Abrasive and impact-abrasive wear testing of steels for mining, transporting,...
03 Haarla ZRI Metal-Mining General Overview (PC) Sept 12_16
1. GOOD CHOICES
FOR MINING & METAL
Haarla Americas | 365 118th Avenue SE, Ste. 100 | Bellevue, WA, USA | 98005
www.haarla.com
2. For complete quality control
TECHNOLOGY
SOLUTIONS
GOOD CHOICES
FOR MINING & METAL
High-quality chemicals to
improve your processes
BENEFICATION
CHEMISTRY
Dust suppression for
gangue and tailings
handling, crushing
and haul roads
DUST
CONTROL
Angle of repose improvement
TAILINGS CONTROL
Balls and Rods in various sizes
GRINDING MEDIA
Bio-Polymer solutions
for water treatment
processes
WATER
PURIFICATION
Getting the most out of your Raw Materials
HAARLA ZRI CONCEPT
4. Surface impurities (oxidation, gangue minerals, clay, oils) occur on all
metal mineral grain surfaces and/or within interlayered grains.
Surface impurities reduce flotation selectivity and diminish recoveries.
THE ZRI AIMS TO IMPROVE FLOTATION SELECTIVITY
THROUGH SURFACE CONDITIONING …
THE CHALLENGE
5. Slurry (20%-40% density) introduced into ZRI chamber.
Slurry passes through specially tooled blades (rotating at high RPM).
THE METHOD
SURFACE CONDITIONING / DELAMINATION
Ultrasonic Energy Micro-cavitation Nano-bubbles
Nano-bubbles develop and “implode” (energy).
Grain surfaces are “polished” through detachment processes.
Layered minerals are delaminated exposing more surface area.
Little if any reduction in particle size.
Impact, shear and attrition between mineral grains and rotating blades.
6. PARTICLE SIZE DISTRIBUTION
0
10
20
30
40
50
60
70
80
90
100
0.1 1 10 100
Cumulativevolume[%]
Particle size (um)
ZRI feed (steel)
ZRI feed (PU)
After ZRI (steel)
After ZRI (PU)
• ZRI treatment using steel,
tungsten-carbide or
polyurethane blades had no
significant effect on particle size.
• Tests on large-flake graphite
resulted in some destruction of
larger flakes – looking at blade
configuration and/or blade
material and/or blade teeth
spacing to resolve issue.
12. • For PGEs, ZRI treatment
increased their flotation
selectivity.
• Lowest Energy
consumption with ZRI and
highest for ultrasonic:
Case: Sulphide Ore
13. Case: Gold Ore Concentrate
• In sulphide flotation,
kinetics are a bit slower.
• Several %-units improved
yield and selectivity.
15. Case: Gold Tailings
• Gravity Tails: native gold, electrum and gold bismuth tellurides.
• ZRI treatment prior to rougher flotation (Actlabs, Thunder Bay, Ontario).
• ZRI treatment vastly improved the flotation.
• Recovery increased by 6.3% and gold grade nearly tripled.
Sample
Cumulative
Recovery (%)
Cumulative
Grade (g/t Au)
No ZRI 56.9 43.2
After ZRI 63.2 127.6
Change: +6.3% +84.4
*curve: 2nd time interval concentrate grading higher
than the initial interval concentrate.
16. Case: Graphite
ZRINO ZRI
light areas = oxidation ZRI treatment = cleaner
• ZRI treatment may also have the effect of delaminating layered minerals.
• results could be lower costs in production of higher purity concentrates.
17. Case: Graphite
• Rougher Tailings: flakes in all sizes up to +600 µm (super jumbo).
• ZRI treatment prior to scavenger flotation stage (Actlabs, Thunder Bay, Ontario).
• Recovery was reduced but grades were significantly higher in all fractions (except the
finest) at >90% graphite.
• Original process required a polishing/re-grind stage and an additional cleaner stage to
reach equivalent ZRI grades.
• ZRI could reduce number of flotation stages required to achieve saleable grades.
Sample
Cumulative
Recovery (%)
Cumulative
Grade (% Cg)
No ZRI 91.8 73.9
After ZRI 88.8 80.8
Change: -3.0% +6.9
18. • Power Inverter :
• (30%=160Hz/ to 60%=210Hz).
• Mechanical Seal Water Pressure Gauge:
• minimum detectable pressure is adequate.
• Motor:
• 380V-500V,8.6A, 3,000-3,600 rpm).
• Outflow Line (moveable).
• Feed Tank (8L max.).
• ZRI Reactor (slurry chamber/mechanical seal).
• Cleanout Line.
• Backbone (supports Inverter).
ZRI LAB UNIT: COMPONENTS
Inverter
ZRI
Feed
Tank
Outflow Line
Motor
Seal Water
Backbone
Steel Plate
Cleanout Line
19. • Grain Size: <500µm (important).
• Sample Material: slurry – pumpable.
• Treatment Consistency: 20%-40% density (solids).
• Charge: typically 2L-4L (can be ~1L).
• Sample Run: <10 minutes (incl. staging & cleaning).
• Process: batch (~2-4L) or continuous (~500L/hr).
• Treatment: single (<1 min.) or multiple passes.
• Power Consumption: 4kWh/tonne.
• Blades (current): RI+RII steel, RIII+RIV tungsten-
carbide.
ZRI LAB UNIT: SAMPLES
Inverter
ZRI
Feed
Tank
Outflow Line
Motor
Seal Water
Backbone
Steel Plate
Cleanout Line
20. • Stator: forms a series of concentric rings containing gapped “teeth”.
• Rotor (blades): embedded gapped “teeth” on concentric rings seated and rotating
within the stator rings.
THE ZRI REACTOR CHAMBER
• Operation: fluid is fed through the centre of the stator
and forced to flow outwards through the teeth filings
(slots) and rotating slots of the blades.
• Result: ultrasonic energy and strong viscous shear
forces into the fluid, interact with mineral
grains/surfaces.
• Configuration: blades can be configured with different
slot sizes (typically ~1mm) and mediums (i.e., steel,
tungsten-carbide, polyurethane) depending on the
mineral of interest.
rotor (blades)
stator
ZRI chamber
21. ZRI COMMERCIAL UNITS
• Commercialized in paper fibre industry
(de-inking).
• Range from 5m3/hr to 250m3/hr – can
be customized.
• Pilot units range from 7-12m3/hr.
• Can be installed in parallel to handle
higher volumes.
• Can be installed in series for multiple
passes.
250m3 ZRI Reactor
