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MSU –Iligan Institute of Technology

College of Engineering

Met E 128
Mineral Dressing Laboratory

Laboratory Policies and Procedures

In order to maintain efficient and optimum utilization of equipment and

apparatus in the laboratory, the following policies and procedures are to be observed
and implemented in the Mineral Dressing Laboratory.

The Laboratory is manned by a technician who is responsible for the safe

keeping of equipment. As such, materials required for specific laboratory exercises
are signed out. A log book is maintained for such purpose. Equipment(s) that is not
signed out is to be used with permission and a specific log book is also maintained in
order to determine the frequency of utilization.

Care of Equipment

1. Prior to utilizing the apparatus, make the necessary inventory of the

accessories required in the performance of the experiment. (ex. Flotation
machine: banks of cells, agitators, etc.)

2. Take not of the power rating before plugging the cord in the electrical outlets.

3. Clean the area where the exercise is to be carried out before and after each
experiment.

4. Clean the equipment or apparatus before returning them to the stock room
prior to putting them away.

5. When you BREAK, you PAY. That is why it is important for user to log
equipment use to facilitate identification of responsibilities.

6. Handle analytical equipment (ex. Electronic balances, fine mesh sieves, etc.)
with extra care.

Lockers

1. Each group may select a locker where to keep the checked out apparatus.

2. Provide your own padlock and label appropriately to establish “ownership” for
the semester.

3. Each group should provide for their own soap, hand towels, rags, and broom.
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4. At the end of the semester, clean out the locker. End of semester clearance will
not be signed if lockers are padlocked and not cleaned out.

Recording of Experimental Data

1. Each group will keep a large spiral notebook where laboratory activities for
the day are recorded. You use this as scratches as well as for computations.

2. Each member of the group will sign the end of the log report and noted by the
instructor. A duplicate page will be prepared and submitted to the instructor at
the end of each laboratory period.

Safety in the Laboratory (Clemente, Laboratory Manual in Mineral Processing, UP,

2000)

The principal danger in the laboratory is being ignorant of specific hazards and
forgetfulness during the conduct of activities. The following are safety reminders that
must be given attention:

1. Determine the potential hazards and review the safety procedures appropriate
for any experiment before the beginning of work.

2. Know the location and the proper use of the safety and emergency equipment
such as fire extinguishers, safety glasses, etc., emergency phone numbers and
emergency exits.

3. Call attention to unsafe conditions that you may observe. Someone else’s
accident can be dangerous to you as well.

4. Check all electrical equipment carefully before plugging it into the power line.
Otherwise, electrical fires, or worse, explosions may occur. Unplug electrical
equipment before making any changes in the electrical connections.

5. Always use a pipetting bulb when drawing out chemicals into a pipette.

6. Always wash your hands thoroughly with soap and water immediately after
working in the laboratory.

7. Wear gloves, safety glasses and other appropriate eye protection when dealing
with acids and other fuming chemicals.

8. Use dust masks during crushing and grinding operations.

9. Follow accepted waste disposal procedures to avoid environmental

contamination and avoid safety hazards.

10. Beware of high voltage electricity.

11. Unplug electrical connections after operating electrical equipment.

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12. Limit the use of open flames and never use them in the presence of flammable
materials.

13. NEVER WORK IN THE LABORATORY ALONE. In the event that working
alone becomes necessary, inform the guard on duty or any other person to
check up on you every so often.

Extension of Laboratory Activities

Exercises are designed to be accomplished within the specified period.

However, unforeseen make up activities may become inevitable. There are two types
of permits that are required when conducting make up activities:

(a) Activities conducted within regular working hours (M – F; 8-12, 1-5) but
outside scheduled period. Permit from the instructor is required and presented
to the technician.

(b) Activities conducted after regular working period (after 5pm or

Saturdays/Sundays). Permit from the Dean or Asst. Dean must be secured by
writing a letter. The technician or the faculty member must present during the
make up period.

General Conduct

1. The laboratory is a training and study area. Therefore, horseplay is strictly

prohibited.

2. Materials (ex. Chemicals, filter paper, etc.) must be prudently used.

3. NO SMOKING in the laboratory.

4. The lab is not a canteen and eating inside is discouraged. Chemicals are toxic
substances and a high risk of food contamination is always present.

