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THIS chapter and the one following deal with the heat quantities involved in open-hearth steelmaking, including the thermal efficiency of the furnace as a generator of high-temperature heat, the heat storage in the steel and slag produced and in the furnace walls, and the heats of the various chemical reactions involved in combustion, in the formation of slag, and the refining of steel. The fundamental laws to be considered are the simplification of the first two ' laws of thermodynamics as applied to problems involving sensible and potential (or latent) heat only 1. Heat input equals heat outflow plus storage. 2. Heat may be transferred only from a hotter body to a colder one. The first of these laws relates to the various heat quantities or the "heat balance" of the process. No one has as yet made an open-hearth heat balance that came out almost exactly balanced, and we assume that the cause lies in the difficulties of accurate temperature and flow-rate measurements at the high temperatures involved and the inherent complexities of flow distribution, air leakage, etc., present in any real, open-hearth furnace system. Some idea of the magnitude of the heat quantities involved can be obtained- by a brief, crude outline of the heat balance of a 90-ton heat of steel. We will assume a 60 to 70 per cent hot-metal charge in a fairly fast working and only moderately efficient furnace, burning fuel oil, with a fuel consumption of around 4 million B.t.u. per net ton. of ingots produced. The time from start of charge to tap is 9 hr. During this period, the oil burned represents 360 million B.t.u., and the sensible heat in the preheated air at the port ends is 117 million B.t.u. so that the total heat input at the ports is 477 million B.t.u. Heat stored in the steel and slag at the end of the heat, plus the various amounts absorbed by certain bath reactions, amounts to a total of 195 million B.t.u., but 120 million of this is supplied by the heat in the hot metal and by various heat--evolving reactions in the bath, so that only 75 million B.t.u. need be supplied to the bath by the flame.

Jan 1, 1944

By Russell Frith

For many years, underground rock mechanics and in particular, roadway/tunnel roof stability has been underpinned by the often unchallenged assumption that roof strength (as defined by the UCS) and stiffness (E) are key stability controls. This has logically led to the proliferation of laboratory testing of rock specimens and the development of indirect geophysical methods to gain estimates of these two rock parameters. Furthermore, many design methods are significantly focussed on replicating rock mass behaviour through either intact or failed constitutive models. Demonstrably the strength and stiffness of the host rock material is commonly used as one of the key indicators of excavation roof stability and it finds either direct or indirect use in just about every rock mass rating system in use today. In more recent times there has been a common move to consider and apply (even if only conceptually at the current time) structural engineering type principles (e.g. buckling) to coal mine roadway roof (and rib) stability. Similarly our knowledge of the in situ stress environment and its likely origins has improved significantly, largely through stress measurements and subsequent analysis. This paper combines knowledge in both of these fundamental areas through a deterministic model for roadway roof stability and in combination with field examples, reaches the almost certainly controversial conclusion that UCS and E are commonly irrelevant, albeit that the former may provide an indication of other relevant geotechnical parameters (e.g. bedding cohesion). As with all hypotheses or rules, there are naturally exceptions and in this case, the most obvious is the tailgate of the longwall panel (with adjacent goaf). Due to the significant change in the strata loading environment of a longwall tailgate as compared to first workings for example, the stability equation materially changes so that UCS and E become critical controls. The point of the paper is to present a different perspective on a traditional mining problem and to challenge geotechnical professionals to keep thinking ?outside of the square? in the never-ending endeavour to improve our understanding of the engineering problems we regularly face. Such an understanding impacts upon such issues as geotechnical data collection from borecore, support hardware requirements and design capabilities. Therefore making the assumption that our understanding is always fundamentally correct could in fact be limiting the development of new and improved engineering in the future.

