Xstrata Technology Update Edition 13 – April 2012 Building Plants That Work
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From Base Metals and Back – Isamills and Their Advantages in African Base Metal Operations
The Southern African Institute of Mining and Metallurgy Base Metals Conference 2013 H. de Waal, K. Barns, and J. Monama From base metals and back – IsaMills and their advantages in African base metal operations H. de Waal, K. Barns, and J. Monama Xstrata IsaMill™ technology was developed from Netzsch Feinmahltechnik GmbH stirred milling technology in the early 1990s to bring about a step change in grinding efficiency that was required to make Xstrata’s fine-grained lead/zinc orebodies economic to process. From small-scale machines suited to ultrafine grinding, the IsaMill™ has developed into technology that is able to treat much larger tonnages, in coarser applications, while still achieving high energy efficiency, suited for coarser more standard regrind and mainstream grinding applications. The unique design of the IsaMillTM, combining high power intensity and effective internal classification, achieves high energy efficiency and tight product distribution which can be effectively scaled from laboratory scale to full-sized models. The use of fine ceramic media also leads to significant benefits in downstream flotation and leaching operations. These benefits are key drivers for the adoption of the technology into processing a diverse range of minerals worldwide, and offer major opportunities for power reduction and improved metallurgy for the African base metal operations. Keywords: IsaMill, regrind, energy efficiency, inert grinding. Introduction The development of the IsaMillTM, by MIM (now GlencoreXstrata) and Netzsch Feinmahltechnik GmbH, was initiated to enable the development of the fine-grained ore deposits at Mt Isa and McArthur River in Northern Australia. To liberate the valuable minerals and so produce a saleable concentrate this ultrafine-grained ore needed to be ground to a P80 of 7 μm. -
Petrology of Ore Deposits
Petrology of Ore Deposits An Introduction to Economic Geology Introductory Definitions Ore: a metalliferous mineral, or aggregate mixed with gangue that can me mined for a profit Gangue: associated minerals in ore deposit that have little or no value. Protore: initial non-economic concentration of metalliferous minerals that may be economic if altered by weathering (Supergene enrichment) or hydrothermal alteration Economic Considerations Grade: the concentration of a metal in an ore body is usually expressed as a weight % or ppm. The process of determining the grade is termed “assaying” Cut-off grade: after all economic and political considerations are weighed this is the lowest permissible grade that will mined. This may change over time. Example Economic Trends Economy of Scale As ore deposits are mined the high-grade zones are developed first leaving low-grade ores for the future with hopefully better technology Since mining proceeds to progressively lower grades the scale of mining increases because the amount of tonnage processed increases to remove the same amount of metal Outputs of 40,000 metric tons per day are not uncommon Near-surface open pit mines are inherently cheaper than underground mines Other factors important to mining costs include transportation, labor, power, equipment and taxation costs Classification of Ore bodies Proved ore: ore body is so thoroughly studied and understood that we can be certain of its geometry, average grade, tonnage yield, etc. Probable ore: ore body is somewhat delineated by surface mapping and some drilling. The geologists is reasonably sure of geometry and average grade. Possible Ore: outside exploration zones the geologist may speculate that the body extends some distance outside the probable zone but this is not supported by direct mapping or drilling. -
Softening Behaviour of Lead Sinter and Slag At
