Separation Of Ore Research Articles

Stirred media mills of fine and ultrafine grinding for subsequent beneficiation operations

This paper presents a brief review of the designs, characteristics, and operating parameters of Stirred media mills supplied by foreign manufacturers. An analysis of information on Stirred media mills , which are used to improve the efficiency of beneficiation and metallurgical operations, is carried out using available publications. The obtained results indicate the inexpediency of using conventional drum ball mills for flotation separation of ores and concentrates with a fine interpenetration of minerals. The application of conventional mills in extraction of ores and concentrates resistant to cyanidation, where gold is finely disseminated in sulfides, is limited by their high power consumption and the corresponding operating costs. In this work, different types of Stirred media mills are considered, including their vertical and horizontal types. The advantages of Stirred media mills over conventional ball mills, particularly in terms of energy efficiency, are noted. The designs and main characteristics of Stirred media mills , which have received wide application, are presented. According to the data presented in the reviewed publications, the main parameters determining the grinding process in such mills are outlined, including the ratio of bead size to mill feed size, density of grinding medium, density of pulp in the mill, volume loading of beads, stirring speed, etc. The conducted analysis of literature data indicated high efficiency of mills based on agitation of grinding media for fine and ultrafine grinding of ores and concentrates in comparison with conventional ball mills. Given that the volume of ores and concentrates resistant to processing by conventional methods is increasing, the application of Stirred media mills is expected become more widespread, thereby increasing the efficiency of subsequent beneficiation and metallurgical operations.

UTILIZING GAUSSIAN PROCESS REGRESSION FOR NONLINEAR MAGNETIC SEPARATION PROCESS IDENTIFICATION

This paper presents a novel approach utilizing Gaussian Process Regression (GPR) to identify dynamic models with nonlinear parameters in magnetic separation processes. It aims to address the complex and dynamic nature of these processes by employing advanced modeling methods. The effectiveness of GPR is demonstrated through its application to simulated signals representing real iron ore separation processes, highlighting its potential to enhance existing models and optimize processes. Conducted within the MATLAB, this research lays the groundwork for further advancement and practical implementation. The utilization of GPR in magnetic separation offers innovative modeling of nonlinear dynamic processes, promising improved efficiency and precision in industrial applications.

Enhancing the Flotation Separation of Galena and Pyrite in the Presence of Seawater.

The effect of seawater on the flotation of sulfide minerals is a hot research topic at the present. Using seawater instead of fresh water to separate lead-sulfur can save fresh water resources and reduce lime consumption, which has broad prospects in terms of economic and environmental protection. Many studies have shown that divalent calcium and magnesium ions in seawater are hydrolyzed to form hydroxyl complexes under alkaline pH values, which affects the flotation separation of sulfide ore. In this paper, the flotation separation of galena and pyrite in seawater was tested, and the mechanism was analyzed. Compared with that in deionized water, the lead grade of concentrate in seawater flotation increased from 57.40 to 60.20%. Meanwhile, the recovery of galena declined from 68.66 to 61.17%, and the SI value increased from 2.020 to 2.072. With the addition of SHMP, SS, and EDTA, the SI value increased from 2.072 to 2.609, 2.525, and 2.287, respectively. Noteworthily, when EDTA was excessive, the grade of Pb was 69.60%, and the SI value was 3.050. Wettability analysis, zeta potential analysis, X-ray photoelectron spectroscopy, Fourier transform infrared spectroscopy, density functional theory calculation, and E-DLVO calculation verified the microflotation results and revealed the mechanism of action.

Optimizing coarse chalcopyrite separation in fluidized bed flotation: Role of the self-generated bed

Coarse particle separation is important in mineral processing. In this study, the performance of coarse chalcopyrite ore separation (−600 μm, Cu grade 0.375 %) by fluidized bed flotation (FBF) was investigated and the basic function of fluidized bed on the particle separation is discussed. The chalcopyrite grain size distribution mainly ranges from 50 to 300 μm, with over 80 % of the grains being liberated. The results indicate that the FBF system can reject tailings with a yield of 48 % and a Cu grade of 0.06 %. Additionally, concentrate Cu grade reaches 0.62 %, which is around 1.65 times higher than feed, resulting in a total Cu recovery of 91.55 %. The introduction of a fluidized bed increases Cu recovery of −600 + 300 μm from 50 % to73%, as it improves the possibility of bubble-particle attachment, but the variation of bed height has little influence. Particles with a size of −300 + 74 μm can obtain a 96 % Cu recovery in the bubbly flow, while particles with a size of −74 μm lose their separation effect due to hydraulic entrainment.

