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By Wieslaw Wszolek, Kazimierz Trybalski, Ryszard Tadeusiewicz

"The present work is an attempt of neural networks application to the description of complex technological processes of useful minerals enrichment. Neural networks are among the most convenient tools that have been added recently to the professional toolbox of modelling specialists, and they are particularly useful in realisation of multiple practical tasks, characterised by great complexity and relatively low amount of available a priori knowledge about the nature of the modelled processes. They are successfully applied in a wide variety of problems related to data processing and analysis, their prediction, classification or process control. The object of the study was the technological site for copper ore enrichment by floatation, being a part of technological line in the Ore Enrichment Plant ZG „Polkowice”, KGHM „Polska Miedz” S.A.The main floatation is described by parameters measured by the supervision and control system, which can be grouped with respect to the functions performed for the object:a) input function: aFG - copper contents in the feed material for the main floatation [% Cu]b) control: LFG I - level in the first section of the floatation unit [%], LFG II - level in the second section of the flotation unit [%], LFG III - level in the third section of the floatation unit [%], LFG IV - level in the fourth section of the floatation machine [%]. These quantities compose the five elements long input vector.c) output function: ? - copper contents in the waste from main flotation (final waste) [% Cu]The measurement data, containing the above-mentioned parameters, have been collected during the normal operation of the plant. The data contain momentary values of the parameters, registered every 10 minutes, covering the period of 196 hours of the plant’s operation (1176 measurements for each quantity).For construction of the model used in the study classical multi-layer perceptron-type neural network has been used, with one hidden neuron layer, trained by the error back propagation method."

Jan 1, 2003

By L. Tong

Stirred milling of laterites offers possibilities for improving liberation and selective size reduction of soft nickel-bearing minerals in laterites. Batch grinding tests were performed in a Netzsch LME4 stirred mill on a siliceous goethitic (SG) nickel laterite sample (-2000 µm particle size) to evaluate the effect of operating conditions such as stirrer speed, grinding time, pH, solid content, water salinity and charge volume. The target was to produce a -38 µm fraction in the milling product with high nickel recovery and grade. Addition of dispersant (sodium hexametaphosphate) was also optimized with respect to the rheology of the slurry. In terms of stress intensity, the optimum grinding conditions for selective size reduction were: 1000 rpm, 50 per cent charge volume. At higher stress intensity (2000 rpm), Ni recovery in the -38 µm product was higher, but Ni grade was low, due to the breakage of the harder siliceous particles. Decreasing the yield stress by modifying slurry pH or adding dispersant improved the rheological properties of the pulp, but had no great influence on Ni upgrade in the fine product. Modifying water salinity by adding 2 M NaCl had also little effect. The breakage of the +38 µm particles in the feed determined Ni upgrade greatly. Ni grade in the -38 µm product decreased with grinding time, suggesting that the Ni-bearing minerals break first, while the harder siliceous minerals have a lower breakage rate. The breakage rates with respect to sample mass for Ni, Mg and Si indicate that: Mg > Ni > Mass > Si. The optimum grinding time for the highest Ni upgrade was 0.25 min. The Ni grade increased from 0.88 per cent to 1.35 per cent (upgrade 54 per cent), with 24 per cent Ni recovery. Keywords: fine grinding, stirred media mill, nickel laterite, slurry rheology

Sep 1, 2012

By X. Q. Chen

According to the different characters of the middle-low grade bauxite, based on the normal flotation & reverse flotation technology, the author innovates the new technology which is named bi-flotation, it integrates the advantages of normal flotation & reverse flotation, while avoids their disadvantages. Take Henan middle-low grade bauxite as research object, according to the pilot experiment of bi-flotation technology, the concentrate A/S is 9.37 and the recovery of alumina is 80.18% by flotation separate the raw ore which A/S is only 4.19.

