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By Kirsten Corin, Margreth Tadie, Michael Nicol, Cyril O’Connor, Jenny Wiese

"The recovery of base metal sulfides has been emphasized in the study of the flotation of platinum group minerals (PGMs). However, in some ore bodies such as the Platreef of the Bushveld Complex, sulfide minerals do not make up the majority of the more significant PGM mineralization. It is therefore important to develop a fundamental understanding of how non-sulfide and sulfide PGMs respond respectively to the current reagents being used in the flotation of these minerals. The interactions between platinum and palladium sulfides and tellurides with the thiol collectors, ethyl xanthate and diethyl dithiophosphate, have been studied using the electrochemical techniques of mineral rest potential and voltammetry measurements. The differences in the interaction between the two types of minerals with these reagents were of key interest. Rest potential measurements indicated stronger electrochemical interactions of the minerals with ethyl xanthate than diethyl dithiophosphate. These measurements also indicated that there are different forms of oxidized collector present on the mineral surfaces after interaction with ethyl xanthates. Voltammetry measurements support these observations and suggest differences of adsorption on Pt and Pd sulfides than on Pt and Pd tellurides. Voltammetry also showed that there was minimal electrochemical interaction between the Pt and Pd minerals and diethyl dithiophosphate."

Jan 1, 2014

By U. A. Peuker, A. Grohme

"The cost effective and sustainable production of high purity rare earth elements is still challenging. The most commonly used method, known as solvent extraction, is very complex, needs many steps to separate the rare earth ions in a high purity, and causes a lot of environmental problems. An alternative method is the utilization of a separation column filled with adsorbent material. Within the column the desired target substance can be selectively separated out of a multi component mixture in one step. To find out if an adsorption material is suitable for the separation with a column, a characterization of the adsorbent material is necessary. In this paper are described the usage of modified activated carbon (oxygen and phosphorous modification), Di-(2-ethylhexyl) phosphoric acid (D2EHPA) impregnated Amberlite® XAD 7 HP and Lewatit® VPOC 1026 as adsorption materials. Several adsorption isotherms and process conditions are determined to characterize the selectivity between the adsorption materials and different rare earth ions. With these isotherms the mass specific rare earth ion retention for the adsorbent materials can be calculated. In addition to the isotherms the best working parameters are investigated e.g. pH-value and the time for equilibration. Finally, the separation factors between two rare earth elements are determined. The separation factor shows how successful a two element system can be separated."

Jan 1, 2014

By Adam Jordens, Olga Kuzmina, Christopher Marion, Kristian Waters

"In order to meet the growing demand for non-Chinese rare earth suppliers many new rare earth (RE) mineral deposits are currently under development, however these deposits typically include many minerals for which there is little processing information available. One of these deposits is the Nechalacho deposit located in the North West Territories of Canada. This deposit contains multiple RE minerals including bastnäsite, zircon, fergusonite, allanite and monazite. The work presented here investigates the use of different classes of flotation collectors (carboxylic acids, hydroxamic acids, phosphoric acids) typically used in RE mineral flotation to float the Nechalacho ore directly. Flotation tests are also conducted as the final step in a beneficiation process incorporating centrifugal gravity concentration and magnetic separation. This combination of centrifugal gravity concentration and magnetic separation rejects low specific gravity gangue minerals such as K-feldspar and plagioclase and concentrates high specific gravity minerals such as magnetite and hematite. The removal of low specific gravity gangue helps to improve flotation and the removal of ferromagnetic iron oxides is important prior to flotation using certain chelating collectors."

Jan 1, 2014

By Frank van der Meer, Lea Quincke

"High Pressure Grinding is applied to achieve size reduction of the particles by inter-particle breakage and to generate micro-cracks in the product particles as a contributing factor in e.g. leaching or mineral liberation. As alternative to classification, a closed circuit operation for HPGR can be established by product recycling, where a proportion of the coarser edge material and parts of the center material are split-off to be recirculated to achieve a finer final (center) discharge product for subsequent processing steps as ball mill grinding or beneficiation. As a result of the product recycling, the content of fines in the feed material increases and may affect the grinding efficiency in terms of production of fines and the generation of micro-cracks in the particles. In the scope of this paper, the effects of the proportion of fines in HPGR feed on grinding efficiency and micro-crack generation were evaluated. Grinding tests were executed with different feed size distributions, from a fines-void situation (truncated feed) to a fines-abundant situation (high product recycle). The evaluation of grinding efficiency and generation of micro-cracks was done by particle size analysis, Bond Work Index tests, impact tests on HPGR feed and products, and X-ray computed tomography of single product particles. This publication summarizes the main aspects of the outcome of these investigations."

