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By L. Kuzev

Unknown and unpopular vibrational grinding mills possibilities to horizontal working chambers have been discussed. They can be realized under normal conditions with the typical values of vibrations applied with vibrational grinding which are: vibration frequency from 15 Hz to 50 Hz, vibration amplitude to 6 mm and vibration geometry. These possibilities constantly increase involving new raw materials and processes. Vibration grinding is possible with other technological process accompanied by intensified technological processing, while the process decreases. In many cases these technological decisions are original.

Jan 1, 2014

Calcium carbonate has three polymorphs: calcite, aragonite, and vaterite. Needlelike aragonite CaCO3 with a high ratio of length to diameter (aspect ratio) is widely used in plastics, rubber and ceramics as a filler and in pigments and paints as a carrier. This paper investigated the influence of H3PO4 dosage, reaction temperature, CO2 flow rate, and initial Ca(OH)2 concentration on formation of needlelike aragonite CaCO3. It was found that the presence of H3PO4 in Ca(OH)2 suspension resulted in rapid formation of (Ca5(PO4)3(OH)) crystal nuclei, which facilitated nucleation and growth of aragonite CaCO3 on the formed (Ca5(PO4)3(OH)) crystal surfaces. The results revealed that H3PO4 addition of P/Ca of 0. 2~0. 3, high temperature of 75~85 °C, low CO2 flow rate and initial Ca(OH)2 solid concentration of 1. 5 %~5. 6 % are beneficial to formation of aragonite. Well crystallized needlelike aragonite CaCO3 whiskers with length > 20 µm and aspect ratio > 15 were directly synthesized.

Jan 1, 2014

By S. H. Lau

Rapid 3D characterization of multiphase mineral particles in a variety of mineral processing applications is described, including: mineral liberation analysis, grain size, mineral exposure analysis, particle damage, and pore network structure for fluid flow simulation in heap leaching. While micro X-ray computed tomography systems (microCTs) have been used for many years, industrial adoption is limited due to a variety of reasons, including insufficient resolution, the general lack of imaging contrast to differentiate different mineral phases within a multiphase mineral particle and the lack of automated 3D mineral processing software. For example, resolution with industrial CTs and desktop microCT is of the order of tens of microns to a few microns at best, depending on specimen size and CT configuration. We describe a novel lab-based X-ray microscope, XRM, which overcomes these resolution and contrast limitations, notably as the industry is going towards finer grains and more complex ore bodies. Using lens-based optics and detectors (similar to its XRM counterpart in synchrotron beam lines), resolution of the lab based system is in the submicron range with contrast better than conventional microCTs. Hence, visualization, differentiation and segmentation of most mineral phases of interest to the industry are now feasible. Coupling these high resolution and high contrast tomography images with a suite of customized 3D segmentation algorithms and analysis software, applications in mineral liberation analysis for process control, particle damage assessment and other mineral processing applications can be achieved. This non invasive 3D technique which requires relatively little sample preparation is currently being considered for coal, industrial minerals, and base/precious metal ores, complementing existing microscopy techniques such as QEMSCAN and MLA for a variety of applications

Sep 1, 2012

By J. P. Dai

The Fankou Mine in Guangdong province, China, processes a polymetallic ore containing averagely 4.2% Pb, 8.5% Zn, and 90 g/t Ag. The main metal minerals including sphalerite, galena and pyrite are very finely disseminated and unevenly occurred in the ore, making it difficult to liberate them from each other. This paper presents the processing technology of the Fankou plant and the characteristic features of the novel technology applied.

