Physical Processing of Minerals

Physical Processing of Minerals
Dr. Winny Wulandari
TK4046 Dasar-dasar Metalurgi Proses Semester II 2015/2016

TK5057 Teknologi Proses Metalurgi
Introduction
}  Mineral processing is aimed at separation of the phases
}  The process involve separation of mineral grains from an
ore to recover particular minerals, to recover elements
contained within those minerals, or to remove unwanted
material from feedstock.
}  May be adapted to recover metals/materials from scrap
so they can be recycled.

References
}  Hayes, P. Process Principles in Minerals & Materials
Production. 3rd edition. 2003: Hayes Publishing.
}  Will’s Mineral Processing Technology. 7th edition. 2006:
Elsevier.

Ores: extractable minerals & gangue
Gangue: mineral/material ikutan

}  Two stages operations:
}  Size reduction of particles
}  Selection of the desired phases from the mixture

Size Reduction
}  Commercial size reduction processes are required to
fracture irregularly shaped particles at high volume
throughputs of material. These processes use the
following techniques:
}  Slow compression
}  Fast compression (impact)
}  abrasion

Factors affecting the strength or rock
}  Form of applied stress: compressive, tensile, shear
}  Method of application of stress: strain rate, constrained or
unconstrained material
}  Particle of geometry: size & shape
}  Microstructure:
}  Proportion of each mineral present
}  Distribution of mineral grains with the particle
}  Physical properties of individual minerals
}  Pre-existing defects

Characteristic of Common Size Reduction
Processes (Tarjan)
}  Table 4.2.2
Jaw crusher
Gyratory
Cone
Toothed rolls
Impact mills
Hammer mill
Rod mill
Ball, autogeneous mill
Jet mill

Jaw Crusher
}  Applies compression to
the feed particles
}  Useful for crushing very
large particles
}  Carrying work only
halftime because its cyclic
action.

Gyratory Crusher
}  particles are fractured
under slow compressive
stress and some shear
stress.
}  Has higher output than
jaw crusher.

Cone Crusher
}  Modified gyratory crusher
}  The moving crushing face
is supported underneath
rather than being
suspended.

Typical operating characteristic of crushing
machines: (a) blake jaw crusher (Motz)

machines: (b) gyratory crusher (Motz)

machines: (c) cone crusher (Motz)

Operating Characteristic of Crushing
Machines
}  In the gravity crushers described above, frequency of
gyration or the crushing cycle must be adjusted so that
no particles can pass through unless the size is less than
the minimum setting.
}  In all cases, as the size reduction performed on particles is
increased, the throughout of that particular plant is
reduced.
}  For efficient processing size reduction of about 5:1 are
usually carried out at each stage, & the max size should be
less than 85% of the feed opening.

Example: estimation crusher size
}  Run-of-mine ore (-750 mm) is to be reduced in size to
-20 mm at a plant throughput of 600 ton/h. Assuming ore
bulk density of 2 ton/m3, estimate the crusher
requirement.
}  Estimate the volume = mass rate/density

}  From Figure (b), a throughput of 300 m3/h may be
achieved using a gyratory crusher with feed opening of
1070 mm. The product is -160 mm.
}  From figure (c), -20 mm discharge may be achieved using a
feed opening of -210 mm. Since this corresponds to plant
capacity of 50m3/h (Figure (c) ), six units will be required
to handle the 300 m3/h output.

Roll Crusher
}  Roll Crusher
}  Hammer mill
}  Tumbling mills: rod mill, ball mill, autogeneous mill

Roller mill
}  Roller crusher operates by
rotation of spring loaded
horizontal rolls
}  The rolls may have smooth
surfaces or have protruding
teeth
}  Rely on friction between
feed material and the roll
}  Max capacity = 190 }  The breakage mechanism
NDWρS (kg/h) involves high shear stress
}  In practice, the capacity is
}  N = roll speed (rpm), D = roll 75-80% of its maximum.
diameter (m), W = roll width
(m), S= gap between roll (m)
Hammer mill
}  Material is fed into path of
past moving hammer
wgich swing freely frim a
central rotor.

