OpenUCT :: Browsing by Department "Centre for Minerals Research"

Browsing by Department "Centre for Minerals Research"

Now showing 1 - 20 of 23

Open Access
Approximate solution of melt depth inside titanium during laser materials processing
(2015) Ngwenya, Dineo; Kahlen, F J
The use of lasers has increased in areas of science, engineering and medicine. Their advantages over the traditional methods of thermal application are their ability to localize thermal treatments, ability to deliver high power density and to complete thermal processes in extremely short time periods. During the irradiation of a material, only a portion of the laser beam energy is absorbed. If the absorbed energy is high enough, melting can occur. The ability to predict, thus control the melting process is an advantage to manufacturing processes such as laser welding, surface re-melting and alloying. Using analytical approaches that are already in existence, this research adapts a mathematical model to approximate temperature profiles as well as isothermal depths given a single laser pulse. In order to assess the error associated with the adapted model, laser irradiation experiments are carried out on CP titanium samples using a focal spot of 600 μm and nitrogen gas as the shielding gas at a flow rate of 5 l/min. The effects of some important laser processing parameters on the melt depth are discussed. The adapted model approximated that the melt depth increases with both increasing laser power and increasing pulse duration. Furthermore, the experimental results revealed that it is the combination of short pulses and a high laser power that yields melt zones that are relatively free of porosity, craters and cracking. Additionally, an assessment of the error associated with the adapted model revealed that the adapted model generally overestimates the experimental data with increasing laser pulse duration. At a combination of 0.1s and 1200W (representing a combination of short laser pulse and high laser power) the error of approximation was 59%. The error increased to 90% at a combination of laser parameters 5s and 600W (representing a combination of a long laser pulse and low laser power). It is recommended that future studies be undertaken to improve modelling accuracies for a wider range of laser processing parameters.
Open Access
Assessing the effects of the cone force ratio on the performance of hydrocyclones
(2009) Lusinga, D; Augombe, J; Mainza, A
Hydrocyclones are a common feature in almost all mining operations in the world, serving mainly as classifiers. Some of their advantages include low capital costs, low space requirements and their ability to reduce residence time in closed circuit grinding processes. Although an extensive body of literature exists for hydrocyclones, these devices are still inherently inefficient, and more research is currently being undertaken, particularly in the field of modelling. In the vast body of hydrocyclone literature published so far, there has been little or no effort devoted to analysing the effect of the cone force ratio on the performance of ydrocyclones. The cone force ratio is defined as the ratio of the spigot to the vortex finder diameter (Shah, 2005). In this study a total of 44 tests was carried out in a custom-built rig at the University of Cape Town. These tests were aimed at evaluating the effect of the cone force ratio on the performance of a small diameter hydrocyclone. The cut size and water split were used as the criterion for evaluating the performance of the ydrocyclone. Results from the tests showed that the cut size decreased with an increase in the cone force ratio. The cut size also appeared to decrease as the calculated locus of zero vertical velocity (LZVV) shifted inwards. The water recovery to the underflow appeared to increase with an increase in the cone force ratio. The effect on the cut size of adjusting the cone force ratio was found to be higher for a coarser feed than it was for a finer feed.
Open Access
Assessing the influence of lifter profiles on the velocity profile and the charge toe and shoulder using data from the PEPT system
(2013) Hartmut, Brodner; Mainza, Aubrey
The research focus of this thesis is lifter height effect on different charge characteristics. Thecharge characteristics identified were shoulder and toe angle, charge size and toe height. Anattempt was made to develop a model for the velocity profile incorporating lifter height.Therefore the objectives of the study are to: •Determine the effect of lifter height on the velocity profile using the particle tracking data. •Determine the effect the lifter height on the charge shoulder and toe. •Develop a velocity profile model including lifter height using granular flow theory and to compare the model to experimental data. The motivation for the study is that lifters are one of the most important design variables in a mill. Without lifters the mill’s energy efficiency would decrease. In Meaders & MacPherson, (1964) the effect of lifters on energy was quantified to be between 20% and 30%. The lifters control the height and angle of departure from the charge at the mill shell and therefore control the impact area and magnitude. The area and magnitude of the charge impact will affect the grind of the mill and energy utilization in the mill. The thesis was also aimed at generating data that can be used to model the velocity profile that can be incorporated in power models. Most of the power models do not account for the effect of lifters. The experiments involved collecting data from three dimensional particle tracking of selected particles in the charge. using the PEPT system. The PEPT experiments were conducted at IThemba Labs in Cape Town South Africa using a 300 mm x 285 mm experimental mill. The charge used for the experiments were glass beads with an approximate specific gravity (SG) of 2.7. The PEPT system operates by tracking the x, y and z coordinates with respect to time of an irradiated particle (tracer). The experiments were run under different conditions to evaluate the effect of the lifter height. The experiments were operated by varying mill speed (55%, 70% and 85%), mill fill (20%, 30% and 40%) and lifter heights (1.5 mm, 3 mm, 6 mm and 10 mm).
Open Access
The development and demonstration of a practical methodology for fine particle shape characterisation in minerals processing
(2016) Little, Lucy; Becker, Megan; Mainza, Aubrey; Wiese, Jenny
Due to continually declining ore grades, increasing mineralogical complexity, and increasing metal demand, models for the design and optimisation of minerals processing operations are of critical importance. These models do not currently incorporate particle shape, which, although rarely quantified, is known to affect numerous unit operations. Automated Scanning Electron Microscopy (Auto-SEM-EDS) is a widely used tool for mineralogical analysis. It also provides an opportunity for simple, quantitative and mineral-specific shape characterisation. Existing mineralogical databases could therefore become useful resources to facilitate the incorporation of shape effects in minerals processing models. A robust Auto-SEM-EDS shape characterisation methodology is required to ensure that the particle shape information in these databases is interpreted appropriately. For this work, a novel methodology for Auto-SEM-EDS shape characterisation was developed that is suitable for the analysis of fine particles (<75 μm). This involved testing the response of various shape descriptors to image resolution, and measurement with different devices and image processing routines. The most widely used shape descriptor in minerals processing, circularity, was found to be highly dependent on both image resolution and image processing settings, making it a poor choice for shape characterisation of fine particles. Roundness and aspect ratio were found to be more robust descriptors. However, in the interest of being able to compare particulate shape measurements across different studies, the precise definition of aspect ratio is important as variation in 'length' and 'width' definitions can significantly impact aspect ratio measurements. The possibility that preferential orientation of particles would introduce bias to the 2-D cross-sectional measurements was also addressed through comparison of roundness distributions measured from orthogonal cross-sections of a particulate sample mounted within a block of resin. The excellent repeatability of these measurements indicated that the particles were randomly orientated, and thus it can be inferred that 2-D measurements of a sufficient number of particles will be directly related to the particulate sample's 3-D properties. Roundness and aspect ratio were then used in conjunction to produce surface frequency distributions that allow for distinction between non-rounded particles that were smooth and elongated and non-rounded particles that were neither elongated nor smooth. Three applications of the shape characterisation methodology developed were then demonstrated, which highlighted some of the potential contributions that this methodology can make towards minerals processing. The applications were all based on a case study of the Upper Group 2 (UG2) Chromitite, a platinum group mineral (PGM) ore of key economic significance to South Africa.
