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By P. Khattri

At Tata Steel, Coal is washed in gravity and froth flotation circuit at 13-15 mm size and below. Being coal is high in ash (~35%) and difficult washability characteristics (having high (~40 %) NGM at desired ash levels) needs more and timely quality data of ROM for effective optimization and process control. Conventional approach of supplying quality data takes 4-5 hours time. This means during this period, it is assumed that coal is having similar characteristics as of previous set and it is not possible to fine tune during this time which resulted in yield loss. Hence producing clean coal on agreed ash value consistently is a challenging task because of high NGM and variation in input quality. To overcome the problem of collection of representative sample and timely result a new technology was adopted Prompt Gamma Neutron Activation Analysis (PGNAA) technology which is basically an online analyser using Gamma rays as the source to measure the ash content in coal running on a conveyor which gives real time ash analysis. The details of this technological intervention are discussed in details in this paper. Keywords: near gravity material, PGNAA

Sep 1, 2012

By R. Mukherjee

Consistency of Run-Off-Mine (ROM) quality plays an important role in mineral processing which is not very often talked about. The major impediment is limitation of sampling ROM ore, which makes processing plants to run without any realtime feedback on ore quality that comes in. The process of direct determination of Run-Off-Mine (ROM) ore quality is expensive and time consuming as drawing and preparing representative samples from blasted muckpiles are constrained by large sample size and inherent heterogeneity in terms of size and chemistry. In absence of techniques for direct measurement of quality, monitoring and control of ROM, feed to the processing plant at Joda East Mine, like all other iron ore beneficiation plants worldwide, is largely based on blasthole sampling and subsequent chemical analyses of blastcone chips. While such indirect methods proves to be more accurate for representing whole of a mining block or blasted muckpile (~30-50KT/blast), it is indeed a challenge to ascertain and predict day to day input quality for a part there off. This eventually leads to a gap between predicted and actual ROM quality, resulting in difficulties in process control, in turn, and leading to wide swings in product quality. Hence, it is imperative to bridge the gap between predicted and actual ROM quality by arriving at means, which ensure consistent plant feed grade to deliver consistent output. The paper discusses an efficient and affordable alternative for effective prediction of ROM alumina which has been developed by integrating blasthole quality database in GPS based Truck Dispatch System (GPS-TDS) at Joda East Mine. Initially, GPS-TDS has been installed for optimizing production parameters only, but this development has helped in further utilization of GPS-TDS for real time quality monitoring by improving ROM grade prediction and scheduling from several ore blocks in active mining areas. Keywords:run-off-mine (ROM), blast hole, feed grade, GPS-TDS

Sep 1, 2012

By A. D. Bas

Copper minerals present difficulties during the cyanide leaching of gold ores leading to excessively high consumption of cyanide (and oxygen) coupled with low extraction of gold. Copper cyanide species, if present at high levels, adversely affects the downstream processes such as the activated carbon adsorption and the effluent treatment. In this study, the extraction of gold from a copper-bearing gold ore by ammoniacal cyanide leaching was studied. Furthermore, ammonia leaching as a pretreatment process ahead of cyanide leaching was also examined. Only ~12% of gold was extracted by direct cyanide leaching of the ore. The addition of lead nitrate did not affect the leaching of gold. When ammoniacal cyanide leaching system was used, the extraction of gold was significantly improved to >90%. Similarly, the pretreatment of the ore by ammonia leaching was shown to lead to high gold extractions (98%), in subsequent cyanide leaching with significant reductions in the consumption of cyanide. This appeared to be linked with the ready dissolution/removal of copper during ammonia leaching.

Sep 1, 2012

By L. Z. Li

The application of some environment-friendly mineral processing technology was introduced in Xitieshan lead?zinc mine and Hugary copper mine of China Western Mining Co., Ltd, located in western plateau area where the ecological environment is extremely fragile. The results of the significant economic efficiency were obtained by applying these new techniques while the protection of peripheral environment and the improvement of ecology were made.

