Abstract The inefficiency in controlling the slurry/froth interface level of a scavenger column flotation stage was severely impairing the process performance of an iron mining company, increasing the iron content in the tailings to levels above 20% and, consequently, not meeting the company's iron recovery and pellet feed production targets. Based on mass balance and process data, hydraulic calculations were performed and showed that the installed 6.0" (15.24cm) diameter barometric leg tubes and the control system valve were adequate. An equation to determine the maximum barometric leg height was developed for the flotation column and other calculations showed the necessity to reduce this height from 4.6m to a maximum of 3.4m. The barometric leg adequacy considerably decreased the variability in controlling the slurry/froth interface level, reduced the iron content in the tailings from 24.9% to 18.9% and increased the iron recovery in the flotation stage from 97.9% to 98.7%.

Abstract Quartz floatability in cationic reverse flotation depends on the suitable choice of surfactant type and the conditions under which they are applied. The design of experiments (DOE) allows the evaluation of process variables, in a structured and independent way, with statistical validation and a limited number of tests. Tests of microflotation of quartz, in the size range -150 +75 µm, using factorial design of experiments, showed that etherdiamine leads to higher level of quartz floatability than ethermonoamine, favored by increase in collector concentration, at the high level of pH tested (11.0). Floatability values above 90% were achieved with the use of 3 mg/L of ether diamine for both pH levels, while with ether monoamine the target was reached only at pH 11.

Abstract Flotation plays a relevant role in the concentration of iron ores. Conventional flotation technology employing mechanical machines and columns and also circuits combining both types of cells have been utilized in the iron ore industry. The top size of particles in the flotation circuit feed is 150 µm and the slimes below 10 µm are removed as overflow in hydrocyclone classification. The conventional flotation technology faces difficulties in achieving tailings with iron grades lower than 12% and concentrates with SiO2 grades lower than 1%, and requires long residence times, resulting in large volume machines and huge footprints. The pneumatic flotation technology was evaluated in the reverse flotation of quartz from an iron ore sample of the Iron Quadrangle, Brazil. Bench and industrial scale tests were conducted in pneumatic flotation machines at low residence time. Both tests were carried out in open circuit stages with the objective of comparison with mechanical cells. The bench scale tests were carried out in three stages (rougher, cleaner and recleaner) in an 11 L pneumatic cell aiming at final concentrate with maximum 2% SiO2 while the industrial tests were carried out in a 25 m3 pneumatic cell in the rougher stage aiming at comparison with a circuit of five 14 m3 cells in the rougher stage and four 14 m3 cells in the scavenger stage. The collision and particle-bubble adhesion occur in a step before the pulp reaches the pneumatic cell vessel. The results indicate the possibility of achieving concentrates with a SiO2 content of approximately 1% and tailings with iron contents lower than 10% with three stages (rougher, cleaner and recleaner) without the need of scavenger stages. Furthermore, the residence time was three times shorter than that required for conventional mechanical cells. The speed of the pulp at the entrance of the pneumatic cell strongly affects the quality of the concentrate.

Abstract Starches are widely used as depressant in froth flotation operations in Brazil due to their efficiency, increasing the selectivity in the inverse flotation of quartz, depressing iron ore. The starch market has been growing and improving in recent years, leading to better products attending the requirements of the mineral industry. The major source of starch used for iron ore is the cornstarch, which needs to be gelatinized, by heat or sodium hydroxide (NaOH) addition (also known as caustisized starch), prior its use. This stage has a direct impact on industrials costs, since the lower consumption of NaOH in gelatinization provides better control of the pH in the froth flotation and reduces the amount of electrolytes present in the pulp. In order to evaluate the influence of temperature on the NaOH consumption, gelatinization tests were carried out with temperatures ranging from 25 to 65 ºC, measuring the volume of NaOH. All tests were performed in triplicate. A linear model correlating the temperature and the NaOH need for the cornstarch gelatinization has been stablished. This model can allow mineral industries to optimize the NaOH amount used to prepare the depressant used in froth flotation. For example, the reduction in NaOH could easily reach 480 L per ton of cornstarch when performing gelatinization with the cornstarch solution at 35 ºC instead of 25 ºC (reduction of approximately 34% in the NaOH consumed).