Paper Title: THE ISA-YMG LEAD SMELTING PROCESS Paper Presented at: PbZn 2005 Conference, Kyoto, Japan Authors: Bill Errington & Philip Arthur, Xstrata Technology Jikun Wang & Ying Dong, Yunnan Metallurgical Group, Date of Publication: October, 2005 For further information please contact us at [email protected] www.isasmelt.com THE ISA-YMG LEAD SMELTING PROCESS Bill Errington and Philip Arthur Xstrata Technology, Level 4, 307 Queen Street,, Brisbane, Queensland 4000, Australia [email protected] Jikun Wang and Ying Dong Yunnan Metallurgical Group, Kunming,Yunnan, P. R. China ABSTRACT The Yunnan Metallurgical Group (YMG) has constructed a new lead-zinc smelting/refinery complex at Qujing in Yunnan Province, China. The lead smelting process combines an ISASMELT™ smelting furnace with a YMG designed blast furnace. The ISASMELT furnace produces lead bullion plus a high-lead slag that is cast into lump form and fed to the blast furnace. YMG installed a blast furnace in the 1950's to treat high lead slag produced by earlier silver operations. This furnace later treated sinter. For the present project YMG carried out trials at the pilot and commercial scale before deciding on the final blast furnace design. The ISASMELT furnace design was based on the operation of the Lead ISASMELT Plant at Mount Isa. This paper describes the development and the operation of both the ISASMELT furnace and the YMG blast furnace. This combination of new technology and remodelled traditional technology provides an economical solution to achieving an environmentally acceptable lead smelter. Key words: ISASMELT process, lead smelting, lead slag, lead blast furnace www.isasmelt.com 2 INTRODUCTION The new YMG lead smelter forms one part of a new greenfield lead/zinc smelting and refinery complex located at Qujing in Yunnan Province in China. -
Principles of Extractive Metallurgy Lectures Note
PRINCIPLES OF EXTRACTIVE METALLURGY B.TECH, 3RD SEMESTER LECTURES NOTE BY SAGAR NAYAK DR. KALI CHARAN SABAT DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING PARALA MAHARAJA ENGINEERING COLLEGE, BERHAMPUR DISCLAIMER This document does not claim any originality and cannot be used as a substitute for prescribed textbooks. The information presented here is merely a collection by the author for their respective teaching assignments as an additional tool for the teaching-learning process. Various sources as mentioned at the reference of the document as well as freely available material from internet were consulted for preparing this document. The ownership of the information lies with the respective author or institutions. Further, this document is not intended to be used for commercial purpose and the faculty is not accountable for any issues, legal or otherwise, arising out of use of this document. The committee faculty members make no representations or warranties with respect to the accuracy or completeness of the contents of this document and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. BPUT SYLLABUS PRINCIPLES OF EXTRACTIVE METALLURGY (3-1-0) MODULE I (14 HOURS) Unit processes in Pyro metallurgy: Calcination and roasting, sintering, smelting, converting, reduction, smelting-reduction, Metallothermic and hydrogen reduction; distillation and other physical and chemical refining methods: Fire refining, Zone refining, Liquation and Cupellation. Small problems related to pyro metallurgy. MODULE II (14 HOURS) Unit processes in Hydrometallurgy: Leaching practice: In situ leaching, Dump and heap leaching, Percolation leaching, Agitation leaching, Purification of leach liquor, Kinetics of Leaching; Bio- leaching: Recovery of metals from Leach liquor by Solvent Extraction, Ion exchange , Precipitation and Cementation process. -
Profits from the Past
Reprocessing and tailings reduction.qxp_proof 29/04/2020 09:50 Page 1 REPROCESSING AND TAILINGS REDUCTION In Colombia, AuVert's technology is being combined with CDE's experience in dewatering Profits from the past and tailings management to extract the remaining precious metals existing in the ground, while removing up to 93% of residual mercury which has to date prevented this land from being used by the local population reasons why mining companies may be cautious about using tailings as backfill material or relocating current day ‘waste’ to an inaccessible area of the mine, according to Gerritsen. “As technology improves, the opportunity to recover more of the metals/minerals increases,” he said. “There are elements where that may not be the case – coal ash, for example, cannot be reprocessed but can be used to produce cement. While tailings dam liabilities and falling water resources are There are certainly opportunities with gold, affecting the ability of miners to start new