Basics in mineral processing handbook

Basics in Mineral Processing-Enrichment Download Basics in Mineral Processing Sme mineral processing handbook pdf - free owners manual pdf, Daily checked working links for downloading basics in minerals processing ….

What are the minerals processing Parity between this pdf and the present html Below is some information about the products …. Basics in Minerals Processing Handbook The ambition with this handbook, Basics in Minerals Processing Handbook — shanghai Corporation. The ambition with this handbook…. Multiple document upload. This equipment ofers solutions to the mining, construction, industrial mineral and chemical industries.

A wide range of separations are available from 1. Full, lexible engineering design and support is available to ensure full integration. Classiier throughputs range from lab size units to applications processing hundreds of tones per hour. Application, feed type, ineness of classiication and classiication accuracy required inluence the allowable moisture in the feed which Size control typically ranges from 2.

The static and dynamic classiiers ofer tailored solutions for a wide range of applications Machine sizing and selection is normally done in consultation with the product line to ensure correct application and matching with required ancillary equipment. The static air classiiers are designed to achieve extremely accurate separations even though they contain no moving elements in the airstream.

This is achieved through airlow design and use of recirculating, secondary airlow on iner separations to scrub the coarse product before it is discharged. The re- circulating airlow is adjustable so the amount of undersize retained is also adjust- able.

This provides ine tuning of the end products so exact product speciications can be achieved. The design of the recirculating systems mean that adjustments can be done during production and results are instant. The static design of these classiiers ofers excellent wear characteristics through the use of ceramic linings whose lifetimes are measured in years, low maintenance requirements and low power draw. The feed material is spread over the width of the classi- ier and drops as a continuous feed curtain through the top of the classiier.

Low velocity air enters the classiier through the front inlet and is drawn through the feed curtain which is dropping in front of the angled vanes on the air outlet.

The air stream enters the feed curtain perpendicularly and draws the iner particles from the curtain of mate- rial. The air current then draws the particles up almost Size control vertical through the vane rack. The feed material is spread over the width of the classiier and drops as a continuous feed curtain through the top of the classiier. The primary air also enters the top of the classiier in a downward direction with the feed.

The coarser particles that are not drawn away drop down to where a secondary air low is drawn into the classiier. The coarse particle curtain is scrubbed by this secondary air with the iner fraction being drawn by the secondary airlow back into the primary feed curtain.

By making simple adjustments to the secondary air damper the end products can be modiied. As there are no moving parts within the material low stream signiicantly reduces maintenance requirements. Use of ceramic lining throughout the classiier gives impressive wear resistance. The classiier has widespread acceptance in industrial miner- als, cement and ly ash applications where its high degree of separation accuracy and exceptionally low maintenance requirements exceeds operator expectations.

The classiier is used in conjunction with a dust collector and system fan. Systems can have an open or closed loop dependant on application and numerous dust collector and silo storage options. Size control Centrifugal classiier, dust collector and fan Cyclonic ultraine classiiers Specially designed high eiciency cyclonic classiiers with controllable reverse air low systems can achieve adjustable ultraine classiications. The cyclonic ultra- ine classiier is a hybrid air cyclone that combines cyclone and classiier designs to separate very ine particles.

In conventional air cyclones, the aim is to remove as much of the particulate from the airstream as possible. However the cyclonic ultraine classiier is designed to allow the inest particles to be removed in the ascending vortex.

This separation is achieved by introducing a reverse airlow into the specially designed disengaging hop- per that weakens the descending vortex and creates a stronger entraining force in the ascending vortex that draws the required particles away to the ines collector.

Control of the separation point is achieved by varying the percentage of reverse airlow relative to the total air. The cyclonic ultraine classiiers are very low maintenance even on highly abrasive feeds.

The unit contains no moving parts and adjustments can be made on-line. The range of manufacturing materials available includes abrasion resistant, stainless and mild steels and aluminum. For abrasive applications, ceramic lining is available which Cyclonic ultraine classiier give exceptional sliding wear resistance. The gyrotor, a rotating vane air classiier, separates dry, solid, homogenous particles by size.

