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By M Saghaeian, V Sheikhzadeh, R Hejazi

Mining dilution is one of the most important factors affecting the economy of mining projects. Instead of quantifying dilution in mining studies, it is common to assume a general dilution such as 5 per cent for massive deposits. Dilution increases the operating costs in the plant by increasing the tonnage of material to be milled. It prolongs the mine life by reducing plant’s effective capacity. It also reduces the feed grade. In most cases, lower feed grade means lower plant recovery. Dilution also increases the cut-off grade, which in turn reduces the overall ore utilisation of a mine. In this study has been investigated applying pre-concentration by dry magnetic separation for decreasing of dilution impact on reserve estimation and open pit design in low-grade iron ore mine. Based on the preliminary open pit design and assumption 3 per cent as dilution factor, the mineable ore in life-of-mine (measured + indicated) has been estimated with Fe = 25 per cent, SiO2 = 49.7 per cent. Based on the experimental test work on the ore, by dry low intensity magnetic separation of dry HPGR product grinding circuit, it is possible to remove diluted waste material and liberated gangue before concentrate plant, so that around 34 per cent rejected and Fe grade increase from 25 per cent to 33 per cent and by weight recovery 66 per cent. The results of the test work showed that this methodology could decrease largely the impact of dilution in the feed to the plant. It also slightly effect on the reducing of dilution factor impact for open pit design and optimisation and leads to increase the mineable tonnage in the low-grade magnetite iron ore mine.

Aug 24, 2022

By S Basu, P M. Midhun

Electro-Slag Remelting (ESR) is a process capable of producing ingots with much lower centre-line segregation and better internal soundness than conventional ingot casting processes, as well as lower inclusion and sulfur concentrations. This process is commonly used for alloyed steels intended for critical applications like components of marine turbines, supercritical powerplants and rocket motor casings. It involves melting a metal electrode using electrical resistive heating in a slag pool and re-solidification of the resulting metal droplets beneath the slag layer, forming an ingot. Conventional ESR fluxes consist primarily of CaF2, Al2O3 and CaO, along with minor concentrations of SiO2, MgO etc. The emission of fluoride vapour from the molten slag causes several environmental and health problems, triggering a need to develop and reduce the fluoride content in the ESR flux. The present study aims to develop low-CaF2 alternatives to commercial ESR fluxes without compromising on productivity and the surface quality of the refined ingot. Thus, the modification in chemical composition needs to satisfy properties like electrical resistivity, viscosity and liquidus temperature, essential for efficient ESR operation. Since electrical resistivity and viscosity are highly dependent on the ionic structure of the molten slag, it is important to understand the effect of compositional modification on the structure of the flux. The present study employs Fourier-transform infrared spectroscopy (FT-IR) and Raman spectroscopy to investigate the structural variations in the modified fluxes, especially the effect of changing SiO2 concentration, in comparison with conventional CaF2-rich fluxes. Additionally, thermal analysis (Differential Thermal Analysis (DTA) and Thermogravimetric Analysis (TGA)) has been carried out to characterise the melting behaviour of the fluxes. The findings are compared with simulations carried out using the FactSage™ software, ver 8.3 (GTT Technologies, Aachen, Germany). Simultaneous analysis of liquidus temperature and the structure is expected to help in identifying the practical suitability of modified ESR flux compositions for industrial implementation.

Jun 19, 2024

By J H. Park, M J. Lee

Because the environmental problems are occurred by greenhouse gases such as CO2, the industries have tried to increase electric motor efficiency to reduce CO2 emissions. A core material of electric motor is high-silicon electrical steel. The ferrosilicon (FeSi) alloy, a raw material for the production of electrical steel, affects the electric properties of silicon steel. The main impurities such as Ca, Al and Ti make inclusions or precipitates that causes core loss. The slag treatment has been widely used to remove impurity elements. Thermodynamic principles for the refining of several impurities, specifically Ca and Al, have been investigated, whereas thermodynamic behaviour of Ti has not been fully understood yet. Therefore, in the present study, the titanium distribution ratio () between ferrosilicon and CaO-SiO2-Al2O3 slag system at 1773 K was investigated. The results show that is influenced by both the basicity and stability of titanium ion in the slag. Specifically, exhibits a minimum value at about C/S=0.7 indicating a shift in the titanate structure unit from [TiO5]-square pyramid to [TiO4]-tetrahedron because of lack of Ca2+ ions in a C/S<0.8 region, contributing to an increase in titanate capacity and .

