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By K. C. Corin, M. S. Manono

The drive to reduce water usage globally has led to the mining industry reassessing its water usage - owing to past environmental degradation due to effluent discharge, tailings disposal and process water seepage into the water-table (Haggard et al., 2015). Factors such as water scarcity and environmental restrictions have created the necessity for recycling of process water in mining and other industries. Water recycling, however, causes an accumulation of ions in the process water, which may affect the strength of reagent action on the target mineral and in turn critical aspects of flotation may be impacted. Prior studies have shown that certain ions have specific effects on flotation: for example, calcium and copper have been found to enhance the adsorption of depressant onto gangue (Feng et al., 2013, Wang et al., 2016). Calcium and sulfate ions have been seen to give a higher concentrate grade than other ions present in process water (Manono et al., 2012). An increase in ion concentration will increase the mineral grade due to a decrease in entrainment (Corin et al., 2011). This study considers the impact of ion accumulation on reagent action and flotation response. Keywords: Flotation chemistry, water quality, ionic strength

Jan 1, 2020

By J. H. Zietsman, S. Maharajh, J. Muller

In the chlorination process for TiO2 pigment production, blends of titania feedstocks such as ilmenite, synthetic rutile (SR), natural rutile, upgraded slag, and chloride-grade slag are reacted with coke and chlorine at a temperature of around 1000°C to form TiCl4, which is the main product, and other waste metal chlorides. TiCl4 is the main feed material for the TiO2 pigment-making process. Feeding different titania materials to the chlorinator affects the amounts of coke and chlorine required for the process, the amount of waste generated, waste disposal costs, the amount of TiCl4 produced, and bed build-up rates. These factors influence the value of the feedstock. Generally, a higher TiO2 feedstock is more valued since less waste is generated and less reagents are consumed. To quantify the impact of different feedstocks on the chlorinator, a techno-economic model was developed to describe the chlorination process and estimate process variables at steady state. This paper describes the development of the model and studies in which the model has been used to quantify the effects of using different feedstocks.

Jan 1, 2014

By T. Ono, B. Altansukh, S. Kawamura, K. Haga, A. Shibayama, Y. Takasaki

In recent years, the grade of silica in zinc concentrate has increased due to the degradation of zinc content and the increase in impurity content in natural ores. It implies that the development of silica removal technology from zinc concentrate is necessary to solve problems in the smelting process caused by the high content of silica in zinc concentrate. In this paper, the authors investigated the silica removal processes from silica-rich zinc concentrate by mineral processing approaches such as re-grinding and flotation. This study focused on the pulverisation process as a pretreatment for the investigation of individual minerals' liberation from the silica-rich zinc concentrates using different kinds of pulverisers. Flotation experiments were performed to separate silica and zinc concentrate from the pulverizsd feed sample using a pH regulator (NaOH), activator (CuSO4), collecting agent (PAX), and foaming agent (DOW froth 250). Results showed that the liberation rate of silica (SiO2) was reached 75% from 13% by pulverisation in an attritor with a 2 mm ball in diameter, while silica accumulated in a fraction over 20 mm in size. Flotation experiments indicated that silica removal efficiency was achieved by 44% from + 20 mm fraction obtained from pulverisation whereas the grade of silica in froth reached 1.85 mass% from 4.5 mass%. Results indicate that silica could selectively separate from silica-rich zinc concentrate, and 99.8 % zinc recovery is achieved under the studied conditions. Keywords: Zinc concentrate, silica, pulverisation, liberation, sieving, flotation

