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MINERAL PROCESSING AND EXTRACTIVE METALLURGY 100 YEARS OF INNOVATION EDITED BY CORBY G. ANDERSON, ROBERT C. DUNNE, JOHN L. UHRIE MINERAL PROCESSING AND EXTRACTIVE METALLURGY 100 YEARS OF INNOVATION EDITED BY CORBY G. ANDERSON, ROBERT C. DUNNE, JOHN L. UHRIE PUBLISHED BY THE SOCIETY FOR MINING, METALLURGY & EXPLORATION Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. !SME_MPEM_100yr_Innov_TitlePg_L1.indd 1 12/17/13 6:11 PM Society for Mining, Metallurgy & Exploration (SME) 12999 E. Adam Aircraft Circle Englewood, Colorado, USA 80112 (303) 948‑4200 / (800) 763‑3132 www.smenet.org SME advances the worldwide mining and minerals community through information exchange and pro- fessional development. SME is the world’s largest association of mining and minerals professionals. Copyright © 2014 Society for Mining, Metallurgy & Exploration Inc. Electronic edition published 2014. All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME from sources believed to be reliable. However, neither SME nor its authors and editors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors and editors shall be responsible for any errors, omissions, or dam‑ ages arising out of use of this information. This work is published with the understanding that SME and its authors and editors are supplying information but are not attempting to render engineering or other profes‑ sional services. Any statement or views presented herein are those of individual authors and editors and are not necessarily those of SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permis‑ sion of the publisher. ISBN 978‑0‑87335‑371‑7 Ebook 978‑0‑87335‑372‑4 Library of Congress Cataloging-in-Publication Data has been applied for. Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. 2 This book is dedicated to Robert C. Dunne, the originator and driving force for the symposium and this book. 2 Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. Contents PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix CONTRIBUTING AUTHORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi INTROdUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Supply and Demand: Innovation Drivers in the Minerals Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Magnus Ericcson Rules of Engagement for the Innovator in the Minerals Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Martin Kuhn and Robert C. Dunne History of Innovations in Extractive Metallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Fathi Habashi COmmINUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Mine to Mill Value Chain Optimization—Role of Blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Sarma S. Kanchibotla Innovations in Comminution Equipment: Crushers, High Pressure Grinding Rolls, Semi‑Autogenous Grinding, Ball Mills, and Regrind Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Mark T. Erickson Innovations in Comminution Modelling and Ore Characterisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Stephen Morrell Innovations in Comminution Instrumentation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Brian Flintoff, Olivier Guyot, Jeff McKay, and Andre Vien Advances in Discrete Element Method Application to Grinding Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Raj K. Rajamani, Samira Rashidi, and Nikhil Dhawan The Future of Comminution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Jens Lichter SEPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Innovations in Flotation Processing Technology—The Next Hundred Years . . . . . . . . . . . . . . . . . . . . . .147 Michael G. Nelson Major Innovations in the Evolution of Flotation Reagents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 D.R. Nagaraj and Raymond S. Farinato Innovations in Froth Flotation Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 Peter Amelunxen and Kym Runge v Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. Innovations in Flotation Plant Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 Stephen Grano, Massimiliano (Max) Zanin, and Joe Pease Ore Sorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209 Bo R. Arvidson and Hermann Wotruba Magnetic Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223 Bo R. Arvidson and Daniel Norrgran Innovations in Electrostatic Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 Steve Hearn Density‑Based Separation Innovations in Coal and Minerals Processing Applications . . . . . . . . . . . .243 Rick Honaker, Robert C. Dunne, and Kevin Galvin Innovations in Dense Medium Separation Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 Tim Napier-Munn, Jeremy Bosman, and Peter Holtham Innovations in Coal Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277 Gerald H. Luttrell A Review of Industrial Innovations in Phosphate Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297 Patrick Zhang, Regis Stana, Hassan El-Shall, and Brij Moudgil Mineral Sand Separations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317 D. Erik Spiller and C. Alex Norgren Innovations in Liquid/Solid Separation for Metallurgical Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . .333 Mick L. McCaslin, Keith J. Mounteer, and Michael Phillips HydROmETAllURGy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Innovative Strategies for Copper Hydrometallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347 J. Brent Hiskey Innovations in Gold and Silver Extraction and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 John O. Marsden and S. Andrew Sass Innovations in Zinc and Lead Hydrometallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389 Tim Robinson and Corby G. Anderson Innovations in Nickel and Cobalt Hydrometallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403 Corby G. Anderson The