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Agenda 1.Energy consumption and energy costs ?focus and failings 2.Energy efficiency methodologies, people and supporting tools 3.Energy cost saving case studies from three minerals processing plants 4.The operations team and the supporting role of Operations IT 5.Conclusion: Reducing energy consumption and energy costs There are many good Energy Efficiency Methodologies ?Energy and GHG Emissions, Management Guidance Document, The Mining Association of Canada ?Energy Savings Toolbox ?An Energy Audit Manual and Tool, Canadian Industry Program for Energy Conservation (CIPEC) ?Lean and Energy Toolkit, Achieving Process Excellence Using Less Energy, www.epa.gov/lean ?Energy Efficiency Opportunities Assessment Handbook, www.energyefficiencyopportunities.gov.au

May 1, 2010

By M. E. Holter

"Three main potash members are recognized within the Prairie Evaporite Formation of Saskatchewan and have been designated, in ascending order, the Esterhazy, Belle Plaine and Patience Lake members. Each is composed of sylvinite near the geographic center of the member and becomes increasingly carnallitic marginally. Each stratigraphically higher member has a narrower carnallitic margin. The sharp contact between carnallitic and non-carnallitic components of the formation describes a surface which may be traced regionally and is not related to bed-ding. The contact rises higher in the stratigraphic section toward margins of members. Within each of the three members, analyses indicate that carnallite becomes more abundant toward the north whereas sylvite and insolubles, increase toward the south. Within each member, areas rich in carnallite are coincident with areas in which the member as a whole is thicker than averag,e. The Belle Plaine Member contains the highest concentrations of carnallite, the Esterhazy the lowest. A maximum content of about 30 per cent sylvite is common to all three members. Insoluble contents increase in successively higher members.Map studies are combined to outline the economic potential of the potash beds in terms of depth to the top of the Prairie Evaporite, ""salt-back"" thicknesses and sylvite grades for each member."

Jan 1, 1971

By Norman Lecuyer, Jacque Nantel

"The Chadbourne Project, located within the limits of the town of Noranda, Quebec, will make use of backfill materials to fill the voids left by the mining of stopes and pillars. A series of tests were conducted on different mixtures of slag and pyrrhotite tailings materials to evaluate their properties. The tests are described and some pertinent results are given in the paper.IntroductionThe Chadbourne Project is located in the centre of the Town of Noranda, Quebec, with houses as close as 120 m from the blasting operations. The ore is mined using the vertical crater retreat method. The voids left by mining activities will be filled. A program of pillar recovery will follow.Considering the proximity of houses and the need to recover pillars, the backfill program must be carefully laid out. No subsidence can be tolerated on surface.With these objectives in mind, a test program was undertaken by Nantar Engineering Limited and Queen's University to evaluate the possible ba ckfilling alternatives available to Chadbourne. One of the possibilities retained was the use of a backfill composed of broken slag material from the Horne Smelter and pyrrhotite tailings deposited on the Horne's pond a number of years previously.The back fill used at the Horne Mine until the mine closed in 1975 was composed of a mixture of 97% granulated slag and 3% pyrrhotite tailings. The tests leading to its use underground at the Horne Mine were described by Patton in 1952. The structural properties of the Horne backfill were ""intuitively"" known; it was agreed by all at the Horne Mine that the backfill was behaving remarkably well. Some were labeling it ""the best backfilling material in the world"". Its strength was said to be that of a weak concrete. All of the preceding indicate that the Horne backfill had never had its structural and other properties determined in the laboratory."

