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By Achilles Dutra, Everton Santos, José Oliveira

The beneficiation of phosphate ores by froth flotation is the most efficient process used to separate apatite from gangue minerals like calcite, dolomite and quartz. However, the similarity of surface properties between apatite and calcite generally lead to non-selective adsorption of reagents, rendering the selective separation of these minerals a worldwide problem. The phosphate deposit of Itataia, State of Ceará, Brazil, studied in the present work, presents a complex mineralogical composition having uranium associated with the apatite mineral. The main gangue minerals are calcite and quartz. The bulk flotation of apatite and calcite with anionic collectors in an alkaline medium followed by the selective flotation of calcite at pH 5.5 using phosphoric acid as well as citric acid as depressant have been suggested for this ore. This paper presents the results of contact angle measurements obtained using jojoba oil, a natural reagent composed mainly of gadoleic acid (C20:1) and long-chain fatty alcohols (eicosenol and docosenol), as an alternative collector for the selective separation of apatite and calcite minerals. The hydrophobicity studies were carried out using a computer controlled contact angle goniometer. Additionally, the collector adsorption was evaluated via electrophoretic mobility and FTIR measurements. The results indicated that a high selectivity can be obtained by using jojoba oil as collector in a slightly acid pH range, without the use of depressant. The best results were achieved with a jojoba oil concentration of 200 mg.L-1 at pH 6.5, where the apatite was fully hydrophilic and calcite showed a high hydrophobicity (? > 60 º).

Jan 1, 2014

Geopolymers are novel engineering materials with the potential to play a highly significant role in the transformation of the construction materials and building products industry in the push to-wards sustainable development. These materials are formed by activation of industrial aluminosilicate waste materials such as coal ash or blast furnace slag with alkaline solutions. Some mineral waste can also be used, either as fillers or as reactive components. The use of waste-based geopolymers results in significant (up to 90%) reduction in carbon dioxide emissions when used in cement replacement applications. In addition to the formation of conventional pre-cast products, these high performance mineral binders are ideally suited to use in the conversion or encapsulation of toxic waste, including radioactive waste, due to their chemical stability and resistance to acid attack. It is the aim of this paper to review recent developments on the science underpinning this ?green? technology, and to discuss the technical and commercial drivers governing the large-scale adoption of the technology. Some of the recent fundamental breakthroughs in the study of geopolymer technology at the University of Melbourne will be presented. Despite the complexity of this reactive sol-id-gel system, progress has been made in the development of a thermochemical reaction kinetic model that has been validated using both calorimetric data and synchrotron kinetic data. Geopolymerization is potentially a disruptive technology, so that it is normal to expect strong resistance from established companies in the construction materials industry. It is increasingly necessary that waste generating industries such as mining collaborate with industries such as construction that could utilize this waste. The world?s first full scale geopolymer plant utilizing waste and re-cycled material has been commissioned recently in Melbourne, Australia, so progress on commercialization will also be presented. The authors frequently present keynote lectures on geopolymer science and technology at materials science, ceramics and construction materials conferences. However, this interdisciplinary technology that is still in its infancy, deserves more attention in the mineral processing and mining industry in view of its potential use in the mining industry, and also in view of the importance of mineral processing techniques in recent advances in geopolymers.

Jan 1, 2014

By Cesar Gomez, Jaime Álvarez, Lisette Wen

Laboratory mechanical flotation cells are extensively used in mineral processing for running batch flotation tests with a variety of purposes, for example assessing feed characteristics, determining flotation kinetics, or testing of new reagents and procedures. It is known that the results obtained depend on the operation mode, self-aerated or forced-air, and on the operating conditions selected for the test, in particular impeller speed and gas flow rate. These different results are a consequence of changes in size distribution of the generated bubble population and its remarkable evolution when frother is added; variations in bubble size affect the bubble surface area flux (BSAF), a variable which correlates with particle collection. Results of a two-phase (air-water) test program designed to measure bubble size for a variety of combinations of impeller type and speed, gas flow rate, frother type and concentration, and cell volume, demonstrated the wide range of BSAF with which the cell can be operated. The results obtained in this work demonstrated that gas dispersion in a forced-air lab flotation machine is significantly affected by the characteristics of the impeller/cell geometry combination in use, and the operating conditions selected. Operating conditions must be carefully selected and maintained during the test to ensure consistent results, in particular when frother concentrations below 20 ppm are used, because frother concentration in the cell will decrease as flotation progresses as a consequence of frother partitioning to the concentrate.

