Search Documents

By Francesco Vegliò, Luigi Toro, Francesca Pagnanelli

Different hydro-metallurgical processes have been studied in order to recover manganese(II) from oxidised minerals such as MnO2. An innovative acid reductive leaching carried out in mild experimental conditions was here considered using agricultural and industrial wastes containing carbohydrates as reducing agents. The leaching process was investigated from a kinetic and equilibrium point of view in order to optimise the experimental conditions, develop a kinetic model and obtain high purity concentrated MnSO4 solutions. To study the leaching kinetic a Shrinking Core Model (SCM) was modified by a variable activation energy term to take into account both the variable reagent concentrations and the reaction rate change with respect to the manganese dioxide conversion. The influence of the particle size in the kinetic model is discussed with the support of SEM analysis before and after leaching. Manganese extraction yield was maximised (170-190 g/L) using appropriate carbohydrates and acid excesses, while impurity concentrations were kept low (Fe<10ppm and Ca<300ppm) pre-treating the ores, using hydro-alcoholic leaching medium and different combinations of down-stream processes. In particular precipitation, solvent extraction and adsorption onto active carbon were tested to eliminate Fe and Ca from MnSO4 solutions.

Jan 1, 2003

By O. N. Mohanty, S. Mohan Rao, N. D. Rao, T. Mukherjee, P. V. T. Rao

"Tata Steel has its captive chromite resources at Sukinda, Orissa. They contain two ore types, i.e. (i) Ferruginous and (ii) Siliceous. The generation of off-grade ores is an increasing trend and simultaneously customer quality requirements are becoming ever more stringent. The ferruginous type ore also contains a considerable quantity of in-situ fines (~20% particles below 0.5 mm) that compound the beneficiation problem.In this paper, new strategies are discussed for producing additional value.added products after evaluating the present beneficiation practice in terms of changing market scenario, processing capability of the plant and ore characteristic. They would entail use of MGS - an enhanced gravity separator, for recovering additional products from plant tailings; production of ferruginous coarse concentrates (-3+0.5 mm with ~46% Cr2O3) using jigs; production of marketable grade lumpy (-40+10 mm size) concentrates from low grade siliceous ore using jigs and >2.8 Cr/Fe ratio siliceous ore fines treated in the Chrome Ore Beneficiation plant gravity circuit units and low intensity magnetic separator. The studies indicate that it is possible to recover 79-80% of the chromite, against a theoretical maximum of 82% from both the ore types, in the form of several marketable grade concentrates that would also include refractory grade."

Jan 1, 2003

By Felipe Henríquez, Daniel Silva

"Traditionally, the implementation of an automated advanced process controller in any mineral processing complex is a challenge, mainly due to the quality of resources and technologies required, the uniqueness of each control solution and the uncertainty of the engineering hours needed to complete the task. Thus, the use of advanced and proven control technology becomes a key factor when deploying the control strategy. However, success would still not be possible without the presence of common sense, process knowledge and fundamental process data. Minera Los Pelambres, taking advantage of such factors and its accumulated process experience, implemented a novel and successful combination of MPC (Multivariable Predictive Control) and advanced control for secondary grinding and regrinding stages at its copper concentrator plant. In both cases, the control objectives are: being capable of processing a variable feed from the upstream process while at the same time avoiding to become a process bottle neck and yet, maintaining an adequate product quality (in terms of size distribution) to the process downstream. Additionally, for the case of the vertical regrinding mill (vertimill), the control system should also be capable of keeping an adequate circulation load and making an efficient use of the available grinding power. In either case, extending hidrocyclones availability while maintaining their performance is a must, since both factors are required for process and maintenance purposes. Thus, the process control problem becomes one with a multi-variable type of process with multiple control objectives to satisfy simultaneously. In trying to solve it, many mineral processing operations have implemented basic or conventional control or even better yet, expert systems. Minera Los Pelambres believes that better and faster results can be achieved using a combination of MPC and advanced control. Such strategy was successfully implemented, reducing considerably process variability while maintaining high throughput and keeping the process well within constraints limits. Their control philosophy, implementation process, main results and their key performance indicators are discussed here."

