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By Sanjay Gupta, Sorabh Gupta, Ravi Sundaram

A geotechnical forensic evaluation of piles for an industrial facility in Haryana was performed to assess the quality of the piles and to evaluate piles installed using two different types of rigs. Low strain pile integrity tests were performed on all piles to assess the pile length and possible presence of structural defects. Coring was done through questionable piles for the clinching evidence of concrete quality and pile length. Probe holes adjoining piles helped confirm the bulging of piles at shallow depth. The paper highlights the importance of implementing a well-planned quality assurance program to confirm that all piles installed are of the desired quality.

Sep 1, 2022

By Marcus Daubner

This paper explains how BAUER Spezialtiefbau GmbH uses digital methods on projects - starting from work preparation to completion of works. More precisely, the advantages of BIM-based planning during work preparation and the automated and structured data management - both machine production data and the manually recorded quality-relevant reports - during execution phase are displayed. In this context, the benefit of the digital twin to optimize processes, to reduce defect costs, for a more effective reporting sys-tem, and the further usage of as-built information in the BIM or GIS process is described.

Sep 1, 2022

By R W. Shaw

The MTM Process targets treating lower grade and/or problem concentrates that are not attractive to smelters. The process has been developed at laboratory scale for copper and is based on a related development for zinc that has been extensively developed both in the laboratory and through pilot testing. The basis of the process is novel ammonia-ammonium chloride leach chemistry adapted to give high copper extraction whilst being selective over iron, arsenic and many other elements. The preferred flow sheet depends on location, especially infrastructure and utilities. These impact upon the leach and crystallisation stages more than copper reduction.

Aug 24, 2022

By A J. Morrison, K Demir, J Kohmuench, K Runge, C Evans

The Eriez HydroFloat® is a flotation device capable of recovering significantly coarser and lessliberated particles than is possible using a conventional mechanical flotation cell. Originally developed for industrial and bulk mineral beneficiation, the HydroFloat® is attracting increasing interest as a means of increasing the required grind size for metalliferous ore flotation. Doing so would reduce the costs of processing complex ores, either by decreasing the energy required to grind the flotation feed or by increasing the throughput achievable with a given comminution circuit. Processing coarser particles would also result in coarser waste streams, potentially improving the mechanical and hydraulic performance of the waste dams that they are sent to. Recent work at pilot – and industrial-scale has proven the potential of the HydroFloat® technology to achieve these gains in metalliferous applications. However, in order to realise the full potential of the HydroFloat® technology, it is necessary to understand not just its performance but also the drivers for that performance. Doing so will allow the design and operation of HydroFloat® devices to be optimised for different ores and applications. For this work, a HydroFloat® pilot rig was deployed to a coppergold plant in Australia and was used to investigate the effect of stream and operating conditions for treating the tailings stream of one of the plant’s rougher flotation cells. Under each set of operating conditions, samples were taken of the HydroFloat® feed, tailings and concentrate streams, and processed to yield the grade and recovery achieved by the device. At the same time, the bubble size and bed behaviour inside the device were measured. This paper presents preliminary relationships observed between the operating conditions and the performance of the HydroFloat® cell, and thus suggests a range of possible drivers for the measured coarse particle flotation performance.

Aug 24, 2022

By K C. Corin, N Ndamase, M Tadie

Mining operations in arid regions are compelled to reduce their consumption of fresh water. Closed water circuits are an attractive solution and, in addition to reducing freshwater consumption, have the added benefit of reducing reagent consumption as well as the environmental impact by eliminating effluent discharge. Accumulating ionic species have been shown to hinder collector adsorption which reduces the recovery of valuable minerals. Numerous studies have investigated the effect of degrading water quality on collector adsorption however there is very limited understanding as to how this takes place from an electrochemical perspective. This study therefore aims to investigate how the presence of accumulating ionic species at varying concentrations affects the electrochemical adsorption of sodium ethyl xanthate onto galena. The synthetic plant water used in this study comprised of single salt solutions to isolate the effects of the ionic species of interest. The ionic strengths were varied between 0.0242 M, 0.0727 M, 0.1212 M and 0.2426 M which correspond to University of Cape Town (UCT) Centre for Minerals Research (CMR) synthetic plant waters of 1, 3, 5 and 10SPW, respectively. Mineral rest potentials indicated how changing water quality affected xanthate-mineral interactions. Microflotation observed the impact of changing water quality on mineral floatability.

