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By Graham Davey

"Ultrafine grinding of minerals has been in wide spread use in the industrial mineral field for over 30 years. Within the last 10 years the metalliferous industry has shown interest in the ability to produce ultrafine particles, as chemical, physio-chemical and physical separation processes have advanced to be able to treat ultrafine metalliferous particles. Also as the primary mineral deposits are depleted, new more difficult deposits must be mined. Existing operations are also looking to maximize economic return from existing deposits, requiring new thinking and technologies.The recent development of industrially proven and cost efficient technologies for ultrafine grinding has opened up another processing option for the treatment of finegrained metalliferous and refractory gold ores. The current commercial designs are variations of stirred mills used in the industrial minerals sector for the past 30 years. For the purposes of this paper ultrafine grinding is considered to be P80 of less than 15 microns.Attrition milling to fine grind sizes presents some challenging issues relating to scale-up including the dearth of information on the quantitative impact of feed and operating conditions, as well as the precise and accurate measurement of particle size distributions. Two examples from recent installations will be analyzed including Thalanga Copper and Century Zinc Mines. Both have diverse grind size targets for the SMD, yet both have realized significant metallurgical gains."

Jan 1, 2002

By M. Misra

The dispersion of oily collector has significant effect on the flotation recovery of ultrafine coal. Generally, reagent dispersion is accomplished by mechanical mixing and/or ultrasonic agitation, followed by direct addition of dispersed collector into the flotation cell. However, such dispersion and reagent addition techniques are invariably inadequate and non-selective. A new collector utilization technique involving gas phase transport of atomized collector has shown improved results when compared to conventional reagent addition techniques. This new technique involves atomization of the collector into the gas stream. Under these circumstances an aerosol is introduced into the flotation cell. Initially, the oil is dispersed within the gas phase (continuous with respect to oil) and the gas phase is dispersed within the pulp (continuous with respect to aerosol). In the flotation cell, the atomized oil droplets coalesce on the bubble's surface and create a de-facto oil-encapsulated bubble. This approach provides excellent dispersion, increases selectivity, and most significantly increases the flotation rate of ultrafine coal. Furthermore, atomization of collector/frother combinations yielded improved flotation yields and maintained near uniform froth levels which is a desirable feature in coal flotation. In addition to flotation experiments, microscopic examinations of the attachment of oil-coated bubbles at a coal surface were conducted by attachment-time and contact-angle measurements. The oil coated bubbles attach at significantly faster rates and with a higher contact angle than do oil free bubbles.

Jan 1, 1987

By M. Misra, I. Anazia

The dispersion of oily collector has a significant effect on the flotation recovery of ultrafine coal. Generally, reagent dispersion is accomplished by mechanical mixing and/or ultrasonic agitation, followed by direct addition of dispersed collector into the flotation cell. Such dispersion and reagent addition techniques are invariably inadequate and nonselective. A new collector addition technique involving gas phase transport of atomized collector has shown improved results when compared to conventional reagent addition techniques. This technique involves atomization of the collector into the air stream. Under these circumstances, an aerosol is introduced into the flotation cell. Initially, the oil is dispersed within the air phase (continuous with respect to oil), and the air phase is dispersed within the pulp (continuous with respect to aerosol). In the flotation cell, the atomized oil droplets coalesce on the bubble's surface and create a de facto oil-encapsulated bubble. This approach provides excellent dispersion, increases selectivity, and, most significantly, increases the flotation rate of ultrafine coal. Atomization of collector/frother combinations yielded improved flotation recovery and maintained near uniform froth levels, which is a desirable feature in coal flotation. Microscopic examinations of the attachment of oil- coated bubbles at a coal surface were conducted by attachment time and contact angle measurements. Oil-coated bubbles attach at significantly faster rates and with a higher contact angle than oil-free bubbles.

Jan 1, 1988

By J. W. Wilson

In the ultrafine coal cleaning process, small coal particles (-400 mesh) are produced during the pulverizing operation. After the coal cleaning process, these ultrafine particles are very difficult to dewater, and create problems in coal transportation, storage and handling at utility plants. Research work on ultrafine coal dewatering and briquetting has resulted in the development of a single stage operation that is potentially more effective and economic than conventional thermal drying and briquetting processes. The final coal product have a moisture content of less than 15% and possess high strength and water resistance that satisfies coal transportation, storage and handling requirements.

