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By E. G. Bailey

The bituminous coal industry faces a real problem, if it desires to retain the position in the power-generation field to which it is economically entitled. More power is probably produced today for electrical energy, for steam-driven and steam-heating industries and processes, for transportation by rail, water, highway and air, collectively, than ever before, and yet the total bituminous coal production has decreased about 38 per cent, from 575,000,000 tons in 1926 to 357,500,000 tons in 1934. It is not the intention of the writer to recommend coal as a fuel for automobiles and airplanes, but rather to point to these forms of transportation as being responsible in a very measurable degree for reducing the coal consumed by railroads. Petroleum products may still further reduce consumption of locomotive fuel through the extension of the use of Diesel-driven trains. Oil-burning steam-driven locomotivcs are replacing coal in some places, where railroads operating high-speed passenger trains are willing, temporarily at least, to pay a premium for the fuel that is low in ash and produces less smoke and practically no cinders. In the navy and ocean-going passenger ships, oil is so firmly established, and has such definite advantages over coal as formerly fired, in steaming radius, in ease of bunkering, cleanliness, and reduction in firing labor, that very outstanding developments in the handling and burning of coal will be rcquired in order to replace oil. For freighters on the Great Lakes, coal is the logical fuel, but there is great and immediate need of radical improvements in its use, else that market also may be lessened. It is not within the scope of this paper to discuss in detail bituminous coal for either locomotive or marine use, but, rather, generation of power in stationary plants, consisting of electrical generating stations and that very large group of miscellaneous industrial plants, such as paper, rubber, textile, steel and other industries that use electrical, mechanical, and steam power, derived from either hydro or some form of fuel.

Jan 1, 1936

By Grover J. Holt

Low grade ores dwarf high grade, tonnage wise. Bigger and improved-design machines feature modern concentrators. Flowsheets becoming more complex.

Jan 2, 1951

By Norman Weiss

IF we were to measure progress this year in terms of large new mills and discoveries of fundamental significance we should certainly be disappointed. Outside of the uranium field there was little of a spectacular nature. San Manuel and Reserve completed their first year of operation; Erie approached readiness; the Toquepala project in southern Peru broke ground and gained speed. Important mill enlargements occurred at Inspiration, Anaconda, Ray, and Climax Molybdenum. A 3000-ton copper concentrator was completed at Pima, near Tucson. The Republic Mill of Marquette Iron Mining Co. started up in April. Abroad, the great developments in the African Copper Belt can be likened to the rapid growth of the porphyry coppers in this country. Fundamental research was confined nearly entirely to iron ore flotation and recovery of metal values from leach solutions, particularly uranium. The large number of review articles this year reflected a desire to take stock and consolidate past gains before taking the next bold steps. Undoubtedly a shortage of competent young engineers and technicians is stunting the natural growth of theoretical investigation in the field of minerals beneficiation, as well as the conversion of ideas into action. We find our small stock of talented young scientists concentrated in a few centers of erudition because there are not enough to diffuse through the industry. It is safe to say that among mine administrators and managers there is more interest in the education, training, and welfare of the young engineer than ever before.

Jan 2, 1957

By R. J. Snoby, M. A. Short, A. Jungmann

In processing coal, the low concentrate value requires high capacity production and sharp classification/separation techniques to reduce specific production costs. The allflux separator meets these criteria with a unique two-stage design. Through a combination of rising current and fluidized bed technologies, the allflux has extended the state of the art by expanding the particle size range that can be efficiently processed. Using concepts that have proven successful in processing concrete sands, small-scale industrial testing with coal feed stocks looks very promising. Attractive applications for the allflux are projected in fine coal recovery from old settling ponds or as a retrofit in existing fines circuits.

Jan 1, 2001

By M. A. Amarante

Beneficiation studies were conducted on a Portuguese feldspar ore, in order to obtain final products capable of being used in the ceramic industry. A simple scrubbing operation is enough to break the lumps in the feed. The ore deposit contains ca 35 x 106tonnesfrom which, by screening, three main products could be obtained. This paper focuses on the beneficiation of the 500/74 µm fraction, which constitutes about 27% of the ore, assaying 9.42% Al2O3,equivalent to approximately ca 46% feldspar, with a mean iron content of 0.29% iron oxides. Magnetic separation and froth flotation testwork was carried out, in order to decrease the iron contamination and increase the feldspar content. Magnetic separation alone decreased the iron content of the feed to values between 0.04 and 0.08% iron oxides with an average yield greater than 90%. Flotation with HF, provided a feldspar recovery of 45?46% with a concentrate assaying 17.6% Al2O3. The use of H2SO4, gave a recovery of 35?36% of feldspar concentrate, assaying 16.1% Al2O3. However, economic and environmental advantages of using sulphuric acid may compensate for the lower mass recovery. The iron content of0.12% iron oxides in these concentrates, could be reduced to 0.04?0.05%, by further magnetic separation.