Delta-sizers are designed for accurate separation of dry feeds at high eiciency and low power consumption on a continuous basis. Gyrotors can be integrated into a conventional closed or open dry grinding circuit. Gyrotors can also be utilized in a classii- Size control cation only system complete with cyclone, fan, dust collec- tor and rotary air locks. Gyrotor Delta-sizers Delta-sizers are designed for accurate separation of dry feeds at high eiciency and low power consump- tion on a continuous basis.

The Metso Delta-sizer can be integrated into a conventional closed or open dry grinding circuit; or utilized in a classiication only system complete with cyclone, fan, dust collector and rotary air locks. Ancillary air solutions Delta-sizer Ancillary air solutions provide the systems required for the correct operation of the classiier equipment as well as ofering other dry solution capabilities.

High eiciency cyclones High eiciency cyclone technologies are speciically tai- lored to the needs of the mining, industrial mineral and construction industries. The high eiciency cyclones are the product of signi- icant development with the aim of achieving extremely high levels of particle removal from the airstream.

The unique inlet scroll is designed with a smooth low elbow to eliminate currents perpendicular to the main direc- tion of gas low that is present in standard conventional rectangular entrance cyclones. Custom designed disengaging hoppers give high eicient separations by creating a void that hosts the bottom section of the descending vortex and allows the particles to disengage from the airstream before it ascends the gas outlet tube.

Multi-stage luid bed coolers have been developed to ofer simple practical solutions for cooling and cleaning granular feeds. These coolers are designed to work in conjunc- tion with a dust collector and system fan to create a drop in pressure that draws in atmospheric air. The feed enters the cooler through an airlock and is then evenly distributed onto the irst perforated plate tray.

Each tray has speciically designed apertures and is individually vibrated by an electric activator Size control mounted above the plate. The rising airlow passes through the tray apertures and creates a luidized bed of particles whilst carrying the ultraine particles away to the dust collector.

The luidized bed dictates the particles residence time before dropping down to the next level plate. The individual particles eventually pass into the collection hopper where they exit the cooler through the sample valve airlock.

Multi-stage luid bed cooler Smart package dust collectors To fully support the classiication solutions ofering, the ancillary equipment requirement must be considered.

To fully support this ofering, the ancillary equipment requirement must be consid- ered. The smart package was developed to ofer a quality dust collecting solution without unnecessary transportation costs while ensuring quality solutions. Dust collectors tend to be large, bulky pieces of equipment that are expensive to trans- port due to their signiicant volume.

The smart package is designed as an easily transportable solution that ofers a simple, local manufacturing solution to customers requiring pulse jet dust collec- tors. The smart package consists of the tube sheet, solenoids, pulse pipes and air manifold. Smart package designs are available to meet the capacity requirements of the air classiier range and are also suitable for other dust collection duties.

The smart package dust collector. Close up of the smart package tube sheet, solenoids, pulse pipes and air manifold. Below are a few examples of classiiers in closed circuit dry grinding operations.

If the hole size is 20 mm or less, water spraying increases the capacity inversely proportional to the hole size. A medium speed washing drum for scrubbing solids against solids is then the option. The drum is relatively short in relation to its diameter.

Water requirements per ton is the same as for wet screening. Very high energy inputs are possibly used for washing of silica sand for glass making and cleaning of foundry sand. The machine is also suitable for clay blunging and lime slaking, see further page Not only costly, but also containing a lot of washing eluents both coarse and ine. Water and eluents that have to be processed partly to recover some value coarse material and water , partly to protect the environment from damage sludge fractions.

Most washing operations today must have systems for this treatment. Wash water treatment stages Depending on local conditions and restrictions, one, two or three treatment stages may be required, see below.

