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By Robert Peretti, Antonio Zucca, Andrea Manni, Silvia Serranti, Paolo Massacci, Marcello Ghiani

"This research study aims to identify the best way of processing colemanite concentrates, which is sometimes characterised by a high content of As sulphides, finely disseminated in the matrix of the boron mineral.Scanning Electron Microscopy analyses have been carried out to identify all the mineralogical constituents and to evaluate their distribution, frequency and mutual relationships.Colemanite concentrates are mainly used by chemical plants producing boric acid and gypsum. A high As content is unacceptable for further use of tailings coming from the leaching process and is very dangerous if the tailings are released into the environment.Grinding tests were conducted under dry and wet conditions in order to assess how As sulphide minerals are released from colemanite minerals.Some of the difficulties involved in obtaining selective liberation of As sulphides from colemanite minerals were overcome, although a certain decrease in As grade in the higher size classes was registered.All comminution products have been analysed by SEM, monitoring the degree of liberation of the mineralogical constituents.Flotation tests have been carried out, following different comminution flow sheets and adopting different modulating conditions in order to evaluate the influence of the following parameters:- collector concentration versus contaminants concentration (As minerals) in the froths;- kind and quantity of the frothing agent to maximise mineral recovery in the froths;- kind and quantity of the modulating agents to maximise the selectivity of the process;- conditioning modalities in order to obtain a suitable dispersion of fines and avoid segregation of Asbearing particles together with colemanite ones;- solid/liquid ratio of the pulp to minimise the water flow into the plant.Information obtained from SEM analysis has been adopted to evaluate segregation phenomena in pulp and in flotation products."

Jan 1, 2003

By J Moncrieff, P Bellairs

The Black Star Open Cut is located immediately adjacent to the township of Mt Isa and is situated in the middle of extensive pre-existing infrastructure including two concentrators, two smelters, a wet fill plant and two shafts. At any one time there are in excess of 500 people working on the surface within an industry-accepted 600 m exclusion zone from Black Star blasts. Apart from the surface operations there are also the underground operations including the lead mine (closed in December 2005) and the Enterprise and X-41 mines that must clear for all Black Star blasts. The application of industry standard blasting exclusion zones (600 m) was risk assessed as imposing operationally prohibitive constraints which could cause significant business interruption due to the logistical challenges required to ensure that all personnel from surface plants were evacuated for each blast and potential for lost production whilst these personnel were not operating the plant. In was therefore an imperative for the blast exclusion zone to be reduced. This was achieved by the: use of a QA/QC team to ensure that relevant drill and blast implementation is within an acceptable tolerance (KPIs) from design; use of high-quality stemming material called HMR, which is a by- product of the concentrating process and is generally sized at -14 mm with very little fines; implementation of appropriate training and support to Black StarÆs own blast crews, reinforcing the need to achieve the designed amount of stemming in every hole; and provision of appropriate support from Black StarÆs management for additional resources to ensure that every blast achieves design within the KPIs but especially in high-risk areas. The blast exclusion zone was successfully reduced after monitoring the flyrock results from more than 176 blasts. Black Star Open Cut now maintains a minimum blast exclusion of 200 m in critical areas; however, general blasting currently uses a 250 m exclusion as this provides additional risk management whilst still minimising the logistics associated with clearing and securing the slightly increased area.

Jan 1, 2007

By Michel Rodrigo Luiz, Glaucio Augusto Polini, Giardini F. Lazzarin

ArcelorMittal's pickling and cold rolling line has been demanded to increase production since the installation of equipments in 2015. In addition to the improvement in productivity related to these new equipment, one of them the automatic surface inspection system (SIAS), work has also been developed in other equipment seeking improvement of production indicators. The present article exposes the actions and gains that were achieved with actions on two equipments in the same section as the Side Trimmer. The first one deals with the optimization of time gains with sequencing adjustments without financial contribution, using only internal labor seeking reduction of unproductive times by adjustments of the side trimmer in the cold strip mill. The second item discussed demonstrates the actions and the gains generated due to the availability of new resources (installation of SIAS equipment), the optimization of these resources seeking a focus on the reduction of ruptures in the tandem cold mill, configuring the same in the aid of the identification of critical defects and also in the automatic speed reduction action of the tandem cold mill in defects considered serious. In both cases the intention was to improve production, seeking to improve the results of the section and the line.

