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By M. H. Moys, C. Bhondayi, Eric Tshibwabwa

"The relationship between froth bubble size as represented by intra-bubble impact distances (IID) and flotation performance is investigated. Experiments using an artificial ore comprising of limestone as the floatable component and silica as the gangue material were carried out in pseudo-steady-state circuit. A method to measure IIDs developed by Bhondayi and Moys (2014) was then used to measure froth bubble sizes as a function of froth height, superficial gas velocity and feed rate (pulp residence time). Samples for flotation performance evaluation were also taken. Results indicate that as froth height increases, the average IID values increase resulting in a decrease in limestone recovery while the grade increases. Increasing gas rate results in lower IID values that are accompanied by high recovery and low limestone grade. The effect of feed rate on both flotation performance and average IID values depended on froth depth and gas rate. Average IIDs largely remained the same at the two feed rates investigated.INTRODUCTIONIt is regarded as obvious that froth bubble size distribution (FBSD) will have an effect on plant grade and recovery. As the average FBSD decreases, the bubble surface area flux will increase making possible an increase in recovery and a decrease in grade. The opposite trend will be involved if average FBSD is increased. However: no method for measuring FBSD has been available, so these trends have not been studied in any detail. Bhondayi and Moys (2014) developed a novel technique to measure or estimate froth bubble sizes. Although they established a potential to use this method in understanding froth performance, no data have been presented to assess the correlation between the estimates of bubble sizes and actual flotation performance. In this work experiments are done to establish how the change in froth phase bubble sizes affect flotation performance. Flotation performance will be evaluated using recovery and grade. How water recovery to the concentrate changes with changes in bubble sizes will also be evaluated. It is known that water recovery is approximately inversely proportional to the square of the overflowing bubbles sizes. It will be interesting to establish how the rate of change of bubble sizes changes with water recovery."

Jan 1, 2016

By G. Morin, G. Marin, M. C. Parr, J. Carignan

"Investment casting offers many advantages for the near net shape production of complex geometries, however, molten titanium reacts with most of the refractories used in investment casting shelling systems, which leads to the formation of an oxygen contaminated surface layer. This layer, called alpha case, is 0.1 to 0.6 millimeters in thickness according to the casting section size and must be removed either by mechanical or chemical milling processes. Alpha case removal processes affect casting tolerances and may contaminate the part intended for medical applications (e.g. embedding of abrasive grit media in the alloy). A shelling system based on an yttria prime slurry has been developed and was found to almost suppress the mold metal reaction. Yttria is an expensive refractory, but slurry life was found acceptable for small castings using a closed container and flow coating process instead of conventional pattern dipping. Alpha case depth has been determined for Ti6Al4V by metallographic techniques and microhardness measurements on different step block casting cross sections. Alumina and yttria second prime stuccos were evaluated in this study. The shelling system minimizes finishing operations in the production of casting for medical applications.INTRODUCTIONTitanium investment castings have been in the commercial market since the beginning of the titanium era in the mid 50’s. Investment casting is a cost effective way to produce complex parts for medical, aerospace and chemical processes applications. Investment casting of titanium is difficult due to the high reactivity of titanium with air and refractories used for shell mold building especially for the face coat. Melting is done under vacuum and no shelling system has been proven effective to suppress the mold-metal reaction yet. The main issue with the mold-metal reaction is the formation of an oxygen enriched zone at the surface of the castings named alpha case (Frueh et al., 1997; Kim, 2002; Saha, 1986). The alpha case is brittle, reduce the fatigue life in service of the parts and must be removed by chemical milling.For industrial purposes, calcia partially stabilized zirconia based slurries have become widely used in titanium investment casting for primary coats due to a combination of limited metal shell reaction. Calcia stabilized zirconia slurries have an acceptable shelf life and offer an interesting production window. Our experience shows that a resulting alpha case depth is 280 micrometers for a casting section of 6.35 mm in thickness is typical with such a shelling system (Morin, 2013)."

