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By Venkataramana Runkana, Pradip Gautham, Beena Rai, Sreedhar Reddy

"IT enabled platforms are the key to provide an integrated view of the business activity or an enterprise as a whole. Attempts to integrate all functions in an enterprise such as mine-to-market initiatives, wherever and to whatever extent implemented, have provided significant benefits to the industry. The transformative potential of IT enabled integration platforms is illustrated in this communication from our own work in this field. TCS PREMAP (Platform for the Realization of Materials and Products) is a knowledge-driven engineering design and development platform which leverages modeling and simulation and artificial intelligence into the engineering design process. We illustrate the customization of this generic platform for the design and optimization of mineral processing plants in an integrated manner. TCS PEACOCK (Process and Equipment Analytics for Optimization and Control) has been developed to enable automation of data analytics in the operating plants. We illustrate its utility and power in improving the plant performance with the help of case studies from our work on pelletization of iron ores and optimization of flotation plants. INTRODUCTION We are living in an exciting digital era. With the advent of cloud computing and social media on the one hand and rapid advances being made in several research areas of interest to us in the minerals and metals industry such as artificial intelligence (AI) & machine learning, robotics, unmanned vehicles including drones, big data analytics, 3D printing, sensor technologies, renewable energies and internet of things (IoT), many disruptive transformations in our industry are on the horizon. Recent advances in information technology (IT) and knowledge engineering, in combination with appropriate domain expertise, that is, our enhanced understanding of the underlying science of mining and mineral processing operations and the availability of a variety of powerful modeling-simulation tools make it possible to address the challenging problems facing the mining and mineral processing industry, in an integrated manner."

Jan 1, 2018

By N. Vasumathi

Most of the Iron ore washing plants set up in India in the earlier days consist of sizing of the ore by dry / wet screening, washing and classification by screw classifiers. In this classical approach, iron values were lost in the form of fines and ultrafine into the tailing ponds as they had little commercial value in those days and accumulated in huge quantities over the years. As the high grade deposits are getting exhausted and the demand for high grade finer material for pellet making is ever increasing, focus is shifting towards recovering the values from the erstwhile tailing ponds by column flotation. This is also supposed to mitigate to a certain extent the environmental problems caused by the ever expanding and unmanageable tailing dams. A case study is presented wherein a composite sample is prepared from samples drawn systematically from multi - locations in a sprawling tailing dam. Laboratory scale column flotation tests on this composite tailings sample, basically originating from two operating iron ore beneficiation plants of JSW Steel Ltd., one of the leading producers of steel in India are found to be encouraging. Desliming followed by reverse and cationic flotation tests using flotation column resulted in the concentrate of 61.88% Fe, 4.81% SiO2, 2.52% Al2O3 and 3.30% loss on ignition (LOI) from the tailings analyzing 57.86% Fe, 7.10% SiO2, 3.52% Al2O3 and 6.14% LOI with 52% weight recovery. The causes for the quality improvement could be attributed to desliming of un-liberated ultra fines of kaoline and hydrated iron oxides and their further reduction by efficient flotation process. The process and the cationic collector developed for this purpose are adopted in the new flotation plant created to treat these tailings. Keywords: iron ore, washing, ultra fines, tailings pond, column flotation

Sep 1, 2012

By Knut L. Sandvik, Erik Larsen

Crystalline silicon solar cells are the most important solar cells manufactured today. This will most probably remain the situation the next decade. The future silicon feedstock is most likely not reject from the production of electronic-grade silicon. There will probably be a more direct solar-grade silicon route, excluding the electronic-grade silicon "detour". Estimated global solar energy demand in 2001 required approximately 5,500 tons of silicon feedstock. This required 65,000 tons of quartz. If the trend continues, the solar energy demand in 2010 would require approximately 30,000 tons of silicon feedstock and 350,000 tons of quartz, although the need for quartz probably will be lower than this. Quartzite has been regarded as the most suitable primary raw material used in the silicon solar cell production chain. This may change as the raw material requirements for the production of metallurgical-grade silicon are most likely to change. In addition, quartz or other silica-containing minerals from other rocks may be of a higher purity or contain lesser amounts of the most harmful elements. This favours increased beneficiation of primary raw materials in the future solar silicon feedstock production chain.