Jan 1, 2020

By E. Bakhtavar, R. Mikaeil, D. Khademi

"Fuzzy-weighted integer goal programming has been developed and used to select the most suitable site to construct a central processing plant for several adjacent small-scale dimension stone quarries, based on the most effective criteria. In the first step of mathematical modelling, the most important goals and decision variables were defined. Accordingly, an objective function was used in the model for minimizing the sum of undesired fuzzy-weighted deviations. Fuzzy weights were determined by a matrix of pairwise comparisons of various expert judgments in this field and the fuzzy geometric mean. The goal and systemic constraints were also modelled. The most suitable site for the construction of the plant was selected after solving the mathematical model in the ExcelR Solver add-in. The selected site had various advantages over the other sites, such as the shortest average distance to the quarries, the shortest distance to power access and workforce, and the lowest land price. IntroductionSelection of the most suitable site of a plant is one of the most important considerations when constructing an industrial project. A suitable site has a significant effect on a company's competitiveness in the market. Selecting a desirable location for constructing plants such as mineral processing facilities is an essential part of the economic planning that will enable a company to meet the needs of related upstream and downstream operations. These units are considered to be best built near the relevant mining sites because of technical difficulties, the cost of transporting minerals, and the traffic hazard caused by the movement of trucks transporting materials. Two main types of research using multiattribute decision-making models have been reported for selection of a processing plant site (Safari et al. 2010, 2012). In that research, the analytic hierarchy process (AHP) and fuzzy technique for order preference by similarity to ideal solution (TOPSIS) approach were applied to select the suitable locations for the mineral processing plants for phases 1 and 2 of Sangan iron ore mine."

Jan 1, 2017

By L. Morin, S. Mortazavi, K. Volchek, A. Demers, A. Di Feo

The objective of this paper was to investigate the possibility of reducing process (fresh) water and increasing recycled water (thickener tank overflow water). As part of the investigation, rougher flotation tests were done with the two water types and a mixture of the two (50%/50%). The effect of recycled water on the grade-recovery response and rougher recoveries was investigated. When thickener tank overflow was used (50% and 100%), the nickel+copper grade versus nickel recovery decreased. The decrease in the grade-recovery was due to higher pyrrhotite recovery. Also, there were no effects on nickel and copper recoveries, which was confirmed using multivariate statistical analysis at the 95% significance level. Keywords: Flotation, nickel, copper, water recycling, multivariate statistical analysis, MANOVA, reverse osmosis

Jan 1, 2020

By T. van Heerden

A range of supported gold catalysts was prepared by ion exchange, varying many of the preparation variables, including concentration in the precursor solution, washing procedure, as well as drying and calcination procedures. These catalysts have been characterized extensively. TEM images show essentially the same crystallite size distributions, between 2?5 nm, for almost all catalysts, the only exception being catalysts not washed in ammonia, which did not show any small crystallites. Additional characterization with SEM yielded an interesting discovery. Catalysts that appear identical on the TEM also contain some large crystallites in the range of 50?500 nm. Differences in dispersion due to the drying procedure not seen on the TEM can now be observed. Oxygen chemisorption is being investigated as an additional method to characterize gold based catalysts to complement the typically used electron microscope techniques.

Jan 1, 2012

By C. S. Kucukkargoz, A. Bhalla

"The solid-state reduction of ilmenite concentrate with graphite was studied under argon atmosphere at temperatures between 1050°C and 1350°C. The rate of reduction increased with increasing temperature and decreasing particle size, with the maximum extent of reduction found to be 80% at 1350oC with a particle size in the range of -106 +90 µm. The activation energy for the reduction reaction was calculated to be 257 kJ/mole. The trivalent iron oxide was reduced first to divalent iron oxide and then to metallic iron. An annular ring of a partially reduced oxide phase containing metallic nuclei was formed around the core of ilmenite, which grew in size as the original ilmenite core shrank with progressive reduction. The reduction of titanium dioxide also took place during this stage, which produced the Magneli oxides in the form of TinO2n-1. The metallic phase had very high Fe and low Ti contents throughout the reduction, whereas the partially reduced oxide phase adjacent to the metallic phase was high in Ti and depleted in Fe. The metallic phase globules formed during this stage were small and are considered suitable only for leaching and not for other concentration processes. The core of the particle generally retained the composition of the original ilmenite. The purpose of this work was to remove iron and increase the titanium oxide content of the ilmenite to produce a high-titanium containing charge for subsequent smelting.IntroductionThe titanium-bearing minerals ilmenite (FeTiO3) and rutile (TiO2) are the primary natural raw materials used in industry to produce titanium metal and titanium-based products. The common titanium-bearing minerals are ilmenite, rutile, anatase, brookite, leucoxene, arizonite, and perovskite. Although the formula of ilmenite is commonly expressed as FeTiO3, the mineral can accommodate Mn and Mg, which are chemically bound in the form of (Fe,Mn,Mg)TiO3. Ilmenite concentrate can also contain Fe2O3 and Al2O3 in addition to the physically separable oxides such as SiO2 and CaO. The crystal structure of ilmenite is an ordered derivative of the corundum structure with a trigonal-rhombohedral symmetry. Fe2+ and Ti4+ ions occupy the octahedral sites, leaving the tetrahedral sites unoccupied. In each FeTiO3 unit, there are three O2- ions creating three octahedral sites, two of which are occupied by Fe2+ and Ti4+ (Wilson et al., 2005)."

