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By F. Sheykh-Jaberi, S. L. Cockcroft, A. B. Phillion

A coupled fluid/structure model has been developed to simulate semi-solid deformation in an industrial aluminum casting alloy, A356. Although this alloy has a significant eutectic fraction, nearly 50%, it still shows susceptibility to hot tearing. The model geometry consists of solid grains, created from a Voronoi tessellation of the domain, surrounded by liquid. The simulation is performed using the commercial codes, Abaqus Standard and Abaqus CFD. The solid model calculates the velocity, stresses and distortions in response to an applied uniaxial strain, and transmits them to the fluid-flow model, which computes the velocity and pressure fields in the liquid. It was shown that grain size and configuration, fraction solid and fluid properties all affect the semi-solid deformation behaviour.

Jan 1, 2014

By Rudolph P. Frizzi

"Abstract Pile design for building structures in the United States is typically performed by: 1) investigating and assigning engineering parameters to the respective ground bearing materials, 2) calculating ultimate pile to ground (geotechnical) capacity which is then reduced by a Safety Factor deemed appropriate by a registered Design Professional thereby arriving at an allowable pile geotechnical pile capacity, and 3) determining the required pile structural section using allowable pile section material properties. It is advantageous to use a Working Stress Design Method (WSDM) approach as one system of loads (service loads) are used in both the geotechnical and structural evaluation. There are a variety of methods used to determine the ultimate and allowable geotechnical capacity, and Building Codes often require a registered Design Professional to determine the appropriate method(s) and capacities. The International Building Code is the Code typically referenced in building design and construction in the United States. Structural design usually follows Building Code requirements and Allowable Stress Design (ASD) procedures. As design of the overlying structure typically follows a Strength Design Method (SDM) approach using factored loads, in some cases piling is first designed for pile-to-soil interaction using service loads, followed by evaluating the pile geometry for factored loads. Construction is the finalization and implementation of the designed piling. As such, project-specific technical specifications are typically developed by a registered Design Professional such that a project Owner can bid, buy, and instruct a Contractor as to the desired piling work and acceptance criteria. There are several Industry groups, including DFI, PDCA, ADSC, and ACI that provide guidance documents which the registered Design Professional can refer to in developing the piling technical specifications. It is the author’s opinion that the registered Design Professional is best suited to observe and verify the piling installation; many Building Departments require verification and documentation by a registered Professional as a condition of final acceptance.INTRODUCTIONPile design for building structures consists of: investigation, design, specification, and verification. In major metropolitan areas within the United States, Building Codes typically identify minimum requirements for each of the above steps. The International Building Code (ICC, 2012) is the Code typically referenced in building design and construction in the United States. Recognizing the ground conditions as well as piling construction means and methods can vary on a site-by-site basis, latitude is given to the registered Design Professional and Contractor to optimize the piling system for the respective project conditions. Field testing and quality control / assurance measures are typically implemented to verify the design intent is attained for the production pile elements."

Jan 1, 2014

By J. H. Cloete, S. M. Bradshaw, D. K. Chibwe

"The primary function of a tundish in the steelmaking industry is to serve as a buffer tank, accepting molten steel from the batch ladle process and allowing it to be cast continuously. However, modern steelmaking has more stringent demands for the quality of the steel product, requiring increased control over the properties of the molten steel before casting. For this reason tundishes have been developed as metallurgical reactors to serve as the final step in refining of the molten steel by removing non-metallic inclusions, preventing the formation of new inclusions, and promoting chemical and thermal homogeneity. In this study the flow behaviour in a four-strand tundish was investigated by means of a half-scale water model as well as numerical modelling. Both the numerical study and physical model were used to characterize residence time distribution (RTD) in the vessel and calculate properties pertaining to the tundish flow regime. Three different tundish configurations were investigated: a bare tundish with no flow control devices, a tundish with a turbulence inhibitor and a tundish with both a turbulence inhibitor and a dam.The physical and numerical models showed that a tundish without flow control devices was prone to significant short-circuiting. A tundish with a turbulence inhibitor was shown to be successful in preventing short-circuiting and provided surface-directed flow, which aids inclusion removal in the slag. Despite the benefits of the use of turbulence inhibitors, it was observed that the upward-directed flow increased the maximum turbulence kinetic energy near to the surface by approximately 120% compared with the bare tundish. Therefore the potential for slag entrainment should be considered during the design and operation of tundishes utilizing turbulence inhibitors."

