Basics in Mineral Processing-process Systems

8/8/2019 Basics in Mineral Processing-process Systems

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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


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11:2 Product Handbook

Process Systems

ProcessSystem


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


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Process Systems

ProcessSystem


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.


= refering to actual chapters and pages7:5


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Process Systems

ProcessSystem


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


= referring to actual chapters and pages7:5


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Process Systems

ProcessSystem


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.


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


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


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Process Systems

ProcessSystem


Process System Gold Bearing Ore

Process System Coal


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


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



5:6 5:12 4:2

5:12 6:21

6:3

5:13

6:23

6:48


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Process Systems

ProcessSystem


Silicarock

Primarycrushing

Secondarycrushing

Screening Grinding Screening

Polishingscrubber

SIZE REDUCTION


Cone AG, SAG, Rod, BallDry processingJaw

-750micron

Dewatering

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


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



3:3 3:8 3:133:2 3:2

4:6 5:3 5:224:6 5:13

6:21

6:3


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Process Systems

ProcessSystem


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


Classificationcyclones

Thickening

Dewateringtube press

17% H2O



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


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Process Systems

ProcessSystem


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


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Process Systems

ProcessSystem


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)


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Process Systems

ProcessSystem


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

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Basics in Mineral Processing-process Systems