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By P. L. Li, B. X. Song, C. H. Wang, T. Wang, Z. Hu

"The treatment of an oxidized copper-gold ore by stage cyanide addition was investigated. For cyanidation, free cyanide ion concentration can be an indicator of whether there is copper dissolved in cyanide solution, and maintaining the free cyanide ion concentration lower than 1.0 g/L could be an effective way to prevent copper dissolution and reduce cyanide consumption. For that purpose, stage cyanide addition was introduced to control free cyanide ion concentration within the range from 0.8 to 1.0 g/L. Cyanidation tests results indicate that gold extraction was still acceptable at reduced cyanide consumption with a lower copper extraction. Based on the experimental study, industry application works at Beiya concentrator of Yunnan province, China were successfully conducted. When the raw ore contains 2.95 ppm Au and 0.75% Cu, by stage cyanide addition method, the gold extraction was still 93% at reduced cyanide consumption of 2135 g/t, which was only half of one addition method, and the copper extraction dropped to only 5%, which indicated that dissolution was prevented for almost 75% of the malachites.INTRODUCTIONCyanide with its competency to form a strong complex with gold, is the most preferable lixiviant for gold leaching. However, cyanidation is not inherently a selective process since many other minerals present in the ore are also readily soluble, especially the copper minerals. Muir (2011) reported that every 1% reactive copper present in the ore consumes about 30 kg/t NaCN, which can have detrimental effects on the process efficiency and economics due to high cyanide consumption, reduced gold leach rates and poor gold recovery."

Jan 1, 2016

By Nessetech Consulting, L. A. Cisternas, E. D. Galvez, S. H. Kuan, L. H. Saw

"In Malaysia, there were two rare earths processing plants namely Asian Rare Earth (ARE) and the Malaysian Rare Earth Corporation Plant (MAREC) in Perak, which were operated until 1992 and were subsequently closed due to problems pertaining to disposal of large amount of radioactive waste. Recently, Lynas Advanced Materials Plant (LAMP) has become one of the largest rare earths processing plant in the world producing rare earth elements (REE) in Gebeng, Pahang. The primary raw material is lanthanide concentrate (LC) which is imported from Mount Weld mine in Australia and shipped to Malaysia. LC is produced from lanthanide ore after mining and mineral processing. The ore has a lower impact than Bayan Obo, Mountain Pass and adsorbed clay deposits, given the small footprint of the mine itself and the remoteness of the location. The type of ore being mined (rare earth phosphates: carbonatite, monazite) may have higher thorium content than bastnasite ore from the Chinese or American mines but still far below radiation concerns. This paper was written to review the processing flowsheet at the Lynas Advanced Materials Plant (LAMP), the environmental impact associated with the processing of the said ores and the sustainability of the operation.INTRODUCTIONRare earth minerals are one of a set of 17 minerals or chemical elements which consists of yttrium and scandium, as well as the 15 lanthanide elements (lanthanum, cerium, praseodymium, neodymium, promethium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium). Despite their importance, rare earth minerals rarely exist in economically viable concentrations and they are usually difficult to extract. Rare-earth minerals create strong magnets when added to magnetic elements such as iron, and are useful for the production of electronics systems as well as electric cars. They are also used extensively in automotive catalytic converters, fluid cracking catalysts in petroleum refining, wind turbines, phosphors in colour televisions and flat panel screens, displays for mobile phones and laptops, rechargeable batteries, and various medical devices. The elements are typically split into two subgroups: the cerium sub-group of ‘‘Light’’ rare earth elements (LREEs) which includes La to Eu and the yttrium sub-group of ‘‘Heavy’’ rare earth elements (HREEs) which include the remaining lanthanide elements, Gd to Lu, including yttrium (Gupta and Krishnamurthy, 1992; Jordens et al., 2013; Trifonov, 1963). Scandium, however, when it is classified as a rare earth element, is not included in either the LREE or HREE classifications (Gupta and Krishnamurthy, 1992; Jordens et al, 2013). Half of the world’s 110 million tons of reserves exist in China while other sizable deposits are found in Russia, United States, Brazil, India, Australia, Canada, and Greenland. The countries known to be actively mining REE are China, Russia, India, Brazil and Malaysia (Hao et al., 2015). Among these countries, China has the largest REE production, accounting for more than 93% of global supply (Yap, 2015). The critical metal report (Moss et al. 2011) listed 14 economically vital raw materials that are prone to supply disruption and concluded that supply disruption would threaten the goal for cleaner transport and sustainable energy since rare earth metals are used in products using green technology, such as hybrid/electric vehicles, carbon capture systems, wind power generation, low-energy lighting, and energy efficient flat-screen displays."