Hydrocyclone 4. Conventional clariier 6. Dewatering spiral 5. Compact clariier 7. Feed Recovered Dewatering water Sedimentation For more information see section 6! Depending on their behavior, diferent technologies are applied. We will cover the classical methods of separation as per below. Separation by gravity covers two diferent methods. One is the efect of hindered settling meaning that a heavier particle will settle faster than a light particle.

The other one is the separation process in an upward low of water which will separate the particles by their density. These two actions are combined in a Jig by slurry pulses generated mechanically or by air. It should not be confused with a spiral classiier which usually separates particles of diferent size, see section 4. A spiral concentrator consists of one or more helical proiled troughs supported on a central column.

As slurry travels down the spiral high and low density particles Enrichment are stratiied and separated with adjustable splitters at the end of the spiral.

Particles build up behind each rile and stratiication occurs with heavier particles sinking to the bottom. The light particles are carried over each rile to the tailings zone. The shaking action of the tables carries the heavy particles along the back of each rile to the concentrate discharge. Particle size, shape and density all afect the eiciency of the separation. Dense Media Separation DMS takes place in luid media with a density between that of the light and heavy fractions that are to be separated.

The surfaces of selected minerals are made hydrophobic water-repellent by conditioning with selective reagents. The hydrophobic particles become attached to air bubbles that are introduced into the pulp and are carried to a froth layer above the slurry thereby being separated from the hydrophilic wetted particles. Air bubble Hydrophobic Air bubble reagents Particle Enrichment Particle surface In addition to the reagents added, the lotation process depends on two main parameters.

Modern lotation equipment gives opportunities to use larger cells and shorter circuits. Typical igures for diferent minerals are given later in this section. Simple circuit e. The scavenger cells would have a cell volume equal to the total rougher stage and are included when particularly valuable minerals are being treated or a very high recovery is needed. Cleaner cells are used to maximize the grade of the inal concentrate. Less cells per bank than for rougher duties can be used.

Gearbox drive for m3 and above. See data sheet Typical igures for diferent minerals are given overleaf, alternatively the retention time may be speciied by the customer or be determined from testwork.

Select the number of cells per bank The table overleaf shows typical amount of cells per bank for common mineral lotation duties. Divide Vf calculated above by number of cells selected to calculate volume m3 per cell. Check that Q is in low rate range for cell size selected. Reselect if necessary. Select the bank arrangement To ensure necessary hydraulic head to allow slurry to low along the bank intermediate boxes may be required.

Maximum numbers of cells in a section between intermediate or discharge boxes are given overleaf. Each bank will also need a feed box and a discharge box. Typical bank designation is FID, i. Feed box, four cells, intermediate box, three cells, discharge box. Required retention time for cleaning is approx. Copper lotation.

Retention time 16 minutes, determined by continuous pilot plant test. Normal range for copper is 8 - 12 cells, so this is a valid selection. If this was not the case choose the next cell size up or down as appropriate. Enrichment 9 x RCS 50 cells required. Select the bank arrangement For RCS 50 the maximum amount of cells in one section is 3. So to have 9 cells choose bank arrangement. If higher slurry sg, consult Metso 4 Per cell and applicable up to 1.

The DR design may be speciied for certain applications, particularly where de-slimed coarse particles have to be handled such as in glass and potash processing. If higher slurry sg, consult Metso 3 Per cell and applicable up to 1. Column cells do not use mechanical agitation impellers.

Instead, mixing is achieved by the turbulence provided by the rising bubbles. Columns are mostly used to produce inal grade concentrates because they are capable of high selectivity.

Other features which distinguish them from mechanical cells are their shape, bubble generation system and the use of wash water. An optimum lotation circuit is a combination of mechanical cells and column cells. Tailings slurry is pumped from the base of the column through the static mixers where air and slurry are mixed together under high shear conditions to create the bubble dispersion. The bubble suspension is introduced near the column base.

Enrichment Slurry level control is achieved by using ultrasonic sensor or diferential pressure transmitters to automatically adjust the tailings low control valve.

