Abrasão-corrosão em corpos moedores na moagem de minério de ferro.

O desgaste de corpos moedores constitui um custo importante na indústria mineral, que depende da operação de cominuição para promover a liberação das espécies minerais e produzir concentrados. Embora se conheça alguns dos mecanismos individuais que afetam o desgaste, a interação entre eles num sistema tão complexo quanto um moinho ainda precisa ser melhor entendido. Este trabalho avaliou o efeito da corrosão no desgaste de bolas de aço e de ferro fundido branco de alto cromo durante a moagem de minério de ferro, através de ensaios eletroquímicos e de desgaste em moinho de laboratório. Foi feita uma alteração no modo tradicional de realização do ensaio de polarização potenciodinâmica, utilizando polpa de minério de ferro a 70% de sólidos (em peso) como eletrólito. As curvas de polarização obtidas foram compatíveis com os resultados de desgaste, de modo que as curvas correspondentes aos metais na condição mais ativa estavam associadas às menores taxas de desgaste nos ensaios de moagem em laboratório, demonstrando que os ensaios de polarização realizados podem ser utilizados como indicativo do comportamento do metal na moagem de minério de ferro. Sobretudo, os testes demonstraram que o desgaste das bolas de aço é devido, principalmente, à abrasão, já que uma pequena diferença, de apenas 8%, foi observada nas taxas de desgaste nas condições avaliadas (polpa no pH 5 e pH 8). Por outro lado, as bolas de ferro fundido branco de alto cromo, que são mais caras, são mais propensas a resistir ao desgaste em polpa ácida, em que a taxa de desgaste foi 40% menor que a determinada em pH 8.

Avaliação da influência do efeito de ultrassom na lixiviação de metais de placas de circuito impresso obsoletas.

Os equipamentos elétricos e eletrônicos (EEE) possuem uma grande importância na sociedade contemporânea, e estão presentes no cotidiano das pessoas de forma ubíqua. Com o aumento no consumo de EEE juntamente com a obsolescência precoce, surge um novo tipo de resíduo, chamado de Resíduos de Equipamentos Elétricos e Eletrônicos (REEE). Os REEE não devem ser descartados em aterros, pelo risco de contaminação e pelo desperdício de material. Assim, a reciclagem se faz necessária. As placas de circuito impresso (PCI) estão presentes na grande maioria do REEE e contem a maior variedade de metais, incluindo metais valiosos como Au, Ag, Pt e Cu. A complexidade torna a reciclagem destas placas muito difícil. Rotas hidrometalúrgicas tem surgido como uma alternativa mais limpa para o tratamento de PCI, em detrimento aos processos pirometalúrgicos. Nas rotas hidrometalúrgicas, os metais são extraídos pela lixiviação realizada por ácidos ou bases. O efeito ultrassônico tem sido empregado na síntese de novas substâncias e também em alguns casos no tratamento de resíduos. O processo central no uso de ultrassom é a cavitação acústica, capaz de produzir microbolhas na solução com temperatura da ordem de 5000 K e pressão de 500 atm localmente. Além disto, a implosão das bolhas de cavitação em meio heterogêneo causa um jato de solução na superfície, que pode alcançar velocidade de 100 m.s-1. Assim, esta tese tem como objetivo a investigação do efeito do ultrassom sobre PCI obsoletas. Dois efeitos foram investigados: o efeito da cominuição das PCI promovido pela cavitação e a influência da cavitação na lixiviação com ácido sulfúrico de Fe, Al e Ni. Os parâmetros investigados na cominuição foram: tipo de placa, granulometria da placa moída e potência de ultrassom. Os parâmetros de lixiviação avaliados foram: razão sólido-líquido (S/L), concentração de ácido e potência de ultrassom. Também foram realizados ensaios de lixiviação sonicados com meio oxidante. Foi feita a análise cinética para se determinar qual é o controle da reação de lixiviação.

Two empirical hydrocyclone models revisited

There has been an abundance of literature on the modelling of hydrocyclones over the past 30 years. However, in the comminution area at least, the more popular commercially available packages (e.g. JKSimMet, Limn, MODSIM) use the models developed by Nageswararao and Plitt in the 1970s, either as published at that time, or with minor modification. With the benefit of 30 years of hindsight, this paper discusses the assumptions and approximations used in developing these models. Differences in model structure and the choice of dependent and independent variables are also considered. Redundancies are highlighted and an assessment made of the general applicability of each of the models, their limitations and the sources of error in their model predictions. This paper provides the latest version of the Nageswararao model based on the above analysis, in a form that can readily be implemented in any suitable programming language, or within a spreadsheet. The Plitt model is also presented in similar form. (C) 2004 Elsevier Ltd. All rights reserved.