Jan 1, 2014

By David G. Hulbert, Daniël J. Oosthuizen, Bernard Muller, Daniël de V. van der Spuy

"OVERVIEWExpert Online is a software system that aims to mimic an informed expert on a minerals processing plant. The primary objective of Expert Online is to provide operators with effective training and on-the-job assistance. Training will mostly be done off-line (e.g. using simulators of the plant), while on-the-job assistance will help the operator during normal operation to run the plant in an effective manner. Although Expert Online focuses on the operator, it is expected to also be of value to other plant personnel, including supervisors and plant managers.Expert Online will make use of novel artificial intelligence technology (developed by MINTEK) known as the Interpreting Expert System (IES). Previously the IES was only able to explain the actions taken by the controller. Expert Online will extend this functionality to also take the process dynamics into account.Expert Online is being developed by a South African consortium comprising MINTEK (focusing on the research and development of the system as a whole), Lonmin (globally one of the biggest platinum producers, with plants suitable to test Expert Online on) and the University of Natal (academic partner, providing consultation and focusing on complex process modelling). The initial application of Expert Online will be on milling- and flotation plants.This paper discusses the structural design of Expert Online for implementation on the latest version of MINTEK’s open control platform, PlantStar, as well as several advances and additions since the previous implementations of the Interpreting Expert System."

Jan 1, 2003

By Carin Laubscher, Francis W. Petersen, Jaap P. Smit

"Waste streams, such as acid mine drainage, are often characterised by low pH values and high concentrations of heavy metals, dissolved solids, calcium and sulphates. Although lime remediation effectively removes most of the heavy metals as hydroxides, it is less effective at lowering levels of sulphates. Various methods of removing sulphates from effluents exist, such as precipitation with lime, precipitation with barium salts, co-precipitation with calcium carbonate, reverse osmosis, and ion exchange. Mintek developed a chemical precipitation (SAVMIN) process to treat acid mine drainage, which entails the addition of lime to precipitate the metal hydroxides, and the subsequent formation (precipitation) of calcium sulphoaluminate or ettringite. The key to the viability of the new technology lies in the correct use, regeneration and recycling of Al(OH)3 used to precipitate the ettringite. The water produced by this process is suitable for disposal to watercourses or for agricultural, domestic or industrial consumption. No brines are produced as the salts are converted to solid hydroxides, gypsum and calcium carbonate.The SAVMIN process has been tested successfully during several laboratory scale operations, and during two pilot plant operations at Stilfontein Goldmine for Anglogold and Navigation Plant, Witbank for Anglocoal. During the pilot plant campaign at Navigation Plant, metal and mineral precipitation was achieved with lime addition. The sulphate concentration in the water was reduced from 2136 mg/L to an average value of 102 mg/L and the calcium concentration was reduced from 727 mg/L to an average value of 70mg/L.The SAVMIN process generates a number of different waste streams including metal hydroxide sludge from neutralisation, gypsum sludge from the gypsum crystallisation steps, and calcite sludge from carbonation. The metal hydroxide sludge is composed of Mg, Ca, Mn and Fe hydroxide, and could be disposed of on a slimes dam. Gypsum sludge was greater than 99% CaSO4.2H2O. This gypsum could be used for dump or road capping, underground backfilling, production of wallboard and cement. The calcite sludge is pure CaCO3, which is recycled back to the neutralisation stage."

Jan 1, 2003

By Nicolás Caussade

"The IMPC 2014 slogan "Optimizing Water and Energy Usage for Sustainable Mining" refers to the ever decreasing availability of fresh water and energy, which has turned out to be a crucial aspect in assuring the competitiveness of the mining sector in Chile and the Andes region in general. The concern for sustainability and the supply of water and energy is nowadays part of the top priorities of mining countries and communities. This is also the case for Antofagasta Minerals. Several years ago its mining group implemented an energy policy based on intelligent, strategic and sustainable management, in order to successfully face the challenges imposed by the market. It is called an intelligent policy because it intends to provide energy through a diversified range of sources, which includes the development of in-house alternatives. It is also a policy focused on efficient energy consumption and one that is strategic. Because it is in line with the characteristics of the mining activity, it is developed for the long term. Finally, what makes the policy sustainable is that it gives priority to energy usage from renewable resources and as such, the required capacities have been developed to generate innovative solutions that respond to the restrictions that characterize the industry today."