Report and Format of Reports

The laboratory activity log book is not final evidence of completed laboratory
requirement. A formal written (word processed or type written) report must be
submitted at the end of each activity. These are later compiled and submitted in a
folder with appropriate table of contents and an alphabetically arranged list of the
group members.

Format of Report

The following is the order of the report:

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I. Introduction – indicates an overview of the experiment and its objectives.

II. Methodology – a summary of the manner by which the experiment is carried out.

III. Results and Discussions – data of the outcome of the exercise must be presented
as well as the appropriate reasons for the results obtained and illustrations. Follow the
guide questions at the end of each activity.

IV. References

V. Appendix – Calculations

Prepared by:

Ma. Teresa T. Ignacio, MSMetE

Department of Ceramics, Chemical and Metallurgical Engineering
College of Engineering
MSU – Iligan Institute of Technology
Iligan City

Laboratory activities in the mineral processing course are defined and

recommended by the CHED- Technical Panel on Engineering Education. These
activities and procedures as outlined in the CHED – TPEE manual oftentimes need
modification due to the unavailability of the materials.

This manual consists of a compilation of the experiments needed to properly

understand and appreciate the mineral separation operations and processes. It adheres
closely to the CHED – TPEE requirement. For the students, this manual would serve
as a guide in performing each experiment. When necessary sample calculations are
included, the main principles and concepts of each topic are to be read from the text
and references provided for in the Mineral Processing lecture classes.

CONING AND QUARTERING (M)

This is one of the oldest forms of sampling and has been used for years as the
standard method for the sampling of a material. This sampling method can be used for
up to 50 tons of ore. Expensive equipment is not necessary and the only tools needed
are a shovel, brooms and a wheelbarrow (optional). It can also be applied to all types
or classes of ores.

Objective: This experiment aims to demonstrate the use of the conventional coning
and quartering method for cutting down the amount of sample to be processed,
regardless of size.
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Materials and Equipment: large floor area 3m x 3m; square shovel; round shovel;
wooden slat of at least 6 in wide and 18 in long; broom; different sized gravel and
sand or other ore material.

Procedure:

1. Clean the floor area thoroughly with a broom. Make sure no substantial
amounts of ‘foreign” materials contaminate the sample.

2. Weigh the ore to be used fro this experiment (wi).

3. Dump the ore on the floor in two or three heaps, some distance away from the
middle of the floor.

4. Using a square shovel, take a shovelful from one heap and drop them in the
middle of the floor, make sure the shovel is elevated waist-high before
releasing the ore.

5. Take a shovelful from the next pile and dump it into the heap, dumping each
directly onto the apex to form a right-conical heap.

6. Successive shovelfuls should be taken as to contain similarly segregated sizes

of the ore. The object of coning is to form a heap in which segregation should
be symmetrical with respect to the vertical axis.

7. Take turns in shoveling the ore into the heap until all the sample which has
been dumped is placed onto the heap.

8. Using a 6-in wide wooden slat, cut the cone into even quarters, combine two
opposite quarters together and place them in a sack. Weigh this material (wr).

9. Repeat the coning and quartering following the procedure outlined from step
4. In step 8, however, take two opposite quarters and weigh them (w r2) before
combining them with those in the sack.

10. Repeat until the sample has been cut down into about five kilograms.

11. Weigh the final sample of the ore left (Wf).

12. Repeat the whole experiment, this time using a round shovel.

GUIDE FOR DISCUSSIONS:

1. As the sample is shoveled, the cone does not mix the ore uniformly. How do
the large pieces behave as they are heaped into the cone? Illustrate.

2. Differentiate the form of the heap when the shovelful is dumped directly onto
the apex, and when it is dumped in the usual manner. Illustrate.
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3. Is there any observable difference in the form of the cone or in the behavior of
the ore with the differences in the shape of the shovel? Illustrate.

4. Calculate the efficiency of each step in the coning and quartering process.

THE JONES RIFFLES (M)

The Jones Riffles is the most satisfactory device which has been used
to cut down the amount of sample to a size which is comfortable for the assayer to
handle. The rifles are made of gauge 20 galvanized iron sheets and can be easily
fabricated. This consists of a frame with alternate slots which should be uniform
thickness. The method is very simple and is easy to follow.

