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By B. Rai

Aluminum is produced by the Hall-Héroult process, which involves passing a current through a molten mixture of alumina dissolved in cryolite (Na3AlF6) to reduce the alumina to aluminum. This process occurs in an electrolytic cell comprising a steel shell lined with a carbon cathode and refractory bricks. After a certain period of operation, the carbon cathode deteriorates and is removed from the cell along with the refractory bricks. These removed materials are referred to as spent pot lining or ?SPL?. Typically, 30 Kg of SPL waste is generated for every ton of Aluminum produced. Globally aluminum smelters produce more than 500,000 tons of SPL each year. Even though SPL has a high fuel value (8000 to 9000 BTU/lb) and contains valuable metals, it is classified as a hazardous material due to its cyanide content and leachable fluorides. Various disposal/recycle techniques have been developed over the years for SPL but none of them is satisfactory. Thus, large quantities of SPL are still being dumped in landfills. In some countries, even the land filling of SPL is not permitted. The safe disposal of SPL thus remains a challenging problem to the aluminum industry and the search continues to find methods of converting SPL into a non-hazardous waste and/or recovering the valuable materials contained in the SPL. We have developed a process to produce hydraulic setting cements (eco-cement) containing a novel fluoride rich cementitious phase, from SPL by an energy efficient, low temperature clinkering route. A raw mix blend of SPL, lime/limestone, calcium sulfate and tailings sands based on a set of design criteria developed by us, is clinkered in a two stage process; 2 hours soak at 800 °C followed by clinkering at 1000 °C for another 2 hours, to produce a soft clinker. The SPL eco-cement is made by grinding the clinker to a fineness of 5000 cm2/g Blaine with 1% by weight borax as a set retarder. A good quality cement having as high as 20 % by weight of SPL in the raw mix (28 % by weight in the cement clinker) is thus produced. The physical properties of the SPL cements are found to be comparable to the Indian standard (IS) specifications for Ordinary Portland Cements (OPC). We have produced the cement in a few Kg batches and tested the reproducibility of results from batch to batch for further scale up. Once commercialized, this process has a potential of converting SPL into value-added cement products. Keywords: cement, spent pot lining, clinkering, fluoride, aluminum, ordinary portland cements

Sep 1, 2012

By M. S. Prithvi

Over the decades, mine and mineral processing plant operations for the most part, have been found to have had adverse impacts on the environment. At the same time, mineral processing and mining operations produce mineral products that are indispensable to modern society. Thus, the sector has desirable and undesirable attributes simultaneously. The situation presents itself as a contradiction (i.e.) the mineral processing and mining operations are wanted by society, and at the same time unwanted by society. The existing methods of addressing the issues raised above have evidently not been very successful in reducing the opposition to new projects and to the related activities such as land acquisition. This paper attempts to show the relevance and applicability of TRIZ for addressing the issue. TRIZ, or Teoriya Rezheniya Isobretatelski Zadach, is a Russian acronym meaning Theory of Inventive Problem Solving. TRIZ is a powerful tool that can be usefully applied to resolve such contradictions, using resources usually available within the system of interest. Accordingly, this paper introduces the issue background, followed by an introduction to some key concepts of TRIZ such as the 40 principles, separation principles and directed evolution. The paper goes on to apply the 40 principles to two case studies. The results show that TRIZ could be a useful tool to generate potentially innovative and sustainable approaches. Its most appropriate position would be as a supplement to current decision-making procedures, and as a validation tool to review existing solutions for possible improvements. Keywords: minerals, environment, TRIZ, contradiction, resources

