ASSOC. PROF. DR.

HASHIM HUSSIN

1st Lecture

There is an ancient saying that you cannot make a student learn you can only create the circumstances to help him or her want to learn.

I have an apple, you have an apple. We change the apple, you and I still have an apple. If I have a knowledge and you have a knowledge, we change the knowledge, I will have two knowledge and you will have two knowledge.

Course Structure Form

Course Outcomes vs Program Outcomes

References


Wills, B., A. 1995. Mineral Processing Technology: An Introduction To Practical Aspect of Ore Recovery (6th edition). Pergamon Press. Hayes, P. Process selection In Extractive Metallurgy. Hayes Publication. Kelly, E., G. and and Spottiswood, Introduction To Mineral Processing. Willey. D. J. of 1989. Mineral

Weiss, N., L. (editor). 1985. Handbook Processing. Vol 1 and vol 2. SME Publication.

Lynch, A., J.Developments In Mineral Processing: Mineral Crushing and Grinding Circuits. Elsevier. Burt, R.O. Elsevier. 1984. Gravity Concentration Technology.

Copper Mine In Sabah

Map of Mining Operation of MAMUT Sdn. Bhd

DECISIONS ON THE APPROPRIATE PROCESS FLOWSHEET FOR A GIVEN FEED DEPENDS ON THE FOLLOWING:

 FIRST QUESTION : Product 1 Product 2

Starting Material

Product 3 Product....N
Which Product ?

WHICH PROCESS ?

Route A

Starting Material Route B

Product

Route C

How to produce the product ?

EXAMPLE 1 Copper occurs primarily as the mineral chalcopyrite : 34.7% Cu in CuFeS2. The mineral typically constitutes 0.5 to 4.0% of the host rock (0.2-14% Cu) and the remainder is silica, pyrite (FeS2), dolomite, etc. The mineral grains are typically about 400 m diameter.

Process
Crush and grind all rock to <100 m: most grains are liberated, some with adhering gangue (complex or binary particles). Flotation separates chalcopyrite particles from the gangue : some misplaced gangue (pyrite, silica, etc) report to the concentrate. Produce a concentrate of 80% chalcopyrite (~28%Cu) which is economical to process to copper metal in the smelter.

EXAMPLE 2 Titanium from ilmenite the raw materials are beach sands which typically consist of 90-98% quartz and 2-10% heavy mineral (ilmenite FeO.TiO2, rutile TiO2, zircon ZrSiO4, and monazite).

Process
Wet gravity concentration to produce a HMC (heavy mineral concentration. Drying followed by magnetic and electrostatic separation and further gravity concentration to produce individual minerals products (including ilmenite at ~$100/tonne) SR (synthetic rutile) production by roasting and acid leaching of ilmenite to remove FeO) produces SR worth $ 350/tonne. Fine pure TiO2, used as a paint pigment and worth more than $1000/tonne, is produced by a chloridizing fluidized bed roast. Reduction smelting with magnesium produces titanium metal worth more than $4000/tonne.

Quiz 1


Calculate the amount of Fe in Magnetite and Hematite.

Examples of Mineral Deposits With Various Grades

Diamond ore Gold ore Tin ore Copper ore Mineral sand Aluminium Coal

1ppm (0.001%) 2ppm or 2gm/ton (0.002%) 100ppm or 100g/ton (0.01% - alluvial ore), 1% (rock) 0.5% (Bouganville) to 2.6% (Escondida, Chile) 1% to 10% by weight of mineral 55% Al2O3 (Weipa) 60% to 90% from the products obtained

Metals
Nikel Zink Aluminium Silver Lead

Copper Tin

Iron

WHAT IS MINERAL PROCESSING ?

Mineral processing: prepares the ore for extraction of the valuable metal in the case of metallic ores, and produce a commercial end product of product such as iron ore and limestone respectively.

What are the purpose of Mineral Processing?

Liberation

To separate valuable minerals from gangue minerals.

To reduce the amount of the ore to smelter by removing most of the waste at mine site.

To reduce the amount of chemical to be used if physical processing cannot make it.

Main Operations in Mineral Processing

Liberation of Valuable Minerals

Mineral Concentration

Mineral Liberation

Jaw Crushing

Rod Milling

Total Liberation

Ball Milling

Partial Liberation

Particle Size Reduction and Mineral Liberation

Products from comminution process

Consider the particle shown, which will produce the daughter products along with gangue on grinding. Particle 1 will report to the concentrate, although the grade would be limited by amount of locked gangue. Particle 4 is tailings, representing a loss of values. Particles 2 and 3 could be midlings (possibly concentrate) although they require different degrees of grinding to achieve liberation.

MINERAL PROCESSING

FEED/ORES FROM THE MINES (ROM)

MINERAL LIBERATION

MINERAL ENRICHMENT (CONCENTRATION)

CONCENTRATE
(contains the valuable minerals)

MIDLINGS

TAILING
(contains the gangue minerals)

Product Handling

Tailings Disposal

Run of mine ore

Comminution

Separation

Product handling

Simple block flow sheet

Ore Crushers Screens (-) Grinding (+) Classification (-) Separation Tailing

(+)

Concentrate

Line flow sheet (+) indicates oversized materials returned for further treatment and (-) undersized material which is allowed to proceed to the next stage.

Feed Primary grind Pre concentration Midlings

Tailings

Re grind

Separation

Concentrate

Midlings

Tailings

Flow sheet for process utilizing two stage separation

Ore from mine

Crushing

Grinding

Sizing (classification)

Flotation

Galena concentrate Filter

Dry concentrate to smelter

Tailing

Tailing pond storage

Schematic flow sheet

2nd Lecture

Sampling and sample preparation

Assoc.Prof. Dr. Hashim Hussin

Introduction
Even though sample preparation is a dull and tedious job, but a processing plant costs many millions of dollars to build and operate are relies on the assays of a few small samples. Therefore, very important that this small fraction to be treated in laboratory should representative as possible of the bulk material in all aspects physical, chemical and mineralogical.

A formal definition of the term is that all particles present in the stream have an equal chance of being selected in the sample by the sampling device. - stream A small amount of materials is taken from the main bulk in such a manner that it is representative of that larger amount. - bulk

upon which accurate analyses of the value components can be undertaken

OBJECTIVE
The objective of sampling is to obtained a representative sample - A sampler must be designed so that every particle, regardless of size or composition, has an equal chance of becoming part of the sample.

Why sampling

iv. Thus the bulk sample should be subjected to size reduction for better mixing, proper sampling, and reasonable size for treatment. iii. Coarse lumps are not amenable to mineral processing of the metalliferous ores, at least in the laboratory smallscale apparatus.
ii. The

i. The run-of mine sample - very wide range of particle sizes.

natural changes in the mineral constituents, hardness and fracture properties, variation in chemical and mineralogical composition of the various size fractions is expected.

Quantitative (% Assays, moisture content, size distribution)

Qualitative (mineralogical study, morphology,)

Type of sampling
Site sampling  Laboratory sampling


A. ON SITE SAMPLING METHODS

Grab sampling
Cheapest and easies and rapid method but least accurate. Small quantities of material (ore) are chosen at random from different spots in the large bulk and these are mixed together to form the base for the final sample.

Mineral Identification

DRILLING - Log Sample

Quantitative and qualitative analysis

Chp

Chp

Chp
Au

Gold (Au)

Left - vein shows fractures infilled by chalcopyrite (chp), intergrown altite (Alt), and galena(Gal) replacing chalcopyrite(chp) with the occurrences of tiny electrum(Au). Right -A submicroscopic inclusion of gold (15m) embedded in chalcopyrite (yellow) is also visible.

