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By H. R. Manouchehri

"In mining and minerals industry, except profitability, there are some crucial factors that represent components in economic machinery of a mine and related activities. These are sustainability and minimizing environmental impact factor. Environmental concerns combined with the water and energy availability and related costs, as well as public license to operate all contrive to demand for more efforts targeting sustainability. Mining industry is highly energy-intensive (estimated to consume 6-7% of total world’s energy), with varying the energy efficiency across the industry resulting in significant costs. Size reduction is the main energy consumer contributing to almost 50% of the total energy used in mining. That means efforts must be made to introduce energy efficient comminution flow-sheets and machineries for sustainable development. Since the crushers are more energy efficient than mills, it is logic to push down-sizing in crushing stage(s) as far as technically possible. That has been strategy for Sandvik Mining and Rock Technology in supplying advanced and effective crushers to provide fine crushed product for subsequent milling stage. Lowering the energy consumption and related costs as well as increasing throughput have been the main objectives in design and development of comminution circuits and related machineries. Inefficiency in comminution technology, particularly in grinding, has long been regarded as a major area for investigation and development, especially when production of fines and ultra-fines are considered. In an attempt to explore the potential of fine crushing and its effects on subsequent milling process the fine crushing performance of Sandvik’s conventional cone crusher and Vertical Shaft Impactor (VSI) in pilot scale to define the energy consumption and circulating load in fine crushing. Tests were conducted to obtain fine crushed products at P = 2 mm in a close circuit. Furthermore, the crushed products were characterized and compared by grind-ability, morphology, and surface area measurement tests. Finally, the energy consumption to grind the crushed products to specific grind size was calculated."

Jan 1, 2018

By Matt Kilburn, Liming Lu, Steve Suthers, Alexander Edenton, Rodney Smyth, Matt Adam

"Magnetite concentrate is naturally good for pelletising. However, due to the depletion of reserves of traditional high grade hematite iron ore worldwide, the usage of magnetite concentrate in sintering is expected to increase substantially. Magnetite concentrate is typically high in Fe grade and releases extra heat when oxidised to hematite. This will not only improve the quality of agglomerates produced, but also have a potential beneficial impact on the fuel consumption of the agglomeration process. There are an increasing number of magnetite projects currently being considered and developed. However the concentrates from some of these projects are too coarse as pellet feeds and much finer and denser than normal sinter feeds. Accordingly, special strategies are required in order to utilise the coarse magnetite concentrates at high proportions in pelletising and sintering. This paper discusses various raw material preparation technologies and blending optimization methods demonstrated to be effective for improving the sintering and pelletising performance of coarse magnetite concentrates. Pre-granulation and addition of binders, such as hydrated lime, were found to be particularly efficient in recovering the sintering productivity of sinter blends containing magnetite concentrates. In pelletising, HPGR (High Pressure Grinding Rolls) grinding enabled production of good quality pellets from 100% magnetite concentrates and optimized blends containing up to 70% magnetite concentrates also formed good pellets.INTRODUCTION Magnetite concentrates are often used as feed materials for pellet plants or sinter plants depending on their grades and grain sizes. To achieve the required quality of green and fired pellets, the concentrates often need to be ground very fine (80% passing 38- 45 m), which inevitably consumes a great amount of energy. Therefore, efficient grinding processes are required to reduce the amount of energy consumption needed to achieve the sizing and chemical specification of pellet feeds. The use of magnetite concentrates in sintering has the potential to improve sinter chemistry, which is deteriorating over time due to the slowly decreasing grade of direct shipping iron ores around the world (Yang and Mathews, 1997; Yang and Witchard, 1998, Yang and Davis, 1999; Yang 2005). However, methods are required to allow the utilisation of high levels of concentrates in sintering while maintaining productivity and sinter quality (Han and Lu, 2017)."

Jan 1, 2018

By Roberto Galéry, Braz J. C. Filho, Marcelo M. Stopa, Douglas B. Mazzinghy, Priscila M. Esteves