Sep 1, 2012

By Rogerio de Oliveira Baldoino

The sedimentary phosphate deposit of Bayovar is located in a very dry area of Peru (desert of Sechura) which is close to the Pacific coast. It consists of seven superposed layers (beds) which call for different strategy of concentration. The ore is composed predominantly by apatite (84% in weight basis) plus silicates (16%). In order to treat the ore from beds 1-5, a suitable standard mineral processing circuit (composed of scrubbing, screening, attrition and desliming) started its operation in 2010, yielding 3.9 Mt/y of concentrate assaying 30% of P2O5. To concentrate phosphate from beds 6-7, however, it is necessary to carry out further cationic reverse flotation of silicates, at neutral pH, to yield a concentrate, which meets market specification. The new process was developed in laboratory scale by a collaborative program conducted between Vale S.A. and the University of Sao Paulo-Brazil. A pilot plant has currently been running in order to confirm the very good results yielded in laboratory scale. The successful accomplishment of flotation in the current beneficiation flow sheet will enable a capacity expansion of 1.9 Mt/y of concentrate assaying 30% of P2O5. As water resources are very limited at Bayovar region, all the steps of concentration, including flotation, must be performed with seawater, which must be continuously recycled. This work addresses some relevant topics related to the use of seawater in the reverse cationic flotation of silicates: influence of temperature, water quality (ageing and chemical composition) and collector type (ether amine versus condensate). The results indicate that condensate amine works better than ether amine. If flotation is conducted with the former collector, the separation process is able to tolerate changes in temperature (25-40oC) and water quality caused by either evaporation or ageing. Keywords: phosphate, flotation, seawater, temperature, ageing, concentration, salt

Sep 1, 2012

By Andrew Logan

Newcrest has a strong history of growth over the past 20 years, yielding value from previously marginal ore bodies. We have grown regionally in Asia Pacific through our operations in Australia, Indonesia and Papua New Guinea, and also established a beachhead in West Africa. The company has a reputation of realizing value from large, low-grade deposits adopting step change approaches. Newcrest is focused on an overall strategy of gold, low cost, long life and moderate growth. Capability step changes play a large delivery role. They transition from a business offline-to-online approach as opportunities mature. Newcrest believes in a) Knowing what ?good? looks like, b) An open innovation approach to actively working with others, c) The leap frogging leverage of making the ?old new again?, d)An adopt-adapt-develop methodology enabled by rapid prototyping/piloting, e) Getting our handsdirty with test work and plant analysis, and f) Staying focused on a few high business leverage areas. This paper describes Newcrest?s approach and our experiences in establishing renewed metallurgical processes, specifically aimed at increasing innovation adoption. Some of our step changes discussed include: 1) Early waste rejection to avoid high energy processing downstream, 2) Broader gold product channels to reduce site based processing needs, 3) Lower energy processing, and 4) Geo-Metallurgy approaches. Keywords: Newcrest, gold, step change, open innovation, adopt, adapt, develop, offline, online, prototyping, old new again, waste rejection, low energy, geo-metallurgy

Sep 1, 2012

By Jim Pae Lem

This study investigates the mode of occurrence of uranium in a copper concentrate from the Prominent Hill mine. Mineralogical and liberation studies of a high grade Cu concentrate (monthly composite) containing uranium (U) were undertaken using QEM-Scan in combination with QXRD and ICP-MS. The study aimed at determining in what form U was recovered, and by which mechanisms. The deportment of U was studied in 3 size fractions; +20µm, -20+8µm and -8µm. QEM-Scan analysis showed that uranium was present as U(Cu)-silicates, U-silicates, UPbOx/FeOx or traces of UThOx and UTiOx, with the U-silicates present across the size fractions. The association of uranium bearing minerals with copper sulphides varied across the size ranges. Interestingly, most of the U (46% by weight) was distributed in the finest fraction (-8µm), in which the deportment of Cu was low (6%). Over 40% of the U mineralisation in the -8µm was liberated. In terms of the floatation response, while recovery of the uranium minerals as a result of their association with copper sulphides (as composite particles) was evident, recovery of UPbOx locked in hydrophilic haematite in the +20µm size fraction suggests, that other mechanisms (e.g. Inadvertent activation by Pb from radioactive U decay) are possible. Furthermore, the high amount of fine liberated U bearing particles in the concentrate points at entrainment as another major mechanism for uranium recovery, and therefore, a target for process optimisation.

