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By M. Leijd, K. S. Forrester, M. Saxon, M. Oczlon

This paper provides an introduction to wet high intensity magnetic separation (WHIMS) and its successful application to the beneficiation of rare earth element (REE) enriched eudialyte. The analysis includes an in-depth reporting of the deportment of key elements as well as a statistical interpretation of the relative importance of operational parameters including magnetic field intensity, flow velocity, and matrix loading density. Conclusions are drawn on the relative success of the technology, potential areas for process improvement, and the research direction that continues to be investigated. Three original equipment manufacturer (OEM) technologies were subjected to a series of screening and characterization tests to identify the optimal operating parameter set to magnetically beneficiate eudialyte from Norra Kärr, Sweden. Upon the completion of the characterization test it was apparent that the Metso HGMS technology was superior with respect to REE recovery and gangue rejection for the Norra Kärr composite. The Metso HGMS was then subjected to a series of verification tests to confirm the repeatability and reproducibility of the system.

Jan 1, 2014

By S. Belair, V. Weigel

As a growing mining company, ERAMET is looking for new positions on the strategic metals market. In this context, the Gabonese Maboumine pyrochlore deposit is currently being studied for the recovery of niobium, tantalum, rare earth elements (REE), and uranium. This ore shows mineralogical and chemical characteristics that make it challenging to process by already known practices, from both technical and economic points of view. In this context, ERAMET has developed since 2008 an innovative hydrometallurgical process which has been successfully operated at a pilot plant scale. While the upstream part of the process aims to dissolve the valuable elements in sulphuric acid, the downstream part of the process aims to recover them separately in a marketable form. The focus here will be on the recovery of the REE. The ore deposit contains approximately 1.4% of REE including 87% of light REE and 13% of medium-heavy REE. The challenge in this process lies in the fact that the major elements in the matrix are iron and aluminum. An innovative process has been developed in order to recover all of the REE in these unfavourable conditions, described in this paper.

Jan 1, 2014

By J. -P. Lempainen, K. Haavanlammi, K. Valkama

The Outotec nickel matte chloride leaching process is especially suitable for small capacity standalone nickel refineries. The matte is leached with hydrochloric acid and oxygen in multiple steps in atmospheric OKTOP® reactors. Oxygen feed prevents reductive conditions and hydrogen formation in the leaching process. A sufficiently high acid concentration keeps the iron dissolved in the solution. The iron is removed after leaching by precipitation and the pregnant leach solution continues to metals recovery. The metals recovery from the chloride solution is done by solvent extractions, where ammonia is used for pH control. Copper and nickel are stripped from the organic phases into sulphate solutions. Metals can be recovered from the purified solution by conventional electrowinning. Other alternatives are precipitation or hydrogen reduction processes. The ammonium chloride in the solvent extraction raffinate is regenerated into ammonia. The calcium chloride solution from ammonia regeneration is routed to acid regeneration where sulphuric acid is added and ultra-pure gypsum is precipitated. The hydrochloric acid solution from this step is recycled back to leaching. The process yields good overall metal recoveries and expensive

Jan 1, 2014

By Carlos Antônio de Morais, Renata Dias Abreu

The present work describes a study of the separation of terbium and dysprosium from heavy RE concentrate through a solvent extraction circuit in a counter-current system. As the efficiency of the REE extraction by acid extractants rises with the increase of the atomic number of the element, the aim of this work is to extract the elements with higher atomic number maintaining Tb and Dy in the aqueous phase. Thus, terbium was separated first with subsequent separation of dysprosium. The experiments were carried out by using IONQUEST®801 as the extractant and a REE-hydrochloric liquor as feed solution. The optimum operational circuit in terbium separation was comprised of 37 stages: extraction, scrubbing, stripping, and solvent washing. For the dysprosium separation 39 stages were required. Terbium separation over 92% with over 95% purity and a Dy separation over 97% with over 95% purity were obtained.

Jan 1, 2014

By Jae-Chun Lee, Sadia Ilyas

We investigate the technical feasibility of bioleaching of metals from low grade sulphidic ore. Experiments were conducted with an adapted consortium of Sulfobacillus thermosulfidooxidans and Thermoplasm acidophilum in batch bioreactors (1.5 L), small columns (10 kg ore load, 8 % S0 sludge) and large columns (80 kg ore load, 12 % S0 sludge). Approximately 83 % Ni, 85 % Cu, 55 % Fe and 81 % Zn was leached out in batch mode while 93 % Ni, 89 % Zn, 81 % Cu and 65 % Fe was leached out in column reactors. Bioleaching potential improved by acid pre-leaching, adaptation of microbial consortium and periodic bleeding of effluents.

