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SEPARATION TECHNOLOGIES SEPARATION T FOR MINERALS, COAL, AND EARTH RESOURCES E CS HE P N EDITED BY COURTNEY A. YOUNG AND GERALD H. LUTTRELL OA TECHNOLOGIES R L OA GT Separation Technologies for Minerals, Coal, and Earth Resources is I IO E an authoritative digest of the latest developments in the mineral SN processing industry. FOR MINERALS, AF The book is a compilation of 78 state-of-the-art papers presented by leading NO scientists and engineers at the fi rst-of-its-kind international symposium. DR M E AI Dozens of authors share their insights on how practitioners can develop RNE COAL, AND EARTH earth resources more economically while simultaneously addressing TR HA vital factors ranging from sustainability to environmental stewardship. RL S E S, C RESOURCES The book examines coal processing, surface forces and hydrophobicity, OO process improvements and environmental controls, dewatering and UA RL drying, gravity separations, industrial minerals fl otation, base metal C, E fl otation, fl otation equipment and practice, process reagents, magnetic S and electrostatic separations, modeling and process control, and resource engineering. Important current issues such as gas hydrates, oil sands, secondary materials, metals and waste, and process waters are also discussed. Dedicated to industry giant Dr. Roe-Hoan Yoon, this book includes fi ve EDITED BY leading-edge papers co-authored by the legendary scientist and founder COURTNEY A. YOUNG of the Center for Advanced Separation Technologies at Virginia Tech. AND GERALD H. LUTTRELL Separation Technologies for Minerals, Coal, and Earth Resources belongs on the bookshelves and e-readers of all mining professionals involved in process engineering, especially those working with minerals and coal. The Society for Mining, Metallurgy, and Exploration, Inc. (SME), advances the worldwide mining and minerals community through information exchange and professional development. With members in 71 countries, SME is the largest association of mining and minerals professionals. !SME_SepartionTechMCER_FullCV_F3.indd 1 1/6/12 2:46 PM Separation technologieS for MineralS, coal, and earth reSourceS edited by courtney a. young and gerald h. luttrell Published by society for Mining, Metallurgy, and exPloration © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. Society for Mining, Metallurgy, and Exploration, Inc. (SME) 12999 E. Adam Aircraft Circle Englewood, Colorado, USA 80112 (303) 948-4200 / (800) 763-3132 www.smenet.org SME advances the worldwide mining and minerals community through information exchange and professional development. With members in more than 50 countries, SME is the world’s largest association of mining and minerals professionals. Copyright © 2012 Society for Mining, Metallurgy, and Exploration, Inc. Electronic edition published 2012. All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. Any statement or views presented here are those of individual authors and are not necessarily those of SME. The mention of trade names for com- mercial products does not imply the approval or endorsement of SME. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. ISBN: 978-0-87335-339-7 Ebook: 978-0-87335-357-1 Library of Congress Cataloging-in-Publication Data Separation technologies for minerals, coal, and earth resources / edited by Courtney A. Young and Gerald H. Luttrell. p. cm. Includes bibliographical references and index. ISBN 978-0-87335-339-7 (print) -- ISBN 978-0-87335-357-1 (ebook) 1. Separation (Technology) 2. Coal--Cleaning. I. Young, Courtney, 1962- II. Luttrell, Gerald H. TP156.S45S455 2012 660’.2842--dc23 2011047121 © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. Contents Preface ............................................................................... ix Biographical Sketch: Dr. Roe-Hoan Yoon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi PART 1: Surface Forces and Hydrophobicity ................................................1 Effect of Frother Mobility on the Bubble Behavior in Bubble Rise Velocity Measurements at the Initial Stages of Bubble Formation ...................................................1 K. Heiskanen, Z. Javor, G. Wierink, B. Omelka, N. Schreithofer Role of Model Systems in Fundamental Studies on Particle-Bubble Interaction .....................7 Janusz S. Laskowski Surface Deformation During Bubble-Particle Colloidal Interaction Quantified by Atomic Force Microscopy and Numerical Modeling .....................................................19 Elena Taran, Anh V. Nguyen Dynamics of Bubble-Particle Interaction ..................................................27 Yihong Yang, Sunghwan Jung, Juan Ma, and Roe-Hoan Yoon Inter-Bubble Attractions in Aqueous Solutions of Flotation Frothers .............................35 Liguang Wang A Novel Induction Timer to Study Interactions Between an Air Bubble and a Bitumen Surface ........47 Louxiang Wang, David Sharp, Zhenghe Xu, and Jacob Masliyah Kinetics of Thinning of Wetting Films Formed on Gold Surfaces Treated with Potassium Amyl Xanthate .......................................................................57 