Jan 1, 2016

By Earl Sweet

This overview of economic and financial market prospects examines the current and future state of the global and Canadian economies with a focus on commodities. Housing prices and global conflicts all have effects on the overall economy and metal prices and mining developments in particular. This presentation outlines where we are today and where the author and BMO see the economy moving over the next few years.

Jan 1, 2016

By Tommee Larochelle, Henry Kasaini

"Simulation of rare earth element solvent extraction processes for plant design and optimization is complex, requires extensive bench scale and pilot scale testing, and is traditionally performed using proprietary algorithms. The complexity of simulation is mainly due to traditional simulation software solvent extraction modules not being designed to simulate rare earth separation processes because of the interaction between each element. This paper presents an alternative method for designing and optimizing rare earth element solvent extraction separation processes using METSIM to converge each stage of the battery individually until the full battery reached ultimate convergence. A feed-forward controller is used to control the organic to aqueous flow ratio feeding the solvent extraction modules. This method minimizes the complexity of simulating such processes by using inexpensive batch solvent extraction data, and allowing for rapid theoretical optimization, by varying the process configuration and parameters from a graphic interface instead of the traditional code-based interface of most proprietary models. Comparison of the model predictions to pilot plant data reveals that the method can be used to accurately model rare earth solvent extraction processes, as illustrated by its application in the development of Rare Element Resources innovative process.INTRODUCTIONThe Rare Earth Elements (REEs) consist of 16 metals, specifically the 15 lanthanide elements and yttrium, which is typically found in the same mineral deposits as the lanthanides. Scandium can be associated with the rare earth elements, but is usually only present in trace amounts, and therefore omitted. The term “rare earths” originates from an old term used to designate minerals (earths) and their believed scarcity upon their initial discovery. The rare earths designation is now considered a misnomer because it was demonstrated that the crustal abundance of some rare earth elements, such as cerium, is known to be higher than many common metals, such as copper. However, enriched deposits are fairly uncommon compared to other similarly abundant metals. The REEs are typically divided into groups commonly consisting of light rare earths (LREEs), medium rare earths (MREE), and heavy rare earths (HREEs). Light rare earth elements include lanthanum to neodymium, medium rare earths include samarium to gadolinium and the heavy rare earth elements include terbium to lutetium, and yttrium. The REEs exhibit similar chemical characteristics and are usually extracted from the ore and processed into a mixed rare earth concentrate. The rare earth concentrate requires further processing in order to separate the REEs from each other and produce a series of single element products."

Jan 1, 2016

By M. S. Moats

"The effects of commercial copper electrorefining additives (glue and thiourea) on the electrochemical removal of bismuth are of importance in copper production. It was found that Bi(III) electrodeposition occurs readily from acidic sulfate solution via a diffusion-controlled quasi-reversible reduction. The diffusion coefficient of Bi(III) was measured and found to be less than reported values of copper in similar solutions. The presence of thiourea and/or glue was found to accelerate or de-polarize Bi(III) reduction on stainless steel as compared to the inhibition or polarization of Cu(II) reduction. The additives also inhibited the dissolution of the Bi-Cu co-deposit during cyclic voltammetry. During short term deposition studies, the additives increased the concentration of Bi in co-deposited Cu-Bi products from solutions with low concentrations of Cu (<2 g/L). Bi deposition was significantly suppressed by increasing the Cu(II) concentration in the solution. The formation of a copper layer on the stainless steel electrode appeared to significantly suppress the reduction of Bi(III). This study demonstrates that glue and thiourea depolarize the deposition of bismuth on stainless steel. Therefore, the additives could be used to improve Bi impurity removal during third stage liberation.INTRODUCTIONThe production of high purity copper has been steadily increasing due to the wide application of the metal and its alloys in electrical and electronic products, infrastructure construction, industrial machinery and equipment, general products and transportation (Moskalyk et al., 2003). Most high purity copper is manufactured from copper sulfide mineral concentrates and/or scrap via a pyrometallurgical process followed by electrorefining (Navarro et al., 1999). During the electrorefining process, cast anodes of 99-99.5% purity are electrochemically dissolved into an acidified copper sulfate solution while high purity copper (>99.99%) is plated on stainless steel blanks or copper starter sheets (Davenport et al., 2002). The control of cathode deposit growth (purity and morphology) while maintaining a high current efficiency is of significant importance for copper refining (Ilkhchi et al., 2007). At typically applied current densities for industrial copper electrorefining, mass and charge transfer play important roles in the quality of cathodic products (Hiskey et al., 1998). If the real current density at some surface points is substantially higher owing to uneven current distribution, then rough spots can and will grow faster leading to nodules (Suarez et al., 1992). Nodulated deposits tend to capture solution and anode impurities (slimes) resulting in unacceptable cathode quality (Afifi et al., 1987). Furthermore, these nodules can grow until they eventually contact the anode leading to short circuits and current efficiency reduction (Ilkhchi et al. 2007)."

