High Chromium Cast Iron Grinding Media for Copper Sulfide Flotation
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Solution Overview
Problem
Current methods for recovering copper sulfide concentrates from ores containing iron sulfides face challenges in achieving high concentrate grade and recovery while minimizing chemical consumption and adapting to varying ore compositions.
Innovation Solution
The method involves wet grinding of copper sulfide ore using high chromium cast iron alloy grinding media and adding hydrogen peroxide to the mineral pulp before or during froth flotation, which synergistically improves concentrate grade and recovery, reducing the amount of hydrogen peroxide needed and allowing for adjustments based on dissolved oxygen levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon steel grinding media are used for wet grinding, then the cost is lower, but the recovery of copper sulfides during flotation deteriorates due to corrosion and adsorption of iron species
Solution Approach 1:
The invention changes the material parameter of the grinding media from carbon steel to high chromium cast iron alloy, which has superior corrosion resistance. This parameter change eliminates the corrosion problem and prevents iron species adsorption onto copper sulfide surfaces, thereby maintaining high recovery rates without the need for additional chemical treatments.
Solution Approach 2:
The invention uses high chromium cast iron alloy, which is a composite material combining iron with chromium elements. This composite structure provides both mechanical strength and corrosion resistance, solving the contradiction between durability and performance in the grinding media.
2Reliability
If high chromium cast iron alloy grinding media are used, then the recovery of copper sulfides improves, but the cost increases
Solution Approach 1:
The invention changes the material composition parameter to high chromium cast iron alloy, which although more expensive initially, eliminates the need for continuous replacement due to corrosion and reduces chemical consumption for corrosion inhibition, providing long-term economic benefits.
3Reliability
If large amounts of hydrogen peroxide are added to raise redox potential, then the selectivity for copper sulfide flotation improves, but the chemical consumption increases
Solution Approach 1:
The invention changes the operating parameter of redox potential elevation from using large amounts of hydrogen peroxide to using small amounts in combination with high chromium cast iron alloy grinding media. The alloy itself contributes to maintaining favorable redox conditions through its corrosion resistance, reducing the chemical dosage needed.
Solution Approach 2:
The high chromium cast iron alloy acts as an intermediary that stabilizes the system against corrosion and iron species release, thereby reducing the burden on hydrogen peroxide to maintain redox potential and selectivity, allowing lower chemical consumption.
4Reliability
If oxidants are added to raise redox potential by 20 to 500 mV, then the separation of copper sulfide from iron sulfide improves, but the process complexity increases
Solution Approach 1:
The invention simplifies the process by changing the approach from actively managing redox potential through controlled oxidant addition to passively maintaining favorable conditions through the use of corrosion-resistant high chromium cast iron alloy grinding media, reducing process complexity while maintaining separation efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances copper sulfide concentrate grade and recovery, reduces chemical consumption, and improves selectivity over iron sulfides, enabling adaptation to changing ore compositions without additional optimization experiments.
Implementation Method 1
adding hydrogen peroxide to the conditioned mineral pulp between steps b) and c) or during step c)
Implementation Method 2
The document teaches to add an oxidant in an amount that raises the redox potential of the mineral pulp by 20 to 500 mV
Implementation Method 3
conditioned with a collector compound that adsorbs to the surface of copper sulfide minerals and makes the surface of copper sulfide minerals more hydrophobic
Implementation Method 4
A gas is then passed through the mineral pulp to form gas bubbles, hydrophobic particles of the mineral pulp attach predominantly to the gas/liquid phase boundary of the bubbles and are carried with the gas bubbles to the froth
Implementation Method 5
high chromium cast iron alloy grinding media improve recovery of copper sulfides during flotation due to the better corrosion resistance of such alloys
Data Source
AI summary
In a method for recovering a copper sulfide concentrate by froth flotation from an ore containing an iron sulfide, wet grinding of the ore with grinding media made of high chromium cast iron alloy having a chromium content of from 10 to 35% by weight is combined with an addition of hydrogen peroxide to the conditioned mineral pulp before or during flotation in order to improve concentrate grade and recovery of copper sulfides.