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By G. K. Nimal Subasinghe

The performance of Knelson Concentrators (KC) used in gravity gold circuits often rely on manufacturers recommendations for selecting operating parameters such as, fluidising water flow rate and cycle time. These parameters are not only dependent on the machine parameters but also on the feed characteristics such as, size distribution of the gold and gangue particles and the composition of its constituent minerals. Particles entering a KC experience a centrifugal acceleration due to the high bowl rotational speeds. The required centripetal force to maintain a circular orbit is provided by the fluid drag force created by inwardly moving fluidising water and the Bagnold?s force arising from the particle/particle collisions. When the fluidising water flow rate is low particles move towards the outer rim of the bowl forming a packed bed within the grooves. On the other hand, if the fluidizing water flowrate is high the bed expands and some particles would move towards the centre of the bowl and gets carried to the tailings stream, thereby reducing the amount of material retained within the grooves of the bowl. Based on a force balance on a particle captured within the KC, a criterion which can be used to predict the amount of material recovered in the bowl has been derived and validated by experimental data. It has been shown that this criterion may be used to demarcate the transition of the bed from a packed-bed state to a fluidised state depending on the fluidizing water flowrate. By identifying the conditions for the optimal expansion of the bed comprising different constituent mineral particles, it is possible to estimate the optimal fluidising water flow rate that would maximise gold recovery while minimising gangue recovery. It was also observed that the accumulation of valuable mineral in the bowl takes place by the displacement of the gangue particles in the bed by the incoming heavy mineral particles. The kinetics of this segregation process was also studied using synthetic mineral mixtures. The experimental data suggests that this process follows first order kinetics and that the build up of heavy mineral reaches a maximum which could be used to identify the optimal cycle time. In this work, the suitability of the above model in optimizing the performance of a KC have been reviewed. Also the necessity and merits of testing an unaltered

Jan 1, 2014

By Luís Marcelo Tavares, Juliana Segura

Comminution is one of the most energy consuming stages in a mineral processing plant. This consumption is not only related to the power supplied to equipment, but also to the indirect or embodied energy, mainly associated to materials that are worn during operation, including grinding media and liners. Until recently, preparation of iron ores in Brazil did not use comminution intensively, given that plants mainly produced sinter feed, natural pellet fines, besides lump ore. However, with decreasing ore grades, size reduction now occupies a centre stage in nearly all new plants. Technologies used up to date for processing low-grade iron ores in Brazil, in particular itabirites, have consisted of three or four stages of crushing followed by ball milling. A number of new plants are either being built or are currently being designed that will process the same type of ore, so that engineers are investigating alternative comminution routes. The paper analyses comparatively four comminution routes for processing a particular itabirite ore, many of which using technologies and layouts that have not yet been used in such application. Using data from bench scale and/or pilot-plant tests, the different routes are compared on the basis of sustainability principles in accordance to the Brazilian energy matrix, which is quite particular. It is concluded that if the sustainability criterion is used, then the optimal route would correspond to a circuit that uses HPGR technology with truncated feed followed by ball milling. Given the particular case of itabirite iron ores and specially to the one in the present work and the source of Brazilian energy, it is evident that indirect energy expenditure in comminution plays a significant role in greenhouse gas emissions when compared to direct energy, being the reason for the great attractiveness of HPGR technology. Evidently that these will have to be balanced against CAPEX, OPEX, NPV and other qualitative criteria, which can certainly lead to a different optimal circuit.

Jan 1, 2014

By C. L. Tang

Parts of the wastewater are reused directly and the rest moderately purified and reused, so the utilization rate of wastewater of the whole processing plant reaches 100 percent. At the same time, beneficiation indicators have been improved stably, and great economic and social benefits have been achieved.

Jan 1, 2014

By Ö. Genç

In this paper, full-scale mill data collected from three different circuit configurations in cement plants demonstrated the size reduction performance of dry ball mills in relation with the ball size classification achieved by the classifying liners used in the grinding compartments. Findings indicated that, breakage rates at the last 2 ~ 4 meters of the mill are not sufficient to give reasonable size reduction ratios for the production of fines. Application of only damming rings without classifying liners resulted in inverse ball size classification which lead to reduction in size reduction performance thus specific breakage rates.