Jan 1, 2016

By K. Swedburg, M. Samuels

"The expansion of the concentrator at New Gold’s New Afton copper-gold mine in British Columbia, Canada, completed in 2015, included an increase in the required retention time of the cleaning circuit. On site pilot testing of a Woodgrove Staged Flotation Reactor (SFR) had shown that a high grade copper concentrate would be produced with excellent recovery. The SFR was selected rather than conventional tank cell technology based on the much smaller footprint (which rendered a separate and expensive building extension unnecessary), high concentrate grades demonstrated in testing, and the lower energy requirement. Three SFRs, each capable of taking a nominal feed of 700 cubic meters per hour were installed and commissioned 10 months after the receipt of order. The SFRs operate in series and all of the cells produce a final concentrate typically grading 32% Cu, while the overall SFR stage recovery averages 55%. The tailings from the SFRs are treated in the original conventional three-stage cleaner circuit where the remaining values are recovered in a concentrate grading 28% Cu. Design production was achieved within days of the initial start-up of the SFR circuit.INTRODUCTIONThe New Afton concentrator, located near Kamloops, British Columbia, Canada processes a copper-gold ore with a designed head grade of 0.96% Cu, 0.72 g/tonne Au, and 2.22 g/t Ag.The New Afton Mine is a block cave mining operation. Ore is undercut from the bottom up and removed at the extraction level from a grid of draw points. Ore is trammed to the ore passes by underground loader and dropped to a haulage level for transport by trucks to the gyratory crusher. From the crusher, the ore is conveyed to the mill via a 4.5 kilometre long conveyor system. Block caving was chosen for the New Afton deposit because the underground infrastructure could be built below the historical open pit of the Afton Mine (a previous operation of Teck Resources) and this method is favorable to large-scale low-cost mining.The New Afton deposit is a copper-gold, alkalic porphyry system. Hypogene mineralization is characterized by discontinuous copper sulphide veinlets and disseminations, principally chalcopyrite and minor bornite, along with pyrite as the second most dominant sulphide. Gold particles vary in size from 5 µm to 40 µm and occur as native gold and electrum, associated mostly with the chalcopyrite grains and never with the pyrite. In some instances, a second alteration phase has resulted in the copper sulphides being replaced by tennantite-tetrahedrite locally and along faults that transect the mineralized body. The design head grade of arsenic is 244 PPM, although the presence of tennantite is inconsistent and can vary from trace levels to 15% of the total copper. No arsenopyrite is present in the hypogene ores. Supergene mineralization, consisting of native copper with accessory chalcocite occurs in minor amounts along faults and highly oxidized near-surface portions of the deposit."

Jan 1, 2016

By A. R. Sheik, A. A. Baba, M. K. Ghosh, K. Sanjay, R. B. Bale, A. G. F. Alabi, F. A. Adekola, L. Ibrahim

"This paper studies the characterization and dissolution of a Nigerian pyrolusite ore, reporting the results of ore physicochemical analyses and detailed ore characterization before and after leaching at optimal conditions. Ore dissolution rate increased proportional to acid concentration and temperature, but decreased with ore particle size. In a 4 M H2SO4 solution at 80°C with a particle size of –90+75 µm and moderate agitation, ore dissolution rate reached 78.7%. Unleached residue produced under optimal leaching conditions consisted of silica with admixtures of cristobalite and stishovite. The calculated activation energy supported the proposed diffusion control mechanism for the process.RÉSUMÉ Le présent article étudie la caractérisation et la dissolution d’un minerai de pyrolusite du Nigeria, il donne les résultats des analyses physicochimiques du minerai et de la caractérisation détaillée du minerai avant et après la lixiviation sous des conditions optimales. Le taux de dissolution du minerai augmentait proportionnellement à la concentration de l’acide mais décroissait avec la taille des particules. Dans une solution 4 M H2SO4 à 80 °C, avec une granulométrie de –90+75 µm et une agitation modérée, le taux de dissolution du minerai a atteint 78,7 %. Les résidus produits sous des conditions optimales de lixiviation étaient constitués de silice avec un mélange de cristobalite et de stishovite. L’énergie calculée d’activation supportait le mécanisme de contrôle de la diffusion proposé pour le procédé."

Jan 1, 2016

By Luis Bergh, Juan Olivares, Juan Durán, Juan Yianatos

"In the last decades heuristic approaches based on logic rules have been one favored tool to control flotation units and plants on top of distributed control systems. Fundamental knowledge on flotation processes, expressed in reliable models, and programs to assure the quality of the information, contained in available measurements, are still insufficient to develop robust predictive control strategies. In this paper the idea of using simplified models, when a known disturbance is coming into the process, is explored. As a first approach, the set points of the froth depth and air flow rate controllers are estimated based on this model. Since these target predictions are only approximate, a conventional feedback expert system, based on logic rules, continues the task of calculating the set points of the distributed controllers, in order to decrease the gap between actual and desirable metallurgical targets. This combined actions permitted a fast response of the process to change the operation of the circuit when a measured disturbance is detected. This control system was implemented and experimentally evaluated in a pilot rougher flotation circuit, with three pneumatic cells, with froth depth and air flow rate controllers in each cell. Since the circuit is operated for the air-water system, a phenomenological model, with parameters estimated from industrial data, is fed on-line with real operating variables and virtual values, characterizing the feed (grades, solids%, particle size distribution), in order to predict the metallurgical targets (recovery and concentrate grade). Several cases are discussed showing the benefits of this control system and the possible improvements to work on. INTRODUCTIONToday, large size mechanical flotation cells of 100 to 300 m3 are used in rougher operation in different flotation industrial plants, in Chile and worldwide. However, in spite of the advances in fundamental research and the notable growing in equipment size, with more complete instrumentation systems, there are still a lack of reliable data for industrial flotation modeling and simulation to advance in better control systems design."

