Original Research Paper
Mineral Processing
Chol Ung Ryom; Kwang Hyok Pak; Il Chol Sin; Kwang Chol So
Abstract
Shaking table and flotation are often used in scheelite (CaWO4) beneficiation, and usually they are applied in sequence. In this paper, analysis of mineral movement have been investigated in shaking table in which pulp was conditioned with xanthate as a collector and fed, heavy scheelite was concentrated, ...
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Shaking table and flotation are often used in scheelite (CaWO4) beneficiation, and usually they are applied in sequence. In this paper, analysis of mineral movement have been investigated in shaking table in which pulp was conditioned with xanthate as a collector and fed, heavy scheelite was concentrated, while heavy pyrite removed directly on the deck by the action of collector. Artificially mixed mineral with 1% scheelite and 2% pyrite was used in CFD simulations and experiments. Through CFD simulations, it was found that pyrite particles, which were hydrophobic by collector, were attached to the water-air interface and subjected to upward buoyancy, which increased the density difference between scheelite and pyrite particles and enabled the separation of both minerals in the shaking table. The experiment results showed that the concentrate grade in conventional table concentration was 23.5% WO3, the separation efficiency was 77.89%, while the concentrate grade of scheelite in the table concentration of xanthate presence was 65.0% WO3 and the separation efficiency was 80.88%. The combination of flotation in table with collector addition not only eliminated the flotation to remove pyrite after table but also resulted in a lower rate of scheelite loss.
Original Research Paper
Mineral Processing
Chaimae Loudari; Moha Cherkaoui; Imad El Harraki; Rachid Bennani; Mohamed El Adnani; EL Hassan Abdelwahed; Intissar Benzakour; François Bourzeix; Karim Baina
Abstract
Energy efficiency and product quality control are critical concerns in grinding mill operations, particularly within the innovative context of Mine 4.0. This study introduces a novel Genetic Algorithm (GA)-based optimization framework specifically developed to address these challenges. Given the mining ...
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Energy efficiency and product quality control are critical concerns in grinding mill operations, particularly within the innovative context of Mine 4.0. This study introduces a novel Genetic Algorithm (GA)-based optimization framework specifically developed to address these challenges. Given the mining industry’s significant energy consumption, especially in grinding processes, the proposed approach optimizes key parameters such as feed composition, water flow rates, and power consumption levels, while maintaining sieve refusal near the target threshold of 20%. Using real operational data from a Moroccan plant, the GA achieved a Mean Absolute Error (MAE) of 0.47, outperforming Simulated Annealing (SA) and Particle Swarm Optimization (PSO), which yielded MAEs of 1.14 and 0.74, respectively. The GA also demonstrated superior convergence stability and robustness, as evidenced by lower variability in predicted power consumption. These results validate the effectiveness of the GA framework in navigating nonlinear, high-dimensional parameter spaces and improving energy efficiency while ensuring product quality consistency. Ultimately, this research confirms the potential of metaheuristic optimization in enhancing grinding mill efficiency and supports the broader shift towards intelligent and sustainable mining operations under the Mine 4.0 paradigm.
Original Research Paper
Mineral Processing
Ayman M. Ibrahim; Han Wang; Nazar Mekawi; Jaber A. Yousif; Emadeldin Adam; Alfarouq Alnoor; Mohammed Kabashi; Dianwen Liu
Abstract
This work investigates the surface enrichment of malachite during sulfurization flotation to enhance copper recovery. The goal is to improve flotation efficiency by modifying malachite’s surface properties through sulfurization, using sodium sulfide as the sulfurizing agent. The effects of pre-treatment ...
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This work investigates the surface enrichment of malachite during sulfurization flotation to enhance copper recovery. The goal is to improve flotation efficiency by modifying malachite’s surface properties through sulfurization, using sodium sulfide as the sulfurizing agent. The effects of pre-treatment reagents on flotation recovery were evaluated, focusing on their impact on the surface chemistry of malachite. The findings indicated that malachite treated with ammonium sulfate ((NH₄)₂SO₄) exhibited superior flotation recovery compared to ammonium phosphate ((NH₄)₃PO₄), achieving an optimal recovery rate of 87.5%. FESEM-EDS and ToF-SIMS analyses revealed a significant increase in sulfur species on the surface, promoting the formation of copper sulfide (CuS) films and enhancing the mineral's reactivity during flotation. Theoretical solution chemistry calculations corroborated these findings, showing that ammonium salt treatments facilitate the formation of copper-ammonium complexes, stabilizing copper ions in solution and preventing their precipitation as copper hydroxides or carbonates. By maintaining copper in a stable reactive form, these complexes improve flotation efficiency. Both theoretical calculations and experimental observations confirm that stabilizing copper ions is crucial for enhancing flotation, ensuring copper remains available for interaction with flotation reagents and ultimately, improving copper recovery. The integration of theoretical and experimental approaches enhances the understanding of the sulfurization process and provides an optimized method for improving flotation performance and copper recovery.
