Search Documents

By W. Krieglstein

Due to the natural variability of ores, it is necessary to carefully test flotation behavior of flotation cells before designing flotation circuits. For performing quick and versatile tests in the laboratory, Siemens developed a laboratory-size Hybrid Flotation Cell, which has been down-scaled from the 300 m³/h production cell to a 0.6 m³/h flotation cell. This small cell is being used as a test bed for technical and chemical concepts, the improvement of decisive components and the characterization of customer ores. In this study the evaluation results for Andean porphyry copper ores are shown. Total recovery rates of the order of 45 to 50 % have routinely been achieved in a single flotation cycle over a wide range of feed grades. In addition, the Hybrid Flotation Cell has proven to be particularly well suited for the flotation of fine particles below 20 µm down to below 1 µm, at high recovery rates and concentrate grades.

Sep 1, 2012

By A. A. Remes

High precision on-line particle size distribution measurement of mineral slurries has recently be-come available. It provides new tools for the development of monitoring and optimization methods for mineral grinding and separation circuits. The paper presents the development work at the Kemi chromite concentrator plant of Outokumpu Tornio Works in Northern Finland. The Kemi concentrator processes annually 1.2 Mt of chromium ore. The products are upgraded lumpy ore and metallurgical grade concentrate. The concentrate is produced using gravity separation methods, preceded by a rod mill - ball mill grinding stage. The separation process performance is strongly dependent on the particle size distribution of the grinding product at the Kemi plant. Particle size distribution has a significant effect on the concentrate grade and recovery. Currently a new laser diffraction based on-line particle size analyser is used for monitoring the grinding product. The analyser system allows the measurement of the whole cumulative particle size distribution simultaneously. It provides a wealth of new measurement information for process control. A monitoring and optimization scheme for grinding and gravity separation based on the particle size information is presented. The goal is to minimize the production of fine slime, and subsequently to improve the concentrate quality and minimize chromite recovery losses. Data-based recursively identified linear PLS process models are developed for optimization purposes. The preliminary results of the monitoring system operation in on-line use are presented.

Jan 1, 2014

By F. C. Araújo, T. Tavares, J. Leite

"This work presents the small-scale mining cluster of kaolin in Rio Grande do Norte (RN) and Paraiba (PB), both Brazilian states, including the following information: number of companies, process flowcharts, production numbers, mineralogical (XRD) and chemical (XRF) composition, granulometric distribution (screen and laser granulometer) and image analysis (SEM). Some social indicators in the region of the RN and PB States are presented in association with these data. The number of companies and their flowsheet were obtained through in situ visits and sample collection for technological characterization. The comparative study of the different flowsheets for kaolin production in the world was done using the databases and presenting the state of the art of kaolin processing. The results indicated that the mean feed typically contains 35-39% kaolin with quartz, muscovite and kaolinite as main mineralogical components and SiO2 (65.83%), Al2O3 (21.19%), K2O (3.9%), and Fe2O3 (0,63%) as main chemical constituents. The products of mineral processing are twofold, one between 74 µm and 37 µm, and the other smaller than 37 µm. The wastes of operation had major quantities of kaolin. The average Human Development Index (HDI) of the cluster region is approximately of 0.61, which shows an association between mineral processing plant and social indicators. The kaolin recovery, however, is between 30-55% for the three most common types of flowsheets that are currently used in the small kaolin mining cluster, indicating a need for technological improvement to achieve regional development. These data could be used incrementally to adapt the process plant currently used in the small-scale mining cluster of kaolin."

