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By M. R. Tavakoli Mohammadi

Novel solvent extraction technologies in recent decades have made attempts to show the problems in applying this method for dilute solutions and find appropriate solutions to overcome them. Improving the equipments performance used in this method for dilute solutions, cause development of usable resources and reduction of operational costs. Furthermore, appropriate conditions provide for using dilute solutions produced in various industries as a new source of valuable elements. Thus, this proposal can be a very good solution for treatment of these solutions and reduce the environmental impacts associated with them. The purpose of this study is to introduce a new method of Column Floto Extraction (CFE), which has been invented in this regard. In this method, using spargers similar to Jameson cell downcomer in floatation process, the organic phase bubble dispersion has been used instead of its drop dispersion in aqueous phase for the two-phase mixture operation. This operation mode has caused a higher extraction percentage of solute in high aqueous to organic ratios due to enhancement of contact area. In this study, in addition to explaining the advantages and features of this method, we have dealt with its design and performance mode.

Sep 1, 2012

By S. V. Bogdanov, S. I. Grishaev

"The article presents the materials about the appropriateness of the use of rental indices to assess the effectiveness of the use of deposits of rare earth elements (REE). The authors suggest from the standpoint of rent payments to rate for the owner the possibility of using the anticipated rental income as the indicator for the analysis of preferences and economic significance of enrichment of extracted raw materials in the emerging field of rare earth metals (REE). Usually from ore mined at the fields, for flotation technology to produce concentrates with collective REE, then they are subjected to chemical-metallurgical processing of the received products are divided into pure oxides, chemical compounds or isolated from them pure metals and alloys. This commercial product is shipped to the buyer. REE were a non-renewable natural resources, so the calculations for determining differential and specific rent showed that during the development of the technologies of mineral processing of a specific field it is necessary to consider what the expected rental income depends on the magnitude of differential rent is related to the volume of production of REE for the whole planned period of exploitation of natural resources. This income is determined by the amount of stock field. For long-term exploitation of the deposit is observed in almost direct proportional dependence between the annual differential rent and the rental income. The decrease in rents in the long run is determined by the change in the composition of ores included in the extracted raw materials and the balance between light and heavy REE. The largest 70% reduction of the rent projected for ""cerium"" fields, while for ""yttrium"" these losses are considerably smaller. Tomtor, Chuktukon and Katuginskoye Russian deposits are characterized by a level of rent that is comparable to the mastered foreign sources of REE. Thus, the enrichment of minerals with REM in the domestic deposits is quite competitive at the world level. INTRODUCTION Deposits of rare earth metals (REE) are non-renewable resources that should be developed and used so that it would be possible to provide a reduction due to payment of appropriate resources for future generations. This compensation, due to the reduction of natural resources, can be carried out both in natural and in economic terms (1). When analyzing economic compensation options, particular attention should be paid to rental income in assessing the attractiveness of using different REE deposits. It is known that absolute and differential rents are summands when calculating the value of natural rents. The value of the absolute natural rent is proportional to the unit price of the product obtained from mineral raw materials and sold on the commodity market. Limitations, as well as the use in production processes and business, contribute to the gradual reduction of natural resources, which increases their consumer value and affects the price of commodity products from primary raw materials."

Jan 1, 2018

By Jorge Misle, Daniel Silva

"This paper addresses the need for advanced control technologies and strategies in the mining industry, its potential and actual impact on mining processes and the best practices for their implementation, operation, and long term sustainability. It is well known that advanced process control (APC) can be a very good source for incremental process improvement for the mining industry, yielding to higher production rates or helping maintain consistent production rates despite ore changes. The application and integration of new technology, process knowledge and innovation are key elements in building such a supporting structure. More specifically, and this cannot be emphasized enough, the correct application and assembly of control tools, the in-time presentation of key data to decision makers and the development of relevant statistics and KPI’s (key performance indicators) can and will make a difference not only in terms of production, but also in plant stability, availability and production costs. In deploying such ideas and aiming at the long-term goal of "Operational Excellence", Minera Los Pelambres (MLP) has developed a number of successful control strategies, best practices and technologies, which are not only the application of state-of-the-art automation and computing tools, but rather the assembly of the above presented structuring factors. This work discusses some of the key tools and ideas implemented for SAG & Ball milling and Flotation areas, their performance results and the roadmap taken for the integration of process knowledge and control tools. Also, cases studies are presented and discussed further to not only show the main areas of improvement, but also to highlight the benefits of such strategy that for the most part, deviate from the traditional mining industry control approach. Also, a word is given on the need for innovating in the design of control strategies and leveraging best practices and process knowledge that ultimately, will contribute to long-term reliable operations, improved mineral processing and, although unmeasured, lead to a superior overall performance and productivity of all mining personnel involved."

