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By Shen Zhengchang

Based on the flotation features of coarse particle mineral, a new type of impeller & stator unit is developed. Particles suspension state generated by this impeller & stator unit under different speeds are tested in laboratory, and critical impeller speed suit for coarse particles flotation is presented. Comparing particle suspension parameters of the new impeller & stator unit with that of KYF impeller and stator unit, it comes up that the distance between the interface of two slurry circulation channels and the cell bottom is larger in the flotation cell with new impeller & stator unit. The test results indicate that the new type of impeller & stator unit is suitable for processing coarse particles due to its good suspension capacity for coarse particles. Keywords: coarse particles, flotation, suspension, critical speed, impeller and stator unit

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 S. Gaydardzhiev

Laboratory batch tests having preliminary and orientation character aiming at improvement of the molybdenum flotation at Ellatzite copper processing plant in Bulgaria have been conducted. The following technological parameters have been screened to study their influence on the grade and recovery of copper and molybdenum during the rougher flotation stage: flotation pulp density, pH, addition of secondary collector and replacement of MIBC by pine oil as a frother. The results have shown that slightly better grade/recovery figures could be obtained for both copper and molybdenum at lower flotation pulp densities. The addition of kerosene has improved the recovery of molybdenum however, on the expense of that of copper. The effects from pH variation and the replacement of MIBC by pine oil as a frother have been almost negligible.

Sep 1, 2012

By T. C. Sun

Two wasted activated sludges (WAS), from an industrial wastewater treatment and a sewage treatment plant respectively, and 7 collectors are used to investigate the feasibility of air flotation thickening of WAS by adding the collectors used in mineral processing. The collectors experimented include straight chain fat acids with different chain length, sodium oleate, alkyl sodium sulphonate, sodium dedecylsulfonate, and dodecylamine. The results show that the thickening efficiency varied depending on different collectors. Of the collectors experimented, dodecanoic acid and dodecylamine are best collector for thickening both sludges.

Jan 1, 2014

By E. Kusaka, M. EL Salmawy

"The electrokinetic behavior of EL Maghara coal has been investigated in the presence of nonyl and octyl nonionic surfactants containing polyethoxy of different sizes with trade names of Triton-X100 (TX-100), Triton-X 705 (TX-705), Triton WR-1339 (TWR-1339) and Brij 58. The electrokinetic behavior was determined by zeta potential measurements. Zeta potential measurements were conducted by Laser-Doppler electrophoresis technique using zetamaster. The results show that the zeta potential of Egyptian coal varies with pH value, the hydrocarbon chain and number of ethoxy groups in the hydrophilic group of the surfactant. It was found that the polymeric surfactants reduce the negative values of zeta potential of coal. The shift of PZC of coal upon deashing appears to be closely relevant to silicate mineral removal."

Jan 1, 2014

By F. Molhem, S. Banisi, H. R. Montazari, E. Arghavani, Gh. R. Biniyaz, Gh. A. Parsapour

"Water plays a key role in mineral processing plants and to process one ton of ore 2.5 ton water is needed. Thickeners are commonly used for dewatering and recovering water in most processing plants. The underflow pulp density is increased by sedimentation of particles and clear water is recovered from the overflow. One of the issues related with using the process water is the presence of suspended fine particles in the clear overflow water which can create blockage in transfer pipes. The froth formed on top of thickeners is the main cause of this problem. In this study, a method to decrease the froth formed on the Sarcheshmeh Cu-Mo thickener surface was introduced and implemented. At the first stage, the old punched plate feedwell was removed and it was replaced by a vane type feedwell. A spray water ring using fish-tail type nozzles was then installed to break froth layers by water. These modifications led to 63% relative reduction in the water turbidity, 11% relative increase in the underflow solids concentration, 20% relative reduction in torque, 19% relative reduction in its standard deviation and an increase of 6% in water recovery.INTRODUCTION The Sarcheshmeh copper complex, the largest copper producer in Iran, located in southern Iran. In the processing plants of this complex, over 250,000 m3 of water is consumed daily. Because of a lack of water in this area and very low yearly rain fall (150 mm), water plays a vital role in the complex. As a result, it is then aimed at maximum water recovery by taking all necessary measures. The recycled water in order to be used should not contain any suspended solids indicated by low turbidity."

