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By F. Y. Kang

Graphite with layers structure is easily to form graphite intercalation compounds (GICs) by means of intercalation reactions due to the weak cohesion force among carbon layers, van der Waal?s interactions. By controlling the oxidation-intercalation, high quality exfoliated graphite with low residual sulfur content and MClx-GICs (M=Fe, Co, Ni, Cu, Zn) powder for electromagnetic wave absorbing and shielding materials have been invented. The expansion volume of expandable graphite can be larger than 160 mL/g while the residual sulfur content is less than 800 ppm. The MClx-GICs powder can shield infrared ray and laser completely up to 15 min. We have also in-vented exfoliated graphite for heavy oil adsorption and mild-expansion exfoliated graphite for anode materials in lithium ion battery by controlling the intercalation/de-intercalation. The exfoliated graphite can adsorb heavy oil up to 80 g/g, it also exhibits better performance than commercial active carbon in sewage treatment. The mild-expansion exfoliated graphite as anode material shows high capacity of 370 mAh/g and good cycle performance.

Jan 1, 2014

By S. J. Dai

The cadmium and cyanide are main poisonous components in cyanide electroplating cadmium waste water of an electroplating plant in Shenyang. The content of cadmium is about 26 mg/L and the content of cyanide is about 11.782 mg/L in this waste water. The main form of cadmium and cyanide are ions which are Cd2+and CN?. Because the cadmium and cyanide exceeded the standard seriously, the waste water must be disposed before it discharges. The microbiological method of treating heavy metals in wastewater has many advantages. For example, it has a fast adsorption velocity, high processing efficiency, wide range of pH and temperature, few invest, low running cost, no the second pollution and so on. At the same time, the CN? could be degradated by some microbiology. The physical nature, the chemical nature of Bacillus mucilaginosus, the adsorbing condition and adsorbing regular of Bacillus mucilaginosus to cadmium in the wastewater are studied by using Bacillus mucilaginosus as adsorbent removing cadmium from electroplating wastewater. The experimental results show that the adsorbing rate of cadmium is over 92%, under the room temperature(about 25?), stiring revolution in adsorption being 800 r/min for 30 min, pH being 5 , the bacteria being cultured after 5d with the biomass of Bacillus mucilaginosus 40g/L (wet weight). The mechanism in biosorption process of Bacillus mucilaginosus to cadmium is analyzed and discussed by TEM , Zeta potential,and infrared spectroscopy analysis. The results showed, the chemical involving is main adsorbing form, while electrostatic attraction, ions exchange, hydrogen bonding and Van Der Waals force are concerned cooperatively. ?NH2 ?, ?C=O?, ?C=O?NH?CH2, ?CH3, ?OH are main adsorbing groups. At the same time, the floatablity of removing cyanide by Bacillus mucilaginosus is explored.

Jan 1, 2014

By R. P. Bhagat

The paper reports results on sinterability of iron ores from the mines of Tata Steel Limited. The objective was to improve tumbler index (TI) of sinter and its reduction parameters, reduction degradation index (RDI) and reducibility (RI) while maintaining strand productivity same or to improve. Pot sintering experiments were carried out with Joda and Noamundi mines having LOI 3.8% and 2.9% respectively. Sinter basicity (CaO/SiO2) was varied in the 2.1 to 2.5 range and its MgO content was kept in the 1.4% to 1.8% range according to the blast furnace requirement. The ignition condition and vacuum was maintained according to the plant practice. The effect of variables namely, granulometric composition of ores vis-à-vis that of sinter mix, bed height, solid fuel, moisture content of green mix on the sintering indices was studied. The productivity with Noamundi ore (26 %+6.3 mm) was lower than that with Joda ore (45% +6.3 mm) at 4% coke in the mix and sinter basicity (CaO/SiO2) 2.1. However, with 4% coke (ash 22%) the RDI value was significantly high in case of Noamundi Ore, which decreased significantly to 29% with 5% coke. The size parameter of ore fines and its LOI content do influence the sintering speed and the sinter properties significantly. At 2.1 basicity ratio, the sinter with the Joda ore having coarsergranulometry had highest TI (=70.2%). The RDI (27%) in this case was inferior to that (23.2%) when Joda ores with finer size was sintered. Better RDI with finer sized ore could be attributed to better assimilation of CaO/ MgO with more balanced and uniformly distributed hematite minerals. The size parameter has been inter-influenced by the coke requirement. With the lower mean sized Joda ore the sinter RDI decreased significantly to 23% and the productivity improved to 42.9 T/(sq m*d) when the coke in the mix increased from 4% to 5%. An attempt to reduce the coke in the mix from 5% to 4% with respect to both the ores was not successful as it resulted higher RDI and lower strand productivity. The present study has revealed that sinter RDI improves (decreases) with decrease in the sintering time, while such correlation was absent between TI of sinter and speed of sintering. Corollary to this observation, one can take advantage of other stronger parameters to increase the sintering speed (and hence sinter productivity) without affecting the sinter strength. In the present study higher FeO sinters has displayed excellent RDI, however cold strength of sinter was not correlated with its FeO content. The TI and RI parameters of sinter improves marginally with increase in its MgO content while RDI got worsened. Keywords: LOI content, iron ore, reduction properties, sinter, noamundi, joda

