Search Documents

By M. H. Farjadi, J. Azari

Cost analysis of chrome ore reduction is one of the important issues facing ferrochrome producers in today?s competitive environment. Much of this depends on quality and various ratios in the actual ore. The latter can have a direct bearing on electricity consumption and optimum efficiency of the furnaces. While the industry has been successful in reducing costs by designing larger and more efficient furnaces, the role of the optimum blend of ore has perhaps been given less emphasis. This paper will discuss the general specification and metallurgical characteristics of various chrome ores for producing high carbon ferrochromium on industrial scale. By analysing the results obtained from smelting, including chromium recovery and energy consumption, the determining parameters in total cost of ferrochromium i.e. chrome ore; reductant and energy consumption can be optimized. Our study is based on actual experiences obtained from Faryab Ferroalloy Plant over a period of approximately three years.

Jan 1, 2004

By A. S. Malicsi, Vathsala Rajagopal, I. Iwasaki

Corrosion and abrasion properties of a series of chromium-containing, cast-iron balls, with Cr contents ranging from 0% to 29%, were evaluated and compared with austenitic stainless-steel and mild-steel balls. Marked ball wear tests were performed on artificial ore samples consisting of 95% quartzite, with either 5% pyrrhotite or 5% chalcopyrite, under a nitrogen or oxygen atmosphere. The electrochemical mechanism was investigated by correlating the corrosive wear with the corrosion currents obtained from potentiodynantic polarization curves under abrasion. Flotation recoveries were determined on a 95% quartzite + 5% pyrrhotite sample ground with various cast-iron ball materials under an oxygen or nitrogen atmosphere. Electrochemical results are found to be in good agreement with flotation results and with corrosive wear data obtained from marked ball wear tests.

Jan 1, 1993

By Renato Oliveira, Walter Valery, Alex Jankovic, Birol Sönmez

"The ball mill is the most common ore grinding technology today, and probably more than 50% of the total world energy consumption for ore grinding is consumed in ball mills. On the other hand, high pressure grinding roll (HPGR) technology is relatively new to the mining industry, with significant application only since the beginning of the 21st century. Both ball mills and HPGRs are typically used in closed circuit with classifiers. There is a general consensus within the industry that classification efficiency and circulating load both have a major effect on the efficiency of closed circuit ball mills. Metso Process Technology & Innovation (PTI) conducted a laboratory test program to understand the relationship between classification efficiency and circulating load, and the impact on the performance and capacity of ball mill circuits. However, the effects on HPGR performance are significantly different. Metso PTI has initiated a pilot scale test program to evaluate the size reduction performance of the HPGR under different circuit configurations. A series of pilot scale HPGR locked cycle tests were performed to simulate the following circuit configurations: including closed circuit with a screen, partial product recycle and edge recycle. This paper discusses the results from the pilot scale HPGR and laboratory scale ball mill test programs. The effect of circulating load and classification efficiency on the performance of ball mill circuits is compared to the effect on HPGR circuits. The fundamentals of grinding behavior are also discussed in order to explain the difference."

Jan 1, 2014

The reactivity of clay minerals and variety of these reactions are greater than any other known colloidal material. While it is acknowledged that clay minerals can cause problems in mineral flotation, the literature contains conflicting evidence, particularly with respect to the effect of clays on froth stability. It is well known that achieving and maintaining optimum froth stability is an influential factor in determining froth flotation performance. However, the presence of clay minerals in the ore is a major challenge to obtaining a stable froth. In fact, clay minerals could reduce froth flotation performance by both decreasing and increasing froth stability. The mechanism by which clay minerals affect froth stability is not fully understood and needs to be investigated further. In order to improve flotation performance, reliable knowledge of the effect of clay minerals on froth stability is essential which is discussed in this paper. Keywords: froth flotation, froth stability, clay, clay minerals

