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By Diogo R. Prado, José Aurélio M. da Luz

Drying operation can have a major importance in a mineral processing undertaking. The proper sizing of dryers can ensure the specified dewatering level without energy wastage. However, often the sizing of fluidized bed is done disregarding the actual residence time distribution (RTD) of the particles inside the reactor. In this case it is usual to adopt the average residence time as a design criterion. In this work, we have quantified the effect of residence time distribution on drying, ensuring that a previously adopted fraction of the particles remains inside the reactor for the required time lapse needed for drying. Design criteria such as particulate flow rate and drying time, taking into account the statistical distribution of residence time was studied, matching the thermodynamic and fluid dynamic aspects of the drying process. Experimental tests carried out have confirmed the RTD for a teetering bed as the same for a canonical ideal mixing system. Although the fluidized bed volume using the proposed formulation was higher than that found for the average time based procedure, the efficiency gain in drying has proven advantageous.

Jan 1, 2014

By Bhargav Dhavala, Sristy Raj, Ashok Kumar, Suman Krishna Sit, Adity Ganguly, D. P. Chakraborty

"Tatasteel’s West Bokaro washery#3 is designed to deslime raw coal at 0.5mm; the oversize (+0.5mm) is beneficiated in dense media cyclones (DMC) while the undersize (-0.5mm) is beneficiated in froth flotation (FF) cells. Nearly, 80% of the raw coal feed reports to the DMC circuit consisting of four parallel streams. Presently, the performance of DMCs at washery#3 is interpreted by: (a) comparing the actual plant yield w.r.t the lab predicted yield and (b) misplacement of clean coal to middllings.However, the comparison between actual & lab predicted yield is fallacious given the fact that the lab predicts yield of the borehole sample while the feed received at the plant has different characteristics altogether due to the dilution during mining. To mitigate the said limitations, a quick diagnosis tool using the past data has been developed that will give a prediction of performance of different coal seams in the DMCs, inputs being feed ash to DMCs and stream wise feed specific gravity (coal & magnetite combined).The tool also will help in identifying the root cause on real time basis thereby helping the operator to take necessary corrective actions. The operator can intimate the mining personnel in cases of shale reporting to the feed as a result of dilution during mining. In events of higher standard deviations between the parallel streams w.r.t feed specific gravity, the operator can adjust the parameters accordingly to minimize the yield loss. INTRODUCTION West Bokaro came into existence in 1948, as an independent coal company, managed by M/S Anderson Wright. Tata Steel acquired the Company in 1956 to meet its requirement of metallurgical grade coal for Iron making. Subsequently, in 1976, it was made a division of Tata Steel. In 1974, when coal mines were nationalized, West Bokaro was exempted as it produced coal only for captive consumption of the Steel Works. The first washery of India was set up in West Bokaro. The business objective of the West Bokaro division is to produce clean coal at optimum cost for captive use in the steel plant of Tata Steel at Jamshedpur. The strategy is to reduce ash with minimum loss of yield so that quality of coal improves and yet the cost is beneficial vis-a vis imported coal. The primary product is the metallurgical grade coal for coke ovens, which converts coal into coke for use in the Blast Furnaces."

Jan 1, 2018

By L. C. Zhou

The floatability of andalusite and associated minerals are studied and their action mechanisms of andalusite and associated minerals with collector alkyl benzene sulphonate are also studied. Through the mensuration of electrical potential and the infrared spectroscopy, as well as desorption tests, it is confirmed that the interaction of andalusite with sodium dodecyl benzene sulphonate (SDBS), is in addition to physical adsorption, but also is chemical adsorption. The study results of the pure minerals are used for the flotation of actual andalusite mineral. By flotation from contain-ing 45.68% andalusite ore, the fine andalusite concentrate is gained which Andalusite grade is 85.88%, containing Al2O355.29% and Fe2O3 less than 1.5%.

Jan 1, 2014

By G. G. Dong

This paper presents BF flotation machines in brief which are manufactured by Beijing General Research Institute of Mining & Metallurgy (BGRIMM). Dimensional analysis and similarity criteria have been used to scale up BF flotation machines. These scale-up criteria can be used to determine mechanical structure and hydrodynamic parameters including mixing, solids suspension, air transfer and power and so on. Similarity criteria are used to design 40m3 flotation machine being based on data from 1.2 m3 to 20 m3 flotation machines. Hydrodynamic tests of 40 m3 flotation machine in water are discussed.