Jan 1, 1983

By Xiaoxing Hu, Guibing Zheng, Yangge Zhu, Xingrong Zhang

"In China, more than 90 percent of titanium resources are reserved in vanadic titano-magnetite deposits. In this type of ore, the same elements such as Ti, Fe, Ca, Mg exist on surface of both ilmenite and titanaugite (the gangue mineral) because of isomorphism, which makes selective flotation difficult. Therefore, how to enlarge the floatability difference between these two minerals has always been a research emphasis and still needs to be studied further. In this paper, the pre-treatment methods using ultrasonic wave were proposed. The results indicate that ultrasonic treatment shows beneficial effect to enlarge the floatability difference, and the effect will be strengthened by extending the ultrasonic treatment time or increasing the ultrasonic power. The mechanism was investigated through infrared spectroscopic (FT-IR) analysis. Collector interacts with Ca and Mg which results in titanaugite flotation, after ultrasonic treatment, the dissolution of Ca and Mg is intensified, which leads to the lack of active points on mineral surface, so the floatability of titanaugite is depressed. Meanwhile, collector mainly interacts with Fe which results in ilmenite flotation, and the present of ultrasonic might promote its oxidation (Fe2+ to Fe3+), so the floatability of ilmenite after sonication is increased.INTRODUCTIONUltrasonic is the sound wave with frequency of 2 × 10-4 Hz~2 × 10-9Hz. Since the first International Symposium of Sonochemistry in 1986, the application of ultrasonic wave is more and more extensive. In researches about mining and metallurgy, various investigators have shown that intensive acoustic fields can modify the state of a mineral, leading to chemical or dispersive effects. Generally, the effect of ultrasonic vibration depends upon the nature of the mineral and also the way ultrasonic wave is applied (Celik, 1989; Ozkan, 2002). In addition, ultrasonic treatment usually plays roles of removal of reagents adsorbed layer from minerals and emulsification of flotation reagents when it is used in flotation (Nicol, Engel, & Teh, 1986; Slaczka, 1987; Djendova & Mehandj, 1992; Farmer, Collings, & Jameson, 2000; Gurpinar, Sonmez, & Bozkurt, 2004)."

Jan 1, 2016

By W. E. Cockfield

"The Stump Lake mining camp is in Nicola mining division of southern British Columbia. It lies about halfway between the cities of Kamloops and Merritt.The deposits at Stump Lake are among the earliest lode discoveries of British Columbia, many of the claims having been staked between 1882 and 1885. A considerable amount of work was done prior to 189Cl, after which very little was done until 1916. Since that time mining has been carried on at intervals, much of it on the same deposits, by a number of companies, including the Donahue Mines Corporation, the Planet Mines and Reduction Company, the Nicola Mines and Metals Company, the Consolidated Nicola Goldfields, Limited, and others. According to the British Columbia Department of Mines, total production from the area has been: gold, 8,520 oz.; silver, 259,413 oz.; copper, 40,822 lb.; lead, 2,208,859 lb.; and zinc, 367,869 lb. Most of the production has come from the Enterprise vein and a branch of the Enterprrsethe King William vein."

Jan 1, 1954

Strips of AA6111 automotive alloy were cast on a horizontal single belt strip casting simulator, Pure copper and carbon steels substrates plasma sprayed with different coatings for improving the strip surface quality, were used as chill moulds, Experimental studies revealed that a graphite coating provided the greatest benefit in achieving good surface quality. The interfacial heat fluxes during solidification of AA6111 strip were calculated by the IHCP method (Inverse Heat Conduction Problem). Temperature variations and cooling rates within the strips were then calculated through numerical simulations based on the time-dependent heat fluxes obtained by IHCP, The effects of casting parameters, including casting temperature and strip thickness, on interfacial heat fluxes, cooling rates and microstructures, were investigated, Although the maximum interfacial heat fluxes on the chill copper substrate were much higher than the results obtained from the steel substrates, the solidification times of the melts were mainly determined by strip thickness. Very fine equi-axed grains were obtained for both 1.2mm and 2.5mm thick strips thanks to the rapid extraction of heat, and effective grain refinement.

Jan 1, 2005

By D. F. Sangster, P. J. Hood, G. A. Gross

"Some results are presented of an integrated geological and geophysical study of Precambrian magnetite-quartz iron-formation in the Kapiko Iron Range north of Nakina, Ontario. Detailed geological and topographical mapping was carried out in conjunction with detailed geophysical investigations such as vertical magnetic field, vertical magnetic gradient, hammer seismic, horizontal-loop electromagnetic and magnetic susceptibility surveys. In addition, oriented drill cores were obtained for magnetic polarization studies.Vertical-force magnetic anomalies within individual rock units showed a strong positive correlation with topographic relief. Moreover, magnetic intensity was found not to be quantitatively proportional to the magnetite content in the rocks, due to the presence of high remanent magnetization of the magnetite. Also, the remanent polarization direction was sub parallel to the plunge of the fold structure and mineral lineation in associated rocks.Vertical magnetic gradient measurements were found to be more accurate in locating buried contacts between magnetite-quartz iron-formation and country rock than the vertical magnetic force data.An in-situ magnetic susceptibility meter was used to measure the magnetite content of iron-formation, and the measurements were subsequently compared with vertical-force magnetic results.The results of the EM survey were inconclusive; some magnetite-rich zones produced anomalies in the out-of-phase component. whereas others did not. The reasons for such inconsistencies are not yet apparent.Longitudinal seismic wave velocities measured parallel to the bedding in magnetite-quartz iron-formation ranged from 10,600 ft/sec. to 14,500 ft/sec. The seismic velocity appears to increase with an increase in deformation of the rocks."