Jun 19, 2024

By I Govender, T L. Moodley

Tumbling mills are grossly inefficient, using only 5 per cent of the total energy supplied for actual breakage. A significant proportion of this inefficiency is unavoidable owing to geometric limitations; rotating drum systems are prone to exhibiting certain regions (energy barriers) that resist particle entry thereby restricting the transfer of energy. Though such systems are inherently inefficient, improved modelling schemes may lead to slightly enhanced efficiency through better microscale predictions of key breakage drivers (stress, force). Central to achieving such incremental advances is the development of a universally accepted rheology for dense granular flows. Armed with a better understanding of these macro-scale ingredients, classical process modelling offers an efficient, spreadsheet friendly framework for recovering the spatial distributions of the comminution drivers. At this real-time level of process control, it should be possible to tune comminution operations towards more energy efficient configurations – the ultimate goal of this research. The present work employs validated DEM data to recover the full continuum field which will ultimately serve as a basis for calibrating process model outputs based on different rheological hypotheses. Such a continuumbased approach captures tensor properties like the shear stress and strain rate – both of which are necessary to developing a dense granular rheology. Moreover, DEM captures this data at the momentum transfer timescale of 10-6 s – no other measurement technique is capable of this level of spatial and temporal resolution. Importantly, the confidence in this DEM data is strengthened because it has been validated at the continuum scale using Positron Emission Particle Tracking (PEPT) kinematic measurements. Validated DEM data is derived from batch experiments conducted within a 300 mm ID laboratory drum using three and five millimetre glass beads at 60 and 75 percent critical speed; such mill speeds are typically encountered in the tumbling mill industry. Dimensional analysis is conducted using critical rheological parameters (shear rate, shear stress, granular temperature etc), which are key to not only developing a granular rheology but ultimately will be used to tune our mechanistic models.

Aug 24, 2022

By L Klemettinen, A Jokilaakso, D Attah-Kyei, P Taskinen, M Tiljander, D Sukhomlinov, D Lindberg

In this study, the use of carbon neutral biochars as reducing agents in the pyrometallurgical treatment of nickel slag was investigated at 1400°C in order to recover valuable elements such as copper and nickel from the slag. A large amount of slag is generated during the nickel matte smelting. Nickel slag contains valuable elements such as copper, nickel and cobalt, which can be recovered. Disposal of this slag results in loss of resources and may cause pollution of the environment. It is important to retrieve these metals for environmental and economic reasons. In this study, the slag was reacted with non-fossil reducing agents (biochar) which were produced from hydrolysis lignin and black pellet biomass pyrolyzed at 600 and 1200°C and with metallurgical coke for comparison. The reduction experiments were done at 1400°C for 15, 30 and 60 mins under inert gas atmosphere. The samples were quickly quenched and analysed with Electron Probe X-ray Microanalysis (EPMA). The results showed that the use of biochar resulted in faster reaction kinetics in the reduction process compared to coke. The fast reaction kinetics is attributed to the relatively high content of volatiles in this biochar, leading to gas formation and thus mixing of the sample material. Moreover, thermodynamic modelling was also performed using FactSage™ to simulate equilibria with different amounts of biochar. The metal to slag distribution coefficient calculated from the results of thermodynamic modelling were consistent with experimental results. In addition, thermodynamic calculations confirmed that nickel is reduced rapidly and it deports to the metal alloy phase. As the reduction progresses or extra reductant is available for reactions, more iron is deported to the metal phase. The calculations also revealed that Zn vaporises into the gas phase.

