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By Susanna A. C. Stadler, Chris Aldrich, Jacques J. Eksteen

Slag foaming occurs in several pyrometallurgical processes. These processes include steelmaking in basic oxygen steelmaking furnaces and electric arc furnaces as well as various non-ferrous operations like sulphide smelting/converting and base metal slag cleaning. Although slag foaming in steelmaking processes has been extensively researched, little attention has been given to slag foaming in non-ferrous operations. Slag foaming phenomena are complex because often the system consists of three or more phases. With this in mind, factors previously identified as influencing slag foaming were investigated. These include the slag basicity, physical properties of the slag, namely viscosity, surface tension and density, the formation of particles due to undercooling of the slag and the FexO concentration in the slag. The effect of increasing FexO concentration was found to decrease the foam index due to lower viscosities, but higher surface tension depression appears to have led to increased foam index values at high FexO concentrations. The foaming index decreases with increasing basicity, until precipitation of solids occurs. After this point, the foaming index was found to increase with increasing basicity due to increased solids precipitation. In general, increasing amounts of slag-wettable solids led to higher foam indices, but the precise nature of the effect on slag foaming was dependant on the nature of the solid precipitate.

Jan 1, 2003

By G. B. Abaka-Wood

"The versatility of froth flotation has made it vital in the beneficiation of rare earth elements (REE) minerals from either high or low grade ores of complex mineralogy. There has been a significant increase in the tonnage of rich iron oxide tailings obtained from extraction of primary commodities such as copper and gold in Australia, which have been identified to have very low grade rare earth oxides (REO) (= 1%). There is a vast knowledge gap in the upgrade of REO from such tailings. The aim of this research is to investigate the feasibility of the use of fatty acids for the upgrading of REO from selected iron-oxide rich tailings. Two forms of fatty acid collectors (oleic acid and sodium oleate) were employed in this investigation. Bench scale flotation tests were carried out using a Denver D-12 cell.The effects of pulp pH, fatty acid dosage, particle size distribution (-150 +75 µm, -75 +38 µm and -38 µm) and conventional depressants (sodium silicate and starch) dosage on flotation recovery of REO were investigated. A comparison of the flotation results indicated that sodium oleate was the more efficient fatty acid for REO flotation at all the pulp pH investigated. The flotation performance is demonstrated to be particle size-dependent. The results on the effect of depressants dosage indicated that both sodium silicate and starch were unselective in reducing the recovery of hematite (Fe2O3) and quartz (SiO2) with corresponding decrease in REO recovery. Generally, Fe2O3 and SiO2 formed substantial contents of the flotation concentrates obtained, both in the absence and presence of depressants, which indicates liberation is a major challenge in achieving selective REO upgrade and recovery.The flotation tests carried out on the iron-oxide rich tailings suggest the possibility of REO upgrade using fatty acids, although particle size distribution and minerals liberation are key limiting factors in achieving selective REO upgrade and recovery."

Jan 1, 2018

By L. A. Nemchinova, M. A. Arustamian

"For a long time tailings piles of mining and smelting complexes have met the eye being a prospecting feedstock source for many industries. Nowadays, 6.5 million tons of copper and cooper-zinc processing tailings are stockpiled in the Urals annually, as there is no technology of its processing to provide a full and complex metal extraction within mining and processing operations. In spite of large volumes of mining wastes, not more than 20% of annual overburden, approx. 10% of processing wastes, approx. 40% slags (1) are involved into processing.Based on today’s complex of economic, environmental and social challenges of ore processing, waste processing technology using existing capacities is a burning issue. Mining wastes characteristics (including fine dissemination, variability of physical and chemical properties of mineral surfaces under impact of oxidizing, leaching, etc.) predetermine challenges arising out of its involving into processing and justify high capital intensity of new construction or reconstruction projects followed by replacement of existing processing lines with new ones.In this paper, the authors propose flotation technology for mature tailings of copper, copper-zinc and polymetallic ore processing. The technology developed provides for upgrade of existing process flowsheet diagrams at minimum costs to produce additional saleable products including low-grade copper concentrate, saleable zinc concentrate and gold concentrate thus facilitates sustainable use of depleting minerals and operational efficiency due to cost-efficient processing of already mined materials, being in fact, final semi-products located near existing operations. This is particularly important for operations with standby capacities and not engaged workforce."

