeolite minerals were chabazite and clinoptiolites and minor amounts of erionite and mordenite were as well present. The five natural zeolite samples, 500~710 µm, were conditioned to obtain zeolites in the Na-form. Ammonium adsorption onto natural zeolites depends mainly on the zeolite mineral type. The chabazite containing zeolite was superior over the four clinoptiolite samples for the removal of low concentrations of ammonium from water (pH of 7.5, flow 5 mL/min, room temperature). The adsorption capacity of chabazite was 48.3 mg NH4+/g zeolites, i.e. 73% of the theoretical exchange capacity 69 mg NH4+/g, during duration over 107 days and almost 6700 bed volumes exchanged. The four tested clinoptiolites had an ad-sorption capacity of 15.7mg to 25.0 mg NH4+/g zeolites. The natural zeolites were rapidly regenerated by an alkaline sodium chloride solution fed to the columns.

Jan 1, 2014

By Ela Mielczarski, Jerzy A. Mielczarski

"The adsorption of xanthate takes place at a different potential on each major sulfide mineral, hence, as it was demonstrated in the past, each mineral component can be selectively separated from ore under well controlled potential conditions. In real flotation this concept never works out for two reasons: the potential of single mineral particle results from complex surface reactions controlled by solution chemistry, and there is a galvanic interaction between different mineral particles present in the flotation pulp.In this study the formation of amyl xanthate hydrophobic products on pyrite, galena and chalcopyrite has been spectroscopically investigated in the presence of combinations of these minerals. The type of the adsorbed species and their amount were determined directly on mineral surfaces by infrared external reflection technique. Galvanic contact between grains of two different minerals has tremendous consequence on the adsorption of collector on both minerals. The detected changes are dramatic, from no adsorption to a coverage formation of a few monolayers. The results obtained indicate clearly that the observations and conclusions about the collector adsorption, hence also the surface hydrophobization, made for a single mineral system does not describe the real situation in a multi-component mineral system such as flotation pulp."

Jan 1, 2003

By V. Runkana, N. K. V. Nadimpalli, S. Sahu

"IsaMill™ has been in operation in the recent past for fine grinding of low grade ores to extract non-ferrous minerals. IsaMill™, typically, consists of a series of uniformly spaced identical disks mounted on a rotating shaft which is encased in an outer shell. The mill offers high energy efficiency for fine grinding and an inherent scalability. But, it encounters certain operational challenges such as non-uniform distribution of grinding media coupled with high wear rate of the disks and solid walls of the mill at specific locations—which adversely affect the mill performance. To circumvent these operational challenges, design modification of the disks through heuristics, by introducing a reduced diameter disk (RDD) at specific locations, is a common practice in industry. But there is no systematic scientific study in this regard. In the current work, we developed a discrete element method (DEM) based model and simulated for the IsaMill™ operation to study the effect of RDD on the efficiency of the mill and wear rate of the solid walls and disks. Since the first set of disks experience the high wear rate due to the high loading of the charge, the RDD was introduced at the first two disks. The simulations were performed at different diameters of the RDDs and at different media loadings. The performance of the mill was analyzed based on the power consumption, the wear rate on disks and the distribution of media particles inside the mill. Besides, the performance variables such as mean velocity of media particles and total impact energy provided useful insights into the milling operation. It was observed that the reduction in disk diameter yields lower wear rate of the disks at the cost of decrease in power draw at a constant high media loading. Whereas, when the media loading was decreased, the amount of wear and power drawn was comparable for both the most reduced and least reduced disk diameters. Therefore, there is an optimum choice of RDD for a given mill loading to maximize the mill performance while reducing the wear rate of the disks."

