Modeling of an Automatic Optimization System of Cyanide Concentration in Carbon in Leach for Optimal Ore Processing in a Mining Company

The optimization system, which was the subject of our study, is an autonomous chain for the automatic management of cyanide consumption. It is in the phase of industrial automation which made it possible to use the machines in order to reduce the workload of the worker while keeping a high productivity and a quality in great demand. Furthermore, the use of cyanide in leaching tanks is a necessity in the gold recovery process. This consumption of cyanide must be optimal in these tanks in order to have a good recovery while controlling the concentration of cyanide. Cyanide is one of the most expensive products for mining companies. On a completely different note, we see huge variations during the addition of cyanide. Following a recommendation from the metallurgical and operations teams, the control team carried out an analysis of the problem while proposing a solution to reduce the variability around plus or minus 10% of the addition setpoint through automation. It should be noted that this automatic optimization by monitoring the concentration of cyanide, made use of industrial automation which is a technique which ensures the operation of the ore processing chain without human intervention. In other words, it made it possible to substitute a machine for man. So, this leads us to conduct a study on concentration levels in the real world. The results show that the analysis of the modeling of the cyanide consumption optimization system is an appropriate solution to eradicate failures in the mineral processing chain. The trend curves demonstrate this resolution perfectly.

Leaching kinetics of acid-soluble Cr(Ⅵ) from chromite ore processing residue with hydrofluoric acid

Leaching kinetics of acid-soluble Cr（VI） in chromite ore processing residue （COPR） using hydrofluoric （HF） acid solution as a leaching agent was investigated for potential remediation of COPR with industrial waste water containing HF. The results show that HF can effectively destabilize the Cr（VI）-bearing minerals, resulting in the mobilization of Cr（VI） from COPR into the leachate. Particle size significantly influences the leaching of acid-soluble Cr（VI） from COPR, followed by leaching time, whereas the effects of HF concentration and leaching temperature are slight and the influence of stirring rate is negligible. The leaching process of acid-soluble Cr（VI） from COPR is controlled by the diffusion through the product layer. The apparent activation energy is 8.696 kJ/mol and the reaction orders with respect to HF concentration and particle size is 0.493 8 and -2.013 3, respectively.

Distribution Characteristics of Minerals and Elements in Chromite Ore Processing Residue

In this paper, environmental scanning electron microscopy （ESEM） is applied to characterizing the mineral and element distribution of chromite ore processing residue （COPR）. The test results show that Cr-bearing brownmillerite occurs in the rim of COPR particle, while hydroandradite with Cr （Ⅵ） in its structure presents inside the COPR particle. Periclase and calcite occur in the interstitial area. Element analyses show that Ca, Fe and Al are distributed throughout the COPR particle, and Mg exists mostly in the interstitial area or on the particle surface. A lower content of Cr is evenly distributed in the COPR particle, while slightly higher concentration of Cr occurs inside the particle. It is suggested that it will take a relatively longer time for Cr to migrate out of COPR, especially fbr hexavalent chromium, so the leaching time and the particle size may be two important factors to affect the release of Cr （Ⅵ）.

Speciation and spatial distribution of Cr in chromite ore processing residue site,Yunnan,China

Remediation of COPR sites requires the key information including chromium oxidation, speciation and spatial distribution. Samples were gathered from a COPR site in Luliang County in Qujing, Yunnan Province of China. The total Cr, Cr(VI) and chromium species were investigated. Results indicated the concentration of total Cr was between 110.5 and 21,774 mg/kg, and the concentration of Cr(VI) was between 0.1 and 1075 mg/kg. The map of total-Cr and ratio of Cr(VI)/total-Cr(%) showed that the maximum of total-Cr and Cr(VI) appeared in the layers near the surface. In the horizontal direction, the pollution was more serious in the middle and southeast part than that in the west. Additionally, acid extractable chromium increased in the layers at depth from-0.3 to-2.0 m, and it decreased in the deeper layers. There was a trend that the movable Cr(VI) migrated to the deeper layers, and then it turned into Cr(III). Water played an important role for the Cr distribution. Cr(VI) in COPR released to the soil solution after rainfall, and then gravity led the solution down to the deeper layers. After repeated rainfall and leaching,Cr(VI) moved to the deeper soil layers. Due to capillarity and evaporation, Cr(VI) migrated and was enriched at thesurface layer. Therefore, measures on controlling water movement should be taken in the remediation of the COPR site.

