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By Jingzhong Kuang, Zheyu Huang, Chuanzhou Guo, Pengfei Liu

"In this paper, scheelite and scheelite coated with Pb2+ (SC) were synthesized by chemical precipitation with the help of ultrasonic. The role of the Pb2+ on scheelite was evaluated. Additionally, the dissolution behavior of minerals and the adsorption mechanism of collectors were investigated systematically via SEM, XRD, EDS. The results indicate that the ultrasonic cavitation can promote the formation of scheelite with large particle size and high crystallinity. Due to the exchange of WO4 2- and OH-, the dissolution of scheelite are not in a 1:1 equivalent amount by chemical formula and the concentration of WO4 2- is higher than that of Ca2+ in the solution because Pb2+ promotes the transfer of WO4 2- from scheelite surface into the solution. The dissolution of scheelite is an endothermic reaction and its enthalpy reaches the maximum value of 692.59J·mol-1 at pH=8~10. But the coating of Pb2+ changes the thermal effect of scheelite in the solution and the dissolution of SC is an exothermic reaction with the dissolution enthalpy of -262.30 J·mol-1. At pH=8~10, the adsorption capacity of sodium oleate and salicylhydroxamic acid on the surface of SC is higher than that of scheelite which delivers that Pb2+ contributes to the scheelite surface dissolution and enhances the adsorption of collectors on the mineral surface, thus achieving activation.INTRODUCTIONIn modern society, tungsten is a type of quite important rare metal and also a strategic resource. Because of its low vapor pressure, high melting point, good electrical and thermal conductivity properties, it is widely applied in high-temperature technology, lighting, machine and engine construction (Zhao,Z.W, 2013; Yan, W, 2017; Ilhan, S, 2013). Both scheelite and wolframite are the major tungsten deposits. With the depletion of easily-processed wolframite, scheelite has drawn a great deal of scientific and industrial attention. Scheelite can be recovered by flotation due to the metathesis of polarity and chargeability on minerals surface via adding regulators and collectors."

Jan 1, 2018

By S. Banisi

Thickening is the most widely applied dewatering technique in mineral processing. Thickeners are used to increase the concentration of suspension by sedimentation, accompanied by the formation of a clear liquid. As the particles get finer the thickening process encounters difficulty due to a significant change in the settling behaviour of particles. The batch settling tests of coal refuse of a coal washing plant which contained 91% particles smaller than 38µm and 0.6% coarser than 75 µm showed that the optimum feed percent solids that provided highest flux (solids handling capacity) was 4%. The flux of the pulp with the plant solids concentration (i.e., 10%) was 60% lower than that of the pulp with 4% solids. A thickener with a diameter of 22m based on the dilution of feed from solids concentration of 10% to 4% was designed. Monitoring of the thickener performance for a period of one month in the plant indicated that on average the feedrate of 25t/h (dry solids) with solids concentration of 10% could be thickened to the underflow concentration of 26.5% with a clear water overflow. It was found that the key component of the successful operation of the thickener is the dilution of the feed without which the overflow loses its clarity and the system ceases to operate under predetermined conditions. Specially designed feeding system which efficiently dissipated the energy of the incoming flow and staged flocculant addition regime are among the main contributing factors in making the design and operation of such thickener possible.

