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Carbothermal Reduction of Ilmenite Concentrates and Synthetic Rutile in Different Gas Atmospheres

Sep 13, 2010

By Q Zhou, Y Ma, J Zhu, R L. Frost, P Yuan

A series of organoclays with different surfactant arrangements were prepared by ion exchange. The resulting organoclays were investigated using a combination of characterisation techniques, including X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), thermogravimetric measurement (TG) and N2 adsorption-desorption. In the present study, the pores within the organoclays were discussed on the basis of the micro- structural parameters, including BET-N2 surface area, pore volume, pore size, surfactant loading and distribution. The results show that both BET-N2 surface area and pore volume decrease from low to high packing density of the surfactant as the average pore size increases. Two basic organoclay models were proposed for hexadecyltrimethyl- ammonium bromide (HDTMAB) modified montmorillonites: 1. the surfactant mainly occupied the clay interlayer, and2. both the clay interlayer space and external surface were modified by surfactant. This study demonstrates that the pore structure of the resulting organoclays has a significant influence on the sorption efficiency and mechanism of p-nitrophenol onto the organoclays.

Jan 1, 2008

Dilution in underground coal operations can be underestimated by up to five times during feasibility studies, with disastrous economic consequences. Every one per cent of stone waste introduced can reduce an in situ specific energy of 25 MJ/kg by some 0.25 MJ/kg and increases the abrasiveness of the run-of-mine coal. Where a wash plant is not in place, penalties imposed for not meeting contractual specifications alone can amount to some $A 1 million per year. This paper presents a method for monitoring, reporting and ultimately controlling dilution in an underground coal mining operation and presents the dilution trends from a continuous miner/longwall mine over an eight year period. The overall dilution level for the mine can be back-calculated by comparing the run-of-mine coal quality to the predicted in situ, undiluted quality. However, this will not identify the actual contaminant types, areas of the mine responsible for the dilution and the reasons for the dilution. This additional information is essential for controlling dilution to acceptable levels. Quality and horizon control using existing sampling information is generally only adequate for longer-term control purposes, and is not suitable for monitoring mining-induced dilution. The cost of close-spaced surface drilling to collect the information necessary for short-term control is prohibitive, particularly for deeper mines. However, much of this data can be collected through underground channel sampling and horizon control measurements taken during continuous miner development and longwall extraction. The mine runs the risk of not meeting contractual quality specifications and of increased equipment wear if this additional information is not available and the sources of dilution cannot be controlled. The information can also be used to plan longwall extraction heights on a short-term scale with resulting improvements in productivity.

Jan 1, 2003

By Rao A. B, Rao V. D

Northeast of Brazil is situated in the polygon of drought. It covers some very important states like Bahia,Pernam- buco, Paraiba, Rio Grande do Norte, Cea- ra and Piaui , which have a potential for mineral production. Of them the main contributions that comes from Rio Grande do Nor to , Ceara and Paraiba are the scheelite and im portant quantities of granitic pegmatite mine- rals like tantalite-columbites, micas, beryls, precious stones, lithium minerals etc. On the other hand flourishing mineral economy in gold, tin, emeralds, chromium, lead, apatite is most- ly from Bahia; and potassium, salts, and petro- leum are from Sergipe, Alagoas and Bahia res; pectively. The most interesting aspect coninues to be the nucleus of the drought zone constituted of the Rio Grande do Norte, Paraiba and Ceara sta- tes.The first two authors have worked for twel- ve years in the region and have dedicated atten tion and time to two systems, namely skarns and granitic pegmatites. Their mineralogy,petrogra- phy, geochemistry, origin and economy is being worked upon from time to time to accompany the progress that is being achieved both in the sec tors of geology and economy. Besides, during the field campaigns, evidences have been sought to find the best guide horizons for mineralisa- tion and options for the location of target areas and prospection methods for scheelite, tantalites and other pegmatite minerals.

Jan 1, 1988

The Kalkadoon Granite is regarded as composite in character with at least two different phases. The older phase is considered older than the sediments of the Western Geosyncline, and the younger phase is considered younger than the sediments of the Western Geosyncline.Consequently, the older phase could be a time equivalent of the Ewen Granite, whereas the younger phase could not. An age of 1760 million years seems plausible for the older phase, and an age of 1540 millionyears seems appropriate for the younger phase.

Jan 1, 1967

Construction of Western Mining Corporation's nickel refinery at Kwinana, Western Australia, commenced in July, 1968. Production of 15,000 tons per annum of refined nickel metal will commence early in 1970, The plant will also produce approx- imately 150,000 tons of ammonium sulphate0 The ammonia leach process which was developed by Sherritt Gordon Mines Ltd., and has been in operation at their plant at Fort Saskatchewan, Alberta, Canada, for the past 15 years, will be used at Kwinana. The refinery will cost approximately 435 million, and will employ upwards of 250 people.

