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By J. S. Roti

Calcium-based scale precipitation is a common problem in mill reclaim waters. An accumulation of these adherent deposits can result in a rapid reduction in water flow, loss of pump efficiency and eventual interruption in ore production. Heap leach applications can also experience the added problems of plugged sprinkler heads, blinded leach pads and fouled carbon columns when scale control is not maintained. The primary cause of scaling in precious metal recovery is the relative insolubility of calcium carbonate. The presence of the calcium ion and bicarbonate alkalinity is common in almost every water source. If the temperature or pH of the water is allowed to increase, the bicarbonate breaks down to carbonate and combines with calcium by the following reaction: Ca +2 +2HCO3 ? CaCO3 + H2 + CO2

Jan 1, 1986

By Laura A. Sanders

Mineral scale formation is prevalent in numerous mining operations. Such scale formation can occur in the direct-contact heat exchangers ahead of an autoclave. In these heat exchangers, the incoming slurry comes into contact with steam in a stage-wise fashion, which is re-circulated from the downstream flash vessels to heat the slurry in stages ahead of the autoclave. Calcium sulfate scaling causes severe problems in mining operations where increased temperatures are involved due to rising temperatures promoting calcium sulfate scaling through a decreasing solubility. In a number of these operations, the scale formation can occur in the presence of mineral solids, where fine-grained charged particles are at concentrations in excess of 35%. Scale prevention is not difficult in standard aqueous systems; however, the presence of solids leads to significant deficiencies in the prevention of scale due to the adsorption of the polymer onto the charge solids instead of the polymer interaction with the scale. Therefore, a technical solution to prevent mineral scale build up occurring in presence of pulp slurry in mining operations is needed. Several novel antiscalant technologies were developed and evaluated which provided a substantial improvement in the scale prevention in such systems.

May 1, 2013

By J Wu

Swirl Flow Technology (SFT), a novel approach for agitation in large industrial slurry tanks, was jointly developed and patented by CSIRO and Queensland Alumina Ltd (QAL). Currently, SFT is used in 16 alumina precipitation tanks at QAL, with the first installation in January 1997. This paper provides insight to the underlying fluid dynamics, which were investigated through pilot-scale experiments. A key finding was that SFT produces tank wall velocities approximately four times that of conventional draft tube agitator systems for the same power input, whilst for solids suspension, much less power is needed. SFT is energy efficient and practical in scaling suppression as demonstrated by the full-scale experience at QAL.

Aug 8, 2011

By Michael J. Friedel

The scale-dependent hydraulic properties in a fractured porphyry copper oxide deposit are investigated for relevance to in situ leach mine (ISLM) design. In most well field designs, mine operators assume that hydraulic properties represent a continuous spatial function, or continuum. The problem, however, is that the representative elemental volume, the volume over which hydraulic properties are described as a continuum, is a domain (if it exists) that occurs between end members representing varying degrees of heterogeneity. At the Cyprus Cas a Grande mine, transmissivity fluctuations are spatially correlated suggesting that at the scale of ISLM, the hydraulic process is heterogeneous and a typical continuum representation is inappropriate for design. Alternatively, a conditional stochastic approach using the simulated annealing (SA) technique is deemed useful for the imaging of heterogeneous hydraulic properties. Specifically, SA preserves transmissivity extremes and spatial complexity, both necessary for accurate conditioning of a flow simulator. Also, the stochastic continuum approach provides an avenue whereby uncertainty (or risk) may be addressed. Currently, the SA weaknesses are that it is computationally time consuming, and uncertainty may increase when simulating under conditions of statistical isotropy. Recognizing that ISLM exerts a dynamic influence on hydraulic properties with time, the mine design should be reevaluated at intervals throughout the evolution of the leaching process.

