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By M. Rudolph, D. H. Hoang, N. Kupka

"Froth flotation has been subjected to modelling since the 1930s and there is a large variety of approaches that intend to portray the entire process. Among these, three fundamental models could be considered exhaustive: the Pyke model [1], the Yoon model [2] and the Schwarz and Koh model [3]. The first model makes use of the generalized Sutherland equation collision model, the Dobby-Finch attachment model and its own stability model, the second model considers an extended DLVO approach for the attachment and stability whereas the third model makes use of computational fluid dynamics. Using a scheelite ore as a test case, a specific batch flotation test was repeated ten times and analyzed for chemical assays, mineralogical studies and froth properties. The detailed data are used to feed the three flotation models aforementioned in order to compare the outcomes of the three approaches, their capacity to reflect reality and to predict it. This article intends to pave the path towards reliable process models incorporating in depth mineralogy information, e.g. surface liberation, particle size and particle shape. KEYWORDS Froth flotation fundamental models, scheelite, automated mineralogy, critical assessment. INTRODUCTION In mineral processing, only three approaches aiming at describing froth flotation fundamentally could be considered exhaustive: Pyke’s collision and sliding approach [1], Yoon’s kinetic approach [2] and Schwarz and Koh’s approach [3]. The models will hereafter be referred to as Pyke model, Yoon model and Schwarz and Koh model. The first model makes use of the generalized Sutherland equation collision model, the Dobby-Finch attachment model and its own stability model, the second model considers an extended DLVO approach for the attachment and stability whereas the third model makes use of computational fluid dynamics. All three approaches rely on the widely accepted idea that flotation is a kinetic reaction dependent on a flotation rate constant kp, as expressed in Eq. [4]:"

Jan 1, 2018

By H. G. Hedlund

Tailings in Mining Industry can be handled in different ways. Today tailings disposal is in focus by projecting new plants as well as treating and handling of old Tailings dams.The trend today is to process minerals, detoxify the Tailings and place them as dry surface Deposition or Underground Backfill. This paper will briefly present five different Mining plants in North and Central America, where Tailings have to be dewatered for dry depositing. The Metso-Sala VPA is a filter especially developed for dewatering and drying of Mineral Concentrate and Mineral Tailings. Keywords: tailings disposal, dewatering, drying, mineral tailings

Sep 1, 2012

"This research represents a shift away from empirical models that lock the industry into 50-year old inefficiencies with little response to operating variability. The mechanistic and intrinsically dynamic mill model under development steps up to a new paradigm using the latest computing capabilities and physical understanding of breakage and transport to transform predictive capabilities for design, optimisation and on-line control with variable feed. The milling process is broken down into discrete sub-processes, each of which can be modelled as an object in the whole model and in the model code. These objects can be upgraded or exchanged without having to rewrite or restructure the remainder of the code. Sub-processes include: feed into mill; transport along mill; presentation to impacting events; range of impacting forces; probability of being impacted in different zones in the mill as a function of particle size and density; suspension in slurry; and discharge out of the mill. The unit and processes surrounding the mill (feed and recycle conveyors, slurry pump and pipe, cyclone and recycle crusher) have also been modelled, in order to incorporate the effect of recirculating load coming from a cyclone or a recycle pebble crusher, respectively for ball mills or SAG mills. Each unit is modelled dynamically and PID controllers have been added to control pumping flowrate from sump and water addition for cyclone feed dilution. The paper demonstrates the predictive capability of a dynamic, mechanistic model and is used to test the sensitivity to the sub-processes, comparing different formulations and highlighting the aspects that require further development. Validation on pilot tests and application to industrial data is presented. This approach is currently undergoing industrial trial on sites, for use in on-line model-informed process control. Considerable further development is required to incorporate the full mechanistic structure planned for this model."

Jan 1, 2018

By Seher Ata

This paper is concerned with the coalescence behaviour of two bubbles in dilute solutions of cetyltrimethylammonium bromide, methyl isobutyl carbonil and triton x-100. Two bubbles were produced at the tips of adjacent capillaries and the time elapsed between the first contact of the bubbles and film rupture was determined by means of a high speed camera. It was found that the amount of surfactant required to stabilise the bubbles increased in order of CTAB>TX-100>MIBC. The probability of coalescence decreased sharply with increasing surfactant concentration in CTAB and TX-100 solutions while with MIBC each bubble pairs resulted in coalescence, giving hundred per-cent coalescence probability.