Oct 1, 2019

By Liangying Wen, Feng Xia, Chenguang Bai

"The situation of the Ti-V-Magnetite samples reduced with microwave has been investigated in laboratory. Firstly, the paper focuses on the heating behaviors of vanadium-titanium magnetite and characteristics of carbothermic reduction of V-Ti-magnetite in the microwave field. The effect of concentrate's size, quality on heating behaviors and reduction processes were researched. Results show that microwave heating may be a new heating resource replace of carbonic combustion reaction in reducing reaction. When the allocation of carbon is (16.7-30)%, carbothermic reduction of V-Ti-magnetite in the microwave field can proceed; with the increasing of carbon mixed, the metallization rate increases; and Fe, V can be reduced from their oxides in the microwave field; Titanic low oxide can be reduced from TiO2.1. IntroductionThe resource of Ti-V-Magnetite is abundant in the western area of Panzhihua in China, so far a mineral deposit of 4.64 billion tons have been proved up, it contains 14.75 million tons of V2O S which accounted for 87% of the vanadium and 5.93 hundred million tons of TiO2 accounted for 94% of the titanium resource respectively in China. The previous study proved that the major composition of mineral of the Ti-V-magnetite are Ti-magnetite, limonite, iron spinel, magnesium spinel etc, and the main elements of the Ti-V-magnetite in this area are Fe, Ti, V, Cr, Co, Ni, Ga, Sc etc[1] Due to the restrict of the BF-BOF process technical, during the smelting of the iron, the level of extracting the vanadium, titanium as well as other metal elements is limited. This results serious wasting of resources. To develop a new reduction process of Ti-V-magnetite is on the agenda, the microwave assistant reduction could meets this need, based on its characteristic of easy controlling of heating rate. To make use of the microwave energy to substitute the released heat sources of carbon combustion with air, use the solid phase state reduction at a relative lower temperature, make the beneficial element in Ti-V-magnetite transferred into the metal phase, then separated from the impurity. It is well worth to point out that once the microwave based reduction method has its industrial scale, it will take an outstanding position by its less release of carbon dioxide. This new environment-friendly process will play a vital role in the development of social industry and economy."

Jan 1, 2008

Reduction of titania and ilmenite ores by Cf4-H2-Ar gas mixture was investigated in a laboratory fixed bed reactor. Titania was reduced to titanium oxycarbide in the temperature range of 12OO-1500°C. At 1400-15000C, the extent of reduction of titania to titanium oxycarbide achieved more than 85% in 90 min. Optimum conditions for titanium oxycarbide synthesis by reduction of titania include temperature in the range of 1300-1450°C, methane content 8 vol% and hydrogen content above 35 vol%. Ilmenite ore was reduced by Cf4-HrAr gas mixture to metallic iron and titanium oxycarbide. Metallic iron catalyzed methane cracking and solid carbon deposition. Titanium oxycarbide formed at temperatures as low as 950°C. The optimum temperature for reduction of ilmenite is 1200°C and the optimum methane content is 8 vol%. Increase in hydrogen content increased both rate and extent of reduction. With 5 vol% CH4-75 vol% Hr20 vol% Ar gas mixture, the reduction of ilmenite completed in 60 min. Reduction of titanium oxides to oxycarbide with following chlorination may be an efficient alternative technology for processing of titanium minerals.

