Search Documents

By S. E. Phifer

The Haile Gold Mine was the largest gold producer east of the Mississippi River prior to 1942. It is currently the only producing gold mine in the Southeastern United States. Current development involves the mining and heap leaching of some 1000 TPD. Carbon is employed as a recovery medium. Due to its clayey nature and excessive fines in the oxide ore, agglomeration using Portland cement is required prior to leaching. The ore ranges in screen size from two inches to -200 mesh. The agglomerating step combined with certain other conditions has enabled Piedmont Mining Company to achieve recoveries of 90%.

Jan 1, 1987

By R. K. Komarek, F. E. Jr. Briber, G. M. Hanson, Fred D. DeVaney, J. H. Blake, C. L. Matson, T. E. Ban, N. E. Shields, R. D. Frans, R. B. Greenwalt

Metallurgically, the term agglomeration is used to describe processes whose goal is to form balls, briquettes, nodules, flakes, or other sized shaped particles from loose, usually fine, incoherent particles. In practice it includes such varying processes as the briquetting of coal dust and other substances, the balling and induration (heating) of such nonmetallics as cement, fluorspar, lightweight aggregates, etc. It includes such widely used processes as the sintering of nonferrous concentrates, such as those copper, lead, zinc, etc. The agglomeration of specific nonferrous metal concentrates is discussed in detail in the section of this handbook devoted to that particular metal. Agglomeration processes are of particular value to the iron and steel industry where the nature of the primary reduction process, the blast furnace, requires for best results a burden essentially free of fines. This is a change that has taken place since about 1960. Prior to that time many fine unsized ores were fed to the furnace. The development of the pelletizing process gave to the industry a chemically controlled closely sized product that increased the produc¬tion rate and reduced the costs so much that unsized fines are seldom used in modem furnaces. Steel plants produce many fine sized waste products such as fine dust (fine ore coke and gangue) and mill scale. These products, which have a valuable iron content, are usually sin¬tered directly at the plant for reuse. Fine sized ore concentrates are usually pelletized at the mine and shipped as pellets to the steel plant. Common practice in some areas producing natural high grade ores is to screen the ore at the mine to about 3/8 in. The oversize is shipped "as is" and constitutes blast furnace feed. The / in. may be shipped to the steel plant where it may be sintered or otherwise agglomerated. At some mines the fines may be pelletizied prior to shipment. With the development of large ocean ore carriers, and with the transportation of slurried concentrates or fines, a trend has developed of constructing large pelletizing plants or other types of agglomeration plants near large consumption centers (i.e., in the Netherlands or Japan) where ores of many types are brought together, ground if necessary, blended, and agglomerated. As an indication of tonnages of agglomerated materials produced, for iron materials alone (the largest share of the total) production in 1970 in the U.S. was Million gross ton Sinter 40.7 Pellets 43.1 Briquettes, nodules, & others 0.1 Total 83.9 During the 1960s, U.S. production of sinter rose from 40.3 million gross tons in 1961 to a high of 48.7 million in 1964, then settled back to almost the 1961 figure in 1970. Pellet production rose steadily from 14.4 million gross tons in 1961 to the 59.9 figure for 1975. Worldwide, sinter production in 1966 was estimated at 340 million mt (mainly in Europe, Russia, Japan, and the U.S.) and pellet produc¬tion the same year at 64 mt (primarily Canada and the U.S.). World pellet production capacity rose to 200 million tons in 1976.

Jan 1, 1985

By Ramiro da Conceição do Nascimento, Horst Guenter Feldhagen, Rafael Piumatti de Oliveira