Jan 1, 1997

By Siqing Liu

A low-grade cassiterite-magnetite ore from Sichuan province, China, is finely disseminated, assaying 0.39% Sn and 23.20% Fe, respectively. Mineralogy studies show that the fine-sized cassiterite is mainly disseminated in iron minerals and gangue. Moreover, the embedded size of cassiterite is very fine and must be ground to -0.01 mm to achieve a degree of liberation of about 90%. Therefore, fine grinding needs to be conducted to get a high quality tin concentrate and a great loss of tin cannot be avoided when treating the ore by gravity concentration. Based on the above facts, a two-stage separation, with a low intensity magnetic separator and a shaking table, was selected to test the ore. Compared with other similar plants, a relatively good separation has been achieved. Three acceptable products for smelters were obtained as following: iron concentrate assaying 61.69% Fe with a recovery of 75.09%, tin concentrate assaying 27.21% Sn with a recovery of 56.97% and a sulfur concentrate assaying 40.86% S with a recovery of 32.03%, respectively.

Jan 1, 2011

By Yang Zhao, Wanping Wang, Siqing Liu, Shuming Wen

"In China, most reserves of rich iron ores have now been depleted and sustainable development of low-grade iron ores has become a critical discussion topic in the mining industry today. The aim of this study was to evaluate the applicability of beneficiating a low-grade, hematite-magnetite ore (assaying 18.64% Fe) for subsequent utilization. In this study, process mineralogy and beneficiation of the ore were carried out in the laboratory. First, mineralogical investigation shows that the main metal minerals are hematite, magnetite and a little octahedrite that cannot be used at present, and the main gangue minerals include albite, quartz and ankerite. Based on the above, a combined process of magnetic separation and gravity concentration has been developed by using laboratory low- and high- intensity magnetic separators and a slimes shaking table, respectively. Factors affecting these separation methods are discussed, including process mineralogy on the tailings of the high-intensity separator, where the iron minerals were found to be finely disseminated in the gangue as inclusions. By applying a two-stage grinding step and a magnetic separation stage together with gravity concentration, a marketable iron concentrate assaying 60.79% Fe at a recovery of 60.23% can be obtained, when the feed assays 18.75%Fe, which provides some useful information for the sustainable use of low-grade iron ore.IntroductionIron is the world’s most commonly used metal. Steel, of which iron ore is the key ingredient, represents almost 95% of all metal used per year, primarily in structural engineering applications and for maritime purposes, automobiles and general industrial applications. By the end of 2009, the iron and steel production in China ranked the first in the world, and reached 0.567 and 0.537 billion tons, respectively. The domestic supply of iron ore was 0.88 billion tons and about 0.628 billion tons of iron ore were imported in 2009."

Jan 1, 2015

By Ande&apos, Bengt n

The first Model 480 SALA-HGMS R carousel high gradient magnetic separator was recently manufactured (Figure 1). The carousel's design was based upon the high gradient magnetic separation technology developed and owned by Sala Magnetics Incorporated, Cambridge, Massachusetts. After a short (approximately 300 hours) in-house mechanical and electrical test and break-in period, the carousel was ready for a long term demonstration test. This paper describes the demonstration plant and operational performance of the Model 480 HGMS treating a low grade iron ore tailings. A location convenient to Sala International's main office in Sala, Sweden was desirable because Sala engineers and technicians were to operate the demonstration plant. The Strassa iron ore mine in central Sweden was chosen because it fit most of the criteria that was important for a good demonstration site. The Strassa mine is part of the state owned Svenskt Stal AB. The mine produces about 320,000 tons of iron concentrate per year consisting of 200,000 tons of magnitite concentrate and 120,000 tons of hematite concentrate.

Jan 1, 1980

By J. Nolan, B. Ande’n, E. Lindgren

Field testing was conducted at the Strassa Iron Ore Processing Plant to evaluate high-gradient magnetic recovery of iron from the plant's tailings. The installation is the first commercial application of the Sala Continuous High-Gradient Magnetic Separator (HGMS) Model 480 Carousel. The objectives of the five-month testing program included optimization of the operating parameters using SSDEVOP techniques to maximize iron recovery, along with establishing a long-term operating history for the SALA 480 HGMS Carousel. The effectiveness of the optimization procedure, the net benefit in term of iron recovery, and equipment performance are discussed in the paper.

