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(Established in 2013)
Course File
B. Tech IV - I SEM
Subject: MINERAL PROCESSING
Subject Code: 40720
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CONTENTS
S. No Topic
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Malla Reddy Engineering College
(Autonomous)
Department of Mechanical Engineering
VISION
MISSION
To train students with latest technologies and equip them with skills to run the
industries with safety conservation and productivity.
To have regular contacts with industries research organizations and other institutions and to
provide technical solutions. Continued research activities to understand and analyze all
technical issues and to find solutions with a stress on safety and production.
PEO1: To upgrade students knowledge in Basic Sciences, Earth Sciences, Humanities & Social
Sciences, Management, Environmental Sciences and Basic Engineering domains with an
objective of application of these domains in Mining Engineering.
PEO2: To enrich the field oriented knowledge base of the graduates in the areas of geology,
exploration, mine planning, management, safety, mine valuation, mineral development,
exploitation, mineral beneficiation, environmental impact assessment, reclamation, mine closure
and socio-economic and legal issues through inter disciplinary inputs and guidance with an aim
of producing wholesome mining engineers.
PEO3: To enhance technical and intellectual competence of the students in mining and allied
domains and encourage them for pursuing higher education and carry out R&D activities in the
area of mining & other earth science disciplines that support environmental compliance and
energy security needed for the societal growth.
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PROGRAMME OUTCOMES:
b an ability to design and conduct experiments, as well as to analyze and interpret data,
an ability to design a system, component, or process to meet desired needs within realistic
c constraints such as economic, environmental, social, political, ethical, health and safety,
manufacturability, and sustainability,
the broad education necessary to understand the impact of engineering solutions in a global,
h
economic, environmental, and societal context,
an ability to use the techniques, skills, and modern engineering tools necessary for
k
engineering practice.
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The Graduate Attributes for UG Engineering Student
1. Engineering Knowledge: apply Knowledge of mathematics, science, engineering fundamentals and
an engineering specialization to the solution of complex engineering problems.
2. Problem Analysis: Identify, formulate, research literature and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences
and engineering sciences.
3. Design / Development of Solutions: Design solutions for complex engineering problems and design
system components or processes that meet specified needs with appropriate consideration for public
health and safety, cultural, societal and environmental considerations.
4. Conduct investigations of complex problems using research-based knowledge and research
methods including design of experiments, analysis and interpretation of data and synthesis of
information to provide valid conclusions.
5. Modern Tool Usage: Select and apply appropriate techniques, resources, and modern engineering
and IT tools, including prediction and modeling, to broadly-defined engineering activities, with an
understanding of the limitations.
6. The Engineer and society: Demonstrate understanding of the societal, health, safety, legal and
cultural issues, and the consequent responsibilities relevant to engineering technology practice.
7. Environment and sustainability: Understand the impact of engineering/technology solutions in
societal and environmental context, and demonstrate knowledge of, and need for sustainable
development.
8. Ethics: Understand and commit to professional ethics and responsibilities and norms of engineering
technology practice.
9. Individual and Team work: Function effectively as an individual, and as a member or leader in
diverse technical teams.
10. Communication: Communicate effectively on Broadly-defined engineering activities with the
engineering community and with society at large, by being able to comprehend and write effective
reports and design documentation, make effective presentations, and give and receive clear
instructions.
11. Project Management and Finance: Demonstrate knowledge and understanding of engineering
management principles and apply the same to ones own work, as a member and leader in a team and
to manage projects in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the ability to engage in independent and life-
long learning in specialized technologies.
PEO 1 * * *
PEO 2 * *
PEO 3 * * *
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Subject Mapping with PEOs
The components of the curriculum and their relevance to the POs and the PEOs
Total no of
Curriculum Content contact hours
Course Total number
(%of number of credits POs PEOs
Component TOTAL of credits
of the programme)
HOURS= L+T
Professional IV year
core Mineral Processing 2+4 4 a, b,c,e,f,h,k 1,2,3
IV YEAR
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MALLA REDDY ENGINEERING COLLEGE (AUTONOMOUS)
VI Year B.Tech. Mining Engg. I-Sem L T/P/D C
MINERAL PROCESSING (2016-17) 3 1/-/- 4
UNIT-I
UNIT-II
Size Separation: Laboratory size analysis and interpretation; settling of solids in fluids;
industrial screens, mechanical classifiers and hydro cyclones.
