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By M. Guo

Coal-based Direct Reduction in Interior-combustion Shaft Kiln (CDR/ISK) is a brand-new technique. Compared with the traditional Coal-based Direct Reduction (CDR) technique, its main character is to use Interior-combustion Shaft Kiln (ISK) as the reactor of direct reduction. After being crushed and grinded, iron ore is made into green pellet, which will be surface-coated by coal fines. Then, the surface-coated green pellet can be directly reduced in ISK. The pellet should not be too dry and should be charged from the top of ISK. Oxygen-contained air should be blasted into ISK to keep the temperature in it higher than 1000 degrees centigrade, at which iron oxide will start direct reduction. The reduced pellet will be discharged from the bottom of ISK and after de-surface-coated, spherical Direct Reduced Iron (DRI) can be gained. The volume of carbon monoxide in the off-gas discharged from ISK is less than one per cent. By using this technique to get one tonne DRI, the consumption of coal is about 300kg of fixed carbon, which is much lower than the energy consumption by using other CDR techniques. There is a lot of complex refractory iron ore in China, which remains unexploited. The iron-bearing minerals in this kind of the iron ore can not be beneficiated economically by present technique of gravity, magnetic, flotation or magnetic roasting because the iron minerals are too very finely disseminated to be liberated, or, the iron minerals are too similar to gangue to be separated each other. By using CDR/ISK, complex refractory iron ore can be directly reduced in lower temperature and all kinds of iron mineral can be turned into iron metal. As the grains of iron metal growing larger during direct reduction, magnetic separation can be used to separate iron metal from gangue mineral, thus high-grade iron metal fines can be gained. According to the experiments, the grade of iron metal fines is above 90 percent and the recovery of iron is higher than 90 percent. The consumption of coal to process one tonne of complex refractory iron ore is only about 90kg of fixed carbon.

Jan 1, 2014

By Frank van der Meer, Lea Quincke

"High Pressure Grinding is applied to achieve size reduction of the particles by inter-particle breakage and to generate micro-cracks in the product particles as a contributing factor in e.g. leaching or mineral liberation. As alternative to classification, a closed circuit operation for HPGR can be established by product recycling, where a proportion of the coarser edge material and parts of the center material are split-off to be recirculated to achieve a finer final (center) discharge product for subsequent processing steps as ball mill grinding or beneficiation. As a result of the product recycling, the content of fines in the feed material increases and may affect the grinding efficiency in terms of production of fines and the generation of micro-cracks in the particles. In the scope of this paper, the effects of the proportion of fines in HPGR feed on grinding efficiency and micro-crack generation were evaluated. Grinding tests were executed with different feed size distributions, from a fines-void situation (truncated feed) to a fines-abundant situation (high product recycle). The evaluation of grinding efficiency and generation of micro-cracks was done by particle size analysis, Bond Work Index tests, impact tests on HPGR feed and products, and X-ray computed tomography of single product particles. This publication summarizes the main aspects of the outcome of these investigations."

Jan 1, 2014

By Alan Bye, Nick Beaton, Wayne Stange, Emmy Manlapig, James Groutsch

"For over 50 years the JKMRC has applied a unique education-based research strategy to develop modelling and simulation tools that are "fit for purpose" for industrial application. These tools are widely used for the analysis and optimisation of mining and mineral processing systems. As the mining industry context evolves to deal with declining head grades, falling commodity prices, professional skill shortages, and an exponential growth in the volume of data, a re-evaluation of what "fit for purpose" means in the future is required. It is contended that future industry needs for simulation-based decision support requires tools and systems that incorporate: • Multi-component modelling, • Models of complex sensor behaviour, • Integration across the physical value-chain e.g. resource to market, • Financial analysis including risk and uncertainty assessment, • Enabling multi-criterion decision making (technical, financial and environmental), • Ore-body knowledge at multiple scales, • The use of fundamental numerical models to provide insight for the development of practically useful models, and • Decision support delivered through remote operations centres. JKMRC and CRC-ORE are collaborating to develop a next-generation simulation-based decision support system that assists in addressing these challenges. The Integrated Extraction Simulator (IES) combines many years of pragmatic and successful work integrated with modern technology trends - in particular the rapid move to cloud-based computing."