AUGERING

1.0 - 1.5 m

Plan views
N

Legend
Track Pond Hole no Contour lines Over burden Thickness of the sand dune Depth of hole Water level scale
88

3.0 4.0 m

PITTING

A. STEADY STATE OPERATION

The circuit must have been running steadily for 30 to 60 minutes before sampling starts and must continue to run steadily during the campaign. To ensure stability, all circuit inputs i.e., ore feed rate, water addition rates, ore type and feed sizing distribution and all measured variables such as flow rates and levels must be steady. If a disturbance occurs either; a) terminate sampling if close to the end of campaign or otherwise. b) abandon sampling and restart at another time.

4th lecture

B. SAMPLE SEQUENCE AND SURVEY DURATION For slurry streams, a sample should be cut from each stream in turn, preferably following the flow of ore through the circuit. The sequence is repeated around the circuit at least four times, each sample being combined with the previous sample at each point. This procedure should be achieved as quickly as possible without undue haste and will take about an hour.

C. SAMPLE SIZE
Statistical analysis shows that the larger the sample, the more representative it will be of the entire stream.
For slurry streams, two 9 litre buckets at each sampling point are necessary and a total sample volume of not less than 8 litres is adequate. The tare weight of each bucket should be determined before sampling and clearly marked on the bucket. All buckets must be labelled with the sample identification.

For rod mill or primary ball mill feed, being significantly coarser, a larger sample is necessary. It should be as large as can be easily handled in the plant and also easily screened about 30 to 40 kg minimum. The tare weight of the containers used should be determined before sampling and the containers must be adequately labeled.

D. SAMPLING TECHNIQUE
For slurry streams, a suitable mechanical sampler or a hand held sample cutter can be used. The cutter opening must be significantly larger than the largest particle present and for large flows a cutter of large volume is necessary. Cutters of different sizes will be required for different streams. It is essential not to overfill the cutter as this gives a biased sample.

Where possible, manual cuts should be through the entire stream and the direction should be alternated. If it is not possible to cut the entire flow, cuts of each part of the stream should be taken and combined. The volume of each sample should be approximately proportional to the volume flow of that part of the stream.

Recommended minimum sample mass based on top particle size . -After Taggart (1945)

Feed sampling

Tailing sampling

E.

HAND HELD SAMPLE CUTTER

The best results are obtained by taking cuts at regular intervals of time and by using a cutter, that its operation approaches that of a properly run mechanical sampler. The cutter should be large enough so that there is no danger of overflow while making one passage through the stream of pulp. The aperture should be at least four times the diameter of the largest grain in the pulp; the cutter should be smooth inside, watertight, and designed to clean itself readily.

Typical hand held sample cutter design (after Taggart). Length dimensions (A1 & A2)depend on the size of stream to be sampled and depth dimensions (B1, B2 & B3) the pulp velocity. Maximum size is limited by the ability to manouver the sampler when full. Generally the sampler should not be filled to more than 33% when taking a cut to avoid sample splashing out. The slot width (C) should be 7 to 10 times the size of the largest particles in the stream. The base width (D) will determine the capacity of the sampler and should be at least twice the slot width.

Variations On Handle Design

The sample cutter must be washed in the slurry stream and tapped to ensure it is empty before sample cuts are taken. This is necessary, as dilution with water will alter the % solids figures obtained from the sample.

For dry streams on a conveyor belts it is not possible to take adequate samples without stopping the belt (and this would cause a major disturbance). The conveyor belt is stopped and a narrow cut taken from the entire width of the belt and discarded. Material is then removed from the full width of the belt starting at the first cut for a measured length of belt sufficient to give the mass required. Fines should be swept off the belt and included. The length of the sample and the speed of the conveyor should be recorded to give an additional estimate of flow rate.

Sample Transport


All samples should be transported without spillage, evaporation or contamination. Lids on buckets are of considerable assistance.

Sampling of Sample
All samples should be submitted to sample preparation as soon as possible after collection.

Sampling point : SAMPLING POINTS size distribution analysis mineral liberation (metallic mineral) Pulp density / percent solid
Product 2 Feed Ball mill Product 1

Hydrocyclone

+
Recycle

BALL MILL HYDRO CYCLONE CIRCUIT

Rules of sampling
The cutter must make a complete traverse of the following stream with each cut. The cutter must have parallel edges and move at right angles to the following stream. The cutter opening must have a width at least four times that of the largest particle size being sampled. The cutter speed must be constant. The following stream to be sampled must be in free fall The sample must be passed quickly through the cutter to prevent buildup or blockage.

Lecture 5th

QUIZ 2
Composite samples of cassiterite ore of chute to a ball mill were weighed. Dry weight is 40kg/s. Calculate:
1. 2.

the weight of ground ore for one shift (8 hours). If the grade of the ore is 10% SnO2, what is the weight of cassiterite to be recovered during that shift.

Answer
1.

Feed rate

= 40 kg/s x 3600s/h 1000 kg/t = 144 t/h

Ground ore in one shift = 144 t/h x 8hrs = 1152 t 2. If 10% SnO2 in the ore, 10/100 x 1152 t =115.2 t of SnO2 to be recovered. =115.2

SAMPLE PREPARATION
Scoop Sampling Coning and Quartering

Chute Riffler
Spinning Riffler

Scoop Sampling
It is the simplest and least accurate technique of sampling. suitable for sampling homogenous bulk materials such as silica sand, aggregates, etc. A scoop is used to collect a suitable sample size from various locations in the heaped material.

Coning and Quartering

This technique is used for splitting a large sample (10n kg) to obtain a sample of several kilograms. On a clean flat surface, the particulate material is mixed and heaped into cone. The cone is flattened into a frustum.
n=3

The top surface of the frustum is marked into four quarters using a hard stick or a straight edge. The coning and quartering process is repeated until the proper sample size needed for a certain test is obtained. The cost of this technique is low and sample obtained from large bulks are reasonably representative.

CONING AND QUATERING

A B B A B

C D Plan view A Side view B D

Schematic diagram showing the sequence of sampling

Bulk Sample Coning and quartering Quarter A Quarter B Quarter C Quarter C Combined B+D S2 S5 S6

Combined A+ C S1

S3

S4

S7

S8

Joness Riffler or Chute Riffler

This consists of a V-shaped perspex or steel trough containing an equal number of similar chute openings on both sides, arranged alternatively.
The material is fed along the V-shaped trough to be split approximately into halves, which will be received into two trays, placed on either side of the trough. Each passage through the instrument reduces the sample to one half of the previous sample until the required sample size is obtained.

JONES RIFFLE SAMPLER

Rotary Riffle Sampler

Very accurate and suitable for dry sample

This comprises a mass flow hopper feeding through variable outlet. The receiving unit consists of a number of glass bottles (12 or 24) in a full circle This sampler may be used to split a sample of a few kilograms into an even number of approximately equal samples.

ROTARY RIFFLE SAMPLER

Case study (Quiz 3)



A quartz vein sample contains quartz and other trace minerals was cut into 5 portions as shown in Figure. Portions I V were then analyzed separately for mineral characterization studies (XRF, XRD, SEM-EDX..etc). From the statement and observation give your comments and suggestions from the sampling and analysis point of view.

II III IV

Schematic diagram of a quartz vein sample

15 cm

Lecture 6

MINERAL CHARACTERISTIC EXPLOITED

Colour , Lustre

PROPERTY UTILIZED
Optical response

TYPE OF OPERATION
Hand sorting of ore or automated device triggered by reflected light

Radio - activity

Gamma ray emission

Automated device triggered by scintillation counter Gravity separation of sands and gravels by heavy media,jig,table,spiral

Specific gravity and mass

Differential displacement in a fluid due to difference in buoyant effects

Shape

Frictional force developed in a stream flow Adsorption of specific cations or anions to modify surface tension

Flowing film table separators

Surface activity

Froth flotation and agglomerate tabling to recover aerophilic minerals

MINERAL CHARACTERISTICS EXPLOITED

Chemical reactivity

PROPERTY UTILIZED

TYPE OF OPERATION

Dissolution by appropriate reagents

Hydrometallurgy leach processes to recover gold silver,certain base metals Magnetic fields used to recover wanted mineral

Ferromagnetism

Magnetic

Surface conductivity

Mobility of electrons on the particle surface

High voltage separator

Texture hardness

Difference in the response to crushing, grinding, screening classification.