Jan 1, 1995

By Rob Robertson

The problem of fine coal slimes has been addressed in a unique way at A. T. Massey Coal?Company. Several plants have employed two-stage classifying cyclones to separate the minus 1 mm raw coal into 3 sizes. Larger cyclones make the initial cut at approximately 150 µ (100?mesh) sending the underflow to a cleaning circuit (usually spirals) while the overflow is pumped to a secondary cyclone circuit using smaller cyclones. The small cyclones make a cut at near 70 µ (200 mesh) and produce an underflow that is a des limed flotation feed. The overflow is discarded to refuse due to its high ash and superfine size which would produce a high moisture product even if suitably recovered.

Jan 1, 1998

By Abrahan Barriga

The present study demonstrates the feasibility of the ultrafine grinding and atmospheric leaching process applied to refractory gold concentrates from Salave Project located in northern Spain. At bench scale, it was found acceptable sulfide oxidation was about 84-85% and CIL gold recoveries between 95-96% applying specific energy consumption between 30 and 60 kWh/t during ultrafine grinding. The atmospheric oxidation of the sulfide concentrate was controlled between pH 4.4 and 4.8 with a mixture 90/10 of CaCO3/NaCO3 with residence time of 48 hours for the atmospheric oxidation and 30 hours residence time for the CIL process.

Sep 30, 2022

By Sergey Ulianov, Arkady Senchenko, Alexey Shvets, Arkady Bakotin

"This paper is devoted to ultrafine grinding of processing products. This process allows one to include into operation complex ores which earlier were considered as inefficient and economically inadvisable to treat. Fine dissemination of valuable component often does not allow its liberation via standard grinding in ball mills, and therefore requires modern methods of ultrafine grinding (UFG). An example of successful ultrafine grinding usage is its application for crude flotation concentrates regrinding before cleaner flotation stages. A problem often arises with a commercial copper concentrate production in the course of copper ore flotation. Crude flotation concentrate regrinding in a ball mill does not provide for good liberation of the material before cleaner stages. UFG application allows one to get commercial copper concentrate with copper grade of 20% and higher. Another example of ultrafine grinding application is its usage for highly refractory pyrite product received after gold-lead scavenger flotation of polymetallic ore. Earlier this product treatment was economically inefficient. At current application of ultrafine grinding down to 85% minus 20 µm and subsequent gravity processing it is possible to pass major part of gold (73.4%) into concentrate. The constraining factor for UFG application in processing may be the chemical activation of minerals. In the result of this, flotation selectivity may decrease. Therefore ultrafine grinding application extends the areas of efficient usage of metallurgical processes. New technologies allow increasing the level of valuable metals recovery."

Jan 1, 2014

By Eugene E. Hively

The Tower Kill is a vertical "stirred" ball/pebble mill recently introduced in the Western Hemisphere. This device offers a significant power savings on wet fine grinding applications when compared to conventional tumbling mills. This paper describes the laboratory application of this mill wet grinding hydrated alumina to products of 50 percent passing 2 to 6 microns.

Jan 1, 1983

By Martin H. Stanczyk

In recent, years the demand and consumption of finely ground industrial minerals has substantially increased for such uses as fillers and chemically reactive components. The size, specifications for these types of industrial mineral materials vary to a great extent and depend on the particular end purpose' and on the physical properties of the mineral itself. Size reduction of industrial minerals usually is obtained by conventional crushing and grinding methods. However, some specialized milling techniques have been developed for producing these minerals in extremely fine particle size ranges. During recent years the Bureau of Mines has been investigating an attrition grinding method to produce ultrafine subsieve-size mineral particles. The Bureau developed process, which has been patented,2 comprises the intense agitation of a slurry composed of the material to be ground, a relatively fine granular grinding medium, and a suspending fluid. The process has been shown to be effective for the comminution of kaolin in the particle size range of 2 microns and finer on a batch3 and continuous basis.4,5 This report presents the results of batch tests made to determine the effectiveness of the attrition grinding process for comminuting commercial products of (1) mica, a tough lamellar material, (2) fluorite, a brittle intermediately hard material, and (3) barite, a relatively soft, massive material.

