Search Documents

By Aysan Molaei, Kristian Waters

Solvent extraction is the one of the most common techniques for recovering metal ions from aqueous systems. However, solvent extraction is generally limited to relatively high concentrations and requires a high organic/aqueous ratio. Predispersed solvent extraction (PDSE) is a modified solvent extraction technique in which organic phase pre-comminute into colloidal liquid aphrons (CLAs). In this study, the extraction of copper by the PDSE technique was investigated. The main focus of this study was on the characterization and application of CLAs under different operational conditions, and to investigate the effects of different parameters on the extraction of copper from dilute streams. The effect of phase volume ratio (PVR), initial extractant concentration and initial copper concentration was studied and optimum conditions for copper removal using CLAs generated by LIX 984N as extractant, oil soluble and water soluble surfactants were proposed. Experimental observations indicated that PVR and initial LIX 984N concentrations had a significant effect on copper extraction.

Jan 1, 2014

Most of the Indian coking coals are medium coking and of very high ash content. Beneficiation of these coals is a must for their utilisation in coke making. During washing while the ash content of the coal is reduced, the same is expected to affect the reactive-inert ratio and the proportion of various petrographic constituents in the clean coal. This will affect the coking behaviour, including the expansion characteristics, of such coal. An increase in expansion behaviour of coal increases the wall pressure and may damage the battery wall. Therefore, close monitoring of coking properties along with drop in ash is necessary for smooth use of the coal in coke ovens. An effort is, therefore, essential to understand the impact of washing on its coking properties. The studies were carried out with captive coals of Tata Steel, India. Three medium coking coal samples namely, VII A, VI A and XI SEB seam coals of West Bokaro Colliery were used for the study. The coal samples after washing to different ash levels were subjected to the following analysis: proximate, crucible swelling number (CSN), LT GK test, dilatometer and plastometer tests and petrography. The experimental data were then analysed to assess the relationship of various coking properties of the coal with its ash content. The studies clearly show that there is a strong impact of beneficiation of the coal on its coking behaviour. The impacts are more at lower level of ash in the clean coal. In general, the coking properties increase with a decrease in ash. This is primarily due to an enrichment of vitrinte materials in the clean coal and an increase in the reactive-inert ratio in the coals. However, the most important impact of the lowering ash is on the increase in the swelling nature of the coal. The coals with lower ash become highly expanding in nature. This may be very critical from operations of coke ovens point of view, especially stamp charged coke ovens. Necessary precaution should be taken in selecting the other coal blend constituents when these coals are beneficiated to a very low level of ash content.

Jan 1, 2014

By J. Jung, W. Keller, N. Rohn

In hydrometallurgical minerals processing slurries are often processed at very small grind sizes and high solids concentrations. This normally results in flow anomalies of such slurries. Due to flow limits or yield stress the slurry tends to stagnate close to the vessel bottom, the walls and at any internals. The main mixing task therefore generally is not suspending of the solids but the homogeneous blending of the entire vessel volume. If not considered during the agitator design only a fraction of the vessel contents will be mixed. Therefore the knowledge of the slurry rheology as well as the variations in process parameters is vital to design e.g. storage or surge tanks. The integral mixing solution considers the motor power, the choice of the impeller type and number, the impeller diameter as well as the design of the baffles and feed and discharge positions.

Jan 1, 2014

Deposit of Jinbaoshan platinum group metals (PGMs) ore ranks the second in Yunnan province, China. Study on process mineralogy shows that the grade of copper and nickel in the ore is just 0.16% and 0.20% respectively. Moreover, the impurities magnesium and iron and silicon are rich in the ore. The copper and nickel sulfides in the ore, especially the minerals of PGMs, are finely disseminated with the gangues like serpentine. Fine grinding is necessary, and high content of MgO in the concentrate is inevitable through traditional flotation technology on the basis of process mineralogy studies. Achievements on process mineralogy studies are applied to guide the flotation tests successfully. Progress on flotation has been made through comprehensive studies. Suitable grinding by two stages is required for the finely disseminated PGM sulphide ore to achieve the liberation of valuable minerals. Stage grinding and stage separation shall be conducted for a better recovery of valuable minerals. The oxidation state of mineral surface of sulphides has a profound effect on flotation of the ultra-fine sulphides, especially the pentlandite. The combined use of collectors enhances the selective collecting on the ultra-fine and low-grade valuable minerals, is of critical importance.

