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.

Using DEM to model ore breakage within a pilot scale SAG mill

The best accepted method for design of autogenous and semi-autogenous (AG/SAG) mills is to carry out pilot scale test work using a 1.8 m diameter by 0.6 m long pilot scale test mill. The load in such a mill typically contains 250,000-450,000 particles larger than 6 mm, allowing correct representation of more than 90% of the charge in Discrete Element Method (DEM) simulations. Most AG/SAG mills use discharge grate slots which are 15 mm or more in width. The mass in each size fraction usually decreases rapidly below grate size. This scale of DEM model is now within the possible range of standard workstations running an efficient DEM code. This paper describes various ways of extracting collision data front the DEM model and translating it into breakage estimates. Account is taken of the different breakage mechanisms (impact and abrasion) and of the specific impact histories of the particles in order to assess the breakage rates for various size fractions in the mills. At some future time, the integration of smoothed particle hydrodynamics with DEM will allow for the inclusion of slurry within the pilot mill simulation. (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.

Experimental study of phase equilibria in the Al-Fe-Zn-O system in air

The phase equilibria in the Al-Fe-Zn-O system in the range 1250 °C to 1695 °C in air have been experimentally studied using equilibration and quenching techniques followed by electron probe X-ray microanalysis. The phase diagram of the binary Al2O3-ZnO system and isothermal sections of the Al2O3-“Fe2O3”-ZnO system at 1250 °C, 1400 °C, and 1550 °C have been constructed and reported for the first time. The extents of solid solutions in the corundum (Al,Fe)2O3, hematite (Fe,Al)2O3, Al2O3*Fe2O3 phase (Al,Fe)2O3, spinel (Al,Fe,Zn)O4, and zincite (Al,Zn,Fe)O primary phase fields have been measured. Corundum, hematite, and Al2O3*Fe2O3 phases dissolve less than 1 mol pct zinc oxide. The limiting compositions of Al2O3*Fe2O3 phase measured in this study at 1400 °C are slightly nonstoichiometric, containing more Al2O3 then previously reported. Spinel forms an extensive solid solution in the Al2O3-“Fe2O3”-ZnO system in air with increasing temperature. Zincite was found to dissolve up to 7 mole pct of aluminum in the presence of iron at 1550 °C in air. A meta-stable Al2O3-rich phase of the approximate composition Al8FeZnO14+x was observed at all of the conditions investigated. Aluminum dissolved in the zincite in the presence of iron appears to suppress the transformation from a round to platelike morphology.

A comparison between capillary and imaging techniques for sizing bubbles in flotation systems

This communication reports a laboratory and plant comparison between the University of Cape Town (UCT) device (capillary) and the McGill University bubble sizing method (imaging). The laboratory work was conducted on single bubbles to establish the accuracy of the techniques by comparing with a reference method (capture in a burette). Single bubble measurements with the McGill University technique showed a tendency to slightly underestimate (4% for a 1.3 mm bubble) and the UCT technique to slightly overestimate (1% for the 1.3 man bubble). Both trends are anticipated from fundamental considerations. In the UCT technique bubble breakup was observed when measuring a 2.7 mm bubble using a 0.5 mm ID capillary tube. A discrepancy of 11% was determined when comparing the techniques in an industrial-scale mechanical flotation cell. The possible sources of bias are discussed. (C) 2003 Elsevier Ltd. All rights reserved.

Effect of particle hydrophobicity on particle and water transport across a flotation froth

Froth recovery measurements have been conducted in both the presence (three-phase froth) and absence (two-phase froth) of particles of different contact angles in a specially modified laboratory flotation column. Increasing the particle hydrophobicity increased the flow rate of particles entering the froth, while the recovery of particles across the froth phase itself also increased for particle contact angles to 63 and at all vertical heights of the froth column. However, a further increase in the contact angle to 69 resulted in lower particle recovery across the froth phase. The reduced froth recovery for particles of 69 contact angle was linked to significant bubble coalescence within the froth phase. The reduced froth recovery occurred uniformly across the entire particle size range, and was, presumably, a result of particle detachment from coalescing bubbles. Water flow rates across the froth phase also varied with particle contact angle. The general trend was a decrease in the concentrate flow rate of water with increasing particle contact angle. An inverse relationship between water flow rate and bubble radius was also observed, possibly allowing prediction of water flow rate from bubble size measurements in the froth. Comparison of the froth structure, defined by bubble size, gas hold-up and bubble layer thickness, for two- and three-phase froths, at the same frother concentration, showed there was a relationship between water flow rate and froth structure. (c) 2005 Elsevier B.V. All rights reserved.

Application of central composite rotatable design to modelling the effect of some operating variables on the performance of the three-product cyclone

The central composite rotatable design (CCRD) was used to design an experimental program to model the effects of inlet pressure, feed density, and length and diameter of the inner vortex finder on the operational performance of a 150-min three-product cyclone. The ranges of values of the variables used in the design were: inlet pressure: 80-130 kPa, feed density: 30 60%; length of IVF below the OVF: 50-585 mm; diameter of IVF: 35-50 mm. A total of 30 tests were conducted, which is 51 less; an that required for a three-level full factorial design. Because the model allows confident performance prediction by interpolation over the range of data in the database, it was used to construct response surface graphs to describe the effects of the variables on the performance of the three-product cyclone. To obtain a simple and yet a realistic model, it was refitted using only the variable terms that are significant at greater than or equal to 90% confidence level. Considering the selected operating variables, the resultant model is significant and predicts the experimental data well. (c) 2005 Elsevier B.V. All rights reserved.