Jan 1, 1966

By Zorigtkhuu Davaanyam, Fisher Wang, Bern Klein, Amit Kumar

"The High Pressure Grinding Roll (HPGR) is an increasingly popular energy efficient solution for comminution of competent ore deposits that primarily competes with conventional crushers and tumbling mills. A significant barrier to increased adoption of HPGRs is the requirement for large amounts (one tonne or more) of sample for pilot testing which may not be feasible for most early staged projects.Various researchers have worked towards developing piston-die and JK drop weight tests to model and predict the energy requirements for an HPGR. Two small scale laboratory test procedures (the SMC test (Morrell, 2009) and the piston press tests (Davaanyam, 2015)) have been developed in recent years to provide necessary information to size an HPGR.These two methods were used to estimate the required specific energy for an HPGR unit and compared to HPGR pilot scale test results from a copper deposit. The comparison provides insight into the benefits and limitations of these tests.INTRODUCTIONHigh pressure grinding rolls (HPGR) have gained popularity in recent years because of their energy efficiency in comminution. Various researchers have suggested that approximately 50–80% of the total energy consumed in a mineral processing plant is used by the comminution equipment (Haque, 1999; Abouzeid & Fuerstenau, 2009; Wang, 2013). Haque (1999) showed that the efficiency of grinding equipment can be as low as 1%. Due to the energy intensive nature of comminution, mining industry has been forced to explore alternative energy efficient processes.An HPGR based circuit has been shown to be 10–25% more energy efficient than a conventional SABC circuit (Von Michaelis, 2009; Wang, 2013). A significant barrier to the increased adaptation of HPGRs is the requirement for a large amount of sample for pilot testing (up to 5 tons), even on a prefeasibility level. Numerous studies have been performed to utilize piston press test to analyze the performance of the HPGR circuit and to predict the energy consumption for an industrial application. This paper uses two small scale laboratory test procedures, the SMC test and a piston press test, to compare the energy requirement to the pilot HPGR data."

Jan 1, 2016

By L. A. Anestiev

A method based on use of calorimetric data for the determination of solidification kinetic parameters is proposed. The method incorporates recent theories of nucleation and growth and allows modeling heat fluxes observed in calorimetric experiment. Statistically optimal estimations of the kinetic parameters, which include the activation's energies of nucleation and growth, are derived from experimental data by means of nonlinear regression analysis. The method is applicable to pure substances and alloys. The evaluation of the kinetic parameters characterizing solidification of pure Al is used for clarifying and exemplifying the method.

Jan 1, 2004

By Masatsugu Morimitsu

This paper introduces new technology of oxygen evolution anodes which can be applied to produce copper, zinc, cobalt, and other metals by electrowinning. The anode consists of nano iridium oxide particles dispersed in amorphous tantalum oxide matrix as a catalytic layer formed on a titanium substrate. The anode can reduce oxygen evolution potential by 0.25 to 0.55 V compared to commercially available lead alloy anodes and can suppress unwanted side reactions such as manganese oxyhydroxide, lead oxide, cobalt oxyhydroxide which occur during oxygen evolution in the electrowinning solutions. This technology is effective for environmentally friendly electrowinning processes with low energy consumption and less anodic deposition.

Jan 1, 2011

By Shantanu Patel, C. Derek Martin

"The objective of this work is to develop a practical numerical approach for applying the confining pressure to discrete element cylindrical triaxial tests. A layer of membrane particles with very low stiffness and extremely high contact bond strength was created around the lateral boundary of the cylindrical numerical specimen. To prevent the membrane particles from penetrating into the rock specimen on application of confining forces and to provide a smooth boundary surface, the space between the membrane and rock particles was filled using small-diameter packing particles. The results of this method were compared with those of rigid boundary method with confining pressure of 20MPa. The results obtained show that new approach gives both peak strength and post peak response that are in closer agreement with laboratory findings. BACKGROUNDThe discrete element method (DEM) has become the cornerstone for simulating both intact material and discrete fractures for low porosity strong rocks (ISRM Classes R3 to R6). Despite the advances in its application, simulating realistic behaviour of intact rock using the DEM remains a challenge. The bonded particle model was introduced as a potential solution for simulating the complex mineral grains in strong rock and other granular materials (Potyondy and Cundall, 2004; Utili and Nova, 2008; Salot et al., 2009). While some issues were resolved, a remaining challenge is the lack of the bonded particle model to simulate the brittle response commonly observed in strong rocks during the triaxial compressive test. Such behaviour is shown in Fig. 1 for Lac du Bonnet Granite at a confining pressure of 20MPa."

