1.

0 INTODUCTION
In order to obtain relevant information for mill control and economic appraisal, routine
sampling of various products at different stages is essential. The routine check is not limited to
concentrates only, but it should cover the check at all possible stages, such as crushing,
grinding, pulp preparation, conditioning, etc., and also the other products, such as tailing,
middlings, waste water, etc. Further, check should be made whenever any additional control
point is introduced. A metallurgical balance sheet should have the basic form as the following:

Units of values in concentrate + units

Units of values of values in transit + units of value in
=
received in ore tailing + units of values
unaccountable

Metallurgical accounting is an essential feature of all efficient metallurgical operations.

Not only is it used to determine the distribution of the various products of a mill, and the values
contained in them, but it is also used to control the operations, since value of recovery and
grade obtained from the accounting procedure are indications of process efficiency. Good
metallurgical accounting enables a close check to be kept on losses from the plant, and on
sampling and assaying procedures. If theoretical recoveries, determined by accounting, and
actual recoveries, determined by weighing the products, differ by more than about 1% large
unaccounted losses are taking place, which are probably the result of poor sampling and
assaying.
In additional to the information about recovery, the tests on sample give other technical
information, such as moisture content, crushed state, oxidation, etc., of the arriving ore and the
ways in which various processes have been conducted.
With the growing complexity of ore treatment, importance of maintaining optimum
conditions at various stages of process has increased. These requirements can be met through
removal of samples, their test, and application of necessary changes with the help of automatic
control circuits. Recently, the use of computers in ore-processing plants has also been made
successfully, resulting into fully automatic control of the process. Sampling and process control
are associated together. Accuracy of control at various stages has resulted in high efficiency and
smoothness of operation. Now it has become possible to have continuous check on important
processing factors, and the use of automatic resulting in a smooth operation.
2.0 SAMPLING AND CONTROL IN CIRCUIT
2.1 IN GRINDING CIRCUIT
a) Ball mill
The check of solid-liquid ratio is the most important control at this point, which is
affected by collecting a canful of mill-discharge pulp at regular intervals and weighing it. If the
pulp density is too high, the mill feed water should be increased, and vice versa. Sometimes, a
sample is collected during the shift and the size analysis is performed. Sometimes the pH of the
pulp is also checked. However, size analysis is performed on the products of classifier. The
density of mill discharge is an important factor which affects the coating of ball and linears and
thereby affecting the grinding action.
b) Classifier returns
Hand samples are collected from the classifier return at certain intervals and sizing
analysis is performed. This makes a check on the efficiency of oversize returns and undersize
released from the closed circuit; a check on quantity of circulating load is also possible.
c) Classifier underflow
the sample of classifies underflow is of utmost importance in checking the efficiency of
grinding. The sample should be cut automatically and subjected to assay analysis and sizing
analysis. The assay analysis would check for the head value which should check roughly with
that of the solid head sample, unless a concentrate is being withdrawn from the closed grinding
circuit. The sizing analysis is performed to check the grinding efficiency which is essential, since
the concentration efficiency depends on optimum liberation. In addition to the samples taken
for assay and sizing analyses, the dip samples are taken regularly at their weir and tested for
density and pH value. These running controls are employed to adjust water and alkali to
maintain the correct mesh-of-grind and alkalinity of the pulp. The pulp density can be roughly
measured with the help of a hydrometer. However, the usual method is to weigh a known
volume of pulp. Balances are also available which give direct reading of specific gravity.
2.2 PULP
The process control depends to a certain extent on the testing and control of pulp streams. The
best point of withdrawing the samples is at the launder overflow, where the pulp stream is
falling freely in a flattish cross-section, e.g. the points where classifier overflow launders deliver
the pulp to pump sumps or conditioners. The samples may be withdrawn either by a periodic
diversion of the entire pulp stream, or by means of a cutter ( a rectangular bottomless box with
its length normal to the flow ) and diverted to the sample bucket by means of a flexible hose.
The general purpose of sampling the pulp is to provide information, which will help in
preparing a metallurgical balance sheet, which accounts of the unit of value fed into the mill
and those leaving as concentrate and tailings. Some specific information are also obtained at
each sampling point, which checks the state and sustainability of pulp for its transfer to the
next stage of treatment. In case of pulps, reduction of the sample is performed very accurately
and systematically. The whole sample is the first made into suspension by stirring and the
poured through a vessel which splits the pulp into two equal halves. One-half is rejected and
the other half is split again after stirring. The process of stirring and splitting is repeated to
obtain a convenient size for drying and further tests.