Sep 1, 2012

By L. S. Zhou

HermesTM metal magnetic liner (MML) has been invented and manufactured by China Metallurgy and Mining General Co. (CMMC). This paper describes its mechanism, structure, magnetic field distribution, application, economic benefit and safety performance. The 10 years? service life in Benxi Steel?s Waitoushan Mine, along with 6 years? technological analysis on its application in 5500mm×8800mm (diameter × length) ball mill in Anshan Steel?s Diaojuntai mineral processing plant, has proved its advantages such as super reliability, long service life, light weight, thin thickness, low noise and short payback period. It has also demonstrated its positive effects on the grinding process such as high productivity, energy-effective performance and low consumption of grinding media. It reduces labour intensity and improves working conditions, due to its easy installation, free maintenance and the fact that it doesn?t require fastening bolts or cause slurry leakage. It is de-signed scientifically in accordance with the varieties of processing lines, mill specification, ore type and grinding media, and has been applied in different grinding processes for magnetite, hematite, gold ores, nonferrous ores and other materials. HermesTM MML has three types of products: General, Composite and Heavy-duty. They are designed to meet the requirements from customers in China and abroad. So far, more than 400 sets of MML have been applied in ball mills with diameter rang-ing from 1500mm to 5500mm. It has become highly popular in American market recently due to its safe and effective performance.

Jan 1, 2014

By Hossein Zarei, Masoud Kashani, Mehdi Safari

The feed of flotation unit in Angouran mine, as a part of Iranian Lead and Zinc National Corporation, contains about 34.26% zinc (about 12% Zn sulphide) and 10.14% lead (about 2% Pb sulphide). The grade of Pb and Zn in the final concentrate (rougher+scavenger), under optimal conditions (200 g/ton PEX, 500 g/ton zinc sulfate, 30 g/ton MIBC and pH = 7.5), was 63.18% and 13.01%, respectively, and the total Pb (sulphide-oxide) recovery was about 19% which included 95% Pb sulphide. The grade of Pb and Zn in rougher concentrate step was about 71.86% and 5.97%, respectively, when PEX (Potassium Ethyl Xanthate) was used as collector. While in the presence of PAX (Potassium Amyl Xanthate), the grade of Pb and Zn in rougher concentrate step was 66.8% and 10%, respectively. Tailing of the galena flotation (with 8.48% Pb grade and 34.92% Zn grade under the optimal conditions) was used as a feed for sphalerite and oxide section flotation.