Jan 1, 2014

By Montaser S. EL Salmawy, Takahide Wakamatsu, Eishi Kusaka

"In conventional flotation, fluoride ions selectively would react with the aluminum site on the microcline surface and produce negative charged sites for amine to be adsorbed (Smith, 1976). According to this view, aluminum site is considered as a key feature in feldspar flotation. Generally, fluoride ion has been widely used as a modifying agent in silicate flotation. Since O'Meara's patent appeared on HF -amine reagent system to selectively float feldspar from quartz in 1942, relatively few contributions have been devoted in this issue. The reason might be that the process works very well, and accordingly there is no initiative to investigate in this area. However, due to the awareness of international community to restrict using of hazardous reagents like HF, sound engineering practice to search for alternative methods, not utilizing HF, has been launched. Inspection of literature, one can find several works dealing with this issue.In this contribution, the effect of ethoxylation of long chain alcohols on the quartz and feldspar flotation behaviors was investigated for surfactants of the octylphenol polyoxyethylene family. The tests were carried out with an average of 7.5 (Triton X 114), 9.5 (Triton X 100), 30 (Triton X305), 40 (Triton X 405) and 70 (TritonX 705) oxyethylene units. Electrokinetic and flotation studies on quartz have shown that at low pH values, quartz could be floated with polyoxyethylene octytlphenols. The possible mode of adsorption of these nonionic surfactants may be suggested to be due to hydrogen bonding between the oxygen of ether and hydrogen in the free hydroxyl groups on quartz surface. It was anticipated that the selectivity between quartz and microcline would decrease as oxyethylenic chain length increases."

Jan 1, 2003

By Volker Vogt, Wolfgang Sand, Eberhard Gock

"For about 20 years, the use of bacteria to control the flotation process for the production of raw material concentrates has been the subject of worldwide scientific and engineering efforts. The objective is to reduce the consumption of biologically non-degradable toxic reagents. The principle idea is to use the activity of bacteria in natural leaching processes – known since the middle of the last century – for controlling flotation processes.It was discovered that the selective activity of bacteria during the extraction of raw material concentrates by means of flotation could also be achieved with extracellular polymeric substances (EPS), excreted by bacteria. EPS, which is extracted by means of centrifuging bacterial cultures, can help to significantly reduce the use of cyanides, approximately 200,000 t/a are used for ore dressing today.The bacterium used was Acidithiobacillus ferrooxidans. In order to identify the bandwidth of the oxidation activity, 21 bacterial strains of the strain collection of the University of Hamburg were attracted to iron(II) sulfate and pyrite under defined conditions. All strains oxidized iron(II) sulfate ten times faster than pyrite.EPS has so far been derived from four strains. In general, EPS extracts are divided into a hydrophilic and a hydrophobic fraction. The hydrophilic fraction is composed of e.g. fucose, rhamnose and glucose; fatty acids such as dodecanoic acid, hexadecanoic acid, octadecanoic acid and nonadecanoic acid were found in the hydrophobic fraction. Pure mineral phases and mineral mixtures were used for the flotation tests. The outcome was reproducible results with technical flotation machines. The research results known so far are mainly based on investigations with micro flotation devices, which are usually used for the characterization of reagents and which do not allow a direct translation to the technical scale."

Jan 1, 2003

The addition of copper sulfate to mineral slurries in order to ?activate? sulfide mineral surfaces for enhanced collector molecule adsorption, and hence enhanced recovery via flotation, is a com-mon mineral processing practice. It has been established in a laboratory situation that the addition of CuSO4 in conjunction with xanthate collector increases the flotation rate of pentlandite as compared to the addition of collector alone. However, it remains unclear whether the addition of CuSO4has a similar effect within mineral processing circuits. We examine here the effect of pre-activation oxidation on the copper activation of pentlandite and monoclinic and hexagonal pyrrhotite. All activation experiments were carried out at pH 9 using a total solution content of copper ions equivalent to one monolayer (0.210 -4 moles, 110-4M). Copper loss from solution was extremely rapid in all cases with less than 10 % remaining after 10s. EDTA extraction and solution analysis clearly demonstrated that copper activation was via direct surface adsorption and not an ion exchange process, as is the case for sphalerite, and that most copper on the surfaces is in the form of Cu(I). ToF-SIMS analyses of the mineral surfaces subsequent to copper activation show increased surface oxidation on increased conditioning time prior to copper activation. However, there is a significant decrease in surface oxidation on comparison of samples that have otherwise been prepared in the same manner but where one has been exposed to copper solution rather than water. This suggests that copper activation stabilises the surface and reduces the propensity for oxidation. Regardless of the length of pre-activation oxidation time only Fe(III) (no Fe(II)-S) was observed by XPS analysis, indicating a highly oxidised surface layer dominated by Fe-O-OH species. The presence of Cu(II) on the mineral surface is indicative of the formation of Cu(II)-containing precipitates and indicates non-mineral specific activation resulting in increased recovery but lower grade. Mineral specific copper adsorption, as evidenced by the presence of Cu(I), is required to improve both grade and recovery. Prolonged oxidation prior to copper activation causes a reduction in the Cu(I) to Cu(II) ratio on the mineral surfaces as compared to either fresh surfaces or surfaces oxidised for 1 minute only. This strongly indicates that the copper activation process is less effective on highly oxidised surfaces.