Mixed hydroxide precipitate (MHP) is a nickel intermediate product that has economical benefits to downstream leaching of lateritic marginal ores. Usually, this product is subsequently processed and refined to produce nickel by hydrometallurgy, but an alternative route can be made integrating hydrometallurgy and pyrometallurgy. Assessing the overall consumption of ferroalloys to obtain stainless steel, as an increasing practice performed in China, the synergy of nickel extraction from laterites by leaching and precipitation asMHP with the production ofMHP agglomerates applied as rawmaterial to furnaces of ferronickel production is a very attractive practice. This work aims to further the technological development of an agglomerated product feasible to hydro-pyro integration. The agglomeration experiments were performed by traditional pelletizing (firing the pellets) and cold bonded pelletizing (aging the pellets by appropriate stocking). Appropriate compositionswere prepared withMHP, additives and binders for each of these routes. A specific study of binder composition was made to find an adequate melting point. The produced pellets were tested to prove their properties by crushing strength tests. The standardization applied to iron ore was followed. The best result of crushing strength was 98.52 daN/pellet. The agglomerates with approved crushing strength for use in electric furnaces were smelted to produce alloys containing nickel; the agglomerates were characterized by scanning electron microscopy. The alloy obtained was metallic ferronickel with sulphide precipitates. Therefore, MHP pellets can be precursors of nickel alloys, which have to be refined to obtain the desirable composition.

Jul 6, 2020

By C. A. Holley

The generation of coal fines is a growing problem which has serious environmental and resource recovery Impact. Several methods of agglomeration are studied including the production of briquettes for the consumer market. Simplified process flow diagrams, "order of magnitude" plant capital cost and operating costs are presented.

Jan 1, 1986

By Ataollah Nosrati

Agglomeration of fine mineral particles is an important step in heap leaching processes employed for a cost-effective hydrometallurgical extraction of value metals from low-grade ores. In this study, the effect of acidic binder composition and feed ore particle size on binder dosage requirement and isothermal, batch agglomeration behavior of siliceous goethite nickel laterite has been investigated. Agglomeration tests performed with tap water and 30, 44 and 98% w/w H2SO4 solutions as binders revealed the key role of binder formulation in controlling ore particle wettability, nucleation and granule growth behavior. Both lower binder acid content and higher dosage led to greater wetting, nucleation and granule growth rates. Variation of feed ore fine/coarse particles? mass ratio dramatically impacted on binder dosage requirement for effective particle wetting, nucleation, and growth agglomeration behavior. Increasing fine (-150 µm) fraction mass content in a -2 mm feed ore, led to higher binder dosage requirement and enhanced nucleation, however the overall agglomeration rate/granule size growth decreased. In contrast, the presence of coarse (5 ? 15 mm) particles in feed ore led to (i) lower binder dosage requirement, (ii) enhanced initial agglomerate size growth rate, and (iii) reduced coalescence. For dry agglomerates of similar sizes, competent coarser feed particles led to remarkably higher compressive strength than did finer feed particles. Microstructure analyses indicated that the granules containing coarser particles exhibited a distinctive, competent core/shell (fines) structure which led to their structural reinforcement. The appropriation of the findings for optimizing agglomeration behavior for enhanced heap leaching of complex, low grade laterite ores are discussed in this context.

Sep 1, 2012

By S. Kawatra, K. Lewandowski

Heap leaching efficiency is reduced by poor solution flow characteristics (channeling and ponding), which result from fines migration. Agglomeration of the ore can immobilize fines, but copper leaching requires an acid-resistant binder to stabilize the agglomerates. Until now, there has not been a satisfactory way to evaluate whether a binder was effective, other than squeezing a handful to see if it “feels right”. We have developed procedures to quantitatively determine whether a binder gives good performance in an acidic solution, and have identified several binders that will be suitable for copper heap leaching.

Jan 1, 2007

Agglomeration for Copper Heap Leaching Agglomeration of ore is a method which can be used to eliminate the migration of fine grained particles throughout a leach heap. Without agglomeration, fine ore particles are able to migration within the heap, clogging flow channels and producing large areas where access of the solution is poor. In order to gain the benefits of agglomeration and improve agglomerate strength even further in copper heap leaching, an economical, acid-resistant binder is needed. However, most binders have been used without any systematic reasoning. A set of novel testing methods were developed, including a soak test, percolation flooded columns, and larger long-term leach columns. The soak test compares the degree of breakdown when agglomerates are subjected to an acidic environment. While the percolation flooded columns and larger long-term leach columns evaluate the flow of leach solution throughout the ore bed. Systematic studies have been completed on a wide range of binders using these novel testing procedures. It was found that for a low grade chalcocite ore, which was rich in silica, from a southwest US mine, polyacrylamides reduced the fines migration the best in the novel soak test. The non-ionic binder, in particular, was found to reduce fines migration as much as 93 per cent. Several of the binders tested were shown to increase the hydraulic conductivities of the agglomerated ore up to 2.5 mm/sec, compared to a hydraulic conductivity of only 0.25 mm/sec when no binder was used. These binders also prevented 'slumping' of the ore, which indicates a decrease in breakdown of the agglomerates. The use of a binder also showed no interference with leaching reactions in long-term leaching experiments.

