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By Alexey P. Tatarinov

Under modern economic conditions in Russia, gold heap leaching is the most effective way of investing into gold-mining industry. Gold is recoverable from small-size deposits, low-grade ores from oxidation zone, cut-off grades, and overburden rocks using heap leaching. This technology is cost-effective and allows a saleable metal to be obtained within the first year of operation. The investments for heap leaching are lower than those of for a traditional plant technology. Production cost per one gram of Au is 5-7 times lower than that of during a plant flow sheet. A seasonal development of mines can be possible. With reference to this, heap leaching resembles the technology of placer deposits development. One of the major advantages of heap leaching is the form of the product. Gold can be obtained as dissolved in a clarified PLS, which allows the further quick treatment. The amenability of ores to heap leaching depends on their mineralogical composition. Oxidized porous ores with a good access of a lixiviant to valuable particles can be treated without pre-crushing. Clayish minerals are often found in oxidized ores with free gold. In order to build ground for heap, several major methods combined with various pad materials are used. These methods have been used at many plants and are reliable. The development of heap leaching technology for gold ores for the deposits from Yakutia, Zabaikalsky region, Primorye region, Uzbekistan, Tadjikistan, and Kazakhstan began in the 70s. However, it has been commercially used only since 1990. The first heap leach plants were built and commissioned in the USSR in 1991 at Vassilkovsloye deposit (Kazakhstan) and at Maiskoye deposit in Russia in 1994. Pilot plant testing was conducted in 1996 using ores from Kuranakh ore field, deposits Phiskulturnaya-Kholodnaya and Lopukhovskoye from the Aldan region. After the first successful commissioning of heap leaching plant in Russia, this technology has been commercially applied for deposits. Every year 1-2 heap-leaching plants were commissioned. More than 30 heap-leaching plants have been commissioned both in Russia and in the former Soviet Union using technologies developed by IRGIREDMET. Keywords: cyanide leaching, heap leaching, ore, percolation, solutions, lime technology

Sep 1, 2012

By V. F. Petrov

Today, sodium cyanide is extensively used for extracting gold, however it is highly toxic to the environment if not managed properly. This paper discusses the key challenges presented to gold operations in efforts to come into alignment with the Russian environmental regulations and suggests solutions to overcome these challenges. It is a fact that the major environmental threat cyanide poses to water sources. Therefore, natural water sources should be well protected from the adverse effect of cyanides used in hydrometallurgical processes. For this, the following site procedures and facilities are practiced: in-site and external water recycling systems, reclaim water treatment if required and tailings ponds with water impermeable screens (tailings ponds with controlled leakage). Cost comparison analysis of cyanide destruction methods was carried out. It was revealed that the aldehyde treatment method developed by Irgiredmet JSC demonstrated the best economics. Cyanide emissions are treated by mass-manufactured packed and membrane devices which allow to keep cyanides at the acceptable limiting values established by environmental regulatory agencies.

Jan 1, 2014

By S. Gaydardzhiev

Initial experiments towards preparation of hollow ceramic microtubes by dip-coating of fibrous plants with water based alumina gel-casting slurries using hemp and coconut fibres as templates have been done. It has been found that the wettability of fibres and accordingly the stability of the developed ceramic layer on their surface during slurry gelation varied significantly within the different fibre types. Good correlation between the diameters of the template fibres and the resulting channels has been found at the level of solids loadings used, 31 %. Hemp fibres used as bundles have led to formation of multi channel patterns while the coconut fibres-templated process resulted in uniform monochannel materials. The micro tubes have show good mechanical handling.

