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By Osvaldo A. Bascur, J. Pat Kennedy

"The profitability of mining and metallurgical operations continues to lag behind that of other industries despite the technical advances that have occurred in recent years. A primary reason for poor performing in this economic sector is the lack of integration of mining and metallurgical information. The mine cut-off grade can be optimized if mining and metallurgical engineers have the data to optimize milling for the type of ore in hand.Integration of mine transactions, stockpile inventories, process flows and assays is the key to determining the economics for each blast strategy in a mining site. Real-time information from manufacturing assets greatly affects the profitability and flexibility of a company, but gross errors from faulty sensors, inaccurate instrument calibration, or incorrect process models may corrupt actionable information. New software tools can model the process, sift through available data to identify and eliminate gross errors, and use statistical data reconciliation to create materially balanced and consistent readings. The reconciled data is unified for use by both monitoring and decision making processes.Creating a real-time information environment where upgrade and change are allowed is becoming an accepted methodology to accelerate and simplify the integration of applications such as production monitoring, equipment performance management and yield and inventory management."

Jan 1, 2003

By Gi-Chun Han, Ki-Suk Han, Korea Energy Management Corp., Jin-Sang Cho, Hyung-Seok Kim, Jae-Hyun Oh

This study has been carried out to use the waste sludges generated at Pohang Iron & Steel Co. Ltd. (POSCO) as the raw materials of Ordinary Portland Cement (OPC). The burnability index of the raw mixture and the hydration characteristics and compressive strength of clinker have been examined. The waste sludges were mainly composed of CaO, SiO2, Al2O3, and Fe2O3, the main component of OPC. The Burnability index of mixture was improved, according to the replacement content of POSCO sludge increase. POSCO sludge can be used as a raw material for cement because the state of mineral development and property of clinker produced from POSCO sludge are similar to the plain. Therefore, POSCO sludges can be used as the source materials of iron and calcium oxide.

Jan 1, 2003

By Takashi Furuyama, Sukeyuki Mori, Abel Bissombolo

"In flotation practice, a good recovery of minerals largely depends on the degree to which the valuable minerals have been liberated from the associated gangue during the grinding process. Therefore, a regular measurement of the degree of liberation can provide data for the assessment of the quality of separation and predicts the effect of changes in the grinding-classifying circuit on flotation process. Generally, the standard procedure for measuring the degree of liberation requires the preparation of polished sections - a time consuming operation that also has the disadvantage of providing an overestimated number of free particles because of the stereological nature of produced samples.The present work is an alternative approach to avoid these miscalculations and establish a system of control for fluorite flotation plants. The system deals no only with the state of liberation but also the dynamic behavior of individuals particles and mineral components within the grinding-classifying and flotation circuits. It involves methods such as sieving, x-ray diffraction analysis, study of polished sections and microscopic counting of preliminarily sieved minerals particles from a fluorite processing plant, randomly dispersed on a glass slide, but not embedded in a resin mounting medium. If a complete information on the textural properties of minerals in the ore (including its mineral components distribution) can be obtained through x-ray diffraction analysis and study of polished sections, the microscopic counting is used to determinate with enough accuracy the mineral liberation, estimate the grade of fluorite ore and products, determinate the deportment and approximate recovery of individuals particles and mineral components within the investigated circuit. For a count of 100-1000 particles in each n-size range, the counting method was found to be a particularly reliable and less time consuming operation that could substitute the chemical analysis of fluorite ore for an estimate of the grade:"

Jan 1, 2003

By S. Fiore, M. C. Zanetti, C. Clerici

The processes and fluxes of a cast iron foundry plant located in the North of Italy were analyzed in order to determine the amount and kind of wastes produced from the different activities. The main fractions are the molding sands, furnace muds and powders coming from the dust abatement plant, the exhaust lime, the furnace refractory, the metallic shotting and the sludges and powders coming from the dust abatement plant of molding lines for a total production equal to 800 t/d. All wastes were sampled and particle-size and chemically characterized to evaluate the best recycling or reuse solutions. Wastes were sieved and divided in three categories according to the particle-size dimensions: below 0.1 mm, between 0.1 and 0.6 mm and above 0.6 mm. The fraction above 0.6 mm dimension underwent magnetic separation to recover and quantify the potentially available iron fraction. The fraction between 0.1 mm and 0.6 mm was chemically characterized in order to understand if it could be fed to the sand regeneration plant. The below 0.1 mm fraction was characterized to evaluate the following recycling and reuse solutions: additive for molding sands and/or raw material for the concrete industry.