Rod mill
}  The grinding medium: rods
of assorted diameter
whose major axes are
parallel to the axis of
rotation of the mill.

Ball mill
}  Grinding media: hard steel or

ceramic balls. }  In zone C, size reduction is cause
}  In zone A & B, size reduction by impact of particles that fallen.
occurs by abration and impacts.

Autogenous mill
}  Large particles of the ores
itself are used as the
grinding medium.
}  Since there is no density
difference between the
grinding medium and the
feed, breakage is achieved
using mills of high
diameter to length ratio
so that the particles fall
through larger distances

}  The breakage mechanism }  M: mass, D: diameter of
in the mill are critically mill, v = velocity of mill
dependent on the motion shell.
of the charge within the
mill. }  Critical speed Nc,
}  𝑁↓𝐶 =42.3/√⁠𝐷  (𝑟𝑝𝑚)
}  Max vertical force on
particle Mg
}  Mill usually rotated at less
}  𝑀𝑔=2𝑀𝑣↑2 /𝐷 
than this critical speed

}  The differences between crushing machines and tumbling
mills:
}  Crushing machines:
}  Energy is applied directly to ores particles
}  Restriction on feed and product size
}  Tumbling mills:
}  Energy is direacted into rotating the mill and its charge
}  Tumbling mills impose comparatively little restriction on feed
and product size to crushers

Choice of Size Reduction Circuit
}  Efficient operation of each size reduction process
requires that the feed and product within an optimum
size range.

Estimation of Power Requirement for
Crushing and Grinding (Kelly & Spotishwood)
Material W (kWh/ton)
Barite 7
Basalt 22
Cement clinker 15
Clay 8
Coal 13
Emery 64
Feldspar 13
Galena 11
Glass 3
Granite 16
Iron ore 17
Lead ore 13
Limestone 13
Mica 148
Oil shale 20
Phospate rock 11
Quartz 14
Particle Selection
}  The characteristic of materials include phases present,
their compositions, the mass fraction of each phase & the
sizes & shapes of the grains.
}  Also characterised by the physical & chemical properties:
sizes, densities, magnetic susceptibilities, electrical
conductivity, colour, radioactive, or surface chemistry of
the particles.

Example: selection of sets mineral particles
on the basis of the material characteristics
}  A set of particles may
contain more than one
mineral species.
}  Within each set the value
of the measurement
property will vary, this
variation can have
significant effect on the
efficiency of the selection
of a given set of particles.

}  All particles in set A have a property value less than those
of set D. Separation and selection of the two sets is
possible.
}  Under ideal condition, B and D can be separated by
setting cut off at P4.
}  Separation of A and B is a problem typically encountered
in mineral processing operation. A good but incomplete
separation of A and B is possible using a process setting
between P3 and P4, depending on production requirement.

Typical Grade-Recovery Curve
}  The shape of curve

dependent on both material
and technology.
}  As the grade of the product
stream is increased, there is
a decrease in the overall
recovery of the value
mineral.
}  Lowering metal recovery
means a loss of metal values
in the process, means loss of
revenue.

Selection on the basis of size
}  Selection on the basis of size can be carried out by:
}  Physical barriers or screen
}  The differential movement of the solid particles through
fluids, referred as classification

Screen

Stationary Grizzly
Heavy duty surface
of fixed bar
Roll Grizzly
Surface of rotating rolls
Sieve bends
Slurry feeds,
fixed bar surface
Revolving Screen
Screen surface
rotating around
cylinder axis

Vibrating
Screens
High speed motion

Designed primarily
to lift particles off
surface
Shaking Screens
Slow linear motion
Rotary Sifters
Circular motion
applied to
screen surface

Typical separation sizes of the basic screen
type

Factors Affecting Screen Efficiency
}  Material: bulk density, size distribution of particles, shapes
of particles, surface moisture
}  Machine:
}  Screen surface: area, % area which is aperture, aperture size,
thickness of screen
}  Movement: amplitude, frequency, direction
}  Angle of inclination
}  Method of feeding screen

Preliminary Estimate of Screen Size
}  A: net screening area (m2)