Sep 1, 2012

By Xiaoming Wang

This paper presents an arcuate magnetic separator to remove the grinding ball fragment directly from the mill discharge, which will cause wear to downstream processing equipment such as pump, hydro cyclones and pebble crusher. Furth more this type separator was applied in Wushan mine under China National Group Corporation in China. After months of operation, the equipment has been a success. It removes majority of ball fragments from mill discharge. Keywords: magnetic separator, sag mill, pebble crusher, grinding ball fragments

Sep 1, 2012

By D. P. Chakraborty

Joda East Iron Mine, one of the captive iron ore sources of Tata steel, located in the state of Odisha in eastern India caters to approximately 45% of the iron ore requirement of the Jamshedpur Steel Plant. The iron ore occurring in the mine having high in iron content along with high in alumina. Clay and gibbsite are the predominant mineral phases present as surface coating, fracture filling and/or free occurring and are responsible for alumina content higher. Alumina in iron ore impacts the techno-economic performance of a steel plant by impacting sintering and blast furnace productivity. The impact is even higher when it comes to fine ore used in the blast furnaces in the form of sinter as it constitutes a major portion of the blast furnace burden. Therefore, it is beneficial to upgrade iron ore in the mine head and to reduce alumina before it is subjected to agglomeration. Mineralogical test works reveal, that alumina in iron fines is mainly associated with the clay attached to the hematite particles, either free or interlocked to a very fine size. The paper describes the efforts made to reduce alumina in the iron fines in Joda East processing plant, without much of capital investment for a very sophisticated fines beneficiation circuit. In this process, a suitable dispersant was added in the plant that dispersed the masked slime coating over the iron ore fines, thereby making a better quality iron ore fines with reduced alumina content. The alumina in fines improved by 0.2 units? means from a label of 2.4-2.6 % reduced to 2.2-2.4 %. With this initiative, not only the primary objective of alumina reduction is met but also it has given substantial benefit in reduction of silica and as well as moisture in product. This moisture reduction also has given bottom line impact by reducing idle freight and royalty.

Sep 1, 2012

By S. Castro

Molybdenite flotation is strongly depressed at pH higher than 9.5 in the flotation of Cu-Mo ores in sea water. Chemically sea water contains mainly Na+ and Cl- ions, but also some secondary ions, such as SO42-, Mg2+; Ca2+, HCO3-; etc., which are not necessarily indifferent for the flotation of molybdenite. The natural floatability of molybdenite in sea water and in NaCl solutions containing different secondary ions is investigated by micro-flotation tests. The tests indicate that the floatability of molybdenite in alkaline media in 0.6 M NaCl solutions is not affected by the presence of anions, such as, SO42- and HCO3-, at concentrations similar to those occurring in sea water. However, a strong depression of molybdenite at pH ranging from 9.5-10.0, is produced by the alkaline earth metal cations (Ca2+ and Mg2+ ions), dissolved in distilled water or in 0.6M NaCl solutions. It was found that effect of Mg2+ions is significantly stronger than Ca2+ ions. Effect of both ions is attributed to hydrolysis and adsorption of MOH+ hydroxy-complexes. This is followed by subsequent precipitation of hydrophilic colloidal hydroxides at the molybdenite/solution interface, and in bulk solution.

Sep 1, 2012

By N. I. Tyushkova

On the basis of detailed studying of mineral structure of ore and treatment products it is established that the given ore refers to oxidized Pb-Zn vein-disseminated ores. Technological special features of the basic ore minerals and the reasons causing their obstinateness that is defined by following features are revealed, presence at dominating quantity difficult to float lead minerals: mimetesite (9.67%), green lead ore(0.48%); non float: bindheimite (2.16%) and plumbojarosite (0.36%) and high assay of oxides and hydrous ferric oxides; also thin, emulsive and submicroscopic segregations of the defined minerals in swamp ore. As a result of researches the scheme of gravitational-flotation treatment was conducted in semi-industrial scale. It allows to receive two concentrates from ore: a lead gravitational concentrate of mark ??-4 with the assay of 55.5 % of Pb and 0.77 % of Zn; and a Pb concentrate of mark ??-7 with assay of Pb of 40.97 % and Zn of 1.39 %. The total assay of Pb in concentrates makes 81 %. The efficiency offered by gravitational-flotation schemes is defined by possibility for recovery of big impregnated lead minerals under gravitation. The use of this method of gravitation has allowed to recover such mineral as beudantide and to exclude irrevocable losses of lead in tails which are connected with this mineral. Scientific value of the presented researches is connected with the fact the problem of extraction of the oxidized minerals of Bb and Zn is rather difficult and insufficiently studied. Keywords: flotation, oxidized forms of Pb and Zn