Bayer Hydrometallurgical Alumina Process Evolution and Innovations . . . . . . . . . . . . . . . . . . . . . .427 Joseph L. Anjier and Corby G. Anderson Rare Earth Hydro‑ and Pyrometallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441 Karl A. Gschneidner Jr. Biohydrometallurgy Innovations—Discovery and Advances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447 James A. Brierley Uranium Processing Practices, Innovations, and Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457 Henry Schnell Innovations in Hydrometallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467 Corby G. Anderson vi Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. PyROmETAllURGy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 Brief Overview of Some Innovations in Pyrometallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505 Patrick R. Taylor Innovations in Copper Smelting—Keys to Productivity and Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . .515 Eric H. Partelpoeg Innovations in Zinc and Lead Pyrometallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535 Len Harris Technology Advancement in the Refining of Platinum Group Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . .543 Neville Plint and Stephen Woollam Metallurgical Innovations in the Iron and Steel Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .551 Glenn E. Hoffman mINERAlOGy ANd ANAlyTICAl CHEmISTRy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567 Innovations in Process Mineralogy and Laboratory Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .569 Wolfgang Baum Innovations in Measurement of Mineral Structure and Surface Chemistry in Flotation: Past, Present, and Future . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .577 Roger St.C. Smart, Andrea R. Gerson, Brian R. Hart, David A. Beattie, and Courtney Young Innovations in Analytical Chemistry—The Key to Metallurgical Advancement . . . . . . . . . . . . . . . . . . . .603 Meg Dietrich ENvIRONmENTAl INNOvATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 The Generation and Treatment of Acid Rock Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619 Thomas Wildeman, Katherine Vatterrodt, and Linda A. Figueroa A Perspective of Innovations in Tailings Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629 Dirk van Zyl Innovations in Water and Brine Treatment Using Membrane Technology . . . . . . . . . . . . . . . . . . . . . . . .639 Larry A. Lien Innovations in Chemical and Bacterial Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645 Brian Park, Jay McCloskey, and Larry Twidwell Innovations in Air Pollution Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655 Catherine “Carrie” MacDougall, Michael D.S. Blois, and Robert W. Reisinger INdEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679 vii Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved. Preface “We stand on the shoulders of giants” is possibly an overused phrase; however, in the production of the raw materials necessary for our ever improving standard of living and the advancement of society, it holds true time and again. With the eye of a historian, it is easy to see the advancement of metallurgy, starting with such valuable historical texts as Georgius Agricola’s De Re Metallica, widely accepted to be the first text on minerals processing, to other groundbreaking and still invalu‑ able books such as Arthur F. Taggart’s Handbook of Mineral Dressing and Norman L. Weiss’s SME Mineral Processing Handbook, to the plethora of high‑quality journals and books of today. Through these texts, time reveals how innovation continues to push our industry forward. And as such, the Minerals and Metallurgical Processing Division of the Society for Mining, Metallurgy & Exploration is very proud to publish these proceedings of the successful sympo‑ sium of the same name held in 2013: Mineral Processing and Extractive Metallurgy: 100 Years of Innovation. Innovation is different than invention or improvement. Innovation represents creative think‑ ing that provides value and the capacity for a business to achieve the future it desires and hence allows a new avenue or path for growth. Other books are available on how innovation has worked in the commercial consumer sector, but very little information exists for the mining industry. This volume presents a century of the innovation drivers that have changed the U.S. mining industry with topics from experts in pyro‑, hydro‑, and electrometallurgy. In addition, current and future trends, developments, and improvements in these areas are discussed in depth, and likely areas for future innovations are explored. The labors of many have gone into the preparation of this volume. We are indebted to the individual authors for contributing their life’s knowledge, experience, and passion to this text, but also to their respective employers for allowing them the time and resources necessary to produce and share their work. Thanks must also be given to the employers of the organizing committee, Newmont Mining Corporation, and Colorado School of Mines for allowing the time to develop the idea of the symposium and to see it through to fruition. We thank Henry Kasaini of RER for graciously and expertly stepping in on short notice to give the rare earths presentation. Also, we thank Barney Guarnera of Behre Dolbear for his opening keynote presentation. The symposium could not have been possible without the direct support and sponsorship of Tetra Tech Engineering, Cytec Industries, Weir International, Hatch Engineering, and, most importantly, Air Products. ix Copyright © 2014 Society for Mining, Metallurgy & Exploration, Inc. All rights reserved.

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698 Pages·2014·23.42 MB·English
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