Jan 1, 2014

By P. Somasundaran

Treatment of mineral surfaces with appropriate surfactants plays an important role in mineral processing operations such as flotation, flocculation and dewatering. Recently biosurfactants, in particular, have received a considerable amount of attention because of their unique surface active properties and biodegradability. In this work we examined the performance of biosurfactants, sugar based alkyl glycosides and sophorolipid esters as reagents to control the hydrophobicity of minerals with selectivity of adsorption on mineral surfaces for flotation applications. It was discovered that n-dodecyl-ß-D-maltoside adsorbs on alumina, titania and hematite but, interestingly, not on silica. The hydrophobicity obtained is governed both by the surface coverage as well as the nanostructure of the adsorbed layer in terms of orientation of the adsorbed species. Surprisingly, even though the above surfactants are non-ionic, their adsorption was pH-dependent. We have correlated this pH dependence to the type of species on the mineral surface. Also it is shown that mixing of these surfactants with traditional ones can help reduce the carbon footprint due to synergy between the reagents and help selectivity due to antagonism. The experimental results were analyzed to get information on optimal pH and dosage conditions, for mineral surface modification. The study provides guidance for mineral treatments using biosurfactants and the potential use of these next generation reagents in mineral processing.

Jan 1, 2014

By E. Guerrini, M. Maccagni, J. Nielsen

"The solution for the treatment of the EAFD has not yet been fully achieved. Some of this dust has still not found an appropriate final destination. Large consortium treatment plants are quite expensive both in terms of investment and operating cost. Meanwhile, the tolling expenses for steel production companies are becoming very important, causing them to look for alternatives. Some steel plants are looking to close their production loop by internal treatment of their dust. Some years ago, Engitec began studying the coupling of the EZINEX® Process, an ammonium chloride electrolysis to recover the zinc contained in the EAFD, with the INDUTEC® Process, a pyro process based on an induction furnace that can convert EAFD into a C.Z.O. similar to the Waelz oxide. The combination of these two processes provides an alternative to the existing treatment options and is particularly interesting for relatively small capacities. In this paper, we would like to give the latest update about these two processes and their possible integration INTRODUCTION Zinc is contained in numerous wastes and secondary raw materials that can be thought of as high zinc concentrate mines. This is a very interesting source of Zn that is typically easily exploitable. Unfortunately, only a portion of these materials are currently processed to recover the metal value, while stabilized or unstabilized landfilling is often the final destination. Pyrometallurgical processes are mainly used to convert the zinc into crude zinc oxide (CZO). The various processes are very similar and characterized by the fact that the zinc bearing materials are usually submitted to a thermal treatment [1] in which the zinc is reduced, vaporized and re-oxidized producing CZO. This material not only contains zinc oxide, but also relatively high concentrations of heavy metals. Many potential CZO sources, such as electric arc furnace dust (EAF), galvanizing ashes, brass foundry and converters fumes also contain chlorides, fluorides and alkali metals that will transfer to the CZO. The classic example is the Waelz oxide [2]. This CZO is an intermediate product that must be transformed into zinc salts or zinc metal. Until now, the conversion to zinc metal is done through two main processes: the sulphate leaching and electrowinning system and the Imperial Smelting Process (ISP). ISP is facing a crisis for technical and economic reasons that has led to the closing of most of the existing plants. In any case, before being fed to one of these two processes, the CZO must be treated to eliminate or reduce some of the contained impurities. In particular, the halides are most harmful to these processes."

Jan 1, 2018

Mineral processing is an energy and water intensive activity. Mill comminution equipment usually has high energy requirements which necessitate extensive cooling to remove heat. Cooling requirements are typically 10% to 20% of the comminution energy. If there is an adequate supply of suitable water, open water-based cooling systems are the simplest, cheapest and most energy efficient cooling method available. This paper describes a method to determine the water demand for open water-based cooling systems at a plant and to determine whether the mine has sufficient water to meet that demand.