Jan 1, 2001

By D. C. Valdemeri, Oppermann J. P. Z., R. G. Schaarschmidt, C. S. Mendonca

This case study was conducted in an aggregate company, located at Estância Velha town, RS, Brazil. The study was based on the results of vibration monitoring mainly in terms of PPV (peak particle velocity) and frequency. Changes in the blasting design were performed to adjust the limits determined by the Brazilian standard NBR 9653:2005. Understanding the seismic wave attenuation for the site, changes in the blasting design were tested to fit the limits, such as reduction of maximum charge per delay, initiation orientation and sequencing and finally the replacement of accessories like "shock tube" by electronic initiation system. The results are shown below.

Jan 1, 2015

By D. Sanguinetti, A. Consigny, M. Nodwell

"Alkali precipitation of dissolved metals is an inexpensive but non-selective means of treating mine wastewater. Alternatively, sulphide precipitation can treat to below parts-per-million concentrations while selectively recovering valuable metals. While technically feasible, sulphide treatment of dilute waste streams increases the size and cost of the plant relative to the metals loading. Ion exchange has been applied at two separate sites to pre-concentrate nickel containing wastewater prior to recovery in smaller and more cost effective sulphide precipitation circuits. The result is a dual-circuit system that can maintain high selectivity and reduce overall facility cost while meeting strict effluent regulations.INTRODUCTIONAlkali precipitation using lime is the most common method of treating mining effluents for dissolved metals removal. This method is generally sufficient for waste streams containing mixed metals of little value, and for meeting modest metal concentration limits in the final effluent. Due to the non-selective nature of the lime process, the produced metal hydroxide sludge is of little value. All metals are removed together in a sludge product which cannot be re-processed for further value recovery.By contrast, sulphide precipitation can be used to selectively remove and recover valuable base metals (such as copper, zinc, nickel and cobalt), since the sulphide will preferentially target these metals without reacting with less valuable metals (such as iron and aluminum). The low solubility of the metal sulphide solids also supports the removal of base metals to lower concentrations than can be achieved with alkali precipitation in addition to other benefits discussed more fully in a prior paper (Bratty, Lawrence, Kratochvil & Marchant, 2006). The corollary to this solubility feature is that sulphide precipitation can function on influent streams containing low (< 10 mg/L) metals concentrations to meet very low parts-perbillion final effluent concentrations. Reagent overdosing is also minimized when compared to alkali precipitation."

Jan 1, 2012

By Franz Albert Nonnen

Backfill systems have been used for as long as mining activities have existed. Various backfill methods have been developed over the centuries with consideration for geological necessities, the technical means available, security requirements, and available finances. In the past, backfill systems were introduced and upgraded geographically in accordance with local experiences. In modern times, mining engineers participate in international forums for the exchange of knowledge so that backfill techniques and experiences are shared concurrently in mining areas all over the world. Mine backfilling increases the cost of mining so that great attention must be paid to choose a low-cost, reliable, and low maintenance backfill system. Some methods are described in this paper.

Jan 1, 2001

By Yoon-Bong Hahn

A mathematical model has been developed to analyze and predict the reduction process of iron ore particles in a two-stage fluidized bed system. This model includes the effect of particle degradation to elucidate its effect on reduction of iron oxides. Although the particle degradation is dependent on kind of iron ores, it was found that eighty to ninety percent of overall degradation is occurred in the prereduction stage mainly due to thermal stress and volume expansion. The degradation of particles in the?final stage is not much, but is mainly due to interparticle collision and abrasion. It was also found that to obtain a target reduction degree, it is of great importance to control the bed temperature and the residence time of paarticles in R1 rather than in R2. Optimum range of residence time was 15-20 minutes in the prereduction stage; 30-35 minutes in the final reduction stage.

