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By Urs Peuker, Thomas Mütze, Thomas Leißner, Inga Osbahr

"Mining in the Ore Mountains (Germany) has taken place for hundreds of years and in several stages. Each stage produced its typical tailing. According to the former state of the art of the processing much valuables could not be extracted. This was caused by complex interlocking of the minerals, low grades, or by upgrading processes not sensitive enough for small particle sizes. Thus the processing of these fractions was uneconomically. Modern technical possibilities and rising metal prices bring these tailings disposals into focus for the processing of strategic metals. Mining disposals can be classified in heaps with coarse, low grade rock, which did not undergo a processing, slags and fly ash from smelting, and tailing disposals from mineral processing. The latter is under investigation to integrate them into a geographic information system. The mineral processing of the material will be part of the database besides information about geographic location, structure, amount of valuables, and details of ownership of the heap. The tailings disposals are composed of coarse, low grade, interlocked particles from density separation processes, medium size particles, which are tailings from flotation, and fines with liberated valuables, which did not undergo flotation. Therefore mineral processing of these disposals comprises the separation of liberated gangue by classification, beneficiation of locked valuables with density separation, liberation of valuables by grinding, and beneficiation of liberated valuables with flotation. The presented work shows the results concerning the composition of one exemplary heap and results of the classification as well as of the preconcentration tests achieved with material from this heap."

Jan 1, 2014

By D. Johann, E. Zanetti, I. A. S. Brum, P. M. Zancan, A. F. Castro

"This study was done from a sample of coal mined at the Vale-Mozambique mine, located in Moatize district, Tete Province. The aim of this work is to analyze the reagent system in the flotation of coal fines belonging to the Upper Chipanga layer (UC). Among coal processing methods, flotation stands out as one of the most important for the concentration of this material, in particular in the treatment of fine particles. The total feed of the Vale-Mozambique processing plant is 8,000 tph of coal, where 10% of this feed corresponds to the fine fraction that feeds the flotation circuit. The material used in this study had a particle size of 96% smaller than 0.25 mm. The reagents used in the flotation tests were betacol and diesel oil as hydrophobizing agents and MIBC as frother. The range of betacol concentrations in the first test phase was 200 g/t to 500 g/t, and in the second phase 200g /t to 500g /t while diesel oil and MIBC were kept constant at 300 g/t. The immediate analysis followed the Brazilian standards NBR 8289, NBR 8293, NBR 8290; and NBR 8299. The results showed that it is possible, from a feed with ash content around 22.84%, to obtain products with levels below of 10% ash, with a mass recovery around 50%. The recovery of carbonaceous matter was also evaluated and presented positive results. Complementing this study, the effect of H2O recovery was evaluated and it was observed that for the concentrations of betacol the recoveries ranged from 6 to 9%, and for diesel oil plus MIBC were 4 to 7%.INTRODUCTION Considering the increase in population and energy consumption as humanity has been living along the last decades and the consequent demand for non-renewable natural resources, it is clear the challenge of the mineral industry in the search for new technologies and improvement of the existing ones. This challenge is justified by the need for better industrial results and to meet the market specifications, taking into account the reduction of deposits with higher contents and the need for beneficiation of more complex ores, lower levels and lower release granulometry. Usually in these situations, processes already well-established as the gravimetric (Sampaio and Tavares, 2005) have not good results."