Jan 1, 2014

By A. J. Lynch, D. K. Tungpalan, Y. Reja, E. C. Avelar, G. Figueroa, S. Gómez, R. Alanis, M. A. Corona-Arroyo

"Have you been on a mine site? This question was posed by Emeritus Professor Alban Lynch to Higher Degree by Research (HDR) Students from the Sustainable Minerals Institute - Julius Kruttschnitt Mineral Research Centre (SMI-JKMRC) in the Student Technical Presentations in 2015. From that question, five HDR students from SMI-JKMRC organised a placement on mine sites in Mexico. The SMI-JKMRC is well known for its tradition to provide their students with opportunities to enhance and test their skills in mineral processing plants. The Student Venture became a short internship for HDR students which had the objective of establishing collaboration with mining companies in Australia and overseas, and of providing a unique experience for the HDR students in regard to their training, professional development, networking and cultural interchange. In return for the companies’ support, the students conducted plant audits to evaluate the process performance thereby providing valuable data to the host company. The 2016 Student Venture was held at the Grupo Peñoles & Grupo Fresnillo in Mexico, in which three mine sites received five HDR students from JKMRC and one young researcher from Universidad de Guanajuato (UG). This paper describes the positive outcomes for the mining company and the students for this experience. The Venture was considered very successful, as it provided valuable training for the students as well as in depth information about the operation of the comminution and flotation circuits of the host sites for the Grupo Peñoles & Grupo Fresnillo. The experience also provided an opportunity for an exchange of knowledge between the HDR students and the site personnel from the host operations. The indication of the success of the experience for all involved was the support of the host company in future student internships."

Jan 1, 2018

By A. Otsuki

This paper describes the evaluation method of dispersion and coagulation of silica nano-particles by means of interactive force apparatus. The apparatus measures the size of fine particles in aqueous solution or organic solvent of high concentration and/or low optical transparency. Other conventional apparatus for size measurements (such as, apparatus utilizing dynamic light scattering) are difficult to measure the size of particles in such conditions accurately, due to multi-scattering of light in the sample solution or solvent. The apparatus measures the interactive force between two surfaces, i.e. the gold-coated glass hemisphere and the brass flat plate, (which is fixed at the bottom of the sample cell). The apparatus has three parts, i.e. main part (which consists of electric balance, hemisphere and flat plate), control part (i.e. personal computer, piezo-stage controller and voltage supplier), and detecting part (i.e. multi-meter and oscilloscope). During the measurement, electric field is applied between the hemisphere and flat plate, and thus dielectric particles are arranged toward the direction of electric field in the area between two plates. When the two plates are close to each other, two different forces (i.e. repulsive force and attractive force) will alternately act on particles due to the structure change of the particles. The repulsive force occurs when the structure of particles is stretched by compressive force; whereas the attractive force occurs when the aggregate structure is broken. The cycle of the repulsive and attractive forces is a primary size of particle or size of aggregate, which depends on the degree of agglomeration. The measured size of particles, which is varied depending on their degree of dispersion and coagulation, determined the characteristics of the silica particles. In this research work, the effect of size and concentration of particles in aqueous solution on the degree of dispersion and coagulation of the silica particles were investigated. Spherical silica particles were selected for this investigation due to their variety of size. This apparatus can be used to evaluate the degree of dispersion and coagulation of other nano-particles in various solvents in many process industries.

Jan 1, 2014

By Sirish L. Shah

It is now common to have archival history of thousands of sensors sampled every second over long time. Yet we frequently have process engineers complain:??.We are drowning in data but starving for information??. How can these rich data sets be put to use? This paper addresses the issue of information and knowledge extraction from data with emphasis on process and performance monitoring including fault detection and isolation. Most of the major plant, factory, process, equipment and tool disruptions are avoidable, and yet preventable fault detection and diagnosis strategies are not the norm in most industries. It is not uncommon to see simple and preventable faults disrupt the operation of an entire integrated manufacturing facility. For example, faults such as malfunctioning sensors or actuators, inoperative alarm systems, poor controller tuning or configuration can render the most sophisticated control systems useless. Such disruptions can cost in the excess of $1 million per day and on the average they rob the plant of 7% of its annual capacity. Over the last decade the fields of multivariate statistics and data visualization and analysis methods have merged to develop powerful sensing and condition-based monitoring systems for predictive fault detection and diagnosis.These methods rely on the notion of sensor fusion whereby data from many sensors or units are combined with process information, such as physical connectivity of process units, to give a holistic picture of health of an integrated plant. Such methods are at a stage where these strategies are being implemented for off-line and on-line deployment. This article attempts to outline the field of sensor fusion - the application of signal processing methods, in the temporal as well as spectral domains, on a multitude and NOT singular sensor signals to detect incipient process abnormality before a catastrophic breakdown is likely to occur Keywords: Process analytics, process and performance monitoring, multivariate statistical analysis, sensor-fusion

