Mineral Processing Flowshe. By. Dr. Corby G. Anderson. Colorado School of Mines eral Processing Flowsheets. By. Dr. Corby G. Anderson olorado School of ...
Mineral Processing Flowsheets
By Dr. Corby G. Anderson Colorado School of Mines
Flowsheets These are the combinations of unit operations linked together into an industrial process.
Flowsheets Unit Processes Any chemical process, on whatever scale conducted, may be resolved into a coordinated series of what may be termed unit actions, as pulverizing, mixing, heating, roasting, absorbing, condensing, lixiviating, precipitating, crystallizing, filtering, dissolving, electrolyzing and so on. The number of these basic unit operations is not very large, and relatively few of them are involved in any particular process.
Flowsheets Unit Operations The complexity of chemical engineering results from the variety of conditions as to temperature, pressure etc., under which the unit actions must be carried out in different processes and from the limitations as to materials of construction and design of apparatus imposed by the physical and chemical character of the reacting substances. A.D. Little
Generic Unit Operation
Unit Operation Options
Generic Flowsheet Liberate And Separate !
Liberate And Separate
Recovery (%)
Medium-Floating
Slow-Floating
Particle Size (um)
Flotation Rate
Fast-Floating
Liberation Unit Operations
Separation Unit Operations
Separation Unit Operations
Separation Unit Operations
Generic Flowsheet Liberate And Separate !
Fundamental Concept of Metallurgy Law of Conservation of Mass and Energy Matter Momentun, and Energy Cannot Be Destroyed But Altered and Accumulated Heat and Mass Balances Based on Stoichiometry Kinetics and Thermodynamics
Fundamental Concept of Metallurgy F = Mass Flow in Feed (TPH or Tons) C = Mass Flow in Con T = Mass Flow in Tail f = assay (grade) of Feed (% Metal or OPT) c = assay (grade) of Con t = assay (grade) of tail Cc = Mass Flow of Metal in Con (TPH or Ounces) Ff = Mass Flow of Metal in Feed Tt = Mass Flow of Metal in Tail
WATCH YOUR UNITS!!
Fundamental Concept of Metallurgy Feed (F)
Unit Operation
Con (C)
F= C+T
Tail (T)
Fundamental Concept of Metallurgy Feed (F)
Unit Op
Unit Op
Final Con (C)
Unit Op
Final Tail (T)
Does F = C + T still?
Fundamental Concept of Metallurgy Feed (F) Assay (f)
Unit Operation
Con (C) Assay (c)
Ff = Cc + Tt
Tail (T) Assay (t)
Ff
Unit Op
Unit Op
Cc
Unit Op
Tt
Does Ff = Cc + Tt still?
Fundamental Concept of Metallurgy R = Recovery = Percent of Metal in Feed Reporting to Con = Cc/Ff = N/K N = Enrichment Ratio = Upgrade Factor = Ratio of Con Metal Grade to Feed Metal Grade = c/f K = Concentration Ratio = Weight Reduction Factor = Ratio of Feed Weight to Con Weight = F/C
Flowsheets Generic Applications
Typical Flow Sheet
Closed Circuit Size Reduction Flow Sheet
Closed And Open Circuit Size Reduction Flow Sheets By-Pass Scalping Closed Circuit Crushing Open And Closed Circuit Grinding Dust Control
Gravity Separation
Gravity And Leach Flow Sheet
Beach Sands
Beach Sand Flow Sheet
Beach Sand Flowsheets Some resources may be treated by utilizing the differences in properties (density, magnetic susceptibility, conductivity) of the minerals.
Heavy Mineral Sand Flow Sheet
Flotation Flow Sheets
Flotation Flow Sheet
Flotation Flow Sheet
Lead & Zinc Differential Flotation Flowsheet
Copper & Molybdenum Differential Flotation Flowsheet
Flowsheets Primary Production Applications
Twin Creeks Mine Flowsheet
Ahafo Mill CCD Flowsheet
Phoenix Mine Mill Flowsheet
Gordonsville Zinc Concentrator
Produced Zn Concentrates Flowsheet from 1982 9000 st/d One 16-ft dia separating cone 2.9 sg ferrosilicon medium
Copper Mine Process Flow Sheet
Ernest Henry Mine Flowsheet
Ernest Henry Mining (EHM) is situated 38 km north-east east of Cloncurry in the Mount Isa –Cloncurry mineral district of North-West Queensland. The EHM ore body is an iron oxide copper gold deposit with an average grade of 1 %copper, 0.5 g/tonne gold and 23% magnetite, with current reserves of approximately 88 million tonnes.The copper concentrator is a single line plant with a nominal throughput rate of 1,300 tonnesper hour. An average of 350,000 tonnes of concentrate is produced each year containing around 100,000 tonnes of copper metal and 120,000 troy ounces of gold.In December 2009 Xstrata Copper announced approval of a $589 million investment to extend the life of EHM to at a least 2024, through the transformation of open pit mining operations to a major underground mine together with the construction of an associated ass magnetite extraction plant.