Jan 1, 2014

By R. Haecker, S. Bajic, R. Thorpe, A. Palko, M. Kalstrom

"Historically, mineral processors have used inferential data like plant instrumentation, assays, and grind sizes to monitor the performance of their plants. The ability to monitor the minerals themselves on a daily basis has eluded all but the very largest and richest of operations. The advent of a new generation of compact, robust, and user-friendly SEM-based automated mineralogy systems looks set to accomplish this, aiming to bring daily mineral monitoring of plant performance within the reach of all mills from mid-size upwards. This paper describes the use of this machine at Greens Creek Mine, a 2.5 ktpd Ag-Au-Pb-Zn operation with a complex flotation flowsheet. During the trial, the machine provided turnaround from sample collection to reporting averaging 24-36 h for key daily samples. All equipment was located within the compact mill, and proved highly reliable despite the challenging environment. Turnaround time was fast enough for metallurgists to understand, and, where possible, respond to ore and process changes while they were still happening. The plethora of data generated was filtered to a simple report whereby mill management could quickly absorb key daily mineral-based performance indicators. This paper will describe how the data was used to understand the key drivers behind metallurgical efficiency at Greens Creek, and how metallurgists began using the information to enhance daily mill performance."

Jan 1, 2014

By I. C. Spangenberg

The status of sampling practices in the gold mining industry in Africa was determined as an initial step in a process to standardize sampling practices in the mining industry. Twenty-one gold mines, twenty metallurgical plants, and thirteen laboratories were rated for the potential influence of the relevant sampling errors on each component of the particular sampling system. The findings of the study on the status of equipment, standards, procedures, and management principles were presented in a dissertation (Spangenberg, 20121) and are now used by AngloGold Ashanti?s mines in the quest for correct sampling practices. The information is also used to compile a guideline on leading practice procedures for sampling methods in gold mining. This article is an overview of sampling best practice found in African mining Keywords theory of sampling, best practise, sampling errors, sampling standards.

Jan 1, 2014

By Carlos Avalos Casillas, Saul Ortiz Landeros

The current work shows metallurgical results obtained at the Centro de Investigación y Desarrollo Tecnológico (Peñoles CIDT), as a continuation of the work first published in February 2012. With the aim of optimizing the economic values of the products, ores from San Julian (Fresnillo) were selectively floated to produce a lead concentrate and a zinc concentrate containing high silver values. In the laboratory, this included regrinding of the rougher and scavenger lead concentrate to increase the liberation of mineralogical species and thus lower zinc recovery. Cyanide leaching bottle tests were conducted to improve the value of the silver. It is proposed to leach the silver contained in the zinc concentrate and then recover the silver using the Merrill Crowe process. The results show a reduction of zinc recovery in the lead concentrate from 11.3% to 2.0% after regrinding to a P80 of 10 microns, improving the metallurgical quality and economic value of the lead and zinc concentrates. Also laboratory and pilot scale cyanidation tests showed that about 65 to 80% of silver will be leached from the zinc concentrate, after regrinding to a P80 of 10 microns. The proposed processing increases the economic recovery of silver from 72.7% to 78.8%.

