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By Carlos G. Rudolp, Julio C. Videla, Mario Zuleta

"The present paper summarises the results of gravity pneumatic concentration of a borax ore with 17.5 % B2O3. The sample was extracted from the Tincalayu ore deposit located in the Salta Province of Argentina.The applied methodology was based on a former study (Zuleta, 1985). It consisted of sample characterization by means of physical and mineralogical determinations, chemical analyses as well as pneumatic table concentration tests. In this, a simplified concentrating flowsheet was utilized.A concentrate with 30.6 % B2O3 and 74.7 % recovery was obtained. The recovery was 8.8 % less than previously reported and that was of 30.6 % B2O3 with 87 % recovery. Nevertheless, the simplified flow sheet presented processes only two granulometric fractions, - 6.4 mm + 0.3 mm and - 0.3 mm, compared to the three granulometric fractions used in the previous study: - 6.4 mm + 1.4 mm; - 1.4 mm + 0.3 mm and . 0.3 mm. This would simplify industrial implementation."

Jan 1, 2003

By Zehong Wang

Selecting sodium polyacrylate (PAAS) as grinding aid, the effect of grinding aid on the grinding efficiency of bauxite taken from Shanxi province was studied and its mechanisms were analyzed by measuring the variation of adsorption characteristic, pulp viscosity, surface electric potential of the bauxite and the surface appearance of particles. The results showed that, compared with no grinding aids added the content of -0.074mm in the ground product was increased by 5.45 percentage points under the optimal grinding conditions adding PAAS as grinding aid when the amount of PAAS was 0.7%wt of bauxite. Because the physical adsorption and chemical adsorption were occurred on the bauxite surface, which could reduce the pulp viscosity, change the surface electric potential of the bauxite, enhance the surface appearance of particles and lower the surface hardness of the bauxite, the grinding efficiency of bauxite was increased by PAAS. Keywords: bauxite, grinding aids, grinding efficiency, mechanism

Sep 1, 2012

By Kwan Ho Kim

The beneficiation study of low quality pyrophyllite is conducted to enhance the value of it by selective grinding. In mining stage, the main gangue mineral is quartz, and the content of quartz in ore has an adverse effect on the quality of pyrophyllite. Using the huge difference in hardness between quartz and pyrophyllite, the selective grinding is accomplished using stirred ball mill. As a result, a finer pyrophyllite particle can be easily separated from coarser quartz particle by simple size classification, and the content of Al2O3 of fine particle smaller than 45um increased largely. It means that the pyrophyllite particle is ground selectively compared to the quartz particle, and the quality of pyrophyllite is enhanced.

Sep 1, 2012

By T. S. Reddy

Research and Development Centre for Iron and Steel (RDCIS) a unit of Steel Authority of India Limited (SAIL) is continuously engaged in reduction of energy consumption at SAIL plants by implementing innovative and new concepts. In this regard, continuous efforts are being made to recover waste heat in Sinter Plants. This paper discusses existing waste heat recovery measures taken and proposed measures planned in Sinter Plants. One such effort is on waste heat recovery from sinter coolers. Hot sinter is discharged to the crusher at the end of the sinter machine at a temperature of 500 to 800°C. Temperature of hot sinter is brought down to nearly 100°C in the sinter cooler with air-cooling. The air after cooling the sinter is generally discharged to the atmosphere at about 225 to 300°C. It is planned to recover heat from the hot air that is being released to atmosphere and heat the process water, which is being added at ambient temperature in mixing drum at Bhilai Steel Plant. The temperature of raw sinter mix will be raised by addition of this hot water, which will help in improving the productivity of sinter machine. It is estimated that Waste heat recovery to the tune of 1.5 to 2.0 Gcal/h is possible with reduction in CO2 emissions in the range of 4000 to 5000 ton/year. The novel approach that is being adopted is addition of hot water in mixing drum for higher sinter productivity for the first time in India. Keywords: waste heat recovery, sinter plant, hot water generation, emission reduction, CDM

