The evolution from "mineralization" to "mineral processing"

1. Overview of the subject

Mineral processing is a subject system developed on the basis of the study on the evolution of mineral formation.

Studies are mineral, natural mineral resources (typically including metallic minerals, non-metallic minerals, coal, etc.) with physical and chemical methods of sorting, separation, enrichment of valuable minerals which science and technology, the purpose of metallurgical , chemical and other industries provide qualified raw materials.

Mineral processing is developed on the basis of mineral processing. It uses physical, chemical and biological methods to process natural mineral resources (including separation, enrichment, purification, extraction, deep processing, etc.) to obtain useful substances. Science & Technology. Its purpose is not simply to provide qualified raw materials for other industries, but also to directly obtain metals and mineral materials.

2 Formation of mineral processing disciplines

Humans have used mineral resources for thousands of years. Whether it was ancient Egypt in the thousands of BC or the Roman Empire in the Middle Ages, or in ancient China, due to the overall backwardness of science and technology and low social productivity, the mineral resources used by humans were mainly obtained from natural ore by manual work. Original flotation methods such as gold mining, artificial chute, manual jigging sieve, washing tank and other raw re-election methods and gourd oil scraping gold powder floating on the water surface. In ancient China, the original re-election and flotation were summarized as “Cheng, Amoy, Fly, and Fall”. Our Sung Ming Dynasty book "Heavenly Creations" (1637), a book on the exploitation of iron sand and tin sand sorting has been described as shown in Figure 1-1. Although these manual operations have the shadow of modern “surface flotation” and “re-election”, they are not an industrial technology. This phenomenon has been extended to the mid-19th century.

Picture 1-1

In the late 19th and 20th 1920s, the world's industrial production developed rapidly, and the demand for mineral raw materials increased, prompting the development of technology, especially in the early 1920s, the industrial application of flotation reagents in flotation, enabling mineral processing technology ( Including crushing, sieving, grinding, re-election, electro-election, magnetic separation, flotation, etc.) can handle most natural mineral raw materials. Since then, mineral processing technology has become a mature industrial technology for humans to select and enrich useful mineral raw materials from natural ore, and has been widely used.

2.1 The theoretical basis for the re-election of the theoretical basis of the mineral processing discipline:

With the development of fluid mechanics, the basic research of gravity beneficiation started earlier. In the second half of the 19th century, the Austrian Rittinger proposed the "equal drop phenomenon", and Mo nroe et al. further proposed "interference settlement." In the 1940s, the former Soviet scholar Schmatskov proposed that the jigging is in the ascending water flow. The theory of stratification according to the relative density of the suspension; German scholar Mayer explained the stratification process from the perspective of bed potential energy drop; British scholar Bagnoid observed the multi-layered granules in the laminar flow and the slant flow under the shear movement in the 1950s. Loose stratification.

These doctrines constitute the theoretical basis for re-election

Electromagnetic theory

In the field of electromagnetic beneficiation, due to the development of physics, it has long been recognized that permanent magnets can be used to select magnetite ore. The electromagnetic beneficiation theory has also been preliminarily established when the electromagnet is used as the magnetic field of the magnetic separator and has various industrially produced electromagnetic concentrators.

Fundamental theory of flotation

In terms of flotation, from the 1930s, Taggart of the United States and Plaksins of the former Soviet Union proposed the "chemical reaction hypothesis" or "solubility accumulation hypothesis" of collectors to explain the floatability of heavy metal sulfide ore. order. Gaudin in the United States, Bogdmov in the former Soviet Union, and Wark in Australia have studied the relationship between the wettability and floatability of minerals, the adsorption mechanism of flotation agents, and the activation of flotation. The relationship between the electrical properties of the mineral surface and the floatability was systematically studied by DW Fuerstenau et al. By the 1960s, the three basic theories of flotation (wetting theory, adsorption theory, and electric double layer theory) had taken shape. Important books are:

Handbook of Ore Dressing of Taggart, USA (1st edition, 1927, 2nd edition, 1944); Gaudin's Flotation (1st edition, 1932, 2nd edition, 1957); Australia's Sutherland and Wark's Principles of Flotation (1955) The first edition); the former Soviet Union Bogdmov Theory and Technology of Flotation (1959).