Mountain Pass Rare Earth Flowsheet
Mountain Pass Rare Earth Flowsheet A very complex flow sheet that requires significant energy and chemicals. Research may lead to alternative surface chemistry and flotation processes.
Baotou, China Rare Earth Flowsheet
Kotalahti Copper Nickel Mill
Copper Cliff Copper Nickel Iron Mill
Lynn Lake Copper Nickel Mill
Falconbridge Copper Nickel Mill
Cambove Cobalt Mill
Kamoto Cobalt Mill
Dima Mixed Cobalt Ore Mill
Kolwezi Cobalt Oxide Mill
Typical Stibnite Ore Mineral Processing Results Operation
Conc. Grade, % Sb
Tails Grade, % Sb
Recovery, %
Hand sorting
Ore Grade, % Sb 2.25
7.80
0.12
95.95
Heavy media
1.58
2.65
0.18
95.11
Flotation
3.19
47.58
0.21
93.97
Average
2.68
19.44 9.44
0.18
94.11
Chinese Stibnite Ore Flotation Flowsheet
Sunshine Mining Tetrahedrite Ore Flotation Flowsheet
Flowsheets Secondary Recycle Applications
Mineral Processing of Obsolete Cars Shredderfluff (light ASR)
Dismantling
Spare parts Fuel, oil, etc.
Shredder
Magnetic separation
Steel
Non-ferrous mix
Non-ferrous separation Heavy ASR
Non-ferrous metals
Companies Involved in Car Scrap Processing
Separation of the Heavy Non-Ferrous Mix Pre-oncentration oncentration by Eddy Current Separators
Processing of the Non-Ferrous Non Mix
Screening of the Non-Ferrous Non Mix Trommel screen
Auto Recycle Shredder Plant Flowsheet Whole Automobile Scrap Yard
Hand Stripping
Stripped Hulks
Resaleable Parts/Rebuild
Shredder
Screen
- 8mm Disposal
Dust & Fines +8mm (~1/4 inch)
NonNon-shreddable Parts (Battery & Fuel Tanks) (1) In Europe this combined product is called “Resh”, from residue of shredder
Magnetic Separation
Magnetic Ferrous Product Iron & Steel Recycle/Sale
NonNon-metallic
Commonly called Fluff/ASR(1)
Eddy Current Separation Nonferrous 50% Metallic
Non-Ferrous Ferrous Metals and Residue From Shredder Plant Flowsheet Material from 50% Nonferrous Metals
Various Shredder Plants
-60mm (2-1/2 inch)
Elutriation Water Wash
Float
Light Plastics Wood Dirt
Sink
Metal Portion (Suppliers Paid)
Dense Medium Separation Ferrosilicon - 3.0 sp.gr.
Sink
Float
Dense Medium Separation Magnetite - 2.0 sp.gr. Mostly Aluminum, Tramp Rock & Wire
Sink
A Alloys of Aluminu m
Rewash Laser or Aluminum Wire & Rock Induced Sold Disposed Spectroscopy Sortation
Float
Heavier Plastics, Rubber, Glass, Light Metal/Laminate
Scavenger Eddy Current Separator Metal (Circulate Internal)
Sold or Disposal
Source: Huron Valley Steel Co., Belleview Michigan Plant
Processing Non-Ferrous Ferrous Metals and Residue From Shredder Plant (Continued) Sink Product from Dense Medium Separation A Mostly Zinc, Copper, Brass, Stainless Steel
Screen Sizing 8 x 20 mm (~ ¼ x ¾ inch)
Slot Tumblers
20 x 30 mm (~ ¾ x 1¼ inch)
30 x 60 mm (~1¼ x 2½ inch)
Size Fractions Process Independently High Intensity Magnetic Separation 20 T/hr
Copper 70% Reject (Weakly Magnetic) Image (Color) with Zinc & Stainless Steel Sorting Stainless Steel Sold Sold - Low Quality U.S. Mint Sold for Hand Sorting Zinc Image (Tiwan) (Color) Refining Sorting 99.999% Purity LME Coins
Brass Sold
Copper Sold
Source: Huron Valley Steel Co., Belleview Michigan Plant
Mineral Processing Flowsheets
By Dr. Corby G. Anderson Colorado School of Mines