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By N. Acarkan

Beneficiation of the pyrite concentrate of the Kastomonu-Küre (Northern Turkey) copper ore seems to be attractive due to its high Cu, Co, and Zn contents. Pyrite concentrate were used in the experimental studies. Cu, Co, and Zn were recovered from the concentrate by the sulphatizing roasting, leaching and the precipitation using H2S. Sulphatizing roasting experiments were carried out in a rotary furnace and the optimal roasting conditions were found to be at 650°C roasting temperature and 3.0 h roasting period and addition of Na2SO4 of 3 % for the concentrate containing 0.58% Cu, 0.22% Co, and 0.04% Zn. Then, the roasted product was repeatedly leached with 10 g/L H2SO4 solution. Optimal conditions were found to be 60 oC leaching temperature, 2 h leaching period, and 30% pulp density. Leaching efficiencies for Cu and Co were over 99 %. The valuable metals in the pregnant solution were selectively precipitated by H2S as sulfides. Selective precipitation of Cu, Zn, Co was achieved by adjusting the pH and the temperature of the leach solution. Final metal recoveries of 99.20% Cu, 99.40% Co, and 95.60% Zn were attained. The precipitated sulphides are marketable products. Roasting gases with their 15% SO2 content are suitable for the production of H2SO4 and the leach residues can be integrated with the iron ore processing plant as they contain 57.50 % Fe, 17.70% gangue (SiO2, CaO, etc.), 0.04% S, and 0.06% non-ferrous metals.

Jan 1, 2014

By Steven Bradshaw, Edson Charikinya

The application of high power microwave energy to secondary crusher products has been shown to induce micro fractures and cracks in the ore. This suggests that heap leaching could benefit from microwave-induced fractures, as the extent and kinetics of heap leaching processes depend on the accessibility of grains to lixiviants, which can potentially be improved through microwave treatment. The density and pattern of microwave induced cracks and how these cracks subsequently affect heap leaching recovery has not yet been investigated. The objective of this study was to apply X-ray micro computed tomography (X-ray CT) to investigate microwave induced cracks in large cone and HPGR crushed sphalerite particles within 3D space. The ore particles were microwave treated in a single mode microwave applicator coupled to a switched mode power supply and a water cooled microwave transmission sub system operating at 2.45 GHz. The ore particles were treated at specific absorbed microwave heating energies of between 2 and 3kWh/t by treating at 6 kW of forward power for treatment times of 1 s. X-ray tomography analysis was conducted on fine (-5+4.75) mm, medium (-16+9.5) mm, and large (-25+19) mm sphalerite particles before and after microwave treatment at voxel resolutions of 5 µm, 15 µm and 25 µm respectively. Image segmentation, thresholding and spatial registration techniques were used to study crack patterns in 3D images of HPGR and cone crushed particles. Analysis of the X-ray CT images after microwave treatment shows considerable micro crack formation within the Cone and HPGR crushed particles. The cracks pattern showed interphase cracks propagating across all phases, with no evidence of preferential cracking. A greater density of microwave induced cracks was observed on fine (-5+4.75) mm particles compared to the medium (-16+9.5) mm and (-25+19) mm large particles. The results showed overall increased particle porosity following microwave treatment.

Jan 1, 2014

By Gaurav Soni, Roe-Hoan Yoon

A first principle flotation model has been derived from the basic mechanisms involved in flotation. The model consists of a series of analytical equations for bubble generation, bubble-particle collision, attachment, detachment, and froth phase recovery. The model can predict flotation from both hydrodynamic and surface chemistry parameters such as bubble size, particle size, energy dissipation rate, ?-potentials, contact angles (?), etc. The model predictions have been compared with the results of a series of laboratory flotation tests conducted using mono-sized glass beads of different particle sizes and contact angles under different operating conditions. Some of the experiments were conducted using a 1:9 mixtures if hydrophobic silica and hydrophilic magnetite, so that the product graded could be readily determined by simple magnetic separation. The model predictions are in good agreement with the experimental results both in recovery and grade. A computer simulator developed on the basis of the model is capable of designing a preliminary flotation circuit on the basis of feed characteristics, e.g., size-by-liberation data, and the hydrodynamic information on the flotation cells to be incorporated in the circuit.