Sep 1, 2012

By E. V. Manlapig

"Some researchers postulate that the floatability of a particle in the streams of an industrial flotation circuit is a function of only its size and liberation properties. They do not discount the importance of reagent or surface contamination on particle floatability but assume that the reagent coverage or surface contamination of the particle surfaces is essentially uniform for particles of similar size and mineralogical properties when subjected to a particular chemical regime.In this paper, samples collected from batch tests performed on different streams of the Red Dog lead cleaning circuit have been characterised with respect to their size, mineral association and mineral surface exposure. An analysis of this data set indicates that particle recovery rate is significantly affected by mineralogical properties - in particular the degree of valuable mineral surface exposure.However, through the use of a nodal analysis technique developed by the authors, it can be concluded that particles with the same size and mineral composition do not all float with the same rate, but with a distribution of rates. The characteristics of this floatability distribution do not change during the flotation process. It is suspected that the particles within a size mineralogical class in this study have varying degrees of surface oxidation and that this results in varying particle flotation rates. Thus basing particle floatability on size and mineralogical effects, alone, in a flotation model is not always valid."

Jan 1, 2003

By M. R. Robben

Carbonates have gained significant economic importance for the human kind. On one hand over a hundred uses are listed for carbonates. On the other hand, carbonates host base metal deposits. Although the carbonates play a significant part in the development of those deposits, in the mineral processing they consume acid and cause selectivity problems during flotation and leaching. Carbonates also accompany other industrial minerals as waste rock. For all those cases it necessary to find a technique to separate carbonate as early as possible in the processing chain. In this paper, the applicability of near-infrared spectroscopy (NIRS) sorting for the separation of carbonates is discussed. NIRS sorting is a sensor-based sorting technique, in which particles are singularly detected by a sensor and then rejected by an amplified mechanical, hydraulic or pneumatic process. This technique can for example be implemented in the process as a pre-concentration step for coarse particle sizes up to 300 mm. NIRS sorting discriminates among materials based on the difference that exist between their spectral properties in the near-infrared (NIR). Vibrations of molecular bonds in carbonates cause characteristic spectral properties in the NIR, which makes carbonates detectable, possible to identify, distinguish and separate from other rock materials. The spectral properties can also be used to distinguish between different carbonate minerals and mixtures. If the spectral variations are large enough for detection, sorting based on NIRS is possible. Feasibility studies on sensor-based separation of carbonates in the processing of talc, borate, fluorite, marble, zinc-oxides, copper sulphide and iron ore as well as the discrimination of calcite and dolomite mixtures are conducted and indicate the high potential of NIRS sorting in the minerals industry. Keywords: carbonate separation, sensor-based sorting, near infrared spectroscopy, NIRS sorting

Sep 1, 2012

By C. P. Lowes

"The REFLUX™ Classifier (RC™) consists of a fluidized bed housing, with a system of parallel inclined channels above. This system performs a simultaneous gravity separation and desliming of the feed material, utilising the inclined channels in order to retain the relatively fine dense particles. These particles promote the formation of an autogenous dense medium within the fluidized bed. Relatively large, low density particles are displaced from the fluidized bed and conveyed upwards through the inclined channels reporting to the overflow with other finer particles. Given the hydrodynamic role of both the particle size and density in determining the particle transport through a water based suspension, all gravity separators operate over a limited size range. In the case of the REFLUX™ Classifier, efficient separations can be produced across a very broad size range, from nearly 10 mm down to 10 m, however, for a given application the size range is much more limited. This study was concerned with the processing of dense minerals over a broad size range, and the need for multistage processing. Here the overflow from the first stage cascades to the second stage, incorporating coarse gangue rejection. This approach is shown to deliver remarkably high grades and recovery.INTRODUCTION The performance of the REFLUXTM Classifier (RC™) in beneficiating fine coal is well documented (Galvin, 2012). Although the technology can be applied to relatively fine particles below 0.1 mm, or coarser particles below 2.0 mm or even 8.0 mm (Galvin et al., 2010), in each case the technology is applicable to limited particle size ranges. In coal preparation, the most common size range is 0.25 to 2.0 mm, covering an eight-fold range in the particle diameter. Coal has a relatively low density, typically below 1600 kg/m3, with a significant portion below 1400 kg/m3. In water, the buoyant density difference (~ 400 kg/m3) is therefore low compared to that of gangue minerals (1600 kg/m3) by a factor of 4, enhancing the potential for separation. Thus, in coal preparation, the technology can be applied over a commensurately broader size range, typically up to eight-fold."