Objective: The Jones Riffles aims to divide the sample evenly into half. A bank
of riffles therefore will cut down the sample size into manageable amounts.

Materials and Equipment: Jones Riffles, 5 aluminum sample pans, the length of
which is equal to or larger than the width of the riffles, broom.

Procedure:

1. Clean the area to be used with a broom. Weigh the sample before using (wi).

2. Place enough sample into the pan such as no segregation in size is noticeable.
Dump this sample directly into the riffles, collecting the two products in
separate pans.

3. Repeat step 3 until the entire ore sample has been processed. Combine all the
samples from one pan and label it as sample A. Do the same for the other pan.
Weigh both sample (wA and wB).

4. Using sample A, repeat the riffling, collecting final sample C and D. Weigh
sample C (wC). Save sample C as reject.

5. Repeat this step for sample B, collecting final sample E and F. Weigh the
sample E (wE) and combine sample F with sample D.

6. Proceed with the riffling until only around 500 grams of the sample is left in
the pan. Weigh the final sample (wfinal).

GUIDE FOR DISCUSSIONS:

1. Draw a schematic illustration of a 5-pass riffle bank.

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2. Discuss the advantages and disadvantages of using a Jones Riffles, as

compared to other sampling methods.

3. Differentiate this method with coning and quartering.

4. Calculate the overall efficiency of this method, as well as at each pass.

Compare with that obtained from the previous experiment.

GRAB SAMPLING (O)

This method involves the manual sampling of a material using the hands. It
was the most inexpensive form of sampling in use for several decades due to its
cheapness. This, however, is subject to personal elements, making it difficult to
obtain repeatable results specially when it comes to the assaying of the sample.
Where machine sampling is sometimes too difficult to institute, or where the
material is not suitable for it, hand sampling is usually performed. The sample is
usually crushed and pulverized and is ready for testing. This method involves
taking grab samples from heap placed onto a rubber mat and rolled as thoroughly
as possible.

Objective: This experiment aims to familiarize the student with the manual
methods of sampling and its effect on the assay of an ore material.

Materials and Equipment: crushed sample, pulverized sample, thick rubber

matting, at least 3’ x 3’ in size, spatula or scoop.

Procedure:

1. Clean the rubber matting thoroughly and wipe with a wet rag. Allow to dry
thoroughly.

2. Weigh the crushed material (wi) and place onto the rubber matting and hold
the mat at two opposite corners. Roll the sample thoroughly by pushing the
amt inward while raising it slowly until the sample has reached the middle of
the rubber mat. Repeat, holding the opposite corners.

3. Repeat this step at least twenty times to ensure thorough mixing.

4. Flatten the top of the heap and divide into at least ten equal portions. Take a
spatula and scoop out one spoonful of ore atop each of the parts. Ensure that
equal amounts of sample are taken from each portion. Place the grabbed
portions in a plastic bag and weigh (wf). Pulverize and save.

5. Repeat this procedure, this time using the pulverized material.

6. To evaluate the efficiency of the grab sampling for each type of the ore. Run
one copper assay for the sample and compare.
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GUIDE FOR DISCUSSIONS:

1. Based on the visual examination of the material after sampling, can you draw
conclusions as to the efficiency of the sampling method? Which sample can
considered as having a higher efficiency of sampling?

2. How does the personal element affect grab sampling?

3. What steps can be taken to prevent individual differences from influencing this
sampling method?
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HAND PANNING (O)

The use of vanning pan as a means for separating heavy minerals from the
gangue has been a practice which dates back to the 15 th century. During those
days, it has been found that minerals of copper and lead tended to separate from
the invaluable portions of an ore by using a shallow pan with a slight indentation
in the center. Up to this time, this procedure is still being used, especially by the
small scale miners in the various provinces in the Philippines.

Objective: This experiment aims to familiarize the student with the use of a
vanning pan in the separation of chalcopyrite from gangue.

