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    Tailings theory

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    © All Rights Reserved
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    29 Ansichten38 Seiten

    Tailings

    Hochgeladen von

    jufrejj
    Tailings theory

    Copyright:

    © All Rights Reserved
    Als PDF herunterladen oder online auf Scribd lesen
    Markieren Sie unangemessene Inhalte
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    TRANSPORTATION OF TAILINGS Richard £, MeSLvain General Manager & Vico President Warman Zauipnent. (International) Inc, Madison, Wisconsin 1. Cave Senior Project Engineer Warman Equipment (Internstional) Ltd, Artarmon, N.S.W, fustratia 1. Zureomerton Pumping of tailings is usually one of the major op erations in any mineral treatment plant, Because it ds often necessary to transnort tatlines over considerable distances, the heads" required for punp= F ine are often higher than for other operations ins treatnont. plant, Introduction of Legislation controlling environnent and pollution often requiros tailings disposal areas to be Located at considerable distances from the ' froatment plant. ich friction losses are encoun tored ‘and tailing pumps to develop higher heads are required, One installation in the north of Jepan collectives 2y pumps tailings frori throo mines a distance of ule miles to a disposal area in coastal sxanps. ‘i 164 ‘TRANSPORTATION OF TAILINGS Hodorn mining mathods hava allowed exploitation of Large low grade mineral deposits, | munber of plants throurhout the world are milling nore than $0,000 tons per day. Most. of this waterial has to. be handled as tailings. The coarser the sizing of the tailings particles tho hichor the velocity required for transvortation and consequently the higher the head and the higher the poxer requiresent, If it 4s possible to sepa- rate the coarser fractions of the teilings and dis~ pose of these close to the plant, considerable sav= ings ray bo made, (See Fig, 1 for various mothods used.) The velocity required for the longer dis- tance haul (of fine solids only) is reduced and cone sequently Less power is required, In association with underground mining operations, At ds often possible to utilize the separated coarse or fractions as underground fi11 material. For very long pipelines where high pressures aré required, positive displaconent pumps are employed for shorter distances and lower pressures, centri- fugel pumps are preferable: & For a punping syston, the flow rate, pipe size, com centration (density) of solids, punp size and speed should be capable of handling maxiaua requirenents and at the sane tine provide econonically for aver~ age conditions, 2.2, . SONCENTRATTON It ds usually preferred to punp solids at as higit a concentration as possible, This Teluces water usage (or return water pumping) and, within Limits), reduces the size of pumps, pipelines and motors. TAILING DISPOSAL TODAY (A) In plant segregation (1) Primary rejeets such as non- magnetic cobber tailings. (2) Screen rejects on barren sized pieces. 3) Scavenger etreuits for Process water and mineral value return. (®) Tattings and segregation systenis (1) Spiral classifiers (@) Cyclones (3) Sereens (4) Hydraulic sizing equipment for process solution return p (€) Thickeners for the entire plunt tail- ings are currently used in most mineral Process plants. Flocculating agents are normally used. ‘The water circuit is completely closed with the over flow and tailings pond water recirculated. q Methods of segregating tailing by particle size and q water reclanation. Figure No. 1 2 Es IAL K »— eg 7 ie N= : * 2 Ea e 6 wo 06 10500 wo 700 OscHARGE Imp dpm Wead depression as a function of concentration of solids by weights {lmenite 0,17 millimeter. 184 Figure No. 10 “TRANSPORTATION OF TAILINGS To dovelop a required head of slurry At is necessary to run a puap at a higher speed than that which is required to dovelop the sare head of water. then Hm has been determined ER is then apslied to obtain fia, Pomp speod for Hr may then be selected fron pup water performance curve, To calculate pump horsepower, the water efficiency obtained from the curve must be modified ty BM to obtain officlency on slurry. 