Jan 1, 2014

By F. Karakas

Organo-bentonite production enjoys important applications including solvent based paints and, more importantly, the production of polymer/bentonite nanocomposites. Quarternary ammonium salts in this regard are still considered as the most versatile reagents in the process of hydrophobization. In this study, a purified form of Resadiye region bentonites, which is one of the most significant sodium bentonite deposits in the world, was used. The raw Na-Bentonite was typically characterized by chemical analysis, XRD and DTA analysis and more importantly for its cation exchange capacity (CEC). Other technological properties such as swelling index, pH, apparent viscosity, water absorption, oil absorption were also conducted on the raw bentonite. The mineralogical analysis of the raw bentonite reveals that it contains about 80 % montmorillonite together with other associated gangue minerals including feldspar, quartz, calcite, dolomite, coloured impurities and other clay minerals. The raw bentonite was subjected to two stage processing involving a series of hydrocylones. Different apex and vortex diameters and different pressures were employed in order to produce a bentonite concentrate with 95 meq/100g CEC from a CEC of 71 meq/100 g. This high quality concentrate was used in the production of organo-bentontonite. The modification was performed with two different quaternary amines, i.e. Trimethyl Phenyl Ammonium Chloride (TPAC) and Hexadecyl Trimethyl Ammonium Bromide (HDTMA-Br). In the modification procedure, three parameters, i.e., adsorption density, zeta potential, swelling index and apparent viscosity were studied simultaneous-ly from the same suspension to identify both the mechanism of the process and also the degree of hydrophobicity. Adsorption measurements were made as a function of conditioning period, pH, and reagent concentration. Simultaneous examination of the adsorption density, zeta potential and apparent viscosity enabled us to pinpoint the optimum region of hydrophobicity which was subsequently tested by settling and critical coagulation concentration in both water as polar and toluene as nonpolar solvents. The results are analyzed in the light of experimental data.

Jan 1, 2014

By M. L. Cao

In this study, a montmorillonite organo-intercalation compound (MOIC) was synthesized by using a Na-modified bentonite (NaB) as a matrix and hexadecyltrimethylammonium (HDTMA) bromide as an intercalating reagent under microwave irradiation. The synthesized products were characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), organic carbon content measurement, and adsorption density determination. The results show that, at 10% suspension concentration and 10 minutes irradiation in a 130-W microwave oven, the basal spacing d(001) of the synthesized MOIC increases to 2.209 nm from the original 1.218 nm of NaB. The MOIC has much higher adsorptive densities to nitrobenzene and aniline from aqueous solution than the NaB. The adsorption isotherm of nitrobenzene on the MOIC is linear, and the adsorption is mainly the result of nitrobenzene?s preferred partition in MOIC over aqueous solution due to MOIC?s hydrophobicity. The adsorption isotherm of aniline on MOIC follows the Freundlich equation and the increased adsorption is not only the result of aniline?s preferred partition in MOIC over aqueous solution but also that of the MOIC?s surface adsorptions.

Jan 1, 2014

By D. Krawczykowski, D. Saramak, T. Gawenda

"Annual world zinc consumption is as high as nearly 14 millions of tonnes. Approximately 50% share of zinc is used for corrosion protection in processes of continuous galvanization and the hot dip processes. In the latter, two zinc containing residues are produced: zinc ash and hard zinc, which constitute around 10% each. Paper concerns the method of possible separation of metallic zinc from the non-metallic zinc compounds from the zinc ashes – the waste product of hot dip galvanization process. The investigative programme covered the comminution tests of the feed (zinc ash) in selected crushers: jaw crusher, roller crusher and impactor. Results of investigations show that application of individual crushing device results in various breakage of the feed sample. Impact force caused the highest increase in finest particles size fractions of the product, while metallic and non-metallic fractions were comminuted differently. The compression force, in turn, caused the selective comminution, i.e. the breakage of metallic zinc was observed in a higher degree. The presented approach appears to be an economical supplementary method of initial recovery of metallic zinc from metallurgical zinc waste. For the high demands for the zinc in the world and the need of corrosion protection, the method presented in the paper helps in more effective zinc recovery and environmental protection.INTRODUCTION AND METHODOLOGY World production of metallic zinc during last decade shows a slight increase and in recent years its consumptions reach 14 millions of tonnes. Figure 1 shows world production of zinc in the time period 2009 – 2016. Main directions of zinc utilization include: - Galvanization - Production of zinc alloys - Brass and bronze production - Semi-manufactures of zinc - Chemicals The major share in global zinc consumption constitute galvanization process (Bright 2007). Two main types of zinc galvanization are: hot-dip galvanizing (HDG) and electro-galvanizing."