Jan 1, 2018

By Ricardo Montero

At this time, over 300 tons of Au are used in electronic equipment each year with other precious and strategic metals such as Ag, Pt, Pd, Cu, Nb, Ta, etc. After the use-phase, the electronic devices become electronic waste (e-waste); consequently it is important to consider e-waste as a secondary supply for recovery of these metals. One of the most important components is the printed circuit boards (PCBs) because the amount of their precious metals is ten times higher than rich precious metals bearing ore. This paper presents the recovery of Au, Ag, Cu and Nb from PCBs of discarded computers using leaching column technique. The amount of these metals in used PCBs was: 613 g/ton of Au, 1515 g/ton of Ag, 36 g/ton of Nb and 23.4 % of Cu. The PCBs were crushed with a hammer mill until reaching a particle size between 3.33 mm to 0.43 mm. Then, it was leached with sodium cyanide solution in a glass column using the following conditions: sodium cyanide concentration 4 g/L, flux 20 L/kg PCBs day, pH between 10.5 to 11 and leaching time 15 days. Every day, after leaching, the pregnant solutions passed through a column with activated carbon to complete the closed loop system. The following recoveries were obtained: 46.6% of Au, 51.3% of Ag, 47.2% of Nb and 62.3 % of Cu. The products obtained are: a) loaded carbon that contains the desired metals and b) processed PCBs with precious metal contents. A preliminary technical-economic study shows the feasibility to create a small-scale PCBs recycling plant. The initial investment is on the order of US$ 155 639, considering the recovered metals from loaded carbon. The internal rate of return for 10 years period (IRR) and net present value (NPV) estimated are 27% and US$ 105 926 respectively. Keywords: printed circuit boards, recovery, precious metals, niobium, leaching column

Sep 1, 2012

By L. Ya Agapova

Emissions from pyrometallurgical processing of copper concentrates are usually subjected to wet scrubbing. The washing sulphuric acid so produced contains up to 0.2 g/L of rhenium, which is recovered by solvent extraction in the form of crude ammonia permeate (NH4ReO4). The mother liquor, obtained from the sulfuric acid wash, contains up to 35 g/L of rhenium and significant amounts of impurities. Crude rhenium salt is commonly processed by double recrystallization to produce marketable salt. A ton of high grade NH4ReO4 can be produced using 3.0-3.5 m3 of mother liquor. We propose an efficient technology of mother liquor pre-treatment aimed at removal of water-soluble organics with subsequent electrodialysis. Electrodialysis of mother liquor in a multichamber electrodialyzer resulted in the production of pure rhenium acid, from which a marketable NH4ReO4 is precipitated using ammonia solution. Multiple steps of recycling consisting of dissolution of NH4ReO4 salt, rhenium acid production from NH4ReO4 salt by electrodialysis and precipitation of NH4ReO4 from rhenium acid made it possible to upgrade the purity of obtained rhenium compounds by 1-2 orders of magnitude. A rhenium metal powder of 99.997% purity was produced by high-temperature reduction of high-purity NH4ReO4 with gaseous hydrogen. Rhenium metal powder of high purity can be produced from sulfate solutions of NH4ReO4 by non-platinum anode-based membrane electrolysis processes also. Keywords: rhenium, mother liquors, membranes, electrodialysis, rhenium acid, ammonia perrhenate, reduction, powder, electrolysis

Sep 1, 2012

By Y. De Gao, C. Gang Zhong, X. Yang Qiu, Li Wan

The chelating reagents are used as effective collectors in wolframite flotation, and certain metal cations need to be added using chelating collectors so as to activate valuable minerals and obtain good flotation indexes. Different metal cations will result in different reactivity with collectors, in order to select the effective activator in BHA flotation of wolframite, the activation effectiveness of different metal cations on wolframite ((Fe,Mn)WO4) flotation were studied using pure minerals. The results showed that the wolframite activation by Pb2+was the best among the selected cations. The maximum flotation recovery of wolframite was found to be 95.58 % under conditions of 100mg/LBHA and 1×10-4mol/L of Pb2+at pH 9. The dosage of Pb2+needs to be controlled in an optimum range. Also, the activation mechanism of Pb2+ on BHA flotation of wolframite was investigated by measurements of contact angle, zeta potential, adsorption capacity and IR spectroscopy. It was found that Pb2+ could chemically adsorb onto the wolframite surface improving the flotability of wolframite and enhancing the adsorption of BHA on wolframite. When the dosages of BHA and Pb2+ were 100 mg/L and 1×10-4 mol/L, the adsorption quantity of BHA on wolframite sharply increased up to 0.30 mg/L at pH 9 compared with wolframite treated with only BHA.