Sep 1, 2012

By G. Hwang, S. Park, H. Kim, J. Choi, P. Seo

"In the mineral processing, clay minerals have negative effects on the flotation of valuable minerals. In this study, we investigated how the floatability of malachite (CuCO3·Cu(OH)2) is affected by presence of the clay minerals in the fundamental aspects. Flotation experiments were conducted by using Na2S and PAX (potassium amyl xanthate), and the floatability of malachite was compared between the cases in the presence and absence of clay minerals. The results showed that floatability was greater in the absence of clay minerals than in the presence of clay minerals and decreased with increasing weight percent of kaolinite under same conditions applied. In addition to examine how clay minerals affect malachite floatability, we conducted flotation experiment with changing clay adding order. The results indeed showed that malachite floatability was affected by clay adding sequence. INTRODUCTION The demand of copper is growing as industrial development increases, but mineral resources are limited. Therefore, studies for Cu oxide flotation are being conducted to improve their recovery(1-3). However the mining industry is well aware of the difficulty in treating copper ores in the presence of clay minerals(4). Clay minerals have unique properties and these properties may affect flotation. In the previous studies, the effect of slime coating of clay minerals on flotation was investigated(4-6). For example, Zhao and Peng (2014), Peng and Zhao (2015), and Arnold and Aplan (1986) found that clay slime coating on chalcopyrite, chalcocite and coal surfaces through the electrostatic attraction reduced surface hydrophobicity and then depressed the flotation. Other researchers have also reported clay minerals have impact on pulp rheology. Especially in the case of bentonite, pulp viscosity increased with increasing amount of bentonite and the higher pulp viscosity have deleterious effect on copper recovery(7, 8). However, these studies only focus on slime coatings and pulp rheological behavior. Forbes et al. attempted to decoupling rheology and slime coatings effect on flotation but this study has limitation that individual role of two clay species either attached to mineral or suspended in bulk solution was excluded(9). Hence, in this study, we aimed to investigating the effects of individual clay (suspended and attached) on malachite flotation."

Jan 1, 2016

By L Basnayaka, N Subasinghe, B Albijanic

"It has been recognised that the presence of clay minerals in ores adversely affect flotation performance. In this study, changes in rheological properties of the flotation pulps under normal operating conditions were studied with additions of bentonite and kaolinite clays at various concentrations. Zeta potential measurements were also carried out to determine the changes in surface charge due to adsorption of clay particles. The results showed that bentonite clay adversely affects floatability of pyrite while kaolinite clay had a lesser influence on flotation of pyrite. The addition of Ca2+ ions to the pulp containing bentonite modified the rheological characteristics and in turn improved the pyrite flotation. It was also observed Ca2+ ions suppressed the swelling properties of bentonite and altered surface charge properties of bentonite clay particles. It has been shown that the flow index affected the ultimate recovery and it may provide a means to monitor flotation performance in routine plant operations.Citation:Basnayaka, L, Subasinghe, N and Albijanic, B, 2016. Effect of Clay Rheology on Flotation of a Refractory Gold Ore, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 77–84 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

The presence of clay adversely affects the floatability of copper and molybdenum during processing porphyry copper/molybdenum ores. In addition, reagent consumptions are much higher than when treating clay-free ores. Ores containing kaoline, brammollite, illite and montmorillonite were examined in the laboratory to determine how clay minerals affect the floatability of copper and molybdenum, and to find a possible solution to alleviate the harmful effect of clay slimes. It was demonstrated that the presence of clay mostly affects floatability of coarse and middling particles, and reduces selectivity. The results of the research work showed that there may be several possible ways of reducing the detrimental affects of clay slimes on flotation, some of which include a) use of alternative flowsheets, b) flotation at reduced pulp density, and c) the use of special frothers. The applicability of the findings in plant practice are discussed.

Jan 1, 1999

By W. L. Doyle

SLAG weights were taken on a series of twenty-eight 6-ton bottom-pour heats. These weights varied from 573 to 1050 lb. Of these, four were chosen for study of the effect of cleaned and uncleaned foundry scrap on the variations of slag weights. Data regarding the make-up and results of the heats are given in Table I. For heat No. 3 the actual slag weight was checked, using the Mn-MnO calculation method-weight 1050 lb. [5,600 X 0.0055 = 30.80 heads and gates 6,000 X 0.004 = 27.00 plate scrap 800 X 0.0083 = 6.64 pig iron 450 X 0.0034 = 1.53 iron ore]

