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By Homero Delboni, Mauricio Guimarães Bergerman

"At the regrind or secondary grinding stages of metal ores, usually the concern about the energy efficiency is extremely important. In general, the specific energy consumption at this stage is higher than in the primary stages of grinding. In addition, it has been observed a tendency of finer grinding in the new projects of metallic ores, due to the finer mineral liberation, which leads to an increasing capital and operational costs. In Brazil, during the last 10 years, regrind P80 sizes of approximately 40 to 20 ?m have been necessary in all new iron and copper plants. The use of conventional ball mills, adequate for primary grinding, can result in low energy efficiency with products below a P80 of 50 ?m. This paper presents an overview of the regrind circuits in Brazil that operate with vertical mills and the results of industrial surveys at selected vertical mill circuits. Where possible, comparison is made between the plant results and the design criteria and laboratory regrind tests used for the mill sizing."

Jan 1, 2014

By Pawel Strzalkowski, Marta Baszczynska, Urszula Kazmierczak

The paper presents issues related to interference of mining activities with the environment. Exploitation of mineral resources causes primarily a modification of the landscape. All of the negative impacts on environment are short-lived and last as much as it takes to exploit the raw material. After the mine closure reclamation is necessary during which all aspects that reduce harmful effects of the mining activities on the environment must be taken into account. Current ways of reclamation allow recreating natural environment, which is different from the original and enriched in diverse new values. This requires propositions of new forms of converted land development through a detailed analysis of technical, natural, planning, economic and social sphere requirements. Before making final decisions regarding selection of direction of reclamation, a thorough analysis of the key factors has to be carried out. All steps related to the implementation of the reclamation project are shown in the paper using Limestone Mine "Górazdze" located in the south-western part of Poland as an example. This paper also presents an analysis of current ways of post-mining reclamation towards agricultural and forestry landscape, along with our own suggestion for their extension in order to preserve biodiversity. For choosing optimal solutions the most relevant criteria were considered: existing natural values and possibility of their protection. Taking into account the economic and social aspects, supported by natural potentials, implementation of tourism and recreation in this area were proposed. It was shown that this proposition would not interfere with the current trends of the natural landscaping. Finally, after completion of reclamation and land development in the considered mine area, creation of a geo-park was proposed along with appearance of geotourism in the area. To illustrate the proposed forms of post-mining land development in the form of maps, an ArcGIS(ESRI) software was used.

Jan 1, 2014

By E. Lee

Cone crushers are widely used within the mining and aggregate industries for the size reduction of minerals, ores, and rock materials. In mining applications for example, the product from cone crushers is often fed to HPGRs or directly to mills in the subsequent grinding circuit. An improved cone crusher performance can therefore result in an overall improved and more efficient comminution process. The objective of this paper is to systematically study a number of different ways of applying compressive crushing. By mathematically modelling these different crushing concepts and then theoretically optimizing crushing sequences accordingly, each concept can be studied and evaluated. In addition, aspects concerning whether or not the results are mechanically or practically achievable are considered. This study thus explores the advantages and disadvantages of different crushing concepts. In this paper, four different theoretical crushing concepts are presented and studied. The results show that in terms of interparticle crushing, optimal crushing sequences with varying compression ratios can be replaced by easier implemented series of constant compressions without significant deterioration. It is also shown that that considerably better performance is obtained for crushing sequences with both breakage modes. The subsequent comparison between such concepts indicates that different approaches can achieve the same results, and that the different concepts are comparable. It is further concluded that interparticle crushing should be kept to a minimum if fines generation or energy consumption is to be minimized, and that each of the studied concepts presents different challenges for implementation. Keywords: compressive crushing, cone crusher, optimization, modeling, crushing concept

Sep 1, 2012

By Fedotov Pavel

One of the efficient means of ore disintegration during the processing is its volume breakage in such machines as roller-presses. Up to date neither the ore disintegration mechanism in roller-presses nor the reasons of their high efficiency are thoroughly investigated. In this work, the mathematical model of Finite Element Method of bad material disintegration in roller-press is discussed. The mechanism of the interparticle ore disintegration is traced.