Air separation of asbestos fibres : separation of diamonds from quartz and other waste.

Gravity Concentration
A process where particles of various sizes, shape and specific gravity can be separated from one another using the gravity and centrifugal forces. Applied not only in mineral but also in other industries such as food and agriculture. Declined in important when new method of separation found in the twentieth century.

Gravity Concentration Factors that influenced of using gravity concentrators

Easy to operate Low equipment cost Low operation cost Minimum environmental effects Coarse particle not efficient to process by flotation New design can process up to 10 m particle.

Principle of Gravity Concentration



This methods separate minerals of different specific gravity by their relative movement in response to gravity and one or more other forces, the later often being the resistance to motion offered by a viscous fluid such as water or air.

Specific gravity of typical minerals Mineral gold cassiterite Magnetite Hematite Ilmenite Rutile Quartza Specific gravity (s.g) 15.6 - 19.3 7 5.2 4.9 5.3 4.5 -5.0 4.2 2.6 -2.7

Concentration Criterion, CC

Dh - Df = ---------Dl - Df

where Dh = specific gravity of heavy mineral Dl = specific gravity of light mineral

Df = specific gravity of the liquid media

Criteria

Application Will Depend on the Size Range Separation is easy until fine size (- 75 m) Separation is effective until -355 m Separation can be done until ~ 1.68mm Separation can be done until ~ 6.35mm. however, with difficulty. Relative processes like gravity concentration cannot be use, but absolute processes like the heavy medium separation (HMS) can be use.

> 2.5 2.5 1.75 1.75 1.5 1.5 - 1.25

< 1.25

Lecture 7

Quiz 4
Calculate the CC for a sample containing silica and ilmenite.

Mass Balancing
 

To assess plant performance and to control the operation Mass balancing is particularly important in accounting for valuable mineral or metal distributions. Two product formula is of great use in this respect.

Feed (F,f)

Processes

Tailing (T,t)

(Weight, grade) Consentrate (C,c)

Material input = material output

Assume the weights of the feed, concentrate and tailing are F,C and T respectively, and their corresponding assays are f, c and t; Then; F =C +T
-------------(i)

and Ff = Cc + Tt ------------(ii)

The valuable metal/mineral is balanced Therefore; Ff = Cc + (F-C)t --------(iii) Which give; Ff = Cc + Ft Ct F(f t) = C (c t) F/C = (c t)/(f t) F/C represents the ratio of concentration

The plant recovery is:

R = (Cc / Ff ) X 100%
or

R = 100 c (f t) /f (c t) %

Question 1
15,000 ton of chalcopyrite ore is processed per day. The feed of the is assays is 1.15% Cu. The concentrate produced assays 32.7% Cu and the tailings 0.18% Cu. Calculate:
1. 2. 3.

The ratio of concentration Weight of the concentrate produced Recovery of copper

Answer
1.

The ratio of concentration From the Two product formula

F =C+T ------------------- (1.1) Ff = Cc + Tt -------------------- (1.2) From (1.1) T = F- C Therefore, Ff = Cc + (F C)t = Cc + Ft Ct Ff Ft = Cc - Ct F (f t) = C (c- t) F/C = (c - t) (f t) = 32.7 0.18 1.15 0.18 = 33.53

ii)

Weight of concentrate ton C = __ F__ 33.53 = 15000 ton 33.53 = 447.62 ton

iii)

% Recovery R = Cc Ff R = 447.62 x 32.7 15 000 x 1.15 = 84.85 %

GRAVITY SEPARATORS / GRAVITY CONCENTRATION

There are two main classes of gravity concentrators; 1. Gravity separators : in which the separation is effected in water or air. 2. Dense medium separators: in which the separation is effected in a fluid or slurry with a density intermediate between the light and heavy fractions
   

Feed preparation is an essential part in gravity separation. Classifiers work best on feeds with a restricted density range; gravity separators work best on feeds with a narrow size range. Gravity separation is most efficient at larger sizes. Apart from the need to effect liberation and sort the material to be treated into appropriate size ranges such separators are sensitive to slimes which increases the viscosity of the slurry in which the separation is being effected and hence decrease separation efficiency. Desliming is usually performed by hydrocyclones.

Gravity Concentrators
Common concentrators used in mineral processing : Sluice (Palong) Jigs Shaking table (Meja ayun) Spiral(Pilin) Willoughby box (Kotak Willoughby) Lanchute Air table (Meja udara) Mozley table (Meja Mozley) panning (Dulang)

Palong


Palong is a structure made of wood with the inclination of 1:20. (this is suitable for ore contating slime)
Length of a palong is between 150 (~45 m) to 180 (~55 m) Normally divided into two section; head and tail. One palong may contains 10 -12 lanes. Splitters/riffles were made every 5 to 7 using woods 2 x 3 dan 2 x 2.

 

Scene at Palong

The woods were used to trap heavy particles like tin, ilmenite, rutil and other heavy minerals.  Slime and silica which are lighter than those minerals will flow to the tailing pond. (due to the turbulent flow)


ore bin and monitor

grizzly bar +2 -2 hopper to stockpile

trommel + to stockpile - in

Palong

Tailing pond

ore bin and monitor

grizzly bar 2 (5 cm) - 2 (5 cm) hopper trommel

+3/4

+3/4 Palong to tailing pond

Lecture 8

Quiz 5
The feed (250t/h)to a processing plant assays 51% Fe. The concentrate produced (186 t/h) assays 65% Fe and the tailings 8%.Calculate; 1.The recovery 2.The ratio of concentration

Jig


One of the oldest methods of gravity concentration, and still in used to separate heavy minerals ( cassiterite, tungsten, gold,and iron) from silica and slime. To concentrate relatively coarse mineral ~ (3 -10 mm). It will be good separation if the size range of a fairly narrow.

Finer materials may be treated on a jig where the screen aperture is larger than the dense particles and a layer of ragging or coarse grained heavy minerals overlies the screen. The evenly sized ragging is large enough to be relatively unaffected by the water movement. Efficient separation requires more than one stage : a typical coal jig would have five to seven hutches. Large jigs (up to 1000 tph) are used in iron and coal processing ; overseas, jigs are also used for cassitierite (SnO2), tungsten and gold.

Advantages Cheap, low installation costs, efficient separator in the absence of significant near gravity material. Disadvantages Poor separation efficiency unless run well (experienced operators) inefficient separator for difficult separations.

If the feed is close sized (3-10 mm) then efficient separations can be made even over a narrow density range (flourite 3.2 vs quartz 2.7) When the density range is large (coal 1.25 vs shale 2.6) good concentration is possible over a wide size range say 10-80mm)

Uses Coal (coarse) Iron ore (coarse) Cassiterite , gold (fine) good recoveries to 150 microns acceptable to 75 microns

 Basis of separation : pulse water through a bed of materials; bed dilation, hindered settling and interstitial trickling result in stratification.  Short fast strokes : best for fine minerals (initial acceleration is independent of size)  Longer slower strokes : more control and better stratification, especially for larger particles. Therefore best to screen feed into different size ranges.  Hindered settling : upward water current can be adjusted to remove small light particles and facilitate settling of coarse heavies.  Consolidated trickling : the bed is compact the larger particles interlock and the finer particles move down under gravity. Significant in the separation of fine minerals.

Pneumatic Jig

Basic jig construction

Cross Section of Jig

Differential initial acceleration

Hindered settling

Consolidation trickling

Ideal jigging process

Jigs

Diaphragms

Feed

Side view of jigs

When the specific gravity difference is large, good concentration is possible with a wider size range. The separation of minerals of different specific gravity is accomplished in a bed which is rendered fluid by pulsating current of water so as to produce stratification. Factors influence the settling of the particle in water;
1. 2. 3.

