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02 Mineral Processing PDF
02 Mineral Processing PDF
02 Mineral Processing PDF
MP01
Lorenzo Reyes-Bozo
Departamento de Ciencias de la Ingeniera, Facultad de Ingeniera, Universidad Andres
Bello.
Alex Godoy-Fandez
Facultad de Ingeniera, Universidad del Desarrollo, Santiago, Chile.
Ronaldo Herrera-Urbina
Departamento de Ingeniera Qumica y Metalurgia, Universidad de Sonora, Hermosillo,
Sonora, Mxico.
ABSTRACT
MP02
Winston Rocher
ABSTRACT
Over the past fifty years, technology has advanced quicker than in any other time
and this has impacted greatly on peoples lives, on the equipment and at work.
The small grinding mills had an entry in the mill feed end for the spout feeder that
didn't allow the entry of a person. The discharge of many of them had grates and the only
way for people, liners and tools to get into them was via the manhole. The liners were
installed manually with brute force, using tools like chain blocks, rope and chains,
extending mills shutdown for many hours and increasing the risk of accidents.
The increased size of mills and the high prices for metals means equipment
designers and mining companies need to work constantly to surpass their mechanised
technology, the quality of the materials and their components, increasing their capacity, by
making them faster, more accurate and safer. In addition, the operators are working more
strategically. The result has been a significant decrease of relining time and an increase in
operator's safety.
Mineral Processing
MP03
ABSTRACT
An extensive database of Sauter mean bubble diameters, D32, and superficial gas
rates, JG, measured in different industrial flotation plants, is presented. Results involved
mechanical flotation cells of 10 300 m3 from Rougher, Cleaner and Scavenger circuits
and columns from Cleaner circuits. A significant effect of superficial gas rate on bubble
diameter was observed in mechanical cells with different bubble generation mechanisms,
cell design (self-aerated or forced air) and under different operating conditions (frother
dosage, impeller speed). This result implies a dominant effect of the superficial gas rate on
the gas dispersion. Also, higher D32 values were observed in flotation columns because of
the bubble sparger system and mainly due to lack of maintenance. From the D32 and JG
values, the bubble surface area flux, SB, was evaluated in order to determine normal
operating conditions. The gas dispersion database is useful to select proper operating
conditions and to define control criteria in flotation circuits.
Mineral Processing
MP04
Carlos Rabanal
Moly-Cop Adesur S.A.
crabanal@adesur.com.pe
ABSTRACT
The concern regarding grinding media wear is as old as the invention of the
tumbling mills. Over the years many materials and grinding media shapes have been tested,
through all this, steel grinding balls have proved to be the most effective media for
comminution in tumbling mills.
In the same way, no accurate technique for estimating the wear of the ball charge
has been developed. The mining industry still utilizes the Bond Abrasion test that was
developed in the 60s, this test is based in the ore properties having an error higher than
60%.
Lately in 2007, Radziszewski proposed a decouple total grinding media wear model,
this model is based in decoupling the effect of abrasion, corrosion and impact wear
mechanism, this new decoupled model gets an error of +/- 17% which is an improvement in
comparison to Bond model, but still shows high degree of error.
Also In 2007, Benavente from Moly-Cop Group presented an empiric model based
in operational conditions that affect wear mechanism. This new model shows an average
error of +/- 10% which represent a higher improvement in comparison with other models.
This paper present the research developed by Moly-Cop in order to improve the
capability of the empiric model developed by Benavente to estimated grinding media wear.
The work performed includes extensive determination of Bond Abrasion Index for different
kind of ores, operational information from concentrators and statistical analysis to
determine the more significant variables over the wear.
The result of the research let us to build a more robust and confident model to
estimate grinding media wear rate. The average error of this new model was in order of +/-
5.0% which means a higher improvement over the models previously described.
Mineral Processing
MP05
ABSTRACT
Copper clays are a common mapping term to describe parts of argillic and advanced
argillic alterations associated with Andean type copper deposits. They are very fine grained
materials with a bluish hue, which may or not expand when humidified. These copper
clays accompany chrysocolla, atacamite and secondary sulphide mineralization. Copper
clays have been characterized by X-ray diffraction, Qemscan, Transmission Electron
Microscopy and complemented by determination of cation exchange capacity.