Jan 1, 2014

By Alan Bax, John D. Lewins

"Platinum Australia Limited (“PLA”) is currently undertaking a Feasibility Study into the development of the Panton Platinum Palladium Project located in the Kimberley region of Western Australia. The Panton Intrusive is a layered, differentiated mafic to ultramafic structurally complex body that has undergone numerous folding and faulting events. This has resulted in a southwesterly plunging synclinal structure some 10 kilometres in length and 3 kilometres wide.High grade PGM mineralisation is hosted within a number of stratiform chromitite reefs within the ultramafic sequence. The focus of the Feasibility Study is on the Top Reef which is situated approximately 150 metres below the mafic/ultramafic interface. The average true width of this reef is approximately 1.2 metres and the reef has a defined resource is 10.1 million tonnes at an average grade of 6.1 g/t PGM + Au.The Palladium to Platinum ratio of the Top Reef is approximately 1.15:1 and the reef also contains an average of 0.4 g/t Au and 0.3 g/t other PGM’s. The Panton ore is considered refractory in nature and standard flotation techniques achieve a PGM + Au recovery of less than 65% with a concentrate grade of less than 100 g/t PGM + Au. As part of the Feasibility Study Platinum Australia in conjunction with their major shareholder Lonmin Plc developed a new metallurgical process which has achieved an overall PGM + Au recovery of approximately 80% into a high grade PGM concentrate which is suitable for feeding direct to a PGM refinery.THE PANTON PROCESSThe Panton Process incorporates a two-stage Milling and Flotation circuit with no cleaning stages to produce a low grade, high recovery flotation concentrate. Typically the concentrate mass constitutes 25% of the feed and has a PGM + Au grade of 25 g/t.This low-grade concentrate is subjected to calcination in a rotary kiln or fluid bed at a temperature of approximately 400 0C for a period of 60 minutes. This step is designed to render the platinum minerals soluble in cyanide and both the temperature and the duration of calcination are critical to the efficiency of the leaching process."

Jan 1, 2003

By Brian Hart, Rong Fan, Roger Smart, Andrea Gerson, Ning Xu

A complete strategy has been developed for identification of the reasons for losses in recovery and/or grade, due to changes or complications in mineralogy and in mineral surface conditioning, and their subsequent correction. The sequence of methods starts with comparison of mineral phases between QEMSCAN/MLA (compositional) and Rietveld XRD (crystalline diffraction) with bulk assay reconciliation. This methodology has recently led to identification of unrecognised amorphous content (12-40 wt.%), previously attributed to crystalline phases, in the fine fraction (<35 µm) of some problematic flotation feeds. Attached amorphous silica, talc- and chlorite-like fines have direct influence on the hydrophobic/ hydrophilic ratio on value mineral surfaces adversely affecting flotation. SEM/EDS is used in the backscattered imaging mode to determine possible problems with liberation (e.g. remnant local locking), not detected in standard liberation analysis, resulting in gangue flotation. EDTA extraction is used to assess bulk feed pre-oxidation and sequential oxidation product loading through the circuit. Changes in circuit solutions are assayed with speciation modelling of precipitates and potentially adsorbing species. ToF-SIMS with principal component analysis is then used to correlate surface species with specific minerals and can be used to assess the effectiveness of specific reagents particularly collectors. This approach identifies unwanted activating species and interference with value surfaces by adsorbed hydrophilic ions, precipitates and fine particles. When the interference or ineffective reagents are specifically identified, remedial action can be targeted. This method has identified residual talc-like layers (<10 nm thick) inducing gangue flotation of pyroxene and chromite in PGM flotation. Recent case studies of application of the full methodology to losses of molybdenite at KUCC and to sphalerite activation in the Cu/Pb circuit at Brunswick Mines with remedial action are discussed.