Jan 1, 2018

By A. Sand

Within stamp-charged coke making a large volume of coal is compacted to one single coal cake before entering the coke oven chamber. This is done by means of several falling stampers in a stamping machine having a mold nearly of the oven?s dimensions. Producing a high quality coke also from inferior coals requires a cake density of approximately 80% of the coal density. Besides that the industrial stamp-charging process demands a minimum mechanical strength of the coal cake to move it from the stamping mold into the oven chamber without failure. Densification and the build-up of cake strength were investigated earlier in stamping tests using a micro-stamping device. The quantities derived from these tests (as e.g. cake density or porosity) represent average values for the entire cake. Statements describing the local compaction state at different heights are difficult to achieve without destructing the cake. In order to gain better insight into the densification process and the inner structure of the coal cake a computational model based on the discrete element method (DEM) has been set up using 2 and also 3-dimensional simulation software. The stamper?s position and velocity as well as the force acting on the stamper were monitored and the model?s response was compared against measurement data from laboratory stamping tests. It was possible to reproduce the force and displacement pattern of the stamper in response to the viscoelastic properties of the cake using standard DEM bonding and contact models. Furthermore, the rearrangement of particles in response to the compaction by the stamper was tracked by calculating their displacement at the point the stamper hit the coal surface. The latter can also be used as indicators of particle deformation or breakage. By defining control points at different heights the particle displacement, stress and strain rates, porosity could be studied at different heights. Keywords: coke making, coal stamping, compaction, agglomeration, DEM, simulation

Sep 1, 2012

By Mojtaba Ghorbannezhad, Abbas Sam, Soroush Arabzadeh

One of the dewatering methods in mineral processing plant is filtration system. Disk filters are included the porous surface with pressure drop on both sides, Water in the pulp passes through the surface and solid particles remain as a cake on it. Wet concentrate production of magnetite processing plant at Golgohar Mining and Industrial Company with solid tonnage of 160 ton per hour and 49% solid amount contains 166 m3/h of water. In the present study, in addition to studying disc filter performance, the effective parameters on cake moisture were studied using Vacuum Bottom-Feed Leaf method (in the laboratory scale). Optimization was performed using the Taguchi method. The results showed that the cake moisture is reduced by increasing particle size and solid percentage (because of specific resistivity reduction), while the rate of cake formation and its thickness are increased. Also, it was found that by increasing pressure, the cake moisture is reduced and cake formation rate and its thickness are increased. In this study, the effect of fabric texture was also examined. Lowest cake moisture was obtained in condition of using compressed plain fabric with mono-multi filament fibres, pressure at 75kPa, solid percentage of 65 to 70, particle size (D80) equivalent to 123µm and disk rotation speed of 1.25 rpm.