Observations are contrasted with literature data on (1) the attempts of synthesis of Cu-
phyllosilicates, (2) the modification of phyllosilicates with Cu bearing molecules for
catalysis and (3) larger than clay-size phyllosilicates incorporating Cu phases between
individual sheets. For the studied copper clays, discrete copper phases were found to be
intercalated between individual phyllosilicate layers on a nanometric scale. For acid
extraction of Cu from these combined clay and Cu phase aggregates, rock texture and acid
stability of the phyllosilicate species are of fundamental importance.
Mineral Processing
MP07
ABSTRACT
CdI-JRI has designed and built two pilot columns for this purpose, 1 and 4 meters
high respectively, equipped with a rake and different feedwells. Both implemented columns
allowed Cdl-JRI to develop its own methodology for characterizing the thickening of
mining slurries in batch and continuous tests.
This paper presents the main results obtained: thickener unit area, concentrations of
solids in underflow and overflow, the effect of the feedwell on the quality of the overflow,
and the effect of the rake on the concentration of solids in the discharge.
Mineral Processing
MP08
N. Rojas.
P. Garrido.
ABSTRACT
Thickening calculation and design, hydraulic transport of mine slurries, and final
disposition of tailings are some of the areas in which a rheological characterization
containing at least viscosity and yield stress is indispensable.
This paper studies the influence of particle- size distribution on the rheological
characteristics of tailings. Three sizes known as fines are considered: material under mesh
200 (74 micron), material under mesh 400 (37 micron), under mesh 500 (25 micron). Each
of these is incorporated into the original tailings at different percentages, generating tailings
with a new particle-size distribution, which are then rheologically characterized.
With these results we are able to conclude that the three sizes of fines that were
studied, especially the 37-micron size (under Tyler mesh 400), generate an increase in yield
stress, shifting the yield stress curves versus the percentage of solids towards the left. This
may have a decisive impact on the thickening, transport and disposition of slurries.
Mineral Processing
MP09
Tsuyoshi Hlrajima
Kyushu University
ABSTRACT
Sumitomo Metal Mining Co.LTD, Niihama Research Laboratories (NRL) has been
developing Cu/As separation technology from chemical approach (investigating and
optimizing solid-liquid interfaces) and physical approach (studying the effect of flotation
equipment).
MP11
ABSTRACT
A company of the mining medium, located in the II Region of our country, requires
to increase the treatment capacity of the current plant. Long enough to make the
modifications, settled into place 2 G-Cell 18 type pneumatic cells that replace 100% to the
primary circuit. The implementation of this type of cells relies mainly to the reduced space
that they occupy and almost no structural alteration of what already exists, in addition,
update the process to a technology that most recent flotation that could result in
improvements mainly metallurgic.
The general objective of this work, is to evaluate technically and economically the
use of pneumatic cells, type G-Cell in a primary circuit of copper concentration.
The main conclusion, derived from the results, both technical and economic, is
achieved by processing ore from the Sulfurado 2.
Mineral Processing
MP13
T. Wisdom
ABSTRACT
The use of slurry impoundments have traditionally been the primary method of
disposal of waste slurry resulting from the recovery of metals and minerals. However,
current difficulties in obtaining permits to build new impoundments for grass-roots plants,
or as the existing ones near the end of their projected life, has made it necessary to explore
other alternatives for tailings disposal. Fresh water resources are becoming more precious,
and environmental pressures are increasing leading to the elimination of slurry tailings
impoundments.
But as with the equipment used to mine and move the harder lower grade ores,
equipment to process the resulting tailings slurries have increased in size, efficiency, and
capacity to meet the demand, as well as to reduce the number of people needed to operate
them. This paper discusses the technical and financial considerations, OPEX and CAPEX,
that influence equipment selection and optimization of the filter pressing system to produce
a satisfactory, transportable and stackable tailings product. Multiple tailings samples have
been investigated incorporating lab and pilot scale testing. The impact of different
minerologies and grain size will be discussed.
