Basics in Mineral Processing-process Systems

Process Systems Process System – Introduction A machine working in a mineral process flow cannot perform better then the process environment will allow it to. Parameters like type, size and amount of feed, % solids in slurries, additives, discharge dischar ge conditions etc. will always guide equipment performance and operation economy. There is a strong trend amongst both suppliers and users to work in terms of systems, meaning solutions to various operation problems more than installing equipment. This will effectively increase the operation values as presented in section 2.9 Examples covering systems levels and system modules are shown in this section.

System Levels in Ore / Minerals Processing Mineral concentrate production

Complete systems Comminution circuits

Process systems

Cr us hi ng

G r i n di ng

Dewatering circuits

Separation circuits

Separation

Thickening

Filtration

Product systems Products

Crushers

Grinding mills

Separators

Thickeners

Filters

s e u l a v n o i t a r e p o d e d d A

System Levels in Rock Processing (Quarrying) Aggregate production

Complete systems

Crushing and screening circuits

Process systems

Crushing

S creening

C o nv e y i n g

Product systems Crushers

Screens

s e u l a v n o i t a r e p o d e d d A

Conveyors

Products

BASICS IN MINERAL PROCESSING

Product Handbook 11:1

m e t s y S s s e c o r P

Process Systems System Modules – Aggregates A good way to understand and work with process systems is to use system modules in various combinations.

Primary crushing module

Intermediate crushing module

From rock front

Closed 1 Screening

Feeding

4:2 4: 2

7:5 7: 5

Closed II Crushing II, III or IV

3:8 3: 8

Crushing Scalping

3:3

Final products module

Screening

Open

4:2 4: 2

Slurry handling module Recycled process water

Classification Washing

4:6 4: 6

5:1 5: 1

Sedimentation Sand

6:2

Product screening

To slurry circuit

Filtration

6:19

4:2

System Modules – Sand and Gravel Sand and gravel module

Sand and gravel module Water


Coarse

Screening

4:2 4: 2

Washing (Aquamator)

Medium coarse

5:1

Washing (Aquamator)

Classifiying

4:6 4: 6

5:1 5: 1

Fines

Washing (Log washer)

Sandtrap

5:1 5: 1 To sand module

To slurry handling handl ing

Slurry module

= option or alternative

7:5 7: 5

= refering to actual chapters and pages

11:2 Product Handbook


Process Systems System Modules – Ore and Minerals Crushing module Options ROM Secondary crushing

Primary crushing

3:3

Grinding

Screening

3:8

4:2

Grinding module

Primary grinding

Secondary grinding

3:13

3:3

Classification

4:6

Enrichment module

Tertiary grinding

3:13 Upgrading module

Wet Tailings Primary separation

Sedimentation

Sedimentation

5:5

6:2

Dewatering

Secondary separaton

5:5 5: 5

Tailings dry

Final separation

6:2 6: 2

Tailings disposal

Drying

Wet Concentrate

6:47

5:5 5: 5

Dry conc.

6:2 6: 2

Optional

Dry tailings

Conc.


7:5 7: 5

= refering to actual chapters and pages




Process Systems Process system – Railway Ballast Primary crushing module

Feeder (Grizzly)

Primary crusher

7:6

3:3

Secondary crushing module

Secondary crusher

Screen 18 mm

3:8 3: 8

4:2 4: 2

Screen 35 - 64 mm

4:2 4: 2

Scalping 0 - 35 mm

0 - 18 mm

Primary crushing module 35 - 64 mm Water recovery

Washing screen

Wash

Slurry handling

5:2

water

5:4 Chips & fines

R W-ballast

Washing module

Process Systems – Asphalt / Concrete Ballast Primary crushing module

Secondary crushing module

Feeder (Grizzly)

Primary crusher

Screen

7:6

3:3

4:2 4: 2

Secondary crusher

3:8 3: 8

Screen

4:2

Scalping


Tertiary crusher

Screen Final products

3:10

Screen Final products

4:2 4: 2

4:2 4: 2

12 - 16 mm 16 - 22 mm

0 - 2 mm

2 - 4 mm 4 - 8 mm

+ 22 mm

Tertiary crushing module

8 - 12 mm

Final products module


7:5 7: 5

= referring to actual chapters and pages



Process Systems Process System – Ferrous Ore (hosting apatite) SIZE REDUCTION Optional

ROM Secondary crushing

Primary crushing

4:2

3:8 3: 8

3:3 3: 3

Primary grinding

Screening

3:13

Classification

Ball, Pebble

Spiral/Cyclone

3:13

AG, SAG, Rod

Cone

Gyr. jaw

Secondary grinding

4:6

ENRICHMENT & UPGRADING Tailings

LIMS wet

HGMS

5:24 Fe Apatite removal

5:31

conc.