Jan 1, 2014

By C. Igathinathane

Coal is the most widely used fossil fuel in the world, providing more than 25% of world?s electrical power. Since, the behavior of coal particles in crushing and grinding circuits, concentration operations, and solid-liquid separations is strongly dependent on size, a reliable and accurate measurement of particle size and particle size distribution (PSD) is a vital aspect in coal cleaning. This paper presents a method for the characterization of ground coal particles using image analysis. We utilized a machine vision (MV) approach that used a document scanner as the imaging device and a user-coded ImageJ plug-in that processed the image and automated the PSD analysis and output results in textual and graphical forms. This approach used a sum of volumes (SVolume) as weighting factor for particle length as the primary dimension of analysis and was successfully applied to ground coal. The plug-in was further improved for computational performance in this study. Mechanical sieving (MS) was also used to compare the MV results. MV results showed that the PSD of ground coal followed a uni-modal normal distribution, and the log-normal plot against particle size exhibited a linear trend for most of the range. MS results, however, had three linear segments, when the width-based sieving results were transformed to lengths by applying the shape factor (width/length), but a definite deviation between the PSD plots was observed. This study demonstrates successful application of the MV SVolume approach for PSD analysis of ground coal, which can be extended to similar particulate minerals and products. Keywords: dimension, fiji, image j, image analysis, coal, particle size, plug-in

Sep 1, 2012

By G. Prabhulingaiah, D. M. R. Sekhar

"A phosphate deposit of estimated 6 billion tons of P2O5 is located 180 to 300 meters below the sea level, 185 kilometers north of port Luderitz, Namibia. The ore bed is 6 kilometers wide and 220 kilometers long. The ore deposit analyzing 16% P2O5 is loose sediment of 1.5 meters thick without over burden. Sizing of the ore to - 1.4 mm + 0.150 mm improves the grade to 23.54% P2O5 with a P2O5 recovery at 83.75% containing phosphate pellets and flakes of sea shells. Clay, bacterial debris as organic matter, flakes of broken sea shells and fine phosphate containing particles report to - 0.150 mm fraction and + 1.4 mm fraction contains sea shells and few phosphate containing pellets. The mineralogical composition of phosphate containing pellets is estimated (Droste, T.C., 2004) 80% frankolite, 6% pyrite, 4% illite, 3% quartz, 3% amorphous SiO2, 1% carbonates, 1% organic carbon and = 1% ilmenite, magnetite, zircon etc. The phosphate content in the pellets is around 27.7% P2O5. Trials to separate by gravity or flotation processes were not successful. Leaching of carbonates (sea shell flakes) under mild acidic condition (= 2% acetic acid or HCl solutions) or calcinations followed by leaching however yielded residues (concentrates) of grades 27.85 - 32.74% P2O5 at P2O5 recoveries ranging from 78.45 - 96.8% P2O5."

Jan 1, 2014

By X. Q. Ma

The beneficiation test on low grade phosphate ore from a state of Russia is carried out. The rougher-cleaner ? re-cleaner system is used in the flotation process, The fineness of grind is 39.07% minus 200 mesh. The result indicates that concentrate containing 31.25% P2O5 can be obtained from the flotation feed assaying 6.18% P2O5, with 93.54% P2O5 recovery. The test result is also a guideline for further development of some currently operated phosphate beneficiation plants.

