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Contents 2009 INNEHÅLLSFÖRTECKNING/CONTENTS Page Forssberg, Eric, Luleå University of Technology Energy in mineral beneficiation 1 Acarkan N., Kangal O., Bulut G., Önal G. Istanbul Technical University The comparison of gravity separation and flotation of gold and silver bearing ore 3 Ellefmo, Steinar & Ludvigsen, Erik, Norwegian University of Science and Technology Geological Modelling in a Mineral Resources Management Perspective 15 Hansson, Johan, Sundkvist, Jan-Eric, Bolin, Nils Johan, Boliden Mineral AB A study of a two stage removal process 25 Hulthén, Erik & Evertsson, Magnus, Chalmers University of Technology Optimization of crushing stage using on-line speed control on a cone crusher 37 Hooey1, P.L., Spiller2, D.E, Arvidson3, B.R., Marsden4, P., Olsson5, E., 1MEFOS, 2Eric Spiller Consultants LLC, 3Bo Arvidson Consulting LLC, 4, 5Northland Resources Inc. Metallurgical development of Northland Resources' IOCG resources 47 Ikumapayi, Fatai K., Luleå University of Technology, Sundkvist, Jan-Eric & Bolin, Nils-Johan, Boliden Mineral AB Treatment of process water from molybdenum flotation 65 Johansson, Björn, Boliden Mineral AB Limitations in the flotation process 79 Kongas, Matti & Saloheimo, Kari, Outotec Minerals Oy New innovations in on-stream analysis for flotation circuit management and control 89 Kuyumcu, Halit Z. & Rosenkranz, Jan, TU Berlin Investigation of Fluff Separation from Granulated Waste Plastics to be Used in 99 Blast Furnace Operation Mickelsson1, K-O, Östling2 J, Adolfsson3, G., 1LKAB Malmberget, 2Optimation AB Luleå, 3LKAB Kiruna New apatite flotation at Svappavaara 117 Sandvik, Knut L, NTNU & Norkyn, Paul Inge, Nordic Mining Processing of a world class rutile deposit in Norway 133 Thurley, Matthew, Luleå University of Technology Fragmentation Measurement in LHD Buckets using 3D Vision 145 Weihed, Pär, Luleå University of Technology Nordic Mining School (NMS) for Advanced Extractive technology and Natural Resources Management 157 Wotruba1, H, Robben1, M, and Balthasar2, 1RWTH Aachen University, 2TiTech GmbH Near-Infrared Sensor-Based Sorting in the Minerals Industry 163 Energy in mineral processing. By Eric Forssberg, Mineral Processing, LTU, SE 971 87 Lulea, Sweden 1. Introduction. A first study on energy issues in mineral processing was made in the wake of the first oil crisis in 1973. The results have been published in a report from Statens Industriverk. A basic report has been issued by the Swedish Mining Association. The study was based on literature and information compiled from industry. Different mineral processing plants were analysed in detail regarding the energy consumption. For a plant like Aitik with low grade copper ore the comminution, especially the grinding is a dominating unit operation. About half of the electrical power was consumed by the grinding. In other cases like iron ore plants flotation and transportation is dominating. Often the energy needed for heating of buildings accounted for as thermal energy as GWh is much higher than the electrical power need for the process itself. It is well known that transportation consumes a large proportion of the energy. This is especially significant in the aggregates industry. Front end loaders and trucks use diesel oil while the process itself dominated by crushing and screening is fairly efficient. Another study on energy in mineral processing and mining was undertaken in 2007 as part of a larger project within Jernkontoret called “Energihandboken”, www.energihandbok.se . The emphasis, of course is on the steel industry but there is one chapter on the mining industry. The study on the mining industry is based on literature and detailed surveys made for different plants by consultants on behalf of the mining companies. Consultants like Vattenfall Power Consultant and ÅF – Process AB have made the surveys. A foreign document has been obtained from Rio Tinto “Energy and climate change – Challenges and opportunities for the mining industry” 2007, R Batterham and C Goodes. Valuable input was obtained from the Mining Association of Canada. “Benchmarking the energy consumption of Canadian open pit mines” and “Benchmarking the energy consumption of Canadian underground mines”, both in 2005. 2. How to save energy or increase the efficiency. There are many ways to decrease the specific energy consumption: -New technology -Control of processes and unit operations -Material technology. Comminution is often regarded as the most important area for new technology. The energy efficiency of comminution is considered to be low. The frequently cited figure of 1 % energy efficiency is nonsense. However rotary mills consume a lot of power for tumbling of balls, rods or rocks. Much of this is converted into low grade heath. If tumbling mills are compared with other types like vertical mills or HPRM a figure for the energy efficiency at 30 à 50 % can be calculated. An increased use of the latter type of mills is hindered by the lack of suitable wear materials, especially for vertical mills. 