Separation Technologies for Minerals, Coal, and Earth Resources

756 Pages·2012·41.625 MB·English

by  Edited by Courney A. Young and Gerald H. Luttrell

SEPARATION TECHNOLOGIES
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FOR MINERALS, COAL, AND EARTH RESOURCES
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EDITED BY COURTNEY A. YOUNG AND GERALD H. LUTTRELL OA TECHNOLOGIES
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Separation Technologies for Minerals, Coal, and Earth Resources is I
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an authoritative digest of the latest developments in the mineral
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processing industry.

FOR MINERALS,
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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
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Dozens of authors share their insights on how practitioners can develop RNE COAL, AND EARTH
earth resources more economically while simultaneously addressing TR
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vital factors ranging from sustainability to environmental stewardship. RL
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S, C RESOURCES
The book examines coal processing, surface forces and hydrophobicity, OO
process improvements and environmental controls, dewatering and UA
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drying, gravity separations, industrial minerals fl otation, base metal C,
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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.
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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
[phone] / [phone]
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.