Exploring Low-Grade Iron Ore Beneficiation Techniques: A Comprehensive Review

The beneficiation of low-grade iron ores is a key research and development topic in the mineral processing industry. The gradual exhaustion of high-grade iron ore reserves, and rising consumer iron and steel demand globally necessitate efficient low-quality iron ore beneficiation to meet steelmaking quality requirements. This comprehensive review explores various beneficiation techniques for low-quality iron ore, focusing on conventional methods including comminution, froth flotation and gravity separation. This article discusses the principles, processes, and equipment used in these techniques and highlights recent advancements and research efforts in the field. This review also emphasizes the importance of effective beneficiation processes in enhancing economic viability, sustainable resource management, and environmental conservation. Furthermore, it presents a case study of iron ore deposits in Botswana, highlighting the potential economic growth and sustainable development that can be achieved by maximizing resource utilization through reductive roasting, followed by magnetic separation of iron ore using semi-bituminous coal as a reductant. Overall, this review provides valuable insights into low-grade iron ore beneficiation techniques and their significance in meeting the growing demand for high-quality iron and steel products.

Insights into flotation separation mechanism of chalcopyrite from galena using mercaptosuccinic acid as a novel depressant: Experimental and MDS studies

The separation of polymetallic sulfide ores by flotation is a difficult task in the mineral processing industry. In this investigation, a small-molecule organic compound, mercaptosuccinic acid (MSA), was used as a new depressant for inhibiting galena in chalcopyrite flotation. Micro-flotation and surface wettability tests indicated that MSA pronouncedly weakened the floatability of galena but not chalcopyrite, resulting in marked differences in their flotation recovery. Findings of Fourier transform infra-red (FT-IR) spectroscopy measurements and reagent adsorption trials showed that MSA was strongly adsorbed on galena, resulting in the inability of the collector to effectively interact with galena. Atomic force microscope (AFM) and X-ray photoelectron spectroscopy (XPS) analyses further corroborated that MSA showed a greater affinity for galena than chalcopyrite, this behavior markedly altered the superficial chemical environment of galena. Molecular dynamic simulations (MDS) showed that MSA increased the concentrations of H2O molecules on galena, which enhanced the surface hydrophilicity of galena.

Selective depression mechanism of polyaspartic acid and calcium oxide on arsenopyrite after copper ions activation and its effect on flotation separation performance

The arsenopyrite activated by copper ions have similar flotation properties to chalcopyrite. Polyaspartic acid (PASP) and calcium oxide (CaO) using as combination depressants for the selective separation of copper-activated arsenopyrite and chalcopyrite were carried out by micro-flotation experiments, contact angle measurements, surface adsorption capacity tests, zeta potential measurements, X-ray photoelectron spectroscopy (XPS) analyses, inductively coupled plasma-optical emission spectrometer (ICP-OES) tests and time-of-flight secondary ion mass spectrometry (ToF-SIMS) analyses, and its depression mechanism was investigated. The results of flotation experiments showed that the recovery of arsenopyrite after addition of the depressants reached only 7.80 %, while the recovery of chalcopyrite reached 94.02 %. The results of contact angles, adsorption capacity tests and zeta potential measurements showed that the PASP-CaO can selectively enhance the hydrophilicity of arsenopyrite surface, but has little effect on the chalcopyrite. XPS analyses and ICP-OES tests further verified that the depressants first eliminated the activation of copper ions and then selectively adsorbed on the surface of arsenopyrite. ToF-SIMS analyses showed that the PASP-CaO would achieve selective depression of arsenopyrite in the form of PASP, PASP-Ca complexes and Ca(OH)+, respectively. Finally, the mechanism diagram of PASP-CaO selectively depressing arsenopyrite was derived. These results will provide an excellent theoretical reference for the flotation separation of copper arsenic sulfide ore.