Jan 1, 2015

By Behzad Vaziri Hassas, Firat Karakas, Esra Tanisali, Mehmet S. Çelik, Ahmad Hassanzadeh

Coagulation is basically an aggregation process where particles settle under the influence of interfacial forces with electrostatic forces playing a governing role. Although particle morphology consisting of shape and roughness dictates the physical encounter of two particles, their eventual coagulation is not only influenced by columbic forces but also other interfacial forces such as hydrophobic interaction, which affects the extent of aggregation of particles through increasing the distance of interaction. Roughness is well known to increase the effective contact angle on hydrophobic surfaces and also enhance interfacial forces. In this study, the effect of morphology of particles and particularly roughness on the settling velocity and in turn coagulation tendency was investigated. Batch settling tests (BSTs) of different particle morphologies were investigated as a function of pH. Two different morphologies of silica particles were utilized with the same particle size distribution (PSD) including smooth-spherical and rough-spherical (Etched). Rough particles were prepared by acid etching technique using hydrofluoric (HF) at different time intervals (15-300 sec). Etched samples were identified and quantified by optic profilometry. Settling test results showed that the settling velocity of particles in a suspension of 2% solids in the massive settling region is significantly affected by particle morphology of the suspension. Coagulation results further revealed that aggregation of rough particles is faster than smooth-spherical particles. Coagulation results are elucidated on the basis of particle morphology and its effect on distance of separation through hydrophobic forces.

Jan 1, 2016

By M. Mahdi, L. So, A. MacMillan, D. Metcalfe, J. Woloshyn, D. Sauter, N. Uys, JP. Janse van Rensburg

For city smelters, with limited real estate, efficient slag cleaning furnaces followed by water granulation to produce an iron silicate product is the preferred process approach. Water granulation, however, consumes large volumes of water and requires high maintenance due to abrasive slag/water slurries. Air granulation offers an alternative to water granulation, which eliminates water use and has low maintenance requirements. Although full-scale operation has not been implemented for copper slags, full-scale operation for platinum group metal (PGM) converter slag has been implemented. A review of full-scale air granulation performance for PGM converter slag is provided. Based on PGM converter slag granulation performance, parallels to copper slag granulation are drawn and full-scale operation for copper slag is modelled using computational fluid dynamics (CFD). INTRODUCTION Typical slag management practices in the copper industry include dumping, slow air cooling, and water granulation, as shown in Figure 1. Dumping is the most commonly used slag handling method for most metal production plants, but presents challenges including the requirement for a large slag pit, requirement for expensive/high-maintenance “hot” mobile equipment, risks associated with transportation of molten slag, and no value recovery from slag as a sellable by-product or from slag as a source of heat.

Jan 1, 2019

By N. Morrison, E. J. Rogans, A. J. Macintosh, N. Schoeman

"The design of carbon-in-pulp (CIP), and carbon-in-leach (CIL) adsorption circuits has essentially remained unchanged since the early days of the carbon process for gold recovery. For CIP circuit the pulp residence time is traditionally fixed at one hour per contactor with a carbon concentration of between 15 and 20 grams per litre, and the counter current carbon transfer rates are in the region of 15% pulp recycle. For CIL, the pulp residence time is usually three hours per contact or, with lower carbon concentrations ( 5 to 10 grams per litre).The drawbacks of using the counter current CIP/CIL adsorption circuits are discussed using modeling developed for CIP/CIL plant design. Counter current CIP/CIL, circuits are then compared with the carousel method of adsorption circuit design.The use of equipment suitable for the carousel approach is discussed which is, the AAC cylindrical and pumping (MPS) screens, the AAC pump-cell plant and launder designs.Finally, two plants at the Vaal Reefs Gold Mining and Exploration Company that use carousel adsorption circuits, namely the Vaal Reefs No. 1 Gold Plant, a CIL plant with stepped contactors, and the Vaal Reefs No. 2 Gold Plant, a CIP using a very short residence time (AAC pump-cell) are discussed."