4,5. HBAD sup pours cuncimatzos ‘The folloiing 4s an oxanple of the estimation of pump speed and power consumed when pumping a slurry mixture, Duty; A punp de reautred to handle 1800 (200% tons por hour of tailings having a specific cravity S= 2,65, at a concentration C= 504 solids by weight agcinst a total dynamic head Hix = 160 fost of slurry, Average particle size of sélids d50 = 150 microns, (100 mesh) ° Solution: (1) Weight of solids an slurry = 1800 TPH (2) Weight of volune of uater equal t6 volune of solids 1800 «= 680 TPE 2.65 (3) Weight of water in slurry Ow of 50% = 1800 TPH (4) Total weight of slurry add (L) and (33600 TPH (5) Total’ weight of equal volume of water add (2) and (3) = 280 TPH = (6) quantity of starry 2180 x 200. = 992% PHS 60x 7 6, of Sm] . See TO ‘yoo = 1s (sm) 185 TAILING DISPOSAL TODAY (8) % solids by volune (Cv) eivide (2) by (5) x 10 100 = 27,4 £20 6 108 = 27. & (Cv) Velues for Sa (7) and Cy (8) can also bo read direct fron Fig. 7 using $ of 2,65 and Cw of 50% solids by weight. (a) The head ratio (HR) and efficiency ratio (ER) for this duty may be obtained fron Fig, 11 where s = 2,65 and 450 = 150 microns, (100 mesh), the derating factor iss k= 0,075 Using the equation in Fig. 111 R= R= 1- kx a 1 = 0.075'x 27. 0,90 (b) Total head in fect of mixture Hin = 160 fect (elven) Required Head on Water (Hw): Hin . 160, = 178 feot of water i 0.95 Fron the aman Series ‘Mt punp selection chart, Fig. 12, a Verman 16/1 HA pimp has been selected for this particular duty, The per fornance curves for the 5 vane closed inpeller in this punp aro shown on Fig, 13 and wil be used for determining pump speed and efficiency as follows: y (c) Referring to the 5 vane closed impeller per formance curve Fig. 13, the speed at which the 186 ‘TRANSPORTATION OF TAILINGS. Tos 70 9399333 187 2 von aandzy ony ? eAbau V S995 weuxey 203 axey> uoqa00Teg 1H Wwio (50m susie ova Cav 230 OV3H TWiOL TAILING DISPOSAL TODAY TRANSPORTATION OF TAILINGS WARMAN EQUIPMENT eons Pune TAPELLER RA cenrmrvca “pee [rmane [vere [omnes | wre [unre | om | tire ruauen ESV 580%, Jena| HAH | 3 Ptoceoverac| a2 testa 70 A SITRTE FEREGR SNES TON CLEAR WATER [HHL TACRTC[cOaCUR | WoW FSET = FoR 16/14GAM PUMP p600 Performance curves for 5-vane closed impeller in pump. Figure No. 13 Late 188 TAILING DISPOSAL TODAY pump must operate to develop a head of 178 feet of wator wher, handling 9925 US gallons of water Por minute is 505 RP. Note that this is also the speed required for the punp to develop a head of 160 feot of mixture when handling 9925 gallons of slurry mixture, (a) The punp efficiency (ew) corresponding to the 178 fect of water is 76% when pumping water. (e) Tho efficiency (en) shen pusping the sand mize ture is then given by: oy xm 78x 0.90 686 (£) Pump Shaft Horsepower consumed Qx Sn xn x10 “35,000 % en 9925" 1.45 x 160 x 8.33 33,000 x = 855 HP 5S. MADEREALS oF consmaUCsToN Sl. REQUIRE This discussion is Limited to materials suitable for resistance to wet abrasive wear as encountered with. an slurry pumps, ani is mainly concerned with appli- cation to centrifugal slurry pumps, Materials to be suitable must M1fil1 the following requirenentss (2) Provide an economical cost wear performance, (44) Bo suited to forming to the required shapes and tolerances, G11) Have the, necessary mechanical strength. 190 TRANSPORTATION OF TAILINGS vergus auton eh one sk SSO Be frenetic 5.2. RUBBER pobber has a unique abitity to withstand cortain Feet of abrasion, This 4s apparently duo to the Beer rebounding after snpact with abrasive parti vreeydthout. denage to the rubber. ‘The size of ab- iSiyo particles which ean effectively be acconno~ date) by Tubbor 4s Linited, Where particles Garfictently Large to oat or tear the rubber 1 will freak dom quickly, ‘The exact size of particle there rubber ceases to be economical is dependent on Ning factors, but most materials vp to 35 mesh sre handled by rubber parts with mich coerser (up to 1/2") particles sometimes punyed with conbinations of rubber and metal. Whore conditions are best sulted to its use, @ cood abrasive resistant rubber will outlast