Jan 1, 2014

There are some problems in the beneficiation of fine-grained oxidized iron mineral such as high cost, severe sliming, poor results and low recovery due to the fine disseminated size of the mineral. Taking several representative types of finely-disseminated oxidized iron minerals as examples, the author analyzed the main difficulties in the beneficiation of such kind of ores and discussed the existing problems in grinding-classification, technological process, flotation reagents and separation equipments and the resolvents of these problems.

Jan 1, 2014

By Walter W. Focke, Zola Kwela, Willem van der Merwe, Arao Manhique

"The advantages of the de Wet zirconium process for the manufacture of AZST from zircon sand include: Fewer processing steps; removal of radioactivity by leaching rather than by precipitation; alkali reagent recovery in the form of a sodium silicate solution that is essentially free of radioactivity; fewer waste streams and less waste to discard.Here we report on our efforts at maximizing the alkali recovery in the sodium silicate product stream: Milled zircon, d50 ˜ 9 µm, was fused with caustic soda pearls in open reaction vessels at temperatures between 650°C and 850°C. Fusion times of 1, 2, 4, 24 and 336 hours (with intermittent milling) were investigated.For prolonged fusion times the fusion products approached equilibrium compositions. However, the phases Na2ZrSiO5 and Na4Zr2Si3O12 observed at 850°C did not form at 650°C. Since they do not hydrolyse in water they limit the recovery of alkali. For 2-hour fusions a broad spectrum of non-equilibrium reaction-products, that are rich in sodium silicates, is formed. Optimum process conditions, with respect to NaOH recovery, correspond to a 2:1 stoichiometry and fusing for 2-hour at 850°C. At these conditions the alkali recovery is ca. 78% and the zirconia yield is ca. 57%."

Jan 1, 2003

By C. S. Gundewar

About 90% of the barytes produced the world over is used for oil and gas drilling as weighting agent in drilling mud to control pressure, prevent blow out and provide lubrication. This is because of its unique properties like high specific gravity, water insolubility and intentness. India is one of the leading producers and exporters of barites. The Mangampeth Baryte deposit in Cuddapah district of Andhra Pradesh, India being the largest single deposit in the world having a reserves of about 80 million tonnes. Approximately 50% of the total reserves of grey barites of Mangampet deposit assays less than 92% BaSO4, the minimum stipulated grade for oil and gas drilling industries. To reach and recover the high grade barite, the overlying low grade has necessarily to be mined out and removed. At present this is being stacked separately at the mine site involving lot of labour and transport cost. Considerable barites is contained in the dumps adversely affecting the conservation and creating lot of environmental hazards. IBM being the premier organization in India in the field of conservation of minerals and environmental protection in mining has recognized the importance of adverse effect of these huge dumps at site. The Ore Dressing Division of IBM, Nagpur has characterized these dumps and developed the flotation process on a sample assaying 66% BaSO4 and 23.3% SiO2. The flotation concentrate obtained assayed 93.7% BaSO4, 2.38% SiO2 with BaSO4 recovery of 80% and meets the requirement of the oil industry. The flotation concentrate being non-wetable, can not be used as such as weighting agent, and hence the collector coating on the concentrate was removed either by acid treatment or heating to make it water wetable. The concentrate was 92% -325 mesh and having a specific gravity 4.3. The barites concentrates so produced meets the size, grade and specific gravity specifications required for use in oil drilling industry. Apart from the financial benefits the process augurs well for the commercial exploitation of these huge dumps in terms of (1) additional recovery of these valuable minerals and conservation, (2) reduction in dumps value, (3) improvement in environment and offering an excellent potential for export.