Jan 1, 2014

By N. P. Haran

A detailed study was undertaken to beneficiate sub-grade iron ore sample from Kenojhar District, Orissa, India containing 57% Fe (T), 7.7% SiO2, 4.8% Al2O3, 4 % L.O.I. 0.4% TiO2,1.3 % Mn and traces of S(T) to make it suitable for the user industry. The mineralogical study indicated that it predominantly consists of haematite with subordinate amounts of goethite and clay. Quartz, Cryptomelane / Psilomelane, Pyrolusite, Gibbsite, Feldspar and Muscovite mica were present in very minor to trace amounts. The Denver grind ability tests indicated, that the sample could be categorized as ?medium soft to medium.? The Bond ball mill work index was determined to be 14.19 kwh per short ton. The beneficiation process involved classification followed by tabling of the classified sand, ground to minus 48 mesh size. The table slimes were subjected to Wet High Intensity Magnetic Separator (WHIMS). The developed process yielded a composite concentrate from tabling and WHIMS operations assaying 65% Fe(T), 2% SiO2, 1.8% Al2O3, 2% Mn and 0.9% LOI with a recovery of 60.1% Fe (T), amounting to 52.5 wt.% yield. To meet the size specifications for pellet making, it was further ground. Dewatering studies were also carried out on the ground combined concentrate and rejects. The thickener area of ground combined concentrate using 0.02 kg/t of Sufloc A 1115 flocculant was 0.02 m2/tonne of dry solids per 24 h. And for the combined rejects using 0.12 kg/t of flocculant, it was 0.035 m2/tonne of dry solids per 24 h. The moisture content, in the pressure filtration cake, in the ground combined concentrate product was 10.0%, and productivity was 506.7 kg/m2h. Thus, by thickening and filtration of process products, 90% of water used in the process could be recovered. The study highlights the development of a simple and cost effective flowsheet with almost complete water recovery for a subgrade iron ore sample. Keywords: tabling, WHIMS, thickener, filtration

Sep 1, 2012

By Mauricio Guimarães Bergerman

At the regrind or secondary grinding stages of base metal ores, the concern about energy efficiency is usually extremely important. In general, the specific energy consumption at this stage is higher than during the primary grinding stages. In addition, a tendency of finer grinding has been observed in the new projects of metallic minerals, due to the finer mineral liberation, which leads to increasing capital and operational costs. At Vale?s new copper projects in Brazil, regrind sizes with a P80 of approximately 40 to 20 µm have been necessary. Conventional ball mills, adequate for primary grinding, usually bring about low energy efficiency with products bellow 50 µm. Vale is using the vertical mill on its copper projects ? Sossego and Salobo, in order to optimize the regrind of rougher concentrates and reduce energy consumption. This paper presents the results of industrial surveys carried out on the Vertical mill circuits of Sossego plant during its initial years of operation, and compares these results with the design criteria and laboratory regrind tests used for the mill scale up. Keywords: grinding, regrinding, copper, vertical mill, stirred mill

Sep 1, 2012

By H. J. Wu

The optimum performance in mineral processing plants usually demands the optimum size reduction, which is frequently achieved by a closed grinding circuit. Due to the difficulty associated with fine size classification, the size separation efficiency in closed grinding circuit is usually very low, which leads to huge circulating load and significant overgrinding. Recent development of Der-rick Stack Sizer has made an efficient fine size separation down to 200 mesh with a satisfactory screening capacity. With the efficient fine size separation with Derrick Stack sizer, the problems commonly associated with typical closed grinding circuit, including high circulating load and over-grinding, have been eliminated. Feedback from numerous Stack Sizer applications in iron ore industry indicated that, compared with conventional fine size classification equipment, the circulating load achieved by Derrick screen was usually decreased from approximate 300% down to 60% or so, while the iron recovery has been increased by 6% to 8% only by more efficient size separation in the closed grinding circuit. To study this phenomenon, this paper discusses the relationship between size classification, circulating load and mineral recovery in the closed grinding circuit. A simulation model to predict the improvement in the grinding circuit from more efficient screening is also introduced with this paper.