Sep 1, 2012

By Klaus M. Hahn, Hermann Wotruba, Bernd G. Friedrich

"Due to an increasing demand for nickel and cobalt and the depletion of nickel sulphide deposits worldwide, the production of ferronickel from lateritic nickel ores becomes more significant. About 60 percent of nickel reserves are present in laterite deposits. Common production methods like acid leaching or smelting operations implicate high material and energy consumption. Physical processing methods are also not efficient, because of the fine microstructural intergrowth of the minerals carrying valuable elements such as nickel and cobalt. Due to the high energy consumption of metallurgical treatment of lateritic nickel ore (nickel grade: 0.8 - 3.0%, Co: 0.05 - 0.15%), the separation of waste material (about 75 - 85%) before the metallurgical treatment is desirable. Therefore, an alternative process has been developed, combining a pyro-metallurgical pre-treatment with selected mechanical processing methods. The developed process consisted of a selective pre-reduction and non-selective segregation of the contained metal phases in the first stage. By this, the properties of the metal carrying minerals were changed and could become subject to concentration by means of fine beneficiation processes afterwards. The parameters of the pre-reduction and segregation were varied and the pre-treated samples were examined concerning their efficiency of metalization grade and metal grain size. This paper describes the investigation of pre-treatment methods of a lateritic nickel ore. The pre-treatment and possible subsequent separation methods were examined with regard to the recovery of the valuable elements. Metalization grade was around 80% for both Ni and Co with metal phase grain sizes below 20 µm. Scanning electron microscopy revealed distribution of new metal phases not only on the reducing agent, but also on the “slag” material.INTRODUCTION Nickel laterites are characterized as strongly weathered regoliths with several zones containing reserves of nickel (Ni) and cobalt (Co). These laterites are formed on serpentinites and ultramafic rocks under climatic and/or tectonic conditions that have changed over time (Butt & Cluzel, 2013). The formation of Ni laterites is influenced by numerous geological and environmental factors. In general, there are three ore types named according to the dominant Ni hosting minerals: oxides, hydrous magnesia (Mg) silicates and clay silicates (Butt & Cluzel, 2013). The most Ni laterite deposits contain two of these ore types, usually an oxide zone and an either clay or Mg silicate zone. Distribution of these principal deposit types, their average Ni-bearing phases and mean Ni grade are shown in Table 1. A schematic profile of the different deposits based on the development on serpentized ultramafic rocks is given in Figure 1 (Butt & Cluzel, 2013)."

Jan 1, 2018

By Wei Qu, Yongsheng Song, Xingyu Liu, Wenjuan Li, Shuang Liu, Guiying Zhou, Bowei Chen

The Pb,Sb,Zn multi-metal sulphide ore is processed in sequence of beneficiation of jamesonite, sphalerite . Due to relative large amount of collector (xanthate), activator (CuSO4) and regulator (lime) during different flotation stage, the flotation wastewater from sphalerite beneficiation stage can’t be directly recycled to the first lead flotation stage. In this paper, the flotation wastewater from sphalerite beneficiation stage was treated by Ozone and BAC technology, results showed that when the influent concentation of COD and copper ion were 850 mg/L, 10.48mg/L respectively, the Ozone and BAC technology could effectively treat such type of water. In the treated wastewater, the COD is 60mg/L, copper ion concentration is 0.023mg/L, pH is 7.0, which satisfy the need of Pb,Sb-Zn preferential floatation separation process. After recycle of the treated wastewater to Pb,Sb floatation circuit, qualified Pb,Sb concentrate and Zn concentrate were obtained.

Jan 1, 2014

By E. Lee

With the growing environmental concern, as well as the increasing concern for sustainability of natural resources, the need of improving the performance and efficiency of today?s crushers is be-coming increasingly important. However, the development of existing crushers requires an extended basic knowledge about the crushing process itself. The aim of the present study is therefore to find the theoretically optimal way of crushing compressively under given circumstances. In the present paper, optimizations have been performed with the purposes of maximizing product yield and minimizing energy consumption. Performed on an ideal crushing stage free from physical limitations, the optimization results have been obtained in terms of number of compressions and their corresponding compression ratios. Complementing earlier results on interparticle breakage (Hulthén et al., 2006), presented here are thus the results from corresponding optimizations with single particle breakage and interparticle breakage. It is concluded that modern crushers are not working optimally in any of the studied aspects for gneiss. In fact, optimizations indicate that a lowering of the compression ratio, as well as a shortening of the crushing sequence, are theoretically favourable. The outcome of this study is therefore highly promising as to giving new ideas and suggestions of improvements in existing crushers, and can even result in redesign of compression crushers.