Jan 1, 2018

Considerable attention has been, and is being, given to the physics of water-films associated with bubble interactions at surfaces. In contrast, little information on the chemistry of such films has been reported. This communication reports a method using sum frequency vibrational spectroscopy (SFVS) to describe hydrogen bonding of interfacial water molecules in water films created with bubbles at hydrophilic and hydrophobic surfaces. The SFVS spectra of water films at hydrophilic silica surfaces differ significantly from the spectra of water at a hydrophobic silica surface. The SFVS spectra indicate that a very ordered water structure exists in water films at the hydrophilic silica surface during contact with a bubble and that the extent of hydrogen bonding increases with an increase in contact pressure. Such structural considerations as well as repulsive electrostatic and Van der Waals forces account for film stability for a bubble at the hydrophilic silica surface. In contrast, the SFVS spectra of water at a hydrophobic silica surface show a lack of hydrogen bonding and are characterized by a distinct absorption at about 3700 cm-1 similar to the spectrum of the air/water interface. These results suggest the presence of a water void, or water exclusion zone, at the hydrophobic surface, as supported by X-ray reflectivity measurements reported in the literature, by atomic force microscopy, and by the results from molecular dynamics simulations. Of course the water film at the hydrophobic surface is unstable with film thinning and rupture upon bubble contact. Under these circumstances it is shown that an attractive Van der Waals force between the bubble and the hydrophobic surface can be expected when the water exclusion zone is taken into consideration. As the thickness of the water exclusion zone increases to a thickness corresponding to the size of nano bubbles, the calculated attractive Van der Waals force increases. This analysis may help to explain the so-called ?short range? and ?long range? hydrophobic forces. Keywords: SFVS spectra, hydrophilic silica surface, hydrophobic silica surface

Sep 1, 2012

By Ventsislav Stoilov, Angel Angelov, Ivan Korolev, Antti Remes, Todor Pukov, Stoyan Gaydardzhiev

"The process modeling and simulation studies aim for better process operation and favorable environmental impact. The objective of this work is to set up a simulation model of the Assarel copper flotation circuit for planning and optimization of the process with the aim of increased metal recovery. The model is parameterized based on laboratory flotation tests of ore samples from the Assarel mine together with mineralogical studies by X-ray diffraction (XRD) and Mineral Liberation Analysis (MLA). A combination of several techniques allows reliable identification of mineralogical composition of the selected samples. The changes in the proportion between sulfide minerals in various products along the circuit have been also documented. Further, this information is used in the simulation model and in data reconciliation procedures for establishing mass balance. The simulation accuracy is studied by comparing the simulations with the plant survey based mass balance. Constructed simulation model can be used to run alternative process scenarios. As an example, the flotation circuit performance with different reagent regimes is simulated based on data from batch flotation tests. Two reagents were considered for this purpose, dithiocarbamate-based one and xanthogen formate/mercaptan blend. It has been revealed that these reagents do not have the same influence on the selective flotation. The one improves flotation of gold and overall recovery but without notable selective action. In contrast, the other showed better selectivity towards copper, rejecting more gangue and lowering gold recovery. The model is also applicable for process optimization studies with different feed compositions, flowrates and circuit configurations. INTRODUCTION In the pursuit for elevated technological indicators, finding an optimal set of process parameters fully utilizing the potential of the equipment is a key factor to success. Over the past decades, there has been a substantial development in flotation circuit optimization through performance benchmarking using metallurgical modelling and steady-state computer simulation. Practical simulation engineering tools are based on experimental data obtained from laboratory tests and from plant surveys and operation data. With the help of flotation models, it is possible to study grade-recovery response with different feed compositions and throughputs, and with various cell-operating parameters, as well as to evaluate and design different flowsheet configurations. Outotec’s HSC Chemistry® software, which incorporates simulation and mass balancing modules alongside with several other tools, can assist with this optimization (Mattsson et al., 2015)."

