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By Ronald Smeink, Ton de Gouw

"Reagents are an important cost-factor in the flotation of minerals. The mechanism of collectors and frothers has been studied extensively, but on depressants – probably the biggest cost-factor in the reagent suite – very little is actually known. Theories are frequently faced with the bare facts, pointing in another direction. Fundamental research is complicated by the fact that the amount of possible interactions in the flotation cell is almost unlimited and makes “change-one-parameter-at-a-time” experiments questionable and at least difficult to interpret. Also, the adsorption of depressants on the ore is very strong and desorption merely impossible. Detection methods therefore tend to be indirect and – therefore - non-specific about the location of the depressant on the ore.Depressants are supposed to adsorb selectively on gangue minerals; not on the valuable minerals in the froth. In order to be able to develop better and ‘’smarter’’ depressants, an analytical method is therefore required that will enable to detect which (=qualitatively) depressant, in which concentration (=quantitatively) sits where exactly (= selectively) on the mineral surface. (Answering the question: ‘’ Which minerals is located direct under the depressant?’’)And also: does the depressant compete with other reagents for that location? (like collectors) This analytical method is under development. The actual status of the method is promising and the results will be shown."

Jan 1, 2003

By John Ralston, Jonas Addai-Mensah, Patience Mpofu

The flocculation and dewatering behaviour of kaolinite (non swelling) and smectite (swelling) clay dispersions has been investigated using hydrolysable metal ions Mn(II) and Ca(II) and anionic polyacrylamide-acrylate copolymer (PAM) at pH 7.5 and 10.5. A pH-dependent, specific metal ion adsorption behaviour, accompanied by a marked reduction in particle zeta potential and slurry shear yield stress, was observed to have a profound influence on the colloid stability of both types of clays. Due to the differences in the cation exchange capacity, the smectite clay dispersion required a higher amount of metal ions than kaolinite dispersion to produce similar effects. The adsorption density of the anionic PAM at the negatively charged clay particle surfaces correlated well with metal ion hydrolysis and adsorption behaviour, all of which had a strong effect on slurry settling rate and extent of consolidation. At pH 7.5 where Mn(II) ions hydrolyse, metal ion and flocculant adsorption densities were both greater in the presence of Mn(II) than Ca(II) ions. At pH 10.5, however, where Ca(II) ions begins to hydrolyse, higher adsorption densities were observed for Ca(II) ions in comparison with Mn(II) ions, as the latter hydrolysed completely and precipitated. The metal ion mediated flocculant adsorption led to improved hydrogen bond driven particle bridging and facilitated charge neutralisation flocculation mechanisms which significantly enhanced the dewaterability of both clay dispersions.

Jan 1, 2003

By Briony C. Ruse, David V. Boger, Fiona Sofra1

"The sustainability of the mining industry must be addressed through improving tailings management. The use of thickened tailings and pastes stems from a paradigm shift towards designing tailings disposal sites to suit their surrounding environment, rather than manipulating the environment to accommodate the tailings. Thickened tailings and pastes usually exhibit non-Newtonian behaviour, so a thorough understanding of the rheological characteristics of the material is required in order to determine the disposal plant operating conditions.As environmental factors translate into economic issues, minimising waste production using dry disposal methods is gaining popularity. The use of rheological information is of high importance in evaluating the spreading characteristics, the transportation and the dewatering of thickened mineral tailings. The principles outlined may be applied to many industries encompassing a wide range of waste materials. The main obstacle to the widespread implementation of dry disposal methods has been the high initial capital cost of the methods due to the dewatering step, and the high cost of pumping thick suspensions across any great distance. Proper and thorough costing of tailings disposal activities combined with an accounting approach that shows closure and post-closure care costs on a per tonne basis of tailings disposed throughout the life of the tailings facility will show that dry disposal methods are more favourable than they might seem on initial appraisal."