Determination of lifter design, speed and filling effects in AG mills by 3D DEM

The power required to operate large gyratory mills often exceeds 10 MW. Hence, optimisation of the power consumption will have a significant impact on the overall economic performance and environmental impact of the mineral processing plant. In most of the published models of tumbling mills (e.g. [Morrell, S., 1996. Power draw of wet tumbling mills and its relationship to charge dynamics, Part 2: An empirical approach to modelling of mill power draw. Trans. Inst. Mining Metall. (Section C: Mineral Processing Ext. Metall.) 105, C54-C62. Austin, L.G., 1990. A mill power equation for SAG mills. Miner. Metall. Process. 57-62]), the effect of lifter design and its interaction with mill speed and filling are not incorporated. Recent experience suggests that there is an opportunity for improving grinding efficiency by choosing the appropriate combination of these variables. However, it is difficult to experimentally determine the interactions of these variables in a full scale mill. Although some work has recently been published using DEM simulations, it was basically. limited to 2D. The discrete element code, Particle Flow Code 3D (PFC3D), has been used in this work to model the effects of lifter height (525 cm) and mill speed (50-90% of critical) on the power draw and frequency distribution of specific energy (J/kg) of normal impacts in a 5 m diameter autogenous (AG) mill. It was found that the distribution of the impact energy is affected by the number of lifters, lifter height, mill speed and mill filling. Interactions of lifter design, mill speed and mill filling are demonstrated through three dimensional distinct element methods (3D DEM) modelling. The intensity of the induced stresses (shear and normal) on lifters, and hence the lifter wear, is also simulated. (C) 2004 Elsevier Ltd. All rights reserved.

Comparison of grinding media - Cylpebs versus balls

Cylpebs are slightly tapered cylindrical grinding media with a ratio of length to diameter of unity. The manufactures have made conflicting claims regarding the milling performance of Cylpebs in comparison with balls. One major point of interest is which one grinds finer at the same operating conditions. The difficulty in comparison is due to the shape difference. The two grinding media have different surface area, bulk density and contact mechanisms in grinding action. Comparative tests were conducted using the two types of grinding media in a laboratory Bond ball mill at various conditions of equality such as media mass, size distribution, surface area and input specific energy. The laboratory results indicate that at the same specific energy input level the Cylpebs produce a product with slightly less oversize due to their greater surface area, but essentially the same sizing at the fine end as that produced with the balls. The reason may be that the advantage of greater surface area is balanced by the line contact and area contact grinding actions with the Cylpebs. A new ball mill scale-up procedure [Man, Y.T., 2001. Model-based procedure for scale-up of wet, overflow ball mills, Part 1: outline of the methodology. Minerals Engineering 14 (10), 1237-1246] was employed to predict grinding performance of an industrial mill from the laboratory test results. The predicted full scale operation was compared with the plant survey data. Some problems in the original scale-up procedures were identified. The scale-up procedure was therefore modified to allow the predicted ball mill performance to match the observed one. The calibrated scale-up procedure was used to predict the Cylpebs performance in the full scale industrial mill using the laboratory tests results. (C) 2004 Elsevier Ltd. All rights reserved.

HPGR model verification and scale-up

This paper summarises test results that were used to validate a model and scale-up procedure of the high pressure grinding roll (HPGR) which was developed at the JKMRC by Morrell et al. [Morrell, Lim, Tondo, David,1996. Modelling the high pressure grinding rolls. In: Mining Technology Conference, pp. 169-176.]. Verification of the model is based on results from four data sets that describe the performance of three industrial scale units fitted with both studded and smooth roll surfaces. The industrial units are currently in operation within the diamond mining industry and are represented by De Beers, BHP Billiton and Rio Tinto. Ore samples from the De Beers and BHP Billiton operations were sent to the JKMRC for ore characterisation and HPGR laboratory-scale tests. Rio Tinto contributed an historical data set of tests completed during a previous research project. The results conclude that the modelling of the HPGR process has matured to a point where the model may be used to evaluate new and to optimise existing comminution circuits. The model prediction of product size distribution is good and has been found to be strongly dependent of the characteristics of the material being tested. The prediction of throughput and corresponding power draw (based on throughput) is sensitive to inconsistent gap/diameter ratios observed between laboratory-scale tests and full-scale operations. (C) 2004 Elsevier Ltd. All rights reserved.