Jan 1, 2014

By K. Adham

"Fluidized beds are utilized in a wide range of high-temperature applications throughout the metals and materials industry. Their main advantage is the fast and uniform heat and mass transfer between the hot combustion gases and the particulate solid feed. A further benefit can be the lowering of the processing plant's energy consumption, through heat recovery from the fluid bed processes used for solids heating. Here, the enhanced energy efficiency of fluidized systems is investigated and the modeling results are discussed for three configurations: the flash tube, the single bubbling bed and the multi-stage fluid bed. Key thermal design aspects of each system are identified based on results from process simulations, in order to benchmark their main operating features and overall energy efficiency. Suitability and applicability of each configuration is also discussed based on a number of process and material property considerations.IntroductionCombustion based heating of particulate solids is commonly done using three different types of fluidized beds. The flash tube (FT) is similar to a hot pneumatic transport system. The single-stage fluidized bed (FB) typically uses in-bed combustion. The multi-stage fluidized bed (MSFB) can have two or more stages stacked into a tower.Flash tube (FT) suspends the incoming solid charge in a high-velocity stream of hot combustion gases. To maintain the solids suspension in the FT, two parameters are required: high velocity for elutriation of the particles and adequate solid-to-gas ratio for avoiding high pressure drops and solids drop-out [l].The fluid bed (FB) works at much lower velocities than the flash tube. Therefore, most of the solids are not conveyed in the gas stream, but are only suspended in a liquid-like manner. At minimum fluidization velocity (Umr), the gas flow exerts just enough force on the solids to keep them suspended in place [2].Multi-stage fluid bed (MSFB) heats up the solids as they are transferred from an upper bed level to a lower one, counter-current to the rising flow of hot gases generated at the lowest stage. As the temperature and volumetric flow of the gases decrease from bottom to the top stage, smaller bed diameters can be used in the energy recovery stages [3]."

Jan 1, 2014

By B. Q. Xiao

The nitrate content is an important factor for environmental water samples and flour. In a 0.35 mol/L H2SO4-2NO solution, has a strong catalyzing function on the decolourization of Gallocya-nine (GC) oxidated by NaBrO3. Based on this, a novel method was developed to measure the NO and -3NO concentrations in water and flour. The flow injection technology was introduced into the analysis system. A single-valve dual- cingulums to inject which the Copperized-Cadmium slice and the reduction zone are isolated. The optimum solution for this method contains 1.48×10-4 mol/L GC, 0.06 mol /L NaBrO3 and 0.2 mol /L of NH4-2NOCl. Two empirical equations were proposed to calculate the and -3NO concentrations based on the measured signals. It can be used to measure -2NO of from 0.001 mg / L to 2.0 mg/L and -3NO of from 0.002 mg / L to 2.5 mg/L. The measurement frequency can be up to 20 samples / h. The relative standard deviation for eleven samples is less than 5%.

Jan 1, 2014

By R. X. Li

The overall flow-sheet of producing chromium (III) sulfate is described in this paper. The suitable conditions of each process such as sintering, leaching, aluminum removal, reduction, and de-composition conditions were experimentally studied. The results show it is reasonable to produce chromium (III) sulfate with the flow-sheet pointed out in this research work. The final product is Cr2(SO4)3 solution contained 150~250g/L Cr.

Jan 1, 2014

By M. A. C. Goes

Over the last twenty years CETEM has been involved in the preparation and certification of reference material from ores, concentrates and related materials for use in analytical laboratories associated with mining, metallurgy and earth sciences. CETEM provides reference materials from mineral samples, not available from the existing sources, to meet the needs of the mining and mineral industry. CBPA-1 and CBPA-2 respectively are samples of copper sulphide ore and flotation concentrate, both originated from Sossego Mine, located in Pará State, Brazil. The batch characterization was carried out by a collaborative measurement program with participation of 20 industrial, commercial and government laboratories from South America, North America, Europe, Asia and Africa. The certificates and report were issued in December 2007 (http://www.cetem.gov.br/ mrc/ing). The objective of this paper was to describe the procedures for material preparation and the collaborative approach involving a collaborative interlaboratory measurement program to certify CBPA-1 and CBPA-2.