"The purpose of the research is to monitor ball mill filling by means of signals usually measured in its electrical drive. The method is based on the mill torque estimated from rotor speed and induction motor stator voltage and currents. New signal processing is presented in both time and frequency domain for measurements in a dry laboratory ball mill. Statistical analysis is applied to time series resulting in good correlation to mill filling. Fast Fourier Transform (FFT) and power spectral density (PSD) also resulted in an accurate filling indicator. The proposed method does not need any sensor to be installed directly on the mill and requires only sensors usually available for motor control purposes. The experimental results showed that the method have potential to be used to construct an automatic system for monitoring operational variables in ball mills. The aim of this monitoring is to improve energy efficiency, reliability and productivity.INTRODUCTION Recently, a great number of papers have pointed the importance of ball mill filling monitoring and also of grinding control (Lu, et al., 2014) (Ramasamy, et al., 2005) (Tsamatsoulis, 2014) (Zhou, et al., 2009). Additionally, great amount of control techniques have also been presented with several complexity degrees (Tsamatsoulis, 2014). According to Eremenko (2015) the lack of effective and accurate methods for fill level measurement is the main reason that makes mill optimal control so complicated. It happens because nonlinearity, long time delay and time varying features of the ball mill turns difficult to develop a truly efficient method for monitoring filling. At the same time, fill level has a determining role in charge motion and consequently on particle breakage. For low levels of filling many energy is expended in impacts with very low breakage efficiency. Those impacts can also damage mill liner. In contrast, high levels of filling causes damping effects that reduces breakage and can also affect energy consumption. Based on this it is conclusive that fill level measurement of ball mills is an important issue for grinding efficiency. This fill level information can be used for operators to control ball mills and also for engineers to run simulations and improve confidence levels of circuit designs (Shi, 2016)."

Jan 1, 2018

By A. V. Myaskov, V. S. Valavin, K. D’Elia, I. O. Krylov, Vu Van Toan, T. I. Yushina

"The purpose of this research is the development of a technology for processing the concentration tailings of limonite ores at Kamysh-Burun Mining and Processing Complex into an iron- containing product for ROMELT process. In the concentration and metallurgical processing of iron ores, substantial amounts of waste are generated (tailings, slimes, slags, metallurgical dust, etc.) that can be converted into a commercial product if is properly processed. This article presents the results of experimental studies of the feasibility of processing iron- containing tailings of Kamysh-Burun deposit (slimes from Verkhne-Churbash storage facility (VCh sample) and dumped waste of Kamysh-Burun (KB sample)) to obtaining valuable components for further uses. Applying Mossbauer spectroscopy has been shown that the iron minerals in the studied samples are technogenic varieties of iron hydroxides. The most suitable technology is the magnetic roasting process, since iron hydroxides are easily transformed into a magnetic, easily recoverable form. Have been shown the advantages of a two-stage magnetic separation, in a strong field and with polygradient separators. Concentrating this material through magnetic methods makes it possible to increase the iron content to 20-21 %. Magnetic concentration of the deeper layers materials results in iron- containing concentrates with a total iron content of up to 58% whit a phosphorus content of about 2%. Reducing the phosphorus content is possible by blending upper and lower layers of the material at a ratio of 1:1. Thus, it is possible to process the material accumulated in the slime storage facility using the ROMELT process combined with preliminary three-stage magnetic concentration and disposal of tailings with the permissible iron content of less than 5%. Wastes from smelting will be slags suitable for use in construction industry. The Kamysh-Burun material preparation for ROMELT process should be performed applying gravity-washing with separation of the -0.4 mm fraction and additional blending for dephosphorizing the concentrate. The smelting will produce pig iron and slag."

Jan 1, 2018

By E. Guerrini, M. Maccagni, J. Nielsen

"Lead is the most important material able to meet the current demand for energy storage. The lead acid battery is reliable, efficient and inexpensive. Continuous developments in battery construction are providing improvements in all aspects of the batteries’ performance. The lead acid battery is both the main lead product and the main raw material for lead production. More than half of the lead produced is from secondary smelters where batteries are the most important feed material. The environmental pressure on lead production has been increasing for many years, and continues to become stronger and stronger. The lead production processes and technologies themselves will require updating to meet the new regulations. Although they are very strict now, they will become even more so and current technologies may not be sufficient. Because recyclability is a strong point for the lead acid battery, the secondary smelters need to reduce the environmental impact as much as possible. In recent years, the secondary smelters underwent impressive changes in this direction, but some more improvements are possible. Electrochemistry can offer a step change improvement in making secondary lead production more environmentally friendly. Engitec has developed an electrochemical process base on a very high current density (high productivity) cell using an inexpensive electrolyte and at a relatively low cost. In this paper, the latest update on the technology is provided. INTRODUCTION The lead acid battery is considered the “walking dead” by some new technologies trying to replace it. It has played and will continue to play a very important role in our lives because it is inexpensive, fully recyclable and the existing lead and the mine reserves guaranty enough material for the extended future. According to the life cycle, the lead acid battery is the cheapest and the most effective system to store energy. Lead is practically a close loop where lead battery production consumes more than 80 % of the produced lead but contemporarily it is the most important raw material for the production of metallic lead. In fact, nowadays, the secondary production has overcome primary production and this trend is expected to continue. Primary lead is the make-up material for the existing battery production and the source of lead for the construction of the new ones."

