Amenability of a Plant Slimy Tails to a Nil Waste Process for Reuse

B P Ravi1*, K G Sanjaykumar1, G.Abhishek1, G.Shyala2 and P Sharathkumar2

1 TVJ Mineral Processing Projects P Ltd, Bangalore 560091
2 Mineral Processing Department, VSKU PG Centre, Nandihalli 583119,
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*Corresponding Author Email: [email protected],
Abstract
An attempt was made to study the amenability of Au CIP plant tails to a nil waste
processing, by flotation of CIP tails for desulfurization followed by pelletization of
desulphurized product producing granules, to mitigate the problems, due to lack of full
availability of river sand and environmental effect of surface tailing impoundment. Bulk
flotation tests were carried out to reduce sulphur to maximum extent varying the activator,
collector dosage. Granulation tests were done on bulk flotation rejects in a disc pelletizer
varying rpm, angle of inclination, cement [OPC] binder %. The amenability tests indicated
that desulphurized micro pellets assaying 0.15%As, 0.25%S, 0.15ppm Au, meeting the
specification could be produced at low feed quantity, high angle of inclination of 60 o, low
rpm of 30, 10% 1:1 mix of cement and anhydrous gypsum as binder and 10-11% moisture,
while the bulk float at 16% yield, assayed 1.4ppm Au, 6.68%S and 4.08% As, which may
reused in the plant for recovery of gold after breaking open the aresenopyrite lattice by eco-
friendly chemical processing.
Key words; Bulk flotation of sulphides, granulation of fine tails, Nil waste process evolution.

1. Introduction
In industrialized countries, issues pertaining to environmental regulatory compliance
have become the impetus for comprehensive engineering design and effective management of
mining, other wastes and industrial by-products. This has resulted in a renewed interest
within the mining industry to explore and evaluate innovative strategies for managing
potentially acid generating mining waste leading to arsenic poisoning, besides to backfill
mined empty stopes by tails. Yanful (2013) reviewed the role of binders for CPT as mine
backfill and recommended use of cement kiln dust, fly ash in addition to cement for cemented
paste backfill [CPB] and it is gaining importance Annon (2012). Alternatively, a mix or
standalone of granulated tails with binders like cement, granulated blast furnace slag sand,
granulated fly ash is being investigated to solve the vexed problem of mine back fill, acid
mine drainage and contamination of sub surface waters by heavy metals, As etc. In view of
the above about 25 kgs of tails were received from HGML to study the recovery of S and As
bearing minerals from tails followed by granulation of desulphurised tails for subsequent use
in mine back fill. The agglomerate shall have size range from 0.2 to 5mm with mean size of 3
mm. The agglomerates should have a minimum drop number of 10 and a compressive
strength of 2kg/cm2. Such cured agglomerates mixed with granulated slag sandand may be
used as back fill andshould be pumpable during hydraulic back filling.
2. Experimental
The materials consist of CIP tails, Commercial grade (>90% assay / purity) potassium
amyl xanthate (KAX) Pine oil. CuSO4, CaO, H2SO4, NH4OH, NaOH Ordinary port land
cement [OPC] and Anhydrous gypsum [CaSO4] of -100 mesh [-0.15mm]. MPE 175 x 350
mm ball mill with 10 kg 25 mm steel balls, Denver Laboratory flotation machine, Elico pH
meter, were used. 600 mm dia Disc pelletizer of M/s MPE Co Ltd. Mumbai was used for
granulating. The as received sample was dried and subjected to standard sampling methods
and stored in 16 plastic bags. The as received sample was subjected to [1] Characterization

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studies. [2] Bulk flotation to concentrate S, As and Au values and [3] The standard
granulation / pelletization method as enumerated by the manufacturer and hand books was
followed. The micro pellet / granulated product was subjected standard tests for determining
% Moisture after drying, strengths, drop tests and size analysis after curing the pellets for 72
hours. During the Pelletization experiments, the choice of binder, binder dosage, effect of
machine parameters like rpm and inclination were studied. The optimum condition products
were sent to HGML for their review.
3. Results and discussion
3.1 Characterization studies
The representative samples were subjected to physico-chemical analysis,
mineralogical studies, and diagnostic amenability tests. The physico-chemical analysis
indicated that the as received sample was dark grey coloured fine powder of ~3.0 specific
gravity and analysed 0.35 ppm Au, 28.6 ppm Ag, 0.74% As, 1.27% S, 76.51% SiO 2, 7.24%
Fe, 4.85% Al2O3, 2.83% CaO, 1.74% TiO 2, 1.55% Alkalies. The sample contains mainly
quartz (50 – 55%) occurs as aggregates with minor to subordinate amounts of arsenopyrite,
pyrite, iron oxides-carbonates. Sink and float tests yielded a heavy fraction rich in Au, As
and S. The size analysis of sample is shown in Table 1& Fig 1
Table1 Size distribution of CIP tails sample

Mesh size Size in microns Cumulative wt% U/S

-150+200 106 100.0
-200+250 74 85.0
-250+270 60 80.0
-270+325 53 46.0
-325+400 45 40.0
-400+600 37 33.3
-600 25 25.0