Jan 1, 2014

By Z. F. Dai

The Thompson Nickel Belt, located in Northern Manitoba, Canada, contains more than 400 million tonnes of ultramafic low-grade nickel mineralization in 9 deposits. One of these, the Pipe deposit, was mined between 1971 and 1983 producing a Ni concentrate of 9% to 11% grade at 73% recovery. The operation was terminated because the poor recovery, low Ni grade and high MgO con-tent of the concentrate made processing this ore uneconomical at the metal prices prevailing at that time. Vale Inco is now re-evaluating these deposits with the intent of providing a new source of concentrate for its Thompson integrated processing facility. It is known that serpentine slimes coating on the sulphide surfaces are responsible for the poor metallurgy. Various desliming methods were tested including settling, elutriating, tabling and hydrocycloning. Hydrocycloning has proven to be the most effective means of desliming. With a feed assaying 0.70% Ni and 33% MgO, a rougher flotation concentrate assaying 22.7% Ni and 4.8% MgO was produced at a Ni recovery of 62.5% (relative to the feed to grinding), with no utilization of slimes dispersants. Another 16.6% Ni recovery was achieved in scavenger flotation resulting in a total Ni recovery of 79.1%. Batch flotation tests using various flowsheet configurations to optimize the grinding, desliming, reagentizing and flotation conditions are in progress.

Jan 1, 2014

By G. G. Dong

This paper presents BF flotation machines in brief which are manufactured by Beijing General Research Institute of Mining & Metallurgy (BGRIMM). Dimensional analysis and similarity criteria have been used to scale up BF flotation machines. These scale-up criteria can be used to determine mechanical structure and hydrodynamic parameters including mixing, solids suspension, air transfer and power and so on. Similarity criteria are used to design 40m3 flotation machine being based on data from 1.2 m3 to 20 m3 flotation machines. Hydrodynamic tests of 40 m3 flotation machine in water are discussed.

Jan 1, 2014

By P. Oliveira, A. Peres, A. Silva

"The decrease in iron content and increase in contaminants grade, associated with greater participation of compact and semi-compact materials, has impacted the recovery of a mechanical cells flotation circuit in the Iron Quadrangle, Brazil. The recovery decrease in the flotation stage motivated the current conventional flotation circuit reevaluation seeking alternatives to restore the recovery, without affecting the final concentrate quality parameters, with low investment. Sampling, chemical characterization of samples, bench scale flotation experiments, and mass balances were conducted. Analysis of the results showed opportunities to improve the circuit performance. The stages prior to the flotation circuit changes were: rougher, cleaner, recleaner and scavenger. In the previous configuration, recleaner was operated as cleaner scavenger and the iron grade in the scavenger concentrate was 23%, representing 38% of the new feed. After the circuit change, the circulating load was reduced from 38% to 15% and the iron content was upgraded to 42%, resulting in increased residence time. The iron content in the global tailings of the concentrator was decreased from 10.9% (year of 2013 average) to 10.2%, representing gains in both mass and metallurgical recoveries.INTRODUCTIONRegarding plant practice, the year 1972 represents a landmark for the concentration of iron ores in Brazil. VALE started up 28 units of WHIMS (wet high intensity magnetic separators) at the Cauê plant in Itabira, each one producing 1x106 t/year of concentrate. Later 17 WHIMS machines were commissioned at Conceição. During the 80’s decade of last century, changes in the ROM required the addition of a cleaner flotation stage to decrease the silica content in the pellet feed.The first company to use reverse cationic flotation as the only concentration operation of iron ore was SAMARCO (start up in 1977). Since 2015 flotation has been utilized at VALE in Itabira as major concentration process, magnetic separation acting as scavenger stage.The Jones matrix type WHIMS were manufactured for decades under patent by KHD Humboldt Wedag. After the expiration of the Jones patent, Eriez Magnetics took the world leadership regarding WHIMS manufacturing. The Brazilian branch of Eriez is Inbras. Based on plant practice experience at the Fabrica concentrator, the Brazilian company Gaustec was established (RIBEIRO and RIBEIRO, 2010) and is now present in different countries. The mega sized WHIMS GHX-1400 (18.000 Gauss, gaps smaller than 1.5 mm) were developed to face the challenge of huge throughput required by iron ore processing (Ribeiro et al, 2017)."