Jan 1, 2014

By J. C. Moreno, G. Rios, M. Palacios

The Huelva smelter was commissioned in 1970 coinciding with the shutdown of the old smelter in the Rio Tinto mine site. That new smelter consisted of two Momoda blast furnaces with a capacity of 500 dmtpd of concentrate. Nevertheless, soon after their start-up, it was clear that an increase in the smelting capacity was needed. After an analysis of the existing alternatives at that time, the flash smelting technology was chosen. The new Outokumpu Flash Smelting Furnace (FSF) came into operation on 18 September1975, with an initial capacity of 900 dmtpd of concentrate, using four Venturi-type burners and preheated atmospheric air. Since that date the Huelva Smelter team, together with Outokumpu (now called Outotec), have continuously improved our FSF design, process conditions and operational practices, leading to a present capacity of 3,500 dmtpd of concentrate. Since 1975, five smelting campaigns have been completed, the last ending in November 2013 with the rebuilding of the original FSF hearth. This paper describes the history of these improvements and the lessons learned.

Jan 1, 2014

By Wei Wang

The SMCO copper plant is located in DR Congo, and was designed by China NERIN Engineering Co., Ltd. The process is a typical hydrometallurgical plant with Leach-SX-EW, with the project treating the oxide minerals with agitation leaching, followed with three stage of solvent extraction and two stages of stripping, and using permanent SS cathodes to produce LME grade copper. Because of the special characteristic of the ore, what contains 2 different type of oxides (one high carbonate oxide and the other low carbonate), there are several new technical measures that have been developed and adopted for the plant. For example, different grinding, leaching, and filtering are used to treat different oxides. This paper, presents the project process, engineering design, construction and commissioning. The paper also describes some of the problems encountered during plant commissioning, such as the agitation leaching tank issues, and corrosion in the settler-mixer. This paper discusses some NERIN solutions to these problems, and explains the use of the CN filter, which is used to filter PLS to treat high level suspend solids, instead of the traditional sand filter. Finally, this paper also proposes steps / measures for further improvement for future plant operation.

Jan 1, 2014

By F. Cheuk, E. Krause, V. G. Papangelakis, G. A. Moldoveanu, S. Abendschein

Systematic studies have been conducted at the University of Toronto in order to evaluate lanthanide extraction from clay minerals from different geographical regions. It was found that rare earth elements (REE) are easily recovered into an aqueous solution via an ion exchange mechanism by leaching with electrolyte solutions containing monovalent cations under ambient conditions. In this study we assessed extraction levels of individual REEs as a function of initial clay composition and leaching conditions. It was found that, in spite of variations in clay origin, all clays consistently reached peak REE extraction levels with fast kinetics. However, terminal extractions were clay-specific. The feasibility of using seawater as a leaching solution and potential synergies with ammonium sulphate as a lixiviant was also investigated. Seawater was found to be inferior to using ammonium sulphate, and provided no observable synergy in leaching performance when used together. The aqueous phase trapped in leached clays was shown to contain significant amounts of REE, as demonstrated in clay washing tests. Techniques to improve the REE concentration in leachate through process variations were investigated. However, it was found that most techniques capable of increasing REE concentrations in the resultant leachate also resulted in reduced REE extraction.

Jan 1, 2014

By O. G. Olvera, L. S. Quiroz-Castillo, P. J. Valenzuela-Guerrero, D. G. Dixon

The effect of sulfuric acid concentration on the extractions of arsenic and copper in the catalyzed batch leaching of an enargite concentrate was studied. The acid concentrations studied were 60, 45, 30 and 15 g/L. The experimental series yields maximum copper extractions of 96 to 98% in an interval of 81 - 185 h leaching time for 60 - 15 g/L initial sulfuric acid concentration; all the copper extractions plateaued after these values; the rates and plateaus of copper extraction are increased with higher acid concentrations. Arsenic extractions reached maximum values of 89% in 57 hours, 57% in 49 hours, 33% in 25 hours, and 25% in 112 hours respectively; these maximum values were followed by a steep decrease in arsenic concentration, which indicates a precipitation event occurs in the process. According to the literature and process conditions, the arsenic precipitates obtained are iron arsenates similar to scorodite. The stability of the residues was tested using the Toxicity Characteristic Leaching Procedure (TCLP) from EPA; the residues for the four concentration levels passed the TCLP test, reporting arsenic leaching values below 1 mg/L.

