Mineral Processing Design

371 Pages·1987·13.605 MB·English

by  Z. M. Dogan, B. Yarar (auth.), B. Yarar, Z. M. Dogan (eds.)

Mineral Processing Design
NATO ASI Series
Advanced Science Institutes Series
A Series presenting the results of activities sponsored by the NATO Science
Committee, which aims at the dissemination of advanced scientific and technological
knowledge, with a view to strengthening links between scientific communities.
The Series is published by an international board of publishers in conjunction with the
NATO Scientific Affairs Division
A Life Sciences Plenum Publishing Corporation
B Physics London and New York
C Mathematical and D. Reidel Publishing Company
Physical Sciences Dordrecht, Boston, Lancaster and Tokyo
D Behavioural and Martinus Nijhoff Publishers
Social Sciences Boston, Dordrecht and Lancaster
E Applied Sciences
F Computer and Spri nger -Verlag
Systems Sciences Berlin, Heidelberg, New York
G Ecological Sciences London, Paris, Tokyo
H Cell Biology
Series E: Applied Sciences - No. 122
Mineral Processing Design
Editors:
B. Yarar
Colorado School of Mines
Department of Metallurgical Engineering
Golden, CO 80401, USA
Z.M. Dogan
Middle East Technical University
Department of Mining Engineering
Ankara, Turkey
1987 Martinus Nijhoff Publishers
Dordrecht / Boston / Lancaster
Published in cooperation with NATO Scientific Affairs Division
Proceedings of the NATO Advanced Study Institute on Mineral Processing Design,
Bursa, Turkey, August 20-31,1984
NATO Advanced Study Institute on Mineral Processing
Design (1984 : Bursa, Turkey)
Mineral processing design.
(NATO advance4 science institutes. Series E,
Applied sciences ; no. 122)
"Proceedings of the NATO Advanced Study Institute
on Mineral Processing Design, Bursa, Turkey, August
20-31, 1984"--T.p. verso.
Includes bibliographies and index.
1. Ore-dressing--Congresses. 2. Mines and mineral
resources--Congresses. I. Yarar, Baki. II. Dogan,
Z.M. III. Title. IV. Series.
TN500.N26 1984 622'.7 86-33126
ISBN-13: 978-94-010-8087-3 e-ISBN-13: 978-94-009-3549-5
DOl: 10.1007/978-94-009-3549-5
Distributors for the United States and Canada: Kluwer Academic Publishers,
P.O. Box 358, Accord-Station, Hingham, MA 02018-0358, USA
Distributors for the UK and Ireland: Kluwer Academic Publishers, MTP Press Ltd,
Falcon House, Queen Square, Lancaster LA 1 1R N, UK
Distributors for all other countries: Kluwer Academic Publishers Group, Distribution
Center, P.O. Box 322, 3300 AH Dordrecht, The Netherlands
All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted, in any form or by any means, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the
publishers,
Martinus Nijhoff Publishers, P.O. Box 163, 3300 AD Dordrecht, The Netherlands
Copyright © 1987 by Martinus Nijhoff Publishers, Dordrecht
Softcover reprint of the hardcover 1s t edition 1987
v
TABLE OF CONTENTS
FOREWORD .......... . 1
CHAPTER 1 - APPLIED MINERALOGY IN ORE DRESSING 2
1. Int~oduction. . . . . . . . . . . 3
2. Studies On Unc~shed O~es . . . . 3
3. Studies of C~shed Mill P~oducts. 5
3.1 Metal and Mine~al Balances. 6
3.2 Mine~al Libe~ation. 6
3.3 F~ee Grains. . . . . . . . 7
3.4 Unliberated G~ains. . . . . 9
4. Applied Mine~alogy in Circuits Treating Volcanogenic Ores 11
4.1 Cu-Pb Ci~cuits. . . . . . . . . 11
