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By Sonia Helle, Ursula E. D. Kelm

"From a metallurgical point of view, acid leaching of oxide zone copper ore is considered in the first place in terms of ore grade, whole rock mineralogy, rock granulometry, crushed aggregate size distribution, porosity, permeability and corresponding fluid flow characteristics. Despite exhaustive physicochemical and general mineralogical characterization, drops in copper recovery occur and are often attributed to and “unquantified mineralogical misbehaviour” of the gangue phases. This study establishes an experimental link to monitor and quantify the chemical interaction of chrysocolla, malachite and atacamite with reactive gangue phases.Laboratory-scale sulphuric acid (15%) leaching in small columns is carried out using a synthetic rock composed of 57% quartz, 1% ore phase, and 42% reactive gangue. Gangue phases were selected to represent mineralogy found in argillic, advanced argillic, and propylitic alteration zones. Exotic copper ores of Codelco Norte (in particular Mina Sur) served as model for the modal distribution of mineral phases. Natural reactive gangue phases (<200 Tyler mesh) were chosen as pure as possible: Saz-1 and Swy-1 montmorillonites, KGa-1B and KGa-2 kaolinites (all Clay Mineral Society, USA, Source Clays) Nau-2 nontronite, Imt-1 illite (both Clay Mineral Society Special Clays) and Chilean mordenite, laumontite and bentonite. Ore phases are: mineraloid chrysocolla from Radomiro Tomic (Codelco Norte), reagent grade malachite and a purpose synthesized atacamite-paratacamite mixture. Complete chemical, physicochemical and mineralogical characterizations were carried out for ore and gangue phases.The following observations hold for samples with and without mineralization: Smectite-rich gangue increased up to 75% in volume. Once wet, air-filled vesicles formed due to the rapid sealing effect of overlying smectite in the column. No volume change occurred for illite, mordenite and kaolinite gangues. For kaolinite mixtures acid puddles formed on top of the column during initial leaching due to the delamination and barrier formation of this phyllosilicate. Fluid recovery was <60% for expandable phases and reached up to 80% for non-expandable mixtures. These observations confirm the very low extractions obtained in ore with a combined smectite – kaolinite gangue for Mina Sur. The most important mineralogical changes observed in the solid residues are: reduction of basal smectite phase reflections (XRD), and slight loss of illite intensities. This is also reflected in the major element composition of the residues, which demonstrate a loss of Mg, Mn, Ca, Na, K followed by Fe, Al and Si; with their proportions depending on the starting materials. Furthermore, alunogen and meta-alunogen formed, with related phases coquimbite (illite) and godichite (nontronite) also depending on gangue mineral chemistry. For laumontite samples, meta-alunogen and alunogen precipitated from the leachate."

Jan 1, 2003

By Stoyan N. Groudev, Ioannis Paspaliaris, Irena I. Spasova, Kostas Komnitsas

"Acid mine drainage waters generated in the uranium deposit Curilo, western Bulgaria, were treated by means of a constructed wetland located in the deposit. The waters had a pH in the range of about 2.5 - 4.1 and contained uranium, radium, some heavy metals (iron, manganese, copper, zinc, cadmium, cobalt, nickel, lead), arsenic and sulphates in concentrations much higher than the relevant permissible levels for waters intended for use in the agriculture and/or industry. The wetland covered an area of about 140 m2 and was characterized by an abundant water and emergent vegetation and a diverse microflora. Typha latifolia, Typha angustifolia and Phragmites australis were the prevalent plant species in the wetland but species of the genera Juncus, Eleocharis, Scirpus, Carex and Poa as well as different algae were also well present.The water treatment was started in July 2001 and until now (August 2002) the wetland effluents were characterized by pollutants concentrations decreased below the relevant permissible levels. The water flow rate through the wetland during this period varied in the range of about 0.2 - 1.0 l/s. The water clean-up markedly depended on the temperature but was efficient even in the cold winter months at air and water temperatures close to 0oC. The removal of pollutants was due to different processes but the microbial dissimilatory sulphate reduction and the sorption of pollutants on organic matter (viable and dead plant and microbial biomass) and clay minerals played the main role. Negative effects of the pollutants on the growth and activity of the indigenous plant and microbial communities were not observed."

