Search Documents

By Hans-Åke Häggblad, Bertil I. Pålsson, Jan Stener, Kent Tano, Andreas Berggren, Pär Jonsén

Numerical modelling of grinding in tumbling mills is traditionally done with the discrete element method (DEM). The grinding balls are then represented by DEM particles and the mill structure is considered rigid. To include more physical phenomena several numerical methods can be combined. One important improvement is to include the mill structure response, using the finite element method (FEM). The interaction between charge and lining can then be studied in detail. The pulp can also be included using a particle-based continuum method e.g. smoothed particle method (SPH). The strength of SPH lies in modelling of free surface flows and very large deformations and it is suited to model simultaneous fluid and granular flow. Still, the coarse particles (grinding balls) in the charge are suitable to be model using DEM. Each of these methods has their strength and weaknesses, but combined they can successfully mimic the main features of the charge movement. With these numerical tools the complex interaction between the different components of the grinding process; pulp, charge, lining and the mechanical behaviour of the mill, can be studied together. This work will present novel numerical approaches to model, simulate and validate charge behaviour in tumbling mills. These numerical models give possibilities to better understand the physical and mechanical behaviour of particulate material systems during grinding in a tumbling mill. This is important in order to develop and optimise future high-capacity grinding circuits and save energy.

Jan 1, 2014

By Tsuyoshi Hirajima, Hideyuki Okamoto, Himawan .. T. B. M. Petrus, Keiko Sasaki

"Flotation of arseno bearing minerals from their copper ore has been an interest due to the increasing awareness on protecting the environment by minimizing the possibility of exposed arsenic compound. Some approaches have been proposed, but the mechanisms of separations have not yet fully understood. In this study, oxidation using oxygen was applied. Instead of the complex copper ore flotation results, pure single mineral of tennantite and chalcopyrite foatability was conducted using Hallimond tube. Resembled with the flotation results of copper concentrate containing tennantite, the separation possessed the best result at alkaline condition (pH 11) at where the arsenic content was reduced from 3300 ppm to 1800 ppm. In order to be able to understand the mechanism of the separation atomic force microscope (AFM) was utilized. AFM images showed changes in morphology and behavior when minerals were treated in both acid and alkaline condition. It was found that the morphological change showed the reaction products representing the rate of reactivity of tennantite and chalcopyrite. From the measured force of adhesion, it can be observed that in alkaline condition the surface of both minerals is more hydrophilic than that in acidic condition possessing higher value. This is in accordance with the X-ray photoelectron spectroscopy (XPS) spectra in which hydroxide moieties occupied the mineral surface in alkaline condition while elemental sulfur is in acidic condition."

Jan 1, 2014

By Megan Becker, Cyril O’Connor, Jenny Wiese, Gaynor Yorath

The effect of particle shape on true flotation has been widely reported. The present paper presents results obtained in investigating the effect of particle shape on the entrainment of particles during the flotation process. Different hydrophilic minerals with particles of varying aspect ratios were used and their shape determined using rheological tests and QEMSCAN. Their entrainment properties showed a close relationship to their shape with the recovery due to entrainment increasing as the aspect ratio of the particles increased. The effect of surface charge, by changing pH, and size of particles showed that the effect of shape was sustained at different pHs and particle sizes. Proposals are made to explain these observations in terms of the known relationships between drag coefficients and terminal velocities and shape. Since it has been previously reported that different milling procedures can affect particle shape, these results indicate that it is possible that such different procedures may result in increased entrainment of hydrophilic minerals.