Jan 1, 2014

By Mohana Rao Andavarapu

Sandur Schist Belt of Karnataka Craton constitutes a hub of iron ore mining activity. The iron ore deposits of the region are closely associated with Banded Hematite Quartzite (BHQ), Shale, phyllites, & Graywackes. The gradual depletion of high-grade iron ores due to extensive utilization has necessitated the exploitation of low-grade iron ore including BHQ, which are available abundantly in different parts of India. In the present investigation, BHQ samples from Kammaturu mines of Sandur schist belt was studied to assess the possibility of upgrading the iron content to the maximum possible extent, so that it may find the better use in iron and steel industries. The sample collected from the study area analyzing 39.76% Fe, 39.8% SiO2, 0.66% Al2O3, and 1.92% LOI was subjected to beneficiation studies. The mineralogical studies reveals that the samples are predominately consists of hematite as an iron mineral and quartz as gangue mineral. Liberation studies and chemical analysis were carried out prior to the beneficiation process, which is flotation. Cationic Reverse flotation studies were carried out and discussed by varying different process variables such as feed size, depressant, collector cum frother dosage & pH. The results obtained are encouraging with an appreciable improvement in the iron content up to 62.8% Fe with Fe recovery of 50.43%. The concentrate obtained from the flotation can be used for pellet making process.

Sep 1, 2012

By A. Luszczkiewicz

An innovative hybrid technology for beneficiation of difficult-to-process sedimentary copper ores comprising acidic leaching stage of the feed combined with subsequent flotation has been presented. Acidic leaching, preceding the flotation process, plays a beneficial role of efficient chemical grinding for liberation of copper sulphide minerals finely disseminated in the copper-bearing carbonate-shale rocks. The process was applied on a fully industrial scale. Flotation results were analysed for both chemically modified and unmodified flotation feeds. After several months of industrial scale operation, it was found that both metals recovery and concentrate grade remarkably increased as a result of application of chemical modification of the flotation feed. Beneficial effects of chemical pre-treatment of flotation middlings on selectivity at a comparable concentrate yield in industrial flotation scale, revealed a considerable increase of the total copper recovery by 3.5percent. Based on the industrial and laboratory investigations we consider a further development of the process and introduction of hydrometallurgy for better recovering of metals from low-grade copper concentrates

Sep 1, 2012

By G. K. Palshikar

Mining operations offer many opportunities for the use of IT and communication technologies to improve automation and thereby deliver higher levels of productivity, cost, quality and safety. In this paper, we discuss a particular application, namely, building a fully automated train control and operation system within a mining area. We first outline the basic architecture and functionality of such a system and then present a real-life case study where the railway system within a remote iron ore mine in Canada was converted to a fully automated train operation system. This hard real-time safety-critical system required the use of advanced technologies such as embedded systems (e.g., on-board train controller), radio communications, formal methods, optimal scheduling, and extensive simulations. We focus on the design aspects for maintaining the system in safe states.

Sep 1, 2012

By Qiuyang Hong, Bo Li, Dongyun Liang

"A weathering-crust niobium-rare earth-bearing deposit is formed by the weathering alterationof alkaline granite, which is refractory due to its low grade and complex properties. The mineralogicalcomposition of ore, the grain size of majorminerals as well as the occurrence of Nb and REE are studied in this paper using MLA combined with traditional methods. According to the results, a wide range of Nb-Ti-REE compound minerals including titanoniobite, uranpyrochlore, chlopinite, samarskite and ilmenorutile areformed for the extensive isomorphous substitution among the elements of Nb, Ta, REE, Fe, Ti, U and Th. The occurrence of REE is extremely complex. First, the REEexistingas rare earth minerals including monazite, xenotime, bastnaesite,etcaccount for 21%. Second, the REEexist in the lattice of Nb and Zr minerals as isomorphous additions, which account for 18%. Third, the REE exist as colloidal rare earthdeposit,which account for 35%. Last, the REEexistingas ion-adsorption-type rare earth,which are adsorbedon the kaolinite in the form of hydrated hydroxyl ions, account for 26%.Based on the results of mineralogy, the combined technology process "mineral processing- hydrometallurgical separation" is needed to deal with the ore. The mineral processing tests show that, for the feed ore containing Nb2O5 0.065%, REO 0.13%, an Nb-REE concentrate containing Nb2O5 1.38%, REO 1.98% can be gained by "high intensity magnetic separation-regrinding-gravity separation by shaking tables". The recovery of Nb2O5 and REO is 62.42% and 44.78% respectively. The Nb-REE concentrate is dealt by the metallurgy process "direct reduction- acid leaching & acidulating- neutralization & precipitation- chlorination & distillation" and the rare earth oxide of 92.34% REO as well as the Nb-Zr oxide of 24.62% Nb2O5 can be obtained with the recovery of REO and Nb2O5 being 76.83% and 59.37% respectively."