Sep 13, 2010

By P. D. Chamberlin

Agglomeration for the heap leaching of gold and silver ores can be defined as the process of attaching fine ore particles (less than 100 mesh) to coarser particles so the fines are immobilized and uniformly distributed throughout the heap, thus making the heap more porous and uniformly permeable to the flow of a leaching solution. Agglomeration techniques and equipment to be described include drum and disc agglomerators, stockpile and belt agglomeration, and the use of vibrating deck and reverse running conveyors.

Jan 1, 1986

By R. Hogg

"The basic population balance models for agglomeration processes are reviewed and procedures are described for extending their applicability to systems with size-dependent rate constants and to the formation and growth of porous agglomerates from rigid, solid particles. Simplified procedures for the further extension of the models to include simultaneous agglomerate growth and breakage arc also described. IntroductionThe association of small particles into clusters or agglomerates is a significant factor in many facets of particle processing. Agglomeration processes are widely used to facilitate handling, storage and utilization of fine powders. Processes such as coagulation or flocculation are used to aid solid-fluid separation in dispersed particulate systems. Agglomeration also occurs as an accompaniment, often unwanted, to other particulate processing operations such as fine grinding, mixing and blending, transport and flow.Reliable agglomeration models are needed for improved understanding of the processes in general and of the complex role of numerous, interacting variables as well as for direct application to the design and control of industrial processes such as flocculation, granulation and pelletization. Ideally, the models should account for the primary forces responsible for agglomerate ·formation and growth, the effects of external forces on process dynamics, the development of agglomerate structure and its role in the process itself, and the effects of concurrent processes such as structure modification (e.g. compaction) and agglomerate breakage or degradation.In its most general form, the process of agglomeration involves taking discrete, independent particles, bringing them into contact with one another, promoting (or allowing) interparticle adhesion to occur and then causing structure rearrangement, usually under the action of external forces. The relative importance of these steps varies with the nature of the particulate system being agglomerated and with the kinds of agglomerates being produced. Coagulation or flocculation of particles dispersed in fluids is generally dominated by the contact and adhesion steps. In the granulation of powders, on the other hand, particles are already in contact so that structure rearrangement is the principal step."

Mar 1, 1992

By R. Hogg

"The basic population balance models for agglomeration processes are reviewed and procedures are described for extending their applicability to systems with size-dependent rate constants and to the formation and growth of porous agglomerates from rigid, solid-particles. Simplified procedures for the further extension of the models to include simultaneous agglomerate growth and breakage are also described.INTRODUCTION The association of small particles into clusters or agglomerates is a significant factor in many facets of particle processing. Agglomeration processes are widely used to facilitate handling, storage and utilization of fine powders. Processes such as coagulation or flocculation are used to aid solid-fluid separation in dispersed particulate systems. Agglomeration also occurs as an accompaniment, often unwanted, to other particulate processing operations such as fine grinding, mixing and blending, transport and flow.Reliable agglomeration models are needed for improved understanding of the processes in general and of the complex role of numerous, interacting variables as well as for direct application to the design and control of industrial processes such as flocculation, granulation and pelletization. Ideally, the models should account for the primary forces responsible for agglomerate formation and growth, the effects of external forces on process dynamics, the development of agglomerate structure and its role in the process itself, and the effects of concurrent processes such as structure modification (e.g. compaction) and agglomerate breakage or degradation."

Jan 1, 1989

By Thomas E. Ban

During recent years fuel consuming industries of the United States have been caught between environmental restrictions and the uncertainty of obtaining an inexpensive fuel. With the advent of the National Energy Act of 1978 there has been added impetus to switch from gas and oil to coal. For industrial furnaces and boilers that were designed to bum coal, returning to an available compliance coal might be feasible. However, furnaces and boilers designed for gas or oil cannot reasonably be converted to coal unless the coal is initially gasified. All cases, nevertheless, depend upon the availability of an adequate structured coal of a compliance composition, a challenge to the coal mining industry. The foregoing problems have contributed to the current energy-coal crisis of today's economies. It therefore would be worthwhile to capitalize on previous experiences of the mineral processing industry.