Size shape Specific Gravity

The different of specific gravity in a jigs.

s.g valuable mineral > s.g ragging > s.g gangue mineral

** Ragging - adalah mineral hematite (Fe2O3)



Binaan asas sebuah alat jig adalah terdiri daripada sebuah takungan yang berbentuk segi empat pada bahagian atasnya dan berbentuk piramid terbalik pada bahagian bawahnya. Di hujung piramid tersebut terdapat satu bukaan yang bersambung dengan satu paip yang digunakan untuk menyalurkan konsentrat

Bahagian atas takungan dipasang skrin yang digunakan untuk konsentrat masuk. Di atas skrin ini diletakkan ragging (hematit) yang berfungsi sebagai injap untuk menutup lubang-lubang pada skrin dan seterusnya menghalang mineral gangue daripada memasuki bahagian konsentrat (hutch).

The Mechanism of Jig

Note: e.g concentration of cassiterite


 

On the pulsion stroke the bed is normally lifted as a mass, then as the velocity decreases it tend to dilate, the bottom particles falling first until the whole bed is loosened. On the suction stroke it then closes slowly again and this is repeated at every stroke. The frequency usually varying between 55 330 c/min.

Apabila air disedut semula akibat daripada tindakan sedutan (suction) partikel kasiterit yang mempunyai spesifik graviti yang lebih tinggi daripada ragging akan masuk melalui lubang skrin dan diikuti oleh pergerakan ragging. saiz ragging yang lebih besar daripada saiz lubang menyebabkan ragging terperangkap di atas skrin dan menutup lubang-lubang skrin tersebut. Partikel mineral reja yang mempunyai spesifik graviti yang rendah tidak sempat masuk melalui lubang skrin kerana telah ditutup oleh ragging.

Akhirnya partikel mineral reja dihanyutkan di hujung alat jig dan disingkirkan sebagai tailing. Proses ini berlaku secara berulang-ulang kali. Partikel kasiterit yang tidak sempat masuk semasa tindakan denyutan dan sedutan pertama tadi mempunyai peluang kedua untuk masuk ke dalam takungan yang dinamakan hutch iaitu di bahagian bawah penapis.

 

Mekanisme Pengoperasian Alat Jig

Note: Short and fast stroke are used to separate fine particle. Longer and slow stroke are used to separate coarse particle. Therefore good practice to screen the feed to jig into different size ranges and treat these separately.

ragging

concentrate

Water Water Water

PULSION

SUCTION

Sp.Gr, Concentrate > Sp. Gr. Ragging > Sp. Gr. Gangue

Dalam litar pemprosesan biasanya terdapat dua atau tiga peringkat jig digunakan (primary, secondry dan tertiary). Saiz ragging untuk primary dan secondry ialah 3.0 cm dan untuk tertiary pula ialah 1.5 cm. Saiz lubang skrin ialah 0.5 cm. Sebuah alat jig mempunyai 6 sekatan untuk diisikan dengan ragging (bahagian atas skrin). Setiap sekatan diisi dengan ragging setebal 15 cm.

   

In gravity separators the particles are held slightly apart so that they can separate into layers of heavy and light particles. The major classes of gravity separator are classified according to how this dispersion is included.

Jigs apply a vertical oscillatory motion Shaking concentrators (tables, panning) apply a horizontal motion. In gravity flow concentrators a slurry flows down an inclined surface.

Lecture 8

Quiz 6
Describe briefly the separation mechanism in a jig.

Spiral


Spirals are widely used in coal and heavy minerals sands (ilmenite, zircon, rutile and monazite) processing. Feed pulp between 15 % to 45 % by weight and in the size range 3 mm to 75 m is introduced at the top of the spiral. As particles flow down the spiral they are stratified by centrifugal action and the differential settling rates and the effect of interstitial trickling through the flowing particle bed. Spirals take a feed of 15 45% solids and as the pulp flows down the spiral, the coarse, heavy particles concentrate in a band along the inner side of the profile. The denser particles slump to the inside of the spiral being removed by intermediate cutters and discharge cutters; the lighter particles remain in the faster flowing, more turbulent transport zone.

Spirals are used to treat 0.15 - 2.0 mm coal;( 25 spirals plants treat about 5% of Australian washed coal). Spirals are stable, low maintenance reliable device. A further major applications is the concentration of the 1-10% heavy mineral from quartz in beach sands plants.

There are two fluid flows on the spiral : primary flow which is the transport flow down the spiral; and the secondary flow , which is the radial flow which effects separation.  A variety of profile types are used depending on the application. Capacities range from 1-5 tph per spiral; typical spirals have 5-6 turns.

Construction or Design of a Spiral

Construction or Design of a Spiral

Tailings Midlings

concentrate

Nest of spirals

Silica Sand Processing

See video

Factor need to be considered for good separation

       

Feed rate Wash water pulp density Size range of feed Mineral density splitter After sizing Wide, height and number of helics/spiral

Shaking Table
Tables treat smaller sizes than jigs (0.6 mm down to 100m for minerals) but are lower capacity devices and used for gravity separation of minerals (tin, gold etc).

A differential shaking action is applied to the table along its horizontal axis, moving the particles along the table and opening the particle bed to allow dense particles to sink.

The water velocity decreases to zero at the table surface, so that high density particles move more slowly than lighter particles. A lateral separation, based on density, results. The stratification due to the shaking actions (slow forward stroke and rapid return) occurs behind the riffles, which run parallel to the long axis of the table and decrease in height towards the discharge end to the table. The riffles therefore act to move the denser particles towards the end of the table, with the fines moving the furthest due to the riffle taper.

Basic construction of shaking table

Action in a flowing film

Water closest to surface is retarded by friction of water absorbed on the surface. Velocity increases toward water surface. Small particles will not move rapidly as coarse particle because its submerged in the slower-moving portion of the film. High density particles move more slowly then lighter particles. Effectively separates coarse light particles from small dense particles.

Distribution of table products

Vertical stratification between riffles

Wash water Tailings

Feed

Midlings Concentrate

Lecture 9

Quiz 7


With the aid of a diagram show the fraction of concentrate, midlings and tailings in a spiral during processing of heavy mineral.

Gemini Gold Table

 

Gemini table has grooves on the table deck instead of riffles. Heavy gold is trapped in the grooves and the light gangue is washed over the groove and off the table. The gold migrates from groove to groove working its way along the table by the action of the shaking mechanism. The wash water is introduced along the centre of the table, dividing the table into two sloping surface.

Low capacity  Used to upgrade of gold concentrates from other gravity concentration devices.  The advantage is that a very high grade at high recovery is achieved and this can be directly smelted to produce gold bullion.  Feed size is less that 850 microns  Top feed rate of 0.12 t/h for the Gemini 250 which is 1.32 m wide by 2.0 m long.


Gemini Table

Kotak Willoughby (Willoughby Box)



Kotak Willoughby adalah alat pemprosesan yang berbentuk kotak yang diperbuat daripada zink, aluminium, dan stainless steel. Saiznya adalah 0.6 x 0.6 x 0.6 m. Lantainya dibuat berlubang-lubang supaya air boleh masuk melalui bahagian bawah. Kotak Willoughby ini digunakan untuk mengasingkan partikel-partikel berdasarkan spesifik graviti.

 

Wiloughby box

Air digunakan sebagai media pengasingan. Di samping itu kotak ini juga boleh digunakan untuk mengkelaskan partikelpartikel kasar daripada partikel-partikel halus.

Kes pengasingan
Konsentrat yang mempunyai spesifik graviti yang tinggi diasingkan daripada mineral gangue yang spesifik gravitinya lebih rendah. Contohnya, kasiterit/pasir, kasiterit halus/ mika.

Kes pengkelasan


Sebelum melakukan proses pengapungan buih, konsentrat kasiterit diasingkan kepada kelompok yang bersaiz halus dan kelompok yang bersaiz kasar. Proses pengapungan buih tidak boleh beroperasi dengan baik jika julat saiz adalah terlalu besar. Partikel kasiterit halus akan terlepas bersama-sama dengan mineral gangue yang kasar.