Abstract This paper presents a potential condition to separate kaolinite through flotation when it is present in bauxite ore. This research anticipates a Brazilian industry requirement, considering the tendency towards the need for aluminosilicates removal from bauxite ores, as has already occurred in China. Kaolinite is the most abundant aluminosilicate, and gibbsite is the main aluminum bearing mineral in Brazilian bauxite ores. The first step was a fundamental study involving microflotation experiments with pure samples of kaolinite and gibbsite. Ammonium quaternary salts and amines were used as the collector and corn starch as the depressant. In a fundamental study, the best conditions determined in the first step were evaluated for the flotation of kaolinite from bauxite ore using laboratory scale experiments. Tests with AQ142/starch (pH 10) and CTAB (pH 7) led to satisfactory results. In general, the highest values of alumina/silica mass ratio were obtained with AQ142/starch and the highest values of mass recovery and metallurgical recovery were achieved with CTAB.

Abstract The dispersion degree of the mineral particles in the pulp is especially relevant regarding the performance of the cationic reverse flotation of iron ores. The gangue minerals should remain dispersed while hematite particles should be selectively flocculated. The present study addressed determinations of dispersion degree and zeta potential of hematite in the presence of different dispersants, classified as organic polymeric (natural and synthetic), organic monomeric, and inorganic. Special attention was paid to results achieved at pH 10, used in plant practice. For natural organic polymers, correlation was observed between the dispersion degree and the increase in the negative value of zeta potential. Some synthetic organic polymers enhance the dispersion of hematite particles despite not affecting significantly the zeta potential. Sodium silicates, irrespectively of the SiO2/Na2O ratio, at pH 10, did not impact significantly either the dispersion degree or the zeta potential.

Abstract In iron ore pelletizing plants a range of process parameters such as particle size distribution, specific surface area, and moisture, must be controlled to achieve optimized operation conditions. Particle size distribution and specific surface area are controlled during the grinding operations. Moisture, however, is controlled during filtration of the ground products. This work investigates the relationship between particle morphology, filter cake moisture and filter capacity. The samples were taken during the filtration tests and referred to three different blends presenting distinct mineralogical features and similar chemical compositions in order to investigate the effects of only the hematite surface characteristics. Six types of morphology are distinguished: granular hematite, tabular hematite, martitic hematite, polycrystalline hematite, hematite-goethite aggregates and goethite. For each filtration test, the filter cloth product was characterised. The characterisation analysis revealed that blends containing martitic hematite concentration above 11.45 percent increased substantially the filter capacity. However, it had also caused an increasing in final moisture content that reached values around 10.0 % compared with industrial moisture specification that can vary on the range of 8.5 to 9.5 %.

A forte demanda por bens minerais verificada nas últimas décadas tem levado o setor mineral a ampliar sua capacidade produtiva. Diferentes métodos de concentração têm sido propostos para separação seletiva da apatita dos contaminantes carbonatos e silicatos presentes em minérios fosfáticos. Separação magnética, hidrogravimétrica e calcinação são métodos que apresentam baixa eficiência e custo elevado. A flotação é o método mais indicado, porém a seletividade é dificultada devido à similaridade da composição química superficial entre fosfatos e carbonatos, a alta atividade superficial dos coletores utilizados, interações entre espécies iônicas dissolvidas de um mineral sobre outro e, também, entre espécies iônicas dissolvidas e reagentes. Nesse estudo, realizado em laboratório, oito diferentes depressores, orgânicos e inorgânicos, foram testados na flotação aniônica direta de um fosfato sílico-carbonatado. O melhor desempenho foi obtido com fécula de mandioca, que exerceu boa depressão sobre a calcita e os silicatos.

A high demand for mineral resources observed in recent decades has led to an expansion in production in the mining industry. Different process alternatives have been proposed for selective separation between apatite and contaminants (carbonates and silicates) present in phosphate ores. Magnetic separation, calcination and gravity separation processes are methods that present low efficiency and high cost. Flotation is the most common process; however the selectivity is hampered by the superficial similarity of the chemical composition of phosphates and carbonates, high surface activity of the collectors used, interactions between dissolved ionic species of certain mineral with another and also interactions between dissolved ionic species and reagents. In this study, conducted in a laboratory scale, eight different depressants, organic and inorganic, were tested in the direct flotation of a Brazilian silicate-carbonate phosphate ore. The best performance in the depression of calcite and silicates was achieved with cassava starch.