Jun 19, 2024

By W Polkowski, M Tangstad, M Wallin, J Jiao

Fe-26Si-9B (wt per cent) alloy has been identified as a potential high-temperature phase change material (PCM) due to its attractive properties, such as its high latent heat of fusion and low volumetric change during solid/liquid transition. For the successful utilisation of this alloy into thermal energy storage (TES) systems, the development of a cost-effective production method is essential. Presently, the Fe-26Si-9B alloy is produced by mixing FeSi alloys with either pure boron element or FeB alloys. However, the use of pure boron is financially prohibitive, and the carbothermic reduction results in high greenhouse gas emissions and high energy consumption in the production of FeB alloys. In this regard, our study proposes a silicothermic reduction method to produce Fe-26Si-9B PCM by using FeSi alloys and B2O3-based oxides. Accordingly, the influence of various parameters on the production process was investigated, including operating temperature, holding time, B2O3 content in the added oxides, and initial Slag/Metal (S/M) ratio. Based on the experimental results, the optimal parameters for producing FeSiB alloys with over 9 wt per cent boron were determined. Consequently, it was documented that the FeSi alloys and the added oxides enriched with 50– 65 wt per cent B2O3 should be subjected to temperatures ranging from 1550–1650°C, maintain an initial S/M ratio exceeding 1, and ensure a holding duration beyond 1 hr. Moreover, the energy consumption of this process was estimated to be ~1.86 MWh/t metal and the mass loss was lower than 7 per cent. Therefore, silicothermic reduction offers a sustainable approach for producing FeSiB alloys with a boron content above 9 wt per cent.

Jun 19, 2024

By R Hao

Uncertainties in large open pit geotechnical modelling has been a major concern for slope stability analysis. The level of confidence in the in-put assumptions, such as structural and rock mass model, dictates the modelling results to some extent. This article is to detail a case study of Kalgoorlie Consolidated Gold Mines (KCGM) regarding a predicted inter-ramp failure on an as-built pit walls by a 3D numerical modelling. Significant concerns were raised across site and multiple preventive plans were considered. After intense data collection work, it was confirmed that the risk of failure had been overestimated. The case study has improved the understanding of geotechnical data in-put and has enhanced the process of creating and updating geotechnical structural models at KCGM.

Jun 22, 2022

By S N. Nyoni, K C. Corin, C T. O’Connor

Considering future water scenarios, as influenced by the increasing scarcity of water and the move towards sustainable process engineering etc, the closed water circuit becomes an important point of study in metallurgical operations, such as in milling and flotation. However, a deterrent in the use of recycled process water is often a lack of understanding of the effects of the accumulation of dissolved ions and other process chemicals. Recovery of the valuable minerals may be impacted by the concomitant complex mineral-pulp chemistry interactions. Literature indicates that these interactions are not necessarily antagonistic to process outcomes. Wet milling using steel media results in the dissolution of Fe from the media, the rate of which is dependent, inter alia, on the type of media and the chemical conditions of the aqueous environment in the mill. The pulp-phase interactions of dissolved ions with sulfide minerals may result in significant changes to the chemical conditions in the mill, which may subsequently impact negatively on the flotation recoveries. To understand the effect of these interactions in the context of the processing of sulfide minerals, this study seeks to consider the effect of three factors, viz mineral type – pyrite (Py) and galena (Gn) -, milling media of different compositions – forged steel (FS), 21 per cent high chrome and ceramic media -, and water chemistry, viz, deionised water (DI) and synthetic plant water (SPW). Ceramic media and galena are used for the respective control cases where the milling media and sulfide mineral contribute no Fe species. Using DI as a control case, a high ionic strength case is used to mimic the changes in water chemistry for a closed water circuit. Batch flotation tests are used as a diagnostic tool to determine the effects of these media-water-mineral interactions to investigate correlations between the chemical reactions occurring and chemical species present during the milling process and the ultimate flotation performance.