Jan 1, 2014

By L. A. Vaisberg, E. V. Shishkin, S. V. Kazakov

"This research is targeted at finding solution to the problem of reduction of specific energy consumption during disintegration of solid materials with the help of machines, operating in a quasiresonant mode. The objective of the research is the development of an energy-saving method of disintegration of supestrong rock and by-products on the basis of vibrational units with two movable crushing elements, operating in a rigorous synchronous-antiphase mode without stringent kinematic links. In the course of investigations a mathematical analysis of the dynamics of vibrational units was performed to determine required mechanical parameters, allowing for adjustment of the machine actuating elements to high-frequency synchronous-antiphase oscillations in the quasiresonant frequency range. As a result of performed pilot tests, the reliability of desktop studies was confirmed and the dependency of process parameters on the machine regulated parameters in the quasiresonant frequency range was identified. The analysis of obtained data showed that during machine operation with cone-shaped crushing elements in the quasiresonant frequency range, the yield of the high-quality finished product (WFA grits of -3+1 mm grain size class) in one pass reaches 35%, whereas the form of the particles corresponds to the grain form with sharp edge. The quasiresonant operation mode of the vibrational unit with two freely suspended crushing elements (without stringent kinematic links) provided substantial reduction of energy intensity during crushing down to 0.16 kWh/t, which shows reduction of power consumption for crushing by more than 15% compared to conventional equipment.INTRODUCTION The most common and energy-consuming processes in the mining industry are the crushing and grinding of various solid materials. Such large energy costs are due to the fact that the capabilities of the existing crushing and grinding machines are based on traditional methods of destruction, and are limited by their kinematic features, which do not allow to reduce the energy intensity of processes, to lower the irreversible loss of useful components, to improve the quality of marketable products. In connection with the foregoing, the task of energy costs reducing for disintegration is one of the most important issues in the enrichment of both minerals and processing of man-made raw materials. The solution of this problem is possible only through the creation of a fundamentally new highly efficient technique and technology for processing raw materials [1, 2]. It seems that the greatest prospects in this respect are the vibration methods of disintegration, in particular, the vibratory cone crusher based on a two-mass system without rigid kinematic connections between the crushing bodies, with vertical vibrations of the working bodies. In this machine, the principle of rational material destruction is realized – crushing without re-grinding [3-5]."

Jan 1, 2018

By Rod Hocking, Nenad Djordjevic, Randolph Pax

"Semi Autogenous (SAG) mills exhibit complex interactions between the competing processes occurring inside them. Traditional practice is to measure the operation of the SAG mill at an operating point in terms of its load, power draw, steel load, ore throughput rate, water addition rate and more recently the feed size distribution. However significant departures of operating conditions can occur due to changes, for example, in ore hardness, the quest for higher throughputs and mill internal geometry.Fundamental to SAG mill operation are the internal processes that ensure that a given ore throughput and discharge grind size are obtained and maintained. These processes can be measured using non-contact acoustic emissions from the SAG mills which utilise the information rich noise that is generated by the grinding, flow and charge movement inside a mill.Non-contact acoustic in-mill measurements can be used for the validation of discrete element modelling (DEM). The approach being reported in this paper is to model the individual physical processes and then to simulated the assemblage of a physical mill."

Jan 1, 2003

By Sanja Miskovic, Manjunath Basavarajappa

In this study, a coupled CFD-DEM (Computational Fluid Dynamics-Discrete Element Method) approach is used to simulate two-phase, solid-liquid flow within the flotation cell. Turbulence plays a key role in flotation cells and level of turbulence is affected locally by the presence of particles. Turbulence in the flow is modelled using Reynolds Averaged Navier-Stokes (RANS) based k-e model. Using particle transport and spatial distribution, mixing mechanism for differed sized particles are analysed. By including the effects of particle-particle collision, particle rotation, and particle translation, as well as the volume occupied by the particles in the fluid, CFD-DEM approach can be used to accurately predict the motion of particles in the turbulent solid-liquid flows with strong coupling. Electrical resistance tomography (ERT) is used to investigate the effect of impeller size, shape, off-bottom clearance and impeller speed on mixing and suspension behaviour inside flotation cell. The effect of flotation impeller design, impeller size, and off-bottom clearance on flow hydrodynamics is investigated. In the case of moderate and high solids loading (> 10 %w/w), energy is dissipated through inter-particle interactions and four-way coupling becomes important (Derksen 2003). The main goal of this study is to understand the effect of particle size and concentration on flow dynamics at high Re in highly turbulent systems using advanced modelling and measurement techniques. Experimental measurements obtained by ERT) system allowed detailed mapping of temporal hold-up profiles of the dispersed phase. Impeller size and off-bottom clearance are found have significant effect on the particle suspension characteristics.