Jan 1, 2014

By A. K. Majumder

In an effort to test the extent to which fundamental fluid mechanics can provide a prediction of particle separation, a study on a simple parallel-sided sluice has been carried out using glass bead and ilmenite mixtures at various particle concentrations and flow rates. Great care was taken to devise a flow splitter at the end of the sluice that permitted accurate measurement of the fluid flow profile and collection of slurry samples, allowing evaluation of the particle species concentration profiles. The actual particle separation taking place was compared to predictions made by first describing the fluid flow by a modified ?law of the wall? model. The hydrostatic pressure variation in the flow was taken into account and the eddy viscosity was calculated from a mixing length expression incorporating Van Driest?s damping function. Using an average density and viscosity provides an explicit expression for the velocity gradient that can be numerically integrated for the flow profile. The particle concentration distributions were then modelled with Hunt?s sediment transport model assuming the particle eddy diffusion coefficient to be the same as that for the water. Hindered settling velocities of the particles were calculated using Brauer and Thiele?s formula, which takes the particle size and density distributions and solids volumetric concentration into account. The resulting predictions of particle separation are shown to be a strong function of the settling velocities of the particles used. Keywords: flowing film concentrators, fluid velocity

Sep 1, 2012

By Sravya Kosaraju, Christian Ekberg, Stefan Allard

Li-ion batteries are now used in electric vehicles (EVs), plug-in hybrid vehicles (PHEVs) and, hybrid electric vehicles (HEVs). Nanostructured Li(NiyMnzCo1-y-z)O2 is one of the more popular cathode chemistries for automotive Li-ion battery, due to its enhanced properties such as large surface area, short diffusion length, enhanced ionic and electronic conductivity, improved mechanical strength and structural integrity [Pan et al, 2013]. Recycling of Li-ion batteries helps to mitigate environmental effects of virgin metal extractions along with improper disposal of end of life batteries. To fulfill these objectives of the recycling, recovery of pure streams of the involved metals should be considered. In this study, the batteries were first discharged and dismantled in an inert atmosphere (Ar). The electrodes were then heat treated in a box furnace. This was done in order to break the chains of the adhesive (PVDF) and consequently separate the metallic substrates Cu and Al from the electrochemically active compound. This heat-treatment also helped to simplify the dissolution of the metal constituents in the electrochemically active compound from the cathode in the acid leaching process. Solvent extraction was chosen to achieve separation and recovery of metals with higher purity from these leachates. In the scope of the present work, a complete process from the point of dismantling to separation of constituent metals using solvent extraction was studied.

Jan 1, 2014

By Andrew Logan

Newcrest has a strong history of growth over the past 20 years, yielding value from previously marginal ore bodies. We have grown regionally in Asia Pacific through our operations in Australia, Indonesia and Papua New Guinea, and also established a beachhead in West Africa. The company has a reputation of realizing value from large, low-grade deposits adopting step change approaches. Newcrest is focused on an overall strategy of gold, low cost, long life and moderate growth. Capability step changes play a large delivery role. They transition from a business offline-to-online approach as opportunities mature. Newcrest believes in a) Knowing what ?good? looks like, b) An open innovation approach to actively working with others, c) The leap frogging leverage of making the ?old new again?, d)An adopt-adapt-develop methodology enabled by rapid prototyping/piloting, e) Getting our handsdirty with test work and plant analysis, and f) Staying focused on a few high business leverage areas. This paper describes Newcrest?s approach and our experiences in establishing renewed metallurgical processes, specifically aimed at increasing innovation adoption. Some of our step changes discussed include: 1) Early waste rejection to avoid high energy processing downstream, 2) Broader gold product channels to reduce site based processing needs, 3) Lower energy processing, and 4) Geo-Metallurgy approaches. Keywords: Newcrest, gold, step change, open innovation, adopt, adapt, develop, offline, online, prototyping, old new again, waste rejection, low energy, geo-metallurgy