Jan 1, 2018

By Marco Le Roux, Martha Van Rensburg, Quentin Campbell

Fluidised bed drying is currently receiving much attention as a dewatering option during the beneficiation of fine (defined here as between 1 mm and 2 mm particles) coal. Apart from concerns about safety and combustion, the operating costs can be high if very high gas or air temperatures are used. The aim of this study was to investigate the removal of moisture from fine coal by using air at a lower temperature (25 - 55°C) within a controlled environment by lowering of the relative humidity of the air. It was firstly proven that fluidization has a major advantage over non-fluidized beds, with regards to drying rate and final moisture content. Hereafter several parameters that influence the dewatering rate and final moisture content were tested, from which it was concluded that the relative humidity of air acts as the largest driving force for dewatering. Parameters tested included relative humidity, temperature and coal composition. Energy balances showed a positive nett energy increase in the dried coal during combustion when related to the energy input during drying. In comparison with thermal drying technologies, fluidized bed drying was proven to be less energy intensive. It was therefore shown that this is a viable technology for the dewatering of fine coal.

Jan 1, 2014

The multiphase reactive flow in process equipments, e.g., fluidized beds, involves complex coupling among flow, heat/mass transfer and reaction kinetics over scales ranging from molecules, sub-particle eddies up to equipments. Conventional two-fluid model (TFM) ignores the effects of meso-scale structures, and hence is not suitable for describing the intrinsically multi-scale heterogeneity within multiphase systems. To be consistent with the meso-scale structures, we proposed a structure-dependent multi-fluid model (SFM), and closed its drag force by invoking the stability condition defined in the energy-minimization multi-scale (EMMS) model. The SFM reduces to the conventional TFM if homogeneous distribution is assumed within each grid, and reverts to the original EMMS model if it is used to describe steady state, global behavior of a fluidized bed. The multi-scale computational fluid dynamics (CFD), which is characterized by coupling of TFM and EMMS drag coefficient, can then be viewed as a simplified solution of the SFM. We demonstrate that the SFM significantly improves the accuracy and at the same time enables higher efficiency by allowing for much coarser grid used than in TFM. Recent application of it in 3D, full-loop, transient simulation of industrial processes, e.g., fluid catalytic cracking, coal combustion, gasification, kaolinite clay calcinations, shows its advantages in helping design and troubleshoot multiphase process equipments. Keywords: meso-scale, SFM, multiscale, CFD, simulation, structure, EMMS, multiphase

Sep 1, 2012

By A. Üçyildiz

Magnesium borates of varying compositions and properties are synthesized using different reagents and methods for the possible potential uses as termoluminescent material, anti-wear and anti-friction additive, fire retardant, catalyst for the conversion of hydrocarbons, whisker material and ferroelastic material. In the current work, the conditions for synthesizing MgB4O7 compound by high-temperature solid-state reactions were investigated using boric acid and magnesium oxide as the starting materials. The MgO:B2O3 mole ratios applied in the experiments were 1:1, 1:2, 1:3 and the thermal behaviours of each mixture were studied between 25~1200°C by TG/DTA analyses under static air atmosphere to find out the probable formation temperature of MgB4O7 phase. Considering TG/DTA results, freshly prepared boric acid and magnesium oxide solid mixtures were heated at predeter-mined temperatures and the phases were identified by XRD analyses. Accordingly, MgO:B2O3 mole ratio of 1:2, heating temperature of 950°C and a reaction time of 2 hours were selected as the optimum conditions for the formation of maximum amounts of MgB4O7. After obtaining solids prepared at the pre-determined optimum conditions, their chemical composition, IR spectrum, TG/DTA pattern, B.E.T. surface area value, particle size distribution and SEM images were deter-mined to point out the possible use areas. Experimental results showed that it was not possible to obtain pure product at the optimum conditions due to formation of minor amounts of t-Mg2B2O5 and the presence of some unreacted B2O3. The product synthesized has the potential for use as a corrosion inhibitor on some metal surfaces.