Jan 1, 2018

By M. A. Hampton

The surface oxidation of sulfide minerals in aqueous solutions is an important sub-process in sulfide flotation and hydrometallurgy, but a full understanding of the oxidation process and products is still lacking. Many oxidation pathways and products involving elemental sulfur, metal polysulfide, metal-deficient sulfide and sulfate have been proposed, confirmed and argued. In this paper we provide further insight into the surface electrochemical behaviour of galena in aqueous solutions. For this research we have developed a novel experimental system, that combines chronoamperometry and AC-mode AFM surface imaging, which allows for in-situ, synchronized electrochemical control and examination of oxidative surface morphology. At pH4, the morphology of elemental sulfur (detected by ex-situ Cryo-XPS) formed on the oxidizing galena surface depends on the electrochemical potential pathway. In multi-step chronoamperometry (i.e. four potential steps from 0 mV to + 350 mV) the sulfur forms as nanoscopic domains, whereas in single-step chronoamperometry (i.e. one potential step from 0 mV to + 350 mV) sulfur forms as a heterogeneous layer. In each case the oxidation is controlled so that the number of electrons (coulombs) passed per unit area is the same, therefore the amount of sulfur produced is also the same. The differences in morphology with electrochemical potential pathway are explained using a nucleation and growth model. The formation of sulfur on the surface increased both advancing and receding contact angle of galena, but the morphological changes induced by different electrochemical potential pathways did not significantly alter the hydrophobicity of the surface. Keywords: galena, lead sulfide, oxidation, Atomic Force Microscopy, electrochemistry, collectorless flotation, hydrophobic

Sep 1, 2012

By Y. Nahmad- Molinari

We present a novel on line inductive sensor for the determination of the quality of the concentrates of iron ores. This device is coupled with a cheap USB Data Acquisition System that makes it versatile enough to simultaneously control up to seven fluxes at a very low cost (< $300 US dollars), and achieves a resolution better than 0.5 % on the determination of the magnetic iron content in the concentrate. A RLC circuit with its inductive element placed surrounding a sample of pure magnetite concentrate is tuned at its resonance frequency, by means of adjusting, the feeding voltage of a voltage-controlled oscillator (VCO) and several samples with mixtures of different contents of silica and magnetite are placed in order to get a calibration curve. After some signal conditioning, a National Instruments USB-DAQ NI-6008, acquires the amplitude of the signal via USB port on a PC using a Lab-View program designed for such purpose, in which the calibration curve is used for on-screen data presentation directly in percent of magnetite content. The implementation of this device for control purposes on line directly placed on the concentrators would allow better efficiency of the process and higher quality of the final concentrate by con-trolling; the rotation speed, the rising or dilution water fluxes or bypasses towards milling recirculation cycles.

Jan 1, 2014

By Chris A. Fleming

"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, 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.There is arguably an even more compelling reason for mining companies to consider cyanide recycling. With the growing storm of negative public opinion that the use of cyanide in the mining industry is attracting - following several highly publicized spills over the last couple of years - the time has come for the gold industry to demonstrate environmental diligence and stewardship in the use of this commodity that is so vital for their industry. There is no doubt that the widespread implementation of cyanide recycling will reduce the impact of the cyanidation process on the environment, both by reducing the risk of spills (with less cyanide being transported from manufacturing plants to gold mines), and by reducing the loading of toxic and nontoxic metals and ions in the tailings.This paper briefly discusses the pros and cons of the different processes that are available for the treatment of gold plant tailings to regenerate and recovery cyanide for recycling, and presents a techno-economic argument for the incorporation of this technology into many gold plant flowsheets today."

Jan 1, 2003

By Ajay K. Jha1

Drilling and Blasting are two important unit operations in the production cycle of a mine and a strong link exists between these two and other unit operations/subsystems like loading, transportation, and crushing. Under the present concept of ? Mine to Mill?, it is important to optimize the drilling and blasting operations by applying scientific approach to drilling and blasting using sophisticated instruments and new technologies, which depends heavily on Information technology (IT) to meet this imperative. Development of innovative models and software has lead to blast optimization process. Till date, the blast results are evaluated in terms of available empirical approaches like powder factor, which are too simple to exclude some key parameters or lack in providing reliability because of non-availability of user friendly IT enabled techniques. Although with the help of developed approaches, formulation of user-friendly software to assist the site engineers in effective post blast assessment has started but there is a dearth of holistic approach to design an optimum blast considering the techno-economic feasibility of the subsystems and the geo-mining conditions to achieve blast optimization. The science of IT enablement in drilling and blasting is capable to build innovative models for achieving blast performances which will be doped with productivity, economy and safety with due regard to environment. The present paper discusses the use of existing IT enablement in various mines of India citing the Indian scenario and the future requirements for achieving the techno-economics in overall mining operations.