Aug 24, 2022

By X Zhang, Y Zhu, P E. Ngoepe, P P. Mkhonto, W Xiong, L Han, L Lu

The triazine molecules have not been given much attention and they are potential collectors that may positively impact the mineral processing industry. The adsorption of triazine as collectors such as sodium 2,6-dithio-4-butylamino-1,3,5-triazine (SDTBAT) on pyrite form a basis in design of flotation collectors that may be applicable in a wide range of sulfide minerals. The SDTBAT collector was compared with the sodium normal butyl xanthate (SNBX) and sodium normal butyl dithiocarbamate (SNBDTC). All collectors were adsorbed in their neutral form containing sodium on the pyrite (100) surface. The computational calculations found that the adsorption energies followed the order: SDTBAT (-300.35 kJ/mol) > SNBX (-186.10 kJ/mol) > SNBDTC (-163.78 kJ/mol). It was observed that the SNBX and SNBDTC adsorbed through the S atoms, while the SDTBAT adsorbed through the S atoms and N atoms onto Fe atoms. It is clear that the SDTBAT had a strong binding energy which is attributed to the presence of the triazine group that is electron depositing to the active S atoms compared to the SNBX which possessed the oxygen that is electron withdrawing. Moreover, the SDTBAT collector was found to bind stronger than the xanthate. This was complimented by microflotation tests that showed fast floating and higher recoveries of pyrite when using the SDTBAT collector than the xanthate and DTC. This clearly demonstrated that the SDTBAT is a potential collector to replace the xanthate collector due to its high selectivity and flotation power.

Aug 24, 2022

By M S. Manono, K C. Corin

The optimisation and process developments surrounding the beneficiation of Cu-Ni-PGM ores is of fundamental importance when considering the continued rise in global demand for these precious metals. The selective sequential flotation of these ores is accompanied with various processing challenges such as the successful separation of the Cu-Ni-PGMs from non-sulfide naturally floatable gangue and pyrrhotite. Reagents such as sodium iso-butyl xanthate (SIBX) and sodium carboxymethyl cellulose (CMC) have proven to significantly improve the selectivity of the flotation process in their respective roles. The use of recycled water with abnormal inorganic electrolyte concentrations can modify the selectivity of these reagents, as ions may adsorb onto minerals such as pyrrhotite, thereby hindering or promoting the hydrophocity and floatability of pyrrhotite. Process water quality effects on the behaviour of pyrrhotite may have negative or positive influence on the recovery and grades of the wanted Cu-Ni-PGMs as valuable minerals associated with pyrrhotite such as pentlandite may be affected in like manner. Thus, the impact of concentrator process water quality on the behaviour of pyrrhotite needs to be determined. In this study synthetic process water at various ionic strengths was investigated against various CMC dosages to understand the behaviour of pyrrhotite during the flotation of a Cu-Ni-PGM Merensky ore in a batch flotation cell. This study showed that pyrrhotite grades increased with an increase in CMC dosage for fixed ionic strengths whereas the recoveries of pyrrhotite increased with an increase in ionic strength until 3SPW, then a trend of a decrease in recoveries was seen with 5SPW resulting in the lowest pyrrhotite recoveries. Furthermore, this study showed that moderate CMC dosages of 100 g/t resulted in the highest pyrrhotite recovery for all four ionic strengths of synthetic process water tested. It can be said that to maximise value recovery from Cu-Ni-PGM ores, understanding the behaviour of pyrrhotite against degrading water quality and reagent suites could be of paramount importance given the sensitivity of pyrrhotite to oxidising chemical conditions.