Jan 1, 2014

By C. Dorfling, P. Albertyn

"Hydrometallurgical recovery of metals from printed circuit board waste typically involves multiple leaching stages; conventionally, base metals dissolution by mineral acids is followed by leaching of gold using cyanide or halide based lixiviants. Alternative lixiviants for gold leaching can reduce the potential hazardous nature of operation. The aim of this study was to investigate the feasibility of using thiosulfate as lixiviant for gold leaching from waste printed circuit boards. Batch leaching tests were performed to investigate the effects of thiosulfate concentration (0.1 – 0.2 M), ammonium concentration (0.2 – 0.4 M), pH (9 – 10.5), solids content (25 – 50 g/L), and copper content of the feed material on the gold leaching behavior. The concentrations of metals in liquid samples were determined by means of inductively coupled plasma atomic emission spectroscopy, and high pressure liquid chromatography was used to evaluate thiosulfate degradation/consumption. The ratio of thiosulfate to ammonia was found to have the most significant effect on the extent of gold leaching, with the best gold extraction observed at a ratio of 0.5 mole thiosulfate per mole ammonia. The lower pH range of 9 – 9.5 generally produced better Au leaching, while low copper extraction during the first stage base metal leaching stages has proven to be detrimental to gold leaching from the residue. Thiosulfate degradation/consumption increased and gold extraction decreased with higher residual copper in the feed. An optimum gold extraction of 78.5 % from base metal leach residue was achieved with 0.2 M thiosulfate, 0.4 M ammonia, and 0.02 M cupric ions at 25°C in the pH range 9 – 9.5.INTRODUCTION Background and Aim The recycling of e-waste is becoming increasingly important as it provides certain economic benefits apart from the obvious environmental benefits. Printed circuit boards (PCBs) are found in most forms of e-waste and contain especially high concentrations of base and precious metals. Hydrometallurgical processes are often considered for the recovery of valuable metals from PCBs; these processes normally implement several leaching stages to selectively recover certain metals."

Jan 1, 2018

By Vladimir G. Kochnev

An innovative AG and SAG technology aimed to be applied in grinding of ores and in the production of construction materials is described. A novel design of a cantilever-type mill capable to operate in autogenous, semi-autogenous and ball grinding mode ensures easy delivery and installation even in remote areas, and low capital and operating costs. Results of the tests of the new heel-shaped liners performed by TTD jointly with ALROSA, MINTEK and Anglo-American Corporation are reported. The approach includes also a novel discharge grid design and a technique of treating the material of critical size. These innovations make grinding in AG and SAG mills dramatically more effective, with an increase in the throughput rate and a reduction in power consumption ranging from 1.5 to 2 times.

Jan 1, 2003

By Kari Niiranen, Andreas Fredriksson

LKAB (Luossavaara-Kiirunavaara AB) is operating iron ore mines, concentration plants and pelletizing plants in Northern Sweden. Geometallurgy, which combines geological and metallurgical information is not a new way of thinking at LKAB, but rather a revised and updated version of an old working process. A project called "Silica in the Mine" which started in 2007, was an important reason to set a new focus at the geometallurgy. The target of the project was to develop a simplified method in laboratory scale to predict SiO2 grade in the magnetite concentrate in Kiruna and further predict the physical properties of the crude ore with respect to processing characteristics. The connection between mineralogy and products properties have started to be even more vital and necessary to examine due to the future exploiting new iron ore deposits. Geometallurgy at LKAB can be described as a mental and strategic framework where the Research and Development department (R&D), and others within the organization of LKAB, aims towards the connection of the minerals-production-products. It could in its basics be called "research & development", but it must be clarified that changes have been made, mainly due to the development on the instrumental analysis side. LKAB’s idea is to work quite broad, with internal educations, an active working process in ongoing projects, together with external parties (such as universities), with several PhD-projects and an upgrading on the instrumental side at the LKAB Research & Development department. This paper is a summary about the concept Geometallurgy at LKAB and some of the actions within its framework.