Jan 1, 2014

By A. R. Hasankhoei

Water recycling is of prime importance in mineral processing due to consumption of large amount of water. This issue is vital in areas with a low rainfall such as Shahre-Babak (Kerman, Iran). Deep cone thickeners, unlike conventional thickeners, have a low diameter to height ratio where large amounts of flocculants are used to increase particles settling rates. The high bed heights (over 10 m) produce enough pressure to create a paste type underflow indicating maximum water recovery. Flocculent preparation, conditioning, and distribution along with the bed height are among the important factors affecting the performance. Four deep cones are used to recover water from the tailings of the plant. Plant data indicated that the thickener never reached the target underflow percent solids (63%) and the average underflow concentrations were between 49 and 57%. By modification and optimization of flocculent preparation and distribution methods the underflow percent solids increased by 3-4%. This translated to an increase of water recovery from 67 to 73%. This was equivalent of 53000 m3 saving in monthly water consumption. Keywords: deep cone thickener, water recovery, flocculant, copper tailings

Sep 1, 2012

By Venkataramana Runkana, Aditya Pareek, Vishnu Masampally, Nagaravi Kumar Varma Nadimpalli

"Recovery and grade of the ore produced are two important metrics, which define the profitability of a mineral processing plant. Achieving high grade and high recovery at the same time in a mineral processing plant is difficult due to conflicting nature of the two objectives. To explore the operability limits of the plant operations and find the set of operating conditions that can help achieve the best possible recovery and grade, there is a need to solve a multi-objective optimization (MOO) problem. Past research focused on building a plant-wide simulation model or on optimization of individual units or a part of a mineral processing plant like grinding circuit, crushing circuit, etc. However, it is necessary to consider optimization of the complete plant in order to optimize the plant performance. Here, we have formulated the mineral processing plant performance optimization as a MOO problem. We have applied machine-learning algorithms such as random forest to build models to predict the recovery and grade of the ore. A non-dominated sorting-based multi-objective evolutionary algorithm called NSGA-II (Non-dominated Sorting Genetic Algorithm II) was employed to solve the MOO problem. Since the number of parameters that influence recovery and grade are quite large, we have applied machine-learning algorithms for feature selection or identification of key process variables. Pareto optimal conditions were determined for manipulated variables like grinding mill throughput, speed ratio at SAG mill, speed of centrifugal pump, water addition at different locations etc. The results obtained are useful in identifying the operability of a mineral processing plant to achieve the optimum grade and recovery for a given feed grade and the processing circuit. INTRODUCTION Copper is majorly mined or extracted as copper sulfides from large open pit mines in porphyry copper deposits. Among all the available ores, sulfides are the most commercial ores, especially chalcopyrite (Greenwood and Alan, 1997). Copper grade in these ores generally lies between 0.4 to 1.0%. In order to perform smelting operation, the grade of copper has to be improved to around 30% (Biswas et al. 2013). This targeted copper grade is achieved through two stages of mineral processing. Firstly, the copper in the ore has to be liberated by crushing the mineral rock. Secondly, the liberated copper in the crushed ore is then physically separated from other minerals like nickel by froth flotation techniques."

Jan 1, 2018

By Antony Amberg, Gonzalo Saldías, Romke Kuyvenhoven, Catherine Souza, Heriban Soto, Francisco Soto