Jan 1, 2014

By K-O. Mickelsson, S. Töyrä, H. Esbensen

Accurate information of physical, chemical and metallurgical quality characteristics such as moisture content, iron grade and particle size are crucial for successful process control and for producing products within customer specifications. Correct moisture content of pellet feed is an important variable for successful balling of iron ore pellets and to minimize power consumption in the sintering process. Control of the filtering process in the pelletizing plant is therefore essential for both productivity and high product quality. The current measurement systems for moisture content at LKAB are based on two types of manual grab sampling, subsequently analyzed with rapid moisture determination methods. Previous studies of the measurement systems have indicated high sampling variability resulting in lowered possibilities for successful process control. The objective of the present study is to evaluate an alternative filter sampling approach and testing of on-line Infra-Red analysis (IR-analysis). On-line IR-analysis has the advantage of eliminating physical sample extraction and allowing for continuous monitoring of moisture content. However, this approach is sensitive to the surrounding environment, making careful calibration and control crucial for the quality of measurement results. Furthermore, as IR-sensors only target the surface of the conveyed pellet feed, several incorrect sampling errors need to be considered and counteracted to eliminate sampling bias and reduce the remaining measurement variability. Variographic characterization was applied to the two current grab sampling approaches of combined filtered material, to the alternative filter sampling method, and to the On-line IR-analysis. The results indicate that both the sampling of separate filters (using composite sampling and ISO-standardized moisture analysis), as well as a calibrated and well- maintained IR-sensor can improve the relative variability significantly, by lowering the total measurement system variance from 60% to 25%.

Jan 1, 2018

By G. H. Lind

The Minerals Tertiary Education Council (MTEC), over the past decade, has worked closely with Australian higher education partners in metallurgical education to build capacity in this discipline to deliver high quality graduates for the Australian minerals-industry. This paper explores the benefits of industry engagement through a national innovative collaboration, the Metallurgical Education Partnership (MEP), and specifically the final year Process Design Project (PDP), over the four year period from 2008-2011. Some of the benefits discussed in this paper include outcomes of the student experience during an industry-intensive workshop, collaboration between higher education providers and aligning graduate attributes to meet industry requirements.

Sep 1, 2012

By P. Raghavan1

Reverse froth flotation experiments were carried out in the laboratory using two different types of kaolins for the separation and removal of coloring titanoferrous impurities from cryo-filtered clay after subjecting to high shear pre-treatment. This high shear pre-treatment consists of high shear agitation of a high solids clay slurry with the dispersant (high shear dispersion, HSD) followed by high shear agitation with the collector (high shear conditioning, HSC). After this pretreatment, the slurry is diluted and reverse flotation is carried out. One sample is from, Gujarat, India (Mamuara clay, ?MC?) while the 2nd sample is from Amberg, Germany (AKW clay, ?AC?). While MC consisted of 89% particles below 2µm and analyzed 1.06% of TiO2 and 0.29% Fe2O3 and measured a brightness of 83.4 %ISO, the corresponding values for AC are 67% below 2µm, 0.3% of TiO2? 0.49% Fe2O3 and 83.4 %ISO. The flotation performance is found to be greatly influenced by the conditions of high shear treatment. Important variables are HSD intensity (rpm), HSD time, HSC intensity (rpm), HSC time, HSD/HSC time ratio, ?HSD+HSC? total time etc. Higher shear intensities favor both the impurity liberation and collection. For both clays, it could be shown that impurity removal increases as total pretreatment time (?HSD +HSC? total time) increases up to a certain limit. For MC, the HSD time was only half or less than that of HSC time, while for AC, HSD time is at least twice (or more) than HSC time which is just an opposite manifestation. This is believed to be due to the striking differences between these two clays. Most importantly, the shear frequency is found more influential than the shear rate for the overall flotation performance for both clays. Interestingly, at high shear frequencies, i.e., when a stirrer with more number of teeth on the rotor is used, the ?HSD+HSC? total time is greatly reduced. Again, increased shear frequency helps to reduce flotation time and significantly improves flotation performance. At optimum conditions, product titania reduced to 0.35% for MC whereas the same reduced to 0.13% for AC. The product of flotation of MC measured 85%ISO brightness while that of AC measured84.6%ISO thus enhancing the value of the final product. It could also be established that the high shear pre-treatment shows better flotation performance than that due to collector dosage. Keywords: high shear dispersion, high shear conditioning, titanoferrous impurities, shear rate, shear frequency, brightness, clay recovery, Mamuara clay, AKW clay

