A non-invasive technique for sorting of alumina-rich iron ores

This paper describes an Infrared (IR) thermography based technique for sorting of iron ores consisting of alumina-rich particles of relatively low thermal absorptivity as compared to iron-rich particles in the ores. The technique primarily consists of selection of iron ores with Fe compositions ranging from 59 to 69 wt.% and alumina (Al₂O₃) from 0.35 to 8.85 wt.%, crushing the ores up to the particle size range around 10 mm. The iron ore fines are uniformly heated using heat source of wavelength ranging from 10⁻² to 10⁻⁶ m for a period of time sufficient to create a difference in infrared emission between the ore particles. The thermal image of the heated ores is captured by IR thermography. The alumina-rich iron ore particles are heated up less as the thermal absorptivity of these ores is less than the ores with high iron content. Thus, the alumina-rich iron ore particles can be identified by observing the temperature profile and/or thermal image of these ores. This technique of ore recognition can be useful in improving the feed quality of iron ore to the blast furnace in iron and steel industries by rejecting the alumina-rich ores through modification in the presently existing processes.     

Utilization of optical image analysis and automatic texture classification for iron ore particle characterisation

Optical image analysis is a very convenient tool for obtaining comprehensive information about fine iron ore size fractions. Data can be obtained on mineral abundances, porosity, particle shape and ore textures with a high level of accuracy. A range of techniques has been used to characterise iron ore samples on a particle-by-particle basis. Automatic textural classification of iron ore particles was used to establish classes containing particles with very similar mineral composition and texture. Image analysis coupled with probe analysis and mineral density measurements provided information about the chemical composition and density of each particle class. The combination of these results enabled a “virtual feed” to be created, which can be a key input into a beneficiation unit model for predicting its performance. Identification and classification of the textural type of each particle was performed according to the CSIRO-Hamersley Iron Ore Group Classification Scheme. If more detailed classification is needed, further classification can be performed based on dimensional, chemical or mineral criteria, such as the presence of certain minerals in particles or total iron content. Some deficiencies of the current image analysis procedures and their further improvement and automation are also discussed.     

Infrared thermography: An approach for iron ore gradation

There are insufficient high-grade iron ores currently being mined to meet world demand for steel production. In order to meet raw material demand in India, lower grade ores with high alumina contents are being crushed and beneficiated, mainly by gravity techniques requiring water. However, the scarcity of water in the mining areas warrants the development of some dry gradation techniques for iron ores so that the inferior ore specimens can be rejected in order to improve the grade of the concentrate. The present gradation of ores by mineralogical/chemical methods is time-consuming and cumbersome. This paper presents an Infrared (IR) thermography-based non-invasive technique for the faster gradation of iron ores, taking into account the variation in thermal absorptivity of the ore constituents. Iron ore samples from the Joda, Noamundi and Barsua mines, with Fe contents ranging from 52 to 67 wt.%, were selected and crushed to around 10 mm particle size. The crushed iron ores were uniformly heated using a microwave oven, for a time period sufficient to create a difference between the ore particles in the extent of their respective infrared emissions. The thermal images of the heated particles were captured by IR thermography and the peak temperature of each ore particle was obtained from the thermal profile. A computer program was developed for ore gradation based on the peak temperature of each ore particle which corresponds to its iron content. A threshold was selected through chemical verification of the ores and accordingly the ores were categorized as high-, medium- and low-grade.     

尼日利亚某高磷铁矿石工艺矿物学研究

利用化学多元素分析、化学物相分析、X射线衍射、扫描电镜和电子能谱等综合手段,研究了尼日利亚某铁矿石的化学组成、矿物组成、结构构造特点、嵌布特征及磷的赋存状态。结果表明:矿石以鲕状构造为主,有用矿物为赤铁矿和褐铁矿,脉石矿物很少且难以确定。铁矿物嵌布粒度细,且与脉石矿物共生紧密,不易充分解离,将给分选带来困难。矿石中有害元素磷的独立矿物较少,杂质磷主要以类质同象和极细的机械混入物的形式存在于铁矿中。该矿石属于高磷难选铁矿石。     

