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By L. F. Mashburn, T. J. Ferree

A Reichert cone concentrator was installed in an aggregate plant circuit to recover the extremely fine "flour gold" known to exist in the deposit. The gold content of the bank- run gravels averages about 0.1 g/t-about $1.29/t, based upon $12.86/g ($400 per oz) gold. The fineness of the gold averages between 950 and 960. The Reichert cone, in conjunction with a conventional shaking table, recovers in excess of 85% of the gold. A screen analysis of the gold particles shows 44.1 % is - 74pm (-200 mesh) in size. The plant operates with a two-man crew.

Jan 1, 1983

By R. H. Mozley

It is not my intention in this paper to review recent developments in the mineral processing industry which might fall under the above heading, but to refer to some of the research that I have done over the past 25 years or so. To begin with then, my student days at the Camborne School of Mines, the year 1952. Equipment from the last century was still in everyday use at the local tin mines. At South Crofty Ltd a steam beam engine 100 years old was pumping mine water from 2000 feet, the motive force being conveyed from surface to the pump at the bottom of the mine by a 14 inch square pitch pine rod joined with forged iron straps, steam winders were still in use, and in the mills, stamps ground the ore, and the cassiterite was recovered by equipment with exotic names like "buddies, kievs, and round frames." And to equip us students for the brave new world, we included in our practical mineral dressing a day's test programme with a Californian stamp -- experience that I am still waiting to put to good use!

Jan 1, 1984

Fine Gravity Separation in the Reflux Classifier, Exploiting a High Shear Rate, Laminar Flow Mechanism The Reflux Classifier is used in the gravity separation of particles over a broad range of particle sizes. The device consists of a fluidised bed zone, with a system of parallel inclined channels above. The inclined channels provide a significant hydraulic advantage over conventional fluidised beds via the so-called Boycott Effect (Boycott, 1920). This paper describes a new advance in fine gravity separation based on the high shear rate and laminar flow profile that arises when closely spaced inclined channels are deployed. As reported recently (Galvin et al, 2009a), a powerful density based separation mechanism develops from this arrangement, suppressing the effects of particle size. In this paper we focus on two areas, firstly the application of the separator in the laboratory for batch fractionation of particles of varying size and density to determine the grade recovery curve and hence the liberation, and secondly the step change in separation performance achieved on a continuous steady state basis when closely spaced inclined channels are used. The variation in the separation density with particle size decreases significantly, and the Ecarte Probable Error (Ep) remains at low levels over a broad size range.

Sep 13, 2010

By Walter Nummela

This acronym may be readily deciphered, and it represents the programming theme for the SME Sessions at the Centennial Meeting of AIME in New York in 1971. The Concentration Committee thus charged out to grab, to induce, and to accept volunteered papers within that framework. The program for the Concentration sessions is in and hopefully all deadlines will be met as specified in the instructions to authors. Without spelling out what is to be seen and heard in New York, how well did the Committee satisfy the theme described in the title? Perhaps it was by virtue of the international makeup of the Committee (Member Dan Pickett is with the Mines Branch in Ottawa) that an international slate of authors was assured. Four countries are to be represented-Bolivia, Canada, Italy, and the United States.

Jan 1, 1970

By Burt C. Mariacher

Two AIME sponsored symposia to be held during the year 1970 will examine copper, lead and zinc metallurgy in considerable depth. MBD and the Extractive Metallurgy Division of The Metallurgical Society will participate in both. Thus, the full field of minerals and metals processing including milling, smelting, and refining will be covered. Since these symposia hold special interest to MBD members, it was felt that a useful purpose could be served by devoting this column to a description of what has been arranged for the registrants.

