Hydrodynamic and kinetic characterization of industrial columns in rougher circuit

In the present investigation the relationship between collection zone rate constant (k_c) and gas dispersion parameters, viz. bubble size (d_b), superficial gas velocity (J_g), gas hold-up (ε_g) and bubble surface area flux (S_b) was evaluated. Experiments were conducted in an industrial (4 m in diameter and 12 m high) and a pilot (0.1 m in diameter and 4 m high) flotation column in rougher circuit at Miduk copper concentrator in Iran. Gas hold-up was measured using pressure difference technique and mean bubble sizes were estimated from a drift flux analysis. It was found that the collection zone rate constant was not correlated with d_b and J_g solely but was linearly dependent on ε_g and S_b for the range of interest. Collection efficiency (E_k) and floatability factor (P) in the industrial columns were quantified (E_k = 3.1%; P = 7.7 × 10^?3). The influence of operating parameters comprising superficial gas velocity, slurry solids% and frother dosage/type on S_b and flotation kinetics was discussed. Analysis of available industrial data suggested that S_b and ε_g were related by S_b = 4.46ε_g over the range 30 < S_b < 60 s^?1 and 7% < ε_g < 14%.     

Prediction of the metallurgical performances of a batch flotation system by image analysis and neural networks

It is now generally accepted that froth appearance is a good indicative of the flotation performance. In this paper, the relationship between the process conditions and the froth features as well as the process performance in the batch flotation of a copper sulfide ore is discussed and modeled. Flotation experiments were conducted at a wide range of operating conditions (i.e. gas flow rate, slurry solids%, frother/collector dosage and pH) and the froth features (i.e. bubble size, froth velocity, froth color and froth stability) along with the metallurgical performances (i.e. copper/mass/water recoveries and concentrate grade) were determined for each run. The relationships between the froth characteristics and performance parameters were successfully modeled using the neural networks. The performance of the developed models was evaluated by the correlation coefficient (R) and the root mean square error (RMSE). The results indicated that the copper recovery (RMSE = 2.9; R = 0.9), concentrate grade (RMSE = 1.07; R = 0.92), mass recovery (RMSE = 1.94; R = 0.94) and water recovery (RMSE = 3.07; R = 0.95) can be accurately predicted from the extracted surface froth features, which is of central importance for control purposes.     

Relationship between the bubble surface flux that overflows and the mass flow rate of solids in the concentrate of flotation processes

This paper presents the relationship between the bubble surface flux that overflows and the mass flow rate of solids in the concentrate. Even though this study was carried out in a flotation column, the knowledge derived from this paper may be applied to all froth flotation processes. The experimental set up was equipped with an image analysis system to estimate the froth bubble diameter and the air recovery. This study describes the difference between the bubble surface flux entering the froth zone (S_bI) and the flux that arrives to the top of the froth (S_bT) and then overflows to the concentrate (S_bO), the latter being most directly related to the mass flow rate of solids in the concentrate. It was observed that the superficial area of the overflow increased with increasing collector addition and air flow rate, but decreased with increasing froth depth and particle size distribution. Visual evidence and experimental results suggest that, it is common that the superficial area of air that overflows in the concentrate is covered by particles. Only when this condition is almost achieved does overflows occur; otherwise, a high level of coalescence and bubble bursting take place at the froth surface. This was concluded after finding compatible trends between the estimated and predicted mass flow rates of solids in the concentrate, when a tractable geometrical model was used (R² = 0.8).     

Boundary conditions for gas rate and bubble size at the pulp–froth interface in flotation equipment

This paper describes the effective boundary conditions for the gas dispersion parameters of bubble size, superficial gas velocity and bubble surface area flux, in mechanical and column flotation cells. Using a number of previously derived correlations, with appropriate simplifying assumptions, and experimental data reported from plant practices, the boundary conditions were identified. Thus, it was shown that these constraints typically allow for a mean bubble diameter range of d_b = 1–1.5 mm and superficial gas rate of J_g = 1–2 cm/s, in order to maximize the bubble surface area flux, S_b = 50–100 s⁻¹. Under these conditions there is no carrying capacity limitation, while keeping a distinctive pulp–froth interface.     