Jan 1, 2014

By M. Marinov

The Bulgarian deposits of quartz-kaolin raw materials are localized in the NE Bulgaria. For many years, the quartz-kaolin sand separation has been performing by water washing technology. After wet separation the raw material yields two products ? washed kaolin (different grades) and quartz sand (different grades). Research and development program has started to improve the quartz-kaolin sand separation. The program has undertaken an increasing of processing capacity, to decrease the losses in the tailings and to provide production of new quartz sand grades. The kaolin-silica raw materials from Vetovo open mine and the technological tailings from Vetovo processing plant were characterized. It was established that there are a lot of losses of quartz in final tailings. New approach on kaolin-silica raw material separation was tested in laboratory scale. The test work was performed on Derrick Stacksizer screening machines. The results of laboratory experiment show that there are possibilities to increase the quartz sand recovery and to start the production new grade sand. The full-scale pilot test was performed including the following units: two Derrick Stacksizer screening machines equipped with 0.430 mm and 0.150 mm opening Derrick Urethane Panel, respectively; Flat bottom DN 500 Hydrocyclone and DN 100 Hydrocyclon. The pilot test data clearly demonstrate that the Derrick Stacksizer screening machines are suitable for Bulgarian silica-kaolin raw material. Based on the test data a new quartz-kaolin separation technology was developed. The new technology was introduced in Vetovo processing plant increasing processing capacity and decreasing the losses of quartz in final tailings. Additionally the production of silica sand grade PK 0.16 is increased and starts the production a new grade PK 0.10.

Sep 1, 2012

By Marlize Barkhuizen, Chris Aldrich

"Owing to environmental constraints, safety considerations and competitive pressures, the development of model-based process control and other automated systems have experienced considerable growth in the last few decades. Reliable process models are usually critical to the successful implementation of these systems. In complex processes, these models are often constructed from process data, as modelling from first principles may not be feasible or cost-effective.Even so, modelling or identification of nonlinear systems from historic plant data can be a daunting task and in the process industries the problem is complicated by the presence of noise from various sources, nonstationarity of the data, intermittence, such as observed in particulate flows, etc. Traditional methods, such as frequency analysis and linear modelling do not handle these systems well. Similar problems arise with the application of nonlinear theory developed over the last few decades, where much of the analysis depends on embedding of the data in a phase or pseudophase space, since these methods were not originally designed to deal with noisy systems.With singular spectrum analysis, the data are embedded in a high-dimensional reconstruction, followed by the introduction of a new coordinate system, where the origin is moved to the centroid of the reconstructed system states and the axes are represented by the dominant principal components of the states (points)."

Jan 1, 2003

By E. V. Manlapig, M. C. Harris

"The complexity of the flotation process has made the identification of an appropriate model structure for the predictive simulation of flotation circuits far from obvious. Work performed under the auspices of the AMIRA P9 flotation program has indicated that the metallurgical performance achieved from a flotation cell arises from the interaction of two essentially independent property classes, namely the cell operating conditions and the properties of the cell feed stream. These observations have led to the development of a model structure that associates a constant set of flotation parameters to the streams of the circuit, which are transformed into a flotation response depending on the operating conditions within the flotation cell.A variety of alternative model structures exist within the literature which do not make this distinction between cell and stream flotation properties, and many of these models are in widespread use for flotation optimisation and design studies, both in industry and academia.In this paper, circuit survey and laboratory batch flotation data collected from an industrial flotation circuit are analysed. The data demonstrate that streams in an industrial flotation circuit exhibit varying particle floatability – concentrate streams typically float faster than tailing streams (Figure 1(a)). This floatability, however, is generally conserved around the various units within the flotation process (i.e. the effective floatability of the combined feed and product streams of a unit is equivalent (Figure 1(b)))."