Jan 1, 2014

By F. B. Waanders

Coal, as energy resource, possesses numerous characteristics and properties which all have an influence on its gasification behaviour. The two properties considered as critically important when evaluating a coal source for gasification is its mineral content and slagging behaviour. Research has indicated that slagging formation can be inhibited or even prevented by the addition of a fluxing agent. It is thus of great importance to understand the mineral interaction during gasification in order to select a suitable fluxing agent for the prevention of slagging and clinker formation in the gasifier. The aim of the present project is to evaluate the effect of iron as a fluxing agent and study the transformation of the mineral and added iron during gasification. A pre-determined amount of pure elemental iron (between 2wt% and 20wt%) was added to a base case coal sample in order to study the effect of the addition of iron to the coal. The transformation of the iron in conjunction with the possible iron containing minerals present in the coal was studied by means of Mössbauer analyses. Typical characterisation techniques included proximate analyses, ultimate analyses and ash composition analyses. The ash fusion temperature analyses (AFT) were used to study and predict the slagging behaviour of the iron-spiked coal samples. Even though AFT analyses only provide an average flow property, it gives a good indication of the changes that the iron addition induces on coal properties. FactSage modelling was carried out in conjunction with the Mössbauer and AFT analyses. From the proximate, ultimate and ash composition analyses it was clear that the coal used con-formed to the average characteristics measured over an extended time period. From the AFT values it was seen that an increase in the flow temperature occurred with the addition of pure elemental iron to the coal, which can be of importance for operational purposes as to raise the gasifier temperature and not to have slagging problems to occur in the gasifier. The Mössbauer data show that he-matite is the main Fe-component that forms from the pyrite originally present and from the added iron to the coal, consistent with FactSage modelling, which shows that the partial oxygen pressure determines which mineral species will form. This study opens up new possibilities when considering operational problems experienced in in-dustrial gasifiers. Successful completion of this study and a study to look at reducing conditions in the gasifier will also add to the knowledge that already exists regarding fluxing agents.

Jan 1, 2014

By J. R. Cui

The production of electric and electronic equipment (EEE) is one of the fastest growing areas. This development has resulted in an increase of waste electric and electronic equipment (WEEE). In view of the environmental problems involved in the management of WEEE, many counties and organizations have drafted national legislation to improve the reuse, recycling and other forms of recovery of such wastes so as to reduce disposal. Recycling of WEEE is an important subject not only from the point of waste treatment but also from the recovery of valuable materials. Consumer electronic equipment (brown goods), such as television sets (TV), radio sets, and video recorders, are most common. However, recent work on recycling of waste electric and electronic equipment (WEEE) primarily focused on personal computer and printed circuit boards scraps. Based on a detailed characterization study of consumer electronic scraps, recycling of TV scraps oriented to recovery of metals is highlighted by utilizing air table separation, eddy current separation, and optical (metal) sorting process. The result indicates that a high recovery of copper could be obtained by utilizing an effective gravity separation process. The separation results reveal that air table separation is an effective technology to recover metals from consumer electronic scraps. By using a DGS table, approximately 90% of non-ferrous metals were recovered in the heavy product with a purity of 40%. Printed circuit boards and cables in TV scrap cause metals loss due to the fact that metals in printed circuit boards and cables are not liberated from plastics and ceramic materials. The study shows that eddy current separation and optical (metal) sorting process provide alternatives for recovery of metals from shredded TV scraps.

Jan 1, 2014

By P. Raghavan1

Reverse froth flotation experiments were carried out in the laboratory using two different types of kaolins for the separation and removal of coloring titanoferrous impurities from cryo-filtered clay after subjecting to high shear pre-treatment. This high shear pre-treatment consists of high shear agitation of a high solids clay slurry with the dispersant (high shear dispersion, HSD) followed by high shear agitation with the collector (high shear conditioning, HSC). After this pretreatment, the slurry is diluted and reverse flotation is carried out. One sample is from, Gujarat, India (Mamuara clay, ?MC?) while the 2nd sample is from Amberg, Germany (AKW clay, ?AC?). While MC consisted of 89% particles below 2µm and analyzed 1.06% of TiO2 and 0.29% Fe2O3 and measured a brightness of 83.4 %ISO, the corresponding values for AC are 67% below 2µm, 0.3% of TiO2? 0.49% Fe2O3 and 83.4 %ISO. The flotation performance is found to be greatly influenced by the conditions of high shear treatment. Important variables are HSD intensity (rpm), HSD time, HSC intensity (rpm), HSC time, HSD/HSC time ratio, ?HSD+HSC? total time etc. Higher shear intensities favor both the impurity liberation and collection. For both clays, it could be shown that impurity removal increases as total pretreatment time (?HSD +HSC? total time) increases up to a certain limit. For MC, the HSD time was only half or less than that of HSC time, while for AC, HSD time is at least twice (or more) than HSC time which is just an opposite manifestation. This is believed to be due to the striking differences between these two clays. Most importantly, the shear frequency is found more influential than the shear rate for the overall flotation performance for both clays. Interestingly, at high shear frequencies, i.e., when a stirrer with more number of teeth on the rotor is used, the ?HSD+HSC? total time is greatly reduced. Again, increased shear frequency helps to reduce flotation time and significantly improves flotation performance. At optimum conditions, product titania reduced to 0.35% for MC whereas the same reduced to 0.13% for AC. The product of flotation of MC measured 85%ISO brightness while that of AC measured84.6%ISO thus enhancing the value of the final product. It could also be established that the high shear pre-treatment shows better flotation performance than that due to collector dosage. Keywords: high shear dispersion, high shear conditioning, titanoferrous impurities, shear rate, shear frequency, brightness, clay recovery, Mamuara clay, AKW clay