Jan 1, 2014

By K. H. Luo, J. Y. Liu

An experimental study on interparticle breakage of three iron ores was carried out by compressive stressing of particle-bed in a piston-die device. The feeds to the particle-bed stressing were five narrow size fractions in the size range of 0.2~3.2 mm respectively and a wide size fraction of 0/4.0 mm. The pressures applied were in the range between 30 and 360 MPa. The results show that the energy absorption of the particle bed increases linearly with the pressure; the increase of the product fineness with the pressure declines as the pressure goes up; and the product size distributions resulting from interparticle breakage of different narrow size fractions have no self-similarity. Using data obtained from the piston-die compressive stressing test, the suitability of a previously-developed material-characterization model for interparticle breakage was verified for these ores. It is shown that the particle-bed compression test conducted with piston-die device in lab-scale may provide a cost-effective way of studying and modelling size-reduction of ore materials by interparticle breakage.

Jan 1, 2014

By D. Izerdem, S. L. Ergun

"Beneficiation of the finely disseminated valuable minerals has been an important issue in the mineral processing field for decades. Treatment of the fine materials becomes difficult with using traditional gravity concentration equipment. To investigate particles behavior in a commonly used conventional gravity concentration equipment, a comprehensive study was undertaken in a plant, which only consists spiral concentrators as concentration units. Spiral concentrators require relatively coarse material to effectively concentrate valuables as well as offering greater simplicity for especially higher grade feeds. In the current work, chromite ore (d80 = 290 µm) was treated using spiral concentrators and the performance of spiral concentrators was examined. The design of the separation circuit comprised of rougher, cleaner and scavenger stages. The resultant fractions produced by each separation unit and feed samples were analyzed to identify the particle sizes, mineral liberations and chromite content. Grade and recovery comparisons were presented in size-by-size manner and the separation tendency of the particles were determined in varying feed rate conditions. The overall results indicated valuable mineral loss of the plant and alternative suggestions were pointed to reach the target values.INTRODUCTION Spiral concentrators are simple low energy consuming devices, which are generally used for pre-concentration of the minerals. They are cost efficient equipment separating minerals mainly based on density differences of the minerals. The adjustable splitters remove the concentrate as the remaining stream continues to move down the spiral. Separation on a spiral is achieved through a combination of forces that act on particles as they move down the trough of the spiral. The main forces known to act on the particle on a spiral are the gravitational force, centrifugal force, hydrodynamic drag and Bagnold force (Atasoy and Spottiswood, 1995; Burt, 1984). Since the classification in a spiral concentrator depends on particle specific gravity and size, the operation of spirals can be analyzed using size recovery or partition curves (Bazin et al., 2014). Spiral concentrators possess multiple design parameters for a variety of applications. The design parameters that govern the performance of the spiral can be identified as the diameter, number of turns, slope, pitch and the profile of the trough. For an efficient separation on a spiral concentrator, the properties of the slurry flowing on a spiral, ore texture, percent solids and flow rate play important roles."

Jan 1, 2018

By M. Alvarez-Silva

The control of the amount of chromite reporting to the concentrate during the flotation of UG2 ore is of critical importance since its presence affects the downstream smelting process. It is generally reported that the main mechanism responsible for chromite recovery is through entrainment. This is reflected in analyzing the solids and water recoveries. These in turn are strongly dependent on the froth phase. In the present investigation a laboratory scale column flotation cell was used to investigate the role of the froth phase in the flotation of UG2 ore. Such a device is superior to a standard batch cell since it operates at steady state in open circuit and also allows for a greater degree of flexibility in terms of froth heights. The mass of solids and water recovered in the concentrate as well as chromite (Cr2O3) recovery by size class was determined as a function of froth height, superficial gas velocity and depressant dosage. The results showed that depressants had little effect on chromite recovery but increased the grade due to the depression of gangue minerals. A 60cm froth height always resulted in slightly lower solids, water and chromite recovery than for 30cm. Typically only 20-25 % of solids reaching the pulp-froth interface reached the launder. The relationship between solids and water recovery for a wide range of conditions indicated that chromite is mostly recovered by entrainment. Keywords: UG2 ore, column flotation cell