Jan 1, 1983

By Ghiani M, Currelli L, Fuganti A

the results of an experimental study aimed at beneficiating a complex ore containing bastnaesite and other rare-earth minerals, with associated barite and fluospar are illustrated. Owing to its minero-petrographic, physico-mechanical and structural characteristics, the crude ore is not amenable to classic concentration methods, such as flotation, magnetic and gravity separation. Therefore the technical feasibility of selective disintegration followed by size classification has been studied, whereby bastnaesite and the other rare-earth minerals can be concentrated into the finest size fractions. Leaching and subsequent extraction of rare-earth metals by liquid-liquid separation represents the final stage of beneficiation.

Jan 1, 1993

By E. Finch

Beneficiation tests were conducted on samples from three ore zones in the Los Monos, Navay orebody in Táchira State, Venezuela as part of an overall feasibility study. The scope of work included ore sample characterization, flowsheet development, and optimization of beneficiation variables on a bench scale followed by confirmation on a pilot plant scale. Phosphate in the ore samples occurred primarily as francolite and was associated with quartz, kaolinite, and feldspar. Liberation of the phosphate began at 589 microns (28 mesh) for the main ore zone sample and at 295 microns (48 mesh) for the lower-grade ore zone samples. Development tests on simulated mining composites demonstrated that the samples responded well to 589 micron (28 mesh) grinding, two stages of high intensity scrubbing, conditioning at high % solids with caustic and equal amounts of tall oil and fuel oil, and separate coarse and fine flotation circuits with one stage of roughing and two stages of cleaning (reflotation). Concentrates in the range of 31.5-34% P205 with recoveries from 64-70% were obtained from the mining composites. Product quality for all concentrates in the range of 31.5 % P205 was good; 1.40 CaO/P205 and 0.04-0.05 minor element ratios. Confirmation testing in a continuous pilot plant produced results similar to those achieved in the laboratory.

Jan 1, 1993

By Donald W. Jenkinson

Many types of gravity concentration equipment have been employed throughout the years since beneficiation of materials has been practiced. These include jigs, concentrating tables, vanners, sluice boxes, heavy media cyclones, and static heavy media separators or sink-float separators. In the beneficiation of coarse aggregate for concrete mixes, static heavy media separation employs the same principles of gravity concentration involved in separating lead-zinc ore, dolomite, limestone, diamonds, manganese, iron, and many other minerals. In aggregate beneficiation, as in most metallurgical operations, sink or heavy fraction is the product. The undesirable portion of coarse gravel is usually much lighter than the desirable particles, allowing most aggregates to be amenable to gravity concentration methods.

Jan 7, 1960

By Joseph Singewald

THE problem of the utilization of the low-grade red iron-ores has peen before the iron-mining industry of the South for several decades. the experiments by W. H. Coghill1 of the U. S. Bureau of Mines to determine the degree of liberation of minerals in the Alabama low-grade red iron-ores after grinding interest the writer very much because 10 fears ago, while a member of the U. S. Bureau of, Mines, he experimented similarly on the same ores using a heavy solution .2 Extensive experiments were made in the nineties by W. B. Phillips3 in association with H. A. J. Wilkens and H. B. C. Nitze. The ores were rushed to pass 15 mesh and were separated by magnetic machines into concentrates, middlings and tails. The experiments were made with carload lots in an experimental mill. Most of the ores tested, however, were soft, whereas the main problem is the utilization of the low-grade hard ores. Phillips gives the results of only four tests of hard ores; two of these are of self-fluxing ores of the grade now utilized and two of ower grade and less amenable to concentration than the average low-grade ore that underlies the self-fluxing ore of the Big Seam. The average of these least favorable samples shows the production, from an ore analyzing 32.30 per cent. Fe, 10.34 per cent. CaO, 33.40 per cent. insoluble, of a concentrate with 43.82 per cent. Fe, 8.90 per cent. CaO, 18.48 per Sent. insoluble with a ratio of concentration of 2 and an iron recovery of 39.2 per. cent. The grade of this concentrate compares favorably with the average grade of washed brown ores of the district which is given by Burchard4 as 45 per cent. Fe, 14.6 per cent. Si02. The slightly lower iron