Gravity Concentration Methods: Jigging, Heavy media separation, flowing film concentrators
theory, applications and limitations.
UNIT-III
UNIT-IV
UNIT-V
Flow Sheets: Simplified flow sheets for coal, zinc, iron, and manganese ores.
Magnetic methods of concentration Principles, Fields of Application and Limitation.
OUTCOMES: Student can understand characteristics and processing of minerals and size
separation after crushing, different methods of separation, flow charts for coal, zinc, iron and
manganese.
TEXT BOOKS:
1. Introduction to Mineral Processing V. Malleswar Rao, Indian Academy of Geoscience
2. Mineral Processing Barry AWills, Elsevier.
REFERENCE BOOKS:
1. Mineral Processing S.K. Jain, CBS Publishers & Distributors
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COURSE OBJECTIVES & OUTCOME:
OBJECTIVES:
The student with this course is exposed to the topics of mineral processing and different steps
involved in mineral processing, comminution theories, different crushing and grinding
equipments, different concentration techniques such as classification, jigging, heavy media
separation, flowing film concentration, flotation, electrical and magnetic separation, flow charts
for coal, zinc, iron and manganese.
OUTCOME:
Student can understand characteristics and processing of minerals and size separation after
crushing, different methods of separation, flow charts for coal, zinc, iron and manganese.
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MALLA REDDY ENGINEERING COLLEGE
(AUTONOMOUS)
COURSE STRUCTURE
LECTURE PLAN AND SCHEDULE
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crushing and grinding
12 UNIT-2 Introduction of the unit and outline.
13 Laboratory size analysis and interpretation;
16 industrial screens
17 mechanical classifiers
18 hydro cyclones
31 Flotation machines
32 Flotation of Sulphides
33 Flotation of Oxides
34 Flotation of Coal
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35 Review of the unit.
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58 Limitations of magnetic separation processes
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Time Table:
I II III IV V VI VII
12.50 to
Period/Day
9.30 to 10.20 to 11.10 to 12.00 to 1.30 1.30 to 2.20 to 3.10 to
10.20 11.10 12.00 12.50 2.20 3.10 4.00
MON MP L MP
TUE MP
U
WED
N
THU MP MP Lab / RM Lab
SAT MP H
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INTRODUCTION TO THE SUBJECT
The practice of minerals processing is as old as human civilization. Minerals and products
derived from minerals have formed our development cultures from the flints of the Stone Age
man to the uranium ores of Atomic Age.
This enrichment process considerably increases the contained value of the ore
to allow economic transportation and smelting. Compared with chemical methods, the physical
methods used in mineral processing consume relatively small amounts of energy. This subject
deals about the steps involved in mineral processing. The liberation methods such as crushing,
grinding and equipments involved in crushing and grinding are briefly explained. The
concentration methods employed in mineral processing industry such as jigging, dense media
separation, flowing film concentration, flotation, electrical and magnetic methods of separation
processes are briefly explained for different minerals and coal.
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SHORT AND LONG ANSWER ESSAY QUESTIONS:
UNIT - I
1. Define Reduction ratio? Write its value ranges for crushing and grinding?
2. Give different stages of size reduction in comminution with size ranges.
3. Explain about Kicks law of size reduction in detail.
4. Briefly explain about Gyratory crusher and mention its types?
5. Write the empirical formula to calculate the capacity of Jaw crusher and Roll crusher,
also elaborate the parameters involved?
6. Briefly explain about Hammer mills with neat sketch?
7. Briefly explain about rod mills and its working?
8. What are the various ball mills used and explain?
9. What do you understand by Open Circuit and Closed Circuit grinding?
10. Define liberation and comminution.
11. Draw a flow chart showing principal steps in a mineral processing and explain?
12. Explain briefly Rittingers, Kicks and Dobies law of size reduction.
13. Define Comminution? Give different stages of size reduction in comminution with size
ranges.
14. Draw a simplified diagram of Blake Jaw Crusher showing different parts and explain?
15. What are the types of grinding? Differentiate between Open-circuit and Close-circuit
grinding?
16. Briefly explain about Autogenous grinding mills and its types?
17. What are the types of grinding? Differentiate between Wet and Dry grinding?
18. Explain about roller crusher? Draw a relationship between roll diameter, particle size,
gap between rolls and angle of nip?
