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By Roberto C. G. Oliveira, Scott C. Brown, Brij M. Moudgil

"The wettability or surface energy of particle surfaces dictates a number of multiphase ensemble interactions that have a significant impact in mineral processing. Dispersion, bulk powder handling and flotation are just a few of the processes that are largely influenced by the degree of hydrophillicity or hydrophobicity on particulate surfaces. Because of the importance of surface wettability, a number of simple, precise and accurate techniques for accessing surface wettability or contact angle on macroscopic flat surfaces have been developed. However, these techniques cannot be directly applied to the particulate surfaces that are often in query. Though a number of techniques are available for accessing the wettability of particulate surfaces, these methods are either relative, application specific or prohibitively tedious. In the present study, key features of existing techniques are combined to formulate an improved method to delineate particle wettability that is simple, versatile and capable of providing reproducible measurements in an industrial environment.Through the use of an inert adhesive and an inert macroscopic surface as a support, it is illustrated that precise measurements of particle wettability are obtainable under suboptimal or ‘shop floor’ conditions. The measurement of the maximum external meniscus height formed between a test liquid and a particlecoated rod is employed to estimate phenomenological contact angles on particles ranging form a few nanometers to several hundred microns in size."

Jan 1, 2003

By Dominic Howarth, Diana Drinkwater, Don McKee

"The pressures on mining and minerals education at the tertiary level are well known. Within Australia, for example, the number of undergraduate mining engineering courses with 30 or more students in each year has reduced to three (University of Queensland, University of New South Wales and Curtin University). Similar declines in both student numbers and participating institutions are evident in many other parts of the world, and notably in USA and most countries in Europe.An in depth study of the Australian sector was conducted in 1997/1998, resulting in the Back from the Brink report (Carter 1998). The Australian situation was summarised as follows.Australia’s minerals education system, in its current form, is fragile and is in no position to seize the opportunity (i.e. world leadership in minerals education) and is more likely to succumb to the threat.Current trends include:- an acute shortage of talented academic staff, as a result of University remuneration packages having become hopelessly uncompetitive with those in the minerals industry;- small student populations and high relative costs, making mineral specific courses vulnerable to closures, when Universities are under extreme cost pressures; this situation will be exacerbated if enrolments drop in response to, say, a cyclical down turn in the industry; and- under-resourcing of minerals departments because of their comparatively small size, making these departments incapable of delivering top class teaching in all aspects of their courses, despite being excellent in some areas.Most of the Australian issues identified above have direct parallels in other countries.The most common response of institutions to the threats is to seek strength, and in some cases survival, through various forms of linkages and networks. A number of these associations, which are frequently defensive in nature, are outlined in the paper."

Jan 1, 2003

By John Nell, Paul den Hoed

Carbochlorination tests were conducted with matched particle-size fractions of rutile, ilmenite and high-titania slag in a small bubbling fluidized-bed reactor. The effects of temperature, the type and proportion of solid reductant in the charge, and the fraction of Cl2 in the fluidizing gas were investigated. Tests confirm the need for solid carbon in the bed if chlorination is to run at high rates. With solid carbon in the bed, CO supplied with the fluidizing gas does not increase significantly the degree of chlorination after 75 minutes. Ilmenite is chlorinated more quickly than titania slag, which in turn is chlorinated more quickly than rutile. Rates of chlorination at 1100°C and 1000°C are much the same and significantly higher than at 900°C. Chlorination is associated with significant increases in particle porosity (even for rutile), which is brought about by the rapid initial chlorination of FeO and MnO (in ilmenite and slag) and (it is argued) by the chlorination of Ti2O3 which forms at high-energy surface sites. A reaction mechanism is presented; where possible, its validity is demonstrated by the support of empirical observations.