Jan 1, 2014

By Rodney J. Hundermark, Sharif Jahanshahi, Shouyi Sun

"The major platinum producers in South Africa make use of electric furnaces for the melting of platinum group metal (PGM) bearing nickel – copper concentrates. To gain better understanding of the furnace operation, research was conducted at CSIRO Minerals in Melbourne, Australia. One aspect of the research project was the investigation of the factors affecting the electrical conductivity of melter type slags.Electrical conduction in slags can occur through two mechanisms: ionic and electronic. There is good understanding of the ionic mechanism. In slags containing high levels of iron, the dominant mechanism is electronic as a result of charge hopping (electrons or holes) between ferric and ferrous ions. There is limited understanding of the electronic mechanism and one of the aims of the research was to investigate this mechanism further.Experimental work was carried out at 1450 °C on Al2O3–CaO–FeOx–MgO–SiO2 slags similar in composition to the melter slags (typical composition range (wt%): Al2O3: 5, CaO: 5-15, FeOx: 10-30, MgO: 15-25, SiO2: 40-60). The approach was to vary the oxidation state of three different basicity slags and measure the conductivity response. The slags had molar (CaO+MgO)/(Al2O3+SiO2) ratios of 0.43, 0.64 and 0.94 and FeOx contents of up to 40wt%. A twoelectrode technique was employed with a shallow layer of slag contained in a magnesia crucible. The small amount of slag facilitated relatively quick equilibration (up to one hour) with the gas atmosphere. Experiments were typically started in air and sequentially reduced using different ratios of CO and CO2 gases.Conductivity increased with increasing basicity and increased significantly with iron oxide content. Above 20wt% FeOx, electronic conduction was significant and the conductivity varied with the oxidation state of the slag. The typical response of the conductivity to the change in oxidation state was the following: starting in air, as the slags became more reduced, the electrical conductivity increased to a maximum at around pO2 = 10-7 to 10-4 atm and then decreased with further reduction. The value of the pO2 at which the maximum occurred was dependent on the total iron oxide content and basicity of the slag. The magnitude of the conductivity of the slags increased with increasing FeOx content in a range of 20 to 170 S/m for 20 to 40wt% FeOx. For a given FeOx content in the slags, the oxidation state dependence of the conductivity varied with slag basicity. The trend observed was that the maximum in the conductivity occurred at higher oxygen partial pressures for the lower basicity slags."

Jan 1, 2003

At times the phosphate industry, in Florida, encounters phosphate rock that gives lower than expected P2O5 recovery in the rougher plant section. The drop in recovery is typically 10% and as much as 30% or more. Variations in feed quality from day to day, shift to shift and even from drag-line to drag line, represent a challenge to the beneficiation plant operators and reagents? suppliers. Therefore, this characterization study has been initiated to identify the reasons for the differences in flotation behavior of such feeds. The study involves many samples to cover such variations. The characterization work includes: ? Mineralogical and chemical analysis; ? Size, shape, surface roughness and porosity analysis; ? Surface charge and surface contamination with other phases (minerals); ? Clay content and its relationship to phosphate and silica particles. The results correlated with flotation data and adsorption density measurements clearly establish the statistically significant variability in characteristic features that influence flotation response. This article discusses results from the above listed studies. On the basis of the obtained data, recommendations of practical approaches to overcome the problem of feed variability in phosphate flotation plants are delineated.

