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By Mark Freberg

"IntroductionThis chapter is intended to provide information on the operation and maintenance of several pieces of equipment used in heavy media separation. Most heavy media separation circuits, particularly those involving bath separators can be considered as high maintenance areas. Because of this the efficient operation and maintenance of these circuits is very important if the cost per ton of material treated is to be kept to an acceptable level.Heavy media separation (HMS), is a process used to separate particles of different specific gravities. Under laboratory conditions the ideal way to separate two types of particles which have different specific gravities is to suspend them in a heavy liquid which has a specific gravity between those of the two types of particles. Those particles with the lower specific gravities will float on top of the liquid while the higher specific gravity material will sink to the bottom. Given enough time and a sufficient volume of heavy liquid this process will be essentially insensitive to the sizes of the particles involved.Heavy media separation circuits make use of the same principles described above. The material to be treated is introduced into a mixture of finely ground solids, called media, and water which takes the place of the heavy liquid; the mixture of solids and water is known as medium. The separating force can be either gravity or centrifugal force. The type of solids used as media varies but it is usually a high specific gravity material such as magnetite, galena or ferrosilicon.Heavy media separation is used extensively in the cleaning of coal and to a lesser extent as a preconcentration step in base metal and iron ore operations."

Jan 1, 1989

By Colin G. Wilson

This paper considers the heavy liquid laboratory tests used to determine the amenability of a potential ore to the heavy media process. The results of the laboratory testing are correlated to actual plant performance and establish design parameters for the heavy media process. These parameters are used in the development of the metallurgical flow sheet and in the sizing of equipment in the metallurgical plant design.

Jan 1, 1978

By E. L. Michaels

Laboratory and pilot scale tests have been made to deter- mine the utility of heavy media separation, particularly a cone type separator, as a means of recovering aluminum from shredded municipal solid waste. The effect of the method of shredding on the behavior of aluminum in a heavy media system was deter- mined. Two-stage pilot scale heavy media separations were made with size fractions of shredded refuse. Recoveries of aluminum, as well as other components of the refuse, were measured and medium losses were determined. The experimental results indicate that with certain reservations a heavy media cone system can be utilized for aluminum separation and recovery from shredded and air classified municipal solid waste. Observations made using two-stage heavy media separation in a drum unit are included. Qualitatively, the results from the two types of separators are similar.

Jan 1, 1974

By W. L. Freyberger, H. Alter, K. L. Woodruff, E. L. Michaels

Laboratory and pilot scale tests have been made to determine the utility of heavymedia separation, particularly a cone-type separator, as a means of recovering aluminum and other values from shredded municipal solid waste. The effect of the method of shredding on the behavior of aluminum in a heavy-media system was determined. Two-stage pilot-scale heavy-media separations were made with size fractions of shredded refuse. Recoveries of aluminum, as well as other components of the refuse, were measured and medium losses determined. The experimental results indicate that with certain reservations a heavy-media cone system can be utilized for aluminum separation and recovery from shredded and air-classified municipal solid waste. Observations made using two-stage heavy-media separation in a drum unit are included. Qualitatively, the results from the two types of separators are similar.