Jan 1, 2003

By M. Barsky, E. Barsky

It is generally accepted that the optimal flow velocity for gravity classification is the final particle settling velocity or, which is the same, the particle spin velocity. However, we have found differences between the settling velocities and the spin velocities of the very same particles. Here we present the results of experiments in a cascading gravitational classifier comprising eleven stages. The feed material was introduced at each stage successively, from the first to the eleventh. The optimal flow velocity was determined for each case. From these experiments it follows that the value of the optimal flow velocity depends to a greater extent on the point of introduction of the feed (i.e., on the design of the device) than it does on the interaction between the solid phase and the flow.

Jan 1, 2003

By P. N. Mohan Das, K. Harikrishna Bhat

"The major ilmenite reserves are located in India at Chavara (CH), Manavalakurichi ( MK) and Chatrapur, Orissa (OR). India stands first in terms of ilmenite reserves, which are estimated to be 278 million tonnes out of which, 142 million tonnes are processable. Mineralo-chemical analysis showed that Chavara ilmenite is the most weathered one with about 60% TiO2 while Chatrapur is the least weathered with about 50% TiO2. XRD and SEM studies of different magnetic fractions of these three mineral deposits established the co-existence of ilmenite with pseudorutile, rutile and haematite phases in substantially varying amounts. It is observed that the tropical weathering rather than the source rock difference has apparently played an important role in imparting major compositional and structural dissimilarities among the ilmenites in different places. Further, the chemical analysis, XRD and SEM characterisation of differently weathered samples of MK ilmenite separated by the magnetic fractionation showed that the degree of alteration was invariably associated with the decrease in magnetism, increase in the rutile phase and the change in Fe2+/Fe3+ ratio of ilmenite grains. Magnetically separated fractions when subjected to metallisation with carbonaceous reductant such as coke showed that the degree of reduction increases with the degree of alteration and with the decrease in the Fe2+/Fe3+ ratio.In the processing of ilmenite through the Becher process, aeration rusting of pre - reduced ilmenite is found to be the rate-limiting step thus, affecting the productivity and economy of the process. Investigations have proved that the addition of some organic compounds such as glyoxal, sucrose etc., to the system accelerates the reaction to such an extent that the rusting time has been reduced to less than half. The formation of acids by the these organic compounds during the rusting reaction was proved responsible for maintaining the pH of the solution in the range 3-4 at which iron hydroxide do not precipitate and block the pores in the reacting surface of the grain."

Jan 1, 2003

By Roberto C. G. Oliveira, Scott C. Brown, Brij M. Moudgil

The wettability or surface energy of particle surfaces dictates a number of multiphase ensemble interactions that have a significant impact in mineral processing. Dispersion, bulk powder handling and flotation behavior are just a few of the parameters that are largely due to the degree of hydrophillicity or hydrophobicity on particulate surfaces. Because of the inherent impact of surface wettability in nearly all industries, fields, and multi-phase interactions, a number of simple, precise and accurate techniques for accessing surface wettability or contact angle on macroscopic flat surfaces have been developed. However, these techniques cannot be directly applied to the particulate surfaces that are often in query. Though a number of techniques are available for accessing the wettability of particulate surfaces, these methods are either relative, application specific or prohibitively tedious. In this study, key features of existing techniques are combined to formulate an improved method to delineate particle wettability that is simple, versatile and capable of providing reproducible measurements in an industrial environment.