Jan 1, 2014

By B. McFadzean

Thiol collector mixtures are commonly used in the flotation of base metal sulfides and platinum-bearing ores. There are synergistic benefits claimed for these collector mixtures, with mixtures lowering total dosage requirements, improving coarse particle recovery and the rate of flotation. Some of the secondary collectors are known to have frothing effects. Therefore, a previous study aimed to decouple froth and pulp effects and considered only the bubble-particle attachments in the pulp. This was achieved through microflotation experiments, where various ratios of the ethyl and isobutyl chain lengths of xanthates, dithiocarbamates and dithiophosphates were used as collectors. Results from these experiments showed a marked increase in galena recovery using mixtures of xanthate with either dithiophosphate or dithiocarbamate. In the current study, the froth phase was introduced in the form of batch flotation studies to determine whether benefits noted during microflotation experiments would be carried through to a more realistic froth flotation scenario. The findings show that there was no significant difference in the flotation recovery between the best single collectors and mixtures of these collectors. In addition, single collectors that behaved poorly in microflotation experiments showed good flotation performance in the batch flotation experiments. The differences between the microflotation results and the batch flotation results are attributed to differences in particle froth stabilizing properties and/or differences in energy input between the microflotation and batch flotation cells. In addition, galena and pyrite showed marked differences in frothing effects and in their preferences for collector type. Keywords: froth flotation, collector mixtures, sulphide minerals

Sep 1, 2012

By N. Naudé

The theory on particles displacement subjected to upwards and settling movements in water, using a water pulse, is described in literature, but very little experimental data is available to verify these theoretical ideas. The aim of this research work was to visualize the displacement of solid particles in a mixture of water and solid particles created with the aid of water pulses in the Mineral Density Separator. From the literature it is known that lighter particles are subjected to higher levels of displacement than heavier particles, and when the particles then settled down, layers of material are formed ac-cording to the densities of the material. By removing the individual material layers, the materials can then be separated according to their densities. During this study the individual material layers were investigated regarding the density and size distribution in that specific density layer. It is important for this project to have a statistical prediction of the ?real? flow of the particles with different density and size distribution, inside the Mineral Density Separator. The information gathered during this study will be used to show the correlation between a two dimensional model of the particle flow and that of the real three dimensional flow inside the Mineral Density Separator.

Jan 1, 2014

By Marko Hilden

"A stochastic model of mineral texture is discussed and used to demonstrate that grain association within the intact texture has a significant effect on the liberation characteristics of breakage products. The majority of previous models have simulated texture and liberation of binary systems. This new model is able to simulate complex multi-component (multi-mineral) aggregate textures and their breakage products. Grain size distributions can be defined for each of several minerals. Mineral-mineral associations can be controlled by inserting mineral grains within grains of another mineral. Repeated Monte Carlo sampling of the aggregate is used and the liberation properties of the fragments are calculated. These are analysed to generate data in a similar form as reported by mineral liberation analysis systems, including density distributions, liberation distributions, and particle class distributions. Simulations results are presented where the model has been fitted to complex sulphide ores with four minerals. Comparison of the simulated particles and experimental data show that the model is able to reproduce similar particle class distributions as measured by QEMSCAN. The texture of real complex ores can be simulated and fitted to conventional mineral liberation analysis data. The model should provide a useful and practical means of modelling the effects of mineral texture on separation processes and in geometallurgical models."