2.2 Discipline system

(1) Grinding. Based on the discipline of rock mechanics, the ore blockiness is reduced by mechanical force to a particle size range suitable for process selection, and the useful minerals and gangues are dissociated from each other.

(2) Re-election. Based on the discipline of fluid mechanics, different minerals are sorted in a certain medium according to the density difference of different minerals.

(3) Electromagnetic selection. Based on the discipline of electromagnetism, different minerals are sorted according to the difference in magnetic properties of different minerals.

(4) Flotation. Based on the surface chemistry, the separation of different minerals is realized according to the differences in physical and chemical properties of different mineral surfaces.

The beneficiation in this period is mainly from the natural ore (metal ore, non-metallic minerals, coal, etc.), separating and enriching the useful minerals, providing raw materials for metallurgy, chemical industry and building materials.

The “mineralization” vocabulary used abroad is mostly “ore dremng” or “mineral dressing”.

2.3 Problems facing mineral processing

Since the 1960s, with the rapid development of the world economy, on the one hand, human demand for mineral resources has increased. On the other hand, mineral resources have decreased rich minerals, increased lean mineral resources, and wastewater discharged from mines and smelters. Environmental pollution and treatment issues such as solid waste are receiving increasing attention. Traditional mineral processing techniques and theories cannot fully adapt and solve these problems.

3 Formation of mineral processing disciplines

This requires comprehensive use of multidisciplinary knowledge and new achievements, the search for new disciplines, the development of new science and technology, to achieve the comprehensive utilization of mineral resources, including the separation and enrichment of new technologies and equipment for lean mineral resources. Purification and finishing of minerals, comprehensive management of the environment, development of new mineral uses, etc. The use of mineral resources is not simply a matter of obtaining mineral products through “mineralization”, but a problem of comprehensive “processing” utilization. To this end, in recent decades, scientific and technological workers in mineral processing and adjacent disciplines have conducted a large number of basic theories and techniques in the field of mineral processing and interdisciplinary research. At the same time, due to the development of adjacent disciplines, such as electrochemistry, quantum chemistry, surface and colloidal chemistry, turbulence mechanics, bioengineering, metallurgy, materials science and engineering, and the application of computer science and technology in the field of mineral processing, many New disciplines and new technologies for processing mineral resources.

With the development of new technologies utilizing mineral resources, mineral processing cannot cover most of the new scientific fields of processing and utilizing mineral resources, and “mineral processing” is on the horizon. The discipline of mineral processing is far wider and deeper than the traditional mineral processing disciplines, regardless of the subject base, subject areas and research objects.

In fact, since the 1960s, foreign countries have gradually adopted “mineral processing” instead of “ore dressing”.

In China, after nearly 10 years of brewing, the “mineralization” was renamed “Mineral Processing” in the enrollment catalogue of the State Education Commission in the 1990s. Scholars have published a large number of books.

During this period, some important works in China were: Hu Weibai's "Flotation" (1986); Wang Dianzuo, Hu Yuehua's "Flotation Solution Chemistry" (1988); Lu Shouci's "Mineral Particle Sorting Project" (1990); Hu Xigeng Etc. "Flotation Theory and Technology" (1991); Zhu Yushuang, Zhu Jianguang, "Chemical Principles of Flotation Chemicals" (1991); Feng Qiming, Chen Wangjun, "Sulfurized Mineral Flotation Electrochemistry" (1992); Yao Shudian's "Heavy Principles of Selection (1992); Liu Shuzheng's "Magnetic Ore Dressing" (1994); Xu Shi's "Selection of Ore Selectability" (1995); Wang Dianzuo, Lin Qiang, Jiang Yuren's "Molecular Design of Mineral Processing Metallurgical Agents" (1996); Fu Juying, Jiang Tao, Zhu Deqing, Sintering Pelletology (1996); Qiu Guanzhou, Jiang Tao et al., “Direct Reduction of Cold-Consolidated Pellet” (2001); Qiu Guanzhou, Yuan Mingliang, et al. 2003); Wang Dianzuo et al., "Mineral Processing" (2003) and so on.

3.1 Tasks and processes for mineral processing

With the development of disciplines, mineral processing disciplines have taken place and are undergoing tremendous adjustments and changes. Some technologies suitable for processing lean ore, complex ore and direct extraction of useful ingredients are being developed.