Jan 1, 2003

By Claudio L. Schneider, Peter R. King, Reiner Neumann

"Predicting the liberation spectra that are produced from breakage of two-phase ores under the random fracture assumption can be accomplished by measuring the conditional, on length, linear grade distribution directly from images obtained from a representative sample of the unbroken texture. The technique tremendously simplifies the prediction problem by avoiding the multiple convolutions that arise from the traditional method based on a description of texture from a measurement of the chord length distributions associated with each phase in the unbroken texture. For a 3-phase system, the phase transition probabilities associated with the textural information make the traditional calculation an almost insurmountable mathematical problem. The direct measurement procedure on the other hand can be expanded to three phases comparatively easily.A coal sample is used here to demonstrate the procedure. It is concluded that the conditional, on length, linear grade distribution can be predicted in the same fashion for multi-phase systems. Accurate stereological conversion is the practical hurdle to be overcome for multi-phase systems, but it is already a reality for 3- phase systems."

Jan 1, 2003

By U. M. J. Boin, E. V. Verhoef

Pyrometallurgical reactors constitute a key processing component in the total primary and industrial/recycling resource cycle, being involved both in primary smelting, converting and extraction, as well as the reprocessing of scrap, from aluminium cans to end-of-life automobiles. Therefore the pyrometallurgical reactor?s role in achieving sustainability is the central theme discussed in this paper since optimising their operation minimises waste, residue and offgas (NOx, dioxin, CO2) and maximises product quality and therefore efficiency. To effectively control the overall resource cycle, one needs to take a systems modelling approach of the whole cycle, seeking to also understand the dynamic process behaviour of the individual components of the cycle, and then especially the part that contributes most to the chemical conversion, namely the pyrometallurgical reactor. This paper highlights the role of pyrometallurgical thermodynamics in the whole resource cycle and specifically places equilibrium thermochemistry in the context of process dynamics where large, variable inventories are recycled or maintained within the system. This paper will therefore review the semi-empirical dynamic modelling tools, which are used to model complex systems with the specific goal of developing dynamic predictive models, which also include slag-alloy chemistry, towards controlling the recycling in a feed forward manner. To illustrate the primary production of metals, high carbon ferrochrome and Ni-Cu-matte smelting will be presented as a brief case study. Also fundamental studies in blast furnace and waste incineration kilns will be given. It also will show how the distributed nature of the chemistry of melts in the case of primary extraction, and industrial (recycling) materials such as recycled end-of-life vehicles, have a significant impact on the process outcomes and model predictions. It is therefore argued that the fundamental thermodynamics and kinetics in metallurgical reactors play a final crucial role in modelling the closed material cycle, but only when it is used in conjunction with process systems theory based on reconciled data for parameter estimation and model calibration. System models for aluminium and car recycling will be given as well as a dynamical system model that describes the interconnected material flows for Ag, Au, Bi, Cu, Fe, Ni, Pb, PGM, Sn and Zn for a study on lead-free solder.

Jan 1, 2003

By R. Van Hille, A. E. Lewis

"The precipitation of a selection of metals from both a synthetic and an actual metal-rich effluent was investigated. The experimental aspects of this study were carried out in a two-stage process consisting of a pre-treatment clarifier and a fluidised bed (pellet) reactor. Each unit operation in the two-stage process was investigated separately. The pretreatment clarification stage at pH ˜ 5 resulted in a 99.9% removal of iron and 97.3% removal of aluminium.The pellet reactor was used to precipitate nickel as nickel hydroxy-carbonate from a pure stream and a removal efficiency of 99.6% was achieved. The high local supersaturation at the reagent inlet points caused the formation of a large amount of fines, but these agglomerated onto the pellets up the length of the bed (See Figure 1).For copper precipitated as copper sulphide from a pure stream, a maximum removal efficiency of 92% was achieved. The high local supersaturation at the reagent inlets also caused the formation of a large amount of fines, but the extremely sparingly soluble nature of copper sulphide meant that the fines were not agglomerated up the length of the bed. In Figure 2, the global supersaturation ratio was relatively low, and thus there is little homogeneous nucleation and degree of fines formation. However, the fines occurring after the third sulphide input point (at 30cm from the bottom of the bed) indicate that local supersaturation also plays a critical role in fines formation. It was therefore concluded that, for the copper sulphide case, it is essential to control the supersaturation at the inlet points in order to prevent fines formation altogether, as it is not possible to agglomerate the fines once they exist in the bed."