Jan 1, 2014

By P. K. Sen, Mrinal K. Ghose

Tailing slurry is usually abrasive and possesses high viscosity. This paper examines the existing iron ore beneficiation process and focuses on some of the key environmental issues related to the disposal of tailings. It identifies that almost 32% of the iron ore extracted ends up as tailings and they are usually disposed in slurry form in tailing ponds. By the year 2000, 27 Mt of iron ore tailings were generated in India, which has become one of the biggest waste handling problems to the industry. Characteristics of the tailings vary widely. So the physical nature of tailings cannot be considered separately in isolation without considering the mill effluent from the beneficiation plant. In the present investigation, studies were carried out in three iron ore mines in India to evaluate the characteristics of tailings from the beneficiation plant. The tailing samples were collected from different locations during a time period of one year and analyzed. The results will be discussed and the characteristics of the tailings have been evaluated. The disposal system of tailings at the three mines was evaluated. The research on the settling characteristics of tailings indicates that the area provided in the existing tailing ponds in India is much more than that of the experimental results. This paper concludes that sedimentation tests are essential to design appropriate tailings pond with respect to size. In the proposed scheme it is suggested that an additional unit process, i.e. sedimentation tank be added to the process before the disposal of tailings to the tailing pond.

Jan 1, 2003

"The most common comminution testing methods and the associated analytical procedures provide average values and do not capture the variability in breakage behaviour of ore particles. Therefore, plant designs and process performance predictions use only average values; hence, the inherent variability that exists within an ore domain translates into variation in process performance. This paper discusses the drawbacks of using the average approach to impact comminution testing and plant design. It considers breakage intensity from a single-particle testing perspective. To clearly delineate breakage behaviour of each broken particle, an experimental technique using the JK Drop Weight Tester (JKDWT) has been developed by which actual comminution energy per particle and breakage intensities were measured directly. Four different ore types in ranges of -45+37.5mm and -22.4+19mm were tested at three energy levels of 0.1, 0.25, 0.5 kWh/t and six energy levels of 0.5, 1.0, 2.0, 2.5, 3.0 and 4.0 kWh/t, respectively. Sieved results of individual particles, notionally, t5, t10 and t50 showed the presence of large variability in their breakage behaviour, which was not captured by the standard JK impact breakage testing approach. In addition, the original JKMRC model is modified by introducing a third parameter, ‘Emint10’ which describes the minimum energy required to produce the minimum percent t10 for a given ore type and its significance is tested statistically. These results suggest that the analysis of breakage variability may lead to more robust plant designs. Perhaps, the most useful insight from this work is to extend single particle breakage model developed by JKMRC to a comminution percentile envelope which may provide a more detailed picture of ore breakage variability. INTRODUCTION Rock consists of mineral grains, pores, voids and cracks that may differ markedly in size/density which make rock a heterogeneous material by nature. The degree of heterogeneity in rock affects its breakage characteristics where these variations increase local differential strain and stress within a stressed rock (Scholz, 1968) and it depends on many factors such as rock genesis, alterations, etc. One important aspect of this heterogeneous feature is presence of a large amount of experimental scatter in rock breakage results when considered from a quantitative perspective (Bieniawski, 1967; Liu, Roquete, Kou, & Lindqvist, 2004)."

Jan 1, 2018

By E. V. Konoplev

Russia is one of the largest manufacturers of potash fertilizers in the world. Processing of potash ores basically is carried out by a flotation way. Potash ores of the Verhnekamsky potash deposit contain sylvite (KCl), halite (NaCl) and water insoluble impurity (up to 8 %), presented silicate- carbonate minerals, easily slimed by ore crushing in rod mills. Ore of some deposit sites, developed by ?Uralkali? Co, contains a significant amount of a carnal-lite (KCl.MgCl2.6H2O). Work practice of flotation potash plants has shown, that increase of car-nallite content in ore leads to increase magnesium ion content in a circulated plant brine (saturated salt solution of potassium and sodium chlorides-sylvite brine) and to deterioration of indicators of ore processing. In the Paper we present results of researches of floatability of various size sylvite and influences silicate-carbonate slimes on sylvite flotation in brines with the various magnesium chloride content. It is established, that with increase magnesium chloride content in the brine mainly decreases the flotation of coarse sylvite and amplifies adverse effect of silicate-carbonate slimes on sylvite flotation. In this connection deterioration of potash ore flotation is caused not only decrease sylvite floatability but also strengthening adverse action of water insoluble impurity on potash flotation. It is shown that the application of frothing agents, which render the stronger dispersive action on the colloidal-micellar structures of amine in the salt solution increases the absorption of collector on the sylvite and improves the flotation of sylvite into magnesium the containing salt solutions. The application of an organic depressor to the greatest degree of decreasing the absorption amine on the slimes and to the smallest degree possessing anionic properties proves to be most effective with the flotation carnallite of the containing potassium ores. It is offered the application the frother on a basis of glycol ethers and organic depressor on a basis of urea-formaldehyde resin. Results of industrial tests developed reagent modes for flotation treatment of ores with the raised carnallite content (to 6 %) on ?Uralkali? Co plant have shown that their application has allowed to receive equivalent indicators potash flotations at change of magnesium chloride content in the brine from 0.7 % up to 2.4 % .