Jan 1, 2014

By P. Huang

Chitosan was tested as a depressant in the differential flotation separation of chalcopyrite and galena. The micro-flotation results showed that chitosan selectively depressed chalcopyrite while galena was floated by potassium ethyl xanthate in acidic solutions. With the addition of 0.67 mg/L chitosan (CT) in the slurry of chalcopyrite-galena mixtures at pH 4, the recovery of galena was 95% while that of chalcopyrite was 30%, indicating that chitosan could potentially be used in differential Cu-Pb sulfide separation. Furthermore, the study of chitosan with either low (LCT) or high molecular weight (HCT) in the differential flotation indicated that better separation was achieved by the chitosan with lower molecular weight (LCT). ToF-SIMS was employed to study the distribution of CT on the surface of chalcopyrite-galena mixtures by ion mass spectra analysis and surface imaging, which showed that CT adsorbed heavily on chalcopyrite but barely adsorbed on galena. The positive ion ToF-SIMS spectra provided information on the surface composition of chalcopyrite-galena mixtures after CT treatment. It appears that the selective adsorption of CT on chalcopyrite was originated from the strong interaction between NH3+ and Cu. Keywords: differential flotation, micro-flotation

Sep 1, 2012

By Anuttam Patra, Romain Bordes, Andreas Fredriksson, Tommy Karlkvist, Krister Holmberg, Kota Hanumantha Rao

The present investigation aims to develop and distinguish mineral specific reagents with two functional groups for use in flotation of calcium containing minerals. For this purpose, a series of dicarboxylate-based surfactants with varying length between the carboxylate groups (one, two or three methylene groups) were synthesized. As reference, a surfactant with the same alkyl chain length but with only one carboxylate group in the polar part was synthesized. The adsorption behavior of these new reagents on pure apatite and calcite mineral surfaces was studied using Hallimond tube flotation, FTIR and ? potential measurements. The relation between the adsorption behavior of a given surfactant on a specific mineral surface and its molecular structure over a range of concentration and pH values, as well as the region of maximum recovery were established. It was found that one of the reagents, with a specific distance between the carboxylate groups, was much more selective for a particular mineral surface than the other homologues synthesized. This selective adsorption of a given surfactant to a particular mineral surface relative to other mineral surfaces as evidenced in flotation studies is substantiated by ? potential and infra-red spectroscopy data.

Jan 1, 2014

By Z. H. Liu

We experimented with slurry which from one of coal preparation plant in Guizhou province and made researches on double hump gradation, one of critical factor of gradation technology, which can influence pulping character in the process of making coal water mixture (CWM). The purpose for it is to find the best particle gradation which can meet the requirements in concentration, viscosity, and stability for CWM. The final result is that the concentration, viscosity, stability of CWM can meet the requirement for industrial use while the rate of fine particle in the slurry is 70%~75% and the maximum concentration of 62%.

Jan 1, 2014

By R. Mukherjee

Consistency of Run-Off-Mine (ROM) quality plays an important role in mineral processing which is not very often talked about. The major impediment is limitation of sampling ROM ore, which makes processing plants to run without any realtime feedback on ore quality that comes in. The process of direct determination of Run-Off-Mine (ROM) ore quality is expensive and time consuming as drawing and preparing representative samples from blasted muckpiles are constrained by large sample size and inherent heterogeneity in terms of size and chemistry. In absence of techniques for direct measurement of quality, monitoring and control of ROM, feed to the processing plant at Joda East Mine, like all other iron ore beneficiation plants worldwide, is largely based on blasthole sampling and subsequent chemical analyses of blastcone chips. While such indirect methods proves to be more accurate for representing whole of a mining block or blasted muckpile (~30-50KT/blast), it is indeed a challenge to ascertain and predict day to day input quality for a part there off. This eventually leads to a gap between predicted and actual ROM quality, resulting in difficulties in process control, in turn, and leading to wide swings in product quality. Hence, it is imperative to bridge the gap between predicted and actual ROM quality by arriving at means, which ensure consistent plant feed grade to deliver consistent output. The paper discusses an efficient and affordable alternative for effective prediction of ROM alumina which has been developed by integrating blasthole quality database in GPS based Truck Dispatch System (GPS-TDS) at Joda East Mine. Initially, GPS-TDS has been installed for optimizing production parameters only, but this development has helped in further utilization of GPS-TDS for real time quality monitoring by improving ROM grade prediction and scheduling from several ore blocks in active mining areas. Keywords:run-off-mine (ROM), blast hole, feed grade, GPS-TDS

Sep 1, 2012

By C. L. Xiao

With reference to the test report carried out by Guangzhou Nonferrous Metal Research Institute in 1983, the mineral process flow sheet of Yichun Tantalum-niobium mine is determined based on the characters of ores and successful experiences in light of the problems in the existing flowsheet: The ore is desilted before crushing; the primary slime is separately treated; the staged grinding process used while the fine slime is collectedly treated with tantalum and niobium as the main recoveries and lepidolite and feldspar powder as the secondary. The flowsheet is featured by comprehensive recovery, low investment and low energy cost.