Jan 1, 2003

By Christopher Robben, Alexander Mosser

"X-ray transmission (XRT) sorting has been introduced into the minerals industry in 2006 and has found various applications in diamonds, industrial minerals and metal ore processing since. The technology offers planar projections of the atomic density of single particles similar to the principle known from airport scanners, but being capable of treating up to 150tph per metre working width. In 2010, a pilot operation using a belt-type sensor-based sorter went into production at the Mittersill mine to treat the fraction 16-28mm. After an optimisation phase, the results were superseding expectations and therefore in 2012 a bigger production plant was set up. Two XRT-based sorters are parallel in operation since. One is treating the fine fraction 16-30mm while the other one is treating the coarser fraction 30-60mm after the secondary crushing stage. The XRT sorters are operated with the objective to reject barren waste before it enters the mill and flotation plant. 105,000tpa of waste material are rejected per year and can be sold as aggregate for road construction. This means that about 22% of the run-of-mine ore are rejected at an early stage with a waste reject grade lower than 0.03wt%WO3. The installation has not only led to lower specific operating costs but also led to reduced tailings disposal in an environmentally sensitive area. This allows the mine to reduce its headgrade which allows for a longer mine life. Alternatively it is possible to produce more tungsten concentrate, which is delivered to the smelter. This article will introduce the technological principle of XRT-based sorting and will discuss the flow-sheet of the Mittersill mine. Experiences that have led to the current plant design are described as well as the impact it has on the operation."

Jan 1, 2014

By Gaom M. W.

The Mount Isa copper concentrator started operation in 1973. Its secondary grinding circuit consisted of two 5 meters diameter ball mills in closed circuit with 505 mm cyclones. At the design throughput of 800 t/h, the 80% passing size of the circuit product (P80) was about 140 µm. The then Mount Isa Mines Limited (?MIM?) installed two autogenous grinding (?AG?) mills in 1991 to replace two stages of crushing, a rod milling stage and one primary ball milling stage. One of the AG mills was later converted to semi-autogenous grinding (?SAG?) operation by the addition of a steel grinding medium to achieve the designed plant throughput of 800 t/h. The cyclone over-flow P80of the secondary ball mill circuit was reduced to 120 µm by the increased operating power in the AG/SAG mill circuits. The two secondary balls mills had a grinding power of 5.2 MW. A mineralogical study of the milled products indicated that half of this grinding power was sufficient for adequate chalcopyrite liberation. Eliminating one of the secondary ball mills could reduce energy and operating costs by more than A$2 million dollars per year. An optimisation project team was established to achieve the predicted power saving. Grinding circuit simulations were conducted for different circuit configurations. Ball mill parameters such as ball size, ball charge and feed slurry density were optimised. Cyclone body diameter, spigot and vortex finder sizes, and cyclone types were tested. The secondary ball mill circuit was redesigned and several proposed circuits were run as trial production campaigns to determine their operability and efficiency. The plant trials confirmed that one of the secondary ball mills could be decommissioned. Significant cost savings were achieved as a result. The success of the project demonstrates optimising grinding circuits can not only deliver the plant performance, but also a much lower unit operating cost through energy and maintenance savings.