Wash water addition improves grade by removing mechanically entrained particles. Selection Applications For detailed column design Applications for lotation columns — contact your support center include: supplier.

When MIMS becomes available the above data may alter. The magnetic assembly comprises a stationary magnetic array installed in a rotating outer drum. The drum rotation speed and direction are selected for the application in question. The upper particle size limit for wet processing is about 8 mm but with special arrangements coarser material can be processed by wet methods. It is also used for steel slag and pyrite cinder treatment. The metal powder industry uses the separator for inal product control.

Wet LIMS are also used in other mineral industries for e. Please always check with Metso for inal selection! The uniform ield in itself cannot alone create any separation process but by insertion of sharply edged ferromagnetic material, a matrix, in the void the magnetic ield is greatly disturbed and the required magnetic ield gradient for the process is produced in the separation space.

Models and dimensions Enrichment The cyclic unit models are deined by canister diameter, matrix height and magnetic ield. The available magnetic ield can always be adjusted to a lower rating.

The highest available rating appears as the last digit s in the HGMS model name. HGMS had a diameter of mm a matrix height of mm and a magnetic rating of 10 kG. Rinse 1. Select the separator size. Total cycle time 7. Calculate the actual separation time feed from 1. Calculate the volume low of 4. Kaolin very ine particles means matrix of W-type.

It is normally used for magnetic iltration of liquids and eluents. Model deinition In the model name canister diameter, matrix height and nominal magnetic rating are appearing, e. HGMF has a diameter of mm a matrix height of mm and a magnetic rating of 10 kG. Oversize control 2. Separator 4. Power supply 5.

Rare earth minerals 3. Industrial minerals reduction of paramagnetic contaminations 4. Coal desulphurization and de-ashing 5. The data in the tables below are only indicative.

In the heap leaching process the ground is protected by a sealed surface, collecting the leaching chemicals, re- circulated by pumping. In this case, the pregnant solution has to be recovered from the solids by mechanical dewatering due to particle size, see section 6. If free coarse gold is released during size reduction, this fraction typical — 1mm is recovered in gravity spirals, see If iner fractions of free gold are present centrifuge technology can be applied not covered here.

Alternatively, when processing an ore containing gold metal only, leaching with carbon adsorption are frequently used. Leaching by agitation to dissolve Au by reaction above. Agitators are arranged in con current low. Enrichment CIL Carbon in leach is a method where the gold adsorption by carbon is done in the leaching circuit. The method, seldom used due to high operating costs, is not covered here. CIP Carbon in pulp adsorption by slow agitation using active carbon granules to adsorb the Au solution from the pulp.

Agitators are arranged in counter current low carbon travelling towards the pulp low. See lowsheet on next page. Carbon granules must be: a. Hard to resist abrasion made from coconut shells b.

Coarse to be separated from slurry by sizing mm, Mesh c. High in speciic surface 3. Carbon recovery is done by sizing over a screen cut at 0,7 mm, 24 Mesh bringing the loaded carbon out of the pulp system 4. Carbon reactivation is needed after the washing to restore the active surface of the granules.

Cyanide destruction of the pulp leaving the CIP circuit is done in an agitator adding an oxidant typical hypocloride bringing remaining cyanide to a harmless state. Au electrowinning by plating out the gold metal is done with steel wool cathodes. These cathodes are sent to luxing and smelting 8. Enrichment Trash 2. Coal 3.

Carbon to CIP 5. Reclaimed process water 7. Tailings 8. AU-metal Agitation, see Sedimentation, see Mechanical dewatering, see This is valid both concerning the valuable minerals the concentrate and the waste minerals the tailings. In the irst case upgrading means improving the product value by bringing the concentrate to transportability or into a completely dry form. Processing can also go further to calcining and sintering.

On the tailing side upgrading means that waste material wash water, process eluents etc. The rules are simple! Can we do the job with sedimentation only? If not — how far can we reach by sedimentation thereby saving money in the following dewatering stage? How far can we reach with mechanical dewatering? Can we save a thermal stage by increasing the dewatering pressure?