Simple texture-based liberation modelling of ores

Mineralogical analysis is often used to assess the liberation properties of particles. A direct method of estimating liberation is to actually break particles and then directly obtain liberation information from applying mineralogical analysis to each size-class of the product. Another technique is to artificially apply random breakage to the feed particle sections to estimate the resultant distribution of product particle sections. This technique provides a useful alternative estimation method. Because this technique is applied to particle sections, the actual liberation properties for particles can only be estimated by applying stereological correction. A recent stereological technique has been developed that allows the discrepancy between the linear intercept composition distribution and the particle section composition distribution to be used as guide for estimating the particle composition distribution. The paper will show results validating this new technique using numerical simulation. (C) 2004 Elsevier Ltd. All rights reserved.

Influence of explosive energy on the strength of the rock fragments and SAG mill throughput

Extensive in-situ testings has shown that blast fragmentation influences the performance of downstream processes in a mine, and as a consequence, the profit of the whole operation can be greatly improved through optimised fragmentation. Other unit operations like excavation, crushing and grinding can all be assisted by altering the blast-induced fragmentation. Experimental studies have indicated that a change in blasting practice would not only influence fragmentation but fragment strength as well. The strength of the fragments produced in a blast is clearly important to the performance of the crushing and grinding circuit as it affects the energy required to break the feed to a target product size. In order to validate the effect of blasting on fragment strength several lumps of granite were blasted, under controlled conditions, using three very different explosive products. The resulting fragments were subjected to standard comminution ore characterisation tests. Obtained comminution parameters were then used to simulate the performance of a SAG mill. Modelling results indicate that changes in post blast residual rock fragment strength significantly influences the performance of the SAG mill, producing up to a 20% increase in throughput. (c) 2004 Elsevier Ltd. All rights reserved.

Slurry flow in mills with TCPL - An efficient pulp lifter for ag/sag mills

The difficulties associated with slurry transportation in autogenous (ag) and semi-autogenous (sag) grinding mills have become more apparent in recent years with the increasing trend to build larger diameter mills for grinding high tonnages. This is particularly noticeable when ag/sag mills are run in closed circuit with classifiers such as fine screens/cyclones. Extensive test work carried out on slurry removal mechanism in grate discharge mills (ag/sag) has shown that the conventional pulp lifters (radial and curved) have inherent drawbacks. They allow short-circuiting of the slurry from pulp lifters into the grinding chamber leading to slurry pool formation. Slurry pool absorbs part of the impact thus inhibiting the grinding process. Twin Chamber Pulp Lifter (TCPL) - an efficient design of pulp lifter developed by the authors overcomes the inherent drawbacks of the conventional pulp lifters. Extensive testing in both laboratory and pilot scale mills has shown that the TCPL completely blocks the flow-back process, thus allowing the mill to operate close to their design flow capacity. The TCPL performance is also found to be independent of variations in charge volume and grate design, whereas they significantly affect the performance of conventional pulp lifters (radial and curved). (c) 2006 Elsevier B.V. All rights reserved.

Using two dimensional sectional distributions to infer three dimensional volumetric distributions - Validation using tomography

The critical process parameter for mineral separation is the degree of mineral liberation achieved by comminution. The degree of liberation provides an upper limit of efficiency for any physical separation process. The standard approach to measuring mineral liberation uses mineralogical analysis based two-dimensional sections of particles which may be acquired using a scanning electron microscope and back-scatter electron analysis or from an analysis of an image acquired using an optical microscope. Over the last 100 years, mathematical techniques have been developed to use this two dimensional information to infer three-dimensional information about the particles. For mineral processing, a particle that contains more than one mineral (a composite particle) may appear to be liberated (contain only one mineral) when analysed using only its revealed particle section. The mathematical techniques used to interpret three-dimensional information belong, to a branch of mathematics called stereology. However methods to obtain the full mineral liberation distribution of particles from particle sections are relatively new. To verify these adjustment methods, we require an experimental method which can accurately measure both sectional and three dimensional properties. Micro Cone Beam Tomography provides such a method for suitable particles and hence, provides a way to validate methods used to convert two-dimensional measurements to three dimensional estimates. For this study ore particles from a well-characterised sample were subjected to conventional mineralogical analysis (using particle sections) to estimate three-dimensional properties of the particles. A subset of these particles was analysed using a micro-cone beam tomograph. This paper presents a comparison of the three-dimensional properties predicted from measured two-dimensional sections with the measured three-dimensional properties.