Jan 1, 2006

Lime-enhanced carbothermic reduction may provide an alternative process for treating low grade chalcopyrite concentrates. To date, most research on lime-enhanced reduction has been on pure, synthetic sulfides. In this study, preliminary experiments were carried out on natural chalcopyrite using a thermal analysis system to assess the rate and extent of reaction at several temperatures and identify the major solid and gaseous reaction products. Calculations were performed to establish the thermodynamic limits of the reactions in the temperature range of interest in order to identify the potential conditions for processing chalcopyrite concentrate. The study found that finely ground chalcopyrite can be reduced carbothermically in the presence of lime at moderate temperatures and in a reasonable time to form metallic copper, with the sulphur reporting virtually entirely to calcium sulfide. At temperatures below about 750?770ºC calcium ferrite is the stable form of iron whereas at higher temperatures metallic iron is stable. Further work is required to demonstrate the reaction on a scale to obtain sufficient sample for evaluation of subsequent processing steps to remove the gangue material and iron products from the copper.

Jan 1, 2009

By S Döpp

Commencing with early experiences in iron ore beneficiation made at Beeshoek Mine, the paper follows through the process of extensive mineralogical and metallurgical investigations carried out during feasibility study. The paper will discuss the design process and logic followed over the last years, the challenges and decisions the design team faced in order to draw the conclusions that ultimately resulted in today’s value add approach at Assmang’s Khumani Operations.As integral part of the benefi ciation concept, a focus is set on the jigs, explaining the plant concepts, planned expansions and their contribution to the overall value add approach at the mine.The case study is intended to describe the outcomes of the design versus the actual achieved and the further value add projects to be implemented. As for future prospect, the incorporation of Wet High Intensity Magnetic Separation (WHIMS) demonstrates Assmang Khumani’s pursuit to maximise productivity and overall recovery.DMS was evaluated as an alternative to jigging within a comparative test work study, but in conclusion the option had to be excluded due to its inability to achieve the high density cut point required to achieve the sales specifi cations. In contrast, the investigation on producing an additional middlings fraction on the lumpy ore jigs prove to be an adequate option for further improvements of overall mass yield. With further liberation, a saleable product will be achieved by secondary beneficiation on Fines Jigs and WHIMS.Concluding, jigs are considered the most viable and cost effective benefi ciation process for off-grade ore +0.8 - 32 mm at Beeshoek as well as at Khumani, while WHIMS is the process under consideration for super fines recovery.

Jul 11, 2011

By Frank W. Cole, Sharanjit S. Dhillonn

A new method has been developed for calculating flowing bottom hole pressure in a gas well, using as a basis the general energy equation. Fundamentally, the method shows that a plot of flowing pressure versus depth for a gas well can be represented as a series of incremental .straight lines, with the accuracy in-creasing as the number of increments increase. It is shown mathematically that for most cases the slope of the flowing pressure versus depth curve is essentially constant, in which case a single calculation based on surface conditions will yield acceptable results. In all cases studied no more than two iterations were required for very good accuracy, and in most cases only one iteration was necessary. Several example calculations are shown and the results are compared to other commonly used methods of calculating bottom hole pressures These examples show that the method provides answers which are at least as accurate as other methods usually used, and results in a considerable reduction in computation time.