Jan 1, 2014

The reactivity of clay minerals and variety of these reactions are greater than any other known colloidal material. While it is acknowledged that clay minerals can cause problems in mineral flotation, the literature contains conflicting evidence, particularly with respect to the effect of clays on froth stability. It is well known that achieving and maintaining optimum froth stability is an influential factor in determining froth flotation performance. However, the presence of clay minerals in the ore is a major challenge to obtaining a stable froth. In fact, clay minerals could reduce froth flotation performance by both decreasing and increasing froth stability. The mechanism by which clay minerals affect froth stability is not fully understood and needs to be investigated further. In order to improve flotation performance, reliable knowledge of the effect of clay minerals on froth stability is essential which is discussed in this paper. Keywords: froth flotation, froth stability, clay, clay minerals

Sep 1, 2012

By Bruno Michaux, Markus Reuter, Martin Rudolph

"It is relatively well-established in the literature that the flotation of calcium minerals using fatty acids as collector is very sensitive to the process water composition. In particular, hard waters have often been reported to strongly reduce the target mineral recoveries due to the formation of insoluble compounds such as calcium and / or magnesium dioleate, thus reducing the amount of collector available for adsorption onto the mineral surface. In this study, the flotation of a fluorite pre-concentrate was performed with tall oil, an industrial collector essentially containing fatty acids. The tests were performed in a variety of synthetic waters to simulate multiple degrees of water hardness, and to differentiate the role of magnesium and calcium ions on the flotation performance. The flotation tests revealed that, under the studied conditions, a significant difference between flotation in calcium-rich and magnesium-rich waters was observed, suggesting strong ion-specific effects in the system. Specifically, calcium-rich waters slightly improved the fluorite recovery, whereas magnesium-rich waters caused a decrease in recovery by as much as 20%. This paper is focused on the flotation kinetics aspect of the system. This approach highlighted the interesting finding that calcium ions did not simply increase the fluorite recovery, but also significantly increased its flotation kinetics. The magnesium ions, on the other hand, had the exact opposite effect.INTRODUCTIONAs the mining industry is facing an increasing number of issues related to its fresh water consumption, the idea of using alternative water sources for mineral beneficiation is gaining significant momentum. As a result, a proper understanding of the role of water chemistry in flotation is becoming more and more urgent, leading to an increasing number of studies on this topic."

Jan 1, 2018

By Heikki Häkkänen, Tommi Kauppinen, Navid Khajehzadeh

"There are a variety of methods suitable to analyse elemental and mineralogical contents of rock drill core samples. Current demands are on fast exploration and objective analysis of ore samples. This paper proposes a combination of Laser-Induced Fluorescence (LIF) and image processing, entitled LIF-imaging, as a potential method for automated mineral analysis of the drill core samples. It is shown that LIF-imaging can produce a mineral map of the fluorescent minerals existing on the surface of the drill core samples. The test cases are drill core samples from a Ni-Cu mine situated in Kevitsa, Finland. The main prerequisite of LIF-imaging technique is a reference data, linking colours to the minerals. This study describes the calibration of LIF-imaging technique using precise but slow Raman spectroscopy. Using regularized logistic regression, a model is obtained that classifies the minerals based on their emitted fluorescent colours in the digital images. The abundance of each mineral group is estimated by pixel counting. The results are compared with X-Ray Diffraction laboratory assays performed on the same samples. The results show that the interpretation of the fluorescent minerals through LIF images corresponds to the XRD results. Furthermore, the utilization of the logistic regression to interpret the existing fluorescent minerals greatly improves the technique."

Jan 1, 2014

By W. Z. Zu

In proved reserves of vanadium-containing titanomagnetite in Panxi, China, iron grades of ores were 50% ~ 15%. China?s metallurgical industry departments defined the iron ores containing 50% ~ 20% TFe as exploitable resources and the extreme lean iron ores containing 20% ~ 15% TFe as temporary unexploitable resources, the extreme lean ores were as waste rejected into waste dump in mining process. This paper researched process mineralogy of the extreme lean ores, adopted mineral processing technology responded to the properties of the ores to treat the ores and obtained quality vanadium-iron concentrate, titanium concentrate and sulfur concentrate, therefore successfully utilized the extreme lean ores, changed the ores from waste resources to exploitable resources.