Jan 1, 2014

By Jochen Petersen, Steven Bradshaw, Guven Akdogan, Ngoie Mpinga, James Mwase, Jacques Eksteen, Cornelius Snyders

"The platinum group metals (PGMs) and associated minerals are particularly refractory to most traditional direct leach processes. However, the remoteness of many new ore deposits, socio-political risks, the scarcity of skilled labor and constraints on the availability of water and electrical power makes it increasingly more difficult to implement the conventional mill-float-smelt-refine process routes to extract and refine PGMs in remote areas. This paper discusses a process to extract PGM’s from low grade ore and concentrate using a sequential stage heap leach process entailing heap bioleaching and high temperature cyanide leaching, and evaluates the feasibility of implementing a carbon-in-pulp process to recover the PGMs from the pregnant leach solution. The heap bioleaching extracts the base metals in an acidic sulfate medium using a mixed culture of thermophiles. After heap bioleaching the heap is reclaimed, rinsed, agglomerated and restacked for high temperature cyanide leaching where the cyanide liquor is directly heated via solar energy in panels. Palladium, gold and platinum are recovered during the cyanide leaching stage. The pregnant leach solution was evaluated for potential carbon-in-pulp adsorption and subsequent elution similar to gold processing. The kinetics of adsorption and elution compared well with gold adsorption and elution."

Jan 1, 2014

By E. V. Zelinskaya

"Mineral and industrial raw material mining and preparation make a negative impact on the environment. The main types of impact are the land resources gathering, soil and water balance disturbance, surface-water, underground space and atmospheric air pollution, as well as the vast amount of solid and liquid waste production. Considerable attention in recent decades has been given to waste recycling. The task is to maximize the use of both newly formed and accumulated solid and liquid wastes. The mining and mining and smelting enterprises industrial waters are a very promising source of secondary hydromineralic raw materials. They have high concentrations of not only calcium, sodium, but also, for example, lithium, rubidium, heavy non-ferrous metals. In general, unfortunately, we have to state that today there is no wide practice of extracting valuable components from waste enrichment, as well as processing of man-made waters to extract metals from them. The quantity of extracted components from underground, and furthermore passing waters, is insignificant. At the same time there is a tendency to increased demand for rare metals: Sr, B, Br, I. This is explained by their wide use in many industries. For example, the consumption of lithium products is steadily increasing. The obtained results showed that in the liquid phase in connection with high salt content and a significant difference in the macro- and microcomponents contents, conditions are initially created for the microcomponents selective isolation possibility. The identified conditions realization is most possible in such technological processes as cryotechnology, sorption and ion flotation. There is an urgent need to expand research in this direction and to recognize as a publicly important task the mining and industrial waste processing full-scale introduction into the practice of operating mining and processing enterprises and iron and steel companies.INTRODUCTION Mineral and industrial raw material mining and preparation make a negative impact on the environment. The main types of impact are the land resources gathering, soil and water balance disturbance, surface-water, underground space and atmospheric air pollution, as well as the vast amount of solid and liquid waste production."

Jan 1, 2018

By Wantae Kim, Hoon Lee, Kwanho Kim, Sangbae Kim

Mechanochemical activation of starting minerals and their effect on the solid-phase synthesis and properties of ceramics with lower thermal expansion coefficient was examined. The mineral mixture, pyrophyllite-gibbsite-lithium carbonate, was prepared for the synthesis of ?-eucryptite (Li2O•Al2O3•2SiO2). Dry grinding using a planetary ball mill promoted the amorphization of the starting mixtures. XRD and FT-IR results showed that the crystallization of the target materials occurred from the ground mixtures by calcination. The crystallization of them increased with increment of grinding time and calcination temperature. In the synthesis, the trace of undesired phases such as quartz and cristobalite once formed during calcination at the temperature range from 750 to 850 °C almost disappeared and monophase ?-eucryptite was formed in the ground mixture at 950 °C. The lowest liner thermal expansion coefficient (TEC) of ?-eucryptite prepared was -2.5x10-6•°C-1. The thermal expansion behavior characteristics of the calcined

Jan 1, 2014

By A. Bahrami

Andalusite, silimanite and kyanite are polymorphs of aluminosilicate known as kyanite group. Minerals of this group are used in refractory. Sarband andalusite deposit is located in Markazi province in Iran. Mineralogical studies showed that the main minerals of this sample are andalusite (5%~10 %), mica, quartz and feldspar. Processing of the samples was carried out using two sizes, i.e. +500 µm and -500 µm. In the processing of +500 µm scrabble test was carried out on -4750 +500 µm and -2380 +500 µm. For -500+300 µm shaking table and magnetic separation were applied. For -300 µm fraction, flotation was carried out. The results of this tests showed that the processing of Shazand andalusite was not possible, because silica and iron impurities were diffused inside the andalusite mineral grains.