Jan 1, 2014

By S. Gaydardzhiev

Initial experiments towards preparation of hollow ceramic microtubes by dip-coating of fibrous plants with water based alumina gel-casting slurries using hemp and coconut fibres as templates have been done. It has been found that the wettability of fibres and accordingly the stability of the developed ceramic layer on their surface during slurry gelation varied significantly within the different fibre types. Good correlation between the diameters of the template fibres and the resulting channels has been found at the level of solids loadings used, 31 %. Hemp fibres used as bundles have led to formation of multi channel patterns while the coconut fibres-templated process resulted in uniform monochannel materials. The micro tubes have show good mechanical handling.

Jan 1, 2014

By Khoi Nguyen, Keeney. Luke

An outcome of geometallurgical mapping and modeling is the generation of continuous down hole profiles of quantitative geometallurgical attributes at assay scale. These attributes vary from traditional routine data collection methods such as assays and geotechnical logging (e.g. RQD, Fracture Frequency), to new measurements including petrophysical attributes, EQUOtip hardness data and modelled estimates of metallurgical performance indices (e.g. A*b, BMWi). Highly variable continuous geometallurgical data with high spatial resolution can make it difficult to identify spatially continuous domains. An automated method based on the well known time series analysis technique of cumulative summation (CuSum) has been developed which uses statistical analysis to identify domain boundaries in down hole profiles. A bootstrap analysis automatically identifies potential domain boundary locations with associated confidence levels and a series of t-tests determine the significance of defined populations. A hierarchical clustering algorithm is applied to results to enable data sensitivity to be taken into account. The method produces statistically significant populations and is suitable for application on either single or multiple drill hole datasets. Domains defined preserve the inherent variability of the continuous down hole data and provide a method for scaling up variability data (i.e. assay interval scale) to mine scale (i.e. bench scale, block model). A major advantage of the method is its ability to provide suitable input parameters for use in spatial modeling of non-additive and non-linear geometallurgical attributes through conditional simulation techniques.

Jan 1, 2014

By Z. D. Tan

The continuous digestion technological conditions of phosphate tailings with high magnesium content in sulfuric and phosphoric mixed acid is studied in this paper. The influences of excess coefficient of sulfuric acid, weight liquid to solid, reaction temperature and time on conversion of P2O5 and MgO are discussed. The influence of infiltration capacity of phosphogypsum by the concentration of liquid-phase SO3 is discussed too. Under the optimal technological conditions, the conversion of P2O5 is 95.56% and MgO 98.63%, the filtration rate of phosphogypsum increases with the increasing of liquid-phase concentration of SO3, the optimal apparent concentration of SO3 is 0.135~0.14g? mL-1 in liquid-phase. The filtration rate of phosphogypsum is 1473kg? m-2? h-1. N-P-Mg compound fertilizer was produced by adding magnesia powder and inflating ammonia in filtering medium.

Jan 1, 2014

By R. Mukherjee

Consistency of Run-Off-Mine (ROM) quality plays an important role in mineral processing which is not very often talked about. The major impediment is limitation of sampling ROM ore, which makes processing plants to run without any realtime feedback on ore quality that comes in. The process of direct determination of Run-Off-Mine (ROM) ore quality is expensive and time consuming as drawing and preparing representative samples from blasted muckpiles are constrained by large sample size and inherent heterogeneity in terms of size and chemistry. In absence of techniques for direct measurement of quality, monitoring and control of ROM, feed to the processing plant at Joda East Mine, like all other iron ore beneficiation plants worldwide, is largely based on blasthole sampling and subsequent chemical analyses of blastcone chips. While such indirect methods proves to be more accurate for representing whole of a mining block or blasted muckpile (~30-50KT/blast), it is indeed a challenge to ascertain and predict day to day input quality for a part there off. This eventually leads to a gap between predicted and actual ROM quality, resulting in difficulties in process control, in turn, and leading to wide swings in product quality. Hence, it is imperative to bridge the gap between predicted and actual ROM quality by arriving at means, which ensure consistent plant feed grade to deliver consistent output. The paper discusses an efficient and affordable alternative for effective prediction of ROM alumina which has been developed by integrating blasthole quality database in GPS based Truck Dispatch System (GPS-TDS) at Joda East Mine. Initially, GPS-TDS has been installed for optimizing production parameters only, but this development has helped in further utilization of GPS-TDS for real time quality monitoring by improving ROM grade prediction and scheduling from several ore blocks in active mining areas. Keywords:run-off-mine (ROM), blast hole, feed grade, GPS-TDS