Jan 1, 1979

By Peter Ryan

A patented process for agglomeration of Smelter ESP dusts is described. Addition of suitable binders followed by compaction, transforms fine, difficult to handle material into a dry, flowable agglomerate suitable for plant reentry. Details for the agglomeration process metallurgy and laboratory pilot plant testing are discussed. An example of full scale plant operations is described.

Jan 1, 1999

By David S. Cahn

Pilot-plant and laboratory tests were made on blends of steel plant flue dust and portland cement to determine whether the flue dust could be pelletized for use as a source of iron in dry process cement manufacture. Strength and setting time results showed that an acceptable agglomerate can be made with a Type II portland cement binder. Abrasion-resistant and well-sized pellets were made in a horizontal drum, using a simulated closed circuit, with a binder content of 7.5% and a moisture content below 15%. Pellet quality was found to be relatively insensitive to changes in binder concentration above 5%. Simulations of stockpiling and weathering indicate that little difficulty would be encountered with use of the flue dust pellets in cement plants.

Jan 1, 1972

By J. A. Finch, J. Vergouw

"Flotation selectivity becomes progressively more difficult to achieve with decreasing particle size. One of the possible problems is agglomeration, i.e. particles clustering together. One mechanism derives from the surface charge all particles develop in water. Agglomeration driven by surface charge is known as coagulation. One form is coagulation between particles of two different minerals of opposite charge. Another is coagulation between particles of the same mineral when conditions are such that the charge approaches zero.The paper describes the method of measuring charge and a new automated settling technique for measuring agglomeration. The phenomena are illustrated with galena and pyrite. Methods of assessing the importance of agglomeration in the plant environment are still to be developed.IntroductionFine particles can agglomerate (i.e. adhere to each other) under certain conditions. This is counter-productive for any physical separation process, including flotation. One cause of agglomeration derives from the surface charge that all particles develop in water. Agglomeration due to surface charge effects is referred to as coagulation. There are two forms of coagulation. If the surface charge is brought to near zero then the force of repulsion is lost and particles coagulate. This usually applies to particles of one mineral type and the technical tenn is homocoagulation. On the other hand, if two particles have opposite charge there is an attractive force. Since the particles in this case are usually different minerals this is known as heterocoagulation.Both types of coagulation can cause minerals to be misplaced. In the case of heterocoagulation this is fairly obvious. One example that may be familiar is slime coating (fines of one mineral coating larger particles of another) But even homocoagulation can be a problem an agglomerate of the same mineral particles can entrap particles of another mineral."

Jan 1, 1997

By G. K. Lee, E. R. Mitchell

Designers of combustion processes may select aerodynamic conditions which produce only superfine fly ash. Although it is not usually anticipated that this will create a problem, such as has been found to agglomerate in high-velocity gas streams, to plug mechanical dust separators in a short time, and to contribute to atmospheric pollution. The problem is a fundamental one, and may be approached in several ways. The authors, in the course of their combustion research program, had occasion to examine the agglomeration of ash, ranging from sub-micron to 17 microns in size, produced in a (coal and oil) dual-fuel-fired steam generator. Several theories, supported by extensive laboratory studies, have provided some understanding of a probable mechanism of agglomeration. As a result, certain precautions are suggested in the design and selection of combustion processes and equipment.