Jan 1, 2003

By B. Gorain, O. A. Bascur

"The advent of digital revolution has now enabled us with numerous tools that could be leveraged to transform our operational data into actionable insights. Key opportunities with digitization include better visualization, transparency, integrated planning and execution for value-chain optimization, that results in smarter production, intelligent response to changes in ore, process and equipment conditions, reduce energy and waste along with prevention of asset breakdown, safety and environmental issues. It is important to realize that these digital tools have limited value, from a metallurgical operational context, if we cannot bring-in the appropriate domain expertise along with getting the basics right. The focus within Barrick is to ensure that there is adequate depth of different disciplines built into our platforms along with breadth to integrate other disciplines such as geology and mining for an effective Mine-to-Mill integration. A gold recovery improvement strategy based on optimal Gaudin size distribution, leaching performance monitoring and guidance via feed grade maps is discussed. Simultaneous identification of process and equipment constraints enable finding the best overall conditions for Gold recovery. This paper discusses the methodology, findings, and challenges in the ongoing journey of implementing a Metallurgy Analytics platform that evolves from being retrospectively descriptive to anticipatively prescriptive.INTRODUCTION The last few decades have seen some remarkable advancement in information technology, but recently various digital technologies have resulted in several synergies to deliver innovation in diverse applications. The mining industry has been relatively slow in adopting these technologies compared to the other industries, but this scenario is changing fast. Mining companies globally are going through a series of challenges such as declining ore grades with complex metallurgy, increasing depth of ore bodies, high capital and operating costs, lower productivity, shortage of technical resources, significant pressure from stakeholders to deliver, along with growing environmental and corporate social responsibility issues. Improvement in profitability would need significant improvements in operational performance."

Jan 1, 2018

By Q. Shi

An investigation into the hydrophobic aggregation of ultrafine smithsonite in surfactant solution has been undertaken through a combination of hydrophobic flocculation experiments, zeta potential measurements, surface tension measurements, and contact angle measurements. The experimental results have revealed that the behaviors of hydrophobic aggregation were closely correlated with the particle hydrophobicity, but they were not lowered byte change of the particle surface charges due to surfactants adsorption. On the other hand, the liquid (solution) surface tension (?LV) plays an important role in hydrophobic aggregation, and the hydrophobic aggregation could not occur below the critical liquid (solution) surface tension (?c). Meanwhile, this flocculation has been observed to require sufficient stirring strength and magnitudes of kinetic energy input to achieve the maximum aggregation degree. From the microflotation results, it has been found that the flotation kinetics response of smithsonite fines is markedly improved due to sufficient stirring strength, and the stirring strength influenced the floc flotation in a manner quite similar to their influence on the hydrophobic aggregation, suggesting that the formation of hydrophobic flocs is a promising means to recover smithsonite in the fine size range.

Sep 1, 2012

The ball level and pulp load play a key role in the operation of industrial scale ball mills. These two operating variables have a significant influence on the performance of the ball mill and any attempts to optimize these devices require manipulating either one or both of these variables. There are several models that can be employed to perform simulations to optimize the performance of industrial ball mills. However, most of these models require ball load and pulp load measurements as inputs to calibrate the model. The changes suggested by the simulator also provide operating regimes that involve moving either the ball level or pulp load and sometimes both of these variables. A ball mill model coded in JKSimMet was used in conjunction with the Sensomag to optimize the secondary ball mill at Waterval concentrator in South Africa. The results show that the perfect mixing ball mill model can be used in conjunction with the Sensomag to optimize the performance of the secondary ball mill.

Sep 1, 2012

By G. C. He

Effects of irregularity, rough surface and aggregation of fine particles on ultrasonic attenuation are significant. The effects should be considered while predicting particle size by ultrasonic attenuation technology. The scanning electron microscope micrographs analysis also shows that particles surface is rough and irregularity. Any slurries has its fractal structure and its special fractal scale and dimension, so, effects of irregularity, rough surface and aggregation of fine particles can be de-scribed by fractal model. The discrepancies between predictions of ultrasonic attenuation based on the assumption of smooth spherical particles and data obtained from slurries of irregular particles indicated that there were different fractal structures. The ultrasonic attenuation model was modified by fractal dimensions. The result of experimental data and analogue calculation indicated that pre-dictions of the fractal modification of ultrasonic attenuation model show good agreement with experimental data. On the other hand, from the values of fractal obtained by inversely calculation, the degree of effects of irregularity, rough surface and aggregation of particles can be estimated. The positive value of fractal dimension indicates that the aggregation has the dominant effect on ultra-sonic attenuation, otherwise, the irregularity and rough surface has the dominant effect.