Jan 1, 1998

By S. C. Cohen, A. F. Mikkelsen

"This paper describes the improvements made to the operation of a liquid phase, 300°C, heat transfer system in the paste plant of an aluminum smelter. These improvements were achieved by replacing the original heat transfer fluid, a synthetic aromatic, with a new technology, petroleum-based product. This new fluid, Calflo HTF, provided better thermal stability, with lower toxicity, and improved plant working conditions.The procedures for fluid selection, changeout and performance monitoring are described along with a summary of control analysis over the last three years."

Jan 1, 1993

By J. Palarski

Hard coal, mined in Silesia Region as well as in the eastern part of Poland, is a key national resource. In Polish underground coal industry, modern mining technologies have been successfully tested and used in the last 50 years. More than 98% of the coal produced underground is extracted by longwall mining method. Current underground coal mining expands into increasing depths. The use of conventional coal extraction methods ? room and pillar and longwall with caving - is becoming increasingly difficult. The coal mining is modifying existing methods and is testing innovative technologies. Backfill is an important component of modern underground mining operations. In Polish underground mines, backfill is recognized as an integral component for extraction of coal from greater depths in a densely populated environment. The modifying and innovative methods require the use of backfill or grouting of caving to provide structural support in underground excavations and to ensure that the mining operations are safe. Depending on the geological structure, mining conditions and environmental requirements there are several variations of longwall methods used in underground coal mining in Poland, in particular: longwall with caving, longwall with backfill, longwall with grouting of caving area. This paper will discuss the different components of an effective longwall production and filling process of caving area. The paper will give a overview of the current application of backfill technology, focusing on Polish coal mining operations. This paper will also briefly describe how backfill contributes to an innovative method ? underground coal gasification. The paper discusses specific requirements for fill materials and the technology of backfilling for underground coal gasification (UCG) operations and problems of implementation and correlation of backfill parameters with other processes that occur during thermal processing of coal.

Aug 1, 2013

By Yuhua Wang, Wei Sun, Dongfang Lu, Yuehua Hu, Tao Jiang

"With the continuous depletion of high-grade tungsten ores, the low-grade refractory wolframite has become an important source for the tungsten industry. However, the large-scale utilization of low-grade refractory wolframite is disappointedly scarce, it is due to leanness of valuable minerals, complex mineral characterization and use of toxic collectors.The aim of this study was to develop an environment-friendly processing flowsheet, which was used for beneficiation of low-grade tungsten ore containing 0.45% WO3 from New Brunswick in Canada, and the content of arsenic is 0.68% in this materials. The objective of beneficiation studied was to obtain a concentration containing 60% WO3 with less than 0.5% of arsenic under the condition without any flotation reagents. In this environment-friendly processing flowsheet, magnetic separation technology, classification and gravity separation technology were combined and employed. Firstly, magnetic separation was employed for the first pre-concentration process, over 95% of the feed was rejected as the final tailings, meanwhile, over 85% of arsenic minerals were removed with tailings. Secondly, gravity separation tests were employed on the classified magnetic pre-concentrate in the second pre-concentration process, a second pre-concentrate with WO3 grade of 54.32% and As grade of 5.41% was obtained. Finally, two stage magnetic cleaning were conducted on the second pre-concentrate for upgrading the second pre-concentrate, the mostly arsenic and gangues were removed from the second pre-concentrate. Finally, this novel processing achieved an effective recovery of fine wolframite from low grade tungsten ore with high arsenic. A concentrate with WO3 grade of 64.81% were obtained in new opened processing flowsheet, and As grade was less than of 0.5% in this concentrate. Furthermore, remarkable feature of this processing flowsheet is environment-friendly due to avoid using the toxic flotation reagents during the whole mineral processing.INTRODUCTIONTungsten is an essential metal and is the most widely used in industrial production such as national defense, electro-mechanical products, textile and leather sectors (Srivastava et al., 2000). Wolframite and scheelite are the main mineral sources of tungsten metal. With the continuous depletion of high-grade tungsten ores and the increasing demand for tungsten alloy, the low-grade refractory wolframite has become an important source for the tungsten industry. However, the large-scale utilization of low-grade refractory wolframite is disappointedly scarce, it is due to leanness of valuable minerals, complex mineral characterization and heavy use of toxic collectors."