Jan 1, 2014

By Chuanyao Sun, Longli Liu, Fayu He, Guiye Wu

Utilizing thioglycolic acid (TGA) as a template and using structure-guided design, a molecular modelling approach has been used to design and screen appropriate dispersant for chalcopyrite. A series of organic dispersants based on a TGA substitution with hydroxyl and amino and sulfonic functional groups have been examined on chalcopyrite surface. 20 organic depressors of chalcopyrite have been investigated to study the quantitative structure-activity relationship (QSAR) of chalcopyrite depressors. For the chalcopyrite surface, depressor containing carboxyl and sulfonic group is generally stronger than the depressor containing hydroxyl group. Increasing the number of hydrophilic group can effectively enhance the inhibition. Increasing the number of Solidophilic group does not necessarily lead to enhanced inhibition ability; steric factor is one of the important factors to affect the interaction. Extension alkyl carbon chain length cannot enhance the interaction of depressors. Isomers principle as well as applies to the chalcopyrite depressor molecular design. Flotation verification tests further confirmes the accuracy of the molecular simulation. Through the Computer Aided Molecular Design (CAMD) technology, we can save enormous time and resources to design novel surfactants. This research and application will play a great significance role in sulfide flotation.

Jan 1, 2014

By Mario Terceros H., Bengt H. Fellenius

"ABSTRACTFour strain-gage instrumented bored piles were constructed in a sedimentary, dense to very dense, fine to medium sand in Santa Cruz, Bolivia. Two of the test piles were the normally used bored pile constructed with bentonite slurry and two piles were Bauer Full Displacement Pile (FDP). One of each pair was equipped with the Expander Body, an inflatable steel cylinder that on pressure-grouting provides an enlarged pile toe. Head-down static loading test were performed on three of the piles and a bidirectional test was performed on the fourth pile, a standard pile with Expander Body and a bidirectional cell placed immediately above the EB. The latter pile was tested in 3 phases. First by activating the cell, second, by a head-down test, and, third, by a repeat bidirectional cell test. The static loading tests proved the shaft resistance of the FDP pile to be about twice that of the standard bored pile and that the Expander Body more than doubled the toe stiffness. The strain-gage records showed that the standard bored piles had multiple bulges and neckings, which affected the evaluation of the axial stiffness and load distribution of the piles. The testing programme was used for a prediction event with 60 persons, ahead of the tests, submitting predictions of the load-movement curves for the test piles and also a capacity appraised from the curves.1. INTRODUCTIONOn April 23 - 26, 2013, the First International Conference and Seminar on Deep Foundations was held in Santa Cruz, Bolivia under the auspices of INCOTEC SRL, the UAGRM University, and the Bolivian Association of Civil Engineers and Chamber of Construction. To coincide with the conference, a research study on construction and static and dynamic testing of four instrumented bored piles was undertaken. To ""add spice"" to the conference, a prediction event was organized on the test programme. This paper presents the soil conditions at the site, the type and construction of the test piles, the outcome of the prediction event, and the results of the static tests.2. SOIL CONDITIONSGeotechnical studies comprising SPT and CPT tests with routine laboratory analysis were performed on recovered soil samples. Three SPT boreholes were put down at three of the locations of Pile TP1, TP2, and TP3, at 5.0 m distance from each other. The SPT procedure consisted of manual hoisting of the weight by three crew members pulling on ropes over a pulley supported by a tripod and letting the weight fall by gravity. The groundwater table lies at 3.5 m depth.Figure 1 shows diagrams of the SPT N-indices and the distribution of water content in the three boreholes. The SPT-indices show the soil density to be compact. The average water content is about 15 %, plus-minus a few percent."