Jan 1, 1976

By Frank F. Aplan

Introduction Heavy media separation (HMS), also called dense media or float¬sink separation, is one of the newer forms of gravity concentration. Though the concept can be traced to the last century, the process has enjoyed its major growth since 1940. Heavy liquid separation is a mutation. The heavy media process is used extensively to clean coal and for the concentration of a wide variety of ores such as those of iron, lead-zinc, chrome, manganese, tin, tungsten, fluorspar, magnesite, sylvite, garnet, diamonds, gravel, etc. It may be used where ever a significant density difference occurs between two minerals, and commercial separations are typically made in the range of 1.3 to 3.8 sp gr. The particle size treated ranges downward from 6-8 in. top size. Particles greater than about 1/16-in. (10 mesh) may be treated in a "static" bath, though for reasons of separation efficiency, + 1/2 -in- feed is usually preferred. For particles less than this size, separation in a heavy media cyclone is generally used. The flowsheet of a typical heavy media process, in this case one using a ferrous medium, is shown in Fig. I. In essence, the process consists of: (1) preparation of the feed usually by wet screening to remove undesired fines, (2) heavy medium separation, and (3) removal and recovery of the medium from the separated products. Many muta¬tions of the basic scheme are possible and numerous options are possi¬ble. HMS offers the following potential advantages:12 1) Ability to make sharp separations. 2) Ability to change the specific gravity of separation quickly to meet changing conditions. 3) Ability to remove products continuously. 4) Ability to treat a broad size range of products. 5) Ease of start-up and shutdown without loss of separating efficiency. 6) Relatively low medium cost and low media losses. 7) Low operating and maintenance costs. 8) High capacity with the use of relatively little floor space. 9) Relatively low capital investment per ton of capacity. The process may be used to produce a finished concentrate, two finished concentrates, or a concentrate and a middling of differing quality, or a preconcentrate by rejection of unwanted gangue. It is an ideal method for the reprocessing of coarse waste dumps. The greatest use for the process lies in coal cleaning and in the preconcentration of ores. The relatively inexpensive heavy media process may be used advantageously to reject large quantities of coarsely crushed gangue. When used in this way, the process will allow: (1) the use of lower cost but less selective mining methods with the "overbreak" material being removed at the front end of the concentrator or preparation plant; (2) a substantial reduction in the quantity of ore that must be finely ground for subsequent mineral liberation and separa¬tion. Since comminution is often the single most expensive step in beneficiation, it is desirable to eliminate as many essentially barren pieces of rock as possible before the grinding step, (3) a decrease in overall plant capital cost per ton of concentrate since the size of the plant from the dense medium step onward will be smaller. Several general references are available,12-18 though much of the technical data on the process is widely scattered in the general litera¬ture. Heavy Liquid Separation Organic Liquids Given sufficient settling time, it is possible to make a perfect separa¬tion between two particles of differing density by placing them in a liquid whose density is intermediate between the two. This means of achieving a perfect separation has proven to be elusive because of problems in feed preparation, particle settling rates, operational considerations, and economic constraints. There are a wide variety of heavy liquids that could be used, most of them halogenated hydrocarbons, and a few typical examples are given in Table 4. These liquids are most commonly used in ore dressing for the laboratory fractionation of ore particles on the basis of specific gravity. Laboratory Separations. Using liquids typified by those given in Table 4, separations are made to develop either the standard washability curves used to estimate the response of a given sample to gravity concentration or to prepare a partition curve to evaluate the effective¬ness of a given gravity separation process or piece of equipment. A typical washability curve is given in Fig. 2.19 Such curves are generated for raw coal, e.g., by treating either the whole or various size fractions of the sample in a series of heavy liquids and analyzing the various specific gravity fractions so produced. The procedure is relatively simple for coal samples because of the ready availability of a wide variety of relatively low cost heavy liquids in the density range 1.2¬-2.0. For ores the problem is much more complicated, because only a few high density liquids, all of rather high cost, are available. Parti¬tion curves are generated in the same manner by treating the separated products in the same liquids. Greater details on the procedures to be used in heavy liquid separa¬tions are to be found in the literature (for coal, Refs. 13, 14 and 19 and for ore, Refs. 20 and 21). For testing coal, calcium and zinc chloride solutions have been used extensively in the past, though today halogenated hydrocarbons (available under the trade name Certigrav) are the preferred media. The liquids shown in Table 4 may

Jan 1, 1985

By Edward Skolnik

The concept of using fluid dense media to separate heavy ore constituents from the lighter gangue dates back to 1858, when it was patented by Sir Henry Bessemer. Its use in coal did not begin until after 1917, however, when Chance invented a process (which bears his name) in which lighter coal floats in a suspension of fine sand in water while heavier refuse sinks. Conklin used fine magnetite in suspension as a medium for floating anthracite in 1922, DuPont designed a plant employing organic liquids in 1936, and Belknap used a solution of calcium chloride (which Bessemer had suggested, among other media) in 1937. Separation of magnetic media by magnetic separators from the suspensions in which they were carried was introduced in a Butler Brothers ore concentrator pilot plant in 1937. The media first used were crushed steel and various grades of ferrosilicon. Since 1940, when American Cyanamid used magnetic separators to recover and clean magnetite in a coal washing circuit, virtually all heavy medium circuits have been of that type. As long as static baths are employed, as they are in the processes above, coal smaller than 9.5 mm or 6.4 mm cannot be cleaned economically in heavy medium. The settling velocities of the fine material are very low, and consequently the time required to separate the lighter coal from the heavier refuse becomes excessive. In addition, stray currents in the vessel and the upward velocities induced to keep media solids in suspension affect the finer solids to the degree that physical size becomes a more important factor than specific gravity.