Jan 1, 2014

By V. A. Chanturiya

The results study the minerals oxidation were obtained by us during the methods of microscopic, FT-IR spectroscopic, XRD and chemical analyses of sulphides in tailings of copper-nickel wastes in Kola peninsula. Sulphide minerals begin to oxidize already at the stage of stockpiling and initial stages of storing. The proportion of non-ferrous metals and magnesium oxide increases with time, calcium partially precipitating in the form of gypsum. Comparison of heavy metal contents in pore solutions in cur-rent and stale copper-nickel ore concentration tailings has revealed a significant difference in practically all the parameters. The lower metal contents in current tailing pore solutions (by 5~30 times) are probably due to the presence of float reagent residues blocking oxidation. Much lower concentrations of magnesium and calcium can be accounted for by the difference in kinetics: the rate of sulphide oxidation at this stage is much higher than that of solution interaction with non-metallic minerals as the result of which the solid phase ? solution equilibrium is not achieved. It is generally believed worldwide that it the mining wastes with acidic pore solutions that pose the greatest hazard for the environment. Our findings suggest that although the solution pH in all the samples is higher than 7.8, the contain heavy metal concentrations by far exceeding permissible values. The direct determination of the total and silicate Ni contents in the tailings from current production and in storage tailings has shown that both sulphide and silicate Ni forms occur in tailings. However, the role of silicate Ni is much larger in the storage tailings. The average silicate Ni content accounts for 10% of the bulk Ni content in the current tailings and it increases to 40% in the storage tailings. Thus, the storage tailings are marked not only by sulphide oxidation and the removal of water-soluble sulfates, but also by the interaction of sulfates with the silicate matrix. Although complete equilibrium is not achieved even within 30 yr under polar-region conditions, the major part of the Ni in fine-grained fractions passes into silicate form. The probability of Ni transition to the silicate form directly correlates with the dispersion of the material and the amount of chemically reactive serpentine and hydrochlorite. The migration of Ni as sulfates and its precipitation by chemically active silicates distorts the distribution of this component in the coarse- and fine-grained fractions that are typical of tailings from the current production of copper-nickel ores. On the one hand, the variation of the mode of Ni occurrence in storage tailings lowers the value of technogenic raw materials as a source of this metal.

Jan 1, 2014

By M. P. Krasteva

The froth flotation process for separation of mineral ores depends on the establishment of care-fully controlled froth. The formation of very stable froth in the flotation circuit is a problem that may occur in many plants, resulting in down-time, low quality and grade of final product and considerable expenses. Froths build up on the top surfaces of thickeners, tanks and flotation cells until they overflow, or until the efficiency of the circuit is impaired. A similar problem exists in Assarel concentrator, Assarel-Medet PLC, Bulgaria. Copper and copper-pyrite ores are dressed in Assarel concentrator. They are characterized with variable and complex mineral and physical composition. During the flotation cycle, resilient and difficult to break-down froth is formed, which subsequently impedes the process of thickening and clear overflow obtaining. Due to this problem continuous sampling in the cycle of thickening was conducted. The mineralogical, chemical composition, particle size distribution and solid phase content of the products were determined. It was established that the solid phase of the froth build up on the top surface of the thickener differs considerably from this one of the thickener underflow. The data clearly indicates that a separation process takes place on the top surface of the thickener ? fine particles of chalcopyrite are concentrated in the froth. The role of chemical reagent addition in the break-down of the flotation froth is investigated in terms of surface chemical phenomena involved in the stabilized froths. Measurements of the coper minerals wettability and surface tension at the air/liquid interface were performed. The surface active agent AERODRI® dewatering aids were laboratory tested. Bench-scale froth collapse tests were conducted. Reagent addition into pulp-froth system promotes and leads to a bubble coalescence, an improvement of the wetting of the mineral particles and a decrease of the surface tension at the air/liquid interface. The results of the laboratory experiments showed that the presence of the surface active agent leads to considerably decrease of the froth stability and the destruction of the deleterious froths build up on the top surface of the thickeners in Assarel concentrator.

Jan 1, 2014

By Donovan J. Benton

Photogrammetric methods are advancing rapidly and show considerable promise as a ground control research tool. The ability to quickly capture three-dimensional geometry, especially changes in geometry, in underground and laboratory settings is a significant advance from point distance measurements. Photogrammetry is being applied in both of these settings as part of the NIOSH ground control research. This paper describes these applications and the equipment and software being employed. It also describes tests conducted to quantify the accuracy of these systems. Accuracy varied with system specifics and procedures. A factory-calibrated camera produced results within 1/32 of an inch, plus 0.04%. A user-calibrated camera was found to be less accurate, at 1/20 of an inch, plus 0.24%. These calibrations demonstrate that photo grammetry can produce research quality measurements in laboratory and mine settings.