Effects of frother type and froth height on the flotation behaviour of chromite in UG2 ore

About 70% of the UG2 reef consists of the gangue mineral chromite (FeO · Cr₂O₃). In the processing of UG2 ore by flotation for the recovery of platinum group elements (PGEs) the presence of chromite in the concentrates can cause serious downstream processing problems and a grade of less than 3% Cr₂O₃ is sought. This constrains operating procedures and compromises optimum recovery of the PGEs.In this study, the influence of the froth phase on the recovery of chromite was investigated by changing both frother type and dosage and froth height in batch scale flotation tests. The results obtained showed that it was possible to obtain concentrates with less than 3% Cr₂O₃ content by increasing the froth height, allowing for better drainage of both entrained gangue particles and coarse particles with low hydrophobicity. At a 3 cm froth height, very low water and mass recovery were obtained and thus low entrainment. Nevertheless a small amount of chromite particles coarser than 45 μm was persistently recovered which may be attributed to the true flotation of these particles.The mechanism of chromite recovery was discussed on the basis of the difference in the appearance of the froth structure and water recovery.     

青海小沙龙铁矿石工艺矿物学和可选性研究

详细阐述了青海小沙龙铁矿矿床的矿床地质特征、矿石的类型及结构构造、主要化学成分、铁物相、矿物组成及含量、主要铁矿物的嵌布特征、磁铁矿的嵌布粒度及解离特征,并对原矿进行了多种选矿工艺流程的可选性对比试验。研究表明磁铁矿大多呈细粒、微细粒稠密或稀疏浸染于脉石矿物中,与其他矿物嵌布关系比较密切;磁铁矿的嵌布粒度比较细,当磨矿细度为-0.028 mm 占85%时,磁铁矿的单体解离度达到85%左右;2段磨矿-2段磁选工艺流程更简洁,能耗和经济效益指标更优越。     

Application of near infrared sensors to preconcentration of hydrothermally-formed copper ore

Near infrared sensors can be a very useful technique for the qualitative analysis of complex ores, and thus could be useful for the preconcentration of ores. In this paper, individual particles of hydrothermally-formed copper ore sampled from a mine in the Los Pozos mining district, northern Chile, were classified as product, middling and waste based on their near infrared response. The classification of copper bearing minerals (product) from gangue (waste) was considered for vibration combination bands at longer wavelengths from 2000 to 2400 nm. This region exhibits characteristic features for carbonates and hydroxyl gangue bearing minerals. The near infrared features at 1400 and 1900 nm were not considered favourable for classification and subsequent discrimination because they can be influenced by moisture and other environmental factors and are easily suppressed by iron-rich minerals.Two near infrared preconcentration strategies were applied for particle discrimination. Results indicate that targeting only the calcite (carbonate) dominated particles for discrimination as waste provided the best option for preconcentration. The near infrared discrimination analysis correlates well with mineralogical (QEMSCAN® and XRD) and elemental (XRF) data classification. The results indicate that near infrared spectroscopy is a suitable preconcentration method for supergene copper ore.     

Bitumen-air aggregates flow to froth layer: II. Effect of ore grade and operating conditions on aggregate composition and bitumen recovery

Size, rise velocity, shape, and composition of bitumen-air aggregates floating to the froth layer during the processing of 11.1% bitumen Estuarine ore, and 7.2% bitumen Marine ore under various operating conditions (caustic dosage and feed density) were determined. The flux of the bitumen-air aggregates inside a Primary Separation Vessel (PSV) processing 2 tonnes/hour of the ore was in-situ monitored and video recorded. The mass of bitumen contained in the aggregates floating to the froth layer under different operating conditions was calculated on the basis of the measured rise velocities and dimensions of the aggregates. It was found that the type of ore processed was the parameter having the largest effect on size and composition of the bitumen-air aggregates floating to the froth layer inside the PSV during a 50°C warm slurry extraction process. In the case of the Estuarine ore the average mass of bitumen contained in an average aggregate was ca. 9^*10⁻⁴ g, and the average aggregate size was ca. 1.0 mm. During processing of the low grade (Marine) ore the aggregates were smaller (within 0.33–0.69 mm) and they carried much less (from 0.17–1.37^*10⁻⁴ g) bitumen, depending on other operating conditions (caustic dosage and feed density). A good correlation between size of the bitumen-air aggregates and bitumen recovery in the primary separation vessel was found. Thus, size of the aggregates can be used as an indication of better flotation recovery.     