Jan 1, 2018

By G. V. Kalabin

"The paper supports applicability of satellite imagery at regional and local level for rapid quantitative assessment of natural environment in zones of activity of mining complex enterprises. Exacerbation of environmental problems during mineral mining and processing associated with their scale and geography of field distribution through the vast territory of our country requires constant monitoring of natural environment status, which necessitates engagement of space surveillance nowadays. It is proposed to use the monitoring of land cover and land use at regional and local level for the environmental assessment of a particular production or complex productions. You must establish the dependence of NDVI change trend with the magnitude of anthropogenic impact on the source or multiple sources of environmental pollution a particular area.. We present the results of studies of vegetation remote sensing methods in a number of territories placing mining enterprises. INTRODUCTION Ensuring a healthy environment is necessary both in untouched areas and disturbed. The condition of the developed territories should be monitored with particular attention, since the restoration of the disturbed territories requires great efforts and financial costs. More narrowly, the health of the environment (Zakharov V.M. and etc.,2001) means its quality ensuring the health of man and other species of living organisms, which includes two aspects (Zakharov V.M. and etc, 2000): - ensuring an environment conducive to human health as a biological species: - maintaining the health of the natural environment, i.e. its constituent species of living organisms and plants. The consequence is the disturbance of natural ecosystems, which determines the quality of the environment, favorable for human habitation and the state of health of the population in total determine the status of the territories where enterprises for the development of georesources are located and allow them to be ranked according to the degree of environmental danger. Without knowledge of the trajectory of ecosystem successions, it is impossible to offer adequate requirements for the technologies used to ensure the implementation of the preserved natural potential after the removal or reduction of man-made stress."

Jan 1, 2018

By William Skinner, Jonas Addai-Mensah, Keith Quast, David Robinson, Jason Connor

A review of the laboratory- and pilot plant-scale physical separation techniques for the beneficiation of nickel (Ni) laterites shows limited efficacy. To date, the only upgrade technique adopted commercially, prior to hydrometallurgical processing of Ni laterites, is the removal of a barren, coarse size fraction in the feed by classification. In the present work we investigated two low grade (~ 1%), goethite-rich Ni laterite ores’ upgrading by magnetic separation, attritioning/coarse, (lower Ni-grade) gangue rejection and flotation techniques. Low intensity (0.1T) dry magnetic separation at ambient temperature of raw samples and those pre-heated at temperatures up to 450 °C showed evidence of pay metal Co and Mn bearing asbolane and/or lithiophorite minerals pre-concentration in the magnetic fractions. Ni distribution, however, did not show any noticeable magnetic upgrade but followed the weight distribution. Other ore pre-treatment methods (e.g., desliming and sulphidisation) followed by froth flotation with anionic and cationic reagents also led to noticeable (~35%) Ni upgrade. This is due to the deportment of Ni across several gangue host mineral phases (i.e. Fe oxide/hydroxide and a range of silicate/aluminosilicate minerals). From chemical analysis, after disaggregation of ~ 1% Ni grade feed ore, coarse (-600 + 38 µm) and fine (-38 µm) fractions of ~0.6% and 1.3% Ni grades respectively, were also produced, suggesting that a significant upgrade in Ni content can be achieved by rejecting the + 38 µm fraction with the loss of <40% of the Ni. The ore mineralogy, particularly the complexity and high number of un-liberated Ni-bearing phases, greatly compromises physical separation methods for these ores, with the possible exception of screening after disaggregation of the fines inherent in the run of mine ores.