Aug 24, 2022

By D K. Weatherley, A N. Mainza, I Govender, L M. Tavares, M S. Powell

It is understood that rocks do not instantaneously transport along a grinding mill and are consequently not perfectly mixed, but this is conveniently overlooked in mill modelling. A lack of understanding of the transport phenomenon and the difficulty of modelling realistic transport in a complex tumbling system, contribute to this. Visual observation of segregation in AG and SAG mills and measured lag time of mill response to changes in feed provide evidence of the influence of axial transport within mills. Incorporating this lag in dynamic models should underpin dynamic simulation of milling circuits for design and for model-based control. Limitations and errors in predicting the influence of increased power via mill length versus diameter, inability to predict pebble production, and a lack of the differential in residence time across rock sizes and competences, all contribute to inadequate design prediction that can be especially acute for large Autogenous mills. Examples of dramatically under – and overloaded pebble regrind circuits and the inability to predict pebble load in AG milling discouraging the application of this energy-efficient option, point to the need for predictive modelling of breakage by competence linked to transport through and out of mills. Incorporating progress in granular flow and mixing, coupled to computational advances enable models to be based on complex breakage and transport models at high spatial resolution. This allows mechanistic models to simulate thousands of times faster than real time, opening the door to more accurate mill design, including dynamics in process simulation and to live simulation for process control – all with advanced mechanistic models. The value of grasping this opportunity is not easily refuted.

Aug 24, 2022

By M Hilden, G Forbes, Z Ye, M Yahyaei, F Reyes, V Jokovic

Soft sensors offer several practical advantages for the process control of comminution circuits by combining multiple conventional sensors and other data sources with real-time analysis using mechanistic, phenomenological or machine learning models. While there has been a growth in the use of machine learning techniques for developing soft sensors in minerals processing applications, this paper describes advantages and challenges of using soft sensor models developed on the basis of process knowledge. Recent experience with three new soft sensor technologies developed by the authors are discussed. The Mill Filling Inference Tool which has been implemented at several mine sites, compares SAG mill load cell and power draw measurements with outputs of a semi-mechanistic power model to estimate the mill ball and total filling in real time. The progressive wear of the mill liners is modelled, allowing the model to correct the load mass due to the mass loss automatically and to estimate the charge trajectory. This information enables the mill to be operated more confidently near its limits. A coarse-ore stockpile soft sensor as been recently developed using a 3D cellular automata-based model to track ore size throughout the pile, and estimating the live capacity and size at each stockpile feeder to the primary mills. Finally, a hydrocyclone soft sensor is being developed to monitor performance using available hydrocyclone models to estimate the size and flow balance around the cyclone in real time. The model-based soft-sensor approach aims to synthesise and analyse existing data and provide operators and engineers with process- and model-relevant information that can facilitate making better process decisions. Maintenance data has proven useful for model development as it allows soft sensors to automatically adjust and compensate for the effect of progressive wear, for example for mill liners, thus helping the models to maintain calibration throughout the equipment life.

Aug 24, 2022

By Z Gao, D Liao, W Sun, S G. Pooley, J Wang, Z Shi, G Jing, S Ren, Q Chen

Yuanjing processing plant is a scheelite and wolframite plant in southern China. Water shortages and recent environmental regulations mean that the plant must reuse the wastewater that comes from the mining operation. This paper describes the efforts to reuse the mining and ore washing wastewater (MOW) in the processing plant. Initial attempts to reuse the MOW in the strong magnetic separation were unsuccessful because the magnetic media pack was seriously fouled by the micro-fine precipitate generated. The focus changed to reuse the MOW in the scheelite flotation circuit, which includes one roughing, one cleaning and three scavenging steps. Laboratory batch tests showed this would likely be successful because using MOW reliably improved the flotation performance in the laboratory tests. Then a 20 day industrial trial was run in the plant. The trial was very successful with the enrichment ratio of WO3 increasing from 17.4 to 23.6, while the recovery remained around 79.2 per cent. The industrial trial was so successful the company immediately adopted the new scheme, which has remained in use ever since. This technical solution not only alleviated serious water shortages, and satisfied environmental regulations but also improved the plant performance.