tho hardest alloy Sorns by as much as 10 to 1. Mechanical. strength of rubber presents limitations of its use and Lt must be fully supported or reinforced, ‘Tho use of rubber in high head centrifugal puns is Limited and special care must be taken in design and construction to avoid breakdown of rubber at points of high energy dissipation. Tailings from most pro- cesses are of a sizing ideally suited to handling with rubber components unless rubber is precluded for other reasons, 5.3» HARD Cust 2 Eevly designs of slurry pumps used chilled cast iron coxponents; in nore recent tines the notallurey of parts has becone more sophisticated, ani ost of the « Lesding elurry ponp mamifacturers are using «lloy dons vith consistently controllod hardnesses of the order of 600 Erinell. These irons, for many eppli- cations, provide the most economical compromise bee ‘tween cost and wear performance, ¥ 191 ) ‘TAILING DISPOSAL TODAY 5.4, CERMTOS Various corantes are used for some components; how ever, except for special applications, end coneider- ing present manufacturing techniques, ceramics do not appear to be attractive because: (3) Cost As high compared to performance, (41) Manufacture to required tolerances is diffi- cult (341) Parts are sonovbat fragile and require special care in handling. 55. SxuMHETTe = Various synthetic elastomers including Neopreno, Butyl, Mtrile, polyurethano and others navo some: application where their special properties lve then an advantage, For gonoral abrasion resistance, however, they have no particular merit, compared to natural rubber, 5.6. SoucrnstoNs oN warnNe yapmer ats The present trends on metal to elastomers back to motel parts ney seen like simple changes in fashion but the established results are very clear when eritical pump-cireuits (with a puap change out) dime prove frou less than six weeks to over six months contimious operation, 4A careful review on the total systen is justified but, reslistically, the oporators are being held ac- countate for production and total costs, Tho pump manufacturer mst offer a well designed pump which wall produce the desired results, preferably include ing completely interchangeable parts of very hard alloy, rubber and other elastomers, 192 ‘TRANSPORTATION OF TAILINGS 6. DESIGE F Slurry punp designs are a compromise between hydrau= de performance an¢ resistance to wear, Large dia~ neter inpellers require a lower speed and therefore reduce wear at the vane inlet; on the other hand, Large Anpellers result in lower hydraulic efficiency. ‘gain, a conpromise must be nade to establish an econonic balance between cost and performance, Wear is greatest whore turbulence is greatest or where eddics occur, High velocities do not necessar= ily cause a high wear rate, Severe wear occurs dovn strean of any disturbance to flow such as sudden change of section or projection into the flow, Whore rubber Liners are used, it is advantageous 4f Liners are so constructed that they are self con tained components which can be sinply attached and renoved fron the pump, Linings vhich require bond- Ang to casings with adhesives have many disadvantages; there is always tho risk of wearing through the eas- Angs before a breakthrough in the linings is detected, Inferior material cannot bo econonically offset by Ancreasing thickness of components. As wear occurs the rate of wear increases and the bad effects are therefore cumlative, As woar occurs hydraulic per formance is elso inpaired and this can only be part= ly offset by component design. 7. SERIES OPERATTON OF CENRTRUGAL PUMPS Installation of centrifugal pumps in series may con- sist of several pumps close coupled in one pumping tation or single pimps epaced at intervals along a peline, Advantages of arranging punps collectively in one station include the following: ‘ton, (4) Simplicity of control, inspection and opera» 193 TAILING DISPOSAL TODAY (44) Grouping of electrical controls and instrue mentation in ono conter, (454) Central maintenance and spare parts handling 4s simplified, ‘The main objections to grouping of punps are assoct= ated with the higher pressuro to be contained and its effects on pipelines, glands, bearings