Jan 1, 2014

By O. Martinsson

The Kiruna area is an important mining province in northern Sweden, which is dominated by Fe- and Cu-Au deposits. Economically most important for the region, are the apatite iron ores with an annual production of c. 43 M ton of crude Fe-ore and a total production of more than 2000 M ton of ore the last 100 years. The apatite iron ores in the Kiruna area are dominated by either Magnetite or Haematite and contain varying amounts of apatite giving them a content of Fe and P, which varies between 30-70 % and 0.05-5 %, respectively. A typical geochemical feature of the ores is the strong enrichment of REE that is caused by a high content of REE in apatite and the occurrence of Allanite and Monazite containing 22.4 and 69.8 wt% REO, respectively. At Kiirunavaara, the content of REE in apatite varies between 0.07 to 1.57 wt% REO with a dominance for the light rare earths. The variation in REE-content of apatite depending on textural and paragenetic aspects is not known but apatite grains may display a strong LREE-depletion due to hydrothermal alteration. Monazite occurs as rod-shaped or tabular inclusions in apatite and is suggested, to have formed in response to hydrothermal alteration of apatite after the emplacement of the ore. Inclusions are mainly found in the central part of apatite grains occurring in veins and schliren, while they are rare in apatite occurring disseminated in the ore. Monazite also occurs as larger grains outside apatite and together with Allanite is found in texturally and paragenetically different settings within the ore. These occurrences of REE-minerals may largely be a product of LREE mobilized by alteration of apatite after the emplacement of the ore. However, REE-minerals including Allanite and Monazite might also have formed directly from late magmatic fluids. Keywords: apatite, monazite, allanite, ree, kiirunavaara, iron ore of kiruna type, mineral chemistry

Sep 1, 2012

By J. P. Dai

The Fankou Mine in Guangdong province, China, processes a polymetallic ore containing averagely 4.2% Pb, 8.5% Zn, and 90 g/t Ag. The main metal minerals including sphalerite, galena and pyrite are very finely disseminated and unevenly occurred in the ore, making it difficult to liberate them from each other. This paper presents the processing technology of the Fankou plant and the characteristic features of the novel technology applied.

Jan 1, 2014

By Peter Ay, Florian Logsch, Satyanarayana Narra

"The traditional lignin separation process from the precipitated suspension creates severe filtration problems by plugging of the filter medium due to the small particle size (20 to 60 µm) of the suspended lignins. The plugging causes further problems in the successive processing of the filter cake. A new lignin separation process has been developed at the Brandenburg University of Technology (BTU) Cottbus as a part of the Research and Development and Demonstration (R & D & D) project "LignoBioFuel". The new developed process separates lignin in the form of granules with diameters ranging from 100 µm to 300 µm. The restrainment of the granule’s size in their successive treatments is expected to result in higher filtration efficiencies and reduction in plugging of filter mediums. To evaluate the filtration efficiency, the filtration resistance of the produced granules as well as the conventional suspensions has been investigated. The results show that there is a 60 to 80 % filtration efficiency increase and around 60 % reduction in plugging of filter mediums with the lignin granules in comparison to the conventional suspensions. Furthermore the successive processing of lignin granules was easier due to their porous structures removing the impurities such as adherent acids and salts. The purity of the separated lignin was measured with their sulphur (reduced from 7 % to 2.7 %) and ash (reduced from 46 % to 0.5 %) contents. The newly developed process has displayed better results in comparison to that of the conventional process. The new process displays high potentials in optimizing and improving the present state of the art treatments and is promising several ecological, economical and environmental improvements."

Jan 1, 2014

By A. Ghadyani

This investigation was undertaken to assess the possibility of ash and sulfur removal by microbial action of high sulfur-content coal. Thiobacillus ferrooxidans and Thiobacillus thiooxidans have been used for biodesulfurization of coal. Feed samples were provided from Tabas coal mine located in Yazd province, Iran. The sample contained 28.80% ash and 2.30% sulfur. Flotation tests were implemented to optimize the effective parameters in these cells which were constant during bio-flotation tests. According to the results, obtained from various tests using Taguchi orthogonal array design (L27), the values of optimized parameters were pH at 7, 1000 g/t gas oil as a collector, 10% solid content, 15 min conditioning time, 100 g/t MIBC as a frother and 800 rev/min rotor speed. Bio-flotation tests are carried out by means of laboratory double discharge cell and mesophilic bacteria as depressant reagent using above mentioned optimized parameters. The bio-flotation experiments were conducted based on a Taguchi orthogonal array design (L9) with four variables (bacteria type, bacteria count, rotor speed of mixer and bio-conditioning time). The collected data was analyzed by using DX7.0, Minitab14.0 and WinRobust1.02 softwares for evaluation the effect of each parameter on the optimization criteria. Considering the highest combustible recovery and the lowest ash and sulfur content, the value of optimized bacteria type, bacteria count, rotor speed of mixer and bio-conditioning time were Thiobacillus ferrooxidans, 5×107 cells/g(coal), 100 rev/min and 20 min respectively. Under this condition, ash and sulfur content and combustible recovery were predicted 12.39%, 2.08% and 82.03% respectively.