Jan 1, 2014

By Trevor Saldanha, Stephen Grano

A key uncertainty in flotation modelling is determining, a priori, the proportion of each mineral which will develop a certain rate constant for different feeds of variable liberation and hydrophobicity. First and foremost is the ability to predict the proportion of minerals that will not be recovered, even at very long flotation times, and which therefore report to the tailing stream as the non-floatable fraction (i.e., having a zero rate constant). Recent empirical evidence has shown there are at least two factors which contribute to heterogeneity in flotation rates and, in particular, the appearance of a non-floatable fraction - heterogeneity in the distribution of adsorbed collector amount on a particle-by-particle basis, even for the same liberated mineral in the same size fraction, and the existence of a critical contact angle below which the bubble-particle union is unstable. In this paper, inferred measures of the critical contact angle for liberated particles are compared with stability model calculations. This has demonstrated that the dependency of the critical contact angle with particle size and mineral specific gravity are explicable by bubble-particle stability considerations. This argument is further extended to the flotation behaviour of composite particles, as a function of liberation class, in which the wetting perimeter of the attached bubble on the composite particle surface is constrained by the presence of a surrounding hydrophilic domain for the case of simple binary composites. Reasons for the different flotation behaviour of composite particles having different textures, as noted in the literature, are also discussed in terms of the stability of the bubble-particle union.

Jan 1, 2014

By Narasimha Mangadoddy

The complex nature of multi-phase flow in dense medium cyclones has restricted plant operators and designers to rely on empirical equations for predicting the performance. A number of empirical cyclone models have been developed in the past (Wood, 1990; Dunglison, 2002). In recent years, this subject has been broached with computational fluid dynamics (CFD). Most of the CFD models have not considered the correct rheological behavior of magnetite medium while simulating the medium segregation inside the cyclone. These models mostly predict excessive underflow volumetric flow rates. In this paper simulations of magnetite medium in a dense medium cyclone, were conducted in FLUENT where the particle phases were simulated using the modified Mixture model. The turbulence was resolved using Large Eddy Simulation (LES) model. The rheological behavior of medium was considered in the form of Granular viscosity, Newtonian and Non-Newtonian models corrected with particle loadings and fraction of ultrafines. Multi-phase simulations using granular viscosity option although predict the overall split product medium densities reasonably close to experiments, the mixture viscosity values are restricted to substantially lower values, similar to water viscosity. Simulations using Newtonian viscosity model corrected with particle loading, and fine fraction below 53µm size is predicting overall mixture viscosity levels well over water viscosity levels, but under predicting the under flow the underflow medium density. Multi-phase simulations using Non-Newtonian Herschel-Buckley model, calibrated for superfine magnetite medium measured viscosities, is closely predicting the medium segregation with gamma ray tomography data. Overall predicted product medium densities, underflow volume split are close to the experimental data. This model is can be further used to simulate coal portioning and hence in developing new designs.

Sep 1, 2012

By A. Collings, A. Farmer

Power ultrasound may be used in the processing of mineral suspensions to clean the particle surfaces of oxidation products and fine coatings, mainly through the large, but very localised forces, produced by cavitation. This effect may be utilised in lowering the level of iron contamination in silica sand used for glass making, in improving the sharpness of electrostatic separation of heavy mineral concentrates, in shortening the time of leaching of minerals and in improving the selectivity and recovery of flotation processes. Parameters affecting the efficiency of these processes, such as input power and levels of reagent addition, are discussed. In particular, we present data showing the relationship between power input and the particle size of surface coatings removed, which can be explained by the Derjaguin approximation for the energy of interaction between a sphere and a flat surface. Pilot scale studies, using commercially available components, are currently being used to assess process viability and will be compared with laboratory scale results.

Jan 1, 2003

By S. Banisi, E. Arghavani, Gh. Parsapour, S. Mousavi

Maximization of water recovery in thickeners is an essential step in the mineral processing industries. The Gol-E-Gohar iorn ore processing plant uses a center pier thickener with a diameter of 38 m and depth of 4 m. The feed rate is 50 t/h solids with a concentration of 5% (w/w), and it has been designed to provide an underflow containing 50% solids. The performance of the thickener was not as expected judged by the overflow stream containing 0.6% solids and water loss of 52 m3/h in the underflow. A criterion called the index of flocculation incorporating the perimeter-based fractal dimension of flocs, floc size, and settling velocities was proposed and used to determine the optimum flocculant dosage which was found to be 20 g/t. The fractal dimension of flocs in a pulp containing 5% solids was found to be between 1.16 (no flocculant) and 1.56 (40 g/t flocculant) which indicated highly branched and loosely bound structures for the flocs as flocculant dosage increased. At these conditions, the size of the flocs which was recorded by a digital microscope increased from 93 µm to 403 µm. A new feedwell with a special design with the aim of preventing flocs breakage and maximizing energy dissipation of pulp was constructed and installed. These modifications led to an increase in the thickener drivehead torque from 5% to 18% of the rated torque, indicating a higher bed depth. Finally, installation of a PID controller reduced the drivehead torque relative oscillation from 52.0% to 12.7%. These changes increased the solids concentration of the underflow from 49.0% to 56.9%, decreased the overflow solids concentration from 0.6 % to values smaller than 0.01% and resulted in a reduction of 27% in water loss in the thickener underflow.

