Ore Washing Research Articles

Integrating selective flocculation techniques for enhanced efficiency in manufacturing processes: A novel approach through artificial neural network modeling

The use of medium and low-grade iron ore is gradually becoming more important due to the depletion of high-grade iron ore reserves and stringent environmental acts/rules. Slimes from iron ore washing were discarded in tailing dams; however, there is currently consideration for recovering iron values from ultra-fines as well. There are enormous fine dumps that are still unutilised. Hence, this study attempt to delve the optimization of iron ore slimes an indeed requirement for manufacturing and design in industries. Leveraging a flocculation process, coupled with the implementation of an Artificial Neural Network (ANN) predictive model, the Kiriburu processing plant serves as the primary source for iron ore slime samples. Chemical analyses of the collected iron samples reveal a composition featuring 58.24 % iron content, 3.47 % Al2O3, 4.72 % SiO2, and 5.18 % LOI (Loss on Ignition). The investigation explores the performance of the flocculation technique under varying pH levels, different pulp densities, and diverse flocculant dosages. Furthermore, the varying parameters selected are pH from 6 to 11, pulp density from 1 % to 15 %, and flocculant dose from 0.03 to 0.27 mg/g. The study's findings showcase a substantial improvement in the Fe grade of iron ore, escalating from 58.24 % to 66.12 %, with an impressive recovery rate of 82.54 % achieved using a flocculant dosage of 0.09 mg/g at pH 10. Additionally, a performance assessment of the selective flocculation method for iron ore slimes is conducted using an ANN predictive model, with recovery as the pivotal parameter. The input parameters for this model encompass pH, pulp density, and flocculant dosages. Employing a three-layer ANN model with a 3–3–1 architecture and utilizing feed-forward back propagation, the study demonstrates a close alignment between predicted values and experimental data, confirming the model's effectiveness for practical manufacturing applications. Information regarding the potential applications of the model's iron ore slime beneficiation efficacy for the manufacturing sector should be considered. This could entail lower waste, more effectiveness, or cost savings. Emphasise any possible ramifications for sustainability or the environment that would make the study pertinent in a larger perspective.

Field method for preservation of total mercury in waters, including those associated with artisanal scale gold mining.

Analysis of mercury (Hg) in natural water samples has routinely been impractical in many environments, for example, artisanal and small-scale gold mines (ASGM), where difficult conditions make monitoring of harmful elements and chemicals used in the processes highly challenging. Current sampling methods require the use of hazardous or expensive materials, and so difficulties in sample collection and transport are elevated. To solve this problem, a solid-phase extraction-based method was developed for the sampling and preservation of dissolved Hg in natural water samples, particularly those found around ASGM sites. Recoveries of 85% ± 10% total Hg were obtained during 4 weeks of storage in refrigerated (4 °C, dark) and unrefrigerated (16 °C, dark) conditions, and from a representative river water spiked to 1 μg L-1 Hg2+, 94% ± 1% Hg recovery was obtained. Solid-phase extraction loading flow rates were tested at 2, 5, and 10 mL min-1 with no breakthrough of Hg, and sorbent stability showed no breakthrough of Hg up to 2 weeks after functionalisation. The method was deployed across five artisanal gold mines in Kakamega gold belt, Kenya, to assess Hg concentrations in mine shaft water, ore washing ponds, and river and stream water, including drinking water sources. In all waters, Hg concentrations were below the WHO guideline limit value of 6 μg L-1, but drinking water sources contained trace concentrations of up to 0.35 μg L-1 total Hg, which may result in negative health effects from long-term exposure. The SPE method developed and deployed here is a robust sampling method that can therefore be applied in future Hg monitoring, toxicology, and environmental work to provide improved data that is representative of total dissolved Hg in water samples.