Jan 1, 1960

By J. Kretschmann

"By the end of the 1950s, the German hard coal mining industry produced 150 million tons of hard coal per year in 170 collieries with 600,000 employees. At that time, 70% of the primary energy demand of the Federal Republic of Germany was covered by domestic coal. However, due to coal mining becoming an increasingly globalized business and the oil and gas industry producing with lower costs, the German domestic hard coal industry stood constantly under restructur-ing pressure. The industry declined until the end of its life cycle. In 2007, a political understanding was arranged to phase out German hard coal mining in a socially acceptable manner by the end of 2018. This decision required a new strategy for the coal mining industry. Being strictly finalized, the German hard coal mining industry has to be prepared for the post-mining era. To create a sustainable development strategy, the long-term impacts of coal mining activities in Germany concerning the environmental, economic and social dimensions will be analyzed systematically and forward-looking. The regional and social responsibility during the closing process and for the post-mining era will be emphasized. High technical standards in environmental protec-tion and post-mining technologies, as well as long term experiences in the development of former mine sites to create new jobs are significant from an international point of view. The traditionally constructive social partnership between employers, union, and employees has enabled long-term stable adaption processes and avoided social friction. The sustainability strategy of the German hard coal mining industry can be regarded as a role model for other mining countries and regions facing similar transition challenges. INTRODUCTION Principally, mining is a finite business that reaches its end if the deposits are depleted or the raw materials can no longer be mined in an economically profitable way. However, the impact of mining is po-tentially an infinite one – at least if you measure it at a human time scale. Mining always means interfering with geological and ecological structures that cannot be reversed to their original condition. In general, the mining cycle (Figure 1) can be divided into three phases: 1. The exploration phase, in which the deposit is investigated to determine its technical and economic profitability. The period of these undertakings is relatively short and can lead to the launch of mining operations. 2. What follows is the actual mining phase which usually lasts for a long time and ends latest when all deposits are fully depleted. This lifespan may be shortened if the economic conditions (production cost or market price) deteriorate. Nevertheless, mining may be resumed if those conditions become favorable once more (examples are silver mining in Germany or rare earths mining in the USA). 3. The longest phase, however, is the post-mining phase as the human interference into geology and nature is usually inten-sive and irreversible. Mining can lead to consequences which have a permanently adverse impact on people and the environment; therefore, they have to be managed as best we can (1)."

Jan 1, 2017

By Robert L. Llewellyn

The Wharton No. 2 Mine of Eastern Gas and Fuel Associates is located about 60 miles south of Charleston, West Virginia in Boone County. Daily production is 6,000 T.P.D. on a two-shift basis. The Hernshaw Seam is mined by conventional equipment with one continuous miner in areas where conditions are suitable. The plant is on Cow Creek .Branch of Pond Fork, which in turn flows into the Little Coal River at Madison, West Virginia. When the mine was opened in 1948, plans were developed to build a dual Baum jig plant complete with mechanical and thermal drying, and because full production would not be reached for several years, it was decided to install only one Baum jig setup although the complete structure was erected. This phase of the plant was placed into operation early in 1949, The rated capacity was about 300 T.P.H. of 5" x 0 raw feed to the jig. Being a drift mine, the 10-ton mine cars are dumped at the Headhouse, crushed to 8" in a double roll crusher, conveyed 780 feet downhill to the picking .house where the +5" slate is removed by pickers. All coal is crushed to 5" and 5" x 0 is conveyed 150 feet to the cleaning plant. Further describing the plant growth, the second jig setup was installed in 1954 to clean the increased production. During this operating period, exhaustive tests had ,been run on the plant bleed which was an overflow from the large sludge tank located inside the plant, When the second jig addition was undertaken, 5-14' diameter and 12-8" diameter cyclones with a 9-disc filter were installed for the solids recovery and water clarification system, However, the circuit was not closed and a bleed of part of the overflows from the 8" diameter cyclones was still necessary, To comply with the State Water Commission regulations on stream pollution abatement, four pumps in series were installed to discharge the waste water behind the refuse pile.

Jan 1, 1959

By Chaoxun Zhao, TAIYOU LI, JIAQI JIN, Jan D. Miller, Chen‑Luh Lin

A large portion of the energy consumed in copper concentrators is used to reduce the particle size of the feed by crushing and grinding. The cost of metal production could be reduced if low-grade particles of cm size were removed prior to further processing. Two copper sulfide ore samples (3 × 1 cm) from Arizona were analyzed by micro X-ray computed tomography (Micro-XCT) to determine the grade of copper sulfide in each particle. For copper ore sample A, a significant number of particles contained very low amounts of copper, while some particles had copper sulfide grains of mm size. Based on Micro-XCT, it was expected that 85% of the copper for sample A could be recovered at 65% of mass rejection during preconcentration by sorting. However, in sample B (a different copper ore), distribution of copper sulfide was dispersed primarily in each ore particle, so for the particle size class of 3 × 1 cm, liberation of copper sulfide and gangue minerals was not significant. In view of the XCT results, dual energy (DE) X-ray radiography was used as a basis for sorting. Previous DE X-ray radiography of a drill core sample demonstrated that this rapid detection method can be used to identify rich or poor Cu-bearing coarse particles. Pilot scale X-ray sorting of sample A (10 × 1 cm) showed 31% rejection of a 0.08% Cu gangue product with a corresponding recovery of 90% copper.