Jan 1, 2014

By T. Badrujaman

In September 2005, after 30 years experiencing in operating an ESF using a falling water film shell cooling system, Antam entered the new era in operating an ESF, after completely modernized its ESF No. 2 from a falling water film shell cooling system to a copper cooling system. Further, in the beginning of 2007, Ferronickel plant No. 3, where its ESF also uses copper coolers, was successfully commissioned. By operating an ESF using a copper cooling technology, Antam has to face some challenges to establish the operation stability. Besides that, the chances to maximize the furnace efficiency are greatly opened. The shielded-arc mode of electrode tip is selected to operate an ESF under relatively high furnace power to produce metal having tap temperature below 1500? and slag having tap temperature below 1600?. It leads to electric current unbalance. Further, operating an ESF using a copper cooler system under high voltage as consequence of the furnace power raise increases metal and slag tap temperature. This condition damages furnace integrity fast. Besides that, relatively high metal temperature increases its pressure during metal tapping. It leads to failure in closing the metal tap hole. The main different ways in operating an ESF using a falling water film shell cooling system and a copper cooling system lie in the electrode tip mode, the water specification used for cooler, metal tap block maintenance and allowed metal & slag level in furnace. Since a copper cooler system allows an ESF to be operated by consuming nickel ore having ratio Fe / Ni up to eight and producing slag having relatively high Fe content in slag, an undesirable silicon reversion phenomenon becomes an obstacle in reaching the operation stability. A copper cooler technology lets Antam to take a chance to increase its capacity. Modernizing the ESF No.2 had increased its furnace power from 17 MWh to 25 MWh. Meanwhile the ESF No. 3 can be operated up to 42 MWh. This technology allows an ESF to be operated under relatively high furnace power above 25 MWh safely as well as prolong the campaign life of ESF brick. Further, lowering ESF power consumption, extending the limitation of ratio S/M in nickel ore consumed and adjusting Ni grade in ferronickel product can be gained by applying this technology.

Jan 1, 2014

By Ali Dehghani Ahmadabadi

Gravity separation technique is widely used in mineral beneficiation practices for its low cost, ease of operation, and eco-friendly nature. The most commonly used gravity methods for beneficiation of iron ores are shaking table, jig and spiral methods which aren't very effective for iron mineral fines. Multi-Gravity Separator (MGS) is suitable for the treatment of fines with a maximum particle size of approximately 500 µm. This study was performed on a low-grade haematite iron ore from Chadormalutailing dams. Detailed mineralogical, physical and chemical characteristics of a goethiticlateritic iron ore showed that the sample contained porous and friable oxides and hydroxides of iron. The ore sample had a feed grade of 35% Fe, 1.1% FeO, 15.5% SiO2 and 8.5% Al2O3. Haematite and goethite are the main iron-bearing minerals while quartzite and kaolinite are the major gangue mineral constituents. In this paper, the statistical evaluation and optimization of grade and recovery using a factorial design of experiment (DOE) method has been carried out for Chadormalulow grade ultra-fine haematite tailings with MGS. The input process parameters considered are drum speed, tilt angle, wash water flow rate and pulp density. The results show considerable improvements in both the quality characteristics such as grade and recovery with statistical evaluation and optimization, compared to the initial value of grade and recovery. Keywords: multi-gravity separator, mgs, statistical evaluation, optimization, haematite

Sep 1, 2012

By L. Pan

As an air bubble approaches a mineral surface, a thin liquid film (TLF) is formed in between. The excess pressure (p) in the film determines the kinetics of drainage, which is of critical importance in flotation. We have developed a new method of monitoring the kinetics for both stable and unstable wetting films and analyzed the results using the Reynolds lubrication theory. It has been found that initially a TLF is thinned by the Laplace pressure (pcur) due to changes in bubble curvature and subsequently by the disjoining pressure (?) created by the surface forces present in a wetting film. In the present work, we have derived an analytical expression for determining ? from the temporal and spatial profiles of TLFs on mineral surfaces. The results show that ? > 0 in a film formed on a hydrophilic surface and ? < 0 in a film formed on a surface hydrophobized by collector. Thus, the role of collector in flotation is to create a hydrophobic force and hence a negative disjoining present in wetting films. It is also found that smaller bubbles can create higher Laplace pressure, which helps the TLF drain faster.