4.2 Copper-Lead Separation Circuits 12
4.3 Lead Ci~cuit. 12
4.4 Zinc ci~cuit. . . . . . . . . . 12
4.5 Tin Circuit . . . . . . . • . . 13
5. Examples of Beneficiation Problems Explained by Mine~alogical
Studies . . . . . . . . . . . . . . . . . . . . 13
6. Equipment for Performing Mine~alogical Analysis 18
7. Methods of Mineral Identification. . . . . 21
8. Methods of Determining Mine~al Compositions . 21
9. Methods of Determing Mine~al Quantities . 22
10. Methods of Determining Mine~al Libe~ation and Size Dist~ibutions. 22
11. Presentation of Data. . . . . . . . . . . 22
11.1 Presentation of Data for Mill P~oducts. .......... 24
11.2 Modal Analysis. . . . . . . . . . . .. .......... 25
11.3 Proportion of Minerals as Free Particles or Unliberated Mineral
Grains. . . . . . . . . . . . . . . . . . . . . . . 26
11.4 Percent Inclusions of Unliberated Valuable Minerals 31
References .. 34
CHAPTER 2 - CHEMISTRY OF SULFIDE MINERAL FLOTATION 37
1. Introduction. . . . . . . . . . . . . . 37
1.1 Sulfide Minerals-Water-Oxygen System ... . 39
2. Modulation of Collector Coating ...... . 44
2.1 Hydrophobization of Sulfides by xanthate Coating. 44
2.2 Hydroxyl Ion as a Depressant and Critical pH Values 45
2.3 Cyanide as a Depressant 49
2.4 Sulfide as a Depressant ....... . 53
3. Electrochemical Studies ........ . 57
3.1 Galena-Oxygen-Xanthate Flotation System 57
3.2 Favorable Area for Flotation of Galena on a Potential-pH
Diagram .................... . 62
4. Silver Sulfide Electrode and Its use in Controlling Flotation of
an Oxidized Lead-Zinc Ore . . . . . . . . . . 66
4.1 Silver Sulfide-Xanthate-Oxygen System ... 66
4.2 Concentration of an Oxidized Lead-Zinc Ore. 69
References . . . • . . . . . . . . . . . . . . .. 72
VI
CHAPTER 3 - COAL FLOTATION . . 76
1. Introduction. . ..... 76
2. structure and Composition of Coal, Affecting Coal Flotation 78
2.1 Chemical and Petrographic Compositin of Coal, Affecting Coal
Flotation . . . . . . . . . . . 78
2.2 Impurities Associated with Coal . . . . 82
2.3 Natural Flotability of Coal . . . . . . 82
2.4 Effect of Oxidation on Coal Flotability 87
3. Operational Factors Related to Coal 87
3.1 Reagents Used in Coal Flotation 88
3.1.1 Non-Polar Oils. . . . . 88
3.1.2 Heteropolar Reagents. . 89
3.1.3 Inorganic Electrolytes. 90
3.1.4 Depressants . . . . . 92
3.2 pH and Zeta-Potential . . . 92
3.3 Size and Specific Gravity of Particles. 97
3.4 Pulp Density and Temperature. 97
3.5 Presence of Slime 98
3.6 Feed Rate. . . . 99
3.7 Conditioning Time 99
3.8 Air Flow Rate . . 99
3.9 Type of Flotation Machines. 100
3.10 Flotation Circuit. . . . . 100
4. Cost of Coal Preparation Plant. 101
5. Conclusion. 102
References . . . . . . . . . . . . . 102
CHAPTER 4 - GRAVITY CONCENTRATION METHODS. 106
1. Introduction. . . . . . . . 106
2. Principles. . . . . . . . . 108
3. Mechanism of Concentration. 109
4. Unit Processes. . . 110
4.1 The Duty Required 111
4.2 Size Range. 112
4.3 Throughput. . . . 113
4.4 Efficiency. . . . 114
4.5 Heavy Medium Separation 114
4.6 Jigging. . . . . . . . 116
4.7 The Sluice Box or Palong. 118
4.8 The Pinched Sluice and Reichert Cone. 120
4.9 Spiral Concentration. 122
4.10 Shaking Tables. . . . . . 124
4.11 Slime Plants. . . . . . . 127
4.12 Dry Gravity Concentration 130