mines, or expand copper and even coal, for instance.” The strategies companies ultimately pursue for existing ones, these issues are strengthening the case for these ‘waste streams’ depend on the technology reprocessing and retreating ‘waste’ sites or streams. Dan available and the safety of the facilities, Gerritsen Gleeson explores an increasingly diverse market focused on remarked. revenue generation and risk reduction “For instance, it may not be economically viable to reprocess the material currently in a ith improved transparency around recycling and thickening, or SART, plant from BQE tailings storage facility and, therefore, the owner tailings dams and waste stockpiles now Water will only bolster cash reserves through the may decide to close it or put it into a non-active Wpart and parcel of being a responsible recovery of a high-grade saleable copper sulphide state,” he said. -
Chapter 11: Beneficiation
CHAPTER 11 Beneficiation – Comminution Sponsored by: SPONSOR PROFILE Through pioneering the introduction of modern process • project controls and reporting plants and associated technologies to remote and logistically • contract management challenging locations, Lycopodium Minerals Pty Ltd has • procurement and logistics management developed a successful track record in developing and • inspection and expediting commissioning major resource projects worldwide. • quality assurance/quality control Since its establishment in 1992, Lycopodium has become a • financial evaluations leading international engineering and project management • client representation. consultancy, with an enviable reputation for providing Engineering technically innovative and cost-effective engineering solutions. They are focused on the evaluation and development of projects • Conceptual through to detailed design in the fields of minerals processing, materials handling and • across all disciplines: earthworks, civil infrastructure. • structural, mechanical, piping • electrical, instrumentation, control Lycopodium Minerals has undertaken studies and projects across a broad range of commodities including gold (free, • systems, automation and infrastructure. gravity, refractory, preg robbing), base metals (concentrators, Process hydrometallurgy), iron ore, uranium, rare earths and industrial minerals. Their resume of projects reflects diversity in not • Metallurgical test work design only commodity, but client background, technology, scale of • management and interpretation -
Calcium-Looping Performance of Steel and Blast Furnace Slags for Thermochemical Energy Storage in Concentrated Solar Power Plants
View metadata, citation and similar papers at core.ac.uk brought to you by CORE provided by idUS. Depósito de Investigación Universidad de Sevilla Calcium-Looping performance of steel and blast furnace slags for Thermochemical Energy Storage in Concentrated Solar Power plants Jose Manuel Valverde a*, Juan Miranda-Pizarroa,c, Antonio Perejónb,c, Pedro E. Sánchez-Jiménezc, Luis A. Pérez-Maquedac aFacultad de Fisica, Universidad de Sevilla, Avenida Reina Mercedes s/n, 41012 Sevilla, Spain. bDepartamento de Química Inorgánica, Facultad de Química, Universidad de Sevilla, C. Prof. García González 1, Sevilla 41071, Spain. cInstituto de Ciencia de Materiales de Sevilla (C.S.I.C. - Universidad de Sevilla). C. Américo Vespucio 49, Sevilla 41092, Spain. Abstract The Calcium Looping (CaL) process, based on the carbonation/calcination of CaO, has been proposed as a feasible technology for Thermochemical Energy Storage (TCES) in Concentrated Solar Power (CSP) plants. The CaL process usually employs limestone as CaO precursor for its very low cost, non-toxicity, abundance and wide geographical distribution. However, the multicycle activity of limestone derived CaO under relevant CaL conditions for TCES in CSP plants can be severely limited by pore plugging. In this work, the alternative use of calcium-rich steel and blast furnace slags after treatment with acetic acid is investigated. A main observation is that the calcination temperature to regenerate the CaO is significantly reduced as compared to limestone. Furthermore, the multicycle activity of some of the slags tested at relevant CaL conditions for TCES remains high and stable if the treated samples are subjected to filtration. This process serves to remove silica grains, which helps decrease the porosity of the CaO resulting from calcination thus mitigating pore plugging. -