Jan 1, 2016

By Alan B. Morrow, William A. Poe

"Minerals processing operations are constantly challenged with improving production rates, yields, energy efficiency and process stability. Advanced Process Control has proven to be an effective tool for improving operations by capturing the full process capabilities consistently. However, the velocity of applying the technology as well as the sustainment of these significant benefits has been hampered by the usability of the software and adaptability of the applications.Some of the new technology developments that improve the usability and adaptability of advanced process control include:• modern and intuitive user interfaces,• customizable models to support unique process behavior,• fast and flexible OPC connection tools,• automated model building,• integration with first principles dynamic models and• improved performance monitoring.This paper will briefly discuss the new technology developments that have improved the usability and adaptability of advanced process control and how this can affect minerals processing operations.In today’s environment, Minerals Processing plant managers continuously face new challenges and requirements including:• higher energy efficiency,• increased run lengths,• reduced product quality variability,• reduced emissions,• higher availability, and• lower operating costsOperating a unit to meet these challenges in real time is not easy for operators and conventional process control systems. However, innovatively using existing technologies in Minerals Processing plants can improve operations on a minute by minute basis and reap significant benefits.Advanced Process Control (APC) can extract the maximum performance benefits from existing equipment while respecting plant operating constraints. Expensive capital projects to upgrade equipment are not always necessary. Advanced Process Control can deliver significant economic benefits by maintaining the plant at its most profitable point as conditions change."

Jan 1, 2016

By Kyle Selga, Christopher J. Greet

"The Pulp Chemistry Monitor (PCM) has been installed and operated in a number of concentrators in Australasia, and has produced some very interesting results. PCM measures the pH, Eh, dissolved oxygen, temperature and oxygen demand of process streams within a concentrator continuously and in real time.In the example presented in the paper the cleaner feed pulp chemistry is measured, and related back to changes in the mineralogy as well as variations in metallurgical response. For example, a decrease in Eh and dissolved oxygen as well as an increase in the oxygen demand. These changes in the pulp chemistry appear to coincide with increases in the feed grades, probably higher pyrite grades. Further, these variations in pulp chemistry and feed mineralogy have a negative impact on the concentrate grade and recovery.The implication is that if the pulp chemistry is monitored it is possible to predict changes in the mineralogy of the system, and from this the metallurgical response. Further, the changes in pulp chemistry can be used in a control system to counter the changes in mineralogy and maintain the metallurgy.IntroductionIt has long been recognized at a fundamental level that the flotation behaviour of sulphide minerals is dependent on the pH and Eh of the system (for example: Tolun and Kitchener, 1964; Woods, 1976). However, measuring pulp chemical parameters within an operating concentrator has had limited attention. Woodcock and Jones (1970a and b) were among the first to actually collect data from operating plants. Jones and Woodcock (1984) identified some of the chemical complexities of flotation pulps, and noted that most concentrators already operate at high levels of metallurgical performance but there was still considerable scope for improvement. These gains would, in part come from more effective chemical control. In the same volume, Healy (1984) discussed metal ion hydrolysis and precipitation, redox chemistry and how the surface chemistry of sulphide minerals can be influence flotation behaviour. The impact of grinding environment on the pulp chemistry and flotation response of a complex polymetallic sulphide ore is discussed by Forssberg and Subrahmanyam (1993). Their work essentially contrasts the pulp chemical and flotation performance of pulps ground with conventional ferrous grinding media to a fully autogenous system. The data suggested that the reduction or removal of iron hydrolysis contamination from the system could have a positive influence on flotation behaviour, and perhaps the first stage of “controlling” the chemistry of the system should be in the grinding circuit. Grano et al (1995) demonstrated that the collection of pulp, solution and surface chemical data could identify weaknesses within a concentrator, and from these data develop, test and implement solutions that improved the process. Greet et al (2006) showed that the pulp chemical trends observed through primary grinding and rougher flotation circuits of most sulphide flotation concentrators are approximately the same. There are differences in the magnitude of various pulp chemical parameters (pH, Eh, dissolved oxygen, temperature and oxygen demand) as a result of variations in the feed mineralogy and processes employed. Further, it was noted the Eh shifted to more reducing values of the ten days measurements were collected, and this change could be traced to an increase in the iron sulphide content of the feed. Metallurgically, this resulted in an increase in nickel recovery through the recovery of nickeliferous iron sulphides, and a decrease in nickel concentrate grade."

Jan 1, 2016

By Gonzalo Díaz, Diego Mesa, Willy Kracht

"It is well known that frothers affect the amount of water that is transferred to the froth, which has an effect on both the froth stability and the water recovery. On the other hand, since non-selective recovery by entrainment is directly related to water recovery, it can be said that frothers have an indirect effect on flotation selectivity. Recent research on this subject has shown that the non-selective recovery by entrainment, which is characterized by the entrainment factor, is frother dependent. In other words, the entrainment factor is not unique, but depends on frother type.Having different entrainment factors implies that for the same water recovery, the amount of undesired particles reporting to the concentrate may vary if one changes the frother type, which suggests, as a possible explanation, that it is not only the amount of water in the froth what is affected by frother type, but also the froth structure.The purpose of the current work is to study the effect of frother type on foam structure (two phase froth). A quasi-2D cell operated with a slot sparger was used to study the foam structure in the presence of three different frothers: Methyl Isobutyl Carbinol (MIBC), OrePrep®549, and Octanol at the same gas flow rate and reagent dosage. The foam structure was studied using image analysis, and an algorithm based on textural analysis was developed to classify the foams. The results show that it is possible to classify foams according to the frother used, which proves that frothers have an effect on the foam structure.INTRODUCTIONFrothers are usually dosed paying attention to froth stability, condition that is commonly estimated by sight, according to the operator's criteria and experience. This happens because there is not an established procedure or technique for frother characterization, generating qualitative descriptions such as “powerful” or “selective” frothers, which lack of scientific thoroughness and remain under subjective factors. Nevertheless, several works have been done in this line of research. Moyo et al. (2007) classified frothers based on their water-carrying capacity, proving that this characteristic is related with gas holdup and frother type. Previously, Trahar (1981) had related water recovery and gangue particles recovery, defining the entrainment value (ENT). Nowadays it is known that entrainment affects both hydrophilic and hydrophobic because it is not a selective process. In the last decade some studies (for example the one of Konopacka and Drzymala (2010)) delved into different entrainment behaviours dependent mainly on the flotation type (batch or continuous, agitated or columnar, etc.), but there were no studies on the effect of frother type regarding entrainment, since Rahal et al. (2001) argued that the ENT factor was independent of the frother type and concentration, and froth height."