Sep 1, 2012

Nowadays, the more successful plants are those who have adopted effective and efficient strategies to optimise their plant operation. As the ?heart of the plant? could be viewed as the mil-ling/grinding area, one of the key steps in plant optimisation is, therefore, ensuring the mill is operating properly. In the past, when primary, secondary and tertiary crushers fed material directly to large ball mills, the energy efficiency of the concentrator was determined for the most part by the ball mill operation, whereas now the energy efficiency of a plant often rests largely on the semiau-togenous grinding (SAG) mill operation. As a result, mines have shifted their emphasis in optimization from ball mills to SAG mills. The grinding mill?s energy efficiency essentially depends on ore characteristics and the discharge rate of broken particles, which in turn depends on how efficiently the discharge pump (grate and pulp lifters) operates. The essential function of pulp lifter being to transport the broken material and slurry out of the mill, its design optimization therefore affects the discharge capacity (or mill throughput) of AG and SAG grinding mills. This paper will discuss how the optimised design of the pulp lifter/ discharger has helped to eliminate material transport issues such as flow-back and carry-over of slurry and pebbles to in-crease the energy efficiency of SAG mill using the actual operational data.

Jan 1, 2014

By N. Pradhan

In the Sukinda valley, Orissa, India, a large quantity of overburden material is generated during the mining of chromite mineral (on average 10 tons for every ton of ore). The overburden hereby depicted as ?lateritic nickel ore? contains on an average 0.5% Ni. IMMT Bhubaneswar is working on this material for extraction of nickel and cobalt. But for better recovery of metal values, thermal activation or thermal reduction of ore is required. An alternative biotechnological route for reduction of ore is hereby attempted. An anaerobic dissimilatory Iron (III) reducing bacterial consortium (here denoted as IRB), capable of imparting iron phase changes in the lateritic nickel ore was established which improves the subsequent extraction of co-precipitated Co (III) and Ni (II) from the ore. In this study, properties of thermally and microbially reduced lateritic nickel ore are compared vis-à-vis original ore. Due to the phase changes, original light brown color of the lateritic nickel ore changes to dark brown on IRB treatment. This dissimilatory reduction of ore leads to formation of some magnetic particles, which were separable by hand held magnet. Roasting and IRB treated ore on acid leaching with H2SO4 show about 45 % and 36 % leaching of nickel ore compared to about 18 % leaching from the original lateritic ore. If bacterial reduction method is successful, cost intensive method of ore roasting process can be eliminated. Thus, it is possible to make use of dissimilatory iron reducing bacteria for recovery of valuable metals from off grade iron ore/ laterites. Keywords: lateritic nickel ore, bacterial reduction, thermal reduction, dissimilatory fe (iii) reducing bacteria

Sep 1, 2012

By Bern Klein, Givemore Sakuhuni

Flotation is the dominant base metal extraction technique and it requires ore to be ground below the liberation size for effective recovery due to its dependence on mineral surface properties. For a poly-metallic ore, differential hardness of constituent minerals leads to over grinding of softer minerals before the harder minerals are fully liberated, which makes selection of a target grind size complex, and the complexity increases when treating leaner ores. Flotation recovery deteriorates above 100 and below 10 microns causing significant loses of valuable minerals in most flotation circuits. Although enhanced gravity concentration is known to be effective at recovering particles above 100 microns, which are difficult to hydro-dynamically transport, exploiting differential specific gravity for base metal separation was not an option in the past. This was partly due to the absence of high mass yield gravity techniques. The advent of continuous gravity concentrators with flexible mass yields, in the past two decades, has necessitated investigation of possible base metal applications. The Knelson CVD, one of the continuous discharge centrifugal concentrators, has an established application niche for sulphides associated with gold. However, its base metal applications have never been rigorously tested. Considering the dependence of flotation recovery on particle size, continuous discharge centrifugal concentration can be integrated in flotation circuits to capture flotation non-recoverable coarse particles. This paper explores how particle size, liberation and mineral hardness influence application of continuous centrifugal technology to regulate galena deportment in a polymetallic base metal plant. The results show that particle size affects galena recovery more than liberation. In view of these results, the CVD can be integrated in the primary grinding circuit to pre-concentrate the heavy sulphides at a coarser grind size with potential grinding energy savings.