Jan 1, 2018

By S. Jeon, N. Hiroyoshi, N. Kitajima, S. Tanaka, M. Ito, R. Pongsumrankul, C. B. Tabelin

"Gold (Au) extraction is inefficient when crushed waste mobile phones (WMPs) are directly leached by ammonium thiosulfate likely because of the cementation/precipitation of dissolved Au in the presence of base metals like copper (Cu), iron (Fe) and/or aluminum (Al). This study applied physical separation techniques to remove base metals as well as plastics and concentrate the Au containing fractions from WMPs prior to leaching. Coarse fraction of crushed WMP (+2-5.6 mm) was pretreated by jig and magnetic separation to remove plastics and base metals like Fe, Cu, and Al, while the fine fraction (-2 mm) was pretreated by flotation, and float and sink separation. The leaching results showed that Au extraction increased in both of the size fractions. In the coarse fraction, Au extraction increased by as much as 2-fold after pretreated (from 4 to 7%). Improvement of Au extraction in the fine fractions after pretreatments were even more dramatic. Au extraction increased from 4 to 61%. These results indicate that physical pretreatment to remove co-existing common metals and plastics is effective to improve Au extraction from WMPs. INTRODUCTION Global sales of mobile phones are expected to increase steadily in the foreseeable future because a lot of people buy newer phones with upgraded and more advanced functions almost every two years, which leads to the higher generation of waste mobile phones (WMPs). WMPs contain a wide variety of materials including plastics, glasses, base metals and precious metals such as gold (Au). Among all the valuable materials in WMPs, Au accounts for over 80% of its total metal price (Park et al., 2017), so recovery of Au from WMPs is needed."

Jan 1, 2018

By Kazutoshi Haga, Atsushi Shibayama, Altansukh Batnasan

The objectives of this study were to propose a viable alternative method for recovery of precious metals such as gold (Au), silver (Ag) and palladium (Pd) from waste printed circuit boards (WPCBs) and to regenerate the spent lixiviant solution for reuse. The proposed method generally consists of several steps as follows: 1). iodine-iodide leaching for metals extraction; 2). separation and recovery of precious metals and metal impurities from a pregnant leach solution; 3). regeneration of the spent iodine-iodide solution/lixiviant. In this method, more than 99% of Au leaching was achieved in the iodine-iodide solution from the solid residue of WPCBs that was obtained via sequential processes including incineration at 800 ?C and high pressure oxidative leaching with a diluted sulfuric acid at 120 ?C, while the leaching of Ag and Pd was less than 1%, respectively. Besides Ca, Cu, Ni, Co and Zn as main metal impurities, leaching efficiency of other metals did not exceed 1%. The precious metals and base metals as metal impurities present in the pregnant leach solution were separated and recovered by precipitation using L-AA and NaOH solutions. About 99.8% Au, 81.7% Ag and 72.8% Pd were recovered from the pregnant solution at pH of 2 with the addition of 0.1 M L-AA as precipitating agent. The remained small amounts of precious metals and metal impurities were precipitated at pH 13 using 1 M NaOH. The spent lixiviant after sequential precipitation was regenerated in the presence of hydrogen peroxide, hydrochloric acid and potassium iodide. It was revealed that over 90% of gold could be extracted from the residue of WPCBs with the regenerated lixiviant solution.

Jan 1, 2018

By K. Price, G. Wang, L. R. Moore, Y. R. Xiong, J. Gu

"Sand is a naturally occurring granular material that is a result of the physical or chemical breakdown of rocks. Raw/natural sand contains various minerals, and it is this combination of minerals that brings the value to the construction aggregate industry. However, it is the quartz component of sand that is valued in its application as industrial silica in glass, high purity quartz, foundry sand, and oil and gas fracturing. Depending on the industry, the grade requirements can be the concentration of SiO2, particle size or shape, as well as contaminants such as the heavy refractory minerals, clays, fines, and alkali metals. With the ever declining mineral feed grade, processors continue to face challenges making the industry specific concentrate grade. As such, it becomes more important to tailor make the processing reagents to fit the mineral, processing conditions, and desired quality specification. This paper focuses on the application of novel collectors towards the beneficiation of sand for each of the major industrial silica applications. INTRODUCTIONQuartz is a mineral composed of a framework of silicon and oxygen atoms. It is the second most abundant mineral in the Earth’s continental crust. There are many species of quartz, which are defined by the particle size, shape, and color. Silica sand is one of those species, which is the byproduct of the physical or chemical breakdown of quartz containing rocks or crystals. Geologist define silica sand as a silica mineral with a particle size between 0.05 and 2 mm in diameter (Zdunczyk, 2001). Silica sand has significant value to society in recreation (beach sand and toy boxes), construction aggregate (concretes and asphalt), industry (iron & steel casting, fracturing proppants, and glass), as well as specialty products such as semiconductors or silicon wafers used in electronics.The aggregate business is the dominant consumer of silica sand products. Conversely, glass making, foundries (casting material), abrasives, and fracturing proppants are the dominant applications for industrial silica sand. Not much beneficiation is required for sand products going into the construction industry, other than sizing and scrubbing to remove clay. However, the industrial silica sand applications are dependent on particle size, shape, and degree of contaminants, which sets the market value (table 1). Therefore, as the more specialty products are produced, more sophisticated techniques and chemistry need to be applied to ensure the appropriate quality is met."