Jan 2, 1927

By V. Itkin

"Three methods were tested for the beneficiation of aluminum scrap, generated by heavy medium separation of non-ferrous automobile scrap residue. These were: crushing in a shredder followed by screening; grinding in a ball miff followed by screening; and eddy current separation. The best results were obtained with the grinding-screening method. IntroductionThe usual method of aluminum alloy reclamation from non-ferrous automobile scrap residue consists of a two-step heavy medium separation to remove materials lighter than and heavier than aluminum. The resulting aluminum scrap still contains over 15% impurities such as stones and glass, heavy rubber, insulated copper wire , plastics and heavy metals entrapped by macerated aluminum piece s, composite fragments, etc.(2). Upon melting, these impurities create difficulties and yield a low ingot recovery-65% to 70%, hence small foundries avoid this material.There are a number of ways to improve the quality of aluminum scrap such as:(1 ) crushing of the scrap, which powders the brittle content , a major impurity component, followed by screening out of the dust(2) eddy current separation , which removes metals from the material flow, and(3) implement better methods for density separation.The eddy current separation and two variants of the comminution-screening technique were studied by Intermetco Ltd., Hamilton , Ontario."

Jan 1, 1986

By L. Piga, P. Cipriani, F. Pochetti

High-temperature roasting of alunite in the presence of K2CO3 gives rise to a reaction that results in up to an 80% recovery of its potassium content as K2SO4 by leaching of the roasted mixture. K2SO4 is also generated from the reaction between the added K2CO3 and the SO3 driven off during roasting of the alunite. This limits the environmental and corrosive problems involved in the thermal treatment of this mineral. A solid residue containing mainly aluminum oxide is also obtained. This could be used as raw material for the production of aluminum, as the use of K2CO3 does not introduce different cations than are in the ore. A statistical study was performed on the factors assumed to affect the recovery of potassium, namely, roasting temperature, K2CO3- alunite stoichiometric ratio and leaching temperature.

Jan 1, 2000

By G. E. Karantzavelos

Introduction Pure alunite (KAl3 (SO4 )3 (OH)6 ) contains 37% A1203. In the alunite ore found on Milos Island, Greece, opal is the principal gangue while some aluminum, iron, and titanium oxides are also present. Processing of alunite ore leads to the recovery of potassium sulfate, alusil (alumina-silica mixture), and sulfur dioxide. An interesting process has been developed in Greece (Svoronos, 1977) consisting mainly of roasting the alunite ore mixed with KCl to disrupt the mineral lattice in preparation for separating its components. The thermal decomposition of alunite at approximately 600°C occurs by the reaction: KAl3 (SO4)3 (OH)6 + nSiO2 + 6KC1 - 4 K2SO4 + 3 A1203 . nSiO2 + 6 HCl + 3H20 According to the process pure alunite mixed with 543 kg KCl, 840 kg K2SO4, 370 kg alusil, 264 kg HCl, and 65 kg H2O are produced. The roasted calcine is leached in hot water. The potassium sulfate leach slurry is then thickened and washed to obtain a solid residue (alusil) plus a solution rich in potassium sulfate. Assuming the alunite ore feed consists of 50% to 60% alunite, the solid residue might consist of approximately 22% to 27% A1203, silica, iron, and titanium oxides. This leach residue could be digested in a hot sodium hydroxide solution to dissolve alumina. An amount of the alumina (approximately 10%) would not dissolve. In addition, part of the silica would dissolve requiring removal from the solution in a subsequent desilication operation. The same leach residue could be attacked by mineral acids such as a diluted hydrochloric acid to extract aluminum chloride (Sawyer et al., 1983). Alumina and aluminum are presently produced from bauxite of which Greece has important reserves. If this aluminous material (alusil) could be beneficiated by any physical process, then it would be considered as a raw material for the production of fire-clay refractories instead of an alternate source of alumina. Experimental procedure Extensive laboratory work (mineralogical and chemical analyses) indicates that alusil is a mixture of liberated (mostly) alumina and silica particles, not a natural silicate mineral. Table 1 shows the chemical assays of two alusil samples that were obtained from a roasted alunite ore leaching pilot plant. The samples used for the experiments were a very fine alusil powder (K80 = 400 mesh, 38 µm). These were pulped in tap water. Desliming of the pulp before each flotation test was ineffective. Flotation tests were performed in a 2000 ml Denver cell. A standard 500-g sample was first conditioned at a pulp density 50% solids for 5 min with hydrofluoric (HF) acid solution (40%). The temperature of the conditioned pulp was measured and kept nearly constant at 50°C. The pH of the conditioned pulp was also regulated to 2.5-3 with HF solution. Then ARMAC C solution (2%) as well as two drops of fuel oil and one drop of AEROFROTH 65 were added and the pulp was reconditioned for 2 min. After conditioning, the viscous pulp was transfered to the flotation cell. It was then diluted with warm water to about 15% solids and floated to separate silica from alumina particles. A rougher froth product that was cleaned and recleaned was obtained from the flotation tests.