Jan 1, 2014

By S. Banisi, E. Arghavani, M. Pourkani, M. J. Rajabi, Gh. A. Mohamadian, H. Bidshahri, Gh. A. Parsapour

The Sarcheshmeh copper complex flotation circuit of plant No.1 consists of two identical north and south sections where each includes four rougher (each bank consists of 14 cells), two cleaners (each bank consists of 8 cells), two recleaners (each bank consists of 2 cells), and two scavenger banks (each bank consists of 10 cells). The reduction of feed grade along with a change in the mineralogical composition is the main reason of current lower concentrate grade (24%) compared with the design concentrate grade (32%). Because of a lower feed grade, the amount of rougher concentrate has decreased which in turn has significantly reduced the feed rate to the cleaner, recleaner, and scavenger banks. This has increased the mean residence time of the material in the cleaner section resulting in a lower final concentrate grade. A laboratory study showed that the final concentrate grade can be increased by 2-4% if one cleaner stage is added to the flotation circuit. In this research, based on the laboratory results, one cleaning stage was added to the current flotation circuit. In order to make this modification instrumentally possible in the plant, the final concentrate was gravity transported to the Mo-Cu thickeners. This released 2 pumps and associated tanks which made addition of one cleaning stage practicable. Finally, a part of the cleaner and scavenger cells were used as the third cleaning stage. This decreased the residence time in the cleaner and scavenger banks. After implementation of one cleaning stage in the south section of the plant, the performance of the circuit compared with the identical north section. It was found that at the same recovery, the concentrate grade of the south section increased by 2.5%. The promising results led to the implementation of adding one cleaning stage in all sections of the flotation circuit.

Jan 1, 2018

By Vladimir Vigdergauz, Elena Belogub, Dmitriy Makarov

The influence of supergene oxidation on physicochemical and technological properties of polysulfide ores was studied. Modeling and analysis of oxidation pyrite copper-zinc ore samples from the Valentorskoye deposit show that sulfide floatability is decreased by the longer-term oxidation. The treatment of oxidized samples by sulfuric acid in oxidative conditions and its impact on the elemental sulfur composition on the surface of sulfides was discussed. It is shown that an enhancement of the floatability of sulfides of oxidized polysulfide ores after leaching by sulfuric acid could be perspective for the developing of combining floatation-hydrometallurgical technology of the nonferrous metals recovery.

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 I. Gombköto

Mining and mineral processing operations are usually generating huge amount of tailings. These tailings often gives lots of maintenance work in order to protect environmental resources from heavy metals slowly leaching out of tailing are due to Acid Rock Drainage (ARD) process. Handling leakage could be active or passive such as using of Permeable Reactive Barriers (PRB). PRB?s are used worldwide treating underground contaminations, using different type of matrix materials. All generally used matrix material has its advantages and disadvantages such as selectivity, sensitivity of precipitation generation or not satisfying hydraulic conductivity. Nowadays cheap and effective matrix material which is ignorant to pore plugging caused by precipitation within the PRB could be one solution to the demands of the industry. The authors have been carried out an investigation at University of Miskolc on lignite as high humid acid containing material for determining the ability of heavy metal adsorption and pore plugging resistance. Moreover, using hydraulic and chemical simulation methods, complete PRB dimensioning protocol based on new lignite matrix had been introduced. Within the frame of this paper the results are going to be discussed.

Sep 1, 2012

By Tomasz Niedoba

Coals occurring in nature are characterized by various properties. According to Polish norms, the classification of coals taking into consideration their calorific value contains coals from type 31 (flaming coal) until type 43 (meta-anthracite). The samples of coal of type 31 were taken for investigation. To this purpose, the approximations of ash contents and density distribution functions were done for this coal type (determination of marginal distribution functions). They were the basis for application of so-called Morgenstern distribution functions to approximate the function Z=L (?), where Z is ash contents and ? - coal density. Then, the comparison between obtained results was performed and the results were statistically evaluated. They are the basis for the further research of other types of coals.