Sep 1, 2012

By P. Hatefi, O. Rahmani, M. Noor-Mohammadi, A. Tohry

"Depressants play an important role in the selective separation of impurities from iron minerals by direct or inverse flotation. In this paper, sodium co-silicate (SCS) with chemical formula of Na4SiCO6, as a depressant with pH modifier features, has been synthesized and used for phosphorus bearing iron ore in anionic reverse flotation. In this process, phosphorus is floated while the iron oxides are depressed, using fatty acids as collector in an alkaline medium. Batch and pilot flotation tests were carried out to investigate the influence of SCS on the separation selectivity of phosphorus from iron oxides. Also the depression mechanism of SCS on hematite surface was investigated by microflotation tests and FTIR spectroscopy measurements. The flotation results indicated that without using a pH modifier, the pH of pulp could reach up to 10, when SCS was used as depressant. In this condition, a better depression performance was observed compared to sodium silicate (SS). Using the SCS, phosphorus and total iron content in iron concentrate was 0.046% and 66.29%, respectively, compared to SS where these values were 0.06% and 65.75%, respectively. As a result the weight recovery of iron concentrate was increase by around 4%, compare to SS. It was also found that 238 g/t of SCS could be used instead of 3 types of reagents collectively, including 32 g/t of NaOH, 151 g/t of Na2CO3 and 400 g/t of SS gel.INTRODUCTIONThe phosphorous presents in iron ore minerals is mainly in the form apatite mineral. The apatite is separated from iron ore minerals by magnetic and flotation methods (Ma, 2012). The reverse anionic flotation of iron is one of the most common method for removing phosphorus from iron concentrate (Araujo et al., 2005).Usually apatite minerals are readily floated using anionic collectors such as fatty acids (Ma, 2012). In this conditions the iron minerals are depressed and by modifying the pH in alkaline conditions, selective separation of phosphorus from iron concentrate can be achieved. Depressants including; sodium silicate (SS), starch, dextrin, guar gum and humic acids play an important role in the reverse flotation of iron ore (Kar et al., 2013; Ma, 2012; Turrer and Peres, 2010; Araujo et al., 2005). Studies have shown that SS has a better effect on iron recovery and phosphorous reduction, compared with other depressants (Tohry and Dehghani, 2016; Qi et al., 1992, Dho and Iwasaki, 1990). In most flotation processes, modifiers are used to adjust the pH. To achieve alkaline conditions, mainly pH modifiers such as carbon dioxide and sodium carbonate are used."

Jan 1, 2018

By I. Gombköto

Mining and mineral processing operations are usually generating huge amount of tailings. These tailings often gives lots of maintenance work in order to protect environmental resources from heavy metals slowly leaching out of tailing are due to Acid Rock Drainage (ARD) process. Handling leakage could be active or passive such as using of Permeable Reactive Barriers (PRB). PRB?s are used worldwide treating underground contaminations, using different type of matrix materials. All generally used matrix material has its advantages and disadvantages such as selectivity, sensitivity of precipitation generation or not satisfying hydraulic conductivity. Nowadays cheap and effective matrix material which is ignorant to pore plugging caused by precipitation within the PRB could be one solution to the demands of the industry. The authors have been carried out an investigation at University of Miskolc on lignite as high humid acid containing material for determining the ability of heavy metal adsorption and pore plugging resistance. Moreover, using hydraulic and chemical simulation methods, complete PRB dimensioning protocol based on new lignite matrix had been introduced. Within the frame of this paper the results are going to be discussed.