A otimização de circuitos industriais de moagem tem sido realizada com sucesso, utilizando-se modelos matemáticos que relacionam dados industriais com parâmetros de quebra determinados através de testes de moagem em escala de laboratório. O material estudado é um minério de ouro moído através de um circuito fechado de moagem de bolas. A classificação foi realizada por hidrociclones. Várias campanhas de amostragens foram realizadas com o objetivo de fechar um balanço de massas e fornecer material para os testes em laboratório. Os parâmetros determinados nos testes em laboratório, foram utilizados para prever, por simulação, o comportamento do circuito operado com baixo enchimento de bolas e com distribuição balanceada de tamanhos de bolas.

The optimization of industrial grinding circuits has been successfully performed using mathematical models that describe the industrial scale data from breakage parameters determined in laboratory grinding tests. The test material studied here is a gold ore ground in a closed ball mill circuit with hydrocyclone classification. Several sampling campaigns were carried out aiming to produce mass balances and provide material for laboratory tests. The parameters determined in the laboratory tests were used to predict, by simulation, the circuit behavior with a low ball charge level and a balanced ball size distribution.

A flotação é um dos principais processos de concentração, sendo empregada para diversas classes de minerais (sulfetos, óxidos, silicatos, fosfatos, etc.), em relativamente ampla faixa de tamanhos de partículas. Na indústria de minério de ferro, a flotação reversa de quartzo tem sido empregada com sucesso para partículas abaixo de 150um, após a etapa de deslamagem. A elevada demanda por produtos de minérios de ferro torna a flotação o principal processo de concentração dessa indústria, sendo assim necessária uma melhor compreensão dos mecanismos do processo, assim como do efeito do tamanho das partículas nesse processo. Foram realizados ensaios de flotação com três diferentes frações granulométricas de um minério de ferro itabirítico, obtidas por classificação em ciclones, após a etapa de deslamagem. Os resultados obtidos mostraram diferenças de comportamentos entre as três frações, com maior dosagem de eteramina para as frações grossa e fina flotadas separadamente. A flotação em separado apresentou maior sensibilidade às variações de processo, principalmente no que diz respeito à dosagem de eteramina e ao pH. As diferenças granulométricas e de área superficial específica podem justificar as diferenças de comportamento observadas nos ensaios de flotação. A flotação em separado das frações grossa e fina indicou aumento de 3 pontos percentuais na recuperação metálica, com redução no teor de SiO2 no concentrado, aumento de 30 % na dosagem de eteramina e redução de 20 % no consumo de amido de milho em comparação com a flotação em conjunto destas frações. Análise de viabilidade econômica indicou VPL positivo de 50 milhões de dólares com a separação entre os circuitos de flotação de grossos e finos para o minério estudado, considerando a produção de 10 milhões de toneladas por ano de pellet feed.

Flotation is one of the main concentration processes being employed for many classes of minerals (sulfides, oxides, silicates, phosphates, for example) at different particle sizes. In the iron ore industry, reverse quartz flotation has been successfully employed for particle sizes below ISOfim after the desliming process. The high demand for iron ore products has made flotation the main process for concentration in this industry, thus a better understanding of its mechanisms and the effect of the particle sizes in the process has become imperative. Flotation tests were carried out with three different size fractions of an itabirite iron ore, obtained using cyclone classification after desliming. The results showed distinct behaviors of the different size ranges. Higher etheramine dosages are required when coarse and fine fractions are floated separately and also this procedure is more sensitive to variations in etheramine dosages and pH values. The differences in particle size distributions and the specific surface area may explain the different flotation behavior of the distinct size fractions. The split flotation circuits for coarse and fine particles indicated an increase of 3% points in the metallurgical recovery with reduction of SiO2 content in final concentrate, increase of etheramine dosage and reduction of corn starch dosage. Economic feasibility analysis indicated a positive net present value of 50 million of dollars with split circuits for coarse and fine particles, considering a production of 10 million tons per year of pellet feed.