Sep 1, 2012

By Vinay Jain

Beneficiation of alumina rich iron ore slimes is a major challenge for the Indian iron ore industry. One of the methods by which this problem might be addressed is by design/screening of suitable reagents (flocculants/depressants/collectors) which act selectively towards either aluminum containing minerals (gibbsite and kaolinite) or iron bearing minerals (hematite and goethite) in order to separate them. Our earlier work indicates that separation of iron oxide minerals from gibbsite is relatively more difficult than from kaolinite. Accordingly, our research work has been focused on finding selective reagents for iron oxide ? gibbsite separation. We have performed density functional theory (DFT) computations to evaluate the interaction energies of seven different reagent groups - carboxylic acid, flotol, hydroxamic acid, phosphonic acid, iminobismethyl phosphoric acid, xanthate and starch with hematite and gibbsite surfaces. The objective was to identify if any of these groups show selective adsorption towards one of the mineral surfaces. Among all these reagents, starch exhibits the highest selectivity towards the hematite surface with a difference in interaction energy of ~63 kcal/mol between hematite and gibbsite surfaces. This is consistent with experimental findings at our laboratories on slime samples from Noamundi mines wherein it is being observed that usage of starch as a flocculant does lead to an improvement in the final grade of the ore with significant reduction in the Al-content. A binuclear complexation mechanism based on affinity between Fe and Ostarch atoms combined with a geometrical templating effect, arising out of a close correspondence between Fe-Fe distance on the hematite surface and O-O distance in starch, is proposed to explain the strong adsorption of starch on hematite surface. Keywords: slimes, iron ore, alumina, hematite, gibbsite, DFT, adsorption, flocculants

Sep 1, 2012

By Gurubasayya Swamy

This paper presents the consequences of modernization and expansion of process plant by implementing SAG and Ball Mill and Carbon-in-pulp technology at the Hutti Gold Mine. From the inception of the process plant, it has undergone many changes for the improvement. In the beginning, only gravity recovery of gold was carried out by using Pebble Mills and Strake Tables. Later amalgamation, Cyanidation and Zinc precipitation and finally Carbon-in-pulp gold recovery system was implemented. Grinding plant was modernized by implementing SAG and Ball Mill and Knelson concentrator for free gold recovery as a result, the production rate, rate of recovery, reduced man power, Modernization and expansion of process plant has also yielded in safe and smooth running of the plant. Keywords: sag and ball mill, cip, modernization and expansion, productivity, gold recovery

Sep 1, 2012

By A. Pankewitz

The well-established on-line particle size analyzer OPUS manufactured by Sympatec GmbH, has been successfully implemented in several mining and industrial minerals project. OPUS monitors the particle size distribution in 31 fractions as well as the solid concentration in opaque and highly concentrated ore and mineral slurries on-line in real time e.g. behind mills or cyclones applying 31 ultrasonic frequencies for highest resolution. Ultrasonic extinction overcomes all limitations known from optical and mechanical systems like contamination, blockage and wear. OPUS measures slurries in their original state without any dilution, hence no extensive sampling procedure or sample conditioning is required thus no dilution errors occur. Due to the OPUS design and suitable algorithms entrained air bubbles do not affect the quality of analysis at all. The sensor covers particle size distributions from 0,01 to 3.000,00 µm and solid concentrations up to 70 % by volume and can be easily adapted to a number of production lines simultaneously. Jiangxi Copper?s Dexing Mine is one of the biggest copper mines in Asia and among the first users for OPUS on-line particle size and concentration analysis in mining industry. OPUS is connected to 2 process lines. Jiangxi Copper has implemented OPUS for into their central control system for the grinding & classifying circuit of one SAG mill and one ball mill. Analysis data and process control as well as optimization based on OPUS particle size and concentration measurements will be discussed Keywords: particle size analysis, ultrasonic extinction, concentration analysis, grinding control