Jan 1, 2014

By Raquel Franco de Souza Lima, Isao Matsuoka

"Microflotation studies and abstraction experiments were conducted with synthetic oxide spinels relating to chromite (MgCr2O4, FeCr2O4, FeFe2O4 and FeAl2O4), using sodium oleate as collector. An attempt was done to correlate this data with the speciation of oleate in the bulk solution and at the interface solid-water, to explain the floatability curves. The microflotation tests were conducted using a microflotation cell. The abstraction of sodium oleate was measured at 25°C, with one gram of synthetic spinel and the abstraction time was 30 minutes. After centrifuging, the residual oleate concentration in the supernatant was measured by using the spectrophotometric method described by Mizuniwa et al. (1977), that covers the range from 1.5 to 9 ppm. To cover the range from 0.2 to 1.5 ppm, the residual oleate concentration was measured using the spectrophotometric method described by Gregory (1966). The amount of oleate abstracted was calculated from the difference between initial and residual (equilibrium) concentrations.Figure 1 shows the floatability of FeCr2O4, FeAl2O4, FeFe2O4, MgCr2O4 as a function of pH and sodium oleate concentration of 1 x 10-5 M. The IEP of each sample is indicated in the figure by a vertical line in the horizontal axis. The chromium-bearing spinels FeCr2O4 and MgCr2O4 show the lowest isoelectric points (IEP), around pH 6, while in the case of FeFe2O4 and FeAl2O4, the isoelectric points lie at pH 6.5 and 7.3, respectively. It is seen that the flotation-pH curve for FeFe2O4 has a peak at the pH of the IEP, while flotation peak for FeCr2O4 appears at pH below the IEP and that of MgCr2O4 does at pH above the PZC. On the other hand, FeAl2O4 is floated at pH range between about 4 and 7,3 (IEP). This suggests that the pH value at which the maximum flotation occurs is dependent on the sort of spinel to be floated, though it appears in the vicinity of the respective IEP."

Jan 1, 2003

By A. Shandilya

ACC ECOSAND is finely powdered crystalline silica, which can replace natural sand usage in concrete and plasters. ACC ECOSAND ensures a comparatively denser concrete than those made only with natural sand and / or quarry fines / Manufactured Sand (Artificial Sand). Moreover, there is a significant gain in compressive strength (10-15 %) & durability in concretes (Reduced chloride conductivity leads to increased durability). ECOSAND is a by-product of froth flotation of limestone. At ACC Madukkarai cement works, Coimbatore, Tamilnadu, full-fledged mineral beneficiation process is adopted to enhance the usage of flotation reject in concrete and plasters. Optimum level for usage of ECO-SAND is 50%. With 50% usage of natural sand+50% ECO-SAND in concrete mix, 1 day, 3 day, 7 day & 28 day compressive strength is increased by 30.1 %, 22.6 %, 15.1 % & 11.0 % respectively and with moderate chloride permeability as compare to 100% Natural Sand. Keywords: froth flotation process, beneficiation studies, Denver cell, ECOSAND, siliceous material, durability & compressive strength, RCPT

Sep 1, 2012

By André Mans, Frans B. Waanders

"Ferrosilicon (Fe-Si) is an important commercial material and it forms the basis of the powder used in dense medium separation (DMS) of various minerals in a minerals beneficiation process. Current losses of Ferrosilicon (Fe-Si), which is used in the dense medium separation (DMS) of iron ore at Kumba Resources, Sishen, South Africa occur due to adhesion to the separation products and also by being present in the effluent stream, due to abrasion. The losses contribute greatly to the running cost of the plant and the purpose of this project was to determine the characteristics of the unused Fe-Si and then to characterise the changes that occur during storage and the use thereof.A Scanning Electron Microscope (SEM) and Mössbauer Spectroscopy (MS) were used to investigate the characteristics of the fresh and used Fe-Si. The SEM analyses of the Fe-Si yielded a composition of 15 wt.% Si and 85 wt.% Fe with minor impurities of Mn and Cr (<1 wt. %), resulting in an ordered phase with a calculated composition of Fe2Si. The average density of the Fe-Si was found to be 7.177 g.cm-3 whilst the size distribution was determined with the d50 of the particles being approximately 30 µm. A slurry, containing 10% solids was prepared, which had a density of about 1.1 g.cm-3 and this slurry was used to conduct the various experiments under laboratory conditions at the university. Samples were taken at regular intervals from a storage container containing a lime solution as well as from a closed circulation circuit system, kept at a constant temperature of about 60°C. Mössbauer Spectroscopy yielded, for the new fresh Fe-Si-samples, a two-sextet spectrum with hyperfine magnetic field strengths of 19.9T and 30.7T respectively, and the yellow-brown froth was found to be akaganeite or ß-FeOOH.It was found that the biggest loss of Fe-Si was due to the abrasion of the particles during the DMS process. A possible change in magnetic properties was also observed, leading to further losses that could occur during prolonged use of the medium. No clear changes to the Fe-Si occurred during correct storage methods, as was initially thought."