Sep 1, 2012

By Williams Calderon, César Arredondo, Gonzalo Montes-Atenas

The quality of final concentrate in froth flotation circuits is largely dictated by the correct implementation of the froth washing operation in flotation cleaning stages, which are commonly installed in column flotation cells. In flotation plants, this aspect has been largely overlooked and the froth washing is restricted to the use of perforated piping through which process water flows producing a similar effect to that observed in "fountains": jet created with low energy crosses the froth phase washing out entrained particles as well as particles weakly attached to bubbles. The aim of this research study is to assess the efficiency of traditional froth washing systems theoretically and experimentally. A theoretical model was implemented using Fluent® software where a jet of variable speed was introduced in a continuous soft matter phase with physical properties similar to those observed in a froth phase in wet and dry conditions. In addition, a simple experimental protocol was designed to validate the model. It was found that the water process jet-like flow influences the behavior of 2 to 3 times the equivalent volume in the froth phase. Such influence zone is dramatically reduced as the froth phase becomes drier. These results were confirmed by the experimental findings indicating that a better froth washing technologies must be assessed and implemented. Some aspects of the ideal froth washing system are derived and discussed in details.

Jan 1, 2014

By Carlos Pereira, Fábio de São José, Francielle Nogueira

Votorantim Metals Corporation is one of the leader companies in the extraction of zinc in Brazil. One of its mines, located in the city of Vazante - MG, was composed by zinc silicate ores, but recent studies have indicated a change in mineralization type with arise of zinc sulphide’s ore bodies with disseminations of galena (PbS) and silver. The liberation size between sphalerite and galena in this ore occurs in very fine granulometry (approximately 18µm), fact that has negatively influenced into the flotation process. Aiming to reduce this problem, studies about the use of dispersing in the flotation process have started. Thus, this study investigated the action of different reagents dispersing on the stability of the suspensions. The tests were carried out with samples of mineral galena and sphalerite using four types of dispersing within two different dosages and two pH. The reagents tested were sodium hexametaphosphate, sodium silicate, carboxymethiylcellulose, and sodium polyacrylate. The results of the dispersion tests were analysed in relation to dispersion index. The tests with hexametaphosphate showed high dispersion for both galena and sphalerite. The sodium polyacrylate and arboxymethiylcellulose showed a high dispersion index for galena and a low index for sphalerite implying that reagent can be used in the concentration process of galena.

Jan 1, 2014

By D. B. Sundar Ramam

In the recent past, a paradigm shift in terms of resource utilization and beneficiation practices is experienced by the Indian mining and mineral sector. Depleting iron ore reserves coupled with increasing demand for low-alumina iron ore fines to improve blast furnace performance in terms of productivity and reduced slag rate necessitate intensive beneficiation of iron ore. The task is even difficult for Indian iron ores, which are generally high in iron content and at the same time characterized by aluminous gangue. In 2006, M/s Tata Steel commissioned a state-of-the-art Jigging Plant (Batac Jig) at Noamundi Iron Mine (NIM), mainly to reduce alumina in iron ore fines. The jigging plant is incorporated in the existing beneficiation circuit to treat ?10+0.5mm size fraction of classifier fines. Over the course of plant stabilization while the plant could deliver desired ore upgradation and average product alumina, variability in terms of alumina content has been a concern. This paper discusses a case study of process parameters optimization in jigging operation to achieve consistent product quality while improving the effectiveness of gravity concentration for the beneficiation of Noamundi iron ore also to take care of inferior plant feed (input) grade year on year. The operating variables used to optimize jigging operations include bed height, pulsion and suction time, particle size, strokes, and plant throughput rate.

Sep 1, 2012

By F. Molhem, S. Banisi, H. R. Montazari, E. Arghavani, Gh. R. Biniyaz, Gh. A. Parsapour

"Water plays a key role in mineral processing plants and to process one ton of ore 2.5 ton water is needed. Thickeners are commonly used for dewatering and recovering water in most processing plants. The underflow pulp density is increased by sedimentation of particles and clear water is recovered from the overflow. One of the issues related with using the process water is the presence of suspended fine particles in the clear overflow water which can create blockage in transfer pipes. The froth formed on top of thickeners is the main cause of this problem. In this study, a method to decrease the froth formed on the Sarcheshmeh Cu-Mo thickener surface was introduced and implemented. At the first stage, the old punched plate feedwell was removed and it was replaced by a vane type feedwell. A spray water ring using fish-tail type nozzles was then installed to break froth layers by water. These modifications led to 63% relative reduction in the water turbidity, 11% relative increase in the underflow solids concentration, 20% relative reduction in torque, 19% relative reduction in its standard deviation and an increase of 6% in water recovery.INTRODUCTION The Sarcheshmeh copper complex, the largest copper producer in Iran, located in southern Iran. In the processing plants of this complex, over 250,000 m3 of water is consumed daily. Because of a lack of water in this area and very low yearly rain fall (150 mm), water plays a vital role in the complex. As a result, it is then aimed at maximum water recovery by taking all necessary measures. The recycled water in order to be used should not contain any suspended solids indicated by low turbidity."