Jan 1, 2014

By Maurizio Siepi, Fabio Santillan, Lyndon Bedford, Carlo Crippa

"Abstract: Wolf Creek dam, on the Cumberland River in Kentucky, US, operated and maintained by the Nashville District of the USACE, is the Corps' largest reservoir east of the Mississippi river. The 1748 m (5,736 ft) long Wolf Creek dam combines earthfill and concrete gravity sections. Construction began in 1941 and was completed in 1950. The dam showed signs of instability in the 1960’s, and in the late 70’s an in-depth project of rehabilitation was undertaken, using both grouting and secant piles. The works saved the dam, but in the late 90’s further signs of distress worried the Nashville district of USACE which, after a study conducted on the water seepage, concluded that construction of a new concrete barrier cut-off wall was needed. In 2009, the $341.4 USD million contract was awarded to TREVIICOS-SOLETANCHE JV.The new wall, located upstream of the concrete monoliths, has a minimum thickness of 60 cm (24 in.), and runs the length of the embankment, into the right abutment, for about 4,200 feet. The founding depth reaches 84 m (275 feet), well below the zone of solutioning. With a total surface approaching 92,903 sq.m (1,000,000 sq.ft), the Wolf Creek barrier wall is unlike any other project in the world.The construction of the cut-off wall followed a complicated but logical sequence of several operations, involving a variety of technologies: grouting, hydromill, directional drilling, and secant piles with reverse circulation. The intensive rock grouting program was aimed to minimize the risk of slurry loss and extend the positive cut-off further deep. Subsequently, an Encasement Concrete wall was installed with hydromill, toeing into the rock, to protect the embankment during the following phases. Smart holes were then drilled into the Encasement wall down to the final depth. Eventually, the holes were used to install the secant piles by employing the reverse circulation piling method.An extensive verification campaign has confirmed the superior quality of the cutoff wall consisting of 1200 secant piles, exceeding by far USACE’s requirements. The main project was substantially completed in early 2013. A small portion of secant piles wall will be installed downstream of the dam, to close the switchyard, finishing the project in the early months of 2014.IntroductionWolf Creek Dam is located on the Cumberland River in south-central Kentucky. The Nashville District of USACE operates this multipurpose dam to provide hydropower, flood control, water supply, and water quality benefits for the Cumberland River system and surrounding region. Lake Cumberland, created by the dam, impounds 7,400 million cu.m (6 million acre foot) at its maximum pool elevation of 232 m (760 ft) above sea level. This lake is the largest reservoir east of the Mississippi and the ninth largest in the United States, and attracts 4.89 million visitors, more than Yellowstone National Park (2.87 million).This paper describes the recently completed works for the rehabilitation of the dam, accomplished by TreviICOS-Soletanche JV with the construction of a new Barrier Wall."

Jan 1, 2014

By E. L. C. Martins, M. J. Nicol, D. Majuste, A. D. Souza

The effects of organic compounds on the current efficiency (CE), morphology, crystal structure and mechanical properties of the metal deposited during the electrowinning of zinc are described. A flotation collector and lubricating oil were selected based on observations made during the industrial production of zinc from silicate ores, in Brazil. The analysis by Fourier transform infrared spectroscopy of these compounds, which may be present in minor amounts in the electrolyte solution, indicated the presence of a polar amine group in the collector, while the lubricating oil is a non-polar compound. The average CE value obtained from organic-free industrial solution was 91.15 ± 0.26 %. The CE dropped to 54.35 ± 0.73 % in the presence of 100 mg·L-1 of collector in the solution, and a negative effect was also observed in the presence of similar amounts of oil (88.84 ± 0.61 %). The characterization of the deposits by scanning electron microscopy and X-ray diffraction revealed the formation of pores in deposits obtained from solutions containing the oil, while a different growth pattern (perpendicular zinc platelets) was identified when the flotation collector was added to the industrial solution. In the presence of these contaminants in the solution, guided-bend tests revealed that the deposits have a higher resistance to deformation, but lower ductility, properties that may affect the performance of the stripping stage. As a result of this work, simple control and optimization actions were applied in the industrial plant, which resulted in important improvements in the electrowinning process.