Jan 1, 2016

By Jochen Petersen, Diane Taggart

"At an average of 90.3% (for the period of 1 January 2009 to 30 September 2011), Zincor’s zinc recovery was well below the industry standard of 96%. The losses through the residues, in particular the iron residue, were the biggest contributors to the overall zinc loss. It was believed that this loss could be decreased with the implementation of seed recycling. A plant trial was run to test the implementation of a seed recycle. The rate of seed addition through recycle was increased over a 4-week period. The presence of seed decreased the insoluble zinc loss by providing additional surface area for iron to precipitate onto, and reducing coating of unleached neutralising agent. The soluble zinc loss was also decreased at low and moderate seed recycle volumes. The improvement was attributed to agglomeration growth of the recycled particles, which improves the dewatering characteristics of the precipitate. In contrast, the soluble zinc loss increased at high seed recycle rates. This result was attributed to particle crowding and a low wash ratio.INTRODUCTION The Zincor refinery, which closed in December 2011, was situated just outside of Springs in the Gauteng Province of South Africa and employed the conventional Roast-Leach-Electrowin process, which accounts for 75 to 80% of the annual primary zinc production in the world. The refinery fed up to 220 000 t/a of zinc sulphide concentrate. The major portion of the raw material was sourced in Southern Africa from the Rosh Pinah and Black Mountain mines. Between 20 000 and 40 000 t/a of material was imported to make up the deficit and to improve the grade of the feed material. The iron contained in the zinc concentrates, at an average of 6.03% (for the period of 1 January 2009 to 30 September 2011), resulted in the formation of zinc ferrite during roasting, which is insoluble under atmospheric leach conditions. At Zincor, most of the zinc ferrite was dissolved in the residue treatment plant at elevated temperature and high acid strength. The leach liquor from this aggressive leach contained between 15 to 30 g/L of iron, mostly in the ferric form, and was known as the hot iron solution (HIS). The presence of iron in the liquor had an adverse effect on the zinc operation, particularly on the current efficiency in the electrowinning circuit. Therefore the iron needed complete removal."

Jan 1, 2016

By Rolf Andreas Lauten, Yanhong Wang, Yongjun Peng

"In mineral flotation, bentonite as a kind of clay mineral imposes deleterious effects on the flotation of valuable minerals, possibly through its ability to increase the pulp viscosity. A higher viscosity lowers the amount of froth and affects the bubble-particle collision frequency. A previous study found that adding gypsum to a bentonite-ore mixture lowered the viscosity, possibly by inhibiting the formation of interconnected network structures. In this study, sulfate as an anion with different types of cations, Na+, K+, Mg2+ and Ca2+ were used to reduce bentonite viscosity and to improve flotation performance. It was found that at the same concentration, MgSO4 was the most effective salt in reducing bentonite suspension viscosity, while CaSO4 was not as effective likely due to the lower solubility of CaSO4. Na2SO4 and K2SO4 reduced bentonite suspension viscosity at high concentration. Flotation kinetics of ore blended with bentonite was increased with increasing the electrolytes concentration, which generally correlated with the reduction of bentonite viscosity. Meanwhile, significant discrepancies were found between flotation results and rheological measurements in the presence of monovalent ions. It is indicated that the morphology of bentonite aggregates in electrolytes solution is likely to influence the hydrodynamics in the froth zone.INTRODUCTIONClay is present in many ore bodies as a gangue mineral. Presence of clay presents several challenges in the processing of valuable minerals. They are soft compared to valuable minerals, which means that during grinding of the ore, clay particles are likely to obtain a smaller particle size than the valuable mineral. Often clay particles may be within the colloidal size domain (<20 µm). The smaller size increases the probability of entrainment in the concentrate. Another challenge is their anisotropic charge distribution, where depending upon the pH, edges (E) and faces (F) carry charges of opposite sign. This facilitates formation of aggregation structures that may impede percolation of bubbles through a froth, but also increase the viscosity more than expected from the mere change in volume fraction. In addition to lowering the froth mobility, a high slurry viscosity will have implications for the gas dispersion in the flotation column as it affects the dispersion of the suspended particles, and it modifies the bubble-particle collision rate and attachment efficiency (Bakker, Meyer, & Deglon, 2009; Shabalala, Harris, Leal Filho, & Deglon, 2011). A pragmatic approach to this problem is to blend high clay ore with ore of lower clay content, reducing the overall clay concentration. Alternatively, one may lower the solids content of the flotation slurry to counteract the viscosity-building properties of clay. While feasible, this approach has the disadvantage of increasing required flotation volume, and it also affects the properties of the froth. Thus, there are currently limited options in lowering the impact of clays and their tendencies to increase viscosity in flotation slurries."