Sep 1, 2012

By Swati Mohanty

Spiral concentrator, which works on the principle of gravity separation, is widely used in the mineral industries for separation of solid particles based on the size and density. In the present study, CFD simulation of the flow profile on a laboratory scale spiral concentrator of height 2.29 m, pitch 0.435 m and width 0.17m was carried out. A single computational domain covering the entire spiral was considered. Volume-of-Fluid algorithm was used to track the interface and predict the flow profile. In the present study the Donor-Acceptor method was used for the calculation of volume fraction in the cell. Simulation results show that the velocity increases as the water flows down due to the convective force and gravitational force, but the viscous force acting in the opposite direction retards the flow. Thus the maximum velocity is attained at turn three at which the viscous force overpowers the other forces and further down the velocity decreases. Measured water depths along the radius of the spiral at various heights were compared with simulated depths, which were in good agreement. The simulated liquid phase velocity profile was used to carry out preliminary studies on the flow profile of solid particles of size 500 micron and densities 2600kg/m3 and 5100kg/m3, based on the Lagrangian model taking into consideration fluid-particle interaction.

Sep 1, 2012

By E. Guerrini, M. Maccagni, J. Nielsen

"The solution for the treatment of the EAFD has not yet been fully achieved. Some of this dust has still not found an appropriate final destination. Large consortium treatment plants are quite expensive both in terms of investment and operating cost. Meanwhile, the tolling expenses for steel production companies are becoming very important, causing them to look for alternatives. Some steel plants are looking to close their production loop by internal treatment of their dust. Some years ago, Engitec began studying the coupling of the EZINEX® Process, an ammonium chloride electrolysis to recover the zinc contained in the EAFD, with the INDUTEC® Process, a pyro process based on an induction furnace that can convert EAFD into a C.Z.O. similar to the Waelz oxide. The combination of these two processes provides an alternative to the existing treatment options and is particularly interesting for relatively small capacities. In this paper, we would like to give the latest update about these two processes and their possible integration INTRODUCTION Zinc is contained in numerous wastes and secondary raw materials that can be thought of as high zinc concentrate mines. This is a very interesting source of Zn that is typically easily exploitable. Unfortunately, only a portion of these materials are currently processed to recover the metal value, while stabilized or unstabilized landfilling is often the final destination. Pyrometallurgical processes are mainly used to convert the zinc into crude zinc oxide (CZO). The various processes are very similar and characterized by the fact that the zinc bearing materials are usually submitted to a thermal treatment [1] in which the zinc is reduced, vaporized and re-oxidized producing CZO. This material not only contains zinc oxide, but also relatively high concentrations of heavy metals. Many potential CZO sources, such as electric arc furnace dust (EAF), galvanizing ashes, brass foundry and converters fumes also contain chlorides, fluorides and alkali metals that will transfer to the CZO. The classic example is the Waelz oxide [2]. This CZO is an intermediate product that must be transformed into zinc salts or zinc metal. Until now, the conversion to zinc metal is done through two main processes: the sulphate leaching and electrowinning system and the Imperial Smelting Process (ISP). ISP is facing a crisis for technical and economic reasons that has led to the closing of most of the existing plants. In any case, before being fed to one of these two processes, the CZO must be treated to eliminate or reduce some of the contained impurities. In particular, the halides are most harmful to these processes."