"Vizcachitas is an advanced stage copper–molybdenum porphyry deposit, fully owned by Los Andes Copper and located in Central Chile. The property contains an indicated resource of 1,038 million tonnes grading 0.37% Cu and 0.012% Mo, and an inferred resource of 318 million tonnes grading 0.345% Cu and 0.013% Mo (Coffey & Alquimia, 2014). The deposit occurs in the same geological belt as several other giant copper-molybdenum porphyry deposits including Río Blanco-Los Bronces, Los Pelambres-Pachon and El Teniente. In 2018, the original Preliminary Economic Assessment (PEA) study from 2014 was updated; this paper presents the geometallurgical testwork that was performed to support that update. The testwork focused on the metallurgical characterization of 40 DDH samples and the development of a more profound orebody knowledge by relating geological features with metallurgical performance. The scope of work included complete chemical and mineralogical QemSCAN characterization; SAG, ball mill and abrasion testing; complete rougher and cleaner kinetics including locked-cycle-test; environmental ABA and settling tests on rougher tailings. The results show that the ore can be classified as medium-hard, with a hardness that is slightly below the average for large Cu/Mo deposits in the region. A good correlation was found between lithology and breakage characteristics, implying that the specific energy consumption (kWh/t) is well correlated to rock type. The results of the flotation tests were very encouraging and did not show significant variability. An overall Cu recovery of 91% can be expected for the flotation circuit. The use of a relatively coarse primary grind size gave good final recovery and grade for both Cu and Mo, and deserves further attention in future work, as this impacts positively both energy consumption and water recovery.INTRODUCTION Los Andes Copper Ltd. is a Canadian exploration and development company focused on the acquisition, exploration and development of advanced stage copper deposits in Latin America. The company owns 100% of the Vizcachitas project in Chile, the largest copper deposit in the Americas not controlled by the majors. Vizcachitas is a copper-molybdenum porphyry deposit, located 120 km north of Santiago, in an area of very good infrastructure."

Jan 1, 2018

By Arman Ehsani, Ersin Yazici, Haci Deveci

The downstream treatment of chloride leach solutions of WPCB for recovery of base and precious metals by a combination of adsorption and precipitation processes were carried out. A synthetic leach solution (1 M HCl, 116.5 g/L Cl-, 30 g/L Cu2+, 2.5 g/L Fe3+, 5 mg/L Au3+, 10 mg/L Ag+ and 20 mg/L Pd2+), which was prepared based on the composition of the pregnant leach solution obtained in the previous study was used in the tests. The leach solution was initially subjected to activated carbon (AC) adsorption (20 g/L AC, 80°C) in which gold was selectively recovered over silver and palladium i.e., 88% Au recovery at 0.5 h (92% at 3.5 h) compared with only 3-6% for Ag/Pd. Copper and iron were also observed to adsorb on AC as indicated by 1.4% and 17% decline, in their respective concentrations. Following the adsorption and filtration stage, metallic copper was added into the gold-barren solution to allow reduction of Cu2+ to Cu+, and to cement Pd on metallic copper. Over the mixing period (1 h), 93% of the Pd was recovered while only 1.4% of silver was cemented onto metallic copper. Subsequently, the leach solution was gradually neutralised by NaOH to pH 4, 7.5 and 9.5 for the precipitation of copper as cuprite (Cu2O). It was found that 41% and 46% of Cu and Ag, respectively, were precipitated at pH 4 at which iron was almost totally (99.8%) removed from solution. Precipitation of copper and silver was increased further at high pHs. At pH 9.5, cumulative recoveries for copper and silver were 91% and 85%, respectively. XRD analysis of the precipitates confirmed the presence of cupric copper oxides/hydroxides and revealed that copper losses occurred at pH 4 was due to the undesired presence of cupric copper in the solution.

Jan 1, 2014

By David G. Hulbert, Daniël J. Oosthuizen, Bernard Muller, Daniël de V. van der Spuy

"Expert Online is a software system that makes use of novel artificial intelligence technology, known as the Interpreting Expert System (IES), to mimic an informed expert on a minerals processing plant. Previous implementations of the IES were only capable of explaining the controller actions. Expert Online will also take on the more difficult task of explaining the complex process behaviour to the operator in simple language.The primary functions of Expert Online are to serve as a training tool and an online assistant to operators. However, it is also expected to be of value to supervisors and plant managers.A number of additional features are envisaged, including different operating modes, fault detection, speech synthesis and advanced message filtering. Expert Online will increase the operator’s knowledge of the process and his/her understanding and acceptance of the complex control systems. Users would be supplied with relevant and timeous information required to make informed decisions to ensure smooth plant operation.This paper discusses the structural design of Expert Online for implementation on the latest version of MINTEK’s open control platform, PlantStar, as well as several advances and additions since the previous implementations of the Interpreting Expert System."