Jan 1, 2014

By S. Chuanyao

In last decade, along with its booming Chinese economy, China?s higher education has experienced rapid growth. In 2010, the number of various colleges totals more than 3500, with 2.2 million faculties registered. Currently there are almost 30 million students studying in the colleges, 3 times more than 10 years ago. Mineral Processing was initiated in 1949 as a sub-discipline of Mining Engineering, one of the 13 first level disciplines. Mineral Processing is now established in 34 Chinese colleges, recruiting 2600 undergraduate students, 540 postgraduate students and 100 PhD students every year. A further 9 institutes offer postgraduate education in this field. More than 3000 graduates majoring in Mineral Processing join the industry or institutions each year. The four-year undergraduate teaching and practical training in the colleges is designed to produce qualified mineral processing professionals. This includes courses in mathematics and natural science, fundamental engineering and basic and specialization courses. Recently, the ?Excellent Engineer Program? was launched to strengthen students? practical capabilities. This is a 3+1 teaching and training model; 3 years of theoretical course study plus 1 accumulated year of various practical studies, either inside or outside the college. As for graduate employment, mining-related major graduates have been in a good demand thanks to the intensive investment in mineral sector by Chinese companies. The shortage of experienced metallurgists generates a greater than 90% employment rate for Mineral Processing graduates. However, the biggest problem we are still facing is the gap between the quality of the graduates and the requirements of industry, as a result of occupation attraction, teaching systems, faculty quality, and so forth. Another problem is international orientation. Although nowadays Chinese-foreign cooperation in college education is popular, collaborative mineral related projects are far less common, leaving much room for improvement. Looking ahead to the next 10 years, we still have the right reasons to estimate continued prosperity in the minerals sector as well as mineral processing education in China. A brief analysis and views on this will also be shared in the presentation. Keywords: China, mining engineering curriculum, excellent engineer program

Sep 1, 2012

By E. Szelag

The adsorption and stabilization of mineral dispersed systems by using Pluronic copolymers with different molecular weights and EO content has been studied. The role of sequential adsorption of EO-PO copolymers and cationic surfactant (CTAB) on the carbonate particle properties and in determining the stability of their suspension was studied with particular attention to the conformation of the polymer at the solid-liquid interface. The purpose of this work was to investigate the flocculation phenomena, influence of polymer molecular size on stability of suspensions of magnesite and dolomite and the effect of addition mode of polymer and surfactant. The suspension stability measurements and the determination of sedimentation speed were carried out using an optical analyser (Turbiscan). In most of investigated cases, the biggest floccs and the fastest sedimentation were found for low concentrations of copolymers.

Jan 1, 2014

New technology for on-line particle size analysis of mineral slurries has opened up new applications for particle size measurement. In some cases the particle size distribution of the final concentrate is an important quality issue. This paper discusses established on-line particle size analysis technologies and presents experiences on the use of a new technique employing laser diffraction in several minerals processing operations. The main innovations in the new instrument are a simple dilution system and multiple scattering correction algorithm, which allows wide solids content variations of diluted sample in the measurement cell. Representative sample for laser measurement is produced by a simple and reliable dilution system. The applications discussed are; Blaine number measurement of Fe concentrate before pelletizing, grinding of variable batches of ore and paste thickener control.

Jan 1, 2014

By A. M. Muhamedilova, S. M. Narbekova, L. V. Semushkina, D. K. Turysbekov, N. K. Tussupbayev

The research and development of new, more selective collectors in order to improve flotation efficiency represent one of the main priorities in the development of innovative technologies pertaining to flotation separation of various substances and minerals. The use of collectors’ mixtures is considered as the universal instrument for ensuring necessary proportion of chemically and physically sorbed collecting reagents in every individual case. Currently hard-dressed, refractory ores and man-made raw materials, which are characterized by low content of valuable components, fine dissemination of mineral assemblages and similar technological properties of constituent minerals, are widely involved in the recycling processes. The possibility of processing tailings, which are left after flotation beneficiation, has been considered in the case study of tailings of the Zhezkazgan beneficiation plant and the Tishinsk copper ore deposit with utilization of the modified multifunctional flotation reagents. Modified poly-functional collector is the mixture of composite Aerofloat, TC-1000 and butyl xanthate. Reactants ratio is 1:1:3. The advantage of the suggested flotation reagents is that they are composed of two polar groups and have a long hydrocarbon radical. This structure, being in the water during flotation process, plays a dual role: first, as a collector adsorbing on the mineral surface it produces metal complexes with polar groups in the form of bridges; second, apolar radicals flocculate valuable slimed components, thereby intensifying flotation process. It has been shown that flotation of Zhezkazgan tailings with utilization of the lesser modified reagent amount compared to butyl xanthate has enabled to produce crude copper concentrate with 13.0 % copper grade and 80.22 %recovery. Compared to the baseline technology, copper content of crude concentrate has been increased by 5.1 % and the recovery by 31.4 %. It is shown that tailings flotation of the Tishinsky field by applying modified collector allows for increase of the of useful components extraction in a collective concentrate with: copper 9.63 %, lead for 8.41%, zinc 9.2 %, iron 2.73 %, gold 3.57 %.