Jan 1, 2003

By D. Moradkhani

The heap leaching of oxide copper ores with copper cathode recovery by solvent extraction and electrowinning is now well established as a low-cost method of copper recovery. The main purpose of this study was to extract copper from the copper low-grade oxide ore of Chodarchaei mine using column leaching. The copper oxide ore contained 1.1% Cu and 1.75% Fe. The mineralogical analysis indicated the malachite (Cu2(OH)2CO3) was mainly composed of oxidized phases. The sulfuric acid leaching experiments were performed under the laboratory conditions. The influence of several parameters on the course of the reaction such as particle size, acid concentration, flow rate, and time was examined. The optimum collective extraction of copper and iron was obtained at a particle size of +10-15 mm for a leaching duration of 3 days with sulfuric acid concentration of 100 gpl and using a flow rate of 2.5 cc/min. Under these conditions, the recovery of copper and iron were 98.54% and 41.99%, respectively. Keywords: column leaching, copper, iron, working diagram.

Sep 1, 2012

By X. O. Xia

This paper introduces a kind of flotation machine for nonferrous metal, ferrous metal and non-metal minerals. With the application and development of flotation machine, researching the designment of master parts, including tank, impeller, stator, false bottom. Through the commercial run to validate the correctness of designment, achieving satisfied technical and economic target and supplying a kind of efficient and reliable flotation machine.

Jan 1, 2014

By A. V. Neretin

This paper is a continuation and extention of the previous paper on energy-efficient placer mining methods which was presented in 2007 at the World Gold Conference in Cairns, Australia (Nere-tin, 2007a). The paper reports the results only on gravel processing as they were not fully discussed in the previous paper. It is common knowledge that placer gold mining requires processing of large tonnages of gold-bearing gravels by wash plants of different types. In Russia, gold-bearing gravels are mostly disintegrated and screened by the following types of wash plants: a water canon, a derocker or a scrubber trommel. Gold-bearing gravel processing is regarded as highly energy-intensive due to high energy consumption for transportation of large tonnage of material and high pressure water flow rate. The industries requiring a significant expenditure of energy normally estimate the process efficiency by energy consumption per product unit. In order to obtain quantitative data on energy consumption for gravel processing and to estimate placer mining costs, in 2003~2006 four placer gold mines located in the Irkutsk Region were thoroughly investigated through time and motion studies. At all these placer mines gravels were processed by a water canon, a derocker or a scrubber trommel. The objective of the study was to investigate the following parameters: ? wash plant throughput rate per hour; ? hourly diesel fuel and power consumption per cubic meter of gravel processed; ? volume per cent and shape of oversize material; ? different combinations of gravel processing methods. The results from this study were as follows: ? specific energy consumption per cubic metre of gravel processed for different combinations of gravel processing methods was estimated; ? a correlation between energy consumption and unit cost of gravel processing was determined; ? effect of yield and shape of oversize material on wash plant throughput rate per hour was de-fined; ? energy-efficient gravel processing methods were developed. Based on these results, an improved method of gold-bearing gravel processing was proposed. Implementation of this method at a placer mine saved US$ 123 000 in operating expenses only during a short-time Siberian placer mining season. At the same time, this method improved gravel disintegration, screening and processing operations used at the mine. Another advantage of the pro-posed method was higher gold recovery due to reduced yield of undersize material. In order to improve efficiency of gravel processing, a wash system including a derocker for primary gravel processing and a lightweight scrubber trommel was developed. There are two economic benefits of replacing water cannons with the proposed wash system. The first benefit includes lower operating costs for gravel processing due to lower specific energy consumption, while the second benefit is lower gold losses during slurrifying (disintegration and screening) and sluicing of the undersize material.