5. Testing for Gravity Concentration 130
6. Plant Operations. 131
References . . . . . . . . . . . . . . 135
VII
CHAPTER 5 - PROCESSING OF MINERAL ORES BY MODERN MAGNETIC SEPARATION
TECHNIQUES . . . . . 138
1. Introduction. . . . . . . . . . . . . . . . . . . . . 138
2. Particle Entrapment Devices . . . . ... 140
3. The Kolm-Marston 'High Gradient' Magnetic Separation. 144
4. Particle Deflection Devices . 157
5. Prototype OGMS Systems ..•. 161
6. Projected Future Developments 163
References . . . . . . . . . . 163
CHAPTER 6 - THE METHODOLOGY OF FROTH FLOTATION TESTWORK. 166
1. Introduction. . . . . . . . . ... 166
2. Objectives and Evaluation Criteria. 167
3. Mineral Appraisal 167
3.1 Sampling .... 167
3.2 Chemical Assay. 167
3.3 Mineralogy ... 168
4. Types of Flotation Testwork 169
4.1 Small Scale Tests .. 169
4.2 Batch Flotation Tests - "One-variable-at-one-time". 169
4.3 Batch Flotation Tests - time samples. 174
4.4 Locked Cycle Tests .. 174
4.5 Pilot Plant Tests .. 175
5. statistical Aspects of Flotation Testwork 176
5.1 Planning the Experiment 177
5.2 Significance Testing .. 178
5.2.1 The t-distribution. 179
5.2.2 The F-test ..... 181
5.3 Analysis of Variance (ANOVA). 183
5.3.1 Flotation Test. One-way ANOVA. 183
5.3.2 Flotation Test. Two-way ANOVA. 185
5.4 Reduction of Factors ...... . 186
5.5 Calculation of Results, criterion of Success and Error. 186
6. Model Development and Optimization. 188
6.1 Kinetic Models .... . 188
6.1.1 Batch Tests ... . 188
6.1.2 Pilot Plant Kinetic Model 191
6.2 Factor Models 192
6.3 Optimization. 194
6.4 Scale-up. 196
References . . . . . 198
CHAPTER 7 - MINERAL PROCESSING FLOWSHEET DEVELOPMENT 202
1. Introduction. . . . . . . . . . .. ... . 203
2. Objectives of Metallurgical Testing ... . 203
3. Choice of Sample(s) for Metallurgical Testing 204
4. Laboratory Testwork Programming ... 206
4.1 Pertinent Information to Collect .. 206
4.2 Planning the Metallurgical Testwork 209
5. Execution of the Laboratory Batch Testwork. 210
6 . Cycle Tests . . . . . . . . . . . . . . . . 212
7. Complementary Testwork for Design Purposes. 216
VIII
8. Pilot Plant Testwork. 216
9. Final Recommendations 217
References 219
CHAPTER 8 - MASS BALANCE EQUILIBRATION 221
1. The Origin and Classification of Errors 221
2. The Need for Systematic Approach to Data Validation 224
3. Principles of Mass Balance Computation ..... . 228
4. Application to a Grinding-Classification Process .. 230
5. Extended Balance Equilibration .......... . 234
5.1 The Variables Classification and the First Decomposition. 234
5.2 Partitioning the Network .. 238
Partitioning the Equations ......•.. 241
Mass Balance Equilibration. • . . . . . . . 242
A Computer Aided Design System Dedicated to the Data Valiation
Problem 244
References . . . . . . . . . . 246
CHAPTER 9 - CONCENTRATING PLANT DESIGN-CAPITAL AND OPERATING COSTS 250
1. Concentrating Plant Design. 250
1.1 Mill Design .. 251
1.2 Mill Layout ... 251
1.3 Design Features . 252
1.4 Crushing, Grinding, and Classification. 254
1.5 Flotation. . . . . 256
1.6 Flotation Products Handling 257
1.7 Energy Consumption ... 258
1.8 Environmental Problems. 258
1.9 Porphyry Copper Ores. 259
1.10 Lead-Zinc Ores. 259
2. Capital Costs .. 260
2.1 General .... 260
2.2 Pre-feasibility Engineering 260