Jan 1, 2014

By X. H. Zhou

Column flotation is being widely adopted for fine particle treatment by the mineral processing industry due to its simplicity of structure, high efficiency and good separation performance. Cyclonic static micro-bubble column flotation (FCSMC) is an innovative column separation technology that has been successfully applied in the coal preparation industry in China. Recently, the application of this equipment has been further expanded to the separation of several minerals such as fluorite, copper, iron, etc. The bottom of the FCSMC is a cone in which cyclonic field is generated when circulating pump is injected tangentially into the column. The unique cyclonic structure is believed to help enhance the column separation performance. Since the FCSMC is a new flotation device, little work has been done to understand the fundamentals of this technology. In this research, a computational fluid dynamics software, ANSYS/ FLOTRAN, was employed to simulate the flow field of a lab FCSMC system (F0.2 m, F3.0 m by length.) The distribution patterns for velocity field and flow field were investigated under single phase condition. It has been found that axial velocity of the slurry decreases and becomes stable along the height of the column from bottom to top, and the slurry performs as a descending flow pattern. Another observation is the velocity fluctuates vigorously near the wall due to wall effect. Compared to axial velocity, the radial velocity distribution is smaller and more complicated. The basic pattern is that on a given cross section of the column radial velocity increases from the wall to the center and it the velocity changes greatly around the center. Under the condition of column height less than 0.8 m, the axial velocity is negative and it directs from the wall to the column axis. When column height is higher than 0.8 m a reverse pattern is obtained, i.e., axial velocity is positive while directing from column axis to the wall. Special efforts were directed to investigate the tangential velocity pattern. Results indicate that the tangential velocity patterns of different cross sections are similar and showed a symmetrical distribution. Tangential velocity distribution concluded two zones: outer whirlpool and inner whirl-pool. And, interestingly, it has been found that on different cross sections the highest tangential velocity always occurs at the same position of the cross sections.

Jan 1, 2014

By M. Kalicinski, M. Lyssyy

"Access to information is a key component for making improvements to any process. This is particularly true for all aspects of the iron mining and steelmaking process. The ability to make rapid control decisions can significantly influence process outcomes, including ensuring product specification, mining quality, transportation limits, upgrade factors, waste bypass and direct shipping, among many others. While traditional laboratory methods provide feedback for such processes, having access to analysis results in real-time can lead to positive reactive and predictive control decisions to be made rapidly, leading to significant improvements throughout the process. Scantech has been designing, manufacturing and supplying technological products to the minerals industry since 2002 to enable the availability of such real-time information to a mine or plant, with the benefits being enjoyed by a wide range of operators. This paper provides a summary of the available technologies used in the iron ore and steel industries, as well as providing case studies of their use in African and Australian iron ore and European steel, as well as a description of the potential benefits of a range of analysis equipment.INTRODUCTION Access to information is critical for any process, and is a fundamental component for making process control decisions. In order to yield effective processing outcomes, it is important for that information to be readily available, preferably as quickly as possible, and to be as accurate as possible. While speed and accuracy are often traded off against each other, there are numerous technologies available in a processing environment that allow for both rapid flow of information and a high level of accuracy. The use of on-belt analysis equipment has a long trusted history of use in a number of mining and processing environments and industries, providing information such as elemental composition and grade of conveyed materials, moisture content, waste proportion and energy information. Australian company Scantech has been a provider of such equipment since 1981, and has become an industry leader in both the supply and development of on-belt analysers across a range of industries."