Nov 30, 2021

By R Forster

Direct ship iron ore (DSO) operations at Extension Hill in Western Australia’s Midwest region have commenced, with fi rst product railed to the port of Geraldton in July 2011. Reserves are 14.8 million tonnes (Mt) of haematite-goethite ore overlying an Archaean BIF-hosted larger magnetite deposit which Mount Gibson Iron Limited (MGI) sold to other parties in 2006.Some unique geological aspects of the deposit shape DSO mining and processing operations. Owner-operator selective mining, blending, crushing and screening on site will produce three million tonnes per year (Mt/a) of Lump and Fines product to be trucked 86 km to Perenjori, railed 232 km to Geraldton, and loaded aboard Panamax-sized ships through the dedicated iron ore shiploader at the Geraldton Port Authority’s Berth 5 facility.The statutory approvals process for this project formally began in 2004, dominating delays in a predevelopment phase which extended over a longer period than the likely life of DSO operations. The lack of transparency, uncertainties and costs inherent in state government processes have influenced decisions made by MGI while assessing other development opportunities in Western Australia. Potential for additional Reserves exists at Extension Hill, however MGI’s ability to extend the mine life will hinge on statutory approval to explore for and evaluate other DSO resources on surrounding granted mining leases.The nature of the resource and use of existing infrastructure for product transport have enabled MGI to keep operating costs and capital intensity of this project relatively low. A tenacious development approach by MGI and robust project economics have fi nally enabled this site to take its place as a revenue earner beside the company’s other DSO operations at Tallering Peak and Koolan Island.

Jul 11, 2011

By N. Ward

The Gualcamayo Mine is located in the Andes Mountains north of San Juan, Argentina (Figure 1). A property of Yamana Gold Inc, it declared commercial production in July 2009 and has a total mineral reserve and resource base of approximately 88,000 kg of gold. Crushing operations for the open-pit mine are located in a 13,500 m3 underground cavern with a ceiling height of 22 m. More than 3,600 m of tunnels are used to access the cavern and convey the ore. The Project as described in this paper relates to the design and construction of the Main Cavern, Conveyor System Exit Tunnel, the Mechanical System Access Tunnels, and two 4.20 m diameter shafts (Ore Pass #1 and Ore Pass #2) as shown in Figure 2. [ ] Preliminary engineering for the Project was performed by Hatch Chile. Rizzo Associates Argentina, S.A., a division of Paul C. Rizzo Associates, Inc (Rizzo) was contracted to provide geomechanical and geotechnical support for the construction of the access tunnel system and geomechanical design and construction supervision for the cavern and shafts.

Jan 1, 2011

By Dominik Hofer

A broad spectrum of tantalum containing input materials can be processed for the production of synthetic tantalum concentrate (“SynCon”). The use of these low grade substances offers a secure alternative to mining of coltan in Central Africa. SynCon is produced in a multi-stage pyrometallurgical process, wherefore the melting behaviour of slags presents an important factor especially regarding the energy consumption and its optimisation. The characteristics of a slag comprising mostly Al2O3, CaO, SiO2 and MgO are influenced by the amount of other oxidic constituents which enfolds the main focus of this study. A hot stage microscope serves for the investigation of the slag behaviour in a temperature range from 1000 to 1600 °C under reducing atmosphere (CO/CO2 gas). The experimental results are compared with thermodynamic calculations (FactSage) to get a better understanding of the process.

By K P. Tully

In August 1996 a Microseismic Monitoring System developed by ISS International Limited was installed at the Pasminco Broken Hill Mine -Southern Cross area. The project aims were to:Assist in daily safety management in a mine environment which exhibits one of the highest occurrences of microseismic activity recorded in the Australian mining industry. Be used as a proactive tool in design of future development and stoping. The project to-date has been an unqualified success in achieving both goals. Consequently the system is being expanded from 6 to 14 monitoring sites.