Jan 1, 2018

By H. J. Liang

In this study, zeta potential and contact angle measurements of pyrite before and after interacting with Thiobacillus ferrooxidans are carried out to investigate the changes in its surface properties. The results show that, after pyrite interacting with Thiobacillus ferrooxidans and its metabolite, the surface electricity of pyrite changes obviously, resulting in a notable shifting of isoelectric point to lower pH value, but the contact angle varies little. Bacterial protein plays the most important role in the interaction. This work is helpful to disclose the mechanisms of Thiobacillus ferrooxidans de-pressing pyrite flotability.

Jan 1, 2014

By Nirmal Weerasekara, Malcolm Powell, Mohsen Yahyaei

"The conditions under which rocks become superficially damaged during the grinding process are not well understood. The main purpose of the work presented here is to understand how superficial breakage occurs under incremental low-energy impacts. To enable this study a series of abrasion tests with multi-size pilot mills have been performed. Outcomes of numerical simulation corresponding to each test were examined to investigate the experimental results. Abrasion tests have been conducted using three grinding mill sizes (i.e. 1.8, 1.2, and 0.8 m). Two types of ore were used to investigate different hardness strengths. To ensure abrasion was the dominant mechanism, in all tests the mill speed was reduced to 40% of critical speed. The relationship between the Fractional mass loss rate and particle size was investigated by randomly collecting seven tracer particles from sizes -73+63, -53+45, and -37.5+31.5 mm. It was evident from the results that the Fractional mass loss rate of angular particles declines as the particle size increases whereas the Fractional mass loss rate decreases from fine to coarse in rounded particles. Results of Discrete Element Method (DEM) simulations indicate that fine particles experience higher levels of collision energy per particle and this value reduces as the particle size increases and mill size reduces. This explains the higher Fractional mass loss rate of smaller particles as well as the increase in the Fractional mass loss rate as the mill size increases. Linked DEM and experimental data indicates that under these test conditions surface damage attrition is the dominant mechanism. This work suggests that DEM simulation can be implemented to predict the abrasion wear of particles in mills."

Jan 1, 2014

By Sarah K. DeBono, Alan J. Monaghan, Emmanuel V. Manlapig, Gregory J. Harbort

"The Jameson Cell is a type of flotation machine in which air and pulp are brought together in a vertical tube called a downcomer. Within the downcomer the air and pulp are dispersed into a dense foam of fine bubbles, which creates a favourable environment for bubble-particle collision and subsequent collection of hydrophobic particles. The intense collection zone within the downcomer can be considered similar to the zone between the rotor and stator in mechanical flotation cells.Research into the bubble-particle collision and fluid dynamics of mechanical cells rotor-stator zone has been limited by the difficulty of achieving accurate measurements in production sized machines. With the Jameson Cell the downcomer is largely external and separated from the flotation tank, allowing ready access to the primary contacting zone for measurement and analysis.An investigation has been undertaken into the operating characteristics of the downcomer relating to bubble-particle collision. An effective mapping of the downcomer has been made through measurements of void fraction and bubble size taken across cross sections of the downcomer. Analysis of these measurements has provided an interpretation of the variations in the air and fluid dynamics, bubble size and distribution throughout the downcomer chamber."