Sep 1, 2012

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 Johannes Käppeler, Alexander Weh, Harald Giese, Klaas van der Wielen

"High voltage breakage is a novel comminution technology that shows considerable potential for various applications in mineral processing and recycling. It relies on highly energetic electrical pulses to induce electrical explosions in rocks, causing the formation of plasma channels and powerful shockwaves that result in fracturing and fragmentation of particles. There has been considerable interest in this technology for its ability to weaken rocks and preferentially liberate target minerals, as previously demonstrated by other authors. Weakening has the potential to significantly reduce energy consumption during comminution, or alternatively, increase throughput of a circuit. Better liberation may yield an improved concentrate grade and/or recovery, reduce fines losses to tailings or increase the grind size required for liberation, thereby also reducing energy requirements. This review aims to increase general awareness of this technology, and promote further research into it by providing a general summary of the theory underlying high voltage breakage, as well as the envisaged applications of this novel technology. A brief history of the technology is presented before progressing onto the physics underlying the electrical and geomechanical aspects of high voltage breakage. Key results regarding weakening and liberation are discussed, and some mention is made of current challenges and planned developments to increase the throughput of high voltage breakage units to the level where it can be integrated into new and existing processing circuits."

Jan 1, 2014

By Cheng Gan, Gui Xiahui, Li Shulei, Cao Yijun, Liu Jiongtian, Wu Lun

Flotation rate constant is an essential parameter in the flotation process. The fine coal sample utilized in this investigation is anthracite from the Shenhuo mine in eastern China. Fine coal flotation rate tests were conducted to compare the flotation rate constant at constant power input with that at gradually increasing power input. Results indicate that the flotation rate constant decreases with the flotation process and increases as the flotation energy is increased. In addition, the flotation rate constant is close to the maximum value. The increasing trend of the flotation rate constant gradually slows down as the flotation energy input increases.

Jan 1, 2014

By Francisco Vicuña, Miguel Becerra, Nelson Iglesias

"The following article presents the development of a dynamic tool for the estimation of Jb/Jc rate (ball filling level / total load filling level) of a SAG mil operating in a single stage mode. Using the methodology detailed in this article, it is now possible to have a dynamic estimation tool in the operation, which enables strategic decision making and achieving a continuous development in process optimization. The estimating of the load filling level (Jc) was conducted using a power model, which in this case corresponds to the C-Model developed by (Morrell, 1993) that was calibrated by measuring the load filling levels (Jc) and balls (Jb) using the FARO laser scanning technology by means of Grind-Out and Crash-Stop procedures during the year 2013 and 2014. Finally, to estimate the dynamic filling level of full charge, Jc, three independent models were developed that allowed to feed the adjusted power model: •,SAG mill discharge grate slot wear model •,SAG mill internal volume wear model •,Ball filling level estimation model."

Jan 1, 2014

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

Almost all of the flotation reagents used today were discovered by continued application of empirical methods and/or trial and error experimentation. Moreover, with the metal-ion specific approach used so far, it is difficult to separate the minerals containing the same constituent metal ion. A critical assessment of molecular recognition processes involved in biomineralization suggested the possibility of using reagents which are surface specific. The concept that the molecules consisting of two or more functional groups having appropriate spacing between those so as to achieve structural/stereochemical compatibility during interaction with the mineral surface exhibit structure-specificity is thought to be extended to the design of specific collectors in flotation processes. In the present study, for the first time, a rational design of surface active molecules, and thereby the recognition of crystal faces (of minerals) by these molecules through structural and stereochemical matching is being utilized successfully to selectively float various minerals. For this purpose, carboxylate-based collectors (for mineral specific flotation of calcium minerals) as well as xanthate-based collectors (for mineral specific flotation of sulphide minerals) with a fixed alkyl chain length but having two functional groups with varying geometrical distances (separated by a spacer of one, two and three carbon atoms) between them have been synthesized. In this article, we have discussed the design, synthesis, purification of these novel mineral specific collectors as well as their important solution parameters in relation to flotation processes.