Rheological behaviour of lateritic smectite ore slurries

The characterisation and rheology of several nickel laterite smectite ores and pure minerals are compared to assess the effect of mineralogy and particle size on the viscosity of high pulp density slurries. A vane viscometer was used to determine the “optimum pulp density” (OPD) that gave a yield stress of 100 Pa which is considered to be optimal for pumping slurries into autoclaves in the HPAL process. In general, slurries containing finer particles were more viscous and smectite slurries exhibited poor rheological behaviour as compared to slurries of goethite < kaolin < talc < hematite < maghemite < magnesite. Blending the smectite ores with a fraction of the pure minerals improved the rheological behaviour of the pulp and can increase the optimum pulp density of the smectite blend by over 5% w/w.When the physical properties of the smectite ore and slurry were examined, a very good linear correlation was obtained between the optimum pulp density and the settling density which provides a simple measure of predicting rheological behaviour of slurries. The variation in the viscosity of the nickel laterite ores depends largely on their mineralogy and particle size distribution. The mean particle size and P₈₀ values of various smectite ores containing the same mineral phases were also found to have a reasonably good linear correlation with OPD in saline water, but the correlation of ore surface area with OPD was a poorer fit.     

Characterisation of coarse composite sphalerite particles with respect to flotation

The flotation response of a typical zinc-lead (Zn/Pb) ore, with respect to coarse composite (sulphide/non-sulphide) particles is reported. The flotation tests were carried out on a selected feed particle size range (−600 + 75 μm, at P₈₀ of 390 μm) and the recovery of Zn composite particles analysed on a size by size basis. The best results were achieved with the use of 75 g/t sodium isopropyl xanthate (SIPX), obtaining a Zn recovery of 77%, with a significant improvement at the coarse end of the particle size distribution. Computerised scanning electron microscope (QEMSCAN) was used to characterise value mineral grain size and degree of liberation, as well as gangue and sphalerite association in particles reporting to both concentrate and tailings. A new characterisation function (Locking ratio, LR) was developed based on the data from the automated mineralogical analysis to characterise particles into two-phase composites with different degree of locking texture (simple and complex). The function, which is based on the mode of occurrence of sphalerite, grain size, proportion and composition of the constituent minerals in each particle, was used to study the flotation response of the particles with different degrees of locking. The results highlight the difference in recoverability of the sphalerite bearing particles with different degrees of locking, with simple locking texture giving higher recovery than complex locking texture, for the same overall liberation.     

A t10-based method for evaluation of ore pre-weakening and energy reduction

Currently the effect of the pre-weakening of ore particles by high voltage pulses is evaluated by the percentage change of A 1 b values between pulse-treated and untreated ore particles. The values of A 1 b, widely used as an ore breakage competence indicator in the mineral industry, are determined from the parameters of the JKMRC breakage models. In this study a t₁₀-based method was developed to predict the degree of size reduction, t₁₀, of pulse-treated particles from that of untreated particles broken at the same size/energy level. This method incorporates one parameter, C_Ab, which is equivalent to the percentage change of A 1 b values.The t₁₀-based method was validated using nine sets of comparative JK Rotary Breakage Tester data on pulse-treated and untreated ore samples over a wide range of impact specific energies and particle sizes. The t₁₀-based method can be used to calculate the energy reduction due to the pre-weakening effect in the downstream comminution process. It indicates that the energy reduction by pre-weakening increases with an increase in the target product fineness and the degree of pre-weakening, and with the decrease in feed particle size.     

Bonded-particle modelling of microwave-induced damage in ore particles

Microwave heating of mineral ores offers a mechanism to induce fractures around grain boundaries due to the different rates of microwave power dissipation and the differences in thermal expansion coefficient among various minerals in the ore particles. As a consequence, this has the potential to reduce the energy required in subsequent grinding and to enhance liberation of valuable minerals. In this paper, numerical simulation using a bonded-particle model was undertaken to provide a better understanding of the mechanism of microwave-induced micro-fracture and to predict the effect of microwave power delivery and ore texture on microwave treatment of ores. Computational simulations of microwave heating and thermal damage have been carried out on two-phase conceptual ores. It was shown that the extent of damage and the crack pattern in an ore sample for the same microwave energy input depend strongly on the applied power density and the microwave absorbent phase grain size. It is possible both to reduce the energy input and to localize the microwave-induced damage around the grain boundaries by operating at high power density. It was also shown that high power pulsed equipment would be more efficient than continuous wave equipment for treating fine-grained ores.     

Acid leaching and rheological behaviour of a siliceous goethitic nickel laterite ore: Influence of particle size and temperature

This study investigates the isothermal, batch, H₂SO₄ acid leaching behaviour of siliceous goethitic (SG) nickel (Ni) laterite ore and its links to pulp rheology. Specifically, the effect of feed ore particle size (−0.2 vs −2.0 mm), leaching temperature (70 vs 95 °C) and pulp rheology on Ni and pay metal, cobalt (Co) extraction kinetics and yield was studied for 4 h on 40 wt.% solid dispersions at pH 1. The leaching behaviour was distinctly incongruent, reflecting the disproportionate proliferation of major gangue mineral’s constituent elements (e.g., Fe, Al, Mg, Na, Si) alongside Ni and Co in the pregnant leach solution. At 70 °C, Ni/Co extraction rates were notably lower (<20%) in contrast with 95 °C where a significant increase in Ni/Co extraction to 78/77% and 74/77%, respectively, for the −0.2 and −2.0 mm feeds occurred. The slurries displayed a non-Newtonian, shear thinning Bingham plastic rheological behaviour of which the viscosity and shear yield stress increased markedly in the course of 4 h leaching. The pulp viscosity and shear yield stress were greater at lower temperature than at higher temperature and they were also greater in slurries with finer than coarser feed particles. The dynamic pulp rheology, however, had no marked effect on the overall Ni/Co extraction rates. Whilst the feed ore particle size had no remarkable impact on overall Ni/Co extraction, it led to noticeably higher acid consumption and enhanced slurry rheology in the finer sized ore. The mechanism of leaching the SG ore followed a two-stage, first order chemical reaction-controlled shrinking core model, the kinetics of which gave higher rate constants and lower activation energies for the release of Ni, Co, Fe and Mg in the first stage. A faster leaching process involving more reactive minerals during the first 30 min is envisaged to be followed by leaching of the more refractory minerals.     

基于机器视觉的矿石块度智能识别及应用

给矿粒度特性以及矿石可磨性对半自磨过程的影响远大于常规碎磨流程,通过对给矿皮带上矿石图像进行矿石粒度特性分析,可从给矿源头上实现矿石块度实时检测。基于多尺度的矿石图像分析系统,实时采集半自磨给矿矿石图像,通过图像处理技术,实现矿石块度有效分割以及粒级统计,为半自磨给矿矿石块度控制提供数据支撑。     

秘鲁某矽卡岩型难选铜钼矿石工艺矿物学研究北大核心

为制定合理的铜钼矿选矿工艺流程和选矿指标,采用光学显微镜、化学多元素分析、物相分析等分析测试手段对秘鲁某矽卡岩型难选铜钼矿进行了系统的工艺矿物学研究。研究结果表明,矿石主要有用元素为Cu和Mo,品位分别为0.58%和0.019%。矿石矿物组成复杂,主要有用矿物为黄铜矿、辉铜矿、辉钼矿等,脉石矿物为石英、长石、云母、蛇纹石、透闪石、绿泥石等。铜钼矿物嵌布粒度细小,且常沿黄铁矿或磁铁矿或脉石矿物的边缘、孔洞及裂隙分布,少量微细粒黄铜矿呈稀疏浸染状分布在脉石矿物中,嵌布关系复杂,影响铜钼矿的选矿回收。     

