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Increasing yield on Tungsten and Tantalum ore production by means of advanced and flexible control on crushing, milling and separation process

Fact Sheet

Result in Brief

Reporting

Results

Objective

Modern economy is highly dependent on specific raw materials, and it is envisaged that this dependency will increase in the near future. Most of them are scarce in EU and of poor purity, being mixed within complex and low grade aggregates which need to be processed by means of a separation process consuming high quantities of energy and water, and even in some cases this makes its exploitation unfeasible due to production costs.
Being EU dependent on some of these materials, as identified by EIP initiative, our society is demanding more efficient extracting processes to contribute to major European independency on these Critical Raw Materials.
Tungsten and Tantalum ores are two recognized CRMs: In a market currently dominated by China and Russia production (among others), in Europe Tungsten (limited) production is mostly concentrate into UK, Spain and Portugal . On the other side, Tantalum is a key element on electronics with clear EU external production dependency, as it is naturally really scarce in Europe (only 1% of world production is concentrated in EU).
Knowing this situation, OptimOre Project proposes the research and development of modelling and control technologies, using advanced sensing and advanced industrial control by means of artificial intelligence techniques, for the more efficient and flexible Tantalum and Tungsten ores processing from crushing to separation process, with the participation of relevant international players in the mining field on research (Chalmers University- Dr. Magnus Evertsson, Exeter University with Dr. Richard Pascoe, Freiburg University with Dr. Holberg Lieberwirth, among others). The project proposes a 3 years collaboration among 8 partners of 4 different countries.

Programme(s)

H2020-EU.3.5.3. - Ensuring the sustainable supply of non-energy and non-agricultural raw materials

Topic(s)

SC5-11b-2014 - Flexible processing technologies

Call for proposal

H2020-SC5-2014-one-stage

See other projects for this call

Funding Scheme

RIA - Research and Innovation action

Leaflet | Map data © OpenStreetMap contributors, Credit: EC-GISCO, © EuroGeographics for the administrative boundaries

Coordinator

UNIVERSITAT POLITECNICA DE CATALUNYA

Address

Calle Jordi Girona 31
08034 Barcelona

Spain

Activity type

Higher or Secondary Education Establishments

EU Contribution

€ 1 069 250

Website

Contact the organisation

Participants (7)

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CHALMERS TEKNISKA HOEGSKOLA AB

Sweden

EU Contribution

€ 837 156,25

THE UNIVERSITY OF EXETER

United Kingdom

EU Contribution

€ 550 000

UNIVERSIDAD DE OVIEDO

Spain

EU Contribution

€ 471 312,50

TECHNISCHE UNIVERSITAET BERGAKADEMIE FREIBERG

Germany

EU Contribution

€ 632 687,50

INTERKONSULT LTD

United Kingdom

EU Contribution

€ 329 875

EDMA INNOVA SL

Spain

EU Contribution

€ 693 500

HELMHOLTZ-ZENTRUM DRESDEN-ROSSENDORF EV

Germany

EU Contribution

€ 500 687,50

Project information

OptimOre

Grant agreement ID: 642201

Project website

Start date

1 December 2014
End date

28 February 2018

Funded under:

H2020-EU.3.5.3.

Overall budget:

€ 5 084 468,75
EU contribution

€ 5 084 468,75

Coordinated by:

UNIVERSITAT POLITECNICA DE CATALUNYA

Spain

DE EN ES FR IT PL

A new way of extracting critical raw materials in Europe

To increase Europe’s critical raw material independence, the EU-funded OptimOre project developed an efficient process for extracting tungsten and tantalum here in Europe.