Jan 1, 2016

By Niels Verbaan, Ron Molnar, David Dreisinger

"An acidic chloride leach solution was generated from the treatment of an ore containing the following value elements: silver, gold, indium, gallium, copper, zinc and lead. Iron was also co-extracted into solution as a ferric chloride species. Iron extraction was a significant component of the overall acid consumption of the leaching process. The recovery of iron by solvent extraction and water stripping was investigated. Tri-butyl-phosphate (TBP) was very effective at recovering iron from the leachate. The water strip solution could be decomposed to produce ferric oxide (hematite) and hydrochloric acid for recycle via hydrothermal hydrolysis or pyrohydrolysis.INTRODUCTION The Malku Khota deposit is situated in the eastern part of the Bolivian Altiplano at elevations between approximately 3,800 and 4,580 meters above sea level (Figure 1). The project is located 98 km east-southeast of Oruro, and 85 km south of Cochabamba in a relatively remote area."

Jan 1, 2016

By Michael Loken, April Montera

"The process of blending consistent and predictable feed for the roasters is critical to optimizing product quality and controlling production costs. To assist in this process, Online PGNAA Slurry Analyzers have been installed and evaluated at a Sudbury Ontario smelter. They are used to measure 100% of the full process stream to obtain elemental composition data in real time. This paper explains the application details at Sudbury and the benefits achieved from their Full Stream, Elemental Slurry Analyzers.INTRODUCTIONSudbury Integrated Nickel Operations (Sudbury INO), a Glencore Company consists of two underground nickel/copper mines in Sudbury, Nickel Rim South and, Fraser, along with the Strathcona mill and the Sudbury smelter. The facilities are spread throughout the 60 kilometer-long, oval-shaped geological formation known as the Sudbury Basin (Figure 1). The company has been mining nickel-copper ores in the Sudbury area since 1929. Nickel and copper are the primary focus of operations at Nickel Rim South and Fraser. Other base metals such as cobalt and precious metals are also produced."

Jan 1, 2016

By S. V. Ulianov, A. Y. Senchenko, A. A. Shvets, A. V. Aksenov

Development of an efficient technology to process complex ores containing gold and antimony as well as silver is described in the paper. The results from the testwork aimed at the valuables recovery by means of flotation are presented. A process sample of antimonite gold-bearing ore was studied in TOMS institute aiming at development of a technology to process such an ore with generation of antimony concentrate and sulphide gold-containing concentrate. Material composition study indicated that the ore included 5.3% of sulphides: arsenopyrite – 2.4%, pyrite -2.4%, and antimonite – 0.5%. Gold is present as an isomorphic dissemination in arsenopyrite. At sighter testing stage a direct selective flotation flowsheet was chosen to process the ore. Antimonite flotation was activated due to addition of lead nitrate. A single cleaning of a rougher flotation concentrate resulted in antinomy concentrate with 30% Sb content and 71% recovery. Au recovery into antimony concentrate did not exceed 1%. Sb flotation tailings were used to float the remaining sulphides and gold. The resulted sulphide concentrate was characterized by Au content of 20 g/t at about 80% recovery, arsenic content - 10% at ~80% recovery, and sulphur content - 18% at ~81% recovery. The sulphide concentrate can be forwarded to further processing aiming at gold recovery. Given that the concentrate is highly refractory it should be pretreated (bacterial or pressure oxidation, Albion process) prior to cyanidation in order to liberate gold from sulphides. The proposed technology allows one to solve the problem of precious metals recovery from antimonite ores.