Jan 1, 2018

By A. A. Sirkeci

In the scope of this investigation comparison between impact breakage and compression breakage were carried out for the separation efficiency of minerals using a chromite ore sample. The ore sample was broken below 1 mm employing a laboratory type roll crusher and an impact crusher. Concentration tests were conducted on -1+0.5 mm, -0.5+0.2 mm and -0.2 mm size fractions using a Wilfley type shaking table. Test results showed a remarkable difference between two types of breakage. Both concentrate grade and recovery was in the favour of impact crushing. Furthermore, the shape of the broken particles also showed differences such that in the case of impact breakage they were more spherical compared to compressive crushing. The results of the shaking table con-centration tests showed that a concentrate assaying 48.4% Cr2O3 were obtained with 78.5% recovery in the case of impact breakage. On the other hand the concentrate grade and recovery values were 48.8% Cr2O3and 52.4% respectively in the case of compression crushing. The losses in the tailings were also in favour of impact breakage proving that differential breakage occurred between chromite and gangue minerals.

Jan 1, 2014

Traditional mineral processing techniques are more and more difficult to recover the increasingly low grade phosphate ores today. Although bioleaching method has been attempted to process low grade ores in hydrometallurgical field due to economical and environmental reason, it has been hardly used in leaching phosphate ore at home and abroad. Strains of Acidithiobacillus thiooxidans and Acidithiobacillus ferrooxidans were collected and separated from the acid drainage of a coal mine in Anhui province of China. Ultraviolet irradiation and Microwave inducement were applied to the bacterial cultivation process to produce strains of Acidithiobacillus thiooxidans and Acidithi-obacillus ferrooxidans able to tolerate extremely low pH conditions and generate sulphuric acid by oxidizing elemental sulfur or sulphide and the mutagenesis can achieve higher leaching rate. The bioleaching result will improve more by the addition of Tween series surfactants.

Jan 1, 2014

By K. C. Corin, M. S. Manono, J. G. Wiese

"It has been suggested that hydroxo species, particularly those of calcium, selectively adsorb onto gangue minerals. Such species enhance the depressive action of carboxymethyl cellulose (CMC) onto gangue via an acid-base interaction between the positively charged mineral surface and the negatively charged CMC molecule. Thus, the hydrophilicity of gangue minerals is enhanced, preventing the dilution of the concentrate. However, as there is little evidence to support these claims it is important to investigate. Adsorption data and mineral surface charge analyses will allow a fundamental understanding into how electrolytes and their ionic strengths affect gangue-depressant adsorption. It is strongly anticipated that decoupling these effects will allow process operators to tailor their process water quality needs towards best flotation operating regimes and in the long run effect closed water circuits. Thus, using talc and pyrrhotite as proxies, this work investigates the influence of the ionic strength of process water on the adsorption of CMC onto minerals in sulphide flotation.INTRODUCTIONThe phenomenon of gangue depression in mineral flotation is of critical importance as regards the attainment of a required concentrate grade. This thus suggests that the depressant of choice has to have a highly selective affinity for the targeted gangue minerals. This would ensure the necessary prevention of gangue from reporting to the concentrate without inadvertently depressing the value bearing mineral. The chemistry of the environment regulates the manner in which gangue depression occurs. In sulphide flotation, polysaccharides are used as depressants of choice to depress naturally floatable gangue which may in the case of Merensky ores exist as talc. The two widely used polysaccharides in the South African context are carboxymethyl cellulose (CMC) and modified guar gum. It is suggested that polysaccharides depress gangue by rendering the surface of gangue hydrophilic or by preventing the formation of hydrophobic layers on gangue mineral surface, forming large gangue aggregates and thereby increasing their heterocoagulative nature (Shortridge et al., 1999)."