CLIMATE CHANGE AND ENVIRONMENT

Our economy is highly dependent on specific raw materials – a dependency that will only increase in the near future. For example, tungsten and tantalum are two raw materials used in many of our everyday electronic devices. As our use of consumer electronic goods increases, so too does our dependency on the raw materials that power them. The challenge is that materials like tungsten and tantalum are scarce in Europe – and what does exist is of poor quality. Thus, the EU must either import these minerals from outside Europe or process the poor-quality materials found here. The problem with the former is that these minerals are often mined in conflict zones or in conditions that violate human rights. However, processing the poor-quality ore mined here requires the use of high quantities of energy and water – making exploitation costly and unfeasible. To increase Europe’s critical raw material (CRM) independence, the EU-funded OptimOre project developed an efficient process for extracting the minerals found in Europe. Specifically, the project optimises the crushing, milling and separation processes for tungsten and tantalum by means of a fast and flexible production process based on new software models and advanced sensing technology. “OptimOre applies intelligent technologies to create a more efficient and flexible process for crushing and separating tantalum and tungsten ores,” says Project Researcher Josep Oliva. “As a result, our process increases yields by between 7 % and 12 % and energy savings by 5 % over the best processes on the market today.” New models, new technology The OptimOre system introduces new models for crushing machinery and high-precision milling, along with improvements to the gravity, magnetic and flotation separation processes. It also utilises advancements in artificial intelligence to automate various control tools. For example, crushing machinery models are based on equipment type, operational mode and characterisation of the ore. Models look at improving energy consumption, particle size distribution predication and mineral composition. “By using the composition, or element concentration, as a model parameter, we are able to better understand the liberation of critical raw elements during the crushing stage,” explains Oliva. The project also investigated technologies for dry and wet high- and low-intensity magnetic separation. Based on laboratory experiments in the wet high-intensity magnetic separator, a calculation model was created and validated with different materials. “The challenge here was to create a new calculation model with an error of less than 10 %,” says Oliva. “The error for the established model ranges from 8.6 % to 26 %, whereas the average error for the model we created ranges from 1.9 % to just 4.5 %.” Sustainable mineral processing According to Oliva, the OptimOre project helps push the EU to the forefront of sustainable mineral processing technologies and solutions. Furthermore, the technology developed during the project offers added value and new jobs in both the material production and downstream industries. The system also optimises energy and water consumption, thus increasing the overall efficiency of the process and reducing the industry’s environmental footprint. “The technology developed within OptimOre allows for the processing of the low-grade deposit types found in Europe,” adds Oliva. “By using the technology we developed, the mineral processing industry will increase their yield, thus enabling a more efficient way for exploiting critical raw materials here in Europe.”

Keywords

OptimOre, mining, critical raw materials, minerals, tungsten tantalum

Project information

OptimOre

Grant agreement ID: 642201

Project website

Start date

1 December 2014
End date

28 February 2018

Funded under:

H2020-EU.3.5.3.

Overall budget:

€ 5 084 468,75
EU contribution

€ 5 084 468,75

Coordinated by:

UNIVERSITAT POLITECNICA DE CATALUNYA

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Periodic Reporting for period 2 - OptimOre (Increasing yield on Tungsten and Tantalum ore production by means of advanced and flexible control on crushing, milling and separation process)

Reporting period: 2016-06-01 to 2018-02-28

Summary of the context and overall objectives of the project

The main objective of the OptimOre project is to optimize the crushing, milling and separation ore processing technologies for Tungsten and Tantalum mineral processing, by means of improved fast and flexible fine tuning production process control based on new software models, advanced sensing and deeper process physical study increasing yield in 7-12% on the current best production processes, increasing energy saving on a 5% compared to the best available techniques.
The project was divided into work packages that covered the whole mineral processing domains but also the management and scientific coordination technology watch and intelligent control and design software development, system integration and validation and dissemination and exploitation objectives.
OptimOre aimed to set up the starting point of the project with the most advanced SoA technologies available. In terms of mineral processing, a full minerals characterization and the development of new models for crushing machinery and to address high precision milling models which can predicate product with a suitable mineral liberation degree. New improvements on gravity separation equipment modelling, commonly used for tungsten and tantalum processing, to develop new gravimetric separation process models and to develop and evaluate a predictive approach for froth flotation equipment and reagent regimes commonly used for the beneficiation of tungsten and tantalum ores, were also important objectives. All the process work packages had to be integrated and for this, the design of an expert control system for the tungsten and tantalum crushing, milling and separation processes, reducing energy consumption and increasing the yield was developed. The integration and validation was carried out in three main stages: (1) In a virtual simulated environment using proprietary software and expertise; (2) In a pilot test plant facility; (3) In several companies in the mining sector in Europe. Finally, the last objective was to ensure that the dissemination and exploitation strategies and project-wide training, communication and dissemination activities reached the target audience.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Project information

OptimOre

Grant agreement ID: 642201

Project website

Start date

1 December 2014
End date

28 February 2018

Funded under:

H2020-EU.3.5.3.

Overall budget:

€ 5 084 468,75
EU contribution

€ 5 084 468,75

Coordinated by:

UNIVERSITAT POLITECNICA DE CATALUNYA

Deliverables

Websites, patent fillings, videos etc. (1)

Documents, reports (3)

Technology watch

with a yearly periodicity, this deliverable will content all existing available technologies related to the OptimOre objectives, including new machinery types, models, control, etc…(online, yearly).

Workshops plan and execution

workshops plan is designed (Month 16) and executed (Months 24 and 36). Conclusions are adequately reported.

European CRM perspective and technology selection

European sociological perspective on CRMs and the different technologies selected for its use during project Execution (including analysis and sensing) will be selected (Month 5).

Publications

Conference proceedings (16)

Comparing existing froth flotation models in a case study of a scheelite ore

Author(s): Kupka N. and Rudolph M

Published in: FIA Tagung, Issue November 2017, 2017

Size Reduction and Liberation Analysis for Tantalum Ore

Author(s): Guldris et al.