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 Larry A. Cramer

"Three primary drivers are setting the trend for base and precious metal processing . they are: continued low real base metal prices, environmental concerns, and continued high prices for PGM.s. Low base metal prices are increasing the search for economies of scale and company consolidation as well as the development of some hydrometallurgical technologies. Environmental concerns are pushing for continued reductions in SO2 emissions and hydrometallurgical technologies. The high prices for PGM.s are driving major expansions and a focus on minerals processing recoveries and, to a lesser extent, reductions in the refining metal lockup.In nickel, HPAL operations on laterites have failed economically but Inco is still pursuing some alternatives. BHP-Billiton and others are developing bioleaching alternatives for nickel laterites and sulphides.Copper continues to be dominated by the hydrometallurgical and pyrometallurgical debate; new hydrometallurgical developments are being tested at several sites whilst the pyrometallurgists continue to make competitive cost and environmental improvements.Gold processing developments are dominated by the use of improved gravity recovery equipment and by the development of thiosulphate as a more environmentally acceptable lixiviant.PGM processing trends are the use of fine grinding technologies, higher power input flotation cells, and new pyrometallurgical technologies. Hydrometallurgical options for some applications are being sought.OVERVIEW The metals industry has remained under price pressure for some time; low and decreasing real prices for most metals have become an expected scenario. Occasional price spikes give some relief but invariably bring expansions and new entrants into an already oversupplied commodity market, thus leading to the continued price pressure. Technical innovation, economies of scale, and improved work systems are continually sought, so as to improve the competitive position of each individual company in such a climate; however, these developments add to the downward price pressure. In such a situation the application of scarce funds to research and development is a difficult task. Excess funding is not available in tight economic times and yet the main route to higher profits is clearly the application of technical developments to lower the cost of producing a metal commodity. Many technical centers have closed as a cost saving exercise and some have coalesced to obtain economies of scale. The Australian based AMIRA research organisation has grown to serve the R&D part of the market well in Australia and in South Africa by acting as the catalyst to form research partnerships between a number of industry players and as an administrator to direct the funding of research projects towards the various applicable research institutions. AMIRA has developed closer ties to Camiro (Canadian Mining Research Organisation) through the appointment of Camiro.s metallurgical processing research director as AMIRA.s North American based director. AMIRA is continuing discussions with MIRO (Minerals Industry Research Organisation) in regard to a merger, with a report outlining the merger proposal expected in March of 2003. Company focused research centers continue to be effective at Anglo American Research Labs, Teck-Cominco Research, Falconbridge Research center, Inco Research and some others."

Jan 1, 2003

By T. Norvell, R. Gosine, S. O’Young

"This paper describes the use of dynamic scheduling and discrete event control to provide coordinated control of multiple automated vehicles. This work has been carried out within ongoing research into multi-robot coordination developed around the underground mining scenario. Demonstrations using scaled laboratory models of underground mines illustrate the potential for this technology for full-scale implementation for mine-wide automation. IntroductionIn the past decade, the mining industry has been improving the efficiency of underground mining operations. Robotics and automation have demonstrated the potential to further reduce costs. Tele-operation of underground vehicles from above ground and autonomous navigation have reduced travel delays and allowed for single operator control of multiple vehicles (Bloomquist and Hinton, 2001). Other recent projects include the automation of the digging process as well as the drilling and blasting operations. Infrastructureless guidance systems are also being developed (Bloomquist and Hinton, 2001).Mine-wide automation requires significant developments at two levels: (1) the development of mining robots capable of performing tasks either autonomously or semiautonomously; and (2) the development of methods for automating operations at a systems level. This paper focusses on the latter, and describes a general framework for the coordination of multiple mobile robots in an unstructured or semi-structured environment."

Jan 1, 2003

By K. W. Stöckelhuber, A. Wenger, H. J. Schulze

"An important elementary step of the flotation process is the forming, drainage and rupture of a thin intervening liquid film between bubble and mineral particle.After the encounter of the bubble with the solid surface a wetting film is formed. The initial thinning of this film is driven by the capillary pressure inside the bubble. When the film has reached a certain thickness rupture can take place. There are two possible mechanisms describing this process:(a) Gas nucleation, caused by nano bubbles inside the film.(b) Growing fluctuation waves (spinodal dewetting) on fluid interfaces under the influence of any kind of attractive forces (electrostatic, van der Waals).Metastable wetting films on negatively charged, hydrophobic glass surfaces (gaseous phase methylated), or on hydrophilic, positively charged glass surfaces (with Al3+ ions), have been analysed by means of the kinetics of film thinning according to the Reynolds law. These experiments demonstrate that both mechanisms can be responsible for the rupture of a thin wetting film."