Jan 1, 2017

By J. W. Drelich, H. Zeng, L. Xie, X. Cui, Z. Gao, M. Tian, Y. Hu, W. Hu, W. Sun

Flotation is a mineral separation technology that uses the surface hydrophobic difference of valuable minerals and their associated gangue minerals to separate them. The flotation collector adsorbs on the valuable mineral surface to improve its hydrophobicity, and metal ions are usually used as activators to enhance the collector adsorption. Different mineral surfaces show different charging properties and adsorption behaviours with the collector or metal ions. Moreover, the order of adding metal ions and the collector also show significant and different flotation performance for the same mineral. The adsorption or flotation behaviour or both are governed by mineral surface chemistry, such as surface charging and reactivity. In our recent studies, force measurement using atomic force microscopy (AFM) was employed to study the surface charging and adsorption mechanism of metal ions and collectors. By preparing collector-functionalised AFM tips, AFM can directly measure the adsorption strength of the collector on the mineral surface to determine the anisotropy of mineral surface reactivity. The preparation of collector-functionalised AFM tips provides the foundation for further study of the activation role of metal ion in the collector adsorption. The application of AFM for force measurement in the surface chemistry of mineral flotation can provide important information on developing flotation reagents and lays the foundation for the specific regulation of mineral surface characteristics. Keywords: Scheelite; flotation; surface chemistry; AFM force measurement

Jan 1, 2020

By M. Thurston

This case study shows that for a set of lognormal data with a low coefficient of variation the semi-variogram of the logs has almost the same shape as the semi-variogram of the raw data. This means that the variogram of the logs, which is numerically more stable, can be used to krige the raw data. This technique is tested on samples from a sedimentary gold deposit and the results compared to those obtained from ordinary and simple lognormal kriging.

Jan 1, 1987

The above paper is an important contribution to the field of physicochemical studies in ferromanganese production. The authors are to be congratulated on the well planned and competently executed experimental work and on the interpretation of the data. Although the paper is essentially descriptive, the results lend themselves to thermodynamic interpretation (but in such a complex system as that studied this cannot be done rigorously), as well as to an examination of the probable reduction mechanisms that operate at various stages.

Jan 1, 1979

By K. Kabezya

A study on slag dispersion in a model of bottom-blown bath smelting converter was undertaken at room temperature. The aim was to investigate the behaviour of the dispersed slag phase at various operating conditions with very high gas flow rates in low slag volume (10%) systems. For simulation purposes water, paraffin-oil, and air were used to represent the bulk steel, molten slag, and gases respectively in a one-fifth cold model of the commercial 100 t Creusot-Loire-Uddeholm (CLU) converter used in the manufacture of stainless steel in South Africa. Dimensional analysis was done to correlate mathematically the dispersed phase holdup with the operating conditions and the modified Froude number. The overall expression of the holdup revealed that the dispersed slag phase decreased with the vertical distance from the original interface between the liquid phases. The dispersed phase also decreased with the radial distance in the water plume zone toward the sidewall. The holdup was apparently much higher on the side of the reactor where there were no tuyeres. The modified Froude number ensured the correlation between the model and the prototype.

Jan 1, 2014

By A. D. Pienaar

The aqueous chemistry of niobium and tantalum compounds with hydrofluoric acid is a mature field of investigation. In contrast, very little attention has been paid to reactions of these compounds in non-aqueous environments. Similarly, reactions of elemental fluorine with niobium and tantalum compounds have received little more than cursory attention in literature. This work discusses the isothermal reaction kinetics derived from thermogravimetry, using a less redundant approach than is currently the standard. We also discuss the most likely kinetic models for this reaction.