Jan 1, 2018

By Xiaoming Wang

This paper describes a new magnetic separator integrating dynamic permanent magnetic force, gravity and flow dynamics to enhance the quality of the iron concentration. This equipment can increase the grade of concentrate by controlling the formation of magnetic agglomerations to reject most gangue. Test results indicates that the compound force field separator can be applied in improving the quality of iron concentrate and has a wide range of potential market applications. Keywords: magnetic separator, compound force field, rotating magnetic system, magnetite concentration

Sep 1, 2012

By H. J. Cao

Valuable elements could be extracted by microorganism ferment fluid from bauxite, which mainly due to bacteria acid namely organic acid. And after leaching, reclaiming the remainder organic acid in leaching solution was an important procedure for bauxite leaching process. the re-searching status about organic acid reclaiming process from bauxite ore bioleaching solution was summarized. Common processes for recycling organic acid from bauxite bioleaching solution in this period and their advantages and disadvantages, research aspects which need being confirmed for the future were Indicated

Jan 1, 2014

By Takashi Furuyama, Sukeyuki Mori, Tetsuo Ikejiri, Abel Bissombolo, Yoshitsugu Koga, Masamichi Hata

In Japan, the increasing number of automobiles newly put into circulation is followed by a larger amount of end-of-life vehicles from which valuable metals are being recovered in shredder and related plants. Nevertheless, the processing of these scrapped automobiles which has reach a recycling rate of about 75%, generates a huge volume of waste, locally known as .shredder dust., which is commonly dumped on landfills. The saturation and depletion of valuable disposal sites in the near future, as well as the social and environmental problems related to the accumulation of these residues disposals are a major challenge for the automobile shredding industry. To promote an alternative way for the management of these disposals, the authors have initiated and developed a system for their processing, on the basis that more than 90% of these residues are combustible materials that could be used as refuses derived fuel. The developed processing system points out the mechanical/physical separation of shredded automobiles residues into two streams by means of an ascending airflow passing through a vertical zigzag separator and, the compaction of the light-density fraction of materials (that is about 60% of auto shredder residue recovered as float products and mainly composed of cotton, sponges and light plastics) to form a refuse derived fuel (RDF), the density, calorific value and ignition loss of which are 1.19 g/cm3, 4470 kcal/kg and 60.7%, respectively.

Jan 1, 2003

By P. Somasundaran, Tarun Bhambhani, D. R. Nagaraj, P. Patra

"Certain non-sulfide gangue minerals are known to have a detrimental impact on flotation performance. When present in large amounts, they can negatively affect recoveries, grades and throughput at current operations, and dictate the viability and economics of a greenfield project. While the problem has been investigated for a long period of time, a scientific understanding of the mechanisms by which these minerals affect performance has not been obtained, and no acceptable solutions have been developed. This study focused on the role of physical aspects (e.g. shape, size and morphology) of these minerals as the underlying factors for poor performance. Flotation tests were conducted using model mineral systems to understand the impact of one phyllosilicate mineral (muscovite) on flotation kinetics, recoveries and grades. The study reveals that there is minimal impact on flotation kinetics, no impact on recoveries, but a very strong detrimental impact on concentrate grade. The traditional mechanisms of transport such as true flotation and entrainment are not sufficient in describing the extent of transport. The transport is attributed to the unique platy morphology of muscovite, which allows for action of buoyancy forces. Data also shows that the muscovite transport to the froth phase depends on particle size; coarser sized muscovite (100-150@) report to the froth phase in much larger amounts than medium sized muscovite (50-100@). At finer size fractions (<50@) the transport is also increased, and this is likely due to entrainment."