Sep 1, 2012

By Fedotov Pavel

"Today the main objective of improving the process of ore dressing is to reduce energy consumption and performance of the basic rule of auxiliary enrichment processes. One of the modern means of ore destruction with a minimum of energy consumption is the interparticle fracturing, for example in the roller press. There still remain the unsolved problems of the energy consumption determination and the particle size distribution of the crushing product .Existing methods for determining these parameters are empirical and require considerable expenses and time. The improved finite element was developed to solve these problems using finite element contact interaction of the rock. Also it was developed to clarify the stress-strain and the rock fracture energy in a layer. These elements are used to study ore destruction in the layer and allows to create a model taking into account the interaction of crushing particles surfaces. The same algorithm was developed determining crushing product particle size distribution in the layer on the base of the Bond’s theory of crushing. The presented finite element model allows to determine the quantity of strain energy and particle size distribution of crushed product during the destruction processes of the material in the roller press with fair accuracy."

Jan 1, 2014

By V. Avdochin

The main reason of flotation process fluctuations is mixing ores of various properties from various sections of a deposit. Other, also important reasons are changes in parameters of facilities of technological cycle, as well as properties of reagents applied. According to estimates, instability and non-optimized parameters of flotation owe 3% to 6% of valuable component losses. Without ore averaging systems flotation process is characterized by considerable fluctuations of all input, output and intermediate parameters. Stab One more way is optimizing the process, providing for determination and maintaining optimal parameters of the process. In these conditions application of various mathematic models does not allow controlling the process by the way of action on input parameters of the process with further precise reaching required values of output parameters. More effective is to be application of flotation models for solution of questions of choosing and optimizing of automatic control systems. The work presented examples of application mathematic model of flotation process for estimation of effectiveness and choice of parameters of automatic control system that reduces considerably a stage of preliminary studies in elaboration, designing and modernizing automatic control systems.

Jan 1, 2014

By S. A. Bogidaev, M. Yu. Tiunov

"The paper describes the results of the flotation tests with complex rare metal ores from deposits in the Trans-Baikal Territory. Correlations between the quality of produced wolframite, hubnerite and mica concentrates with or without the presence of various alkaline modifiers are determined. Commonly, rare metal ores contain minerals of comparable value to main elements recovered in processing plants using gravitational methods. The paper describes the results of flotation recovery of valuable minerals – main and associated – from gravity tailings of deposits in the Trans-Baikal Territory. It was found that gravity tailings from the first deposit contained fine-grained wolframite, mica (muscovite, lepidolite etc.), feldspar; hubnerite, scheelite, beryl, fluorite, rubidium-containing muscovite from the second deposit, correspondingly. This paper presents the results of the stage flotation tests with the production of tungsten (wolframite, hubnerite), fluorite and mica concentrates from gravity tailings. Figure 1 demonstrates the flowsheet of tungsten ore minerals and mica stage flotation from gravity tailings of the first deposit.Wolframite can be floated using oleic acid with the presence of soda ash, a complexing collector (IM-50), under slightly alkaline conditions in combination with a nonpolar collector [1, 2, 3, 4]. The study included wolframite flotation using the combination of two alkaline modifiers. Flotation of wolframite was performed after pulp desliming, using tall oil saponified with soda ash. The recovery of wolframite in the concentrate of rougher flotation reached 80-85%; the concentrate contained up to 1% of tungsten oxide that can be upgraded to a saleable product using gravitational methods. This procedure was tested during flotation of wolframite, tantalite-columbite and pyrochlore, and provided high performance regardless of a season, at pulp temperatures of 8-10°C, though fattyacid collectors are significantly inefficient at such low temperatures due to low solubility, dispersion and increased collector consumption, consequently. The introduction of two alkaline modifiers in pulp appears to improve these characteristics.The first stage of the tests was focused on increase of iron-bearing tungsten ore minerals recovery from gravity tailings and stabilization of the cold pulp flotation process."