Jan 1, 2014

Domestic production of pyrite cinder reached 15.95 million tons in 2006. The pyrite cinder used in cement industry accounts for about 30% production. The remaining 70%, 11.17 million tons, was thrown away as waste, which brought serious environmental and resource problems. A new technology of composite pellet reduction-roasting and magnetic-separation (CPRM) has been developed to utilize pyrite cinder. Pyrite cinder sample, containing 45.56% Fe, 0.19% Cu and 1.45% S, was pelletized with addition of 5% composite agent in balling disc. Green balls after drying were reduced at 700~800 ? for 20min with 300kg/t pulverized coal injection in rotary kiln. After two stages of ball-grinding and four stages of magnetic separation, high grade magnetite concentrate with 66.23% Fe was produced, meanwhile impurities Cu and S was decreased to 0.048% and 0.053%, respectively. And iron recovery of 73.32%, desulphurization of 96.34% and decoppering degree of 74.73% were achieved. Key technique is that composite agent can accelerate reduction of Fe2O3 and transfer copper and sulphur into water-soluble inorganic salts, which can be removed during wet magnetic concentration. This new technology can be used to fully utilize pyrite cinder and produce high quality magnetite concentrates as feed for steel industry, which will help tackle the pollution problem of pyrite cinder and extend iron-bearing raw material sourcing for Chinese steel industry.

Jan 1, 2014

By Z. C. Shen

As core part of flotation column, aerator has been always priority research. A new type of porous aerator made of stainless sintered microcellular material is designed , which diameter is between 20µm to 40µm. High bubble surface area flux is obtained at low air pressure 20kPa by this type of aerator in water. In order to extend its applied range ,experiments were carried out in alkali slurry (pH=12) , resulting with porous aerator clogged after working 20 days . Sampling the cross-section of aerator detected by microscope and X-ray diffraction ,the reason clogging was found. Then plugging aerator was reactivated after putting it in acidic liquor treated by ultrasonic for about ten minutes. On-line aerator maintenance can be done in no down time , and it can be repetitive-used after recovered ,so reduced capital costs.

Jan 1, 2014

By Johannes Käppeler, Alexander Weh, Harald Giese, Klaas van der Wielen

"High voltage breakage is a novel comminution technology that shows considerable potential for various applications in mineral processing and recycling. It relies on highly energetic electrical pulses to induce electrical explosions in rocks, causing the formation of plasma channels and powerful shockwaves that result in fracturing and fragmentation of particles. There has been considerable interest in this technology for its ability to weaken rocks and preferentially liberate target minerals, as previously demonstrated by other authors. Weakening has the potential to significantly reduce energy consumption during comminution, or alternatively, increase throughput of a circuit. Better liberation may yield an improved concentrate grade and/or recovery, reduce fines losses to tailings or increase the grind size required for liberation, thereby also reducing energy requirements. This review aims to increase general awareness of this technology, and promote further research into it by providing a general summary of the theory underlying high voltage breakage, as well as the envisaged applications of this novel technology. A brief history of the technology is presented before progressing onto the physics underlying the electrical and geomechanical aspects of high voltage breakage. Key results regarding weakening and liberation are discussed, and some mention is made of current challenges and planned developments to increase the throughput of high voltage breakage units to the level where it can be integrated into new and existing processing circuits."