Sep 1, 2012

By E. V. Manlapig

"Some researchers postulate that the floatability of a particle in the streams of an industrial flotation circuit is a function of only its size and liberation properties. They do not discount the importance of reagent or surface contamination on particle floatability but assume that the reagent coverage or surface contamination of the particle surfaces is essentially uniform for particles of similar size and mineralogical properties when subjected to a particular chemical regime.In this paper, samples collected from batch tests performed on different streams of the Red Dog lead cleaning circuit have been characterised with respect to their size, mineral association and mineral surface exposure. An analysis of this data set indicates that particle recovery rate is significantly affected by mineralogical properties - in particular the degree of valuable mineral surface exposure.However, through the use of a nodal analysis technique developed by the authors, it can be concluded that particles with the same size and mineral composition do not all float with the same rate, but with a distribution of rates. The characteristics of this floatability distribution do not change during the flotation process. It is suspected that the particles within a size mineralogical class in this study have varying degrees of surface oxidation and that this results in varying particle flotation rates. Thus basing particle floatability on size and mineralogical effects, alone, in a flotation model is not always valid."

Jan 1, 2003

By P. Saha, D. M. Chakrabarti, J. P. Srivastavam, P. Bhattacharyya, B. R. Sarkhel, Banerjeem B.

The phosphatic soil deposit at the Sukulu hills region of Uganda contains 10-12% P2O5. The ore occurs as a naturally degraded soil deposit containing a very sticky slime composed of earthy lateritic minerals. Desliming of the ore, which is imperative for its further beneficiation, is an extremely difficult hurdle to overcome for its commercial utilisation. Earlier studies on samples of the same ore at the National Metallurgical Laboratory (NML) and abroad established that it was necessary to pass the ore through a series of three stages of desliming, each consisting of a step of vigorous attrition scrubbing followed by hydrocycloning, for effective elimination of the sticky slime. In the present paper an innovative use of the very strong shear-fields created inside a hydrocyclone has been discussed, that could effectively eliminate the stubborn slime from the ore. The standard design of the hydrocyclone was suitably modified to increase the shearing effect on the slurry. It was possible, through the application of this modified hydrocyclone, to not only totally eliminate all the stages of attrition scrubbing, but also to reduce the subsequent stages of hydrocycloning. The modified technique yielded a concentrate of grade comparable to that obtained by employing the earlier more complex flow sheet, with about 25% higher P2O5 recovery.

Jan 1, 2003

By Steven Bradshaw, Edson Charikinya

The application of high power microwave energy to secondary crusher products has been shown to induce micro fractures and cracks in the ore. This suggests that heap leaching could benefit from microwave-induced fractures, as the extent and kinetics of heap leaching processes depend on the accessibility of grains to lixiviants, which can potentially be improved through microwave treatment. The density and pattern of microwave induced cracks and how these cracks subsequently affect heap leaching recovery has not yet been investigated. The objective of this study was to apply X-ray micro computed tomography (X-ray CT) to investigate microwave induced cracks in large cone and HPGR crushed sphalerite particles within 3D space. The ore particles were microwave treated in a single mode microwave applicator coupled to a switched mode power supply and a water cooled microwave transmission sub system operating at 2.45 GHz. The ore particles were treated at specific absorbed microwave heating energies of between 2 and 3kWh/t by treating at 6 kW of forward power for treatment times of 1 s. X-ray tomography analysis was conducted on fine (-5+4.75) mm, medium (-16+9.5) mm, and large (-25+19) mm sphalerite particles before and after microwave treatment at voxel resolutions of 5 µm, 15 µm and 25 µm respectively. Image segmentation, thresholding and spatial registration techniques were used to study crack patterns in 3D images of HPGR and cone crushed particles. Analysis of the X-ray CT images after microwave treatment shows considerable micro crack formation within the Cone and HPGR crushed particles. The cracks pattern showed interphase cracks propagating across all phases, with no evidence of preferential cracking. A greater density of microwave induced cracks was observed on fine (-5+4.75) mm particles compared to the medium (-16+9.5) mm and (-25+19) mm large particles. The results showed overall increased particle porosity following microwave treatment.