Jan 1, 2014

By J. Cueto, M. Torres, J. Fernandez, J. Nuñez, C. Salgado, G. Zarate

Anglo American has used the extractant M 5640 in all the Divisions, which is an aldoxime modified with TXIB formulation, except in Los Bronces, where an aldoxime modified with tridecanol (TDA) formulation is used. It is a well-known fact that the aldoxime degrades while the modifier does not. With time the aldoxime/modifier ratio decreases significantly depending on the operating conditions of each plant. In order to evaluate the effect of this increasing modifier content in the organic of the plant, especially in the organic losses, a complete metallurgical test work program was started at laboratory and pilot plant scale. Results showed that the addition of aldoxime without modifier does not affect the chemical performance of the organic phase, but there is a significant decrease in the viscosity and density of the organic phase. Based on the results obtained in the metallurgical program, it was decided to run plant scale tests at both SX plants, Mantos Blancos and Mantoverde. In these tests, instead of adding the usual formulation of aldoxime modified with TXIB to maintain the organic inventory, CuPRO MEX™ 3406 which is an aldoxime without modifier is going to be added until the original aldoxime/modifier ratio is reached. The plant tests started in April 2013 at Mantos Blancos and in June 2013 at Mantoverde and will last 18 months. The results obtained at the laboratory and pilot plant scale, together with the preliminary plant test results, are discussed in this paper.

Jan 1, 2014

By Y. Yhang, D. C. Sego

ABSTRACT This paper evaluates the potential of freeze-thaw dewatering using Albian mature fine tailings (MFT). Freezing tests were first performed to study the effect of freezing rate on dewatering efficiency. Lower freezing rate resulted in higher thawed solids content and shear strength. Subsequently, large strain consolidation tests were conducted to investigate consolidation behaviour and how it is affected by freeze-thaw. The consolidation behaviour was presented in terms of effective stress versus void ratio and permeability versus void ratio. The results can be used to predict the field behaviour of Albian MFT and optimize the application of freeze-thaw for MFT dewatering.

Jan 1, 2014

By Bruce Conard

For many years, Bruce Conard has been engaged in reading about and discussing the desired sustainability of the mining and metals resource industry. He has, however, become concerned that there is a greater issue that requires our urgent attention: what challenges do we face as a global society? His Distinguished Lecturer presentation traces the idea of environmentally sustainable economic development but concludes that a business’ interest in its sustainability is predicated on the sustainability of our global society. Conard reviews some of the most serious challenges, including population growth, clean energy supplies, freshwater availability and climate change, and calls on scientists and engineers not only to apply their skills in helping solve these challenges, but most urgently, to speak with intelligence and passion about the need to act now.

Jan 1, 2014

By R. U. Seneviratne, B. K. Ahlgren

In this paper we follow various technological discoveries and developments in the purification of minerals and metals in the mining industry by ion exchange. For approximately 100 years, ion exchange has been a known and variously applied purification and separation technology used by scientists and producers. It would seem obvious that the producer’s objectives have always been to achieve the highest quality products and the lowest operation costs, but also with the least amount of technological complexity. As a strategy to reach these goals, much effort has been expended in the quest to improve continuous ion exchange (CIX) systems by reducing utility needs and resin degradation or loss while at the same time improving productivity and reliability. Recent developments from a number of companies have pushed equipment boundaries, resulting in a variety of unique commercial equipment designs each with a varying degree of success. The challenge set forth for all new designs has been a truly continuous process with no sacrifice in the afore mentioned benefits. One very recent equipment design based on system symmetry appears to meet many of these objectives with greater flexibility and less complexity resulting in better economics for the producer.