Jan 1, 2016

By Z. Bibak, S. Banisi, A. Ghasemi, E. Nematollahi

"The use of large AG/SAG mills in the mineral industry has been on the rise recently due to a significant reduction in the capital and operating costs for achieving significant increases in plant throughputs. The major reason for downtimes in these mills is the time taken for the replacement of broken or worn liners. This loss of “availability” of these units has a significant impact on the productivity of these plant operations. The ability to predict liner life time and its evolving shape could help to optimize these comminution operations. In the past decades, various models have been proposed to estimate liner wear rate, but because of their empirical nature they could only be used within certain limited operating conditions. In this research, a phenomenological model which could predict the liner wear rate was proposed and tested. This model considers parameters such as; operating conditions, liner hardness, pressure on the lifter, and, relative velocity of particles and mill shell. Data from industrially measured liner profiles were taken during the liner life time at the Sarcheshmeh and the Gol-E-Ghohar SAG mills to provide a solid base to calibrate and validate the model. The comparison of the model predictions with the actual measurements of the liner wear rate showed that the results were in a good agreement at both, the Sarcheshmeh (R2=0.94), and the Gol-E-Ghohar (R2=0.97) concentrators.INTRODUCTIONAG/SAG mills are one of the most important technologies in the mineral processing industry in the recent decades. The “Availability” of these units in a plant operation is one of the most important economic parameter for evaluating their performance. The major reason for the downtime of these mills affecting their “availability”, is the time required to change worn or broken liners (Yahyaei, Banisi, & Hadizadeh, 2009; Maleki-Moghaddam, Yahyaei, & Banisi, 2012). The knowledge about the magnitude and profile of liner wear not only enables more accurate liner life estimation to prevent unwanted interruptions of the SAG milling in mineral processing plants and more strategically plan the scheduled mill outages for liner changes. It also could provide key information needed to select an appropriate liner design (Yahyaei et al., 2009; Rezaeizadeh, Fooladi, Powell, & Weerasekara, 2010a)."

Jan 1, 2016

By T. Grammatikopoulos, A. Jordens, C. Gunning

"Exploration activity for rare earth element (REE) deposits (i.e., alkaline complexes, carbonatites) has increased significantly in the last decade. A number of deposits have been evaluated around the globe. However, new mines have not been commenced in the last few years with the exception of Mount Weld (Lynas) and Mountain Pass (Molycorp).Resource estimation of REE can follow similar guidelines to other metal projects. However, the inherent mineralogical characteristics of the REE deposits, despite their complex nature, have been generally overlooked by many exploration companies. These include variability of the ore, liberation and association of the REE minerals, and grain size, all of which can affect the processing of the ore. Each deposit appears to be different in terms of matrix and REM (rare earth minerals). Light REE bearing minerals such as allanite, monazite, bastnaesite, synchysite, and HREE bearing minerals such as fergusonite and xenotime can vary widely in composition, grain size and association (e.g., carbonates or hard silicates). On the other hand, although not really REM, zircon, Zr-silicates, titanite, fluorite, apatite, and in some cases many other common silicate minerals can carry trace to significant concentrations of REE.The evaluation of REE deposits should include an appropriate mineralogical characterization in order to quantify the REM, distribution, liberation and association by quantitative mineralogical techniques (i.e., QEMSCAN, MLA, TIMA and others); chemistry of the REM by electron probe micro analysis (EPMA), Laser Ablation ICP-MS or ToF SIMS.These techniques provide valuable data for geological purposes such as: defining quantitatively, the variability and distribution of the REM; differentiating between LREE and HREE zones to delineate ore; and metallurgical purposes to predict minerals/REE behaviour during processing. The lack of a comprehensive mineralogical characterization often leads to the wrong processing path and ultimately affects the elemental/mineral recovery."

Jan 1, 2016

By N. H. J. Freire, D. Majuste

In this paper, the effects of some organic compounds on the current efficiency, cell voltage and specific energy consumption during nickel electrowinning, and on the deposit features (morphology, crystallographic orientation and nanohardness) were described. The organics tested here (extractant, diluent, flocculant, lubricating oil and acid mist suppressant) are currently used in industrial plants. The results indicated that only the flocculant and acid mist suppressant exhibit relevant negative impacts on the current efficiency and energy consumption. The current efficiency dropped from 93.6 % (organic-free solutions) to 86.0 % and to 92.8% in electrolytes containing 100 mg.L-1 of acid mist suppressant and flocculant, respectively. At this concentration, their addition to the electrolyte led to increases of the specific energy consumption in the order of 18 % (acid mist supressant) and 2 % (flocculant). Cyclic voltammetry showed that Ni nucleation occurs at more negative potentials at 50 and 100 mg.L-1 of these organics in the electrolyte, thus indicating an inhibition of the deposition process. The deposit quality decreased at the higher concentration of all organics, when more hydrogen pitting was observed. The acid mist suppressant caused delamination of the Ni deposit at 50 and 100 mg.L-1. The addition of 100 mg.L-1 of flocculant and acid mist suppressant to the electrolyte increased the nanohardness of the deposit around 31 and 72%, respectively. The increase in Ni deposit hardness may lead to a decrease in the material ductility, thereby affecting the stripping and cutting of Ni sheets. Our findings may be helpful since strong adverse effect of some organics that may be present in the electrolyte were identified, thus the industry can control and optimize the organic´s dosage in the corresponding operations.

