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By Jian Zhang, Yongfu Yu, Fuguang Zhang, Liping Che

There is one large-scaled iron ore deposit in Inner Mongolia of China, but it is very complex which includes about 170 types of minerals and 71 elements. The hematite, magnetite are mainly iron ores. It is difficult that the iron mineral can be separated efficiently by common dressing methods due to the complexity, and the iron concentrates in the mineral processing factory contains many foreign substance such as K, Na and Si so that the process in iron mill is influenced because of the foreign substance, so it is vital reducing the foreign substance.

Jan 1, 2003

By Chen Shuwen, Yao Zhihua

In the process of thickening dewatering_the motion state of two- phase flow in a thickener has a very great influence on thickening efficiency. The investigation was made using copper mill tailings. In this investigation the authors explored the formation conditions and motion range of density current in the thickening process by model experiments, and analyzed the influence of density current on thickening efficiency. The results have shown that the formation of density current has relations with the structure parameters of a thickener and thickening process. The density current and its forming location affect thickener’s working efficiency. The author measured the motion state of two- phase flow in a 53-m dial. thickener for copper mill tailings under its operation conditions and analyzed the density distribution and motion state of two-phase flow in the thickener. The results obtained by the industry tests have shown that the motion state of two- phase flow in the thickener can be greatly improved by modification of its structure, achieving a great improvement in its thickening efficiency. It is concluded that, a thickener’s working efficiency depends on the formation and motion range of density current in it, which is of great importance to designing and establishment of thickener’s working parameters.

Jan 1, 2003

By Daniela Venter, Stephen Chryssoulis, Ken Stowe

"A sampling campaign was conducted at Kemess in order to identify and assess the chemical and physical factors, which control free gold flotation kinetics in the rougher and cleaner circuits. The rationale behind this approach was that accurate knowledge of the parameters affecting free gold flotation kinetics, can be used to determine how to accelerate free gold flotation. Collected samples were composites of 5-6 cuts over a four-hour period, at steady plant conditions.In the rougher circuit, coarser equidimensional gold particles floated ahead of the finer grained and the flaky gold. Sulphur followed by molybdenum and to a lesser extent silver enhanced gold flotation kinetics, while hydroxyl followed by carbonate ions induced depression."

Jan 1, 2003

By John Ralston, Jonas Addai-Mensah, Patience Mpofu

The flocculation and dewatering behaviour of kaolinite (non swelling) and smectite (swelling) clay dispersions has been investigated using hydrolysable metal ions Mn(II) and Ca(II) and anionic polyacrylamide-acrylate copolymer (PAM) at pH 7.5 and 10.5. A pH-dependent, specific metal ion adsorption behaviour, accompanied by a marked reduction in particle zeta potential and slurry shear yield stress, was observed to have a profound influence on the colloid stability of both types of clays. Due to the differences in the cation exchange capacity, the smectite clay dispersion required a higher amount of metal ions than kaolinite dispersion to produce similar effects. The adsorption density of the anionic PAM at the negatively charged clay particle surfaces correlated well with metal ion hydrolysis and adsorption behaviour, all of which had a strong effect on slurry settling rate and extent of consolidation. At pH 7.5 where Mn(II) ions hydrolyse, metal ion and flocculant adsorption densities were both greater in the presence of Mn(II) than Ca(II) ions. At pH 10.5, however, where Ca(II) ions begins to hydrolyse, higher adsorption densities were observed for Ca(II) ions in comparison with Mn(II) ions, as the latter hydrolysed completely and precipitated. The metal ion mediated flocculant adsorption led to improved hydrogen bond driven particle bridging and facilitated charge neutralisation flocculation mechanisms which significantly enhanced the dewaterability of both clay dispersions.

Jan 1, 2003

By Patrick A. Turner, Timothy J. Olson, Abraham J. Schutte, Roman van Ommen

"The use of classifying devices in grinding circuits dates back to the early 1900’s when classifiers were installed to close ball mills. The search for ways to further improve grinding circuits led to the use of hydrocyclones in place of mechanical classifiers in South Africa in the early 1950’s. Today Hydrocyclones are considered as the best classifying devices to close grinding circuits. After 50 years of development the hydrocyclone has changed significantly when compared to the designs of the early days, but the focus to circuit optimization must be expanded to an understanding of the integral system consisting of mill, cyclone feed pump and cyclone.The key to good cyclone circuit design and operation in primary grinding circuits will be discussed including individual cyclone design features such as cone angle or materials of construction, as well as orientation and manifold configuration.Cyclone performance issues as well as maintenance considerations will be detailed in an effort to achieve consistent cyclone operation with minimal coarse solids in the overflow. “The importance of constant cyclone feed conditions is unquestioned today. The challenge of Cyclone sizing is a large number of not fully known variables prior to startup. The most significant unknown variable is slurry viscosity. Because of this, engineers often specify a conservative cyclone system that produces a finer than required separation. However, this approach often leads to higher circulating loads and a higher overflow density in order to produce the required separation. The higher cyclone overflow density results in a less efficient cyclone separation. The average concentrator can pick up 2-4% finer overall grind by having a more aggressive cyclone operation.”"