Jan 1, 2016

By Minerals Refining Company, Gerald Luttrell, Biao Li, Robert Bratton, Roe-Hoan Yoon, Stan Suboleski, Nikhil Gupta

Flotation is regarded as the best available method of upgrading coal and mineral fines in the mining industry. However, its efficiency deteriorates rapidly with decreasing particle size. Furthermore, ultrafine concentrates are difficult to be dewatered economically. Due to these technological problems, some operators are forced to discard at least part of the ultrafine materials to tailings (or refuse) ponds, causing significant losses of valuable resources and creating environmental concerns. To address these technological issues, a new separation process named hydrophobic-hydrophilic separation has been developed on the basis of the recent advances in the science of hydrophobic interactions. The results obtained to date show that the process can recover and dewater ultrafine particles simultaneously with high separation efficiencies. Following a series of extensive laboratory tests, the process has been scaled up to proof-of-concept and pilot-scale continuous tests. The results obtained with desliming cyclone overflows, screenbowl effluents, and by-zero coal flotation feeds can be cleaned to less than 4% ash and moisture with over 97% organic matter (or coal) recoveries. The results obtained with mineral fines also showed encouraging results.

Jan 1, 2016

By David Deglon, Martin Harris, Mehdi Safari

"This study investigates the effect of energy/power input on the flotation of a platinum ore in a pilot-scale oscillating grid flotation cell. Oscillating grids generate near ideal hydrodynamic environments, characterised by turbulence which is relatively homogeneous and isotropic. Secondary rougher feed and primary cleaner tail streams were floated in a pilot-scale oscillating grid flotation cell at power inputs from 0 to 2.5 W/kg, using 0.50 and 1.50 mm bubbles. From this study one may conclude that the effect of energy/power input on the flotation rate is strongly dependent on the particle and bubble size. Flotation rates generally increase with increasing particle size and decreasing bubble size. Increasing energy input generally leads to an increase in the flotation rate for finer particles and an optimum flotation rate for intermediate & coarse particles. Optimum conditions for intermediate/coarse platinum ore particles are using small bubbles at low energy inputs, or large bubbles at higher energy inputs. These results suggest that higher energy inputs are generally beneficial for the flotation of platinum ores as these consist predominantly of finer particles (-75 µm) and most industrial flotation applications operate with larger bubbles (1.0-2.0 mm).INTRODUCTIONThere is a considerable body of experimental and theoretical evidence to suggest that energy/power input plays an important role in flotation kinetics, particularly in the finer particle sizes where flotation efficiency is poor (Deglon, 2005). A number of excellent studies into the effect of energy on flotation kinetics have been carried out in impeller stirred cells (Ahmed and Jameson, 1985; Deglon, 2002; Pyke et al., 2003; Newell and Grano, 2006). Investigations using this type of cell have a number of limitations. The impeller influences particle suspension, bubble break-up and agitation in the cell. In addition, turbulence is highly inhomogeneous and anisotropic, with power intensities near the impeller orders of magnitude higher than those found elsewhere in the cell (Deglon, 1998; Koh and Schwarz, 2003; Schubert, 1999, 2008). These limitations have resulted in the development of novel cells for the investigation of energy input."