Review Paper
Mineral Processing
Mona Mohamed Fawzy; Mahinaz Shawky; Ahmed Ismail; Mostafa Bayoumi; Hassan Shahin; Bahaa Emad; Ahmed Orabi; Gehan Ali; Ahmed Abdelmouty; Mohamed Diab
Abstract
In response to rising global demand for critical minerals and the need for environmentally responsible resource utilization, this study explores sustainable recovery methods from low-grade placer deposits in the Wadi Rahba area along the Southern Coast of the Red Sea of Egypt. The focus is on the beneficiation ...
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In response to rising global demand for critical minerals and the need for environmentally responsible resource utilization, this study explores sustainable recovery methods from low-grade placer deposits in the Wadi Rahba area along the Southern Coast of the Red Sea of Egypt. The focus is on the beneficiation of ilmenite and titanite as primary valuable minerals. Twenty-eight samples, including a composite technology sample, were analysed using XRD, SEM-EDX, and ED-XRF techniques. Results indicate that total heavy mineral (THM) content ranges from 4.5% to 17.7%, averaging approximately 10%, with 11% in the composite sample. Identified valuable minerals include titanite, ilmenite, leucoxene, zircon, magnetite, and rutile, alongside high concentrations of heavy silicate minerals such as epidote, pyroxene, and amphiboles. Estimated contents are 0.44 wt.% titanite, 0.15 wt.% ilmenite, and trace amounts of zircon (0.04 wt.%), spessartine (0.01wt.%), and magnetite (0.29 wt.%). To enhance recovery, a combination of gravity separation (Wilfley shaking table) and magnetic separation techniques (LIMS and HIMS) were applied. These methods effectively concentrated titanite and ilmenite, achieving recovery rates of 85.08% and 79%, respectively. The findings highlight the potential for economically viable extraction from low-grade sources using environmentally sustainable physical upgrading techniques.
Original Research Paper
Mineral Processing
Sajad Kolahi; Mohammad Jahani Chegeni; Asghar Azizi
Abstract
In Part 2 of this research work, five types of liners, i.e. wave, step, step@, ship-lap, and ship-lap@, are examined. These liners all have similar connected lifters with different volumes. Their difference is in the width, height, and type of the lifter profile. All the five liner types, from 8 to 64 ...
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In Part 2 of this research work, five types of liners, i.e. wave, step, step@, ship-lap, and ship-lap@, are examined. These liners all have similar connected lifters with different volumes. Their difference is in the width, height, and type of the lifter profile. All the five liner types, from 8 to 64 lifters, are simulated using the Discrete Element Method (DEM). In this research work, for the first time, data from the sum of the kinetic and potential energies of individual balls (79,553 particles) are used to find the appropriate range for the number of lifters. In other words, the kinetic and potential energies of all particles within the system (inside the ball mill) are the basis for determining the appropriate number of lifters. The results suggest that for the wave liner, the appropriate range of the number of lifters is between 8 and 16, for the step, step@, and ship-lap liners; it is between 12 and 20, and for the ship-lap@ liner, it is between 8 and 20. In fact, using the data on the kinetic and potential energies of the balls inside the mill, it is possible to determine the appropriate range of the number of lifters, which is done for the first time in this study. In general, it is suggested that the data on the kinetic and potential energies of the balls can be used to determine the number of mill lifters, and unlike what has been done. So far, by other researchers, the number of mill lifters should not be determined solely by using its diameter or the dimensions of the lifters. Also the effect of mill-rotation direction on the values of kinetic and potential energies in step and ship-lap liners is investigated. It is shown that the step@ and ship-lap@ liners transfer more energy to the balls than the step and ship-lap liners, and have a suitable direction of rotation.
Original Research Paper
Mineral Processing
Meysam Nikfarjam; Ardeshir Hezarkhani; Farhad Azizafshari; Hamidreza Golchin
Abstract
Geometallurgical modeling (GM) plays a crucial role in the mining industry, enabling a comprehensive understanding of the complex relationship between geological and metallurgical factors. This study focuses on evaluating metallurgical varibles at the Sungun Copper mine in Iran by measuring and predicting ...
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Geometallurgical modeling (GM) plays a crucial role in the mining industry, enabling a comprehensive understanding of the complex relationship between geological and metallurgical factors. This study focuses on evaluating metallurgical varibles at the Sungun Copper mine in Iran by measuring and predicting process properties, including semi-autogenous power index (SPI), recovery (Re), and concentration grade. To overcome the additivity limitations of geostatistical methods, we utilized machine learning algorithms for enhanced predictive modeling, aiming to improve decision-making and optimize mining operations in geometallurgy. The research incorporates crucial data inputs such as sample coordinates, grades, lithology, mineralization zones, and alteration to assess the accuracy and reliability of different machine learning regression methods. The Relative Standard Deviation (RSD) is highlighted as a significant metric for comparing the accuracy of predicted process properties. Evaluation metrics such as Root Mean Square Error (RMSE), Mean Absolute Error (MAE), and coefficient of determination (R2) further confirm the superiority of specific modeling methods in certain scenarios. The K-Nearest Neighbors (KNN) method exhibits superior accuracy, lower error metrics (RMSE and MAE), and a higher R2 for modeling the SPI test. For modeling Cu grade in concentrate, Support Vector Regression (SVR) proves to be effective and reliable, outperforming the Multilayer Perceptron (MLP) method. Despite MLP's high R2, its higher RSD suggests increased uncertainty and variability in the predictions. Therefore, SVR is considered more suitable for modeling Cu grade in concentrate. Findings optimize operations at Sungun Copper mine, improving decision-making, efficiency, and profitability.