Jan 1, 2003

By Harri J. Lehto, Marja I. Oja

"The purpose of grinding circuits is to produce a particle size distribution that has as much as possible the wanted particle size class. In practise, however, the production of the wanted size class is not at all as simple as it sounds. In the case of industrial minerals for example the end user may give very tight specifications for the particle size distribution and for the chemical composition of the product. This leads in many cases to a very demanding grinding process, if we want to reach and maintain these specifications. In other words, the required size distribution is not necessary the best possible for the chemical composition.Screen models aim to predict the size distribution and flow of the products when a feed size distribution, feed tonnage, and grade efficiency curve are known. The approach used in this study was to select the most suitable empirical model for classification. Suitability of the existing models has been evaluated and accuracy compared. The tests showed that best grade efficiency model was the Rosin-Rammler model.The performance of a screen was evaluated in order to minimize the amount of fine material in the screen overflow. The experiments were carried out using Derrick single-deck screen, first alone with recycling and then in the closed circuit with a rod mill using two different scales. The separate screen tests showed the expected behaviour of the grade efficiency curves. In the pilot tests the Leonard screen efficiencies stayed almost constant. This suggests that the screen works better in a milling circuit. However the loading of the screen turned the product of the mill coarser that helped screening. The grade efficiencies obtained from the pilot tests had the same general shape. The regression analysis of the pilot test runs did not give an acceptable correlation for the parameters. This suggests that pilot tests cannot be directly used to scale or to optimise industrial milling circuits. However they can be used to predict the trends of behaviour of an industrial circuit."

Jan 1, 2003

By Sun Chuanyao, Jia Muxin

Generally, if the bond valence (BV) between metal ion and oxygen of the mineral is greater than 0.8, only surface species –Me-O-H or –Me-O exposures on the mineral interface, if the BV is between 0.2-0.8, the metal ion exposures on the interface, and if the BV is less than 0.2 the metal ion dissolves into water. The PZCs of oxide minerals and island silicate minerals are determined by the bond valence of the bond in the mineral crystals, the higher the bond valence the lower the PZC of the mineral. So the PZC sequence of Al2SiO5 minerals is kyanite> andalusite> sillimanite. The general rule for framework silicate minerals is as: The higher the Al content, the lower the PZC of the mineral, when the ratio of Al to Si in the tetrahedron skeleton is below 1:3. The higher the Al content, the higher the PZC of the mineral, when the ratio of Al to Si in the skeleton is between 1:3 and 1:1. The general rule for layer silicate minerals is summarized as: the three-layer silicate minerals have much lower PZCs than that of the two-layer silicate minerals. The threelayer silicate mineral with the octahedron layer occupied by lower charged cations has lower PZC than that of the three-layer silicate mineral with the octahedron layer occupied by higher charged cations. The twolayer silicate mineral with the octahedron layer occupied by lower charged cations has higher PZC than that of the two-layer silicate mineral with the octahedron layer occupied by higher charged cations. The layer silicate mineral with Al substitution in the tetrahedron layer has lower PZC than that of the layer silicate mineral without Al substitution in the tetrahedron layer. Such pyroxene minerals whose M1 is occupied by a trivalence cation and the M2 is occupied by a monovalence cation has lower PZCs than those both M1 and M2 are all occupied by bivalence cations. Such hornblende minerals whose M2 is occupied by a trivalence cation and the M4 is occupied by a monovalence cation has lower PZCs than those both M2 and M4 are all occupied by bivalence cations. There is no Si4+ or 4 coordinated Al3+ exposures on the surface of framework silicate minerals, the metal ions of three layer or chain silicate minerals are compact between tetrahedron layersor chains, they hinder the metal ions to interact with oleate acid radical, the metal ion octahedron layer exposures on the surface of a two layer silicate mineral, but the the oleate acid radical can not attach to a metal ion by replacing a –OH- that connects three metal cations in the same time, So the floatability of such silicate mineral is bad. The metal octahedron chain style of an island silicate mineral affects it floatability, the mineral exposures octahedron chain metals with two dangling bonds in two directions floats better than the mineral exposures octahedron chain metals with two dangling bonds in one direction.