Jan 8, 1980

By David G. Chedgy, Edward A. Zawadzki, Robert D. Stoessner

Extensive research and testing in commercial facilities has clearly demonstrated that heavy medium cyclones are the most effective process for cleaning a 0.6 x 0.15mm (28 x 100 Mesh) coal at low separating gravities, less than 1.35. This paper describes testing performed to deter- mine system characteristics at these lower gravities and the type of circuitry required to maximize performance. The results of these studies include both pilot and commercial scale tests of cleaning 0.6 x 015mm (28 x100M) coal.

Jan 1, 1988

By Carter LC

Following the perception by the Groote Eylandt Mining Company of a need to further beneficiate a fines product, and preliminary metallurgical testing to demonstrate the feasibility of such beneficiation, a comparison was made of the various configurations of cyclonic heavy medium separators available. This comparison consisted of (i) a pilot plant test in which a dynawhirlpool (DWP) and a pump fed cyclone were compared, and (ii) a survey of operating plants using the systems under consideration. Little metallurgical difference was found-between the different systems. The gravity fed cyclone configuration was finally chosen based on a particular need to minimise degradation of ore and on a desire, in so isolated a location, to use established and locally supported technology.

Jan 1, 1987

Heavy medium separation is widely used because of the precision of separation achievable and the flexibility of control. Good design is manifest in the eventual achievement of the operational objectives. These objectives which take account of the assessed quality of raw feed, market requirements and production cost levels need to be carefully prepared and realistic.

Jan 1, 1987

The Sishen iron-ore-mine produces 3 pro= ducts with size gradings of 25 to 8 mm, 11 to 5 mm and 5 to 0,2 mm and has a product capacity of 20 Mtpa. Ore is produced at an average Fe content of 66,2 % Fe for the two coarser pro= ducts and an average of 65,3 % Fe for the fine ore product. Three stage crushing is practised to re= duce the run-of-mine ore to -90 mm after which it is screened into five different size frac= tions of which four are heavy media beneficiated in static baths and cyclones and the fifth frac= tion discarded to slimes dams. A final three stage crushing and screening process is employed to produce the final three Products which are homogenized by means of blen=ding systems nrinr to despatch.

Jan 1, 1987

By C. P. Broadbent

Due to growing .public awareness of environmental issues and greater sensitivity towards waste management, many countries around the world are implementing more stringent legislation governing the storage and disposal of hazardous wastes containing heavy metals such as As, Sb, Pb, Cd or Hg. These wastes can no longer be dumped without providing clear guarantees that the material concerned is environmentally safe and will not leach toxic elements to the surroundings. In the Netherlands the current dumping charge for chemical waste (i.e. worst category) is $280/t, and for industrial waste this cost reduces to $75/t. If the material can be reused there may be a small positive credit for selling it, for example discard slag as an aggregate to the construction industry. A number of (pyre)-metallurgical operations, mostly associated with the extraction of metals from sulphidic ores, produce arsenic residues in the form of As2O3 containing flue dusts and speises. If the flue dust is of high purity it can be sold, though many traditional uses are being substituted by other materials. In many cases upgrading the quality of the arsenical dusts is not possible for either technical or economic reasons. Traditional practice is to dissolve these dusts in acid prior to precipitation as ferric arsenate, which is at present classified by many countries as industrial waste and can be dumped. Recent work, however, has cast doubt on the stability of arsenates for disposal and alternative disposal routes have been investigated. Tests have shown that up to 10% (dm) As can be incorporated into "glassy" silicate slags with very low levels of arsenic leaching in the cooled product. Calcium arsenate was added to a range of synthetic and industrial slags from the system SiO2-FexOy-CaO-A12O3-AsmOn, under mildly oxidising conditions and quenched subsequently in water. It would appear that this represents an environmentally acceptable method for the disposal of many arsenical residues and there is some optimism that this method will be equally applicable to the disposal of other toxic metal residues.