Prinsip Kerja Kotak Willoughby



Air dari paip disalurkan ke dalam tangki yang terletak di bahagian bawah kotak yang lantainya berlubanglubang. Air tersebut mengalir ke atas melalui lubang-lubang kecil yang terdapat di lantai kotak Willoughby dengan suatu halaju tertentu.

Air di dalam kotak di laraskan supaya satu aliran nipis akan keluar melalui sisi bahagian hadapannya. Bahan suapan dimasukkan melalui permukaan atas. Partikel-partikel kasar/berat mempunyai halaju ke arah bawah yang lebih besar jika dibandingkan dengan halaju air ke arah atas.

Partikel-partikel halus/ringan mempunyai halaju ke arah bawah yang lebih kecil daripada halaju air ke arah atas.  Oleh itu partikel-partikel kasar dan berat akan tinggal di dalam kotak Willoughby manakala partikel-partikel halus/ringan keluar bersama-sama aliran air dan dikumpulkan di bahagian luar kotak.


Vb = halaju partikel kasar Va = halaju air

Va Vk Vb

Vk = halaju partikel halus @ Vb > Va > Vk

Lanchute


Lanchute adalah alat yang digunakan untuk mencuci konsentrat kasiterit dari alat jig, meja ayun dan palong. Biasanya tailing daripada Lanchute dimasukkan semula ke dalam alat penggiling bebola untuk tujuan liberasi (liberation). Kasiterit diasingkan daripada pasir dan amang dengan menggunakan suatu aliran air yang nipis. Lanchute dibina di atas satu konkrit yang mempunyai kecerunan yang sederhana dan bentuknya adalah seperti peti mayat.

Lanchute

Lantai dan dindingnya dilapik dengan papan supaya mudah diperbaiki jika berlaku kerosakan di samping itu papan juga adalah murah dan tidak mudah dikakis oleh asid. Partikel-partikel dicuci dengan menggunakan satu aliran nipis yang seragam. Kasiterit yang lebih berat daripada pasir dan amang akan tinggal di pangkal Lanchute manakala pasir dan amang akan dihanyutkan oleh aliran air yang nipis ke hujung Lanchute.

Meja Udara (Air Table)

  

Alat ini direkabentuk pada abad ke 19 untuk pengasingan bijirin. Selepas beberapa lama ia telah menjadi salah satu alat yang penting dalam pengkonsentratan mineral berat. Pengasingan dengan menggunakan alat ini selalunya adalah diperingkat akhir proses pengkonsentratan dan saiz partikel adalah pada julat saiz yang kecil. Alat ini menjadi amat berguna terutamanya kepada bahan yang sangat sensitif terhadap air ataupun kepada logi pemprosesan yang sumber airnya amat kurang dan mahal.

Meja udara biasanya dibuat samada berbentuk trapiozoid atupun segi empat tepat dan berada dalam keadaan condong pada kedua-dua arah iaitu pada arah memanjang dan juga pada arah pendek. Meja udara beroperasi dengan mengunakan udara yang disalurkan secara berterusan daripada bahagian bawah permukaan meja yang poros. Disetengah-setengah logi pemprosesan permukaan meja ini hanya dilapisi oleh kain kanvas yang ditegangkan.

Dulang


Teknik yang tertua digunakan untuk mengasingkan mineral yang berat daripada mineral yang ringan. Akibat daipada tindakan daya emparan, mineral yang secara relatifnya ringan disingkirkan di bahagian tepi dulang dan mineral berat (emas, kasiterit) akan kekal di dalam dulang.

Dulang

Mozley Table

Meja Mozley (Mozley Table)



Penggunaan alat pengkonsentratan ini semakin penting di makmal. Alat ini terdiri daripada tray pemisah yang berada dalam keadaan cerun dan terdapat dalam dua bentuk: Tray rata : untuk partikel yang bersaiz halus iaitu di antara 10 100 Qm Tray berbentuk V (Vee-shaped) sudut dalaman ialah 165o, untuk partikel yang bersaiz kasar iaitu di antara 100 2000 Qm.

  

Alat ini beroperasi berasaskan ayunan harmonik. Tray berayun secara bersudut tepat dengan arah kecerunan. Ayunan harmonik ini dilakukan oleh crankshaft (aci enkol) Pemisahan menjadi lebih baik dengan dengan penambahan tindakan knock pada arah memanjang. Teknik pengoperasian kedua-dua tray adalah sama iaitu dengan meletakkan sampel sebanyak 50 100 g pada bahagian atas tray tersebut. Sebelum ayunan tray dimulakan. sampel hendaklah dibasahkan.

Ayunan dan pergerakan partikel ini akan berlaku untuk suatu jangka masa tertentu bergantung kepada beberapa kritiria misalnya berat sampel jumlah air basuhan, saiz partikel dan kecerunan tray.
Pemisahan berlaku di atas tray dengan terbentuknya sekurang-kurangnya dua kelompok partikel iaitu; mineral berat akan berada di bahagian belakang manakala kelompok mineral ringan akan berada di bahagian hadapan dan seterusnya disingkirkan ke takungan hampas.

Mineral berat yang tinggal di atas tray dibasuh dan dikumpulkan di dalam bekas yang lain di hujung tray. Parameter yang selalu dikawal Jenis tray Kecerunan 1.75 3.0o Irrigation water 3 l/min Ayunan 60 110 rpm dan standart yang digunakan ialah di antara 80 100 rpm. Amplitud 6 15 mm dan standart yang digunakan ialah di antara 6 10 mm.

     

Bucket Drop Chute Revolving screen Distributor Feed Chute Primary Jig

Stripping Chute

Dump

Stone chute

Dump

Tailing O/F

Dredge Treatment Plant

Sump 24 cyclone 3 way distributor Tailing Secondary jig Sump Cyclone Distributor Tertiary Jig Bucking storage Tailing chute Dump

Screen
+ 8 mesh oversize

To hand treatment

Generalized flow sheet of Tin dry plant for Upgrading of dredge heavy Mineral concentrate

Willoughby washer Cone Filter

Overflow fines

Shaking Table

Dryer
+ 28 mesh

c
- 28 mesh

Quartz to waste

Screen High intensity Magnetic separator

Non magnetics Conductors

1# High tension separator

Non conductors

1st magnetic Ilmenite

1st magnetic Columbite

Screen Sizing Air Tables

Conductors

2# High tension separator

Non conductors

High intensity High intensity Magnetic separator Magnetic separator

Magnetics 1st magnetic Ilmenite monazite Non magnetics

Quartz to waste Sno2

Pyrite removal
Sn02 concentrate

1st magnetic Columbite

Shaking table
Zircon Quartz

Dredge material Grizzly

oversize

oversize Trommel slimmes overflow

cyclone (dewatering/desliming) Primary Jig

Tailing

Dewatering Cone concentrate Secondary Jig Tailing

Dewatering Cone Tertiary Jig Tailing Midlings Tailing disposal

Dewatering screw

Concentrate to shore based tin shed or Dry Plant

Rougher Flotation Tailings

Pumps Distributors
Tailings

Humphreys spiral(2) Pumps

Overflow Concentrate

Cyclones (3)
Concentrate

Pyrite flotation (4)

Tailings

Tables (5)
Overflow

Bin

Classifier (6) Monazite flotation (7) Classifier

Concentrate

Dryer Dryer (8)

Pack Monazite Concentrate Magnetics

Magnetic separator (9)

Non magnetics

Magnetic separator (10)

Non magnetics

To tailing pond

Bin
Pack Tin Concentrate Pack Tungsten concentrate

Flow sheet of Climax byproducts plant.(1) four D41-5 hydroscal pumps; (2) 784-model 24A 5- TURN Humphreys spirals; (3) four D10B Krebcyclones ; (4) 12 36 inch. Weinig flotation machines ; (5) 20 No. 6 Diester tables ; (6) two banks, eight cells each, Sterans flotation machines ; (8) one AllisChalmers steam dryer ; (9) one Dings 8-pole 18 in, cross belt magnetic separator ; (10) one 4-pole Dings cross belt magnetic separator