Sep 1, 2012

By I. A. Agapov, I. S. Anisimov, N. V. Rylov, A. M. Sagitova

"The smelter slags represented silicate crystalline rock with medium to coarse-grained structure with spinifex skeletal network of olivine in hedenbergite matrix. Accessory magnetite, pyrrhotite and copper sulfides chalcopyrite, bornite, covellite, chalcocite and digenite occurred in dissemination in silicate matrix. The sample was studied by optical and electron microscopy with support of quantitative XRD. Modal mineralogical composition included olivine, pyroxene, magnetite, chalcopyrite, quartz, pyrrhotite. Copper deportment showed copper distributed in chalcopyrite (40 %), cuprite (22 %), covellite (21 %), bornite, chalcocite, digenite (5 %), Cu-bearing pyrrhotite (4 %) and spinel (2%). Liberation of copper minerals in the material ground to P80=71 µm was good with over 90 % sulfides in free grains and floatable binaries. The results showed theoretical possibility of 65 % copper recovery by flotation. Conclusion based on mineralogical data was precisely confirmed with flotation tests studies that proved to recover around 60 % of copper to commercial grade concentrate. INTRODUCTION Annual world copper matte smelter slags production is estimated to be millions of tones and contain thousands tones of unrecovered Cu, Zn and significant amounts of Ag and Au. Mineralogical study of one large processing sample of material of historical piles of Cu matte smelter slag was carried out to find possibility to recover copper and define theoretical recovery by flotation. The study of the slag material was aimed to determine possibility of upgrading the material on existing copper flotation plant to develop additional mineral resources. The objectives for mineralogical investigation were to target for best liberation fineness, determine theoretical recovery and possible concentrate quality for sulfide flotation tests. MATERIALS AND METHODS Large representative processing sample was collected by mixing of 120 t of slag material representatively excavated from historical piles of Cu matte smelter slag. The sample was used to define the processing technology to recover copper and gold from the material."

Jan 1, 2018

By S. H. Lau

Rapid 3D characterization of multiphase mineral particles in a variety of mineral processing applications is described, including: mineral liberation analysis, grain size, mineral exposure analysis, particle damage, and pore network structure for fluid flow simulation in heap leaching. While micro X-ray computed tomography systems (microCTs) have been used for many years, industrial adoption is limited due to a variety of reasons, including insufficient resolution, the general lack of imaging contrast to differentiate different mineral phases within a multiphase mineral particle and the lack of automated 3D mineral processing software. For example, resolution with industrial CTs and desktop microCT is of the order of tens of microns to a few microns at best, depending on specimen size and CT configuration. We describe a novel lab-based X-ray microscope, XRM, which overcomes these resolution and contrast limitations, notably as the industry is going towards finer grains and more complex ore bodies. Using lens-based optics and detectors (similar to its XRM counterpart in synchrotron beam lines), resolution of the lab based system is in the submicron range with contrast better than conventional microCTs. Hence, visualization, differentiation and segmentation of most mineral phases of interest to the industry are now feasible. Coupling these high resolution and high contrast tomography images with a suite of customized 3D segmentation algorithms and analysis software, applications in mineral liberation analysis for process control, particle damage assessment and other mineral processing applications can be achieved. This non invasive 3D technique which requires relatively little sample preparation is currently being considered for coal, industrial minerals, and base/precious metal ores, complementing existing microscopy techniques such as QEMSCAN and MLA for a variety of applications

Sep 1, 2012

By J. S. S. Allwin Ebinesar

The bioremediation of zinc was carried out using Pseudomonas alcaligenes, a Gram negative heterotroph. The parameters such as pH, bacterial cell number, initial metal concentration, and interaction time on the biosorption of zinc were studied. The maximum zinc uptake was found to be about 95% at pH 5 and biomass loading of 2.7x1010cells/mL. The biosorption isotherm for zinc exhibited Langmuirian behavior and the Gibbs free energy of biosorption was determined to be -31.2 kJ/mol, indicative of coordination of zinc with the functional groups on the bacterial surface. The adsorption kinetics followed a pseudo-second order equation. FTIR and EDAX studies confirmed the interaction of zinc with the biomass. The mechanisms of metal-microbe interactions are discussed.