Sep 1, 2012

By G. Alfano

This investigation is concerned with the optimization of ultrafine grinding of solids. It is focused on a dynamic classifier for recovering the fine fraction, for automatic recycling of the oversize particles and for reducing power consumption. Power consumption plays a major role in these energy intensive processes and depends on several parameters such as nature of the solid, degree of fineness of the finished product and, above all, grain size of the feed. This study indicates the optimal conditions for a dynamic classifier, that is, geometric characteristics of the apparatus and its capacity, inlet air flow rate and dimensions of the classification circuit. It is also shown that a mean grain diameter (dm) of about 2.00 µm with top size (dmax) of 50 µm can be achieved with an imperfection value of below 0.40 and energy consumption of 215 kWht-1. Keywords: air classification, dynamic classifier, jet mill, energy

Sep 1, 2012

By Y. Y. Emelianov

The results of the test work of four treatment options of three refractory gold-pyrite and gold-arsenic flotation concentrates are presented. These concentrates were obtained during the concentration of primary ores of large gold deposits. It was found that ultrafine grinding of refractory flotation concentrates did not increase the recovery of gold during subsequent cyanidation. The elimination of sulfur and arsenic during oxidative roasting is 99 per cent. 88-93 per cent of gold is recovered by cyanidation from calcines. After biooxidation of the flotation concentrates with a mixture of strains Acidithiobacillus thiooxidans and Acidithiobacillus ferrooxidans 88-91 per cent of gold is recoverable by direct cyanidation. The recovery of gold from flotation concentrates by pressure oxidation is 88-99 per cent. These results suggest that gold recovery is important but the following strategies would have an impact on a plant performance and would be considered when developing an option to treat refractory ores: capital and operating costs, ore reserves, mine location, infrastructure and qualified staff. Keywords: gold, flotation concentrates, recovery, cyanidation, roasting, biooxidation, pressure oxidation

Sep 1, 2012

By F. Henríquez

Traditionally, the implementation of an automated control for a ball mill has been a challenging one. First, it must be capable of processing a variable SAG mill feed while at the same time avoiding to become a process bottle neck. Second thing is, it must deliver an adequate quality product (P80) to the process downstream. Then the ball mill itself and its associated classification equipment has problems of its own: it must maintain adequate control of cyclone?s pressure, density and pump-box level with often, less manipulated variables than needed, namely, variable pump speed and the opening/closing of cyclones. Thus, it becomes a non-linear multi-variable type of process with often too multiple and contradictory control objectives to satisfy simultaneously. On top of that, to extend cyclones availability and yet, maintaining their performance, is must both for process and maintenance purposes. Trying to solve the puzzle, Minera Los Pelambres implemented a novel and successful combination of MPC (Multivariable Predictive Control) and advanced control in two of its newest ball mills, reducing considerably process variability while maintaining high throughput and keeping the process well within constraints limits. Because of their differences in processing capacity, size and topology, two different stabilizing-control strategies were developed, tested and tuned. Hence, for both control approaches their implementation process, main results, areas of applicability, limitations and their key performance indicators are discussed further. This paper also discusses the need of such advance control technologies in the mining industry, including the impact of these technologies on best practices for their implementation, operation and long term sustainability