Jan 1, 2016

By D. Groenveld, M. Rozou

"Recent trends move towards automation, smart sensors, internet of things, powerful DCS, and more data. Are those trends already utilized in a real time production environment? Today operators still have to monitor several complex processes at the same time and predict their behavior based on an overwhelming amount of data available.The fact of the operator being overloaded and humans being unable to process multivariable problems shows the need of a tool merging essential data and providing consistent, sound decisions for long-term profitability.This paper shows a successful execution of ABB’s process improvement services in Aitik (Boliden SA), a copper mine located in Sweden. Soft sensors, fuzzy rule blocks and model predictive control were seamlessly integrated in the control system of the grinding area, resulting in proper control of mill loads and particle size without violation of any constraints.INTRODUCTIONDepending on the ore characteristics and the targeted plant capacity, the design of the grinding circuit may vary significantly. Typically, the circuit consists of several mills (rod, ball, SAG, AG) in series and/or parallel with a number of classifiers and sumps at appropriate locations. The goal of the grinding section is to reduce the ore particle size to a level that enables efficient separation between gangue and precious metals in the subsiding processing step. The trade-off between quality and quantity has to be made. It is also crucial to execute this process step at the lowest possible energy and grinding media consumption.An optimal grinding process controller must manage to maintain a given fresh feed level while keeping the product size within a given range without violating any constraints such as power, torque or load limits. To accomplish the aforementioned, it is necessary to manipulate the ore feed rate, water feed rate and the mill speed. The most significant disturbances adding another degree of complexity to this control problem are ore hardness and the amount of circulating load."

Jan 1, 2016

"Dry crushing trials at pilot scale have shown that the IMPTEC Super-fine Crusher has the capacity to generate ultra-fine products from hard mineral assemblages presenting at either coarse or fine feed sizes. The super-fine crusher was introduced at the 27th International Mineral Processing Congress in Santiago Chile, with results from a range of duties, which demonstrated the crusher’s potentially expansive operating scope. This paper focuses on current preparations to progress the technology from pilot scale to commercial scale within a concrete production plant, where lead blast furnace slag will be crushed to ultrafine sizes to generate an active silica product for use as a supplementary cementitious material, which can replace Ordinary Portland Cement. A key objective of the operation is to demonstrate an economical route to reducing the cost of concrete production, improving concrete quality and reducing greenhouse gas emissions. The paper also highlights the potentially key contribution super-fine crushing can make to the long-term viability of iron ore beneficiation by simplifying comminution flow-sheets and reducing operating costs. There is every indication that the technology has the potential to feature universally in metalliferous and industrial mineral flow-sheets. INTRODUCTIONToday’s IMPTEC super-fine crusher is the successful end product of development work over 19 years and is the third particle size reduction device conceived, built and tested over that time. The concept evolved as engineering design progressively developed a mechanism capable of harnessing a highly efficient combination of fundamental particle breakage mechanisms. Early development trials at pilot scale indicated that super-fine crushing had the potential to establish a wet or dry, media free, low energy route to ultra- fine products from hard mineral assemblages. Having achieved some impressive results from open circuit pilot tests on fly ash and granulated blast furnace slag it became clear that the cement industry may well provide opportunities to apply the technology commercially. Following expressions of interest from local cement and concrete plant operators, IMPTEC negotiated an agreement to undertake commercial trials with a SFC 350 super-fine crusher installed on site at a concrete supply plant in South Australia. Super-fine crushing scope was recently expanded following further expressions of interest from research groups involved in the processing of iron ores. Pilot trials are progressing in these areas."

Jan 1, 2016

By Rufus L. Chaney

A new technology is available to the Ni mining and remediation community to “phytomine” Ni from mineralized or contaminated soils using rare plants which hyperaccumulate Ni to over 1% of shoot dry matter. Research has identified useful plant species, and even bred improved cultivars of Alyssum murale and Alyssum corsicum for commercial phytomining in temperate regions. All agronomic practices (fertilization, soil amendments, planting and harvest methods) needed for economic phytomining were identified to attain high yields and high Ni concentration in the biomass. In tropical regions, other species are available such as Phyllanthus which accumulate over 1% Ni in dry shoots. These species are perennial so they regrow after annual cutting to harvest biomass. Expiration of our patents on the technology opens the opportunity for other organizations which control Ni rich natural soils or contaminated soils requiring remediation to commercialize the technologies. Inexpensive methods to remediate/revitalize Ni contaminated phytotoxic soils using agronomic approaches have also been developed and demonstrated at Port Colborne, Ontario, but adoption is delayed until formal agreements with government are completed. These new simple remediation and profitable phytomining technologies can obtain Ni from soils which contain Ni well below levels considered economic for current mining technologies, and the plants biopurify the Ni so it is easy to recover Ni metal from plant ash by pyrometallurgical or hydrometallurgical technologies. Although increasing pH decreases the solubility of Ni in all soils, raising pH increases Ni accumulation by Alyssum species. Hence usual chemical extraction methods for phytoavailable soil metals such as the DTPA- or NH4-OAc-extraction cannot predict Ni accumulation by Alyssum species.