Sep 1, 2012

By F. Q. Cheng

As the important potash, the product yield of KCl in winter is low and the resources waste is serious according to the deficiency of collectors, which can be used in this condition currently. This paper studied on the change of contact angle, turbidity, and flotation recovery of KCl particles when different chain lengths, ratios of amines were used as collectors in KCl flotation process to get a new mixed collector. The contact angle values of KCl crystal in its brine solution added different amine collectors were first measured by captive bubble method. The turbidity of brine solutions were then measured by the laboratory turbidimeter at room temperature when different amine collectors were contained. In the end micro-flotation experiment using mixed amine with fixed ratios and ODA as collectors respectively at 5 °C, 23 °C were performed. The results show when the ratio of the mixed amine is DDA- 20%, ODA-60%, C20-20%, the contact angle at KCl surface is the maximum and the hydrophobic state is best. Meanwhile the result of turbidity measurement indicates that the dispersion of mixed amine colloids is better than the ODA collector due to the addition of DDA, which plays the role of frother. The flotation results also prove that the mixed amine is not only fit for the KCl flotation at room temperature but also fit for its flotation at low temperature. This study provides strong technical support to extend the production time of potash business in Chaerhan areas in China.

Sep 1, 2012

By Mario Gerards, Marco Steinberg, Jan Huben

"Wet high intensity magnetic separation or WHIMS is a widely used technical process for the recovery of magnetic susceptible iron ore particles, mostly for fine and ultrafine grain sizes. The JONES® WHIMS - Wet High Intensity Magnetic Separator, has been used for many years and in countries all around the world. This paper outlines the physical principles utilized for the separation inside the unit, as well as some of the recent changes and developments on the design. It will also give an outlook on the theoretical potential of different alternative yoke materials. The aim of this paper is to analyse the suitability of different yoke materials to improve the equipment. This will be done comparing the magnetic and mechanical parameters and analysing availability and price to find the best compromise regarding cost and benefit. As far as the different kinds of materials are concerned, a special material has been identified as suitable during the comparison exercise. After running the economical calculations, especially with respect to the reduction of the total power consumption of the equipment, a tremendous reduction of the total power consumption has been determined. In addition, to the theoretical exercises and due to the promising results of the same, the Pilot Unit P 40 of the JONES® WHIMS has been manufactured with the special material in order to get practical results as well. Finally, this paper outlines the theoretical and practical results focused on the power consumption. The results are showing that the total power consumption can be reduced tremendously. Hence, the way for a new generation of JONES® WHIMS - environmentally friendly - has been paved."

Jan 1, 2014

By H. U. R. Kattentidt, W. L. Dalmijn, T. P. R. de Jong

"Research at Delft University aims to develop systems for automatic inspection and sorting of bulk solids which can be applied in the mineral processing and recycling industry. A recent development includes an automatic sorter based on airport X-ray inspection technology. It is designed for continuous inspection and sorting of 5 – 150 mm solids and has as objective a cost effective and high capacity on-line inspection and sorting.Dual energy X-ray transmission imaging provides instantaneous data about particle dimensions and the atomic number distribution. The system provides particle thickness and average atomic number on a pixel level at scanning speeds between 250 and 500 lines / second. With existing X-ray components inspection speeds between 0.5 and 2 m/s at approximately 1-meter inspection width and between 1.5*1.5 and 5*5 mm2 sensor resolution can be achieved.Imaging algorithms that were developed by Delft University for applications in recycling, waste cleaning and other applications acquire shape, size distribution and composition data. Currently on-line processing of a product at a rate of around 200 particles per second is possible using a standard PC. Experiments with a demonstration X-ray unit indicated good potential for various applications in solids processing. They include continuous inspection of organic content, sulphur, chlorine, ash, and metal distribution. It is applicable for coal cleaning, ore sorting, industrial minerals, and various applications within waste cleaning and recycling. Dual energy X-ray transmission fundamentals and recent progress in system development and applications are presented."