The objects of mineral processing have expanded from natural mineral resources to the recovery and utilization of secondary resources. Various solid wastes, such as tailings, slag, fly ash, metal scrap, electrical waste, plastic waste, domestic waste and even soil, have been processed and converted into useful resources.

Due to the development of modern science and technology and the advancement of human society, it is necessary to develop mineral raw materials and mineral materials with ultra-pure, ultra-fine and special functions. Chemical extraction and the combination of bioengineering and machining have long been common in the processing of metal ore and non-metallic minerals. The deep processing of non-metallic minerals further expands and enriches this combination, such as ultrasonic stripping of kaolin , graphite and organic and inorganic inlays of various layered minerals.

The task of mineral processing has also changed. Mineral processing has not only provided qualified mineral raw materials for various industries, such as concentrate or intermediate products, but has expanded into an industry that can produce ultra-pure, ultra-fine and special-function mineral materials and mineral products. The mineral material engineering mainly uses non-metallic ore or mineral as raw material (or base material) to obtain inorganic non-metallic materials and devices with certain physical and chemical properties through certain deep processing techniques. Mineral material has potential application, for example, solar panels zeolite, montmorillonite desiccant, pyrophyllite high temperature insulation materials and missile sealing, the sealing material paragonite, hydroxy apatite bone material, diatomaceous earth dental molding material, fireproof material volcanic Wait.

Unit operations in modern mineral processing engineering, which generally include: crushing, grading, ultrafine particle preparation, physical sorting (reselection, magnetoelectric selection, photoselection, radioactivity selection, etc.), flotation and other interface sorting, Chemical treatment and biological extraction, solid-liquid separation (sedimentation, filtration, drying), forming and granulation, gas-solid separation, dust collection, material storage and transportation, etc.

3.2 Directions in mineral processing

(1) Flotation chemistry. These include flotation electrochemistry, flotation solution chemistry, and flotation surfaces and colloid chemistry.

1 Flotation electrochemistry. According to the principle of electrochemistry, the mechanism of the flotation process is studied, mainly for sulfide ore. Electrochemical reaction dominates the action mechanism of sulfide ore and flotation agent, and achieves separation of polymetallic sulfide ore by electrochemical regulation.

2 flotation solution chemistry. According to the principle of solution chemistry, the flotation behavior is studied, mainly for non-sulfurized ore. According to the chemical reaction behavior of mineral-floating agent solution, the separation conditions and flotation mechanism of non-sulfurized ore are predicted.

3 flotation surface and colloidal chemistry. According to the surface and colloidal chemistry, the interaction between particles was studied, and the selective cohesion, dispersion and flotation separation behavior of fine-grained minerals were discussed. Discuss the process mechanism of ultrafine particle processing, such as hydrophobic coagulation, selective flocculation, carrier, mainly for ultrafine minerals, coal processing and utilization and wastewater treatment.

(2) Composite physics mineral processing.

According to rheological, turbulent mechanics, electromagnetics, etc. to study the motion behavior of particles in the gravity field, electromagnetic field or composite physics (gravity + magnetic force), determine the classification and sorting conditions of fine minerals, such as magnetic fluid hydrocyclone Sorting, vibrational artery dynamic high gradient magnetic separation, fluidized bed dry coal preparation, etc.

(3) Molecular design of high-efficiency and low-toxic agents.

According to the relationship between structure and performance of quantum chemistry, organic chemistry, and surface chemistry, a new type of highly effective mineral processing agent is designed for specific applications.

(4) Biochemical extraction of mineral resources.

With bioleaching, chemical leaching, solvent extraction, ion exchange complex lean fine mineral resources, such as low-grade copper ore, uranium, gold extraction of coal desulfurization. Because bacteria have the functions of oxidation, adsorption and degradation, biochemical extraction not only strengthens the leaching process, but also has unique advantages in environmental and process control. The research on basic theory and technology of biochemical extraction has become one of the important directions of mineral processing discipline in recent years.

(5) Direct reduction and mineral raw material agglomeration.

Mainly engaged in scientific research on the agglomeration and finishing of mineral raw materials, researching the mechanism of direct reduction of iron concentrate coal gene rotary kiln and molding of powder materials.

(6) Comprehensive utilization of complex and poor mineral resources.

Research on the technology and basic theory of some large-scale complex lean polymetallic ores, such as the combination of metallurgy, metallurgy, and various mineral processing techniques (heavy, magnetic, and floating), to study the comprehensive utilization of resources.