Jan 1, 1994

By Paul Dean Proctor

The known northern ore zones of the New Lead Belt of Southeast Missouri extend to the drainage divide between the Meramec River draining north and east and that of the Black River draining southward. Intensive geochemical studies related to the environmental impact of the new mining area have been carried out in the vicinity of some of the newly developed mines, mills and smelter complexes (Bolter,1970; Gale, et al, 1973; Wixson, et al, 1969, 1977). Other investigations have related to fringe studies of the Northern New Lead Belt and the possible additions of heavy metals to the surface waters, stream sediments and selected aquatic life (Proctor, et al, 1975, 1976). Similar studies have been completed in the Joplin area in the Tri-State district, and in the fringe area near Springfield, Missouri (Proctor, et al, 1974). A surface geochemical study is currently underway on the lead-zinc-copper-cobalt-nickel province near Fredericktown, Missouri (Proctor and Sinha, 1977). This report summarizes some of the distribution patterns of heavy metals in the waters, stream sediments and selected aquatic life in the Upper Meramec River drainage basin just north and west of the known northern portions of the New Lead Belt of Southeast Missouri. The region studied includes the site of the proposed and somewhat controversial Meramec Dam and the reservoir site behind it. Some 3905 km2 (1508 mi2) are included within the drainage basin of the Upper Meramec River. Six distinct drainage areas are included within the drainage basin; 1) a combined, lightly industrialized and farm area around Rolla and Salem, Missouri representing the Dry Fork drainage; 2) a primitive, mostly forested area with some farms and cattle rancheseast and north of Salem, Missouri comprising the Upper Meramec River

Jan 1, 1977

By Bhudeo N. Sinha, Paul Dean Proctor

Heavy metal contents in stream waters, sediments, and selected aquatic algae were determined for the upper Meramec River basin, Missouri, of 3905 km2 (1508 sq mi) area and site of the proposed and controversial Meramec dam and reservoir. Six distinct drainage areas within the basin are: (1) a lightly industrialized and farm area, (2) a primitive forested- ranch area, (3) an area which includes the Northern New Lead Belt, (4) the westward drainage of an old and extensive barite mining area, (5) the main trunk of the Meramec River, and (6) short north-divide tributaries of the Meramec River. Lower Paleozoic sediments rest nonconformably upon eroded and hilly Precambrian igneous basement. This locally rises as major inliers and also makes up the St. Francois Mountains to the east. Major lead, and lesser zinc, copper, cobalt, and nickel mineralization occurs in the buried Cambrian Bonneterre dolomite. Residual barite is present along the eastern fringe of the basin and is derived from the Potosi formation. Some 62 water samples, active stream sediments (AS), bank samples (BS), and 11 selected aquatic algae samples were collected in the various drainage areas and analyzed for copper, lead, zinc, cadmium, nickel, arsenic, and mercury contents. Heavy metals in water have a maximum range of 1-120 ppb (parts per billion), and this for zinc. The AS and BS sediments have orders of magnitude greater acid leachable metal contents in the -80 mesh fraction, with lead hawing the greatest range of 11-1028 ppm. Heavy metal content of stream-algae approaches that of the sediments in which they grow. Most anomalous heavy metal accumulations occur near mining and milling activities and in the streams draining such areas. Significant distortions of the primary dispersion pattern militate against geochemical exploration for hidden ore zones, but do demonstrate the mining, milling, and smelting activities of man, and sporadic mineral occurrences in younger horizons.

Jan 1, 1980

By J. L. Boyd

The mining and processing of basic metals relies on water as a medium for transport. Metallurgical ores are ground, concentrated, leached and refined in an aqueous medium. Water is used for temperature control during processing and in air pollution abatement during smelting. All of these process steps result in liquid wastes. Many of the aqueous wastes from ore processing areas become the raw product for a second stage and water recycling may begin. The point at which water recycling or reuse has been initiated in the past, rather than water discharge, was where water conservation was manditory due to a shortage, where process conditions would allow or benefit from reuse, and where economic considerations demanded reuse. The Fontana, California plant of Kaiser Steel Corporation is an example of an integrated steel plant that was forced to practice water conservation and reuse due to its location in an arid environment.1 Only a small amount of water required to maintain the water reuse system in balance with respect to dissolved solids and product quality is discharged. The Butte, Montana copper ore processing plant of The Anaconda Company obtains 66% of the water required for production by recycling, after clarification and chemical treatment, 30 MGD of wastewater from its tailings ponds. This operation is estimated to save the company about $1200/day over a once through water system.2 Here plant location and economics favored water reuse.