3.2 Bulk flotation studies

The representative samples of 1 kg each were subjected to bulk flotation studies to
float sulphides varying the dosages of activator copper sulphate, collector Potassium amyl
xanthate and % Solids.
3.2.1 Effect of activator copper sulphate dosage;The activator copper sulphate dosage
was varied from 0, 1 and 2 kg/t. The results are shown in Fig 2. The results indicate that
optimum results with selectivity and recovery was obtained at 1 Kg/t CuSO 4 similar to
findings of Ravi et.al. (2003 and 2013).
3.2.2 Effect of collector dosage; The collector KAX dosage was varied from 0.06, 0.18
and 0.24 kg/t. The results are shown in Fig.3. The results indicate that optimum result was
obtained at 0.18kg/t similar to findings of Ravi et.al. (2003 and 2013).
Fig.2; Effect of CuSO4dosage Fig. 3.Effect of KAX dosage

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3.2.3 Effect of %S: The % S was varied from 20, 28 and 36. The test results are shown in
Fig 4. Increase in %S increases %S recovery
Fig4. Effect of % Solids

3.2.4 Final bulk desulphurization flotation test; The material for granulations studies
were prepared by bulk flotation tests at natural pH8, 0.25kg/t ammonium hydroxide, 1kg/t
CuSO4, 0.18kg/t KAX,0.16 kg/t Pine oil and 28% S. The bulk float at 16% yield, assayed
1.4ppm Au, 6.68%S and 4.08% As, which may reused in the plant for recovery of gold after
breaking open the aresenopyrite lattice by chemical processing, while the flotation tails
[ pellet feed] assayed 0.15%As, 0.25%S, 0.15ppm Au. The results are given in Table 2.

Table2; Final bulk flotation desulphurization test under optimum conditions

pH 8 natural, D8060 microns, 28%S, 0.25kg/t Ammonium hydroxide and1kg/t CuSO 4 with
conditioning time of1’ and 15’ each, 0.18kg/t KAX in 2 stages with conditioning time of
1’,0.16 kg/t Pine oil in 2 stages with conditioning time of 1’ each. The bulk flotation time was
2’ and 4’ respectively for 1 and 2 stage.

Product Wt% %S %As Ppm Au %Distn S %Distn As % Distn Au

Bulk float 16.0 6.68 4.08 1.40 80.4 83.8 64.0
Bulk tails 84.0 0.25 0.15 0.15 19.6 16.2 36.0
Head Cal 100.0 1.07 0.79 0.35 100.0 100.0 100.0
Feed Actual 100.0 1.27 0.74 0.35 100.0 100.0 100.0

3.3 Granulation studies

Pelletization experiments were conducted varying angle of inclination and rpm for the
disc pelletizer. The disc pelletizer was chosen as the product size of granules can controlled
through observation as compared with drum pelletizer. In the material parameters the
experiments were conducted varying the dosage of OPC and to choose between Portland
cement [OPC], mix of OPC – anhydrous gypsum – fly ash at optimum binder dosage. Since,
the aim of the experiment was to obtain granules <5mm, the feed rate and residence time was
controlled. Residence time data indicated that pellet diameter increases with residence time.
Hence to avert production of pellets larger than 5 mm the quantum of material fed to
pelletizer was reduced to ¼ that is normally practiced for ore Pelletization process, whose
aim is to produce pellets of -30+6 mm pellets. The micro pelletization process was carried
out in batches to avert oversize pellet production due to assimilation – snow ball growth with
fresh material. The atomized water addition was place at the top of free falling cascading
balls to avert over size pellet growth
3.3.1 Effect of pelletizer rpm; The pelletizer rpm was varied from 25 to 45 keeping other
parameters like angle of inclination [45 degrees], OPC binder dose [5%], moisture [11%] as
constant. The results are given in Table 3and Fig.5. The results indicate that the size of
agglomerate is large at very low rpm and the agglomerate is non-spherical and weak. Further
increase in rpm reduces the size to minimum and subsequently increases the size at high rpm

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which is not acceptable for hydraulic mine back fill. Optimum results were obtained at an
rpm of 25. This may be due to extreme low or high angles the charge may not be lifted
leading to formation of coarse agglomerates. Pandey et.al. (2012) while optimizing
parameters for producing iron concentrate pellets of 10mm size indicated that very low rpm
produced very large pellets while optimum results were obtained at 2.8 m/sec tip speed.