Jan 1, 2014

By Kaioeng Wang, Qi Liu, Yahui Xiang

"In the differential metal sulfide ore flotation it is desirable to replace the toxic inorganic depressants with environmentally benign chemicals. Chitosan, as a natural and non-toxic polymer, has been proven to be an efficient depressant for chalcopyrite while allowing galena to be floated by xanthate collectors. However, the poor solubility of chitosan limits its potential applications as the flotation could only be carried out at about pH 4 where chitosan is soluble. A carboxymethyl derivative of chitosan, named N-carboxymethyl chitosan (N-CMC), was synthesized by substituting the amino groups of chitosan with carboxymethyl groups. The substitution significantly improved the solubility of chitosan. The structure of N-CMC was studied and compared with chitosan via Fourier transform infrared spectroscopy (FTIR). Flotation tests were performed on single minerals and mineral mixtures (with weight ratio of 1:1) with the addition of appropriate amount of potassium ethyl xanthate (KEX) and N-CMC. The solution pH was varied from neutral to alkaline. The flotation concentrates and tailings were collected and analysed for the contents of copper and lead. FTIR measurements showed that new peaks of C=O stretching of -COOH and N-H deformation of -NH- appeared in N-CMC, which indicated that the carboxymethyl groups were introduced and the amino groups were the sites for the substitution. Flotation results indicated that N-CMC could depress either chalcopyrite or galena depending on the pH. The results were not affected by the sequence of KEX and N-CMC addition. Therefore, N-CMC is potentially useful in Cu-Pb sulfide separation following a bulk Cu-Pb flotation. The N-CMC was also found to have surface cleaning functions, and was able to remove contaminating copper ions from galena surfaces. Therefore, its application in sulfide ore flotation is expected to be more robust than the original chitosan."

Jan 1, 2014

By Francesco Vegliò, Luigi Toro, Francesca Pagnanelli

Different hydro-metallurgical processes have been studied in order to recover manganese(II) from oxidised minerals such as MnO2. An innovative acid reductive leaching carried out in mild experimental conditions was here considered using agricultural and industrial wastes containing carbohydrates as reducing agents. The leaching process was investigated from a kinetic and equilibrium point of view in order to optimise the experimental conditions, develop a kinetic model and obtain high purity concentrated MnSO4 solutions. To study the leaching kinetic a Shrinking Core Model (SCM) was modified by a variable activation energy term to take into account both the variable reagent concentrations and the reaction rate change with respect to the manganese dioxide conversion. The influence of the particle size in the kinetic model is discussed with the support of SEM analysis before and after leaching. Manganese extraction yield was maximised (170-190 g/L) using appropriate carbohydrates and acid excesses, while impurity concentrations were kept low (Fe<10ppm and Ca<300ppm) pre-treating the ores, using hydro-alcoholic leaching medium and different combinations of down-stream processes. In particular precipitation, solvent extraction and adsorption onto active carbon were tested to eliminate Fe and Ca from MnSO4 solutions.

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 P. Basarova

The attachment of bubbles onto a collecting surface is an ubiquitous natural phenomenon, playing a critical role in numerous practical processes. The goal of the project is to broaden the knowledge about hydrodynamic interactions between small bubbles and large solids that occur in nature and industrial processes. Focusing on collision processes between a single rising bubble (Db<1 mm) and a larger falling spherical particle in stagnant liquid, the theoretical model describing the bubble trajectory is given here. The model is based on analysis of forces acting on the bubble, and utilizes equation for the bubble motion. Mobile and immobile type of bubble surface mobility are considered. The calculated results are compared with the experimental data; here a high-speed video camera was used to capture the bubble motion and bubble-particle interaction. Very good agreement between experimental and calculated data was found. For both types of surface mobilities, the bubble deviation in the horizontal direction is nearly linear. The proportion constant is bigger for immobile bubble surface and increases with the bubble size. Furthermore, particular forces acting on bubble were studied. A similar course of relative bubble velocity and force impact was observed for identical bubble position. For cases when the bubble centre is close to the particle axis, only deflection in one direction is observed. When the bubble is reaching the maximum trajectory, the force ratio is changed. The bubble is firstly pushed away from the particle, but when it is within close distance from the particle, the bubble is pushed towards the particle.