Sep 1, 2012

By L. X. Yu

As is known, the oxidized antimony and antimonate are hard to treat. A new combined mineral processing flowsheet which is controlled in grinding and classification ?bulk floatation?gravity separation is adopted to dispose of gravity-separated tailings (antimony content: 1.48%; oxidization rate: 68.92%) in Muli Antimony Mine, the grade of floatation antimony concentrates is 32.64%; the grade of gravity-separated antimony concentrates is 26.99%; the combined grade of floatation and gravity-separated antimony concentrates is 30.85%, and the total recovery of antimony is 70.64%. Adopting the new mineral processing technique have solved the problem of over grinding of antimony ore by controlling grinding and classification, recovering effectively the sulfide antimony and the easy floatable oxidized antimony of fine size by bulk floatation, recovering effectively the oxidized antimony which is hard to float by classified gravity separation. This is a great breakthrough in the mineral processing technique of the recovery of the oxidized antimony. At present, favorable economic benefit has been obtained from the application of this processing technique in Muli Antimony Mine.

Jan 1, 2014

By H. D. Mendoza, M. J. C. Zerna

This study aims to determine the stability of Philippine nickel laterite ore by investigating the behavior of fine minerals of silica (dave=1.514 µm), hematite (dave= 0 1.351 µm), and nickel oxide (dave=1.426 µm) and their mixed-components in dilute aqueous suspension as a function of pH and electrolyte concentration. The zeta- potentials of the minerals are measured and stabilities of different component systems in aqueous suspension are determined. Hamaker constants of the minerals in aqueous medium are derived by getting their respective critical coagulation concentrations (c.c.c.) at stable pH conditions and at various concentrations of KNO3. The iso-electric points (i.e.p) for silica, hematite, and nickel oxide particles are at pH 2, pH 7.5, and pH 8.5, respectively. The stability behaviors of component systems are as follows: a) Silica dispersion is stable at pH range 3-11and unstable at pH 2; b) Hematite dispersion is stable at pH 2-5 and pH 8-11, and unstable near pH 7; c) Nickel oxide dispersion is stable at pH range 10-11 and unstable at pH 3-9; d) Hematite-silica dispersion is stable at pH range 6-11 and unstable at pH range 3-5; e) Hematite-nickel oxide dispersion is slightly stable at pH range 3-4 and unstable at pH range 5-11; f) Silica-nickel oxide dispersion is stable at pH range 10-11 and unstable at pH range 3-9; and, g) Hematite-silica-nickel oxide dispersion is stable at pH range 10-11 and unstable at pH range 3-9. The stability of nickel laterite ore is similar to that of the three-component system in an aqueous environment. The stability tests are analyzed using the classical DLVO theory. The stability conditions in an aqueous environment are essential in developing the appropriate process flow for the separation/ recovery of nickel laterite mineral components and also in the treatment of nickel laterite -laden wastewaters.

Jan 1, 2018

By Olgac Kangal, Ali Guney, Gulay Bulut, Guven Onal, Ayhan A. Sirkeci

This paper presents the results of pilot scale column flotation applications in the two different copper concentrators in Turkey. The Kure Copper Plant is located in the Black Sea Region of Turkey. In Kure, a very fine grinding requirement for an adequate level of liberation makes a successful flotation difficult and consequently the final concentrate can hardly assay above 16% Cu Column flotation tests were conducted at the plant site using two different column types The experiments proved that the grade of the concentrate could be increased from about 14% Cu to 25-26% Cu. Murgul Cakmakkaya Copper Concentrator is the largest copper concentrator in Turkey. Although concentrate production capacity is around 170,000 tons annually with 22-23% Cu content, this figure tends to be much lower than that. In Murgul a Turbo Column of Multotec Company of South Africa was employed. As a result of systematic column flotation tests, the grade of the concentrate was increased from 20.3% Cu to 28.7% Cu.