Aug 24, 2022

By Y L. Ma, Y Yang, M Chen, W Bruckard

To improve the understanding of the reactions and mechanisms occurring during the leaching of sulfide ores at high temperatures a range of advanced characterisation and sensing tools have been combined to provide a sophisticated and powerful methodology to examine sulfide leaching systems. These include advanced electrochemical methods, surface chemistry and materials characterisation techniques such as synchrotron X-Ray Absorption Spectroscopy (XAS), X-Ray Photoelectron Spectroscopy (XPS), Scanning Electrochemical Microscopy (SECM), and in situ X-ray diffraction (XRD), together with new robust solid state chemical sensors for in situ real time monitoring of key aqueous chemical parameters. The methodology was employed to investigate various sulfide mineral leaching processes. For example, oxidation of arsenopyrite at elevated temperature involves complicated multiple reactions and the process is strongly influenced by the solution conditions, component speciation and mineralogy. The methodology was used to study this system both ex situ and in situ to gain a detailed understanding of the complex chemical reaction mechanisms operating. These mechanisms are discussed in terms of the observed leaching efficiency. The application of this methodology enables complex sulfide leaching systems to be understood more fully such that process efficiency can be improved.

Aug 24, 2022

By G H. Park, Y J. Jun, J H. Park

The carbon solubility of the CaO-Al2O3-FeO-SiO2-MgO slag, the main system formed in the Ruhrstahl-Heraeus (RH) vacuum degasser, was measured at 1873 K to understand the effect of slag compositions on the carbon contamination in the ultra-low carbon (ULC) steels. The stable form of carbon was demonstrated to be carbonate by plotting the log [(wt%C)/aC] ratio against the log p(O2) which ranged -11 < log p(O2,atm) < -9. The carbon solubility of the CaO-Al2O3-FeO-SiO2-MgO slag can be estimated using thermodynamic model. The distribution ratio of carbon increased with increasing concentration of FeO due to the FeO reduction reaction and increased basicity of slag. The carbonate capacity of the CaO-Al2O3-FeO-SiO2-MgO slag can be expressed as a linear function of the activity of lime and the optical basicity.

Jun 19, 2024

By J Cortinez, P Vallejos, J Yianatos, M Rodriguez

Nowadays, one of the main problems in current flotation plants and new projects is the significant decrease in feed grades and changes in the mineral composition, which has an important effect on the mineral liberation and associations. Additionally, flotation plants usually operate with feed throughput higher than the original design, which has a significant impact on the feed particle size. All these conditions affect metallurgical performance, and must be evaluated and addressed, by improving control strategies for banks optimisation. For this purpose, the flotation of valuable minerals along the circuits requires better understanding, considering the compromise between performance and selectivity in flotation circuits. This paper presents a characterisation of the different minerals recovered along industrial flotation circuits. Plant sampling campaigns, performed in a copper industrial concentrator in Chile, provided the data for the study. Two rougher flotation banks consisting of cells of 130 m3 and 300 m3 were analysed. All the samples from the industrial surveys were analysed by screening and mineralogy, and the mineral recovery along the circuits was evaluated per particle size class, liberation class, type of associations, and others. Additionally, operating data on froth depth profiles complemented the evaluation of the mineral composition of concentrate streams, along the circuit. The results allowed for identifying and quantifying the main factors that affect the copper recovery and concentrate grade along the flotation banks. It was found that minerals with liberation lower than 50 per cent have a significant impact on the recovery. On the other hand, the decrease in the Cu grade in concentrates along the flotation circuits is mainly due to the relative increase of middling minerals (less liberated), non-valuable floatable minerals, such as free pyrite, and gangue entrainment. The characterisation of the gangue entrainment flow rate along the flotation banks showed a strong relationship with froth depth, which becomes more critical towards the last cells of the banks.

Aug 24, 2022

By L Scheunis, A Van den Bulck, E Jak, K Verbeken, M Shevchenko, R Starykh, I Bellemans, P-J Boeykens

As a result of the globally increasing consumer use of electronic devices, it is expected that pressure will increase on the supply chain of precious metals. Hence, recycling of these electronics becomes increasingly important, as well as optimising the current processes. One major issue in metallurgical processes is the amount of metal that is lost into the slag. This metal loss is inherent to the production process and therefore, additional processing steps such as slag cleaning may be required. Slag cleaning can be done in electrical resistance furnaces where heat is produced using the Joule effect, making the slag’s electrical conductivity an important operating parameter. Since slags are ionic liquids, the electrical conduction happens via the movement of ions which is called ionic conductivity. However, within the presence of transition metal oxides, a second mechanism of conductivity occurs as electrons are able to hop from one transition state to another, which is known as electronic conductivity. As ‘FeO’ is a common slag component in the non-ferrous pyrometallurgical industry, both mechanisms are present, but their proportions vary with the respective amounts of the two forms of the multi-valent ions and hence, with the oxygen partial pressure. The goal of the present study is to develop an experimental set-up and methodology for measuring the electrical conductivity of synthetic SiO2 – CaO – AlO1.5 – ‘FeO’ slags at various oxygen partial pressures.