Jan 1, 2018

By H. R. Manouchehri

"In mining and minerals industry, except profitability, there are some crucial factors that represent components in economic machinery of a mine and related activities. These are sustainability and minimizing environmental impact factor. Environmental concerns combined with the water and energy availability and related costs, as well as public license to operate all contrive to demand for more efforts targeting sustainability. Mining industry is highly energy-intensive (estimated to consume 6-7% of total world’s energy), with varying the energy efficiency across the industry resulting in significant costs. Size reduction is the main energy consumer contributing to almost 50% of the total energy used in mining. That means efforts must be made to introduce energy efficient comminution flow-sheets and machineries for sustainable development. Since the crushers are more energy efficient than mills, it is logic to push down-sizing in crushing stage(s) as far as technically possible. That has been strategy for Sandvik Mining and Rock Technology in supplying advanced and effective crushers to provide fine crushed product for subsequent milling stage. Lowering the energy consumption and related costs as well as increasing throughput have been the main objectives in design and development of comminution circuits and related machineries. Inefficiency in comminution technology, particularly in grinding, has long been regarded as a major area for investigation and development, especially when production of fines and ultra-fines are considered. In an attempt to explore the potential of fine crushing and its effects on subsequent milling process the fine crushing performance of Sandvik’s conventional cone crusher and Vertical Shaft Impactor (VSI) in pilot scale to define the energy consumption and circulating load in fine crushing. Tests were conducted to obtain fine crushed products at P = 2 mm in a close circuit. Furthermore, the crushed products were characterized and compared by grind-ability, morphology, and surface area measurement tests. Finally, the energy consumption to grind the crushed products to specific grind size was calculated."

Jan 1, 2018

By B. McFadzean

Thiol collector mixtures are commonly used in the flotation of base metal sulfides and platinum-bearing ores. There are synergistic benefits claimed for these collector mixtures, with mixtures lowering total dosage requirements, improving coarse particle recovery and the rate of flotation. Some of the secondary collectors are known to have frothing effects. Therefore, a previous study aimed to decouple froth and pulp effects and considered only the bubble-particle attachments in the pulp. This was achieved through microflotation experiments, where various ratios of the ethyl and isobutyl chain lengths of xanthates, dithiocarbamates and dithiophosphates were used as collectors. Results from these experiments showed a marked increase in galena recovery using mixtures of xanthate with either dithiophosphate or dithiocarbamate. In the current study, the froth phase was introduced in the form of batch flotation studies to determine whether benefits noted during microflotation experiments would be carried through to a more realistic froth flotation scenario. The findings show that there was no significant difference in the flotation recovery between the best single collectors and mixtures of these collectors. In addition, single collectors that behaved poorly in microflotation experiments showed good flotation performance in the batch flotation experiments. The differences between the microflotation results and the batch flotation results are attributed to differences in particle froth stabilizing properties and/or differences in energy input between the microflotation and batch flotation cells. In addition, galena and pyrite showed marked differences in frothing effects and in their preferences for collector type. Keywords: froth flotation, collector mixtures, sulphide minerals

Sep 1, 2012

By Smuts. E. M.

This paper describes a methodology used to develop a numerical model for the study of particulate suspension rheology. Initially, Computational Fluid Dynamics (CFD) models of different rheometer geometries were tested with both a Newtonian fluid (water), and a non-Newtonian Herschel-Bulkley slurry. Rheograms were reproduced from these models and compared to experimental values. Once a single-phase model had been validated, a coupled model combining CFD and the Discrete Element Method (DEM) was created. Two open source software packages were chosen. CFD is implemented using Open FOAM®, and DEM using LIGGGHTS. These two different codes were coupled via another program called CFDEM. This coupled model is currently capable of modeling spherical particles in a suspending liquid. DLVO forces have been included in some models to account for inter-particle forces due to the surface charge on the particles. The coupled model is currently being validated. Preliminary results show good qualitative behavior of the model. Keywords: rheology, cfd, dem, suspensions, modeling