Jan 1, 2016

By R. S. James, D. C. Peck, P. T. Chubb

"The East Bull Lake gabbro-anorthosite intrusion is one of several Early Proterozoic layered mafic intrusions occurring along the Southern Province - Superior Province boundary in the Elliot Lake - Sudbury region, Ontario. The base of the East Bull Lake intrusion comprises abundant plagioclase cumulates (Leucogabbronorite Zone) hosting two distinct styles of sulfide mineralization: (1) disseminated magmatic sulfides, and (2) disseminated to massive, structurally controlled sulfides. Both types of mineralization are enriched in Pd, Pt, Au, Cu and Ni. The host rocks to the sulfide mineralization display a range of interesting features including nodular textures, dendriticpegmatitic mafic pods, inclusion-rich zones (pyroxenite, anorthosite and granitic inclusions) and magmatic breccias. Disseminated chalcopyrite, pyrrhotite and pentlandite occur in concentrations of up to 100/0 within erratically distributed gossan pods near the base of the intrusion. The sulfides were originally precipitated from intercumulus liquids, but were subsequently recrystallized and locally remobilized along fractures during the major period of metamorphism and deformation that affected the East Bull Lake intrusion. The base- and precious-metal tenor of the structurally controlled sulfides can be explained by extensive remobilization and reconcentration of the pre-existing magmatic sulfides in the vicinity of a major shear zone. Both styles of sulfide mineralization locally contain ppm abundances of POE + Au and are generally Pd- and Cu-rich, although both display large variations in Pd:Pt and Cu:Ni ratios. The magmatic sulfides are more strongly enriched in POE and contain up to 1470 ppm Pd in 100% sulfide. Several factors, including source characteristics, magmatic processes (crustal assimilation, fractional crystallization) and post-magmatic interaction with hydrous fluid, have influenced the present distribution of POE, Cu and Ni in the East Bull Lake intrusion.The magmatic sulfide occurrences from the East Bull Lake intrusion compare favorably with marginal-type deposits from rift-related intrusions (Noril'sk-Talnakh region, Siberia; Duluth Complex, U.S.A.) in terms of their distribution, but are most similar to reef-type POE deposits with respect to their base- and precious-metal geochemistry. The combination of high POE tenors and large tonnages that is observed for the POE-Cu-Ni mineralization from the East Bull Lake intrusion suggests that a good potential exists for the presence of economic concentrations of Pd, Pt, Au, Cu and Ni in the intrusion. On a global scale, the East Bull Lake intrusion is part of a suite of Early Proterozoic plutons, many of which contain significant volumes of stratiform and/or marginaltype POE-Cu-Ni mineralization. The East Bull Lake intrusion is also one of the oldest mineralized intrusions derived from a sub-Superior Province mantle source region that has given rise to several significant magmatic POE-Cu-Ni deposits during the period 2.5 Ga to 1.1 Ga."