Jan 1, 2014

By V. F. Bannikov, A. P. Kozlov

"The purpose of this study was to develop a theoretical and technology framework for designing new combined technologies for processing tailings containing non-ferrous and noble metals using dry separation. The main goals of the study were: identifying the distribution patterns of valuable components in various fractions in dry separation processes; examining the patterns identified for different types of non-ferrous and noble metal tailings; developing a theoretical and technology foundation for the development of innovative technologies for the efficient processing of tailings with minimal process water consumption. To examine the possibility of efficient recovery of valuable components from refractory tailings using dry separation, an experimental laboratory unit was designed and built, composed of novel or modified lab equipment: plasma unit for increasing the magnetic susceptibility of Fe - containing minerals; magnetic separator supporting isodynamic and polygradient fields; pneumatic separator for the dry separation of finely dispersed mineral mixtures; dielectric separator using the resonant frequency of the electric field. The laboratory unit supports various modifications and combinations of the lab equipment. The experimental studies led to the development of a unified process scheme for lab tests of mature and non-ferrous smelter tailings using dry separation methods.INTRODUCTION The huge amount of waste from mining and processing of mineral resources Russia inherited from the extensive use of mineral resources in the Soviet Union and amount of waste continue to grow. Often the content of valuable non - ferrous, rare and noble metals in waste exceeds the balance contents in natural ores of the developed deposits. The availability of a rich scientific reserve for the creation highly effective innovative technologies for waste processing determines the necessity of the acceleration in the resolution of problems of the complex assessment, capitalization and involvement in the processing of technogenic resources in Russia (Chanturiya and Kozlov, 2014.)."

Jan 1, 2018

By Arun Appadurai

Pneumatic transport systems play a vital role in conveying discrete particles over a sizable distance with minimal energy consumption. However if such a system is not designed keeping particle physics in mind, it leads to intractable problems which could possibly assume dangerous proportions, including but not limited to expensive redesign of the entire system. This paper describes a novel method, which harnesses the powerful technique of Computational Fluid Dynamics (CFD) to investigate a problem occurring in rotary kilns using coal as a major fuel source. In some of the sites, a unique phenomenon of abnormally high CO emission was observed and owing to the highly random nature of occurrence, it was difficult to scientifically investigate the problem and its cause. Most of the published solutions for the high CO problem tend to concentrate on the incomplete combustion aspect of the kiln and resolve the situation by increasing the air supply thereby improving the stoichiometric ratio of combustion. This paper offers an alternate correlation that relates high CO emissions to the phenomenon of coal delivery fluctuations caused by the sub-standard operation of the coal transport system. A CFD model for the coal delivery pipe is validated by utilizing the actual process data sourced from the measurements taken from a functioning plant. The results of the model are used to derive correlative conditions that point to the unstable operating conditions of the coal delivery pipe prevalent in the industry. The conclusions are summarized into a series of recommendations for optimized design of coal delivery systems which are implemented in a pilot plant. The results irrevocably prove a statistically significant reduction in CO emissions without resorting to increased air supply and power consumption. Keywords:CFD, Pneumatic Conveying, Saltation Velocity, Particle Flow