Jan 1, 2016

By N. Kolev, M. Poibrenski, I. Nishkov

"The following paper examines the flotation of copper porphyry ores in Assarel concentrator with focus on the reasons for low molybdenum recovery in the final copper concentrate. The copper-porphyry ore of the Assarel deposit is characterized by its variable mineral composition and high clay content, which influence the process efficiency of their concentration. Particle size distribution, chemical and mineralogical analyses have been made on various flotation products showing the distribution of the main elements of interest - copper and molybdenum. It was found that molybdenum is not concentrated into the final copper concentrate as usual in the flotation of copper-molybdenum ores but into the tailings of the copper selective flotation (cleaner tailings). An attempt to explain these results has been made with proposals to improve molybdenum flotation. Low floatability of molybdenite is caused by the ultrafine clay minerals content in both the run-of-mine ore and copper flotation streams. In order to achieve selectivity of copper minerals against pyrite a significant amount of lime is used in the plant leading to higher pH conditions, which could be another possible explanation for the molybdenite depression. The results obtained after the laboratory experiments, showed that it is possible to restore molybdenite floatability using traditional reagents such as diesel, kerosene, etc., and introducing a new polymeric reagent as froth modifier.INTRODUCTIONOne of the main technical difficulties in the area of copper-molybdenum flotation is the selective recovery of both metals, especially the fine (<40 micron) mineral particles. The problem is even more serious when Cu-Mo ore treated contains a lot of natural fine particles, predominantly clays, micas and other gangue minerals. Peng and Zhao (2011) conclude that the mineral processing industry is well aware of the difficulty in treating ores in the presence of clay minerals. Tremolada et al (2010) found that clay minerals have been named as the main problem in ore beneficiation processes due to their small size, which cause a higher viscosity in grinding. In flotation, these clay minerals have natural hydrophobicity or float by entrainment.The impact of clay mineralogy on flotation performance has been reviewed in the literature and the various deleterious roles of clay minerals have been investigated (Bulatovic, Wyslouzil & Kant 1999; Jorjani et al, 2011; Farrokhpay, Bradshaw & Dunn, 2013). It is widely accepted that the actual flotation recovery problem appears to be caused by the properties of these fine particles: small mass (and/or momentum) – high interfacial free energy (Rubio et al., 2007; Farrokhpay, 2011). In most cases, the loss in recovery is found to be insignificant, but the detrimental effect on the concentrate grade is found to be more prominent. The main reasons for the flotation inefficiency are the low probability of bubble-particle collision and adhesion, formation of dense froths and as a result - low process kinetics. A great deal of fine valuable minerals is discarded as slime in flotation due to lack of effective recovery methods."

Jan 1, 2016

By M. Maldonado, P. Olivares

"A submersible sensor for real-time gas holdup measurement in the collection zone of industrial flotation machines is introduced. The working principle is based on the generation and measurement of a pulp flow using a gas-exclusion cell immersed in the aerated slurry. The gas exclusion cell consists of a variable-area open vertical tube designed to be filled only with pulp by preventing gas bubbles entrance. The higher density of the fluid column within the cell generates a downward flow of pulp; the rate of this flow is proportional to the gas holdup outside the cell. The gas holdup measurement is achieved by tracking the velocity of the pulp flow leaving the gas-exclusion cell, using a magnetic flowmeter. Construction details of a prototype and its testing in two- and three-phases are discussed.INTRODUCTIONFlotation process optimization consists of finding and maintaining operating conditions that maximize flotation performance measured in terms of recovery and grade. The selective separation of mineral particles proceeds in two interactive zones where different and simultaneous phenomena take place: in the collection zone, the valuable particles are separated by collection on the surface of bubbles, while in the froth zone, the bubble-particle aggregates are gathered, drained to remove entrained particles, and taken into the concentrate stream. The cell overall performance, which can be determined from proper stream sampling, is a function of the recoveries in the individual zones. These zone recoveries cannot be independently measured nor calculated from operating variables. Progress in the assessment of these recoveries has been slow because on-line and reliable sensors to measure properties of the drastically different dispersions existing in both zones are not available.In the case of the collection zone, it has been demonstrated that the recovery of hydrophobic particles on the surface of bubbles, considered as a process with first-order kinetics, correlates with the bubble surface area flux (Finch et al., 2000; Hernandez, et al., 2003; Lopez-Saucedo et al., 2012). Bubble surface area flux (bubble area generated per unit time and cell cross-sectional area), is a variable affected by gas flow rate, bubble size distribution, and frother type and concentration. Gas holdup (volumetric fraction of gas dispersed in the slurry) is also affected by the same variables, and as such, carries information on the interacting variables that define the performance of the process. Therefore, a correlation between gas holdup and bubble surface area flux was expected and demonstrated (Finch et al, 2000), and since gas holdup is easier to measure as no bubble size is required, it has the potential to be the basis of a cell control and optimization strategy if a continuous sensor is available."