Fe

Flotation

Pressure filtration

6:3 6: 3

5:13

Sedimentation

5:18 Fe conc.

Tailing disposal

Conventional.

conc.

Flotation

Fe conc. final Conventional

Sedimentation

Dewatering

6:11

final

6:30

Inclined plate

Apatite conc.

Pressure filtration

Sedimentation

Sedimentation

6:2 6: 2

6:2 6: 2

Dewatering

Dewatering

6:30

6:30 Pelletizing (optional)

6:55

Iron conc.

Process System – Base Metal Ore SIZE REDUCTION Optional

ROM

Secondary crushing

Primary crushing

4:2

3:8 3: 8

3:3 3: 3

3:13 AG, SAG, Rod

Cone

Gyr. jaw

Primary grinding

Screening

Secondary grinding

Classification

3:13

4:6

Ball, Pebble

Spiral/Cyclone

ENRICHMENT & UPGRADING

Primary Cu flot.

5:13 Fe

Tailings

Primary Pb flot.

conc.

5:13

Regrind

Primary Zn flot

3:13 3:13

Final flotation

Conventional

5:13

Sedimentation

Pb conc.

5:3 5: 3

Tailings disposal

Final flotation

final

6:3 6: 3

Dewatering

5:13 Zn conc.

final

Dewatering

6:30

Sedimentation

6:30

6:3 6: 3

Dewatering

6:30 Pressure filtration

Cu conc.


6:3

3:13

Final flotation

Sedimentation Pressure filtration

Sedimentation

Regrind

5:17 Conventional

5:13

Regrind

Fe conc. final

’

Pressure filtration

Zn conc.

Conventional. Pb conc.

:5 = referring to actual chapters and pages




Process Systems Process System – Gold Bearing Ore SIZE REDUCTION Optional

ROM Secondary crushing

Primary crushing

4:2 4: 2

3:8 3: 8

3:3 3: 3

Primary grinding

Screening

3:13

Spiral/Cyclone

5:8 5: 8

Recovery by flotation

Recovery by flotation

Lime Carbon Cyanide

Tailings

Primary flot.

Ball, Pebble

4:6

Gravity separation

Coarse free gold


Classification

3:13

AG, SAG, Rod

Cone

Gyr. jaw

Secondary grinding

5:13 Leaching stages

Sedimentation

5:43

6:3 6: 3

Regrind

Gold contained in loaded carbon

3:13

Mixers Disposal

Adsorption stages Final flot.

5:43

5:13

Mixers

Tailings

Conc. final

Sedimentation

Dewatering

Sedimentation

6:3 6: 3

6:30

6:11

Pressure filter

Gold contained in bulk concentre

Dewatering

Final tailings

6:23

Inclined plate

Process System – Coal ROM Separation Dense Media

Float

Media Screen

5:12

5:6 5: 6

Sink

12 - 125 mm

4:2 4: 2 0 - 12 mm

Dewatering Screen

Media Screen

5:12

Coarse tailings

Sizing Screen

0.5 - 12 mm

6:21

- 0.5 mm

Blending and storage

Heavy media recovery


Recycle water

Fine tailings

Flotation

5:13 Sedimentation

- 0.5 clean coal

6:3 6: 3 Tailings

Dewatering

6:23 Vacuum

filter

Drying

6:48

- 0.5 mm

Indirect


7:5 7: 5




Process Systems Process System – Industrial Mineral Fillers SIZE REDUCTION Fine grinding (small tonnages)