Jan 1, 2014

By W. Y. Gao

Diaojuntai Concentrator adopts a process of low intensity and high intensity magnetic separation and anionic reverse flotation, with all the concentrate from magnetic separation being treated by re-verse flotation to obtain a qualified final concentrate. The high reagent cost and energy consumption of the reverse flotation have led to a high concentrate cost. The test research on reducing the feed to the reverse flotation was therefore carried out. Based on the study of the properties of the ore sample, the concentrate of low intensity magnetic separation was screened at 0.076 mm and the undersize fraction was concentrated by concentrator with gravity and magnetic field. The results show that a qualified concentrate can be obtained at various rising current rate, pulsating current and power-on style, with the operation rate over 85%. The extraction of some part of qualified concentrate from the concentrate of low intensity magnetic separation by magnetic separation can reduce the feed to the reverse flotation by about 35% so as to reduce the production cost of concentrate.

Jan 1, 2014

By Carlos Gualdron, Elizabeth Gomez, Rafael Bolivar

The productivity index of the Coopracarcegua Ltda., a mid-size coal mining company of Norte de Santander, Colombia, was related absenteeism using accident, productivity and profit data four years. The analysis was based on type, severity and frequency of accidents, number of absentee days; price per metric ton, and other relevant parameters. The enterprise is formed by 5 different mines of thermic coal, each one with different exploitation technologies and different productivity. Each mine was analysed separately and the loss of profit due to absenteeism was calculate for each one. The study showed that the foregone earnings due to absenteeism in terms of the whole productivity of the enterprise was about of 6.6% of the total profit average the 4 years, with calculated values of 14.7%, 3.5%, 8.4% and 4% per year in the evaluated period. The study identified that the most important cause of absenteeism was "General Disease". The foregone earnings in 2009, the highest loss for the analysed period, was about US$ 0.937 million and during the whole evaluated period was US$ 2.46 million.

Jan 1, 2014

Incomplete liberation of mineral particles is one of the key factors limiting the performance of industrial flotation circuits. This work aims to quantify the relationship between different breakage modes and how these affect mineral liberation properties. A copper porphyry (bornite) ore sample was subjected to breakage using a piston-die compression unit and an impact mill. The particles produced as a result of each mode of breakage were then characterised using Mineral Liberation Analysis (MLA) to quantify the mineralogical and liberation properties of the progeny particles. The impact mill was found to produce bornite that was finer grained relative to the host particles. In con-trast, bornite discharged from the piston-die unit closely followed the size distribution of the host particles and was retained to a greater extent in the larger/intermediate size fractions. The results provide insight into what breakage methods are optimal for the purposes of downstream separation.

Jan 1, 2014

By Heramb M. Bal

This paper will underpin the future development of intellectuals having greater understanding of patent law and legislation, IP rights, and innovation. To understand this idea, I present a case study of China?s progress in the last 31 years in the rare earth research, innovation, and simultaneously patents area. Rare earth elements (REE) are at the centre of high technology and are the next wave of world innovation. Much of modern society depends on rare earth elements through their use in computers, lasers, telecommunications, iPods, medical technology, military applications, and so on (Long et al, 2010). The rare earth research, a large research body is being provided by Chinese sources. China devoted three or four university centers to the study of rare earths (Lifton, 2009). These measures are all designed to keep China at the forefront of REE production, materials, technology, and innovation. As a result in the last fifteen years there has been a shift from a US-dominated REE industry patents to Chinese patents. The world must identify strategic areas of rare earth innovation and provide funding to firms and universities that conduct such research. Not only research and innovation is vital but filing patents and preserving IP rights for research and innovation is even more important. We (rest of the world) need a comprehensive strategy to guide the development of patent and IP rights for research and innovation. To achieve this, the development of intellectuals with superior knowledge of patents and IP rights are the future need of minerals industry. Keywords: innovation, rare earth, patent, IP rights