Modeling of bubble surface area flux in an industrial rougher column using artificial neural network and statistical techniques

Previous studies in mechanical and column flotation cells have shown that bubble surface area flux (S_b) is an appropriate indicator of gas dispersion in a flotation cell which has a relatively strong correlation with flotation rate constant. In the present investigation, based on extensive tests conducted in an industrial Metso Minerals CISA flotation column (4 m in diameter and 12 m in height) in a rougher circuit, S_b as a function of the most significant operating variables which affect gas dispersion in a flotation column (i.e. superficial gas velocity, slurry density (solids%) and frother dosage/type) was modeled using artificial neural network (ANN) and statistical (non-linear regression) techniques. The models were developed taking into consideration a data set consisting of 82 experimental tests conducted in an industrial rougher column (at a copper concentrator in Iran) operating under a variety of experimental conditions.This paper outlines the development of the models and validation using a number of randomly selected datasets. Limitations of the present models are discussed and comments and recommendations on further investigations are given.     

Recovery of phosphate ores in the modified three-product column (3PC) flotation cell

This work details the results obtained for the rougher flotation of phosphates in a modified flotation cell known as a three-product column (3PC), at both the laboratory and pilot plant scales. Results were compared to a conventional column cell-CCC. The 3PC cell separates the drained (rejected) particles from the froth zone (third product) and uses a secondary wash water system between the feed and the froth zone (II). Bench-scale studies measured the effect of the two water surface rates on mass and metallurgical recoveries and concentrate grades (P₂O₅, Fe₂O₃, and SiO₂) in all the flows. At pilot scale, the influence of wash water (J_W2) and column design on the flotation separation parameters was studied. Results showed that, compared with the conventional column cell (CCC), the 3PC yielded, in all cases, clean high-grade concentrates, with a minor concentration of impurities (Fe₂O₃ and SiO₂). Concentrate recoveries ranged from 40% to 70% for apatite and were lower when compared to CCC, but it is believed that the third product could be recycled to the fee. This drop-back product operating with J_W2 = 0.0 cm s⁻¹ might yield 5–10% extra in apatite recoveries and enhancing this J_W2 values, the apatite recovery decreased by 0.5–3% but rejection of impurities was very high. Results appear to show that the 3PC may be used as a rougher-flash or Cleaner unit with an optional recycle of the third product into the rougher or simply discarding it. Data on the influence of some cell design and gas dispersion parameters on process efficiency are reported, and the potential practical applications for this type of cell are envisaged.     

Review of rate constants for thiosulphate leaching of gold from ores,concentrates and flat surfaces: Effect of host minerals and pH

A review of literature data for different types of sulphide concentrates and gold ores has been carried out to examine the impact of host minerals and pH upon gold leaching. Analysis of initial rate data over the first 30–60 min of gold leaching from sulphide concentrates or silicate ores over a range of ammonia, thiosulphate, and copper(II) concentrations, pH (9–10.5) and temperatures up to 70 °C shows the applicability of a shrinking sphere kinetic model with an apparent rate constant of the order k_ss = 10⁻⁶–10⁻³ s⁻¹. The dependence of apparent rate constant on pH and initial concentrations of copper(II) and thiosulphate is used to determine a rate constant k_Au(ρr)⁻¹ of the order 1.0 × 10⁻⁴–7.4 × 10⁻⁴ s⁻¹ for the leaching of gold over the temperature range 25–50 °C (ρ = molar density of gold, r = particle radius). These values are in reasonable agreement with rate constants based on electrochemical and chemical dissolution of flat gold surfaces: k_Au = 1.7 × 10⁻⁴–4.2 × 10⁻⁴ mol m⁻² s⁻¹ over the temperature range 25–30 °C. The discrepancies reflect differences in surface roughness, particle size and the effect of host minerals.     