Jan 1, 2014

By D. B. Dreisinger, M. Mokmeli, B. Wassink

Dissemination of selenium and tellurium in sulphide minerals results in the contamination of pregnant leach solutions and electrolytes in the hydrometallurgical treatment of sulphide ores and residues. The selenium and tellurium content of the copper sulphate-sulfuric acid solution may be reduced into insoluble precipitates of copper selenides and tellurides using cuprous ion. This study presents the use of the thermodynamics and kinetics for the removal process of selenium and tellurium in real life application. Dominant species of selenium and tellurium in acidic copper sulfate solutions were identified and the reduction rates of species were compared. The findings were applied to industrial conditions by modeling the Vale’s CRED (Sudbury, Canada) plant’s selenium and tellurium purification circuit. Rate reducing factors on selenium and tellurium removal were identified and discussed.

Jan 1, 2014

By Q. Zhang

Phosphate tailings through Flotation contains large amount of dolomite which is difficult to be separated from apatite. In this present research, phosphate tailings is recycled by Flotation i.e. re-processing. High-purity dolomite with purity as high as 91.17% is seperated, which contains 19.82% of MgO. The results of orthogonal test show that the effect of various levels of different factors on the high-purity dolomite floatated. Future utilization of purified dolomite is also discussed: magnesium fertiliser especially magnesium phosphate is expected to be an ideal product from high-purity dolomite.

Jan 1, 2014

By D. H. Ryan, B. Abdul, M. Pernechele, E. Asselin

Hydrometallurgical processing of sulphide concentrates at medium temperature (150°C) produces residues, which contain valuable metals (Cu, Ni) as well as sulphur and iron bearing minerals and phases. The low solubility of iron during the medium temperature processing of sulphide ores can favour the formation of poorly crystalline, nano-scale iron oxide/oxyhydroxide phases. A better understanding of the formation and structure of these iron precipitates may elucidate key factors that would ultimately result in lower valuable metal losses and more stable leach residues. Residues from two medium temperature leach processes were characterized by Mössbauer Spectroscopy. Some portions of the Mössbauer Spectrum were suspected to be linked to jarosite but could not be positively identified as such. There was a broad range of disorder and substitution present in the material and solely attributing it to jarosite proved difficult. Various synthetic jarosites with Cu substitution were precipitated for Mössbauer analysis. These were then characterized by Quantitative X-Ray Diffraction (QXRD), Scanning Electron Microscopy (SEM), Inductively Coupled Plasma Mass Spectroscopy (ICP-MS) and Mössbauer Spectroscopy. The Mössbauer Spectra of the synthetic jarosites is compared with that of the residues from medium temperature (150°C) sulphide concentrate leaching.

Jan 1, 2014

By Alexander Burns, David Dreisinger

The kinetics of the oxidation of uranium(IV) by oxygen gas in aqueous systems is dependent on acid concentration, oxygen partial pressure, and temperature. In order to better understand the relationship between these variables and the speed of oxidation, a series of experiments have been conducted where each parameter has been varied in turn. Data were collected continuously using UVVis spectroscopy, allowing for a detailed examination of the reaction rate over the course of each experiment. The data fit an overall apparent rate law that is 1.5order in uranium(IV), -2order in H+, first order in oxygen, and unaffected by uranium(VI). This relationship does not appear to hold for solutions with <0.2 mol/L initial acid, where a different kinetic mechanism appears to be dominant.