A reinvestigation of phase equilibria in the system Al2O3-SiO2-ZnO

The phase equilibria and liquidus temperatures in the binary SiO2-ZnO system and in the ternary Al2O3-SiO2-ZnO system at low Al2O3 concentrations have been experimentally determined using the equilibration and quenching technique followed by electron probe X-ray microanalysis. In the SiO2-ZnO system, two binary eutectics involving the congruently melting willemite (Zn2SiO4) were found at 1448 +/- 5 degrees C and 0.52 +/- 0.01 mole fraction ZnO and at 1502 +/- 5 degrees C and 0.71 +/- 0.01 mole fraction ZnO, respectively. The two ternary eutectics involving willemite previously reported in the Al2O3SiO2-ZnO system were found to be at 1315 +/- 5 degrees C and 1425 +/- 25 T, respectively. The compositions of the eutectics are 0.07, 0.52, and 0.41 and 0.05, 0.28, and 0.67 mole fraction Al2O3, SiO2, and ZnO, respectively. The results of the present investigation are significantly different from the results of previous studies.

Phase equilibria in the system Fe-Zn-O at intermediate conditions between metallic-iron saturation and air

The phase equilibria in the FeO-Fe2O3-ZnO system have been experimentally investigated at oxygen partial pressures between metallic iron saturation and air using a specially developed quenching technique, followed by electron probe X-ray microanalysis (EPMA) and then wet chemistry for determination of ferrous and ferric iron concentrations. Gas mixtures of H-2, N-2, and CO2 or CO and CO2 controlled the atmosphere in the furnace. The determined metal cation ratios in phases at equilibrium were used for the construction of the 1200 degrees C isothermal section of the Fe-Zn-O system. The univariant equilibria between the gas phase, spinel, wustite, and zincite was found to be close to pO(2) = 1 center dot 10(-8) atm at 1200 degrees C. The ferric and ferrous iron concentrations in zincite and spinel at equilibrium were also determined at temperatures from 1200 degrees C to 1400 degrees C at pO(2) = 1 center dot 10(-6) atm and at 1200 degrees C at pO(2) values ranging from 1 center dot 10(-4) to 1 center dot 10(-8) atm. Implications of the phase equilibria in the Fe-Zn-O system for the formation of the platelike zincite, especially important for the Imperial Smelting Process (ISP), are discussed.

Kinetics of reduction of lead smelting slags with solid carbon

Research techniques and a methodology have been developed that enable the reduction kinetics of molten lead smelting slags with solid carbon to be studied. The rates of reduction of PbO-FeO-Fe2O3-CaO-SiO2 slags with carbon have been measured for a range of slag compositions for PbO concentrations between 3 and 100 weight percent, and temperatures between 1423 and 1573 K. The reduction rates were determined for both graphite and coke. Within the range of process conditions examined, it has been shown that the reaction rates are almost independent of carbon reactivity, SiO2/CaO and SiO2/Fe ratio in the range of compositions investigated and are not influenced by the presence of sulphur in the slag.The apparent first order rate constants for oxygen removal increase with increasing PbO concentration and oxygen activity in the slag. The data indicate that the rate limiting reaction step for the reduction of lead slags with solid carbon is the chemical reaction at the gas/slag interface.

Phase equilibria in the Fe-Zn-O system at conditions relevant to zinc sintering and smelting

Zincite and spinel phases are present in the complex slag systems encountered in zinc/lead sintering and zinc smelting processes. These phases form extensive solid solutions and are stable over a wide range of compositions, temperatures and oxygen partial pressures. Accurate information on the stability of these phases is required in order to develop thermodynamic models of these slag systems. Phase equilibria in the Fe–Zn–O system have been experimentally studied for a range of conditions, between 900°C and 1580°C and oxygen partial pressures (pO2) between air and metallic iron saturation, using equilibration and quenching techniques. The compositions of the phases were measured using Electron probe X-ray microanalysis (EPMA). The ferrous and ferric bulk iron concentrations were determined using a specially developed wet-chemical analysis procedure based on the use of ammonium metavanadate. XRD was used to confirm phase identification. A procedure was developed to overcome the problems associated with evaporation of zinc at low pO2 values and to ensure the achievement of equilibria. An isothermal section of the system FeO–Fe2O3–ZnO at high ZnO concentrations at 1200°C was constructed. The maximum solubilities of iron and zinc in zincite and spinel phases in equilibrium were determined at pO2 = 1 × 10-6 atm at 1200°C and 1300°C. The morphology of the zincite crystals sharply changes in air between 1200–1300°C from rounded to plate-like. This is shown to be associated with significant increase in total iron concentration, the additional iron being principally in the form of ferric iron. Calculations performed by FactSage with a thermodynamically optimised database have been compared with the experimental results.

Modelling of entrainment in industrial flotation cells: the effect of solids suspension

Solids concentration and particle size distribution gradually change in the vertical dimension of industrial flotation cells, subject primarily to the flotation cell size and design and the cell operating conditions. As entrainment is a two-step process and involves only the suspended solids in the top pulp region near the pulp-froth interface, the solids suspension characteristics have a significant impact on the overall entrainment. In this paper, a classification function is proposed to describe the state of solids suspension in flotation cells, similar to the definition of degree of entrainment for classification in the froth phase found in the literature. A mathematical model for solids suspension is also developed, in which the classification function is expressed as an exponential function of the particle size. Experimental data collected from three different Outokumpu tank flotation cells in three different concentrators are well fitted by the proposed exponential model. Under the prevailing experimental conditions, it was found that the solids content in the top region was relatively independent of cell operating conditions such as froth height and air rate but dependent on the cell size. Moreover, the results obtained from the total solids tend to be similar to those from a particular gangue mineral and hence may be applied to all minerals in entrainment calculation. (C) 2004 Elsevier Ltd. All rights reserved.