Reuse of mine and ore washing wastewater in scheelite flotation process to save freshwater: Lab to industrial scale

This paper describes an economical and eco-friendly technology that utilises carbide slag to treat mine and ore washing wastewater (MOW) and reuses the treated wastewater in a scheelite flotation circuit. The results of systematic bench-scale and industrial-scale experiments indicate that the wastewater reuse process can reliably improve the WO3 grade with negligible effect on the recovery of scheelite. At the Yuanjing processing plant, the WO3 enrichment ratio improved from 17.4 to 23.6 and the recovery was maintained at approximately 79.2 % when recycled wastewater was used. The fourier transform infrared spectroscopy (FTIR) and X-ray photoelectron spectroscopy (XPS) analyses consistently implied that the interaction between the collector of sodium oleate and scheelite in the recycled wastewater was stronger than that in plant water. Specifically, the adsorption of Ca2+ on the scheelite surface and the formation of colloidal complexes by Ca2+ and oleate ions were responsible for the superior selectivity, while the gangue minerals such as quartz were effectively depressed by the depressant of water glass. Consequently, the treated MOW could be a suitable alternative to reduce freshwater consumption in mining areas, which is of great significance for the mining and mineral processing industries.

Safe and effective methods for mining thin tilt and steeply dipping deposits with ore drawing via mud flow

For mining of thin (1–3m) tilt (15–45°) ore bodies, it is recommended to use the mining method with induced mud–water–stone flows to deliver broken ore up-dip the bodies in combination with scraper handling of ore along the strike and water jet washing of ore when forming columnar pillars, including underhand ore cutting, with division of blocks into many long stopes along the block strike, heading of one or two tilted accumulation and haulage rooms to be close-looped with the long stopes, scraping of broken ore to the tilt accumulation and haulage rooms and mud flow of ore along these rooms. This method can increase the stoping capacity as per the number of stopes in a block: for example, in a 160 m wide, only two tilt rooms are required to be headed between levels. The artificial mud flows in mining (or re-mining) of thin and steeply dipping ore bodies which have their girtwise bottom boundary skewed at 15–45 °, are no less effective. For the purpose of mining (re-mining) of such reserves, it is proposed to use a process flowsheet as follows: broken ore flows under gravity to the lower part of the extraction block and, then, along the tilted bottom of the block, it goes down under the action of gravity and energy of water flow in the mode of the mud–water–stone flow to the ore intake room on this level. In this case, as against mechanical haulage, the mud flow of broken ore essentially enhances the ore production output owing to the high capacity of the mud flow, and greatly reduces the scope of the preparatory and actual mining operations connected with the block bottom formation.The study was supported in the framework of the Target Financing Program of the Ministry of Education and Science of the Republic of Kazakhstan, Program No. 2018/ВR05236712.

Design of Air Table Equipment for the Separation of Metal Minerals by Gravity Concentration with Wind Media

This research is an air table device design and laboratory scale experimentation. Air table is a tool to separate valuable minerals from mineral impurities of tin ore based on differences in specific gravity, shape and size using air/wind media. The design of the tool starts from the design and manufacture of the table as well as the manufacture of other main components, including; feed hopper, ventilation and tertoron cloth. Then the next stage is the calculation and selection of a table driving motor in the form of an electric motor with a pulley system and the last is the calculation and selection of a blower machine as a machine that functions to blow pressure into the table. The installation of the air table was carried out at the Materials Processing Laboratory, Faculty of Engineering, Sriwijaya University. To determine the success rate of designing and evaluating the performance of the air table, experiments were carried out using several combinations of variables, including table slope, feed weight (grams), and processing time (minutes).). The experimental process of the tool was tested using tin ore samples from the remaining tin ore washing (SHP) from the Toboali Washing Plant, PT Timah, Tbk. The experimental results show that the performance of the tool shows good but not optimal performance where the lowest concentrate gain is achieved at 50.20% and the highest is 79.14% at a deck slope of 5.8°, feed weight is 600 grams and processing time is 15 minutes. The results of the evaluation show that the air table device functions relatively well, but needs to be improved and adjusted for more varied variables as well as representative samples and quantities of tin ore, so as to produce maximum concentrate and grade.