Effect of microwave pre-treatment on ultramafic nickel ore slurry rheology

Low-grade ultramafic nickel ores, while representing a large potential nickel resource, are difficult to process due to their high serpentine content. Serpentine is anisotropic and the mineral particles tend to be non-spherical, resulting in challenging slurry rheology. In general, suspensions of serpentine minerals have high viscosity and yield stress, which can be detrimental in comminution and flotation operations. It is proposed that ultramafic nickel ores be treated with microwave radiation prior to grinding in order to reduce slurry viscosity and yield stress. The rheology of two different ultramafic nickel ores, before and after microwave pre-treatment, was characterized in this work. Serpentine minerals were found to dominate the rheology of the untreated ultramafic nickel ores, with the ore containing minor chrysotile exhibiting higher viscosity and yield stress than the ore containing strictly lizardite serpentine. Microwave pre-treatment was found to greatly reduce the shear viscosity (average 80% reduction at 200 s⁻¹) and direct yield stress (peak yield stress reduced by 92–93%) of ultramafic nickel ore slurries. The reduction in slurry viscosity and yield stress of the ore slurries as a result of microwave pre-treatment was attributed to the conversion of serpentine to olivine.     

司家营铁矿矿石工艺矿物学及选矿影响因素研究

对司家营铁矿矿石的化学成分、矿物组成、嵌布特征、粒度及结构构造等工艺矿物学特征进行了详细的研究。结果显示,矿石可利用组分主要为Fe;铁矿物主要由赤(褐)铁矿和少量磁铁矿组成;脉石矿物主要为石英和云母,其次为角闪石、绿泥石;铁矿物平均嵌布粒度为0.116 mm;铁矿物与脉石矿物的关系主要为毗连和镶嵌结构。结合矿石化学分析和镜下鉴定结果,证实闪石类矿物与磁性铁有着密切关系。根据矿石工艺矿物学研究结果,该区域矿石可划分为易解离易选、易解离难选、难解离难选等3种工艺类型,并分析了每种类型矿石的特征及选矿影响因素。     

某风化粘土型钛矿工艺矿物学研究

为综合回收利用风化残坡积型钛矿中有价金属,探讨钛等有价元素的可回收性,采用传统工艺矿物学研究方法对国内某风化粘土型钛矿的矿石特性进行了系统的研究,并分析了影响选矿工艺的因素,提出了可行的选矿工艺方案。研究结果表明,该矿TiO₂品位4.5%,主要含钛矿物为钛铁矿、白钛石和钒钛磁铁矿,矿石含泥量近80%。钛铁矿多为单体,部分氧化蚀变为白钛石,均被粘土矿物包裹或与其连生,钒钛磁铁矿为次要回收矿物,其中包含部分呈固溶体分离的钛铁矿片晶。矿石中钛分散较严重,采用物理选矿分选钛的理论回收率为48%左右,铁理论回收率仅为4%左右。结合矿石特点与工艺矿物学研究结果,该矿石选矿试验可采用“擦洗脱泥-重选-磁选”联合流程,在重选前应采用强力搅拌脱泥以消除“粘结效应”,继而采用重选预先抛尾后再磁选,之后利用强磁选、摇床精选等手段进一步提高精矿品位。该研究为选矿回收该矿床中有价金属提供了方向性指导。      

Phase distribution identification in the column leaching of low grade ores using MRI

Heap bioleaching is gaining importance as an approach for the recovery of valuable metals (e.g. Cu²⁺) from low grade ores. In this process iron and/or sulfur oxidising microorganisms are used to aid the oxidation of base metal sulfides in the ore, thereby liberating the metal ions into solution. Leach performance is strongly influenced by the contacting of the leach solution and the ore particles. In order to better understand the distribution of the leaching solution on the pore scale in these heaps, Magnetic Resonance Imaging (MRI) was used to acquire images non-invasively of a section of an irrigated ore bed. This was made possible by the use of specialist MRI acquisition sequences suited to the magnetically heterogeneous environment as presented by the ore material. From the images we were able to determine the pore-occupancy of the liquid and gas phases and to provide novel measurement of the interfacial area between air, leach solution and ore.