Jan 1, 2018

By G. I. Voiloshnikov, V. E. Dementyev

"One of the most important advances in the world gold metallurgy is the introduction of adsorption technologies for processing of ores and concentrates. «Adsorbent-In-Pulp» process allows to eliminate pulp filtration that is especially important during processing of clay and slime bearing ores. “Adsorbent-In-Leach” process is one of the ways for processing of preg-robbing (carbonaceous) products. High efficiency, increased metals recovery, decrease in capital and operational costs, possibility of easy control and adjustment are the advantages of adsorption processes. Anion-exchange resins and activated carbons are used as adsorbents. This paper presents Irgiredmet experience on gold adsorption technology using both adsorbents (RIP, RIL, CIP, CIL processes). It includes results of long-term studies of different theoretical and practical issues of adsorption processes. Irgiredmet started development of ion exchange technology (RIP, RIL) in 1964. Laboratory and pilot plant tests were conducted to develop process design criteria for 15 RIP plants of the former USSR. During this test work a great number of newly synthesized resins including strong- and medium-base resins was studied, different types of adsorption feed (ores and concentrates) were tested; some theoretical regularities of adsorption process were investigated; the technology of two stage adsorption for silver gold ore, improved flowsheet for gold elution and resin regeneration, designs of technological equipment for adsorption, elution, electrowinning processes including pulsation columns, electrowinning cells etc. were developed. Irgiredmet took part in commissioning of practically all RIP plants in the former USSR. Due to its efforts RIP process became to be the standard technology. Last Irgiredmet RIP projects include the development of adsorption technology using medium-base resin for the three mines owned by GC Petropavlovsk (Amur region, Russia). The complex of the testworks on activated carbon gold adsorption technology including the search of prospective activated carbons; study on gold adsorption mechanism; development, testing and introduction of process flowsheets and the equipment for their realization was conducted. The original gold elution process was developed. The developed CIP technology was firstly introduced at Lebedinsky gold plant (Yakutia). Now carbon adsorption technology is widely used at Russian gold mines as CIP, CIL, CIC processes. The most relevant example of CIP introduction is Svetlinsky gold plant (Ural, Russia) with capacity 8 Mt of ore/ year."

Jan 1, 2018

By Sanjay Chaudhuri, V. K. Kalyani, Pradeep Kumar Singh, T. Gouri Charan

"Indian coal industry is the world's third largest in terms of production and fourth largest in terms of proven coal resources. Indian coal deposits are generally of high ash content varying from 24 to 50%. The coking coal reserves of India constitute about 12% of the total coal inventory, and the coals are washed in washeries, before being used for metallurgical purposes. The processes used for washing coking coal is Jigs, Heavy medium bath and Cyclones for the sizes upto 0.5mm, while the coal fines are washed in spirals and conventional flotation cells. Extensive studies were carried out for understanding the performance of an operating conventional flotation plant. The performance studies revealed that appreciable quantity of clean coal is being lost in the tailings due to varied reasons and the required quantity and quality was not achieved. In this study, laboratory Flotation experiments were carried out to examine the cleaning characteristics of the said tailing and to determine the effective process parameters for recovery of clean coal at desired ash level ( 16-17%). Response Surface Methodology was applied to investigate the operating conditions of the Froth Flotation for modeling and optimization. Primary study reflects that there is a possibility to recover clean coal at 16-17% ash level with a yield of about 60-70% from that Flotation tailing of feed ash about 28%.INTRODUCTIONMost of the Indian coking coals are difficult in cleaning characteristics and high ash content due to its drift origin and its age of formation for more than 225 million years. Indian coking coal reserve is limited about 12% of total coal reserve. The minerals are homogeneously mixed with the coal macerals. The open cast mining practice and mechanized mining methods are being adopted to meet the increasing demands of coals resulting in generation of more coal fines and subsequently the quality is deteriorated. Indian good quality coking coal reserves of higher seams are fast depleting and hence coking coals of difficult cleaning characteristics of lower seams (LVC) are being now explored. Due to increased mechanization of coal mines to cope up the increased demand and followed by size reduction of lower seam coals in search of better liberation , the coal fines are increasing by leaps and bounds. The processes used for washing coking coal is Jigs, Heavy medium bath and Cyclones for the sizes upto 0.5mm, while the coal fines are washed in spirals and conventional flotation cells."