XRF Standardless Comparison of Mining Head and Tail Grades to Screen and Display Ore Processing Recoveries

Separation of target elements or minerals from their host rock or ore is essential to successful mining operation. The inevitable loss of a portion of the desired material that accompanies each step in the extraction process must be documented to develop the operational protocol. Superposition of the characteristic X-ray fluorescence spectra of head (crushed rock ore particles, pre-processing) and tail (post-processing particles) samples provides a direct visual comparison of relative peak sizes, and thereby the relative concentrations, of elements of interest. If the head and tail peaks are identical, none of the element was recovered in the extraction process. At the other extreme if the tail peak “flat lines”, i.e., there is no peak, there was 100% recovery of that element. Standardless visual comparison is valid if the same mass of identical starting material is incorporated into the head and tail sample analysis pucks, and XRF analytical conditions are identical. The considerable time and expense of acquiring and calibrating the standards associated with XRF analysis of 75 or more elements are avoided, a significant advantage during initial broad screening of an experimental extraction procedure. Full quantitation by XRF or an alternate technique can proceed at a later project stage, if desired. The approach retains and presents all features of the original data, thus eliminating questions about data quality, standards and their calibration, and data manipulation in processing from raw counts to concentrations in printout tables. This form of display is ideal for both the mining professional and such less technical groups as corporate staff, investors, regulators, and the public. Examples presented herein are for heap leaching;the protocol can be applied as well to any of the other traditional ore processing and beneficiation procedures, e.g., gravity concentration, magnetic and electrical separation, froth flotation, and ore sorting.

Chromium steel from chromite ore processing residue——A valuable construction material from a waste

As species we humans generate excessive amounts of waste and hence for sustainability we should explore innovative ways to recover them.The primary objective of this study is to demonstrate an efficient and optimum way to recover chromium and iron from chromite ore processing residues(COPR)for the production of chrome steel and stainless steel.In Hudson County,New Jersey,there are more than two million tons of leftover COPR.Part of COPR was used as fill materials for construction sites,which spread the problem to a larger area.With high solubility along with their toxicity leached chromate from COPR is threatening the environment as well as human health.In this research,COPR was thermally treated to recover iron with chromium by applying techniques used in steel manufacturing.An extensive experimental program was performed using a Thermo-Gravimetric Analyzer(TGA)and bench scale tests to thermally treat the processed chromium contaminated soils with carbon and sand at varying temperatures and under reducing environment.The optimum chemical composition of COPR and additives to be used in the melts were evaluated based upon the thermodynamic properties of the mixture to ensure good phase separation,least amounts of iron and chromium oxides in the slag and minimum variability of final product(steel or iron with chromium).The impact of other oxides on the steel making process was evaluated to minimize the adverse impact on the process.The research demonstrated the feasibility of recovering a valuable construction material(chrome steel)from a waste(COPR).

Extraction of Cr(Ⅵ) from chromite ore processing residue via hydrothermal-assisted phase transformation

The effective extracting Cr(Ⅵ) from chromite ore processing residue(COPR) is the key to achieve COPR detoxification and recovery.We developed an effective method to extract Cr(Ⅵ) from COPR via controlling the phase transformation of Cr(Ⅵ)-containing minerals.Characteristic analysis showed that Cr(Ⅵ) was mainly incorporated in the hydrocalumite(NaCa4Al2O6(SO4/CrO4)1.5-15H2O) in COPR,which was a layered-double hydroxide(LDH) with multilayer structure.In the hydrothermal treatment experiments,the Na2CO3 solution showed significant extraction effect of Cr(Ⅵ) and detoxification effect of COPR.After treatment,95% of Cr(Ⅵ) was removed and the Cr(Ⅵ) concentration in the leachate was decreased to 1.6 mg/L by the toxicity characteristic leaching procedure(TCLP),within the regulatory limit disposal standard(HJ/T 301-2007,3 mg/L).Further study revealed that,during the treatment,hydrocalumite transformed into calcite(CaCO3) under the effect of mineralizer,therefore,the layered structure collapsed and the incorporated Cr(Ⅵ) was released to the supernatant.Meanwhile,the Cr(Ⅵ)desorbed from calcite with the calcite particles grew into large size with smooth surface.Stir-flow experiment revealed that the amount of chromium released from CORP to the environment was significantly reduced after treatment,and it is safer for landfill disposal.This work will provide an instructive guidance for the detoxification and recovery of COPR.