Jan 1, 1975

By R. Markovic

The objective of this research study was the investigation of heavy metal removal from wastewaters of the "SARAKA" stream by using low-cost materials. These wastewaters flow into Krivelj River and through the network of existing rivers into regional water reservoirs. Sawdust, cardboard and fly ash were used as reactive materials in laboratory studies. Sawdust was obtained from oak and fir-wood while fly ash from heating station Bor, bitter-oak and oak. Experiments were carried out using real Saraka stream wastewaters and the degree of removal for iron, copper, manganese and zinc was investigated. The content of these heavy metals in Saraka stream wastewaters was under the limit of III and IV class of water (Law on Water - Official Register of the Republic of Serbia). Parameters such as flow rate of water, pH and effluent volume, contact time between water and reactive material, etc, were monitored during the experiments. All used materials give satisfactory results for iron and other heavy metals removal; the highest degree of removal was obtained by using fly ash.

Jan 1, 2006

By D. Leppert

Large deposits of natural zeolites may provide cost-effective alternatives for treatment of soil and water contaminated ) with heavy metals and radionuclides. Research on the Bikini atoll demonstrated that addition of clinoptilolite to the soil significantly reduces cesium uptake by plants. Re- search on the potential use of zeolites in soils at Bunker Hill, ID indicated only minor benefits at very high contamination levels vs. US Bureau of Mines (USBM) work on the use of zeolites for treatment of mine waste waters emphasized problems with natural waters that previous studies have not addressed. High levels of competing calcium in natural waters significantly decrease the effectiveness of zeolites for heavy metal sorption and may limit the usefulness in these applications.

Jan 1, 1991

By D. Leppert

Clinoptilolite zeolite may offer attractive, cost-effective alternatives for remedial cleanup of old minesites, smelters and other sites with heavy metal contamination. Previous research demonstrates the relatively strong affinity of clinoptilolite for numerous metals and clinoptilolite displays a particularly strong affinity for lead (Loizidou and Townsend, 1987), one of the most toxic and problematic heavy metals. Since clinoptilolite can also selectively absorb some radionuclides and organic compounds, it may offer practical solutions to a wide variety of environmental problems.

Jan 1, 1989

By Keith E. Forrester

This paper presents results of laboratory and field optimization of a proprietary processes developed by FESI for the stabilization of heavy metal bearing wastes. The specific waste studies presented within the paper include foundry ash, aluminum sweat furnace ash and a heavy metal contaminated soil. The FESI process chemistry and engineered processes were found to be the most cost efficient demonstrated and available method of stabilizing heavy metals and highly successful in passing regulatory limits.

Jan 1, 1994

By G. Gaidajis

Sea water samples collected from coastal waters in the vicinity of the Stratoni mining operations, in North-Aegean Sea were analysed for dissolved metals and elements. The maximum concentrations observed were one to three orders of magnitude lower than the environmental limit which coincides with the quality of sea waters suitable for swimming purposes. The quality of the coastal sea waters are affected by the natural mineralization of the area and the urban activities drained through local small rivers, the past mining activities present in the sea bottom sediments in the form of disposed tailings, and finally by the presence of the adjacent Mill-Flotation Plant. The relative importance of the treated final effluents discharged from the mining operations is considered to be insignificant.

Jan 1, 2006

By F. Sachanidis

The lignite surface mines of Ptolemais basin operate according to special environmental terms regarding the concentrations of heavy metals and trace elements in water discharges. Based ?n the results of lab analyses and in-situ measurements conducted so far it is concluded that the concentrations of heavy - toxic metals and other trace elements are low or negligible. The deviations from the upper concentration limits specified by laws and regulations are rare and non-systematic both on their spatial or temporal distribution. The same results prove also the relation between water quality and type and nature of the sediments forming the Ptolemais basin and the carbonated and metamorphic rocks forming the surrounding mountain areas.

Jan 1, 2006