A History of Tailings1
A HISTORY OF MINERAL CONCENTRATION: A HISTORY OF TAILINGS1 by Timothy c. Richmond2 Abstract: The extraction of mineral values from the earth for beneficial use has been a human activity- since long before recorded history. Methodologies were little changed until the late 19th century. The nearly simultaneous developments of a method to produce steel of a uniform carbon content and the means to generate electrical power gave man the ability to process huge volumes of ores of ever decreasing purity. The tailings or waste products of mineral processing were traditionally discharged into adjacent streams, lakes, the sea or in piles on dry land. Their confinement apparently began in the early 20th century as a means for possible future mineral recovery, for the recycling of water in arid regions and/or in response to growing concerns for water pollution control. Additional Key Words: Mineral Beneficiation " ... for since Nature usually creates metals in an impure state, mixed with earth, stones, and solidified juices, it is necessary to separate most of these impurities from the ores as far as can be, and therefore I will now describe the methods by which the ores are sorted, broken with hammers, burnt, crushed with stamps, ground into powder, sifted, washed ..•. " Agricola, 1550 Introduction identifying mining wastes. It is frequently used mistakenly The term "tailings" is to identify all mineral wastes often misapplied when including the piles of waste rock located at the mouth of 1Presented at the 1.991. National mine shafts and adi ts, over- American. Society for Surface burden materials removed in Mining and Reclamation Meeting surface mining, wastes from in Durango, co, May 1.4-17, 1.991 concentrating activities and sometimes the wastes from 2Timothy c. -
Challenges Related to the Processing of Fines in the Recovery of Platinum Group Minerals (Pgms)
minerals Review Challenges Related to the Processing of Fines in the Recovery of Platinum Group Minerals (PGMs) Kirsten C. Corin 1,* , Belinda J. McFadzean 1, Natalie J. Shackleton 2 and Cyril T. O’Connor 1 1 Centre for Minerals Research, Chemical Engineering Department, University of Cape Town, P Bag X3, Rondebosch, Cape Town 7700, South Africa; [email protected] (B.J.M.); [email protected] (C.T.O.) 2 Minerals Expertise Tech Pty Ltd., Germiston 2007, South Africa; [email protected] * Correspondence: [email protected] Abstract: In order to increase the recovery of PGMs by flotation, it is necessary to optimise the liberation of the key minerals in which the platinum group elements (PGEs) are contained which include sulphides, arsenides, tellurides, and ferroalloys among others, while at the same time ensuring the optimal depression of gangue minerals. In order to achieve this, comminution circuits usually consist of two or three stages of milling, in which the first stage is autogeneous, followed by ball milling. Further liberation is achieved in subsequent stages using ultra-fine grinding. Each comminution stage is followed by flotation in the so-called MF2 or MF3 circuits. While this staged process increases overall recoveries, overgrinding may occur, hence creating problems associated with fine particle flotation. This paper presents an overview of the mineralogy of most of the more significant PGM ores processed in South Africa and the various technologies used in comminution circuits. The paper then summarises the methodology used in flotation circuits to optimise recovery Citation: Corin, K.C.; McFadzean, of fine particles in terms of the collectors, depressants, and frothers used. -
Effect of Comminution Method on Particle Damage and Breakage Energy