Jan 1, 2014

By N. Vasumathi

Most of the Iron ore washing plants set up in India in the earlier days consist of sizing of the ore by dry / wet screening, washing and classification by screw classifiers. In this classical approach, iron values were lost in the form of fines and ultrafine into the tailing ponds as they had little commercial value in those days and accumulated in huge quantities over the years. As the high grade deposits are getting exhausted and the demand for high grade finer material for pellet making is ever increasing, focus is shifting towards recovering the values from the erstwhile tailing ponds by column flotation. This is also supposed to mitigate to a certain extent the environmental problems caused by the ever expanding and unmanageable tailing dams. A case study is presented wherein a composite sample is prepared from samples drawn systematically from multi - locations in a sprawling tailing dam. Laboratory scale column flotation tests on this composite tailings sample, basically originating from two operating iron ore beneficiation plants of JSW Steel Ltd., one of the leading producers of steel in India are found to be encouraging. Desliming followed by reverse and cationic flotation tests using flotation column resulted in the concentrate of 61.88% Fe, 4.81% SiO2, 2.52% Al2O3 and 3.30% loss on ignition (LOI) from the tailings analyzing 57.86% Fe, 7.10% SiO2, 3.52% Al2O3 and 6.14% LOI with 52% weight recovery. The causes for the quality improvement could be attributed to desliming of un-liberated ultra fines of kaoline and hydrated iron oxides and their further reduction by efficient flotation process. The process and the cationic collector developed for this purpose are adopted in the new flotation plant created to treat these tailings. Keywords: iron ore, washing, ultra fines, tailings pond, column flotation

Sep 1, 2012

By V Radmehr

Ammonia and Amonium salts have been recognized as effective leaching agents in hydrometallurgical processes due to low toxicity and cost, easy recovery and high selective recovery of metals. New research findings of considerable advantages of leaching by these agents and elimination of problems associated with acid leaching has resulted in a new approach in the world to this method. The investigations in this field indicate more frequent use of this method for extracting copper from ore and concentrate relative to other basic metals. In this paper, we have attempted to describe the basis and different ammonia leaching methods and present the major research activities in this field for copper. We have also presented the latest findings and related novel processes. Comparative assessment of advantages and disadvantages of this method relative to acid leaching method, kinetic study of copper ammonia leaching and evaluation of Eh-pH diagrams in a system containing water and ammonia are other parts of our study. Finally, by describing the studies on copper extraction from the resulting pregnant solutions, the applicable extraction agents have been reviewed.

Sep 1, 2012

By M. Zolghadri

MIBC and sodium metasilicate are used as a frother and a dispersant in coal flotation respectively. In order to study interaction between them, flotation experiments were performed on fine coal (<150 microns). It was found that if the frother (MIBC) dosage is in excess of a certain limit, it has an activation effect on the gangue minerals associated with coal. In addition, it was found that however sodium metasilicate can disperse clay slimes eliminating slime coating, but in the case of excess dosage, could intensify activation effect of MIBC, which is undesirable in coal flotation. Keywords: coal flotation, sodium silicate, frother, dispersion, activation

Sep 1, 2012

By R. B. Shu

A moderate thermophilic microorganisms, has been isolated (45?) from a typical sulphide mine in the region of Mo Jiang located in the southwest of China. The culture has been used to extract copper from chalcopyrite concentrates obtained from De Xing copper mine. The majority of experiments were carried out in 300mL Erlenmeyer flasks containing 150mL volumes of mineral suspension. Effects of some variable parameters such as solids concentration, pH and the concentrations of inorganic nutrients on the bioleaching of chalcopyrite obtained from De Xing copper mine were investigated. For a given concentrate the most important factor affecting the fractional copper extraction was the size of the mineral particles. The overall rate of leaching was found to be limited by the area of mineral surface. The attack started in cracks and genetic defects and finally reached the whole chalcopyrite surface. As a consequence of this, the ore showed strongly cracks. The additive of ferrous sulfate increases the bacteria activity, but did not improve chalcopyrite bioleaching. The results indicate that the nature and relative proportions of the various minerals present have been shown to be important factors.