A simple spectrophotometric method for determination of gold (III) in aqueous samples

A simple method for rapid determination of trace Au in natural water was presented by using UV–vis spectrophotometry after reaction of gold (III) with 3,3′, 5,5′-tetramethylbenzidine hydrochloride (TMBH) in acidic solution. Under the optimum conditions, in a concentration range of 100–2000 μg L^?1 of Au (III) a good linear calibration graph was obtained (r = 0.9969, n = 7). The percent relative standard deviation (RSD) for determination of 1000 μg L^?1 Au was 10% (n = 3) and limit of detection based on a signal-to-noise ratio (S/N) of 3 (3S_bl) was 50 μg L^?1. The proposed method has been successfully applied to the determination of gold spiked and real aqueous samples.     

Single and binary component sorption of the fission products Sr2+, Cs+ and Co2+ from aqueous solutions onto sulphate reducing bacteria

This study investigates the removal of the fission products Sr²⁺, Cs⁺ and Co²⁺ in single and binary metal solutions by a sulphate reducing bacteria (SRB) biomass. The effect of initial concentration and pH on the sorption kinetics of each metal was evaluated in single metal solutions. Binary component equilibrium sorption studies were performed to investigate the competitive binding behaviour of each metal in the presence of a secondary metal ion. Results obtained from single metal equilibrium sorption studies indicated that SRB have a higher binding capacity for Sr²⁺ (q_max = 416.7 mg g^?1), followed by Cs⁺ (q_max = 238.1 mg g^?1), and lastly Co²⁺ (q_max = 204.1 mg g^?1). Among the binary systems investigated, Co²⁺ uptake was the most sensitive, resulting in a 76% reduction of the sorption capacity (q_max) in the presence of Cs⁺. These findings are significant for future development of effective biological processes for radioactive waste management under realistic conditions.     

Oxidation of cyanide in effluents by Caro’s Acid

Caro’s Acid (peroxymonosulphuric acid: H₂SO₅) is a powerful liquid oxidant made from hydrogen peroxide that has been adopted for the detoxification of effluents containing cyanides in gold extraction plants in recent years.The present work reports the findings of a study on the kinetics of aqueous cyanide oxidation with Caro’s Acid. Experiments were conducted in batch mode using synthetic solutions of free cyanide. The experimental methodology employed involved a sequence of two 2³ factorial designs using three factors: initial [CN⁻]: 100–400 mg/L; H₂SO₅:CN⁻ molar ratio: 1–1.5–3–4.5; pH: 9–11; each one conducted at one level of Caro’s Acid strength which is obtained with the H₂SO₄:H₂O₂ molar ratio used in Caro’s Acid preparation of 3:1 and 1:1. The objective was the evaluation of the effect of those factors on the reaction kinetics at room temperature. Statistical analysis showed that the three investigated variables were found to be significant, with the variables which affected the most being the initial [CN⁻] and the H₂SO₅:CN⁻ molar ratio. The highest reaction rates were obtained for the following conditions: H₂SO₅:CN⁻ molar ratio = 4.5:1; pH = 9; and Caro’s Acid strength produced from the mixture of 3 mol of H₂SO₄ with 1 mol of H₂O₂. These conditions led to a reduction of [CN⁻] from an initial value of 400 mg/L to [CN⁻] = 1.0 mg/L after 10 min of batch reaction time at room temperature. An empirical kinetic model incorporating the weight of the contributions and the interrelation of the relevant process variables has been derived as: −d[CN⁻]/dt = k [CN⁻]^1.8 [H₂SO₅]^1.1 [H⁺]^0.06, with k = 3.8 (±2.7) × 10⁻⁶ L/mg min, at 25 °C.     

Effect of entrainment in bubble load measurement on froth recovery estimation at industrial scale

Froth recovery was calculated in a 130 m³ mechanical cell of a rougher flotation circuit. This was done by bubble load determinations along with mass balance surveys. Valuable grade in the bubble load decreased in the −38 μm due to fine particles entrained to the chamber of the device. The effect of fine particle entrainment on froth recovery was evaluated. A comparison between results from the raw bubble load data (assuming all particles were transported by true flotation) with those from corrected bubble load information (subtracting fine particle entrainment) was carried out. Entrainment occurred due to hydraulic transport in the bubble rear, which corresponds to the worst case scenario for froth recovery estimation. Results showed that the relative error was less than 0.3%, which allowed validation of the bubble load measurement as an effective methodology for froth recovery estimation at industrial scale.     