Original Research Paper
Mineral Processing
Hosein Najmaddaini; Mostafa Maleki Moghaddam; Saeid Zare; Masoud Rezaei; Mohammad Ali Motamedineya; Gholamreza Biniaz
Abstract
AbstractThe structural characteristics of mill liners, such as lifter shape and mill speed, significantly influence the grinding process. At the Sarcheshmeh slag flotation plant, the 6×6 meters SAG mill was initially equipped with 48 rows of liners, designed in a Hi-Lo configuration for the first ...
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AbstractThe structural characteristics of mill liners, such as lifter shape and mill speed, significantly influence the grinding process. At the Sarcheshmeh slag flotation plant, the 6×6 meters SAG mill was initially equipped with 48 rows of liners, designed in a Hi-Lo configuration for the first half and a Lo-Lo configuration for the second. Throughout the mill shell liner's 1700-hour operational period, monitoring identified 30 failures. Investigations revealed that defects in the liner design and improper charge motion were the main causes. This study proposes modifications and standardization of the shell liner design, tailored to the specific circuit conditions, to enhance performance and reliability. The redesign included several key changes: 1) Reducing the number of rows: The number of liner rows was decreased from 48 to 32. 2) Adjusting lifter angle: The lifter angle was increased from 23 to 30o to optimize performance. 3) Eliminating Hi-Lo design liners: The Hi-Lo design liners were changed to Hi-Hi, and 4) Reducing liner variety: The variety of liners was streamlined from 5 types to 2. The installation of the proposed liners optimized the charge trajectory for grinding, resulting in higher liner's lifetime. It extended the liner life by 30% and eliminated liner failures, reducing them from 30 to zero. The wear rate for the proposed design was 0.05 mm/hour, while the original design had a wear rate of 0.11 mm/hour. This difference corresponds to a factor of 2.3 times improvement.
Original Research Paper
Mineral Processing
Fatemeh Kazemi; Ali akbar Abdollahzadeh
Abstract
This research work aims to explore the intricate mineralogy and texture of the tailing piles of iron ore processing plants to present a particle-based prediction for magnetite recovery. Three samples were taken from different points of tailings piles of an iron ore processing plant. Davis tube tests ...
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This research work aims to explore the intricate mineralogy and texture of the tailing piles of iron ore processing plants to present a particle-based prediction for magnetite recovery. Three samples were taken from different points of tailings piles of an iron ore processing plant. Davis tube tests were performed on each sample under various operating conditions. Process mineralogy studies were conducted to determine the mineralogy modal of the feed and product of each test. An Artificial Neural Network (ANN) model was used to make a model that related the grade and recovery of magnetite in the product to the mineralogy modal of the tailing piles. The magnetite grade and association index of feed, the magnetic intensity, and the water flow rate were the inputs to this network. The grade and magnetite recovery correlation coefficients were 0.954 and 0.86, respectively. The grade of magnetite in the feed emerged as a limiting factor on the grade and recovery of magnetite in concentrate. An increase of one unit in magnetite grade in the feed resulted in a 1.68 decrease in the recovery. The association index changes with the coefficients of -0.173 cause the changes in predicted magnetite recovery in the concentrate.
Original Research Paper
Mineral Processing
Hossna Darabi; Faraz Soltani
Abstract
The main characteristic of mechanical flotation cells is to have an impeller, which is responsible for creating particle suspension, gas dispersion, and producing turbulence necessary to create effective bubble-particle interactions. For this purpose, in this paper, the conditions for complete gas dispersion ...
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The main characteristic of mechanical flotation cells is to have an impeller, which is responsible for creating particle suspension, gas dispersion, and producing turbulence necessary to create effective bubble-particle interactions. For this purpose, in this paper, the conditions for complete gas dispersion in a Denver laboratory flotation cell have been investigated. Then, the critical impeller speed has been investigated for quartz particles with different size fractions. The effect of complete dispersion of introduced gas and critical impeller speed on the flotation rate constant (k) of particles was investigated. The results showed that k was the minimum value at an impeller speed of 700 rpm in the superficial gas velocity of 0.041- 0.125 cm/s for all size fractions. The impeller speed of 700 rpm was sufficient to keep -106µm quartz particles suspended, but at all superficial gas velocities, the minimum impeller speed required for complete gas dispersion was 850 rpm. Therefore, it can be stated that the reason for the low k value at a stirring speed of 700 rpm is the incomplete distribution of bubbles and particles (+106µm), resulting in a reduced probability of air bubbles colliding with solid particles. By increasing the impeller speed to values greater than 700 rpm, the k value increased, which is due to the complete distribution of particles and air bubbles in the flotation cell (increased probability of bubble-particle collision). Therefore, it is necessary to provide suitable operating conditions for the complete dispersion of air bubbles and also to keep solid particles suspended.