Jan 1, 2003

By G. K. Nimal Subasinghe

The performance of Knelson Concentrators (KC) used in gravity gold circuits often rely on manufacturers recommendations for selecting operating parameters such as, fluidising water flow rate and cycle time. These parameters are not only dependent on the machine parameters but also on the feed characteristics such as, size distribution of the gold and gangue particles and the composition of its constituent minerals. Particles entering a KC experience a centrifugal acceleration due to the high bowl rotational speeds. The required centripetal force to maintain a circular orbit is provided by the fluid drag force created by inwardly moving fluidising water and the Bagnold?s force arising from the particle/particle collisions. When the fluidising water flow rate is low particles move towards the outer rim of the bowl forming a packed bed within the grooves. On the other hand, if the fluidizing water flowrate is high the bed expands and some particles would move towards the centre of the bowl and gets carried to the tailings stream, thereby reducing the amount of material retained within the grooves of the bowl. Based on a force balance on a particle captured within the KC, a criterion which can be used to predict the amount of material recovered in the bowl has been derived and validated by experimental data. It has been shown that this criterion may be used to demarcate the transition of the bed from a packed-bed state to a fluidised state depending on the fluidizing water flowrate. By identifying the conditions for the optimal expansion of the bed comprising different constituent mineral particles, it is possible to estimate the optimal fluidising water flow rate that would maximise gold recovery while minimising gangue recovery. It was also observed that the accumulation of valuable mineral in the bowl takes place by the displacement of the gangue particles in the bed by the incoming heavy mineral particles. The kinetics of this segregation process was also studied using synthetic mineral mixtures. The experimental data suggests that this process follows first order kinetics and that the build up of heavy mineral reaches a maximum which could be used to identify the optimal cycle time. In this work, the suitability of the above model in optimizing the performance of a KC have been reviewed. Also the necessity and merits of testing an unaltered feed samples in a larger KC as op-posed to the commonly adopted GRG test has been discussed.

Jan 1, 2014

By Qidong Zhang, Yongsheng Song, Wenjuan Li, Guiying Zhou, Kun Song

"Molybdenum is a very important rare mineral resources, which exists largely in oxidized ores and sulphide ores in nature. About 99% of metallic molybdenum comes from molybdenite. The talcose molybdenum resources are abundant but the resources utilization is low, because the talc is naturally hydrophobic and the floatability of talc is similar with molybdenite, which lead to difficult separation by flotation. Talc is easy entry into concentrate in flotation which can cause the content of MgO overhigh, therefore the molybdenum concentrate grade can not meet the industrial requirements. Thus the utilization level of talcose molybdenum resources has been restricted greatly.The adsorption of water on talc and molybdenite surfaces and natural floatability of minerals were studied by density functional theory method. The results showed that molybdenite and talc were layered minerals which exhibited similar surface wettability and H2O molecule prefers to stay with water rather than the minerals surfaces. N2 is adsorbed on talc and molybdenite surfaces more easily than H2O. The interaction and flotation behavior were studied by SEM and flotation experiments. The reason why talc interferes with the flotation molybdenite has been revealed. The agglomeration between molybenite and talc was caused easily in neutral or acidity solution, and it was dispersing between molybenite and talc particles in alkaline solution. The flotation results showed that good floatability of talc was the key factor causing a low grade of concentrate in alkaline solution. Thus, it is the key factor to enlarge floatability difference between molybdenite and talc.INTRODUCTIONMolybdenum is a kind of important rare metal and strategic reserve resources (Zhitao Y et al, 2016a). Due to excellent characteristic, such as high melting point, good thermal property and et al, it’s widely used in metallurgy, machinery, chemical, aerospace, and many other areas. It has become an indispensable metal in modern industry. Molybdenum generally exist in the form of molybdenite which is a kind of mineral with excellent natural floatability. Talc is a kind of typical hydrous and layered magnesium silicate minerals (Beattie D et al,2006a), which is one of the most common gangue mineral of the platinum group metal ores and metal sulfide ores (Tao L et al,2011). Due to its good native floatability, talc is easy entry into the concentrate product with foam in the process of sulfide ore flotation (Kelebek S and Smith S, 2006b), which resulted in decreasing concentrate indexes. Not on that, the high-content MgO of concentrate will also produce a series of adverse impact to the subsequent smelting (Lotter N O et al, 2008). Therefore, it is difficult to separate talc from sulfide ore concentrate effectively."

Jan 1, 2018

By Danilo Zim, Matheus Paschoalino, Denis Guimarães, Jasbir Gill

The shortage of water supply in some regions of the globe is particularly problematic and forces mining companies to adopt alternatives like pumping sea water from the ocean up to the mining sites. Although deaeration of sea water or the use of lined pipelines are known options to prevent corrosion during pumping, a recent development of a new corrosion inhibitor allowed the use of simple mild steel pipelines for this purpose. The objective of this study is to demonstrate the recent advances of this technology in protecting against not only general corrosion but localized corrosion, main cause of corrosion-related pipeline failures. Corrosion studies were carried out using electrochemical techniques, weight loss balance as well microscopy surface analysis in order to measure and therefore evaluate the treatment efficiency. The right dosage of corrosion inhibitors may vary depending on water composition and characteristics of each system. Differences were observed depending on the sea water source. Pretreatment of metallic surface impacts the observed corrosion rate which can be as low as 3.6 mpy. The absence of pitting or localized corrosion was achieved in aerated seawater.