Jan 1, 1998

By AIME AIME

HE State of Utah has an area of 84,990 sq. mi., and like other inland states in the West its population, although steadily increasing, is relatively small. The fact that it is a state possessing vast mineral resources is attested by a careful study of statistics which have been compiled by Federal and State investigators. Some idea of the extent of these resources and the degree of development of a particular state or region may be gained by such a study, but in the case of Utah statistics and other available information fail to portray completely the true extent and value of its existing metallic and non-metallic resources. The State is probably more widely known for its production of metallic ores which has placed it in an eminent position among the metal mining states of the Nation.

Jan 1, 1925

By A. Tosun

Muckpile fragmentation formed by blasting depends on the specific charge factor, the discontinuities in the rock mass, and the rock strength. Determination of the discontinuity characteristics and rock strength is a long and difficult process. These two parameters are directly associated with the rock drilling speed. Therefore, it is the drilling speed of the machine used for the blast-hole, rather than the blasthole discontinuity characteristics and rock strength parameters, that is used in the prediction of muckpile fragmentation before blasting. Primarily, it has been suggested that the muckpile fragmentation values can be correctly determined by establishing correlations between the efficiency of the loader and muck pile fragmentation, since fragmentation is directly correlated with the former parameter. Subsequently, a correlation predicting the drilling speed of the drill machine was developed according to the discontinuity characteristics of the blasting surface and the rock strength. Finally, a correlation was developed predicting muckpile fragmentation according to the specific charge factor and the drilling speed of the drill machine The data was obtained by conducting blasting tests in two different limestone quarries.

Nov 30, 2022

By Dominic Parmantier, Jason Page

"In the past, the designers of DSM have analyzed various failure modes and then specified a minimum unconfined compressive strength (UCS) for the soil-cement. The specified minimum UCS reflected the compressive stress in the soil-cement under design loads and an appropriate factor of safety. With the increased use of finite element analysis for the design of DSM applications where allowable strain as well as stress are considered, there is a growing trend for designers to specify a modulus and occasionally a tensile strength for the soil-cement in addition to the UCS. This paper compares the relationship of modulus and tensile strength to UCS for soil-cement from a recent DSM project with unique testing requirements. These results are compared to published data. The case is made that designers should utilize published relationships to characterize the required strength and stiffness by a single acceptance criterion: UCS.INTRODUCTIONAs the use of DSM has increased in popularity so has the use of service state deformation analysis in lieu of more traditional failure mode analysis. Most DSM designers are interested in the appropriate modulus values and occasionally tensile strength values of soil-cement as well as simply the unconfined compressive strength (UCS) of soil-cement.Although there are numerous published correlations between the UCS, tensile strength and modulus of soil-cement, some DSM project specifications are produced which have acceptance values for tensile strength, modulus, and UCS. If this specification of multiple strength properties is consistent with the nature of soil-cement, then there is really no harm except for the expenditure of client money on unnecessary testing. If however the multiple strength properties specified are inconsistent with the material properties of soil-cement, then the specifications can create the expectation that the DSM contractor can somehow create a custom soil-cement with tensile strengths and modulus characteristics which are unachievable.This paper presents a brief summary of a project in Burnaby, B.C. which specified minimum values for the tensile strength, modulus, and UCS of the soil-cement. A comparison of those test results to published correlations between the UCS and the tensile strength is presented. Additionally, a comparison of modulus derived from two different methods of testing is presented along with a comparison to published correlations between UCS and modulus for soil-cement."