Study on the mechanism of action of various metal ions on the surface of monazite

By studying the various metal ions released from the grinding process, and conducting the flotation test of monazite and symbiotic ore, using zeta potential measurements and FTIR infrared spectrum analysis methods, the influence of metal ions on the surface of monazite and the mechanism of action are obtained. The results showed that the main metal ions in the flotation environment of monazite are Ca<sup>2+</sup>, Ba<sup>2+</sup>, and Fe<sup>3+</sup>. When the pulp pH value was 8, Ca<sup>2+</sup>, Fe<sup>3+</sup>, and Ba<sup>2+</sup> concentration was 3×10<sup>-4</sup> mol/dm<sup>3</sup>, 3×10<sup>-5</sup> mol/dm<sup>3</sup>, and was 2×10<sup>-4</sup> mol/dm<sup>3</sup> respectively, and OHA collector dosage was 5×10<sup>-4</sup> mol/dm<sup>3</sup>, while the flotation recoveries of monazite, calcite. And fluorite was above 95 %, 40.43 %, and below 45.32 %, and the recovery rate of barite and bastnaesite in the presence of Ca<sup>2+</sup> and Fe<sup>3+</sup> is below 54.32 % and 38.68 %, respectively and the effective separation of monazite and symbiotic ore was obtained. The zeta potential measurements showed that when only metal ions are added to monazite, monazite (IEP) shifts to the right, and the negative charge on the surface of monazite decreases, which may be due to the positive charge of metal ions adsorbed on the surface of monazite, increasing the positive charge on the surface of monazite. When Ca<sup>2+</sup>, Ba<sup>2+</sup>, Fe<sup>3+</sup>, and OHA were added to the monazite pulp, the IEP of monazite moved to the left, and the negative charge of monazite shifted to the positive direction as a whole, indicating that Ca<sup>2+</sup>, Ba<sup>2+</sup>, and Fe<sup>3+</sup> were adsorbed on the surface of monazite and increase the positive charge on the surface of monazite. When the pH value was 7 ~ 10, the surface of monazite was the same as that before and after the action of the agent, and both were negatively charged. At this time, OHA can still adsorb on the calcite, that was, the chemical affinity overcomes the same electric repulsion and adsorbs, so that the potential of the monazite after the action is reduced, which is chemical adsorption. The FTIR showed that when the metal ions Ca<sup>2+</sup>, Ba<sup>2+</sup>, and Fe<sup>3+</sup> are added to activate the surface of monazite, the peak area of the organic functional group-CH2−CH3 at 3000-2800 cm−1 was enhanced, and a new peak appears at 1382 cm<sup>−1</sup>. The reason is that the N-O-H functional group of OHA collector was adsorbed on the surface of monazite, and a red shift (44 cm<sup>−1</sup>) occurs, and a new peak appears at 1454 cm<sup>−1</sup>. The reason is that the C-N functional group of OHA collector is adsorbed on the surface of monazite. The lone electron pair of the nitrogen atom of the amide group in the OHA forms chelates with Ca<sup>2+</sup>, Ba<sup>2+</sup>, and Fe<sup>3+</sup> atoms, which further increases the adsorption amount of OHA. This showed that the adsorption of monazite surface by metal ions provides active sites for the adsorption of OHA collectors. These phenomena indicate that the adsorption capacity of OHA on the surface of monazite activated by Ca<sup>2+</sup>, Ba<sup>2+</sup>, and Fe<sup>3+</sup> is enhanced and a stable five-membered ring metal chelate is formed. Combined with flotation results and zeta potential data, infrared spectroscopy analysis, the adsorption capacity of Ca<sup>2+</sup>, Ba<sup>2+</sup>, and Fe<sup>3+</sup> activated monazite surface: Fe<sup>3+</sup>>Ca<sup>2+</sup>>Ba<sup>2+</sup>.