}  F: total feed to screen deck (ton/h)
}  C: basic screen capacity (t/h.m2) (Table 4.3.4a)
}  Kd: oversize bed depth correction factor, 0.85
}  Kh: half size factor, based on percentage of total feed
smaller than one half width of the aperture (Table 4.3.4b)
}  S1: deck location factor(Table 4.3.4c)
}  S2: material shape factor (Table 4.3.4d)
}  S3: material weight factor (Table 4.3.4e)
}  S4: aperture shape factor (Table 4.3.4f)

S2
1,2
1,0
S4
1,0
0,83
1,3

Classification
}  The possibility of selecting
particles on the basis of
size using their relative
velocities through a fluid
depends on the flow
condition of the particles.

}  Sedimentation Classifier : consists of large pool or thanks,
where slurry of solid/liquid is fed.
}  Spiral classifier: uses a continuously revolving screw to
remove oversize material via an inclined through. Spiral
classifier do not operate on more than 50% solids.

Sedimentation tank
}  Size selection of fine particles (precipitates) from a

solution may be carried out in large cylindrical gravity
sedimentation thanks which can range 2-50 m in diameter
and 1-7 m in depth TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015
Hydrocyclones
Slurry tangentially
injected into the
classifier, results in high
centrifugal forces on the
particles and therefore
accelerates the settling/
separation of particles.

}  In selecting a cyclone for a particular application, the first
parameter determined is the size of feed: oversize fraction and
undersize fraction.
}  Separation size, throughput and pressure drop in cyclones are
correlated.

Selection on the basis of Density
}  The simplest gravity separation involves the use of liquids
of high relative density.
}  As the feed material is introduces to the liquid, those
particles lower than the fluid float, while the greater
density sink.

Selected Relative Densities of Common
Minerals & Materials
Metal Ore Formula Relative Density
Aluminium Diaspore AlO(OH)2 3,2-3,5
Gibbsite Al(OH)3 2,3-2,4
boehmite AlO(OH) 3,0-3,1
Copper Chalcopyrite CuFeS 4,1-4,3
Bornite Cu5FeS4 4,9-5,4
Cuprite Cu2O 5,9-6,2
Gold native Au 12-20
Iron Hematite Fe2O3 5-6
Magnetite Fe3O4 5,5-6,5
Pyrite FeS2 4,9-5,2
Zinc Sphalarite ZnS 3,9-4,1
calamine ZnCO3 4,3-4,5
Tin Casserite SnO2 2,65
Manganese pyrolusite MnO2 4,5-5,0

Jig
}  Slurry containing minerals
is fed onto a permeable
screen.
}  Jig operates by periodic
movement of water pulse
through screen. The
upward velocity bring the
mineral particles into
suspension.
}  The process is used for
particle size above 0.2
mm.

Flowing film concentrators
A thin film of particle moves

in a slurry down a surface
the the centre of gravity of
the mixture is lowered by
the movement of the
denser particles to the
bottom of the film

Selection on the Basis of Magnetic
Properties
}  Two broad categories:
}  Diamagnetic materials: which are repelled by a magnetic
field and which move to positions of low field intensity
}  Paramagnetic materials: which are attracted to magnetic
field and move to positions of high field intensity

Magnetic separation Process
}  Dry magnetic drum
separator utilise the
competing magnetic and
gravitational forces to
achieve separation.

(a)  Co-current
Slurry is passed through
in the same direction as
the rotation of the drum
(b)Counter-rotating
Produces a high recovery
but generally a low
concentrate low grade
(c) Counter-current
Often used as finishing
separator., produces
clean concentrate with
good recovery.

High Intensity Separator
}  Weakly paramagnetic
materials may only be
effectively separated from
particle strems using high
intensity magnetic
processes.
}  Under influence of high
field, the magnetisation of
paramagnetic material
approach saturation.

}  In the Jones carousel type }  The high intensity field
separator feed boxes made induced in the grooved
from ferromagnetic material ferromagnetic plate material
are arranged in cicular magnetises weakly
frame. paramagnetic particles,
}  By rotating the frame, each which remained attached to
boxes is both magnetised the plates.
and demagnetised as it }  The unmagnetised material
moves about the flow through the boxes and
electromagnet. collected as tailings.
}  A slurry containing feed
partciles is fed into the
boxes as they enter the field
of weakly paramagnetic
particles.