Jan 1, 2018

By Yuexin Han, Jie Liu, Shuai Yuan, Yanjun Li

"In order to improve recovery efficiency of iron minerals from iron ore tailings and to reduce its connected environmental pollution, this article investigated the reducing roasting of iron ore tailing in a laboratory fluidized magnetization roasting reactor to optimize the roasting method and conditions. The examined parameters included roasting temperature, roasting time and reducing atmosphere. The parameters evaluating magnetizing roast efficiency and theoretical value were determined. X-ray diffraction (XRD) analysis was used to investigate the conversion of iron phase after roasting. The results show that the best magnetizing roast conditions are roasting temperature of 540?, holding time of 15min, and CO concentration of 20%. The magnetization conversion ratio of roasting products is over 80%, under the best magnetic separation condition, the concentrate grade of iron is 65.61 % and the recovery of iron is 83.77 %. The XRD analysis shows that Fe exists in hematite and siderite before roasting and exists in magnetite after roasting. The technique not only recovers the iron minerals from tailings with good economic benefit, but also reduces the environmental pollution of tailings accumulation.INTRODUCTION Iron ore tailings are the solid wastes generated during the beneficiation process of iron ore concentration and are one of the main pollution concerns in the mining industry (Das et al., 1996). Continuous development of the iron and steel industry has led to the increasing amount of iron ore tailings; there are over 300 million tons of iron ore tailings discharged per year (Rao et al., 2016). The huge amount of stockpiled iron ore tailings brings a series of environmental and social problems. Comprehensive utilization of iron ore tailings can not only reduce environmental load but also conserve resources, promoting sustainable development of the society. In recent years, iron ore tailings as secondary resources have received considerable attention in many countries in the word and numbers of studies on utilization of iron ore tailings were carried out, such as recycling the valuable minerals (Datta et al., 1996; Jia et al., 2013; Panda et al., 2018), used in construction material compositions as alternative source of raw materials (Das et al., 2012; Zhou et al., 2012; Luo et al., 2016) and other utilization. The iron minerals were recovery by magnetization roasting (Rao et al., 2016; Yang et al., 2013; Yang et al., 2011) and flotation (Kumar and Mandre, 2016). By comparison the reduction roasting has more advantages, but it was found that the conventional roasting equipment was inefficient, high energy consumption and un-economically applied on an industrial-scale."

Jan 1, 2018

By I. V. Makarskii, D. N. Nikitin, L. G. Tarasova

"The extent and nature of the damage to diamonds at processing plant is largely determined by the design features of the equipment, the characteristics of the feed ore and the parameters of the ore disintegration process (change in the rotational speed of the autogenous mills, variations of the water supply to comminution process, choice of the optimum charge, etc.). To monitor the intactness of diamonds, an instrumental method using the X-ray tomography system and colored synthetic indicator diamonds was developed for identifying the process-related damage. The X-ray tomography system consists of a CT-Portable X-ray tomographic scanner, a crystal positioning device and customized software (developed by the Fraunhofer Institute and Aliud GmbH, Germany). The developed method enables improvement of the accuracy of the results, exclusion of the subjectivity of the mineralogical assessment, acceleration of data processing and promptly planning of the activities aimed at reducing the process-related damage to diamonds. KEYWORDS Diamonds, colored indicator diamonds, process-related damage, loss of mass, instrumental method, X-ray tomography system. INTRODUCTION Industrial tests of ore processing technology at the enterprises of ALROSA PJSC are accompanied by assessment of the process-related damage to diamonds. The assessment of the process-related damage to crystals is carried out for prompt elimination of factors contributing to the increase of impact forces in the process flow sheet of ore treatment plant. For this purpose a specially selected parcel of -4.0 + 2.0 mm sized natural indicator diamonds is used. The diamonds are exposed to ionizing radiation in order to turn them green and thus to create a distinctive feature. Colored natural indicator diamonds are described, photographed in several views and introduced into the process flow sheet of the processing plant, then extracted from the process flow, described and photographed again. The comparison of diamonds before and after their passing through the process flow sheet of the plant allows to find evidence of process-related impact on the crystal and to calculate the factor of process-related damage (the number of crystals damaged during liberation and recovery), the loss of crystal weight and the degree of damage to the crystals. The method of colored indicator diamonds is used to select processing methods, equipment or regime which would be the safest for diamonds based on the analysis of the factors of process-related damage. There are limitations of the method, such as:"