Modelling of a six-case hardware object for control of potassium ore flotation based on systems thinking

This article discusses computer modelling of the flotation process taking into account the hydrodynamic structure of interacting flows. Modern technologies and processes ensure the effective separation of potash ores into individual components, allowing you to obtain the desired product in its pure form. An important aspect is to minimize the loss of useful substances in order to maximize its use in the production of fertilizers. This is achieved through strict control over each stage of raw material processing, optimization of chemical reagents and improvement of separation systems. Various options have been studied and the possibility of using differential equations of material balances has been shown. This made it possible to justify a multi-stage method for identifying a flotation object. The results obtained made it possible to develop acceptable computer models of the dynamics of the flotation process. Methods for modelling the facility and control systems for flotation complexes have been developed based on computer models of the process occurring in the gas and liquid phases.

Efficiency of preliminary gravity separation of gold-bearing ore from the Malinovka deposit

Efficiency of preliminary gravity separation of gold-bearing ore from the Malinovka deposit

Numerical Simulation of Stacked Step Flowincentrifugal Force Field for Copper Ore Separation

In this study, the flow field of a stacked step flow device was simulated using Fluent 19.2 software. The simulation results show that: the combination of rotational motion and reverse fluidization of the fluid in the cone of the equipment makes the slurry dispersed and separated in the radial direction, and the upward motion of the fluid can promote the solid phase, especially the smaller particle size and lower density of the silica phase, to realize the separation of the copper phase and the silica phase in the axial direction; the vortex generated by the sudden change of tangential flow velocity at the step can significantly improve the settling efficiency of the copper phase in the upward process. Fluent simulation results show that: when the rotational speed is 50r/min, the feed speed is 0.5m/s, and the reverse fluidization speed is 0.018m/s, the copper recovery rate is 87.70%, and the enrichment ratio is 13.45.

Ultrasound-enhanced separation characteristics of gas-solid fluidized bed for fine-grained fluorite ore

Due to the increasing mechanization of mining, there is an urgent need to develop dry separation technology for effective pre-enrichment of fine-grained fluorite ore and promote the efficient use of fluorite in arid or water-scarce areas. Therefore, we tried to enhance the separation performance of fine-grained fluorite ore by introducing ultrasound into the gas–solid separation fluidized bed. Fluidization test and high-speed dynamic image analysis were used to reveal the mechanism of density separation of two-component materials enhanced by ultrasound. The effects of gas velocity, static bed height, separation time and amplitude transformer diameter on density segregation of two-component materials were further studied. In addition, a gas–solid fluidized bed separation system under the action of ultrasound was established for the pre-enrichment of fluorite ore with different particle sizes. The study showed that the stability of the bed is improved by the introduction of ultrasound. And the separation efficiency was increased by 15.46% compared with ordinary fluidized bed. The possible deviation (E) values of 1–0.5 mm and 0.5–0.25 mm fluorite ore were 0.22 g/cm3 and 0.175 g/cm3 respectively. This study provides new insights into the separation of fine-grained fluorite ore by gas–solid fluidized bed under the action of ultrasound.

Quantitative evaluation of collector flotation performance II: The creation of a collector property index based on molecular structure

The evaluation and prediction of flotation performance is a key step in the development of high-performance collectors for the efficient flotation separation of low-grade complex ores. In our previous work, we have created the flotation index (FI) for a comprehensive and standardized evaluation of collector flotation performance. However, as an experiment-based index, FI does not possess the quantitative predictive power that is fundamental to rational flotation reagent design. In this work, the collector properties were obtained by quantum chemistry (QC) calculation. By ranking the importance of the QC properties, machine learning (ML) aids the selection of key properties representing different aspects of a collector (polar, non-polar and overall polarity). The key properties were incorporated into a theory-based collector property index (CPI). Based on a quantitative structure–activity relationship (QSAR), the bridge between theory and experiment were established by searching for the relationship CPI and FI, enabling convenient evaluation and prediction of collector flotation performance. The accuracy of our QSAR model was verified using the galena-pyrite separation system. Our QSAR model demonstrates transferability in that it can predict collectors with diverse skeletons or types, pushing the limit of most conventional QSAR models, which only apply to collectors with similar skeletons or types. This work provides an alternative pathway for the rational design and performance prediction of flotation surfactants.