Aug 24, 2022

By H Ishikawa, S Palaniandy

The gravity-induced stirred mill such as the TowerMill is an energy-efficient grinding solution used in secondary, tertiary, and regrinding duties in the mineral processing concentrator. The interest in this technology is emerging, with more than 300 mills installed globally in various grinding duties and commodities for the last 30 years. Although the technology is matured, there are still opportunities for improvement and the development of new knowledge to improve its circuit energy efficiency and reduce water consumption. Recent studies show that a combination of stress intensity, ore hardness, slurry density, and mill feed configuration can be used to evaluate the performance of the grinding circuit. A recent pilot-scale TowerMill test work at various stress intensities shows that a lower operating work index and size-specific energy were achieved at higher agitator tip speed and using medium size grinding media. These outcomes were confirmed through several site trials. A smaller 17 mm grinding media has reduced the operating work index and size-specific energy by 18 per cent and 11 per cent, respectively, compared to the 20 mm in a magnetite concentrator. Moreover, the conversion from top feed to bottom feed configuration has reduced the operating work index and size-specific energy by 13 per cent and 37 per cent, respectively. The circulating load was reduced by 34–38 per cent, leading to a reduction in the dilution water consumption in the hydrocyclone feed sump by 20 per cent. A variable frequency drive offers flexibility to change the stress intensities on the TowerMill, where a 35 per cent reduction in specific energy was achieved when the ore became soft. This paper explores the potential design and operating strategies that can be implemented to enhance the energy efficiency, reduce water consumption and reduce CO2 emissions in the circuit and finally evaluate its impact on the total cost of ownership.

Aug 24, 2022

By R Schmitt, Y Ghorbani, I McElroy, N J. Bolin, M Parian

Aitik is a large copper porphyry type deposit located in northern Sweden, currently exploited at an annual rate of approximately 45 Mt. The ore’s exceptionally low head grade of 0.25 per cent Cu and varying degrees of hardness across the entire deposit pose challenges to the two fully autogenous grinding lines, each of which comprises a primary autogenous mill in series with a pebble mill. The variability in ore grindability frequently leads to fluctuations in mill throughput. Within the framework of a geometallurgical approach, the present study investigated the relationships between ore grindability and modal mineralogy. For this purpose, drill core samples from different lithologies were subjected to Boliden AB’s in-house grindability tests. This fully autogenous laboratory-scale test generates a grindability index mainly related to abrasion breakage, which is a significant breakage mechanism within autogenous mills. The test results suggested divergent degrees of grindability within and across the selected rock types. A combination of scanning electron microscopy, X-ray powder diffraction, and X-ray fluorescence analyses was performed for the grinding products and bulk mineral samples. The resulting mineralogical and elemental properties were subsequently correlated to the parameters from the grindability tests. It was shown that the main mineral phases, such as plagioclase, quartz, and micas, correlate well with the grindability indices. Similar correlations were found regarding the sample’s chemical composition, attributable to the main mineral phases. A further inverse correlation was established between the sample’s calculated average Mohs hardness and the grindability indices. Moreover, mineral liberation information provided by scanning electron microscopy was associated with the parameters mentioned earlier. The identified relationships between grindability, modal mineralogy, and element grades may help Boliden develop a predictive throughput model for Aitik based on the mine’s block model.

Aug 24, 2022

By D Felipe, G J. Harbort

In the past 40 years substantial changes have occurred in flotation machines. This has included increases in mechanical cell size to 630 m3 , significant changes to flotation column aeration design and widespread use of the Jameson cell and other pneumatic flotation cells. Over the corresponding period there has been increased used of machine characterisation measurements to benchmark and optimise flotation circuit performance. JKTech maintains a database of industrial flotation machine characterisation measurements. The database contains over 4000 entries and includes gas dispersion measurements, such as bubble size, gas hold-up and superficial gas velocity, cell dimensions and impeller tip speeds. Data comes from numerous operating sites and commodity groups, including gold, copper, molybdenum, nickel, palladium, lead-zinc, platinum, silica, phosphate, coal and iron ore. Flotation duties registered include flash flotation, preflotation, roughing, scavenging and cleaner circuits. Measurements have been conducted on a wide range of flotation machines from different manufacturers. This includes forced air machines, such as Outotec and Dorr Oliver, and self-aerated machines, such as Denver and Wemco. The database also includes substantial flotation column entries, such as the Microcel, Eriez/CMT Slamjet and Jameson cell. This paper describes the flotation machine characterisation database and discusses the variation between different types of industrial flotation machines, in operating production circuits.