Reuse of Mine and Ore Washing Wastewater in Scheelite Flotation Process to Protect Freshwater: Lab to Industrial Scale

Reuse of Mine and Ore Washing Wastewater in Scheelite Flotation Process to Protect Freshwater: Lab to Industrial Scale

Pollutant removal from mining processing wastewater by electrochemical method

<p>Discharging wastewater from industries without any treatment causes environmental pollution and endangers biotic life. In this study, pollutant removal by electrocoagulation (EC) process was investigated using wastewater of the ore processing plant (magnesite crushing and screening plant). In the EC process, iron-iron and copper-copper electrodes were used in parallel in the reactor. Chemical oxygen demand (COD), Sulphate, Chromium (VI), Nickel, Zinc, Magnesium, and Total Suspended Solids (TSS) removals were investigated in the EC process of mineral processing industry wastewater with the iron electrode. These pollutants were calculated as %97.6, %95.1, %98.2, %98.1, %97.8, %88.2, and %98.9, respectively. COD, Sulphate, Chromium (VI), Nickel, Zinc, Magnesium, and TSS removals in the EC process of mineral processing industry wastewater with the copper electrode are %92.8, %94.9, %99.5, %98.7, %96.1, %91.6, and %96.9 respectively. It has been observed that high removal efficiency can be achieved by using the electrocoagulation process in the treatment of ore washing wastewater resulting from the crushing and screening processes in the Chrome Magnesite processing plant.</p>

Utilization of iron ore slime and bottom ash: An overview

Steel plants are the primary producer of solid waste materials like slags from blast furnaces and L.D. Plant with fly ash /bottom ash from the power plant, iron ore slimes from ore washing plant, coal/coke from coke ovens, etc. It is estimated that about 84% of total solid waste generation is in iron ore tailings (Fines/ Slimes), coal combustion residues (Fly Ash or Bottom Ash), and the remaining 16% constitute all others, including slag. The above wastes (Iron ore slime & Bottom ash/ Fly ash) are being used for landfilling and in few countries to get value-added products. However, the partial or bulk utilization of such waste is still an academic issue in India.The present paper reviews past and recent research work to utilize two significant unutilized waste (Iron ore slime & Bottom Ash). The promising areas for utilization of Iron Ore Slime and Bottom Ash are the making of bricks (constructional, insulation), use as bed filter materials, and Ferro / master alloys' production as a part of metal recovery using smelting reduction process. (e.g., Al, Si, etc.).

Waterminer – a regional spatio-temporal approach to water reuse management in mining areas in Vietnam

Abstract Mining is usually associated with draining of large quantities of water. On the other hand, mining operations themselves are water users for purposes like coal or ore washing, dust mitigation, recultivation, etc. The normally existing water surplus can be seen as a resource for public purposes instead of discharging the water to rivers and the sea. It is typical for the mining operation that these water amounts vary spatio-temporally according to the mining process. The R&D project WaterMiner investigates the example of the Hon Gai hard coal mining area in Ha Long, Vietnam, as to how and to what extent under the variable spatio-temporal conditions the mine water can cover the water demand in the mines themselves and contribute to the public water supply in the surrounding settlement area of Hon Gai. The spatio-temporal change of mine water drainage, mine water treatment and mine-internal water use and the potential mine-external water use volumes in the project region are investigated by a material flow model and visualized by Sankey diagrams, maps, and tables. Several options for delivery of mine water for mine-external water uses as a contribution to the public water supply are shown.

IA: The Journal of the Society for Industrial Archaeology, Theme Issue: The Archaeology, by Frederic L. Quivik, ed.

IA: The Journal of the Society for Industrial Archaeology, Theme Issue: The Archaeology, by Frederic L. Quivik, ed.