Jan 1, 1967

By Yury V. Kulikov, Rakan Rahbani, Arkady Y. Senchenko

"The relevancy of complex minerals treatment is constantly increasing taking into account mineral resources depletion. Different refractory ores and concentrates, oxidized and polymetallic ores, as well as metallurgical products (slags) can be assigned to such mineral type. The treatment of such products via conventional flowsheets requires considerable capital and operational costs and does not always provide high recovery level of valuable components into a saleable product. Therefore, considerable amount of ores and metallurgical products are not treated, or treated inefficiently. One of the most promising approaches that allows economic treatment of refractory products is their ultrafine grinding down to 5-20 µm with subsequent processing or hydrometallurgy. Horizontal bead mills - the IsaMillTM, developed by Xstrata Technology, received their wide application in mining industry. Standard testing is performed under laboratory conditions in an M4 IsaMillTM (volume - 4 liters) to define the parameters of fine grinding. This mill completely simulates the operation of full scale industrial mills up to 50 m3 in volume (up to 8000 kW motor). The paper describes fine grinding technology performed in bead mills, and the importance of testing according to a certified method for industrial equipment selection. The paper contains description of promising directions of fine grinding technology application for several projects in Russia and Kazakhstan."

Jan 1, 2014

By Pollmans GJ, Hoberg H, Schneider FU

The Institute of Mineral Processing at Aachen University of Technology has been engaged in fine and ultrafine comminution for several years. Former investigations had been dealing with the mechanical activation with the aim of increasing the solubility of highly resistant oxides such as tantalite and niobite while research on the product of ultrafine powders is of major importance at the moment. Materials of that kind are of increasing interest in the production of extremely resistant ceramics, in the development of new raw materials, in powder metallurgy and in the production of fillers (extender pigments) and pigments. The creation of ultrafine powders is difficult and very expensive. They can be produced by means of condensation or dispersion methods. One important method of dispersion is mechanical comminution. Due to long and intensive research and development all over the world important advances have been achieved but still a great number of questions and problems occur especially in producing materials of submicron and nanometer grain sizes which could be answered or solved only insufficiently up to now. These mentioned difficulties refer especially to: ò the required energy input into the feed material, ò the forming of strong agglomerates and wall stickings, ò the required product qualities, and ò the entire and reliable characterisation of the products. Basic investigation aim to clarify the micro and macro processes of ultrafine grinding and work towards solutions to the difficulties mentioned above. The aim of the Institute's research is the development of a new grinding device for producing ultrafine powders. First results of a laboratory scale mill of that type will be presented in this paper.

Jan 1, 1993

By D. G., Bosse&apos

Equipment choices for ultrafine grinding encompass several different types of dry and wet size-reduction devices. These need to be put into functional perspective for systematic analysis of capabilities and limitations versus processing requirements of the materials to be satisfactorily ground. Particle strengths plus maximum and average sizes are the primary variables controlling grinding action requirements and equipment options for efficient processing. These are fairly well understood and provide the starting point for decisions. Particle space requirements under dynamic processing conditions vary with particle shapes and size-distributions by as much as 30X. This additional major variable is not widely appreciated and does need adequate description to provide a firm basis for selecting processing compositions and procedures.

Jan 1, 1983

By W. C. A. van Niekerk, M. H. Fourie

The carcinogenic potential of chromium (VI) has been the subject of numerous environmental and occupational studies, from which many regulatory efforts emanated. Besides the regulation of levels of known toxic substances (e.g. Cr (VI)), the classification of dusts for regulatory purposes has thus far depended on broad definitions of particle size, mainly used to distinguish only between inhalable and respirable particles. In the past, ultrafine particles (less than 0.1 µm diameter) (PM0.1) were often regarded as a non-issue, because it was believed that significant doses would not deposit in the lungs. A growing body of scientific data is indicating that ultrafine particles are more toxic than their coarse counterparts. Increased toxicity can be related to the unique dosimetric aspects of the deposition and disposition of inhaled ultrafine particles. Secondly, ultrafine particles have a larger surface area per given mass. The increased surface area can act as a carrier for co-pollutants, specifically transition metals (including chromium) that could form a coat on the particle surfaces during particle formation. This suggests that the presence of ?inert? ultrafine particles in the environment may enhance the potential for exposure to reactive airborne compounds, including Cr (VI). These factors are particularly important when information on occupational epidemiology is interpreted. It is desirable to consider the particle size distribution, for example when occupational exposure to hexavalent chromium compounds is assessed. Since ultrafine particles are more toxic than coarse particles with the same chemical composition, it could be speculated that cancer slope factors might be related to particle size distribution. This is relevant not only to carcinogenic chromium compounds, but also basically for any particle-associated toxicants. In general, the probability of developing health effects associated with occupational toxicants is likely to be higher when these are associated with the ultrafine particle range.