Sep 1, 2012

By M. Saghaeian, R. Hejazi, A. Dehghani Ahmadabadi, M. Zare

"In the most iron ore beneficiation plants, reverse flotation is the best method for removing silicate gangues from final iron ore concentrate. Many previous studies show, if the major portion of impurities include quartz minerals, the flotation process is simple, but if iron silicates are dominant, reverse flotation is so complicated and mostly not very effective. In this study which was performed on the Sangan iron ore concentrate, the performance using of reverse flotation and magnetic flotation separator for elimination of silicate gangues from the magnetic iron concentrate was investigated. The operational parameters for reverse flotation are considered as: collector and frother types and dosages and also modifiers. But for magnetic flotation separator parameters were magnetic field intensity as well as overflow and underflow water rates. Results showed that reverse flotation has not a significant effect on the elimination of impurities. Because of the silicate gangues of Sangan concentrate including a mixture of quartz and iron silicates (amphibole, pyroxene and feldspar), so downgrading of the SiO2 content for the flotation concentrate was rather low and only average reduces of 20.60% were possible. But the findings of using magnetic separator was more satisfactory. Results of the weight recovery, iron grade and also SiO2 and S grades of final concentrate were better with magnetic flotation device. So at the best and optimum condition, we could reduce 51.01% of the total silicate (SiO2~ 2.19%) along with 74.66% of sulfur content (S~ 0.076%) and concentrate weight and Fe recoveries of 92.04% and 94.51% respectively, final Fe grade of 68.73%.INTRODUCTION Chemical/traditional flotation is one of the most effective methods for separating valuable particles from waste minerals, which is used in most mineral processing industries. In the iron ore processing industry, the major impurities present in iron ore concentrate include sulfur, silica and phosphorus (Bruckard et al, 2015), which are often carried out by reverse flotation methods for the removal of sulfide and oxide impurities (Donald, 1967: Araujo et al., 2005: Ma, 2012)"

Jan 1, 2018

By J. Z. Yuan

The purity of rectorite is only about 70% after preliminary mineral processing, which has limited its application. In this research, different pulp densities, different dispersants, different dispersing methods and purification flow sheets were used to purify rectorite. The results show that it is possible to obtain high pure rectorite clay with the purity above 90% and concentrate yield between 24.9% and 29.4% by the purification process with composite dispersants, stirred mill grinding dispersion and so on. The obtained high pure rectorite can be further used in rectorite nanocomposites.

Jan 1, 2014

By David Morrow

Fly ash is a by-product from coal-fired power stations that is captured from the exhaust gas stream by electrostatic precipitators (ESPs) or bag houses. It is mainly derived from the inorganic components in coal but also contains residual carbon from unburnt fuel (measured as LOI). In the past, nearly all fly ash was sent to landfills or tailings ponds by power generators but this trend is quickly changing due to landfill costs, sustainability requirements and the inherent value in correctly processed fly ash. The main property that makes fly ash suitable for recycling is its use as a pozzolan. Pozzolans exhibit cementitious properties that make them suitable for partial cement replacement, and that can have beneficial properties for concrete mix designs. Fly ash can be used to replace up to a third of the of the Ordinary Portland Cement (OPC) requirement. Suitable fly ash nearly always requires the removal of the less reactive coarser fraction from the finer fraction. Due to the pozzolanic nature of fly ash, it must be processed dry and separation is normally required at 45 micron. In response to the increasing demand from a range of dry classification applications, Metso purchased an established air classification technology suitable for both mining and construction applications. The classifiers intelligent design efficiently utilizes the air flow which keeps power requirements low whilst including a scrubbing/recirculating function within the classifier that allows extremely efficient separations even at very fine sizes. This technology is of global interest to Fly Ash processors, but should be of particular interest in India which is both the second largest cement producer in the world as well as producing 80% of its power from thermal sources. This paper is intended to give a brief overview of fly ash and requirements for use as a pozzolan, air classification of fly ash and a case study from an established and experienced fly ash producer. Keywords: air classifier, fly ash, pozzolan, fineness, cement, cholla, salt river materials group