Froth flotation of sphalerite: Collector concentration,gas dispersion and particle size effects

This experimental work on sphalerite flotation investigated the effect on flotation performance of three particle size fractions, namely, coarse (d₈₀ = 100 μm), medium (d₈₀ = 39 μm) and fine (d₈₀ = 15 μm), bubble size distribution, superficial air velocity, and collector dosage. Bubble size distributions were characterized with the image analysis technique. The two-phase (liquid–gas) centrifugal pump and frother addition (MIBC, 5–30 ppm) allowed generating bubble diameters between 150 and 1050 μm, and air holdup ranging from 0.2% and 1.3%. Main results showed that each particle-size distribution required an optimal bubble-size profile, and that sphalerite recovery proceeded from mechanisms involving true flotation (when J_g = 0.04 cm/s and 1.9 × 10⁻⁴ M SIPX). However, cluster-flotation occurs at high collector dosage (when J_g = 0.04 cm/s and d₃₂ between 285 and 1030 μm), and requiring further investigation.     

Bioleaching of djurleite using Acidithiobacillus ferrooxidans

The bioleaching of djurleite using Acidithiobacillus ferrooxidans (LD-1) was investigated in this paper. Experiments were carried out in shake flasks at pH 2.0, 160 r/min and 30 °C. The leaching residues were analyzed using X-ray diffraction (XRD), Scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS). The total copper extraction of djurleite under optimal condition reached 95.12%. The XRD analysis indicated the residues mainly consisted of ammoniojarosites and S₈. It was observed by the SEM image that the djurleite was heavily etched. The XPS results confirmed the intermediate product formed during djurleite leaching was CuS. The result indicates the reaction pathway is: Cu₃₁S₁₆ → CuS → tCu²⁺ and S⁰.     

Using a high pressure hydrocyclone for solids classification in the submicron range

A 10 mm hydrocyclone was operated using a barite suspension with a maximum particle size of d^max = 7 μm. The test rig was equipped with a piston diaphragm pump for pressures up to 60 bar. At 40 bar and 20 °C, cut sizes d₅₀ were obtained down to 0.7 μm; increasing the temperature to 50 °C resulted in d₅₀ values down to 0.5 μm for a throughput of 0.6 m³/h. Another experiment was conducted at 40 bar using a batch hydrocyclone technology. Only the overflow was recirculated to the feed box, whereas the underflow was discharged via a collection box. Increasing the number of recirculations increased the separation of fines in the submicron range. The results showed that after 20 min particles with d^max = 1 μm were obtained in the hydrocyclone overflow. After 120 min, the particles size distribution had a d^max = 0.5 μm and a mean size of d⁵⁰ = 0.2 μm. This procedure requires high energy consumption and is thus suitable only for fractionating small quantities of particles in the submicron range.     

Heavy metals removal from solution by palygorskite clay

The possible use of palygorskite clay, mined in the Dwaalboom area of the Northern Province of South Africa, as an adsorbent for the removal of metal ions such as lead, nickel, chromium and copper from aqueous solution, was investigated. In this work, adsorption of these metals onto palygorskite has been studied by using a batch method at room temperature. The results of adsorption were fitted to both the Langmuir and Freundlich models. Satisfactory agreement between experimental data and the model-predicted values was expressed by the correlation coefficient (R²). The Langmuir model represented the sorption process better than the Freundlich one, with correlation coefficient (R²) values ranging from 0.953 to 0.994. The adsorption capacity (Q₀) calculated from the Langmuir isotherm was 62.1 mg Pb(II) g⁻¹, 33.4 mg Ni(II) g⁻¹, 58.5 mg Cr(VI) g⁻¹ and 30.7 mg Cu(II) g⁻¹ at a pH of 7.0 at 25 ± 1 °C for a clay particle size of 125 μm. Kinetic investigations were performed to investigate the rate of adsorption of metal ions. The Lagergren’s first-order rate constants were calculated for different initial concentrations of metal ions. In batch mode adsorption studies, removal increased with an increase of contact time, adsorbent amount and solution pH. Adsorption of metals from the single-metal solutions was in the order: Pb > Cr > Ni > Cu. Data from this study proved that metal cations from aqueous solution can be adsorbed successfully in significant amounts by palygorskite. This opens up new possibilities and potential commercial uses in the palygorskite market.     