Jan 1, 2016

By Peter A. Amelunxen, Richard LaDouceur, Courtney A. Young

"Many of the rare earth elements, the lanthanide series on the periodic table, are on the U.S. Department of Defense Strategic and Critical Materials list. In this regard, the U.S. Army Research Laboratory (ARL) has funded several projects at Montana Tech focusing on rare earth element recovery from natural resources. Current froth flotation operations utilize octyl hydroxamate for rare earth mineral extraction, however recovery is not ideal and flotation performance can be improved. Salicylhydroxamic acid (C7H7NO3) was identified as a novel collector due to similarities with n-octyl hydroxamate, notably the amine head group. Salicylhydroxamic acid is primarily used in the medical industry but due to the amine head group is ideally suited as a collector for rare earth mineral flotation.Parametric studies were performed for the flotation of rare earth minerals by modifying a wide range of variables. Mechanical variables of a 6L bench scale flotation cell, such as air inlet flow, rotor speed, and milling time for liberation were modified to elucidate energy input parameters for the desired minerals. Chemical parameters such as collector concentration and pH were varied to understand solution chemistry considerations of the salicylhydroxamic-rare earth mineral system. The study obtained a statistically significant experimental model for the flotation of rare earth minerals. A two stage compartmental model was also utilized for the determination of the first order flotation rate constants for each mineral. Optimized recovery of rare earth minerals was found to occur at near neutral pH ranges using salicylhydroxamic acid with maximum recoveries approaching ideal industrial standards although rare earth mineral grades were still not sufficient.INTRODUCTIONRare earth elements (REEs) are found in minerals that contain several REE which makes costeffective separation of the rare earths difficult. Significant scientific challenges have hindered mineral separation. The molecular similarity of rare earth elements results in minerals containing several REEs, such as bastnaesite [(Ce, La) CO3F]. This prevents efficient separation during concentration steps, for instance flotation, and has a direct impact on successive metallurgical processes. Consequently, concentration during flotation is of rare earth minerals (REM) as opposed to REE."

Jan 1, 2016

By C. T. Dzgoev, S. S. Gudkov, IRGIREDMET JSC, S. G. Schtoick, A. V. Yepiforov, S. V. Balikov, I. I. Yevtuschevich

The pressure oxidation (POX) and pyrometallurgical process comprises POX of gold containing sulfide and polymetallic lead-zinc concentrates prior to reduction smelting of POX products to generate a lead-silver-gold alloy. Refined lead and gold-silver alloys are then obtained using conventional processes. Zinc and other base metals are recovered from the POX solution. In the course of POX, zinc dissolves in the solution and lead concentrates in a solid residue in the form of sulfate compounds. Sulfur forms the major iron sulfates and jarosites. In order to dissolve sulfur and arsenic from solid residues to the solution, the slurry hot curing was carried out at the temperature of 95°C within 2 hours. After filtration of the slurry, zinc was recovered from the solution. The resulting cake was washed with water and subjected to hot alkaline treatment. After alkaline treatment, the cakes were blended with fluxes and subjected to reduction smelting to generate lead concentrate containing precious metals. This concentrate was refined to obtain refined lead and gold-silver alloy. After iron and arsenic were removed from POX solutions using sodium carbonate, zinc was precipitated as carbonate. After thickening and filtration, zinc precipitate was roasted to generate saleable zinc oxide. Using this process, the recoveries of values to saleable products were 97% Au and 95% Ag to the alloy, respectively, 91% Pb to refined lead and 5% Pb to lead and antimony alloy and 94% Zn to zinc concentrate. The features of the technology is that it has high recovery indices of precious and base metals to saleable products and can be used to process various polymetallic ore and technogenic raw materials.

Jan 1, 2016

By Malcolm Powell

"Predicting the performance of the whole mining process is surely the holy grail of predictive simulation. This can be named ‘Integrated Process Prediction’.The objective is to be able to predict the response of the processing chain, from mining to concentration, to changes in the ore type. This can apply to greenfields design – selecting processing options to optimise the overall mine performance within the constraints and aspirations of the greater community and environment; expansion and optimisation of existing plant to deal with changes in economic drivers and ore types; and on-line control – predictive reaction to ongoing changes in ore processing types in an operation.In order to achieve this there are several broad key components that are required: ore characteristics based on in-situ rock properties; a reliable 3D map of the ore body by the key processing parameters; prediction of how the rock fragments and the energy requirement to break it; the ability to predict and track progressive mineral liberation of the rock through the reduction process; the response of rock to separation processes as a function of the rock mineralogical properties. This requires the identification of primary rock properties and associating them with the rock particles as they move along the mining process chain to a concentrate or various forms of waste.This paper looks at the value of this integrated approach; the challenges it poses; the technology and capability we require; and how as a mineral processing community we can address the challenges."