Jan 1, 2003

By Indrajit Paul, Atanu Pal, Kapil Modi, Sanjay Chandra, Chandra Sekhar, Srinivas Dwarapudi

"High alumina content in the Indian iron ore fines (2.5% Al2O3) resulted in poor quality pellets at the recently commissioned 6 MTPA pelletizing plant and a study was under taken to establish suitable pellet chemistry through proper fluxing agents. Limestone fluxed pellets were prepared at varying basicity (0 to 0.8) and pyroxenite fluxed pellets at varying MgO contents (0 to 3%) to study their effect on the metallurgical properties. Fired pellets were tested for their strength, RDI, reducibility and swelling. Microstructural studies, optical and SEM-EDS, were carried out to quantify different phases and their chemistry. Acid pellets exhibited poor quality whereas limestone pellets at 0.8 basicity and pyroxenite pellets at 1.5% MgO exhibited optimum metallurgical quality. Formation of widely distributed silicate melt in limestone pellets and high melting point slag & magnesioferrite in pyroxenite pellets found to improve their quality. However during commercial production of MgO bearing pyroxenite pellets, their room temperature and low temperature properties found to be inferior, but exhibited better high temperature properties, viz. softening-melting behavior. Contrary to this, commercially produced limestone pellets, comprising CaO, exhibited better strength and RDI but showed poor high temperature properties. To yield the benefits of both CaO (for good strength and RDI) and MgO (for low swelling and high softening), a dual flux combination was established by using both limestone and pyroxenite/olivine together that resulted in optimum metallurgical properties. Coke rate at the blast furnaces found to be reduced by 1kg for every1% increase of dual flux pellets in the burden.INTRODUCTION Iron ore agglomerate quality plays a vital role in decreasing the reducing agent consumption and increasing the productivity of blast furnace. In most of the integrated steel works, the burden mix for blast furnace is decided as per the availability of the iron ore agglomerates like sinter and pellets. More attention has been given in recent years to the use of fluxed pellets in blast furnace due to their good strength and improved reducibility, swelling and softening melting characteristics. Generally, quality of pellets is influenced by the nature of ore or concentrate, associated gangue, type and amount of fluxes added and their subsequent treatment to produce pellets. These factors in turn result in the variation of physicochemical properties of the coexisting phases and their distribution during pellet induration. Hence properties of the pellets are largely governed by the form and degree of bonding achieved between ore particles and the stability of these bonding phases during reduction of iron oxides (Panigraphy et al., 1990). It is important to note that conditions and parameters of pelletizing are specific to given ore or concentrate; the present study is undertaken for typical Indian hematite ore fines high in alumina. Except authors earlier work on quality of pellets from Indian iron ore (Dwarapudi et al., 2008, 2010), there is no considerable literature reported on the effect of pellet basicity and MgO content in the basicity range of 0 to 0.8 for Indian hematite ore."

Jan 1, 2018

By Susanna G. de Jager, Francis W. Petersen

"The aim of the project was to develop a methodology applicable to different South African coal types to be able to predict with a high degree of certainty what kind of reagent will be suitable for flotation of a certain coal type.The study included 5 coal samples from different collieries and included Highveld seam 3 and 4 coal (as one sample), Waterberg coal (zone 10 -11), Highveld seam 5 upper coal and Witbank seam 2 and seam 4 coal. Seam 3 and 4 (mixture) coal, Waterberg and the seam 5 upper coal were all found to be vitrinite rich coals. The coal characterisation study included petrographic analysis, proximate analysis, float-sink analysis, oxygen-containing functional groups, surface extraction, flotation release analysis and contact angle measurements.The flotation tests showed that the best reagents to float all of the coal samples studied are iso-decanol and dodecene. These reagents produced flotation products that are near to the release curve. Statistical relationship for predicting ash content and yield that can be expected for a certain coal type and selected collector was obtained. From the relationship, the accuracy of the yield is above 95% (p-value below 0.05) with a linear regression of 0.9289. The accuracy of the ash is slightly lower with a linear regression of 0.7841 but also above 95%."

Jan 1, 2003