Jan 1, 2014

By Y. F. Li

Fengning ilmenite ore is a magnetic deposit in gabbro containing high phosphorus and low titanium, the main minerals in which are ilmenite, magnetite and apatite. The dissemination size of magnetite is so fine that even the percentage of -0.010mm level is up to 36.50%. The fine and vein magnetite are distributed in gangue and ilmenite, so the majority of the magnetite is difficult to be separated from the gangue. Ilmenite is difficult to be recovered by low-intensity magnetic separation even through fine grinding. In high-intensity magnetic separation of ilmenite, the gangue inter-growth with the magnetite and the Fe-containing silicates may be enriched in the concentrate, and the ilmenite of the concentrate will be reduced. Based on the processing mineralogy research, combined gravity-flotation process is suggested to recover the ilmenite. The method is also good to reduce phosphorus in the ilmenite concentrate.

Jan 1, 2014

By Y. M. Zhu

Lead in environment often causes a serious health hazard. The removal of Pb2+ from aqueous phase is a beneficial project. In this paper, deposited Saccharomyces cerevisiae (S.c.) was chosen as adsorbent, Pb2+ ions as adsorbate, and the process of biosorption was studied. The dynamics of the adsorption was investigated. The adsorption mechanism of Pb2+ by S.c. cells was also investigated by detecting microstructure, zeta potential under different pH value, FT-IR spectra of the S.c. particles before and after biosorption. It was shown that the biosorption of Pb2+ by deposited S. c. is a rapid process, and the adsorbing equilibrium is reached within 10 minutes. The Zero point of zeta potential of S.c. cells is pH=3.3. When 2.0<pH<3.3, there exists biosorption (biosorption rate 76%~88%), which means static bio-sorption been not the only kind of biosorption. FT-IR spectrum analysis showed that groups on bacteria surface were mainly characteristic groups of protein and amylase; oxo-groups and nitric-groups on S.c. cell surface could chelate with heavy metal ions. Chemical adsorption might exist in the process.

Jan 1, 2014

By B. Orberger

The fine fraction (< 2 mm) of the high grade Mn-ore from the world class Moanda deposit, Francevillan basin, in Gabon, contains up to 30 wt. % of manganese and about 0.4 wt. % phosphorous. A pilot study at laboratory scale integrating mineralogy and geochemistry before and after ultrasonic treatment was conducted on the fine fraction (< 2 mm) of oxidized Mn ore in order to reduce the phosphorous content and enrich this fraction in manganese. The fine fraction was dried, crushed at 2 cm and sieved at 2 mm. The two fractions (< 2 mm and 2 mm ? 2 cm) were investigated by X-ray diffraction and scanning electron microprobe ? electron dispersive spectroscopy analyses. Both fractions contain lithiophorite, cryptomelane and pyrolusite as Mn carrier, and goethite, muscovite, illite and quartz as contaminants. The Mn hydroxide nsutite was only found in the fraction 2mm ? 2 cm.The < 2 mm fraction is significantly richer in goethite, muscovite/illite, and quartz. Phosphorous carriers are mainly goethite (up to 2.8 wt. % P2O5), while the Mn minerals contain up to 0.8 wt. % P2O5. The Mn minerals are partly included in an agglomerate of goethite, muscovite/illite, and quartz. The < 2 mm fraction was treated by ultrasound for 30 s in normal water. Mineralogical and chemical analyses after ultrasound treatment showed that the Mn-minerals were largely liberated from the goethite-muscovite-illite agglomerate. Mass balance calculations show that after ultrasonic treatment the < 2 mm fraction was ? 50 % enriched in Mn and ?50 % impoverished in P.

Sep 1, 2012

By X. Y. Liu

A culture-independent approach based on 16S rRNA gene clone library was used to analyze the bacterial community change both associated to the solids and in the liquid phase during pyrite bioleaching process. Phylogenetic analyses of 16S rRNA fragments revealed that the retrieved se-quences mainly related to genus Leptospirillum, genus Sulfobacillus and genus Acidithiobacillus. During the bioleaching process, genus Leptospirillum trends to grow associated to the solids while major of genus Sulfobacillus were in the liquid fase, only accounting little portion in the solids. Genus Acidithiobacillus can grow both on the solids and in the liquid phase, but accounting high portion on the solids.