Jan 1, 1996

By Muhlis Nezihi Saridede, Burak Birol

"Plastic wastes become a huge problem day after day due to the growth of plastic industry. Hence, plastic wastes are used as a raw material for other industries to eliminate this problem. Polyethylene Terephthalate (PET), which is a commonly used for plastic bottles, may be used as a reductant for iron production because of its C and H content. In this study, composite pellets containing iron ore concentrate, flux and reductant were prepared. Crystallized PET bottles and coke were used as reductant after ground. The prepared pellets were reduced at 1400°C for 30 min. and iron nuggets were produced successfully. Usage of waste PET purely as reductant in composite pellets gives a higher metallization degree and proper carbon content than coke or PET and coke mixture.IntroductionPlastics can be seen everywhere, especially at packaging industry in our common life. The increase of plastic usage ends up with an important problem, the increase of plastic wastes. Many studies have been carried out about usage of plastics as reductant in blast furnace such as Ogaki et al.[1], Heo and Baek [2], Saridede [3], Minoru et al.[4], etc. Besides, Kato et al. [5], Nomura and Kato [ 6] and Rongfang et al. [7] have pointed out the use of plastics in coke ovens regarding to its calorific content. In EAF steelmaking, a mixture of coal/coke and plastics can be used as an energy resource instead of only coal or coke. [8] Also, the usage of PET and PC in self-reducing composite pellets increased the reduction rate. [12]PET (Polyethylene terephthalate ), which is commonly used for soft drink plastic bottles, is an important municipal waste due to its C and H content. Its molecular formula is (C10H8O 4)n. Demir and Dincer showed that PET can be crystallized at 250°C to have the ability to be ground to a size of -100 µm. [11]"

Jan 1, 2011

By Takamitsu Nakasuga, Haiping Sun, Kyushu University, Katsumi Mori

"The kinetic behavior of reduction of chromite ore by liquid iron containing carbon and silicon has been investigated under various experimental conditions to clarify the reduction mechanism. It was found that the reduction rate of chromium ore by liquid Fe-C alloy was very slow. In addition, when carbon and silicon coexisted in the iron melt, silicon was found to preferentially oxidized to form silica, which favored for the fonnation of liquid slag and the rate of reduction was considerably accelerated. The similar effect was obtained by the addition of some fluxes, such as SiO2, Na2B407, CaO-SiO2, which also promoted the formation of a liquid slag and thus the reduction rate in the early stage also increased.IntroductionThe reduction of Cr2O3 is a basic reaction for production of ferro-chromium from chromite ore and for chromium recovery from the slag fonned during the decarburization period of a stainless steel-making process. The reduction of chromite ore consumes much energy and its reaction rate is not so high. Thus, in order to increase the reduction efficiency, it is strongly desired to clarify its reduction mechanism from the practical and the theoretical points of view."

Jan 1, 2000

By P. P. Kim, M. Tangstad, T. A. Larssen

"The kinetics of MnO and SiO2 reduction in SiMn slags based on Assmang/Comilog ore and HCFeMn (highcarbon ferromanganese) slag were investigated between 1500 and 1650°C under a CO atmosphere. The results showed that charges containing HCFeMn slag had relatively faster reduction rates than those without. The difference in the driving force for MnO reduction was insignificant among the SiMn slags at 1500°C, which implies a low contribution of the driving force for reduction rate. The slag viscosities were also rather similar, around 1 poise at 1500°C, which could not explain the different reduction rates. Instead, the different charges containing various sulphur contents are believed to give rise to the varying reduction rates. The estimated activation energies for MnO reduction were around 500–920 kJ/mol for charges containing HCFeMn slag, and between 250–300 kJ/mol for those without. Based on the estimated kinetic parameters, the considered rate models were able to describe the reduction of MnO and SiO2 in SiMn slags between 1500 and 1650°C. IntroductionManganese ferroalloys such as ferromanganese (FeMn) and silicomanganese (SiMn) are important ingredients in steel production due to the beneficial effects of manganese on the physical properties of steel. Mn enhances the strength, toughness, and hardness of steel products, and both Mn and Si are used as deoxidizers to prevent the development of porous structures (International Manganese Institute, 2014; Olsen, Tangstad, and Lindstad, 2007; Subramanyam, Swansiger, and Avery, 1990; Tomota et al., 1987).The thermodynamic background of manganese ferroalloys is well established (Olsen, Tangstad and Lindstad, 2007), but kinetic information is rather scarce, especially for the SiMn process (Tranell et al., 2007; Tore-Andre Skjervheim, 1994). The absence of kinetic information makes it more difficult to understand the reduction mechanisms of MnO and SiO2. It is not clear how different raw materials affect the SiMn process. The main metal-producing reactions in the SiMn process are described by Equations [1] and [2]:"