Open Access
The effect of energy input on flotation kinetics
(2018) Safari, Mehdi; Deglon, David A
SYNOPSIS Energy/power input in a flotation cell is an important parameter which, if optimised, can increase the flotation rate. The optimum energy/power input within a flotation cell is still a matter of conjecture and there is a need for a better understanding of the effect of energy input on flotation kinetics. This study investigates the effect of energy/power input on flotation kinetics in an oscillating grid flotation cell (OGC). The OGC decouples the processes of solid suspension and bubble generation as well as producing relatively isotropic and homogeneous turbulence with zero mean flow. Due to this, oscillating grids provide a potentially ideal environment for investigating the effects of energy input on flotation kinetics, which cannot be achieved in a mechanical flotation cell. The first objective of this thesis was to determine the effect of energy/power input on the flotation kinetics of sulphide minerals (galena, pyrite & pentlandite) and oxide minerals (apatite & hematite) in a laboratory scale oscillating grid flotation cell. The second objective was to compare the results from the laboratory OGC to comparative studies in the flotation literature and to fundamental models for particle-bubble contacting. The third objective was to determine whether the experimental results from the laboratory OGC are consistent with those from a pilot-scale OGC operating on a platinum ore. Galena, pyrite, pentlandite (-150 μm), apatite (-650 μm) and hematite (-75 μm) were floated in the laboratory OGC at energy inputs from 0.1 to 5.0 W/kg, using 0.13, 0.24, 0.58 and 0.82 mm bubble sizes (d₁₀), and at three collector dosages. Platinum ore (-75 μm) was floated in the pilot-scale OGC at energy inputs from 0 to 2.5 W/kg, using 0.71 and 1.47 mm bubble sizes (d₁₀). The effect of energy input on flotation kinetics was interpreted through trends in experimental flotation rate constants, simulated flotation rate constants and attachment-detachment flotation rate constants. Here, simulated flotation rate constants were calculated using a literature fundamental model for flotation in turbulent systems. This model is based on suitable expressions for the collision frequency, collision efficiency, attachment efficiency and stability efficiency, Attachment-detachment flotation rate constants were calculated using a kinetic model which allows for the two separate processes of bubble-particle collision/attachment and detachment. This model is based on kinetic expressions using empirical correlations for the attachment and detachment rate constants. Experimental flotation results show that the effect of energy input on the flotation rate is strongly dependent on the particle size and particle density and less dependent on bubble size and contact angle. Flotation rates generally increase with increasing particle size, decreasing bubble size and increasing contact angle, as is commonly found in the literature. Increasing energy input generally leads to an increase in the flotation rate for fine particles, an optimum flotation rate for intermediate particles and a decrease in the flotation rate for coarse particles. The optimum in the flotation rate for minerals with higher density is at a lower energy input than that for lower density minerals. The changes (increases/decreases) in the flotation rate with increasing energy input are very large for most of the conditions, indicating that this is an important parameter in flotation. Pilot scale results generally support the trends observed in the laboratory OGC. These findings are attributed to the effect of energy/power input on bubble-particle collection which is a balance between two competing effects, those of bubble-particle collision/attachment and those of bubble-particle detachment. Increasing energy input generally leads to significant increases in the flotation rate of fine particles, due to increased bubble-particle collision/attachment. Increasing energy input generally leads to an optimum flotation rate for intermediate particles, due to a combination of increased bubble-particle collision/attachment and detachment. For coarse particles, increasing energy input leads to significant increases in bubble-particle detachment. The relationship between the flotation rate and energy input is often described as k  ɛᴺ, in the absence of significant bubble-particle detachment. The typical values of N are in the range of 0.44-0.75 for theoretical studies and 0.7-1 for experimental studies. The values of N found in the current study are in the range of 0.7-1, which suggests that bubbleparticle collision/attachment has a stronger dependence on energy input than theory suggests. Simulated flotation results for fine particles compare well to the experimental data in terms of both trends and magnitude. This suggest that the turbulent collision model used is appropriate for fine particles. For intermediate particles there are differences between the simulated flotation rate constants and the experimental data, primarily in terms of trends. For coarse particles there are very large differences between simulated flotation rate constants and the experimental data. This is attributed to under prediction of the collision frequency/efficiency and incorrect prediction of the stability efficiency. Here, the stability efficiency is considered to be under predicted at low energy inputs and over predicted at high energy inputs. This suggests that the stability efficiency has a much stronger dependence on energy input than theory suggests. Attachment-detachment results show that the attachment rate constant has a stronger dependence on energy input than theory suggest, supporting finding from the experimental results and simulated results for coarser particles. In addition, the detachment rate constant has a much stronger dependence on energy input than theory suggests, supporting findings from both the experimental and simulated results. Based on the objectives of this study and literature reviewed, the following hypotheses were made at the outset 1) Increasing energy/power input will increase the rate of flotation of fine particles but will result in an optimum for intermediate and coarse particles. The position of this optimum will depend on the particle density, bubble size and contact angle. 2) Fundamental models based on the RMS turbulent velocity will be appropriate for describing flotation kinetics as turbulence in the oscillating grid cell is relatively homogeneous and isotropic and 3) Trends in flotation results for a laboratory and pilot-scale oscillating grid flotation cell will be comparable as the distribution of turbulence in OGCs at equivalent specific power inputs is scale independent. Hypothesis 1 was found to be valid for both fine and intermediate particles, but for coarse particles increasing energy input resulted in sharp decreases in the flotation rate. In addition, the increase in the flotation rate with increasing energy input was found to be more dependent on the particle size and particle density than the bubble size and contact angle. Hypothesis 2 was found to be valid for fine particles but not for intermediate or coarse particles. Here, it was found that the processes of bubble-particle collision/attachment and detachment have a stronger dependence on energy input than theory suggests. Hypothesis 3 was supported by general trends in results for the laboratory and pilot-scale oscillating grid flotation cells, but was not convincingly demonstrated.