Jan 1, 2014

By T. Wajima

We tried to convert paper sludge ash (PSA) into zeolitic product with high cation exchange capacity (CEC) through acid leaching. Typically, PSA from incineration of paper sludge contains a high percentage of calcium in the form of anorthite (CaAl2Si2O8) and gehlenite (Ca2Al2SiO7). It is difficult to convert the ash with a high Ca content into zeolites, or at least into more desirable zeolite phases. Acid leaching with HCl was applied to reduce the Ca content to synthesize zeolitic product with high CEC. The raw ash was treated with 1 M, 3 M, and 5 M HCl solution for 0.5~24 hours (the ratio of the ash to volume of HCl solution was 1/4), and then zeolitic product was synthesized from leached ash through the reaction with 2.5 M NaOH solution at 80 oC for 24 hours. During acid leaching, gehlenite is readily dissolved in a lower HCl concentration solution than anorthite. With increasing HCl concentration, the amounts of Ca, Mg, Si, Al, Fe and Ti extracted from the ash increased. Ca and Mg contents were easily extracted from ash than other elements. The contents of Ca and Mg extracted rapidly at initial stage, and then levelled off. The saturation times of Mg and Ca are almost 0.5 h using all concentrations of HCl solutions. After the synthesis from leached ashes, zeolite-A and -P were synthesized from ash leached in 1 M HCl solution, and 3 M and 5 M HCl solutions, respectively, regardless of leaching time. With in-creasing HCl concentration, the Ca content eluted from the product decreased, due to the removal of Ca via acid leaching before the synthesis, while the Na content eluted from the product increased to 3 M HCl and then decreased, which was almost similar to the CEC of the product, due to the ion exchange of Na-type zeolitic phase in the product. The change of zeolite phases in the product and the CEC of the product depend on the concentrations of Si and Al in the solution during the synthesis. The highest CEC of the product is about 220 cmol/ kg, which was synthesized from the ash leached in 3 M HCl solution.

Jan 1, 2014

By Arkady Senchenko, Andrey Vasiliev, Alexander Aksenov, Metodi Zlatev

"This paper considers the issue of treating argillaceous oxidized ores with low gold grade (around 1.0 g/t). These ores according to their gold recovery level can be treated by heap leaching and agitation cyanide leaching, but low gold grade makes this treatment uneconomic. Heap leaching of argillaceous ores requires high consumption of binding agent for pelletizing to create suitable hydro-physical properties of material, which leads to increasing process cost and makes the material treatment unprofitable. Agitation cyanide leaching of this ore requires grinding processes; these expenses would not be paid back by the amount of gold recovered. Considering the above, poor argillaceous oxidized ores are recommended to be treated according to a combined technology including fractionation of ore, heap leaching of coarse fraction and agitation leaching of argillaceous fraction. Complex approach application allows one to avoid expenses incurred for material grinding and high consumption of binding agent for pelletizing. The success of this technology implementation will firstly depend on the quality of material fractionation, therefore the section of disintegration and division of ore into different components will be the most important part of flowsheet development for gold production. When disintegrating minerals at positive temperatures both standard (mechanical disintegration - scrubbers) and innovative (hydraulic method of disintegration - HydroClean units) equipment is applicable. HydroClean units are characterized by lower energy and water consumption. In a number of cases it is required to treat frozen ores. When treating frozen material standard approaches to disintegration are not reasonable due to their low efficiency. In order to treat frozen material a two stage disintegration flowsheet with screening after each stage is recommended. The first stage is recommended to be performed in a scrubber, the second - in a HydroClean unit. This technological flowsheet will provide high and steady values for ore separation into fractions at low energy consumption for disintegration."

Jan 1, 2014

Mineral flotation is effective over a relatively narrow particle size range of approximately 10 µm to 150 µm. If the upper particle size limit can be increased, however, a run-of-mine ore may be coarse ground, and only the middlings are ground further to achieve required grades. This will result in significant energy savings and increased throughput. In this communication, methods of increasing the upper particle size limit will be discussed on the basis of a flotation model that can predict flotation from both hydrodynamic and surface chemical parameters. An example of increasing flotation recovery by control of a chemistry parameter is given.

Jan 1, 2014

By R. Kobialka

In the article results of experiments over jaws? linings in jaw crushers with different shaping of working surface were presented. Following sets of jaws were under investigation: immobile plain jaw and moving jaw with grooving surface. Grooving jaws have groves with circular, triangular and trapezoid cross section. In order to evaluate efficiency of comminution both the grain composition of product and the content of irregular grains were determined, as well as the size of crushing forces and process efficiency were measured. For the combination: plain jaw with grooved one, a good results were obtained as regards the grain composition of product and the content of irregular grains. Crushing forces were higher at crushing with mixed types of jaws (the one plain, the second grooved), in comparison to crushing with using both grooved jaws. Efficiency of the process was definitely higher for mixed jaws.