Jan 1, 1962

By Sara Swiokla Korsikas, Toren Olson, Amado Guzman, Yuri O. Zepeda P

Ore agglomeration has been used as part of the heap leaching process for the last 40 years. However, industrial experience shows that the lack of a universal agglomeration standard has limited the benefits of this, otherwise, valuable unit process. The more complex the ore, in terms of the nature and relative abundance of fines (<74 μm), the more important that the agglomeration product satisfies some minimal requirements. This paper presents an agglomeration scale that identifies the quality standards for agglomerates and documents the resulting mechanical, physical, and hydraulic (hydrodynamic) behavior associated with each level on the agglomeration scale. The hydrodynamic properties of an agglomeration product are critical for the proper design of a leaching operation and, as shown in this paper, can be used to select the optimal pretreatment method for a given ore sample. Agglomeration as a unit process not only allows better conditioning of the hydrodynamic behavior of the ore but also creates an opportunity for optimized delivery of reagents to kick-start the leaching process which may ultimately improve the economic performance of leaching. Industrial case data is used to demonstrate the shortfalls associated with low-quality agglomeration and the benefits of improved agglomeration which range from enhanced porous structure (better percolation and drainage characteristics) to better metallurgical response (faster kinetics and higher metal recovery). Proper agglomeration has been used to render otherwise untreatable ores into valuable leaching resources.

Feb 9, 2024

By D Readett

The most critical variable in the successful establishment of the Murrin Murrin Heap Leach plant was the effective agglomeration of the Ni laterite ore. This paper describes the test work undertaken to establish the key agglomeration parameters including state of the art testing and analysis procedures. These parameters were then utilised to establish the key design and operational concepts for the world’s first commercial scale Ni laterite heap leach. Following the technical and economic success of the operation, the actual operational data is compared back to the original test work data.

Aug 8, 2011

By C. A. C. Sequeira, G. N. Anastassakis

"The separation of fine or even smaller size mineral particles with conventional methods is inefficient due to the specific properties of fines (small mass, high specific surface area, and high surface energy per unit area). Hence, the production of high-grade concentrate with high recovery is very difficult to impossible and a significant share of mineral values is lost to the tailings. The aim of the current research is to investigate the possibility to efficiently separate value minerals from gangue of fine particle size. The objective of the current work is to develop separation schemes of fine mineral particles by combining an initial stage of particles agglomeration with the use of collectors (hydrophobic agglomeration) with a subsequent conventional separation method. In the current research, magnesite was used as mineral value to be separated: a) from quartz, and b) from mineral mixture (serpentine, ilmenite, and olivine). In each case, tests on single minerals and artificial mixtures were carried out. After hydrophobic agglomeration, the separation of magnesite from quartz was achieved by settling; in the second case (gangue: serpentine, ilmenite, and olivine), magnetic separation of the co-agglomerated gangue was applied. In both cases, the results of the preliminary tests on single minerals suggest that the separation of mineral value is feasible and efficient. These findings were also confirmed from the results of the tests on artificial mixtures of magnesite and gangue, either quartz only or mineral mixture. Both separation schemes provided with magnesite concentrates of commercial grade (95% magnesite) with high recovery. INTRODUCTION The generation of fine particles is inevitable in many operations of mineral commodities processing. Especially in the case of low-grade ores, the mineral value is finely disseminated in the ore, and considerable liberation occurs at a fine size range. Although there is not a uniform classification system with respect to mineral particles size, fines are usually characterized the particles with a size range of -100µm+20µm, very fines those of -20µm+5µm, ultra fines of -5µm+1µm, and colloids smaller than 1µm (Sivamohan, 1990)."

Jan 1, 2018

By S. M. Marshall

The investigations recorded in this bulletin were conducted by the Pacific Coke & Coal Co. in cooperation with the United States Bureau of Mines and the University of Washington. They cover one phase of a comprehensive investigation to determine whether coals from an extensive, undeveloped area of Pierce County, Wash., can be used in the manufacture of coke for the iron blast furnace. The completed investigation had three parts: (1) A geological survey of the coal property, (2) washing and crushing tests of the coals, and (3) coking and by-product tests. The geological survey, which was not conducted in cooperation with the Bureau of Mines and the University of Washington, included systematic tracing of the coal beds by test holes throughout the property, except some portions covered by an impenetrable layer of glacial drift. By this means all of the beds were correlated, their thickness and general character were determined, and tonnage estimates were made. Only such parts of the survey results as are necessary to a full explanation of the investigations described herein are included in this bulletin.

Jan 1, 1931

By C. L. Glorioso

As an introduction and credentials for our talk, let me take a moment to introduce you to Wimpey Worldwide and specifically to Wimpey Minerals, USA, Inc.

Jan 1, 1995