19. Define Grinding and explain the objectives of grinding? Briefly explain about different
types of grinding?
20. Explain the theory and working of ball mills? Mention the names of different types of ball
mills?
UNIT II
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12. What is classification? Explain about Dorr bowl classifier with neat sketch?
13. Explain about Fixed screen plunger Jig with neat sketch?
14. Explain about Fixed screen Diaphragm (Denver) Jig with neat sketch?
15. Explain about different types of movable screen jigs and write an application for each?
16. Derive the equation for terminal velocity of fine particles as per Stoke's law?
17. What is free settling ratio? Derive the equation for it as per Newton's law?
18. Explain in brief Dense Media Separation. Describe different media employed for the
operation with examples
19. Explain about flowing film concentration process and explain the working of wilfley
table?
20. Explain in brief the construction and working of shaking tables in flowing film
concentration process?
UNIT III
1. Write any two examples for frothing agents in flotation of sulphide ores?
2. Explain why flotation process is used for fine particles only?
3. Explain about pulp preparation step involved in flotation process?
4. Write down the purpose of frothing agents in flotation process?
5. Write down the purpose of collectors in flotation process?
6. Write down the purpose of Wetting and Resurfacing agents used in flotation process and
Give an example for each?
7. Give any four applications of flotation process?
8. Write a note on Modifying agents and their action in flotation process?
9. Explain in detail about the different steps involved in the flotation process?
10. Write down the purpose of fallowing in flotation process and Give an example for each:
a) Collector
b) Frother
11. Explain the working of Denver flotation cell with neat sketch?
12. Explain the working of Fagergren flotation cell with neat sketch?
13. Explain the working of Shallow pneumatic air-lift cell with neat sketch?
14. Explain the working of Column flotation cell with neat sketch?
15. Write down the purpose of fallowing in flotation process and Give an example for each:
a) Dispersing agent
b) pH regulators
c) Depressors
16. Explain about different types of collectors? Explain them in detail.
17. Explain the process of flotation of Sulphides?
18. Explain the process of flotation of Oxides?
19. Explain the process of flotation of Coal?
20. Define flotation? Explain about different physico-chemical principles that affects the
flotation process?
UNIT IV
UNIT V
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OBJECTIVE QUESTIONS:
UNIT I
UNIT II
2. Among fallowing, which screen does not belong to fixed type of screen? ( )
a) Grizzly b) Punched screen c) Flat screen d) Trommel
3. Among fallowing, which does not affect the settling of particles in a fluid? ( )
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a) Density of fluid b) Viscosity of fluid c) Size of particle d) all the above.
4. Presently ferro-silicon is most widely used media in DMS process due to its
.. ( )
a) Magnetic property b) Reluctance to oxidise
c) High Sp. Gravity d) All the above
5. Initially, was used in the treatment of lead-zinc ores. ( )
a) Magnetite b) ferro-silicon c) Cacl2 Soln. d) Galena
6. Gravity concentration in streaming currents is also known as . ( )
a) Classification b) Flowing film concentration
c) Jigging d) Flotation
UNIT III
UNIT IV
Unit V
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Fill in the blanks:
UNIT I
1. The stationary grizzly screen is set at a slope of ________ to ensure the free slide of ore.
2. Give an example for autogenous media employed in DMS __________
3. The maximum terminal velocity for coarse particles can be represented as v =
_______________________.
4. _________ is a separation process in which particles of various shapes, sizes and
specific gravities are separated by their different rates of travel through a fluid.
5. The free settling ratio can be represented mathematically as _____________.
6. Give an example for soluble salts type media employed in DMS ________________.
7. Cyclone can also be called as ______________________.
8. Dense media separation (DMS) is generally applicable to a feed ranging from about
_____________ to _____________.
9. The maximum terminal velocity for fine particles can be represented as v =
_______________________.
10. _________________________ is an example for fixed screen jig.
UNIT III
UNIT VI
UNIT V
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10. Wet magnetic separators are basically two types, they are __________________ and
_______________________.
Unit I
1. Draw a simplified diagram of Blake Jaw Crusher showing different parts and explain?
2. What are the types of grinding? Differentiate between Open-circuit and Close-circuit
grinding?
3. Briefly explain about Autogenous grinding mills and its types?
4. What are the types of grinding? Differentiate between Wet and Dry grinding?
5. Explain about roller crusher? Draw a relationship between roll diameter, particle size,
gap between rolls and angle of nip?