Jan 1, 2003

By Volker Vogt, Wolfgang Sand, Eberhard Gock

"For about 20 years, the use of bacteria to control the flotation process for the production of raw material concentrates has been the subject of worldwide scientific and engineering efforts. The objective is to reduce the consumption of biologically non-degradable toxic reagents. The principle idea is to use the activity of bacteria in natural leaching processes – known since the middle of the last century – for controlling flotation processes.It was discovered that the selective activity of bacteria during the extraction of raw material concentrates by means of flotation could also be achieved with extracellular polymeric substances (EPS), excreted by bacteria. EPS, which is extracted by means of centrifuging bacterial cultures, can help to significantly reduce the use of cyanides, approximately 200,000 t/a are used for ore dressing today.The bacterium used was Acidithiobacillus ferrooxidans. In order to identify the bandwidth of the oxidation activity, 21 bacterial strains of the strain collection of the University of Hamburg were attracted to iron(II) sulfate and pyrite under defined conditions. All strains oxidized iron(II) sulfate ten times faster than pyrite.EPS has so far been derived from four strains. In general, EPS extracts are divided into a hydrophilic and a hydrophobic fraction. The hydrophilic fraction is composed of e.g. fucose, rhamnose and glucose; fatty acids such as dodecanoic acid, hexadecanoic acid, octadecanoic acid and nonadecanoic acid were found in the hydrophobic fraction. Pure mineral phases and mineral mixtures were used for the flotation tests. The outcome was reproducible results with technical flotation machines. The research results known so far are mainly based on investigations with micro flotation devices, which are usually used for the characterization of reagents and which do not allow a direct translation to the technical scale."

Jan 1, 2003

Thallium is a very minor element found in lead ores. It's behaviour during lead smelting has recently become of much greater interest due to the effects it had on the health of waste heat boiler maintenance contractors at a Canadian smelter. In this paper the behaviour of thallium in both traditional and direct lead smelting processes will be examined using computational thermodynamics techniques. Yazawa and his coworkers have made extensive use of computational thermodynamics to examine and illustrate pyrometallurgical processes. It has been shown that thallium behaviour during smelting is strongly influenced by the extent of oxidation of the lead concentrate and by the presence or absence of chlorine in the charge. The condensation behaviour of thallium species in the waste gas handling system was also modelled and it has been confirmed thallium-rich deposits can form at the high temperatures prevailing in waste heat boilers.

Jan 1, 2003

By J. B. Rubinstein

"The paper gives an overview of the history of flotation machine development. The laws of their evolution are stated and the place and role of column flotation are demonstrated.The major parameters of column cell diameter and height are discussed. Options are proposed for optimization of the hydrodynamic characteristics of large-capacity column cells. The high efficiency of columns with cell height of 4-6 m is demonstrated. The optimum parameters of multisectional column machines are determined. Their advantages compared to monocells are shown. A scaling-up procedure for column machines was developed based on flotation macro- and microhydrodynamics simulation."