Jan 1, 1969

By R Dimitrakopoulos

Optimisation and mathematical formulations for open pit design and long-term production scheduling have been available since the 1960s. There are two main concerns in the application of existing mixed integer programming (MIP) models in open pit mines: a. the feasibility of generating both optimal solutions and practically mineable scheduling patterns and b. the inability to deal with in situ variability in orebodies and account for uncertainty. In dealing with these issues, a general open pit production scheduling method for multi-element deposits is presented and subsequently used to optimise the long-term production schedule in a nickel laterite deposit. The application shows the weaknesses of MIP formulations in terms of generating optimal solutions as well as practically feasible mining patterns. The application of the same formulation in the presence of in situ orebody variability and uncertainty uncovers a major reason for deviations of scheduled production from actual production, and outlines additional limits of traditional optimisation formulations as well as future needs.

Jan 1, 2003

By Jones

Extractive metallurgy in the mining industry in Western Australia has diversified and increased in the last 11 years. Before 1980, the industry mainly produced alumina, nickel, mineral sands and iron ore, with the gold industry restricted to five operating plants using Merrill-Crowe technology. In 1981 Carbon-in-pulp (C]P) plants were commissioned at Kambalda, Kalgoorlie and Meekatharra.Currently, the gold industry has some seventy CIP plants in operation, production of synthetic rutile has increased tenfold to 500 000 tpa, alumina production has doubled and production of copper, lead and zinc concentrates has begun. Other extractive metallurgy plants recover tin, niobium and tantalum, silicon, titanium dioxide and zirconia. Current proposals include vanadium, steel and rare earths.

Jan 1, 1992

By Forssberg KSE

Purification of GAsgruvan Limestone is carried out by anionic, cationic and cationic followed by anionic flotations in order to obtain a calcite concentrate that is acceptable to the paper industry. The results indicate that such a concentrate could be achieved by first carrying out the separation of siliceous gangue minerals by cationic flotation followed by the separation of carbonate during the anionic flotation. Stearylamine acetate (Flotigam SA) and a modified fatty acid (OMC 357) are found to be selective during cationic and anionic flotation, respectively. A final product containing 99.25 per cent calcite with a recovery of around 80 per cent is obtained. It is hoped that these results could be further improved by the follow-up process variable studies, in particular, the effect of reagent dosages and conditioning time at each stage of cationic and anionic flotation steps.

Jan 1, 1993

By J Szymanski, Y Hu

Excavation engineering involves complex processes for primary and secondary extraction of materials. The shovel excavators bear varying mechanical energy input and stress loading across the working bench during excavation. These varying mechanical energy input and stress loading effects cause significant wear and tear and fatigue failure in equipment components. These effects further result in unplanned downtimes, reduced efficiency and high production costs. In addition, the mechanical and electrical control systems must be operated in efficient profiles to generate maximum outputs and efficiency from these excavators. Efficient technologies are therefore required to solve these problems in order to reduce production costs and increase efficiency. In this paper, the authors develop a rigorous simulator for a hydraulic shovel in a surface mining environment. The finite element model is used to capture the stress profile within the shovel components during excavation, such as, the bucket, stick and boom assemblies. The profiles are classified into normal, critical and extreme ranges, with appropriate corrective measures to avoid extreme loading conditions. The loading capability of shovel excavators can be examined by assessing its structural strength against all possible maximum loads working on the equipment. The dynamic model is used to define efficient profiles of the critical structural components of hydraulic shovels during digging operation. This assessment is used to locate the maximum possible loads and the critical sections of the structures. The method presented in this paper forms the basis for developing comprehensive simulator models for efficient shovel operations in constrained mining environments.

Jan 1, 2003

The overall mineral assemblage of the Broken Hill orebody is similar to that of a skarn. However unlike the classical skarns it does not represent contact metamorphism of pre-existing limestone beds. It is a stratiform accumulation of exhalative-sedimentary silica, sulphides, (Ca, Fe, Mn) silicates and carbonates, fluoride and phosphate that has later undergone regional metamorphism. The resulting development of coarse-grained quartz, sphalerite, galena, rhodonite, bustamite, mixed carbonates, fluorite, apatite and many minor phases has produced a sulphide-rich skarn- like mass that like many others of its kind, might best be referred to as a stratiform skarn. Recent investigations of occurrences of this type are showing that the incidence of concentrations of particular metamorphic minerals in and adjacent to such orebodies are closely related to bedding and to former sedimentary facies patterns. From this it appears that the mineral assemblages may be used to deduce not only the nature of the materials laid down in the beds, but also the physico-chemical conditions under which sedimentation took place. Several stratiform deposits, including Broken Hill, are used as examples to show that variations in these conditions may have a profound influence on the subsequent response of the rock to regional metamorphism and hence on the mineral assemblages that finally develop.