Jan 1, 2003

By S. V. Petrov

In recent years, heap leaching of gold is becoming wide spread due to low capital and operational costs that allows economically feasible processing of low-grade and cut-off grade ores. Currently, over 30 heap leach projects are operated in Russia. Some of the deposits treated by heap leach methods are almost depleted. Therefore, they will soon require spent heaps detoxification and reclamation. Traditionally, spent heaps are detoxified by chemical treatment. This process is characterized by relatively high kinetics and requires expensive reagents and additional equipment. The main disadvantage of this process is secondary contamination of the solutions by products of detoxification reactions and impurities contained in reagents. If there is enough time, spent heaps can be detoxified by natural degradation. The advantages of the proposed method are low operational costs due to use of existing heap leaching facilities and eliminating the need for chemicals for spent heaps detoxification. Residual concentrations of cyanides and thyocyanates in liquid phase (wet ore) of spent gold ore heaps after detoxification were 0.2~0.3 mg/L. Heavy metals were almost completely removed. The method was successfully used for detoxification of spent heaps at two gold mines.

Jan 1, 2014

By O. A. Bascur

"In recent years, metal producing companies have increased their investment in automation and technological innovation, embracing new opportunities to enable transformational change. Internet of Things (IoT) is one of many transformational initiatives, which can fundamentally revolutionize how industrial complexes operate. Whatever the issue, the answer is in the abundant and growing quantity of real time data and events collected in the grinding and flotation circuits in a mineral processing plant. Based on earlier work, today a grade recovery model permits identifying the best operating conditions in real time. We will review the strategy for increasing the value of the abundance instrumentation in current plants. An optimal Gaudin size distribution model provides augmented information from traditional sensors to find the optimal grind cut to reduce metal losses in the flotation circuits. The large amount of sensors in a flotation circuits permits to estimate the recovery and to find the optimal froth depth and aeration using an air holdup flotation model. The paper will describe the strategy of classifying data for on line generation of insights to using operational intelligence tools. We will discuss the implementation Recovery/Grind strategy with industrial examples in non-ferrous mineral processing and iron beneficiation.INTRODUCTIONThe declining supplies of high grade ores and increasing consumption of mineral and metal products have demanded higher operational efficiencies with minimum capital investments. The objective of copper flotation objectives are based on maximizing the dollars return on the concentrate produced. The economic efficiency is maximized by manipulating the circuit along the grade/recovery curve relationship. To achieve such objective improved stabilization of the grinding and flotation circuits are required (Oosthuizen, Craig, and Jamsa-Jounela, 2017)."

Jan 1, 2018

By Rob Morrison, Andrew Scott

"Long before a modern mine commences operations it has already become a wealth of information. After start up, it can generate enormous quantities of data – especially with semi-automated data acquisition by instrumented mine equipment. Much of this data is of limited use for evaluation of (potential) performance unless it links in some way to the site business model.An underlying reason for this waste of data is that the different cultures, financial, technical, community, environmental, etc, not only have many areas of interest but also have very different conceptual models by which they evaluate performance.It is too ambitious to attempt to bring all of these cultures together – in a single step. However, the success of the Mine to Mill ™ project has demonstrated that substantial operational value can be added by using a more integrated approach to comminution. The next logical step is to integrate measured data and then to track performance from ore body model to saleable product and waste disposal.The path from resource to product also represents a path from very sparse, highly variable data to much more detailed measurement and more representative sampling. However, in both cases the data collected is usually strongly focused on the technical requirements – not on the business model.This paper emphasises the difference between data and information. There is considerable potential for confusion between the two as both data and information are often expressed as numbers. For the purpose of this paper, data and information are distinguished by their uses.A data point (or datum) is a measurement. By way of contrast, information provides a basis for decision making."

Jan 1, 2003

By Moris Fresko, Julia Sun, Charles C. Golembewski, Vytas Svalbonas

"A history of mill strain gaging at Metso is presented. The output of these strain-gaging programs is compared with calculated stress ranges from different finite element solutions. These comparisons expose the amount of approximation that exists in the analytical solutions, starting from geometry, and material properties, and ending with different forms of internal load models. The influence of strain gaging results on mill design and analysis practices is also discussed. While these instrumentation programs are valuable in identifying areas of high stress in mills, and locations of stress concentration factors, they are by no means extensive or comprehensive enough to verify general internal load models. The vast majority of the programs were aimed at getting additional data about potential failure points, rather than describing overall mill stress behavior. This is especially true since the more recent gaging programs have not included the difficult task of gaging the mill rotating structure interior. This paper tries to avoid the novice path of leaping to general conclusions on the basis of insufficient data."