Aug 24, 2022

By S Nkwanyana, I Govender

Batch experiments in a 0.6 m diameter mill have shown that improvements of about 13 per cent in the efficiency of energy utilisation can be realised in ball mills by replacing 25 per cent of the ball charge by an equivalent volume of cost-free critical size pebbles from AG/SAG mills. For a mill of a given size, speed and charge filling, the rate of size reduction of ore particles depends on (i) the frequency of grinding media collisions (ii) the probability of capture of ore particles between the colliding grinding media (iii) the probability of fracture of the captured particles. The probability of fracture depends on the magnitude of collision energy. The distribution of collision energy into shear and impact events determines the relative strengths of attrition breakage and impact breakage. The efficiency of energy utilisation depends on which of the two mechanisms of breakage is more desirable in a particular milling stage. In this paper collision data from a series of DEM simulations of a mill charged with steel media and a mixture of steel media and pebbles is presented in energy spectra and spatial distribution maps. The data provides the necessary detail to elucidate the improvements in the efficiency of energy utilisation in ball mills when using a mixture of pebbles and steel media.

Aug 24, 2022

By J Harding, S Munro, R A. Bearman

Despite the importance of the primary crushing stage, performance optimisation is not well analysed with sufficient focus to give improvement opportunities. At the Newcrest owned Telfer operation, liner life plays an important part in scheduling planned maintenance. Major consideration is given to monitoring crusher performance, as the highly abrasive nature of the feed significantly impacts the liner wear life. A study was undertaken by the lead author which focused on establishing a strong baseline of accurate data pertaining to the performance of the crusher, in terms of, operating parameters, liner life and key machine design factors. As part of the study, mining feed materials were examined for a particular set of liners and this revealed that improved methods should be pursued. Due to the competitive nature of the mining industry, the business solution to complex problems with long shutdown cycles should be streamlined to incorporate a non-operational modelling approach that is significantly more efficient than traditional online trial and error methods. In order to dramatically reduce the time and business risks, it was decided to engage services to model and simulate the liner life by varying main operational and mechanical factors. The key to all simulation work is gathering high quality baseline data. Such data allowed deployment of the Kinematic Crusher Model and validation of the model against worn 2D wear liner profiles. The proven model was then successfully deployed to predict operational values that defined crusher performance. To enhance the study, further investigation into a set of mechanical and operational simulations generated a sensitivity matrix measuring key performance parameters throughout the wear life of the liners. The study revealed throughput as a highly sensitive parameter and a change in eccentric throw provided the greatest improvement in extending liner wear life.