Sep 1, 2012

By Francesco Vegliò, Luigi Toro, Francesca Beolchini, Francesca Pagnanelli, Stefano Ubaldini

"Biosorption is an innovative technology used to remove heavy metals from aqueous solutions from mining waters and other industrial wastes. A wider application of this alternative process is strictly dependent on the understanding of the chemico-physical aspects involved, in order to optimize the operating conditions. Mechanistic models are the most useful tools used for understanding purposes, even if the empirical models are still widely applied for their simplicity.In this paper especially propagated biomasses of Sphaerotilus natans, calcium alginate and some waste materials were tested as adsorbents for single and binary solutions containing heavy metals at different pH. The equilibrium experimental results were fitted according to empirical and physical models with growing complexity outlining the inadequacy of the predictive models; in fact, the non-ideal interactions among metals require the insertion of additional correction parameters."

Jan 1, 2003

By Carlos Gualdron, Elizabeth Gomez, Rafael Bolivar

The productivity index of the Coopracarcegua Ltda., a mid-size coal mining company of Norte de Santander, Colombia, was related absenteeism using accident, productivity and profit data four years. The analysis was based on type, severity and frequency of accidents, number of absentee days; price per metric ton, and other relevant parameters. The enterprise is formed by 5 different mines of thermic coal, each one with different exploitation technologies and different productivity. Each mine was analysed separately and the loss of profit due to absenteeism was calculate for each one. The study showed that the foregone earnings due to absenteeism in terms of the whole productivity of the enterprise was about of 6.6% of the total profit average the 4 years, with calculated values of 14.7%, 3.5%, 8.4% and 4% per year in the evaluated period. The study identified that the most important cause of absenteeism was "General Disease". The foregone earnings in 2009, the highest loss for the analysed period, was about US$ 0.937 million and during the whole evaluated period was US$ 2.46 million.

Jan 1, 2014

By Sunil Tripathy, Y. Rama, Srinivasulu. A., Amit Ranjan

Process improvements in an operating plant are always challenging. Mineral beneficiation plants based on gravity concentration techniques need continuous evaluation and monitoring of its processes for getting maximum recovery and better grades. But, in an operating plant it is very difficult to control all the parameters due to numerous reasons such as unsteady operation, fluctuation in the quality of run-off-mine ore, overall flow rate etc. For better understanding of the beneficiation circuit, it is necessary to evaluate the critical operating parameters which affect the performance in terms of grade, recovery and throughput including losses of valuable materials into tailing. Accurate data collection and proper data interpretation followed by making necessary change which is implementable in an operating plant play very critical role in performance of the circuit. In case of gravity operated beneficiation circuits of chrome ores where the quality of the feed and physical parameters varies continuously, the operators are required to modify the critical operating process parameters on continuous basis which is very difficult and tiresome. There are many causes of the data variability, including both error (sampling and assay), and real variation in performance due to changes in ore mineralogy, operating conditions and other factors. In this article, attempts made to evaluate the performance of ultra-fine beneficiation circuit in terms of silica reduction in the concentrate of chrome ore beneficiation plant (COB), India are discussed. The approach adopted and practical problems encountered during the study were also discussed. Results obtained from plant audit based on the above methodology has shown that SiO2 content in the concentrate can be reduced to <4%.

Jan 1, 2014

By Jia Ma, Lu-De Qiang, Zhi-Chao Liu, Chun-Feng Li, Guang Li, Bao-Bin Tang

"At present, research on the surface chemical properties of uranium minerals is very scanty, which restricts the research progress of uranium ore flotation process research. The research aimed at exploring the surface characteristics of two common uranium minerals and providing basis for flotation process to enrich uranium minerals in ore. This paper selected pitchblende and uraninite as the object of study, which are widely distributed in uranium deposits. We chose out the pure minerals of pitchblende and uraninite from different ores collected from different uranium deposits. By means of Zeta potential test and X-ray photoelectron spectroscopy (XPS) test, a preliminary study on surface characteristics of the pure minerals of pitchblende and uraninite was conducted. And the significance of the change of Zeta potential, the elements composition and valence state on the minerals surface for flotation was discussed. The research shows that, the Zeta potentials of pitchblende and uraninite in pure water are negative mainly when the pH value varies from 2 to 11, which maybe a result of the difference of ionization capacity between two kinds of oxy-compounds on the surface of minerals. On the surface of pitchblende and uraninite, the metal elements are mainly U, Th and Pb. U is mainly in the form of UO2, Th is mainly in the form of ThO2, and Pb is mainly in the form of Pb and PbO. Based on the surface characteristics of pitchblende and uraninite, we can select process and reagents appropriately in uranium ore flotation.INTRODUCTION Globally, the major challenges associated with exploitation of low grade ores are about finding economically feasible processes for reducing the mass of gangue minerals (Filippov et al., 2012). Among the beneficiation technologies of low grade uranium ores with complex minerals assemblage, flotation is the common process which is used to reduce production cost and eliminate the acid-consuming minerals (Li et al., 2016; Liu et al., 2015)."