Jan 1, 2014

This paper discusses how elemental analysis of conveyed bulk flows in real time using PGNAA (Prompt Gamma Neutron Activation Analysis) technology has resulted in significant improvements in advancing plant control in mineral processing operations. Basis of operation of the PGNAA through belt, full stream, continuous, multi-elemental, real time analysis technology is explained. Capabilities and limitations in plant operating environments are discussed including comparison with other real time, online technologies through review of published information available for on-conveyor minerals applications. Case studies demonstrate benefits provided by this technology in two operating mines. An iron ore company had prior experience with the PGNAA analyser technology, implementing an early model in a minerals application in 2003 to develop confidence in its measurement performance and usefulness of the data. A number of analysers were subsequently included throughout the new plant design for extensive measurement and control of conveyed bulk flows, from conveying after mining through to rail load-out. A copper-gold company installed an analyser to address copper ore blending issues where an on-belt system was the only viable option for the degree of control required. Analyser suitability was evaluated through test work on site samples to determine customised multi-element precision guarantees for each application. Analyser results from normal operation are compared against laboratory analyses of multiple cross stream samples collected from conveyed flows to assess performance. Both projects discussed were able to realise benefits previously unattainable for plant quality control, surpassing capabilities of traditional technologies which were either unsuitable for measuring conveyed flows with adequate accuracy or in real time. Equipment payback within a few months was achieved for both sites. Through proven performance in these applications, the companies consider the technology an essential component in advanced plant control necessary in new process flow sheet designs, rather than an optimisation tool.

Jan 1, 2014

By John C. Stankus

The 3 Right pre-developed longwall recovery entry at Signal Peak Energy?s Bull Mountain No. 1 mine was designed to prevent the abnormal roof conditions encountered in its firsttwo recovery entries. Unique geological conditions, such as the low overburden of approximately 200 feet and prevalence of roof joints in the sandstone overburden, contribute significantly to abnormal conditions during longwall recovery. The 3 Right recovery entry was 42 ft wide and developed in two stages, 21 ft wide in each stage. The entry roof was reinforced with steel wire mesh/non-metallic recovery mesh, high-capacity primary bolts and cables. After all the support was installed, the entry was completely backfilled with specially designed, cuttable, low-density cement. The roof bolting and backfilldesign were based on current practices in this mine and successful practices in other mines in the U.S. and Australia. Extensive instrumentation was installed in the recovery entry for continuous monitoring of load transfer as the face approached and cut into the recovery entries. The support design was completely successful with a smooth cut-through on January 29 and 30, 2014, significantly reducing the shield recovery time and meanwhile protecting the safety of miners. Based on actual observance and practices of the 3 Right recovery entry, recommendations on improvement and modificationsof roof support for 4 Right recovery room are presented.

Jan 1, 2014

By Will Hunt, Darren Thornton

In March of 2013, an undisclosed gold mine (MINE X), located in the Western United States, performed blast movement monitoring of three blasts occurring in one of two active pits. Blast Movement Monitors (BMMs) were placed in the bench before blasting, and located after the blast to determine vectors of movement. Using blast movement software, ore/waste boundaries were translated. These locations were compared to MINE X’s standard ore translation procedure, which consisted of moving polygon boundaries by 17.5 feet (5.3 m) in the burden direction of the blast hole pattern. This translation amount, identified by MINE X as “average” motion, had been ascertained by performing a previous blast movement study.