Jan 1, 2018

By H. Hamza, M. R. MacIver, M. Pawlik, L. Malin

"Size and shape are important properties of aggregates formed in engineering processes and natural systems. Measurement of aggregate size or shape is a challenge when the solids concentration is beyond the gel point, ?? > ??g, when the aggregates are in contact and it is difficult to distinguish or segment individual particles in the network. This paper describes the use of a micro-computed tomography (micro-CT) method for the calculation of the aggregate volume fraction, ??, and a characteristic aggregate length, ??a, based on a 3D chord length measurement algorithm. These parameters can be used to quantify changes in aggregate and pore size during a compressive yield stress test to help understand the impact of flocculation and network structure on dewatering. INTRODUCTION In a thickener, flocculation is often used as a pre-treatment step and the final solids content of the underflow depends on the network strength and permeability of the bed formed by settled aggregates (Usher, Spehar, and Scales 2009). This paper describes the measurement and analysis of micro-computed tomography (micro-CT) of flocculated mineral sediments to obtain a characteristic length, ??a, of the aggregate and pore phases during a staged compressive yield stress experiment. This parameter may be used as an indicator of changes in aggregate and pore size to quantify material behaviour in solid-liquid separation processes that depend on self-weight compression or applied pressure. This analysis was carried out to help understand the effect of flocculation on aggregate structure and the thickening process as part of a broader research on the improved solid liquid separation of tailings produced in the oil sands industry.Aggregate properties The solids phase of an aggregated or flocculated suspension will eventually settle – if left undisturbed – under the influence of gravity. As settling of a flocculated suspension continues, the solids volume concentration, ??, may increase to the gel point or gelation threshold (Landman and White 1994), ??g, above which the aggregates form a network of touching particles, or space-filling structure (Kranenburg 1994). In the sediment bed, the aggregates are surrounded by fluid and occupy a partial volume fraction, ??, according to"

Jan 1, 2018

By B. Gorain, O. A. Bascur

"The advent of digital revolution has now enabled us with numerous tools that could be leveraged to transform our operational data into actionable insights. Key opportunities with digitization include better visualization, transparency, integrated planning and execution for value-chain optimization, that results in smarter production, intelligent response to changes in ore, process and equipment conditions, reduce energy and waste along with prevention of asset breakdown, safety and environmental issues. It is important to realize that these digital tools have limited value, from a metallurgical operational context, if we cannot bring-in the appropriate domain expertise along with getting the basics right. The focus within Barrick is to ensure that there is adequate depth of different disciplines built into our platforms along with breadth to integrate other disciplines such as geology and mining for an effective Mine-to-Mill integration. A gold recovery improvement strategy based on optimal Gaudin size distribution, leaching performance monitoring and guidance via feed grade maps is discussed. Simultaneous identification of process and equipment constraints enable finding the best overall conditions for Gold recovery. This paper discusses the methodology, findings, and challenges in the ongoing journey of implementing a Metallurgy Analytics platform that evolves from being retrospectively descriptive to anticipatively prescriptive.INTRODUCTION The last few decades have seen some remarkable advancement in information technology, but recently various digital technologies have resulted in several synergies to deliver innovation in diverse applications. The mining industry has been relatively slow in adopting these technologies compared to the other industries, but this scenario is changing fast. Mining companies globally are going through a series of challenges such as declining ore grades with complex metallurgy, increasing depth of ore bodies, high capital and operating costs, lower productivity, shortage of technical resources, significant pressure from stakeholders to deliver, along with growing environmental and corporate social responsibility issues. Improvement in profitability would need significant improvements in operational performance."

Jan 1, 2018

By V. M. Mankov, O. V. Zamyatin

"Fine free gold at a size of minus 250-100 µm can be effectively recovered from mineral materials (buried clay placers, saprolites, gold-bearing aggregates, technogenic sands etc.), or MM, using some developed and implemented in practice cost-effective basic technological schemes of MM processing at every stage: exploration, main concentration processes, upgrading of gravity concentrates etc. Such technologies are based on mineral materials composition, different content of fine gold mass fractions, and include improved two-stage sluicing technology, jigging technology, advanced technology and integrated technology. The main operation principle of the given technologies is gravity concentration. They provide recovery of fine gold of any size from MM, including gold finer than 100 µm, using concentration systems and plants with a capacity of 1-2 and up to 100-200 m3 per hour. Selection of a cost-effective technology depends on its technical and economic viability regarding to mineral material composition, optimum performance and concentration rate. The developed technologies of mineral materials concentration establish a balance between technological, technical and economic factors, and ensure profitable development of deposits containing free gold and characterized by a complex composition of concentrating material. Free gold recovery with these systems increases by 2.0-2.5 times for gold particles at a size of minus 250+100 µm and 10-30 times for gold particles of minus 100 µm, compared to conventional sluicing systems. The Irgiredmet Institute has developed and supplies primary concentrate washing machines for upgrading gravity concentrates of up to 100 mm in size, with a capacity of 1.0-5.0 m3/h, fitted with various production equipment including pyro- and hydrometallurgical systems. Additionally, the Irgiredmet Institute develops and manufactures systems of mechanized processing of geological and technological samples (UOMP; registered design certificate No.27505, Russia) designed for complete recovery of free gold in the process of geological samples handling and decreasing of a human factor influence. A system includes a package of technologically associated disintegration, classification and concentration equipment with some “know-how” elements that provide effective recovery of fine gold at the exploration stage. A number of Irgiredmet’s patented technologies and systems (patents of the Russian Federation) have no equivalents in the field of mineral processing and provide designing of technologically practical and cost-effective flowsheets that offer higher recovery of gold of different sizes (fine gold), at every stage of processing of mineral materials including basic concentration processes, upgrading and exploration etc."