Nesse trabalho, é apresentada a caracterização dos finos, estocados na barragem I como rejeito proveniente do tratamento de minério ferro. Na caracterização das amostras, estão apresentadas análises granulométricas por peneiramento a úmido, análises químicas por espectrometria de plasma e análise mineralógica por difração de raios X. De posse das análises de caracterização, foram executados ensaios tecnológicos, visando à obtenção de concentrado para aplicação na indústria metalúrgica. Foram avaliadas duas rotas de concentração em escala de bancada: uma (rota I) constando de classificação (0,15mm), separação magnética (-1,0+0,15mm), deslamagem e flotação (-0,15mm) e outra (rota II) constando de separação magnética (-1,0mm total). De acordo com a distribuição granulométrica dos finos do minério de ferro, 8,21% das partículas encontram-se retidas em 0,150mm e 58,81% abaixo de 0,045mm. A amostra, conforme Tabela 1, apresenta teores médios (calculado) de 48,08% de Fe, 20,58% de SiO2, 3,16% de Al2O3. Os minerais portadores de ferro identificados foram hematita, martita, magnetita e goethita e os minerais de ganga foram quartzo, gibbisita e caolinita. A melhor opção de concentração estudada consistiu na utilização de circuito de concentração somente por separação magnética, rota II. A recuperação em massa e metalúrgica foram, respectivamente, 68,00% e 90,81%, apresentando um concentrado com 67,54% de Fe, 1,50% de SiO2 e 0,49% de Al2O3, atendendo a especificação do produto comercializado pela empresa.

This paper addresses the characterization of fines stocked in a pond as tailings from an iron ore concentrator. The characterization consisted of size analyses by wet screening, chemical analyses by ICP, and mineralogical analyses by X-ray diffraction. The next stage consisted of technological tests. Two concentration routes were evaluated at bench scale: the first (route I) consisting of classification (0.15mm), magnetic separation (-1.0+0.15mm), desliming and flotation (-0.15mm); and the second (route II) consisting of magnetic separation (-1.0mm global), aiming at achieving a concentrate adequate for use in the metallurgical industry. The size distribution of the iron ore fines indicated 8.21% above 0.150mm and 58.81% passing 0.045mm. The calculated average chemical composition of the sample is 48.08% Fe, 20.58% SiO2, and 3.16% Al2O3. The iron minerals identified by X-ray diffraction were: hematite, martite, magnetite, and goethite; and the detected gangue minerals were: quartz, gibbsite, and kaolinite. The best performance came from route II, magnetic separation only: weight recovery 68.00%, metallurgical recovery 90.81%, 67.54% Fe, 1.50% SiO2, 0.49% Al2O3.

O número de estudos a respeito de flotação de caulinita tem crescido nos últimos anos, principalmente, devido às contribuições dos pesquisadores chineses. As bauxitas chinesas apresentam alta quantidade de aluminossilicatos, entre eles caulinita, o que prejudica sua utilização no processo Bayer. Esse trabalho apresenta resultados de testes de microflotação de caulinita com três aminas: dodecilamina (amina primária), Flotigam EDA (eteramina) e Duomeen T (amina graxa). Dodecilamina e Flotigam EDA apresentaram eficiente ação coletora na concentração de 1x10-4 mol/L. DuomeenT se mostrou eficiente em concentração mais alta, 1x10-3 mol/L. O ponto isoelétrico da caulinita, determinado a partir de medidas de potencial zeta, ocorreu em pH = 4,6. O estudo do potencial zeta da caulinita, na presença e na ausência de dodecilamina e Flotigam EDA, mostrou que a presença de amina no sistema altera seu ponto isoelétrico. Tal variação sugere que ocorreu adsorção dos coletores na superfície da caulinita.

The number of studies addressing kaolinite flotation is steadily increasing, mainly, due to Chinese research contributions. The Chinese bauxites present high amounts of aluminosilicates, for example kaolinite, hindering the application of the Bayer process to the ore. Herein are presented the results of kaolinite microflotation tests with three amines: dodecylamine (primary amine), Flotigam EDA (etheramine), and Duomeen T (fatty amine). Dodecylamine and Flotigam EDA presented enhanced collecting action at the concentration of 1x10-4 mol/L. Duomeen T was effective at a higher concentration, 1x10-3 mol/L. The kaolinite isoeletric point, determined by zeta potential measurements, occurred at pH = 4.6. The kaolinite zeta potential determinations, in the presence and absence of dodecylamine and Flotigam EDA, showed that the amine presence in the system changes the isoelectric point. This change suggests that collector adsorption occurred on the kaolinite surface.

O beneficiamento dos minérios fosfáticos com ganga silicatada e carbonatada é estritamente necessário para aumentar a produção de concentrados fosfáticos e para suprir a demanda nacional de fertilizantes. Visando a processar esses minérios, esse trabalho estudou, através de testes de microflotação e medidas de potencial zeta, o efeito do oleato de sódio, do amido de milho e da carboximetilcelulose (CMC) na superfície dos minerais puros originários do minério sílico-carbonatado de Catalão/GO. Os resultados obtidos mostraram a possibilidade de separação seletiva da apatita, por flotação direta em pH igual a 9, usando-se oleato de sódio como coletor, na ausência de depressores, o que seria inviável industrialmente. Tanto a CMC como o amido deprimem a dolomita, mas não são seletivos, pois deprimem, também, a apatita. O amido apresenta ação depressora sobre a apatita mais forte que a CMC.

