basics in mineral processing-process systems
TRANSCRIPT
-
8/8/2019 Basics in Mineral Processing-process Systems
1/11
Product Handbook 11:1
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Process System Introduction
A machine working in a mineral process flow cannot perform better then theprocess environment will allow it to.
Parameters like type, size and amount of feed, % solids in slurries, additives,discharge conditions etc. will always guide equipment performance and operationeconomy.
There is a strong trend amongst both suppliers and users to work in terms ofsystems, meaning solutions to various operation problems more than installingequipment. This will effectively increase the operation values as presented insection 2.9
Examples covering systems levels and system modules are shown in this section.
Completesystems
Processsystems
Productsystems
Products
Mineral concentrate production
Comminution circuits
Crushing Grinding Filtration
Added
operation
valuesSeparation circuits
Separation Thickening
Crushers Grinding mills FiltersSeparators Thickeners
Dewatering circuits
Complete systems
Process systems
Productsystems
Products
Aggregate production
Crushing Screening Conveying
Crushers Screens Conveyors
Addedoperationvalues
Crushing and screening circuits
System Levels in Rock Processing (Quarrying)
System Levels in Ore / Minerals Processing
-
8/8/2019 Basics in Mineral Processing-process Systems
2/11
11:2 Product Handbook
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
System Modules Sand and Gravel
Sand and gravel module Sand and gravel module
Screening
Washing(Aquamator)
Washing
(Log washer)
Fines
To sandmodule
To slurry handling
Coarse
Mediumcoarse
Washing(Aquamator)
Classifiying
Sandtrap
Slurry module
4:2
5:1
5:1
5:1
4:6
Water
Primary crushing module Intermediate crushing module
From rock front
Feeding
Crushing
Scalping
Closed 1
Screening
CrushingII, III or IV
Screening
Closed II
Open
Final products module Slurry handling module
Washing
To slurrycircuit
Productscreening
Classification
Sedimentation
Filtration
Sand
Recycledprocesswater
= option or alternative
= refering to actual chapters and pages7:5
3:3
4:2
4:2
3:8
5:1
4:2
4:6
6:2
6:19
System Modules Aggregates
A good way to understand and work with process systems is to use systemmodules in various combinations.
7:5
-
8/8/2019 Basics in Mineral Processing-process Systems
3/11
Product Handbook 11:3
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
System Modules Ore and Minerals
Sedimentation
Dewatering
Drying
SedimentationPrimary
separation
Secondaryseparaton
Finalseparation
Optional
Tailingsdisposal
Wet Concentrate
Wet Tailings
Tailings
dry
Primarygrinding
Secondarygrinding Classification
Tertiarygrinding
ROM
Primarycrushing
Secondarycrushing Screening
Options
Grinding
Crushing module
Grinding module
Enrichment module Upgrading module
3:3 3:8 4:2
3:13 3:3 4:6 3:13
5:5
5:5
5:5
6:26:2
6:2
6:47
Dry conc. Dry tailings Conc.
= option or alternative
= refering to actual chapters and pages7:5
-
8/8/2019 Basics in Mineral Processing-process Systems
4/11
11:4 Product Handbook
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Process system Railway Ballast
Process Systems Asphalt / Concrete Ballast
Feeder(Grizzly)
Primarycrusher
Screen
18 mm
Secondary
crusher
Screen
35 - 64 mm
Scalping
0 - 18 mm 0 - 35 mm
Washing
screen
Slurry
handlingWash
water
35 - 64 mm
Chips &fines
Water recovery
RW-ballast Washing module
Primary crushing module Secondary crushing module
Primary crushing module
Feeder(Grizzly)
Primarycrusher
Screen Secondarycrusher
Screen
Tertiarycrusher
ScreenFinal products
16 - 22 mm
Scalping
+ 22 mm
ScreenFinal products
12 - 16 mm
8 - 12 mm
4 - 8 mm2 - 4 mm
0 - 2 mm
Primary crushing module Secondary crushing module
Tertiary crushingmodule
Final products module
7:6 3:3 4:2 3:8 4:2
5:2 5:4
7:6 3:3 4:2 3:8 4:2
3:10 4:2 4:2
= option or alternative
= referring to actual chapters and pages7:5
-
8/8/2019 Basics in Mineral Processing-process Systems
5/11
Product Handbook 11:5
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
ROMPrimary
crushing
Secondary
crushing
Screening Primary
grinding
Secondary
grinding
Classification
Dewatering
SedimentationLIMS wet
Flotation
Sedimentation
Pressure filtration
Iron conc.
Fe conc.
SIZE REDUCTION
ENRICHMENT & UPGRADING
Cone AG, SAG, Rod Ball, Pebble Spiral/Cyclone
Optional
Gyr. jaw
Dewatering
Apatiteremoval
Conventional
Pressurefiltration
Tailings
Fe conc. final
HGMS
Flotation
Sedimentation
Fe conc.
Dewatering
Fe conc. final
Sedimentation
Conventional.
Inclined plate
Pelletizing (optional)
Tailingdisposal
Apatite conc.
Process System Ferrous Ore (hosting apatite)
Process System Base Metal Ore
3:3 3:8 4:2 3:13 3:13 4:6
5:24
5:13
6:2
6:30
5:31
5:18
6:2
6:30
6:3
6:11 6:30
6:55
Primary Cu flot.
Regrind
Final flotation
Pressure filtration
Cu conc.
Fe conc.
ENRICHMENT & UPGRADING
Dewatering
Conventional
Pressurefiltration
Tailings
Fe conc. final
Primary Pb flot.
Regrind
Final flotation
Pressure filtration
Dewatering
Pb conc. final
Conventional.
Tailings disposal
Conventional
Sedimentation
Sedimentation
Pb conc.
Primary Zn flot
Regrind
Final flotation
Sedimentation
Zn conc. final Dewatering
Sedimentation
Zn conc.
ROMPrimarycrushing
Secondarycrushing
Screening Primarygrinding
Secondarygrinding
Classification
SIZE REDUCTION
Cone AG, SAG, Rod Ball, Pebble Spiral/Cyclone
Optional
Gyr. jaw
= option or alternative :5 = referring to actual chapters and pages
3:3 3:8 4:2 3:13 3:13 4:6
5:13
3:13
5:3
6:30
5:17
5:13
3:13
6:3
6:30
5:13
5:13
3:13
6:3
6:3
5:13
6:30
-
8/8/2019 Basics in Mineral Processing-process Systems
6/11
11:6 Product Handbook
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Process System Gold Bearing Ore
Process System Coal
ENRICHMENT & UPGRADING
GravityseparationCoarse
free gold
Recovery by flotation
Primary flot.
Regrind
Final flot.
Mixers
Tailings
Conc. final
Pressure filter
Dewatering
Disposal
Tailings
Gold containedin loaded carbon
Inclined plate
Sedimentation
Sedimentation
Gold containedin bulk concentre
Leaching stages
Adsorption stages
Sedimentation Dewatering
Recovery by flotation
Finaltailings
Mixers
LimeCarbonCyanide
ROMPrimarycrushing
Secondarycrushing
Screening Primarygrinding
Secondarygrinding
Classification
SIZE REDUCTION
Cone AG, SAG, Rod Ball, Pebble Spiral/Cyclone
Optional
Gyr. jaw
3:3 3:8 4:2 3:13 3:13 4:6
5:13
3:13
5:13
6:3
6:3
6:30
5:43
5:43
6:236:11
5:8
ROM
SeparationDense Media
Media Screen Sizing Screen
DewateringScreen
Media Screen
Flotation
Float
Blendingandstorage
Dewatering
Drying
12 - 125 mm
0.5 - 12 mm
Vacuum filter
0 - 12 mm
- 0.5 mm
- 0.5 mm
Indirect
- 0.5 clean coal
Sink
Coarsetailings
Heavy media recovery
Sedimentation
Fine tailings
Tailings
Recyclewater
= option or alternative
= referring to actual chapters and pages7:5
5:6 5:12 4:2
5:12 6:21
6:3
5:13
6:23
6:48
-
8/8/2019 Basics in Mineral Processing-process Systems
7/11
Product Handbook 11:7
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Silicarock
Primarycrushing
Secondarycrushing
Screening Grinding Screening
Polishingscrubber
SIZE REDUCTION
ENRICHMENT & UPGRADING
Cone AG, SAG, Rod, BallDry processingJaw
-750micron
Dewatering
Classificationspiral
Classificationspiral
Magneticseparation
Flotation
Silicasand
Slime
Sedimentation
-100 micron Iron removal
Fe, Al, Cr bearing with minerals
Reject water
Slime
-100 micron
Tilings disposal
Clean sand100-750 micron
Process System Industrial Mineral Fillers
Process System Glass Sand
ROM Primarycrushing
Secondarycrushing
Screening Grinding Classifying
Flotation
Grindingtumbling
Grindingtumbling
Classification
Magneticseparation
Ferejects
SIZE REDUCTION
ENRICHMENT & UPGRADING
Cone AG, SAG, Ball, RodVTM, SAM; VBM
Dry processing
Jaw
Fe rejects
Classification
Optional
Magnetic Sep.HGMS
Otherrejects
Wet processing
Sedimentation
Dewatering
2 - 6 mm
15 30 mm
Fine grinding (small tonnages)
Optional
3:3 3:83:34:2
3:13
4:17
3:13
4:17
5:28
4:6
5:31 5:13
5:3
6:38Tube press
= option or alternative
= referring to actual chapters and pages7:5
3:3 3:8 3:133:2 3:2
4:6 5:3 5:224:6 5:13
6:21
6:3
-
8/8/2019 Basics in Mineral Processing-process Systems
8/11
11:8 Product Handbook
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Scrubber Screen Secondarycrusher
ScreenGravity sep.Dense media
Magnetic
separation
Screen
RecrushingVSI
Sink
Cone
2-3%
Fines1-6 mm
Jaw
Non iron reject
Iron reject
X-rayseparation
Diamonds
Diamondsorting
Primarycrushing
Tumbling
Screen Float
Drying Recovery of heavy media
Aftertreatment
Alternatively - AG milling - no crushing
Process System Diamonds (Kimberlite)
Process System Kaolin
Wet hydraulicmining
Optional forincreasing thepercentageof -2 micronmaterial
Products: Kaolin Filler, 45% -2 micronKaolin Coating, 90% -2 micron
H20
Scrubbing(blunging)
Drymining
Tailings
Fine waste
sand, mica a.o.