Jan 1, 2014

By V. E. Dementyev

This paper presents a brief overview of some IRGIREDMET advances in gold hydrometallurgy. Original impulse-percolation technology and equipment for intensive cyanidation of gravity concentrates have been developed and introduced into industrial practice by IRGIREDMET since 1980s (RF Patents N1593250). The process is based on leaching using special hydrodynamic and reagent conditions providing high dissolution rate for coarse gold particles. Gold and silver are precipitated from pregnant solution by cementation or electrowinning. There was also proposed an im-proved cementation method using zinc in a contact with electrically conductive material. The units including closed water recirculation, tails detoxification and semi-dry tails IRGIREDMET is well experienced in gold adsorption technology using ion exchange resins and activated carbons. The comparison of CIL and RIL processes were done for a number of gold mines, for example for Sukhoi Log gold deposit. The properties of prospective foreign and domestic ad-sorbents including strong-base, bi-functional and weak-base resins as well as activated carbons were studied. The Institute has developed some adsorption/elution technologies and equipment, such as a two stage RIP adsorption technology for gold/silver ores, an improved technology for gold elution from loaded resin and carbon, electrowinning cells for gold recovery from RIP and CIP eluates etc. Large scale ?Resin In Pulp? tests using weak-base resin were finalized and process design criteria were developed. Gold plant design is on progress at the moment. Improved technology for carbonaceous (preg-robbing) gold ores was developed. It was tested for some gold deposits including Sukhoi Log. It allows to overcome preg-robbing activities of ores treated and to improve dramatically performance of cyanidation and adsorption circuits. The studies on refractory gold ore treatment including bio-oxidation, pressure oxidation, roasting and ultra-fine grinding were conducted. Heap leach technology was tested and introduced by Irgiredmet for a number of Russian mines. Zinc cementation, activated carbon and ion-exchange resin adsorption were used for gold recovery from pregnant heap leach solutions. The options including combined technology ?Heap leach/ RIL or CIP? for clay ores were also developed and tested. The plant using developed technology is at construction stage now. The study on In-Situ gold leaching was conducted. The comparison of different gold lixiviants for this purpose was carried out. Gold recovery from pregnant leach solution by activated carbon and anionite including gold elution from loaded adsorbents etc. was also studied. In 2000 the In-Situ leaching technology was commissioned at Maminskoye gold deposit (Ural). The technologies for treatment of complex ores and by-products were proposed. For example, the technology of gold, silver, copper and zinc recovery from calcines after sulphuric acid production was developed.

Jan 1, 2014

By D. Seke

Metal inventories are usually reported in financial statements of mining companies. However, the value of these inventories can be reliable only if the metals in stock are measured within acceptable tolerances. Reliable metal balancing requires accurate mass measurement, sampling, and chemical analysis. Many mining companies are usually unable to validate the accuracy of metals in inventories at the end of their financial year. This is mainly due to poor mass measurement, sampling, and chemical analysis practices. This has an adverse impact on metallurgical accounting and metal valuation. In addition, it puts a lot of stress on external auditors, who have the duty to recommend the approval of the financial statements to the board of directors. Although a full value chain of metal reconciliation includes the accuracy of Mineral Reserve definition and grade control at the mine, this paper discusses the implementation of best practices for mass measurement, sampling, and chemical analysis at processing plants. This is an important aspect of sampling and reconciliation that is required in order to improve the reporting of inventories in the financial statements of public mining companies. Keywords metallurgical accounting, corporate governance, sampling, analysis.

Jan 1, 2014

By F. Göktepe

Flotation gases and conditioning of the pulp with them are one of the important parameters of flotation and should be taken into account especially in the flotation of sulphide ores. In this study, flotation of pure chalcopyrite and pyrite samples were investigated with air, oxygen and nitrogen as flotation gas and the effect of conditioning with these three gases also were performed. Flotation gas was introduced for 5min, 10min, 15min and 20 min. For chalcopyrite flotation there was no drastic change in recovery when air, oxygen and nitrogen were used as flotation gas but conditioning the pulp with oxygen for 10 minutes increased the recovery about 8% where pulp potential has been approximately 25 mV with chalcopyrite and 150 mV with platinum electrodes. Conditioning with all three gases decreased the pyrite recovery by about 20% with 20 minutes conditioning. Pulp potential decreased in the presence of nitrogen while conditioning with air and oxygen increased the pulp potential for both electrodes. Generally potential increased for both minerals with oxygenation and aeration time but it was stable or slightly decreased with nitrogenation. Comparison of the gases showed that the different flotation gases do not effect flotation recovery but conditioning the pulp with these gases at pre-flotation effects chalcopyrite and pyrite flotation recovery, most dramatically pyrite.

Jan 1, 2014

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