Jan 1, 2014

"Increasing demand for timely and accurate information about flotation plant performance requires metal accountants to increase the scope and reporting frequency of plant production. This trend has brought in-process inventory estimation at the forefront of metal accounting issues. Such significant in-process inventories can be locked in diverse process equipment (bins, holding tanks, flotation cells, thickeners, pipeline, etc.) or in stockpiles (ore, concentrates, tailings, etc.). Practice has shown that boldly ignoring these in-process inventories or the errors associated with their estimation lead to unreliable metal balances thereby creating confusion in plant production planning and operational performance assessment. To this extent, the characteristics (physical bounds, spatial heterogeneity and residence time) as well as the available measurements (volume, density, humidity, mass, composition, etc.) of each unit/section found in a generic flotation plant are jointly reviewed with respect to the particular metal accounting issues they present. The daily and monthly metal accounting tasks are then reviewed together with possible methods for obtaining reliable inventory estimates including different procedures for end-of month reconciliation.INTRODUCTION Most of the cost reduction initiatives of the mining industry aim at improving capital efficiency and asset utilization. Among the possible paths through which these goals can be achieved are mine-to-metal optimization, real-time plantwide process control (Hodouin, 2011) and knowledge sharing databases (Bascur & Linares, 2006). However, the successful implementation and subsequent monitoring will ineluctably results in an increased demand for timely and accurate information. This more than often requires metal accountants to increase the scope and reporting frequency of plant metal production. A striking example of such scope expansion is the Minas-Rio iron ore project in Brazil (Anglo American, 2013) having a pipeline route of 525 km between the concentrator and the concentrate shipping area. Several other mining companies have also set an increased frequency for their key performance indicators thereby shrinking the metal accounting period from monthly to weekly and daily. Those concurrent trends have brought in-process inventory estimation at the forefront of metal accounting issues. Indeed, as illustrated in Figure 1, improving trading reactivity requires improvements in production planning which strongly impacts the requirements for reliable metallurgical accounting. Furthermore, practice has shown that boldly ignoring significant in-process inventories or the errors associated with their estimation can lead to unreliable metal balances. In other words, since metal balances are the cornerstones of metal accounting, some of the risks associated with important business decisions are linked to errors associated with in-process inventory measurements."

Jan 1, 2014

By David McMullen

Radiation plays a critical role in the thermal behaviour of hydrometallurgical process equipment. This effect is particularly important when designing refractory lined equipment used in pressure leach/oxidation processes. In order to simplify this non-linear mode of heat transfer, the effects of radiation had previously been incorporated in an equivalent convective film coefficient in finite element methods (FEM). This prior method omits the effects of radiosity, a critical aspect of radiation heat transfer, which affects the design of refractory lining systems in autoclave vessels. Given that 60% of the heat loss in actual plant practice of an autoclave is due to radiation, reliability in the FEM is therefore impacted. This study validates the use of radiosity in FEM through thermal loading using a combination of simple geometries to be applied to complex environments such as vessel nozzle clusters. The added benefits of using a radiosity load includes an increase in confidence in thermal distribution results, greater accuracy in determining appropriate refractory lining systems, weld overlay sizing, and increased accuracy in structural analysis.

Jan 1, 2014

By Tobias U. Papst

The German Ruhrgebiet is slowly transitioning into a post-mining state. It has been subjected to industrial-grade hard coal mining operations for more than 150 years. Due to a political decision, German hard coal mining will come to an end in 2018. By then the surface will have subsided up to 20 meters. After all mining activities in the area have ended, there will be no need to maintain the current mine water level. Accordingly, the company operating the last remaining coal mines has decided to let the water level rise to an as yet undetermined level. Alongside other issues that may be caused by rising groundwater levels, the protection of the area?s drinking water supply is of utmost importance. This notion is also represented by European and German law. The primary intent of the applicable laws is to protect the health of the citizenship. This means protecting ground water that may be used by humans from being contaminated by the mine water. This paper outlines the consequences of European and German legislature on mining aftercare using the example of one of Europe?s largest agglomerations.

Jan 1, 2014

By W. P. C. Duyvesteyn, J. R. Cutland, J. R. L. Russell

In 1970 it was decided to build a large new plant at the Chingola Division of N.C.C.M., Ltd., to treat concentrator tailings and leach residues with a low copper content by a leach-solvent extraction-electrowinning process. In order to assist in the establishment of the design parameters for the new plant, and to study the interaction of this plant with the existing leach-electrowinning plant, mathematical models, formulated as linear programs, have been developed and used extensively. The paper outlines the metallurgy of the plants and describes briefly the way in which the models have been formulated and used. The formulation involved the use of separable programming to form the products of some variables.

Jan 1, 2014