Crushed ore -3/8 overflow

Spiral Classifier
Sands

Cyclone

Slimes

3 Cyclone
Sands

- 7 mesh

Ball mill Cyclone Rotary sleve

- 48 mesh

Sulfide conditioner Cu/Zn scavenger Flotation

C T

Hydrosizer

Thickener Shaking tables Sulfide conditioner Bulk sulfide Flotation

C T C T

Low intensity Magnetic separation

Non magnetics

Flow sheet For Concentration Of Lode Tin ores

Regrind

Regrind

Sn conditioner Sn rougher Flotation

C T

Sulfide conditioner

Regrind conditioner Cu/Zn flotation Thickener Filler Dryer

Bulk Cu/Zn concentrate FeS3 FeAsA To tails

Cu/Zn scavenger Flotation

C T C

Sn cleaner Flotation
T

Thickener Filler Dryer

Sn gravity Concentrate

Jones high intensity Magnetic separator

Non magnetics

Thickener Filler
Tailings

Dryer
Sn flotation Concentrate

Ore bin and monitor

Grizzly bar +2 To ore bin

Hopper

Trommel - 3/4 +3/4 To bin feeder and rod mill

Flow Sheet for a palong

Palong

Over flow

Tailing dam 1

Over flow

Tailing dam 2

Under flow

Raw feed Grizzly Rotary scrubber -3 mm -25/50 mm Vibrating screen + 5/10 mm Crusher or by-pass to waste if required Pump Overflow Hydrocyclone / screw classifer + 200/300 m Fines as required Gig circuit - 5/10 mm

Fines classification desliming cone/spiral/table concentration Flow Sheet of Processing Alluvial Gold Ore

HEAVY MEDIUM SEPARATION

In general, to produce a float product (low density mineral) and a sink product (high density mineral), e.g.

Feed

Minerals S.G. - 2.8 (float)

Liquid Medium S.G 2.8

Minerals S.G. + 2.8 (sinks)

Principles of Heavy Medium Separation

Can show the relationship between high density and low density minerals.

Separation based on the differences in density of minerals. Separation in a medium with higher densities than water and the densities of the minerals to be separated. In industrial separation, thick suspension or pulp, is used, where special type of heavy media which behaves like heavy liquid is used as the medium.

Advantages of Heavy Medium Separation

1. The ability for separation which is accurate, clear and real. 2. The ability to change quickly the separation specific gravity with changes in process conditions. 3. The ability to take out the products continuously. 4. The ability to treat a wide size range of materials. 5. Easy to start up and shut down without loosing the separation efficiency. 6. Low medium cost and low loss of medium. 7. Low operational and maintenance costs. 8. High tonnage with minimum use of floor space. 9. Low capital investment per ton of feed.

Applications of Heavy Medium Separation 1. Production of finished concentrate, two or one finished concentrates, or pre-concentration with the removal of unwanted gangue materials. The ideal application is the reprocessing of coarse waste materials. 2. Cleaning of coal and pre-concentration of minerals. 3. When the process is used to remove a large quantity of coarse ground gangue materials, HMS can provide the following advantages:
1. Mining Methods : lower cost where materials which are easily broken can be removed earlier before a concentrator or preparation plant. 2.A distinct decrease in the quantity of the minerals to be finely ground to liberate the minerals or the following separation process. 3. A decrease in the overall plant capital investment per ton of concentrate because the plant size from the HMS step onwards will be smaller.

Two Basic Types of Separation

Static: Usage of trough, drum or cone type of vessel where separation is done in the media under the influence of simple gravity forces. Minerals are in the size range of maximum of 6 inches until minimum of 3 mesh.

Dynamic: Using centrifugal forces up to 20 times of the normal gravity forces on the media and minerals in a vessel/ cylinder to produce separation. Minerals: 2 inches and as fine as 65 mesh.

Heavy medium Use:  Heavy liquids  Suspension / pseudo heavy liquids

Examples of Heavy Liquids

i. Tetrabromoethane (TBE) sg of 2.96. Can be diluted with white spirit or carbon tetracloride (sg of 1.58) to give a range of densities below 2.96

i.

Bromoform

i. Clerici Solution (thalliumformate thalium malorate)

MEDIUM

A suspension of fine magnetite in water, or ferrosillicon (FeSi) or a mixture of both materials depending on the separation density required. Densities 1250 2200 kg/m - magnetite 2200 2900 kg/m - mixture 2900 3400 kg/m - FeSi

Requires medium that is stable, high enough densities and viscosity. Use solids that have high specific gravity, do not easily turn to slimes as degradation will drastically increase with surface areas of the medium.

 must be easily removed from the surface of the minerals with washing and can be recovered from the fine mineral  Not influenced by the minerals and can withstand from chemicals e.g. corrosion.

Example : Static (Gravity Heavy Medium Separator)

Consists of a vessel where the feed and medium are fed and the float is taken out as overflow or using paddles. The sinks will fall to the bottom and taken out The mechanism of removing the sinks is with the objective of minimizing the vertical flow of the medium Removal of the sinks without removing enough quantity of medium that will affect the underflow current in the vessel.

Existence of homogenous and non-agglomerates in the separation vessel.

~ 900 1000 gallons of media ( ~ 10 ton) is needed to process one ton of feed materials through DWP

DWP is tilted to 15 from the horizontal to separate coal and 25 from the horizontal for mineral separation.

Figure A: Flow sheet of processing plant treating 50 ton/hr of feed Figure B : Flow sheet of processing plant treating > 50 ton/hr of feed Differences : numbers of screen/ washing screen etc. magnetic separator. Use to recover and return the media for reuse in the system.

Figure B shows the recover flow of the fine sink product that is required when processing fine minerals of less than 28 mesh.

Figure showing the Heavy Liquid Test Objective: Determination of the washability properties of a given mineral mixture. The test will show the specific gravity and size of particles where one of the components is liberated and concentrated and also to assess the suitability of HMS on a given crushed feed material and to determine the economic separation density.

Heavy liquid analysis is important in coal preparation Determination of the required density of separation and yield of coal with the required ash content. Ash Content amount of incombustible material in coal

Separation density, yield, but this will the ash content.

yield = weight of coal floated total weight of feed

x 100%

Efficiency of Heavy Medium Separation

Depends on the ability of the process to separate the materials that have specific gravity very near to the specific gravity of the medium.

Efficiency is shown by the gradient of the Tromp Curve (Partition Curve) for any feed material and is used to differentiate and to estimate process performance.

Partition curve relates the partition coefficient that is % of feed material with a particular specific gravity that reports to sinks against specific gravity.

TROMP OR PARTITION CURVE

1. Ideal: shows that all the particles that have higher densities from the separation density reports to sinks while the lighter minerals report to the float. 2. Real: shows the highest efficiency for particles that have densities far away from the operating density and will decrease for particles approaching the operating density. - Slope of the curve between 25% and 75% distribution is used to show the efficiency of a particular process: Ep = A B 2 where Ep = Probable error of separation or Ecart Probable * the density difference where 75% is recovered in the sinks fraction and 25% is recovered in the float fraction.

General heavy liquid analysis procedure

Separation Analysis of Coal -Shale

Heavy Liquid Analysis of Coal

General heavy liquid analysis procedure

MAGNETIC SEPARATION
 

Based on the difference in magnetic properties of minerals in a mix. The property of a material that determines its response to a magnetic field is the magnetic susceptibility. Application of magnetic separation :
o o

Separation of tramp iron, Concentration of mineral or metal,

In a mineral concentration process,

o

to separate valuable minerals from the non magnetic gangue minerals, e.g. ilmenite from quartz. to separate other valuable minerals from the non magnetic valuable minerals; e.g. magnetite or wolframite from tin.