EFFECT OF COMMINUTION METHOD ON PARTICLE DAMAGE AND BREAKAGE ENERGY Michael Moats, Jan Miller, Chen-Lun Lin and Raj Rajamani Department of Metallurgical Engineering University of Utah Outline • Our Department • High Pressure Grinding • Particle Damage Characterization • Breakage Energy • Application to Simulant Development Department of Metallurgical Engineering • University of Utah is located in Salt Lake City along the Wasatch Mtns. • Only stand alone Metallurgical Engineering department remaining in the U.S. • Traditional curriculum with critical mass of professors – Mineral Processing – Chemical Metallurgy – Physical Metallurgy High Pressure Grinding Rolls (HPGR) HPGR consists of a pair of counter rotating rolls, one fixed and the other floating. The feed is introduced to the gap in between the rolls and they compress the bed of particles. The grinding force applied to the crushing zone is controlled by a hydro-pneumatic spring on the floating roll. Speeds of the rolls are also adjustable to obtain optimum grinding conditions. Comparison of HPGR and AG/SAG Mills Aspect HPGR AG/SAG Mill Grinding Mechanism Inter-particle compression Impact, attrition and compression Residence Time Low-single pass High (feed migrates through length of mill) Wet/Dry Grinding Dry-Low moisture Predominantly wet milling Availability >90% -2-4 change outs pa >90% -1-2 change outs pa Size regulated feed Required Yes-strongly affects stud breakage AG-No, SAG-Sometimes Critical material size Not required Required Product particle Yes (beneficial for downstream Negligible micro-cracking processes Maximum Throughput 2000tph 4000tph Footprint Small Large Specific power 1-5kWh/t 5-12kWh/t Operating cost Overall plant 20% lower Overall plant 20% higher Capital Cost 25% lower 25% higher Delivery time Substantially faster Substantially longer Variation in feed hardness Single parameter variable High losses •Reference: Koenig, R.L. -
Minerals and Metallurgical Engineering
Course Structure B. Tech. - Minerals and Metallurgical Engineering Applicable to those admitted through JEE from 2019 onwards Department of Fuel, Minerals and Metallurgical Engineering Indian Institute of Technology (ISM) Dhanbad Dhanbad, Jharkhand, India (September - 2019) Page 1 of 41 Course Structure SEMESTER III S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours 1 FMC201 Colloids and interfacial 3 0 0 9 3 phenomena 2 FMC202 Heat and mass transfer 3 0 0 9 3 3 FMC203 Physical separation 3 0 0 9 3 processes for coal and minerals 4 FME221 Particle technology (ESO 3 0 0 9 3 1) 5 E/SO 2 E/SO 3 0 0 9 3 6 FMC251 Particle technology 0 0 2 2 2 laboratory 7 FMC252 Physical separation 0 0 2 2 2 processes laboratory Total Credit 49 19 SEMESTER IV S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. ID (L) (T) (P) Hours Hours 1 FMC204 Electrochemistry and 3 0 0 9 3 corrosion 2 FMC205 Thermodynamics and 3 0 0 9 3 kinetics 3 FMC206 Phase transformation and 3 0 0 9 3 heat treatment 4 FMC207 Fine particle processing for 3 0 0 9 3 coal and minerals 5 FME222 Introduction to fuel 3 0 0 9 3 technology (ESO 3) 6 FMC253 Fine particle processing 0 0 2 2 2 laboratory 7 FMC254 Introduction to fuel 0 0 2 2 2 technology laboratory Total Credit 49 19 Page 2 of 41 SEMESTER V S. Subject Subject Name Lecture Tutorial Practical Credit Contact No. -
Evolution of the Isamill™ Into Magnetite Processing
EVOLUTION OF THE ISAMILL™ INTO MAGNETITE PROCESSING Greg Rasmussen, Xstrata Technology Pty Ltd Tommy Do , Ernest Henry Mining Michael Larson, Xstrata Technology Pty Ltd Katie Barns, Xstrata Technology Pty Ltd Xstrata Technology • Mount Isa Mines (MIM), a large Australian mining company, was acquired by Xstrata in 2003 who then merged with Glencore in 2013 • MIM internal technology group was re-named Xstrata Technology (XT) and became an independent technology developer and supplier to the global minerals industry with 250 staff worldwide • The equipment and processes which are marketed by XT are developed in our own operations • XT offers full-package solutions including: • Equipment and processes • Engineering • Commissioning and Training • Dedicated after-market support IsaMill™ Technology Development ™ • Development of IsaMill driven by inability Broken Hill to efficiently treat fine grained orebodies • Late 1980s, Xstrata required 7µm grind for new Pb/Zn orebodies in Australia • Conventional mining technologies tested (1975-1990), but 0 40 micron − Too high power consumption to achieve target size McArthur River − Ball/tower mills ineffective below 20-30μm − Negative influence of steel grinding on flotation 0 40 micron IsaMill™ Technology Development A technology was found... • Horizontal Bead Mills − Used in industries other than mining (pharmaceuticals, paint, food, etc.) − Small, batch scale − Very expensive and exotic media types • Cross-over into mining required: − Much larger scale − Continuous operation − Ability to use cheap,