Jan 1, 2018

By Danuta Szyszka

This paper presents results of tests performed to determine minimum concentration of a surfactant used at which coalescence of air bubbles during flotation has low probability to occur. The measurements of the critical coalescence concentration, also known as CCC, were carried out in a device consisting of glass cell into which air was pumped by peristaltic pump through capillaries. The flotation foam was recorded with a high resolution digital camera. Basing on the video records, average diameters of the air bubbles were measured and the values obtained were subsequently used to determine the CCC values. The author of paper determined the CCC values of surfactants tested using the linear regression method, and subsequently analyzed the results obtained. To define initially the capability of a tested surfactant to flotation, efficiency of multiparticle model flotation and flotation of individual size fractions were determined in a flotation apparatus for laboratory use in the presence of only foam making agent at CCC value pre-determined during the tests previously carried out. The tests of coalescence phenomenon were carried out with use of selected flotation frothing agents.

Jan 1, 2014

By E. Ashirbaeva

"Ores of ferrous metals traditionally make up the bulk of recoverable reserves of solid minerals, and iron ore concentrates - in the processing and consumption. To obtain concentrates, three main methods are used: dry and wet magnetic separation, gravity and flotation. But even their integration into complex developed schemes with finishing operations often do not solve the problem of obtaining high-quality concentrates, which are necessary for powder metallurgy and electric steelmaking. Increasing the iron content in the concentrate by removing harmful impurities is the goal of this work. The possibility of reducing the operations of wet magnetic separation twice and completely eliminating concentrating operations in ball mills from the scheme of operations has been established. Selective leaching agents for each type of iron ores have been created, allowing to obtain concentrates with an iron content of not less than 68-69% and negligible concentrations of harmful impurities. Methodical recommendations for long-term storage of bioreagents in the active state, their immobilization and preparation in industrial conditions at the enterprise Nedropolzovatelja are developed. The proposed biotechnology, which allows to obtain high quality iron and conditional concentrates for harmful impurities, is protected by patents (RU 2537684 ""Method for fine-tuning of high-sulfur magnetite concentrate"" for magnetite ores and Pat. RU 2599068. For the industrial implementation of the new technology, organizational and technological measures have been developed in the system with Road maps for types of ores. The developed technology makes it possible to condition noble metal, tin, tungsten, nickel and other concentrates in harmful impurities such as arsenic, antimony, mercury, sulfur, copper, zinc, iron, phosphorus, manganese, in total 30 components that pass into solution under the influence of bioreagents.INTRODUCTION Consumption of various metals is steadily increasing every year, the volume of mining is constantly increasing. Ores of ferrous metals traditionally make up the bulk of the recoverable reserves of solid minerals. Enrichment technologies for iron-containing ores are reduced to the combination of three main methods: wet and dry magnetic separation, gravity and flotation. But even the use of complex advanced technological schemes often does not lead to the production of high-quality concentrates suitable for metallurgical processing. In this case, either lapping operations or effective technical and technological solutions are used in the main enrichment cycle. Widely used in practice methods for improving the quality of iron ore concentrates include the use of finishing operations (fine screening, reverse cation flotation), staging of concentrates, the use of more sophisticated equipment (separators with running magnetic field, magnetic gravity classifiers, column flotation machines)."

Jan 1, 2018

By Olga D. Khmelnitskaya

The paper presents the results of research on the development of gold recovery technology from oxidized gold-copper ore of one of deposits in Russian Federation. Gold and copper grades in the ore are 9.5 g/t and 0.4%, respectively. Various options of flowsheets, such as direct cyanidation, thiourea leaching, flotation and gravity concentration followed by subsequent cyanidation of con-centration products, were tested. It was established that gravity-cyanidation technology with filtra-tion leaching tails and the use of solutions in the recirculation is the optimal option for ore treatment. The proposed flowsheet provides gold recovery for 91.0% at NaCN consumption 2.5 kg/t ac-cording to the results of pilot testing. Ammonia-cyanide gold leaching was also examined. In comparison with cyanidation, gold leaching solution in system NaCN-NH4OH-(NH4)2CO3 allows NaCN consumption to be reduced three times from 4.5 kg to 1.5 kg per 1 ton of the ore and provides the same gold recovery. Based on the laboratory and pilot plant tests results of gravity-cyanidation technology of gold dissolution, process design criteria were developed.