Jan 1, 2003

By A. V. Nguye, P. A. Harvey

Previous studies have reported that inorganic electrolytes can enhance floatability of coal. The research has shown that the enhancement, if any, is highly dependent on changes in solution pH, type of electrolyte, and electrolyte concentration. The reasons for this are still not clear. In this study the floatability of coal particles in mono and divalent salt solutions was investigated. The zeta potential and hydrophobicity of the coal was measured experimentally, and a modified Hallimond tube was used to determine the floatability of coal particles by single bubbles, where the collision efficiency was equal to unity. The experimental information was used in conjunction with the Hogg-Healy-Fuerstenau equation to quantify the electrical double layer interaction. It was found that for low electrolyte concentration (less than 0.1 M) solutions the flotation recovery of coal particles was less than that for distilled water, and decreased with increase in concentration. Conversely, at electrolyte concentrations above 0.1 M, flotation recovery increased with increasing concentration. Both of these results are consistent with previous observations, but are inconsistent with expectations when considering the possible influence of electrical double layer interaction. A possible mechanism, based on the existence of the pre-existing submicron-sized gas bubbles, known as bubstons (i.e. bubbles stabilized by ions), present in water in close proximity to the hydrophobic coal surfaces is discussed in line with the early observation of flotation improvements by microbubbles “nucleating” on hydrophobic surfaces. In particular, the dependence of the bubble-particle attachment efficiency on electrolyte concentrations supports hypothesis on the salt-dependent and ion-specific existence of bubstons. However, a theoretical explanation of the transition salt concentration (at about 0.1M) is deficient at present. The existence of these submicrobubbles in close proximity to hydrophobic surfaces is not trivial. They can (as can individual gas molecules or other solutes) mediate and extend the range and magnitude of the attraction between hydrophobic macroscopic surfaces. These bubbstons may explain the curious phenomena of the socalled long-ranged hydrophobic attraction measured with the Surface Force Apparatus and Atomic Force Microscopy, and the slippage at hydrophobic surfaces. Finally, the coalescence of bubbstons affects the rupture of liquid films at a very large thickness (over 100 nm), observed, but unexpected, by flotation chemists.

Jan 1, 2003

By Johan Nell, Paul den Hoed

"Carbochlorination tests were conducted with matched particle-size fractions of rutile, ilmenite and hightitania slag in a small bubbling fluidized-bed reactor. The effects of temperature, the type and proportion of solid reductant in the charge, and the fraction of Cl2 in the fluidizing gas were investigated. Tests confirm the need for solid carbon in the bed if chlorination is to run at high rates. With solid carbon in the bed, CO supplied with the fluidizing gas does not increase significantly the degree of chlorination after 75 minutes.When large proportions (30 wt%) of carbon are added to the charge, then the reactionTiO2 + 2C + 2Cl2 = TiCl4 + 2COis favoured overTiO2 + C + 2Cl2 = TiCl4 + CO2Ilmenite is chlorinated more quickly than titania slag, which in turn is chlorinated more quickly than rutile. Rates of chlorination at 1100°C and 1000°C are much the same and significantly higher than at 900°C. Chlorination is associated with significant increases in particle porosity (even for rutile), which is brought about by the rapid initial chlorination of FeO and MnO (in ilmenite and slag) and (it is argued) by the chlorination of Ti2O3 which forms at high-energy surface sites."

Jan 1, 2003

By R. D. van der Weijden, W. F. C. van Wageningen

"Copper(II) can be recovered or removed from acidic copper sulfate solutions as cuprite or metallic copper powder by reduction with carbohydrates (van der Weijden et al., 2001, 2002). In order to make this process suitable for a commercial scale pipe reactor, process conditions and reactor configuration need to guarantee proper throughput of the dilute suspension. This is where crystal engineering also comes into view. Copper powder characteristics, such as size and shape of particles, influence the tendency to adhere to reactor walls and to agglomerate, which in turn influence the throughput. Furthermore, separation, drying, packaging and product quality, are dependent on the powder characteristics.In this paper the effect of both chemical and physical parameters on the shape and size of particles were systematically studied in a number of autoclave experiments. These parameters include mixing, Cu(II) concentration, pH, temperature, seeding, use of additives and reactor materials. Additionally, Monte Carlo simulations of copper growth inside a Kenics static mixer were made. Results show that the use of additives, and the use of static mixers influence particle characteristics the most."