Sep 1, 2012

By I. Yelkin, Erico Tabosa, Alex Jankovic, R. Hayashida, R. Faveere

"The mining industry faces growing challenges from more complex and lower grade deposits, rising costs, limited energy and water availability, and increasing societal pressure to operate more sustainably. Mining operations need to be more efficient, not just to reduce environmental impact, but also to remain economically viable.To maximize profitability and sustainability, existing operations and new projects must consider integration and optimization of all stages of production. A mining operation is essentially a series of inter-connected processes, with the performance and outputs of each stage affecting the subsequent ones. Optimizing stages in isolation can result in sub-optimal overall performance.The industry has long recognized the benefits of holistic optimization using the Mine-to-Mill concept, and there are many well documented successes. However, it is increasingly common to observe operations simply increasing explosive consumption in the mine and expecting optimization of the entire value chain (mining and processing). For true holistic optimization, blast intensity is not necessarily increased, but rather adjusted to best suit the requirements of the different types of ores treated, the circuit configuration and equipment, installed comminution power and the downstream beneficiation processes. It is a fully integrated effort with optimization of many aspects in the mine, comminution and separation processes.To be successful, optimization of the production chain from mine to process requires a site-specific, structured methodology supported by extensive ore characterization, auditing, surveys, data analysis, mathematical modelling simulations and a cost / benefit analysis. Following this methodology, optimization strategies are rapidly identified and implemented considering mine and plant constraints. Management needs to set up appropriate KPIs and site personnel need to be trained for the new operating strategies to be successfully incorporated into site practices and procedures in the production environment. This will ensure the benefits are achieved and maintained. This paper describes the methodology employed by Hatch to improve overall efficiency and profitability from mine to process. Two case study examples at Russian gold operations and benefits achieved are presented."

Jan 1, 2018

By Xiqing Wu, Tao Yue

"Magnetic seeding co-agglomeration, i.e. adding magnetic seeds, organic depressant (such as the starch), and pre-magnetization for co-agglomeration, was applied in the reverse flotation for hematite ore slimes. Samples of the hematite ore slimes and the pure hematite fines were investigated by the co-agglomeration, respectively. Flotation tests suggest that the depressing effect of starch in the flotation was further enhanced with the addition of magnetic seeds and the pre-magnetization. Following the laser size analysis and flotation tests, TOC adsorption analysis, VSM, surface charge measurement, AFM, FTIR study, and SEM imaging have been utilized to understand the depressing mechanism. Based on the results it was demonstrated that with the addition of magnetic seeds and the low field pre-magnetization, the adsorption of starch onto hematite minerals was strengthened through the magnetic seeding co-agglomeration. The co-agglomeration improved the flotation performance by introducing the magnetic interactions and acting the bridging adsorption of starch between fine hematite and magnetic seeds in a suspension, and then resulting in an intensified coverage of the starch onto hematite particles and positive action in the coagglomeration under the pre-magnetization.INTRODUCTIONFlotation is undoubtedly the most important and versatile mineral processing technique, and both its use and application are continually being expanded to treat greater tonnages and to cover new area. However, its influence was limited to a relatively narrow particle size range of 5–300 µm (Wills and Napier-Munn, 2006). The main reason behind this limitation lies in that fine particles have high specific surface area, so need relatively high dosage of reagents (collectors or depressants), and exhibit poor flotation performance while intermediate or properly-sized particles produce high flotation kinetics and need low consumption of reagents. In order to increase the recovery of fine particles, quite a few of flotation techniques have been investigated. Most of them are based on particle aggregation, namely, by enlarging the apparent particle size, such as carrier flotation (Valderrama and Rubio, 1998; Zhu et al., 2009), shear flocculation (Duzyola and Ozkan, 2010; Yin et al., 2011), selective polymer flocculation (Rubio et al., 2007; Song et al., 2012; Ng et al., 2015), oil agglomeration (Laskowski and Lopez- Vladivieso, 2004; Forbes, 2011), temperature responsive polymer flocculation flotation (Forbes et al, 2011), and etc. However, these techniques above-mentioned are mainly studied for the direct flotation of fine minerals, and most of these techniques have not found applications for iron ore slimes especially recovered by the reverse cationic or anionic flotation."