Jan 1, 2003

By Roberto C. G. Oliveira, Scott C. Brown, Brij M. Moudgil

"The wettability or surface energy of particle surfaces dictates a number of multiphase ensemble interactions that have a significant impact in mineral processing. Dispersion, bulk powder handling and flotation are just a few of the processes that are largely influenced by the degree of hydrophillicity or hydrophobicity on particulate surfaces. Because of the importance of surface wettability, a number of simple, precise and accurate techniques for accessing surface wettability or contact angle on macroscopic flat surfaces have been developed. However, these techniques cannot be directly applied to the particulate surfaces that are often in query. Though a number of techniques are available for accessing the wettability of particulate surfaces, these methods are either relative, application specific or prohibitively tedious. In the present study, key features of existing techniques are combined to formulate an improved method to delineate particle wettability that is simple, versatile and capable of providing reproducible measurements in an industrial environment.Through the use of an inert adhesive and an inert macroscopic surface as a support, it is illustrated that precise measurements of particle wettability are obtainable under suboptimal or ‘shop floor’ conditions. The measurement of the maximum external meniscus height formed between a test liquid and a particlecoated rod is employed to estimate phenomenological contact angles on particles ranging form a few nanometers to several hundred microns in size."

Jan 1, 2003

By Kal Sastry, Anshuman Prasad

"Agglomeration of fine iron ore concentrates is carried out in two steps:Balling, which refers to the production of green pellets by tumbling moist fines powders in drums, discs, or cones, and Induration, which refers to the subsequent thermal treatment of the green pellets in straight grate or grate-kiln systems.This paper addresses computer simulation of balling or green pelletization step. The process of agglomeration from a mechanistic point of view can be described as the transformation of moist feed to well-formed species or pellets. The moist feed is composed of fines of infinitesimal size while well-formed species are of finite size and number. These well-formed species undergo changes in their size and number through different mechanisms of agglomerate formation and growth. Nucleation, coalescence and layering are the three main mechanisms that describe the formation and growth of granules during an agglomeration process. A population balance equation enables quantitative description of the evolution of agglomerate size distribution due to the occurrence of each of the mechanisms.A numerical solution for the population balance model is necessary and is obtained by the use of a sizediscretization approach. The numerical solutions provide a suitable basis for the analysis of the agglomeration process. Also a coalescence kernel has been introduced that is capable of describing the simultaneous occurrence of nucleation, coalescence and layering mechanisms. The effect of feed moisture has been described using a moisture factor with an exponential functional dependence on the moisture content. The effect of the feed to seed ratio is modelled by the introduction of a crowding factor. It was assumed that only the feed particles which are much more in number experience a crowding or restricted in space interactions effect. A computer simulation program has been developed with MATLAB as the simulation language."

Jan 1, 2003

By Dominic Howarth, Diana Drinkwater, Don McKee

At a time when the mining and minerals industry across the world is undergoing unprecedented change, the very fabric of the tertiary education system which is the principal source of trained professionals to the industry is in decline in many countries. The change sweeping the industry is globalisation as evidenced by the emergence of a relatively small number of increasingly dominant corporations with operations in most of the major mining countries. The education sector is struggling to provide sufficient graduates as the viability of small mining schools declines. That is only part of the problem as the global operating industry is increasingly seeking graduates who are comfortable working in different countries and cultures. One obvious response to the industry needs and developments is for the education sector to consider how it can best respond to the global opportunities. This paper presents the case for a global education network which is based on a network of international thinking Universities and which makes use of the latest in educational thinking and technologies to provide a quality education and in the process produce graduates fitted for international careers.

Jan 1, 2003

By James Y. Oldshue

"Very seldom is it possible when contacting a gas with a slurry to measure the dissolved gas concentration in the slurry, and even were it possible, seldom are equilibrium data available with a suitable Henry’s law constant.In general, by assuming a reasonable value for the dissolved gas concentration in the slurry and a corresponding equilibrium gas partial pressure P*, Kga values can be calculated for the pilot plant and scaled up. Then, with the same P* value at various reaction conditions, a mixer can be designed which is quite satisfactory, having a reasonable design factor for full-scale performance.We will take as an example a slurry of a known solids composition and use a continuous 4 tank system. By assuming a percentage saturation of the dissolved gas in the first tank, the dissolved gas concentration can be obtained in the other three tanks. It usually is possible to measure the off-gas composition in each of the 4 tanks. If the top of the tanks is connected in the form of a multi-compartmented horizontal autoclave, then a modified top off-gas composition in each compartment must be used."