and punp ease ings. If stool pipelines are being used then pipe Line pressure is not a consideration unless special conditions apply. Advantages of spacing pumps at intervals along the pipeline include: (4) Possitle use of centrifugal sealing and avoide ance of necessity for gland sealing water, (44) Reduced pipeline pressure allows use of cheap- er pipeline materials such as polythene or asbestos cenent. (444) Where tailings are corrosive or toxte the dane ger of high pressure blowouts with risks to personnel are reduced, Where miltistage installations are enployed in a single station, thrust loads on pipevorie betnoen stages ean be quite largo and special care must bo given to layout of puns and anchorage of pipework to onsure that all loads are satisfactorily acconno- dated without danago to pumps or pipework, 8. VARIABLE SPEED ooNSTDSRATTONS Variable speed drives for tailings punps ean be beneficial for tho following reasons: (4) Quantity of tailings to be handled may vary. duo to variations in mill conditions or vari= ations in grade of head fecd to the mill, 194 Gi) (asi) (Gav) (@) “TRANSPORTATION OF TAILINGS Zt may be required to pam at optiman density An order te conserve water, Length of cischarge Line may vary depending on tailings dan condi tions, Static head may increase height of'dan is raised. Punp perfomiance varios as pumps become worn. With a fixed speed installation, punps must be speeded to moot the required maximum cone itions when parts are worn, ‘This means that pumps are running faster than necessary when parts aro new; parts are therefore being worn Sut faster than necessary and power consunpe ‘tion is higher than it would be at optimun speed, Reliable speed variation with suitable control will allow control of density, mininun power consumption, and mexinun life of wearing parts, Mthough variable speed often Looks attractive at first glance, careful. assessnent of all factors often shows At to be unjustifiable, Inspection of many Anstallations where variable speed units are often dein ‘run at top speed either because the variating equipment ds unserviceable or because the operator finds % 91. At more convenient, ie peves RECIPROCATING PULP DRIVES Positive displaconent reciprocating pumps are nor= nally driven through reduction gear boxes due to the relatively low speeds required, Snatd units may have a belt drive betveon the motor and the goar reducor; larger units would be direct, coupled. 195 TAILING DISPOSAL TODAY PULP DRIVES Centrifugal slurry pumps may be direct coupled, belt driven or driven through gear reducers with or with= out sone for of variable speed coupling. For punps up to 300 HP, Yubelt érives usually prow vide the nost convenient forn of drive, With large pumps, rotational speeds are lower and for the higher horsepowors, belt drives are not practical and coupling of pumps through gear reducers becones necessary, With such installations some form of speed variation in the drive is usually warranted. Another possibility for large drives is to direct couple pumps to slow spocd motors, This is usually more. costly; however, reliability is increased and noise Level reduced, 93. 931. Doe Since the development of heavy duty solid state ro Uflers, D.C, motors are Finding increasing accept ance for pimp drives, Discussion herein, however, As Limited to drives’ suitable for use with A.C, in duction motors. {SLB SPABD DRIVES. votons HoTORS 93-2, VARTABLE SPEED A.C, The simplest form of spood variation which can be obtainod is to use a slip ring induction notor and comnoet permanently rated rosistors into the rotor cireuit, This provides the lowost capital cost but is wasteful of power. A nore sophisticated adaptation of the slip ring motor 4s to provide means to rectify the current Eaken fron tho rotor circuit, invert to mains fre- 196 “TRANSPORTATION OF TAILINGS quency and feed this power back into the stator su ply. wis systen provides an efficient means of epeed Taig eyster provadii tioned elcetriocl hardveres how ware ntreduoes moro points of possible trouble, She Saving of this systen 4s that the control cation font can be arranged so that the motor can be rin as) a fixed specd machine, Af the controls fail. Special A.C, motors with various conmtator arrencen ments are available to provide speed variation over wide ranges ard up to high horsepower ratings. Bf ficiency of these machines is high and with modern Arduetion regulated types the reliability is high and maintenance is reasonable, Mo wltinate for A.C, motor speod variation is pro- ably the use of squirrel cage motors with frequency variation, Such equipment is being developed. 