Jan 1, 2003

By V. Z. Kozin, E. A. Bekchurina, P. S. Volkov, Yu. P. Morozov, A. S. Komlev

"The current sampling systems of ore flows or concentrates are based on the method of cross sections in point sampling and the method of scooping in reducing. The limited number of point samples in sampling and microsamples in reducing lead to big random and probable systematic errors. The paper defines the principles of sampling, which assure the absence of systematic errors and also provides calculation formulas of probable errors in sampling methods of cross and longitudinal sections as well as in samples preparation. The article sets the fundamental laws of sampling: the dependency of minimal mass of gross sample and number of point samples from mass of point sample in sampling from heterogeneous body; the dependency of a sample minimal mass from lumps’ size in preparation of carefully mixed samples; the dependency of point samples’ dispersion from duration of control period. The paper introduces the fundamental notions: lump variance; probable systematic error; methodical error. It also provides a solution of outstanding sample correct application in analysis results calculations. In application of automatic analyzers, mounted in material flows, the probable error connected with sampling, is calculated by the formulas for carefully mixed sampling bodies. The paper describes the developed and introduced sampling systems on the base of combined application of cross and longitudinal sections methods in sampling and preparation of samples. The advantages of this equipment are compactness, reliability, simplicity in service and operation, and for pulps it is adaptability in pipelines. Application of the developed equipment entirely excludes probable systematic error. The new systems of sampling and preparation of samples are introduced at 25 concentrating plants. Introduction of the developed systems at sampling balance points of concentrating plants allowed double reducing balance deficiency."

Jan 1, 2018

By C. Dorfling, C. A. Snyders

South Africa has extensive mineral processing and extractive metallurgy capacity and infrastructure for metal production from natural resources. Decreasing ore grades, increasing labor costs, and more stringent legislation have made economic metal production from primary resources challenging. Opportunities exist for metal production from secondary resources such as mining wastes and end-of-life consumer goods. The objectives of this study were to evaluate the current status of metal production from secondary resources in South Africa and to identify potential opportunities for further development. Two main classes of secondary resources, namely mining waste and electronic waste, were considered. Primary metal producers are dominating metal production from mining wastes; several of the gold, platinum and chrome producers operate low risk and low cost tailings retreatment facilities that contribute significantly to their overall production. Further opportunities exist in, for example, the treatment of more than 450 estimated gold tailings dumps in Gauteng, as well as metal recovery from slags and furnace dust. The majority of companies involved with electronic waste recycling in South Africa focus on collecting and disassembling; only a few perform preliminary physical processing, with the recovered fractions then being sent overseas for metal recovery. Projections are that the rate of waste generation will increase significantly and that treatment will become critical to comply with more stringent environmental legislation. Projects related to process development, techno-economic evaluations and environmental impact studies for metal recovery from batteries, printed circuit boards, and fluorescent lamps are underway. South Africa is ideally positioned to further explore opportunities for synergistic relations between metal recyclers and primary metal producers. Processing of electronic waste for production of technology metals, for which limited natural resources exist in South Africa, would be a key enabler for local manufacturing industries and expansion of the value chain.

Jan 1, 2018

By M. Bhartia

India is the 5th largest producer of steel in the world and is slated to produce more than 180 Mt by 2020. Expectedly about 50 % of this would be through the Blast furnace route and the rest through Sponge iron / DRI route. Considering that there will not be any major change in iron making technology by that time, the Blast operation would require lump ore (10-40mm) with around 64% Fe grade and sinter fines (<10mm) with 60% Fe (min) as its feed. DRI process would need calibrated ore of size 5-18 mm as the most suitable size of feed. It is also expected that of the total requirement of ore for the DRI route a significant part would be DRI pellets. In India, there is considerable debate going on regarding the technology to be adopted for the processing of iron ore and there is a lack of clear consensus. The above scenario indicates that the processing requirement of iron ore in the country would involve both washing technology as well as beneficiation technology. CDE Asia Ltd is in the forefront of iron ore processing in the country and the experience gained by the company over the last few years of functioning has led the company to believe that route to be adopted depends on the end product requirement and the starting grade of the feed. Keeping in mind the nature of the feed required for the Blast furnace & DRI operation; it is obvious that good washing technology would be highly beneficial to the iron ore industry. Depending on the grade of ore available the limits of washing will be decided and equipment for lump ore beneficiation such as jigs could be incorporated into the washing circuit. Scrubbing of ore either before washing or selectively scrubbing the lumps could be necessary. Very low grade ore and jig rejects would be required to be totally ground and beneficiated for the production of pellet feed in order to utilize the iron ore resources entirely. Another source of ore for pelletisation would be slimes generated from the washing process as well as the huge quantities already available in the tailings dams in the operating mines. Deslimimg and magnetic route of beneficiation could release at 30-40% of the Fe locked up in these tailings ponds/dams. The paper describes the concept with examples from operating plants and proposes how the adoption could be engineered through test work and proper plan of integration. Keywords: washing, beneficiation, iron ore, lumps, sinter fines, pellets, jigs, screens, evowash, nanowash, thickeners, log washers, drum scrubbers