Jan 1, 2003

By Pradip, Beena Rai

A molecular modeling study was carried out on an adsorbed oleate monolayer on the surfaces of three calcium minerals, fluorite, calcite and fluorapatite using Universal Force Field (UFF) potentials. The cleavage plane of calcite {104} was the best template for oleate monolayer adsorbed since the surface structure enabled all the calcium sites available on the surface to be occupied by oleate anions. The area occupied per chain of oleate in this well packed monolayer was computed to be 20.2 Å, which exactly matches the value calculated to be the parking area per oleate molecule for a fully packed monolayer based on strictly geometric calculations. On the other hand, the precentage of calcium sites occupied by oleate to achieve a fully packed monolayer in case of fluroite and and fluorapatite was found to be 67% and 75% respectively. The results of this theoretical study suggest that while all the three adsorption conformations, that is unidentate, bidentate and bridging type are equally likely on fluorite and fluorapatite, bridging is most likely on calcite. Interestingly, all the conformations are observed experimentally for calcite-oleate system also. The reasons for this discrepancy between the theoretical predictions and experimental observations are not clear. More work is required to resolve this discrepancy, in particular simulation studies in presence of solvent water molecules on the surface.

Jan 1, 2003

By G. Belardi, N. Shehu, L. Passeri

"This paper illustrates the possibilities of applying what is essentially a physical soil-washing technique for treatment of soil contaminated by semi-volatile hydrocarbons in order to reduce the level of pollution to that permitted by Italian regulations.The ground around a factory producing lubricating-oil additives consists of silty-sandy soils which have long been contaminated by heavy hydrocarbons, especially branched alkyl benzenes and naphthalene derivatives. Pollution is particularly marked in some zones (hot-spots) where Total Petroleum Hydrocarbon (TPH) values are as high as 7000 ppm. The hydrogeological characterization showed the presence of a gravely soil in a sandy/silty matrix, with big stones making preferential paths to the water circulation. The permeability is 10-5 m/s and the water-table occurs at about 3 m below ground level.After laboratory and pilot-scale studies on representative samples of in-situ soils with TPH between 2700 and 7000 ppm a flow-sheet is proposed for reducing TPH values below the acceptable limits in Italy, namely 700 ppm for hydrocarbons with more than 12 carbon atoms and less than 250 ppm for those with fewer.On the basis of indications provided by laboratory tests a mainly physical treatment process of soil washing has been developed. This is used to clean-up soil from a site polluted by non-volatile hydrocarbons with a high TPH value. The process involves a high-density attrition stage followed by wet screening at 0.5 mm and then wet-gravity separation of the minus 0.5 mm fraction in the centrifugal field.The gravity separation products consist of a light fraction with particle size finer than 15 micron which contains most of the pollutants, and a heavy coarse fraction with TPH values conforming to the limits set by Italian regulations (less than 700 ppm hydrocarbons whose structure contains more than 12 C atoms, and less than 250 ppm of hydrocarbons with less than 12 C atoms)."

Jan 1, 2003

By Shailin Lalloo, Allan B. Nesbitt

"Gravity separation by centrifugal equipment, particularly in the mineral processing industry is a novel approach of optimising product recovery. The manufacture and sale of centrifugal equipment by recently established companies is now beginning to have a significant impact on the industry. Some benefits of operating at increased gravity include: reduced environmental issues, a shorter lead time, lower capital cost and improved recoveries of elemental mineral before entering the grinding circuit.Of topical discussion is the use of centrifugal separators for the recovery of less valuable minerals that will form a greater proportion of the feed compared to traditional scalping circuits where the gold content is extremely low. This ultimately results in the centrifugal system having to have a greater mass pull. In addition, the relative density difference between gangue and valuable mineral is likely to be less and therefore modelling and optimisation of this separation process will be necessary. Some researchers have muted using fluidisation models to model the forces present in the separation zone of a centrifugal separator2. It is not unusual for the manufactures of centrifugal separation equipment to use fluidisation terminology to describe what happens in the separation zone. Most fluidisation models are based on the empirical/classic relationship between superficial fluid velocity and voidage postulated by Richardson and Zaki. However, no researcher has proved the effectiveness of this relationship in an increased gravity Environment."