Examples of separability of paramagnetic
materials in high intensity magnetic separator

Selection on the Basis of Electrical
Properties
}  Carried out by utilizing }  Three important
the forces acting on mechanism by which
charged or polarised particles may acquire a
particle in an electric field. surface charge:
}  Contact electrification
}  Conductive induction
}  Ion bombardment

}  surface charge by induction
}  Conductive particle will be the opposite of the non-discharging
electrode
}  Non-conducting particles remain polarised and attracted to the
rotor.

}  A dielectric material
(dielectric for short) is an
electrical insulator that can
be polarized by an applied
electric field. When a
dielectric is placed in an
electric field, electric charges
do not flow through the
material as they do in a
conductor, but only slightly
shift from their average
equilibrium positions causing
dielectric polarization.

}  Applying high voltage
difference between
electrode and ground
}  The feed particles pass
through this stream of ions
as they move between the
electrodes & the charges
attached to the surface of
particles.
}  Particle will low conductivity
will remain in charged state
for longer time.

Selection on the basis of surface chemistry
}  When air bubbles are passed through a slurry containing
fine mineral partciels, certain minerals can become
attached to the bubbles.
}  The particle moves to the surgace of liquid forming froth.
}  The froth & suspended particles are separated from the
slurry by skimming the froth.
}  This can be called “flotation”, which is very useful in
mineral processing.

}  Driving force: surface
energy, γ.
}  Basic condition:
}  𝛾↓𝑠𝑔 −𝛾↓𝑠𝑙 <𝛾↓𝑙𝑔 
}  Main characteristic that
influences the recovery by
flotation: particle size.
}  More information:

Flotation Section at
Hydrometallurgy

}  Factors affecting Flotation
cells:
}  Input: mass flow rates, solids
& liquids
}  Outputs:
}  Operating variables
}  Preset, speed, clearances,
adjustable dimensions,
stochastic, variability
}  Machine dimensions:
}  Volume, area, size, impeller
diameter
}  Reactor design

Bulk Material Handling
}  Storage
}  Larger quantities (103-106 ton) à stockpiles
}  Smaller quantities (1 – 100 ton): bins, silos. Material flows under
gravity and is removed from the bottom of the bin through
what is called the hopper.
}  Transfer
}  Slurries: pumps (dynamic pumps, positive displacement pump)
}  Conveyor

Treatment of Wastes from Mineral
Processing Operations
}  Most mineral separation processes involves the use of
slurry products/solid/water mixtures typically contains
10-90% solids.
}  At some stage, water need to be removed :
}  To adjust the subsequent characteristic of process stream
}  To recover & recycle water within the plant
}  Dewatering:
}  Screening
}  Gravity separation
}  Filtration
}  Thermal drying

100
% Volume moisture
10

Tailings Disposal

Economic characteristic of Mineral
processing operation
}  Size reduction: Mean size kWh /t feed
particle
}  Energy intensive (grinding & 5-10 mm 1-2
crushing 0,5-1 mm 3-4
}  Generation of fine particles 80-100 µm 10
60-80 µm 20
is avoided if possible 40-50 µm 30
}  Mineral selection 20-30 µm 45
-10 µm 70-80
}  - slow process
}  Liquid-solid separation


Physical Processing of Minerals

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Physical Processing of Minerals

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Physical Processing of Minerals

Dr. Winny Wulandari

TK4046 Dasar-dasar Metalurgi Proses Semester II 2015/2016

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

Ball, autogeneous mill

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

} Estimate the volume = mass rate/density

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

} Grinding media: hard steel or

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

} The shape of curve

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

High speed motion

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

} A: net screening area (m2)

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

} Size selection of fine particles (precipitates) from a

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

A thin film of particle moves

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

TK4046 Dasar-dasar Metalurgi Proses Semester II 2014/2015

}  Estimate the volume = mass rate/density

}  Grinding media: hard steel or

}  The shape of curve

}  A: net screening area (m2)

}  Size selection of fine particles (precipitates) from a

}  More information: