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By Richard K. Komarek, Antonios Zavaliangos, Roman T. Dec

Roller presses are widely utilized in mineral industry for fine milling and compaction. Recently used models are providing only limited information about the material behavior in the roll bite. This paper introduces a 2-dimensional finite element model for analyzing those two basic processes. A pressure-dependent plasticity model with linear elasticity was used as a constitutive model for the particular material. Coulomb friction law was used to describe phenomena on the material/roller surface interface. Two basic roller geometries are considered: smooth (used for milling and compaction) and with cavities, commonly used for briquetting. Comparison of the results obtained from the model with experiment indicates that they are following the general trends of experimental values recorded with laboratory roller presses. It is shown, that the model is suitable to analyze material behavior through all stages of the rolling process: feeding zone, nip region, neutral plane and release section. It can predict pressure, shear stress, slip of the material over the roller surface, material velocity field, failure of the compact during release and the course of other important process variables. This allows the process engineer to gain an improved understanding, leading to a better process and equipment design and control.

Jan 1, 2003

By Y. B. Zhang

China is rich in iron ore resources, but most of these ores are low-grade, polymetallic and refrac-tory ones. Furthermore, with the rapid development of chinese iron & steel industry, the comprehen-sive recovery of these ores is becoming more and more important. The tin, zinc-containing complex iron ores are typical polymetallic and intractable ones, and great reserves of them are found in China. At present, they have not been efficiently utilized. In this paper, based on the investigation of basic physicochemical properties of the tin, zinc-bearing iron concentrates, taken from a mineral processing plant, the mineralogy reason that these concentrates are so intractable and refractory is found out, using advanced microscopic testing methods, such as optical microscope (OM), Scanning Electronic Microscope (SEM), X-ray diffrac-tion (XRD), etc. It is found that the symbiotic relationship of iron, tin and zinc metallic minerals are very complicated, and magnetite in the concentrate is closely symbiotic or enwrapped by fine cassi-terite and sphalerite. So it is difficult to separate tin and zinc completely from the iron concentrates by simple regrinding and physical separation method. This investigation provides theoretical guid-ance for developing new approaches for utilizing these concentrates.

Jan 1, 2014

By Moris Fresko, Julia Sun, Charles C. Golembewski, Vytas Svalbonas

"A history of mill strain gaging at Metso is presented. The output of these strain-gaging programs is compared with calculated stress ranges from different finite element solutions. These comparisons expose the amount of approximation that exists in the analytical solutions, starting from geometry, and material properties, and ending with different forms of internal load models. The influence of strain gaging results on mill design and analysis practices is also discussed. While these instrumentation programs are valuable in identifying areas of high stress in mills, and locations of stress concentration factors, they are by no means extensive or comprehensive enough to verify general internal load models. The vast majority of the programs were aimed at getting additional data about potential failure points, rather than describing overall mill stress behavior. This is especially true since the more recent gaging programs have not included the difficult task of gaging the mill rotating structure interior. This paper tries to avoid the novice path of leaping to general conclusions on the basis of insufficient data."

Jan 1, 2014

By S. Z. Khan, Veerendra Singh, Y. Rama Murthy, S. Prasad, Sunil Kumar Tripathy, Gajanan Kapure

"In this study, a low-grade ferruginous low-grade chromite ore was subjected to reduction roasting by using conventional heating as well as microwave heating. Sukinda chromite ore deposit contains majorly iron-bearing minerals as gangue phase. The magnetic susceptibility of these minerals enhances effectively after reduction roasting. Alteration of crystalline structure and magnetic property of these metals enables separation of low-grade ore by using magnetic separation. Conventional roasting studies by varying the temperature, time of reduction and reductant dosage were changed for low-grade ferruginous chromite ore. Similarly, microwave power, retention/exposure time and reductant dosage varied for reduction roasting studies under microwave environment. It is found that low-grade ferruginous chromite ore can be upgraded by reduction roasting and 61.2% Cr2O3 was recovered with a chromium-to-iron ratio of 1.93 from feed chromium-to-iron ratio of 1. Microwave reduction roasting studies resulted in upgradation of chromium-to-iron ratio to 1.73 with a recovery of 21% Cr2O3.INTRODUCTION The chromite ore occurs as a spinel containing oxides of chromium, iron, magnesium and aluminium. Most of the Indian chromite deposits are of ferruginous (rich in iron content) which indicates the abundance of ferruginous gangue minerals along with chromite. The primary use of chromite ore is towards the production of ferrochrome alloys. Chromite ores with less than 40% Cr2O3 and the chromium-to-iron ratio (Cr-to-Fe ratio) <1.8 is considered to be unsuitable for the smelting process (Tripathy et al. 2012, Tripathy et al. 2012a). A considerable amount of low-grade chromite ore and overburden excavated during chromite mining is getting accumulated every year, causing a threat to the environment. Its disposal poses a significant challenge and, hence, the beneficiation of low-grade chromite ore and its utilisation has been attracting a lot of attention. Different physical method of beneficiation methods is generally employed for the improvement of the Cr-to-Fe ratio (Tripathy et al. 2012, Murthy et al. 2011, Tripathy et al. 2012a, Tripathy et al. 2013, Tripathy et al. 2016, Tripathy et al. 2017, Tripathy et al. 2017a). It is observed that the enrichment of the chromite ore is carried out by using gravity and in some places by magnetic separation. However, the enrichment of Cr-to-Fe ratio from low-grade ferruginous chromite ore is difficult by using the above-mentioned beneficiation methods due to the presence of near gravity and near-magnetic susceptibility minerals along with chromite. However, an alternative beneficiation method is needed to explore for the beneficiation of such mineral deposits. Reduction roasting followed by magnetic separation is an alternative option for the separation of these types of ores which is widely reported for the iron and manganese ore (Li, et al., 2010; Chun, et al., 2014, Rath et al., 2018). These processes are majorly focussed on differentiating the magnetic susceptibility between minerals and subsequent separation by using magnetic field. The main advantage of such method is dry process option along with the pre-processed product for the costly smelting process. Also, the roasting of minerals in a microwave environment is also an active research topic in the recent time. So, the amenability of the separation feature of the roasting process by using conventional heating as well as microwave heating can be can be studied for the low grade ferruginous chromite ores."

Jan 1, 2018

By Ahmad Amini, Hadi Abdollahi, Pouya Karimi

Due to detrimental effects of cyanidation process on the environment in gold industry, application of cyanide alternatives such as thiourea are being highly considered in recent projects. In this study, the extraction of gold from poly metal ore, using thiourea was precisely investigated. The representative sample contained 2.5 ppm Au and 160 ppm Ag. The sample was categorized as oxide gold ore, because the main part of its pyrite was changed to iron oxide and hydroxide such as goethite and lepidocrosite. According to mineralogy, the main gangue mineral was quartz. It shows that gold grains are free and interlocked with quartz matrix. Also, the presence of a high amount of silver in free and sulfide forms and also the low content of other sulfide minerals such as base metal sulfides is a remarkable point of these studies. In the gold extraction process with thiourea, there are several parameters that affect the rate of gold dissolution such as concentrations of thiourea as a gold lixiviant and ferric sulfate as an oxidant, pH and size fraction of feed and leaching time. The influence of these parameters on the gold dissolution rate were investigated and optimized. The results showed that the concentration of thiourea is the most influential parameter which could increase the gold recovery to 71% (at 10 g/kg sample). The optimal amount of ferric sulfate was determined as 6 g/kg sample. Also, the optimal levels of size fraction of feed and pH of solution were 88% under 75 micron and 2 as acidity; respectively. Leaching time was 6 hrs. In addition, this sample was leached with cyanide and the optimized values of size fraction of d88=75 microns, pH=10.45, 2500 ppm of sodium cyanide with time leaching of 24 hours were concluded for maximum recovery of gold in solution. Finally, the results of cyanidation tests were compared to the thiourea dissolution after optimizing all affected parameters in cyanidation process.

Jan 1, 2018

By P. T. Nguyen

The analysis of particle capture by an air bubble by two separate phenomena of collision and attachment has been difficult due to the uncertainty in determining when and where the two phenomena begin and terminate at the bubble surface, respectively. Therefore, a unified analysis was developed by solving the motion equation for the particle capture as one process. No distinction be-tween collision and attachment was made. Both the liquid film described by the micro-hydrodynamic resistance functions and the surface forces were included in the new model. The model predictions with the DLVO (Derjaguin-Landau-Verwey-Overbeek) surface forces did not agree with the experimental trajectories of latex and silica spheres. The model predictions with the inclusion of the non-DLVO attractive surface force agreed with the experimental data. The non-DLVO force reduced the repulsion between the non-attaching particle and the bubble, and significantly increased the attraction between the attaching particle and the bubble. The unified analysis is capable of predicting particle capture without the use of the induction time. The unified analysis also shows significant influence of the short-range hydrodynamic interactions on the collision which has been previously ignored.

Jan 1, 2014

By Erico Tabosa

The turbulence characteristics and measurement techniques for agitated tanks are well established for liquid and liquid-gas systems. However, the literature shows that the overall energy dissipation rate (related to turbulence) is affected not only by air addition, but also by the concentration of solids. Unfortunately, there are no reliable measurement techniques for characterizing turbulence in a three phase (liquid-solids-gas) environmental system, which is the case in a flotation cell. Therefore, the effect of turbulence on flotation kinetics is very much one of conjecture. The aim of this work was to develop a sensor to characterize the degree of velocity fluctuation, which is related to turbulence, in a flotation cell operating with slurry and air. This sensor comprises a piezoelectric film transducer that converts mechanical to electrical energy. Hence, when the sensor deflects backwards and forwards an AC voltage is created. Flotation studies carried out using this sensor in a 3m3 Metso RCS cell processing a copper sulphide ore showed a highly turbulent impeller zone with transition to a significantly less turbulent zone in the upper portion of the cell. The transition region moves as the cell operating variables are changed, for instance the impeller speed, impeller size, air rate and feed solids concentration. Keywords: mechanical flotation cell hydrodynamics, turbulence characterization

Sep 1, 2012

By Steven Wright, Sharif Jahanshahi, Shouyi Sun

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

Jan 1, 2003

By X. Q. Wu

Magnetization in slurry (MIS) of weakly magnetic minerals by iron ions was investigated. The magnetic seeds (strongly magnetic particles) were synthesized by ferruginous chlorides directly in slurry instead of previous preparations of magnetic seeds by finely grinding mineral magnetite or specially synthesizing them separately in an aqueous solution. In this way, the growth of the seeds and their adsorption on the minerals simultaneously take place in the same slurry. That after MIS the recovery of weakly magnetic mineral limonite in a magnetic separator increased means the formation and adsorption of magnetic seeds on the surface of iron mineral limonite. The magnetization effect was evaluated by limonite recovery at a magnetic strength of 3.500 Gs in a magnetic separator. Mineral limonite was properly magnetized in the following slurry condition: molar ratio of Fe3+ to Fe2+1:3, slurry temperature of 45 °C and pH 10.5. The selectivity of the magnetization between minerals limonite and quartz was improved by adding surfactant sodium oleate.

Jan 1, 2014

By M. Kalicinski, M. Lyssyy

"Access to information is a key component for making improvements to any process. This is particularly true for all aspects of the iron mining and steelmaking process. The ability to make rapid control decisions can significantly influence process outcomes, including ensuring product specification, mining quality, transportation limits, upgrade factors, waste bypass and direct shipping, among many others. While traditional laboratory methods provide feedback for such processes, having access to analysis results in real-time can lead to positive reactive and predictive control decisions to be made rapidly, leading to significant improvements throughout the process. Scantech has been designing, manufacturing and supplying technological products to the minerals industry since 2002 to enable the availability of such real-time information to a mine or plant, with the benefits being enjoyed by a wide range of operators. This paper provides a summary of the available technologies used in the iron ore and steel industries, as well as providing case studies of their use in African and Australian iron ore and European steel, as well as a description of the potential benefits of a range of analysis equipment.INTRODUCTION Access to information is critical for any process, and is a fundamental component for making process control decisions. In order to yield effective processing outcomes, it is important for that information to be readily available, preferably as quickly as possible, and to be as accurate as possible. While speed and accuracy are often traded off against each other, there are numerous technologies available in a processing environment that allow for both rapid flow of information and a high level of accuracy. The use of on-belt analysis equipment has a long trusted history of use in a number of mining and processing environments and industries, providing information such as elemental composition and grade of conveyed materials, moisture content, waste proportion and energy information. Australian company Scantech has been a provider of such equipment since 1981, and has become an industry leader in both the supply and development of on-belt analysers across a range of industries."

Jan 1, 2018

By Kaioeng Wang, Qi Liu, Yahui Xiang

"In the differential metal sulfide ore flotation it is desirable to replace the toxic inorganic depressants with environmentally benign chemicals. Chitosan, as a natural and non-toxic polymer, has been proven to be an efficient depressant for chalcopyrite while allowing galena to be floated by xanthate collectors. However, the poor solubility of chitosan limits its potential applications as the flotation could only be carried out at about pH 4 where chitosan is soluble. A carboxymethyl derivative of chitosan, named N-carboxymethyl chitosan (N-CMC), was synthesized by substituting the amino groups of chitosan with carboxymethyl groups. The substitution significantly improved the solubility of chitosan. The structure of N-CMC was studied and compared with chitosan via Fourier transform infrared spectroscopy (FTIR). Flotation tests were performed on single minerals and mineral mixtures (with weight ratio of 1:1) with the addition of appropriate amount of potassium ethyl xanthate (KEX) and N-CMC. The solution pH was varied from neutral to alkaline. The flotation concentrates and tailings were collected and analysed for the contents of copper and lead. FTIR measurements showed that new peaks of C=O stretching of -COOH and N-H deformation of -NH- appeared in N-CMC, which indicated that the carboxymethyl groups were introduced and the amino groups were the sites for the substitution. Flotation results indicated that N-CMC could depress either chalcopyrite or galena depending on the pH. The results were not affected by the sequence of KEX and N-CMC addition. Therefore, N-CMC is potentially useful in Cu-Pb sulfide separation following a bulk Cu-Pb flotation. The N-CMC was also found to have surface cleaning functions, and was able to remove contaminating copper ions from galena surfaces. Therefore, its application in sulfide ore flotation is expected to be more robust than the original chitosan."

Jan 1, 2014

By M. Guo

Coal-based Direct Reduction in Interior-combustion Shaft Kiln (CDR/ISK) is a brand-new technique. Compared with the traditional Coal-based Direct Reduction (CDR) technique, its main character is to use Interior-combustion Shaft Kiln (ISK) as the reactor of direct reduction. After being crushed and grinded, iron ore is made into green pellet, which will be surface-coated by coal fines. Then, the surface-coated green pellet can be directly reduced in ISK. The pellet should not be too dry and should be charged from the top of ISK. Oxygen-contained air should be blasted into ISK to keep the temperature in it higher than 1000 degrees centigrade, at which iron oxide will start direct reduction. The reduced pellet will be discharged from the bottom of ISK and after de-surface-coated, spherical Direct Reduced Iron (DRI) can be gained. The volume of carbon monoxide in the off-gas discharged from ISK is less than one per cent. By using this technique to get one tonne DRI, the consumption of coal is about 300kg of fixed carbon, which is much lower than the energy consumption by using other CDR techniques. There is a lot of complex refractory iron ore in China, which remains unexploited. The iron-bearing minerals in this kind of the iron ore can not be beneficiated economically by present technique of gravity, magnetic, flotation or magnetic roasting because the iron minerals are too very finely disseminated to be liberated, or, the iron minerals are too similar to gangue to be separated each other. By using CDR/ISK, complex refractory iron ore can be directly reduced in lower temperature and all kinds of iron mineral can be turned into iron metal. As the grains of iron metal growing larger during direct reduction, magnetic separation can be used to separate iron metal from gangue mineral, thus high-grade iron metal fines can be gained. According to the experiments, the grade of iron metal fines is above 90 percent and the recovery of iron is higher than 90 percent. The consumption of coal to process one tonne of complex refractory iron ore is only about 90kg of fixed carbon.

Jan 1, 2014

By Shailin Lalloo, Allan B. Nesbitt

A fluidised bed was exposed to high gravities by placing it in a centrifuge. The bed expansions were measured and compared with the bed expansions predicted by the Richardson-Zaki model (1954). The Richardson-Zaki model was found to predict effectively the fluidisation behaviour of defined particles in this increased gravity environment.

Jan 1, 2003

Certainly, one of the core processes for the recovery of fine magnetic susceptible iron ore particles, mainly hematite iron ores, is the wet high intensity magnetic separation or WHIMS. This paper outlines a variety of recent developments and innovative process designs in the JONES® type WHIMS. It highlights the latest examples of flow sheets in terms of the diversity of combined rougher, scavenger, cleaner stages and adds to this the new more advanced JONES® type WHIMS equipment technologies like the HIGH FLOW ? HF, the QUATTRO ? Q and the SPLITT OPERATION ? SP. As a result of the increase of the capacity and magnetic intensity, the specific production cost could be decreased. The high worldwide acceptance for this continuous development testifies for the success and state of the art technology.

Sep 1, 2012

By Carsten Gerold

The paper is giving an overview about successful operating Loesche Vertical ? Roller ? Mills (VRM) installations and summarises the main benefits of the dry compressive Loesche grinding technologies in Airflow- and Overflow-Mode. Some of these benefits are optimised energy efficiency of the grinding - classifying - circuits, increased mineral recoveries and decreased OPEX costs, at a parallel simplification of the process route. Within this paper the process values of the Loesche VRM are compared to existing or planned conventional grinding ? classifying circuits. Further advantages discovered in pilot trials and examples for new more efficient process route alternatives are given. The paper reports about production and pilot trial experiences obtained by crushing and grinding Iron Ore, Iron Ore Concentrates, Copper Shale, Copper Matte, Copper Slag, Titanium Slag, Tin Slag, Steel and Stainless Steel Slag with Loesche VRM.

Sep 1, 2012

By V. Panayotov

Slag and by-products of metallurgy bear valuable components and their processing raises an in-creasing interest. Coke and iron have to be separated and other components have to be depressed, in order to obtain sellable high quality copper concentrates. Use of classical mineral processing technologies, such as magnetic separation, sulphidization, hydrometallurgy, etc. yields copper concentrates with grade of 4%~6% Cu. Copper is lost in tailings and the whole technological cycle is low profitable. Technology proposed applies an electrochemical treatment of the industrial water entering the flotation cycle. Iron and iron compounds that do not bear Cu, coke and gangue materials are depressed during the copper flotation. Copper concentrate of grade of 9.8%~10% Cu is obtained at simultaneous increase of Ag recovery by 8%~10%. As a result company profitableness is increased. Technology proposed is easy to implement, it does not require changes in the existing technology flow-sheet, and additional investment is low. The flotation process can be aided by a specially developed system for real-time analysis of the obtained copper concentrate which allows in-time corrections in the flotation parameters and entire process control. Applied flotation schemes, technological parameters and results obtained are described.

Jan 1, 2014

Electrochemical behaviors of synthetic and natural enargite in buffer solutions have been investigated using open circuit potential, stationary polarization and cyclic voltammetry as functions of solution pH, scan direction, scan range, scan rate and dissolved O2. The results indicate that the electrochemical behaviors of synthetic and natural enargite are very similar; solution pH, scan direction, scan range and scan rate have remarkable effects on the electrochemical behavior of enargite while dissolved O2 has little effect on the electrochemical behavior of enargite. The potential range in which enargite possesses the ability of passivation is from ?0.9 V to + 0.83 V vs. SCE. Enargite is most stable in neutral and alkaline solution around potential ?0.2 V vs. SCE. The main oxidation products on enargite surface in alkaline solution are Cu(OH)2 while the potential imposed on it is within the range of ?0.2 V to 0.33 V vs. SCE and Cu(OH)2 + S0while the potential applied is higher than 0.52 V vs. SCE.

Jan 1, 2014

By N. Schreithofer

Varying flow regimes, particle populations and consequently different types of bubble-particle interactions characterize the different zones of a flotation cell. The understanding of the role of the different zones of turbulent intensity on the particle-bubble interactions is of primary importance to optimization and scale-up of flotation processes and machinery. In order to study particle-bubble interaction in turbulent flow a completely new approach was taken. A laboratory scale stationary turbulence device was developed and built. The set-up allows the observation of particle-bubble interactions in various turbulence intensities, particle and bubble sizes and surfactant concentrations. The experimental set-up consists of a transparent, specially designed tank in which liquid flows between carefully designed and placed obstacles that create different turbulent flow fields. Bubble-particle aggregates are introduced into this turbulent zone. The behaviour of the aggregates, such as attachment /detachment of particles to/from air bubbles is recorded by a High Speed Imaging (HSI) system (5400 fps). The images are then analysed and the dependence of attachment/detachment process is described as a function of turbulent intensity in different conditions for different surfactant concentrations. This paper introduces this method to study particle-bubble interactions in turbulent flow and correlation to Computational Fluid Dynamics (CFD) simulation. CFD modelling is validated for two and three phase systems; liquid-gas with liquid and solid tracers respectively. The CFD simulations using the RANS k-S turbulence model showed good correlation to the experimental data and the experimental method is a promising tool for investigation of particle-bubble interaction in turbulent flow.

Jan 1, 2014

By Vinay Jain, Dharmendr Kumar, Beena Rai, Venugopal Tammishetti

"Selective dispersion-flocculation is considered to be an effective process for the beneficiation of ultrafine particles. This process is based on the preferential adsorption of a flocculant on the mineral particles to be flocculated, leaving rest of the mineral suspended. It has been successfully implemented at plant scales for the beneficiation of ultrafine particles of iron ores, for which conventional methods such as gravity separation, magnetic separation and flotation do not work efficiently. However, the key element responsible for the success of any selective flocculation process is the appropriate choice of the flocculant used for achieving the desired selectivity. At our lab, we are working on design and development of such selective reagents for mineral processing applications, including the beneficiation of iron ore slimes, using a combined molecular modeling and experimental approach. In this study we have employed density functional theory (DFT) to calculate the interaction energies and explain the interaction mechanisms of chitosan with the main minerals present in iron ore slimes, namely, hematite [a-Fe2O3], goethite [a-FeO(OH)], gibbsite [a-Al(OH)3] and kaolinite [Al2Si2O5(OH)4]. The magnitudes of the computed interaction energies follow the trend: Hematite > Goethite > Gibbsite ~ Kaolinite Al-OH terminated > Kaolinite Si-O terminated Analysis of the optimized geometries and electronic structures reveals that the O & N atoms of chitosan molecule form coordinate bonds with surface Fe-atoms of hematite while only weak hydrogen bonds are formed in the case of goethite, gibbsite and kaolinite surfaces thus explaining reasons behind the stronger interactions with the hematite surface. The theoretical findings were validated by performing selective flocculation experiments using chitosan as a flocculant. The selective flocculation experimental results show that a final concentrate of ~60% Fe can be obtained from a feed containing 53.13% Fe with Fe recovery of 74%. The mineral estimation in the obtained concentrate indicated that hematite and goethite are recovered in concentrate while gibbsite and kaolinite are rejected in the tails. These observations were consistent with our theoretical findings. Our work highlights the promising role molecular modeling techniques such as DFT can play in the design and development of selective reagents for beneficiation of alumina-rich iron ore slimes."

Jan 1, 2018

By Z. H. Li

In connection with the features of characteristic waste water (containing cyanogen, arsenic and heavy metal) pollutants discharged by gold industry as well as the environmental features at the location of gold production enterprises, this paper briefly described the traditional method of treatment, and focused on the argument for technologies of clean production, advanced treatment and process control technology. Moreover, it clarified the future policies and development trend for treatment on characteristic waste water from gold industry.

Jan 1, 2014