9.303 VARIABLE SPEED COUPI-INGS Variable speed couplings allow speed variation by con trolling slip within the coupling, Two main types are available being the so called eddy-current coupe ‘Lng and the other the fluid coupling. ‘These couplings are not highly efficient because the slip which occurs is a direct energy loss. In select Ang euch couplings the full load slip at maxim speed should be considered because this determines the maximan efficiency which can be obtained, - Efficiency at any reduced speed will be less, The centrifugal punp follows the variable torque charace teristic and is easily controlled, The maxinun loss ds at about 2/3 speed which 4s at’ tho most desirable operating point. 9.3:l, TW SPEED yOTORS Where a mumbor of pumps are arranged An series (or With positive disphacenent pumps in parallel) it ds id 197 TAILING DISPOSAL TODAY not normally required to provide variable spoed drives for all units, One or two units with variable speed drives operating in conjunction with other Mixed speed units will usually provide sufficient control, One novel. noans of providing variablo output fron a multiple puny installation without using sophisti+ cated equipment is to install two speed motors on all or sone of the punps. The installation of 6 pole ~ 8 pole machines vill allow stepping down of output with very simple control equipment, With modern motor winding techniques, two speed notors are only fractionally larger and more costly than single speed machines of the sane rating, 10, GRAVETY FLOW ‘Tho Adeal plant location provides for gravity flow of the tailings, Tho sane enorgy concepts avply on tho transformation of vertical drop equivalent head for useful transportation on gravity as is used on head generated by centrifugal force. This applies only to closed-full pipe operation, ‘A review on open fume and drainage concepts is covered by ARCO (+), The accepted method of dissivating excess energy 15 the use of Jrop boxes, Refer to photo "Fiz. 13" of a model by Lee Aplin of the Clarkson Co, ‘This method roquires considerable individual design following some of the basic concepts of physics and practical enginosring, Tho use of orifices and carefully selected pipe sizes is an art when applied to dropping sand £411 down soveral thousand feet into the mine workings (on sand £111 operations), n. gosts Costs of the total systen depend so mich on the site and operating conditions that estinating the costs 198 ST ‘om sxnf7q-48z0u9 eesoxe Supredzssxp xoy x0q doxp 30 Topo TAILING DISPOSAL TODAY “a 200 “TRANSPORTATION OF TAILINGS any rule ds difficult, Messrs, Wasp, Thompson ané jude (5) illustrated the importance of consider’ the quantity as a vital factor. The equivalent distance should be determined. A detailed Hyevaulic Profile and Gradient Plot similiar {o'Ric. 4, bat in greater detail, is of value for Hin phases of route selection in establishing the cost . ‘the equivalent horizontal Length on the systen shown on Fiz, lis epproxinately 15 miles. The total power 4s 12000 to 11000 HP with a capital cost of perhaps $2 million exclusive of the pine and power Lines. The cost at 12-16 million TYP (including pipeline) for 15 miles (horizontal distance) chowld follov Vasp-Thonpson-fude ostinated at .35f to lsd ver tonemile, ‘The six mile haul with 1325 ft, lift re~ sults An about 1f per ton-mile and 6,6¢ por ton of tailings. At 12-16 miltion tons per year, and at 6.6¢ por ton, the total cost 1s avery sigmfeant figure, Com Eidoring thet sone plants are discharging tice this mount am with future total heads in oxcess of 1000 foot of slurry on a minerel with a snall recovery Tate, tho reswitant transportation cost as

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