Jan 1, 1993

By L. M. Nolan

Chemical Mechanical polishing, or CMP, has four components in the polishing interface; namely the polishing pad, the polishing fluid, the abrasives in the fluid, and the surface being polished. Understanding the way that load is transferred between these components is key to understanding and predicting wafer polishing. Numerous models of CMP and the different load sharing arrangements which occur between these four components have been proposed. These include models by Luo and Dornfield (1) and Fu, Chandra and colleagues (2). Other models focus on just one or two loading arrangements, such as `hydroplaning' when all load is transmitted by the liquid in the case of Runnels and Eyman (3). In this work, we consider four possible combinations of load transfer from pad to wafer in CMP. These combinations are listed below in Table 1 and are illustrated schematically in Figure 1. It is important to note the role of scale in this process; the illustrations in Figure 1 are drawn to scale from actual profilometer scans obtained over a length of 5 with particles of 150 nm in diameter. Table 1 - Load Transfer Combinations Load Regime Illustration Wafer - Fluid - Pad Figure la Wafer - Particles/Fluid - Pad Figure lb Wafer - Particles - Pad Figure lc Wafer-Pad Figure ld The interest in load-sharing between the system components is because some configurations are anticipated to achieve higher polishing rates than others. For instance, in hydroplaning, or hydrodynamic lubrication, the lateral force exerted on the polished surface by the particles can be no higher than the fluid shear force developed in the gap between the pad and wafer. This is not expected to generate high rates of material removal from the surface (4). For contact that is largely between the pad and the wafer, such as the regime depicted in Figure ld, the lateral load is transmitted to the wafer by the pad and is hence limited by the pad's low rigidity. This regime is not expected to generate high material removal rates either. The highest levels of material removal are expected from regimes where the mechanical load exerted on the system is transmitted by the particles, in combination with either the fluid or the pad. Under what circumstances does the polishing regime change from one to another? What must occur in order to initiate or terminate contact between the system components? This is an ongoing question in the field of tribology, and has traditionally been viewed in terms of the pressure and velocity applied to the system, the thickness of the fluid film between the two surfaces, and the roughness of those surfaces (4). In this paper, we propose a new mechanism ? that the load on the particles may be sufficient to totally embed them in the polishing pad, at which point they are no longer able to transmit load and polish the wafer surface. This is illustrated schematically in Figure 1(d).

Jan 1, 2010

By James Y. Oldshue

"Very seldom is it possible when contacting a gas with a slurry to measure the dissolved gas concentration in the slurry, and even where possible, equilibrium data with a suitable Henry.s law constant are seldom available.In general, by assuming a reasonable value for the dissolved gas concentration in the slurry and a corresponding equilibrium gas partial pressure P*, KGa values can be calculated for the pilot plant and then scaled up. Then, with the same P* value at various reaction conditions, a mixer can be designed which is quite satisfactory, having a reasonable design factor for full-scale performance."

Jan 1, 2003

By James Y. Oldshue

"Very seldom is it possible when contacting a gas with a slurry to measure the dissolved gas concentration in the slurry, and even were it possible, seldom are equilibrium data available with a suitable Henry’s law constant.In general, by assuming a reasonable value for the dissolved gas concentration in the slurry and a corresponding equilibrium gas partial pressure P*, Kga values can be calculated for the pilot plant and scaled up. Then, with the same P* value at various reaction conditions, a mixer can be designed which is quite satisfactory, having a reasonable design factor for full-scale performance.We will take as an example a slurry of a known solids composition and use a continuous 4 tank system. By assuming a percentage saturation of the dissolved gas in the first tank, the dissolved gas concentration can be obtained in the other three tanks. It usually is possible to measure the off-gas composition in each of the 4 tanks. If the top of the tanks is connected in the form of a multi-compartmented horizontal autoclave, then a modified top off-gas composition in each compartment must be used."

Jan 1, 2003

By J. Faitli, I. Tarján

One of the basic processes of process engineering is the production of dense suspensions. The major two equipment of this task are the periodically operating propeller mixer, and the continuously operating mixer tank based on the flow principle. In the laboratory of the Department of Process Engineering at the University of Miskolc, laboratory scale experimental setups had been built of both types of mixers in the frame of the FKFP 0504/1999 signed research project, supported by the Hungarian Ministry of Education. By these experimental setups many systematical experimental series had been carried out by test materials of water as the dispersing media and sand, power plant fly ash and magnetite as the granular solids. On the basis of the literature and these experimental investigations, scale-up methods had been developed for both types of mixers for the determination of the main technical parameters of industrial size equipment.