Jan 1, 2014

By Maria Skyllas-Kazacos

The All-Vanadium Redox Flow Battery that was pioneered and has been developed at the University of New South Wales (UNSW) in Sydney since the mid-1980s is currently regarded as one of the most attractive energy storage systems for large-scale implementation in a wide range of grid-connected and offgrid applications. Several companies are now manufacturing and installing MW-scale VFBs in applications ranging from renewable energy storage, load-levelling, emergency back-up power and power arbitrage. The full-scale uptake of the VRB in commercial energy storage systems however, is heavily dependent on the availability and cost of vanadium used in the VRB electrolyte. Cost is also a function of purity requirements and although there is little scientific evidence on the effect of impurities on the VRB life and performance, VRB developers continue to demand high purity vanadium at considerable cost. This paper will provide a brief overview of the current understanding of electrolyte impurities on VRB performance together with an economic analysis of the impact of vanadium prices on overall VRB capital and levelised costs for a range of applications.

Jan 1, 2014

By L. Chunpongtong

ABSTRACT The mining limit in oil sands is regulated by the ratio of total mining volume (ore, interburden, and overburden) one has to mine per volume of bitumen in place (TV/BIP). This paper presents a mathematical solution for creating the most economical pit outline where the TV/BIP ratio upper limit is 12, by combining mining economic theory and the Lerchs-Grossmann (LG) algorithm.

Jan 1, 2014

By G. T. Lapidus, R. Zárate-Gutiérrez

Selective leaching of lead from a Pb-Ag-Zn concentrate with hydrogen peroxide in citrate solutions was studied at room temperature. Leaching tests were performed, varying the H2O2 concentration and the solid-liquid ratio, holding the solution pH constant at 7, and the citrate concentration at 1 M. Lead extractions of 100 % were achieved with 4 and 5 times the stoichiometric quantity needed to form elemental sulfur, with only a small amount of metal impurities dissolved (Ag, Zn and Fe). The lead solubility limit at those conditions was found to be ~21 g L-1. X-ray diffraction analyses of the leach residues were free of galena (PbS), while other metal sulfides, such as sphalerite (ZnS), chalcopyrite (CuFeS2) and pyrite (FeS2), were basically unaffected.

Jan 1, 2014

By M. Isac, R. I. L. Guthrie, S. Ge

The Al-Mg-Sc-Zr alloys have shown exceptional potential as structural materials for transportation applications. These alloys have proved to be good candidates to be processed as thin strips via the Horizontal Single Belt Casting (HSBC) process. The HSBC process is a near-net-shape casting technology, which involves casting molten metal directly into thin strips, close to the final product thickness, at high cooling rates. It offers an efficient, economical and environmentally-friendly approach to the production of metal strips. Fluid mechanics and associated heat transfer are important aspects of any casting process, and the novel HSBC process is no exception. Three dimensional Computational Fluid Dynamics (CFD) simulations using ANSYS FLUENT 14.5 were performed, in order to assess the importance and effects of the various operational conditions of the HSBC process. This enabled process parameter optimization. Numerical predictions were validated against experimental casting results.

Jan 1, 2014

By H. Ardehali, P. Lind

Many gold deposits also contain significant quantities of deleterious elements such as arsenic. Several biological pathways are possible for arsenic exposure; special care and caution must be used while undertaking metallurgical testwork on ores and concentrates that contain high levels of arsenic. Laboratory precautions pertaining to handling of airborne dust concentrations, necessary personal protective equipment, and effluent treatment are discussed.

Jan 1, 2014

By M. Lindgren, M. Latva-Kokko

Process performance can be significantly influenced by proper design of hydrometallurgical reactors. Optimal reactor configuration is case specific and depends on process requirements such as reaction rate limiting factor and particle size distribution. Choice of materials and manufacturing methods also play important roles in highly corrosive and abrasive environment often involved in hydrometallurgical industry. In this paper performance of different reactor designs has been compared in some typical hydrometallurgical applications. Results show that significant improvement in energy consumption, gas utilization efficiency and equipment lifetime can be achieved with process specific reactor design.

Jan 1, 2014

By John Monhemius

Looking back over the past half century, it can be seen that the growth in the importance of hydrometallurgy for the production of non-ferrous and precious metals almost exactly parallels the rise of the environmental movement and its principal NGOs, such as Greenpeace and Friends of the Earth. The paper will review important landmarks in the development of the science and technology of hydrometallurgy and show how many of these have been influenced by pressures on the industry brought about by environmentalists. Successful innovations as well as commercial failures will be considered and reasons for the success or failure will be analysed and lessons drawn to guide future developments.

Jan 1, 2014