Jan 1, 2003

By Kari Moen, John Rasmus Leinum, Jarle Hjelen, Terje Malvik

"Industrial minerals may contain the same elements in approximately the same amount. In these cases backscatter electron imaging or chemical analysis are not sufficient to identify the minerals. Another problem arises when micro textures are not detectable in traditional imaging or the grain size is smaller than the X-ray spatial resolution.As a supplementary technique in these cases, application of crystallographic information by electron backscatter diffraction (EBSD) in the scanning electron microscope (SEM) may be a suitable method. The technique has been demonstrated on three Norwegian mineral raw materials and one Italian marble and shows that it has some advantages compared to traditional techniques.• quantitative measurements by ebsdCommon automatic techniques describing the mineral contents and the occurrence of minerals in free and locked particles, are based on optical-, backscattered electron (BSE)- or X-ray-signals. There are various commercial software systems on feature analysis by backscattered and X-ray signals in combination with image analysis (e.g. Oxford Inca Feature, CSIRO QemScan).Especially in silicates, the occurrence of similar elements in the different minerals is common. Sometimes the various minerals not only contain the same elements, but also approximately the same amount of each element. In these cases BSE imaging and chemical analysis are not always sufficient for identification."

Jan 1, 2003

By Máximo Pérez, Julio C. Videla, Rosa Dzioba

"This paper reports the hydrometallurgical treatment of gravity concentrates of gold samples and outcrops associated with graphite ores obtained from:• flotation tailings of crystalline graphite minerals• outcrop samples of graphitic rock associated with auriferous minerals and free gold located in the Villa Union district and surrounding areas - La Rioja Province - Argentina.Previous studies of the flotation potential of crystalline graphite minerals failed to consider the presence of noble metals.The samples represent a mineralized zone of crystalline graphite which is distributed in different formations with a NE - SW trend in Maz, Punta Colorada and Las Ramaditas hills, covering an area of about 300 square kilometers."

Jan 1, 2003

"This research aims at improving the beneficiation of coals and minerals in fine and ultrafine size fractions. A widely used method for upgrading fine and ultrafine particles is froth flotation, which is generally classified into mechanical flotation and column flotation. The present work is focussed on column flotation. A flotation column equipped with a conventional bubble diffuser/sparger was used with oscillatory air supply generated using a fast-switching solenoid valve. The flotation tests were carried out for coal particles and mineral particles, respectively, and a comparison in flotation performance was made between oscillatory air supply and steady air supply. It was found that use of oscillatory air supply with a proper valve switching frequency and on/off time ratio to replace steady air supply could lead to increased recovery of coals or minerals by more than 14 percentage points and substantial reagent cost savings. The improved flotation performance was attributed to enhanced gas dispersion and flow conditions. This research offers a simple new approach to improving the beneficiation of fine coals and minerals with using flotation columns.INTRODUCTIONFroth flotation has been widely used for the separation and concentration of fine coals and minerals by exploiting the difference in their affinity to air bubbles in aqueous medium. Froth flotation is an effective method for beneficiation of coal and mineral particles in a certain size range. It remains difficult to upgrade ultrafine mineral particles. One of the reasons for the ineffective flotation of fine particles is the low probability of bubble-particle collision in the collection zone (i.e., the pulp zone). According to Reay and Ratcliff (1973) and Yoon and Luttrell (1989), the probability of collision is significantly affected by bubble size and particle size, and the collection zone recovery can be increased by decreasing the bubble size."