Jan 1, 2016

By Guangdong Institute of Resources Comprehensive Utilization, Y. H. Tang, H. X. Hu, T. S. Dong, Z. H. Zhang

"A world class rare metals ore deposit in Africa belongs to a massive granite type poly-metallic pyrochlore-niobium resource. Successful project development in realizing the resource is vital to Africa’s economy and pyrochlore processing technology.The ore properties are quite complex due to the presence of varieties of valuable minerals, fine dissemination and intimate association of minerals and the relative abundance of easy-floatable minerals. The separation of pyrochlore from zircon, calcite and mica is generally considered difficult. Whilst studies have previously been conducted by several independent institutions overseas, no satisfactory process has yet been developed to date for the ore deposit—possibly due to the process designed being too complex; high cost of regents; lower performance.Based on process mineralogy study and extensive testwork, the authors have in recent years developed a new technology—“De-slime—Iron-rejection—Zircon (with calcite) and Calcite reverse flotation—Pyrochlore flotation”. The flow-sheet is characterized by ?1prior removal of slimes and iron minerals; ?2 Zircon (with calcite) and Calcite reverse flotation; and ?3Pyrochlore flotation applying new type of chelating collector GYX3 developed by GZRINM in conjunction with selected regulators and depressants.The process involved in the new technology is simple to implement and facilitates stable operation; the flotation reagent regime is easily adaptable; the cost of main reagent is lower largely because it is easy to manufacture and is environmental friendly. Laboratory test results demonstrated that, for raw ore assaying 0.35% Nb2O5, 0.03% Ta2O5 and 0.45% ZrO2, pyrochlore concentrate grade of >35% Nb2O5 could be obtained with >74% recovery. Meanwhile, the Ta2O5 content in pyrochlore concentrate could be recycled, and ZrO2 recovery >50% could be achieved in zircon concentrate assaying ZrO2>63%—significantly improving the technical-economic indicator. These results were verified in pilot trials of 1.44t/d throughput. The paper presents the new technology in whole, summarizes the key factors affecting its performance and discusses in simple terms the mechanism of separation."

Jan 1, 2016

By Xianglin Yang, Hong Zhong, Jingjing Xiao, Guangyi Liu

"The selective adsorption of a flotation collector to a mineral plays a crucial role in enhancing the hydrophobicity of targeted mineral particles for attaching air bubbles in pulp. The recent progress of the structure-reactivity relationship of flotation collectors, the characterization methods for mineral surfaces with adsorbed collectors and their commercial application are reviewed in this paper. Particular emphasis is placed on the density functional theory (DFT) for understanding the reactivity of new collectors, the surface analysis techniques including time-of-flight secondary ion mass spectrometry (ToF-SIMS), in situ scanning electrochemical microscopy (SECM) and atomic force microscope (AFM) to characterize mineral/collector interface, and the flotation technologies for optimizing recovery of valuable minerals. Especially, the recently developing collectors such as Gemini, alkoxyalkylthiourea, dithiourea, amide-hydroxamate and oximido-thiol surfactants, and their specificity to given minerals are evaluated. Based on this crucial review, it is evident that the structural modification approaches for minerophilic or hydrophobic groups, and combined surface analysis approach for further understanding the adsorption mechanism of collectors on mineral surfaces will lay a solid foundation for the future development of flotation collectors. INTRODUCTIONIn mineral processing, flotation is the main process for separation and recovery of valuable minerals from the ores contained them (Fuerstenau et al., 2007). One of the key requirements in flotation process is to increase selectively the surface hydrophobicity of the targeted minerals by collector adsorption so that these mineral particles can preferably attach to air bubbles in a slurry or pulp (Fuerstenau et al., 2007). Flotation collector is a kind of functional surfactant, which is composed of polar and non-polar groups (Somasundaran, & Wang, 2006). Non-polar portion, commonly being linear, branch or ring hydrocarbon group, is termed hydrophobic group. The polar portion, exhibiting strong affinity to mineral surfaces, is known as minerophilic group (Nagaraj, 1988). According to mineral types including saline, oxide and sulfide minerals, flotation collector divides into sulfide and oxide mineral collectors. For efficient recovery of valuable minerals from the refractory complex ores, insights into the adsorption mechanism, hydrophobic model and subsequent flotation approach of flotation collectors have been regarded as an indispensable issue in mineral processing."