Jan 1, 2018

By Juan Estrada, Mirtha Frómeta, Rubén Alcalá, Emilio Montejo, José Castellanos, Juan Berto, María Rivas

"The oxidized nickel ores from San Felipe deposit are composed mainly Smectites which gives to the pulps very unfavorable rheological .properties (cinematic viscosity and high shearing strength) for transportation processes (pumping), very low settling velocities and very low thickened pulps. These properties do not allow the preparation of high % solids, which affects the economic efficiency if a high pressure acid leach (HPAL) process is used. Pulps of close to 30% solids have very high BYS making pumping impossible. CIPIMM developed three technologies to solve these problems and to substantially increase the % solids in the pulps to be leached without a thickening step. These technologies are: • CIPIMM 2. At Preparation of pulps using additives. This method is based on the effect of some additives (inorganic salts) to improve the pulp’s properties. The use of this method allows increasing the % solids in the pulp up to 40% with good rheological properties • CIPIMM 2B. Preparation of pulps by thermal treatment of the ore previous to the preparation of the pulps. This method is based on the thermal destruction of the clays structure. Its use allows to obtain pulps with 50 - 60 % solids with excellent rheological characteristics. As a collateral effect, the Ni and Co grades increases by 10 - 15%. • CIPIMM 2C. Pulp preparation by chemical treatment. This method is based on the chemical transformation of clays, to obtain without thickening, pulps with 43- 45% solids and excellent rheological properties. The use of one of the three technologies depends on the chemical and mineralogical composition of the ores and the results of technical-economical evaluations to determine which one is the best alternative before running higher scale tests."

Jan 1, 2014

By Steven Wright, Sharif Jahanshahi, Shouyi Sun

"While there is a large industry based on recovering platinum group metals (PGM) from complex sulphide ores containing Cu and Ni, there is little information on the thermodynamics of the matte phase formed on smelting the ore and in particular the behaviour of Pt in the matte.The equilibrium between metallic platinum and industrial mattes was studied in a series of experiments where a small quantity of matte (5g) and platinum foil of 150 µm thickness (0.5 g) were equilibrated in magnesia crucibles at 1400°C under conditions where the oxygen and sulphur partial pressures were fixed.The chemical composition of the phases was determined from EDS analysis using a scanning electron microscope. Line scans were initially used to confirm that the foils had attained a uniform composition across their thickness. The composition of the matte was determined from analysis of an area of matte including the small metallic droplets and dendrites.The results of the equilibrium study are presented in terms of how the oxygen and the sulphur pressure affect the distribution of Pt, between the matte and the alloy foil (Lmatte/alloy). Other variables investigated were matte chemistry, i.e., the Fe content and the temperature. The activities of platinum in the mattes were calculated using a regular solution model describing the activity-composition relationship in the alloy."