Lei Pan, Roe-Hoan Yoon, Sunghwan Jung Adsorption of Collectors on Chalcopyrite Surface Studied by an AFM ...........................65 Jinhong Zhang, Wei Zhang PART 2: Dewatering and Drying ..........................................................75 Dewatering Performance Evaluation of Hyperbaric Centrifugation ..............................75 Serhat Keles, Gerald H. Luttrell, Werner E. Kohler Testing of a Pilot-Scale, Plate-and-Frame Filter Press for Dewatering Fine Silica-Sand Slurries .......85 Shubham Verma, Mark S. Klima, Barbara J. Arnold Effects of Surface Forces on Dewatering of Fine Particles .....................................95 R. Asmatulu, R.H. Yoon Development and Implementation of Novel Dewatering Aids .................................103 M.K. Eraydin, Jinming Zhang, D. Henry OreBind Technology for Limiting Waste Fines Disposal in Impoundments and Slurry Cells .........111 R. Mullins, M.K. Eraydin, S. Blubaugh PART 3: Coal Processing ...............................................................115 Maximizing Mine Profitability Through Development, Implementation, and Auditing of Preparation Plant Best Practices ......................................................115 P.J. Bethell, David De Pasquale Fine Coal Recovery, Coal Slurry Impoundment Structures, Thickener Underflow, and Other Unprocessed Slurry Waste from Existing Preparation Plant Discharges .........................121 C. David Henry iii © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. iv Contents Development of an Automatic Control System for Spiral Concentrator: Phase 1 ..................129 B. Zhang, F. Yang, P.K. Sahoo, H. Akbari, H. Wang, M.K. Mohanty, A. Mahajan Optimal Design of Fine Coal Cleaning Circuitry ...........................................139 Gerald Luttrell, Ali Zufiqar, Robert Bratton, Andy Dynys, Larry Watters Benefits of Using Novel Collectors in Cleaning Fine Coal ....................................149 M.K. Eraydin, J. Zhang, S. Blubaugh PART 4: Gravity Separations ...........................................................153 Application of the Reflux Classifier for Measuring Gravity Recoverable Product ..................153 Kevin Galvin, James Zhou Review of Current Enhanced Gravity Separation Technologies and Applications ....................................................................163 John Cole, Robert Dunne, Aidan Giblett Study on Coarse Slime Separation by Teeter Bed Separator in Chengjiao Coal Preparation Plant .....177 Y. Tao, L. Wang, Z. Li, M. Sun Non-Contacting Sensor Technology for Measuring Level and Density ..........................181 Tony Hart, Soovo Sen Application of Neural Network for Modeling the Coal Cleaning Performance of the FGX Dry Separator .......................................................................189 H. Akbari, B. Zhang, F. Yang, M.K. Mohanty, M. Sayeh, S. Rahimi Application of Air Table Technology for Cleaning Indian Coals ...............................199 Nikhil Gupta, Robert Bratton, Gerald Luttrell, Tathagata Ghosh, Rick Honaker Gekko IPJ Coal Separator Performance in Coal Preparation ..................................211 A. Vince, L. Gibson, P. Purdon, T. Hughes PART 5: Magnetic and Electrostatic Separations ...........................................229 Physical Separation Enhancers: Recent Advances ..........................................229 S.A. Ravishankar Recent Advances in High Gradient Magnetic Separators .....................................241 Ian Sherrell, Peter Dunn Eddy Current Separation of Metallic Granules from Waste Streams ............................249 Swadhin Saurabh, Raj Rajamani Pilot Test of Magnetic Separation of Steel Ball Fragments from a Product of Mill’s Trunnion Magnet System to Produce Cast Steel Balls ...............................................255 N. Purevbaatar, S. Gantulga, L. Bataa, P. Erdenetsogt Development of Advanced Automatic Sorting System for Mixed Plastic Wastes ..................261 Woo Zin Choi, Eun Kyu Park, Ho Seok Jeon Magnetic Concentration of Hematite at Wabush Mines Plant-Scale Application of Rare Earth Permanent Magnetic Separators ........................................................269 Doug Gover, Antoine Berton, Dan Norrgran Recovery of Valuable Materials from Gold Mine Tailings ....................................277 Hee-Chan Cho, Won Oh, Oh-Hyung Han, Hyun-Ho Kang, Jin-Soo Lee PART 6: Resource Engineering ..........................................................289 Surface Chemistry of Layered Silicate Minerals ............................................289 Jan D. Miller, Vishal Gupta, Xuming Wang, Xihui Yin, Hao Du, Jianwei Wang Development of Cellulosic Insulators with Various Mineral Additives ..........................299 Ibrahim Ethem Karaağaçlıoğlu, Firat Karakas, Feridun Boylu, Mehmet Sabri Çelik © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. Contents v Mechanisms for Flotation of Fine Oil Droplets .............................................307 C. Hank Rawlins, Chien Ly Studies on Air-Assisted Solvent Extraction ................................................317 H.M. Tarkan, S.H. Kuan, J.A. Finch Experimental Studies on Flash Oxidation of Chalcopyrite ....................................325 Z. Zhang, R.G. Reddy How to Evaluate Current Efficiency in Copper Electrowinning ................................333 Michael S. Moats Initial Contact and Adhesion Force Measurements of Clathrate Hydrates ........................341 Jae W. Lee, Alexander Couzis, Jung Hun (Kevin) Song Thermodynamics and Kinetics of CO Hydrate Formation ...................................347 2 Jialin Wang, Roe-Hoan Yoon, Yongkoo Seol PART 7: Process Improvements and Environmental Controls ................................357 Hydrometallurgical Separation, Concentration, Recovery, and Fixation of Antimony, Mercury, Arsenic, and Other Rare Metals .................................................357 C.G. Anderson Effect of Metal Sulphides on Gold and Silver Cyanidation: Analysis of Progress ..................369 G. Deschênes Enhancing Gold Recovery Using Hydro-Jex at Cripple Creek and Victor Gold Mine ...............381 Thom Seal, Dale F. Rucker, Jeffrey Winterton Impregnated Activated Carbon for Gold Extraction from Thiosulfate Solutions ...................391 Courtney Young, Nick Gow, Mariam Melashvili, Marc LeVier Statistical Evaluation of Montmorillonite Clay for Zearalenone Extraction .......................405 Kerri-Ann Alicia Hue, H. El-Shall, A.A. El-Midany Minimizing Mercury Pollution During Gold Ore Processing ..................................411 Maurice Fuerstenau, Kangnian Zhong, Manoranjan Misra, Thom Seal, Carl Nesbitt Galvanic Interaction and Particle Size Effects in Self-Heating of Sulphide Mixtures ...............419 Rebecca Payant, Frank Rosenblum, Jan E. Nesset, James A. Finch Cost-Effective Air Separation Plants for the Mining and Mineral Industry .......................431 Goutam H. Shahani, Tony Palermo PART 8: Industrial Minerals Flotation ....................................................437 New Approaches to Particle Attachment and Detachment in Flotation ..........................437 Graeme J. Jameson, Shina Goel Practical and Proven Methods for Improving Ultrafine and Coarse Particle Recovery ..............447 J.N. Kohmuench, M.J. Mankosa, L. Christodoulou Fundamental Studies of Nanobubble Generation and Applications in Flotation ...................457 Maoming Fan, Yuemin Zhao, Daniel Tao Flotation of a Brazilian Bauxite Ore .....................................................471 S. Marino, X. Wang, C.L. Lin, J.D. Miller Atypical Grade-Recovery Curves: Transport of Mg Silicates to the Concentrate Explained by a Novel Phenomenological Model ....................................................479 T. Bhambhani, D.R. Nagaraj, M.Vasudevan, P. Patra Flotation Technology for Yuanjiacun Iron Ore .............................................489 Chen Wen, Liu Xinghua © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. vi Contents PART 9: Base Metal Flotation ...........................................................497 Investigation of n-Octanohydroxamate Reagent Interaction with the Surface of Oxide Copper Minerals and Copper Metal ................................................497 G.K. Parker, G.A. Hope, R. Woods, A. Numprasanthai, A.N. Buckley, J. McLean Evaluation of Pyrite Flotation Efficiency Using Liberation-Limited Grade/Recovery Curves ........509 J.F. Medina, C.L. Lin, J.D. Miller Ore Evaluation at Vale Base Metals .....................................................521 Manqiu Xu Respect Equals Recovery in Flotation ....................................................531 Alejandro Gamez, Fidel Saltijeral, Oscar Lopez, Sami Grönstrand PART 10: Flotation Equipment and Practice ...............................................539 From 10 Cubic Feet to 500 Cubic Meters―Observations on 100 Years of Flotation Technology ......539 Michael G. Nelson Improved Fine Particle Recovery .......................................................547 Devan Govender, Bartosz Dabrowski, Dariusz Lelinski, Harley Schreiber, Frank Traczyk Comparison of Two Bubble Sizing Methods for Performance Evaluation of Mechanical Flotation Cells ............................................................563 Sanja Miskovic, Gerald Luttrell A Novel Approach to Flotation Cell Design ...............................................575 P.T.L. Koh, M.P. Schwarz Turbulence Measurements in a Flotation Cell Using a Fast-Response Probe ......................583 Yihong Yang, Demetri Telionis Cell Power Input or Hydrodynamics—Which Is More Important in Flotation? ....................593 Sami Grönstrand, Alejandro Yañez, Gijsbert Wierink, Juha Tiitinen CFD Simulations of a Dorr-Oliver Flotation Cell ...........................................605 Abdel-Halim Salem-Said, Hassan Fayed, Saad Ragab PART 11: Process Reagents .............................................................617 Challenges in the Beneficiation of Complex Problematic Ores—Case Studies: Phosphates, Sulphides, and Coal ..................................................................617 P. Somasundaran, P. Patra, D.R. Nagaraj Interfacial Chemistry Features of Selected Fluorite Surfaces ..................................627 Xia Zhang, Xuming