Shear Alteration, Mass Transfer and Gold Mineralization: An Example from Jiaodong Ore Deposit Concentrating Area, Shandong, China

Taking the gold ore deposit concentrating area of Jiaodong area in Shandong, China for an example, based on geological analysis, and applying Gresens’ equation, Grant’s isocon diagram and O’hara microelement calculation method, a thorough study on shear alteration, mass transfer and gold mineralization was carried out. The authors also made mathematic simulation and geochemical analysis. The work reveals temporal spatial changing regularities of temperature field and velocity field of fluids, and also reveals fluid transport chemical reaction coupling metallogenic dynamics of the Jiaojia gold ore concentrating area. During shear alteration process of the Jiaodong gold ore concentrating area, all kinds of components transferred with different amounts, fluid rock ratio was rather high and volume strain was of dilation type. Fast flow of ore forming fluid favors the occurrence of mixed fluid. Shear fractured zones are places where there was strong transportation reaction coupling mineralization. Ore bodies were located in dilation space of shear structure where there was the greatest fluid flux. After the emplacement of the rock body, a convex heat field was formed around the rock body. It is one of the main metallogenic forces. The major reason for mineralization is the mobilization, migration and enrichment of ore forming elements induced by shear compressive extensional tectonism. Inclusion gold dominant low grade ores were formed in the early ore forming stage, while high grade ores, which contained fissure gold and polymetallic veinlets, were formed in late ore forming stage.

Analysis of Mineralization System and Prediction of New-Type Ore Deposits

The discovery of new-type ore deposits, an important approach to guarantee the mineral resources supply in the 21st century, often brings about a gigantic increase in the mineral resources reserves. The analysis of mineralization system is of great importance to the discovery of new type ore deposits. ① The understanding of the relationship among various ore deposit types within a mineralization system in a region can help us to locate the unknown ore deposit types from the known ore deposit types, evidence that has been proved in the mineral prospecting history of ore belts in the middle and lower reaches of the Yangtze River, China. ② The understanding of the spatial structure of a mineralization system, especially of the vertical zonation, is helpful for the discovery of the concealed ore deposit types. ③ Clarifying the temporal structure of a mineralization system, including the iteration relationship between the mineral deposit types in the mineralization, leads to the location of the missing mineralization chains from the known mineralization chains (mineral deposit type), a method often proved to be effective in the magmatic hydrothermal mineralization system.④ Clarifying the factors restraining the diversity of mineral deposit types in mineralization system leads to the discovery of the potential of new type mineral deposits in relevant region. ⑤ Studying new mineralization setting and new ore forming processes leads to discovery of new type mineral deposit. More probabilities of discovery of new type mineral deposits are present in biogenic mineralization system, deep sea mineralization system, low temperature mineralization system, tectonic mineralization system and superimposed mineralization system.

Cost-effective integrated strategy for the fabrication of hard-magnet barium hexaferrite powders from low-grade barite ore

Ultrafine barium hexaferrite（BaFe12O19） powders were synthesized from the metallurgical extracts of low-grade Egyptian barite ore via a co-precipitation route. Hydrometallurgical treatment of barite ore was systematically studied to achieve the maximum dissolution efficiency of Fe（～99.7%） under the optimum conditions. The hexaferrite precursors were obtained by the co-precipitation of BaS produced by the reduction of barite ore with carbon at 1273 K and then dissolved in diluted HCl and FeCl3 solution at pH 10 using NaOH as a base; the product was then annealed at 1273 K in an open atmosphere. The effect of Fe^3＋/Ba^2＋ molar ratio and the addition of hydrogen peroxide（H2O2） on the phase structure, crystallite size, morphology, and magnetic properties were investigated by X-ray diffraction, scanning electron microscopy, and vibrating sample magnetometry. Single-phase BaFe（12）O（19） powder was obtained at an Fe^3＋/Ba^2＋ molar ratio of 8.00. The formed powders exhibited a hexagonal platelet-like structure. Good maximum magnetization（48.3 A×m^2×kg^–1） was achieved in the material prepared at an Fe^3＋/Ba^2＋ molar ratio of 8.0 in the presence of 5% H2O2 as an oxidizer and at 1273 K because of the formation of a uniform, hexagonal-shaped structure.

Onset and Stability of Thermally-Driven Fluid Convection in a Vertical Rock Crack and Their Implication for Hydrothermal Ore-Forming Processes

Dynamic equations controlling the thermally-driven fluid convection in a single rock crack are established in the paper . The critical criteria for the onset of convection in such a configuration are found by linear dynamic analysis of the equations and the stability of the convection discussed by nonlinear analysis method . The research demonstrates that the critical Rayleigh number has a magnitude 103. While the Rayleigh number R of real ore-forming fluids exceeds this value , the convection happens , and as R becomes larger , the fluid convection pattern develops from nonequilibrium steady states to double-periodically produced limit cycles and eventually to chaos (turbulences ).The implication of these dynamic analyses for the ore-forming processes of late-magma tic hydrothermal deposits is also discussed in the paper .

Recent collaborative researches between Japanese universities and steel industry on the iron ore agglomeration process

The properties of iron ores used in ironmaking process have been drastically changed in the past couple of decades.Especially,the change has become significant in the last few years because of the considerable increase in the world steel production.The property change of the iron ore is mainly caused by the depletion of the hard and high-grade lump hematite ores.It has led to the increasing use of ores containing a larger amount of goethite/limonite,i.e.,hydro-oxides of iron.Typically,the proportion of pisolitic ores,which are course limonitic ores,has remarkably increased by several times in Japan.Further,large deposits of the fine goethite ores called Marra Mamba have been developed in Australia and exported to Asian countries.Such trends will be continued in future.Since the change of the ore properties affects not only to the productivity and yield of the sinter but also its metallurgical properties in the blast furnace,further improvement in the sintering technology/ process is required including the preliminary treatment process of raw materials.In order to make wide researches concerning the above issues,the research project 'New Sintering Process through Designing of Composite Granulation & Bed Structure' was formed in the ISIJ,which was the collaborative project between Japanese steel companies and several universities.The project was started in 2005 and carried on the wide range of studies for three and half years.Its main objects are the characterization of pisolitic/goethitic ores and the understanding the behavior during the iron ore sintering process.Further,considering the ore characteristics,some basic researches on the optimum designs of raw material blending,granulation,bed structure,and the metallurgical properties of the produced sinter were performed.The project have invented the technical principle of a new sintering process, namely MEBIOS(Mosaic EmBedding Iron Ore Sintering Process),characterized by the composite granulation and bed-structure,aiming to cope with the drastic shift of the ore properties.Another big issue fallen on the steel industry is the global warming.CO,emission from steelmaking industry occupies about 15%of the total value of the artificial emissions in Japan and therefore its reduction is urgently required.In order examine the possibility to minimize or to reduce further the CO_2 emission from the iron ore sintering process,the research project 'Technological Principle for Low-Carbon Sintering' has been formed since 2009 in the ISIJ.In this project,the analyses of the combustion rates of carbonaceous materials and heat transfer in the sintering bed are first examined by referring the previous studies.Further,experimental works will be conducted on the combustion/oxidation characteristics of biomass charcoal,some organic wastes,steel can scraps,mill scale and partially reduced iron ores as alternative agglomeration reagents of coke and anthracite coal.The effect of their use on the sintering process will be evaluated systematically.It is expected that the structural changes of the sintering bed is considerably different between carbonaceous materials,which disappear during combustion leaving a little amount of ash components and metallic iron bearing materials,which increase the mass and volume during its oxidation. Previous studies showed that the use of metallic iron bearing materials such as steel can scrap and mill scale led to significant decreases in the production rate.This project examines the characteristics of such changes of the sintering bed structure and mineral phases and main process parameters,which govern such phenomena.Further, it searches for a new process principle to overcome the demerits and realize the significant reduction of CO_2 emissions from the iron ore sintering process.In the symposium,summary of activities and the major results and progresses of the above two research projects will be introduced.

The Evolutionary History of Ore-forming Processes of Metallic Ore Deposits in Northern Guangxi

The northern Guangxi region is an important rare metal, rare earth metal and polymetallic metallogenic province. In the region there exist five metallogenic series and two metallogenic subseries, whose metallogenesis shows features of polycyclic spiral evolution throughout the geological history. As far as various cycles are concerned, mantle-derived ore substances were reduced while crust-derived ore substances increased from early to late timesfin the whole geological evolutionary history, mantle-derived substances decreased gradually while crust-derived ones increased. Meanwhile ore element associations became more and more varied. In terms of space, mineralization migrated from the old basement outwards, i.e. from west to east during the Precambrian, and from north to south during the Phanerozoic, and again from east to west during the Yanshanian.

Process optimization of rare earth and aluminum leaching from weathered crust elution-deposited rare earth ore with compound ammonium salts

In order to intensify the leaching process of rare earth（RE） and reduce the impurities in the leachate, ammonium chloride（NH4Cl） and ammonium nitrate（NH4NO3） were mixed as a compound leaching agent to treat the weathered crust elution-deposited RE ore. Effects of molar ratio of NH~＋_4Cl and NH_4NO_3, ammonium（NH_4） concentration, leaching agent pH and flow rate on the leaching process of RE were studied and evaluated by the chromatographic plate theory. Leaching process of the main impurity aluminium（Al） was also discussed in detail. Results showed that a higher initial ammonium concentration in a certain range could enhance the mass transfer process of RE and Al by providing a driving force to overcome the resistance of diffusion. pH almost had no effects on the mass transfer efficiency of RE and Al in the range of 4 to 8. The relationship between the flow rate and height equivalent to a theoretical plate（HETP） could fit well with the Van Deemter equation, and the flow rate at the lowest HETP was determined. The optimum conditions of column leaching for RE and Al were 1：1（molar ratio） of NH_4Cl and NH_4NO_3, 0.2 mol/L of ammonium concentration, pH 4–8 of leaching agent and 0.5 mL /min of flow rate. Under this condition, the mass transfer efficiency of RE was improved, but no change was observed for Al compared with the most widely used ammonium sulfate. Moreover, the significant difference value（around 20 mL） of retention volume at the peak concentration between RE and Al provided a possibility for their separation. It suggested the potential application of the novel compound leaching agent（NH_4Cl/NH_4NO_3）. It was found that the relative concentration of RE in the leachate could be easily obtained by monitoring the pH of leachate.

Application status and comparison of dioxin removal technologies for iron ore sintering process

The emission of dioxins from the iron ore sintering process is the largest emission source of dioxins, and the reduction in dioxin emission from the iron ore sintering process to the environment is increasingly important. Three approaches to control the emission of dioxins were reviewed： source control, process control, and terminal control. Among them, two terminal control technologies, activated carbon adsorption and selective reduction technology, were discussed in detail. Following a comparison of the reduction technologies, the terminal control method was indicated as the key technology to achieve good control of dioxins during the sintering process. For the technical characteristics of the sintering process and flue gas, multiple methods should be collectively considered, and the most suitable method may be addition of inhibitors ＋ ultra-clean dust collection （electrostatic precipitation/bag filter） ＋ desulphurization ＋ selective catalytic reduction to sufficiently remove multiple pollutants, which provides a direction for the cooperative disposal of flue gas pollutants in future.