Enhancement of copper recovery by acid leaching of high-mud copper oxides: A case study at Yangla Copper Mine, China

Poor permeability, high mud and impurities contents, severe curing conditions and ore complexity are primary challenges faced by Yangla Copper Mine (YCM) during acid leaching, resulting in a poor 1% copper extraction after 3 months of traditional leaching. A series of technological improvements, which included of antiscalant addition, ore washing, classified crushing and screening, thin-layer conveying and dumping, and mechanical/chemical activation, were applied in YCM to enhance heap permeability and copper extraction from low-grade copper oxides. These improvements increased copper extraction to over 60 and the production of cathode copper reached 2500 t/a. Related topics such as: ore surface erosion, particle size distribution, heap structure, irrigation rate, and passivation and its effects are also discussed in this study. Even though some of the relevant mechanisms for enhanced recovery are still being studied, this successful industrial case provides a good reference for copper oxide mines encountering similar problems.

Can carboxymethyl cellulose be used as a selective flocculant for beneficiating alumina-rich iron ore slimes? A density functional theory and experimental study

India has around 28.52 billion tons of hematite and magnetite ore reserves, over 20% of which is in the form of fines. Also during the mining, crushing and washing of ore, huge quantities of fines are generated, majority of which end up into tailing ponds owing to their high alumina contents (∼10–15%). Selective dispersion flocculation is a promising route for beneficiation of such fine ores as opposed to conventional gravity and magnetic separation techniques; however, one requires selective reagents for effective beneficiation. We are engaged in the design and development of selective reagents for beneficiation of iron ores based on a molecular modelling approach. In the present study we have employed density functional theory (DFT) to calculate the interaction energy of hematite (0 0 0 1), goethite (1 0 0), gibbsite (0 0 1) and kaolinite (0 0 1) surfaces with carboxymethyl cellulose (CMC). The magnitudes of the computed interaction energies follow the trend:Hematite > Goethite ∼ Gibbsite ∼ Kaolinite Al–OH terminated > Kaolinite Si–O terminated.Electronic structure analysis revealed that the O-atoms in the hydroxyl and carboxyl groups of CMC form coordinate covalent bonds with surface Fe-atoms of hematite while forming only weak hydrogen bonds with goethite, gibbsite and kaolinite surfaces thus explaining the trends in the interaction energies.These DFT findings were validated by experimental flocculation results which show that a final concentrate of 64.4% Fe, 4.2% Al2O3, and 1.9% Silica with a yield of 56% can be obtained from a feed containing 56.5% Fe, 7.0% Alumina, and 4.9% Silica.Mineral wise estimation of chemical assay shows that CMC can be selective in flocculating hematite mineral particles over goethite, gibbsite and kaolinite. Our work thus highlights the important role of molecular modeling techniques such as DFT in screening and design of selective reagents for beneficiation of alumina-rich iron ore slimes.

Study on the origin of the new archaeological deposits from the East Zhou dynasty excavated from the Yanyingshan site in Tonglvshan, China

In the 1970s, archaeologists discovered a large group of sites related to the mining and smelting of copper dating back to the Bronze Age in Tonglvshan, Hubei Province. Recently, the Yanyinshan site was discovered in this region. Several hard crust layers in archaeological strata were unearthed from exploration squares and are the first finding both in this area and in China. The phase and composition of the hard crust were analyzed by microscopic observation, X-ray diffraction, X-ray fluorescence spectra, and ICP-AES. Based on the lithological features, spatial distribution, superimposition relationship, features of the ancient ruins, and comparisons of the mineral composition and geochemical characteristics of trace elements with those from the Tonglvshan copper-iron mine, the hard crust proved to include sediments of wastewater after copper ore washing in the Chinese Bronze Age. This constitutes geoarchaeological evidence of the previously unrecognized parts of the ancient metallurgy chain.