Jan 1, 2014

The present study investigates the nature of gold mineralogical distribution and association in a Cu-Au flotation circuit (1.6 g/t Au, feed head grade). The approach used in this study involves a combination of bulk gold assay and quantitative X-ray diffraction (QXRD), on a size-by-size basis, followed by QEMSCAN analysis on the -75+53 µm, -53+38 µm and -38+20 µm size fractions. The QXRD and QEMSCAN analysis showed that gold mineralogy is complex and fine-grained in the flotation feed, particularly in the -38+20 µm size fraction. Gold and pyrite concentration follow each other closely, suggesting gold-pyrite association. Quartz as the major gangue mineral shows a bi-modal distribution with respect to particle size. The identified gold particles were completely locked (~94 %) in pyrite as fine inclusions and 6 % locked as complex aggregates (-75+53 µm size fraction) whereas in the -38+20 µm size fraction, the identified gold grains occur as fine inclusions (~1-3 µm) within pyrite and silicates. However, in the intermediate size fraction (-53+38 µm), 75 % of the identified gold grains (10-22 µm) were over 90 % liberated and 25 % associated and locked in pyrite and complex aggregates (~2-4 µm). The identified gold grains in the -53+38 µm size fraction occurred as native and electrum with varying silver concentration between 8 and 20 % by weight. In the -38+20 µm size fraction, a gold telluride was also identified. Based on the mineralogical analysis of the feed, possible flotation strategies are discussed. Optimizing the flotation of pyrite is suggested as the primary Au recovery strategy. Keywords: flotation, pyrite, gold, liberation, QXRD, QEMSCAN

Sep 1, 2012

By Claudio L. Schneider, Peter R. King, Reiner Neumann

"Predicting the liberation spectra that are produced from breakage of two-phase ores under the random fracture assumption can be accomplished by measuring the conditional, on length, linear grade distribution directly from images obtained from a representative sample of the unbroken texture. The technique tremendously simplifies the prediction problem by avoiding the multiple convolutions that arise from the traditional method based on a description of texture from a measurement of the chord length distributions associated with each phase in the unbroken texture. For a 3-phase system, the phase transition probabilities associated with the textural information make the traditional calculation an almost insurmountable mathematical problem. The direct measurement procedure on the other hand can be expanded to three phases comparatively easily.A coal sample is used here to demonstrate the procedure. It is concluded that the conditional, on length, linear grade distribution can be predicted in the same fashion for multi-phase systems. Accurate stereological conversion is the practical hurdle to be overcome for multi-phase systems, but it is already a reality for 3- phase systems."

Jan 1, 2003

By Elzbieta Mielczarski, Jerzy Mielczarski, Jan Drzymala, Yann Duvalm

Polyethylene glycol monoalkyl ethers (CnEm) render quartz hydrophobic while feldspar remains hydrophilic. As a result quartz can be separated from feldspar in small frothless flotation devices such as the Hallimond tube. The separation can be accomplished at room temperature at pH < 7 and C16E33 concentrations between 10-5 and 10-4 M for quartz particles smaller than 0.4 mm. No separation is observed when feldspar ore containing about 60 % of feldspar and 40% of quartz is subjected to flotation in a laboratory flotation machine. The reason for the lack of separation is a low hydrophobicity of quartz in the presence of polyethylene glycol monoalkyl ethers and high intensity of mixing in the flotation machine. The flotometric tests showed that the contact angle of quartz in monoalkyl ethers of polyethylene glycol solutions is less than about 18 degrees and depends on the structure and concentration of the ether and the pH of the system.

