Mineral Processing Flowshe eral Processing ...

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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