Aug 24, 2022

By L Dzinza, K C. Corin, M Tadie

The recycling of process water comes with increased electrolyte concentrations that affect water quality, which may in turn affect the flotation performance of valuable minerals (Hirajima et al, 2016). Electrolytes such as Ca2+, SO4 2- , Mg2+ and S2O3 2- have been surmised to have an impact on the action of flotation reagents such as collectors (Ikumapayi et al, 2012). Xanthate collectors are known to play a significant role in imparting hydrophobicity on mineral surfaces to enhance their flotation. The interaction between minerals and xanthates is well known to be electrochemical in nature. Such redox processes may be elucidated by electrochemical techniques. Since the mechanisms involving the interactions between electrolytes in process water with sulfide minerals and the subsequent adsorption kinetics of collectors are not well understood, this study therefore aims to provide fundamental knowledge to unpack the mechanisms involved when electrolytes interact with Platinum Group Minerals (PGMs) and how these interactions may affect xanthate adsorption. The interaction of sodium iso-butyl xanthate (SIBX) in the presence of electrolytes at increasing ionic strength was investigated by rest potential measurements, to explain the impact of electrolytes on the adsorption of SIBX on PGMs in the flotation process. Rest potential measurements for PdTe2 and PdS were conducted in an air saturated 0.05 M di-sodium tetraborate decahydrate solution, in the absence and presence of SIBX and electrolytes. It was found that the existence of sulfide and telluride on palladium affects the mechanisms in which electrolytes interact with Pd mineral surfaces. An increase in the ionic strength of Na2S2O3, CaCl2 and MgCl2, increased the interaction between the salts and PdS, thus decreasing the extent to which SIBX interacted with PdS. An increase in ionic strength for Na2S2O3 increased the interaction between Na2S2O3 and PdTe2 and therefore decreased the extent to which SIBX interacted with PdTe2. Other salts investigated in this study increased the rate of oxidation of PdTe2 with an increase in ionic strength thereby enhancing the interaction of SIBX and PdTe2. This study has shown that mineral type, electrolyte type and concentration all have an impact on the mechanisms that result in the adsorption of SIBX on PGMs.

Aug 24, 2022

By T Suwa, S Ishida, J Xue, S Fuchida, H Shimada, Y Aoki, C Tokoro

Pyrite depression with prolonged pre-conditioning treatment in high salinity water has attracted much of researchers’ interest in recent years considering the increased utilisation of multiple stage flotation, closed water circuits, clay minerals, and sea water in flotation plants. In this study, the role of calcium (Ca)/magnesium (Mg) precipitates in stabilising the dissociative ferric hydroxy-xanthate (FHX), and its effect on modifying the balance of hydrophobic/hydrophilic species on the pyrite surface were primarily investigated. The total amount of extractable Fe-bearing species on pyrite concentrates and tailings after floatability test was quantitively determined using ethylenediaminetetraacetic acid (EDTA) extraction tests combined with inductively coupled plasma optical emission spectroscopy (ICP-OES). A more evident accumulation of extracted-Fe in pyrite concentrates rather than it in pyrite tailings was observed at both pH 9 and 10.5 when pyrite was pre-conditioned in Ca/Mg-bearing solutions for 360 min. Fourier transform infrared (FTIR) spectroscopy showed the main xanthate derivatives changed from di-xanthogen (1155 cm-1 ) to FHX (1167 cm-1 ) on the oxidised pyrite samples that were preconditioned in Ca/Mg-bearing solutions. Scanning electron microscopy-energy dispersive spectrometry (SEM-EDS) suggested the preferential accumulation of FHX upon secondary Ca/Mg-bearing precipitates as reflected by the higher Fe/S ratio together with the decrease of O element herein after xanthate conditioning. Although the hydrophilic secondary Ca/Mg/Fe-bearing minerals on the pyrite surface generally deteriorate pyrite’s floatability, the upper section of these secondary hydrophilic aggregates is partially covered by FHX alongside with further multilayer-adsorbed di-xanthogen. The precipitated Ca/Mg-bearing precipitates promotes the immobilisation of dissociated FHX derived from the reaction among iron oxyhydroxides and xanthate anions upon the localised secondary Ca/Mg/Fe-bearing minerals via acid–base complexation. Therefore, this phenomenon alleviates the hydrophilic modification of secondary Ca/Mg/Fe-bearing minerals to pyrite considering the immobilised FHX upon localised precipitates shows a slight hydrophobicity, and meanwhile, the upper FHX benefits the multilayer adsorption of di-xanthogen via the interaction among their inner hydrophobic alkyl chains.