Jan 1, 2012

By K. Basaure, S. Palma, R. L. Castro

"Mud rushes are sudden inflows of fine wet ore within underground mines; they can harm people and equipment as well as cause production delays. Block and panel caving mines are prone to mud rushes in their production levels, with mud flowing from the drawpoints. Different mines have developed methods to control drawpoint conditions and thus perform safe ore extraction. The aim of this study is to develop a decision matrix and apply it to samples from drawpoints for the Diablo Regimiento mine, Codelco, El Teniente Division (Chile). The Abrams’s Cone was used to perform slump tests on mud samples and characterize their consistency by setting the saturation degree and packing. The unconfined strength for different saturation degrees and packing was then evaluated. The results show that conditions for fluid response in slump tests correspond to conditions for low strength in unconfined compression tests. We also found the water content value at which the flowing consistency changes from plastic to soft behaviour according to the slump test classification for each sample. This value varied between 12.2% and 16.9%, depending on the sample tested. Finally, a fluid security factor was defined in order to design an extraction pattern for the samples tested, based on the water content. We conclude that a very densely packed ore is not prone to flowing. The flow properties depend strongly on the specific properties of the ore tested, and consequently a specific criterion should be developed for different types of ore at a particular mine. The criterion developed for Diablo Regimiento ore provides critical water content values from 11% to 15%, depending on the ore type. IntroductionBlock/panel caving has the lowest cost and the highest production rates of all underground methods (Heslop, 2000; Hubert et al., 2000). Good management of the risks is important to ensure the security of personnel and infrastructure. Operational risks for the method include rockbursts, air blasts, and mud rushes (Hubert et al. 2000). A mud rush is defined as a sudden inflow of mud from a drawpoint or other underground opening into the mine (Butcher, Joughin, and Stacey, 2000; Butcher, Stacey, and Joughin, 2005). Mud rushes can cause dilution, production delays, and damage to equipment as well as injuries and fatalities. The elements necessary for mud rushes are mud-forming material, disturbances, a discharge point, and water (Butcher, Joughin, and Stacey, 2000). All these elements are present in block/panel caving mines. Mud-forming material comes from ore milled by the caving process; water comes from underground and surface sources. Drawpoints in the production level are discharge points for the mud. Finally, several types of disturbance could trigger the mud rush phenomena: blasting, earthquakes, operation of equipment (Call & Nicholas, Freeport McMoRan, and Hydrologic Consultants, 1998; Jakubec, Clayton, and Guest, 2012), arch collapse above drawbells (Butcher, Joughin, and Stacey, 2000; Butcher, Stacey, and Joughin, 2005; Jakubec, Clayton, and Guest, 2012) and ore drawing (Butcher, Joughin, and Stacey, 2000; Butcher, Stacey, and Joughin, 2005; Call & Nicholas, Freeport McMoRan, and Hydrologic Consultants, 1998; Jakubec, Clayton, and Guest, 2012)."

Jan 1, 2017

By H. G. M. Rose

Contribution to the above paper by H. G. M. Rose* (Fellow) INTRODUCTION Dr Lawrence is to be congratulated on his most interesting and instructive paper, particularly on his suggestion for a model to increase mining productivity through improved management performance. In view of an experiment initiated in one Union Corporation mine (Mine A) and later extended to a second mine (Mine B), it might be of interest to review the many human factors involved and the initial productivity results achieved.

Jan 7, 1974

By N. E. K. Schuttler

Experience with Mars pumping of underground water by N. E. K. SCHUTTLER (Visitor) As the result of a planned increase in production, Vaal Reefs Exploration & Mining Company Limited increased the hoisting capacity of their existing equipment to its fullest extent and installed Mars pumps and a washing plant. The layout of the installation is described, and details are given of the modifications made to overcome its weaknesses. Plans to change the present four-stage system to a seven-stage system are outlined.

Jan 3, 1977

By J. J. S. de Beer, F. Hunter, A. F. Neethling

SYNOPSIS The paper describes the rib-pillar extraction method now used at Sigma Colliery in the Orange Free State. In this method, access roadways (with a high safety factor) are developed into a block of coal suitable for total extraction; pillars that have a low safety factor are then formed and extracted immediately. The method, together with the current practices of labour management, has resulted in better utilization of the coal resources and capital, increased production and labour productivity, and improved safety.