Materials and Equipment: vanning pan, mineral sample, balance, pail, 250-ml
beaker

Procedure:

1. Crush and grind the ore so that it passes a 150 mesh screen.

2. Grab a handful of the ore and weigh it using a balance.

3. place this ample in a ceramic vanning pan with a slight indentation in the
center. Add a little water and mix thoroughly with your hands.

4. Slowly rotate the pan clockwise and at the same time tap the sides every five
seconds. Throw out the water and collect in a pail.

5. Ad some more water and repeat step 4. Use the same pail for the collection of
the tailings material. Repeat this step until the water which comes out is
already clear.

6. At this stage, add more water and pan the sample slowly, while tilting the pan
slightly to let the concentrate flow to the side. Collect the concentrate in a
beaker. Repeat this step until almost all of the concentrate has been collected.
Weigh the products after filtering and drying.

7. Take the specific gravity of the products.

8. In most cases, these products are also assayed for copper using techniques
learned from Met E 13.

GUIDE FOR DISCUSSIONS:

1. Evaluate this technique for concentrating materials by citing its advantages

and disadvantages.

2. Why do the minerals separate?

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3. In calculating for the recoveries, you find that a substantial amount of copper
is still found in the middlings. What suggestions can you make in order to
minimize these losses?

4. In your opinion, what factors would greatly affect the recovery of the copper
using this technique?

5. Draw the distribution of the particles in the pan.

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Ball Milling

1. Tests are made at all sizes from 4 to 65 mesh, but ordinarily at 14

mesh unless other specific information is required.
*This means you choose a specific size, say 4 mesh or 14 mesh
as ordinarily used 14 m

2. The discharged product is screened on the mesh size tested.

*So 14 mesh sieve is used +14 → - 14

3. The sieve undersize is weighed, (i.e. -14 mesh) and fresh unsegregated
feed is added to the oversize (=14 mesh) to bring its weight back to
that of the1250cc originally charged into the mill.
Fresh unsegregated – the -1/2 in crushed material

4. This is returned to the mill and ground for the number of revolutions
calculated to give a circulating load equal to the weight of the new feed
added.

What is the circulating load? It is the load returned for regrinding. This is
equal to the weight of the product over size.

Product = weight of material charge – weight of screen o’size

= 1146.17 – 796.98
= 349.19

Net weight of product size = 349.19 – 184.99 = 164.2

Wt. of product o’size x 100 = 796.98 x 100 = 228.24%

N size 349.19

Wt of new feed – sample, then screen

- take the wt of undersize of target size (ex. =65 mesh; take the wt of all
– 48 mesh mat’l)
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SINK – FLOAT TEST FOR COAL (I)

This operation involves the separation of minerals having a relatively large

difference in specific gravity, using a heavy medium consisting of a fluid with a
specific gravity lying in between the two minerals to be separated. This method
has been successfully used in the concentration of fine coal particles.

Objective: The experiment aims to familiarize the student with sink – float
process for the concentration of fine particles of coal.

Materials and Equipment: 1000-ml graduated cylinders, zinc chloride,

pycnometer, balance, furnace, 100 – mesh sieve, stopwatch or timer, porcelain
crucibles, furnace, oxygen bomb calorimeter (optional).

Procedure:

1. Weigh out ten grams of a coal sample which has been previously sieved to
pass a 100 – mesh screen. Take its specific gravity.

2. Weigh out enough zinc chloride (ZnCl2) and dilute with water to get a 1000-ml
solution with a specific gravity of 1.7. Determine the actual specific gravity
using the pycnometer.

3. Transfer this solution to clear glass graduated cylinder. With the graduations
facing you, place the coal sample into the solution. Avoid creating any
disturbance while the particles settle. Observe the time it takes for the first
particles to settle at the bottom and the total time it took for all the heavies to
reach the bottom.

4. Scoop out the floating particles and air-dry on some old newspapers. Weigh
the dried sample.

5. Decant the solution and retrieve as much of the sink portion as possible. Dry
and weigh.

6. Using the same solution, determine the specific gravity. If it has lowered
considerably, add more ZnCl2, otherwise, leave it as it is and note down its
specific gravity.

7. Repeat step 3, this time stirring the solution as the sample is fed. Again, note
down the time it takes for the s\first particle to settle at the bottom and the total
time it took for all the particles to sink. Observe the solution carefully.