Jan 1, 2014

By S. S. Yu

In this paper, the producing process of using V2O3 as raw material to obtain vanadium nitride was analyzed through the means of thermodynamic. The analysis shows that conversion follows the principle of reduction step by step in the conversion process of V2O3. The temperature of the reaction system has prominent influence on the nitrogen content of products, and the reaction is very sensitive to temperature. As raising temperature, the fine grain structure of the nitrides is more evident, and the grain size of nitrides increases. At 1703K, the nitrogen content of the products tended to be constant after soaking over 3 hours.

Jan 1, 2014

By M. Brozek, W. Pawlos

"The separation of raw materials in the separator with ferromagnetic liquid occurs due to differences in magnetic and gravitational properties of respective components in relation to each other and to the liquid. In the separator with wedge-shaped pole shoes and the working space axis inclined at a certain angle to the horizontal direction, the paths of grain movement at fixed separation conditions depend on its physical properties. Due to this, the levels of grains outlet from the separator working space are differentiated according to differences in their physical properties. The distance between the levels of outlets from the separator working chamber depends on magnetization of the liquid which is proportional to the liquid density, on the magnetic field intensity and the inclination angle of the separator working passage to the horizontal axis. The separation accuracy is higher the larger is the distance between the outlet levels.The paper will present the methods of visual observation and recording of movement paths of coal grains of different physical properties in the paramagnetic liquid which was the water solution of manganese chloride. The paths were recorded with a video camera in the working chamber by means of a specially constructed device, acting as a periscope, which were then transformed into digital images. Experimental movement paths were confronted to the paths obtained in a theoretical way by means of solving differential equations of movement by a numerical method, achieving good compatibility of experimental and theoretical results. The equations of movement were solved with taking into consideration the drag force, expressed by formula for laminar and dynamic conditions of motion.The course of the path of grain movement depends on grain and liquid physical properties, magnetic field intensity and inclination angle of the working space to the horizontal direction. The two latter parameters can continuously control the process of separation."

Jan 1, 2003

By G. Onal, E. Gock, H. Dincer

"During the conventional chromite dissolution process; chromite ore concentrates were ground to at least <90 µm using the ball mill and after adding Na2CO3 and leaning material (instead of CaCO3 also residues from the leaching process) at a ratio of e.g. 1:0.75:1.2, depending on the specific formulation, follows the digestion e.g. in a rotary kiln, heated in countercurrent. The reaction time is 3 to 8 h. The calcine is comminuted and leached with water or a thin chromate solution. Depending on the type of ore used, the yield is 75-85 %. The disadvantage of the above-described process is that it is impossible, using current technology, to achieve a complete digestion of the chromite ores and that the chromium-containing residues have to be disposed of as special waste, involving a large financial effort.The subject of this study was the investigation of the effect of vibratory milling on chromite dissolution. The impact stress in the vibratory mill causes the mechanical activation of chromite, which is characterised by lattice defects. The degree of mechanical activation can be quantified by measuring the relative X-ray diffraction intensities at the parent lattice planes of chromite. Each relative X-ray diffraction ratio correlates with a certain degree of digestion. As opposed to vibratory milling, a complete digestion of chromite using a ball mill is impossible, even at extremely long grinding times.In this investigation a chromite concentrate from Pulpinar/Kayseri with content of 44 % Cr2O3 and the Eccentric Vibratory Mill was used. In order to verify the effect of the vibrating grinding on chromite dissolution, reaction kinetic investigations on digestion and leaching were carried out."

Jan 1, 2003

By E. Barsky

"The aim of separation is to obtain two products that are as distinct as possible from each other. It is currently believed that the most objective criteria for the quality of a separation are the Hancock criterion and the entropy criterion.1. Hancock criterion:- for yield of fine product"

Jan 1, 2003