Jan 1, 2004

By K. Nagai

The Asian projects are now in their second terms after the five-year first terms. Ultrafined-grained steels were developed in lab-scale and/or in practical process. Basic approach has been performed to explore the evolution mechanisms of ultrafine-grained microstructures. There have been investigated two approaches to make the ultrafine grains: the "recrystallization route" and the transformation route. In the "recrystallization" route, heavy deformation at low temperature is necessary for the ultra-refinement. In the transformation route, making the high density of ferrite initiation sites in the deformed austenite, especially of the heavily compressed austenite structures, is essential for the ultra-refinement, and further hindering the ferrite growth is also inevitable to utilize the high initiation rate. Strength and toughness are dramatically improved by the ultra-refinement. Fatigue property is also excellent. The poor uniform elongation can be enhanced by the design of the second phase dispersion. At the same time the application has been also pursued from various viewpoints of engineering to take advantages of the ultrafine-grained steels. Bridge, ship, construction, automobile and other high strength parts are being attempted for the application.

Jan 1, 2004

By Rodney L. Stone

As part of an overall laboratory and plant test program to determine mixing and other techniques relating to the more economic use of bentonite as an iron ore pellet binder, a settling test was developed for measuring the bentonite content within a pellet or within a batch of pellets. Between pellet batches, each containing a different level of bentonite, the dry fracture load is directly proportional to the bentonite content between pellets of the same batch, however, the fracture load is inversely proportional to the bentonite level; this is explained by a negative correlation between a pellet's size and its bentonite content and the fact that larger pellets can withstand a higher fracture load than the smaller.

Jan 1, 1968

"Real-time, on-stream analysis of the metal content of process slurries is an essential prerequisite for process monitoring and advanced control of mineral processing circuits. On-stream X-Ray Fluorescence (XRF) sensors for base metal applications are available commercially and form the basis of many plant monitoring circuits. To date, these commercial technologies have been insufficiently sensitive to measure precious metals such as gold and platinum group elements, typically present at part-per-million (ppm) and sub ppm levels. CSIRO has developed a novel X-ray based technology, called UltraGold, which enables detection of gold in slurries on a real-time basis with a precision below 100 parts-per-billion. This technology is based on the use of advanced X-ray optics, extensive Monte Carlo computer modelling for analyser design, high accuracy X-ray spectrum fitting where the X-ray intensities are matrix corrected. In this paper, we will introduce this technology and discuss the results of a proof of principle study performed in the laboratory with plant slurries (tailings and concentrate) from an Australian beneficiation plant. Finally, we will discuss further planned improvements. As projected grades in (gold) mining around the world fall and several large-scale mines approach the limits of their economic reserves, this method can enable significantly reduced operating costs by rapid analysis to improve circuit efficiency and hence improve recovery significantly.INTRODUCTION This paper describes a study undertaken to explore the feasibility of applying CSIRO?s UltraGold XRF technology to the on-stream measurement of gold in process slurries. The provision of rapid, accurate information of gold grade in feed, tailings and concentrate streams would facilitate significantly improved process control and early detection of plant upsets, resulting in substantial cost-savings. CSIRO have patented X-ray fluorescence (XRF) techniques for the analysis of key elements in slurries present at part-per-million (ppm) and sub-ppm levels. Conventional, commercially available on-stream XRF instruments generally have detection limits in the tens of ppm range, precluding their use for analysis of elements like gold that are mined and processed at much lower concentrations."

Jan 1, 2017

Provide a rapid, reliable means of warning underground miners of a fire or other emergency. Approach An ultalow-frequency electromagnetic signaling system was designed, breadboarded, and tested at various under around mines. How It Works Current fire warning systems for underground mines, such as stench, audible alarms, and messengers, arc slow, unreliable, and seldom achieve total mine coverage. An ultralow-frequency electromagnetic fire warning alarm system with true through-the-earth signaling capabilities was developed to solve these problems. The system was originally designed for high-back room-and-pillar mines where stench systems are unusable due to the low velocity of mine air flow. However, the system has an application to all underground mines.