Jan 1, 2014

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 Kari Niiranen, Andreas Fredriksson

LKAB (Luossavaara-Kiirunavaara AB) is operating iron ore mines, concentration plants and pelletizing plants in Northern Sweden. Geometallurgy, which combines geological and metallurgical information is not a new way of thinking at LKAB, but rather a revised and updated version of an old working process. A project called "Silica in the Mine" which started in 2007, was an important reason to set a new focus at the geometallurgy. The target of the project was to develop a simplified method in laboratory scale to predict SiO2 grade in the magnetite concentrate in Kiruna and further predict the physical properties of the crude ore with respect to processing characteristics. The connection between mineralogy and products properties have started to be even more vital and necessary to examine due to the future exploiting new iron ore deposits. Geometallurgy at LKAB can be described as a mental and strategic framework where the Research and Development department (R&D), and others within the organization of LKAB, aims towards the connection of the minerals-production-products. It could in its basics be called "research & development", but it must be clarified that changes have been made, mainly due to the development on the instrumental analysis side. LKAB’s idea is to work quite broad, with internal educations, an active working process in ongoing projects, together with external parties (such as universities), with several PhD-projects and an upgrading on the instrumental side at the LKAB Research & Development department. This paper is a summary about the concept Geometallurgy at LKAB and some of the actions within its framework.

Jan 1, 2014

By John Ralston

"Interfacial chemistry plays a pivotal role in bubble-particle capture, for it controls whether or not attachment occurs. Surface heterogeneity, degree of surface hydrophobicity, bubble nucleation and related phenomena influence the stability of the aqueous wetting film between a particle and an approaching bubble. The latter must be unstable if capture is to occur. Various techniques that may be used to quantify this interfacial, chemistry-dominated behaviour, are described.The efficient capture of specific particles by rising bubbles and the delicate control of interfacial chemistry that leads to selective capture are central issues in froth flotation. For efficient capture to occur between a particle and a bubble, they must undergo a close encounter, a collision process dominated by hydrodynamics. Should this encounter bring the particle and bubble within the range of attractive forces, the intervening liquid film between the bubble and the particle will drain, leading to a critical thickness at which rupture occurs. The liquid-vapour interface then retreats over the solid particle surface until a stable wetting perimeter is established. The particle and bubble are then joined after this attachment process. The particle may only be dislodged from this state if it is supplied with sufficient kinetic energy to exceed the detachment energy in this detachment process. These various events are now well documented and may be followed using high-speed videomicroscopy (Schulze, 1984; Nguyen et al., 2001).The process of collision can now be described quantitatively for single bubbles colliding with bubbles under various flow regimes (Dai et al., 1998) and appropriate scale up is possible for multiple bubble particle collisions occurring under turbulent conditions (Pyke et al., 2002). In this paper we will be concerned with the role of interfacial chemistry and how this influences the attachment process."

Jan 1, 2003

By Ronel du Plessis, John C. Davidtz, Jan D. Miller

Xanthates (dithiocarbonates) have been the collector of choice for the flotation of sulfide minerals ever since the flotation process was developed and have been studied quite extensively. Recently, trithiocarbonates have been shown to be very effective in bulk sulfide bench-scale flotation. Fundamental analysis using electrochemical techniques have supported these bench-scale results, illustrating that the trithiocarbonate (TTC) collectors are more readily oxidized to their corresponding dithiolates, than the dithiocarbonate (DTC) collectors, as is shown in Figure 1.

Jan 1, 2003

By G. S. Hansford, G. E. Searby

The rate of bioleaching of pyrite at 70ºC by a thermophilic archaeal culture was measured as a function of the solution redox potential by the staged addition of pyrite to a batch system. The results were compared to the rate of ferrous iron oxidation over the same potential range to determine the applicability of the multi-sub-process leaching mechanism developed for mesophilic bioleach systems.

Jan 1, 2003

By Willis Forsling, Prabhakar Swarna, Hanumantha Rao Kota

"The solubility of wollastonite and its Hallimond flotation behavior as a function of dodecylamine concentration and pH are examined. The flotation response is characterized by adsorption and surface energy in the presence of amine. The methods of UV-Visible and FT-IR spectroscopy for adsorption and sessile-drop contact angle for surface energy estimation are employed.The results of wollastonite dissolution clearly showed its non uniform dissolution. The surfaces are depleted with calcium ions and became rich in silicon within 10 min of flotation time. Maximum flotation of wollastonite corresponds to a half monolayer coverage of amine, which is substantiated by the surface energy parameters as shown in figure 1."

Jan 1, 2003

By Markus A. Reuter, Yongxiang Yang, Jim R. Post

In the upper part of an iron making blast furnace, sinter, coke and pellets are charged. While descending, the burden is heated and the iron oxides are reduced by the rising gases. The iron oxides start to soften and eventually melt. The melt and the remaining coke collect in the lower part of the blast furnace: the hearth. The remaining coke forms a porous bed: the dead man (see Figure 2). The melt flow through the dead man can affect substantially the hearth lining life, the furnace productivity and product (i.e. hot metal) quality. Physical characteristics like porosity and particle size distribution of the porous coke bed play a critical role. Because of the distributed nature of the coke properties, the bed packing structure and porosity will not be constant.