Jan 1, 2015

By R. G. Hudson, H. W. Paxton

The activities of iron and chromium in their binary system have been measured by the Knudsen orifice technique. The system is close to ideal at 1200- 1250 C with slight positive deviations. The effect of this on the liquidus and solidus is discussed and these are calculated for two limiting assumptions. The vapor pressure of pure iron, pure chromium, and one alloy is compared with that obtained by the Langmuir free-evaporation technique. The results agree, indicating a vaporization coefficient close to 1. HERE are no reported data on the thermody-A namic activity of iron and chromium in the solid portions of the phase diagram. It is generally assumed'.' that the liquid solutions of iron and chromium obey Raoult's law. Chen and Chipman" have inferred that the liquid solution obeys Raoult's law. The minimum' in the solidus-liquidus curves for the iron-chromium system shows that there are deviations from ideality in either the solid or liquid or both. Because of the importance of developing reliable techniques for obtaining activity data in alloy systems at high temperatures and of the data so obtained, an investigation of the activity of iron and chromium in the binary at 1200-1250 C was undertaken using the Knudsen cell. Experimental The apparatus and experimental procedures used in this investigation were described in a previous paper." The various materials used for the construction of the Knudsen cell are listed in Table I. The metal used for the determination of the vapor pressure of chromium was 99.9 pet pure, obtained from A. D. Mackay, Inc. The iron was obtained as electrolytic grade from Fisher Scientific Company. The Fe-Cr alloys used are shown in Table 11. The largest error and controlling factor in the accuracy in the experiments reported here are introduced because of temperature uncertainty, which is estimated to be ±3 deg C. This introduces an uncertainty of 26 pet in the measured pressure. Experimental Results and Calculations The vapor pressures of pure iron and pure chromium were calculated from the measurements by the Knudsen equation3 on the assumption that only Cr or Fe atoms were present in the gas phase. For metal vapors, at the high temperatures and low pressures involved in these measurements this should be a reasonable assumption. Whitman" corrections for the cells were made. The data and results of pressure calculations are presented in Table I, and are plotted in Fig. 1. In addition the heat of vaporization at the absolute zero, ?E°°, has been calculated for chromium. These calculations are summarized in Table 111. The data used in these calculations are as follows kelley13 (F° - E°°/T ) Speiser, et al H (F° - E°°/T ) 010 where F" — standard free energy at temperature T It was necessary to calculate the total pressure above the alloys from the total weight loss W of the cell during a run, because of the fact that all attempts to collect and analyze the chromium and iron vapor effusing from the cell in the apparatus available failed. The failure resulted from the re-

Jan 1, 1959

Wire rope, when used for hoisting on a mine is one of the most vulnerable units in the most expensive group of installations on the mine. With the introduction of hoisting on the Koepe sheave, a new technique was established. This innovation brought with it certain advantages which long had been recognized and which are being developed further.A need exists for the development of an infallible non-destructive testing device for wire ropes and it is axiomatic that the development and application of such a device should be coupled with the physical examination of mine hoisting systems. Therefore an integrated type of research programme is necessary in order to correlate the effect of shock loading with rope damage, which may be detected ultimately bynon-destructive means. This paper reviews certain historical aspects of investigations on this topic and it outlines a policy for research which can cope with a.c. or d.c. methods of excitation of the rope.INTRODUCTIONThe importance of wire rope in mining operations is often not fully recognized. A wire rope when used for hoisting in a mine shaft should be regarded as a "machine" forming part of a system of machines, and consequently it should be specified as such when it is purchased, it should be maintained as such during its working life, and it should be discarded only when it has done its duty and has been rendered either unsafe or uneconomic for further use.Every mine shaft, vertical or inclined, has in it one or more wire ropes which are used to transport men, material, and ore. Considering the long history of wire rope haulage and the large number of rope applications, it is a tribute to wire rope makers and to mine maintenance engineers, throughout the world, that not many serious accidents have occurred because of failure of wire rope. However, when a...

Jan 1, 1965

By J. H. Allen

The air lift method of pumping water is discussed. A review of several large diameter hole drilling projects that used reverse- circulation air-lift techniques is presented. Proposals are made for reverse circulation flow rates for slow rates of bit penetration (5 fph) as well as reverse-circulation flow rates for faster rates of bit penetration (10 fph). The Ingersoll-Rand air lift equations are modified for rotary drilling operations. By establishing minimum reverse circulation flow rates and utilizing the modified air lift equations, the establishment of minimum circulation equipment sizes and a more definitive requirement for improved bit body design should result.