(a)

(b)

Tramp Removal and Cobbing

iron removal is used to protect mineral processing equipment such as crushers, screens and conveyors. The equipment selected depends on many factors, including the size and the amount of tramp iron occurring and the point at which protection is required.
Tramp

Coarse strongly magnetic materials can be recovered using equipment similar to tramp removal. Dry cobbing ~ recovery of magnetite, iron value from blast furnace and steel making slag and cleaning of non-magnetics from steel scrap.

Feed

Magnetics

Middlings

Non-Magnetics

Schematic diagram of magnetic separation

Disc magnetic separator

Non-Magnetic minerals

MINERAL GROUPS [Based on magnetic susceptibility minerals divided into three groups]

Diamagnetic
Could not be concentrated by magnetic separation

Paramagnetic
Can be concentrated through high intensity magnetic separation (WHIMS)

Ferromagnetic
High attraction to magnetic force. Can be concentrated through low intensity magnetic separator (LIMS)

 The forces determine the separators performance and depends on the characteristics or features of feed material and separators features. The features of feed material :i. Particle size distribution,

ii. Magnetic susceptibility iii. Physical and chemical properties of feed material.

LOW INTENSITY MAGNETIC SEPARATION

Efficiency depends on the relative magnitude of magnetic force which pulls a particle to the drum and the centrifugal and gravity forces which try to discharge or drop the particle from the drum.
DESIGN OF LOW INTENSITY MAGNETIC SEPARATOR I. II. concurrent counter rotation

III. counter current Example : Drum Separator Separation Principle : pick-up ~ magnetic particles were lifted by magnet and pinned to the drum and taken away from the magnetic field. The waste or gangue materials and minerals were left in the waste compartment. Water was filled up to make the pulp float.

Example : Drum Separator



Separation Principle : pick-up ~ magnetic particles were lifted by magnet and pinned to the drum and taken away from the magnetic field. The waste or gangue materials and minerals were left in the waste compartment. Water was filled up to make the pulp float. Drum separators are widely used to treat low grade taconite ores, containing 40 - 50 % Fe mainly as magnetite or hematite. Fine grinding is necessary to free the iron minerals that produce a concentrate that requires pelletizing before being fed to the blast furnaces.

DESIGN OF LOW INTENSITY WET MAGNETIC SEPARATOR

electromagnetic

+
Feed Magnetic minerals

Concentrate was taken to the front by drum & exit through a space where the concentrate was consolidated or compacted & dewatered before leaving the separator. To produce magnetic concentrate which are very clean from coarse materials. Widely used in the heavy medium recovery system.
For cobbing operation on ore size 6.3 mm.

electromagnetic

Magnetic minerals

The feed flows in an opposite direction to the drum rotation In the roughing operation where the lost of magnetic materials were minimized. Also doesnt require a very clean concentrate. Require high capacity or load of solids.
Roughing operation on ore of 1.68mm size.

electromagnetic

Magnetic minerals

The waste (non magnetic minerals) were forced to flow in the opposite direction to the drum rotation & discharged into waste compartment For finishing operation on fine materials of size <250 m

HIGH INTENSITY MAGNETIC SEPARATION

    To separate paramagnetic minerals which require high degree of magnetic field gradient. a closely pitched matrix assembly rotating between the jaws of powerful magnet. The separator consists of an annular box rotating through one or more high- intensity magnetic fields. The annular box is filled with shaped ferromagnetic material which is inductively magnetized to a high magnetic field intensity and which acts as a collecting medium for the weakly magnetic particles in the field pulp. Non-magnetic particles pass directly through the annular ring and the rotation of the annular box carries the magnetics out of the field where they are washed into a separate collection launder.

Feed flows through a matrix of shaped ferromagnetic material. The ferromagnetic matrix on which paramagnetic particles are collected may be in form of : grooved plates steel balls, steel wool Sheets of expanded metal Aim : To achieve magnetic saturation in the matrix. Thus, maximum field intensity and field gradient in the air spaces formed between the elements of the matrix

i. ii. iii. 

Matrix purpose


To provide a place (sites) for paramagnetic particles collection. So, particles are able to be separated from the non-magnetic particles. Produce or deliver high value of magnetic field gradient in the separation zone to give high magnetic force. To strengthen the magnetic field applied from outside apart from distributing the magnetic field more uniformly through separation zone.

Non-magnetic particles

Schematic diagram of stringers on solid steel plate

Feed and Airflow Matrices

Magnetic pole

Magnetic pole

Preconcentrate Spiral / Tables Dry H.T.S Rolls Induced roll separators Induced roll separators Screen electrostatic separators Non conductors Rutile Wet tables Air - tables Zircon Dry Monazite Garnets Magnetics Silica

Ilmenite

Plate separators

MAGNETIC SEPARATION

Based on the difference in magnetic properties of minerals in a mix.

Application of magnetic separation : i. Separation of tramp iron,

ii. Concentration of mineral or metal, iii. Dealing with magnetic constituents.

In a mineral concentration process, i. ii. to separate valuable minerals from the non magnetic gangue minerals, to separate other valuable minerals from the valuable magnetic minerals.

Magnetic separation is a physical separation of discrete particles based on 3 way interactions of : Magnetic force, Gravity force, centrifugal, abrasion or inertia, Pulling or pushing force among particles.

The forces determine the separators performance and depends on the characteristics or features of feed material and separators features. The features of feed material :i. Particle size distribution,

ii. Magnetic susceptibility iii. Physical and chemical properties of feed material.

BASIC GROUP FOR MAGNETIC SEPARATORS

Wet Magnetic Separator

Dry Magnetic Separator

Standar d

Drum separators Bowl traps Magnetizing coils and blocks Demagnetizing coils

Magnetic pulleys Rectangular suspended magnets Magnetic drum-radial pole types Magnetic drum- axial pole types Plate magnets Grate magnets Magnetic drums-radial pole types Magnetic drums axial pole types Induced roll magnetic separators Cross- belt magnetic separators Ring-type magnetic separators

Medium

Magnetic filters High intensity separators (WHIMS)

High

HIGH INTENSITY MAGNETIC SEPARATION

Separation for paramagnetic minerals (relatively low magnetic susceptibility). Require high degree of magnetic field gradient. In a high intensity magnetic separator, the best arrangement is : a closely pitched matrix assembly rotating between the jaws of powerful magnet: The separator consists of an annular box rotating through one or more high- intensity magnetic fields. The annular box is filled with shaped ferromagnetic material which is inductively magnetized to a high magnetic field intensity and which acts as a collecting medium for the weakly magnetic particles in the field pulp. Non-magnetic particles pass directly through the annular ring and the rotation of the annular box carries the magnetics out of the field where they are washed into a separate collection launder

Feed flows through a matrix of shaped ferromagnetic material. The ferromagnetic matrix on which paramagnetic particles are collected may be in form of : i. ii. grooved plates steel balls, steel wool

iii. Sheets of expanded metal Aim : To achieve magnetic saturation in the matrix. Thus, maximum field intensity and field gradient in the air spaces formed between the elements of the matrix Matrix purpose 1. To provide a place (sites) for paramagnetic particles collection. So, particles are able to be separated from the non-magnetic particles. 2. Produce or deliver high value of magnetic field gradient in the separation zone to give high magnetic force. 3. To strengthen the magnetic field applied from outside apart from distributing the magnetic field more uniformly through separation zone.