1 New technologies like the Selfrag are slowly developing to large capacities. However this technology may rather do a better grinding job than save energy. The Australian development towards the Isamill” and others represent a significant step forward. Fine grinding, or regrinding of concentrates can be undertaken at fairly low specific energy consumption. A similar development has taken place in the industrial minerals industry except that the wish to maintain technology as proprietary is an issue. The tumbling mills have developed towards much better efficiency through the application of simulation methods leading to better design. This is an example of stepwise progress rather than the revolutionary development many people are looking for. In this context the ideas of Evertsson regarding crushing to a finer size can be mentioned. Crushing in terms of specific energy consumption is always more efficient than grinding in tumbling mills. Materials technology, especially for wear resistant parts has been mentioned and its significance cannot be overemphasised. Wear of steel not only represents a cost but also the embedded energy for the production of the alloys and the steel. Sometimes simple solutions are to be preferred. The use of studs in HPRG can be mentioned. Besides comminution sorting, flotation and dewatering are areas where the specific energy consumption has decreased. In the area of control I believe that many of the simple solutions now have been applied. Those may be control of the RPM of fans and pumps and electrical engineering. Thermal processes are becoming more and more efficient. The work within MinFo regarding applied mineralogy for limestone calcining can be mentioned. An increased yield in the lime burning will automatically give decreased specific energy consumption. The pioneering work in iron ore pelletizing within LKAB to develop highly efficient processes is well known. 3. Conclusions The energy consumption is one important factor within the larger area “Sustainability”. Others are water and land. An interesting overview of this area was provided by Wotruba at the XXIV International Mineral Processing Congress in September 2008. The technology platform developed for the European Commission has the name Sustainable Mineral Resources and further European moves in this area can be expected. 2 THE COMPARISON OF GRAVITY SEPARATION AND FLOTATION ON GOLD AND SILVER BEARING ORE Neúet Acarkan, Olgaç Kangal, Gülay Bulut, Güven Önal Istanbul Technical University, Faculty of Mines, Mineral Processing Department, 34469, Maslak- ISTANBUL ABSTRACT Gold and silver are usually found in native form or in sulphide and silicate minerals and as tellurides in nature. Placer and paleo-placer type of gold and silver ores are easily treatable and gold and silver could simply be recovered by gravimetric concentration and flotation methods. In refractory type ores, gold and silver are usually associated with sulphide minerals. Today, gold and silver are usually recovered from metallic ores by chemical processes. Gravity concentration and flotation being one of main processes could be used for pre-concentration and in combination with chemical processes depending on the ore formation conditions. In this study, concentrates were produced from gold and silver bearing ores taken from Bolkarda÷, Ni÷de region of Turkey by using gravity techniques and flotation according to the optimum separation conditions. At the end of the evaluation of mineralogical and chemical results, shaking table and flotation were used for concentration. According to the concentration results performed with different particle sizes, a highly grade of concentrate was obtained as 235 ppm Au, 3740 ppm Ag and 50,60% Pb content by using flotation. 1. Introduction Gold and silver are usually found in native form or in sulphide and silicate minerals and as tellurides in nature. Placer and paleo-placer type of gold and silver ores are easily treatable and gold and silver could simply be recovered by gravimetric concentration methods. In refractory type ores, gold and silver are usually associated with sulphide minerals (pyrite, arsenopyrite, marcasite, pyrrhotite, chalcopyrite, orpiment, realgar, stibnite, etc.). Today, precious metals such as gold and silver are usually recovered from metallic ores by chemical processes. Gravity concentration being one of main processes could be used in combination with chemical processes depending on the ore 3 formation conditions (Allan and Woodcock, 2001, Hendriks and Chevalier,
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