Jan 1, 1987

By R. G. O’Meara, S. M. Runke

THE Bureau of Mines has been charged by Congress to investigate processes for the production of alumina from low-grade bauxite, alunite, and clay. As one part of the program, an investigation of the application of ore-dressing methods to improve the grade of high-silica bauxite is in progress at the Mississippi Valley Experiment Station at Rolla, Mo. This paper summarizes data obtained so far and presents detailed results of tests on four typical samples. MINERALOGY OF BAUXITE The name bauxite originally was used to designate the dihydrous aluminum oxide (A1203.2H20). The designation has been retained, although the existence of a specific mineral of such composition has been disproved. The term is now applied to ores of aluminum consisting of various mixtures of the minerals gibbsite (A1203.3H20), diaspore (A1203.H20), and boehmite (A1203.H20). The predominant hydrous aluminum oxide in most American bauxite, however, is gibbsite. In some instances bauxite may be amorphous mixtures of the hydrous aluminum oxides that approximate the composition of dihydrous aluminum oxide (A1203.2H20). The proposed name for this material is cliachite. Gibbsite and boehmite, the trihydrate and monohydrate, are soluble in a solution of sodium hydroxide at elevated temperature and pressure, whereas diaspore is practically insoluble. The solubility of these two minerals is the basis of the Bayer process of alumina extraction. All bauxites contain certain impurities, the commonest of which, in the order of their importance, are: silica, principally as a constituent of kaolinite, and to a lesser extent as quartz; iron, as hematite, limonite, and siderite; and titanium, as ilmenite, rutile and leucoxene. Minor impurities are zircon, cobalt and nickel. Bauxite is produced commercially in Arkansas, Alabama, Mississippi, Georgia and Tennessee, but the most important deposits in the United States are in Arkansas, in the vicinity of Little Rock. HISTORY OF BAUXITE BENEFICIATION The literature on bauxite beneficiation is limited, but the reports of Gandrud and DeVaney1 and Clemmer, Clemmons, and Stacy2 show the possibilities of flotation as a means of beneficiating bauxite. Their work has also developed reagent

Jan 1, 1944

By C. Ek

Tailings originating from the gravity concentration of a gold ore containing about 14 g/t Au have been treated by various beneficiation methods. These tailings have been screened on the 147 and 74 micron sieves and the two coarsest fractions have been separated on shaking tables with unsatisfactory results, but the concentrates have been examined in polished sections for mineragraphic analysis. Very simple flotation flowsheets have been applied to collect most of the gold, recovery and grade varying with the regrinding time in a ball mill. Cyanidation tests have shown that this type of treatment is also applicable to such tailings.

Jan 1, 1991

By Bisweswar Das, Barada Mishra, Hrushikesh Sahoo, Swagat Rath

Banded hematite jasper (BHJ) containing 45.2% Fe, 32.64% SiO2, 0.63 % Al2O3 and 1.25 % LOI is found difficult to beneficiate either by magnetic or flotation techniques due to fine intergrowth of jasper with hematite. Phase transformation by reduction roasting with activated charcoal followed by low intensity magnetic separation to achieve a suitable iron concentrate has been attempted in this study. The mineralogy of the ore and different roasted products has been studied by X-ray powder diffraction (XRD) and scanning electron microscope (SEM) to understand the reduction mechanism. The magnetite formation is observed at 850ºC while metallic iron appeared at a higher temperature. The effects of reduction variables such as reduction time (30-270 min), temperature (750-1050ºC), and reductant (1-12 %) using activated charcoal are studied. An iron concentrate with 64.65% Fe and 55.8% recovery could be obtained under optimum conditions of temperature: 850ºC, time: 1.5 h, and reductant: 6% by weight.

Jan 1, 2014

By P. R. A. Andrews, R. K. Collings

The beneficiation of barite has been the subject of many investigations at CANMET, thus reflecting barite's importance as an industrial mineral. Fifty-one studies relating to various aspects of beneficiation were conducted between 1920 and 1986, and a review of some of the more important studies is presented. The information, including mineralogy, beneficiation methods and results, flotation parameters, and reagent concentration data, is presented in tabular form. By so arranging the principal data, the research worker and production metallurgist will be assisted in the evaluation of barite ores from a variety of origins.

Jan 1, 1990