Jan 1, 2018

Reverse flotation process tests were conducted for marine sedimentary silicon-calcium phosphate ore in this research. The research findings showed that by adding antifoamer, a concentrate with P2O5 32.36%, SiO2 10.69%, MgO 0.67% was obtained, with recovery of P2O5 being 88.12%. Such is a satisfying result, when compared with the original mineralogical component of P2O5 26.64%, SiO2 11.51% and MgO 3.36%. When using antifoamer, the SiO2 grade of the concentrate increased 0.55%, the MgO grade decreased 0.64%, while P2O5 recovery increased 2.69% compared by adding no antifoamer. Adding antifoamer is favorable to increase the grade and recovery of P2O5. Therefore, antifoamer is necessary. Tests of synergistic reaction of antifomer indicate that the appropriate consumption of the antifoamer is 275g/t CY and 1Kg/t TWF. Keywords: silicon-calcium phosphate ore, desilication, antifoamer, reverse flotation

Sep 1, 2012

Cyanide is reactive to copper minerals and is not suitable to extract the gold from the copper bearing ores. Ammoniacal thiosulfate is considered an excellent alternative lixiviant for leaching copper bearing gold ores. Unfortunately the results of high reagent consumption and poor gold ex-traction were found by thiosulfate leaching of synthetic gold ores containing chalcopyrite, chalcocite or bornite and a mild refractory copper-bearing sulfidic gold ore. In this investigation, several processes have been applied to reduce the impacts of these minerals on gold leaching. The process included: the pre-oxidation of copper sulphide minerals in water or ammonia solution, the reduction of dissolved oxygen in the lixiviant (0.3 ppm DO or 0.7% oxygen), adding phosphate anion in the leach or pre-leach stage, and the addition of a strong copper ligand (e.g., EDA and DETA). The results indicated that the gold extraction could be improved to 93% with the thiosulfate consumption being reduced to less than 8 kg/t. The dissolution of copper minerals was found to be the major reason for increased consumption of thiosulfate and the highly reductive leached surfaces are responsible for the reduced gold extractions.