(7) Mineral finishing and mineral materials.

By means of purification, ultra-fine pulverization, surface modification, etc., the minerals are directly processed into usable materials without smelting, such as the processing of ultra-pure molybdenum ore, which is an excellent performance lubricant, and ultrafine zircon required for functional ceramics. Processing of sand and kaolin, processing of ultrafine rutile required for electronic slurry, processing of civil and industrial briquette, coal water slurry, underground coal gasification, etc.

(8) Computer technology for mineral processing.

Using computer science and technology to simulate, simulate and optimize, predict and design mineral processing, establish an expert system for mineral processing, and realize computer management and control of mineral processing.

3.3 Challenges in the mineral processing discipline

After decades of development, the mineral processing discipline has formed a relatively complete disciplinary system and developed many new mineral processing technologies. However, with the changes in human resources available in the future and the limitations of existing technologies, mineral processing technology Development has faced many challenges. The development of human social life requires that the development of mineral processing technology aims to achieve "high efficiency, low energy consumption and no pollution" in the mineral processing process.

The further development of the mineral processing discipline faces challenges from resource changes and technical difficulties required.

(1) Comprehensive recovery of complex lean mineral resources.

The consumption of mineral resources by humans has increased year by year, and the continuous exploitation and utilization of easy-to-select mineral resources, more and more complex, poor, large-scale polymetallic deposits need to be exploited. These deposits are characterized by metal species and associated rare, There are many varieties of precious metals, low grade and difficult to handle. Existing mineral processing technologies face high energy consumption, low comprehensive utilization, and environmental pollution when dealing with these mineral resources.

(2) Processing and utilization of waste rock and tailings.

In the metal ore beneficiation process, a large amount of raw materials and energy consumption are consumed through the grinding process. Generally, only about 10% of the total ore mass of non-ferrous metal minerals or about 30% of ferrous minerals, and a large number of associated non-metallic minerals are recovered. Tailings) failed to use. Comprehensive processing and utilization of waste rock, off-balance sheet minerals and valuable metals in tailings that are stripped during the mining process require new processing and utilization technologies.

(3) Mineral finishing technology.

Traditional mineral processing mainly provides concentrates and coarse-grade mineral products. The added value of the products is low, and it cannot meet the needs of the development of mineral materials. High-purity, ultra-fine, surface modification and other finishing of metal minerals, especially non-metallic minerals, to produce mineral materials suitable for different industries such as electronics, aerospace, weapons, high-tech ceramics, metallurgy, chemical industry, etc. One of the key development trends in mineral processing technology.

(4) Clean coal technology.

Coal is an important source of energy, especially in China. However, the pollution brought by coal to the environment has become a close concern of the world. The washing and desulfurization and deep processing technology of coal has been and will remain an important issue in mineral processing.

(5) Secondary resource development.

Waste water, waste slag, waste, rare and precious metals in mines, smelters, chemical plants, etc., secondary resources such as used cars, cables, machinery and scrap metal products. Due to the reduction of resources and the gradual reduction of secondary resources, the development of recycling technologies for secondary resources has undoubtedly become an important issue in the field of mineral processing. At present, the technology in this area is still immature. In particular, there is no effective means to recover useful materials from the three wastes and to control the environment, resulting in waste of resources and environmental pollution.

(6) Development of marine resources.

Ocean manganese nodules, cobalt crusts occur in the deep seabed is a huge mineral resources, in addition to manganese, a metal reserves of copper, cobalt, nickel, etc. is also very rich, in the future land resources depleted, exhausted, these will Become a valuable resource for human beings.

(7) Non-mineral resources.

Urban waste, waste paper, waste plastics, oily soil, oily sewage from oil exploitation, metal salts in inland lakes, heavy metal sludge, and even the separation of red blood cells and white blood cells require new processing and utilization technologies.

3.4 The development direction of the mineral processing discipline treats the changes in processing resources and technical problems

Mineral processing technology workers and science and technology workers in related disciplines continue to conduct new explorations and research in the field of mineral processing and related disciplines. The intersection, penetration and integration of mineral processing engineering with adjacent disciplines such as physics, chemical and chemical engineering, bioengineering, mathematics, computer science, mining engineering, mineralogy, materials science and engineering have greatly facilitated The expansion of the mineral processing discipline has resulted in a variety of high-efficiency, low-energy, non-polluting resource processing technologies and new research areas.