Jan 1, 2016

By D. K. Sarkar, Ying Huang

"Superhydrophobic thin films were fabricated on aluminum alloy substrates by chemical etching followed by passivation with organic acid molecules; (ii) electrophoretic deposition (EPD) of functionalized ZnO nanoparticles and (iii) electrodeposition of organic-inorganic composite materials. The physical and compositional analyses of the deposited thin films were characterized by SEM, FTIR, XRD as well as contact angle goniometer. The contact angle and surface roughness of the superhydrophobic surfaces prepared by the chemical etching process were found to be 156° and 2.29 µm, (ii) by the EPD process were found to be 155° and 4.54 µm and (iii) by the electrodeposition process were found to be 159° and 7.11 µm, respectively.The corrosion properties were analyzed with both polarization and electrochemical impedance spectroscopy (EIS) in NaCl aqueous solutions. The results demonstrate that the superhydrophobic thin films on aluminum alloy substrates display better anti-corrosion behavior than the as-received aluminum substrate. The comparison of results pertaining to the compositional and corrosion properties of these thin films on aluminum will be discussed in this work.INTRODUCTIONSuperhydrophobicity is defined as a surface property which provides non-wetting characteristics with a water contact angle larger than 150°. It is observed that the creation of certain micro-nanoroughness structures promotes the entrapment of air in the spaces of the rough surface morphology. In addition, lowering the surface energy helps to reduce the affinity of water drops to the surface, thereby weakening the water-surface interaction. Recently, various fabrication methods for superhydrophobic surfaces have been explored (Sarkar, 2010, Huang, 2010, 2011, 2013, 2015a, 2015b), such as the sol-gel process (Brassard, 2011), plasma treatment (Marchand, 2013), chemical vapor deposition (Zheng, 2009), chemical etching (Saleema, 2011), electrodeposition (Ying, 2011) and electrophoretic deposition (EPD; Huang et al., 2015b)."

Jan 1, 2016

By E. Larsen

Marine tailings disposal may in some cases be the best solution to one of mining’s major environmental problems. The public standing of this solution is poor, partly because of past bad practices. Among the tailings problems spreading of super-fines and toxic substances stand out. The two are often interrelated as heavy metals, insoluble to sea water, tend to adsorb on fines and spread piggyback on them. Only one paper seen, has addressed the mineralogy of fine particles in suspension. The topic was a secondary tailings deposit. Studies on the sedimentation of fines in large river estuaries show that different minerals sediment sequentially as the salinity of the river increase. Mineralogy in the particle size range where particle separation takes place, has so far, naturally been in focus for the mineral processors. Next to nothing is known about the fines which may cause environmental problems. Tailings disposal has, due to its complexity, to a large extent been taken over by specialists in other fields, biologists, engineering geologists, chemists. The basics of the subject ought also to be given more input by the mineral processing community. A drawn out battle about tailings discharge into some fjords has taken place in Norway. The detractors focus at fine particles (could be dangerous nanoparticles) spreading and emphasize the effects. Calculation is simple: 5 million tonnes tailings annually discharged, containing 1 wt. % < 1µm determined by laser diffraction, results in 50 000 tonnes of nanoparticles let loose in the environment. The industry`s difficulty to answer, is lack of basic research on this topic. Test work to develop a methodology to address the problem is described. One thing the mineral processors know is that final tailings may be comprised of tailings from separate separation processes, with different properties, some of which may require special treatment. One tailings stream from a Norwegian mine is investigated in such a context.

Jan 1, 2016

By Maciej Wrobel, Joerg Hammerschmidt, Dana Nurgaliyeva, Alexandros Charitos, Jochen Guentner

"Smelting of copper concentrates in the flash smelter generates a flue dust stream that contains a substantial amount of copper and accumulates more than half of the arsenic input to the smelter. In view of its high copper content flue dust recirculation to the flash smelter is common practice. Globally traded copper concentrates are affected by ever increasing arsenic contents and cause an increasing circulating arsenic load in flash smelter operation. Control of the arsenic level in the smelter slag becomes a challenge. This interaction of arsenic loaded copper feedstock, need for flue dust recirculation and slag quality control call for possibilities to reduce the arsenic load of the recirculated flue dust stream.The technology of partial roasting is known from pre-treatment of copper concentrates before smelting, and gold concentrates before cyanide leaching, to remove the harmful element arsenic. The partial roasting technology can be adapted for use in the purification of the flue dust. A major challenge for flue dust treatment is its extremely fine particle size compared to usual concentrates. For this reason Outotec developed a new process, which allows handling of such fine flue dust. This process solution provides an efficient possibility to reduce the arsenic burden in copper smelter operations.The suggested process aims at reducing the arsenic load to the smelter by treating the flue dust prior to recirculation to the smelter. The presented results are based on test work in the Outotec R&D-centre in Frankfurt. It is possible to remove 80-85% of the contained arsenic and to collect it in an arsenic trioxide residue with a concentration above 90%. The final off gas contains SO2 from decomposition of sulphates that are contained in the flue dust. The off gas stream is relatively small. We assume that it is possible to combine the off gas stream with other smelter process gas streams and to treat it in an existing sulphuric acid plant. Coal is used as fuel and as reductant to reduce pentavalent arsenate to trivalent arsenite. Arsenite can be kept in gas form at temperatures above 450°C. This permits separation of a calcine stream with arsenic levels of 0.2 – 0.3%, which is recirculated to the furnace.Outotec has a wide range of roasting testing facilities from lab-scale to pilot-scale. Outotec has both capability to modify and adapt technology to specific ore or concentrate requirements, but also the necessary infrastructure in its research centers in Frankfurt and Pori to do appropriate validation tests in lab and pilot scale size plants."