Jan 1, 2014

By Thi Hien Tran, Ngoc Anh Tran, Thi Thu Hien-Dinh, Duy Anh Dao

"Natural graphite exists mainly in three types of amorphous graphite, flakes graphite and lump graphite. Graphite from Bao Ha mine, Lao Cai province is with 11.8 carbon-graphite %, forms in flakes and dense crystals. The paper presents the comparison among enrichment of Bao Ha’s graphite by two types of froth flotation with 90 g/t kerosene oil as collector, 50 g/t montanol 800 as frother, in natural pH, and at 20 wt.% of solid. The differences among three flow charts indicated that using middling flotation and re-middling flotation for the cleaning tails and the scavenger concentrates, the final concentrate was improved and containing up to 94 carbon-graphite % of flakes graphite, up to 82 carbon-graphite % of fine graphite with 93.48 % total recovery, moreover, carbon-graphite in the final tail is 0.86 % with 6.52 % recovery. However, a refining mill and a classification stage were applied before doing the middling flotation stages.1. INTRODUCTIONGraphite (black lead or plumbago) is used in many industrial applications due to its high electrical and thermal conductivity, lubricity, and chemical inertness. High quality graphite can be used in metallurgy, molding, brake linings, batteries, and fuel cells. Graphite, composed exclusively of the element Carbon, is rather common mineral, but fine crystals are rare. Graphite is soft (hardness: 0.5-1 Mohs scale); has a layered, planar structure; occurs in platy or acicular (occasionally) morphology (Minerals.net; Pierson, 1993).USGS (2017) reported, global consumption of natural graphite continuing increase in the period of 2012-2016. In 2016, China used up 35% while produced 66% of the world’s graphite. Graphite mining are being developed in Madagascar, Mozambique, Namibia and Tanzania, but production reduced in Canada from 2015. Based on the statistic of Statista.com shows from 2011 to 2014 and a forecast to 2020, the global graphite demand is mostly in refractories, batteries, others, lubricant/crucible, foundry and pencil, and that is increase every year.Graphite Vietnam lies on the fault of the Red river from Yen Bai to Lao Cai, the reserves is estimated around 29.3 million ton and mostly in Lao Cai province where has Nam Thi graphite mine and Bao Ha graphite mine (MOIT, 2008). Vietnamese graphite products could reached to ~92% graphite carbon (Cg) (Tran Thi Hien et al., 2008). Studied samples was collected in Bao Ha graphite mine, is located in Lao Cai province. Graphite Bao Ha exists in two types as graphite flakes and amorphous (Hoang Thi Minh Thao et al., 2017)."

Jan 1, 2018

By P. Pourghahramani

Several structural characteristics change during intensive milling such as chemical composition, phase transformation, crystallite size, lattice strain, lattice parameter (s) and solid reactivity etc. The creation of defects enhances the stored energy (enthalpy) in the solids and consequently causes a decrease of activation barrier for the process and/or subsequent processes. In this paper, the effects of milling on the structural changes of hematite have been investigated using dry millings. The structural changes have been characterized using a combination analysis of BET surface area measurements and X-ray diffraction (XRD) analysis. Besides, the hydrogen reduction behaviors and kinetics of mechanically activated samples and initial sample were studied using simultaneous thermal analysis (STA). The methods of Williamson-Hall and Warren-Averbach were used for analyzing of XRD patterns to resolve and extract the microstructural characteristics of hematite phases. It was concluded that the breakage and aggregation of particles take place mainly in the starting and prolonged stages of dry grinding, respectively. The BET surface area enlarged steadily over the grinding processes whatever milling methods were utilized. The characterization of structural changes revealed that the hematite milled under various conditions did not undergo any significant reaction or phase transformation during milling processes. In addition, X-ray amorphous phase con-tent increased gradually with extending the grinding intensity. The maximum X-ray amorphous phase exceeds about 81% after 9 hours of milling in both tumbling mill and vibratory mill. The Williamson-Hall plots revealed the anisotropic character of line broadening for deformed hematite and changes in the trend of microstructural characteristics as a function of milling time. It was found that the surface weighted crystallite size decreases and lattice strain increases over the grinding periods. The minimum surface weighted crystallites were calculated about 17.3 nm, 12.2 nm for the products of tumbling and vibratory mills respectively. The maximum lattice strain,, in the grinding with tumbling and vibratory mills was calculated about 4.44×10-3 and 3.95×10-3respectively. 21/210nmLe=<> The non-isothermal kinetic analysis of the products revealed that Fe 2O3 reduced to Fe in a two-step process via Fe3O4. Intensive grinding resulted in improved resolution of overlapping reduction events. It was also established that the mechanical activation had a positive effect on the first step of reduction. The prereduction step in the activated samples initiated and completed at lower temperatures than that in non-activated samples. The activation energy of reduction decreased at the first step of reaction with increasing the grinding intensity. Intensive milling increased slightly the average activation energy of the second step of reduction due to the present of finely agglomerated particles and intensive sintering of the particles in higher temperature ranges.