Jun 19, 2024

By S-C Shim, H-R Lee, Y Kang, H Shin

Since iron oxide and silicon oxide are major gangue components in various types of ore, FeO-SiO2 base slag, ie fayalite slag, has been often encountered in pyrometallurgical processes of non-ferrous metals. During most matte production processes such as the smelting of Cu, Pb, and Ni, the FeOSiO2 based slag is inevitably formed and plays an important role in refining crude metal as well as engineering aspects. Recently, similar pyrometallurgical approaches have been attempted in the recovery of valuable metals (Ni, Co, Cr) from wasted secondary batteries. Thus, the viscosity of the FeO-SiO2 based slag has great significance in properly controlling smelting processes. However, when molten metal or matte does not coexist with the slag during the measurement, there has been a serious difficulty in maintaining Fe valance and consequently, the slag composition. In the present research, the viscosity of molten FeO-SiO2 slag was measured in 1573~1673 K using a rotational viscometer. In order to keep the state of iron oxides, the oxygen partial pressure was controlled using CO/CO2 gas mixture. The optimised ratio of CO/CO2 could be calculated using Fe/Fe2+ and Fe2+/Fe3+ equilibria at each temperature. The composition of the slag, particularly Fe valance, after the measurement was analysed with the aid of an inductively coupled plasma – optical emission spectroscopy (ICP-OES) and an automatic potentiometric titrator. The measurement showed that the FeO-SiO2 slag has considerably low viscosity values in the molten state, and it sharply increases as the temperature decreases. In spite of the careful oxygen partial pressure control, a part of Fe2+ was found to be oxidised to Fe3+, with a maximal case reaching about 20 per cent. The increase in viscosity of FeO-SiO2 at low temperatures can be attributed to the composition change due to an unavoidable Fe2+ oxidation. In addition, the relationship between the change in the viscosity and the liquidus temperature of FeO-SiO2 based slag was discussed to understand the composition dependence of viscosity.

Jun 19, 2024

By D Pienaar, B McFadzean, C T. O’Connor

Collector and frother molecules in sulfide mineral flotation are thought to have separate roles in the flotation process, where the collector selectively hydrophobizes the mineral surface and the frother adsorbs onto the bubble surface, inhibiting bubble coalescence. Molecular interactions have been observed between these molecules which allow them to co-adsorb at each of the respective interfaces, improving pulp phase recovery. This study investigated the molecular interactions between sodium diethyl dithiophosphate (SDEDTP) and hexanol, and the mechanism by which these interactions improve the recovery of galena. In this study each of the respective interfaces were investigated for the adsorption of SDEDTP. The adsorption of SDEDTP on galena was measured by UV-Vis spectrophotometry and isothermal titration calorimetry. At the air-water interface foam stability and pulp bubble coalescence was used to quantitatively discern if there are interactions between SDEDTP and hexanol. Microflotation and induction time experiments were performed to determine the effect of SDEDTP, hexanol and their mixtures on mineral recovery and bubble-particle attachment. The results of all these tests were collated to determine if SDEDTP-hexanol mixtures synergistically improve sulfide mineral recovery. It was found that SDEDTP reduced bubble coalescence in the pulp demonstrating activity at the airwater interface. Together SDEDTP and hexanol synergistically enhanced foam stability. This indicated that there are attractive molecular interactions between these reagents. Even though DTP did not adsorb onto galena, DTP-frother mixtures synergistically improved the recovery and attachment probability of this mineral. Adsorption studies with aeration showed that DTP in the presence of a frother transfers from the air-water interface to the galena mineral-water interface during bubble-particle collision. It was proposed that the transfer of hexanol through the thin film enhanced the kinetics of film thinning between the bubble and the particle by destabilising the thin film thus improving pulp phase mineral recovery.