Sep 1, 2012

By G. F. Zhang

Yunnan mineral is a kind of containing Ta-Nb rare earth deposit, the most potential economic valuable element in it is Sc, and raw mineral has 17.0 g/t Sc. Take the character of Sc into account, the key problem in producing scandium chloride molten salt by adaptive technology is how to man-ufacturer anhydrous scandium chloride molten salt. During the course above, the key problem is that preventing Scandium chloride from being hy-drolyzed into ScOCl. The ScOCl content of molten salt not only affect purifying scandium but al-so do harm to the production of Mg-Al alloy. In order to restrain the creation of ScOCl, add ammo-nium chloride into molten salt. As long as ScOCl is created, it would be chloridized. Thus, during the course of dehydrating anhydrous chloride molten salt this method prevents scandium from hydrolyzing. Accordingly, the key phase of this producing course is eliminate ammonium chloride and the surplus crystal water, and the most crucial of it is restrain scandium chloride from being hydrolyzed into ScOCl. This research analyzed the theory that ammonium chloride is trend to be hydrolyzed into ammo-nium chloride, and propose the research scheme of restraining this process from creating ScOCl. The new process of restraining the generating of ScOCl and dehydration for crystal water rare earth chloride is adopted: Inert gas temperature increases rapidly to a certain degree to eliminate ammonium chloride and crystal water. The experimental research were done such as : the temperature of eliminating ammonium chloride and crystal water, amount of ammonium chloride, time, temperature growth speed, influence of inert gas flow toward to scandium percent hydrolysis, whereby, we conclude the optimal process condition in this period: Temperature: 400°C, proportion of oxidized scandium and ammonium chloride is 1:1.5(Proportion of oxidized scandium and additional salt is 1:5.4), time is 120minute, temperature growth speed is 10?/min inert gas flow is 5L/min.

Jan 1, 2014

By Petrus van Staden, Dragan Milanovic, Francisco Sánchez, Eero Kolehmainen, Carlos Frias

"Currently there is no economical and viable process for on-site metal extraction from Low Grade, Complex or Poly-metallic deposits, and even more, there is not any industrial process or technology able to deal with polymetallic or bulk concentrates containing Cu+Zn+Pb base metals and also precious metals. Traditionally, metals recovery from polymetallic sulfide deposits is performed by mining, selective flotation to separate Cu, Pb and Zn concentrates, and finally, smelting/refining of those concentrates to obtain the refined metals. In many cases, selective flotation of that kind of complex ores produces low metals recovery and low concentrate quality containing impurities such as Hg, As, Bi, etc., which results in high penalties in treatment and refining charges, and consequently, worsening the economy of the mining business. Recovery of the valuable metals from Polymetallic, Complex or Low Grade ores could then be maximised by producing bulk concentrates or middling flotation products to feed novel hydrometallurgical processes, like the integral metallurgical system that is currently under development within the INTMET project. For example, producing bulk concentrates would increase more than 100% Cu+ Zn+Pb cumulative recovery versus conventional selective flotation. Founded by the Horizon-2020 EU Programme, the INTMET Project was started in February 2016 and will be running over three years. The INTMET consortium is led by Cobre Las Cruces (Spain) and integrates twelve partners from seven EU countries, and including Serbia and South Africa as well. The INTMET project represents a challenging opportunity to develop suitable technological solutions to deal efficiently with difficult, polymetallic and complex sulphide ores that are abundant in Europe and worldwide. Main activities carried out during the first 18 months of the INTMET project development includes: (i) An atmospheric leaching pilot plant having a capacity of 300 kg/h bulk concentrate which has been installed and operated continuously for nine months at the Las Cruces mine; (ii) Pressure leaching test work developed by Outotec; (iii) Bioleaching test work performed by Mintek in collaboration with MMI Bor. Prior test work was applied on bulk concentrate samples supplied from Spain, Portugal and Serbia. Some of the results of these technological developments have been very positive and are presented in this paper."