Jan 1, 2014

By Ernesto de la Torre, Karla Velín, Alicia Guevara

"The following study shows the improvement and simulation of a gold recovery plant of 24 t/day of capacity by gravity concentration, flotation and leaching. The ore processed had grades of 6 g/t Au, 15 g/t Ag, and 0.69 %Cu with the mineralogy consisting of 2 %chalcopyrite, 12 %pyrrhotite, 7 %plagioclase and 50 %quartz. The recovery process starts with crushing the ore followed by grinding it further in a ball mill. The ground ore is then concentrated in a Falcon centrifugal concentrator with concentrate being processed by amalgamation process. Gravity tails are sent to a flotation circuit where the copper minerals and some gold are concentrated. Lastly, the flotation tailings undergo cyanidation for gold recovery. Currently, the overall recoveries are 82.8 %Au, 49.6 %Ag and 99.1 % Cu. The optimization was developed in the laboratory using a Wilfley table by gravity concentration. Flotation tests in the laboratory were performed using potassium amyl xanthate and pine oil. Lastly, cyanidation was then performed on the flotation tailings. The results showed the optimum concentration of sodium cyanide in cyanidation is 2 g/L, which produced an increase in gold recovery from 30% to 44%. The reduction of diameter particle from 132 to 80 µm also produces an incremental recovery of gold and silver from 11% to 21% Au and 0.4 to 3% Ag in gravity concentration. Likewise in the cyanidation the recovery of gold and silver has shown a rise from 44 to 62% and 8 to 32% for Au and Ag respectively. However, the flotation method the gold recovery is reduced from 68 to 30% Au by reducing the particle size. Computer simulations using the programs, Moly-Cop and ModSim were performed to determine optimum parameters for the recovery of precious metals at the gold recovery plant."

Jan 1, 2014

By Zhaohui Qiu, Yaguan Ji, Hong Zhong, Qingxia Liu, Yada Liu

"Water is a necessary process medium in mineral processing. For the operations where fresh water is not available, sea water could be used as an alternative processing medium to replace the fresh water if we would have built a solid understanding of the interfacial science and flotation chemistry of sulfide minerals in sea water. In this research, micro flotation of chalcopyrite and pyrite in deionized water and sea water were investigated. For chalcopyrite, the recovery starts to drop from pH 10 in deionized water and from pH 9 in sea water, and the flotation recovery close to 100% before it drops. We can found from the results that chalcopyrite flotation is depressed much at pH 11 in sea water when much white precipitate is found. For pyrite, the flotaion recovery changs a lot in deionized water with 1*10-5 M potasium amyl xanthate (PAX) as collector. It’s relatively high at pH 8~10 compared with that at pH<8 and pH>10. While in sea water, the trend is almost the same as that of chalcopyrite. Zeta potential measurements and chemical equilibrium calculation were used to find out that magnesium hydroxide species coats on the surfaces at high pH in sea water are the main reason for depressing the chalcopyrite and pyrite flotation. Through understanding the interfacial science and the solution chemistry of sea water and its impact on processing efficiency, this research will not only helps reduce the use of fresh water to minimize the disposal of spent water for environment protection, but also enhance the recovery of valuable minerals in froth flotation."

Jan 1, 2014

By David Deglon, Martin Harris, Mehdi Safari

This paper investigates the effect of energy input on the flotation of galena in a novel oscillating grid flotation cell (OGC). Oscillating grids generate near ideal hydrodynamic environments, characterised by turbulence which is relatively homogeneous and isotropic. Previous work was limited to quartz (-100 µm). Galena (-150 µm) was floated in the OGC at power intensities from 0.5 to 3 W/kg using 0.13, 0.58 and 0.82 mm mean bubble sizes (d10) and at three collector dosages. Results show that the effect of power intensity on flotation kinetics is strongly dependent on both particle and bubble size. For fine particles (-19 µm), increasing energy input increases the flotation rate at a low collector dosage but leads to an optimum at both the moderate and high collector dosages. For intermediate particles (+19-38 µm), increasing energy input has no effect on the flotation rate at the low collector dosage but leads to an optimum at both moderate and high collector dosages. For coarse particles (+38-150 µm), increasing energy input has no effect on the flotation rate at the low collector dosage and leads to a general decrease at both moderate and high collector dosages. Optimum conditions for fine particles are using small bubbles at a moderate collector dosage and an energy input of around 2 W/kg. Optimum conditions for moderate particles are using small bubbles at a high collector dosage and energy inputs of around 1.0 W/kg. Coarse particles do not benefit from agitation.