Jan 1, 2014

By M. Saghaeian, R. Hejazi, L. Hosseini, M. Zare

Difference between plant feed specifications in practice and design feed is a problem that most of processing plants face during operating and commissioning. This topic has led to inappropriate operating and necessitates repeating the basic tests on new feed. Gol-E-Gohar fourth concentrate line with a capacity of 2 MTPY, located in Kerman province, is the first iron concentrate plant in Iran in which High Pressure Grinding Roll (HPGR) technology has been applied. Plant&apos;s feed consists of 30% AG mills pebbles of lines 1-3 and 70% run of mine crushed ore whose Fe=51%, Fe/FeO=2.5, S=1.7% and work index=15 kWh/t. Desired concentrate has Fe>68% and S<0.7%. After the plant construction and operation commencement, providing design feed was not possible due to the crushing unit`s not being complete, therefore the plant was fed by AG mills pebbles. For predicting optimal conditions of the plant and investigating the possibility of improving the current concentrate specifications, sampling from the new feed and laboratory and pilot tests was performed again. Studies showed that new feed has Fe=41%, Fe/FeO=3.5, work index=17 kWh/t. Results of laboratory tests with Davis tube device and pilot tests run using magnetic separators with simulating the plant`s circuit showed that with current feed, achievable recovery in industrial scale would be 75.52% which compared to plant&apos;s recovery in studied period (75.94%) shows that plant operated in optimal conditions. To improve the current concentrate specifications (Fe=66%, S=1.03%, Ferec=75.94%) and for achieving desired concentrate, samples were reground to four fractions with k100= 300, 212, 100, 45 and Davis tube tests were performed on each of the samples separately. Results showed that the fraction whose k100=212 µm or k80=200 µm has respective Fe and S grades of 68.27% and 0.681% which are consistent with the desired concentrate.

Jan 1, 2014

By M. Brozek

The particle settling velocity is the argument of separation in such processes as classification and enrichment in jigs. It characterizes material forwarded to the separation process and belongs to the so-called complex arguments because it is the function of particle density and size. i.e. the function of two simple arguments. The affiliation to a given subset is determined by the values of two mag-nitudes and the distribution of such argument in a sample is the function of distributions of particle density and size. The paper will present a method of determining the distribution of settling velocity in the sample of spherical particles for the turbulent particle motion in which the settling velocity is expressed by the Newton formula. Because it depends on density and size of particle which are random variable of certain distributions, the settling velocity is a random variable. Applying theorems of probability, concerning distributions of function of random variables, the authors will present general formula of probability density function of settling velocity for the turbulent motion and particularly calculate probability density function for Weibull?s forms of frequency functions of particle size and density. Distribution of settling velocity will calculate numerically and perform in graphical form.

Jan 1, 2014

By Ghislain Bournival, Seher Ata, Graeme J. Jameson

A common method to prevent bubbles from coalescing in a flotation cell is by the addition of surfactants, called frothers. The gas dispersion properties in a column were tested for solutions of 1-pentanol, tri(propylene glycol) methyl ether, and poly(propylene glycol) in the presence of sodium chloride. The dependency of surfactant on the gas holdup can be divided into regions. It seemed that for a sufficiently low concentration of surfactant, even a stronger surfactant could show a transition in gas holdup from constant/decreasing to increasing with concentration. This region, however, was not marked by a decrease in the average bubble size. In addition, PPG gave higher gas holdup values while averaging larger bubbles. On the other hand, sodium chloride mostly affected the gas holdup when the concentration was high enough to prevent bubble coalescence. Another parameter affecting the gas holdup was the superficial gas velocity. A linear dependency was found between the two under a bubbly flow regime. The current study showed that both surfactants and salt could slightly affect the influence of the superficial gas velocity on the gas holdup.