Valentines and Thomas: Ironmasters of Central Pennsylvania. Phase III Archaeological Data Recovery. The Valentine Iron Ore Washing Plant (36Ce526), Proposed Benner Commerce Business Park 82–Acre Parcel Benner Township, Centre County, Pennsylvania

Valentines and Thomas: Ironmasters of Central Pennsylvania. Phase III Archaeological Data Recovery. The Valentine Iron Ore Washing Plant (36Ce526), Proposed Benner Commerce Business Park 82–Acre Parcel Benner Township, Centre County, Pennsylvania

Le complexe d’ateliers du Cabezo del Pino (Sierra Minera de Cartagena-La Unión, Murcia) et l’organisation de l’activité minière à <em>Carthago Noua</em> à la fin de la République romaine. Apports croisés de l’archéologie et de la géochimie

Se presentan los resultados de estudios arqueométricos realizados sobre diversos materiales (mineral, sedimentos de lavado, litargirio) recogidos en las recientes excavaciones de un complejo de talleres de época tardorrepublicana vinculado a la producción de plata y plomo en el distrito de Carthago Nova. Además de permitir la determinación de la signatura isotópica del complejo arqueológico, los isótopos de plomo contribuyen, conjuntamente con la arqueología y la epigrafía, a una mejor comprensión de la organización de la actividad minera y metalúrgica en la Cartagena romana. [fr] Cet article présente les résultats d’analyses isotopiques du plomb (LIA) réalisées sur divers matériaux et objets archéologiques (minerais, sédiments de lavage, litharges) découverts dans le cadre de récentes fouilles archéologiques conduites sur une installation de lavage au sein du district minier d’argent de Carthagène, durant l’époque romaine. Le but de telles analyses était d’affiner la signature isotopique de la laverie de manière à la situer dans ce vaste district. Combinées aux données de l’archéologie et de l’épigraphie, les LIA peuvent contribuer à mieux connaître et comprendre l’organisation de l’activité minière et métallurgique de Carthagène.

Ultrasonic processing of bauxite ore to estimate its washing potential

Silica in the form of clay present in the bauxite ore causes lot of complications in the Bayer hydrometallurgical process for the production of alumina. Therefore, bauxite is processed and washed in trommels to disintegrate and remove the clay before sending the ore as a feed to the Bayer process. Estimation of ore washing potential and the selection of cut size is essential for the establishment of a bauxite washing plant. In the current research study, a simple ultrasonic washing technique has been developed for the removal of clay and to determine the potential of an industrial washing process at various cut sizes. Four feed size fractions of clayey bauxite ore were washed in laboratory for 1, 3, 5 and 6 min using ultrasounds. After 5 min, the steady state washing conditions were observed. It was found that at 36 micron cut size, 70% mass and 77.5% alumina recovers whereas 69% of total silica moved towards the tailings streams. Cut size sensitivity shows that by increasing the cut size from 36 micron to 100 micron, nearly 5% reduction in the recoveries of total mass and alumina was observed whereas the recovery of silica slightly reduced in the concentrate.

Optimization of an Iron Ore Washing Plant

The sustainable viability of a mineral enterprise depends on improving the concentrate quality, generating readily salable by-products, improving recovery, throughput, and reduction of unit cost rate and maximize the unit income rate and thereby unit profit rate. Closing down of iron ore mines due to environmental constraints spurred the captive iron ore washing plants to workon a custom plant mode and also recover the values from their slimy tails. This paper enumerates the difficulties faced by a captive iron ore fine washing plant [treating iron ore fines assaying Fe∼58% yielding sands assaying Fe>60%] due to raw material change yielding unsalable sands and discuss the importance of process plant audit for improving the mineral processing plant performance. Based on the base line study, laboratory tests on typical samples followed by short term modifications, retrofitting of downstream slime concentrating wet high intensity magnetic separators and dewatering of products could produce readily salable sinter grade [Fe>60%] and pellet grade[Fe>62.5%] with an overall increase of concentrate yield by 11.5%. Even the previous wash plant tails [which assayed Fe > 45%] may be reprocessed in the retrofitted slime processing VPWHIMS plant. The final tails assayed 38.60% Fe at weight % yield of 28.5. Efforts are on for utilizing the above tails in bricks- tiles manufacture. Also, R&D efforts to concentrate Fe values from above 38.60% Fe tails by Magnetizing roast followed by magnetic separations in bench scale has given encouraging results. Thus auditing not only improved the quality, quantity and rate of production of concentrate but mitigated the problem of tailing disposal. The investments were repaid within a year of operation and unit operating costs reduced by 20% with reference to base line data.