Jan 1, 2016

By Hatch, A. Reple, W Valery

The mining industry is facing declining feed grades which require the mining and processing of larger volumes of material per tonne of product. Pre-concentration aims to remove barren material at as coarse a particle size and as early in the process as possible to reduce processing costs, energy consumption, water losses, and greenhouse gas emissions while increasing production and profitability. This may be achieved using bulk ore sorting—the separation of barren gangue from a fully loaded conveyor belt based on the grade as measured or inferred from a sensor. This paper evaluates the technical and economic viability of bulk ore sorting for the PanAust Phu Kham copper deposit in Lao PDR. Bulk ore sorting technology is described briefly along with discussion of appropriate sensor and diversion systems for the Phu Kham operation. To evaluate the economic implications, the actual mined material and costs from 2014 were used as the base-case. Sampling data was not available; therefore, the ore grade variability that would feed a bulk ore sorter was estimated using geo-statistical tools based on mine grade control data. The sorter performance when treating this material was simulated considering the accuracy of the sensor measurement and errors associated with material diversion. The impact on inferred cash flow was estimated for several different scenarios considering the additional costs for sorter operation and reject handling. The evaluation demonstrated that bulk ore sorting at Phu Kham has the potential to increase the amount of metal in product and/or reduce processing plant throughput (and costs) to improve the annual inferred cash flow for the conditions investigated. The sorter is the gatekeeper – only material above the cut-off grade (value-adding) reports to the processing plant; no waste dilutes the feed. Likewise, above cutoff grade material is not lost to waste; preventing lost revenue.

Jan 1, 2016

By A. Tylczak, C. Shook, A. Doogan-Smith, S. Loif, B. Hilscher, P. Nayak

"This paper discusses how to effectively conduct energy efficiency studies during the design of new mineral processing plants and plant expansions. Energy management studies for new plants are ideally conducted as part of the feasibility study, but can also be done at the detailed design stage prior to the purchasing of equipment. Energy management engineers work as part of the mineral processing plant design team.Such studies usually result in energy savings of approximately 3-8% of the predicted plant’s energy consumption and energy demand. Potential cost savings can be significant. A variety of mineral processing systems – crushing/grinding, pumping, materials handling, fans/blowers, compressed air, and others – are assessed within this study.Energy Management Information System (EMIS) studies can also be performed for the new plant or plant expansion, as an independent study. EMIS can be incorporated into the electrical and controls design of the plant.Most Canadian Utility companies fund new plant design studies and provide financial incentives based on the predicted energy savings and incremental cost of the more energy-efficient design. A new plant energy efficiency study improves the potential for energy reduction because only the incremental equipment cost is included in the project return-on-investment calculation. After the design and construction phases, energy efficiency projects must justify the entire cost of the upgrade, which is significantly higher than the incremental cost alone.This paper outlines the major steps of a new plant/plant expansion energy efficiency study, the available utility company incentives, and the areas yielding the largest potential energy savings.IntroductionThis paper discusses energy efficiency studies and energy management systems with regards to mining operations. Energy management refers to the systems of monitoring, analyzing, and optimizing energy usage within a facility. It includes energy efficiency optimization of the initial plant design as well as the implementation of an Energy Management System (EnMS) and Energy Management Information System (EMIS) for optimizing energy usage over the lifetime of the facility. An EnMS is the organizational framework and procedures for managing energy use; an EMIS is the system of monitoring, reporting, and tracking process energy use against targets."

Jan 1, 2016