Jan 1, 2018

By D. B. Mazzinghy, D. C. Rocha, H. B. Miller

"The use of ball mills for fine grinding is an inefficient process and has contributed to the increasing popularity of vertical stirred grinding mills in the minerals industry. Over the last decade, the performance and energy efficiency of stirred milling technology has become a preferred alternative to ball mills for fine and regrinding operations. The difficulty encountered in fine grinding is the increased resistance to comminute small particles when compared to coarse particles. Therefore, increased energy inputs are then necessary to raise the number of stress events in a mill to contribute to the comminution of fine particles. This work discusses the effect of operating conditions on the amount of fines produced and torque readings in a screw type batch laboratory vertical stirred mill. A time-based population balance model (PBM) was used to empirically analyze the performance of a vertical mill and to calculate mill breakage parameters for the different operating conditions tested. The results indicate the possibility of applying population balance model to the vertical stirred mill to predict product size distribution with acceptable accuracy. The obtained breakage function shows that the main breakage mechanism in this vertical stirred mill is by attrition, and that the selection function changes with experimental conditions within the mill. Higher agitator velocities are also seen to promote an increase in the degree of attrition between grinding media hence particle selection and fines generation increase.INTRODUCTION Stirred milling technology has been firmly established in the last 20 years as superior to ball mills for fine and regrinding operations due to its superior energy efficiency (Jankovic, et al., 2006). Stirred mills are now commonly used in many sectors of the mining industry, though they have been used in other industries for many years (Stehr & Schwedes, 1983). This technology has proven to be more energy efficient with greater opportunities for future optimization in both fine and coarse grinding."

Jan 1, 2018

By V. E. Dementiev, V. I. Kulikov, G. I. Voiloshnikov, Yu. O. Fedorov

"The report presents the summary of the JSC Irgiredmet’s activities in the field of preconcentration of ores. As of 2018, the Institute has almost 40-years’ experience in this area. Over the years, Irgiredmet has done a lot of work – from development to implementation of new technologies of ore piece sorting and concentration based on X-ray radiometric separation (XRRS). INTRODUCTION Preconcentration has been a challenging issue of the mining industry over the last decades. The implementation of this technology can significantly increase mining efficiency. The main application of preconcentration is improvement of mined ores quality, however new and more complex issues have arisen with the evolution of the technology. Irgiredmet has started to develop an efficient preconcentration technology for gold-bearing and rare-metal ores 40 years ago. The X-ray radiometric method widely used at that date as a method of elements determination in geology and geophysics become the ground for this work (1). Since that time, the Irgiredmet Institute has developed and significantly improved the technology of piece ore sorting, or XRRS (2-5), that is currently also known as the X-ray fluorescence method. The progress of the XRRS development achieved by Irgiredmet in cooperation with Rados LLC, Tekhnoros LLC (Krasnoyarsk), Rados-Service LLC and CJSC Tekhnogen (Ekaterinburg) has proved efficiency and applicability of the XRRS technology for processing a wide range of minerals and solving of various technological problems (7-9) compared to other radiometric methods (6). Furthermore, obtained results are supported by numerous studies, trials and implementations. The significance of ore preconcentration for greenfield and brownfield projects determined the establishing a new subdivision of Irgiredmet, the XRRS Technology Center (XRRS TC), that has provided the Institute with a completed range of processing technologies, from preconcentration to producing final products. Over the past few years, the XRRS Technology Center has carried out studies and testing of a numerous (more than 100) projects, mines and deposits of gold-bearing ores, rare metal ores (Be, Ta, Nb, W, Mo), base metal ores (Cu, Sb, Zn, Pb), ferrous metal ores (Fe, Ti, Cr), rough diamonds and coal. The XRRS Technology Center performs various specific studies and testing not only in Russia, but as well as in Kazakhstan, Georgia and Mongolia. Mines and companies from Chile, India, China, Iran and other countries also take an active interest in the XRRS technology."