Sep 1, 2012

By Z. H. Xu

Flotation as a versatile multiphase separation technology has been practiced for more than 100 years in coal and mineral processing. Although effective over a wide particle size range, flotation for mineral separation has been largely understood as an art rather than a science, treating the flotation system as a black box. With rapid progresses in microscopic technologies coupled with high speed video recording and imaging analysis, ingénue design of visualization systems has made it possible to understand fundamentals of flotation by visualization. In this presentation, the state of the art where visualization plays a key role in advancing our fundamental knowledge of flotation will be reviewed. The areas to be covered include characterization of bubbles (shape, size, velocity and sol-ids loading) in a running flotation system, either column or mechanical cell, bubble-solid attachment, hydrodynamic cavitation in fine particle aggregation and flotation, froth imaging, particle-particle interactions by zeta potential distribution measurements, and heterogeneous gas nucleation by atomic force microscope imaging. With these capabilities, critical roles, good or bad, of ore proper-ties, solution chemistry, slurry hydrodynamics, and operation variables in flotation systems as applied to mineral, coal and oil sands processing were clearly elucidated.

Jan 1, 2014

In this paper High Pressure Grinding Rolls(HPGR) was utilized to pretreat CVRD southern specular hematite for enhancing the pelletization of the refractory hematite. The process parameters of HPGR, balling and firing were optimized, and the mechanism of HPGR was demonstrated by determining the surface activity by means of Blaine specific surface area tester, laser size analysis, scanning electron microscopy (SEM),X-ray diffraction (XRD), micro calorimeter and pelletability index. It is shown that the pelletization of the refractory hematite was greatly improved. The drop strength of green balls increases from 3.4 times to 13.6 times from 0.5m height while the bentonite dosage decreases from 2.2% to 1.3%.The compressive strength of roasted pellets also reaches 2500N/pellet. The mechanism of the pretreatment of CVRD southern specular hematite concentrates by HPGR is revealed that the surface activity is improved by an increases in specific surface area and the amount of micron size fractions, and higher lattice deformation and defects due to the fractures occurring inside particles during static pressure comminution, resulting in more wetting enthalpy, higher pelletability index and good property of roasting.

Jan 1, 2014

By P. K. Fedotov

At projecting mining-concentrating complex at the deposit ?Zapadnoye? (Russia) it was considered to enable an opportunity of refusal from conventional SAG-mills. First time a scheme of gold bearing ore destruction using Roller Press RP 5-100/90 had been developed and integrated. The plant was launched in summer 2003 and presently it has achieved designed technological parameters, processing throughput comes to 1 million tons of the ore per year.

Jan 1, 2014

By Héctor X. Toro, José Francisco Cabello, Douglas Batista, Álvaro Videla, Claudio Luiz Schneider

The Minas-Rio Project, located in the state of Minas Gerais, Brazil, is currently under construction. The new plant will have a regrinding circuit that uses VertimillTM. The objective is to process itabirite iron ores and it is expected that the consumption of media will represent a large part of the plant operating cost. Many studies in the literature indicate that the size of the grinding media directly influences the grinding efficiency. The size distribution of the charge media is related to the surface area of the charge. In this study, a sample of itabirite iron ore was tested with respect to grindability in a laboratory scale ball mill. The test mill was equipped with a torque device to accurately measure power consumption, as required for the determination of energy specific kinetic parameters. Five tests were carried out with different sizes of steel balls and with SICAM (sub-inch Cast Media). The size distributions of the feed and product of the several grinding tests were used to calibrate population balance model parameters for each condition. The results confirmed that the ball charge with smaller diameter is the most efficient among the different media charge tested.

Jan 1, 2014

By G. Bulut

The aim of this study is to produce desiccant clay from a well known Ca-bentonite deposit in Turkey. Towards this aim, bentonite samples were first procured and then subjected to some characterization tests. Various methods were applied to enhance the moisture adsorption capacity of bentonites to a desirable level. These methods include utilization of some additives namely calcium chloride and heat treatment at various temperatures. It is shown that the moisture adsorption capacity Ca-bentonites without any additive are between 14%~17 % (w/w) upon by heat treatment whereas the addition of calcium chloride significantly, raised the moisture adsorption capacities.

Jan 1, 2014