Sep 1, 2012

By F. J. Sotiuo

Variability of the quality of phosphate ore feed to the flotation plant has been of great concern for the industry. This variability sometimes resulted in 10% to 50% decrease of P2O5 recovery, a reduction of P2O5 concentrate grade and/or both due to depression of the system. For this investigation, samples of refractory ore and easy-to-float ore were obtained from the same mining area in Central Florida; and then submitted to bench flotation tests using fatty acids (FA). To understand the cause of difference in flotation behavior of these apparently similar ores (grade, mineralogy, and physical appearance), bulk and surface characterization studies were conducted. Based on the results of characterization studies and bench flotation tests on both refractory and easy-to-float samples, it was possible to determine FA surface coverage. It was found that the surface coverage for the refractory ore was between 6.9% and 9.8%, corresponding to 0% and 80% recovery, respectively; whereas the easy-to-float ore showed surface coverage of 17.2% (89% recovery) to 24.6% (98% recovery). Since size analysis, surface area and pore size measurements showed small differences, it was thought that the surface coverage differences could be caused by the ad-sorption of natural compounds onto the phosphate ore surfaces, depressing the system. SEM, EDS, and Leaching and Solvent Extraction (LSX) studies were performed on the phosphate ores to demonstrate the proposed mechanism. This paper summarized our characterization studies, flotation results, and findings. The study showed that the new identified compounds were responsible for the flotation behaviors of the Florida refractory phosphate ores.

Jan 1, 2014

By Y. M. Zhao

The dry coal preparation technology based on air dense medium fluidized bed is an innovative dry highly efficient technology of coal by introducing fluidization technology into beneficiation.. A modularized 40-60 tones/hr system (KZX-40) with an air dense medium fluidized bed separator was established. The construction cost of the modularized system is only 1/3 of the traditional wet heavy-medium coal preparation plant construction cost with the same capacity, and the consumption of dense medium can be reduced by 50%-60%. The footprint and volume of the system are decreased by 75% and by 89.81%, respectively. These facts show the improved intensity, efficiency and economy of modularized coal preparation technique. The modularized KZX-40 system can be used to separated 50-6 mm coal over a separation density range of 1.3-2.2g/cm3 depending on the variation of <1mm fine coal content. The separation efficiency of the system was investigated at low and high separation densities by float-sink experiments. The partition curve of the products at low separation density shows that the separation density (d) is 1.33g/cm3, and the probable error (E) value is 0.05g/cm3. Using 50-6mm coal with an ash content of 55.35% as feedstock, at a high separation density of 1.61g/cm3, the clean coal with an ash content of 14.67% and the tailing with an ash content of 71.26% are produced with an E value of 0.06g/cm3. It is clear that the modularized KZX-40 system is suitable for separating 50-6mm coal effectively. During the dry coal preparation process, the dust is removed by the bag collector and recycled back into the separator. So the system has the advantages to work without environmental pollution and water. The modularized system greatly reduces the construction and operating costs and decreases the area and volume required, compared with wet dense medium system. The system is applicable to the coals located in arid regions and also to the coals that tend to slime during wet separation. Keywords: modularized, KZX-40, fluidized bed, beneficiation