Published in: Comminution 2016, 2016, Page(s) 1-15

European Union's Horizon 2020 Research and Innovation Programme: OptimOre Project

Author(s): Yousef Ghorbani and Rob Fitzpatrick

Published in: Issue Thursday 26th May 2016, 2016

High pressure grinding rolls modelling with population balance models applied to tantalum and tungsten ores

Author(s): H. Anticoi, E. Guasch, S. Hamid, J. Oliva, P. Alfonso, T. Escobet, L. Sanmiquel, M. Bascompta

Published in: Comminution 2016, Issue April 11-14, 2016, 2016

New results in magnetic separation of tantalum ore

Author(s): Filipp Zolotarev; Prof. Dr. Holger Lieber-wirth

Published in: MEI Conference - Physical Separation 2017, 2017

New approach to ball mill modelling as a piston flow process

Author(s): E. Guasch, H. Anticoi, S. Hamid, J. Oliva, P. Alfonso, T. Escobet, L. Sanmiquel, M. Bascompta

Published in: Comminution 2016, Issue April 11-14, 2016, 2016

Influence of mineralogy on spiral performance of Tungsten ore

Author(s): Yousef Ghorbani, Patrick, Hegarty, Rob Fitzpatrick, Phil Hingston and Gavyn Rollinson

Published in: Process Mineralogy ’17, Issue March 20-22, 2017, 2017

Recovery of fine tungsten-bearing minerals from waste streams using modified Multi-Gravity Separator

Author(s): Robert Fitzpatrick, Patrick Hegarty, Keith Fergusson, Gavyn Rollinson, Yousef Ghorbani and Treve Mildren

Published in: Physical Separation ’17, Issue June 15-16, 2017, 2017

Low grade tantalum ores: mineral liberation analysis

Author(s): . Hamid, E. Guasch, H. Anticoi, J. Oliva, P. Alfonso

Published in: XXVIII International Mineral Processing Conference, Issue September 11-15, 2016, 2016

A process mineralogy approach to gravity concentration of Tantalum bearing minerals

Author(s): Yousef Ghorbani, Rob Fitzpatrick, Melanie Kinchington and Gavyn Rollinson

Published in: Issue October 26 - 28, 2016, 2016

Ball mill Bond work index study as a function of grinding size in different tungsten ores

Author(s): G. González García, J.M. Menéndez Aguado

Published in: XII Jornadas Argentinas de Tratamiento de Minerales (JATRAMI), 2016

A Continuum based Numerical Modelling Approach for the Simulation of WHIMS

Author(s): Raheel Rasool, Prof. Dr. Holger Lieberwirth

Published in: MEI Conference - Computational Modelling ʹ2017, 2017

Back-calculating froth flotation rates of scheelite by size fractions and liberation classes

Author(s): Sterbik N. and Rudolph M

Published in: IMPC 2016, 2016

High pressure grinding rolls modelling with population balance models applied to tantalum ore

Author(s): E. Guasch, H. Anticoi, S. Hamid, J. Oliva, P. Alfonso

Published in: XXVIII International Mineral Processing Conference, Issue September 11-15, 2016, 2016

QUANTITATIVE MINERALOGY FOR IMPROVED MODELLING OF SHAKING TABLES

Author(s): R. S. Fitzpatrick, Y. Ghorbani, P. Hegarty, and G. Rollinson

Published in: XXVIII International Mineral Processing Congress, Issue September 11-15, 2016, 2016

Optimization of the tantalum ore production by control the milling process

Author(s): P. Alfonso, J. Oliva, B, Álvarez, J. Jorge, L. Sanmiquel, D. Parcerisa, O. Tomasa, D. Calvo, E. Guasch, JJ. De Felipe, H. Anticoi, M. Garcia-Valles

Published in: 2nd International Conference on Mining, Material and Metallurgical Engineering, Issue July 20-21, 2015, 2016

Peer reviewed articles (12)

QUANTITATIVE MINERALOGY FOR IMPROVED MODELLING OF SHAKING TABLES

Author(s): R. S. Fitzpatrick, Y. Ghorbani, P. Hegarty, and G. Rollinson

Published in: Minerals Engineering, 2018, ISSN 0892-6875

Optimisation of tungsten recovery using a multi-gravity separator with novel modifications

Author(s): Robert Fitzpatrick, Patrick Hegarty, Keith Fergusson, Gavyn Rollinson, Weiguo Xie and Treve Mildren

Published in: Minerals, 2018, ISSN 2075-163X

Froth flotation of scheelite – A review

Author(s): Nathalie Kupka, Martin Rudolph

Published in: International Journal of Mining Science and Technology, 2017, ISSN 2095-2686

DOI: 10.1016/j.ijmst.2017.12.001

Frequency domain characterization of torque in tumbling ball mills using DEM modelling: Application to filling level monitoring