Jan 1, 2003

By Y. S. Sun, P. Gao, Y. F. Li, J. W. Yu

"Oolitic hematite ore is one of the most refractory iron ores in the world. It is not feasible to separate iron minerals from raw ore by conventional mineral processing methods. In recent years, a new technology called coal-based reduction followed by magnetic separation has been employed to produce metallic iron powder from oolitic hematite ore effectively. In order to find the nucleation mechanism, a thermodynamic analysis of the carbothermic reduction of oolitic hematite ore was conducted by the HSC 6.0 thermochemical software. The phase transition and microstructure changes during the coal-based reduction were also investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results showed that the iron oxides in the oolitic ore were reduced to metallic iron following the route of Fe2O3–Fe3O4–FeO–Fe in reduction process. The reduction reactions preferentially occur in the high activity regions to form a higher concentration of Fe elements, and then more supersaturated Fe separated out to form new phase nuclei. Under the action of homo-aggregation and principle of minimum free energy, the iron cores continuously absorbed migratory Fe around and grew into quasi-spherical iron particles embedded in slag phase. INTRODUCTION With the rapid increase of steel industry, premium grade iron ore in China has been gradually exhausted, and its supply has become bottleneck for the development of iron and steel industry (Guo et al., 2015). Therefore, it is urgent to exploit the refractory iron ores, such as oolitic hematite ore. Oolitic hematite ore is widely distributes in France, Germany, America, Canada, Pakistan, China, and among other countries (Maynard and Van Houten, 2004; Li et al., 2011). In China, the explored reserve of oolitic hematite ore is 3.72 billion tons, which accounts for approximately 1/9 of total iron ore resources of China (Gao et al, 2016). Oolitic hematite ore possesses complex composition,"

Jan 1, 2018

By Danfeng Xu

The majority of the world?s nickel (Ni) resources occur as laterite ores, which are exceptionally complex, lower grade (<1.5% Ni) and expensive to treat using conventional smelting and high temperature/pressure autoclave methods. Heap leaching is a promising, less costly, alternative technology for processing low grade nickel laterite ores. However, significant technical challenges remain with Nickel laterite heap leaching, preventing its general adoption. This paper presents some highlights of laboratory column leaching studies undertaken to characterise, evaluate and optimise sulphuric acid leaching behaviour of Nickel laterite agglomerates. They provide basic but valuable information regarding Nickel laterite agglomerate structure stability and leaching performance under industrially-relevant, continuous acid irrigation conditions. In particular, Nickel and other key metals? (e.g. Co, Fe, Al and Mn) extraction rates, free acid concentration, bed slump and structural changes were determined at a given acid percolation rate as a function of time. Potential implications of the findings, for devising strategies for improved Nickel laterite plant heap leach operations are discussed. Keywords: nickel laterite, column leaching, agglomerates, leaching kinetics, acid consumption

Sep 1, 2012

By V. I. Ryaboy, V. P. Kretov, S. E. Levkovets, I. V. Ryaboy

"Using the flotation of a gold-containing ore from a deposit in Kazakhstan as an example, we have conducted a study designing dialkyldithiophosphate collectors, in addition to xanthates, for the flotation of hard-toenrich gold-containing ores to increase gold recovery.The increased flotational ability of the dialkyldithiophosphates was determined by their surface activity at the liquid-gas interface and their hydrophobic ability, the changing of which allowed us to control the collecting power and selective ability of the dialkyldithiophosphates. The studying of the surface activity of aqueous solutions was done using the stalagmometric method and the evaluation of the hydrophobic ability was done in percentage of the relative value of the zinc ion binding in the solution in standard conditions.Studying the influence of surface activity in our designed dialkyldithiophosphate collectors, with their close hydrophobic ability, showed that even with a small increase in surface activity in their aqueous solutions, gold recovery increased by 2-3% in laboratory conditions. Using this enabled us first to apply the dialkyldithiophosphate collector BTF-161 at a plant in Kazakhstan, and then to introduce the specially designed dialkyldithiophosphate collector BTF-163, which has been in use since. Further study of dialkyldithiophosphate activity based on this concept showed us that for the range of short-chain dialkyldithiophosphate collectors with a chain length of up to ?5, the effectiveness of ore processing became lower the higher their surface activity got, with relatively small differences in their hydrophobic ability. For long-chain dialkyldithiophosphates with a chain length of over ?5, ore processing effectiveness increased with the increase of their hydrophobic ability.Based on these studies, a new effective dialkyldithiophosphate collector, BTF-1517, was designed. Using this reagent in continuous gold recovery tests allowed us to reach an 84.21% recovery with a concentrate quality of 15.66 g/t, while using the applied collector BTF-163 in similar conditions led to the recovery of 82.87% with a concentrate quality of 15.65%. As a result, the Kazakhstan processing plant decided to conduct industrial tests with the BTF-1517 collector."

Jan 1, 2018