Jan 1, 2003

By P. K. Fedotov

Centrifugal separation opens its new application fields in the Mining Industry. The up-to-date equipment for ultra-fine ore and concentrates grinding allows an efficient use of centrifugal concentration for micronic gold grains recovery. Moreover, advanced centrifugal concentrators are presented on the market: concentrators with continuous concentrate discharge designed both for ore and non-metallic minerals concentration process. The conducted tests proved the centrifugal concentration to be efficient process for gold recovery from finely ground concentrates and ores (less than 20 µm). Knelson concentrator application for such a fine material in different process circuits makes possible to raise the total gold recovery level of plants. In the circuits of coal plants and in course of coal slimes treatment the centrifugal concentration may be used before flotation in order to improve process performances. A centrifugal concentrator KC-CVD with continuous concentrate discharge working on 0.3 (0.5)mm fraction before flotation is

Jan 1, 2014

By D. I. Verrelli

Within the flotation community a belief has developed that some particle shapes are more ?floatable? than others. This is usually attributed to an influence of particle shape or roughness on the induction period required to achieve attachment between the particles and the air bubbles in the pulp. Up to now, such measurements have not been able to readily isolate the effect on individual flotation subprocesses. In contrast, our experimental apparatus, the CSIRO Milli-Timer, enables us to directly observe the process of particle?bubble interaction and attachment by means of a high-speed video recording, thus providing a direct measure of the induction period for attachment. To assess the influence of particle shape on induction time we used two varieties of methylated borosilicate glass particles ? spheres and angular ?frit? ? in a range of tightly-sized fractions. In doing this, we take care to account for the influence of other factors that could affect the induction time, such as the polar angle of sliding commencement, and approach velocity. These parameters are recorded as variables for each interaction, and corrected for using multiple nonlinear regression. Our results illustrate the importance of particle shape on induction period, with angular particles exhibiting induction periods that were an order of magnitude lower than those of spheres. Furthermore, the induction period was seen to decrease with increasing particle velocity, or kinetic energy on approach, but increased as the trajectory approached the limit of just grazing the bubble. Particle shape in mineral processing is a consequence chiefly of the mineral type and the type of grinding employed. The results presented herein indicate that attention should be paid to the shape of particles obtained from the grinding operation, besides particle size. Keywords: attachment, bubbles, flotation, induction period, particles, shape effects, surface roughness

Sep 1, 2012

By David De Klerk, Maximilian Richter, Thirunavukkarasu Pathmathas, Indresan Govender

We consider the average power dissipation distribution for dense granular flows of an idealised mono-sized charge (5 mm glass beads) in a 300 mm diameter tumbling mill operated in the cascading-to-cataracting Froude regime. By combining the inherent frictional nature of particles within a dense flow regime and noting that tumbling mills are typically characterised by collisional and turbulent stresses, we derive the power dissipation distribution for athermal boundary conditions. The input data to the model (velocity, solids concentration, pressure and flow depth) are obtained directly from non-invasive measurement using a nuclear imaging technique: Positron Emission Particle tracking (PEPT). The power dissipation due shear stresses is shown to be the dominant mode of dissipation in the tumbling mill with up to two orders of magnitude difference between pressure induced dissipation and shear.