Jan 1, 1991

By Y. Zhang, F. Zhu, Y. Zhao, L. Dong, Y. Li

In order to obtain a more suitable separation medium for fine coal, in this paper a pulsed fluidised bed was used to measure the pressure fluctuation, density characteristics, bubble diameter and rising velocity of Geldart A and B particles in the bed by controlling the pulsation frequency and gas velocity, in order to study the fluidisation effect and two-phase distribution of the bed. The results indicated that with the increase of pulsation frequency, the breakthrough point on the fluidisation characteristic curve caused by particle adhesion disappeared, and there was an optimal frequency, which made the minimum fluidisation velocity of particles reach the minimum. In addition, the bubble rising velocity was also simulated. The relationship between them was established using a model, and the error was within 5%. This provides an effective way to predict the bubble velocity, study the distribution of bubble phase, and improve the stability of bed density. Keywords：Frequency, flow velocity, pressure fluctuation, bed density, bubble

Jan 1, 2020

By S. Krishnannair

Singular Spectrum Analysis (SSA) is an effective data-adaptive multimodal tool for monitoring chemical processes. However, monitoring multiscale signals using principal component analysis obtained from the multilevel decomposition of process signals using basic SSA assume the upper control limits of monitoring charts (" ) to have a Gaussian distribution. This assumption deteriorates the performance of basic SSA when applied to the monitoring of nonlinear processes. To address the issue in this paper, the kernel density estimation (KDE) was used to estimate upper control limits of monitoring charts for basic SSA based nonlinear process monitoring techniques. The monitoring performance of the resulting basic SSA-KDE approach was then compared with a basic SSA approach of which upper control limits of the monitoring charts were determined based on a Gaussian distribution. Application on nonlinear dynamic simulated process and base metal flotation plant chemical processes showed that the SSA-KDE approach provided better overall performance than the SSA approach with Gaussian assumption-based upper control limits for its monitoring charts. Keywords: Fault detection, singular value decomposition, singular spectrum analysis, kernel density estimation

Jan 1, 2020

By Q. Zhang, X. C. Wang, S. Mao

Phosphate ore is an important strategic mineral resource in which apatite is the main valuable mineral. Flotation is the most commonly used method to separate apatite from middle-low grade phosphate rock. Selective flotation separation is based on the difference of physical and chemical properties of minerals occurring at the three interfaces of mineral/bubble/water. Surface and interface chemistry of mineral have been playing an important role in interpreting and governing its flotation phenomenon. In-situ, visualized and high-precision analytical techniques, such as Time-of-Flight Secondary Ion Mass Spectrometry, Atomic Force Microscopy and Molecular Simulation, have been applied to explore and uncover microscopic nature of apatite flotation. Consequently, a great progress at molecular or atomic level on surface and interface chemistry of apatite flotation has achieved in the past decades. In this paper, the research progress of surface and interface chemistry of apatite flotation such as surface wettability, surface-charging characteristics, surface dissolution behavior, adsorption mechanisms of fatty acid collector and depressor on apatite surface were systematically reviewed. This review will be helpful for the development of more selective reagents and efficient technologies for apatite flotation. Keywords: Apatite, Flotation, Surface and interface chemistry, Surface analysis technology

Jan 1, 2020

By D. K. Weatherley, T. P. Oladele, L. B. Bbosa

Comminution is a critical stage of mineral processing which aims to reduce the size of ore particles through breakage, consequently increasing the likelihood of liberation of valuable minerals. Several factors, such as pre-existing cracks, mineralogical composition and particle size, are known to affect ore breakage behaviour. While investigating the contributing role of each factor is essential to improve understanding of breakage, isolating individual factors by experiment is typically impractical. Numerical techniques such as the Bonded Particle Model-Discrete Element Method (BPM-DEM) have been developed as a means of studying closely controlled breakage conditions. This study evaluates this technique in modelling the effect of pre-existing cracks breakage behaviour for synthetic ore specimens during impact breakage in a short impact load cell (SILC). Synthetic ore was modelled as a collection of discrete entities connected by brittle-elastic beams. Model parameters were calibrated against macroscopic material properties of a conventional homogenous synthetic ore. The extent of pre-existing cracks within specimens was prescribed by varying discontinuities between the connecting entities. An approach with the insertion of seed points was used to model the mineralogy of the specimens. Results showed that pre-existing cracks resulted in a decrease in the fracture force as the crack density increased. Additionally, the irregularity of fracture patterns within rock specimens after impact became more apparent as the crack density increased. The findings were used to emphasise some of the attributable causes of the variation observed between ore hardness characterisation tests and in situ ore behaviour. Keywords: Element Method; Bonded Particle Model, synthetic rock sample; rock fracture, preexisting cracks

Jan 1, 2020