Aug 24, 2022

By N Clarke, A Barros

Preconcentration of run-of-mine subgrade and marginal ore by screening has the potential to substantially improve the economics of mining, particularly for large, low-grade orebodies, and to reduce environmental impacts. It has recently been the subject of a major research effort by a joint public-private research body, CRCORE. Yet despite this, there appears to have been only one fully commercial installation, at Bougainville Copper Limited in the late 1980s. Two reasons for the limited application are that not all ores have suitable properties and the economics of all pre-concentration processes on low-grade materials are highly sensitive to the precise balance of mass and value recovery and to the pre-concentration process cost, including materials handling. These factors make it imperative to have good test data on the process response of feedstock across the orebody. Collecting that data presents major challenges, which differ for green and brownfields operations. This paper first discusses the approach to preliminary evaluation developed by CRCORE, which relies on testing of coarse rejects or drill chips available from exploration drilling programs. This method is an efficient first step in evaluating an orebody which is deemed geologically to be potentially amenable to screen upgrading, but it does have limitations and must be followed by larger scale work. A suite of methods have been developed by the authors as a result of test work since the 1990s on several projects, supplemented by published data, which aim to provide statistically robust data at lower cost than large scale bulk sampling tests. For greenfields projects, the upgrade response measured on material crushed to -53 mm has been found to correlate closely with ROM ore, with no scale-up required for material with upgrade responses in the range of commercial interest. Large diameter whole drill core, such as PQ, is expected to be suitable for this method. As drilling such core is costly, the aim should be to establish relationships between upgrade performance and proxy measurements such as multi-element chemical or hyperspectral analyses. This approach was successful at the Gramalote gold project in Colombia. The method is not applicable for ores with thick vein material comparable with the crush size, but such material is not suitable for upgrading by screening and would be eliminated by the preliminary testing. For brownfields projects where blasted material can be sampled, the upgrade response can be accurately measured by sampling only the finer fraction of the ore, selecting a top size which represents 30–50 per cent or more of the ROM size distribution. This is likely to be between 50 and 100 mm. The much finer size compared with the full ROM ore greatly reduces the sample mass required to achieve a given intrinsic sampling error and enables sample preparation to be undertaken with large-scale laboratory equipment rather than mobile crushing plant. The accuracy of the method can be improved by measuring the approximate mass of oversize rejected during sampling. Some ores do show a systematic deviation from the assumed model fit which results in this method slightly underestimating the upgrade response, and it would therefore still be recommended to take one or two full bulk samples to confirm results before a final investment decision.

Aug 24, 2022

By J M. Menacho, L Zhang, A Hoadley, L Verdugo, B Etschmann, W Bruckard

Since the introduction of Lithium-Ion Batteries (LIBs) in 1991, the market for lithium-ion cells has been driven by the high demand for portable electronic devices and more recently for batteries for the electric car industry. It is expected to grow rapidly to reach 2600 GWh globally by 2030 (US Government, Office of Energy Efficiency and Renewable Energy, 2021). However, there is a desperate need to recycle LIBs to recover valuable cathode materials and graphite. For this reason, several physical and chemical recycling technologies have been proposed to recover these materials from spent batteries. Amongst these, froth flotation technology is a potential cost-effective technology for separation of the graphite fraction from the lithium oxide components due to the natural hydrophobicity of graphite and density difference between graphite and cathode materials (Folayan et al, 2021).

Aug 24, 2022

By D K. Weatherley, G R. Ballantyne, S Ali, M Yahyaei, M S. Powell

This paper explores development of a novel ore characterisation method for the precise measurement of practical minimum comminution energy. A monolayer of particles with a narrow size distribution is broken using a precision rolls crusher (PRC); an ore characterisation device developed to overcome the shortcomings of conventional tests. For energy measurement, PRC uses two shaftmounted rotary torque transducers. These transducers acquire precise torque and angular speed data in response to the load applied to the rotating shafts during breakage events, which is converted into energy. The test progressively crushes feed particles down to final product size in many controlled breakage stages. The generation of fines in each breakage stage is then plotted as a function of input energy. The inverse of the gradient of this plot provides the size specific energy (SSE) in kWh/t of material generated below a predefined marker size; -75 μm in this case. The PRC has potential to evolve as a geometallurgical ore characterisation test—it is simple, fast, requires small sample mass (200–300 g), covers a wide feed particle size range (10 mm to 115 µm), and provides ideal SSE measurements that can be used for the calibration of on-site production equipment.

Aug 24, 2022