ROM

Primary crushing

Secondary crushing

Jaw

Cone

Screening

4:2 4: 2

3:8 3: 8

3:3

Grinding

2 - 6 mm

3:3 3: 3

4:17

AG, SAG, Ball, Rod VTM, SAM; VBM

15 30 mm

Dry processing

Classifying

Wet processing

Grinding tumbling


3:13

Optional

Grinding tumbling

3:13

Classification

4:6 4: 6

Classification

4:17 Magnetic Sep. HGMS

5:13

5:31

Fe rejects

Magnetic separation

Fe rejects

Flotation Other rejects

5:28

Optional

Sedimentation

5:3 Dewatering

6:38

Tube press

Process System – Glass Sand SIZE REDUCTION

Primary crushing

Silica rock

3:3 3: 3

Cone

Screening

Grinding

3:13

3:2

3:8 3: 8

Jaw

Silica sand

Screening

Secondary crushing

3:2 -750 micron

AG, SAG, Rod, Ball

Dry processing


Classification spiral

Polishing scrubber

4:6 4: 6

5:3

Slime


Magnetic separation

5:22

4:6 4: 6

Flotation

5:13 m e t s y S s s e c o r P

Slime

-100 micron

-100 micron

Iron removal Fe, Al, Cr bearing with minerals Reject water

Dewatering

6:21 Sedimentation

6:3 6: 3

Clean sand 100-750 micron

Tilings disposal


7:5 7: 5




Process Systems Process System – Diamonds (Kimberlite)

Primary crushing

Scrubber

Screen

5:3

4:2 4: 2

3:3 3: 3

Jaw

Secondary crusher

3:8 3: 8

Cone

Tumbling

Diamond sorting

Screen

Sink

5:12

2-3%

Drying

Gravity sep. Dense media

Float

Screen

5:10

5:12

After treatment

Recovery of heavy media

6:48 Screen Magnetic separation

Iron reject

X-ray separation

Non iron reject

Fines 1-6 mm

5:22

4:12 Recrushing VSI

3:10 Alternatively - AG milling - no crushing

Diamonds

Process System – Kaolin H20

Dry mining

Scrubbing (blunging)

5:3 5: 3

Classification cyclones


Wet hydraulic mining

4:6

4:6 4: 6

Thickening

6:2

Coarse waste sand, mica a.o. Medium waste sand, mica a.o.


Ultra fine grinding

Flotation

Fine waste

5:13

sand, mica a.o.

3:17

Tailings

Optional for increasing the percentage of -2 micron material

17% H2O

Dewatering tube press

6:38

Prod Pr oduc ucts ts::

Kaol Ka olin i n F Filille ler r,, 45% 45% -2 micron c ron Kaolin Coating, 90% -2 micron

17% H2O


7:5 7: 5




Process Systems Mobile Systems In modern quarrying, mining, tunnelling and recycling operations the use of mobile process systems is increasing dramatically. Particularly at rock front operations the technique of “moving the process equipment closer to the front end” using mobile crushing and screening units in many cases gives remarkable cost savings. These mobile units represent one or more complete machine functions including materials handling, power supply etc. Advanced process control secures the “intelligence” of the system.

Mobile Crushing and Conveying System

Key arguments for mobile equipment vs stationary equipment and damp truck haulage are: • Le Less ss hau hauliling ng – les lesss cos costs ts


• Le Less ss fro front nt roa road d main mainte tena nanc nce e • Les Lesss exhau exhaust st gas gas and and dust dust emi emissi ssions ons • Im Impr prov oved ed wo work rkin ing g saf safet etyy • Im Impr prov oved ed fl flex exib ibililit ityy



Process Systems Primary Jaw Crusher + Grizzly (typical)

Type* LT110 LT125 LT140 LT160

Max feed/product size mm (in) 670 / 250 (26/10) 800 / 300 (31/12) 900 / 350 (35/14) 1040/ 400 (41/16)

Cap. tph

H/W/L m (ft)

Weight ton

700 800 1200 2000

4.4/3.0/17.4 (14.5/9.1/57.0) 5.7/4.0/15.8(18.6/15.2/51.1) 6.3/4.3/16.4(20.8/14.1/53.1) 7.6/5.9/20.2(25.0/19.3/66.7)

60 86 110 220

*LT110 *L T110 refers to Jaw crusher crushe r type C110, LT125 LT125 to Jaw crusher type typ e C125 etc. see further fur ther section 3.

Primary Impact Crusher + Grizzly (typical)


Type*

Max feed/product size mm (in)

Cap. thp

H/W/L m (ft)

Weight ton

LT1415

1000/200 (40/8)

80 0

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 *L T 1415 refers refers to Impact crusher type NP1415, LT LT 1620 to Impact crusher type NP1620 etc. see further section 3.



Process Systems Caravan Mill – A pre-assembled Ore Concentrating Plant

1 5 2

4

3

Typical units at approx. 10 t/h capacity 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, reagent Rougher, feeding systems and air blower. blower. Weight app.14ton, transportation measures W= 2,5m, H= 4.2m Units for leaching and gravity separation (dense media, tables and spirals) also available

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




Basics in Mineral Processing-process Systems

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