Sep 1, 2012

By Shuoshi Lu

The Cu-Co ore studied here belongs to the oxide type. The oxidation rates of copper and cobalt are69.30% and 78.78%, respectively. The content of Cu in ROM is 1.34% and that of Co is 0.096%. The ore contains 4.64% carbon.Based on the process mineralogy and previous metallurgy tests, the principalprocess flow-sheet of ?grinding fines 80% -0.074mm, sulphide flotation followed by oxide flotation, and flash flotation for oxides? has been determined.The handling of carbon is determined through tests. The depressant PNL-1 depressed carbon effectively, improved the recovery of sulphide minerals and reduced the reagents consumption.The operation of the flow-sheet was also changed to better at the same time. Keywords: Cu-Co oxide ore, process mineralogy, carbon depression, efficient depressant of carbon

Sep 1, 2012

By Linghu Changjin

Based on the characteristics of typical marine sedimentary phosphate rock in Guizhou, Southwest China, together with the research findings made on the surface electric properties of pure collophanites taken from different areas in pure water and under the action of collectors, a pure minerals flotation test of collophanite was conducted in this research. The differences of collophanite flotation behavior and the effects of the different pH values, varieties, and dosage of collector on flotation separation of collophanite were studied. It is suggested that that in pure water, collophanite had a negative charge within a wide pH range. The electro negativity values of collophanite increased with the addition of collectors GJBW and WF-01. When GJBW and WF-01 were used as collectors, the collophanite was depressed in acid medium, but had a good flotability in basic medium.

Sep 1, 2012

By G. Demi

The biggest chromium mineral processing plant in Albania is Bulqiza plant. It has been in operation for more than 20 years, treating low-grade chromium ores grade 20 ? 26 % Cr2O3 and producing chromium concentrates grade 48 ? 50 % Cr2O3. About 2 million tons of tailings with 13 % Cr2O3 content are stocked in a dam close to the plant. Mineral processing of low-grade chromium ores with less than 16% Cr2O3 content is unprofitable because the mining expenses are high comparing with the current market prices of chromium concentrate. Recycle and enrichment of existing tailings is profitable, because there are no underground mining expenses in this case and because that this kind of raw material does not need expenses operation of crushing and grinding. The existing plant is in operation for more than 8 years treating existing tailings as raw material. Grade of concentrate in the value 40 % Cr2O3 and Cr2O3 recovery in the value 30-35% in the plant are considered low. The main reason of low concentrate grade and recovery is high content of particles under 100 microns, the slimes, in raw material. In the paper is described the study carried out to improve enrichment of the tailings, as well as analyses of existing process, raw material and products. It is concluded that majority of lost is present in the slimes which are not separated in existing spiral separators and shaking tables. Basing in the study is composed the new flow sheet of recycling and concentration of the tailings to produce chromium concentrate grade 41 ? 42 % Cr2O3 and recovery 60 %, decreasing in this way the concentrate production cost two times. In the paper are presented the tests and results of concentration of particle size fraction under 100 microns, using gravimetric, magnetic and flotation methods, as well as equipment and machines suitable for slimes treatment and concentration.

Sep 1, 2012

By Antoineta Boteva

A significant part of the currently production of the non-ferrous and precious metals is from sulfide ores. Character feature of sulfide ores is the presence in them always pyrite and wide range of different sulfide minerals else. These minerals are the carriers of valuable for industry metals. Due to the low content of the main components, very often call on the use of collective- selective flow-sheets. The extraction of minerals in the collective concentrates determined in a large extent the effectiveness of the collective-selective sheets. In conditions of bulk flotation kinetics to floatate of the various minerals is different. Due to why it is and how it can be used for a more effective selection of minerals ?this is the main task of this report. For this purpose are used results from the bulk flotation of pyrite, copper sulfides, molybdenite, galena, blenda. It is separated and place of host rocks. Base it of large experimentation material, including both electro-kinetic measurements of mineral systems, as well as laboratory flotation tests and factories monitoring it is established kinetics of flotation of mineral particles in conditions of collective flotation. Made an effort to clarify the effect as of the species and the proportion of different sulfide minerals involved in flotation pulp else. Traced was the impact of the density and aeration of the flotation pulp on deferens in kinetics of mineral flotation in condition of balk flotation. The obtained results are used to increase the efficiency of the diffraction flotation of the complex sulfide ores containing precious metals. In the schemes, it is possible precious metals to fall in the most appropriate for the next processing products. Keywords: flotation, sulphide ores, kinetic extraction