Jan 1, 2014

By G. Mucsi

This paper deals with the laboratory investigation of cathode ray tube (CRT) glass based glass foam, a relatively new product so called ?Geofil bubbles?. The main process engineering material properties of raw materials, such as particle size distribution, moisture content, density and specific surface area are shown. Then the preparation of raw cathode ray tube glass waste is presented including the following steps: crushing in impact crusher, grinding in laboratory scale ball mill, mixing, pelleting and sintering. We found that it was possible to produce foam glass (with proper mechanical stability and particle density) from the investigated waste CRT glass. The material characteristics of the final product strongly depend on the sintering conditions. Optimum conditions were determined particle size fraction was found to be 4-6 mm, temperature 800 0C, residence time 7.5 min. Keywords: waste CRT glass, grinding, pelleting, sintering, glass foam

Sep 1, 2012

By Vladimir Vigdergauz

"Electrochemical studies of metal sulfides in connection with their floatability are discussed. According Frumkin, sorption of electroneutral organic substances has a maximum near the potential of zero charge. This idea initiated attempts of application of electrochemical methods for the controlling of organic collector sorption and mineral flotation. The lecture reviews results of electrochemical studies of the processes taking place during sulfide flotation: redox-state of mineral surfaces and xanthate solutions, xanthate sorption and hydrophobic layer composition, surface wettability and flotation recovery of sulfide minerals. Redox-transitions of minerals, transport of ions and charging of mineral surfaces, electroreduction of dissolved oxygen and accompanying processes of oxidation of minerals and reagents-collectors, - all these matters became the subjects of detailed research. Cyclic voltammetry, rotating disk electrodes, spectro-electrochemical techniques and other modern experimental methods now routinely accompany studies of mineral processing. Relatively new electroanalytical techniques like the voltammetry of mineral particles immobilised on electrodes using polymeric binders have become extremely useful for studying weakly conductive minerals and dispersed flotation products. Full discussion of electrochemical studies of metal sulfides in relation to mineral processing must include bioelectrochemistry and electrocatalysis which open exceptional possibilities for selective leaching of gold and non-ferrous metals. At this time, the paper focuses on the sulfide flotation as a potential-dependent process; the problem of oxygen and its influence on the sulfide flotation; the electrochemical aspects of xanthate oxidation and sorption; theory of suspended electrodes as applied to the mineral slurries and experimental study of the effect of electrochemical pretreatment of flotation pulps."

Jan 1, 2014

By Dave Deglon

The Western Cape Mineral Processing Facility (WCMPF) is a collaborative educational initiative between the Departments of Chemical Engineering of the University of Cape Town, the University of Stellenbosch and the Cape Technikon. The WCMPF was established in 1989 with the aim of improving mineral processing education in the Western Cape. Since its inception the WCMPF has had a number of successes in this area, especially in improving the quality of mineral processing practical training. In addition, the WCMPF has played an important role in promoting liaison and interaction between tertiary educational institutions teaching mineral processing in the Western Cape. Over the past decade the WCMPF has played a key role in the education of over five hundred mineral processing graduates and diplomates. This paper presents an overview of the activities of the WCMPF and attempts to encapsulate the ‘lessons learned’ from over a decade of successful functioning as a collaborative educational initiative in mineral processing.