Jan 1, 1983

The interaction of flotation collectors with sulphide minerals takes place at the solid - solution interface. The electrochemistry of the processes which affect this interface are discussed. The interaction of xanthates with sulphides is an electrochemical process, xanthates being electro-oxidized to chemisorbed xanthate and dixanthogen. The role of oxygen is to provide a cathodic process to allow the anodic oxidation to occur. The hydrophobic condition of the mineral surface is brought about by the presence of the oxidized xanthate species. The action of reagents which can activate or depress the flotation of sulphides is discussed briefly.

Jan 1, 1980

By Fewings JH

When the mining and milling of 1100 Copper Orebody commenced, difficulties were experienced in producing a satisfactory grade of copper concentrate. The major concentrate contaminants were fine pyrite and silica, particularly in the minus 10 microns fraction. Studies of the 1100 Orebody showed that much of the fine grained pyrite and a proportion of the silica present in the ore contained carbonaceous matter in the form of complete or partial rims and as internal carbon films disseminated throughout grains. The hydrophobic surface property of the carbonaceous material resulted in an inherently flotable fine pyrite and silica fraction. The addition of a 60:40 mixture of nigrosine and dextrine, initially to a prefloat concentrate of the inherently flotable carbonaceous material and finally to'the total copper flotation feed, successfully controlled the flotation rates of the carbonaceous pyrite and silica. The objective of a 25 per cent Cu concentrate grade was then achieved without decreasing copper recovery.

Jan 1, 1970

By Roberts JD

The design and installation of a major on-line stores and purchasing system, with built-in maintenance reporting and plant register capabilities, needs more than just close attention to computer design details. When the system must be available almost 24 hours a day to a number of mine stores sites, and is used by a variety of mining staff including engineers and stores clerks, as well as by remote purchasing and office staff, then simplicity of use, availability, fast response times, and other human factors become vital. Critical aspects include easy to use screen design, involving a change from the traditional hierarchical menu system, and fallback and recovery to the last transaction. Business, people and systems objectives need to be established at the preliminary design stage, so that results can be measured and corrective action taken. The amount and type of user involvement and training, at all stages from initial design to systems tuning, has a major effect on people wanting to use the system. Active user participation in systems design, data definition and collection, and use of relevant training material is needed. Project management and design problems can arise in working with database oriented computer staff, and certain design features are found useful in ensuring a responsive, robust overall system.

Jan 1, 1983

By Moorrees C, Koh P. T L, Tsambourakis G

Examination of Ihe calcination and carbonic acid leaching behaviour of a number of Australian magnesites shows that there are substantial differences between the massively crystalline and the cryptocrystalline forms of magnesites. Crude magnesias formed by calcination of the massive variety of magnesite have considerably smaller surface area and show lower rates of reaction with carbonic acid when compared With those derived from cryptocrystalline magnesites. In order lO producc a rcactivc magncsia from massive magnesite, the calcination conditions must be carefully controlled over a narrow temperature range (eg 680-720°C). For the cryptocrystalline calcines, the temperature of formation has little effect on reactivity.The results confirm the general applicability of the calcination/carbonic acid leach process for producing magnesia from magnesitc. If a mixed crystalline/cryplocrystalline feed is to be processed, then processing conditions must be optimized in terms of the behaviour of the crystalline component of the feed.

Jan 1, 1985

By P J. Colbert, P D. Munro

OZ Minerals' Prominent Hill copper-gold concentrator in South Australia was built in 2008 with commercial production commencing in early 2009. In addition to recovery of valuable minerals, the flow sheet for this iron oxide-hosted copper-gold deposit has to address the issue of producing a good quality saleable copper concentrate by high selectivity against non-sulfide gangue. Detailed mineralogical studies integrated with the metallurgical test work highlighted that liberation of fluorine-bearing minerals and subsequent very efficient rejection in cleaner flotation was necessary to produce a commercial quality copper-gold concentrate. Bench scale laboratory metallurgical tests and mineralogical studies identified the need to regrind rougher concentrate to a P80 of 20 -25 microns or finer for adequate liberation of the fluorine-bearing minerals. Satisfactory separation of the fluorine-rich gangue material from the valuable copper sulfides requires highly efficient cleaner flotation. This is done by a combination of washed froth cleaning and conventional dilution cleaning. Proven equipment developed to meet similar taxing liberation and separation duties for the treatment of the refractory zinc-lead-silver ores of the Carpentaria-Mount Isa Mineral Province have been selected. The combination of Xstrata Technology's IsaMillÖ and Jameson Cell technologies addressed both the liberation and separation issues in the Prominent Hill concentrator. The energy efficient IsaMillÖ technology both regrinds the rougher concentrate while its inert grinding environment prevents contamination of mineral surfaces with 'debris' ensuring subsequent optimum flotation performance. Heading up the cleaner circuit with a 'scalping' Jameson Cell followed by conventional flotation equipment allows this section to take advantage of the Jameson Cell's high intensity flotation environment and froth washing capability to achieve maximum concentrate grade (at minimum fluorine levels) while maximising recovery through the use of conventional flotation machines. This paper looks at the development of the Prominent Hill flow sheet from the initial mineralogical and laboratory test work to the design, scale-up and early operation of the Prominent Hill regrind and cleaner flotation circuits. The mineralogically-based approach of domaining metallurgical ore types combined with the axiom of size-by-size mineral particle behaviour by liberation class gave a clear understanding of the liberation and separation issues involved in the processing of Prominent Hill ore. Technologies developed to meet much more onerous liberation and separation duties for the treatment of the refractory zinc-lead-silver ores of the Carpentaria-Mount Isa Mineral Province were successfully used to improve concentrate quality by rejecting non-sulfide gangue containing impurities. An IsaMillÖ and a Jameson Cell are included in the circuit for fine grinding and for additional concentrate cleaning. Plant performance since commissioning has justified the approach for metallurgical test work and equipment choices for the flotation circuit.