Jan 1, 2018

By S. S. Indi, D. Santhiya, S. Subramanian, K. A. Natarajan

The interaction of sphalerite- and galena-adapted Bacillus polymyxa (B. polymyxa) cells with sphalerite and galena has been investigated through adsorption, electrokinetic and flotation studies. The amount of sphalerite-adapted cells adsorbed onto sphalerite and galena is found to decrease with increase in pH. On the other hand, the adsorption density of galena-adapted cells onto galena shows a feeble maximum around pH 8, and the amount adsorbed is marginally higher in the pH range of 8 . 11.5. In the case of sphalerite the amount adsorbed is higher in the pH range of 5 to 7. The adsorption density of both the adapted cells is higher for galena vis-à-vis sphalerite. Electrokinetic studies indicate significant surface chemical changes on the chosen sulphide minerals and the bacterial cells, consequent to microbe-mineral interactions. Selective flotation tests on a synthetic mixture of galena and sphalerite confirm that sphalerite could be preferentially floated from galena, using galena-adapted cells, but not with the sphalerite-adapted cells. The cells adapted to galena assay a higher polysaccharide content and are more hydrophilic, while the sphalerite-adapted cells have a higher protein content and possess greater hydrophobicity. Transmission electron microscopic studies have provided evidence in support of the differences between the cell surface characteristics of sphaleriteand galena-adapted cells. Possible mechanisms of interaction between the minerals and the bacterial cells are discussed.

Jan 1, 2003

By Jens Markowski

The EU Directive 2000/53/EC on end-of life vehicles (ELVs) states that in 2015 at least 85 wt.-% of a vehicle has to be reused or recycled. This result in the obligatory need to separate additionally metallic and other components of the automotive shredder residues (ASR), so that they can be professionally prepared for recycling and reuse further. Currently the iron-containing fines of ASR are deposited as it is not possible to process in blast furnaces due to its particle size (< 4 mm), composition and material properties. Additionally problems are also caused in handling and transportation (dust) of the material. This work focuses mainly on the ASR materials utilization in blast furnaces. Material was further separated into two consecutive fractions by carrying out repeated crushing and magnetic separation twice. The two fractions have significantly higher iron content (up to 75 wt.-%) compared to the initial material mixture. The materials were assessed for their usage in blast furnaces based on the possible pelletisation with and without binders, stability of pellets, shape and size of pellets, etc. Pelletisation of the material was carried out with a single mould pellet press. Further lignite coal was added to the mixture as additive which improved the pelletisation behavior and the mechanical stability of pellets. Lignite coal was chosen as a reducing agent in the blast furnace process contributing towards additional savings in energy supplied. The experiments reveal that the production of pellets from iron-containing fines is possible with a lignite coal admixture of about 15 wt.-%. These pellets displayed good mechanical stability and can be used in blast furnace processes in recovery of the recyclable metals which are currently not recycled. The recycling of not yet recyclable metals would reduce the deposition and can be easily adopted into the economic cycle by their utilization. Keywords: Automotive shredder residue (ASR), FE-fines, pelletisation

Sep 1, 2012

Dielectrophoresis is a separation technique that uses a non-uniform electrical field to separate particles on the basis of their permittivity. There are many areas of mineral processing that might benefit from the application of dielectrophoresis. These include: coarse removal of gangue, recovery of ultrafine particles, upgrading of flotation concentrates or simply as a laboratory analysis technique. In order to determine the potential value of dielectrophoresis to the mineral processing industry, the response of composite particles was investigated. The electrical properties of composites involve complex relationships between the shape, distribution and permittivity of the individual grains within the rock. The relationship between mineral composition and dielectrophoretic force was measured on single particles from two ore types. The results were used to populate a model that could predict the separation characteristics of the ore. The insights gained from this model separator allowed potential applications of the technology to be examined and their performance evaluated.