Jan 1, 2014

By R. Imhof, S. E. Sánchez-Pino, H. Sprenger, S. A. Sánchez-Baquedano

"In 1992, Ingeniería de Minerales started with the introduction of pneumatic flotation technology in Chile and South America. This technology consists of vertical cells and gyratory cells, used mainly under actual operational conditions, with pilot units directly installed in the concentrator circuits of the industrial process. Successful industrial applications have been observed at Los Pelambres, in the molybdenum plant; at Codelco Andina in the molybdenum plant as pre-rougher to produce directly a final concentrate; in the copper circuit at Las Luces as pre-rougher producing final concentrate using sea water; at Minera Valle Aconcagua where a full automatic plant produces pre-concentrate from fresh tailings as feed; at the silica and silicate reverse flotation circuit of Compañía Minera del Pacífico; in cleaning the final concentrate of Zn by reverse flotation removing ultrafine carbonate; and in a plant that reprocesses fresh tailings from a copper slag flotation process. Positive operational changes in the design of the flotation circuit have been seen in plants using G-cells and V-cells, improving the performance of flotation circuits and the quality of final products. The high concentration of bubbles and micro turbulence produced by the pneumatic aeration units provide a high probability of collision and attachment, reducing dramatically the residence time. Though it is a pneumatic flotation, no compressed air is needed, and the equipment is characterized by low maintenance costs, full automation, savings in investment and energy."

Jan 1, 2014

By A. Lane

Africa is ripe with opportunity for the mining industry. The continent has large, and relatively unexplored mineral deposits, and recent high economic growth rates have meaningfully improved the political, economic, and infrastructural environments. However, these opportunities are accompanied by significant risks, including resource nationalism, uncertain regulation, corruption, and continuing political instability (up to and including war). Forward-looking companies actively manage these risks by creating a sense of shared purpose with the countries and communities that own the resources, using tools such as stakeholder analysis, local narratives, scenario planning, and constituency engagement. They also measure socio-economic impact to insure the creation and demonstration of shared value.

Sep 1, 2012

By Carlos Pereira, Fábio de São José, Francielle Nogueira

Votorantim Metals Corporation is one of the leader companies in the extraction of zinc in Brazil. One of its mines, located in the city of Vazante - MG, was composed by zinc silicate ores, but recent studies have indicated a change in mineralization type with arise of zinc sulphide’s ore bodies with disseminations of galena (PbS) and silver. The liberation size between sphalerite and galena in this ore occurs in very fine granulometry (approximately 18µm), fact that has negatively influenced into the flotation process. Aiming to reduce this problem, studies about the use of dispersing in the flotation process have started. Thus, this study investigated the action of different reagents dispersing on the stability of the suspensions. The tests were carried out with samples of mineral galena and sphalerite using four types of dispersing within two different dosages and two pH. The reagents tested were sodium hexametaphosphate, sodium silicate, carboxymethiylcellulose, and sodium polyacrylate. The results of the dispersion tests were analysed in relation to dispersion index. The tests with hexametaphosphate showed high dispersion for both galena and sphalerite. The sodium polyacrylate and arboxymethiylcellulose showed a high dispersion index for galena and a low index for sphalerite implying that reagent can be used in the concentration process of galena.

Jan 1, 2014

By Kaustubh Joshi, Pradip, Beena Rai, Kesri L. Menaria, Venugopal Tammishetti

"Beneficiation of alumina rich iron ore slimes is a major challenge for the Indian iron ore industry. High alumina is deleterious for the performance of both blast furnace as well as sintering plants. Slimes generally contain 5 - 10% alumina, and hence despite assaying as high as 60% Fe, those are dumped in tailing ponds. The slimes are typically less than 37 microns. Selective flocculation of iron ore slimes using highly selective reagents is thus an option worth exploring. Our research is directed at employing state-of-the-art molecular modeling techniques for the selection/design of selective reagents for this separation. We have earlier reported our results on starch as a selective flocculant for iron ore slimes. In this paper, we present our results on the selective dispersion-flocculation of natural iron ore slimes using guar gum flocculant. With careful selection of various process parameters such as flocculant dosage, dispersant dosage, pH and settling time, we were able to obtain a concentrate assaying >66% Fe and <3.5% Al2O3 with an yield of 65 to 68% (recovery of iron values more than 70%) from a natural iron ore slime sample assaying 58% Fe and 7% Al2O3."

Jan 1, 2014