Jan 1, 2003

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 G. Bueno, L. M. Tavares, T. M. Campos

Iron ore pellet feed pressing has been one of the first and most successful applications of High- Pressure Grinding Rolls (HPGR) in the minerals industry. Vale S.A. has been one of the pioneers in this application, currently with six HPGRs in operation in the pelletising plants of the Complexo de Tubarão (Brazil). In spite of the important advances in the technology, risks still exist when scaling-up the process from small-scale information. The present work takes advantage of the recent advances in the mathematical modelling of the HPGR performance, using the population balance model to evaluate the modified Torres and Casali model prediction in iron ore pellet feed pressing for different scales of operation. Results are presented that compare the HPGR performance in different operational scales for iron ore pellet feed pressing, demonstrating the confidence of this model-based approach for scale-up to full-scale HPGRs used in pressing iron ore concentrates. Keywords: Scale-up, HPGR, pellet feed, modelling, simulation

Jan 1, 2020

By G. A. Wierink

This paper discusses a new method to increase flotation recovery. As known from literature, fine and coarse particles have different flotation rate constants, hydrodynamic behaviour and require different reagent regimes. The device discussed allows separate processing of finer and coarser slurry by extraction of a third stream, carrying finer slurry, from the flotation cell. By separate treatment of fine and coarse slurry operational conditions and so flotation recovery for both may be optimized more efficiently. Extraction and classification of the third stream is accomplished by low speed centrifugation and Taylor-Couette flow separation. This Dual Outlet Device (DOD) can be installed in a traditional flotation cell without need for equipment replacement. In order to asses different design options for the DOD a transparent laboratory scale model was built. For this scale model Computational Fluid Dynamics (CFD) simulations using the RANS k-e and LES turbulence models were performed. Essential insight in the dominant flow systems relevant to optimal operation of the DOD was obtained from the CFD simulations and flow visualization tests with the laboratory scale model. Based on these findings a number of configurations were investigated at pilot plant scale in a 5 m3 Outokumpu flotation cell. The results of the pilot plant study show that utilization of the DOD provides a method for in-cell control over particle size distribution in the slurry. Use of the DOD in a flotation cell may enhance flotation recovery and decrease flotation reagent consumption significantly, against marginal investment and operation costs.

Jan 1, 2014

By A Suwandhi, H Utama

PT. Indo Muro Kencana (PT.IMK) is a gold mine that is located in Central Kalimantan, Indonesia. Drilling and blasting activity is applied in order to support mining production. Drilling and Blasting (D&B) planning is conducted by its engineers. A drilling and blasting contractor conducts drilling and blasting activity. The objective of this paper is to evaluate the implementation of the scaled depth of burial (Chiappetta and Treleven, 1997) in explosive charging sheet application to increase blast efficiency. The function of the scaled depth of burial is to maintain stemming height above explosive charge in order to prevent the ‘over energy’ condition, to reduce the excessive fly rock possibility, to maintain rock fragmentation (digger’s productivity) and to increase blast efficiency. The focus of this paper is to implement the scaled depth of burial as a reference in D&B planning and practice, especially in designing stemming height. The purpose of this paper is to validate that the scaled depth of burial can be used as an engineering tool in D&B practice in PT.IMK. However, scaled depth of burial cannot applied as an engineering tool to determine stemming height above explosive charge for trim blastholes and secondary blasting area. In general, the implementation of the scaled depth of burial in PT.IMK is applicable for production blastholes (ore and waste blasting). In conclusion, it is clear that scaled depth of burial can be used as an engineering tool to create explosive charging sheet and also to increase blast efficiency (ore and waste blasting) in PT.IMK.

Jun 22, 2022

By Ron Board

"Probably the only thing that can he said about conveyor belt scales without fear of contradiction is that they have been responsible for as much or more puzzlement, argument and frustration than almost any other piece of equipment commonly found in ore processing facilities. To be sure, there are certainly a good number of satisfactory installations, some of these having been achieved through forethought and careful consideration in the early stages of plant design, while others seem to owl their success to what seems to be little more than good luck or white witchcraft; and it might also appear that black witchcraft or other gremlins are solely responsible for the poor performance of many belt scales that enjoy well-designed installations with apparently good operating conditions.This paper is intended to acquaint users with the major operational reasons why belt scales seem so fickle (and downright ornery too), and establish some reasonably simple test standards against which the performance of scale hardware can be measured. Then it shall be shown how the design flexibility of electronic scale systems can offer particular advantages in overcoming some of these everyday problems in a practical way, and without undue inconvenience to plant operations."