Jan 1, 2014

By Arkady Senchenko, Yuri G. Seredkin, Alexander Aksenov

"This paper describes the development of efficient technology for the treatment of complex ores containing gold and copper as major valuable components, where silver is present as well. Copper is mostly represented by oxidized minerals in these ores; however, copper sulfides are also present. Gold is present in its free form and in associations with oxidized and sulfide minerals; silver usually accompanies gold. Complex composition of the ore requires complex solutions for their treatment. The results of searching for the techniques to recover valuable components are described in this paper. Gravity methods allow for free gold recovery, flotation methods allow one to recover major part of copper and precious metals in associations; and in the result of leaching process additional amount of copper, gold and silver is reported to solution. Combining all these methods help achieving high levels of valuable components recovery. When implementing a combined technological flowsheet about 80 % of copper goes to concentrates from gravity and flotation of sulfide and oxidized copper minerals; and sulfuric acid leaching allows increasing total copper recovery up to 90 % and higher. Major part of precious metals (up to 90 % of gold and 80 % of silver) is recovered to these concentrates, and after hydrometallurgical treatment it is possible to increase gold recovery up to 96 %, silver recovery - up to 90 %. The suggested technology helps solving the problem of precious metals recovery from complex gold-copper ores, and allows treatment of the ore with different proportion of sulfide and oxidized minerals, and at different valuable components grade."

Jan 1, 2014

By Wu Tao, Lu Shijie, Xia Xiaoou, Zhang Ming

The impeller and stator are the most important components that can significantly influence the performance of flotation cells directly. The performance of the impeller and stator of KYF flotation cell is revealed by CFD (Computational Fluid Dynamic) simulation in this paper. A method of obtaining the circulation volume is proposed. The circulation volume is proportional to third power of impeller diameter. And the circulation volume increases linearly with the increasing of the speed. CFD simulation can draw the conclusions that there is a proportional relationship between power consumption, third power of speed and fifth power of impeller diameter. CFD prediction results agree with the theoretical formula. The difference between the forward and backward impeller is analysed in the paper. The circulation volume of the backward impeller is obviously larger than that of the forward impeller under the same condition, but power consumption of the backward impeller is lower. It is demonstrated that the impeller and stator system of KYF flotation cell is an efficient and reasonable stirring mechanism. CFD simulation could be reliably used in flotation cell design and optimization.

Jan 1, 2014

By P. Banerjee, P. Dash, S. Sriramoju, A. Suresh, R. Lingam, T. Ray

"One single property that influences the quality and market value of coal to the maximum extent is the ash content. The lower the coal ash higher is the energy utilization and potential for different applications. Even though Indian coal washeries aspire to produce coal with low ash, the intimate distribution pattern of ash bearing minerals in the coal matrix becomes the real bottleneck, as it brings down the clean coal yield to the impractical value. Because of this fact, most of the Indian washeries are operated to produce coal with 14-15% ash content at the yield of around 40%. In this context, with an objective to produce low ash coal at higher yield, a novel chemical beneficiation route has been explored to demineralize the high ash containing Indian coals. In this present work, the production of low ash clean coal from high ash Indian coals using chemical leaching process has been studied at pilot plant level. The leaching process parameters such as reaction temperature, reagent concentration, reaction time, coal-liquid ratio and agitator speed have been optimized for the flotation tailings sample from a captive washery of Tata Steel. The results obtained show that 67% demineralization could be achieved in a single stage of leaching process with a product yield of more than 65%. For further demineralization, multistage leaching was carried out and the results showed that 75-85% demineralization could be achieved with significant reduction in alumina to silica ratio. Additionally, the phosphorus content is also significantly reduced from 0.20 % to 0.022 %. Further, it is interesting to note that there is no increment of sodium content in the product coal after chemical treatment."