Jan 1, 2014

By O. Celep, H. Deveci, Ersin Y. Yazici, F. Ahlatci

"There are increasingly stricter environmental regulations imposed for use of cyanide leaching for the extraction of gold from ores. Alternative lixiviants to cyanide, preferably with low toxicity, have been extensively studied. Thiosulphate has emerged as one of the most suitable alternative leaching agent in place of cyanide due to its low toxicity and technical attributes e.g. fast leaching kinetics, high gold extractions from carbonaceous ores in particular. High solubility of most copper minerals in cyanide solutions results in low gold extractions due to excessively high consumption of cyanide. In contrast, low reactivity of copper minerals in thiosulphate solutions makes thiosulphate leaching potentially suitable alternative for treatment Cu-bearing gold ores. The extraction of gold/silver from a copper-bearing pyritic gold concentrate (62 g/t Au, 110 g/t Ag and 0.3% Cu) in thiosulphate solutions was investigated in this study. The concentrate is composed of predominantly quartz (25%) and pyrite (32.7%) as well as sphalerite (5.37%), galena (2.12%) and anglesite (1.13%). Other minor minerals are arsenopyrite, chalcopyrite, covellite and bournonite. Previous studies by the authors indicated that the concentrate did not respond well to cyanide leaching (i.e. 45-46% Au/Ag at 1 g/L NaCN). The effects of concentration of ammonia (0.2-1.5 M NH3), thiosulphate (0.1-0.75 M S2O3) and copper (0-20 mM CuSO4) on the extraction of gold and silver over 8 h. was investigated. Increasing the concentration of thiosulphate and ammonia substantially improved the rate and extent of gold leaching while high copper levels produced an adverse effect particularly at low concentration of thiosulphate (i.e. 0.1 M). Complete extraction of gold was achieved under suitable conditions. In contrast to gold, silver extractions remained consistently at low levels (i.e. 28%). These findings demonstrated that thiosulphate leaching could be used to achieve acceptable levels of gold extraction from the copper-bearing pyritic gold concentrate."

Jan 1, 2018

By Elisabeth Schmidt

The conventional Canadian oil sand processing, the Clark Rowe process, is associated with many risks for the environment and high energy costs. To recover the bitumen from the oil sand (tar sand), large quantities of water have to be heated up and mixed with caustic soda and the oil sand. During this process, tailings with stabilized clay colloids are formed and dumped in tailings ponds. To avoid these disadvantages, a new, non-aqueous extraction process is to be established. Organic solvents are used instead of water and caustic soda to mobilize the bitumen from the sand-clay mixture. Pressure filtration, washing and steam pressure filtration are part of the new concept. A mixture of organic solvents and the oil sand is first pressure filtrated in a nutsch filter until a saturation level of one is obtained. After the cake has been formed, the filter cake is washed with organic solvent to flush the bitumen loaded solvent out of the cake. The following steam pressure filtration mechanically and thermally removes the remaining volatile components of the solvents from the filter cake. The filtrates from the pressure filtration, the washing phase and partly from steam pressure filtration are subsequently thermally treated to recover the organic solvents and obtain a higher bitumen concentration in the mixture. This mixture is then lead to an upgrader to win synthetic crude oil (SCO). The recovery of bitumen in the conventional hot water extraction process based on the Clark Rowe process can, in highly optimized plants, achieve between 88 and 92 %. Variation of oil sand properties leads to an actual range of between 80 and 90 % of bitumen recovery. With the alternative process based on organic solvents, the bitumen recovery exceeds the recovery of the conventional process by up to 16 percentage points. The composition of the two organic solvents in the first step of forming a suspension with the oil sand is important. The aromatic component is crucial for liberating and solving the asphaltenes, which tend to flocculate. The order of the two components of organic solvents is also important in the washing step. The paraffinic component is essential to achieve successful steam pressure filtration with respect to fast steam breakthrough and a filter cake free from organic compounds, as a result of its lower boiling point. Keywords: oil sand, filtration, organic solvents, pressure filtration, steam pressure filtration, filter cake washing