Jan 1, 1947

By E. Burdukova

Rheological measurements have found a wide array of applications in mineral processing research. Rheological properties of mineral suspensions are highly dependent on the mineral surface properties as described by DLVO theory, and the relationship between these properties and inter-particle interactions is well established. In this paper, rheological properties of mineral suspensions are used to study the differences in behaviour of isotropic talc and anisotropic zirconia minerals as a function of varying properties of the suspension medium, such as pH and polymer dosage, specifically carboxymethyl cellulose (CMC). It was found that the rheological tests when carried out in parallel with electrophoretic or point of zero charge measurements, clearly reveal differences between behaviour of the suspensions of isotropic and anisotropic minerals. These differences are further accentuated with the addition of carboxymethyl cellulose (CMC).

Jan 1, 2006

By J. Weyer

"A lot of incorrect, dangerous and misleading statements about the effect of CO2 on the human body can still be found in the internet, the media and in books. It is a fact that already low concentrations can lead to critical reactions, higher concentrations cause a narcosis. The real effect is not a lack of oxygen but an inner suffocation. The breathing reflex is decreased and the transport of oxygen in the blood is reduced due to a low pH value of the blood. Furthermore a reduced oxygen content in the air can also lead to the failure of diesel engines. MOTIVE Different gases can appear in active mines as well in abandoned mines, adits and caves. The most dangerous gases are CO, NO/NO2, H2S, SO2, CH4 and CO2. Although the general danger arising from these gases is mostly known some aspects are underestimated. Furthermore misleading or wrong statements exist about the detection and the effect of gases on the human body. This is especially true for CO2. In the last years a couple of accidents happened with a great number of injured persons and unfortunately also some fatalities. As a result wrong information and comments about the effect of CO2 have been published in the media. A huge unexpected CO2 outburst in a potash mine showed again some additional problems and limits for rescue troops. ORIGIN OF CO2 AND MISLEADING STATEMENTS ABOUT THE EFFECT ON THE HUMAN BODYCarbon dioxide can appear as free gas in the earth crust. It is especially known in significant concentrations in some potash deposits, in hard coal mines and some caves. Furthermore it can be formed due to complete oxidation of carbon. It can appear in technical processes. It is also used for or in technical processes, as fire extinguishing agent, as cooling agent, it is contained (added) in sparkling water or other soft drinks and it is formed by fermentation processes. Up to today a lot of wrong information about the effect of CO2 on the human body is published or is still in the mind of many people and unfortunately even in the mind of members or leaders of rescue troops. On August 16th 2008 a faulty CO2 extinguishing installation in the city of Mönchengladbach/Germany caused the injury of 107 people and the evacuation of further 150 people /1/. People on the streets became unconsciousness and felt down. Fortunately all could be rescued due to the immediate rescue operation of local fire fighters. Furthermore the CO2 concentration on the ground was diminished by help of a helicopter. What could have happen with the engine will be discussed later. After 6 days a second similar accident took place /2/. In the news members of the rescue teams explained that CO2 leads to suffocation due to a lack of oxygen. This is wrong! Also cave explorers often say that a burning candle can detect a low oxygen and/or high Carbon dioxide content in the air. This is also wrong and deadly dangerous! Similar statements we find nowadays in the internet /3, 4 and many other/. In a forum “science and mathematics > chemistry” several people say that winegrowers go with a candle into the vine-cellar to detect CO2 /5/. Again: this can be deadly! Another dangerous statement is that CO2 in higher concentrations leads to headaches so people should leave such areas. A last example found in the literature is that at 3 % the breathing volume is doubled and at a concentration of 20 % one can felt some warmth on the skin. Both is not wrong but can lead to false conclusions. /6/"