Jan 1, 2003

By Kauko T. Ingerttilä, Jouko O. Kallioinen, Jaakko O. Leppinen, Alexander V. Lashkul, Vladimir E. Nenno

"Separation in Froth (SIF) is a process for the separation of mineral particles during their descent downwards through a moving froth layer, generated on the surface of water or some other liquid media by means of a bubble generator and frother. Due to the special operation principles of SIF it is possible to separate mineral particles that are about 10 times coarser than the optimal particle size for conventional flotation. In this paper the performance of the SIF technique is presented in the separation of apatite, calcite and silicate minerals from various industrial sources, based on tests with laboratory and pilot plant-scale SIF machines. Basic laboratory test results of the flotation of pure diamonds are also presented.It was shown that calcite, apatite and diamonds with particle size up to about 3 mm can be successfully floated with SIF at high recovery and grade, provided that the degree of liberation is sufficiently high. Coarse calcite (+0.25-2.8 mm) was concentrated with reverse SIF in one flotation step at 87% recovery with better than 99% grade. Apatite particles coarser than 0.2 mm are not well floated in the conventional flotation circuit leading to high P2O5 content in the coarse size fractions of flotation tailings. On the contrary, SIF is capable of recovering such coarse particles at high recovery. However, P2O5 content of the SIF tailings starts to increase at about 0.7 mm due to insufficient liberation of apatite. At higher particle size the lack of hydrophobicity of apatite particles is also likely to lower the recovery.The pilot plant testwork showed that SIF can be successfully used at operating plants not only for preliminary upgrading of the feed of conventional flotation, but also for producing final grade calcite concentrate (>99.5%) from the screen overflow or from the cyclone underflow in a particle size range up to 1 mm. It was particularly promising that the separation took place in one SIF flotation step, instead of several stages of the conventional flotation circuit, with over 90% calcite recovery. The specific capacity determined with the 1 m2 pilot plant unit was approximately 30 t/m2h. Simultaneously the consumption of chemicals was significantly lower than for conventional flotation."

Jan 1, 2003

By Chris A. Bennett, Glenn S. Dobby, David A. Bulled

Establishing reagent dosing strategies for new ore bodies has traditionally involved a combination of experience and empirical experimentation using standard laboratory tests. The grade and recovery data resulting from these lab tests have historically been used as direct indicators of plant performance despite the obvious differences between the flotation environments. A reagent scheme selected in this way would subsequently be employed to generate the grade and recovery information for the geometallurgical model which in turn was used for metal production and cash flow forecasts. If the reagent scheme was sub-optimal then so too would be the forecasts and the resulting cash flow.

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 J. B. Rubinstein

"The paper gives an overview of the history of flotation machine development. The laws of their evolution are stated and the place and role of column flotation are demonstrated.The major parameters of column cell diameter and height are discussed. Options are proposed for optimization of the hydrodynamic characteristics of large-capacity column cells. The high efficiency of columns with cell height of 4-6 m is demonstrated. The optimum parameters of multisectional column machines are determined. Their advantages compared to monocells are shown. A scaling-up procedure for column machines was developed based on flotation macro- and microhydrodynamics simulation."

Jan 1, 2003

By Jim Petrie, Mary Stewart, Damien Giurco

This paper describes a generic approach to analysing the environmental and economic performance of a generic global mineral/metal value chain, with the express view of improving the quality of prospective decision-making within the industry in order to ensure more sustainable outcomes. As a point of departure we propose that it is not possible to place metals in the context of the sustainable development of society without paying due regard to the entire metals value chain. Thus, the starting point for this analysis is the development of a global stocks flows and transformations model, for the metal of interest. Any aspect of the value chain, e.g. “metals refining, “goods manufacture”, “use and disposal”, can be assessed, either relative to other stages in the value chain, or in more detail by focusing on the technologies used within that stage. The use of this model as a decision support tool is explored here for the case of copper. Both primary and secondary production routes are enumerated, covering a range of processes, for seven distinct geographic regions around the globe. The value of the modelling approach is explored for different energy mixes. In particular, the case study examines the impact of increased recycling on the (re) distribution of global and regional environmental impacts for technologies-in-place in these different regions. The aim of these case studies is to highlight to the minerals processing and metals refining industries their potential role in a more sustainable global society.