Sep 1, 2012

By M. Surracco, M. C. Tilocca

"Mineral comminution is often a costly process which also requires high level of energy. In the course of the studies carried out by the researchers of the Department of Civil-Environmental Engineering and Architecture at the University of Cagliari, aiming at the optimization of the reduction processes, it has been experimented, among of others, the effects of high-speed water jets on minerals grinding. As far as coal is concerned, some of the solutions initially adopted are presented in this paper, which essentially relied on the water jet power only, with secondary use of mechanical actions, to reach the most modern solutions that envisage the use of mechanical energy, normally used in traditional grinding machines, in synergy with hydraulic energy transferred by water jet.INTRODUCTION Mineral comminution can be rather expensive and demand a high-energy consumption, especially for fine sizes (Austin, 1979). Further interesting perspectives in this area may be offered by comminution means aided by high pressure water jets (Ciccu 2007), whose crushing potential is currently used for several operations such as cutting different materials, rock digging and industrial cleaning. The crushing action of water jets may induce a traction stress in materials where substances of a mineral nature, especially if characterised by permeable porosity, oppose a minor resistance (Griffith, 1920). The first solutions to this purpose essentially relied on the sole energy of water jets, with a secondary use of mechanical actions (Ciccu, 1993). Results were encouraging, despite the high values of specific energy for the low capacity of treatment. However, due to the difficulty in making the techniques mainly based on hydraulic energy practically applicable to solids comminution a solution was experimented, with some interesting results, consisting in the combination of mechanical energy, normally used in traditional grinding devices, with hydraulic energy transferred through water jets, in a synergic relationship (Ciccu, 1998; Tilocca, 2016)."

Jan 1, 2018

By Cristiane Ericksson, Ananda Scomazzon, Irineu Schadach, Juliano Tonezer

The state of Rio Grande do Sul, southern Brazil, appears on the national and international scene as an important producer of precious stones and the main gems are amethyst, citrine and agate. However, despite the immense potential of this mining activity, the extraction and processing of gemstones in Brazil present critical issues of infrastructure, which prevents a better development of these activities. In general, local production is still concentrated in small rudimentary mining. Recently some of these mines have begun to regularize their activities, in conjunction with the National Department of Mining Control. Besides these problems best practices for extraction activities and environmental control are not usually observed. Another problem which is placed in a critical way is the absence of aggregate value for the products of small mines. In this situation, the miners have great problems to obtain access to technology and adequate infrastructure. In most cases miners need negotiate their gems without processing, transferring most of the profit to intermediate traders. These results in heavy losses for the producer and for the communities involved. Given this scenario, the present study aimed at defining systems technically and operationally viable to be implemented in these communities in order to add value to gemstones. In this study best practices to thermochemical coloring systems, analysis of effect of raw materials and operating parameters on the final color of the gem were analyzed with attention.

Jan 1, 2014

By G. B. Abaka-Wood

"The versatility of froth flotation has made it vital in the beneficiation of rare earth elements (REE) minerals from either high or low grade ores of complex mineralogy. There has been a significant increase in the tonnage of rich iron oxide tailings obtained from extraction of primary commodities such as copper and gold in Australia, which have been identified to have very low grade rare earth oxides (REO) (= 1%). There is a vast knowledge gap in the upgrade of REO from such tailings. The aim of this research is to investigate the feasibility of the use of fatty acids for the upgrading of REO from selected iron-oxide rich tailings. Two forms of fatty acid collectors (oleic acid and sodium oleate) were employed in this investigation. Bench scale flotation tests were carried out using a Denver D-12 cell.The effects of pulp pH, fatty acid dosage, particle size distribution (-150 +75 µm, -75 +38 µm and -38 µm) and conventional depressants (sodium silicate and starch) dosage on flotation recovery of REO were investigated. A comparison of the flotation results indicated that sodium oleate was the more efficient fatty acid for REO flotation at all the pulp pH investigated. The flotation performance is demonstrated to be particle size-dependent. The results on the effect of depressants dosage indicated that both sodium silicate and starch were unselective in reducing the recovery of hematite (Fe2O3) and quartz (SiO2) with corresponding decrease in REO recovery. Generally, Fe2O3 and SiO2 formed substantial contents of the flotation concentrates obtained, both in the absence and presence of depressants, which indicates liberation is a major challenge in achieving selective REO upgrade and recovery.The flotation tests carried out on the iron-oxide rich tailings suggest the possibility of REO upgrade using fatty acids, although particle size distribution and minerals liberation are key limiting factors in achieving selective REO upgrade and recovery."