17% H2O
Coarse waste
sand, mica a.o.
Medium waste
sand, mica a.o.
Flotation Ultra finegrinding
Classificationspiral
Classificationcyclones
Thickening
Dewateringtube press
17% H2O
= option or alternative
= referring to actual chapters and pages7:5
3:3 5:3 3:84:2
5:12 5:10 5:12
6:48
5:22
4:12
3:10
5:3
4:6 4:6 6:2
5:13 3:17
6:38
-
8/8/2019 Basics in Mineral Processing-process Systems
9/11
Product Handbook 11:9
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Mobile Systems
In modern quarrying, mining, tunnelling and recycling operations the use of mobileprocess systems is increasing dramatically.
Particularly at rock front operations the technique of moving the process equip-ment closer to the front end using mobile crushing and screening units in manycases gives remarkable cost savings.
These mobile units represent one or more complete machine functions includingmaterials handling, power supply etc. Advanced process control secures theintelligence of the system.
Mobile Crushing and Conveying System
Key arguments for mobile equipment vs stationary equipment and damp truckhaulage are:
Less hauling less costs
Less front road maintenance
Less exhaust gas and dust emissions
Improved working safety
Improved flexibility
-
8/8/2019 Basics in Mineral Processing-process Systems
10/11
11:10 Product Handbook
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Type* Max feed/product size Cap. tph H/W/L m (ft) Weight tonmm (in)
LT110 670 / 250 (26/10) 700 4.4/3.0/17.4 (14.5/9.1/57.0) 60
LT125 800 / 300 (31/12) 800 5.7/4.0/15.8(18.6/15.2/51.1) 86LT140 900 / 350 (35/14) 1200 6.3/4.3/16.4(20.8/14.1/53.1) 110
LT160 1040/ 400 (41/16) 2000 7.6/5.9/20.2(25.0/19.3/66.7) 220
*LT110 refers to Jaw crusher type C110, LT125 to Jaw crusher type C125 etc. see further section 3.
Primary Impact Crusher + Grizzly (typical)
Type* Max feed/product size Cap. thp H/W/L m (ft) Weight tonmm (in)
LT1415 1000/200 (40/8) 800 5.4/4.0/15.8 (17.7/13.1/51.1) 73
LT1620 1300/200 (52/8) 1200 6.5/4.8/18.5 (21.3/15.7/60.7) 170
*LT 1415 refers to Impact crusher type NP1415, LT 1620 to Impact crusher type NP1620 etc. see further
section 3.
Primary Jaw Crusher + Grizzly (typical)
-
8/8/2019 Basics in Mineral Processing-process Systems
11/11
Product Handbook 11:11
Process Systems
ProcessSystem
BASICS IN MINERAL PROCESSING
Caravan Mill A pre-assembled Ore Concentrating Plant
1.Crushing unit
Jaw- and cone crusher in closed circuit with a double deck screen
Weight app. 19 ton, transportation measures W= 2,6m, H= 4.2m
2. Grinding unit
Grinding mill (ball or rod), pump and hydrocyclone
Weight app. 25 ton, transportation measures W= 3,0m, H= 3,8m
3.Separation unit (flotation)
Rougher, scavenger and cleaner cells together with conditioners, reagentfeeding systems and air blower.
Weight app.14ton, transportation measures W= 2,5m, H= 4.2m
Units for leaching and gravity separation (dense media, tables and spirals) alsoavailable
4.Dewatering unit
Compact sedimentation (lamella unit) and vacuum filter with auxiliary equipment
5. Power unit
Diesel driven generator including connection terminal
Transportation measures W= 2,5m, H= 3.8m
Typical units at approx. 10 t/h capacity
1
23
45