Author(s): Francisco Pedrayes, Joaquín G. Norniella, Manuel G. Melero, Juan M. Menéndez-Aguado, Juan J. del Coz-Díaz

Published in: Powder Technology, Issue 323, 2018, Page(s) 433-444, ISSN 0032-5910

DOI: 10.1016/j.powtec.2017.10.026

A continuum based numerical modelling approach for the simulation of WHIMS

Author(s): Raheel Rasool, Holger Lieberwirth

Published in: Minerals Engineering, Issue 118, 2018, Page(s) 97-105, ISSN 0892-6875

DOI: 10.1016/j.mineng.2017.12.020

Breakage function for HPGR: Mineral and mechanical characterization oftantalum and tungsten ores

Author(s): Hernan Anticoi, Eduard Guasch, Sarbast Ahmad, Pura Alfonso, Josep Oliva, Marc Bascompta, Lluis Sanmiquel, Antoni Escobet, Rosa Argelaguet, Teresa Escobet, Jose Juan De Felipe, David Parcerisa, Esteban Peña, Maite Garcia-Valles

Published in: Minerals, 2018, ISSN 2075-163X

Quantitative Mineralogical Comparison between HPGR and Ball Mill Products of a Sn-Ta Ore

Author(s): Sarbast Hamid, Pura Alfonso, Hernan Anticoi, Eduard Guasch, Josep Oliva, Marek Dosbaba, Maite Garcia-Valles, Marina Chugunova

Published in: Minerals, Issue 8/4, 2018, Page(s) 151, ISSN 2075-163X

DOI: 10.3390/min8040151

Textural and mineral-chemistry constraints regarding the columbite-group minerals in the Penouta deposit: evidences of magmatic and fluid-related processes

Author(s): P. Alfonso, S. A. Hamid, M. Garcia-Valles, T. Llorens, F. J. López Moro, O. Tomasa, D. Calvo, E. Guasch, H. Anticoi, J. Oliva, D. Parcerisa, F. García Polonio

Published in: Mineralogical Magazine, 2018, Page(s) 1-41, ISSN 0026-461X

DOI: 10.1180/minmag.2017.081.107

New results in magnetic separation of tantalum ore

Author(s): Lieberwirth, H Filipp Zolotarev, Tim Hühner-fürst

Published in: Minerlas Engineering, 2018, ISSN 0892-6875

A Process Mineralogy Approach to Gravity Concentration of Tantalum Bearing Minerals

Author(s): Yousef Ghorbani, Rob Fitzpatrick, Melanie Kinchington, Gavyn Rollinson, Patrick Hegarty

Published in: Minerals, Issue 7/10, 2017, Page(s) 194, ISSN 2075-163X

DOI: 10.3390/min7100194

Performance of acidified water glass in scheelite flotation against calcite

Author(s): Kupka N. Babel B., Chinbat D. and Rudolph M.

Published in: Minerals Engineering, 2018, ISSN 0892-6875

Chemistry of scheelite flotation: impact of pH modifier and interaction with depressant

Author(s): Kupka N. and Rudolph M.

Published in: Minerals, 2018, ISSN 2075-163X

Thesis dissertations (3)

A lab scale froth flotation study of tungsten bearing tailings of the Barruecopardo mine (Spain) within the EU Horizon2020 OptimOre Project

Author(s): Reinol Josef Compañero

Published in: Issue August 3rd, 2016, 2016

Application of a Multi-Gravity Separator to waste streams from Low Intensity Magnetic Separation processing

Author(s): Keith Fergusson

Published in: 2018

the extractability of tantalum from the tailings material at the historic Penouta Mine, northwest Spain, using gravity separation methods

Author(s): Melanie Kinchington

Published in: 2016

Project information

OptimOre

Grant agreement ID: 642201

Project website

Start date

1 December 2014
End date

28 February 2018

Funded under:

H2020-EU.3.5.3.

Overall budget:

€ 5 084 468,75
EU contribution

€ 5 084 468,75

Coordinated by:

UNIVERSITAT POLITECNICA DE CATALUNYA

Project information

OptimOre

Grant agreement ID: 642201

Project website

Start date

1 December 2014
End date

28 February 2018

Funded under:

H2020-EU.3.5.3.

Overall budget:

€ 5 084 468,75
EU contribution

€ 5 084 468,75

Coordinated by:

UNIVERSITAT POLITECNICA DE CATALUNYA

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Last update: 23 June 2017

Record number: 193894

CORDIS

Objective

Coordinator

Participants (7)

Project information

A new way of extracting critical raw materials in Europe

Keywords

Project information

Discover other articles in the same domain of application

Periodic Reporting for period 2 - OptimOre (Increasing yield on Tungsten and Tantalum ore production by means of advanced and flexible control on crushing, milling and separation process)

Project information

Deliverables

Publications

Project information

Project information

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