Jan 1, 1975

By Daniel W. Kappes

Testing ores for heap leach operations traditionally follows a progression of bottle roll tests, bucket and column leach tests, and very expensive large field leach tests. Enough data is now available to streamline the procedures. Data from five different operations shows that recoveries from large field leach tests can be predicted from the bucket tests. Initial recovery times in large field leaches are longer than in bucket tests- a typical response is eight days versus twenty days to the same recovery percentage; but the ultimate percent recoveries (after 60 days) are normally very close. Methods of mining and stacking can radically affect recoveries from clay-rich ores. Leaching of uncrushed ores provides special testing problems, since accurate samples smaller than several tons cannot be taken.

Jan 1, 1981

By R. D. Williams

Several hydrometallurgical leach processes have been recently proposed for the recovery of copper from copper concentrates. These include the Cymet Process of Cypress Metallurgical Processes Corporation, the Arbiter Process of the Anaconda Company, and the Treadwell Process of Treadwell Engineering company(1). These processes and similar processes for recovery of other minerals, have several phenomenological similarities which make their quantitative description difficult at best. These include (a) the presence of more than one phase, (b) non-uniform mineralization of the feed concentrate, (c) surface and diffusional effects, and (d) a particle size distribution which varies with time. Semi-theoretical, rather than purely empirical, treatment of such processes in their developmental stages will result in a better understanding of the physico-chemical mechanisms in effect. This, in turn, will allow reliable process designs to be made on reasonable time scales for reasonable development costs. Once a production unit is built, such an approach will provide straightforward methods for process control and optimization. A research and development effort to determine criteria and procedures for semi- theoretically characterizing such mineral leach recovery processes has been initiated in a joint venture by the Arizona Bureau of Mines and the College of Mines at the University of Arizona. This group has as its task the mathematical characterization of hydrometallurgical leach recovery processes using semi- theoretical mechanisms for the underlying phenomena. The resulting models are experimentally verified and parameterized on the laboratory scale in such a way that they can be utilized with similarity criteria to provide reliable scaleup to production designs. This discussion will be centered around the elements of such an approach and how they fit together.

Jan 1, 1975

By D. D. Gertenbach

"The successful commercialization of a pressure oxidation (POX) process for recovering metal values, including gold, copper, zinc, nickel and molybdenum, is the result of a carefully planned development program. The initial task involves developing one or more conceptual flowsheets, including the POX autoclave and downstream purification and recovery steps. A laboratory program is completed to determine the technical viability of the flowsheets, define the operating parameters for each step and provide information for an initial economic assessment of the process. The process is then confirmed during a continuous pilot plant program, providing engineering design data and other information for the commercial design. A well-thought-out development program has been shown to be critical for reducing the risk of commercializing POX processes. Experiences developing POX processes for refractory gold ores and copper concentrates are briefly discussed. IntroductionPressure oxidation (POX) has become a common commercial operation for processing sulfide-bearing feedstocks. These feedstocks include gold ores and concentrates; copper concentrates; nickel concentrates and mattes; zinc concentrates; and molybdenum concentrates. Drivers for the development and commercialization of POX processes include:• The high cost for pyrometallurgical processing of sulfide ores, much of which is attributed to environmental controls.• The motivation to implement safe and more environmentally attractive alternatives for sulfide ores.• The need to process increasingly difficult ores with complex mineralogy.• Improvements made over the last 25 years in POX equipment design and experience operating commercial POX plants.Although the capital and operating costs for commercial POX processing can be high, this technology is capable of rapid oxidation of most sulfides and arsenic minerals in the feed, with little noxious gases and environmentally stable iron arsenate and other iron compounds in the POX residue (Marsden and House, 2006).In POX operations, sulfides are oxidized to either sulfates or elemental sulfur in an autoclave at elevated temperature and pressure with oxygen gas. An example is the overall oxidation reactions of chalcopyrite when sufficient oxygen is present, shown in the following reactions:"