If the particles are coarse, can gravity dewatering do the job? The cost is close to the same as for sedimentation. If thermal dewatering is needed, can energy be saved in drying by improved mechanical dewatering?

Thickening is the process for concentrating particles in a supension by gravity compression Flocculation All sedimentation technologies are related to particle size. One way of improving the settling speed generally is therefore to increase the size of the particles. Fine particles can be connected together by coagulation or locculation. The settling rate of the combined particles will be higher than that of each individual particle.

This can also be applied prior to mechanical dewatering. Coagulation: Surface charges are neutralized by addition of chemicals of opposite charge.

Upgrading Flocculation: Polymers with molecule chains which physically link the particles together mechanical bridging. A locculated aggregate will not reform after breaking. Flocculation system A handling system is needed for locculent utilisation. This comprises provision to mix, store and dilute the polymer. The dilute polymer is then mixed with the feed slurry and allowed to condition or age before a sedimentation or dewatering process.

Typical surface loads are given below. Surface load is 0. Select clariier diameter. When thickening is also a critical part of the sedimentation process, the tank diameter has to be cross-checked with the diameter for thickener duty, see next page. Conventional thickeners — Sizing Thickener selection is based upon the unit area, deined as m2 of thickener area Upgrading required per tph of solids.

Typical igures for unit area are given below. The equipment can be applied to both duties. If this is the case we have to select the tank area for each duty and select the largest of the two. Mo and Zn are more diicult than i. Cu and Fe. Upgrading Centre pier type For tanks over 30 — 40 m diameter a bridge structure will be impractical. The mechanism and rakes are therefore supported from a centre pier and the bridge is only used for access and to support feed pipe and launder.

Above 20 m tank at ground level with underlow in a tunnel. Options with and without automatic rake lifting system. If the monitoring system detects a torque above this level the drive Upgrading head will stop and a alarm will be raised in order to protect the rakes. Peak torque Practical maximum torque.

Increased torque is a sign that the solids loading in the thickener may be building up. This could indicate a process problem change in feed, blocked underlow etc. In all these cases rakes and drive have to be protected. Examine solids loading or speciications to determine whether duty is thickening or clariication. Proceed to relevant section to select drive head. Example: Select a bridge mounted drive head for a 35 m diameter clariier no lift required.

Application: lime sludge clarifying. Select a drive head type BN 24, cut out torque Nm. Example: Select a pier mounted drive head with a lift suitable for a 50 m dia- meter thickener handling an underlow of tph of solids. Select CL 28 drive head with a 10 year torque of Nm. In this way, the able settling area size and cost of the gravity settler for any available loor area. The area required to clarify a suspension is often greater than Lamella thickening is achieved as that needed for thickening.

The feed for the inclined plate settler enters through vertical chambers on either side of the lamella packs and passes into each plate gap through slotted feed ports. Clariication takes place above the suspension inlet so there is no mixing of the clariied luid with the incoming feed.

Above each pack is a full-length overlow launder itted with throttling holes to create a slight hydraulic back pressure on the incoming feed stream. This method of feed control guarantees equal distribution to all lamella chambers with minimum turbulence at the entry points.

The solids settle onto and slide down each lamella plate to the sludge container where the solids are further thickened and compressed with the assistance of the raking system.

Gear motor 2 2. Vertical grinding mill. Ultra fine vertical grinding mill. MTW european grinding mill. MB5X pendulum suspension grinding mill. Trapezium mill. TX super-fine grinding mill. Micro powder mill. European hammer mill. Raymond mill. Ball mill. GF series feeder.

FH heavy vibrating feeder. TSW series vibrating feeder. Vibrating feeder. Your information is safe. Check our privacy notice for more details. The ambition of Basics in Minerals Processing Handbook is to give technicians, and everyone else interested in mineral operations, practical and useful information about the process equipment, their systems and operational environment.