Jan 1, 2014

By Nirmal S. Weerasekara, Malcolm S. Powell, Mohsen Yahyaei

"An understanding of the fundamentals of different breakage mechanisms is critical for successfully modelling comminution processes. Due to the high frequency of low energy collisions in the grinding process, superficial breakage has a significant role in size reduction in mills. To develop a scaling up methodology for characterising low energy surface damage behaviour of ores, a series of surface damage tests have been conducted using three grinding mill sizes with diameters of 1.8, 1.2, and 0.8 m. Two types of gold-copper ore with different hardness were used: C-ore and T-ore. All tests were conducted using wet mode to remove the products during grinding. To ensure low energy surface damage was the dominant mechanism, in all tests the mill speed was reduced to 40% of critical speed. A surface damage index normalised with product mass and surface based specific energy is determined from the results enabling a study of the grinding performance regardless of mill size, energy level or charge mass. Incremental breakage tests using the JKRBT indicate that the A×b values of the T-ore were 60% higher than C-ore, suggesting the T-ore is considerably softer. The fractional mass loss rate for the T-ore in the 0.8 m and 1.8 m mills started from 16 and 7 (1/kWh/m2) while for the C-ore it was 4 and 2 (1/kWh/m2). After 6 minutes the surface damage index in all tests tends towards steady state a constant value, an indication of steady state surface damage condition. It has been demonstrated that this methodology can be a useful basis for characterising superficial breakage behaviour of ores."

Jan 1, 2014

By Gus Van Weert, Samuel A. Bolorunduro, David B. Dreisinger

"INTRODUCTIONAcid pressure oxidation of high-grade natural acanthite was investigated in the range of 110-150°C and in the sulphate media. High acidity and low pulp density were used to prevent the precipitation of silver.RESULTS AND DISCUSSIONTwo sets of acanthite specimens were obtained from La Valenciana and Ingleterra mines, Mexico. Pressure oxidation tests were conducted on 1 litre scale in a standard 2-litre Parr titanium autoclave.EFFECT OF TEMPERATURE ON THE REACTION OF ACANTHITEThe effect of temperature on the rate of oxidation is presented in Figure 1. The rate of reaction increased with increasing temperature."

Jan 1, 2003

By Igor P. Solozhenkin, Peter M. Solozhenkin, Sanda Krausz

"In this work, authors will show the efficiency of computer technology and chemical programs at studying collectors for flotation of minerals of elements of platinum group (EPG). Clusters various minerals EPG (flotation reagents) are created, named us clusters minerals (reagents) as their structure corresponds to the chemical formula, and the distance between separate atoms corresponds to the known tabulated data. By molecular modeling are investigated clusters sperrylite PtAs2, stumpfilyte PtSb, sadberryte PdSb, sobolevskite PdBi, palladoarsenyte Pd2As, paolovyte Pd2Sn, rustenburgyte (Pt3Sn, Pt6Sn2) and their computer parameters (absolute rigidity, electronegativity, transfer factors of carry, charges of the atoms) are determined. Tellurides of palladium (IV, II) merenskyite PdTl2 and kotulskyte PdTe and platinum clusters are investigated: PtFe4, Pt3Fe, PtFe (Pt2Fe2), Pt2Fe (Cu) Ni. The technique of attachment of the collector (composites) to cluster atoms EPG is offered. For the first time, it is established that at linkage of flotation collectors on monodentate, bidentate and bridged to circuits with atoms clusters the minerals containing atoms As, Sb, Bi, Pb, Sn, reaction of connection with change of a degree of oxidation of these atoms and occurrence of a proton operates. It is executed virtual skirling organic compounds connections by the developed criteria from accessible libraries of a database. The principle of an estimation of interaction energy for flotation reagents with mineral clusters is offered. It is developed the prognosis of collector activity evaluation (P?AE) and his values for candidates in collectors for flotation of minerals EPG are calculated. For flotation of ores containing Pt and Pd minerals, a number of reagents, including compounds on basis P (III), for innovational technology of Pt, Pd mineral flotation are recommended. Key words: flotation, minerals, flotation reagents on the basis of phosphorus (III), molecular modelling, chemical programs, program ????? , electronic energy."