Unit II
1. What is classification? Explain about Dorr bowl classifier with neat sketch?
2. Explain about Fixed screen plunger Jig with neat sketch?
3. Explain about Fixed screen Diaphragm (Denver) Jig with neat sketch?
4. Explain about different types of movable screen jigs and write an application for each?
5. Derive the equation for terminal velocity of fine particles as per Stoke's law?
6. What is free settling ratio? Derive the equation for it as per Newton's law?
Unit III
Unit IV
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Unit V
1. List different types of industrial magnetic separators? Explain with diagram Dry-Drum
magnetic separator and its operation.
2. Draw a simplified flowsheet for the various stages involved in the processing of coal and
explain in detail?
3. Draw a simplified flowsheet for the various stages involved in the processing of iron ores
and explain in detail?
4. Explain about high intensity dry magnetic separator with neat sketch?
5. Explain about working of Drum-type wet magnetic separator with neat sketch?
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I Mid Paper:-
1. Draw a flow chart showing principal steps in a mineral processing and explain?
2. Explain briefly Rittingers, Kicks and Dobies law of size reduction.
3. Draw a simplified diagram of Blake Jaw Crusher showing different parts and explain?
4. What are the types of grinding? Differentiate between Open-circuit and Close-circuit
grinding?
5. Briefly explain about Autogenous grinding mills and its types?
6. What is classification? Explain about Hydrocyclone?
7. Explain the operation of dense media separation?
8. Derive the equation for terminal settling velocity as per Newton's law?
9. What is classification? Explain about Dorr bowl classifier?
10. Explain about Fixed screen plunger Jig?
11. Explain about flotation process of separation?
12. Write down the purpose of fallowing in flotation process and Give an example for each:
a) Collector
b) Frother
13. Explain the working of Denver flotation cell with neat sketch?
II Mid Paper:-
1 Mark Questions:
1. Write the empirical formula to calculate the capacity of Jaw crusher and elaborate the
parameters involved?
2. What is free settling ratio?
3. Explain why flotation process is used for fine particles only?
4. Write limitations of electrical separation process?
5. Mention the purpose of Demagnetisers in Magnetic separation process?
2 Mark Questions:
10 Mark Questions:
1. Draw a flow chart showing principal steps in a mineral processing. Explain each step in
detail and write any two advantages of mineral processing?
(OR)
Explain briefly Rittingers, Kicks, Dobies and Bonds law of size reduction.
2. Explain Jigging operation? Draw a diagram of Harz Jig showing different parts and
explain its operation.
(OR)
What is classification? Give different types of classifier & explain about Hydrocyclone?
3. Explain in detail about the different steps involved in the flotation process?
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(OR)
Explain the working of Denver flotation cell with neat sketch?
5. Explain the mechanism of Magnetic separation? Mention the names of different types of
industrial magnetic separators and give their applications.
(OR)
Draw a simplified flowsheet for the various stages involved in the processing of coal and
explain in detail?
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MALLA REDDY ENGINEERING COLLEGE
(AUTONOMOUS)
Maisammaguda, Dhulapally,(Post via Hakim pet), SECUNDERABAD-500 014
B. Tech IV/I Semester
MINERAL PROCESSING
MODEL PAPER - II
Subject: Mineral Processing Time: 3 Hours
Branch: Mining Engineering
1 Mark Questions:
2 Mark Questions:
10 Mark Questions:
1. List different types of crushers. Draw a simplified diagram of Blake Jaw Crusher
showing different parts and explain. Which factors affect its operation?
(OR)
Define Grinding and explain the objectives of grinding? Briefly explain about different
types of grinding?
2. What is free settling ratio? Derive the equation for it as per Newton's law.
(OR)
Explain in brief Dense Media Separation. Describe different media employed for the
operation with examples.
3. Define Flotation process? How do different flotation reagents like collector, Frother,
Activator & Depressant affect flotation process?
(OR)
Explain the working of Fagergren flotation cell with neat sketch?
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4. What is Electrical Separation? Explain Dielectric Separation system in brief?
(OR)
What is Electrical Separation? Explain with diagram Roll-type electrostatic Separator in
brief?
5. Draw a simplified flowsheet for the various stages involved in the processing of iron ores
and explain in detail?
(OR)
List different types of industrial magnetic separators? Explain with diagram Dry-Drum
magnetic separator and its operation.
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