Jan 1, 2014

By Ramon V. V de Araújo, Roberto B. E Trindade, Pablo R. Fica-Piras

"Lead has been reported to affect blood vessels and kidneys. It also produces adverse effects in the mental and physical development of children and nervous system of adults. It is also considered as a possible cause of cancer. Because of all these threats to the human life, the reduction of its environmental occurrence, by means of recycling, is an important additional advantage to the usual ones derived of the procedures of the secondary metallurgy: lead can be recycled several times maintaining its characteristics equivalent to the primary one.Furthermore, this way of producing the metal avoids the environmental impacts of primary lead melting. Also, as an additional advantage, it triggers the metallurgical process with a raw material in what we observe higher lead content than in the natural ores. Some of the potential sources for these purposes are: ashes, slags, electrode residues, anodic muds, spent electrolytes, solid and liquid wastes, industrial or automotive catalysts, worn-out or obsolete equipment components and/or final consumption products.About 40% of world’s lead production comes from automotive batteries, mainly composed of four parts: plastic box, electrolyte (diluted sulphuric acid), contacts and connectors of Pd-Sb and plates (PbSO4, PbO2 and PbO). The plates represent 75% of the total mass. Metallic parts can be melted at moderate temperatures and then refined. The remaining fraction, constituted by the non-metallic portions, can be recovered by hydro and electro-metallurgical routes. These routes are preferred instead of pyrometallurgical ones due to the ultimate emissions of lead particulates and sulphur dioxide.The principal constituent of the residual paste of batteries is the lead sulphate. In this process, the paste is treated in two stages: in the first, lixiviating with Na2CO3 (desulphurization of the paste), obtaining PbCO3 and Na2SO4; in the second, the lead carbonate is lixiviated with HNO3, producing Pb(NO3)2, soluble, that can be converted to metallic lead by electrolysis. The reaction of PbSO4 with Na2CO3 in aqueous solutions is fast: the global rate is limited by the diffusion of the carbonate ions inside the reaction medium."

Jan 1, 2003

The multiphase reactive flow in process equipments, e.g., fluidized beds, involves complex coupling among flow, heat/mass transfer and reaction kinetics over scales ranging from molecules, sub-particle eddies up to equipments. Conventional two-fluid model (TFM) ignores the effects of meso-scale structures, and hence is not suitable for describing the intrinsically multi-scale heterogeneity within multiphase systems. To be consistent with the meso-scale structures, we proposed a structure-dependent multi-fluid model (SFM), and closed its drag force by invoking the stability condition defined in the energy-minimization multi-scale (EMMS) model. The SFM reduces to the conventional TFM if homogeneous distribution is assumed within each grid, and reverts to the original EMMS model if it is used to describe steady state, global behavior of a fluidized bed. The multi-scale computational fluid dynamics (CFD), which is characterized by coupling of TFM and EMMS drag coefficient, can then be viewed as a simplified solution of the SFM. We demonstrate that the SFM significantly improves the accuracy and at the same time enables higher efficiency by allowing for much coarser grid used than in TFM. Recent application of it in 3D, full-loop, transient simulation of industrial processes, e.g., fluid catalytic cracking, coal combustion, gasification, kaolinite clay calcinations, shows its advantages in helping design and troubleshoot multiphase process equipments. Keywords: meso-scale, SFM, multiscale, CFD, simulation, structure, EMMS, multiphase

Sep 1, 2012

By J. Sachweh

The last few years have shown a significant increase in the demands for fine products, which means everything under 10µm. There are more and more applications requesting extremely fine ground powders leading to the development of several milling machines which are better adapted to the new products. Cost saving machinery is important for the worldwide competition. Especially the energy consumption is extremely important for any fine ground product. A worthwhile field for mechanical engineering companies is the dry milling machinery as there are not as many solutions available compared with wet milling applications. In many cases wet mil-ling is the only solution to reach the requested quality, but there are also a lot of applications which can be performed in a dry way on the premise that the right mill and classifier are available. Dry milling permits to save energy and allows to influence the particle size distribution more easily, as a classifier can be used in that case. This will significantly reduce production costs and can enable the production of new products with better properties. The Tower Mill is well-known already in the field of wet grinding. Recent research work and end user reports have shown clearly that this mill has a lot of advantages compared to a ball mill. Up to now this advantage is limited to wet grinding as only few mills have been used for dry grinding. There is no doubt about the efficiency of dry grinding, but new and improved feeding and discharg-ing systems have to be developed in order to enable the full range of its advantages. Especially the high production capacities are a challenge for mill and classifier designers. The Tower Mill with its special grinding mechanism allows to cope with very high feed rates, because machines with more than 1 MW are available. Improved grinding efficiency will decrease the circulation load through the classifier and also lead to smaller classifier sizes. Together with im-proved mills the classifier can work more efficiently because the feed material is finer. Results of a test center plant production will be shown together with a comparison between stan-dard machinery and the MaxxMill®. Preferential applications for each mill will be explained.