Jan 1, 1978

By E. Maritz

"The localized uniform conditioning (LUC) technique was proposed by Marat Abzalov in 2006. The technique converts conventional uniform conditioning (UC) grade-tonnage curves into single grade values attached to each smallest mining unit (SMU). This is achieved by ranking the SMUs within a panel in increasing order of their grade (based on the direct kriging of SMUs). This ranking is then used to localize the conventional UC grade-tonnage curves for each panel by dividing them into classes and computing their mean grades, which are assigned to the SMUs. The quality of this localization process will depend heavily on the validity of the grade patterns predicted by the direct kriging of the SMUs. Abzalov noted that where the distribution of data available for the direct kriging of the SMU is characterized by strong short-range variability, the advantages of using the LUC approach may be more limited. Consequently, a study was undertaken to determine how valid the predicted grade patterns of a typical Birimian-style gold deposit (with high nugget effect and strong short-range variability) might be expected to be. This was determined by comparing the direct SMU kriging ranking (based on sparse data) with the grade control model ranking (based on close-spaced data and the best available estimate of the deposit). The results showed a satisfactory correlation between these rankings and it was concluded that, although the grade patterns predicted by the direct kriging of the SMUs may be less meaningful for deposits exhibiting strong short-range continuity, there is nevertheless a convincing relationship with the actual (or best available) rankings. Therefore, the LUC technique is still considered to be useful for this style of deposit. IntroductionFor adequate technical and financial evaluation of a project, attempts should be made to estimate the recoverable resources – the portion of the in situ resource that can be economically extracted by mining. To achieve this, the estimates of the tonnage and grade of the mineralization should be produced above a given economic cut-off and should take into consideration the proposed mining selectivity."

Jan 1, 2016

By F. J. Sotillo

"Scrubbing both horizontal (drum) and vertical (attrition) are considered simple unit operations in the beneficiation of phosphate ores. In general, the operating conditions are fixed at high solids content based on the experience of the engineering or equipment manufacturing company responsible of designing this beneficiation step. Nevertheless, scrubbing is a complex unit operation designed to clean the surfaces of phosphate mineral particles of slimes, break loose weak inclusions or attached particles of impurities, and break aggregates of clayish material. Therefore, it is considered that as high solids content as possible should be used to enhance particle-particle interactions (impact and rubbing) without taking into consideration the rheology of the system. However, scrubbing unit operations design requires studying the balance between the increase of particle-particle interactions with the cushion effect that may occur when slimes, clays and fines decrease the availability of free water increasing the apparent viscosity of the phosphate slurry up to that of a paste consistency. This paper presents data from laboratory tests to determine the best operating conditions for the design of these unit operations based on the highest P2O5 grade obtained with the lowest impurities for different size fractions. INTRODUCTION In the beneficiation of phosphate ores, unit operations such as horizontal scrubbing (drum) and vertical scrubbing (attrition) are considered simple unit operations. Therefore, little attention is given to the design of horizontal and vertical scrubbing during the basic engineering studies, and the detail engineering stage, the manufacturers recommending “standard” units and operating conditions based on their experience. Due diligence of several beneficiation phosphate plants at industrial scale indicates that a deficient scrubbing of the phosphate ore results in significant problems in downstream unit operations, such as classification, clarification, gravity separation, magnetic separation, flotation, dewatering, and filtration. Scrubbing is in fact a complex unit operation designed to clean the surfaces of phosphate mineral particles of slimes (clays and fines), break loose weak inclusions or attached particles of impurities, and break aggregates of clayish material. Two phenomena occur, the particle-particle interaction (impact and rubbing), and the rheological effects of releasing significant amount of fines into the slurry. Therefore, high solids contents are recommended to enhance the particle-particle interactions, which may result in a change in the rheological regime of the system due to the slimes, clays, and fines decreasing the availability of free water. This increases the apparent viscosity of the system up to that of paste consistency resulting in a cushion effect that suppresses scrubbing. Under these conditions, not all fines are release and rejected (deslimed), downstream unit operations being affected by the release of clays, resulting in P2O5 losses."

Jan 1, 2017