Jan 1, 1988

By S Bouzalakos, W Timms, H Malli

Combining ultramafic mine tailings and acidic mine drainage via mineral carbonation to sequester carbon dioxide, presents an opportunity to minimise waste on mine sites. Low pH mine water with trace element concentrations can be effectively treated by high magnesium mine tailings, a useful source of finely ground reactive matrix. By using milled tailings for mineral carbonation, there are negligible energy requirements for communition of ore rocks to reduce particle size. This study aimed to assess the technical applicability of reacting ultramafic tailings and acidic mine water through mineral carbonation technology in the mining industry. Dissolution has been identified as the rate limiting stage in mineral carbonation; hence the study focused on identifying optimal dissolution conditions. Ultramafic tailings (particle size <100 µm) derived from serpentinite ore, were reacted with a typical mine water that was synthesised in the laboratory. Through variances in the solid to liquid ratios and temperature of dissolution, a maximum five per cent magnesium dissolution efficiency was reached at 50 g/L and 100°C. The acidic mine water was neutralised (from pH <2 to pH ~6) and iron, copper and zinc ion concentrations reduced significantly during the formation of solid precipitates. Carbonation was undertaken by injecting carbon dioxide into the magnesium-rich solution to form stable carbonates. The experimental work demonstrated proof of concept; however, dissolution efficiency and carbon dioxide sequestration was low, indicating that further research would be required before larger scale implementation.CITATION:Malli, H, Bouzalakos, S and Timms, W, 2015. Ultramafic mine tailings to treat acidic mine water and lock away carbon through mineral carbonation, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 133–136 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By Yves Fouquet

Recent exploration demonstrates that hydrothermal systems related to upper mantle ultramafic outcrops are common in the modern ocean. Most sites are located on slow spreading ridges with a low magmatic budget. Volcanogenic Massive Sulfide (VMS) deposits, associated with basalt, along the Mid Atlantic Ridge (MAR) are volcanically controlled near the topographic highs at the center of the segments. Three preferential settings are identified for ultramafic sulfide mineralization: 1) Off axis, on rift valley walls, near the amagmatic ends of the segments; 2) Non-transform offsets and 3) Ultramafic dome structures at the ridge transform fault intersection. The upper surface of these domes is often interpreted as a detachment fault. Three processes are considered for driving hydrothermal cells in ultramafic rocks: 1) regional heat flow at the ridge axis 2) Cooling of a deep gabbroic intrusion and 3) exothermic heat produced during serpentinisation. Along the Mid Atlantic Ridge, four types of ultramafic hydrothermal mineralization are observed: 1) High temperature (>350°C) sulfide mineralization related to low pH fluids, (ex. The Logachev field at 14°45? N and the Rainbow field at 36°14 N); 2) Medium temperature carbonate chimneys (<100°C) related to high pH fluids (ex. The Lost City site at 30°N); 3) Low temperature diffuse venting associated with extremely high methane discharge and pervasive alteration and silicification of both volcanic and ultramafic rocks (ex : The Saldanha field at 36°34 N); 4) Stockwork mineralization and quartz veins with sulfides related to gabbroic intrusions within ultramafic rocks (15°N). When compared to mineralization in a basaltic environment, sulfide deposits are enriched in copper, zinc and specific elements related to an ultramafic rock source such as Ni and Co. They are also significantly enriched in gold which, unlike in basaltic environments, has a bimodal occurrence both in low temperature Zn-rich assemblages and in high temperature Cu-rich mineral assemblages. The Cu-Zn-Co-Au deposits along the Mid Atlantic Ridge seem to be more common than on land where few similar VMS deposits are known. We consider that ultramafic VMS deposits on slow spreading ridges constitute a specific marine type of mineralization that is less easily than back arc deposits, incorporated into the continent during obduction processes.

Jan 1, 2004

By D. A. Bulled

• "What does it look like?" - describes the appearance. • "How does it work?" - outlines the operation. e "Why does it work?"- explains the principles. • "What about controls?" - indicates possible automatic systems. • "How is it sized?" - discusses the necessary testwork and evaluation. • "What are the results?" - demonstrates test and operating results. • "What's the benefit?" - concludes with gains for the user.

Jan 1, 1999