Jan 1, 2018

By P. Harris

"Comparison of the two most commonly used classes of depressant in the South African platinum industry is complicated by the fact that these polymers induce different effects on the surfaces onto which they adsorb. The use of carboxymethyl cellulose (CMC), which is ionically charged in solution, can lead to increased particle dispersion in addition to the effect of reduced surface hydrophobicity (depression). Guar is typically only slightly charged in solution. Comparison of these two depressants is complicated since it is uncertain whether differences in their action is a result of either depression of dispersion effects.This work investigates the role of dispersion independently to that of depression in the batch flotation of a platinum bearing ore. An inorganic dispersant, sodium hexametaphosphate (NaHMP) was added in parallel to the uncharged guar depressant to simulate the action of depressants with varying degrees of dispersion. By distinguishing between the material recovered by entrainment and the floatable gangue and by including the effects of froth stability it was possible to decouple the effects of dispersion and depression.The results show that both dispersion and depression led to increased grade of the sulphide minerals. Depression leads to a decreased recovery of floatable gangue minerals. Dispersion leads to an increased recovery rate of these minerals and an accompanying decrease in froth stability."

Jan 1, 2003

By Rob D. Morrision, Paul W. Cleary

"The best accepted method for design of autogenous and semi-autogenous mills is to carry out pilot scale test work using a 1.8 m diameter by 0.6 m long pilot scale test mill. The load in such a mill typically contains 250,000-450,000 particles larger than 6 mm, allowing correct representation of more than 90% of the charge. This scale of DEM model is now within the practical range of standard workstations running an efficient DEM code.This paper describes various ways of extracting collision data from the DEM model and translating it into breakage and wear estimates. Account is taken of the different breakage mechanisms (impact and abrasion) and of the specific impact histories of the particles in order to assess the breakage rates for various size fractions in the mills. These impact histories have the potential to be directly related to breakage as they most resemble the single particle breakage tests which are used by the JKMRC to calibrate more traditional population balance models for variations in ore behaviour. However, the specific impact histories also show a background of many low energy collision events within the mill. This Background may constitute what is usually regarded as “abrasion” breakage. As might be expected, high impact events are concentrated in the toe of the charge and near to the mill shell where the forces associated with the load bearing on each particle is more concentrated."

Jan 1, 2003

By Peter N. Holtham, Geoffrey J. Lyman, The University of Queensland, Matthew S. Brennan, Vijay Subramanian, Rui X. Rong

"The cyclone would have a claim to be the commonest, least understood and most abused piece of mineral processing equipment available for study by researchers. It has certainly generated its fair share of publications – 1,000 in the last 60 years would be a fair estimate. However this remarkable degree of interest and scale of investigation is not reflected in our understanding of how they work; cyclones are still installed inappropriately and run poorly, which suggests that there are still things to learn about this deceptively simple process.In mineral processing there are two broad classes of cyclone: the hydrocyclone, used in classification, thickening and dewatering, and the dense medium cyclone, used for concentration by density. Although rarely studied together, the laws of physics presumably apply equally to both and so it seems that there would be interesting things to learn by considering them as a single class of device. The good news is that in recent years there have been spectacular advances in the computational and measurement tools available to study these devices, including computational fluid dynamics (CFD), tomography, and laser doppler anemometry (LDA), and some good progress has been made in an understanding of the fundamental principles involved.The JKMRC has made many experimental studies of hydrocyclones and DM cyclones, leading to useful empirical models. However some recent CFD and tomographic work, in association with work of other institutions, has thrown important light on the workings of these processes. Progress has also been made in novel designs of cyclone to achieve improved separating efficiency, based on an attack on the subprocesses believed to contribute to inefficient operation. This paper describes the work to date.Modelling of the dense medium and classifying cyclone was conducted using the Fluent computational fluid dynamics code. Three phase simulations of the dense medium application (air/water/medium) showed appropriate medium segregation effects but over-predicted the level of segregation compared to segregation measured by gamma-ray tomography. This is believed to be because the basic Algebraic Slip mixture model in Fluent does not model any back-mixing of the dispersed phase due to turbulence."