Open Access
The effect of energy input on flotation kinetics in an oscillating grid flotation cell
(2012) Changunda, K; Deglon, David; Harris, Martin
Energy is known to play an important role in particle-bubble contacting in flotation. This thesis investigates the effect of energy input (or agitation) on the flotation kinetics of quartz in a novel oscillating grid flotation cell. The effects of bubble size and particle size have been recognized as important variables affecting particle-bubble contacting in turbulent systems and are investigated in this thesis. The research work done in this thesis is a continuation of the work done by the Centre for Minerals Research by Deglon (1998) who investigated the effects of energy in a batch mechanical flotation cell. However, this system has a very complex hydrodynamic environment, resulting from the large disparities in turbulence intensity. Previously Breytenbach (1995) had constructed a hybrid flotation column cell, which was essentially a column flotation cell that could be modified into a Jameson cell or a mechanically agitated column cell. He used this to compare particle collection efficiency in these different particle-bubble contacting environments. The third phase of the work was the oscillating baffle column (OBC), a novel flotation column that attains agitation by oscillating a set of orifice baffles through the slurry, thereby producing a more uniform shear rate distribution than would be obtained in an impeller driven system (Anderson, 2008). The OBC unfortunately has significant oscillatory flow and has high shear rates, which often result in detachment effects becoming appreciable. Oscillating grids generate near ideal hydrodynamic environments, characterised by turbulence that is relatively homogeneous and isotropic. The oscillating grid flotation cell used in this study was based on the oscillatory multi-grid mixer used by Bache and Rasool (2001). The oscillatory multi-grid mixer was purchased from these authors and retrofitted to produce the oscillating grid flotation cell. The novel oscillating grid cell consists of a 10 litre tank agitated by 19 grids with a mesh size of 8 mm and grid spacing of 18 mm. The grids were oscillated at a fixed amplitude, equal to the grid spacing, and over a range of frequencies, using a variable speed drive. Frother was added at 100 ppm to be consistent with the work of Deglon (2002) and Ahmed and Jameson (1985). A low gas flow-rate (100 ml/min) and solids concentration were specifically chosen in order that there was minimal influence on the structure of turbulence in the oscillating grid cell, as Bache and Rasool (2001) took measurements in water. Flotation tests were performed on methylated quartz particles (P80 = 100 Î¼m) over a range of power intensities (0.015â€“0.60 W/kg) and using three different bubble sizes, generated by sintered glass discs (0.13, 0.24 and 0.82 mm). The flotation rate constant was found to increase approximately linearly with increasing particle size for all three bubble sizes. This was due to the increased probability of collision for larger particles and is well established in the flotation literature. A number of researchers have found that the flotation rate constant for quartz particles increases almost linearly with particle size, at low power intensities. An inverse power relationship was observed between bubble size and flotation rate constant for all fine, middling and coarse particle size ranges. This inverse power relationship was due to the increased probability of collision for smaller bubbles and is also well established in the flotation literature. More significantly, the flotation rate constant was found to increase almost linearly with increasing power intensity for all particle and bubble sizes used in this study. The majority of theoretical and experimental studies have found energy input to have less of an effect than the proportional/linear dependence observed in this study. In addition, the increase in the flotation rate constant with increasing power intensity was observed to depend on particle size, but to be less dependent on bubble size. These findings suggest that energy input and bubble size may respectively play more and less of a role in promoting particle-bubble contacting in turbulent environments than was noted in the flotation literature. However, a recent study by Newell and Grano (2006) done using a stirred tank also noted this linear dependence. Given the findings of this thesis, it is strongly recommended that further work be done to investigate the OGC at higher energy intensities (~3W/kg) and to scale it up so that it can be more comparable to the widely used mechanical flotation cells. The homogeneous and nearly isotropic turbulence generated by the OGC also makes it an ideal environment to characterize floatability for different ores.
Open Access
An electrochemical and leach study of the oxidative dissolution of chalcopyrite in ammoniacal solutions
(2016) Moyo, Thandazile; Petersen Joachim
Chalcopyrite is not only the most abundant of the copper sulphides, but also the most stable, making it recalcitrant to hydrometallurgical treatment processes especially in atmospheric leaching. Hence, pyrometallurgical processes are traditionally used to treat chalcopyrite concentrates. However, ore grades are falling and concentration processes are becoming increasingly costly, prompting need to revisit hydrometallurgical treatment processes (especially heap leaching), which are otherwise regarded as relatively economic and environmentally friendly. Key hydrometallurgical processes for chalcopyrite treatment are ferric sulphate, chloride and ammoniacal systems. The ferric sulphate system does not work well under atmospheric conditions, except in combination with thermophilic microorganisms, whereas the chloride system has only recently been evaluated more seriously for heap leach processes. The ammonia system remains relatively unexplored and most studies date back more than 40 years, but the system has considerable potential for further development. Ammonia systems can be effectively used to leach copper from chalcopyrite in the presence of an oxidant. The ammoniacal leaching system is heavily reliant on a good surface mass transfer system, hence it being widely studied in high pressure systems where oxygen was accepted to be the oxidant. Leach reactors were designed to use agitation systems which promote the abrasion of an iron based deposit layer thought to passivate the mineral surface. Most research on the ammonia leaching systems has previously been carried out in controlled or bulk leaching studies and only a few used electrochemical studies. A disconnect exits between the two approaches, resulting in different proposed fundamental reaction mechanisms and kinetic understanding. A fundamental electrochemical and controlled leach study of the oxidative leaching of chalcopyrite in ammoniacal solutions has been undertaken. The study covered the following aspects: a description of the mixed potentials, chemistry and kinetics of the anodic reaction, the cathodic reduction of the oxidants, the formation and effect of surface deposits and lastly a look at how results from electrochemical studies compare to those from the leaching of a similar mineral sample under similar solution conditions. A detailed study of the mixed potentials on a more or less pure chalcopyrite electrode has shown the redox reactions on the surface of the mineral to be controlled by the oxidation of chalcopyrite and reduction of copper(II). The presence of oxygen has been found to have no significant effect on mixed