Jan 1, 2003

By G. Demi, G. Belardi, N. Shehu, S. Cico

The physico-chemical interaction between minerals such as olivine, chromite and serpentine and the ions most commonly present in solution, like Ca and Mg and flotation reagents such as EDTA and oleic acid was investigated. The study was conducted via release tests, electrophoretic measurements and microflotation of selected minerals coming from the Kukes deposit (Albania).

Jan 1, 2003

By Leon Lorenzen, Rodrick M. Lamya

"Leaching behaviour of nickel – copper matte in a CuSO4–H2SO4 solution during the repulping stage of a matte pressure leaching process has been studied. The base metal recovery process investigated in this study consists of a matte repulping stage prior to a series of pressure leach stages. The repulping stage is essentially an atmospheric leach stage in which the Ni-Cu matte, containing small amounts of cobalt and iron, is leached in copper spent electrolyte from the tankhouse, resulting in dissolution of the nickel with simultaneous precipitation of almost all the copper.Effects of various process parameters on the kinetics and extent of the leaching reactions, as well as on the cementation of copper from the solution have been quantified. The parameters investigated were temperature, particle size, pulp density, stirring speed, residence time, initial copper concentration and initial acid concentration.Leaching characteristics of the preleached matte during the subsequent pressure leach operation has also been studied. The effects of variations in the conditions in the repulping stage on the kinetics and degree of base metal dissolution during the pressure leach stage have been investigated. Any transformations that occur in the mineral phases of the matte during the leaching process have been studied, and a leaching mechanism proposed."

Jan 1, 2003

By Paul W. Weiblen, Louis J. Cabri, Rolando Lastra

"Preliminary tests were done to determine whether comminution by electric-pulse disaggregation, or EPD (cf. Rudashevsky et al; 1995), was more effective than using conventional crushing for Merensky Reef ore. A hand sample of the Merensky Reef was sawn in two: then one sub-sample was comminuted to – 2 mm using E-PD at the University of Minnesota, and the other sub-sample was crushed to –2 mm using a conventional jaw crusher at CANMET.The products of the electric-pulse disaggregation and jaw crusher were fractionated by sieving and by a separation using a heavy liquid with a specific gravity of 3.3, because the proportion of platinum-group minerals (PGM) and sulphides to silicate minerals is very low. Thus, four mineral separates were produced: –2000 + 833 µm, -833 +208 µm, -208-µm float and -208-µm sink. All the mineral separates were studied by image analysis (Lastra et al; 1998). The main objective was to determine the liberation of gangue (silicate minerals), chromite, pyrrhotite, chalcopyrite, pentlandite and PGM. In the case of the PGM, a specific image analysis program was written to search and measure these minerals."

Jan 1, 2003

By L. Burdukova

In flotation, depressants are used to reduce the amount of gangue that reports to the concentrate and hence increase the selectivity of the flotation process. At the University of Cape Town extensive batch flotation tests are carried out to evaluate industrial depressants and standard procedures have been developed over the years. This study was conducted in order to develop an improved method for comparing depressants using machine vision as an aid. The modified method of batch flotation involved a test with prolonged intervals between scraping to allow more time for the froth to build up and mature.

Jan 1, 2003

By M. T. Spyridopolous, S. J. Neethling

"There has been a significant research interest in the stability of single thin films, including prediction of their failure based on disjoining pressure and film thickness experiments and DLVO theory. It is, however, notoriously difficult to correlate information on the failure of a single thin film with measurements of foam stability. This is particularly true for the prediction of dynamic foam stability indicators, such as equilibrium froth height and surface bubble size.An alternative experimental approach to studying single thin film failure for predicting foam stability is to measure directly the coalescence probability between two approaching bubbles in a surfactant solution. These experiments can be performed under different chemical and physical conditions by using a micromanipulator that allows variation of bubble size, surfactant concentration, approach velocity and stationary position. The interface radius of curvature, the time to coalescence and the film area between the bubbles can be measured directly using image analysis.In a foam, the force exerted on the thin film separating two bubbles depends on the local radius of curvature of the Plateau borders and vertices, which depends in turn on the local liquid content. Results from different bubble sizes in the micromanipulator therefore translate into regions of different liquid content in the foam. Small bubbles, having a high radius of curvature correspond to the low-liquid content (Polyhederschaum) region higher in the foam, and large bubbles to the wetter (Kugelschaum) region closer to the liquid-foam interface. Experiments with different holding distances between the bubbles correspond to differences in bubble size in the foam, as the size of the film between the bubbles varies."