Jan 1, 2003

By N. T. Beukes, W. Banda

Recovery of Co from slag is a recent advancement in the extractive metallurgy of nonferrous metals. In this study a DC arc technology at laboratory scale has been applied to investigate the selective recovery of Co from slag, under three different flux types with an emphasis on influencing the activity of FeOx, SiO2 and CoO in the slag. It is known that reduction of slag by carbon is only up to a certain level after which, the recovery will depend on the chemistry of the slag, hence the need to modify the slag chemistry. Two power settings were employed to induce higher temperatures and aggressive agitation. The results were interpreted by comparing how much Co and Fe was in the slag and alloy. TiO2 reduced the amount of Fe in the product alloy compared to when CaO and CaF2 were used. The change in power did not seem to have had a major effect on the recovery although the amount of material lost to flue dust was more at a higher power rate.

Jan 1, 2003

By S. Kelebek, A. Khan, J. Caceres, D. Beckett

"Pyrrhotite in nickel-copper sulphide ores is nickeliferrous and intimately associated with pentlandite. Due to its low nickel content, pyrrhotite rejection is an important step in processing of these ores. In our laboratory, various reagents were investigated for their effect on pyrrhotite depression. Among these, a combined use of triethylenetetramine and sodium metabisulphite was found highly promising.The work described in this paper has two parts. The firs part is a summary of results obtained on process samples from the pyrrhotite rejection circuit at Falconbridge’s Strathcona Mill. The second part involves simulation of the circuit performance based on the reagent conditions used in the experimental work and the concept of split factors.Two sets of reagent conditions were evaluated. The first one involved baseline conditions, simulating the current reagent performance. The second one simulated the impact these new reagents can have on the circuit performance.The simulation results obtained under baseline conditions indicated a good agreement with the current circuit performance (Figure 1). The simulation results suggest that at practically the same pentlandite recovery and tailing grades, the circuit concentrate nickel grade can be doubled through effective pyrrhotite rejection by these new reagents (Figure 2)."

Jan 1, 2003

By Marlize Barkhuizen, Chris Aldrich

"Owing to environmental constraints, safety considerations and competitive pressures, the development of model-based process control and other automated systems have experienced considerable growth in the last few decades. Reliable process models are usually critical to the successful implementation of these systems. In complex processes, these models are often constructed from process data, as modelling from first principles may not be feasible or cost-effective.Even so, modelling or identification of nonlinear systems from historic plant data can be a daunting task and in the process industries the problem is complicated by the presence of noise from various sources, nonstationarity of the data, intermittence, such as observed in particulate flows, etc. Traditional methods, such as frequency analysis and linear modelling do not handle these systems well. Similar problems arise with the application of nonlinear theory developed over the last few decades, where much of the analysis depends on embedding of the data in a phase or pseudophase space, since these methods were not originally designed to deal with noisy systems.With singular spectrum analysis, the data are embedded in a high-dimensional reconstruction, followed by the introduction of a new coordinate system, where the origin is moved to the centroid of the reconstructed system states and the axes are represented by the dominant principal components of the states (points)."

Jan 1, 2003

By Reuter M. A., R. D. van der Weijden, W. F. C. van Wageningen

"Copper(II) can be recovered or removed from acidic copper sulfate solutions as cuprite or metallic copper powder by reduction with carbohydrates. The copper powder characteristics, such as size and shape of particles, determine the tendency to adhere to reactor walls and to agglomerate. In order to make this process suitable for a commercial scale pipe reactor, process conditions and the reactor configuration were varied in order to influence the copper characteristics in a positive way. The aim was to achieve proper particle throughput in the pipe reactor and to obtain a well defined copper powder.In this paper the effect of both, chemical and physical parameters on the shape and size of particles were systematically studied in a number of autoclave experiments. These parameters include mixing, Cu(II) concentration, pH, temperature, seeding, use of additives and reactor materials. Additionally, Monte Carlo simulations of copper growth inside a Kenics static mixer were made. Results show that the use of additives and the use of static mixers influence particle characteristics the most."

Jan 1, 2003