Mineral Processing
MP16
Francisco Abbott
Minera Esperanza
Gustavo Tapia
Antofagasta Minerals S.A.
ABSTRACT
The Antofagasta plc mining group has been pioneer in the use of raw sea water in
metallurgical process at big scale. In the 90 decade, Minera Michilla began successfully the
use of sea water in the process of leaching copper oxide and secondary sulfide ore followed
by SX-EW. At the end of 2010, Minera Esperanza commissioned a grinding and flotation
plant processing 97 ktpd of sulfide ore, using raw sea water and applied an alternative
depressant for pyrite in the cleaning stage.
Mineral Processing
MP17
ABSTRACT
Xstrata recently completed construction of a new 70,000 tonne per day copper
concentrator near Cusco, Peru. Plant start-up was accomplished during the last quarter of
2012. Comminution will be accomplished by primary crushing, SAG milling and pebble
crushing followed by ball milling. The Concentrator is a single line configuration,
comprising of one 40 ft. diameter x 22 ft. long (EGL) SAG mill driven by a 24,000 kW
gearless drive. The SAG mill feeds two ball mills each 26 ft. in diameter x 40 ft. long
(EGL), each driven by a 16,400 kW through gearless drive. This represents the higher
power of SAG in the world and the first 40 ft. SAG in Peru. This paper reviews the
projects technology.
This represents the first Xstratas Standard Concentrator, the higher power of SAG
in the world and the first 40 ft. SAG in Peru, an overland conveyor of 6.5 km with gearless
drive, the use of an old pit as tailings dam in big mining and the higher torque of tailings
thickener. This paper reviews the history, the background, the grinding circuit design and
the operations start-up considering focus in safety, start-up strategies, main issues,
improvement opportunities.
1
Mineral Processing
MP18
E.Visariev
D. Kirilov; V. Stoilov; E. Djurova; I. Bonchev; V. Stoyanova;
aurubis bulgaria
Industrial zone
Pirdop, Bulgaria 2070
ABSTRACT
At Copper smelter Aurubis Bulgaria, the slag from Flash furnace and Converters is
processed by flotation. The scheme of slag processing comprise: crushing, two stage
grinding and flotation.
Till 2010 the first grinding stage was AG Mill 7023 worked with classifier and the
second stage - ball mill 3.6/5.5 with hydrocyclone. In 2010, a new AG Mill 65x78 with
hydrocyclone was commissioned in order to increase the plant throughput. The second
stage of grinding cycle was not changed.
The Old AG mill processed 55-60 t/h slag with 75% content of size - 0.071 mm or
over 75 t/h with 35-40% content of size -0.071 mm.
The new AG Mill was designed for throughput of 105 t/h with over 70 % content of size -
0.071 mm. After start-up some problems with the equipment occurred block-up of AG
Mills grate and pumps for cyclone feeding. One of the main problems was a fast wearing
of new AG mill hydrocyclone sand nozzles. Different nozzles materials (rubber, ceramic
and metallic) were tested.
MP19
ABSTRACT
Cone crushers have been applied in mineral processing or comminution circuits for more
than five decades. In that period of time, the principle of machine selection and optimization
have evolved from purely empirical methods (capacity tables and product size curves based on
best practice) to include newer simulation based approaches.
These simulation techniques combine the strength of theory with traditional population
balance techniques. Metsos crusher simulation employs DEM with a proprietary fast breakage
technique using the concept of incremental damage. This paper provides an overview of the
Metso cone crusher simulation technology, and highlights the value of the virtual machine for
equipment design and optimization.
Mineral Processing
MP22
S. Castro
Department of Metallurgical Enginering, University of Concepcion,Chile
J.S. Laskowski
NB Keevil Institute of Mining Engineering, University of British Columbia,
Vancouver,Canada
ABSTRACT
Modern ore processing plants must have closed circuits in which process water is
recycled back after removal of fine particles in the solid/liquid separation unit operations.
Flotation of Cu-Mo ores includes two steps: a bulk flotation where molybdenite is
recovered together with Cu and Fe sulfides; and a subsequent selective flotation step where
molybdenite is separated from depressed copper sulfides. Flocculants are usually employed
in Cu-Mo concentrate thickeners preceding the selective molybdenite flotation plant.
However, the floatability of molybdenite, similarly to other naturally hydrophobic minerals,
is highly sensitive to the effect of both natural and synthetic polymers. In this work
flotation testing demostrate that conventional flocculants of the polyacrilamide type (PAM)
are strong depressants for molybdenite flotation. Additionally, shear degraded
polyacrylamides, in spite of loosing flocculation ability, are still able to depress
molybdenite flotation.
Also polyethylene oxide (PEO) have been studied in this project. The results show
that its ability to flocculate is pH dependent. In slightly acidic pH PEO and PAM showed
similar flocculation efficiencies on molybdenite suspensions. In alkaline pH, the
flocculating and depressing effects of PEO increased. In the case of PAM, a simultaneous
loss of flocculating and depressing efficiency was observed in alkaline pH. The proper use
and selection of flocculants for better molybdenite recovery is discussed.
Mineral Processing
MP24
Fernando Pino
Senior Process and Commissioning Engineer
Jacobs Engineering, Chile
ABSTRACT
MP26
ABSTRACT
Frothers play two major roles in flotation: preservation of the formation bubble size
and stabilization of the froth. Many tests have been proposed to characterize one of these
two functions and to classify frother strength based on the results obtained. A technique to
characterize these two roles simultaneously, using a laboratory flotation column, was
developed and successfully used to screen and select a replacement candidate for a
particular concentrator.
The test requires column steady state operation maintaining a constant froth height,
which entails large volumes of plant water. A technique based on batch testing around a
laboratory mechanical cell not only would demand less water, but also would make
possible on-site testing. This communication presents the development results of a batch
test to characterize frother roles in a laboratory mechanical cell, which is done through the
determination of the critical coalescence concentration and the water overflow curve.
Frothers tested follows the same classification sequence previously obtained in the column
tests.
Mineral Processing
MP28
ABSTRACT
The SAG mill is the primary work horse on the majority of comminution circuits
throughout the globe. With declining head grades the need for higher throughput circuits
has become prevalent particularly in Latin America. This paper describes the recent design
knowledge and practical experience gained in both the areas of pulp lifters and integrated
trommel design. The importance of system efficiency in terms of pulp removal is described
together with the need for enhanced slurry distribution onto the trommel screen itself.
Redesign starts with the replacement of the original OEM discharge mill linings,
generally made of Cr-Mo steel alloy castings, by liners made from a steel-rubber-ceramic
composite that acts by using each material property for specific work and application. Thus,
very hard ceramic takes care of wear resistance, the rubber matrix underneath helps absorb
impact loads and steel gives structural support, offering a more efficient solution for the
service required workloads in terms of resistance/weight ratio and endurance.
The unique and complete discharge process from the mill grates to the pebble
collection chute at the end of the trommel was studied in depth. The flow of pulp through
the SAG mill, discharge trunnion and trommel was modeled in detail using modern
techniques such as SPH/CFD and DEM. This enabled the integral design of the pulp lifters,
trunnion section, trommel and trommel panels to be optimized and then finely tuned for
maximum throughput of fresh ore.
The final result with an optimized discharge performance allows a more efficient
energy usage and or a better ore processing mill capability that enhances its performance
and so may pay back significant investment costs. Practical data relating to the influence on
circuit operating times and availability are also described.
Mineral Processing
MP29
ABSTRACT
In the last decades flotation equipment has shown a significant increase in size. At the
present moment, most of the concentrators plants operating in Chile have been fully
equipped with 130250 m mechanical cells and the new projects are considering the 300
m cell on its flotation circuits. This dramatic increase in size poses new challenges in terms
to develop better approaches to optimize the operations.
MP30
ABSTRACT
The average grade of these samples are from 0.33 to 0.86% Total Cu. The host rock
of these boreholes are different. They are: micro-granodiorite, silicified rocks, tuff and
metamorphic rocks and calcite tuff. Regarding presence of both sulphide (i.e. chalcopyrite,
covellite) and oxide (i.e. cuprite, malachite) minerals, flotation tests are carried out in
different conditions, using different reagents.
Based on these tests, the best results are obtained at pH=10.2 with 25 g/t of PAX
and 500 g/t of octyl-hydroxamate. Under this circumstance, the grano-diorite sample is
concentrated with 83.8 % of recovery (the highest one) and the silicified sample is
concentrated with 35.0 % of recovery (the lowest one). Base on obtained results, all 4
boreholes was mixed together and flotation tests were done. The results show that it is
possible to reach concentrate with copper contents15.51% in cleaner stages and 62.9%
copper recovery in rougher stage.
Mineral Processing
MP31
ABSTRACT
This paper provides a summary of pulp chemical and flotation response data for a
variety of copper ores classified by geological type prepared using forged steel and high
chrome grinding media.
The results intend to show that the mineralogical character of the ore has a
profound impact on the pulp chemistry and this effects the flotation behaviour of the
sulphide minerals. Further, the choice of high chrome grinding media, to better control
the chemical environment during grinding, is driven by the mineralogy of the system
under consideration.
Mineral Processing
MP33
ABSTRACT
Since early 2011, the type of rock ore that reached Cuajone Concentrator Plant
showed high contents of basaltic andesite, andesite Intrusive (% IA +% BA) and surface
oxide ores.
This type of mineral affected the low recovery of Cu, low tonnage of treatment, and
high consumption of sparkling lime. In addition to operating flotation problems, low
stability in the area of foaming Rougher flotation stage.
To improve the recovery of copper, sulphidation was considered, which involves the
addition of reagents to provide ionS2- and SH-. The role of these ions is to modify
completely the phisycal chemical nature of its surface structure, allowing the adsorption of
collectors on it, and its subsequent flotation. In our case we use the sodium hydrosulphide
(NaSH) as an agent to enable the affected species in the flotation of copper sulphides,
andesites and oxidized surface.
Cuajone Concentrator Plant started its trial period in 2011. With no technical
background in the industry on the conditions, dosages and addition points of NaSH, it was
experimented in different parts of the flotation. And, from September 2011, it has been
determined that the dosage of 15% concentration in the head Rougher flotation at pH 10,
improved copper recovery, reducing the consumption of frother and milk of lime, is also
achievement stabilize flotation.
The average copper recovery improved 2.3%, consumption of Cal and frother
declined by 21% and 28% respectively.
Mineral Processing
MP35
ABSTRACT
The purpose of this paper is to provide a cost effective solution to flow problems in
the mining industry, by highlighting a well proven and scientific method used to ensure
controlled and reliable flow of bulk solids, based on Jenikes flow of solids technology and
laboratory testing [1]. Knowledge of the material flow properties allows designing new
installations or modifying existing defective equipment, and preventing production
stoppages due to the formation of chute pluggages, cohesive arches and/or ratholes in
silos, which are the most common causes of flow problems in the copper mining industry.
Mineral Processing
Mineral Processing
MP36
N.S. Bekturganov
SC National scientific-technological holding Parasat
18 Republic Ave.
Astana, Kazakhstan 010000
ABSTRACT
Minerals of the oxidation zone of copper deposits belong to the most difficult for
enrichment. To transfer them into the easily floatable sulfide components it is necessary to
have new technologies and methods of enrichment associated with solving of a number of
theoretical issues to which the chemical enrichment refers. Optimization and intensification
of the technology process for the purpose of more complete and complex utilization of raw
materials require certain knowledge of thermodynamic properties of the oxidized minerals
since the thermodynamic analysis and a preliminary simulation of the process are necessary
for creation and choice of ore processing schemes. A basic sulfate of copper antlerite and a
basic phosphate of copper pseudomalachite relate to these minerals along with malachite,
azurite, atacamite, chrysocolla, brochantite, etc.