Jan 1, 1970

By Jan D. Miller

Under the name given to this column, I almost feel obliged to write about some aspect of grinding, but I have decided instead to comment on the future of chemical processing. In recent years, I have seen a tremendous interest in extractive metallurgy develop among undergraduate and graduate students at the University of Utah. For example, of the 12 graduating seniors this year, over half seem to prefer extractive metallurgy to physical metallurgy. In particular, they seem to be most interested in hydrometallurgy, or chemical processing, obtaining industrial exposure to the phenomena they study via part-time employment at the Kennecott Research Center and the USBM Metallurgical Center in Salt Lake City. The stimulus has been generated by society itself. Many students are dedicated to the proposition that new technology can circumvent the destruction of our environment, a concept which provides considerable motivation. At the governmental level, the recent concern for the quality of our environment has created action in the area of chemical processing both through imposition of stringent air and water quality standards, and through increased funding for technological research in this area. The National Academy of Sciences (NAS) gave impetus to this movement when it pointed up the need for development and support of such disciplines as extractive metallurgy, particularly chemical processing, in a recent report on Mineral Science and Technology. The recommendations in the NAS report have prompted governmental action on many fronts, including the Bureau of Mines, and have also given rise to direct legislation in the form of two bills -H. R. 3492 and S. 635- presently before Congress to a mineral engineering education. The report recommends that chemical processing technology (more generally extractive metallurgy) be developed by both new engineering techniques and unconventional chemical techniques such as application of the chemistry of nonaqueous liquids to mineral systems.

Jan 1, 1971

By A. D. Taylor

In recent years there has been an increasing effort to attract students into engineering. Obviously, the effort is necessary because young people find the image of the engineer unattractive. Some of the things they find unattractive are real, some are not, and part of the problem is too little knowledge of the field. First, I would like to comment on some of the ideas which appear to be justified. Engineering is a difficult course of study. True, and nothing can or should be done to change this. The education is continually being improved, but it is unlikely to be made easier.

Jan 1, 1970

By M. C. Fuerstenau

Each year during the AIME Annual Meeting, the MBD Division has its Business Meeting. Because many members cannot attend, it has be- come policy for the secretary of the Division to present highlights of the business conducted at the Meeting in Fine Grind. This year the Meeting was held on March 1 in the Americana Hotel. Five major items of business were brought up for discussion. These were: (1) the proposed name change for the Division, (2) institution of the Taggart Award, (3) a name change for a Unit Committee, (4) MBD funding of scholarships, and (5) authorship of Fine Grind articles. The Matter of What We Should Call Ourselves A lively discussion was held on the issue of a name change for the Division. Two names have been proposed: (1) Mineral Processing Division, and (2) Mineral Engineering Division. A number of strong reasons for changing the name from Minerals Beneficiation Division have been pointed out. Perhaps the most important of these is that the term "beneficiation" does not describe all of the functions that engineers in our Division perform. Further, there are inherent problems associated in the term, in that beneficiation is a long word which has the twofold disadvantage of being both difficult to pronounce and difficult to spell.

Jan 1, 1971

At the MBD Business Meeting held on March 1, 1971, the General Committee of the MBD Division voted unanimously to change the name and expand the role of the Fluo-Solids Separation Committee. The new committee is called the Environmental Control Committee. Such action was taken because of the importance of environmental control and the need for a more active role in this area by our Division.

Jan 1, 1971

By Roshan B. Bhappu

This is the Centennial year of AIME and many of us reading this issue of ' will be getting ready to attend the Centennial Celebration in New York from February 26 through March 4. The officers of the Division sincerely hope that a large number of our members will attend the fine technical sessions and social functions arranged for this really big meeting. The year 1971 will be a crucial one for MBD. This SME Division is a working group organized "to furnish a medium of cooperation among those interested in the basic unit processes and unit operations of minerals beneficiation; and to promote the advancement of this branch of mineral technology through meetings for professional intercourse, and to stimulate the preparation, reading discussion and circulation of papers connected therewith." No one can deny the worthiness of these objectives or minimize the efforts that Division officers and members have made to attain them. Much has been done over the past several years to achieve a smooth-running and effective MBD organization. However, there is still room for improvement and much more needs to be done in order to provide the best possible services for the membership and the profession.