Jan 1, 2014

By Hermann Wotruba, Lars Weitkämper

"Dry coal dressing was popular during the 1950.s and 60.s in many parts of the world. The devices mainly used were air jigs and air tables.The increase in ash and moisture content of run-of-mine coals due to the wide advanced mechanisation of mining mechanisation during and after this period led to that pneumatic devices being unable to treat run-of-mine coals with the desired efficiency. Since the 1960.s almost all new coal preparation plants have been based on wet processes that are highly efficient in terms of coal recovery and their ability to handle damp and sticky run-of-mine coals. (Frankland, 1995)However, water is becoming increasingly costly and the disposal of fine products, containing most of the water, is an environmental concern. There would be significant cost savings and a lower total energy consumption if coal could be cleaned dry. Efficient dry coal treatment would be an interesting solution in desert, arid or cold areas.In Germany one dry coal dressing plant is in operation. The process and the advantages and disadvantages are presented below.Further on new developments in the field of dry density separation of coal are reviewed and analysed. Test results of new dry coal separation methods e.g. new developed air jig and magnetic separator are reported."

Jan 1, 2003

By Jonas Addai-Mensah

Despite the fact that nickel (Ni) laterites accounts for about 60 % of the world?s nickel mineralization, commercial processing of complex, low grade Ni laterite ores by conventional beneficiation (e.g. magnetic, electrostatic and flotation separation) still presents intractable challenges, particularly in heap leaching. Invariably, low grade laterite ores require aggressive hydrometallurgical techniques (e.g., highly acidic lixiviant leaching at ambient or elevated temperatures) for Ni and cobalt (Co) extraction. As a precursor to heap leaching, agglomeration of the multi-mineral phase feed particles into robust and porous granules of 4-10 m permeable bed, is essential. In the present work, several basic and applied studies of the agglomeration behavior of real Ni laterite ores and selected oxides and clay minerals (hematite, quartz smectite and kaolinite) which constitute the predominant host gangue phases of typical laterite ores are performed. Isothermal, batch agglomeration tests involving sulphuric acid solution as a binder were carried out to produce coarse, narrow-sized (5 ? 40 mm) granules which were well characterized. The influential role of feed ore characteristics (e.g., mineralogy/chemistry and primary particle size distribution) and binder composition (30 vs. 44% w/w H2SO4) and dosage (15-25 wt.%) in agglomeration behavior and granule properties were examined through several characterization techniques including granule size, compressive strength, bed percolation and re-wetting stability and 3-dimensional micro-structure analyses. Links between feed mineralogy/chemistry and size, binder formulation, agglomeration behavior, curing conditions and final granule properties and structural characteristics are established. The implications of the findings to Ni laterite plant agglomeration for enhanced heap leaching are discussed. Keywords: nickel laterite, complex low-grade ores, agglomeration, heap leaching, micro-structure

Sep 1, 2012

By M. S. Eygi

This study covers the investigations based on the electrokinetic and rheological properties to explain the interactions between kaolin minerals and commercially available polyelectrolyte in anionic character. Additional adsorption test were also conducted to support the interaction mechanism. Adsorption tests showed that adsorption densities decrease by increasing the solid content. In-creasing the solids contents from 1% to 30% by weight resulted in the decrease on adsorption from 2.14 mg/g to 1.85 mg/g. Because of its difficulty, the solids ratio at 70% was not studied. However, following to trend of the curve plotted adsorption density-solid ratio, an estimation was made and adsorption density at 70% solid content was extracted from the curve as 1.75~1.80 mg/g. The electrokinetic studies pointed out that the presence of polyelectrolyte increase the zeta potential of kaolin from 40 mV to 60 mV which is reasonable conditions to disperse and stabilize the kaolin slurry and lower the viscosity. When these result of the different tests are combined and considered together, 2 mg/g polyelectrolyte concentration was noted as optimal concentration where adsorption density, viscosity and zeta potential of the slurries give maxima and remain constant after this concentration.

Jan 1, 2014