Jan 1, 2018

By R. Prakash

Column flotation has now gained wide application in the recovery of various minerals. The performance of the flotation device depends on the mixing characteristics of the phases inside the devices. In this work, quality of mixing in a flotation column has been analyzed by using information entropy theory. Empirical models have been developed for flotation column with the parameters which affect the quality of mixing. The efficiency of the particle separation in the flotation column has been enunciated based on the quality of mixing. The present analysis on the quality of mixing in flotation column may give insight into a further understanding and modeling of flotation devices in industrial applications.

Sep 1, 2012

By Vasile Murariu, William Pate, John Herbst, Dilek Alkac

"Multiphysics models are essentially first principles models capable of providing very accurate micro scale predictions. The computational requirements for Multiphysics Models are extensive, precluding their direct use for flowsheet simulations. Population balance models get their form from theory but the model parameters have to be provided from experiments. The prediction errors for the population balance models are typically significantly higher than those for the Multiphysics Models but the computational effort for Population Balance Models is typically much less than that for the Multiphysics models. The hybrid model described here takes advantage of the strengths of each of the two primary model types and minimizing the weaknesses of each. The Multiphysics Model is used to perform high accuracy "experiments" that are difficult or impossible to conduct in laboratories or plants. The results of these experiments are combined with standard laboratory or plant data to parameterize and further enhance the Population Balance portion of the hybrid model. The creation of a useful Hybrid Model is demonstrated for a MP1000 secondary crusher. The validation of the hybrid crusher model is also presented. Finally the use of the Hybrid Model is illustrated in a full comminution flowsheet simulator."

Jan 1, 2014

By T. Ueda, T. Oki, S. Koyanaka

"Accurate assessment of the liberation state of crushed ore particles is important for efficient mineral processing. In general, the liberation state is assessed by two-dimensional (2D) measurement of polished ore sample sections. However, this 2D measurement inevitably suffers from overestimation of the degree of liberation, known as stereological bias. This arises from the fact that biphase particle sections of which only one phase happens to have been cut are indistinguishable from liberated particles. To date, several stereological correction methods have been proposed, but their applicability for various types of particles has not yet been sufficiently examined, and this tends to undermine their practicality. We have addressed this problem using a numerical-analytical approach in which various types of biphase particles are modeled, and the 2D sectional information is compared with actual three-dimensional (3D) information. Through simulations, we revealed a general relationship between the internal mineral structure of particles and the stereological bias. Finally, we have developed a unique stereological correction method in which the texture (a 2D pattern characteristic) of particle sections is used to estimate the internal structure of particles, and thereby the stereological bias. KEYWORDS Mineral liberation, stereological bias, texture analysis INTRODUCTION Mineral liberation assessment of 2D particle sections inevitably suffers from stereological bias; that is, overestimation of the degree of liberation. Stereological bias is caused by the fact that a composite particle can be misidentified as a liberated particle when only one phase happens to have been cut in sectional measurement. Stereological bias has attracted attention since Gaudin pointed out its importance in 1939 (Gaudin, 1939). Several attempts have been made to measure the 3D liberation state directly, avoiding the bias, using X-ray computed tomography (Gay and Morrison, 2006; Lin and Miller, 1996; Miller et al., 2003; Miller et al., 2009; Reyes et al., 2017; Videla et al., 2007). These have provided useful information through laboratory testing, but further technical refinement is necessary for practical usage, to overcome the technique’s limitations in terms of resolution, assessment of minerals of similar density, and speed. Therefore, for practical purposes, detailed information regarding mineral phase geometry is obtained by sectional analysis, using automated scanning electron microscopy/energy-dispersive X-ray spectroscopy (SEM/EDX)-based analysis (e.g., with a mineral liberation analyzer (MLA) (Fandrich et al., 2007; Sandmann, 2015)); and the development of an effective method of stereological correction, which predicts the relevant bias and transforms the measurable 2D degree of liberation into its 3D counterpart, is an important research aim."

Jan 1, 2018