Exploratory modelling of grinding pressure within a compressed particle bed

With increasing industry interest in high pressure roll grinding (HPGR) technology, there is a strong incentive for improved understanding of the nature of grinding pressure that exists in the interior of a compressed particle bed. This corresponds to the crushing region of the HPGR. The relationship between applied pressure (stress) to the particle bed and induced pressure (stress) within particles and at contact points between particles is of particular interest. A detailed parametric investigation is beyond the scope of this exploratory paper. However, this exploratory investigation does suggest some interesting behaviour. The compressed particle bed within an 80 turn diameter piston has been modelled using Particle Flow Code for three dimensions. PFC3D is a discrete element code. The total number of simulated particles was 1225 and 2450 for two beds of different thickness. Particle diameters were uniformly distributed between 4 and 4.5 mm. The results of the simulations show that stress intensity within the simulated particle beds and within the observed particles increased with increase of the applied stress. The intensity of the average vertical stress in the selected particles tended to be comparable with the intensity of the pressure applied to the surface of particle bed and was only occasionally higher. However, the stress at contact points between particles could be several times higher. In a real crusher, such high stress amplification at contacts will quickly decrease due to local crushing and a resultant increase the size of the contact area. Therefore, its significance is likely to be relatively small in an industrial context. The modelling results also suggest that failure within the particle bed will progress from the crushing surface towards the depth of the bed. (c) 2006 Elsevier Ltd. All rights reserved.

Analysis of stirred mill performance using DEM simulation: Part 2 - Coherent flow structures, liner stress and wear, mixing and transport

Stirred Mills are becoming increasingly used for fine and ultra-fine grinding. This technology is still poorly understood when used in the mineral processing context. This makes process optimisation of such devices problematic. 3D DEM simulations of the flow of grinding media in pilot scale tower mills and pin mills are carried out in order to investigate the relative performance of these stirred mills. In the first part of this paper, media flow patterns and energy absorption rates and distributions were analysed to provide a good understanding of the media flow and the collisional environment in these mills. In this second part we analyse steady state coherent flow structures, liner stress and wear by impact and abrasion. We also examine mixing and transport efficiency. Together these provide a comprehensive understanding of all the key processes operating in these mills and a clear understanding of the relative performance issues. (C) 2006 Elsevier Ltd. All rights reserved.

Analysis of stirred mill performance using DEM simulation: Part 1 - Media motion, energy consumption and collisional environment

Stirred mills are becoming increasingly used for fine and ultra-fine grinding. This technology is still poorly understood when used in the mineral processing context. This makes process optimisation of such devices problematic. 3D DEM simulations of the flow of grinding media in pilot scale tower mills and pin mills are carried out in order to investigate the relative performance of these stirred mills. Media flow patterns and energy absorption rates and distributions are analysed here. In the second part of this paper, coherent flow structures, equipment wear and mixing and transport efficiency are analysed. (C) 2006 Published by Elsevier Ltd.

Prediction of slurry transport in SAG mills using SPH fluid flow in a dynamic DEM based porous media

DEM modelling of the motion of coarse fractions of the charge inside SAG mills has now been well established for more than a decade. In these models the effect of slurry has broadly been ignored due to its complexity. Smoothed particle hydrodynamics (SPH) provides a particle based method for modelling complex free surface fluid flows and is well suited to modelling fluid flow in mills. Previous modelling has demonstrated the powerful ability of SPH to capture dynamic fluid flow effects such as lifters crashing into slurry pools, fluid draining from lifters, flow through grates and pulp lifter discharge. However, all these examples were limited by the ability to model only the slurry in the mill without the charge. In this paper, we represent the charge as a dynamic porous media through which the SPH fluid is then able to flow. The porous media properties (specifically the spatial distribution of porosity and velocity) are predicted by time averaging the mill charge predicted using a large scale DEM model. This allows prediction of transient and steady state slurry distributions in the mill and allows its variation with operating parameters, slurry viscosity and slurry volume, to be explored. (C) 2006 Published by Elsevier Ltd.

Degenerate dentition of the dugong (Dugong dugon), or why a grazer does not need teeth: morphology, occlusion and wear of mouthparts

The morphology and functional occlusion of the cheekteeth of 57 dugongs Dugong dugon of both sexes were examined using reflected light and scanning electron microscopy, radiography, hardness testing and skull manipulation. The functional morphology of the horny oral pads was also described. Mouthparts and body size allometry was examined for ontogenetic and gender-related trends. We found that the worn erupted cheekteeth of the dugong are simple flat pegs composed of soft degenerative dentine. During occlusion, the mandible moves in a mainly antero-lingual direction, with the possibility of mandibular retraction in some individuals. Anterior parts of the cheektooth row may become non-functional as a dugong ages. As a function of body size, dugong cheekteeth are extremely small compared with those of other mammalian herbivores, and with other hindgut fermenters in particular. The morphology, small size and occlusal variability of the cheekteeth suggest that there has not been strong selective pressure acting to maintain an effective dentition. In contrast, great development of the horny pads and associated skull parameters and their lower size variability suggest that the horny pads may have assumed the major role in food comminution.