Jan 1, 1971

By Robert S. Shoemaker

Recently we read a short article which stated that Marcona Corp. was studying the use of 25,000-hp autogenous grinding mills for an iron ore project in Alaska. As if that weren't enough, they were going to dispense with the primary crusher and feed run-of-mine ore to the grinding mills which were to be driven by wrap-around seven-cycle motors. We see also that Bougainville Copper Co. will be grinding 90,000 tpd of ore in only eight 4250- hp ball mills. At Bougainville too, their float section will be the first large one to be completely equipped with the new 350-cu ft flotation cells. After a half century of relatively peaceful growth in the minerals industry, we are now seeing almost exponential advances in both equipment and plant size. At the same time, we are seeing a constant blending of hydro and pyrometallurgical techniques and processes into minerals beneficiation until the sample grind-'em-up-and-concentrate-'em plant is becoming a rarity.

Jan 1, 1970

By F. F. Aplan

Pollution control will be of utmost importance in the 1970's. In this area, the mineral process engineer has a special competence to understand and remedy many pollution situations. There is an old adage that goes, "Build a better mouse- trap and the world will beat a path to your door." Would that it were so, but the reality of the situation is such that, just as a supplier must sell his machine, a professional man must sell his competence. It is a sad but true fact that mineral processing engineers have not done a very good job in selling their extensive competence in the control of a broad range of pollution problems. Recently one of our students visited a paper pulp mill where he was shown a foam fractionator used to remove paper pulp fibers from plant discharge waters. "Foam fractionator hell, that's a flotation cell!'' was his comment. Ah so, it would appear that large numbers of technical people consider themselves experts on "foam fractionation" Or is it that we have been very remiss in demonstrating the usefulness of our equipment and processes and our professional competence to solve, these pollution problems?

Jan 1, 1970

By M. C. Fuerstenau

Enrollment in the mineral engineering departments at many of our universities has decreased substantially over the past few years, a fact that is due to a number of reasons. Some of the more obvious reasons are: (l) lack of student stimulation in the classroom, (2) absence or lack of salesmanship by the mineral industry faculty, (3) minimal financial support of academic programs by industry (some companies have been very generous, while others have given nothing), (4) failure of some companies to utilize the engineering backgrounds of personnel, (5) salary in some instances, and (6) job location in some in- stances. As some of these problems have been recognized, appropriate steps have been taken to correct them. Only one of the reasons listed is not subject to change, and that is job location. One university' that found itself in the position of reduced enrollment in the mineral industries is the University of Utah. Since the author was in the Department of Metallurgical Engineering at that university, and since data on enrollment and scholarship support have been published by that department, that department will be used for illustrative purposes to show the effect that active scholarship incentive can have on undergraduate enrollment. As Fig. I shows, there were approximately 35 total undergraduates in the department in 1966. Extrapolation of the freshman line from 1965 to 1966 (and previous years) suggested that no freshmen would be enrolled in metallurgical engineering by 1969 unless something drastic were done to alter the trend. In the Spring of 1966, 20 scholarships were offered to high school seniors as an incentive to enroll in metallurgical engineering. These scholarships were financed from a private endowment to the department, but at the present time industry is also contributing to the program. With these incentives, the department essentially doubled its total enrollment in three years, as shown in Fig. 1. Cornparison of this figure with the number of students on scholarships (Fig. 2) shows a direct correlation between undergraduate enrollment and the number of students on scholarship support.

Jan 1, 1970

By Burt C. Mariacher

The Minerals Beneficiation Division meets each year at the Annual Meeting of AIME. All members are invited and encouraged to attend. For the information of those who did not attend the meeting in Denver last February, this column presents a summary of the reports given and topics discussed. Technical Committee Coordination Consolidation of technical programs having common interest to MBD and the Extractive Metallurgy Division is proving a considerable success, both on the technical committee level-through the efforts of the MBD-EMD Coordinating Committee-and in special symposia. MBD Chairman, R. S. Shoemaker, noted that J. D. Prater will be serving as Chairman of both the MBD Chemical Processing Committee and the EMD Hydrometallurgy Committee for 1970-71. R. P. Ehrlich commented on the cooperative effort of both divisions in organizing the Copper Metallurgy Symposium held at the Denver Meeting. This effort, he said, was important to the success of the Symposium. H. R. Spedden discussed inter-Division coordination activities on the SME level. The forthcoming MBD-M&E-EMD Joint Lead-Zinc Symposium is yet another example of progress in this direction.