Towards optimising ball-milling capacity: Effect of lifter design

The effect of liner/lifter profile on kinetics of batch grinding and the milling capacity in general was assessed using mono-size quartz material of 30 × 40 mesh (−600 + 425 μm) as feed. The liner profiles tested were, (i) bevel with 60° lifter face angle to represent the new liners, (ii) bevel with 45° lifter face angle to represent the worn liners and (iii) worn bevel modified with cone-lifters. The tests were conducted under identical conditions to allow a comparative analysis of the results. In all cases, the breakage followed the first order hypothesis. The experimental size distribution data was well predicted by the S and B model, thus allowing for estimation of breakage and selection parameters (i.e., γ and a_T) for the three liner situations tested. The optimised values of the specific rate of breakage, S_i for the three liner profiles tested were 0.381, 0.287 and 0.365 min⁻¹, respectively, which clearly indicates the benefit of cone-lifters. The breakage distribution function (B_ij) values did not vary significantly with liner profile, which echoes the findings by other researchers.     

A study of atmospheric acid leaching of a South African nickel laterite

Nickel and cobalt acid leaching from a low-grade South African saprolitic laterite using sulphuric acid was studied. Ore characterisation was performed by XRD and XRF. Batch agitation leaching tests were conducted at atmospheric pressure investigating main parameters: particle size and percent solids at 25 °C and 90 °C. Ore characterisation showed that the ore is a saprolitic laterite with nickel present in lizardite. Leaching tests showed that nickel and cobalt could be leached from the ore at atmospheric pressure. Nickel was found to be more leachable from the coarser −106 + 75 μm fraction, with 98% Ni being extracted at 90 °C after 480 min. Cobalt was not favoured by variation in particle size and increased percent solids. Increasing ore percent solids improved nickel extraction at 25 °C however at 90 °C extraction decreased due to a diffusion layer build-up as a result of amorphous colloidal silica. The co-dissolution of magnesium and iron was elucidated. Nickel leaching data at increased temperature and percent solids fit the shrinking core model equation, k_dt = 1−2/3x − (1 − x)^2/3 showing that nickel leaching reaction was diffusion controlled under the set conditions.     

Dissolution and passivation mechanisms of chalcopyrite during bioleaching: DFT calculation,XPS and electrochemistry analysis

In this work, density functional theory (DFT) calculation, X-ray photoelectron spectroscopy (XPS) and electrochemistry analysis were carried out to investigate the dissolution process and passivation mechanisms of chalcopyrite in the presence of sulfur and iron oxidizing microorganisms. Both DFT calculation and XPS analysis indicated that the formula of chalcopyrite should be Cu + Fe³ + (S²⁻)₂. Disulfide (S₂²⁻) and polysulfide (S_n²⁻) can be easily formed on the surface of chalcopyrite due to the surface reconstruction. The dissolution process of chalcopyrite in bioleaching was mainly dependent on redox potential. Chalcopyrite was predominantly directly oxidized to polysulfide when redox potential was lower than about 350 mV vs. Ag/AgCl and resulted in low dissolution rate. When redox potential was in the range of about 350–480 mV vs. Ag/AgCl, chalcopyrite was mainly transformed to intermediate species of Cu₂S rather than polysulfide, thus resulting in high dissolution rate. When redox potential was higher than about 480 mV vs. Ag/AgCl, chalcopyrite was principally directly oxidized to polysulfide which caused the passivation of chalcopyrite. Finally, a model of dissolution and passivation mechanisms of chalcopyrite in the presence of sulfur and iron oxidizing microorganisms was provided.