Sep 1, 2012

By Zhou Junwu, Han Long, Song Zhenguo, Sun Chuanyao

The deposit genesis, the ore property, and the mineral characteristics, which has a close relationship with the beneficiablity, could be regarded as the “Genetic Properties”, actually are the determining factors for beneficiation process development. However, in conventional concentrator’s process development and engineering, there have been lack of systematic research and test on those genetic properties, also lack of well-established collecting, statistics and analysis system for those huge amount of data such as the historical mineral processing technique research, process mineralogy study, practical operating and engineering data. Obviously it is far less than enough for profound integration combining modern IT together with traditional mineral processing technology, as a result there are a number of disadvantages in mineral processing R&D and engineering, such as long term, high cost, low efficiency as well as repetitive testwork not making full advantage of previous experiences. Aiming to make utmost of those Genetic Properties and overcome above disadvantages in mineral processing R&D and engineering, the concept of “Genetic Mineral Processing Engineering (GMPE)” is put forwarded, and the strategical study has been conducted on this regard, with the main focus on following aspects: a) Testing and extraction of the “Genetic Properties”; b) Establishment of data base and data warehouse of GMPE; c) Intelligent decision making system for beneficiation process; d) Verification testwork; e) Virtual concentrator. The technical route proposed is to firstly conduct research and test on those Genetic Properties mentioned above, based on that the specific data base will be set up and applied for intelligent process recommendation and simulation with a few verification testwork conducted in the meantime, finally achieve a fast, high efficiency and precise determination of technology and process for ore beneficiation. The systematic study on the three-in-one GMPE would make an innovative breakthrough in conventional mineral process testwork research and engineering methodology, and provide technical support for the concentrator’s design and upgrading.

Jan 1, 2018

By Heiko Schiemann, Christoph Beyer, Thomas Pretz

"Due to multiple experiences in the field of planning and engineering of processing plants for secondary materials the Chair for Processing and Recycling of Solid Waste Materials decided to develop a software tool that supports the engineering and the planning of the basic layout of processing plants for secondary material flows. The detailed description of the material flow and its characteristic parameters is one of the main tasks to be worked out and should be considered as the basis for representative simulation results.The description of the material flow and its characteristic parameters is based on a fraction vector containing 12 material fractions. This is a compromise between a detailed material flow description and a compact and therefore time-extensive calculation model. Each material fraction is characterized by 15 parameters, which can be edited with the help of an easily accessible user-interface. In addition to basic parameters like ignition loss, water content and calorific value more parameters like the material fraction-specific particle-size distribution are contained. Using the model library SimuRec, the processing success and the recovery of complex processing plants for secondary materials can be predicted."

Jan 1, 2003

By A. V. Bogdanovich

In diamond ores processing, final waste tailings size, rejected to dump, is one of the most important parameters. On one side, it is necessary to minimize losses of diamonds, whose size exceeds 1 mm, on the other side ? to provide for the plant high throughput and sufficiently low capital and energy costs, which is in greater part connected with disintegration process. Extensive laboratory, pilot-scale and commercial-scale dressability studies of different types of diamond ores have been performed at JSC ?Mekhanobr Engineering? in recent years. With that, special consideration was given to determination of the required ores? disintegration size that would provide for a high recovery of diamonds. In diamond ores processing, in order to exclude breaking of large diamonds, stage disintegration is used with regrinding of light fractions and heavy fraction X-ray fluorescent separation tailings. On account of rather weak bonds of diamonds with enclosing minerals, in crushing and grinding of diamond ores, selective disintegration takes place, with aggregates? breakup along plane surfaces of least bonding, which facilitates liberation of diamonds and their transition to free state. Heavy components losses with different sizes of final dump tailings were studied in processing of large samples. It was established, that in order to almost completely exclude losses of heavy components over 1 mm size, light fractions had to be ground to 2.5-3 mm size, while X-ray fluorescent separation heavy tailings of -15+3 mm size do not contain diamonds larger 1 mm in aggregates, and their regrinding does not increase total recovery of diamonds. On the basis of the conducted studies, relationships regarding heavy components and diamonds losses with respect to diamond ores final disintegration size were obtained, providing for more rational organization of the ores disintegration and processing flow sheet. Keywords: diamond, waste tailings size, disintegration process, recovery of diamonds