3.4.1 Changes in the subject

(1) Mineral resources: including metal minerals, non-metallic minerals, coal, etc.

(2) Non-traditional mineral resources.

1 Marine minerals: manganese nodules, cobalt crusts, metals in seawater, seabed hydrothermal sulfide deposits.

2 Metal salts and heavy metal sludge in salt lakes and lakes.

(3) Secondary resources.

1 Industrial solid waste: smelting chemical waste, tailings, waste rock.

2 waste electrical appliances. TV, refrigerator, stereo, etc.

3 scrap metal products. Cables, wires, cans, batteries, used cars, etc.

4 city garbage, waste paper, waste plastics, oily sewage, oily soil, etc.

3.4.2 Development of the subject area

Developed from a single mineral processing field to include

Mineral processing

Mineral material processing

Secondary resource processing (seco ndary material processing),

Metal metalurgical processing,

Can be referred to as the subject area of ​​4-MP.

3.4.3 Development of the subject direction

(1) Process mineralogy. Intersection with mineralogy and petrology, study the analysis, identification, characterization of the material composition of resources, basic physical and chemical properties of materials, and provide basic information for "processing".

(2) Powder engineering. Based on rock mechanics, fracture mechanics, and crystal chemistry, the treated resources are selectively disintegrated, dissociated, or superfinely processed.

(3) Separation in the gravitational field and fluid force field. Based on fluid mechanics and fluid dynamics, different materials are separated and enriched according to the density, particle size and shape of the materials being processed. Such as the separation of black tungsten ore and quartz , the separation of polyvinyl chloride and polyethylene, the separation of heavy materials and light materials in municipal waste, and the separation of copper wire and rubber.

(4) Separation in an electromagnetic field. Magnetic separation and electrostatic separation based on electromagnetism and electrostatics, separating different materials according to the difference in magnetic or electrical conductivity of the materials being processed. Isolation Isolation isolated magnetic minerals and non-magnetic minerals, mineral nonconductive separating the conductive minerals, separation of the magnetic toner and the paper, the red blood cells and white blood cells, separating charged plastic uncharged plastic, copper wire and aluminum wire Wait.

(5) Flotation.

The most important technology in mineral processing can process various mineral resources, secondary resources and non-mineral resources, involving inorganic chemistry, organic chemistry, surface chemistry, electrochemistry, physical chemistry and other fields of almost all chemistry, forming flotation Cross-research fields in electrochemistry, flotation solution chemistry, flotation agent molecular design, and flotation surface chemistry. Such as flotation of sulfide ore and non-sulfurized ore, flotation of waste paper and waste plastics, ion flotation in wastewater, oil sewage and oil soil treatment.

(6) Biological extraction. It mainly deals with the difficult selection of various low-grade mineral resources, mineral resources, marine mineral resources and non-traditional mineral resources, and extracts valuable metals directly from these resources. Such as copper, gold mining bio-dip leaching, underground leaching, heavy metal sludge, treatment of marine manganese nodules, etc., involving bioengineering, metallurgical reaction engineering, mineral engineering and mining engineering and many other interdisciplinary.

(7) Chemical separation. Including solvent extraction, ion exchange, membrane separation, chemical leaching, etc., processing complex ore and off-balanced biological heap leaching resources, marine mineral resources, industrial wastewater, etc., involving chemical and chemical engineering, metallurgical reaction engineering and other fields.

(8) Chemical synthesis, including chemical synthesis of mineral materials, mineral composites, mineral-polymer composites, etc., involving chemical and chemical engineering, materials science and engineering.

(9) Surface modification. Chemical treatment of mineral surfaces by surface chemical reaction, selective dissolution, dissolution, etching, coating, etc., preparation of functional mineral materials, etc., involving chemical engineering and materials science and engineering.

(10) Aggregation and dispersion. Aggregation and dispersion of fine particles, stabilization and dispersion of mineral colloidal systems, solvent extraction, preparation of pellets, briquette, coal water slurry, etc., involving surface chemistry, granulation and other fields.

(11) Computer technology for mineral processing. Research resources, mathematical models of processing, expert systems, artificial intelligence, neural networks, simulation, optimization and automatic control, involving computer science and technology, automatic control and other fields.

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