Sep 1, 2012

By Alok Tripathy

A simulation code called SIMJIG and the user interfaces have been developed using discrete element method (DEM) and the .NET platform respectively for the jigging process. DEM platform is used for tracking of particles in the jigging operation. DEM uses the net force balance on the particles to track the trajectory of the particle. Simulation results are compared with experimental results obtained by jigging of low grade iron ore lumps. Two different iron ore samples one from Chatishgarh and one from Odisha were used for the experimental studies. The Alljig? stratification test rig meant for batch laboratory experimental studies has been used in the present work. The behavior of different sizes of material on jigging has been examined. Later, the particle size behavior during jigging at different layers of the jig bed has been studied. Further stratification profile across the jig bed has also been studied. It was observed that simulation results are matching quite nicely with the experimental results. The SIMJIG simulator developed in the present study could be used for predicting the performance of the jigging operation effectively. Keywords: DEM, gravity concentration, jigging, iron ore, simulation

Sep 1, 2012

By Richard A. Williams

The mineral processing community have been amongst the pioneer developers and early adopters of key platform technologies in analytical methods, chemistry, physical separation and advanced modelling. Fundamental research will continue to have a significant impact driven by the continued development of sustainable practices. Major drivers and challenges for change in our industry in the next two decades include: reduction in energy uses in processing; discovery of new energy materials; adoption of green chemistry routes; safeguarding of water resources; and demonstration of adherence to best practice at all times. With increasingly global mining enterprises, the provision of internationally accepted benchmarks for performance will continue to drive the creative process. This lecture highlights major opportunities around a new paradigm of Multi-scale Measurement coupled with Multi-scale Modelling, based on advanced sensors, communications and computing. Connecting real-time measurement sensors with dynamic simulation models opens up new horizons for visualising the process behaviour from an experimental and theoretical basis. Examples are given of the potential of this methodology and its implications for better design.

Jan 1, 2003

By Jing Zhou

In view of the state of the long time use of sodium cyanide in lead-zinc-sulfur-silver multimetallic ore production, we propose alternative reagents system through experimental research. The experiment first used TJ, sodium sulfide to adjust the flotation pulp, after that, zinc sulfate, sodium sulfite was added to low alkaline pulp to inhibiting zinc sulfur mineral and adapted MB, 25# aerofloat and diethyl dithiocarbamate combination collectors to float lead minerals. The obtained test index is as follows: lead concentrate recovery rate of small scale test was increased by 5 to 10%, the recovery rates of gold and silver in lead concentrate were increased by 7% and 11% respectively; the industrial test is conducted under the condition that the total grade of lead and zinc content in raw ore decreased by 4.81%, the total recovery rate of lead and zinc increased by 7%, recovery rates of gold and silver in lead concentrate were increased by 7.62% and 9.65% respectively. So it successfully realizes the target to replace the sodium cyanide, using low-alkaline non-toxic reagents system in mineral processing practice of three kinds of complex lead-zinc-sulfur ore of this mine. Keywords: refractory lead-zinc-sulfur ore, depressant, non-cyanide flotation

Sep 1, 2012

By S. J. Dai

The cadmium and cyanide are main poisonous components in cyanide electroplating cadmium waste water of an electroplating plant in Shenyang. The content of cadmium is about 26 mg/L and the content of cyanide is about 11.782 mg/L in this waste water. The main form of cadmium and cyanide are ions which are Cd2+and CN?. Because the cadmium and cyanide exceeded the standard seriously, the waste water must be disposed before it discharges. The microbiological method of treating heavy metals in wastewater has many advantages. For example, it has a fast adsorption velocity, high processing efficiency, wide range of pH and temperature, few invest, low running cost, no the second pollution and so on. At the same time, the CN? could be degradated by some microbiology. The physical nature, the chemical nature of Bacillus mucilaginosus, the adsorbing condition and adsorbing regular of Bacillus mucilaginosus to cadmium in the wastewater are studied by using Bacillus mucilaginosus as adsorbent removing cadmium from electroplating wastewater. The experimental results show that the adsorbing rate of cadmium is over 92%, under the room temperature(about 25?), stiring revolution in adsorption being 800 r/min for 30 min, pH being 5 , the bacteria being cultured after 5d with the biomass of Bacillus mucilaginosus 40g/L (wet weight). The mechanism in biosorption process of Bacillus mucilaginosus to cadmium is analyzed and discussed by TEM , Zeta potential,and infrared spectroscopy analysis. The results showed, the chemical involving is main adsorbing form, while electrostatic attraction, ions exchange, hydrogen bonding and Van Der Waals force are concerned cooperatively. ?NH2 ?, ?C=O?, ?C=O?NH?CH2, ?CH3, ?OH are main adsorbing groups. At the same time, the floatablity of removing cyanide by Bacillus mucilaginosus is explored.