Jan 1, 2014

By S. Banisi, A. R. Ghasemi, M. Maleki-Moghaddam

Direct observation of the charge shape and its motion in industrial mills are not possible, it is then customary to use transparent end, small-scale mills (i.e., model mills) to determine the charge trajectory directly by visualization methods. Because of a short length of the model mills, the end-wall effects could introduce a significant bias on the observed charge trajectories and shape. The shorter the mill, the stronger the bias. This could be due to some material bridging between the end walls. In this research, the end-wall effects were investigated by gradually increasing the model mill length and analysing the charge trajectory and shape variation at a given operating conditions (i.e., ball filling, mill speed, liner type). The unbiased mill length was assumed to be beyond the mill length where no significant change observed in the charge trajectory and shape. For all tests, the torque of the charge was also measured by a torque sensor. The special design of the model mill with the diameter of 100 cm made possible to increase the mill length in steps of 3.6 cm up to 21.6 cm. Four types of liners, five steel ball fillings (10, 15, 20, 25, 30% v/v) and three mill speeds (55, 70, 85% of critical speed) were tested. The ball sizes ranged from 4 to 12 mm. The results indicated that when the mill length was below 10.8 cm the end walls prevented the charge from free falling. This resulted in lower impact point angles and lower power draws compared with the case of no end-wall effects. When the same experiments were performed using an iron ore instead of balls with the same size range, the impact of end-wall effects was more pronounced. For an increase of 30% in the speed (from 55 to 85%), the torque due the change in the charge shape decreased by 41% (from 3.7 to 2.2 kgf.m) when mill filling was 30%. At the same operating conditions when steel balls used the torque decreased only by 19% (from 9 to 7.2 kgf.m). This was expected due to irregular shapes of the ore particles which facilitated bridging. Three-dimensional DEM simulations also resulted in the similar conclusions.

Jan 1, 2014

By Peter N. Holtham, Geoffrey J. Lyman, Matthew S. Brennan, Vijay Subramanian, Rui X. Rong, Tim Napier-Munn

Studies of the dense medium and classifying cyclone have been conducted using the Fluent computational fluid dynamics code. Experimental measurements of the segregation of medium in a DM cyclone by gamma-ray tomography and the performance of a novel classifying cyclone design have been used to test and interpret the 3D CFD predictions. The predictions of the CFD models were generally plausible, though more work is required to incorporate turbulent mixing of the slurry in the cyclone. The benefits of the novel cyclone design were explained by the model in terms of conditions favouring reduction of short-circuiting at the vortex finder, and the removal of the air core from the wall at the apex. Work is continuing.