Jan 1, 2003

By B. C. Qi

"In water treatment, flocculation or coagulation with aluminium or ferric salts has been widely used for many years to remove natural organic matter (NOM), including humic acids. However, the adsorption of NOM to aluminium hydroxide flocs during conventional coagulation/flocculation processes is very complex, with the flocculation of aluminium hydroxide particles and the adsorption of NOM molecules on flocs occurring simultaneously. Any effect on the surface characteristics and micro-structures of the humic acids and aluminium hydroxides could affect the adsorption efficiency.It has been widely observed that if a reaction system (liquid-liquid or liquid-solid) is exposed to an ultrasound field, under appropriate conditions, a variety of physical (emulsification, aggregation/flocculation) or chemical (the production of radical and exited species; single electrotransfer) actions may be activated. Though the ultrasound effects have been used in biological and chemical decontamination in many conventional environmental protection practices, the idea to explore the ultrasound effects in the removal of humic acids by preformed aluminium hydroxide flocs is relatively new. In this paper, the effect of an in-situ ultrasonication on removal of the humic acids extracted from the acidification fermentation of lignocellulosic residues, by a preformed aluminium hydroxide, was evaluated; the effect of ultrasonication on the surface complexation of the humic acids with the preformed aluminium hydroxides was investigated."

Jan 1, 2003

By James Y. Oldshue

"Very seldom is it possible when contacting a gas with a slurry to measure the dissolved gas concentration in the slurry, and even were it possible, seldom are equilibrium data available with a suitable Henry’s law constant.In general, by assuming a reasonable value for the dissolved gas concentration in the slurry and a corresponding equilibrium gas partial pressure P*, Kga values can be calculated for the pilot plant and scaled up. Then, with the same P* value at various reaction conditions, a mixer can be designed which is quite satisfactory, having a reasonable design factor for full-scale performance.We will take as an example a slurry of a known solids composition and use a continuous 4 tank system. By assuming a percentage saturation of the dissolved gas in the first tank, the dissolved gas concentration can be obtained in the other three tanks. It usually is possible to measure the off-gas composition in each of the 4 tanks. If the top of the tanks is connected in the form of a multi-compartmented horizontal autoclave, then a modified top off-gas composition in each compartment must be used."

Jan 1, 2003

By Johan C. van Dyk, Johan W. van Zyl, Martin J. Keyser

"Coal is a crucial feedstock for South Africa’s unique synfuels and petrochemicals from coal industry and it is used as the main feedstock to produce synthesis gas (CO and H2) via the Sasol-Lurgi Fixed Bed Dry Bottom gasification process. Detailed coal characteristics are essential to predict gasification behaviour when a specific coal source is to be gasified.The principle aim of this paper is to highlight and discuss those specific coal characteristics, which affect gasification behaviour and stability.In order to determine the suitability of a coal source for gasification purposes, the coal is characterized and the results compared with historical data. Benchmark data, where it was possible to operate the gasifier with ease and relatively high stability, is used as a reference.Coal sources with extreme properties (i.e. low reactivity, ash content <10% as is used by Dakota Gasification Company, or “brown coal” with moisture >30%) can probably be gasified in a Sasol-Lurgi Fixed Bed Dry Bottom gasifier provided that certain operational changes are implemented. Other properties, like high caking and extreme ash content for example, require blending to acceptable levels."

Jan 1, 2003

By Chris A. Fleming

"Interest in the recovery of cyanide from gold and silver plant tailings has heightened in recent years. This interest has been spurred by several factors:Increasingly stringent regulations throughout the gold producing world, governing discharge limits for free and total cyanide to tailings ponds and the environment.The increasing cost of active chemical treatment versus passive (natural degradation) treatment of tailing, to bring them in line with environmental regulations.The worldwide trend to processing of more complex gold ore bodies, which is usually accompanied by higher levels of cyanide consumptions and greater concentrations of cyanide (particularly the copper cyanide complex) in tailings.The growing negative perception of the general public for the gold mining industry, due to several highly publicized cyanide spills in recent years (breaches of tailings dams, accidents involving trucks carrying cyanide to gold plants, etc.).The ability to recover cyanide from gold plant tailings has been known almost as long as the cyanidation process has been practiced, but there has been little incentive to process tailings in this way in the past. With the development of technologies that make it possible to recover and recycle free or complexed cyanide directly from gold plant slurry tailings, which indicates, on paper at least, the potential for significant cost savings compared to cyanide destruction, coupled with the introduction of legislation to seriously limit the discharge of cyanide to the environment in most gold-producing regions of the world, many companies are evaluating the cyanide-recovery alternative."