Jan 1, 2018

By Rasool Hejazi

The feed to Chadurmalu iron ore concentrator plant is a mixture of magnetite and haematite iron ore with a Fe/FeO ratio of about 8. The feed to plant, after grinding via wet SAG mill, is pre-separated by wet low intensity magnetic separator. Magnetic product is conducted to magnetite processing circuit for producing magnetite concentrate, and nonmagnetic product is directed to haematite processing circuit. Due to surface oxidization of magnetite particles and a decrease in magnetic attraction properties, significant amount of these particles are misled to tailing which results in decreasing the efficiency of haematite processing circuit. This problem can be remedied by using magnetic drum separator with more magnetic intensity and/or gradient. In this paper, the replacement of LIMS separators with wet medium intensity magnetic separators with a field intensity of 3800 gauss on drum surface (MIMS) have been suggested and considered as the most suitable solution to prevent the loss of magnetite particles. The results of carried out investigations with replacement of drum separators in industrial scale, showed that utilizing MIMS in magnetite processing circuit resulted in increasing final concentrate weight recovery on average by 2.59%, without any adverse effect on the concentrate quality; decreasing the magnetite content in the feed to high gradient magnetic separator (HGMS) by about 3.5%; decreasing the feed to floatation part by about 7% and consequently decreasing consumption of chemical reagents; increasing Fe/FeO ratio of the feed to plant. Keywords: iron ore, medium intensity magnetic separator, haematite, Chadurmalu

Sep 1, 2012

By Kevin Galvin, Simon Iveson

Fine particles are the most valuable because they are the most liberated. However, they are also the most expensive and difficult to recover and concentrate. The Reflux Classifier is a novel invention that combines many of the virtues of existing fine particle separation technologies in a way that provides profound synergies. Multiple parallel narrow channels create a laminar-shear separation zone. The laminar flow provides a well-defined velocity gradient that exposes particles on the wall to a conveying velocity that is approximately proportional to their size, thus reducing the dependence of elutriation velocity on particle size. The high shear rate in these channels generates a hydrodynamic lift force that selectively lifts low-density particles off the channel wall and thus causes them to be preferentially conveyed out in the overflow. Particles that are not elutriated slide back down into the mixing reflux zone beneath the inclined channels which gives them multiple opportunities to re-enter the channels. The resultant suspension of both coarse and fine high-density particles in the fluidized bed zone at the base of the unit generates a strong autogenous dense medium that helps to direct large low-density particles back up to the overflow. The fluidization water also simultaneously de-slimes the high density underflow product. When placed in a centrifuge, the benefits of these features multiply with the improvements in capacity and selectivity that arise from high G-forces. When inverted, these features can be used to perform flotation well beyond the conventional flooding limit. Hence this invention platform has the potential to dramatically improve both gravity and flotation separation performance across the minerals processing industry.

Jan 1, 2014

By Aidan Giblett, Karen McCaffery, Robert Dunne

"A worldwide decline in competency levels of practicing metallurgists over recent decades has become clearly evident and is a common topic of discussion among senior practitioners and professional associations. The associated impacts on the industry are material and include operational inefficiencies, missed optimisation opportunities and suboptimal new plant designs. There are many contributing factors to this condition. Decrease in competency is particularly evident both in regions where imbalance between supply and demand has led to a general reduction in experience levels for comparable roles over time and in emerging regions where a rapid rise in demand for practitioners has occurred in conjunction with rapid economic development and industrialization. The context, depth and breadth of education curricula and levels vary with location such that solutions to the technical competency dilemma may need to be developed specifically for each region with these influences in mind. Delivering, demonstrating and maintaining competencies are a critical requirement of undergraduate training and ongoing professional development. Other factors such as generational and cultural characteristics and expectations, political influences, role requirements and employment reward and recognition systems all play a critical role in determining if core competencies can be effectively developed, applied and subsequently maintained. This paper reviews factors impacting and some common approaches to competency development. The authors’ experiences in the management of professional development efforts within the global industry are reviewed and a blueprint proposed to address industry requirements in this area."

Jan 1, 2014