Jan 1, 2009

Although the flotation cell has been under continuous development over the past 80 years, an understanding of the precise roles of a cell in produc- ing the flotation result had evolved slowly. In fact, detailed studies of cell dynamics began only in the 1940s when flotation practice had almost reached the half-century mark. The earliest generalizations related cell capacity to power intensity (hp/vol- ume) (Rose, 1946), and specific operating features such as aeration and power ' consumption to impeller submergence and operating speed (Read, 1933). In the 1950s hydrodynamic characterization of cells through power coefficients and air flow numbers began (Arbiter and Harris, 1961) and has continued to the present, with increasing industrial use of these concepts (Degner, 1982; Degner and Treweek, 1976). Liquid flow measurements in Wemco cells (Degner, 1982) made liquid flow numbers and turnover frequencies available for more complete under- standing of cell dynamics. The present overview of flotation technology is a critique of cell design. The cell process represents the interactions between cell dynam- ics, cell geometry, and ores, with the latter prepared for that interaction through size reduction and reagent treatment. While previous invest- igations of flotation cells have accepted all cell designs uncrit- ically, the present study considers the physical process components that an effective cell must provide, and then compares a limited number of

Jan 1, 1984

Mining engineering, metallurgy and minerals-related geology have proud traditions and are essential professions to support a safe and sustainable minerals industry. However, the future of these professions is under threat. The courses that produce such graduates are disappearing worldwide and the number of graduates available to enter the industry has been falling in English speaking countries for at least a decade. It is unlikely that this problem will be remedied by æsupply and demandÆ. Instead, some active intervention is required.

Jan 1, 2004

There have been many developments in recent years in pipeline transport to enable them to be more widely used in industry. Substantial tonnages of materials that are not affected by water, such as coal and other minerals, aggregates and wastes, can be moved over considerable distances in quite small diameter pipes. Where there are no existing road or rail facilities, long-distance pipelines are usually cheaper to install, and this advantage increases in difficult terrain. Pipeline operators all over the world assert that hydraulic lines pay for themselves in a relatively short time, in spite of the heavy capital outlay, and this is equally true for lines convey-ing slurries or pastes within a plant complex.'This paper reviews some of the more important investigations in the hydraulic transport field. Although reference to systems carrying a wide range of materials is made, the majority of recent published data centres on coal transport.The paper looks at the application to a wide range of particle sizes, the development of non-aqueous slurrying media and coal/water fuels. The review also looks at some of the equipment being proposed to provide more reliable operation and in particular the range of solids-handling pumps now available.-The paper goes on to identify areas where further research and development is required and some of the many organisations undertaking this work.

Jan 1, 1985

By Riel RG

Nickel and cobalt mineralisation at the Murrin Murrin deposits, in the North Eastern Goldfields region of Western Australia, occurs within laterites developed on Archaean serpentinised peridotite units. Lateritic weathering of the peridotite has produced a resource of 116.8 Mt at 1.10 per cent Ni and 0.082 per cent Co (resource at May 1996 with a 0.8 per cent Ni cut-off; see Fazakerley and Monti, this volume). The mineralogy of the Murrin Murrin laterites was investigated to identify the minerals hosting significant Ni mineralisation. Laterite profiles were studied using X-ray Diffraction (XRD), impregnated polished thin sections, and Energy Dispersive Spectroscopy (EDS) Electron Microprobe analysis, of RC percussion drill chips. This paper summarises the results of these studies, and briefly discusses the nature of the minerals hosting Ni mineralisation.

Jan 1, 1996