May 1, 2019

By T. C. Alex, S Srikanth, Premchand

It has been suggested that reduction of the iron and manganese phases as far as FeO and MnO is preferred for the complete liberation and selective reduction of the copper, nickel and cobalt oxides in manganese nodules. The oxygen partial pressure/temperature regime suitable for this purpose has been delineated. Free-energy minimisation and thermogravimetric results indicate that the requisite conditions can be achieved if more than 10% of neutral oil is used at temperatures greater than 923 degrees C. Neutral oil content, temperature and roasting time have been optimised to maximise leaching recoveries of Cu, Ni and Co: up to 96% of Cu and Ni and up to 85% of Co can be recovered if 15% of neutral oil is used as a reductant at 973 K for 90 min

Jun 21, 1905

By A. R. Udupa

The reduction roasting behavior of chalcopyrite has been investigated using various combinations of a desulfurizing agent, i.e., CaO or Na2CO3, and a reductant, i.e., CO, H2 or C. Using these, combinations the sulfur is removed from the mineral as CaS or Na2S rather than SO2 as is the case with conventional copper smelting and converting. The laboratory reduction ex¬periments were conducted using thermogravimetric analysis (TGA) and boat tests of mixed combinations of fine particulate reactants subjected to a continuous gas stream. The degrees of metallization were determined by both weight loss and chemical analysis methods and the products examined using optical and scanning electron microscopy and electron probe microanalysis. The percent reduction after one hour at 900°C ranged from 60% to 94%. From these data It was possible to provide postulations as to the controlling reduction mechanisms.

Jan 1, 1983

By Thomas P. Battle

Ilmenite (iron titanate) is the source of over 90% of all the titanium produced in the world today. At some point during production of titanium dioxide or titanium metal the iron impurity must be removed. Too often it becomes a waste instead of a product. DuPont and MINPRO have developed a solid-state process which separates the iron and titanium components of ilmenite into different high-purity powders, which can be separated using conventional mineral processing techniques. The main reactor in this process is a unique high-temperature ball mill, where the iron segregates from the ilmenite lattice with the assistance of catalytic quantities of He\. The results of lab, pilot plant, theoretical, and scale-up studies are presented and discussed.

Jan 1, 1996

By E. Molleman

This paper reports on testwork exploring the dissolution/reprecipitation reaction: ZnS + 2HCl ? ZnCl2 + H2S, as part of a process for the production of pure ZnS. In spheroidal form, this would constitute a premium fonn of zinc refinery roaster feed enabling the production of pure ZnO. The research focused on the influence of proton activity on dissolution of zinc concentrates from Brunswick Mining & Smelting, Red Dog and Tara. The results and thermodynamic data suggest that the three concentrates contained significant amounts of the more reactive mineral wurtzite, although XRD analysis showed mainly the presence of the mineral sphalerite.

Jan 1, 1997

By Daniel Amponsah-Berko, Palas Kamlakar Borkar, Kwabena Boafo, Neha Sharma, Timothy Eisele

A series of iron-leaching experiments were conducted to test the ability of metal-reducing anaerobic organisms to reduce iron from Fe3+ to Fe2+ to dissolve it from iron ore tailings. This bioleaching process involves the fermentation of biomass from Typha latifolia (a common wetland plant) to generate organic compounds, which, along with metal-reducing organisms, reduce and dissolve iron. The concentration of dissolved iron over time was studied for one year. Iron concentration above 1150 mg/L was achieved at a pH range of 3.95–5.36. Tailings from multiple locations were examined.