Jan 1, 2003

By John Ralston, Stephen Grano, Yongjun Peng, Daniel Fornasiero

"A specially designed mill which allowed the control of pH throughout grinding was used to study the effect of rgrinding conditions on galena flotation and galena separation from pyrite. The various reactions occurring on the mineral surface were investigated by a range of techniques, including OH- addition to maintain the grinding pH, EDTA extraction, XPS and ToF-SIMS measurements.Galena flotation and galena separation from pyrite were strongly dependent on the metal oxidation species produced on galena and pyrite surfaces under different grinding conditions. Iron oxidation species depressed both galena and pyrite flotation, whilst lead oxidation species activated pyrite but had little effect on galena. Optimum galena flotation and galena selectivity against pyrite were achieved by selecting grinding conditions that enabled lead and iron oxidation production to be controlled."

Jan 1, 2003

By Takashi Furuyama, Sukeyuki Mori, Ltd. Kyushu Metal Industry Co., Abel Bissombolo, Yoshitsugu Koga, Masamichi Hata

"Actually, the recovery of valuable metals such as iron, aluminium and copper is a nowadays practice in factories dealing with the processing of scrapped automobiles (Harder (WERG); Koga et al., 1997). This process has reach a recycling rate of about 75%, and generates a huge volume of waste (including cottons, sponge, plastics, rubber, etc…), locally known as “shredder dust”, which is commonly dumped on landfills; its recycling is either unsatisfactorily or not yet performed (Keller and Schebdat, 2000).The saturation and depletion of valuable disposal sites in the not-so-distant future, as well as the social and environmental problems related to the accumulation of these residues disposals are a major challenge for the automobile shredding industry.To promote an alternative way for the management of these disposals, the authors have initiated and developed a system for their processing, on the basis that more than 90% of these residues are combustible materials that could be used as refuses derived fuel. The developed processing system points out the mechanical/physical separation of a calibrated (–80+5mm) shredded automobiles residues into two streams by means of an ascending airflow passing through a vertical zigzag separator and, the compaction of the light-weight materials (that is about 60% of auto shredder residue recovered as float products and mainly composed of cotton, sponges and light plastics) to form a refuse derived fuel (RDF), the density, calorific value and ignition loss of which are 1.19 g/cm3, 4470 kcal/kg and 60.7%, respectively. A sedimentation tank is used to recover the light-weight materials deported in the heavy fraction stream."

Jan 1, 2003

By David Dreisinger

"The leaching of base and precious metal ores and concentrates continues to progress in both laboratory study and industrial application. These developments are being driven by the need to respond to difficult ores and concentrates that are not amenable to conventional treatment. In many cases alternatives are being developed to conventional treatment (e.g. Pyrometallurgy) for technical and economic reasons.In this paper, a brief general review of some new developments in leaching will be followed by a more detailed explanation of three process developments that have either been industrially applied or are expected to be applied in a short time frame. The three processes to be reviewed in detail are the Mt. Gordon Copper Process, the Anglo American Corporation/University of British Columbia Copper Process and the PLATSOL Process. These leaching processes operate at low (90°C), medium (150°C) and high (220°C) temperature and are successful in quickly and completely extracting metal values from ores and concentrates.INTRODUCTIONThe process of leaching is widely used in hydrometallurgy to selectively recover a metal of interest from an ore or a concentrate. Leaching and by extension hydrometallurgy is well established in the recovery of copper (copper heap leach ? SX-EW), nickel (Moa Bay and Caron process), zinc (roast ? leach ? electrowin and zinc pressure leach), gold (cyanidation) and uranium (acid sulfate leach). Of course this success extends to many of the metals found in nature. Recently, the importance of hydrometallurgy appears to be increasing with hydrometallurgy viewed as an attractive alternative to both traditional mineral processing and conventional smelting/converting/refining. This increasing interest has led to intensive study and increasing application. Selected developments include:Copper ? the Mt. Gordon process and new concentrate processes such as INTEC, Activox, CESL, Dynatec, Total Pressure Oxidation, MIM Albion, BioCop, and the AAC/UBC Process.Nickel ? Voisey Bay process for hydrometallurgical treatment of Voisey Bay concentrate, HPAL processing of laterites at Murrin Murrin, Bulong and Cawse, atmospheric leaching of laterites, heap bioleaching of nickel sulfides by Titan Resources (Australia).Zinc ? establishment of zinc leach, solvent extraction and electrowinning technology for treatment of the Skorpion deposit in Namibia, new developments in atmospheric and pressure leaching, the Hydrozinc process.Gold ? development of a number of thiosulfate leaching processes for recovery of gold from refractory carbonaceous ores or concentrates."