Pulp density (solid-liquid ratio) and flow rate are important control factors, since they
represent throughput, when integrated together. Thus, the pulp density and flow rate should
be recorded continuously. The density of pulp having ore reasonably consistent in its specific
density, can be observed by the absorption of gamma rays by the pulp stream. The result
obtained give the accuracy within 2%. In this method a capsule of cobalt-60is placed on one
side of the flow channel and a scintillation counter is placed on the other side. Variations occur
depending on the amount of radiations rate of pulp, a magnetic flowmeter can be used. The
flowmeter is allowed to spin in the pulp at a point surrounded by a magnetic field. The induced
voltage registered by immersed probe will give the flow rate.
2.3 FLOTATION PRODUCTS
In flotation line, several products are removed successively or diverted to other units
and thus samples of each concentrate, rougher froth, and scavenger froth should be taken out.
Sampling of pulp flowing through intermediate stages may also be necessary. However, the
most important stage is the sampling of each final concentrate, which should be sampled
periodically. The samples withdrawn over certain period (e.g. one shift or one day) are mixed
and assayed for the grade of the concentrate (total sulphur, metal values and any other
element of interest). Generally a simple assay for metal grade will be sufficient. A small quantity
of concentrate may be retained from each shift to form a composite sample, which may be
assayed for complete analysis at weekly or monthly interval. In this case, a portion may be sized
and assaying for grade may be carried out on each screen and subsieve size fraction. These
information on grade and size analysis are used to assess the work being done in the grinding
circuit and the degree of liberation of each value.
The grade analysis of partially cleaned concentrates is performed only periodically on
accumulated bulk sample. However, when the alterations in cells or circuit are planned, the
analysis should be carried out on regular samples until the process is established. The routine
tests for rough concentrate include their sizing analysis and microscopic examination. These
give direct information, which can be applied in maintaining the efficiency, or to improve any
weak detail of the treatment. The tailings from flotation circuits are tested for their grade on
each shift’s cumulative sample. The pH may be checked on each cut of sample to provide a
cross-check on conditioning. The density of the pulp is checked at overflow from cells, which is
generally required when over-dilution of the pulp lowers the flotation efficiency. This situation
may arise when a heavy draft of concentrate is made or when the tailings from a series of
cleaning section dilute the new feed excessively. The samples are tested in the similar way as
concentrate samples. In case of tailing also, a suitable quantity of each sample is retained and
mixed too form a weekly or monthly sample, which is tested for size analysis (by screening and
sedimentation down to 15 microns). Then each size fraction is assayed for the percentage of
floatable product. Heavy and light fraction of each size are separated by panning and examined
under microscope to evaluate the reason for the failure to float, and thereby applying
necessary corrections.
2.4 IN HEAVY MEDIA SEPERATION.
The heavy media employed in separation are generally generated continuously. Sampling may
be used to control the following factors :
a) Optimum viscosity
b) Dilution of medium by ore slimes
c) Rate of settlement of suspended heavy media particles
d) Density of heavy media bath
The density of media is a function of fluid density., viscosity of fluid, and the size-blend
of the particles used to constitute the medium. During the separation, the particles become less
angular due to wear, and the loss of weight is compensated to some extend by decrease in
rubbing surface. For test and control, the samples are withdrawn periodically and tested for
density, rate of settlement, and viscosity.
2.5 IN CYANIDATION PRODUCTS
The pulp samples are collected by cutting through the whole stream at an appropriate overflow
point. Solutions may be sampled continuously by diversion of a steady drip or by drawing-off
periodically. The testing of pulp sample is mainly concerned with the losses of values in the
tailings. The various reasons for the loss of gold are :
a) Gold losses may result due to incomplete washing of the discard, and allowing the pregnant
solution to run to waste. This is checked by washing the filter cake and testing the filtrate for
gold content
b) Gold loss may be loss due to incomplete liberation, particularly that carried in auriferous
pyrite.
c) Gold loss may occur due to formation of iron or aluminium oxide coating on gold particle,
which prevent dissolution of gold
d) Gold may not be completely dissolved due to short time given in agitators.
e) It may also due to failure of the gravity and amalgamation section to trap and hold coarse
particles of gold
f) presence of graphite may also affect the recovery and thus its presence should be watched.
The testing of cyanide solution is required to know about the following factors :
i) Oxygen content of the solution
ii) presence of fouling salts
iii) Strength of the available cyanide
iv) Adequacy of the protective alkali
v) Efficiency of precipitation.
 In order to assess the day’s recovery accurately, the amount of pulp, pregnant cyanide
solution, stock solution, etc., held up in the plant should be known.
3.0 REFERENCE
1. Jain S.K., Ore Processing, 1987, Indian Edition Series 15.
2. Wills B.A., Mineral Processing Technology, An Introduction to the Practical Aspects of Ore
Treatment and Mineral Recovery, First Edition, 1979.
3.
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