Jan 1, 2014

By Kazutoshi Haga, Batnasan Altansukh, Atsushi Shibayama

Results of flotation process combined with atmospheric leaching and high pressure leaching for recovery of copper from low-grade silicate-copper ore have been presented in this study. The low-grade copper ore contains a small amount of copper (0.42 mass %), iron (4.6 mass %), and silicon (38.3 mass%) and among many other metals (Al, Ca, K, Mg, Na, Ti and S). The main mineralogical constituents of the copper ore are calcium aluminosilicate (Ca(Al2Si2O8), amesite (Mg2Al2SiO5(OH)4) and gypsum (CaSO4×H2O), and quartz (SiO2) as resulted from the alteration of an igneous rock. This study has shown that about 92 % of copper can be recovered with a maximum copper grade of 4.2 mass% in a froth after 15 minutes of flotation at pH 8.5 when used potassium amyl xanthate as a collector, MIBC and Dow-froth 250 as frothers and calcium hydroxide as a pH adjuster. The images of bubbles in the cell during flotation process were recorded using a high-speed camera. The froth concentrate with average copper grade of 2.0 mass% was further processed by atmospheric leaching with a solution of sulphuric acid and hydrochloric acid, respectively and high pressure leaching with sulphuric acid solution. As a result, leaching rate of copper reached about 60 % in an atmospheric leaching with sulphuric and hydrochloric acid respectively, whereas the rate can reach more than 70 % by autoclave leaching at high pressure under the controlled condition. A process to recover of copper from its low-grade ore can be developed by optimization of flotation combined with acid leaching.

Jan 1, 2014

By Julian Dimitrov, Kremena Dedelyanova

"The paper presents research on hydrodynamic processes occurring at the elementary act of flotation. Discussed existing models to determine the effectiveness of conflict of bubbles with particles in vibration column flotation machine. The paper presents a disperser for a column flotation machine, in which the dispersion of the gas phase is carried out using vertical vibration with defined frequency and amplitude. The paper presents research of mechanism for the creation of air bubbles in vibratory column flotation machine. The factors influencing the increase in the duration of the bubble in the area of contact with the mineral particles are discussed. Research was carried out on the effect of frequency and amplitude of vibrations on speed of precipitation of mineral grains of different density. Formulas are derived for the parameter effect of vibrations, applicable to the design of flotation machine. The collision efficiency of the bubbles in vibratory column flotation machine is determined. The vibrations of the hydrated layer allow for cost-effective implementation of the elementary act of flotation by providing larger relative velocities at the contact point between the bubble and the solid phase. It is proposed to complement the model more accurate representation the mechanism of attachment of the particles to the bubble."

Jan 1, 2014

Calcium carbonate has three polymorphs: calcite, aragonite, and vaterite. Needlelike aragonite CaCO3 with a high ratio of length to diameter (aspect ratio) is widely used in plastics, rubber and ceramics as a filler and in pigments and paints as a carrier. This paper investigated the influence of H3PO4 dosage, reaction temperature, CO2 flow rate, and initial Ca(OH)2 concentration on formation of needlelike aragonite CaCO3. It was found that the presence of H3PO4 in Ca(OH)2 suspension resulted in rapid formation of (Ca5(PO4)3(OH)) crystal nuclei, which facilitated nucleation and growth of aragonite CaCO3 on the formed (Ca5(PO4)3(OH)) crystal surfaces. The results revealed that H3PO4 addition of P/Ca of 0. 2~0. 3, high temperature of 75~85 °C, low CO2 flow rate and initial Ca(OH)2 solid concentration of 1. 5 %~5. 6 % are beneficial to formation of aragonite. Well crystallized needlelike aragonite CaCO3 whiskers with length > 20 µm and aspect ratio > 15 were directly synthesized.

Jan 1, 2014