Jan 1, 2003

By Wang Xiaotie, Yu Yongfu, Che Liping, Zhang Fuguang

The flotation process of native Rare Earth minerals such as bastnasite, monazite, mixed minerals of bastnasite and monazite, using the new effective collector Dh was studied in this paper, respectively, and the flotation properties are described. The good qualities of the new collector Dh were revealed through comparing with other collector of Rare Earth minerals. The test results of different ore samples show that at moderate pulp pH (8.5-9.5), Rare earth minerals can be effectively separated from barium, calcium and silicon bearing intergrowth minerals (barite, calcite and silicate minerals) and high quality Rare Earth concentrates can be obtained successfully by the new collector Dh, acid silica gel, turpentine and reagents fitting together rationally. In order to determine optimum technical conditions, the effect of pulp pH, pulp temperature, pulp density and the effect of dosage of reagents (Dh and acid silica gel) on the flotation were investigated in the test.

Jan 1, 2003

By Roberto C. G. Oliveira, Scott C. Brown, Brij M. Moudgil

"The wettability or surface energy of particle surfaces dictates a number of multiphase ensemble interactions that have a significant impact in mineral processing. Dispersion, bulk powder handling and flotation are just a few of the processes that are largely influenced by the degree of hydrophillicity or hydrophobicity on particulate surfaces. Because of the importance of surface wettability, a number of simple, precise and accurate techniques for accessing surface wettability or contact angle on macroscopic flat surfaces have been developed. However, these techniques cannot be directly applied to the particulate surfaces that are often in query. Though a number of techniques are available for accessing the wettability of particulate surfaces, these methods are either relative, application specific or prohibitively tedious. In the present study, key features of existing techniques are combined to formulate an improved method to delineate particle wettability that is simple, versatile and capable of providing reproducible measurements in an industrial environment.Through the use of an inert adhesive and an inert macroscopic surface as a support, it is illustrated that precise measurements of particle wettability are obtainable under suboptimal or ‘shop floor’ conditions. The measurement of the maximum external meniscus height formed between a test liquid and a particlecoated rod is employed to estimate phenomenological contact angles on particles ranging form a few nanometers to several hundred microns in size."

Jan 1, 2003

By Jian Zhang, Yongfu Yu, Fuguang Zhang, Liping Che

There is one large-scaled iron ore deposit in Inner Mongolia of China, but it is very complex which includes about 170 types of minerals and 71 elements. The hematite, magnetite are mainly iron ores. It is difficult that the iron mineral can be separated efficiently by common dressing methods due to the complexity, and the iron concentrates in the mineral processing factory contains many foreign substance such as K, Na and Si so that the process in iron mill is influenced because of the foreign substance, so it is vital reducing the foreign substance.

Jan 1, 2003

By K. A. Natarajan

Interaction with microorganisms results in significant surface chemical changes on minerals. For example, chemolithotrophs such as Thiobacillus ferrooxidans and Thiobacillus thiooxidans significantly alter the surface chemistry of several sulfide minerals such as pyrite, chalcopyrite, sphalerite and galena. Heterotrophic bacteria such as Bacillus sp. could alter the electrokinetic properties of oxide minerals such as hematite, alumina, silica, kaolinite and calcite. Microbe-mineral interactions could thus be beneficially utilised in mineral beneficiation as different from bioleaching. Microbially induced mineral beneficiation unlike bioleaching deals with interfacial phenomena at mineral-solution-bacteria interfaces and surface chemical changes are brought about at very rapid rates amounting to a few minutes resulting in mineral separations in an aqueous medium.

Jan 1, 2003

By T. V. Chnyrenkova, J. Troncoso, V. A. Luganov, G. P. Kluev

"Arsenic-gold bearing ores are used as flux in smelting or are leached out with extraction of gold. For decreasing arsenic content in processed materials and for breaking up the lattice and opening up of gold the raw materials are roasted. Some regularity was established for sulfidizing of arsenic bearing compounds in a presence of pyrite and for oxidation of ores and concentrates in the presence of soda.This article analyses the results of laboratory and pilot testing of dissociating and oxidizing roasting of gold-arsenic bearing concentrates. During the dissociation roasting under vacuum arsenic is sublimated into elemental and sulfide forms. This process allows minimizing the negative influence on the environment but requires costly engineering solutions. Roasting in a limited quantity of oxygen in the gaseous phase makes it possible to sublimate arsenic in the form of oxides and sulfides and may be carried out in fluid bed furnaces."

Jan 1, 2003