Jan 1, 2014

By Wei Sun, Ruolin Wang, Jianjun Wang, Xiaodong Li, Honghu Tang, Yuehua Hu, Anh V. Nguyen, Haisheng Han, Kefeng Chen, Zhao Wei

It is difficult to separate scheelite especially from fluorite with fatty acid collectors because the adsorption mechanism of these collectors occurs through chemisorption of the oleate ion onto the mineral surface. A simplified flotation process using Pb-BHA complexes was developed to replace the energy-inefficient Petrov’s process of using a fatty acid, increasing the recovery of scheelite and reducing the cost. The relationship between surface chemical properties (crystal chemistry, solubility, and Zeta potential) of minerals and flotation by using a fatty acid or Pb-BHA complexes was studied in detail to provide new insights into the selective separation mechanism. The results indicate that the scheelite surface exposes more O atoms than Ca and that they are negatively charged due to the anisometric dissolution of Ca and WO4, which provides the possibility for separation using selective interfacial reaction. The FTIR and Zeta potential results indicate that both chemical and electrostatic adsorption play an important role in the adsorption of Pb-BHA complexes on the scheelite surface. The XPS results of the atomic composition and binding energies confirmed the presence of the adsorbed Pb-BHA complexes and that O and Ca may be the active adsorption sites. Therefore, scheelite was able to be collected by forming either a Ca-O-Pbcollector or W-O-Pb-collector (BHA). However, fluorite was only able to be collected by a fatty acid collector and colloidal [H2SiO3]n -, and a high temperature was needed improve the selective desorption of the adsorbed fatty acid collector by forming Ca-[H2SiO3]n - on the fluorite surface, resulting in serious problems in industry. However, the Pb-BHA complexes significantly contribute to improving the recovery of scheelite minerals, simplifying the flotation process, and circulation of the residual reagents and water. The new process has been applied in Shizhuyuan Mine, and improved the recovery by almost 10%.

Jan 1, 2018

By S. Q. Zhu

A newly developed coal flotation collector ZFC and its flotation characteristics for five different coals were introduced in this paper. ZFC is an emulsion composed of 27% diesel oil, 70% water and 3% surfactants. The main surfactant is synthesized with oil which is environmental favorable and reproducible. Compared flotation experiments show that, at the same dosage, ZFC give 2%~5% recovery promotion than typical collector with only a slightly ash content increment, but saving 70% diesel oil. Zeta-potential and Wetting heat measurement indicate that the surfactant helps the interactions between oil and coal particles, the industrial application tests in several coal preparation plants demonstrate that ZFC is suitable both in technical and economical aspects.

Jan 1, 2014

By Jacek Kolacz

A new sensor based sorting system has been developed, based on complex image analysis, where an image texture and a shape pattern is considered for identifying particles for separation. The sorting system employs different images generated by visual light and X-ray to provide maximal information about processed particles. Application of X-ray makes it possible to analyse the internal structure of the particles, which provides a 2D image with complicated texture, however, which contains valuable information. The advanced system for the texture and the pattern recognition is applied to analyse these images simultaneously, to provide the required identification of the particles for efficient separation. The mathematical models applied during identification and separation, are assisted by high speed calculations being specially optimised for this kind of process. This allows sorting with high capacity and high accuracy, which is critical for practical applications in mineral processing. The paper describes a number of tests during sorting of iron ore and coal with high separation efficiency.

Jan 1, 2014

By Tiago de Souza, Caroline Gonçalves, Carlos Eduardo de Castro, Everton Dias

The Miraí plant from Votorantim Metais, has two screening stages to the bauxite classification after scrubbagem. The final product has hold the larger size of 0,84 millimeters (20 mesh). There are two sieves Haver & Boecker (model R-TE 3658 x 10972), which have four modules with cut size sieves of 10 mesh (1.70 millimeters) and ¼ inch (6.35 millimeters) on the primary screen, and 20 mesh (0.84 mm) on the secondary screen, all made of polyurethane. The actual configuration was established according to the empirical tests realized that aimed the increase material load on the secondary screening. However, having in mind the screening process improvement and use the fractions smaller than 0,84 mm, which have significant levels of Alumina and low reactive silica, was proposed a new test of change the sieves opening for 6 mesh in the primary screen and 28 mesh for the secondary sieve. The objective of this work was measure the ore alterations on the particle size distribution on the screening steps, increasing the plant weight and ratio recovery before and after the test.