Table 3; Effect of RPM

Yield %-6mm Wt% Drop C Strength

Particulars variable
+0.2mm of yield Sand No Kg/Cm2
Variable rpm, 15rpm 50 42 21.0 1 0.8
45 degrees, moisture 11%, 25rpm 90 50 45.0 17 3.0
binder OPC 5% 35rpm 97 34 33.0 17 3.4
45rpm 96 39 37.5 13 2.7

3.2 Effect of binder OPC concentration; Review of literature indicated that OPC
consumption for mine back fill varied from 4 to8% in CPB. Hence, OPC binder dose was
varied from 5 to 10% with 2.5% step. The results are given in Table4 and Fig 6. The results
indicate that the crushing strength and drop number increased with binder dosage. Hence as
it is an exploratory test, the binder dosage was kept at maximum of 10%.
Table 4; Effect of Binder OPC dosage

Yield %-6mm Wt% Drop C Strength

Particulars variable
+0.2mm of yield Sand No Kg/Cm2
Variable OPC% 45 degrees, 5.0 % 90 50 45.0 17 3.0
moisture 11%, rpm 25 7.5% 98 50 49.0 17 3.0
10.0% 99 45 44.6 25 3.5

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3.3.3 Effect of angle of inclination: The angle of inclination of the disc pelletizer was
varied from 30 to 60 degrees keeping rpm, moisture, OPC % constant. The results are given
in Table 5.Balling mainly depends on inclination of disc which primarily affects the angle of
repose. The extent to which charge is lifted along the kidney shaped trajectory and size of the
zone occupied by charge are functions of the angle of repose of the material being pelletized
which itself is dependent on angle of inclination of disc. At lower inclination the angle of
repose will be small.This yields coarser pellets.At too steep an angle, not all the charge would
no longer be lifted by friction leading formation of small pellets. The tilt angle for high
production rates with a minimum diameter of 6 mm varies between 45-48 o depending on the
frictional coefficient of ore and the lifting coefficient. The rim height is also determined by
the tilt angle. Filling volume is dependent on both factors. With increasing in inclination the
% desired size reduced [Pandey et.al. (2012)]
Table 5; Effect of angle of inclination

Yield %-6mm Wt% Drop C Strength

Particulars variable
+0.2mm of yield Sand No Kg/Cm2
Variable angle in degrees, 30o 97 34 33.0 17 3.0
moisture 11%, rpm 25 45o 99 45 44.6 25 3.5
binder OPC 10% 60o 99 90 89.1 25 3.5

3.3.4 Effect of combination of Binders: With regard to the aforementioned statistics, PC

appears to be the most expensive component of operations and hence becomes the primary
setback in its use as a sole binder. Atari and E.K. Yanful (2013) reviewed the role of binders
for CPT as mine backfill and recommended use of cement kiln dust, fly ash in addition to
cement for cemented paste backfill [CPB]. Peyronnard and Benzaazoua (2011)have tested
waste gypsum as hydration activator for cemented mine backfill applications and found that
4.5 wt% binder (42%PCe 40%waste glass 18%anhydrite) mixed with mining waste can
produce a monolith with UCS of 0.6 MPa after 14 days of curing. In view of the above the
ratio of OPC with anhydrous gypsum was varied from 0, 50 and 80% keeping total binder
consumption at maximum level of 10%. The results are given in Table 4. The results indicate
the dilution of cement binder with anhydrous gypsum reduced the drop number and quality
was affected significantly when the OPC - anhydrous gypsum ratio was less than 1. The
overall OPC consumption was 5%.

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 Table 6: Effect of ratio of Binder and additive
Yield %-6mm Wt% Drop C Strength
Particulars variable
+0.2mm of yield Sand No Kg/Cm2
Variable binderOPC : CaSO4 100:0 99 90 89.1 25 3.5
Angle 60o, moisture 11%, 50:50 90 95 85.5 17 3.0
rpm 25, Binder 10% 20:80 94 95 89.3 7 1.5

The partially desulphurised micro pellets – granules at 60o inclination angle, disc rpm
25-35 [ average 30],11% moisture, 5% Ordinary Portland Cement as binder.5% Gypsum as
binder additive, yielded micro pellet/ granules sands of -6+0.2 mm with 25 drop number and
3.5kg/cm2 Compression strength assaying 0.25% S, 0.15%As, with 89.1% yield, meeting
the specification. The cured granules may be used for mine back fill along with granulated
slag, in lieu of river sand.

4. Conclusions

The preliminary amenability nil waste bulk flotation - granulation tests indicated that
1 The sample is amenable to the concept of nil waste process of bulk flotation and
granulation and reuse of the products as feed to plant and mine back fill respectively.
2 The bulk sulphide float assaying 1.4ppm Au, 6.68%S and 4.08% As, which may be
reused in the CIP plant for recovery of gold after breaking open the aresenopyrite
lattice by eco- friendly chemical processing.
3 The partially deslulphurised micro pellets – granules at 60 o inclination angle, disc rpm
25-35 [average 30], 11% moisture, 5% Ordinary Portland Cement as binder.
5% Gypsum as binder additive, yielded micro pellet/ granules sands of -6+0.2 mm
with 25 drop number and 3.5kg/cm2 Compression strength at 89.1% yield
assaying0.25% S, 0.15%As, meeting the specification. The cured granules may be
used for mine back fill in lieu of river sand

Acknowledgements

The authors are thankful to:

1 M/s HGML for providing the sample and assays,
2 M/s VSKU Ballari for permission to undertake the work and present the findings
3 M/s TVJ MMPL, Bangalore for the encouragement
4 The Convener of XIV NS MTA, HCL, MCP, MP for enabling to present the findings

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