Aug 24, 2022

By P Holtham, K Duffy, L Pyle, W Valery

The mining industry is becoming increasingly focused on pre-concentration due to its potential economic and environmental benefits, particularly for the more complex, low-grade, high throughput operations now being developed. Advances in technology have seen bulk ore sorting (BOS) trialled at several operations. However, BOS should not be seen as a ‘silver bullet’, it can offer significant benefits, but only under the right conditions. Deposits with interspersed mineralogy or disseminated, fine-grained minerals can be difficult for BOS. Large batches of barren or low-grade material are required for BOS to be effective. Hatch has recently completed several studies for clients who believed that bulk sorting was the most suitable pre-concentration technique for their operation, based only on an assumed sorter recovery or on laboratory trials of the chosen sensor. However, minimal consideration had been given to the heterogeneity of the deposit, the achievable separation batch size or sensor repeatability. Evaluation of BOS needs to consider both heterogeneity and sensor suitability. The valuable or gangue mineral must be present in such a way that it can be separated effectively in the large bulk sorting batch sizes, without competing minerals or changing ore characteristics affecting the metal upgrade or recovery. Also, the sensor chosen must be able to detect either the valuable mineral, a proxy for the valuable mineral, or a gangue mineral for rejection with sufficient accuracy and precision (repeatability). This paper presents three recent case studies, emphasizing markers which indicated that bulk sorting was unsuitable for the project whilst highlighting the pre-concentration technologies which were applicable (including particle sorting, and coarse particle gravity separation). The modelling methodology, equipment sizing and forward work plans developed to verify these alternative solutions are also presented, demonstrating the key factors contributing to a thorough scoping assessment.

Aug 24, 2022

By P Hayes, D Fadhlurrahman

Molten slags, fluxes and salts play key roles in a wide range of the high temperature industrial process applications, including metals production, refining and recycling, metal manufacturing processes, electrochemical metal production cells, batteries, and efficient heat transfer media. Recognising the importance and significance of fundamental scientific knowledge of these systems, the International MOLTEN Conference series was established to provide a forum to bring together leading academic researchers and industrial engineers to present and discuss the latest scientific ideas and findings, and their application in their respective fields. This article presents an analysis of the research carried out in this field over time in terms of the number of journal articles, fields and slag systems studied and geographical origin of the research.

Jun 19, 2024

By X Zhang, B McFadzean, C T. O’Connor, S Pikinini

The Platreef in South Africa contains one of the world’s largest reserves of platinum group elements. One of the major platinum group minerals (PGM) components in this ore is sperrylite (PtAs₂), which has been found to be slow floating compared to the other PGMs. In a study aimed at determining the reasons for the poor floatability of sperrylite and to improve its recovery, tests were carried out to determine the interactions of the mineral with a range of standard and novel collectors. Microflotation tests were carried out to determine the hydrophobicity of the minerals before and after adsorption of collectors. In addition, experiments were carried out to determine the enthalpy and extent of collector adsorption on the minerals and to investigate electrochemical interactions between sperrylite and selected standard collectors. The results indicated that poor collector adsorption was the major cause for the poor floatability of sperrylite. Sperrylite had both poor natural (14.5 per cent) floatability and collector-induced flotation recoveries, the highest recovery of 26 per cent being observed using PNBX collector at pH 9. Moreover, the rest potential tests showed that the interaction of sperrylite with standard collectors such as xanthates was poor. The decrease in potential after the addition of the standard collectors ranged from 7.9 mV to 24.9 mV under alkaline conditions. Furthermore, sperrylite rest potentials remained unchanged with a change in pH from basic to acidic, indicating its resistance to surface alteration. Surface alteration of the minerals is key for the chemisorption of collectors to take place on the mineral surface. This was further emphasised by flotation recoveries at low pH, where only certain collectors responded positively to a decrease in pH and these were shown to have undergone a structural change. This work has highlighted the difficulties associated with sperrylite flotation and provides some direction for future research.