Jan 1, 2018

By A. Singh, M. Ntlhane, V. Ross, M. Dlame

"Fine valuable particles are often lost to flotation tailings streams due to inefficient collection by air bubbles as well as passivation of surfaces by oxidation and slimes. The application of high-shear hydrodynamic cavitation devices (HCDs) to overcome this problem has already proven to be a considerable success in the industry. This paper details the results of further investigations that were undertaken at Mintek to better understand the mechanisms involved when preconditioning feed slurries in an HCD. By promoting inter-particle attrition and conditions of high shear within the reactor, cleaning of particle surfaces is enhanced as well as the formation of superfine (nano) bubbles which are believed to aid their agglomeration and subsequent collection by normal sized bubbles. In order to broaden the envelope of understanding with regard to application of the technology, rather than tailings material as investigated earlier, a Platinum Group Mineral (PGM) UG2 ore from the Bushveld Complex in South Africa was used in this study. The results of a series of batch flotation tests in a 10L Denver cell are presented, being conducted after the feed has been subjected to different methods of preconditioning. It was demonstrated that the preconditioning significantly improved the flotation kinetics of the PGMs, the optimum being obtained after around 20 passes through the reactor. This was accompanied by a much enhanced recovery-mass pull relationship and a significant improvement in the grade-recovery response. Significantly, the selectivity between the PGM and the deleterious chromite (expressed as Cr2O3) gangue more than doubled under these conditions. Modelling of the PGM data by means of the modified Kelsall model indicated that both the fast and slow floating rate constants were improved.INTRODUCTIONIt is well known that the flotation recovery of fine and ultrafine particles, typically less than 10 micron in size, is a challenge (Yoon et al., 1989; Miettenin et al., 2010). Although these particles are typically well liberated, due to their very low mass and inertia, the collision efficiency with air bubbles is low as a result of the inability of particles to penetrate the liquid streamlines around bubbles. Hence the probability of contact is often regarded as the ratedetermining step in flotation of ultrafine particles. Introducing more power into conventional flotation machines is likely to solve only part of the problem, as conventional mechanisms are effective only to a point in terms of shear and micro-turbulence. Further challenges are posed by the treatment of low-grade or oxidised tailings dump material, where valuables are passivated due to prolonged exposure to the atmosphere or slimes. Over the years, various mitigating strategies have been investigated, including the use of dissolved air flotation (Martinez-Gomez et al., 2013; Calgaroto et al., 2015), shear flocculation (Subrahmanyam and Forssberg, 1990), seed or carrier flotation (Tabosa and Rubio, 2010), sonication to clean particle surfaces (Aldrich and Feng, 1999; Newell et al., 2006), high intensity conditioning (Bulatovic and Salter, 1989; Chen et al., 1999; Tabosa and Rubio, 2010), and various electrochemical approaches such as changing Eh in order to promote formation of dixanthogen, dissolution of oxidation products by lowering the pH, activation by sulphidisation (Newell et al., 2006; Becker et al., 2014), and the use of alternative collectors."

Jan 1, 2018

By K-O. Mickelsson, S. Töyrä, H. Esbensen

Accurate information of physical, chemical and metallurgical quality characteristics such as moisture content, iron grade and particle size are crucial for successful process control and for producing products within customer specifications. Correct moisture content of pellet feed is an important variable for successful balling of iron ore pellets and to minimize power consumption in the sintering process. Control of the filtering process in the pelletizing plant is therefore essential for both productivity and high product quality. The current measurement systems for moisture content at LKAB are based on two types of manual grab sampling, subsequently analyzed with rapid moisture determination methods. Previous studies of the measurement systems have indicated high sampling variability resulting in lowered possibilities for successful process control. The objective of the present study is to evaluate an alternative filter sampling approach and testing of on-line Infra-Red analysis (IR-analysis). On-line IR-analysis has the advantage of eliminating physical sample extraction and allowing for continuous monitoring of moisture content. However, this approach is sensitive to the surrounding environment, making careful calibration and control crucial for the quality of measurement results. Furthermore, as IR-sensors only target the surface of the conveyed pellet feed, several incorrect sampling errors need to be considered and counteracted to eliminate sampling bias and reduce the remaining measurement variability. Variographic characterization was applied to the two current grab sampling approaches of combined filtered material, to the alternative filter sampling method, and to the On-line IR-analysis. The results indicate that both the sampling of separate filters (using composite sampling and ISO-standardized moisture analysis), as well as a calibrated and well- maintained IR-sensor can improve the relative variability significantly, by lowering the total measurement system variance from 60% to 25%.