The processing of phosphate ores containing silicates and carbonates in the gangue is strictly necessary to increase phosphate rock production to meet the Brazilian demand for fertilizers. Aiming at the processing of these ores, this investigation addressed, via microfl otation and zeta potential determinations, the effect of sodium oleate, corn starch and carboxymethylcellulose (CMC) on the surfaces of pure minerals from the Catalão/GO silicate-carbonate deposit. The results suggested the possibility of selective apatite concentration via direct fl otation at pH = 9, using sodium oleate as collector, in the absence of depressants; a route that would be industrially unfeasible. Both, CMC and starch, act as dolomite depressants, but the action is not selective, for apatite is also depressed by these reagents. Starch is a stronger apatite depressant than CMC.

Esse trabalho foi realizado com amostras provenientes da mina de Morro Agudo, visando a verificar a influência do potencial Eh na flotação de chumbo e zinco. As amostras foram provenientes da britagem primária. Durante o processo de flotação, o potencial redox foi monitorado, continuamente, usando um eletrodo de platina. Nesse estudo, foram avaliados os efeitos da adição de sulfeto de sódio e sulfito de sódio na recuperação de galena e esfalerita na presença e na ausência de nitrogênio, como gás de flotação. Uma análise estatística dos resultados de recuperação foi feita através do software MINITAB. A interação do sulfeto de sódio com o gás nitrogênio diminui a recuperação de chumbo no concentrado e o gás nitrogênio, isoladamente, aumentou a recuperação de zinco no concentrado, para uma flotação composta por dois circuitos em série, recuperação da galena, seguida da esfalerita.

The work was done with samples from the "Morro Agudo" mine and aimed to verify the influence of the pulp Eh potential on lead and zinc flotation. The samples were from the primary crushing. During the flotation process, the potential was continuously monitored by a platinum electrode. The effects of sodium sulfite and sodium sulfide on galena and sphalerite recovery in the presence and absence of nitrogen, as gas flotation, were evaluated. The software MINITAB was used for the statistical analysis of the recovery results. The interaction between sodium sulfide and nitrogen decreased the lead recovery and the nitrogen by itself increased the zinc recovery.

A mineração iniciou suas atividades lavrando depósitos de alto teor, sem preocupação em maximizar seu aproveitamento. Ainda hoje, milhões de toneladas de minerais úteis são descartados anualmente para as barragens de rejeitos. Nesse trabalho, foram realizados testes de deslamagem e flotação com lamas de minério de ferro, primeiramente em escala de bancada. Várias dosagens de coletor e depressor foram utilizadas. Os resultados promissores dos testes em escala de bancada levaram a testes em escala-piloto. Foi constatado que, com o processo de flotação catiônica reversa em colunas, utilizando-se dosagem mais elevada de depressor, consegue-se recuperação mássica da ordem de 60% e 80% de recuperação metálica, 9 a 12 % de Fe no rejeito, 0,55 % a 0,90 % de SiO2 no concentrado (SiO2+Al2O3 < 2,00 %), além de alta seletividade no processo. A utilização da flotação de ultrafinos é uma alternativa econômica para o aumento das recuperações nos empreendimentos mineiros. A flotação de ultrafinos também pode ser avaliada para a redução ou tratamento de efluentes descartados no meio ambiente.

High grade deposits were mined in the early stages of the activity. No attention was paid to maximizing the use of the deposits. Even nowadays, millions of tons of useful minerals are discarded every year into tailings ponds. This study investigated the possibility of economically retrieving ultrafine tailings (slimes) from an iron ore concentrator via reverse cationic flotation. The promising results of the bench scale tests led to carrying out pilot-scale tests. It was observed that a reverse cationic column flotation process, using high depressant dosage was selective, yielding high levels of iron recovery, approximately 60% mass recovery and 80 % metallic recovery in the flotation stage, from 9 to 12 % of Fe in the tailing and from 0,55 % to 0,90 % of SiO2 in the concentrate (SiO2+Al2O3 < 2,00 %). The ultrafines flotation is an economic alternative for increasing the recovery in mineral processing operations. The flotation of ultrafines may also be evaluated for decreasing or treating effluents disposed to the environment.