potentials in ammoniacal solutions in the presence of initial copper(II). Constant potential and potentiodynamic studies on the anodic reaction have shown the rate of the anodic reaction to increase with an increase in potential in a standard 1M ammonia/ammonium sulphate solution (which buffers at pH 9.6) in exponential fashion supporting conventional Butler-Volmer behaviour with a anodic transfer coefficient of 0.42 and a rate constant k* CuFeS2 of 0.0431 cms⁻¹. Increasing total ammonia increased the rate of reaction only at low concentrations; at higher concentrations increasing total ammonia had no effect on the anodic reaction. An increase of pH at fixed total ammonia concentration showed an increase in reaction rate, but the effect cannot clearly be discerned from the concomitant shift in relative proportion of free NH₃ and NH₄⁺. Coulometric studies have shown the oxidation reaction to proceed via the formation of a thiosulphate intermediate and this to be a 7-8 electron transfer reaction. A surface deposit layer consisting of iron, oxygen and small quantities of sulphur was formed and the sulphur component of this product layer was seen to be gradually depleted during leaching. Anodic currents were found to gradually decrease with time and this was linked to the growth of the surface deposit layer. However, the surface deposit layer did not passivate the anodic reaction; instead, it was proposed that the surface deposit layer adsorbed copper ions and displayed "ohmic" behaviour. The formation of the surface deposit layer was found to apparently promote the cathodic reduction of copper(II). While reduction of copper(II) was shown to be the primary reduction reaction, the presence of oxygen was seen to promote this reduction reaction through the regeneration of copper(II) in experiments that ran for longer time periods. An apparent accumulation of copper(I) on the mineral surface was seen to adversely affect the rate of the cathodic reaction and thus the overall rate of dissolution. The nature and morphology of the surface layer was found to be significantly influenced by the choice of cation in solution, which was thought to influence primarily the complexation/precipitation of ferric species forming near the surface. The degree of agitation during leach studies influences the rate of leaching due to the fragmentation of surface deposits, which are seen to slow the anodic reaction. A kinetic model has been developed for the anodic and cathodic reactions. This thesis presents significant new findings regarding the role of the copper(I)/copper(II) redox couple on the oxidative leaching of chalcopyrite. It also highlights the potentially limiting role of the cathodic reactions which have frequently been overshadowed by the focus on chalcopyrite oxidation reactions. Furthermore, the growth of a surface inhibiting layer which cannot be removed in heap leach systems due to the lack of mechanical agitation can now potentially be addressed by looking into the complexation and precipitation characteristics of cations in solution for ammoniacal leach systems.
Open Access
An electrochemical investigation of platinum group minerals
(2015) Tadie, Margreth; Corin, Kirsten; Wiese, Jenny
The Bushveld complex is the largest ore body in the world hosting platinum group elements (PGEs). It is a stratified orebody with three major reefs namely, the Merensky reef, UG2 reef and the Platreef. Platinum and palladium are the most abundant PGEs found in the Bushveld complex. They occur in the form of minerals/mineral phases with elements such as sulphur, tellurium, arsenic and iron. These minerals/mineral phases are associated with base metal sulphides occuring along grain boundaries. Unlike the Merensky and UG2 reef, the Platreef is almost barren of PGE sulphides and the distribution of base metals sulphides and their association with PGMs is erratic. Froth flotation targeted at the recovery of base metal sulphides is implemented in PGM concentrators to concentrate PGMs. Flotation of sulphide minerals is achieved with the use of thiol collectors to create hydrophobicity, and copper sulphate is often used to improve hydrophobicity and therefore recovery. Sodium ethyl xanthate (SEX) and sodium diethyl dithiophosphate (DTP) are commonly used as collectors on PGM concentrators. The erratic mineral variations in the Platreef ore, however, raise the question of the effectiveness of the application of sulphide mineral flotation techniques on this ore. Previous work by Shackleton, (2007) investigated the flotation of PGE tellurides, sulphides and arsenides. The study highlighted that the mechanisms with which these minerals interact with collectors and with copper sulphate was poorly understood. It is as a result of the findings of Shackleton's work that this study aims to elucidate the fundamental interactions of telluride and sulphide PGMs with thiol collectors and with copper sulphate. Subsequently this work also aims to compare the behaviour of these reagents on sulphide PGMs and telluride PGMs.
Open Access
Fracture mechanics based fatigue and fracture toughness evaluation of SLM Ti-6Al-4V
(2015) Dhansay, Nur Mohamed; Tait, Robert B; Becker, Thorsten
The focus of this research project was to determine experimentally the fatigue and fracture toughness characteristic, from a fracture mechanics perspective, of Ti-6Al-4V titanium alloy manufactured by Selective Laser Melting (SLM). Three build orientations are considered where a fatigue crack is grown parallel and two are grown perpendicular to the build orientation. The project then endeavours to generate a fracture mechanics based Paris equation from the fatigue crack growth rate results and together with the fracture toughness, fatigue life predictions may be determined based on crack propagation lifetimes. SLM is an Additive Manufacturing (AM) technique whereby an object is fabricated in a layerwise manner via the use of lasers, directly from a 3D CAD model. This process allows for the manufacture of complex designs in its net or near net shape form, which is not possible with conventional manufacturing techniques. There are minimal amounts of material wastage and it potentially eliminates post manufacture machining and processing costs. Ti- 6Al-4V is used in many applications where high strength at low density is required at moderate temperatures. Corrosion resistance qualities of the alloy are also considered for many applications. Some of the applications where this alloy is used include turbine engine components, aircraft structural components, aerospace fasteners, high-performance automotive parts, marine applications, medical implant devices and sports equipment. Due to the large use of the alloy in industry and with the potential benefits of manufacturing by SLM, there is a great need for investigating SLM Ti-6Al-4V as a viable alternative to conventional casting, forging and machining. There is limited literature covering the fatigue crack growth rate and fracture toughness of SLM Ti-6Al-4V and the effect of build orientation on these characteristics. However, it is clear, from the limited available literature that fatigue crack growth rate behaviour is affected by build orientation, and so this project investigates the effect of these orientations, and aims to contribute to understanding why these orientation effects occur. Since there is even less literature available on the fracture toughness of SLM Ti-6Al-4V with respect to build orientation, this project also endeavours to characterise orientation effects on fracture toughness, if any, and compares these with those of conventionally manufacture Ti-6Al-4V.
Open Access
The influence of slurry viscosity on hydrocyclone performance
(2012) Waters, Jason G; Mainza, Aubrey; Govender, Indresan
Many of the empirical hydrocyclone cut size models available consider the feed solids content to be an important variable in determining the efficiency and resultant classification. However, feed viscosity as a whole is admittedly a more accurate variable to consider as it can be affected by many factors, including solids content, particle size distribution, particle size, mineralogy, pulp chemistry, particle shape and carrier fluid temperature. Earlier theoretical models did try to incorporate slurry viscosity but were developed for very low solids content systems due to the difficulty in measuring slurry viscosity at higher concentrations. Current hydrocyclone models being applied in industry have difficulty in predicting rheological fluctuations at constant solids content, for example with an increase in feed clay content. Investigations, focussed on expanding the studies of previous researchers in this area, were conducted. Experiments involved the design and operation of two test rigs incorporating three hydrocyclone sizes (75,100, 165 mm), with two different ore types (platreef ore, copper ore) from a secondary stage operation used as the feed material. A change in relative viscosity was investigated by altering the viscosity of the carrier fluid (water) by the addition of sucrose, and modification of the slurry temperature. Hydrocyclone feed flow rate and solids content were also modified. A custom made on-line tube rheometer allowed viscosities of feed concentrations of up to 43% (by vol.) to be measured over a range of shear rates (200/s to 1500/s). The slurries under investigation were found to be settling in nature, and therefore a decision was made to exclude data below the critical settling velocity of the tube. Rheological characterisations revealed both ore types exhibited Bingham plastic behaviour. A concentration versus viscosity relationship was determined from the rheological data and the resultant viscosity values were then linked to hydrocyclone efficiency. The significant findings of this work included the following: * Increased pulp viscosity achieved by 1) sucrose addition and 2) decreased slurry temperatures resulted in a drop in hydrocyclone performance attributed to the combined effect on the partition curve parameters namely - an increased cut size (d50c), decreased water split to O/F (C) and reduced value of alpha. *Increased pulp viscosity achieved by 3) feed solids content had dissimilar effects on the partition curve parameters. An optimum viscosity point was reached for water split to O/F and alpha parameters, however cut size increased with increased pulp viscosity. * Rheological effects on the cut size parameter appeared more significant for the largest of the three cyclone body diameters used in the study. This can be attributed to the decreased tangential velocities inside the larger cyclone radius. The combined rheology and hydrocyclone data from this thesis will provide useful validation data for the new hydrocyclone models currently being developed as part of the P9 project. The models are to be incorporated in the JKSimMet simulation package and consider the effects of viscosity in their equations for cut-size and water split.
Open Access
Investigating collector and depressant performance in the flotation of selected iron ores
(2016) Mhonde, Ngoni Pepukai; Wiese, Jenny; McFadzean, Belinda
As the excessive extraction of high grade iron ore reserves has led to the rapid depletion of these ore bodies, there is a growing need to extract and upgrade low grade iron ores into more economically viable products with an iron content in excess of 50%. The beneficiation of low grade iron ores through the reverse cationic flotation procedure is gradually gaining popularity as a possible processing route of the future for South Africa's iron industry. Reverse cationic flotation employs a reagent suite consisting of an amine compound which functions as a quartz collector in addition to providing the frothing effect in the flotation system, and hydrolysed starch which serves to depress hematite during flotation. The aim of this project was to investigate the effect of using five amine collectors with different molecular structures on the flotation recovery of quartz and the entrainment of hematite in the flotation of a South African iron ore and a Brazilian iron ore. Laboratory batch flotation tests were conducted on both ore samples and the grade and recovery of hematite were recorded. The collectors were characterised through surface tension measurements and pKa value analysis. An attempt at using different polysaccharides as hematite depressants entailed the use of a CMC and a guar gum in batch flotation tests of the Brazilian iron ore.
Open Access
Investigating the potential of using hydrocyclone-fine screen hybrid systems to improve the performance of classification circuits
(2017) Muketekelwa, Saliya L; Mainza, Aubrey; Bepswa, Paul Aaron
Classification is an integral part of comminution operations that controls the performance of the circuit. Hydrocyclones are normally used to perform the classification function. They offer numerous advantages that include, the ability to handle high throughputs, low floor space occupation and relatively low capital and running costs. Despite these advantages, hydrocyclones are inherently inefficient classifiers as they are predominantly dependent on hydrodynamics to effect separation. This effect is more prominent in operations handling complex ores such as a dual-density ore, where the heavy fine particles are misplaced to the underflow and the lighter middling particles report to the overflow. Several attempts have been made to improve the separation efficiency of cyclones either by modification of the cyclone or use of multi-stage cycloning. Most of the results obtained from experimental and simulation studies have shown considerable improvements. Even though some have not yet found wide application in the minerals industry due to practical limitations related to control and unstable operations. More recently, fine screening has gained recognition in the classification role. This development has allowed the use of fine screens in closed-circuit grinding operations resulting in significant metallurgical and economic benefits. Screens provide a sharper cut at the desired size and reduce the fraction of fines bypassing classification compared to hydrocyclones but have capacity limitations at smaller apertures. In an effort to mitigate the classification challenges of both the hydrocyclone and fine screen, this study investigated the potential of combining the high throughput performance of the hydrocyclone operation and the high precision classification characteristics of fine screening to result in a hybrid classification circuit Plant scale tests were conducted using five different classification circuit configurations at an operational Base Metal Concentrator treating a polymetallic ore. The classification circuit configurations considered included (i) a two-stage hydrocyclone with primary underflow reclassification (ii) an inclined hydrocyclone, (iii) a fine screen and (iv) selected permutations of hybrid circuit designs that included a hydrocyclone-fine screen (2 stage) and two hydrocyclones-fine screen (3 stage) variants of the hybridised configurations. The efficiency curves and their respective key performance indicators were used to assess the performance of the circuit configurations tested. The results showed that classification circuits that included fine screens exhibited higher sharpness of separation compared to circuit configurations comprised of hydrocyclones. The fine screen configuration showed the sharpest separation while the hydrocyclone-fine screen hybrid configurations gave relatively higher separation efficiencies than the configurations with hydrocyclones only. The overall sharpness of separation values obtained for the two stage and three-stage hybrid circuits were 3.0 and 2.4, respectively. The two-stage hydrocyclone and inclined hydrocyclone circuits had sharpness of separation values of 1.7 and 0.5, respectively. The inclined hydrocyclone circuit configuration performed the poorest. Furthermore, the two-stage hybrid circuit showed a higher degree of separation compared to the three-stage hybrid configuration. However, it was observed that a finer corrected cut size was realised for the three-stage hybrid circuit design. The fishhook effect was seen at particle sizes less than 38μm for the configurations incorporating a fine screen and an inclined hydrocyclone. Notably, the effect appeared to be more pronounced in configurations involving a fine screen stage. The results have shown that application of hybrid classification configurations can improve the performance of classification circuits. In addition, reclassification of hydrocyclone underflow on fine screens will results in a sharper classification while reclassifying the overflow stream on fine screens will provide a clean circuit final product. An evaluation of the capital and operating costs associated with fine screens should be done to determine the economic feasibility of incorporating the units in conventional milling circuits.