Jan 1, 2003

By Chris A. Fleming

"Interest in the recovery of cyanide from gold and silver plant tailings has heightened in recent years. This interest has been spurred by several factors:Increasingly stringent regulations throughout the gold producing world, governing discharge limits for free and total cyanide to tailings ponds and the environment.The increasing cost of active chemical treatment versus passive (natural degradation) treatment of tailing, to bring them in line with environmental regulations.The worldwide trend to processing of more complex gold ore bodies, which is usually accompanied by higher levels of cyanide consumptions and greater concentrations of cyanide (particularly the copper cyanide complex) in tailings.The growing negative perception of the general public for the gold mining industry, due to several highly publicized cyanide spills in recent years (breaches of tailings dams, accidents involving trucks carrying cyanide to gold plants, etc.).The ability to recover cyanide from gold plant tailings has been known almost as long as the cyanidation process has been practiced, but there has been little incentive to process tailings in this way in the past. With the development of technologies that make it possible to recover and recycle free or complexed cyanide directly from gold plant slurry tailings, which indicates, on paper at least, the potential for significant cost savings compared to cyanide destruction, coupled with the introduction of legislation to seriously limit the discharge of cyanide to the environment in most gold-producing regions of the world, many companies are evaluating the cyanide-recovery alternative."

Jan 1, 2003

By Jeremy Bosman, Niel Lourens

"Cyclones are used in four main applications in primary wet heavy mineral processing plants i.e. upfront desliming, densifying, and concentrate stacking and tails deposition.UPFRONT DESLIMINGMany heavy mineral ore bodies are associated with high slimes varying from 15 to 60%. The increased viscosities arising from the slimes impact negatively on heavy mineral recovery in the spiral plant. Recoveries can be reduced by up to 10%. Cyclones have proven to be able to remove slime efficiently with acceptable loss of valuable heavy mineral in the overflow. For low slime applications, typically below 25%, it is possible to achieve the desired results using a single stage of cyclones, whilst for higher slimes, two stages of cyclones are required. The overflow of the primary stage is retreated through a second stage to minimize heavy mineral loss."

Jan 1, 2003

By Rebecca Hope, Derick Moolman, Frikkie Malan

"Despite the lip service that has been paid to pro-active plant maintenance processes over recent years, a significant portion of maintenance in industry is still reactive. The business driving force to prevent expensive production opportunity costs arising from “break-down maintenance” is obvious. Various benefits can be derived from successfully deploying remote equipment diagnosis technology and associated business processes.From an end-client’s viewpoint these include the ability to predict and take actions to prevent equipment breakdowns, increasing the lifetime of equipment by responding to appropriate operating instructions and therefore improving the return on capital expenditure. Better planning and scheduling of maintenance priorities and resources with performance measures like an Equipment Health Index are also possible. The knowledge that a qualified supplier engineer is constantly in touch with the operating conditions of their equipment, albeit remotely, is more than a comfort, and can be translated into quantifiable cost savings and improved supplier service levels."

Jan 1, 2003

By Jochen Petersen, Harro von Blottnitz

"The landfill disposal of slags is common practice in the metallurgical industry. Chromium may be a minor constituent in many cases. It is present mostly in the form of chromites, which are considered environmentally benign and hence safe for disposal. Wastewaters from metal finishing operations are most commonly treated by reduction and precipitation of dissolved metals, including chromium, by lime addition, and subsequent landfill disposal of the resulting sludge. The metals contained in such sludges are mostly in the form of hydroxides, and as such considered environmentally stable.Thermodynamically, trivalent chromium, which is the predominant form in these waste materials, can be oxidised to the hexavalent form by atmospheric oxygen. Detailed research work on both slags and sludges has shown that a gradual emergence of hexavalent chromium can indeed be observed. The mechanism is governed by close physical contact between chromium oxide (or hydroxide) phases on the one side and calcium oxide (or hydroxide), which is present as flux in slags and residual lime in sludges, on the other. If oxygen can migrate to the points of contact, gradual formation of calcium chromate ensues.Hexavalent chromium is associated with high environmental toxicity, and hence undesirable in landfilled materials. Moisture migrating through landfill deposits can mobilise the highly soluble chromates and thus potentially transport them into natural waterways. Such gradual release from stainless steel and ferrochromium slag deposits has been demonstrated in a column experiment."

Jan 1, 2003