Jan 1, 2003

By David Dreisinger

"The leaching of base and precious metal ores and concentrates continues to progress in both laboratory study and industrial application. These developments are being driven by the need to respond to difficult ores and concentrates that are not amenable to conventional treatment. In many cases alternatives are being developed to conventional treatment (e.g. Pyrometallurgy) for technical and economic reasons.In this paper, a brief general review of some new developments in leaching will be followed by a more detailed explanation of three process developments that have either been industrially applied or are expected to be applied in a short time frame. The three processes to be reviewed in detail are the Mt. Gordon Copper Process, the Anglo American Corporation/University of British Columbia Copper Process and the PLATSOL Process. These leaching processes operate at low (90°C), medium (150°C) and high (220°C) temperature and are successful in quickly and completely extracting metal values from ores and concentrates."

Jan 1, 2003

By Francesco Montanari, Gianni Schena

"Recent improvements in X-ray computed tomography allow investigation of objects several tens of millimetres in dimension with spatial resolutions in the order of a few microns. These improvements are made possible by coupling the micro-focus technology adopted by some of the latest cone-beam X-ray sources with an increase in the efficiency of the detectors. The micro-focus technology allows the production of clearer images at high magnification by reducing the penumbra (fuzziness) associated with larger focal spot size.Even higher resolutions can be expected in the next few years with the commercialisation of nano-focus X-ray tubes. In practice one can inspect a system of fine composite particles and analyze the different mineralogical phases in each individual particle. Computed tomography allows accurate liberation studies, e.g. providing liberation spectra or washability data in tens of minutes. However, on-line application of micro-focus computed tomography is unlikely in the foreseeable future, despite rapid development.Dual-energy (DE) radiography is another X-ray technique, which allows retrieval of the volumetric content of valuable components in two-phase particles in a fraction of a second. A digital radiograph of a single two-phase particle produces a grey level image, where the luminosity of the pixels is determined by the sum of the attenuation levels of all the structures. Thus morphological and compositional effects concur to produce the radiographic image, which does not allow retrieval of the composition of the particle, as the 3D-structure of the particle is compressed into a 2D-image, with an obvious loss of information. Thus, in principle it is not possible to discriminate between thick, comparatively penetrable, and thin, comparatively impenetrable mineralogical components."

Jan 1, 2003

By Johan F. W. Kock

"Hearing loss due to excessive noise exposure is the most prevalent industrial disease. It is ranked on the World Health Organization’s (WHO) priority list for major work related injuries. Uncontrolled noise not only has a physical effect, but is also a psychological hazard affecting the performance and well being of man. Noise induced hearing loss (NIHL) is irreversible, yet it is preventable. The first defence against noise (noise control engineering) is a high priority in the mining industry. Second defences should be a last resort when the engineering control of noise is inadequate. Hearing conservation programs and the use of conventional hearing protection devices seem to have failed in the prevention of noise induced hearing loss. If compensation payouts that quadrupled in the past ten years are used as a barometer for the success of existing hearing conservation programs, then new strategies and technologies need to be investigated. The best practice Hearing Protection Device (HPD) may be seen as the minimum standard for second defence noise control.Conventional hearing protection is widely applied, but also misused in the industry as well as in the mining sector. Empirical research results, ownership, general attitudes of workers as well as qualitative aspects will be explored. The paper provides reasons, evidence, case studies and strategies regarding the best practice hearing protection philosophy (the Noise Clipper Model) as implemented in the Implats Mining Group. Worldwide tendencies towards custom-made HPD’s, findings that indicate improvements in hearing conservation programs and finally the successful application of Custom-made Hearing Protection Devices, will be outlined."