Jan 1, 1970

By E. J. Duggan

CLIMAX ore is an altered and highly silicified granite, about half of the gangue being quartz. Molybdenite is the only mineral recovered and most of it is intimately associated with the quartz in fine veinlets. Other minerals are molybdite, pyrite, and chalcopyrite. Although the molybdite may be readily extracted by hydrometallurgical methods, its content is too low to make this profitable. The pyrite ranges from 2 to 5 per cent and the chalcopyrite from 0.03 to 0.05 per cent. There is not enough copper to make its recovery attractive and one of the problems is its elimination, and that of pyrite iron, from the final product. On account of the high degree of dissemination of the molybdenite and the necessity of eliminating the iron and copper, fine-grinding followed by flotation is the only known feasible method of concentration. Two factors, peculiar to Climax ore, have a predominating influence on the metallurgical attack: (1) Molybdenite is one of the most easily floated minerals. High recoveries may be made with pine oil alone if the

Jan 1, 1946

By Graham Davey

"Low speed stirred milling has been employed for many years in the metalliferous and industrial minerals industries. High speed stirred milling is a relatively new method of grinding in the metalliferous process industries. However it has been it has been in wide spread use in the industrial mineral field for over 30 years for various minerals. Many existing metallurgical operations are looking to maximize economic return from existing deposits, requiring new thinking and technologies. By combining low speed and high-speed milling fine and ultrafine grinding efficiency and operating costs can be improved.The correct selection of different fine grinding technologies is covered, when each mill is applicable and when a combination of the VERTIMILL® Grinding Mill and SMD provides the best economic solution.INTRODUCTIONUltra-fine grinding of minerals has been in wide spread use in the industrial mineral field for over 30 years. Within the last 10 years the metalliferous industry has shown interest in the ability to produce ultrafine particles, as chemical, physio-chemical and physical separation processes have advanced to be able to treat ultrafine metalliferous particles. Also as the primary mineral deposits, around the world are depleted, new more difficult deposits must be mined. Existing operations are also looking to maximize economic return from existing deposits, requiring new thinking and technologies.The traditional approach for gold containing refractory material has been to liberate the locked gold by chemically destroying the pyrite through oxidation. Roasting, pressure oxidation, and bacterial oxidation all employ various degrees of temperature, pressure and catalysis to react the pyrite with oxygen to produce iron oxide and sulfur by-products. However all of these methods are economically impacted due to specific operational added requirements and emissions controls. Pressure and bacterial oxidation have very high capital and operating costs."

Jan 1, 2006

By R. T. Hukki

IT is no great exaggeration to say that present grinding practice and economics are largely determined by lining design. A record of outstanding liner wear can be achieved with any liner surface pattern that will positively lock the outer layer or layers of grinding media. With no slippage, lining wear is bound to be slight. At the same time, popular practice calls for tumbling loads of about 50 pct of mill volume to obtain maximum grinding capacity. Innumerable parallel grinding investigations have verified that optimum speed for such a mill lies within 70 to 85 pct of theoretical critical speed. If the mill is speeded up to 100 pct of critical, little or no grinding can be accomplished. Earlier Work on Supercritical Grinding: First investigations concerning grinding at supercritical speeds seem to be very old. Remarkable work on the subject has been performed by White,1 and his experiments have been described and summarized by Richards1 White's contributions seem to have passed unnoticed by Fahrenwald, 2,3 whose extensive experiments have been well presented, yet apparently very little appreciated. Additional work on grinding at supercritical speed has been reported, e.g., by Lewenson and Tscherny,4 USSR; Anselm5 and Grunder,6 Germany; and Rose and Evans,[6] Great Britain.

Jan 5, 1958

By Fred T. Towne

Recent developments in fine grinding by the means of mechanical impaction are the result of continuing improvements in modern machine construction. This is especially true when related to the bearings and mechanically operated parts of impact mills. These improvements allow manufacturers to increase the speeds of the impacting members Most of the more common forms of size reductions, such as percussion, pressure, friction and sectioning, or cutting were at one time accomplished by human hands. These actions were transferred to machinery. Originally of limited application, their use widened as industrial materials and construction became more sophisticated.