Jan 1, 2015

By G. Kumar

Water for domestic consumption is an essential right of society, which must be over secured. Water reclamation and reuse provides a unique and viable opportunity to augment traditional water supplies. As a multi-discipline and important element of water resource development and management, water reuse can help to close the loop between water supply and wastewater disposal. Effective water reuse requires integration of water and reclaimed water supply functions. During the coal mining activities, large quantities of water get contaminated and loses its potability characteristics. On an average, in coal mine operation, each coal mine discharges effluents at a rate of nearly 0.5 MGD and thereby wastage of nearly 50 MGD of water takes place per day from the famous Jharia Coal Field of the Dhanbad District. In this paper, attempt has been made to control the extremely high turbidity of mine waste water by using different coagulants and it is observed that ferrous sulphate is the most effective coagulants followed by alum, ferric sulphate and lime. Also combinations of coagulants are used for getting the optimal results. Further steps were also discussed to make this water potable and a scheme of low cost water supply system of mine waste water has been suggested under the Water Management Strategies. Keywords: potability, turbidity, coagulants, water management strategies

Sep 1, 2012

By Fred N. Kissell, Maurice Deul

When coal is broken during mining, some of the methane trapped in the coal is released. Some recent investigations by the U.S. Bureau of Mines have shown that this methane released by breakage is only a small proportion of the total methane emission into the working section.

Jan 1, 1975

By V. P. Bhavanandan

The mucus secreted in the respiratory tract provides the first barrier against inhaled particulate and gaseous toxicants. Trachea removed from pathogen-free rats were maintained as organ cultures and used to study the effects of coal dust exposure on the synthesis of mucin. The high molecular weight isotopically labeled (3H-glucosamine, 14Cleucine or 35S-sulfate) mucin could be purified by gel filtration, treatment with testicular hyaluronidase, ion exchange chromatography, delipidation and CsBr density gradient centrifugation. To examine effect of coal dust on mucin production, groups of explant cultures were exposed to media containing coal dust at 100 µg per ml every 2 days for 2 weeks while control cultures were treated with media without dust. Analysis of the spent culture media showed that treatment with dust markedly decreased the production of nondialysable glycoproteins as well as hyaluronidase-resistant acid-precipitable fraction consisting mainly of mucin. Since the synthesis of protein was not affected to the same extent the decrease in mucin production is not entirely due to cell death. In separate experiments rats were subjected to in vivo coal dust exposure in inhalation chambers and tracheae of these and control rats were removed for explant cultures. The incorporation of precursor isotopes into mucin by these explant cultures are being examined. (Supported by U.S. Bureau of Mines through the Generic Mineral Technology Center for Respirable Dust under grant G1135142, project 4210).

Jan 1, 1988

By A. S. Malicsi, M. D. Baker, I. Iwasaki

Fine grinding may he required for- some coals to remove sulfur and ash or to prepare coal-water slurry. Fine grinding leads to increased hall wear and its effect on the surface properties of the ground coal becomes of concern. Marked hall wear - tests were performed to study the effects of oxygen, pH, the soluble species of coal, and the addition of pyrrhotite on hall wear. The synergistic action of coal and oxygen greatly enhanced the corrosion of mild steel halls during grinding. Elec.trochemica1 measurements on a mild steel electrode in coal slurries and SEM observations of grinding hall surfaces were carried out to explore the corrosive wear mechanism.

Jan 1, 1991

By W. V. Bluck, W. L. McMorris

Higher coal quality is being recognized in potentially lowering the cost of power as measured at the bus bar. Assessment of potential coal supplies for most power plants is now going beyond buying at the lowest delivered fuel cost. It is now taking into consideration other factors, such as handling, storage, pulverization cost, boiler fouling, post combustion cleanup, and waste disposal costs. New measurements of quality are being considered now by those producing and those consuming the fuel by assessing numerous variables in the total fuel cycle to achieve the lowest possible power costs.

Jan 1, 1986

The efficiency with which it is expected that a particular coal may be burnt in a power station boiler significantly affects the value of the coal. Consequently many laboratory tests have been developed to provide data on the combustibility of coal. Computer modelling of coal combustion has also provided insight into limits on coal burn- out. Such modelling suggests that burnout of bituminous coal in a power station boiler will be strongly influenced by physical limits on the diffusion of oxygen to the individual coal particles. Coal chemical reactivity appears to be relatively less important. As a consequence of the diffusional limits, significant improvement in burnout is achieved either by producing less large p.f. particles or by providing sufficient furnace residence time to burn the large particles. Field data from a variety of power stations supports these cn.clusions. Burnout was also found to correlate well with volatile content for a number of coals from widely different sources. This is expected as the high vola- tile coals produce less residual char to be burned by the relatively slow heterogeneous Combustion.