Jan 1, 2014

By Carmina Quintanar, Mario Palominos

"The mining industry is currently facing significant challenges to identify and adopt sustainable collector chemistry that effectively recover value minerals in difficult-to-process low-grade resources. These are typically characterized by complex mineralogy and the presence of significant amounts of penalty gangue sulfide minerals, especially pyrit which is a challenge to separate from value minerals at many major mine operations. Three chemical strategies for dealing with gangue sulfides and penalty elements are: a) selective flotation of value minerals while rejecting penalty minerals in the whole circuit, b) rejecting penalty minerals in an appropriate part of the circuit using selective depressants, c) using a combination of selective collectors and depressants in appropriate parts of the circuit. This paper will evaluate different strategies for dealing with those penalty elements and propose the most efficient alternative. New products and application technologies have been developed in the past 25 years by Cytec for implementing these strategies as dictated by the particular needs of a given plant. However, in recognition of the growing interest in meeting the sustainability challenges, Cytec Research and Development have been focused in the development of greener products (collectors, modifiers and frothers) and processes using FLOTATION MATRIX 100TM approach used to develop the optimal collector system for each specific ore. An overview of these new developments is given in this paper using case studies of application of selective collectors and polymeric modifiers including the newer, greener chemistries."

Jan 1, 2014

By David G. Hulbert, Daniël J. Oosthuizen, Bernard Muller, Daniël de V. van der Spuy

"Expert Online is a software system that makes use of novel artificial intelligence technology, known as the Interpreting Expert System (IES), to mimic an informed expert on a minerals processing plant. Previous implementations of the IES were only capable of explaining the controller actions. Expert Online will also take on the more difficult task of explaining the complex process behaviour to the operator in simple language.The primary functions of Expert Online are to serve as a training tool and an online assistant to operators. However, it is also expected to be of value to supervisors and plant managers.A number of additional features are envisaged, including different operating modes, fault detection, speech synthesis and advanced message filtering. Expert Online will increase the operator’s knowledge of the process and his/her understanding and acceptance of the complex control systems. Users would be supplied with relevant and timeous information required to make informed decisions to ensure smooth plant operation.This paper discusses the structural design of Expert Online for implementation on the latest version of MINTEK’s open control platform, PlantStar, as well as several advances and additions since the previous implementations of the Interpreting Expert System."

Jan 1, 2003

By M. Narasimha

The flow in a hydrocyclone classifier is highly turbulent complex nature of multi-phase structure, which has led designers to rely on empirical mathematical models for predicting the performance. A number of classifying cyclone models have been developed and successfully used in mineral comminution circuit simulators over the past four decades (Plitt, 1976 and Nageswararao, 1978). However, most of the mathematical models currently available to describe hydrocyclone classifier performance are based on single average mineral density component behavior. In industrial comminution circuits, the feed to the cyclone composed of a mixture of particles of varying degrees of liberation and sizes. The behavior of multi-component particles in a hydrocyclone is poorly understood and unaccounted for in most of the mathematical model equations available in the literature. There is evidence from a number of experimental data sets indicating the significant influence of the multi-component particles on measured cyclone performance. A concept for modeling the performance of hydrocyclones based on multi-component behavior is proposed in this paper. A set of semi-empirical model equations for cut-size, sharpness of separation are presented and the corresponding model parameters evaluated from the measured data are given.

Sep 1, 2012

By G. Jenny

The particle size distribution of ground minerals is of decisive importance for downstream processes like floatation, separation, drying or others. In order to optimize the process efficiency on one hand and the final product quality on the other hand an early control of the grinding or classification stage is essential. The ultrasound based particle size analyser OPUS is capable of performing on-line particle size distribution (PSD) and solid content measurement of mineral slurries such as iron ore, copper ore, fluorspar, or quartz sand and alumina directly in heavy and rough process environment. The instrument provides a PSD of 31 size classes and can be applied for particles from nanometer range up to several millimetres. Arbitrary interpolations in between the 31 measured points are available. Typical residue values show an excellent agreement to off-line particle size analysis methods such as e.g. sieve analyses or laser diffraction. OPUS is designed as rugged in-line probe made from stainless steel. The applied technique is independent of product flow dynamics, contamination, optical properties, vibrations, pressures or changes in solid concentrations. The instrument provides all data on the system?s PC or on the process control system by a variety of interfaces.