Jan 1, 2018

By Magnus Evertsson, Rebecka Stomvall, Josefine Berntsson

"Understanding the effect of particle shape on dry rheology is considered to be an important aspect in order to replace natural sand used in concrete with manufactured sand. Crushed particles from solid rock are normally less rounded and have less equally shaped dimensions compared to natural sand. Thus, the flowability and workability of the concrete will be different. In previous research, it has been demonstrated how different crushing techniques affects the shape of the particles. In many cases it is believed that Vertical Shaft Impact (VSI) technology is a way forward to replace natural sand. To be able to study the effect of VSI at the smaller fractions (63-2000 µm) sufficient measurements methods to determine particle shape are required. Optical tools to analyze the aggregates would make it possible to study a large amount of particles at small fractions. The determination of particle shape of aggregates is challenging since the shape is highly irregular and the size span of particles are very large. This study aim to evaluate one of the available optical tools, the Camsizer, for digital imaging determination of shape and size distribution. The available default shape parameters of the Camsizer are studied to understand the meaning of the parameters and their suitability for determining the quality of manufactured sand. To evaluate the capacity to determine particle shape, tests are made with 35 different materials. The results are compared with the dry rheology measured with the standardized "flow cone" test. Dependence has been previously proven between particle shape and the mass flow rate in the cone. Three different shape parameters, aspect ratio, sphericity and symmetry, are studied with the Camsizer and the results are compared with the mass flow rates in the cone. The results indicate a strong linear relationship between the optical parameters and the flow cone test."

Jan 1, 2014

By Mojtaba Ghorbannezhad, Abbas Sam, Soroush Arabzadeh

One of the dewatering methods in mineral processing plant is filtration system. Disk filters are included the porous surface with pressure drop on both sides, Water in the pulp passes through the surface and solid particles remain as a cake on it. Wet concentrate production of magnetite processing plant at Golgohar Mining and Industrial Company with solid tonnage of 160 ton per hour and 49% solid amount contains 166 m3/h of water. In the present study, in addition to studying disc filter performance, the effective parameters on cake moisture were studied using Vacuum Bottom-Feed Leaf method (in the laboratory scale). Optimization was performed using the Taguchi method. The results showed that the cake moisture is reduced by increasing particle size and solid percentage (because of specific resistivity reduction), while the rate of cake formation and its thickness are increased. Also, it was found that by increasing pressure, the cake moisture is reduced and cake formation rate and its thickness are increased. In this study, the effect of fabric texture was also examined. Lowest cake moisture was obtained in condition of using compressed plain fabric with mono-multi filament fibres, pressure at 75kPa, solid percentage of 65 to 70, particle size (D80) equivalent to 123µm and disk rotation speed of 1.25 rpm.

Jan 1, 2014

By P. Fecko

The objective of the paper was application of bacterial leaching on two brown coal samples from locality Mine Druzba, seams Antonin and Josef (Sokolov brown coal basin, Czech republic). Based on the results of bacterial leaching and petrologic analyses of the given samples, it is possible to say that application of bacterial leaching gived good results. Applying bacterial leaching it is possible to remove from 34% to 47% of total sulphur and from 45% to 64% of pyritic sulphur from the coal.

Jan 1, 2014

By Z. Q. Zhang

The iron ore from Yichang in China assaying 41.64% Fe and 1.02% P is a low grade and high phosphorus oolitic hematite ore. The separation of iron minerals from gangue minerals in the ore by conventional processing techniques is ineffective owing to their close similar properties. The modification of iron minerals by microwave-assisted reduction was investigated in order to improve separability of the ore. The effects of microwave-assisted reduction on the subsequent low intensity magnetic separation and floatation were examined. The results show that the main factors affecting the reduction and separation process are grinding size, reduction temperature and reductant. Fine grinding of the microwave-treated ore to smaller than 0.074mm was found to be imperative due to the tiny dissemination characteristics of iron oxide minerals. After magnetizing reduction by microwave heating at 500?, the magnetic concentrate containing 58.36% Fe and 0.67% P can be obtained with the Fe recovery of 91.28%. Magnetizing reduction drops the floatability of iron oxide minerals, thus reverse flotation is fit for upgrading the magnetic concentrate to contain 62.13% Fe and 0.21% P with Fe recovery of 81.59%. Compared with present microwave-assisted reduction technique of carbon reductant, using a waste iron powder as reductant is a novel and effective technique without the green house effect caused by the release of CO and CO2. Waste iron powder with a faster response to microwave heating then coke and charcoal can be recovered by magnetic separation in a low cost and plays the role of reductant and microwave heating accelerator.