2.3 Feasibility Engineering . 261
2.4 Construction Engineering. 262
2.5 Project Reports 263
2.6 Examples ... 263
3. Operating Costs . 264
3.1 Introduction .. 264
3.2 Operating Cost Distribution 264
3.3 Examples. 265
References 266
CHAPTER 10 - SIMULATION IN MINERAL PROCESSING. 268
1. Introduction. 269
2. Methodology. . 270
2.1 Simulation .. 270
2.2 Rate Equation 277
2.3 Optimization. 280
3. Experimental Example. 282
4. Conclusion. 285
References . . . • . . . . 285
IX
~
CHAPTER 11 - SLURRY PIPELINE TRANSPORT OF MINERALS AND COAL. 288
1. Intt"oduction .................... . 289
1.1 Majot" Applications of Conventional Slut"t"y Pipelines 289
1.2 Majot" Applications of Coat"se-Coal Slurry Pipelines. 292
1.3 Coarse-Coal Ship Loading/Unloading ........ . 294
2. Technical Aspects of Slurry Pipeline System Components. 294
2.1 Slurry Pumps .. . 294
2.2 Pumping Stations .. . 301
2.3 Line Pipe ..... . 301
2.4 Pipeline Construction 302
2.5 Coal Slurry Preparation Facility. 302
2.6 Coal Slurry Dewatering Facility. 304
2.7 Operational Characteristics ... 306
2.8 Communication and Contt"ol Systems 307
3. Hydraulics of Slurry Flow in Pipelines. 307
3.1 Behavior and Classification of Slurry Flows in Pipes. 308
3.2 Hydraulic Design criteria for Homogenous Slurries .. 313
3.3 Hydraulic Design Criteria for Heterogeneous Slurries. 318
3.4 Hydraulic Design criteria for Hetero-Homogeneous Slurries 320
3.5 Hydraulic Design Criteria for Coarse Solids Slurt"ies .. 323
3.6 Hydraulic Design criteria for Non-Conventional Slurries 325
4. System Component Cost Estimating Methodology ...... . 326
4.1 Summary of Cost Estimate Relationships ........ . 326
4.2 Selected Results for a Coal Slurry Pipeline in Virginia 327
4.3 A Simplified optimization Methodology. . ... . 331
4.4 Transportation Cost. . . . . . . . . ... . 333
5. Brief Assessment of Energy, Economic, and Environmental Aspects of
Slurry Pipelines .. 334
5.1 Energy Aspects .. 334
5.2 Economic Aspects. 336
5.3 Environmental Aspects 340
6. Conclusions 342
References . . . . . 343
List of Participants 350
Author Index . 353
Subject Index. . . . 359
Foreword
This volume is based on the proceedings of the "NATO
Advanced study Institute on Mineral Processing Design" held in
Bursa-Turkey on August 24-31, 1984.
The institute was organized by Professor B. Yarar of the
Colorado School of Mines, Golden, Colorado, 80401, USA, Professor
G. Ozbayoghu and Professor Z. M. Dogan of METU-Ankara, Turkey,
who was the director.
The purpose of the institute was to provide an international
forum on the subject and update the information available.
Participants were from Turkey, England, Greece, Spain,
Portugal, Belgium, Canada, and the USA.
Besides authors contributing to this volume, presentations
were also made by Drs. Yarar, Raghavan, Schurger, and Mr. Kelland.
Many assistants and colleagues helped. They are gratefully
acknowledged. Acknowledgment is also owed to Drs. Ek, de Kuyper,
and Tolun.
Dr. Gfilhan Ozbayoglu, and Mr. S. Ozbayoglu were particularly
helpful in the overall organization and hosting of many
international guests. We owe them special thanks.
NATO, Scientific Affairs Division, is gratefully
acknowledged for the grant which made this activity possible.
Z. M. Dogan
B. Yarar