Jan 1, 2014

By Mario Gerards, Marco Steinberg, Jan Huben

"Wet high intensity magnetic separation or WHIMS is a widely used technical process for the recovery of magnetic susceptible iron ore particles, mostly for fine and ultrafine grain sizes. The JONES® WHIMS - Wet High Intensity Magnetic Separator, has been used for many years and in countries all around the world. This paper outlines the physical principles utilized for the separation inside the unit, as well as some of the recent changes and developments on the design. It will also give an outlook on the theoretical potential of different alternative yoke materials. The aim of this paper is to analyse the suitability of different yoke materials to improve the equipment. This will be done comparing the magnetic and mechanical parameters and analysing availability and price to find the best compromise regarding cost and benefit. As far as the different kinds of materials are concerned, a special material has been identified as suitable during the comparison exercise. After running the economical calculations, especially with respect to the reduction of the total power consumption of the equipment, a tremendous reduction of the total power consumption has been determined. In addition, to the theoretical exercises and due to the promising results of the same, the Pilot Unit P 40 of the JONES® WHIMS has been manufactured with the special material in order to get practical results as well. Finally, this paper outlines the theoretical and practical results focused on the power consumption. The results are showing that the total power consumption can be reduced tremendously. Hence, the way for a new generation of JONES® WHIMS - environmentally friendly - has been paved."

Jan 1, 2014

By Carlos G. Rudolp, Julio C. Videla, Mario Zuleta

"The present paper summarises the results of gravity pneumatic concentration of a borax ore with 17.5 % B2O3. The sample was extracted from the Tincalayu ore deposit located in the Salta Province of Argentina.The applied methodology was based on a former study (Zuleta, 1985). It consisted of sample characterization by means of physical and mineralogical determinations, chemical analyses as well as pneumatic table concentration tests. In this, a simplified concentrating flowsheet was utilized.A concentrate with 30.6 % B2O3 and 74.7 % recovery was obtained. The recovery was 8.8 % less than previously reported and that was of 30.6 % B2O3 with 87 % recovery. Nevertheless, the simplified flow sheet presented processes only two granulometric fractions, - 6.4 mm + 0.3 mm and - 0.3 mm, compared to the three granulometric fractions used in the previous study: - 6.4 mm + 1.4 mm; - 1.4 mm + 0.3 mm and . 0.3 mm. This would simplify industrial implementation."

Jan 1, 2003

By Zehong Wang

Selecting sodium polyacrylate (PAAS) as grinding aid, the effect of grinding aid on the grinding efficiency of bauxite taken from Shanxi province was studied and its mechanisms were analyzed by measuring the variation of adsorption characteristic, pulp viscosity, surface electric potential of the bauxite and the surface appearance of particles. The results showed that, compared with no grinding aids added the content of -0.074mm in the ground product was increased by 5.45 percentage points under the optimal grinding conditions adding PAAS as grinding aid when the amount of PAAS was 0.7%wt of bauxite. Because the physical adsorption and chemical adsorption were occurred on the bauxite surface, which could reduce the pulp viscosity, change the surface electric potential of the bauxite, enhance the surface appearance of particles and lower the surface hardness of the bauxite, the grinding efficiency of bauxite was increased by PAAS. Keywords: bauxite, grinding aids, grinding efficiency, mechanism