Jan 1, 2014

By A. A. Remes

High precision on-line particle size distribution measurement of mineral slurries has recently be-come available. It provides new tools for the development of monitoring and optimization methods for mineral grinding and separation circuits. The paper presents the development work at the Kemi chromite concentrator plant of Outokumpu Tornio Works in Northern Finland. The Kemi concentrator processes annually 1.2 Mt of chromium ore. The products are upgraded lumpy ore and metallurgical grade concentrate. The concentrate is produced using gravity separation methods, preceded by a rod mill - ball mill grinding stage. The separation process performance is strongly dependent on the particle size distribution of the grinding product at the Kemi plant. Particle size distribution has a significant effect on the concentrate grade and recovery. Currently a new laser diffraction based on-line particle size analyser is used for monitoring the grinding product. The analyser system allows the measurement of the whole cumulative particle size distribution simultaneously. It provides a wealth of new measurement information for process control. A monitoring and optimization scheme for grinding and gravity separation based on the particle size information is presented. The goal is to minimize the production of fine slime, and subsequently to improve the concentrate quality and minimize chromite recovery losses. Data-based recursively identified linear PLS process models are developed for optimization purposes. The preliminary results of the monitoring system operation in on-line use are presented.

Jan 1, 2014

By M. Kinnunen

Handling of municipal solid waste (MSW) and control of its potential resources is becoming increasingly important in modern society. The OECD (Organization for Economic Co-operation and Development) average on municipal waste produced in 2003 was that of around 570 kg per inhabitant. In European Union countries around half amount is of MSW landfilled. In Finland still 88% of MSW was landfilled in 2004. Since incineration reduces MSW volume significantly while producing heat energy, it has become one of the most common waste handling techniques. The shortcoming of incineration is however, that incinerated MSW is often not pre-sorted and it produces slags and ashes as side streams from which recovery of metals is difficult. This paper looks into possibilities of scrap metal recovery for recycling from municipal solid waste incineration (MSWI) bottom ash. In order to do that, a flow sheet of physical separation methods was developed and tested with Finnish rotary furnace MSWI bottom ash. In addition, an empirical model for estimation of the recoveries of scrap metals with physical separation methods for treatment of MSWI bottom ash was developed. According to the results of this study, for 1 Mt of incinerated MSW with 30% mass reduction, a minimum resource potential of 100 kt for magnetic metal scrap of roughly 24 % grade and about 19 kt of non-magnetic metal scrap of roughly 65 % grade. In other words, 57 kg magnetic scrap and 12 kg non-magnetic scrap per inhabitant at the mentioned grades, respectively. Although wide variations of parameters affect the MSWI bottom ash quality, it can be said that a considerable amount of metals is drained into MSWI bottom ash. Results of this study show that from MSWI bottom ash significant material streams metal scrap can be reintroduced into the resource cycle which would otherwise be lost.

Jan 1, 2014

By F. Q. Cheng

Despite the successful industrial practice to recovery KCl by flotation, the adsorption state of collectors at KCl salt surfaces is still not fully understood. In this paper, the captive bubble contact angle measurements at KCl and NaCl crystal surfaces in their saturated solutions are reported. The influence of different collectors and their concentration are considered. The results show that both cationic and anionic collectors produce a hydrophobic state at the structure breaking KCl salt sur-face, with finite contact angle values of between 30o and 40o. In contrast, the contact angle at the structure making NaCl salt surface is zero at all collector concentrations, suggesting that no collec-tor adsorption occurs, a supposition that is supported by results from molecular dynamics simulation (MDS). Further, it appears that the presence of surface defects such as edges and corners promote the adsorption of collectors at the KCl surface, and that the flotation is achieved by bubble attachment at the edges/corners of KCl particles with the formation of aeroflocs.

Jan 1, 2014