Feb 1, 2025

By N. A. Jabit

The dissolution behaviour of ilmenite in acid solutions has been studied by many researchers to improve the leaching efficiency. Most studies which utilized natural ilmenite from different origins resulted in different reactivity due to the alteration caused by the weathering process. Previous researchers have suggested that the greater reactivity shown by some ilmenite samples towards sulphuric acid may be a result of the mineral being relatively unaltered. In the present study a rotating synthetic ilmenite disc of 2.2 cm diameter was subjected to leaching studies in hydrochloric acid. The dissolution rates of iron and titanium from synthetic ilmenite were determined in hydrochloric acid solutions (4 M to 9 M) over a temperature range of 50 to 80°C. Results show that the rate of dissolution of both iron and titanium increased with the increase in acid concentration. However, the rates decreased with time and obeyed a parabolic rate law indicating the blockage of the surface by an insoluble product. The rates of dissolution of both iron and titanium were higher in the presence of SnCl2 and remained unaffected with time indicating the reductive role of SnCl2 which inhibits the formation of surface blocking solids. Application to natural ilmenite is also discussed.

Jan 1, 2014

By L. C. S. Dharmasiri, S. M. Shin, A. Senaputra, J. S. Sohn, K. H. Park, J. Avraamides

Reducing agents can be applied to leach metal values from natural and secondary resources such as laterite ores and deep sea manganese nodules and recycled materials such as spent batteries / catalysts which contain high-valent metal oxides of manganese, cobalt and iron. Selective leaching of some metals can be achieved by selecting conditions to control the saturated solubility and dissolution rates of metals from oxides or mixed metal/oxide matrices. The leaching results are rationalized on the basis of chemical species, Eh-pH diagrams and heterogeneous kinetic models. The role of reducing agents such as hydrogen peroxide, sulfur dioxide and iron(II) sulphate, in acid, alkali and in the presence of complexing ligands such as ammonia for the improvement of the leaching of metal oxides and metals is discussed. Previous studies on acid leaching of metals from nickel laterites, manganese nodules and spent catalysts/batteries in the absence or presence of reducing agents show that the rate controlling step involves the diffusion of protons through a thickening product layer on the particle being leached. It is shown that the leaching of nickel and cobalt from manganese nodules and zinc-carbon batteries in ammoniacal sulphur dioxide solutions also obey shrinking core kinetics.

Jan 1, 2014

By Hiroaki Kawamura, Takeshi Yoshikawa, Kazuki Morita, Yutaka Yanaba

"To develop an alternative metallurgical process for phosphorus removal in the production of solar-grade silicon (SOG-Si), slag treatment of metallurgical-grade silicon (MG-Si) was conducted, followed by acid leaching. Phosphorus-doped silicon alloy or MG-Si containing certain amounts of phosphorus and calcium was reacted at 1723 K and 1773 K with CaO--CaF2 of several compositions. Phosphorus removal from the molten silicon into the slag phase was confirmed by reduction to phosphide ions, P3-, and phosphate ions, P3-. These ions were separately determined using a wet chemical analysis method developed by ourselves. The highest phosphorus distribution ratio obtained was 2. 7 after reaction for 18 h with 17.5 mass% CaO--CaF2 slag. We then conducted acid leaching of the silicon and achieved removal of a large fraction (over 90 % ) of the phosphorus, which was much higher than that obtained by ordinary oxidizing slag treatment.IntroductionIn recent years, the production of solar cells has been increasing rapidly. Because of this, the demand for solar-grade silicon (SOG-Si) has also been growing rapidly. The development of lower-cost mass production processes is therefore needed to provide silicon feedstock. Phosphorus is one of the impurities in metallurgical-grade silicon (MG-Si). Because of its large segregation coefficient (kp = 0.35) [l ], it is difficult to remove phosphorus using a solidification refining process. Vacuum melting is considered to be a promising method for removing phosphorous from MG-Si [2], but the issues of high cost and large energy consumption have still to be resolved.Slag treatment is often used to remove impurity elements by oxidizing reactions during general oxidation refining processes. For example, phosphorus in molten steel is removed into a slag phase as phosphate ions, PO4 3-l-, by the following reaction:"

Jan 1, 2013