Wang, Xihui Yin, Hao Du, Jan D. Miller Sulfonate Reagents for Processing Industrial Minerals .......................................635 Guoxin Wang, Sam H. Sutherland, Zhengxing Gu Second Generation of Slime Collectors for Potash ..........................................643 Jan-Olof Gustafsson Applications of Custofloat Collectors in Processing Phosphate Ores from Different Countries .......649 Guoxin Wang, Zhengxing Gu, Sam Sutherland Versatile Uses of Alkyl Hydroxamate in Kaolin Beneficiation Technologies: Flotation, Selective Flocculation, and Magnetic Separation ...................................................655 S.A. Ravishankar, Sheng Jiang, Rajesh Raitani PART 12: Modeling and Process Control ..................................................667 Recent Advances in Modeling, Simulation, and Control of Mineral Processing Operations ..........667 John A. Herbst, Brian Flintoff Paradigm Shift in Advanced Control for Mining ...........................................681 R.K. Jonas, I.A. Craw © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. Contents vii Selection of the Best Control Valve for Flotation Column and Flotation Cell Control, and Choosing the Best Method of Controlling Thickener Underflow ............................689 Todd Loudin Modeling Ball Mills and Semi-Autogenous Mills with Impact Energy Spectra-Based Population Balance Concept ...........................................................695 E. Tugcan Tuzcu, Raj K. Rajamani, Bharada Mishara Development of a Model-Based Flotation Simulator ........................................699 Kyle Kelley, Aaron Noble, Gerald Luttrell, Roe-Hoan Yoon Dynamic Model-Based Flotation Performance Monitoring ...................................709 Osvaldo Bascur Use of a Chemical Transport Code for the Prediction of Gold Heap Leach Production ..............719 Alexander A. Shchipansky, Jianwei Xiang, Robert J. Sterrett, Allen J. Schindler Index ................................................................................729 © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012. Preface The Mineral and Metallurgical Processing Division (MPD) of the Society for Mining, Metallurgy and Exploration, Inc. (SME), organized the International Symposium on “Separation Technologies for Minerals, Coal, and Earth Resources” as part of the 2011 SME Annual Meeting in Denver, Colorado. The symposium provided an international forum where leading scientists and engineers presented and discussed new develop- ments pertaining to separation technologies for various earth resources. The symposium was held in honor of Dr. Roe-Hoan Yoon for his lifelong dedication to all colleagues and students, his leadership and directorship of the Center for Advanced Separation Technologies, and his scientific contributions to the mining industry that have furthered the understanding of mineral and coal processing as well as water and resource engineering. Manuscripts were submitted for publication just prior to the meeting and were reviewed by the session chairs and subsequently by the program organizers to ensure quality. A wide variety of subjects is covered including Coal Processing, Surface Forces and Hydrophobicity, Process Improvements and Environmental Controls, Dewatering and Drying, Gravity Separations, Industrial Minerals Flotation, Base Metal Flotation, Flotation Equipment and Practice, Process Reagents, Magnetic and Electrostatic Separations, Modeling and Process Control, and Resource Engineering. This monograph is intended to provide new information not only for the processing of minerals and coal as the more traditional earth resources but also to address current issues with new resources such as gas hydrates, oil sands, secondary materials, metals, and the environment, particularly waste and process waters. Not only does this information help companies develop earth resources more economically while simultane- ously addressing factors ranging from sustainability to environmental stewardship, it also covers such diverse topics that these proceedings are cross disciplinary and thereby offer solutions for one that could be applied to others. Section Editors Surface Forces and Hydrophobicity Process Improvements and Environmental Controls Liquang Wang and Anh Nguyen John Sabey and Corby Anderson Dewatering and Drying Industrial Minerals Flotation Ramazan Asmatulu and Barbara Arnold Michael Mankosa and Derek Novotny aBase Metal Flotation Coal Processing Jinhong Zhang and Michael Moats Jaisen Kohmuench and Van Davis Flotation Equipment and Practice Gravity Separations Asa Weber and Paul Keyser Rick Honaker and John Cole Process Reagents Magnetic and Electrostatic Separations S.A. Ravishankar and Guoxin Wang Ian Sherrell and Tim Sheehan Modeling and Process Control Resource Engineering Mike Randolph and Tom Hildebrande Zhenghe Xu and Jae Lee ix © 2012 by the Society for Mining, Metallurgy, and Exploration. All rights reserved. Electronic edition published 2012.

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Most books are stored in the elastic cloud where traffic is expensive. For this reason, we have a limit on daily download.