8. Dilute the resultant solution so that it has a specific gravity of 1.3. Repeat the
experiment and note down your observations.
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9. Finally, using a material which has not been screened (coarse and fine
particles are mixed together), repeat the experiments as stated above and note
down your observations.

10. Collect all final sink and float products and label each one carefully. Weigh out
1.000 ± 0.005 gms. of the sample and place in properly labeled porcelain
crucibles. Place in a furnace and burn at 800 °C for at least 1 hour. Cool and
weigh. Calculate the ash content of the sample.

GUIDE FOR DISCUSSIONS:

1. What other minerals can be separated using this technique?

2. If you were to separate chromite ore from a siliceous matrix, what media can
be used?
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FLOTATION

Flotation is a process of separating fine particles of different minerals from

each other by lifting creation minerals at or on a water surface. The mineral
particles which are heavier than water are usually maintained in suspension by
surface tension forces. The separation is then effected by the adhesion of some
solid particles to gas bubbles which are introduced in the pulp. The most
commonly employed technique for metallic minerals is called froth flotation. As
the name implies, this involves the production of fine bubbles either from
appropriate chemicals used or from the introduction of air in the system. The
valuable minerals then adhere to the air bubbles and float while the gangue
minerals remain in the pulp.

This is usually applied for the concentration of metallic sulfide minerals such
as copper sulfides, lead sulfides, etc. At present, however, it has become highly
effective in the treatment of a great variety of oxide ores, native ores, and even
non-metallic minerals.

FROTH FLOTATION (M)

This process is based on the differences in the physico-chemical properties of
various minerals. The difference can be enhanced by the treatment of the minerals
with various reagents. IN this operation, the valuable minerals adhere to the air
bubbles and can be collected by scraping off the bubbles. On the other hand, the
gangue minerals tend to remain suspended in the pulp and can be collected after
the process has been scooped.

Objectives: This experiment aims to familiarize with the concentration of

minerals using froth flotation. The student will also be able to learn the effect of
flotation time, feed size, pH, pulp density, conditioning time and reagent dosages
on the wettability of minerals, thus its ability to float.

Materials and Equipment: Denver flotation cell, low grade copper or chromite
ore, pH meter or pH paper, 325 –mesh sieve, rod or ball mill, vacuum filter,
drying oven, balance, graduated cylinder, graduated syringe, collectors, frothers,
lime, conditioners, aluminum pans and trays.

Procedure:

1. Prepare and clean all materials for the flotation test.

2. From a bulk of ore, crush and grind samples, and obtain six (6) samples each
weighing 1000 grams by using the appropriate sampling techniques. Grind
your samples using the rod mill for 20 to 30 minutes.

3. Determine the amount of slimes by screening through 325 mesh. The -325
mesh portion should be considered as slimes. The +325 mesh portion will be
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used as feed in the flotation test. Calculate the pulp density based on the +325
product.

4. Run a flotation test maintaining the following parameters:

Percent solids: 30%

Conditioning time: 10 minutes

Flotation time: 5 minutes
Particle size: -325 mesh (after grinding for 30 minutes)
pH: acidic or neutral

5. Adjust the pulp density to around 68 to 80 percent solids with around 400 ml
water and turn on the flotation cell. Keep the air cock closed.

6. Add the predetermined amt. of collector per gram of feed, and adjust the pH to
the desired level using lime at least 3 minutes before the required conditioning
time expires.

7. Add water to the desired pulp level of the flotation cell. The pulp level is
usually maintained at around half an inch from the rim of the flotation cell.
This should be done before the frother is added, usually one (1) minute before
the conditioning time expires. Check and adjust the pH.

8. Open the air cock and start collecting the froth using a froth paddle. Continue
collecting the froth or concentrate for 5 minutes. If no bubbles are formed,
stop the air source and add very small amount of frother and condition the
pulp for 30 seconds, then open the air cock.

9. Add water to maintain the pulp level while collecting the froth. Collect as
much of the concentrate as you possibly can. This stage is called the rougher
flotation stage.

