MINERAL SEPARATION
Clariant tackles iron ore ultrafines
Clariant has an offering in the field of magnetic separation focused specifically on the recovery of iron ore ultrafines .
Having recognised a growing need to produce more metals to support global megatrends , falling metal grades across the sector and the increased generation of tailings , Clariant has devised what it believes is a more efficient and sustainable way of recovering ultrafine iron ore particles from tailings slimes .
Kelly Laranjeira Nunes presented the solution at the recent SME MineXchange Conference and Expo , in Phoenix , Arizona , in a talk titled , ‘ Additives for Magnetic Separation of Iron Ore Ultrafines ’.
Nunes and her colleagues believe tailings reprocessing is key to improving the sustainability of the mining process , with its solution looking to improve the slimes process that occurs in iron ore circuits by providing additives with different action mechanisms .
The company sees a future magnetic separation process that includes dispersion of magnetic fines and flocculation of weakly magnetic material to address a process that currently , it says , suffers from a loss of valuable minerals to tailings , a low mass yield and high energy consumption .
By providing additives under its FLOTICOR™ brand that aid dispersion , selective agglomeration and rheology modification , Clariant sees the potential to , Nunes says , add value to the tailings reprocessing sector .
Displaying test work looking at all three mechanisms – dispersion , agglomeration and rheology – Nunes argued that Clariant ’ s additives could help recover metal-rich slime tailings as ore . Considering slime tailings typically represent 10-30 % of mass of the run of mine in Brazilian iron ore operations , Clariant sees the potential to boost iron content from 40 % to 50 % with the incorporation of ultrafine tailings (< 10 μm ).
Nunes said these FLOTICOR additives could also help increase process performance and plant productivity in iron ore operations , with Clariant ’ s additives for magnetic separation increasing the mass yield of ultrafines from 30 % to more than 40 %. This could result in the production of more than 2 Mt / y of iron ore , which represents a revenue increase of more than $ 100 million at current prices .
Lastly , Clariant ’ s solutions could aid tailings storage facility preservation , with the recovery of slimes saving space taken by solids and water in the tailings dams , possibly increasing the life of these facilities by years .
By employing a rheology modification mechanism based on the use of different FLOTICOR additives – at different concentrations – Clariant showed in test work that it could boost recovery of a sample of ultrafine iron ore monitoring system is a key feature of SmartCyclone .
“ This is important as it allows operators to detect wear and troubleshoot issues from a centralised control room , eliminating the need for manual equipment inspections with a reduction in associated risks ,” he says .
By promptly identifying and addressing potential problems , process disruptions are minimised , ensuring optimal performance of the grinding circuit .
The SmartCyclone system also includes a roping detection feature , with FLSmidth explaining that overloaded cyclones , or those experiencing roping , can result in increased bypass of coarse solids to the overflow and greater particle size variation .
“ This accumulation of slurry can adversely affect downstream equipment , such as flotation cells ,” Schutte says . “ By monitoring and detecting roping , operators can confidently operate the plant closer to its limits , thereby increasing production capacity and improving mineral recovery .”
By integrating SmartCyclone with ECS / ProcessExpert software , the grinding circuit ’ s performance can be further optimised , according to FLSmidth . The system dynamically adjusts variables such as water addition , pump speed and the number of operating cyclones based on real-time data from SmartCyclone sensors . This continuous optimisation enhances PSD , maximises mineral recovery and improves the overall efficiency of the grinding circuit , it says .
SmartCyclone offers a comprehensive solution for closed-circuit grinding operations , FLSmidth says . By leveraging advanced sensor technologies , automated monitoring and process control software , this system empowers operators to enhance maintenance planning , reduce wear and optimise the performance of their grinding circuits .
SmartCyclone for closed-circuit grinding optimisation
Efficient operation and minimal downtime are crucial for maintaining productivity and profitability in grinding circuits and , to address these challenges , many operations are opting for the KREBS ® SmartCyclone™ technology from FLSmidth , according to the OEM .
Abrie Schutte , Senior Applications Engineer at FLSmidth responsible for the KREBS pumps cyclones and valves product business line , says this innovative technology combines advanced monitoring and automation features to optimise closed-circuit grinding operations .
“ SmartCyclone integrates various components and software to provide a comprehensive solution for grinding circuit management , and significantly incorporates roping sensor technology , wear detection technology , a wireless controller system and ECS / ProcessExpert ® process control software ,” Schutte says . “ End users have found that by leveraging these elements , maintenance planning is enhanced , wear reduced and there is an overall improvement in grinding circuit performance .”
The wear detection technology of SmartCyclone employs specialised sensors to monitor the wear status of cyclone components . This real-time information enables operators to proactively plan for part replacements and schedule maintenance activities , minimising unexpected downtime caused by component failures .
Schutte further explains that an automated
Bunting ups the magnetiser ante
To meet the increased demand for magnetic separators following a sustained period of sales growth , Bunting has redesigned and refurbished the industrial magnetiser at its Redditch manufacturing facility in the UK . The enhancements make this DC impulse industrial magnetiser the largest in the UK , outside of academia , it claims .
Bunting is a leading designer and manufacturer of magnetic separators , eddy current separators , metal detectors and electrostatic separators .
At the Redditch manufacturing operation , Bunting ’ s industrial magnetiser charges permanent magnet assemblies used in overband magnets , drum magnets and pulley magnets . The
68 International Mining | APRIL 2024