Jan 1, 2014

By Carlos Collado, Oscar Jimenez, Francisco Diaz, Rodrigo Bernal, Carmen Salinas

Water is a strategic resource for the mining industry. The rising cost has forced the industry to become more efficient in their use, reduce and recycle waste as much as possible. The importance of having a reliable water balance is increasingly urgent, because the resource is scarce and vital to the sustainability of human life, animal and ecosystem. Conventional flowmeters can suffer disruptions or failures by corrosion, fouling, presence of elements in the water as acids, salts and suspended solids. Use of radiotracers is advantageous to determine fluid velocities that are transported through pipes, as they are detectable by means of the radiation emitted, the same way for surface flows, such as natural watercourses and drainage from tailings dams, fluorescent tracers are those with the best advantages. For velocity measurements in pipelines a Iodine-131 tracer solution, around 5 mCi was injected into the suction of the pumps. The technique used is the transit time between detectors at known distances and determining the time of passage of the radiotracer. For measurements of surface fluxes using the fluorescent tracer Rhodamine WT by tracer dilution technique, injecting the tracer at a constant rate and measuring it known concentration diluted downstream. This work has been performed in Minera Los Pelambres, located in the IV Region of Chile, measuring the flow rate pumped from 12 pools with 1-7 pumps operating, obtaining speeds of 0.56 to 2.62 m/s. In pumping wells three facilities have been measured at speeds of 0.111-0.223 m/s, plus six surface flows with flow rates of 8.45 to 357.2 L/s.

Jan 1, 2014

By Lucy van de Ruit, Megan Becker, Aubrey Mainza, Jenny Wiese

"UG2 chromitite ore is a complex, highly disseminated platinum ore from the Bushveld Complex in South Africa, with typical platinum group mineral (PGM) grain sizes below 15µm. The introduction of stirred mills to the platinum industry has enabled grinding to finer product sizes, which has improved liberation and recovery of the finely grained PGMs. However, reduction in particle size leads to an increase in chromite entrainment in the flotation concentrate, which has a negative impact on the subsequent smelting process. Factors such as particle size, froth structure, solids concentration and water recovery have all been identified as impacting entrainment, but whether particle shape also has a significant effect is unclear. The purpose of this study was to determine whether the recovery of chromite particles by entrainment during the flotation of UG2 ore is affected by particle morphology. A laboratory vertical stirred mill with inert ceramic media was used for grinding UG2 ore which was then floated in a batch flotation cell. Flotation feed and concentrate samples were analyzed using QEMSCAN to quantify the angularity and aspect ratio distributions of the particles. The stirred mill product was found to have relatively broad aspect ratio and angularity distributions, with the major mineral components (chromite and silicates) having very similar shape characteristics. Analysis of flotation feed and concentrate samples suggested that particle shape does not have a significant effect on chromite entrainment."

Jan 1, 2014

By M. Ito

Cobalt-rich ferromanganese crust and nodule ores from seamount areas contain volcanic and sedimentary rocks as substrate or nuclei and these ores require mineral processing to remove the substrate/nuclei rock before smelting. This paper reviews the results of jig separation and air table treatment for the coarse fraction and flotation and hybrid jigging for the fine fraction. Using these techniques substrate/nuclei rock was removed from the cobalt-rich ferromanganese oxide components. The mineralogical properties and metallurgical treatment methods including hydrometallurgical treatment of low grade ore is also reviewed.

Sep 1, 2012

By Ho-Seok Jeon

The separation in gravity concentrators is based on the density difference between valuable and gangue minerals. In addition to density, many auxiliary parameters like particle size, shape, feed rate, pulp density etc. plays an important role in the separation. The performance efficiency of gravity units is largely based on the interference of such auxiliary parameters during separation. Many gravity concentrators are used for the beneficiation of cassiterite ores and performance of which are varying with different feed material, particle size and required enrichment from the unit. Selection of gravity units is generally based on laboratory testing and data collected from the previous experience. In the present investigation cassiterite ore collected from Uljin deposit, South Korea has been subjected to various gravity units like jig, spiral, and Knelson concentrator with the intension to pre-concentrate the ore. Second stage concentration was carried out using shaking tables. The article mainly summarizes performance evaluation methods employed for gravity concentrators. Selection of gravity circuit for the beneficiation of cassiterite was made on the basis of the recovery-grade curve, and Tromp curve methods. Keywords: cassiterite, gravity concentration, recovery-grade curve, sink-float test, tromp curve