Aug 24, 2022

By K Aikawa, M Ito, K Mitsuhashi, Y Ebisu, J V. Satur, I Park, N Hiroyoshi, T Suto

Copper concentration using flotation is becoming more difficult, because of an increase in ore complexity accompanied by smaller grain sizes of copper minerals than usual, requiring finer grinding in order to liberate them. Project Arqueros, located at the mid northern part of Chile, is a copper mine project with an orebody consisting of various sulfides such as chalcopyrite, chalcocite, and bornite. Some of the copper minerals in Arqueros show low floatability mainly because of their fine grain size and resulted fine grinding size, and also because of the complex mineralogical composition. For example, chalcopyrite in Arqueros floats less than the other copper sulfide minerals. In this study we carried out some kinetic flotation tests with the Arqueros ore using a laboratory-scale forced air type flotation machine by varying the regrinding size. The products were assayed and mineralogically analysed to compare the minerals in their flotation behaviour with respect to size classes and liberation classes. The results were compared with a model calculation according to bubble size measurement. From the flotation testing and mineralogical analysis, it was found that copper minerals of the same size and liberation class floated at the same rate even with different regrinding size. At the same time the comparison between experiment and calculation showed that the fine particles of less than 5 µm size floated faster in actual than in the model applied. These results suggested that interactions among minerals of different species and of different sizes had positive impacts on the flotation rate of the fine particles. It indicates that this phenomenon can be applied to improve copper recovery in the project.

Aug 24, 2022

By X Tian, J Forster, A Olmsted, E R. Bobicki, M Goldbaum, D Boucher, C A. Pickles

As the global demand for metal values expands, it becomes increasingly important to create more sustainable mining operations. Consequently, considerable research and technology development is required to produce processes which are both more energy efficient and have a minimal environmental impact. One potential technology is the utilisation of microwave pre-treatment to reduce the energy requirements in comminution. Microwaves can preferentially heat the valuable mineral phases in an ore and the resulting differential thermal expansion leads to the formation of microfractures along the grain boundaries. As a result of the preferential heating, ore competency is reduced, mineral liberation is enhanced, a coarser grind size can be employed, and plant throughput can be increased. Furthermore, microwave pre-treatment can be combined with advanced ore sorting, to decrease the quantity of gangue material processed downstream and hence reduce tailings production. Previous studies on the microwave treatment of ores over the last 30 years have mainly been limited to low power bench-scale studies and there is a paucity of information on pilot and/or commercial scale studies. In the present research, the microwave heating behaviours of over 40 ores have been studied at the bench-scale. These results were used to generate a database, from which a unique classification system was developed. This system was used to rank the amenability of any given ore for microwave pre-treatment. This knowledge can be employed to predict the performance of the ores in the high-power pilot scale tests and thus can be used as a pre-screening tool. The effects of high-power microwave pre-treatment on grindability and liberation were reported. Additionally, the ore sorting potential was evaluated using a combination of X-ray transmission (XRT) and microwave infrared (MW/IR).

Aug 24, 2022

By T M. Campos, J Silva, L M. Tavares, J Lichter, L P. Alves, B K. N Rocha, H D. G Turrer

The depletion of the richest ore deposits and the increase in number of mining projects involving deposits with complex mineralogy, higher competence and lower grade has led to an eminent need for improving understanding on multicomponent behaviour in mineral processing. One particularly relevant case is the ball milling of itabirite iron ores fed to the processing plant of Minas-Rio operation in Brazil. Dealing with the two main mineralogical components of the ore, namely hematite and quartz, the operation faces some challenges to improve understanding on how the two components behave in the process. Mathematical models have showed potential to give support in this task, but its applications to describe this type of industrial-scale grinding is still missing. The present work demonstrates the application of a multi-component ball mill model to simulate a closed ball mill circuit with hydrocyclones using the commercial software Integrated Extraction Simulator (IES). Model was calibrated on the basis of bench-scale tests and industrial surveys. Multi-component simulation results are then compared to those considering a single component in the feed, demonstrating the value and great insights that can be achieved by using the former in optimising plant operation.

Aug 24, 2022