Jan 1, 2003

By A. V. Golovanov, A. V. Mihailova

"NPO RIVS employs complex approach to engineering and design of the new facilities in close cooperation of Mining, Research, Hydrometallurgy, Design, Construction, Power Supply, Automation, Production and other departments. General Design Contractor (and then General Contractor) is directly involved in geological exploration, engineering surveys, floatability studies, feasibility study of process solutions and construction options. It delivers greenfield project and guarantee its efficient performance in future. Shiralgin is a small gold and copper deposit, gold average grade is 4.7 g/t. RIVS departments have studied ore floatability, developed process procedures for design and performed pilot testing. Construction of integrated plant including ore crushing and grinding, flotation and hydrometallurgy units with Dore gold production of 5 000 thousand tons ore per year (66.7 t/h) is recognized as economically viable. The technology used of separate dry stockpiling of flotation tailings and cyanidation tailings. Water circuit for concentration and hydrometallurgy is separated, too. Process design was performed based on BIM software like Autodesk Revit, Civil 3D, Rocscience slide using process procedures developed by RIVS Research units. Engineers provided modeling of primary crushing unit, coarse ore storage, main building (including grinding, flotation, thickening, filtration, loading, hydrometallurgy), tailings thickening unit, building for reagent storage and conditioning, tailings pond for dry stockpiling of flotation tailings and cyanidation tailings, sedimentation ponds, laboratories, infrastructure including Administration building and camp. Payback period is 3.5 years. 3D model of facility is currently stored at the State Agency of Geology and Mineral Resources affiliated to the Government of the Kyrgyz Republic.INTRODUCTION The Kyrgyz Republic has substantial potential of mineral resources including gold ores. Mining industry actively develops and involves international investors. Inventory includes 42 deposits (Figure 1) that have reserves of 616.4 t [1] of gold. The Kyrgyz Republic takes the third place in gold mining among CIS countries after Russia and Uzbekistan by producing up to 20 t annually."

Jan 1, 2018

By Neill Bartie, Jacques Eksteen, Sharif Jahanshahi, Shouyi Sun

The gradual increase in Cr2O3 levels of UG-2 ores has become a matter of concern for platinum producers in South Africa due to the formation of chromite spinels in melters. The effect of bulk FeOx/MgO ratio, Cr2O3, temperature and oxygen partial pressure on phase stability and composition in the system FeOx-MgOSiO2- Cr2O3-Al2O3-CaO has been studied between 1400°C and 1600°C using the drop-quench technique. An increase in temperature was found to result in a decrease in [Fe/Cr]spinel. An increase in bulk FeOx/MgO caused Mg, Al and Cr in spinel to decrease, forming more magnetite relative to other spinels. [Fe]spinel decreased and [Cr]glass increased with a decrease in oxygen partial pressure.

Jan 1, 2003

By S. Castro

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

Sep 1, 2012

By Sergio Castro, Janusz Laskowski

In the flotation in highly concentrated electrolyte solutions not only ionic strength but also chemical composition, flotation pH and mineral properties play an important role. As a result an improvement or depression may be observed. A strong improvement in the floatability of hydrophobic bituminous coals and other inherently hydrophobic minerals is characteristic for the "salt flotation process", which is carried out in concentrated electrolyte solutions at natural pH and without addition of any flotation reagents. However, pH is a key factor when saline and hipersaline waters with hydrolyzing metallic ions are used as process water. In the case of flotation of Cu-Mo sulfide ores in seawater, molybdenite is strongly depressed by the Mg2+ hydrolysis products when pH is raised to depress pyrite. Process water with a high content of Mg2+ and Ca2+ ions, and this also includes seawater, have deleterious effect on the anionic flotation of industrial minerals with fatty acids. The flotation of potash ores is carried out in NaCl-KCl saturated brine (6-7 mole/L of NaCl and KCl) with the use of long-chain amines. Such a high electrolyte concentration changes dramatically the amine Krafft point making the collector insoluble in brine; its mode of action entirely differs from that in conventional flotation processes.

Jan 1, 2014

By X. Y. Zeng

Most Chinese titanium bearing minerals are the composition of magnetite vanadium and ilmenite. All of such mineral processing plants use low intensity magnetic separators to recover magnetite and vanadium goes with magnetite. In the past years most of the plant tails containing about 10% TiO2 were abandoned. Now many of these plants use SLon magnetic separators to recover ilmenite in the roughing stage, which can throw away most of the gangs and slimes with very low cost. The new development of applications of SLon magnetic separators in Chinese ilmenite processing industry is introduced in the paper.

Jan 1, 2014