Sep 1, 2012

By P. Fawell, C. Castillo, C. Ihle

"The need to reduce fresh water consumption has pushed many Chilean mining companies to utilize seawater obtained from distant locations. At the same time, increasing amounts of fine particles in copper tailings raise new operational challenges, in particular, the thickening and transport of tailings featuring significant fine fractions, which are predominantly clays. In the present paper, we study the role of salinity – using seawater and NaCl – on the flocculation efficiency of copper sulphide tailings to which kaolinite was added. To mimic the water recovery stage in thickeners, flocculation has been induced in jar tests and the corresponding aggregate size distribution has been estimated from chord length distribution data obtained using a focused beam reflectance measurement (FBRM) probe, at various mean turbulence intensities. Results show that for constant flocculant dosing, a measurable influence of the salt on the resulting aggregation exists. For each case, resulting optimal turbulence levels are also reported, a particularly interesting feature when comparing flocculation efficiency of the coarse and fine fraction. INTRODUCTION The concentration of copper minerals through comminution and flotation is intensive in the use of fresh water. The need to reduce the consumption of fresh water and the environmental standards associated with increasingly demanding mining operations have driven improvements in the techniques of recovering water from tailings. The challenges are even greater when required to treat minerals with high clay contents. In Chile, kaolinite is one of the most important clays to consider due to its abundance in the tailings from many operations. The most common and highest throughput unit operation in the mining industry for the recovery of water from tailings is gravity thickening, with sedimentation of fine particles assisted by flocculation. Flocculation is the process of forming aggregates by contacting the suspended particles with a flocculant. The flocculant is typically a water-soluble synthetic long-chain polymer, where copolymers of acrylamide and sodium acrylate are the most common types used in the Chilean mining industry. The aggregation mechanism includes the following key steps: (1) flocculant distribution through the suspended particles, (2) flocculant adsorption onto particle surfaces, and (3) collisions between particles leading to polymer bridging to form aggregates, but concurrently (4) breakage of aggregates becomes a factor under prolonged shear (Gregory, 1988)."

Jan 1, 2018

By Lev Filippov, Lorène Dessalas, Inna Filippova, Yves Foucquet

"Seafloor massive sulphide (SMS) deposits, similar in composition and genesis to terrestrial volcanogenic massive sulphide deposits, are generally found in volcanic seafloor environments along major rifts and mid-ocean ridges. Theyare associated to extensional tectonic settings such as nascent-arc, rifted-arc and back-arc environments. They may represent important source of base metals and be an alternative to on-land resources. Seafloor massive sulphide deposits have particular mineralogical compositions and textural features differentiating them from terrestrial one. When extracted from salty water and exposed to the ambient air, massive sulphide samples strongly oxidize and soon become covered by thin layers of iron, copper and zinc rich sulphates and oxides, as well as elemental sulphur. The textural properties vary according to the degree of maturity and the sample position within the hydrothermal deposit. The total porosity of that type of samples is also relatively high, especially for immature samples such as black smoker chimneys, which can reach 15% of total porosity. Because the secondary mineralization and porosity level are different, seafloor massive sulphides ores respond differently from terrestrial ore to processing methods. Froth flotation, commonly applied to separate all type of sulphides from the gangue, is one possible technique for processing seafloor ore. Sulphide recovery rate is, in most cases, excellent (>90%) however separation of the various mineral phases is difficult to obtain even when applying known methods used for terrestrial ore. Moreover, the flotation behaviour decreases drastically with the time of conservation at the surface, even when the samples were stored in a confined environment. High pH values, which is a good way to depress pyrite and therefore to favour the flotation of copper and zinc sulphides, do not have the same effect on seafloor ore. Consequently, careful flotation procedure must be elaborated to obtain efficient mineral separation technique for this specific marine ores."

Jan 1, 2014