Magnetizing roasting and magnetic separation of highphosphorus brown iron ore from the Kirovskoe deposit

Magnetizing roasting and magnetic separation of highphosphorus brown iron ore from the Kirovskoe deposit

Mineralogical factors affecting the separation behavior of Ta-Nb-bearing minerals in the gravity field: mineral grain size, liberation, and association relationship

Gravity separation is the primary method used to beneficiate Ta-Nb-bearing minerals, however, it performs poorly in low-grade and fine-grained ores. A comparative study of gravity separation products (concentrate, middlings, and tailings) reveals the factors affecting the separation behavior of Ta-Nb-bearing minerals in the process combined with a spiral chute and shaking table from the perspective of mineralogy. The results reveal that columbite-tantalite is the principal Ta-Nb-bearing mineral. The grain size of columbite-tantalite in the concentrate is the coarsest, followed by that in the middlings, and the finest in the tailings, which are mainly distributed in the range of -150+38 μm, -75+20 μm, and-38 μm, respectively. The liberation degree of columbite-tantalite in the concentrate and tailings is positively correlated with grinding time, while that in the middlings is negatively correlated with grinding time. The density of columbite-tantalite-bearing particles in concentrate is mainly distributed above 3 or even 4, due to the high liberation degree of the columbite-tantalite in the concentrate, as well as the high amount of rich intergrowth associated with heavy minerals. The density of Ta-Nb-bearing mineral particles in the middlings and tailings is predominantly distributed in D<3. It demonstrates that the liberation degree is not the most essential factor in determining columbite-tantalite separation behavior in the gravity field, and the mineralogical characteristics of columbite-tantalite including grain size, association relationship, and particle density, may be more important. The results of this investigation can provide theoretical support for the strengthening separation of low-grade tantalum-niobium ore.

Impact of the Mining Process on the Near-Seabed Environment of a Polymetallic Nodule Area: A Field Simulation Experiment in a Western Pacific Area.

With the consumption of terrestrial metal resources, deep-sea polymetallic nodule minerals have been widely exploited around the world. Therefore, the environmental impact of deep-sea polymetallic nodule mining cannot be ignored. In this study, for the first time, a field disturbance and observation device, integrated with multiple sensors, is used to simulate the disturbance process of mining on seabed sediments in the polymetallic nodule area of the western Pacific Ocean at a depth of 5700 m. The impact of the process of stroking and lifting on the bottom sediment in the polymetallic nodule area is 30 times higher than that caused by the waves or the current. The time for turbidity to return to normal after the increase is about 30 min, and the influence distance of a disturbance to the bottom bed on turbidity is about 126 m. The time it takes for density to return to normal is about four hours, and the influence is about 1000 m. At the same time, the resuspension of the bottom sediment leads to an increase in density anomaly and salinity. Moreover, suspended sediments rich in metal ions may react with dissolved oxygen in water, resulting in a decrease in the dissolved oxygen content and an increase in ORP. During the observation period, the phenomenon of a deep-sea reciprocating current is found, which may cause the suspended sediment generated by the continuous operation of the mining vehicle to produce suspended sediment clouds in the water near the bottom of the mining area. This could lead to the continuous increase in nutrients in the water near the bottom of the mining area and the continuous reduction in dissolved oxygen, which will have a significant impact on the local ecological environment. Therefore, the way mining vehicles dig and wash in water bodies could have a marked impact on the marine environment. We suggest adopting the technology of suction and ore separation on mining ships, as well as bringing the separated sediment back to the land for comprehensive utilization.

On the question of the feasibility of the integrated development of mineral resources of the Ural region

Introduction. Te article deals with issues related to the integrated development of the mineral resources of the Ural region. Te integrated development of mineral deposits is a priority area for improving mining, including the maximum possible extraction of the main valuable component of the mineral, as well as the search for technical and technological solutions for the extraction of associated valuable components and marketable products suitable for the production of host rocks. Te purpose of the work is to assess the feasibility of the integrated development of mineral raw materials and the processing of mining and processing waste to obtain commercial quality products. Methodology. Associated components in processed mineral raw materials can be of industrial importance only if the degree of their concentration in the products of enrichment, metallurgical or chemical processing, as well as the technology for the subsequent processing of these products, ensure the cost-efective extraction of these components. Results. Technological schemes of possible hydrometallurgical production based on tailings of wet magnetic separation of titanomagnetite ore of scandium oxide concentrate have been developed. Te results of the study of the chemical composition of the mineral material from the dumps of the gold mining production in the city of Plast for their processing and extraction of valuable components are presented. Te results of the evaluation of the physical and mechanical properties of a number of overburden rocks of AO Uralasbest (peridotite, diorite, gabbro and serpentinite) for compliance with the requirements of regulatory documents for the production of crushed stone are presented. Conclusions. Te implementation of the proposed measures will create conditions for a more rational use of subsoil and land, ensure an increase in gross output and expand the range of commodity at existing mining enterprises without a signifcant expansion of production areas, will reduce the area of land allotment and the cost of storing rocks, increase the load on the mining and processing equipment.