Sep 1, 2012

By Chao Li, Kym Runge, Saeed Farrokhpay, Dee Bradshaw

"It is well known that froth phase has a controlling influence on the overall flotation performance. Froth recovery is expected to be affected by froth transportation behaviour. The latter has been represented by different volume balance and energy balance based models. In froth transportation models based on a volume balance, the froth phase is divided into different zones. The total froth residence time is the sum of the time spent in each zone and is dependent on the cell geometry, bubble burst rate and the position that bubbles enter into the froth phase. Alternatively, the froth transportation model based on an energy balance treats the froth phase as a block. In this model, froth height above the concentrate lip is being predicted by minimising the energy of the system which is dependent on the froth geometry, froth stability and froth rheology. The froth height can be used to calculate the froth efficiency of delivering mineralized bubbles from the pulp to the concentrate lip. This paper critically analyses the current models of froth transportation in flotation, and examines the limitations of these models. The importance of froth rheology, which is the resistance to the froth flow towards the discharging weir, in determining froth transportation, is also highlighted."

Jan 1, 2014

By C. Abbruzzese, F. Vegliò, S. Ubaldini, R. Massidda

"Gold solubilised during cyanidation can be recovered by precipitation (Merrill-Crow process) or by adsorption onto activated carbon, these being the techniques applied in industrial plants.Precious metals (Au, Ag) adsorbed onto activated carbon are extracted during a subsequent stage in aqueous phase, by various technologies, such as hot elution (70-80°C) or under pression desorption (100-130°), with hydro-alcoholic solutions.This stage is of great interest from an economic point of view, due to the high energy costs. Temperature represents the critical kinetic factor.The aim of this paper was to study the influence of different water/organic solvent mixtures (isopropyl alcohol, ethanol and ethylene glycol) on the desorption process.The experimental work was carried out on laboratory scale, using activated coconut carbon with different temperatures and extraction times, without adding cyanide.Best results have been obtained in this order: isopropyl alcohol > ethylene glycol > ethanol. Starting from gold concentration of about 5 g Au per kg of carbon, best kinetics resulted in 97-100% of gold extraction, after 8 hours of desorption, at a temperature of 80ºC."

Jan 1, 2003

By V. A. Masloboev, A. V. Svetlov, D. V. Makarov

"The methods of heap leaching are considered to be the most promising for the low-grade copper-nickel raw materials. The article presents intensification capabilities of the process. Objects of research: the low-grade copper-nickel ores of Moncheplutone deposits (Moroshkovoye Lake, Nyud Terrasa, Nittis-Kumuzh’ya-Travyanaya (NKT), as well as the copper-nickel ore dressing tailings of the “Kola MMC” JSC. The following directions for the intensification of the low-grade copper-nickel raw materials heap leaching have been considered: preliminary electric pulse destruction (EPD) of ore; ore crushing and further sulfuric acid agglomeration. The impact of sulfuric acid concentration (1-3%) on the extraction of non-ferrous metals kinetics from the copper-nickel ore dressing tailings under various conditions of the percolation leaching has been studied. INTRODUCTION The low-grade grade sulfide ores at the abandoned and producing deposits, overburden rocks, mill tailings and non-ferrous slag are thought to be one of the large-scale sources for non-ferrous metals, on the one hand. On the other hand, they are known to be the subjects of emergency environmental danger. For this reason, the use of mine dumps and tailings, as well as the remained ores left in the ground as raw products, and at the same time decreasing the load on environment, are considered to be the pressing ecological and economic issue (Chanturia et al., 2012). Methods of heap hydrometallurgical and bacterial leaching are sure to be potentially productive for processing such low-grade and technogenic raw materials (Petersen, 2016). The early studies of hydrometallurgical method possibility to process copper-nickel ores of the Murmansk region deposits were launched in the seventies of the previous century (Golovko et al., 1978). For referencing purposes, the main types of impregnated ores from the deposits Zhdanovskoye, Kaula, Sopchinsky Plast and Lovnoozerskoye were selected. The metal content varied, as %: 0.46-1.49 of nickel, 0.01-0.62 of copper. In the first experiments, the solution containing 150g/l of H2SO4 and 135g/l of NaCl, was used in the capacity of leaching reagent. The possibility of underground metals leaching from the ores of the Lovnoozerskoye deposit was justified due to the performed laboratory and further large-sized tests."

Jan 1, 2018