Jan 1, 1987

Extraction under very mild conditions - a few minutes at room temperature with poor solvents - yields results characteristic of surface properties for a variety of coals. Such superficial extractions preferentially remove long-chain aliphatic compounds. As coal becomes more oxidized, less of these yellow- colored compounds is extracted, forming the basis for a simple colorimetric test for coal surface quality. The fact that these aliphatic compounds are responsible for surface hydrophobicity is supported by good correlation between extraction results and floatability, which decreases with decreasing extractability. This extraction test is very sensitive to oxi dationb even the effect of heating for an hour at 100 C can be detected. A second extraction test using mild alkali conditions has shown good correlation with plant dewatering Operations.

Jan 1, 1986

By F. Melo, M. Pawlik

Fine coal aggregation in concentrated coal-water suspensions was studied through steady-state rheological measurements. The wettability of coal particles was modified by dry oxidation of a bituminous coal. The degree of hydrophobicity was monitored using film flotation. The rheological measurements revealed that hydrophobic coal particles aggregate in aqueous suspensions, over a wide pH range, and produce slurries with high yield stresses. As the degree of coal oxidation increases, the coal particles become more hydrophilic and such suspensions exhibit lower yield stresses values. The yield stress values for suspensions prepared from oxidized/hydrophilic coal become a strong function of pH and correlate well with the surface charge as determined through electroacoustic measurements. These results indicate that the yield stress of aqueous suspensions of coal, and hence coal particles aggregation, is strongly affected by the wettability of coal particles.

Jan 1, 2004

By K. L. Cashdollar, C. K. Man, J. R. Gibbins

Oxyfuel combustion is currently one of the principal technological options being considered for capturing carbon dioxide from pulverised coal power plants. In oxyfuel combustion, coal is burnt in a mixture of recycled flue gases and added oxygen instead of in air. In principle this yields a flue gas containing only carbon dioxide, water vapour and small amounts other impurities. Oxyfuel combustion is superficially similar to combustion in air, but there are inevitable differences. This paper describes ignition tests on pulverised coal suspensions using a suite of coals of different rank and from different countries of origin and over a range of oxygen and coal concentrations of interest for oxyfuel combustion. The ignition tests were carried out using the National Institute for Occupational Safety and Health (NIOSH) 20-litre explosion chamber. The purpose was to determine how easily the various coals ignite and burn in mixtures of O2 and CO2 compared to their combustion in air. The residual char volatile and ash contents for the ignition residues were measured using a thermogravimetric analyser (TGA), allowing Q factors (i.e., enhancement in apparent volatile yield due to higher heating rates and/or heterogeneous reactions) to be determined and compared. An ignition index has been derived from the explosion and char data. This index has been used to rank low volatile coals for ignition propensity in air. The results show that to obtain ignition and combustion comparable to that in air, the oxyfuel O2-CO2 gas mixture must contain over 30% O2. Keywords: CO2 capture, combustion, pyrolysis, oxyfuel.

By Shunli Z, Jin X, Guanzhou Q

Flotation behaviour can be controlled, due to diminishment of granula quality and extension of specific surface area, by adding coarse particles (high- grade concentrates) to condition pulp. It has been substantiated that coarse particles can intensify fine particle flotation and its mechanisms are effects of carrier, intermedium and assistant aggregation of coarse particles. Calculation and analysis of Reynolds numbers and their variation for different size particles, under specific turbulent dynamic conditions, reveal that agglomeration among granulae is subject to specific turbulent dynamic conditions. Furthermore, sizes and adhesion strength of flocculated particles are the function of specific physical and chemical factors. Based on this research an innovative ramification carrier flotation process has been developed, which has been applied to Fankou Lead- Zinc Mine, Guang Dong province, China, etc, with satisfactory results. These results shed light on distinction between conventional flotation and fine particle flotation, meanwhile, provide a basic approach for further solution of fine particle flotation problem.

Jan 1, 1993