Jan 1, 2014

By Jurgens J. Louw, Vincent C. Smith, Gareth C. Smith, Agit Singh, Dave G. Hulbert

"The flexibility of the PlantStar control platform has enabled Mintek to investigate and easily develop new control strategies for both milling and flotation. This includes a Solids Feed Controller, a Safety Limit Controller, Mill Power Optimiser and Flotation Optimiser, amongst others.The solids feed controller was developed for minerals processing plants using a specialised time delay compensator. Using conventional time delay compensators that are purely model based, results in robustness problems due to model uncertainties. The Mintek Solid Feeds Controller makes use of a plant model, but compensates for model inaccuracies, giving more controller stability and a more robust delay compensation algorithm.The safety limit controller has been developed to switch smoothly between normal and safety control loops without bumping the process. The safety loop output is chosen in accordance with a predefined list of priorities and whether the respective constraint boundaries are exceeded.The Mill Power Optimiser helps to find the power peak on the mill power curve. This insures maximum grind with maximum throughput. It also prevents power dips due to mill overloads, making the milling circuit easier to operate.The flotation optimiser algorithm analyses trends of all accessible variables in the process. The algorithm uses this information to calculate operating conditions that will control the residence times, mass pulls and circulating loads within a flotation circuit to a specified setpoint. Research is being done to now optimise these setpoints in order to achieve better recovery."

Jan 1, 2003

By M. Saghaeian, R. Hejazi, M. Mohammadinejad, M. Zare

"Water quality and quantity at the Tailing Thickening Section of processing plants is considered to be a crucial factor and impacts the performance of several sections. Therefore, gaining stable and effective performance at the Tailing Thickener Section is one of the principal goals of minerals processing plants. Different factors such as: qualitative and quantitative sustainability of plant feed, the balance between the mass of input and output water flow, the dissolving method and distribution of flocculant and the amount of dirt, solid percent of thickener inlet pulp, affect the performance of Tailing Thickener. The present study investigates the successful improvement of Tailing Thickener performance at Jalal Abad Hematite Iron Ore Concentrate plant through optimizing the above operational parameters. For this purpose, the following optimizations have been done: homogeneity and sustainability of plant input feed rates, fine pulp removal collected by the bag filters at the input of the thickener, adding an quietness box before moving the tail pulp into the thickener to reduce the pulp turbulence, replacing flocculant pump and injection pipes, improving water mass balance which leads to optimizing and stabilizing the concentration of input tail pulp into the thickener, adding a mixer to increase the flocculant preparation time, increasing the locations for adding flocculant to thickener from 1 point to 6 points. Applying the above modifications and monitoring the Tailing Thickener performance over the course of months, has led to the improvement of recovered water quality from 500 ppm to 200 ppm, increasing the solid underflow of the thickener from 40% to 48.5%, and similarly, reducing water loss by 60%. Of other important effects, due to improvement of water quality, grade of final concentrate 0.5% increased and because of 73% increase in monthly working hour, concentrate tonnage 55% increased. Finally, sludge thickener optimization has had a significant effect in selecting and designing the dewatering system from the underflow of the sludge thickener."

Jan 1, 2018