MP38
A. Desbiens, . Poulin
Department of Electrical and Computer Engineering
LOOP (Laboratoire dobservation et doptimisation des procds)
Universit Laval
Qubec (QC), Canada
ABSTRACT
For over two decades, the Process Observation and Optimisation Laboratory
(LOOP) has been working in developing and/or improving specific sensors for flotation
columns and their use for process control. Numerous papers have already been published
for the Mineral Processing industrial and scientific community in peer-reviewed journals
and conference proceedings, e.g. for the Copper Conference series. This paper summarizes
the latest completed milestones by the group, since the last Copper conference held in Chile
in 2003, emphasizing on results presented in North America and Europe since Copper
2010.
MP39
ABSTRACT
MP40
D. Gwyther
Picton Group Pty Ltd
30 Malpas Drive
Wallington Vic3222, Australia
dg@pictongroup.com.au
J. Waworuntu
P.T. Newmont Nusa Tenggara,
Jalan Sriwijaya 258 Mataram, Indonesia
Jorina.waworuntu@nnt.co.id
ABSTRACT
MP41
M. Maldonado
Departamento de Ingeniera Metalrgica
Universidad de Santiago de Chile
Avenida Libertador Bernardo OHiggins 3363
Santiago, Chile
ABSTRACT
MP42
J. Menacho
De Re Metallica Ingeniera
Av. del Valle 601, oficina 31, Huechuraba
Santiago, Chile
jorgemenacho@drm.cl
ABSTRACT
MP43
STRUCTURAL DESIGN OF RECLAIM TUNNELS
ADDRESSED AS A MINGA
This work compiles the ideas contributed from both a number of structural engineers
and designers who have addressed the structural design of reclaim tunnels as well as
from people related to other engineering disciplines, as if it was a minga(*) in order to
tackle the topic in a more comprehensive way. While in the process, an attempt will be
done to shed more light on some concepts that in structural practice have been
addressed in many different ways, mainly as a result of the scarce reference material
on criteria and national and international codes to be applied on their design. Seismic
and mineral-associated loads are specially analyzed as well as important design
aspects.
Mineral Processing
MP44
Lorin Redden
FLSmidth Salt Lake City, Inc.
7158 South FLSmidth Drive
Midvale, Utah 84098
lorin.redden@flsmidth.com
ABSTRACT
MP45
De Re Metallica Consultant, Av. Del Valle 601, Oficina 31, Huechuraba, Santiago,
Chile, (562)-738-4493, drm@drm.cl
ABSTRACT
MP47
PNEUMATIC FLOTATION IMHOFLOT
PRODUCTION TECHNOLOGY IN CHILEAN MINING
ABSTRACT
High concentration of bubbles and micro turbulence from aeration unit design, provide
high probability of collision and attachment, reducing dramatically the residence time,
self-sucking air, low maintenance, full automation process and small surface to montage
this kind of plants are some of the main the advantages.
Rotation phenomenon introduced in the vessel of the G Cell creates radial separation
forces which are the main key to separate faster the bubbles with concentrate from the
tailing and the high selectivity to get concentrate, introducing also a very short residence
time in the separation vessel.
As result of the industrial experience in Chile, the pneumatic flotation type G Cell can
be regarded as a technology which has to be considered to remove quickly fines and
ultra-fines liberated particles to end concentrate, reducing the recycling load in the
conventional flotation circuits and this could be consider as a pre rougher cell to
produce end concentrate directly.
Mineral Processing
MP48
Jorge M. Menacho
De Re Metallica Consultant, Av. Del Valle 601, Oficina 31, Huechuraba, Santiago,
Chile, (562)-738-4493, drm@drm.cl
ABSTRACT
This approach combines expert knowledge and modern cloud computing technology to
produce efficient tools for monitoring, optimization and control of critical operational
issues.
Specific examples are given showing potentiality of these tools, directed toward
increasing of productivity and efficiency, reducing water and energy consumption and
improving communities and environment friendship.