Optimization of Flotation Process for Reduction of Alumina and Silica from Screw Classifier Overflow of an Iron Ore Washing Plant

Reverse flotation process was optimized by an experimental programme based on statistical analysis for reduction of silica and alumina levels from screw classifier overflow so as to enrich iron values. Flotation of alumina and silica bearing minerals with Sokem 521C and starch as collector and depressant respectively was studied to estimate their optimum levels at different particle sizes. A two-level three factor design of experiments showed that particle size is insignificant in the ranges of study. Tests on an orthogonal design of the hexagonal type were then carried out to determine the effects of the other two variables, on the response, Selectivity Index (SI), a measure of separation efficiency of iron values from alumina and silica. Regression equations were developed as models and response contours were plotted. Maximum response (SI of 2.25) has been optimized at 0.306 kg/t of amine collector, 1.0043 kg/t of starch at a particle size of 40 µm.

Reconsidering the role of Thorikos within the Laurion silver mining area (Attica, Greece) through hydrological analyses

The aim of the current study is to examine the role played by Thorikos within the Laurion silver mining area from the perspective of metallurgical activities during the Classical and Early Hellenistic periods. Because water availability directly determines the production output of metallurgical workshops, a hydrological analysis of the area is an ideal tool to enhance our understanding of this issue. On a large scale, hydrological modelling is accomplished through the analysis of runoff water accumulation; on a small scale, a water balance model is used to simulate the operated water supply system for industrial purposes, more specifically the purifying of silver ores in washeries. Also, the impact of cistern location on its effectiveness and usability for silver processing is explored. The two focus areas are the Velatouri Hill, where the site of Thorikos is located, and the Soureza Valley, which is situated in the centre of the Laurion. In each area a number of ore washing workshops were chosen to study in more detail.Through the region-wide hydrological and archaeological analysis, it could be shown that the Thorikos workshops contrast sharply with the Soureza ones. The latter relied on ephemeral streams which were consolidated and tapped by large cisterns, thus creating a water stock that was more than sufficient to bridge the dry periods of the year. The former relied on the harvesting of limited runoff during heavy rain events, which in many cases did not provide a sufficient water stock. Furthermore, water supply strategies in Thorikos were not as well-considered in comparison to Soureza. This leads to the conclusion that Thorikos could have never been the large scale processing site Soureza was and, when combined with the small-scale analysis, the site must have had a distinctively more ad hoc character.

Phosphate ore washing by Na2EDTA for cadmium removal: Optimization of the operating conditions

This paper discusses the extraction of cadmium from phosphate ore by the washing method. Various parameters were investigated for the cadmium extraction from phosphate ore. The results from extraction tests showed that cadmium extraction depends on the nature and concentration of the extracting agent, the liquid/phosphate ore ratio, the temperature and the solution pH. The effi ciency of the nine extracting agents for removing cadmium from phosphate ore was found to be in the order: Na2EDTA > citric acid > tartric acid > ammonium citrate > calcium chloride > ammonium acetate > ammonium chloride > oxalic acid > ammonium hydroxide. In this study cadmium extraction kinetics was best described by the product layer diffusion control model.