Jan 1, 2003

By Atsushi Shibayama, Toyohisa Fujita, Wan-Tai Yen, Ke-jun Liu

"A gold has been leached with ammonium thiosulfate solution and several leaching conditions have been studied. The leached solution has been recovered by solvent extraction and the optimum conditions have been investigated.SUMMARYIn this investigation, a sponge gold sample (99.92% pure) has been leached with ammonium thiosulfate solution. The effects of CuSO4, (NH4)2S2O3, (NH4)2SO4, NH4OH and retention time on the gold leaching % (extraction %) and thiosulfate oxidation % (consumption %) have been studied. The copper ion acts as a catalyst in gold dissolution. On the other hand, it also accelerates oxidation of thiosulfate (consumption). It was found in this study that the best gold extraction condition was obtained at 43.2 ks with 0.8 – 1.0x103 mol/m3 (NH4)2S2O3, 30 mol/m3 CuSO4, 2.0 – 3.0x103 mol/m3 NH4OH, 0.4 – 0.5x103 mol/m3 (NH4)2SO4, pH 10±0.2 and 150 rpm. The thiosulfate oxidation was about 15% of the initial concentration."

Jan 1, 2003

By Kang N. Zhong, Hui H. Luo, Yunan Phosphate Chemical Co., Yi H. Wei, Yao J. Li, Yu L. Wang

"The three kinds of phosphate ores (igneous, metasedimentary and sedimentary) found in China have great differences in flotation flowsheets and reagents suite because of their crystal structure and mineral composition. The igneous and metasedimentary apatites have good floatability with fatty acid as collector and waterglass, sodium hydroxide or sodium carbonate as conditioners. The sedimentary phosphate is very difficult to beneficiate by direct flotation because of their poor floatabilities and relatively high content of MgO and SiO2, even though the dolomite depressants are used sometimes.The differences in floatability of apatites in China are closely related to their differences in specific surface area. The amount of collector to float apatite increases with the specific surface area. Apatite with lower specific surface area showed good floatability at lower collector concentration. Apatite with a higher specific surface area needed a higher concentration of collector. The content of CO3 2- will affect the specific surface area of apatite by distortion of its crystal structure and consequently affect its floatability.Dolomite can be easily rejected from apatite in a weak acidic medium (pH=5), especially in phosphoric acid medium by reverse flotation. Quartz and siliceous gangue in sedimentary apatite can be removed by direct flotation using fatty acid or by reverse flotation using amine. Amine is not practically applied because sedimentary apatite in China is usually very fine and needs fine grinding, which always results in excessive, very fine, stable and non-flowable foam.Based on the floatability of phosphate ore in China, a two-stage flotation process, direct and reverse flotation (D+R), was developed to beneficiate sedimentary ore. For the Haikou phosphate ore containing 25.11% P2O5, 3.46% MgO and 16.5% SiO2, a concentrate containing 31.84% P2O5, 0.48% MgO and 14.8% SiO2 can be obtained through a continuous D+R test at a recovery of 89%."

Jan 1, 2003

By E. Barsky

"The aim of separation is to obtain two products that are as distinct as possible from each other. It is currently believed that the most objective criteria for the quality of a separation are the Hancock criterion and the entropy criterion.1. Hancock criterion:- for yield of fine product"

Jan 1, 2003

By G. Kumar

Water for domestic consumption is an essential right of society, which must be over secured. Water reclamation and reuse provides a unique and viable opportunity to augment traditional water supplies. As a multi-discipline and important element of water resource development and management, water reuse can help to close the loop between water supply and wastewater disposal. Effective water reuse requires integration of water and reclaimed water supply functions. During the coal mining activities, large quantities of water get contaminated and loses its potability characteristics. On an average, in coal mine operation, each coal mine discharges effluents at a rate of nearly 0.5 MGD and thereby wastage of nearly 50 MGD of water takes place per day from the famous Jharia Coal Field of the Dhanbad District. In this paper, attempt has been made to control the extremely high turbidity of mine waste water by using different coagulants and it is observed that ferrous sulphate is the most effective coagulants followed by alum, ferric sulphate and lime. Also combinations of coagulants are used for getting the optimal results. Further steps were also discussed to make this water potable and a scheme of low cost water supply system of mine waste water has been suggested under the Water Management Strategies. Keywords: potability, turbidity, coagulants, water management strategies

Sep 1, 2012