Jan 1, 2014

Flinders Power, formerly NRG Flinders, is considering the possible use of low rank coal from Lake Phillipson, South Australia (SA) in its power stations at Port Augusta, SA. Typically, this coal contains about 35% moisture and 10% ash. Unfortunately, it also contains high levels of sodium (1% Na) and chloride (0.95% Cl) with a Na2O level in ash of 18.9%. Such levels cause serious problems during coal combustion, making the use of as-mined coal impractical for power generation. This paper describes the development of an aqueous leaching technique to remove 90% of the sodium and chloride and to yield a product with a Na2 O level in ash of less than 3%. Small-scale agitation leaching tests with good quality tap water at ambient temperatures showed that the coal needed to be crushed to minus 5.6 mm to obtain maximum removal of water-soluble sodium and chloride in 30 min. Leaching kinetics, but not the ultimate removal of salt, were enhanced by the use of higher temperatures (up to 150°C), but this was deemed uneconomic. Varying the pulp density between 20% and 50% had little effect on extractions and there was no benefit in multiple stage water washing. The best results by water leaching were 69%~74% extraction for sodium and 95%~97% for chloride, meaning that the sodium removal was well below the target level. From SEM examinations of the leached product it was concluded that the remaining sodium was organically bound to the carbon atoms in the coal. Further tests using aqueous solutions containing cation exchange additives such as calcium chloride (CaCl2) or ammonium chloride (NH4Cl) or sulphuric acid (H2SO4) showed that significantly enhanced sodium extractions were possible and target specifications were met. Two options, namely a single-stage and a two-stage leach, were then investigated. In a single-stage leach with additive, minus 5.6 mm coal was leached at 33%~50% solids for 30 min at ambient temperature and then filtered and washed with fresh water. This gave a sodium removal level of about 81% and a Na2O level in ash of about 5%. These levels do not quite meet tar-get specifications. In a two-stage leach, the coal was first leached with water alone without an additive as in the single stage leach, and the washed residue re-leached under similar conditions for about 5 min with an additive (CaCl2), and then filtered and washed. This gave a cumulative sodium removal of 96% and a Na2O level in ash of 1.4%~2.4%. These levels are well within target specifications.

Jan 1, 2014

Producing robust agglomerates with desirable structural properties is the key to success of the heap leaching of complex, low-grade nickel laterite ores. Mechanically strong but porous agglomerates with narrow size distribution (e.g., 5 ? 40 mm) are required to build permeable and perennially stable heaps of 4 ? 10 m height. The characterization of granules? microstructure is essential for greater understanding and correlation with the concomitant mechanical properties and robustness. In this study, we used non-destructive, computed X-Ray tomography analyses and scanning electron microscopy (SEM) in tandem with conventional compressive strength,and integrity/stability tests to draw links between nickel (Ni) laterite agglomerate strength/stability, internal microstructure (e.g.,porosity, inter-particle bridges) and binder type. It is shown that binder composition (e.g., tap water vs. 30% w/w H2SO4) and post-agglomeration drying both significantly impact on granules? physicochemical and microstructural properties. Acidic binder, in contrast with tap water, leads to significant incongruent leaching of different species from particles during ore-binder mixing and agglomeration. Upon wet agglomerate curing, solidified/recrystallized leached species form strong intra-granular solid bridges which, lead to greater compressive strength of dry agglomerates. Structural stability/integrity of cured agglomerates in acidic solution, however, decreases dramatically due to greater porosity and acid solubility of intra-granular solid bridges. These findings are useful in shedding more light on agglomerate structure characteristics and their optimization for enhanced column and heap leaching with concentrated sulphuric acid.

Sep 1, 2012

By Shankar Narasimhan

Data Reconciliation is a technique that has been developed more than fifty years ago and has been refined over the past few decades and is now being deployed routinely in several process industries such as refining, petrochemicals, mineral processing and hydro-metallurgy. The main aim of data reconciliation is to obtain accurate estimates of all process variables and parameters using plant measurements that are invariably corrupted by random errors and may also contain biases and other gross errors. These reconciled estimates are subsequently used either in offline exercises such as simulation, retrofitting, and de-bottlenecking or in online optimization and control applications. In this presentation, a brief history of data reconciliation, its assumptions, and uses are reviewed. New developments in this area are highlighted such as robust data reconciliation to handle model uncertainties, and reconciliation using identified models derived purely from operating data. Several case studies in the mineral processing industries reported in the literature are also highlighted to indicate the potential benefits of this technique.

Sep 1, 2012