Numerical and experimental study of inlet velocity effects on separation performance of hydrocyclones for purifying low-grade phosphate ore

Due to the scarcity of phosphorus as a strategic resource, there is a growing trend to extract and refine low-grade phosphate ore using hydrocyclones. This study focuses on purifying low-grade phosphate ore using a hydrocyclone, with experiments conducted to obtain data on inlet velocity, mass flow rate, and pressure of inlet and outlet. These measurements assess pressure drop, separation efficiency and accuracy, thereby validating the numerical simulation outcomes. The Mixture and RSM models are used to simulate and analyze the hydrocyclone's internal multiphase flow field and performance of separation at varying inlet velocities. Findings show that an inlet velocity ranging from 6 to 7 m/s results in over 90% separation efficiency, around 90% separation accuracy, and low energy expenditure. These research findings provide theoretical guidance for low-grade phosphate ore separation and purification using hydrocyclones.

Understanding adsorption mechanism of a novel “Y” structure carboxylate-hydroxamate surfactant towards rhodochrosite

High consumption and low selectivity of traditional collectors limit the efficient flotation recovery of rhodochrosite particles from finely disseminated complex ores. Herein, a novel “Y” structure multi-functional surfactant, 2-decanoylamino-4-hydroxycarbamoyl-butyric acid (DHBA) was developed for flotation recovery of rhodochrosite. The micro-flotation results showed that DHBA exhibited an excellent collecting ability for rhodochrosite than common collector octanohydroxamic acid (OHA) (the recovery reached 85.7% for 7 × 10–5 mol·L–1 DHBA, while only 27.9% for OHA). Meanwhile, DHBA can selectively separated rhodochrosite from quartz at neutral pH and low collector dosages. The experimental analysis combined with the density functional theory calculations revealed that DHBA was lattice matched to the rhodochrosite via the oxygen atoms of carboxyl and hydroxamate groups chelating with two Mn atoms, conferring strong adsorption affinity of DHBA. In addition, intermolecular hydrogen bonds coexist through the amide groups, promoting the collectors' self-assembly on the rhodochrosite surface, improving surface hydrophobicity. This research provides a feasible collector design protocol for the separation and enrichment of manganese carbonate ore.

The effect of copper ions on the surface chemistry of galena in near-neutral and alkaline solution

In the process of flotation separation of copper-lead sulfide ores, the adsorption of copper ions on the galena surface often occurs, which poses a significant challenge in the separation of copper and lead. The adsorption mechanism of copper ions on the galena surface and its impact on the adsorption of the collectors (i.e., sodium diethyldithiocarbamate (NaDDTC) and sodium ethyl xanthate (NaEX)) at different pH levels (6.5, 9.5, and 12.5) with a copper ions coverage of 0.14 pseudo-monolayers, were studied using zeta potential measurements, inductively coupled plasma-optical emission spectrometry (ICP-OES), ultraviolet–visible (UV–Vis) spectroscopy, X-ray photoelectron spectroscopy (XPS), and time-of-flight secondary ion mass spectrometry (ToF-SIMS). The obtained results showed that copper ions were primarily bonded to the S sites on the galena surface, forming Cu(I) sulfides, which could subsequently react with NaDDTC and NaEX to form cuprous diethyldithiocarbamate and cuprous xanthate, respectively. It was observed that the presence of copper ions affects the adsorption capacity of the collectors on the galena surface, depending on the type of collectors and the solution pH. Furthermore, the reactivity of the collectors with Pb sites on the galena surface may be reduced in the presence of copper ions.