Jan 1, 1965

By H Ishikawa, H Zhou, M Spagnolo, R Halomoan, S Palaniandy

The Karara Mine concentrator commenced operation in November 2012 to produce high-grade magnetite concentrate. The circuit consists of three stages of comminution plus magnetic separation at each stage for early gangue rejection. High-Pressure Grinding Rolls (HPGRs) are used for fine crushing, followed by ball mills and TowerMills in secondary and fine grinding duties respectively. In recent times, the plant throughput rate has had to exceed design by 18% to maintain the targeted concentrate productivity. Meanwhile, the ore hardness has increased by 25% to 15 kWh/t, leading to changes in the circuit operation and design. These changes led to coarser and harder feed to the TowerMill circuit that affects the subsequent separation processes. Nippon Eirich (the TowerMill manufacturer) has partnered with Karara Mining Limited (Karara) to optimise the TowerMill circuit operation to achieve a circuit product with an 80% passing (P80) of 35 µm. Several activities, including a TowerMill circuit audit and performance evaluation, multi-component analysis, modelling and simulation, were carried out as part of the optimisation exercise. The circuit audit results revealed that the TowerMill circuit feed size F80 had increased and ranged from 67–75 µm. The circuit product P80 ranged between 42–55 µm. The average circuit specific energy was 3.4 kWh/t. Moreover, the differences in density between magnetite and gangue minerals had affected the hydrocyclone performance where the efficiency curve exhibits coarse end deflection indicating that low-density coarse material was bypassing to the overflow stream. A multi-component analysis was carried out to further investigate the coarse end deflection of the hydrocyclone efficiency curve. The analysis showed that the magnetite and gangue minerals had different cut sizes of 32 and 64 µm respectively. Furthermore, 33% of the magnetite (below 35 µm) was being recycled back to the mill due to the density effect. Based on these findings, several recommendations for process improvement were identified and implemented including:• converting to a bottom feeding configuration to improve the grinding efficiency in the mill• additional grinding power in the fine grinding duty to compensate for the increase in plant throughput and ore hardness• improved classification efficiency by converting to smaller size hydrocyclones. Simulation studies carried out to evaluate the impact of these implementations had indicated that a P80 close to 35 µm with a steeper size distribution could be achieved by using the bottom feed configuration with additional grinding power. The TowerMill circuit was converted to bottom feed configuration and the performance was evaluated. The operating work index, size specific energy and circulating load were 30% lower than the top feed configuration, indicating that the bottom feed configuration had a higher grinding efficiency. This paper discusses the outcome of the circuit audit, multicomponent analysis, circuit simulations, improvement strategies and quantification of the improvements. CITATION:Palaniandy, S, Spagnolo, M, Halomoan, R, Zhou, H and Ishikawa, H, 2017. Fine grinding circuit process improvement at the Karara mine concentrator, in Proceedings MetPlant 2017, pp 101–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By The Staff

THE object of the work was to increase the capacity of the plant and, if possible, to reduce costs of the actual unit grinding while doing so. The accompanying assays of an infra-sizer analysis of the cyanide tail (Table l) illustrate the problem in hand. The cyanide tail is a combination of two products, gangue and FeS2. The assay alters by virtue of a change in gold value due to grinding and the relative quantity of FeS2 in the sizes, which itself varies with the grind. The disposal tail is the residue after the cyanide tail is scavenged by flotation, most of the pyrite being removed for roasting. It presents a somewhat different problem, since grinding gangue is all gain, but -10 micron FeS2 does not float nearly as well as + 10 product. This results in compromise in the final size to be aimed at. Extra grinding has hardly any appreciable effect on the gold extraction from the FeS2. (See Milling Investigations Into the Ore as Occurring at the Lake Shore Mine; Trans. C.l.M.M., Vol. XXXIX, 1936).

Jan 1, 1940