Jan 1, 2018

By V. F. Petrov, O. D. Khmelnitskaya, V. M. Lodeischikov

"The processing of copper gold ores is one of the major issues of gold-mining industry in the beginning of 21st century. In this case, application of ammoniacal cyanidation process for this type of mineral raw materials deserves special attention. Irgiredmet Institute has carried out a wide range of studies on ammoniacal cyanidation process and evaluated the possible commercial use of this process for Russian operating plants. Copper gold-bearing ore from a current Russian deposit was studied. The content of gold and copper in the ore is 9.4 g/t and 0.4%, respectively. Based on the results of preliminary test work, a flow sheet was developed. It included gravity concentration followed by cyanidation of the gravity tailings using CIP. The flow sheet provides sufficient total gold recovery (91.5%). However, this technology has disadvantages, such as high specific consumption of reagents: 4.5 kg/t NaCN and 13.5 kg/t Ca(OCl)2 the ore and the increased gold grade in the liquid phase of the tails slurry (0.2 g/t). In order to improve cyanidation process parameters, test work on gravity tails processing using ammoniacal cyanidation was carried out. After the test work was completed, ammoniacal cyanidation flow sheet for copper gold-bearing ores was developed. Leaching conditions were optimized using recycled process solutions. Recommendations on gold recovery from the solutions and tails detoxification are given. The proposed flow sheet provides 91.5% gold recovery. In this case, compared to the conventional option, the consumption of cyanide decreases by 3-4 times.INTRODUCTION The technology of precious metals recovery from gold-bearing ores is based on cyanidation. This accounts for up to 90% gold recovery and the significant portion of silver (Lodeischikov, 1999). However, there exists the category of so called refractory ores. They are not amenable to direct cyanidation (without using additional expensive processes), or they are characterized by low indices of metals recovery and high consumption of reagents. The latter also include copper gold ores. Their deposits can be found extensively both worldwide and in Russian Federation. A feature of these ores is that they contain not only gold but also copper. It is considered not only as a valuable component but also as a harmful mineral impurity that hinders gold cyanidation, gold precipitation from the solutions by cementation onto zinc dust and adsorption onto activated carbon (CIL, CIP-processes), detoxification of cyanide bearing effluents."

Jan 1, 2018

By M. Kalicinski, M. Lyssyy

"Access to information is a key component for making improvements to any process. This is particularly true for all aspects of the iron mining and steelmaking process. The ability to make rapid control decisions can significantly influence process outcomes, including ensuring product specification, mining quality, transportation limits, upgrade factors, waste bypass and direct shipping, among many others. While traditional laboratory methods provide feedback for such processes, having access to analysis results in real-time can lead to positive reactive and predictive control decisions to be made rapidly, leading to significant improvements throughout the process. Scantech has been designing, manufacturing and supplying technological products to the minerals industry since 2002 to enable the availability of such real-time information to a mine or plant, with the benefits being enjoyed by a wide range of operators. This paper provides a summary of the available technologies used in the iron ore and steel industries, as well as providing case studies of their use in African and Australian iron ore and European steel, as well as a description of the potential benefits of a range of analysis equipment.INTRODUCTION Access to information is critical for any process, and is a fundamental component for making process control decisions. In order to yield effective processing outcomes, it is important for that information to be readily available, preferably as quickly as possible, and to be as accurate as possible. While speed and accuracy are often traded off against each other, there are numerous technologies available in a processing environment that allow for both rapid flow of information and a high level of accuracy. The use of on-belt analysis equipment has a long trusted history of use in a number of mining and processing environments and industries, providing information such as elemental composition and grade of conveyed materials, moisture content, waste proportion and energy information. Australian company Scantech has been a provider of such equipment since 1981, and has become an industry leader in both the supply and development of on-belt analysers across a range of industries."

Jan 1, 2018

By Venkataramana Runkana, Pradip Gautham, Beena Rai, Sreedhar Reddy

"IT enabled platforms are the key to provide an integrated view of the business activity or an enterprise as a whole. Attempts to integrate all functions in an enterprise such as mine-to-market initiatives, wherever and to whatever extent implemented, have provided significant benefits to the industry. The transformative potential of IT enabled integration platforms is illustrated in this communication from our own work in this field. TCS PREMAP (Platform for the Realization of Materials and Products) is a knowledge-driven engineering design and development platform which leverages modeling and simulation and artificial intelligence into the engineering design process. We illustrate the customization of this generic platform for the design and optimization of mineral processing plants in an integrated manner. TCS PEACOCK (Process and Equipment Analytics for Optimization and Control) has been developed to enable automation of data analytics in the operating plants. We illustrate its utility and power in improving the plant performance with the help of case studies from our work on pelletization of iron ores and optimization of flotation plants. INTRODUCTION We are living in an exciting digital era. With the advent of cloud computing and social media on the one hand and rapid advances being made in several research areas of interest to us in the minerals and metals industry such as artificial intelligence (AI) & machine learning, robotics, unmanned vehicles including drones, big data analytics, 3D printing, sensor technologies, renewable energies and internet of things (IoT), many disruptive transformations in our industry are on the horizon. Recent advances in information technology (IT) and knowledge engineering, in combination with appropriate domain expertise, that is, our enhanced understanding of the underlying science of mining and mineral processing operations and the availability of a variety of powerful modeling-simulation tools make it possible to address the challenging problems facing the mining and mineral processing industry, in an integrated manner."

Jan 1, 2018