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By E. V. Manlapig

"Some researchers postulate that the floatability of a particle in the streams of an industrial flotation circuit is a function of only its size and liberation properties. They do not discount the importance of reagent or surface contamination on particle floatability but assume that the reagent coverage or surface contamination of the particle surfaces is essentially uniform for particles of similar size and mineralogical properties when subjected to a particular chemical regime.In this paper, samples collected from laboratory batch flotation tests performed on different streams of Cominco Teck’s Red Dog lead cleaning circuit have been characterised with respect to their size, mineral association and mineral surface exposure. An analysis of this data set indicates that the flotation rate of a particle in an industrial flotation environment is a strong function of its size and also of the mineral composition of its surface (Figure 1). It is a function not only of the proportion of the most floatable mineral on its surface but of the floatability of the other minerals on its surface as well.Nodal analysis is a technique developed by the authors that can be used to determine if the ore floatability of a particle class is changing within an industrial flotation circuit. This technique is used within the paper to show that the floatability of all the different types of particle classes studied within the Red Dog circuit did not change significantly during the lead cleaning stage. However, it was also concluded that particles with the same size and mineral composition did not all float with the same rate in the individual streams of the flotation circuit, but with a distribution of rates. It is suspected that the particles within a size mineralogical class in this study have varying degrees of surface oxidation and that this results in varying particle flotation rates. Thus basing particle floatability on size and mineralogical effects, alone, in a flotation model is not always valid."

Jan 1, 2003

By Barda K. Mishra, Surya P. Mehrotra

"INTRODUCTIONIn a jig, which is primarily a coarse mineral concentration device, the bed of mineral particles is pulsated with a stream of water resulting in the particles of different specific gravities. It operates in a cyclic manner – the jig cycle consists of four stages, namely, inlet, expansion, exhaust and compression. In the inlet stage the bed lifts up en masse. Near the end of the lift stroke the particles at the bottom of the bed start falling resulting in the loosing of the bed which, in turn, causes its expansion or dilation. During the third and fourth stages the particle resettle through the fluid, and the bed collapses back to its original volume. The pulsation and suction are repeated to bring about stratification with respect to specific gravity across the bed height. Various parameters affecting the stratification process include amplitude and frequency of pulsation, bed thickness, rate of hutch water flow, and feed characteristics. This paper first presents a review of various jigging theories and then describes a new approach to mathematical modeling of jigging employing the discrete element method.JIG MODEL BASED ON DISCRETE ELEMENT METHOD (DEM) APPROACHThe jig models based on DEM essentially involve tracking the position of each particle incrementally, applying Newton’s law of motion and a force displacement law at the contact. The model presented here is based on a three dimensional mathematical description of solid-solid and fluid-solid interactions. In this model, the force balance on a particle is extended to account for the effect of continuously varying fluid on the particle. The total force on each particle is made up of a known external body force, fluid particle interaction force and particle-particle and/or particle-wall interaction force. The fluid-particle interactive force is primarily made of drag and buoyancy. Di Felice’s correlation is used to evaluate the drag force. Solid-solid interaction is described by treating particles as discrete elements that are indestructible but interact with each other and any other elements present, such as walls, when they make physical contacts. A pair of spring and dashpot represents a contact The contact forces are computed from the amount and the rate of overlap of the particles at the contact. The motion of the particle is due to movement of the fluid, which transmits its energy through the particle-particle contacts. A computer program incorporating both the contact and the fluid model has been developed. It takes the operating parameters such as amplitude and frequency of the pulsating fluid, pertinent data concerning particle properties and the geometry of the jig bed as inputs."

Jan 1, 2003

By P. Somasundaran

While sustainability itself needs to be redefined in a selfless way, methods of measuring and optimizing it also need to be reformulated. Gone are the days when we had the luxury of abundant resources and the freedom to extract values in self-centered ways. In the past, focus has been mostly on reagent performance, processing operations, and upgrading of tools to maximize rather than optimize value extraction from the earth's crust. Today we as extractors face a new set of challenges that include value separation from low quality resources including wastes, but within the energy, environment, and societal constraints. Development of such technology depends on understanding the role of entities and concepts such as bio-molecular interactions at surfaces, forces involved in inter-granular versus intra-granular fracture in new fragmentation methods, robotic in-situ or extraterrestrial mining, exploiting new membrane and nano technology, use of new sensors and actuators for detection and separation and computation capabilities for faster and economical processing. Equally importantly, we need to communicate with everyone what we foresee and anticipate when we extrapolate the type-performance-cost relationship of ores to the era ahead of us and establish viable schemes for ecological survival. Keywords: sustainable mineral extraction