WET HIGH INTENSITY MAGNETIC SEPARATOR Matrix assembly mounted on a non magnetic rotor, moves between the poles of a powerful stationery electromagnet The feed pulp is introduced through nozzles into the matrix at the leading edge of each magnet zone magnetically susceptible particles are attracted and held within the elements of a matrix,whilst,most of the non-magnetic particles discharge vertically after percolating through the matrix As the matrix rotates along the magnet zone, the particle retained are subjected to low pressure water jets to remove any physically entrained non magnetics or minerals of very low magnetic susceptibility which can be collected separately as a midling. At the point of lowest magnetic induction, midway between each two successive magnet zones, the magnetics are promptly discharged with the assistance of a high pressure water jet The unique design of the magnet unit : at this point in the circuit, the magnetic induction is extremely low, permitting even material of high magnetic susceptibilty to be discharged

Preconcentrate Spiral Tables Dry H.T.S Rolls Induced roll separators Induced roll separators Screen electrostatic separators Non conductors Rutile Flow sheet of separation plant of Associated minerals consolidated Air - tables Wet tables Zircon Dry Monazite Garnets Magnetics Silica

Ilmenite

Plate separators

ELECTROSTATIC SEPARATOR @ HIGH TENSION

1.

A mixture of mineral particles which contains conductor particles and non-conductor particles were introduced through the feed hopper (A) to the surface of rotating cylinder (C).
s

2. All the particles receive surface charge corona discharge from electrode (B).

while passing the high

3. The charging by corona was accomplished by passing the solid through corona discharge which was a tiny wire or a series of needle points placed parallel to the earthed electrostatic separator rotor. Corona discharge will be produced every time the wire or tiny needle lifted to a electric potential (voltage supplied) which might cause ionization to occur. 4. The value of initial surface charge Particle shape Feed rate The exposure time of particles Corona intensity
s,

depends on the :

5.

As soon as the particles leave the corona field, the particles will lost the surface charge depending on the rate which depends to the electrical resistivity of each particles (electrical resistance), the degree to which the particles are in contact with the earthed rotor and the initial magnitude for the particle surface charge. When ionization occur, the mineral particles will receive a spray of electrical charge. a good conductor will share their charge very quickly with the earthed rotor and thrown freely from the rotor through the combination of centrifugal and gravity force.

6.

non-conductor : the high surface charge will be pulled and pinned to the rotor surface.

at a low rotor speed, the conductor particles will slide from the rotor by the influence of gravity force.

Electrostatic Separation @ High Tension Separator

Arrangement of HT in practice

Minerals pinned to rotor (non(non-conductor) Apatite Barite Calcite Corundum Garnet Gypsum Kyanite Monazite Quartz Scheelite Silimonite Spinel Tourmaline Zircon

Minerals thrown from rotor (conductor) Cassiterite Chromite Galena Gold Hematite Ilmenite Limonite Magnetite Pyrite Rutile Sphalerite Stibnite Tantalite wolframite

Typical beach sand minerals

Magnetics Magnetite - T Ilmenite - T Garnet - P Monazite - P

Non magnetics Rutile - T Zircon - P Quartz - P

T - thrown from high tension separator surface P - pinned to high tension separator surface

Typical Beach Sand Treatment Flow Sheet

Wet feed Gravity preconcentrator Quartz / Garnet Low intensity wet magnetic separation magnetite Non magnetic Rutile, Zircon Dry High intensity wet magnetic separation magnetic Ilmenite, Monazite Dry High tension separation

High tension separation

Rutile

Zircon

Ilmenite

monazite

TWO PRODUCTS FORMULAS

Applicable to the simplest separation where only one concentrate and one tailing results from a given ore feed

Products Feed Concentrate Tailing Ration of concentration Recovery %

weight or Wt % Sample assay % Calculated F C T f c t K R

Ratio of concentration can be thought of as the number of tonnes of feed required to produce 1 tonne of concentrate. The ratio K for a separation can be obtained directly from the product weights or from the product assays if the weights are not known :

K=

F C =

c-t f-t

The concentration ratio

At operating plants it is usually simpler to report the K based on assays. If more than one minerals or metals is recovered in a bulk concentrate each will have its own K with the one regarded as most important being reported as the plant criteria. If the tonnage of concentrate s produced is unknown it can be obtained using the product assays and the tonnes of plant feed :

C=

F K

ft = F c-t

The weight of concentrate

Recovery % : Represents the ratio of the weight of metal or mineral value recovered in the concentrate to 100% of the same constituent in the heads or feed to the process, expressed as a percentage. It may be calculated in several different ways depending on the available data ; most commonly : By assays f,c and t only

R=

c (f t) X 100 = the recovery % f (c t)

By K plus assays f and c

c R= Kf
By Weights F and C, plus assays c and t

X 100 = the recovery %

R =100 -

100 ( F C ) t = recovery % (Cxc)+(FC)t

Three products (bi metallic) formulas. Frequently a concentrator will mill a complex ore requiring the production of two separate concentrates, each of which is enriched in a different metal or valuable mineral, plus a final tailing acceptably low in both constituents. Formulas have been developed which use the feed tonnage and assays of the two recovered values to obtain the ratios of concentration, the weight of the three products of separation and the recoveries of the values in their respective concentrates. For illustrative purposes data from a copper zinc separation is assumed.
Product Feed Cu concentrate Zn concentrate Tailing Ratio of concentration Recovery % Weight or Wt % F C Z T % Cu assay c1 c2 c3 c4 % Zn assay z1 z2 z3 z4 K cu K zn R cu R zn Calculated

The ratios of concentration Kcu and Kzn are those for the copper and zinc concentrate, respectively with Rcu and Rzn the percentage recoveries of the metals in their corresponding concentrates. As follows :

C=FX

( c1-c4)(z3-z4)-(z1-z4)(c3-c4) ( c2-c4)(z3-z4)-(z2-z4)(c3-c4)

= tonnes Cu concentrate

Z=FX

( c2-c4)(z1-z4)-(c1-c4)(z2-z4) ( c2-c4)(z3-z4)-(z2-z4)(c3-c4)

= tonnes zn concentrate

C X c2 R
cu

= F X c1

X 100 = copper recovery%

Z X z3 R
zn

= F X z1

X 100 = zinc recovery%

cu

F C

and Kzn =

F Z

= ratio of concentration

FILM CONCENTRATORS Concentration in a layer of liquid flowing down a inclined surface

Two types: I. II. Deposits transport : particles may reside on the surface for a considerable time Non deposit transport : the particle remains in suspension (pinched sluice, spiral) Deposits Devices Long, parallel sided washers, operated on a semibatch basis with the heavy mineral collecting on the bottom which may have cloth to hold the mineral and being removed while the feed is off. Historically used for gold and cassiterite little commercial significance today.

PINCHED SLUICES  Sluices are very old separating devices. An inclined launder about 1 metre long narrows from about 200 mm at the feed end to about 25 mm at the discharge

 Pulp of between 50-65% solids enter gently and strafies as it descends,before being separated on discharge by adjustable splitters

Pinched Sluice

REICHERT CONES
 An extension of the pinched sluice that achieve high capacities by having the pinching effect occurring as the slurry flows to the centre of a comical surface.

Cross section through Reichert cone concentrator system

Each unit consists of a number (typically four) of cones in a stack to provide roughing, scavenging and cleaning operations in one unit. Basically a sluice folded back on itself, increasing capacity and reducing sidewall effects. The problem with these devices are that they are sensitive to feed solids concentration. Typically feeds are 65% solids but even very small variations have a significant effect on separation efficiency. It is necessary to be very careful in installing cones to ensure that the feed percent solids is carefully controlled. As a sedimentation device, the separating efficiency is critically dependent upon feed rate, percent solids and heavy mineral content. Initially widely in the minerals sands and iron industries in Australia, cones now appear to be finding less favour.

FROTH FLOTATION

o o

The most important and versatile mineralprocessing technique Introduced by Haynes in 1860. Initially developed to treat the sulphides of copper-zinc, lead-zinc etc. The field of flotation has now expanded to include oxides, such as hematite and cassiterite, oxidised minerals, such as malachite and cerussite, and non-metallic ores such as fluorite, phosphates and fine coal.

Principle of flotation
o

Froth flotation utilises the differences in physico-chemical surface properties of particles of various minerals. In flotation concentration the mineral is usually transferred to the froth or froth flotation leaving the gangue in the pulp or tailing. This is direct flotation as opposed to reverse flotation.

Froth flotation