Jan 1, 2016

By T. Moyo

"The oxidative leaching of chalcopyrite in ammoniacal solutions has been evaluated using electro-analytical techniques and controlled bulk leaching studies. The anodic dissolution process has been established to be a sevenelectron transfer process under nitrogen in ammonia–ammonium sulphate solutions and ammonia–ammonium carbonate solutions, which suggests that the sulphur is oxidized to thiosulphate and the copper and iron released as Cu+ and Fe2+ in these systems. The deportment of Fe2+ and S2O3 2- is affected by choice of the ammonium salt used in the leaching process. In the perchlorate salt, only five electrons are transferred, supporting formation of different sulphur species as proposed for the sulphate and carbonate salts. Scanning electron microscopy and energydispersive spectroscopic analysis of the mineral surface after leaching indicate presence of an iron–sulphur surface layer completely free of copper in the sulphate system, an iron-rich surface layer in the perchlorate solutions, and absence of surface layer build-up in carbonate solutions. XRD analysis of a bulk leach residue from leaching in ammoniaammonium sulphate solutions showed the surface layer to be mostly amorphous (90%). The crystalline content (10%) is composed of 95% polymorphs of anhydrous iron oxide hydroxide FeO(OH). Choice of ammonium salt and the hydrodynamic environment of leaching have been shown to influence the presence or absence of the surface product, as well as its nature. IntroductionHydrometallurgical processes for copper extraction provide a viable route to recover the metal from mixed and low-grade ores, as well as overcome the environmental challenges faced by the traditional pyrometallurgical processes. Chalcopyrite is not only the most abundant of the copper sulphides, but also the most stable, making it recalcitrant to hydrometallurgical processes. Hence, hydrometallurgical processing of chalcopyrite continues to be an attractive area of research due to the vaguely understood surface chemistry of the mineral in different aqueous media. Different routes for hydrometallurgical treatment of chalcopyrite can be followed. These include thermal treatment prior to leaching, direct leaching and direct electrochemical leaching (Venkatachalam, 1991). Direct leaching of chalcopyrite can be carried out in various solution systems, as reviewed by Roman and Benner (1973) and Venkatachalam (1991). Ammoniacal solutions are attractive and effective lixiviants that form stable amine complexes with some base metal cations while rejecting iron. Leaching of chalcopyrite in ammoniacal solutions in the presence of an oxidant is possible due to the stabilization of copper (I) and copper(II) by ammonia at elevated pH levels. In oxygenated ammonia solutions, it has been suggested that chalcopyrite dissolves according to Equation [1] (Beckstead and Miller., 1977a):"

Jan 1, 2016

By R. Neumann, O. Gomes, S. Gaydardzhiev

"Phosphorus in iron ores is considered as a deleterious component to iron making reflecting in cold shortness of the produced steel. The present study investigates the phosphorus migration pattern resulting from thermal treatment of an oolitic-type iron concentrate with and without additives. To this end focused mineralogical and microscopic observations were performed. The results have shown that roasting with alkaline additive drives phosphorus outside the hematite hosting mineral, however it remains evenly distributed inside the volume of the oolites. It penetrates inside the newly formed cementing phases of Al- Na-Si-Fe-type and also fills the interstices between the crystals. Other than phosphorus, aluminum, calcium and iron tend also to migrate towards the amorphous-type cementing phase. Finally, the possibilities for P removal by means of magnetic separation and acid leaching of the roasted concentrate were evaluated. The obtained final product presents a standard iron concentrate suitable for steelmaking with its phosphorous being dropped from 0.71% to 0.05% and iron grade of a nearly 66% being reached. INTRODUCTIONSignificant proven reserves of iron ores are still not exploitable due to lack of an economically viable and efficient technology for removal of phosphorus. Among them are the oolitic iron ores with high phosphorus which are estimated to nearly 377 billion tons (Hernandez et al., 2012). Phosphorus is a deleterious component giving a cold shortness to steel and often is penalized if exceeding 0.07%. Most of the high-P iron ores are considered refractory since phosphorus is finely disseminated and is evenly met as phosphate groups inclusions inside the limonite structure. Studies on inclusion of phosphorus in artificially synthesized goethite have shown that it is adsorbed as [HPO4]2- groups bridging the adjacent iron ions (Parfit et al., 1975). The high-phos iron ore originating from Lisakovsk deposit, Kazakhstan presents a similar mineralogical issue because the quantity of P, met as solid solution, is substantially higher than the one in P-containing minerals. A potential reason for that is the ore body formation process from the slow deposition of iron-rich precipitates together with clastic erosional sediments in rivers. There is significant quartz and clays inside and around the oolites. The deposit contains about 1.7 billion tons of measured and indicated reserves at 35–41% iron and 1.1 billion tons of inferred ore have been delineated possessing nearly the same chemical composition (Golubovskaya, 2003; Kokal et al., 2003)."

Jan 1, 2016