Jan 1, 2016

By A. Juganda, H. PINHEIRO, J. Brune, N. SANDOVAL, G. Bogin, K. Gallagher, F Wilson

The present work discusses the nuances of scaling and flow similarity to develop a 1/40th scale version of a longwall coal mine. Details on the geometric, kinematic, and dynamic scaling of the physical model are presented and discussed. This works also discusses using a 30% CO2 – 70% He gas mixture as a surrogate for methane. It also presents the implications of various Reynolds numbers (ranging from 7,000 to 140,000) and rotation of the shearer drums in the dynamic representation of the airflow and gas mixtures in the physical scaled model.

Mar 19, 2022

By Ray Nivens, Umit Turunc, Caroline Sui, Nick Morrison, Douglas Steiner

"In most copper mines and concentrators, mill water is continuously recovered and reused, with fresh water added to make up for losses. When mixed, these water chemistries can lead to severe scaling, especially in pipes, tanks and pumps on the mill water supply side, reducing flows and causing significant production losses.At KGHM Robinson Nevada Mining Company, increases in the fresh water addition ratios resulted in severe scaling problems and premature pump failures thereby jeopardizing plant production. What initially appeared to be a few isolated scaling events eventually unfolded into a recurring pattern of water supply-related production losses with increasing severity. Through completion of detailed root cause analysis, chemistry modeling, laboratory work, in-plant testing and system engineering, the mechanisms of scaling were identified and addressed.Advancements in fresh water addition practices and antiscalant application methods resulted in a stepwise reduction of the mill water scaling. Cost savings and production benefits were significant to the plant’s financial metrics.IntroductionThe production of mineral and metal concentrates using the flotation process requires large quantities of water. Flotation is utilized as the primary means for beneficiation with sulfide ores. Mined ores are crushed and ground into a slurry of 20-55% solids. For each ton of ore, 400-900 gallons of water1 are needed to supply the grinding mill. Additional water is needed in the flotation circuit as well. With many modern mills operating at2 11,000-165,000 tons/day, water supply volumes can be upwards of 3,000 gpm to 100,000 gpm of flow.For plants operating at or above capacity, disruptions and restrictions in water supply flow can have a direct impact on the production and recovery of the metal. Water supply flow can be limited for a wide variety of reasons but of interest are those limitations that are due to mineral scaling. Mineral scaling is the selective point precipitation of inorganic species above saturation concentrations. Precipitated species form flow-restricting deposits in the mill water system (tanks, pumps, pipe and valves), that will eventually impact water supply to the concentrator."

Jan 1, 2017

By L. A. Panek

A new pillar strength formula is presented, incorporating a function P of size and shape, which takes into account the size-shape interaction effect as well as the enhanced strength exhibited by wide pillars. Existing pillar formulas, lacking these capabilities, are not suitable for extrapolating small-specimen test results to mine-pillar sizes and shapes. Interpreting compressive-strength test results as function of P clearly reveals wide-pillar behavior in much old test data. Model relationships are discussed, along with their scaling implications.

Jan 1, 1994

By Cornell J. B

Scaling in Bayer Refineries is a natural consequence of the super-saturated liquors used in the process. The caustic liquor is supersaturated not only with alumina but also silica and calcia at various stages of the process. The basic scaling mechanisms are reviewed and examples of the two basic types, growth and settled scales, are given. Examples include gibbsite scales formed in the precipitators and silica scales formed in heat exchangers. The main factors affecting the rate of growth of growth scales are temperature and supersaturation and are highlighted using a silica scale example. For growth scales chemical cleaning rates can readily be predicted from kinetics and an example for a gibbsite scale is given. For settled scales the growth rate cannot be predicted and the hydrodynamics within the system have most effect. There is no simple method to predict the potential for chemical cleaning of settled scales; some of the relevant issues are discussed, in particular methods to identify the cementing phase in the scale. An example of design considerations for a scaling system, transport of slaked lime, is Given.

Jan 1, 1996