Sep 1, 2012

By M. Pischtschan, S. Belz, M. Perrucci

In High Pressure Grinding Rolls (HPGR), the material grinding takes place between the fixed and floating rollers. In this regard, the rollers start to wear over a period of time, which is impacted by for e.g.: ore characteristics, operating pressure, feed material size and non-uniform feed presentation across the roller width. HPGR operational experiences have shown that the rollers do not wear at the same rate. This differential wear rate over time leads to differences in the tangential speeds of the rollers, causing an uneven gap between the fixed and floating rollers in relation to the material. This unwanted but extremely common situation results in a less effective grinding process due to the fact that the slip between rollers is not optimal. As the rollers wear profile increases, the roller with smaller diameter starts to wear further, deteriorating the comminution efficiency up to a point where operators have to stop the HPGR to replace the rollers. Since the wear rate of the rollers is not equal, the replacement of the same cannot be properly planned so that their life-time are fully utilized. In this paper, a dynamic load share control with the use of ABB’s variable speed drive system is proposed, which provides the possibility to the HPGR operator to impact the roller wear in such a way that it equalizes the wear rate to a certain extent and extends the roller life time. Called RollXtend™, this solution includes a load share factor which can be parameterized based on the wear measurement performed manually during maintenance procedure. Additionally, this paper describes an automated load sharing concept based on a non-invasive wear measurement method. The partial results of the technology trial in a copper/gold mine are presented, which aimed at detecting stud damage and estimating the real rollers profile throughout their life time. The final objective of the pilot project was reduce the amount of planned and unplanned downtimes of the HPGR by increasing the rollers life time and avoiding catastrophic stud damages.

Jan 1, 2018

The ore studied occurred in the Three Rivers area in China and was a silver-lead-zinc complex ore containing 400.52 g/t silver, 4.77 % lead and 3.47 % zinc. Silver, lead and zinc were the major valuable elements in the ore and copper, cadmium and tin were the associated elements to be comprehensively recovered, whereas arsenic was the harmful element. The element silver occurred mainly in freibergite with small proportion in dyscrasite and other silver minerals. The carrier minerals for silver were mainly galena and oxidized lead minerals and then sphalerite, arsenopyrite and pyrite. The ore contained numerous minerals with complex mosaic texture and the lead and zinc minerals enclosed each other multiply, which made the separation of the minerals in the ore very difficult. Experimental investigation on the beneficiation of the ore indicated that with flotation separation process it was very hard to obtain single lead concentrate or single zinc concentrate that would meet the requirement of market. In the meantime, during the separation process of lead and zinc, silver tended to be dispersed, resulting in a low recovery of silver. Therefore, a rational utilization technique for the ore should be a combined process of bulk flotation to reduce arsenic? sulphating roasting of silver-lead-zinc bulk concentrate-leaching with diluted sulphuric acid to separate silver, lead and zinc. With this process quality lead concentrate containing silver and high grade zinc product and silver product could be obtained. The recovery of silver, lead and zinc in flotation was 85.10%, 84.48% and 82.48%, respectively. The total recovery of silver, lead and zinc in chemical processing was 97.07%(sum of recovery of silver ingot and lead concentrate), 99.61% and 90.93%, respectively.

Jan 1, 2014

By Z. A. Zhou

In Canadian oil sands processing, flotation is used to recover liberated bitumen droplets from oil sands slurries. Similar to conventional mineral flotation practice, a fundamental limitation of recovering bitumen from low grade oil sand ores is its slow and ineffective aeration of the liberated small bitumen droplets. Gas nucleation and cavitation could provide better mechanisms for accelerating bitumen-bubble attachment. A research program was undertaken to examine factors affecting spontaneous bubble nucleation on bitumen surfaces. The results demonstrate that surface hydrophobicity and existence of gas nuclei in process water play a critical role for bubble nucleation. While there are more bubbles nucleated on highly hydrophobic silanated glass surfaces than on moderately hydrophobic bitumen, bubble nucleation on clean hydrophilic glass surfaces is negligible. Heating process water up to 85 ~ 95oC (as used in commercial operation) or boiling tap water prior to gas nucleation tests is shown to remove sufficient amount of gas nuclei existing in the water, thereby drastically reducing the number of bubbles nucleated on bitumen. Enhancing gas nuclei formation in hot process water is identified as a promising strategy to improve bitumen-bubble attachment during oil sands conditioning, and hence to increase bitumen recovery from low grade ores.

Jan 1, 2014