Jan 1, 2003

By M. Amani, A. Akbarinasab, M. Bazmandeh

The fourth iron ore production plant at Golgohar mining and industrial company consists a ball mill and wet medium intensity magnetic separators (3500 Guss). The ball mill product applies directly into MIMS and the MIMS concentrate directly transfers to the low intensity magnet separators (LIMS). The thickener is used for dewatering of MIMS and LIMS tailings. By sampling from streams of ball mill and separators, it was defined that the grade and iron recovery were 60% and 80% respectively while they would be 66% and 90% respectively based on the designing documentation. The average of P80 in the ball mill was 342 micron in a month that is coarser than optimized value. This problem was related to unsuitable operation of grinding. For optimization of grinding efficiency, the amount of charge volume was investigated as a variable. The measurements illustrated 32% charge volume. For increasing grinding efficiency, the charge volume was increased 1% and 1.6% in two stages. The results showed ball mill power draw average reached from 3650 kw to 4120 kw and the average P80 reached to 329 micron. All of parameters calculated about 35 day before and after change. Average of Ball mill feed iron ore grade before and after change was 49.24% and 50.32% respectively. This change caused an increase in efficiency of MIMS, where the enrichment ratio and concentrate grade increased 2% and 1.9% respectively. For increasing the iron grade of the MIMS concentrate; the orifice of the tail flow exit pipe changed from 4 inch to 6 inch and the concentrate grade increased 2%.

Jan 1, 2014

By Andrey Kozlov

The results of mineralogical?technological studies of PGM mineralization in zoned mafic?ultramafic complexes of the Ural?Alaskan type are given. The most important technological specificity of PGM mineralization hosted in dunites is its occurrence only in the form of free mineral species with predominance of Fe?Pt alloys (ferrous platinum, isoferroplatinum, and tetraferroplatinum). Technological properties, grain size, and good opening of PGM ore in grain size class +80 µm make it possible to concentrate ore using gravity methods with stadial comminution and between cycle separation of relatively large grains and nuggets into high-grade concentrates at the early stage of disintegration. Keywords: platiniferous dunites, PGM mineralization, mineralogical?technological studies and processibility research, recovery technology, gravity methods

Sep 1, 2012

By A. Gueciouer, A. Akkouche, K. Chalah, A. Benmounah

"Drilling solid waste is a typical industrial solid waste, and it is a major pollutant source to ecological environment. Generally, waste management dewatering systems separate solids and fine particles from the liquid phase of drilling fluid, thereby leaving a clarified aqueous solution and allow the cleaning of waste fluids. Typically, dewatering waste management systems clean drilling fluid through coagulation, flocculation and/or mechanical separation. Chemicals used in dewatering are based on the coagulation-flocculation process, which it facilitate the removal of suspended solids and colloidal particles. The factors which can promote the coagulation-flocculation are velocity gradient, contact time, and PH. The objective of this work is to optimize a formulation adequate for dewatering based on the coagulation-flocculation process used coagulant (Aluminum sulphate), anionic flocculants (Partially Hydrolyzed Polyacrylamide) and anionic polyelectrolytes (in solid form with linear chain with very high molecular weight). The results obtained show the good efficiency of the coagulant and flocculants. INTRODUCTION Rig site dewatering of drilling fluids with recycling of processed water can help an operator to comply with environmental rules by reducing volumes of waste and reducing long term liabilities. It can also reduce disposal costs and provide a cleaner drill site overall. Most of the environmental concerns during the 1980s involved hazardous materials and toxic wastes. Drilling fluids, many of which are chemically benign, have escaped many of the difficult-to-comply-with rules and regulations. During the 1990s, however, operators may be required to submit a written plan for liquid waste reduction for even nonhazardous materials. Many states and local agencies may institute total bans on oil field wastes. Drilling rigs typically produce about 1 bbl of liquid waste for every 1 ft of hole drilled. Thus, a typical drilling operation can produce a large quantity of waste [1]. To improve the dewaterability of sludge, different pretreatment processes have been widely studied and developed including thermal, chemical, magnetic, mechanical, acoustic, electric, electro-acoustic and their hybrid treatment processes [2]. Rig site dewatering (figure 1) is the process of injecting coagulants or flocculating chemicals into the mud entering a large clarifying centrifuge. Coagulation occurs when the solid and allowing it to be attracted to other solids by van der waals forces. Flocculation is the binding of individual solid particles into aggregates of multiple particles. It is physical, rather than electrical, and occurs when one segment of a flocculating polymer chain absorbs simultaneously onto more than one particle [3]."

Jan 1, 2018