Jan 1, 2003

By Patrick A. Turner, Timothy J. Olson, Abraham J. Schutte, Roman van Ommen

"The use of classifying devices in grinding circuits dates back to the early 1900’s when classifiers were installed to close ball mills. The search for ways to further improve grinding circuits led to the use of hydrocyclones in place of mechanical classifiers in South Africa in the early 1950’s. Today Hydrocyclones are considered as the best classifying devices to close grinding circuits. After 50 years of development the hydrocyclone has changed significantly when compared to the designs of the early days, but the focus to circuit optimization must be expanded to an understanding of the integral system consisting of mill, cyclone feed pump and cyclone.The key to good cyclone circuit design and operation in primary grinding circuits will be discussed including individual cyclone design features such as cone angle or materials of construction, as well as orientation and manifold configuration.Cyclone performance issues as well as maintenance considerations will be detailed in an effort to achieve consistent cyclone operation with minimal coarse solids in the overflow. “The importance of constant cyclone feed conditions is unquestioned today. The challenge of Cyclone sizing is a large number of not fully known variables prior to startup. The most significant unknown variable is slurry viscosity. Because of this, engineers often specify a conservative cyclone system that produces a finer than required separation. However, this approach often leads to higher circulating loads and a higher overflow density in order to produce the required separation. The higher cyclone overflow density results in a less efficient cyclone separation. The average concentrator can pick up 2-4% finer overall grind by having a more aggressive cyclone operation.”"

Jan 1, 2003

By Hong Nguen Vu, Pavla Ovcarí, Peter Fecko, Barbara Tora

"The goal of the work was verification of bacterial leaching on the samples of black coal. From the results obtained it was clear that the coal is very well leached by Thiobacillus ferrooxidans and this technology can be used for coal desulphurization. A leaching time of one month is required, to remove 65% of total sulphur and 85% of pyritic sulphur.Microscopic evaluation of samples from Jaworzno showed, that it should be classed as a coal with low coalification, probably from black coal hemiphase. Macerals of the liptinite group were well distinguishable; they were of a dark brown colour. Evidence of coal mass oxidation was apparent on the fresh sample; in the test samples (during bacterial leaching) small grains were oxidised."

Jan 1, 2003

By L. Lariviere, M. Grenier, R. Khalili, D. Shook

A mineral processing facility near Montreal, CEZinc, Noranda Inc., has recently implemented a leading-edge intranet solution for monitoring the performance of plant operations, and providing condition-based maintenance. This innovative multi-faceted software implementation incorporates: web-delivered plant information systems; area-wide control loop performance assessment (using sophisticated algorithms to evaluate poorly performing controllers); and integrated alarm management functions.The system has enabled a project to improve plant operations through better process control. Maintenance technicians, engineers, supervisors and managers all can see the performance of the controllers, and the performance of the plant itself, through webdelivered graphics and reports. Information is combined from many sources, real-time, historical, relational and analytical, to provide a complete picture of plant operation.The web-based solution centralizes the administration of user access, and simplifies the deployment of several different kinds of information to many desktops. It is an extensible system that allows users to create and share their own web pages and data views.The paper will discuss the solution architecture and the improvements the IT, operations, maintenance, and engineering groups have experienced, and overall benefits to the facility.

Jan 1, 2003

"The Merensky Reef is a platinum group minerals (PGM) bearing reef in the Bushveld Igneous Complex in South Africa. The reef has been treated by bulk PGM and sulphide flotation with the aim of maximisingthe valuable minerals recovery and gangue minerals rejection.Synthetic water with a calcium concentration of 80 ppm and 500 ppm was prepared and the flotation results obtained were compared to a simple electrolyte in order to determine the effect water quality has on pentlandite and pyroxene surface alteration and, ultimately, floatability. During the study, the possible effect of interactions between the minerals investigated and Ca2+ ions in the presence of sodium isobutyl xanthate was studied at pH 6 and pH 9 by means of zeta potential determinations, microflotation tests and ToF-SIMS analysis.The results obtained on 1:1 pentlandite-pyroxene mixtures showed that the quality of process water plays an important role in flotation. The flotation recoveries of pentlandite and pyroxene were lower in synthetic process water compared to those obtained in a simple electrolyte solution."

Jan 1, 2003