Sep 1, 2012

By M. Brennan, A. Majumder

"The mineral processing research community has devoted enormous efforts to the modelling of mineral separators over the last 50 years. While many efforts have been made to use only fundamental physics as a basis for the models, fluid flow patterns in separators are not simple while the motion of particle swarms through fluids is extremely complex.Sluices are the simplest forms of the flowing film concentrators and have been used in the mineral industry since at least the 15th century (Agricola, 1556). Flowing film concentrators, in general, still have widespread applications in the mineral industry and their designs vary according to the specific need.Particle separation in a sluice appears deceptively simple, but the separation mechanism has proven complex and difficult to quantify. Separation in the sluice takes place in a flowing film a few millimetres thick. The particles are suspended by turbulent eddies and motion relative to the fluid takes place in socalled hindered settling mode. The difficulty arises because the presence of the particles influences the flow pattern and when the particles are fully transported by the flow, the flowing slurry may not have the same viscosity as water and does not have the same density. For this reason a universal theory which can explain the behaviour of a suspension in a sluice or any other gravity equipment has still not been developed. Few attempts have been made to analyse the mechanisms involved in the concentrating processes of pinched sluices and Reichert cones.Fluid flow behaviour and slurry transportation characteristics in open channels have, however, been active research topics in the disciplines of fluid mechanics, chemical engineering and civil engineering for many years. As a result, an extensive literature is available, which has led to the development of the model described in this paper.In an effort to test the extent to which fundamental fluid mechanics can provide a prediction of particle separation, a study on a simple parallel-sided sluice has been carried out using glass beads at various particle concentrations and flow rates, and the actual particle separation taking place compared to predictions from modelling.The modelling strategy was divided into two parts; the first was to predict the horizontal slurry flow velocity profile and the second to predict the solid particle concentration over the depth of the flow at different flow conditions. The predictions were then validated with measured data sets. This can easily be done if the slurry flow is split at different fractional flow depths so that the mass flow of solids over different flow heights is measured accurately over a fixed period. Mass flow splits can then be calculated by integrating the product of the predicted slurry velocity profile and the predicted solids concentration profiles from the base of the sluice bed to the slurry free surface."

Jan 1, 2003

By K. Malysa

Bubble collisions with ore grains and a selective formation of the bubble-grain aggregates are necessary steps for flotation separation of useful and gangue components of an ore. For the attachment of valuable mineral grain to the colliding bubble a liquid film, separating the bubble and the grain needs to rupture during short time of their collision. High hydrophobicity of the grain surface is favorable because stability of the separating (wetting) film is much lower at such surfaces, that is, the film ruptures faster and at greater thickness. Simultaneously, it needs to be kept in mind and taken into consideration that high affinity to air is a typical feature of hydrophobic surfaces. Thus, when the hydrophobic surface is immersed into aqueous phase the air can stay attached to such surfaces and affect kinetics of the bubble attachment. The paper presents results and analysis of dynamic phenomena occurring upon the collision of the rising bubble followed by its attachment to hydrophobic (Teflon) plates of different roughness. The influence of the Teflon surface roughness, solution concentration, bubble size and impact velocity on bouncing of the colliding bubble, time of the three phase contact (TPC) formation and drainage time of the liquid film, formed between the solid and bubble surfaces, is described. High hydrophobicity, as showed earlier (Malysa et al, 2005), does not assure that each collision leads to the TPC formation and attachment of the colliding bubble. Roughness is the parameter of crucial importance for kinetics of the bubble attachment to hydrophobic surfaces (Krasowska and Malysa, 2007; Krasowska et al, 2009; Kosior et al, 2011). Enlarged roughness of the Teflon plate, from ca. 1 to 80µm, results in shortening the time of the TPC formation (bubble attachment) by over an order of magnitude - from 105 to a few milliseconds only. Higher surface roughness means that larger amount of air can be entrapped in bigger scratches and cavities of the Teflon plate during its immersion into aqueous phase. Results documenting importance of the air presence are showed and mechanism of the air facilitated TPC formation and bubble attachment to hydrophobic surfaces is described. Keywords: bubble collisions, hydrophobic surfaces, teflon plate roughness, TPC formation

Sep 1, 2012

By Venkata S. Buddhiraju

Pelletization of iron ores involves balling on a rotating disc to produce wet pellets and induration of wet pellets on a moving grate to produce fired pellets. The quality of pellets produced and the productivity of the pelletization process depend strongly on the characteristics of the feed to the pelletization disc, especially the particle size distribution and the moisture content. The upstream processes involved in the preparation of pelletization feed include grinding, thickening and filtration of the iron ore slurry. The focus of the present work is the closed circuit wet grinding of iron ores. The circuit consists of a primary ball mill, a regrind mill and a hydrocyclone. A population balance model was developed to predict the grinding kinetics and an empirical model was fitted for the separation of fine particles from the coarse particles in the hydrocyclone. Batch grinding kinetics experiments were performed on a laboratory scale ball mill to obtain the ore breakage parameters which were subsequently used for the simulation of the industrial mills. The models were customized for the industrial operations and the effects of different process variables like feed flow rate, water flow rate, etc., on the size distribution of product from the grinding circuit were studied. Additionally, different circuit configurations were simulated to determine operating conditions that could result in the desirable product particle size distribution. The results of simulation were in close agreement with plant observations and the new circuits explored through simulation have helped in identifying potential opportunities for process optimization and control

Sep 1, 2012