Jan 1, 2014

By I. Yochev, A. A. Metelev, A. I. Stepanenko, A. P. Purgin, M. G. Viduetsky, A. M. Panshin, I. F. Garifulin

"Pneumatic flotation cells of the KFM series are intended for the concentration of various ores and technogenic materials. The key operating principle of the flotation cells of the KFM series is the preparation of pulp for flotation in blowers, offering the advantage of an accelerated flotation process. This report summarizes the results of the implementation and operation of the KFM cells at Russian and foreign projects in 2015-2017. Their implementation and operation experience confirms the high efficiency of the KFM cells, especially in the head of lead and zinc, copper and zinc, copper flotation processes:head KFM-600 flotation cell recovers from lead-zinc ore (Rudmetal AD modular concentrator) up to 52% of lead in a single stage (without cleaner flotation) in a salable lead head concentrate (grade of up to 76% lead, 2.3% zinc). The flotation cell proved to be much more efficient than originally expected in the process description in the design phase,flotation of the copper-zinc ore from Novo-Shemur deposit (PJSC Svyatogor concentrator) in two KFM- 1400M cells recovers up to 65% of copper and 70% of zinc in a high-grade bulk copper-zinc concentrate containing 12-13% of copper and 25-28% of zinc. The installation of the two cells with a combined capacity of 26 m3 allowed to decommission 4 chambers of FPM-16 pneumomechanical flotation cells with a combined capacity of 64 m3 with a simultaneous increase in the overall ore concentration performancea single KFM-1400M cell (13 m3) recovers from the copper ore from Volkov deposit (PJSC Svyatogor concentrator) 53% of copper into a high-grade copper head concentrate (33.0% of copper). For comparison, the pneumomechanical cell FPM-16 (capacity 16 m3) has almost half as low copper recovery (29.6%) into the head concentrate at a lower grade (30.5% copper)."

Jan 1, 2018

By D. J. Zhao

The reduction of ilmenite pellets was investigated at 950°C and 1000°C under a CO-N2 gas mixture with 10 L/min gas flow rate. All the reducing reactions were conducted in a furnace with a thermogravimetric analysis system. The reduction rate is higher at 1000°C than that at 950°C. At the early stage of the reactions, with the CO concentration increasing in the gas mixture, the reduction rate increased at 1000°C. In addition, at the early stage of the reactions, a rapid temperature increment and a rapid conversion of oxygen were observed on the curves of temperature versus time and conversion of oxygen versus time under different experimental conditions. The solid reaction products obtained in these experiments were analyzed by Scanning Electron Microscopy (SEM) and Energy Dispersive Spectrometers (EDS). Metallic Fe with small amount of Ti dissolved in it and oxides of Ti were found in the solid reaction products, but the formation of any nitride phases was not found under the prevailing conditions.

Jan 1, 2014

By Andrew T. McBride, Malcolm S. Powell, Indresan Govender

"Current empirical Semi Autogneous Grinding (SAG) mill models contain assumptions concerning the amount of energy available for particle breakage, how this energy is distributed in the mill media and the rate at which the energy is transferred. Despite these assumptions the JK SAG model is highly functional with a proven track record. DEM provides a numerical framework to greatly improve on these assumptions that were necessary due to a lack of available input data.This paper identifies key outputs of the Discrete Element Method (DEM), such as energy spectra and impact probability distribution. It describes how they can be incorporated into current mill models utilising practical rock breakage data. The rate at which energy is transferred is shown to be dependent on particle position and mill rotational speed and not once per cycle as previously assumed. Based upon this an improved energy transfer methodology is presented. The fundamental outputs of the DEM are validated against experimental three-dimensional particle tracking data, so as to establish whether the DEM produces correct energy transfer predictions on the inter-particle level, which is crucial to this work."

Jan 1, 2003