Jan 1, 2014

By Sebastian Fredes, Williams Calderon, Mauricio Toledo, Gonzalo Montes-Atenas

The influence of the temperature on leaching kinetics of copper-bearing minerals has been widely acknowledged: the leaching of copper oxide ores is generally described as exothermic reactions while copper sulfide ores are associated with endothermic reactions. Reports studying the influence of temperature on leaching kinetics at laboratory scale frequently involve the implementation of either fully flooded isothermal systems or jacketed column setups. Nevertheless, at industrial scale controlling or monitoring the temperature or temperature changes is almost impractical. In fact, leaching process is usually a large tonnage operation and changing the temperature of vast amounts of material would require an enormous amount of energy and highly specific heat transfer equipment. Preliminary computations on the amount of energy required to increase the temperature of a heap or dump in 1°C indicates that it would be impossible to find an energy source able to accomplish the task. In order to provide a solution to this matter it is suggested to create an energy managing protocol (EMP) that permits heat up or down the porous body locally taking advantage from the temperature gradients and from the reactivity of different regions within the material as a function of the leaching cycles. The aim of this study is to evaluate different heat transfer regimes in a 1 ton pilot column leach operation. It was found that best results of copper recovery are obtained when heating up the column in horizontal bands starting from the top of the column moving downwards as the leach cycle evolves. The system is expected to be suitable for industrial applications, but further development of the technique is required, particularly in the design of the heat transfer dispositive.

Jan 1, 2014

By N. Ahmed

This paper is concerned with the drainage behaviour of gangue mineral in the froth phase. Experiments were carried out in a continuous laboratory flotation cell in which froth depth and bubble size could be changed independently. The fraction of solids returning from the froth to the pulp zone was expressed using a rate constant. A mixture of hydrophilic solids (silica) and floatable particles (glass ballotini) was used as a flotation feed. Samples of glass ballotini of different hydrophobicities were obtained, using controlled silanation. Three samples, with contact angles of 50, 66, 82 degrees, were used. The effect of the initial bubble size (pulp bubble size), concentration of gangue mineral in the froth zone, and froth depth on the drainage of silica, were investigated. The drainage rate of the entrained solids increases with an increase in the degree of hydrophobicity of the floatable particles. Concerning the effect of pulp bubble size on the drainage rate of entrained solids, larger bubbles always give higher drainage rates due to formation of relatively loose froth structures which allow gangue particles to easily move down to the pulp zone. Conversely, smaller bubbles exhibit lower drainage rate constants, in particular at shallow froth depths.

Jan 1, 2003

By M. Pischtschan, S. Belz, M. Perrucci

In High Pressure Grinding Rolls (HPGR), the material grinding takes place between the fixed and floating rollers. In this regard, the rollers start to wear over a period of time, which is impacted by for e.g.: ore characteristics, operating pressure, feed material size and non-uniform feed presentation across the roller width. HPGR operational experiences have shown that the rollers do not wear at the same rate. This differential wear rate over time leads to differences in the tangential speeds of the rollers, causing an uneven gap between the fixed and floating rollers in relation to the material. This unwanted but extremely common situation results in a less effective grinding process due to the fact that the slip between rollers is not optimal. As the rollers wear profile increases, the roller with smaller diameter starts to wear further, deteriorating the comminution efficiency up to a point where operators have to stop the HPGR to replace the rollers. Since the wear rate of the rollers is not equal, the replacement of the same cannot be properly planned so that their life-time are fully utilized. In this paper, a dynamic load share control with the use of ABB’s variable speed drive system is proposed, which provides the possibility to the HPGR operator to impact the roller wear in such a way that it equalizes the wear rate to a certain extent and extends the roller life time. Called RollXtend™, this solution includes a load share factor which can be parameterized based on the wear measurement performed manually during maintenance procedure. Additionally, this paper describes an automated load sharing concept based on a non-invasive wear measurement method. The partial results of the technology trial in a copper/gold mine are presented, which aimed at detecting stud damage and estimating the real rollers profile throughout their life time. The final objective of the pilot project was reduce the amount of planned and unplanned downtimes of the HPGR by increasing the rollers life time and avoiding catastrophic stud damages.

Jan 1, 2018