Sep 1, 2012

Opportunities to monitor and control primary grinding mill performance are strongly sought after in the mineral processing industry. Currently, limited on-line information about mill charge motion and content is available to mill operations for control purposes, leading to periods of lower throughput, instability, variable product size and accelerated mill liner and lifter wear. In response to this need, CSIRO has developed an on-line surface vibration monitor for primary grinding mills which produces data that has been shown to provide new information about the mill charge in terms of toe and shoulder position, as well as potentially key features such as the overall charge level, the distribution between rock and balls in the mill, and the impact of the charge on the mill liners and lifters. This paper outlines the key features of the on-line monitor system, particularly those relating to data transmission, data analysis, and the design of the monitor and its independent power supply. It describes the coupling of single vibration sensor data from the CSIRO on-line monitor to the actual operating conditions of a SAG mill and how the vibration response and hence mill operating conditions vary as a function of time, including during mill equipment failures such as a broken discharge grate. Opportunities for improved mill control based on the data from the on-line monitor are also discussed, as well as the implications in terms of mill processing and maintenance performance. Recently a CSIRO monitor was also installed on a ROM ball mill and analysis of the vibration sensor data from this installation is currently underway. Preliminary findings from this installation will be presented along with comparisons of generic information, such as toe position (measurement precision and operation variability) and vibration signal (intensity, sensitivity and operation variability), between this type of primary grinding mill and AG/SAG mills.

Sep 1, 2012

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 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 grinding conditions on galena flotation and galena separation from pyrite. The changes occurring on the mineral surface during grinding were investigated by EDTA extraction and ToF-SIMS measurements.Galena flotation and galena separation from pyrite were strongly dependent on the type and amount of 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 flotation but had little effect on galena flotation. Optimum galena flotation and galena selectivity against pyrite were achieved by selecting grinding conditions that enabled lead and iron oxidation production to be controlled.Grinding conditions had a large effect on the flotation of the galena particles of different sizes. Flotation of fine galena particles (-10 µm) was depressed by iron oxidation species derived from the grinding media. Chromium grinding medium decreased the production of iron oxidation species and therefore increased the flotation of fine galena particles."

Jan 1, 2003

By Carlos de F. Gontijo

The flotation of quartz particles was studied over the particle size range from 0.5 µm to 1000 µm and for advancing water contact angles between 0º and 83º. Flotation was performed in a column and in a Rushton turbine cell. Particle contact angle threshold values, below which the particles could not be floated, were identified for the particle size range 0.5~1000 µm, under different hydrodynamic conditions. The flotation response of the particles, either in a column or in a mechanically agitated cell with a similar bubble size, was comparable. Turbulence plays a role, as does bubble-particle aggregate velocity and bubble size. The stability of the bubble-particle aggregate controls the maximum floatable particle size of coarse particles. For fine particles, the flotation limit is dictated by the energy required to rupture the intervening liquid film between the particle and bubble. Flotation of very fine and large particles is facilitated with small bubbles and high contact angles. These results greatly extend our earlier observations and theoretical predictions.

Jan 1, 2014

By Ronel du Plessis, John C. Davidtz, Jan D. Miller

Xanthates (dithiocarbonates) have been the collector of choice for the flotation of sulfide minerals ever since the flotation process was developed and have been studied quite extensively. Recently, trithiocarbonates have been shown to be very effective in bulk sulfide bench-scale flotation. Fundamental analysis using electrochemical techniques have supported these bench-scale results, illustrating that the trithiocarbonate (TTC) collectors are more readily oxidized to their corresponding dithiolates, than the dithiocarbonate (DTC) collectors, as is shown in Figure 1.

Jan 1, 2003

By G. S. Hansford, G. E. Searby

The rate of bioleaching of pyrite at 70ºC by a thermophilic archaeal culture was measured as a function of the solution redox potential by the staged addition of pyrite to a batch system. The results were compared to the rate of ferrous iron oxidation over the same potential range to determine the applicability of the multi-sub-process leaching mechanism developed for mesophilic bioleach systems.

Jan 1, 2003

By A. Boulton

Low molecular weight synthetic polymers substituted with hydroxyl, carboxyl or sulfonate functional groups were used to improve the flotation separation of zinc or copper sulfide minerals from iron sulfide gangue minerals in three massive sulfide ores of different mineral composition. These polymers produced significant improvements in zinc or copper grades as a result of a selective depression of iron sulfide minerals. These results are significant considering the differences in ore type, proportion and type of iron sulfide minerals present, and grinding medium used in this study.

Jan 1, 2003

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

The aim of this paper was to study the influence of different water/organic solvent mixtures (isopropyl alcohol, ethanol and ethylene glycol) on the gold 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 Nóra Schreithofer, Kari Heiskanen

"INTRODUCTIONThe knowledge of the adhesion forces between particles and bubbles is of key importance in the improvement of flotation models. The development of the Colloidal Interaction Force Measurement Apparatus (CIFMA) opened the possibility to quantify the adhesion forces between particles and bubbles. The aim of this study was to examine the effect of three main variables: the approach velocity, the loading force and the loading time on the adhesion force between an air bubble and a hydrophobized silica particle."

Jan 1, 2003