Jan 1, 2003

By Gianni Shena, Francesco Montanari

"Recent improvements in the resolution of X-ray computed tomography (CT) make it a promising alternative to traditional time consuming, error prone laboratory procedures for mineral liberation analysis, such as heavy liquid fractioning and measurements on polished sections. All indications are that in a few years CT will be well-established in many laboratories as a rapid technique for accurate liberation studies. In this scenario it would be able to provide liberation spectra or washability data in tens of minutes following sampling. However, although CT is a fast evolving technology, its on-line application is unlikely in the foreseeable future.Dual-energy (DE) radiography is another X-ray technique originating from non-destructive evaluation (NDE) and medical fields, which allows retrieval of the volumetric content of valuable components from two-phase particles in a fraction of second. Two radiographic images at different X-ray energies of a single particle or a monolayer of particles are taken in short time sequence. The thickness of the two phases is calculated particle by particle by image subtraction, whereupon particle grades can be derived. The development of the method for on-line applications requires the presentation of non-overlapping particles in the gap in the X-ray source detector measurement couple. Straightforward extension of the principle to multiphase systems is not possible. The paper reviews the state of the art of these two techniques as applied to mineral liberation problems."

Jan 1, 2003

By N. Karapinar

Ferrihydrite, a member of iron oxides family, has been used as an adsorbent for the removal of heavy metal ions from industrial wastewater. The success of the operation depends mainly on the efficient removal of ferrihydrite from the aqueous phase. Hence, the emphasis of this study was given on the separation of ferrihydrite by high gradient magnetic separation (HGMS) method to overcome solid-liquid separation difficulties of ferrihydrite. Magnetic seeding technique in which the magnetite mineral was chosen as a seeding reagent was used to make magnetic separation available. The method clearly involves the attachment of ferrihydrite to a magnetic seed material and subsequent magnetic separation of ferrihydrite ? magnetite coagulates. Seeding of ferrihydrite with magnetic particles was achieved by exceeding the solubility limit of the ions in the presence of dispersed magnetite. Magnetic separation results of seeded ferrihydrite showed that maximum seeding performance is obtained in the pH range of 7.0~10.0. Iron/magnetite ratio had a marked effect on the separation of seeded iron oxide precipitate by HGMS. This ratio determines the operation parameters such as magnetic field strength and flow rate. It was concluded that when used with magnetic seeding technique, HGMS can be used to surpass separation difficulties of ferrihydrite used in adsorption-based treatment techniques.

Jan 1, 2014

By I. A. S. Brum

Brazil has large reserves of coal (7 billion tons) located predominantly in the south of the country. Despite the relative ease of exploitation, these resources have been underestimated as a source of energy. Currently the country&apos;s strategic planning aims to minimize the gap between coal and resources traditionally used in the Brazilian energy matrix. In this scenario, the processing of Brazilian coal in columns flotation appears as a promising alternative, having been successful in mineral systems containing fine particles. This paper aims to study the overall process of column flotation for a specific Brazilian coal. The material used in this study consists of fine coal that is usually discarded as waste and deposited in the tailings dams. The objective is to recover carbonaceous matter and reduce the ash and contaminants grade. The variables analyzed were the influence of size particle, solids concentration in the pulp, the concentration of surfactants and frothers to be used. The first results showed that it is possible, from a feed with around 65% of ashes, to obtain products with approximately 35% ashes with mass recoveries about 40%. Concentrations of frother (pine oil) ranged from 50 g/t to 300 g/t and the collector (diesel oil) of 50 g/t to 200 g/t. Keywords: column flotation, coal, tailings, negative bias

Sep 1, 2012

By Carolina Achiardi, Álvaro Videla

"In pre-design a flotation plant copper sulphide is useful to apply a simplified methodology of economic analysis that relates the size of the grinding product (P80) with the throughput and their effect on copper grade and recovery of copper in the final concentrate of a flotation circuit. With this objective, this methodology covers the following analysis, perform by evaluation of five sizes grinding products (P80): 120, 150, 180, 210 and 240 microns. • Flotation testwork (rougher kinetic, open and closed cycle test) has been done to determinate the optimum operating conditions and to estimate the maximum recovery of copper in the concentrate, using Klimpell model • Flotation plant design assumes a conminution product obtained from a 25,000 HP ball mill • Metallurgical balance is performed for the circuit based on flotation testwork • Economic evaluation by calculating capital expenditure (CAPEX), operating expenditure (OPEX) and sales revenue, to determine NPV is performed and relates to the NPV. An optimum grind size is then obtained based on cash flow. The results shows a grinding product size that optimizes flotation and allows a higher NPV and INPV over other alternatives."

Jan 1, 2014