Open Access
Investigating the rheological behavior of Witbank coal water mixtures
(2016) Owusu Gyebi, Prince; Deglon, David
South Africa has large low-grade coal reserves. With the prospect of expanding its coal demands for exports and power generation, it is important that the beneficiation and transport of coal in the country are economical. The current mode of transporting coal has some drawbacks, which include inefficient rail infrastructure, long distances, and several environmental concerns related to air pollution, water pollution, and traffic risks. It is, therefore, important to investigate efficient means of coal transportation, which will also reduce environmental impacts. The transport of highly concentrated coal-water slurries through pipelines has attracted the attention of many researchers as an efficient and economical means of fine coal utilization. The primary objectives of this study are to investigate the importance of surface charge, solids concentration and particle size on the stability and rheological behaviour of Witbank coal. This work was carried out to arrive at a sounder discernment of the function of dispersion addition on coal-water mixtures rheology and stability.
Open Access
An investigation into the relationship between electrochemical properties and flotation of sulphide minerals
(2016) Chimonyo, Wonder; Corin, Kirsten; Wiese, Jenny
There is a growing importance in the mineral processing industry to find ways which are economic and effective in improving the recovery of minerals in the flotation process. The focus of this study was on the recovery by flotation of minerals found in the Merensky reef, which is one of the major reefs in the Bushveld complex. In that reef, base metal sulphide (BMS) minerals are commonly associated with PGMs and this has an effect on the way in which these minerals are concentrated by flotation (Vermaak et al. 2004; Wiese et al. 2005b; Miller et al. 2005; Schouwstra et al. 2000).A major problem in this process has been reported to be losses of valuable minerals (PGMs) associated with the loss of BMS (Wiese et al. 2005b), during flotation. The present investigation has focused on studying the relationship between the flotation of sulphide minerals using xanthates as collectors and the electrochemical properties of the flotation system. It is well known that electrochemical mechanisms in flotation systems have a major influence on flotation since the reactions occurring at the mineral/solution interface are of critical importance in the process (Woods, 1971).The aim of this study was to investigate the extent to which there was a relationship between the electrochemical reactions occurring in this ore which could indicate the effectiveness of the flotation process. The electrochemical reactions were studied by determining the redox potential changes occurring when various changes were made. These were the length of the alkyl chain length of the xanthate collector, changing the pH or using various chemical reagents to change the potential of the system. It was found from the rest potential measurements, that collectors of different chain length have different extents of interaction with mineral surface. A greater interaction, which is indicated by a greater change in the mixed potential after addition of the collector, is considered to be indicative of a greater adsorption of the collector at the mineral surface. It was hypothesized that this stronger adsorption by collectors of longer alkyl chain length would result in improved flotation performance. However, this was not observed to be the case and that was consistent with previous results on the relationship between the recovery of sulphide minerals in the Merensky ore and xanthates of different chain lengths. Thus it was shown that there was no correlation between the interactions between collectors of different alkyl chain lengths as determined through electrochemical studies and the flotation performance of valuable minerals under the tests conditions used.
Open Access
Investigation of operating parameters in a vertical stirred mill
(2016) Edwards, Garren Chad; Van der Westhuizen, Andries P P
Due to the depletion of coarser grained ores, more mineralogically complex ores are being treated. These complex ores usually have finer grained valuable minerals. Liberation of these finer grained valuable minerals lies in grinding finer. Grinding to these fine sizes is energy intensive and using standard ball mills are energy inefficient at these sizes (P80 < 75μm). Therefore, stirred mills are becoming increasingly prevalent in the mineral processing industry. In order to optimize these mills, the effects and mechanisms of the significant variables need to be understood. This project investigated operating parameters against performance in a laboratory scale vertical stirred mill (Deswik mill), in an ultrafine grinding (UFG) application of MG2 reef in the bushveld igneous complex. The operating variables that were investigated are stirrer speed, solids concentration, media size and media filling. The Kwade stress energy model was tested on the grinding results. The grinding performance was quantified in two ways, i.e. grinding efficiency and grinding rate. The grinding performance for this study was also investigated through a statistical analysis. The experiments was designed using a face centred central composite design (FCCD) and the results was statistically analysed using a design of experiments (DOE) software.
Open Access
Measuring the fracture energy of bed breakage using a short impact load cell
(2017) Dube, Thobile Thenjiwe; Bbosa, Lawrence Sidney
Particle fracture is the elementary process that governs comminution. In industrial machines particle breakage occurs mainly through three mechanisms: impact, abrasion and attrition. Of these mechanisms, impact breakage is known to be the most basic form of particle size reduction. Comminution devices are highly inefficient, as the energy used for particle breakage relative to that consumed by the equipment is low and reported to be between 1-2 %. As such, understanding the fundamentals of particle fracture is crucial for the development of energy efficient particle size reduction methods. Research done towards investigating particle fracture under impact loading has led to the development of several devices which include the twin pendulum device, drop weight tester, Split Hopkinson Pressure Bar, Rotary Breakage Tester and the Short Impact Load Cell. In this study the Short Impact Load Cell (SILC) was used to conduct bed breakage experiments on partially confined particles. Breakage tests using this device were conducted by vertically releasing a steel ball of known mass onto a bed of particles from a known height. The bed rested on a steel rod which was fitted with strain gauges to measure the particle response to impact loading. Tests were conducted on two ores, blue stone and UG2, to investigate the effect of three variables: steel ball mass, drop height and bed depth on the breakage behaviour of particles. The effect of each variable was investigated by evaluating the peak forces obtained, the particle fracture energy and the degree of particle breakage attained. For both ores it was found that the peak force increased linearly with increasing steel ball mass and drop height, and it was found that the drop height had a greater effect on the peak force than the steel ball mass. The maximum peak forces were obtained at one layer of particles and increasing the bed depth generally led to a reduction in the peak force. An exponential relationship was found between the peak force and bed depth, where the peak force decreased with increasing bed depth. It was found that the blue stone particles did not break at the range of input energies used in this work, therefore no fracture energy results were reported for blue stone. The fracture energy values for UG2 were low, where the maximum energy used for particle fracture was 2.7 % of the input energy. There was no direct correlation between the fracture energy and the steel ball mass, drop height and bed depth; however it was found that the bed depth had a larger effect on the fracture energy compared to both the steel ball mass and drop height. The greatest amount of energy used for fracture was generally obtained at the largest input energies using the 357 and 510 g balls. The optimum drop height which resulted in the highest fracture energy was generally found to be either 240 or 300 mm. A bed depth of five layers was found to be the optimum bed depth that allowed for the highest amount of energy to be utilized for breakage. No breakage results were obtained for blue stone due to the hardness and stiffness of the ore. For UG2, tests conducted at the same bed depth showed a trend in which the breakage initially increased greatly with increasing input energy; however at larger input energies the breakage obtained approached a constant value. Although the input energy was varied by changing both the steel ball mass and the drop height, the results showed that the degree of breakage was more dependent on the steel ball mass compared to the drop height. For all tests conducted, the maximum breakage was obtained at one layer of particles and increasing the bed depth led to a decrease in the breakage obtained. The results showed that the fracture energy and the degree of breakage were not directly related. It was found that there is an optimum amount of energy utilized for fracture that leads to the greatest breakage, where an in increase in the energy beyond the optimum point does not significantly affect the breakage obtained.
Open Access
Performance of the vertical roller mill in a mineral processing application when coupled with internal and external classifiers
(2021) Little, Warren; Mainza, Aubrey; Becker, Megan
Comminution is applied in all mineral processing plants where mineral liberation is needed for separation and concentration of valuable minerals. The process is energy intensive and is predominantly carried out in tumbling mills which are known to be highly inefficient. Comminution technologies utilised in other industries, such as the vertical roller mill (VRM), a high compression dry grinding device, have the potential to contribute towards enhancing the energy efficiency of comminution and the sustainability of mineral processing. The vertical roller mill is used extensively in cement and coal grinding applications, where it is known to be more energy efficient than traditional tumbling mills. The VRM has a larger reduction ratio and greater flexibility in terms of product quality control and throughput. However, in the majority of operations where the vertical roller mill is applied, the device is coupled with an internal dynamic air classifier. These classifiers are significantly more energy intensive than other classifiers typically used in the mineral processing industry. Operating the vertical roller mill with less energy intensive classification devices could have the potential to further reduce the total comminution circuit energy. Reducing the comminution energy usage in mineral processing is important, however there are other factors which also need to be considered before the vertical roller mill can be considered as a viable alternative to tumbling mills. The effect of grinding with the vertical roller mill on product quality and mineral liberation, and their impact on downstream processing is of critical importance and has not yet been extensively investigated. This study investigates the grinding of the platinum group mineral (PGM) bearing Platreef ore, in a pilot scale vertical roller mill. The research explores the effects of milling variables and methods of classification on the mill performance, energy consumption, throughput, product characteristics and flotation response. The energy efficiency of the vertical roller mill and product flotation response is also compared with that of a traditional ball milling circuit. Vertical roller mill products of three target grinds, typical to primary, secondary and tertiary grinds in PGM circuit, were generated with the VRM operated in the standard airflow mode, with the internal dynamic air classifier, for a variety of grinding pressures (an online control used for maintaining product quality), and dam ring heights (a design variable affecting residence time on the grinding table). The specific grinding energy for the vertical roller mill was found to increase as the target grind became finer, conforming to general comminution theory. Vertical roller mill specific grinding energies were lower than those for a ball mill at all product sizes, and when estimates of classification energy and scale-up of the VRM are included, the specific energy for the vertical roller mill is up to 35% lower than for a ball mill in closed circuit. Grinding at higher pressures yielded greater throughputs and was found to generate products of less steep particle size distribution (PSD), but did not affect specific grinding energy. The effect of varying dam ring height was found to be target grind dependent. Higher dam rings yielded products with a greater proportion of fines, for higher specific grinding energies with the differences more pronounced at coarser target grinds. The grinding component of the vertical roller mill was operated in conjunction with three classification devices - the internal dynamic air classifier, external hybrid air classifier and an external vibrating screen. The external air classification circuit had a lower throughput than the internal air classification circuit, and operated with a 20 - 40% higher specific grinding energy. When including pilot scale estimations for classification energy, the external air classification circuit overall specific energy is lower at intermediate and coarse grinds, and comparable at finer target grinds, to that of the internal air classification circuit. The specific grinding energy in the VRM - external screening system was higher than both air classification circuits, however when considering the lower energy intensity of screening, this circuit may prove more efficient. The flotation response of the tumbling mill product and the vertical roller mill product prepared under different operating conditions in circuits with different classification devices was assessed using a standard reagent suite, in terms of platinum, palladium, gold (3E PGE), and copper, nickel (Cu, Ni) concentrate grades and recoveries. Both vertical roller mill and tumbling mill products yielded greater recoveries as the products became finer and valuable mineral liberation increased. The vertical roller mill products however had substantially higher recoveries, which was linked to higher froth recoveries and differences in oxidation potential within the flotation pulp. Increasing the compressive force in the VRM through the application of higher grinding pressures led to an increase in fines causing a decrease in froth stability during flotation, which corresponded with lower valuable metal recoveries. Variation in dam ring height caused small decreases in discrete PGM liberation but an increase in effective PGM liberation (considering PGMs liberated and locked in floatable base metal sulphide minerals). Flotation recoveries followed changes in froth stability with products prepared at the highest dam ring height, which had greater fines contents, yielding lower valuable metal recoveries. An optimised reagent suite for VRM products should be developed to address issues with froth stability caused by the increase in fines component at higher grinding pressure and dam ring heights. This will allow for the improvements in valuable mineral liberation with these grinding conditions to be realised as increased flotation recoveries. When operating the VRM grinding components with different classification devices, flotation performance was influenced by variation in the particle size distributions of products. External and internal air classification products with closely comparably particle size distributions yielded similar 3E PGE flotation recoveries. Flotation recoveries were however lower for the finest external air classifier product, which had a less steep PSD. A similar difference in PSD was observed for the screening vertical roller mill circuit products, which also had lower flotation recoveries than products generated with the internal dynamic air classifier. The research indicates that the vertical roller mill is able to efficiently prepare material for valuable mineral concentration through flotation. The effects that the vertical roller mill variables grinding pressure and dam ring height have on operation and the comminution product has been investigated. Furthermore the VRM has been successfully coupled with different classification devices to generate a product with flotation response better than that of tumbling mill products.
Open Access
Rheological effects on gas dispersion in a pilot scale mechanical flotation cell
(2013) Shabalala, Ntokozo Zinhle Precious; Deglon, David A; Harris, Martin
Froth flotation is a separation method used for the beneficiation of a considerable portion of the world's mineral ores. The majority of flotation occurs in mechanical flotation cells, where effective gas dispersion is a primary requirement for particle-bubble contacting. Due to the mineralogical complexity of ores, it is required that particles be ground even finer to liberate valuable minerals. Mining operations tend to run flotation circuits at fairly high solids concentrations in order to maximise residence time, accommodate higher tonnages and limit water consumption. Mineral slurries processed at fine particle sizes and high solids concentrations have been shown to exhibit non-Newtonian rheological behaviour. The effect of slurry rheology on gas dispersion in a 100 litre mechanical flotation cell was investigated by varying the solids concentration. The study was conducted using kaolin, Bindura nickel and Platreef slurries. All three ores displayed typical non- Newtonian rheological behaviour where the slurry yield stress and viscosity increased exponentially with solids concentration. Bubble size varied from 0.55 to 1.10 mm for all the ores tested. At low solids concentration bubble size was found to decrease with impeller speed, a characteristic trend that was expected. At moderate solids concentrations bubble size was found to either increase/remain relatively constant with impeller speed; this trend was also expected. Unexpectedly, at the highest solids concentration, a dramatic decrease in bubble size was observed. This unexpected drop in bubble size was attributed to slurry rheology. It was also observed that there was a slight increase in bubble size at the highest solids concentration with increasing impeller speed. This increase was attributed to a trade-off relationship between the rheology of the slurries and the existing hydrodynamics (as a result of the rotating impeller). Gas hold-up varied from 2 to 15% across all the ores tested. At low solids concentrations gas hold-up increased with impeller speed as expected. At moderate solids concentration gas hold-up was viewed to either increase/remain relatively constant with impeller speed. A significant drop in gas hold-up was observed at the highest solids concentration. The gas hold-up however still increased with impeller speed albeit at a lower rate at the highest solids concentrations. This drop in gas hold- up at the highest solids concentration (along with the decrease in bubble size) was attributed to the effect of slurry rheology. At high solids concentrations, all three slurries (kaolin, Bindura nickel and Platreef) exhibit non-Newtonian behaviour illustrated by means of high viscosities and yield stresses. High viscosities result in turbulence damping in the cell which inhibits bubble break-up, resulting in larger bubbles and correspondingly lower gas hold-up. It was concluded in this study that the yield stress is the dominant rheological property due to the significant changes observed with increasing solids concentration. High yield stresses resulted in the formation of a 'cavern' of slurry around the impeller region. Within this 'cavern', high power intensities exist around the impeller where small bubbles are formed. However due to the formation of the 'cavern', the slurry in the bulk cell remains relatively stagnant. As a result small bubbles formed around the impeller remain localised in the 'cavern' and cannot be dispersed throughout the cell. This localization and poor dispersion of bubbles resulted in low gas hold-ups.
Open Access
Scale-up behavior of the froth stability measurement
(2018) Geldenhuys, Armand Stefan; Mcfadzean, Belinda
Froth flotation is a widely used physio-chemical separation method in the minerals processing industry. Two distinct phases are present, namely: the pulp and froth phase. Flotation research has heavily focussed on the pulp performance; however only recently it was found that the froth performance contributes significantly to the overall flotation performance. Numerous parameters have been investigated to accurately quantify froth performance with the most notably being froth recovery. That being said, experimentally gathering data to obtain froth recovery is challenging and prone to large experimental errors. For this reason, the stability of the froth phase has been highlighted as a possible characterisation tool. Froth stability is defined as the time of persistence of the froth and is usually measured using either a dynamic and/or static methodology. Although measurement of froth stability has become common place in numerous flotation research articles, little to no attention has been given to the scale-up behaviour of the measurement. It is easily thought of that a froth constrained within a froth column will behave significantly different to one in an industrial flotation cell. Two common scale parameters, froth column diameter and initial pulp bubble size, was chosen to illustrate the dependence of the current methodology on scale. This does not mean that there are not vastly more parameters that would affect the measurement (column material of construction and/or column shape); however, these are two of the most easily changed parameters from experimental setup to setup. Four different column diameters were used for this study. Column diameter experiments were done on an industrial scale by means on manual tracking of froth growth versus time. Pulp bubble size experiments was performed on a laboratory scale by using different pore size glass frits while maintaining a constant superficial gas velocity. Dynamic stability for the pulp bubble size experiments were done by means of video tracking of froth growth versus time. The column diameter data sets highlighted similar behaviour – an increase in measured dynamic stability is seen with increasing column diameter up until a maximum is reached. This behaviour was attributed to the fact that wall films are thought to drain much faster than interstitial Plateau borders. As the column diameter decreases, the relative ratio of column surface area to bulk area increases and therefore results in an increased drainage rate a subsequently less stable froth. An empirical relationship was proposed to correct for the column diameter effect which is based on a ratio of bubble size to column diameter. The pulp bubble size data sets highlighted similar behaviour – an exponential decrease in measured dynamic stability is seen with increasing pulp bubble size. This behaviour was attributed to two fundamental mechanisms occurring within larger bubbled froths. Firstly, an increase in drainage rate as well as change in the drainage regime is seen as a function of bubble size; where in general froths of larger bubble sizes drain significantly faster. Secondly, on average froths consisting of large bubbles will have less water per volume of froth due to the decrease in bubble surface area. The effect of water content in a froth is well known and it can be said that wet froths experience less coalescence and bursting events. Therefore, the combination of the two mechanism is put forth as an explanation of the observed behaviour of the experimental systems.
Open Access
The Solution Interaction of Tetrathionate Ions and Sodium Isobutyl Xanthate and Its Effect on the Flotation of Galena and Chalcopyrite
(2021-02-15) Mhonde, Ngoni; Pitkänen, Leena; Corin, Kirsten; Schreithofer, Nóra
Tetrathionates have been found in significantly high concentrations in recycled process waters from massive sulphide ore processing plants. These polythionates react with xanthate added to flotation pulps thus reducing xanthate dosages in solution potentially affecting flotation performance. The current study focused on the effect of the tetrathionate-xanthate reaction on sulphide mineral recoveries. Ore dissolution studies confirmed the generation of tetrathionates by copper-lead-zinc ores. In 20 min, the tetrathionates consumed more than half of the xanthate in solution at pH 7. Rest potential measurements and Fourier transform infrared spectroscopy (FTIR) showed that the degree of collector-mineral interactions of xanthate and both galena and chalcopyrite was greatly reduced in the presence of a 2000 mg/L tetrathionate solution. Microflotation tests showed that chalcopyrite recovery was less sensitive to tetrathionates as indicated by small changes in mineral recoveries. Galena was sensitive to the action of tetrathionates on the mineral surface as the galena recovery significantly declined when floated with xanthate as a collector in both a 500 mg/L tetrathionate solution and a 2000 mg/L tetrathionate solution. These fundamental results lay a sound base on which more discussion into the significance and the effect of tetrathionates on flotation performance of sulphide ores can be developed.