Sep 1, 2012

By Stoyan Groudev

Two experimental plots consisting of a slightly acidic soil heavily contaminated with radionuclides (mainly uranium and radium) and non-ferrous metals (mainly copper, zinc, and cadmium) were treated in situ under real field conditions using the activity of some representatives of the indigenous soil microflora. This activity was enhanced by suitable changes in the levels of some essential environmental factors such as pH and water, oxygen and nutrient contents of the soil. The treatment was connected with solubilization and removal of the contaminants from the top soil layer (horizon A) due to the joint action of the soil microorganisms (mainly acidophilic chemolithotrophic bacteria) and leach solutions (diluted sulphuric acid) used to irrigate the soil. In one of the plots, the dissolved contaminants were removed from the soil profile through the drainage soil effluents and were subjected to cleaning by a constructed wetland located near this plot. In the other plot, the dissolved contaminants were transferred to the deeply located soil subhorizon B2 where they were precipitated as the relevant insoluble forms (uranium as uraninite, and the non-ferrous metals as the relevant sulphides) as a result of the activity of the sulphate-reducing bacteria inhabiting this soil subhorizon. This activity was enhanced by injecting water solutions of acetate, lactate, ammonium, and phosphate ions to this soil subhorizon.

Sep 1, 2012

Goethite ore are the third most abundant source of iron. The overwhelming part of these ore is represented by low-grade varieties which cannot be used in iron and steel industry without preliminary beneficiation. Biomass is a renewable solid fuel, which is feasible for the substitution of coke and coal in the manufacturing due to its lower contents of harmful elements and abundant raw material sources. Utilization of biomass in iron ore sintering process as heating agent and reducing agent contributes to energy conservation and emission reduction. The biomass was mixed together with goethite ore for roasting process to investigate the effects of reduction roasting. The results show that the goethite ore is dramatically reduced and magnetized into maghemite by biomass with the biomass dosage less than 20% and the roasting temperature below 650 oC. When the goethite ore roasted with biomass, the magnetization values could be enhanced more than two orders of magnitude, meets the standard of magnetic separation, which could significantly reduce the iron beneficiation cost. Keywords: biomass, goethite, reduction, magnetization, roasting

Sep 1, 2012

By M. Narasimha

The flow in a hydrocyclone classifier is highly turbulent complex nature of multi-phase structure, which has led designers to rely on empirical mathematical models for predicting the performance. A number of classifying cyclone models have been developed and successfully used in mineral comminution circuit simulators over the past four decades (Plitt, 1976 and Nageswararao, 1978). However, most of the mathematical models currently available to describe hydrocyclone classifier performance are based on single average mineral density component behavior. In industrial comminution circuits, the feed to the cyclone composed of a mixture of particles of varying degrees of liberation and sizes. The behavior of multi-component particles in a hydrocyclone is poorly understood and unaccounted for in most of the mathematical model equations available in the literature. There is evidence from a number of experimental data sets indicating the significant influence of the multi-component particles on measured cyclone performance. A concept for modeling the performance of hydrocyclones based on multi-component behavior is proposed in this paper. A set of semi-empirical model equations for cut-size, sharpness of separation are presented and the corresponding model parameters evaluated from the measured data are given.

Sep 1, 2012

Micro-fine disseminated molybdenite was ground in a laboratory stirred mill using steel media and zirconium media respectively. The floatability of ground molybdenite and slurry chemistry was investigated. It was found that the total recovery of ground molybdenite using zirconium media was higher while the pH and Eh of the slurry are lower than that using steel media. When steel media was used, iron oxy-hydroxides had been generated coated on the surface of molybdenite, and decreased the floatability of molybdenite, especially of the -10µm particles. The iron and lead oxy-hydroxides was generated by the reaction between steel media with pyrite and galena associated with molybdenite. It was also found that changing the grinding media to inert can benefit the flotation of molybdenite. Keywords: stirred mill, grinding environment, floatability, micro-fine disseminated molybdenite, fine grinding

Sep 1, 2012