Jan 1, 2014

By Alejandro Uribe-Salas, Fabiola Nava-Alonso, Gloria Dávila-Pulido

This paper presents results of an experimental study performed on the role of calcium sulfate present in flotation water on sphalerite flotation in the Pb/Cu circuit (non Cu-activated sphalerite) and in the Zn circuit (Cu-activated sphalerite). In the Pb/Cu circuit calcium ions adsorb on the negatively-charged sphalerite favoring xanthate adsorption and therefore making sphalerite floatable; experimental measurements show sphalerite contact angle increases with calcium concentration while xanthate adsorption onto sphalerite increases with the increase of pH and calcium concentration. Gypsum (CaSO4·2H2O) eventually present due to calcium sulfate precipitation is not detrimental to flotation at this stage since it is negatively charged at pH 9 and therefore, does not adhere onto the surface of negatively-charged sphalerite. In the zinc circuit, Cu-activated sphalerite decreases its negative charge (or even becomes positively charged) and develops some hydrophobicity due to the polysulfide produced by Cu-activation. At this stage calcium ions do not interact with the mineral surface and therefore do not favor xanthate adsorption; nevertheless, precipitated gypsum particles do adhere onto the mineral surface, greatly affecting its floatability (e.g., contact angle). Addition of sodium carbonate to dissolve gypsum and to precipitate calcium as calcium carbonate, which disperses in the bulk of the suspension, effectively restores mineral hydrophobicity. SEM observations coupled with EDS analysis clearly illustrate and support the above sequence of events.

Jan 1, 2014

By T. Mütze

The progress in comminution is often described by the specific surface area and the energy utilization or the brakeage ratio and breakage function. The principal mechanisms of size reduction are therefore, well known. All four parameters share a common disadvantage: They are limited in describing the behavior of a feed material with fine particles and a wide particle size distribution. An alternative is to describe the progress in comminution with ? The particle size distributions Q(x) before and after the stress or ? The particle concentration ratio pcr(x), which combines these two states. In the case of a self-similar fracture behavior, (in short: self-similarity) the progress in comminution can be simplistically described by the relationship between a reference particle size and the stress intensity. Self-similarity means self-similar breakage functions of geometrically similar particles of the same strength, a certain stress situation and stresses up to the breakage point. Self-similar breakage functions show the same curve at different stress intensities when the fragment size x is normalized with a reference particle size xNorm. This behavior was demonstrated for single particle comminution repeatedly and unequivocally. In the field of particle bed comminution, these results differ in literature. Therefore, the self-similarity in particle bed comminution was systematically investigated at the Institute of Mechanical Process Engineering and Mineral Processing of the TU Bergakademie Freiberg as part of a research project. Limestone, quartz, silicon carbide and glass beads, were examined with a hydraulic press. The particle sizes covered monodisperse fractions in the range of 1-1000 µm, bimodal mixtures of these fractions and polydisperse fractions. The results obviously show that there is no self-similar fracture behavior in the case of glass beads, quartz and silicon carbide. Statements on the self-similarity of limestone are much more difficult: Only some of the investigated limestone fractions show a similar clear, non-self-similar behavior. Self-similar curves appear particularly for fine monodisperse fractions as well as bimodal mixtures, which stressed with pressures above 200 MPa. Considering the measurement accuracy of particle size analysis the coincidence of the curves can be explained by the fact that progress in comminution almost ends above 200 MPa. At this point, a hydrostatic stress state is reached in the particle bed which is known from the literature. This stress state inhibits further fractures. Overall, it has been verified for the investigated materials that there?s no self-similar fracture behavior in particle bed comminution. One reason for the diverse opinions in literature is that there are three types of particles after the comminution in the particle bed: ? Particles which are stressed below their breaking point, ? Particles which are stressed right up to the break point, and ? Particles which are stressed beyond their breaking point.

Sep 1, 2012

By Mingxia Liu, Qi Liu, Tao Jiang

"In addition to physical parameters such as small mass and high specific surface area of fine and ultrafine minerals, chemical parameters such as the adsorption affinity of collectors on the minerals also plays an important role in fine particle flotation. In this study, we have examined collectors with two different ionized groups, carboxylate and hydroxamate, on the flotation of fine niobium oxide (pyrochlore). To facilitate comparison, two hydrocarbon radicals were tested: octyl and oleoyl, which led to four collectors that were studied: octyl hydroxamic acid (OHA), sodium octanoate (C8OONa), oleoyl hydroxamic acid (C18HA), and sodium oleate (NaOl). Small-scale flotation and isothermal microcalorimetric titration measurements were performed to determine the flotation recoveries of different sized pyrochlore and the enthalpic behavior after adsorption of the collectors on pyrochlore. It was found that the flotation performance of the carboxylate-based collectors was generally inferior to hydroxamate-based collectors. Sodium octanoate could not float pyrochlore irrespective of the particle size of the pyrochlore tested. With a longer hydrocarbon chain, sodium oleate was effective to float the relatively coarse pyrochlore (>20 µm) but its collection efficiency dropped sharply for particles smaller than 20 µm. On the other hand, the two hydroxamate-based collectors, octyl hydroxamic acid and oleoyl hydroxamic acid, showed good collecting ability to both the coarse and fine pyrochlore. The isothermal microcalorimetric titration studies indicated a consistent correlation of chain length with floatability of collectors for relatively coarse pyrochlore, as well as a positive relationship between the adsorption affinity and fine pyrochlore flotation recoveries. The key finding of this study was that efficient fine particle flotation could be achieved when strongly chemisorbing collectors were used.INTRODUCTION The first detailed study of the effect of particle size on flotation was made by Gaudin (1931) with sulphide ores. In 1942, Gaudin again demonstrated that (Gaudin et al., 1942) fine particles possess different flotation properties from larger particles. Since then the effect of particle size on froth flotation has been an important research topic by many researchers, e.g., Gaudin (1957), Miettinen et al. (2010), Warren (1976) Jameson (2010), summarizing the behavior of fine particles in terms of their low particle momentum, leading to low rate of collision with bubbles which reduces the chance of adhesion. The suggested remediation methods are mainly based on two approaches: increasing particle size or decreasing bubble size (Warren, 1976). Sand-fine splitting followed by separate flotation treatment of the sand and fines, using deep flotation cells, using starvation quantities of collectors, and using long flotation times, are also strategies to address the problems of fine particle flotation."

Jan 1, 2018

By N. D. Dementieva

Based on lab and pilot-plant tests to recover gold, silver and lead of a Russian deposit, a collective and flotation concentration flow sheet with lead and sulfide concentrates was proposed. The type of the deposit is gold-sulfide-quartz-bearing. The recovery of gold, silver, and lead to a lead concentrate was 47.4%, 68.1% and 70.7%, respectively. The grade of gold and silver grade was 170 g/t and 372 g/t, respectively. The mass percent of lead, zinc and arsenic mass percent was 41.7%, 0.34% and 0.63%, respectively. The recovery of gold and silver recovery to a sulfide concentrate was 50.1% and 28.8% at the grade of gold 20.5 g/t and silver 66.2 g/t. Sulfide concentrate with arsenic mass percent ~3% was biooxidised followed by CIL and obtaining metal at the site as well as zinc concentrate from bioleaching solutions with zinc mass percent 45% at its 64% recovery. The total gold and silver recovery using a developed technology with the account of their treatment at a polymetallic plant was 92.2% and 93.7%, respectively.

Sep 1, 2012

By Olga D. Khmelnitskaya

The paper presents the results of research on the development of gold recovery technology from oxidized gold-copper ore of one of deposits in Russian Federation. Gold and copper grades in the ore are 9.5 g/t and 0.4%, respectively. Various options of flowsheets, such as direct cyanidation, thiourea leaching, flotation and gravity concentration followed by subsequent cyanidation of con-centration products, were tested. It was established that gravity-cyanidation technology with filtra-tion leaching tails and the use of solutions in the recirculation is the optimal option for ore treatment. The proposed flowsheet provides gold recovery for 91.0% at NaCN consumption 2.5 kg/t ac-cording to the results of pilot testing. Ammonia-cyanide gold leaching was also examined. In comparison with cyanidation, gold leaching solution in system NaCN-NH4OH-(NH4)2CO3 allows NaCN consumption to be reduced three times from 4.5 kg to 1.5 kg per 1 ton of the ore and provides the same gold recovery. Based on the laboratory and pilot plant tests results of gravity-cyanidation technology of gold dissolution, process design criteria were developed.

Jan 1, 2014

By S. Fiore, M. C. Zanetti, C. Clerici

The processes and fluxes of a cast iron foundry plant located in the North of Italy were analyzed in order to determine the amount and kind of wastes produced from the different activities. The main fractions are the molding sands, furnace muds and powders coming from the dust abatement plant, the exhaust lime, the furnace refractory, the metallic shotting and the sludges and powders coming from the dust abatement plant of molding lines for a total production equal to 800 t/d. All wastes were sampled and particle-size and chemically characterized to evaluate the best recycling or reuse solutions. Wastes were sieved and divided in three categories according to the particle-size dimensions: below 0.1 mm, between 0.1 and 0.6 mm and above 0.6 mm. The fraction above 0.6 mm dimension underwent magnetic separation to recover and quantify the potentially available iron fraction. The fraction between 0.1 mm and 0.6 mm was chemically characterized in order to understand if it could be fed to the sand regeneration plant. The below 0.1 mm fraction was characterized to evaluate the following recycling and reuse solutions: additive for molding sands and/or raw material for the concrete industry.

Jan 1, 2003

By M. H. Moys, M. M. Bwalya

The use of the Discrete Element Method (DEM) to simulate the interaction of particles in dynamic environments is growing rapidly. This technique is also being applied in the study of milling extensively. However, to date more focus has been on the validation of the model. In spite of the advantages of the detailed information that is available from the simulator, appropriate application of this information remains a daunting task. In this paper a technique that combines particle breakage probability data with the energy spectra generated from the DEM is discussed.

Jan 1, 2003

By Stephen Simukanga, Jewette Masinja

"Mining has been going on commercially in Zambia for over 100 years. The backbone of the mining industry has been copper production and its by-products of cobalt and gold. Over these years, the mining industry ownership structure has swung from private ownership to state ownership in 1972, and back to private ownership in 1995. Environmental management was first introduced into the body of Zambian legislation in 1991 through the promulgation of the Environmental Protection and Pollution Control Act (EPPCA). The Act’s main functions included the protection of the environment and control of pollution, and in particular to provide for the health and welfare of the people, animals, plants and the environment in general. This Act, was replaced in 2011 by the Environmental Management Act (EMA). The new Act has a number of new elements including: mainstreaming environment in national planning, it provides for the domestication of multilateral environmental agreements, enhances public participation issue, creates a central environmental information depositary, elaborates access to information principles, establishes an environment fund, creates enforcement orders, provides for both Zambia Environmental Management Authority and members of the public to sue for damages following environmental pollution, and provides for the appointment of honorary Inspectors. In addition to this, the Mines and Minerals Act of 1995 provided, for the first time, a section on environmental management in the mining sector. This section also created the Environmental Protection Fund (for mining), and made it obligatory to undertake environmental impact assessment before mining permits could be issued. The Environmental Protection Fund has now been established, as provided for by the law, and currently has more than USD9.0 million in the account. Secondly, environmental auditing is now being carried out annually on mines around the country, the effect of this has been a significant improvement in the environmental management of mining in Zambia. This paper looks at the response of the Zambian mining sector to these pieces of environmental management legislation, and the direction that the mining sector is expected to take on environmental management going forward."

Jan 1, 2014

In this study, the effect of different regrinding conditions on the depression of fine pyrite at the cleaner stage was investigated. The regrinding condition was manipulated by different grinding media (stainless steel and mild steel). It was found that, after regrinding with mild steel grinding media, the flotation recovery of pyrite is much lower than with stainless steel grinding media, and it is more difficult to restore by adding more collector. This means, regrinding with mild steel grinding media may depress the pyrite flotation more strongly. The copper activation of pyrite during regrinding was also studied. It was found, that the mild steel grinding media is more beneficial to copper activation than stainless steel media. Additionally, the analysis of pyrite recovery based on the particle size indicated, that the fine particles are more susceptible to different grinding environments than intermediate and coarse particles and therefore are more easily depressed with a much lower flotation recovery.

Sep 1, 2012

By Di Liu, Yongjun Peng

"It was identified that clay minerals adversely affect fine coal flotation through slime coatings. In the study, it was interesting to find that an anionic polymer dispersant, lignosulfonate, successfully mitigated the negative effect of clay minerals in coal flotation using fresh water, but in saline water, it exacerbated coal flotation.In order to understand the mechanisms underpinning the different behaviour of lignosulfonate in coal flotation using fresh and saline water, the adsorption isotherm, and dynamic light scattering (DLS) measurements were conducted in this study. While DLS monitored the molecular conformation change (swelling or shrinking) of the polymer in fresh and saline water, adsorption isotherms enabled polymer adsorbed amount on clay and coal mineral surfaces to be determined. It was found that lignosulfonate adsorbed on the coal and clay mineral surfaces providing effective electrostatic repulsions and resulting in a mitigation of clay minerals from coal surfaces in deionised water. In the presence of saline water, however, polymer molecular conformation changed. Polymer molecules were compressed and adsorbed in form of aggregates. The adsorption amount of lignosulfonate on clay minerals increased in saline water. A low dosage of lignosulfonate could not provide sufficient electrosteric repulsion to disperse clay minerals. Moreover, the high adsorption amount of the polymer on coal and clay surfaces led to a more hydrophilic coal surface, and coal flotation was therefore depressed in saline water. This study provides a new insight into understanding the role of anionic polymeric dispersants in mineral flotation using different quality water."

Jan 1, 2014

By Kyle Bartholomew, Robert McIvor

"Functional performance analysis of closed circuit grinding provides valuable insight into the two components of ball mill circuit grinding efficiency: classification system efficiency and mill grinding efficiency. Classification system efficiency isolates the combined effect of classifier performance and circulating load ratio from other circuit variables, such as ore grindability and the mill grinding environment. Optimization of classification system efficiency ensures grinding energy is applied to particles needing further size reduction and not to overgrinding. Entirely based on size distribution data, classification system efficiency precisely distinguishes subtle changes in classification system performance. Use of the functional performance equation to isolate mill grinding efficiency allows for proper optimization of the mill grinding environment by isolating confounding effects of changes in classification and ore grindability. Variables such as mill percent solids and grinding media selection can be optimized using the mill grinding efficiency subcomponent of functional performance. First published by McIvor in 1988, the functional performance equation provides a set of standardized, quantitative optimization criteria, simple and powerful, which link circuit performance to plant design and operating variables that can be manipulated. Functional performance optimization has been applied in numerous mineral processing plants globally and continues to gain acceptance as a practical means for grinding circuit optimization. In this paper, examples of derivation and industrial application demonstrate the means by which functional performance analysis dissects grinding circuit efficiency into its subcomponents allowing the reader to apply this straightforward, powerful optimization methodology at their mineral processing operation."

Jan 1, 2014

By M. Alvarez-Silva

The control of the amount of chromite reporting to the concentrate during the flotation of UG2 ore is of critical importance since its presence affects the downstream smelting process. It is generally reported that the main mechanism responsible for chromite recovery is through entrainment. This is reflected in analyzing the solids and water recoveries. These in turn are strongly dependent on the froth phase. In the present investigation a laboratory scale column flotation cell was used to investigate the role of the froth phase in the flotation of UG2 ore. Such a device is superior to a standard batch cell since it operates at steady state in open circuit and also allows for a greater degree of flexibility in terms of froth heights. The mass of solids and water recovered in the concentrate as well as chromite (Cr2O3) recovery by size class was determined as a function of froth height, superficial gas velocity and depressant dosage. The results showed that depressants had little effect on chromite recovery but increased the grade due to the depression of gangue minerals. A 60cm froth height always resulted in slightly lower solids, water and chromite recovery than for 30cm. Typically only 20-25 % of solids reaching the pulp-froth interface reached the launder. The relationship between solids and water recovery for a wide range of conditions indicated that chromite is mostly recovered by entrainment. Keywords: UG2 ore, column flotation cell

Sep 1, 2012

"This research aims at improving the beneficiation of coals and minerals in fine and ultrafine size fractions. A widely used method for upgrading fine and ultrafine particles is froth flotation, which is generally classified into mechanical flotation and column flotation. The present work is focussed on column flotation. A flotation column equipped with a conventional bubble diffuser/sparger was used with oscillatory air supply generated using a fast-switching solenoid valve. The flotation tests were carried out for coal particles and mineral particles, respectively, and a comparison in flotation performance was made between oscillatory air supply and steady air supply. It was found that use of oscillatory air supply with a proper valve switching frequency and on/off time ratio to replace steady air supply could lead to increased recovery of coals or minerals by more than 14 percentage points and substantial reagent cost savings. The improved flotation performance was attributed to enhanced gas dispersion and flow conditions. This research offers a simple new approach to improving the beneficiation of fine coals and minerals with using flotation columns.INTRODUCTIONFroth flotation has been widely used for the separation and concentration of fine coals and minerals by exploiting the difference in their affinity to air bubbles in aqueous medium. Froth flotation is an effective method for beneficiation of coal and mineral particles in a certain size range. It remains difficult to upgrade ultrafine mineral particles. One of the reasons for the ineffective flotation of fine particles is the low probability of bubble-particle collision in the collection zone (i.e., the pulp zone). According to Reay and Ratcliff (1973) and Yoon and Luttrell (1989), the probability of collision is significantly affected by bubble size and particle size, and the collection zone recovery can be increased by decreasing the bubble size."

Jan 1, 2018

By Jiongtian Liu, Guixia Fan, Caom Yijun

A cyclonic-static micro bubble flotation column (FCSMC) is an effective separation device for fine grain treatment. The separation of fine ilmenite by FCSMC was explored in this work. The influence of reagents dosage (regulator, collector and auxiliary collector), pulp density, circulation pressure and aeration quantity on TiO2grade and recovery wasinvestigated.The optimal conditions of a rougher are follows: pulp density 45%, pH 5.0, MOH collector dosage 2800 g/t, diesel oil dosage 700 g/t, circulationpressure 0.19 MPa, aeration quantity 0.8 m3/(m2•min). The optimal conditions of a cleaner are follows: pH 4.0, circulation pressures 0.16 MPa, and aeration quantity 0.5 m3/(m2•min).A pilot plant continuous test with a rougher-cleaner by FCSMC for 72 hours was proceeded under the optimum conditions. Compared with industrial flotation machines, the concentrate grade of FCSMC is 48.11% with an improvement of 1.08 percentagepoints, while the recovery is 82.36% with 13.64 percentagepoints increment. Moreover, the flowsheet is simplified from six parts (a rougher-two scavenger-three cleaner) in flotation machines to two parts (a rougher-cleaner) in FCSMC. Proofs were also provided by the analysis of the by-size grade and recovery of concentrate.Results show the FCSMC is an effective separation device to recover -74 µm size fraction.

Jan 1, 2014

By Vincent C. Smith, Agit Singh, Bernard Muller

The control of minerals processing plants is by no means trivial. In order to address some of the difficulties, it was decided to develop and test a model predictive controller (MPC) for a milling circuit. A milling simulator was written to test the MPC controller. Due to the large number of tuning parameters in a controller of this type, an optimising algorithm was written that automatically tunes the controller. Good, robust control was obtained when the controller was tuned using this algorithm. The controller was tested for various scenarios that are often encountered in the minerals processing industry. When problems were encountered, the MPC algorithm was specially adapted to accommodate for these difficulties. Control was further improved by using feedforward control as well as quadratic programming. The movement of the manipulated variables was reduced by using a region of uncertainty that allows the controlled variable to vary within a specified region around the setpoint. Integrators were handled by adapting the algorithm slightly and adding an optional integral error portion in the MPC controller. The performance of the enhanced MPC controller was compared to PI controllers on both the simulator and a commercial plant. The MPC controller showed faster responses with less interaction in both cases.

Jan 1, 2003