Sep 1, 2012

By Evgeni Visariev

In Copper smelter Aurubis Bulgaria, the copper in slag from the Flash furnace and the Converters is recovered by flotation. The scheme of slag processing is crushing, two stage grinding (autogenous and ball) and flotation. Till 2010 the grinding cycle in the plant was in two stages ? the first stage was AG Mill 70?23 working with a classifier and the second stage was ball mill 3.6/5.5 working with a hydrocyclone. In 2010 a new AG Mill 65x78 with hydrocyclone was put in operation in order to increase throughput of the plant. The second stage of the grinding cycle is with the same ball mill. The Old AG mill processed 55-60 t/h slag with particle size -0.071 mm 75% or over 75 t/h with particle size -0.071 mm 35-40 %. The new AG Mill was designed for throughput 105 t/h with particle size -0.071 mm over 70 %. After the start up there were some problems with the equipment ? block up of AG Mill?s grate and pumps for feeding of the hydrocyclone. For optimization of the process a lot of general tests were made. One of the main problem was a wearing of the sand nozzles. Different materials (rubber, ceramic, metallic) for the sand nozzles were tested. The openings of the grate were changed. This paper presents: ? the optimal technological parameters of the old and the new working scheme; ? how the technological parameters of the new working scheme change when the hydrocyclone works with different nozzles; ? the effect of the change of the grate openings; ? the problems with the increase of the circulating load; ? a final decisions for improvement of the grinding cycle work. Keywords: spigot, wearing, classification, effectiveness, circulating load, autogenous, mill

Sep 1, 2012

By R. S. Wang, S. Z. Zhou, L. Wan, K. W. Zeng, Z. J. Sun, W. G. Wu, Z. B. Qian, X. R. Zhang, Z. K. Hu, Y. Yu

"In view of the present situation that the traditional environment friendly depressants for galena aren’t very effective in the separation of mixed concentrate including copper sulfide and lead sulfide, this research describes a new environment friendly depressant PD-1 and investigates its effects and mechanism in the separation of chalcopyrite and galena. This study is carried out through flotation tests, analysis of infrared spectra and absorption measurements. It is shown that when O-isopropyl-N-ethyl thionocarbamate (Z200) is used as collector, chalcopyrite and galena can be separated in the presence of PD-1 under appropriate conditions. Therefore, it can be concluded that PD-1 has an excellent depression ability and great selectivity for galena. Meanwhile, analysis of infrared spectra demonstrates that PD-1 can strongly absorb on the galena surface by chemical interaction with Pb2+, while it hardly absorbs on the chalcopyrite surface. In addition, the results of absorption measurements reveal that competitive adsorption occurs on the galena surface between PD-1 and Z200, PD-1 can block the absorption of Z200 on the galena surface. However, PD-1 has a little effect on the absorption of Z200 on the chalcopyrite surface under above conditions. What’s more, the hydrophilic groups of PD-1 molecules can make galena effectively depressed. The results of mechanism analysis are in accordance with those of flotation tests.INTRODUCTION In the processing of copper-lead sulfide ores, the process, copper increase and lead reduction (Zhang et al., 2017) after reagents removal of rough concentrate produced by mixed flotation of chalcopyrite and galena, is usually adopted. However, as a result of tight symbiosis and the similar flotability of chalcopyrite and galena, the separation is difficult (Hu and Feng, 2006). There are 3 kinds of depressants for galena in the separation of chalcopyrite and galena concentrate,including dichromate, sulfite and combined depressants of organic or inorganic reagents (Wei, 2012). As dichromate would cause serious environmental pollution, it is gradually banned to be used in industry (Xu et al., 2017; Lin et al., 2017). what’s more, due to the need of acidic slurry, using sulfite is not conductive to the maintenance of equipment and stable production(Wang, 1999). As for the combined depressants, they also have disadvantages of complex pharmaceutical system and no ideal separation effect (Wei and Sun, 2008). Therefore, the development of new safe and effective depressants for galena is a research focus for researchers in the minerals processing (Chen, 2000). In this paper, a new type of organic depressant PD-1 is applied to the copper-lead separation process of ""copper increase and lead reduction"" using Z200 as the collector. In addition, the performances and mechanism of its depression to galena are studied emphatically."

Jan 1, 2018