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 Sergey S. Gudkov

In the current climate of changing the approach to mining and treatment of mineral resources, processing technologies are being developed that require little maintenance and are economically as well as ecologically sustainable. This may also involve the development of entirely new ways of ore processing. One promising approach is to use bioleaching for the pretreatment of gold refractory ores to cyanidation. Capital costs for vat bioleaching of concentrates and ores are very high and cannot be applied for small or medium-size deposits. IRGIREDMET JSC carried out bio heap leaching test work on refractory ore samples from three Russian deposits. Following this biological treatment a combination of flotation, vat bioleaching, and cyanidation are used to recover gold. After heap bioleaching, gold recovery was 75-80 per cent. It was found that efficiency of heap bioleaching process depends on ore feed size. High duration of this process is another feature and it lasts for about a year. This process can be also used for carbonates in the combination with other process during which acid generation occurs. The results of our studies have shown that this technology is amenable for refractory gold ores. Its introduction allows an increase gold recovery and to solve a number of environmental problems. Keywords: heap biooxidaton, the refractory of the ores, the degree of oxidation, arsenopyrite, pyrite, CIL

Sep 1, 2012

By Venkataramana Runkana, Shantanu Maheshwari

As the world reserves of high quality ores are getting depleted at a rate higher than ever, the liberation of valuable minerals from low grade ores is becoming more and more relevant and imperative. But, liberation of minerals from low grade ores requires grinding of ore to extremely fine sizes. High energy milling in a planetary ball mill is one such option where one can produce particles in the nano-meter range. Although planetary mill is employed extensively for ultrafine grinding, dynamics of grinding inside the mill is not fully understood because of the dependency of grinding kinetics on many interconnected phenomena like collisions between media, particles and wall, time dependent rheology, adsorption and desorption of dispersant, abrasion of media, agglomeration of particles, etc. It was well articulated in literature that media motion and number of media collisions have strong effect on grinding kinetics and final product size distribution. Simulations were carried out using the discrete element method (DEM) to compare the performance of a planetary mill with a ball mill, with and without lifters, in terms of impact energy and number of collisions and it was found that number of collisions is considerably high in the planetary mill. The high number of collisions might be the reason for production of ultrafine particles in the planetary mill. We have also fitted a population balance model (PBM) to experimental data from a laboratory scale planetary mill for prediction of particle size distribution. Unlike previous models, we have incorporated functional forms for the selection function and the breakage distribution function so that the number of parameters in the PBM is just five. The predicted product particle size distributions at different grinding times are in reasonably good agreement with experimental data.

Jan 1, 2014

By B. Aydin, G. Erturk, G. Bulut

Coal is a complex material because of its structure consisting of carbon constituents and mineral matter. Flotation is readily carried out due to hydrophobic characteristic of coal. Therefore coal flotation is the most commonly used technique for fine coal beneficiation in order to acquire clean coal separating ash forming mineral matter from carbonaceous matter. In the coal flotation, floatability of coal both depends on characteristic of coal and used flotation reagent. Frothers as a flotation reagent are used to facilitate air dispersion into fine bubbles by prevention of bubble coalescence in the pulp phase, and stabilization of flotation froths. In this study, the effects of frother types and concentrations at different pH and particle size on the coal flotation were investigated. The representative sample was taken from Zonguldak, Turkey. It contains 9.1% ash and 7313 (kcal/kg) calorific value. Pine oil, Dowfroth 250, MIBC and Isooctanol were tested as frother types. It is determined that 1.92 ppm frother concentration is sufficient to float coal, except pine oil. In mixed frother tests, it is seen that Dowfroth 250 is more effective than others. No significant difference in coal recovery was observed for flotation tests at the different pH values. The best results are obtained in size of coal (-0.1 mm) with all frothers.

Jan 1, 2014

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

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

Jan 1, 2018