Jan 1, 1993

By H. Matsuoka, M. Kawata, K. Mitsuhashi, C. Tokoro, T. Kato

Copper sulfide minerals such as chalcocite, bornite, and chalcopyrite exhibit high floatability, thus they can be recovered as a froth product by adding only a collector in flotation process. However, when their surface is oxidized, the floatability decreases and the simple addition of collectors is no longer effective. In this case, flotation activators are required to improve the floatability. Sodium hydrosulfide (NaHS) acts as an activator for chalcocite and bornite by re-sulfurizing their oxidized surface portions. Nevertheless, the flotation conditions still require optimization in order to achieve a satisfactory recovery of copper minerals. This work addresses the study of the effect of pH and NaHS dosage on the flotation of a complex Chilean copper ore containing chalcocite, bornite, and chalcopyrite. Flotation experiments were conducted using a Denver-type flotation cell and by investigating the effect of two NaHS dosages (50, 100 g/t) and three pH values (8, 9, 10). Following this process, the surface interaction between the minerals and NaHS were analyzed using zeta potential measurements. INTRODUCTION In recent years in the mining area of metal resources, the complexity of ores and the fineness of grind required to liberate minerals have become serious problems. When ores are complex, several valuable minerals may interact with each other and reactions may become more complicated compared with an ore containing only one valuable mineral. Therefore, more processing steps may be required than for a simple ore. When the valuable minerals exist as fine grains, it is difficult to liberate them and more grinding time is required. Furthermore, the probability of collision of fine particles with bubbles in the flotation process declines and it takes much time to recover them. Flotation is one of the most applied methods to separate valuable minerals from unwanted ones using the difference of hydrophobicity (or hydrophilicity). In the flotation method, the air is fed to a cell filled with the pulp of the mineral of interest and agitation is implemented to introduce air and generate bubbles. The hydrophobic particles attach themselves to the bubbles and float along with the bubbles while the hydrophilic particles remain in the pulp. Copper sulfide minerals such as chalcocite (Cu2S), bornite (Cu5FeS4), chalcopyrite (CuFeS2) are widely known abundant copper resources. Generally, flotation is used to recover and concentrate these minerals. Copper sulfide minerals usually have high floatability. However when their surfaces are oxidized, their floatability becomes lower. When the sulfide surfaces are oxidized, activators are added before flotation to modify the surface property of the Copper sulfide minerals so that they can be floated. Sodium hydrosulfide, NaHS, is known as one of the activators. Zhao (2018) reported that NaHS is often used as a sulfurizer for oxidized sulfide minerals (Becker (2014), Clark (2000), Newell (2006), and Newell (2007)). In earlier work, the authors performed flotation tests on a sample of Chilean copper ore which contained chalcocite, bornite, and chalcopyrite using a Denver-type flotation apparatus. The sample was ground to P80 70 µm with a rod mill and ball mill. In these tests, the following conditions were used: natural pH (about pH 8.5), flotation time of 45 min, 60 g/t AP3477 (sodium diisobutyl dithiophosphate) as collector, and MIBC (methyl isobutyl carbinol) at appropriate dosage as frother. NaHS was applied at the dosage of 0, 67, and 120 g/t, respectively at the conditioning. The concentrates were collected at 6, 18, 30, and 45 min. The weights of the concentrates and tailing were measured and they were assayed for copper by ICP-AES (Optima 5300 DV, PerkinElmer Inc.). The flotation recoveries of the copper minerals were calculated from the results of MLA (mineral liberation analyser) (MLA 650, FEI) measurements.

Jan 1, 2019

By N. P. Hristov, L. V. Kuzev

"A simulation study of the fill factor of a drum mill was conducted using two types of grinding media: balls and tetraballpebs. Each medium was composed of equal number of grinding bodies having equal weight but different shape. The difference was in the density of the two grinding media.Standard spherical grinding bodies (balls), which were used in practice, and equivalent (by weight) grinding bodies in the shape of spheroidal tetrahedrons (tetraballpebs) were studied. The simulation was conducted in a module of a 1.2 m diameter drum mill, whose length exceeded twice the diameter of the corresponding grinding body. The grinding balls had a few percent (3 to 6) higher fill factor than the grinding tetraballpebs in the same shell.Vertical sections of the grinding medium were taken across the studied shell module along its axis. They showed the location of each grinding body in the fill volume. Defects in the packing of the grinding bodies and the contacts between them and with the inner surface of the shell were also show. Differences in the contact points of the balls and the tetraballpebs were noted. For the tetraballpebs, we observed contacts both between the spherical surfaces and with the edges and vertices of the grinding bodies.The topography of the grinding media is shown visually.INTRODUCTIONThe grinding balls have been studied extensively. It is the traditional grinding medium in ore processing industry. The parameter characterising the grinding medium is its density. It is the mass of the grinding medium per unit of volume. The parameter may have a range of values. It depends on:• The physical properties of the material they are made of;• The shape of the grinding body;• The dimensions of the body;• Size distribution of the grinding bodies in the grinding media.In comminution, the fill factor of the mill shell is the process parameter that is representative of the grinding medium. Some publications have indicated the disadvantages of ball grinding. For example, Wu, Xiang, Glen, and Duan (2008) note in the analysis of the mechanism of grinding that the balls are not the best grinding media and disadvantages include among others:• Easy over-grinding resulting from the point contact between the balls;• Attrition surface is the smallest in the grinding media;• Poor selective exposure of minerals resulting from the accidental and often significantly more powerful impact on the feed;• The grinding efficiency drops as the fineness of grind is increased;In the Handbook of mineral processing, Polkin (1950) noted that the shape of the grinding bodies determines the volume of the void spaces therein and therefore the shape affects the grinding efficiency per unit of volume of the grinding medium."

Jan 1, 2016