10. After the test, stop the air inflow. Turn off the flotation cell. Lift the impeller
of the flotation cell slowly, and wash the cell thoroughly to collect any
material which may have attached itself to the cell. Filter and dry the sample
from the cell. Get the final weight of the dry product.

11. Clean a smaller cell thoroughly with water and place the concentrate obtained
in the cell. Adjust the pulp level and the pH, and then add a little bit more of
the collector and the frother. Repeat the flotation and collect the concentrate
for a fixed amount of time.

12. Sample and analyze your products. If the ore sample is pre-mixed, analysis
can be done by the microscopic method. Apply the proper sampling procedure
to reduce the amount of sample and can be analyzed easily by microscopic
method. The analyses of the head, concentrate and tail products should be
conducted in the same way.

13. Repeat the test for the different conditions stated above.
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WORK CAUTIOUSLY TO AVOID UNNECESSARY REPETITION OF

TEST

GUIDE FOR DISCUSSIONS:

1. What are the advantages/ disadvantages of flotation over other mineral

dressing or concentrating processes?

2. Explain the basic principle of flotation.

3. Differentiate sulfide and oxide flotation.

4. Flotation is a very complex process and it requires the investigation of many

parameters that might have an effect on the recovery and separation of
valuable minerals. Conventional flotation test requires many trials and tests in
order to determine the individual effects of each of the flotation parameters.
How do you decrease the number of trials or test and minimize the error in
analyzing the interactions among the flotation parameters?

5. What are the most recent developments of flotation process: in terms of

flotation equipment, reagent application, particle size, and grade of ore?
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DEWATERING

Since fluids are commonly used for various mineral processing operations, the
separation of liquids from solids should be given attention. The separation of a
suspension into a supernatant clear fluid and dense slurry can be readily
accomplished by settling or sedimentation. However, for fine solids, various
methods have been devised to accomplish dewatering and settling.

The mechanical separation of liquids from solids on a commercial scale is

conducted as a continuous process in “thickeners”, which are large tanks which
receive the dilute slurry at the center, permit the overflow of supernatant liquid
and produce sludge from the bottom of the tank. Final moisture is removed by
drying in an oven or under direct sunlight. Separation of solids from gases can
also be accomplished in similar ways, but this is beyond the scope of this manual.

FLOCCULATION

A ground ore consists of particles finer than the finest, that it can be settled in
water with a reasonable time. The pulp can be so conditioned that the fine
particles are grouped together to from floccules large enough to be seen by the
naked eye, the resulting flocs will settle with sufficient rate to provide clear
supernatant liquid and compacted sediment in a reasonable time. This dispersed
state may be considered a natural condition, while that of a flocculated state is
obtained by the addition of some suitable agents. Flocculation depends upon the
conditions or forces present at the solid – liquid interface.

Objective: The experiment aims to familiarize the student with the influence of
flocculating agents on the settling rate of a pulp.

Materials and Equipment: 1000-ml graduated cylinders, clay, alum, separon,

aerofloc, and stopwatch.

Procedure:

1. Prepare a 20:1 clay suspension in the 1000-ml graduated cylinder.

2. Add water until it reaches the 1000-ml mark, and then add 25 ml more.

3. Add the required quantity of flocculant in the form of solutions. Shake the
contents well.

4. Allow to settle until the floccules reach the 1000-ml mark. Start the timer and
note down the height of the supernatant liquor every minute. Should this be
hard to follow, an alternative procedure would be to place marks on the
cylinder and record the time it takes for the clear supernatant liquor to reach
this mark.
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5. Subsequently, add more flocculant, shake well, and repeat the test. Repeat the
addition at the rate of 0.02 lbs/ton until the settling rate steadies out.

GUIDE FOR DISCUSSIONS:

1. Define Brownian Movement.

2. Name at least three industrial flocculating agents and in which stage of a

process they are introduced.

3. How is flocculation induced by the addition of electrolytes?

4. Of what nature is the change which clay particles acquire in water?

5. Sketch a charged particle suspended in water and indicate the following: a.

Stem layer; b. Potential Determining Ion; c. Gouy Layer; d. Zeta potential.
Also draw a curve showing the change in potential with distance from the
particle surface.

SEDIMENTATION (M)

For the design of continuous thickeners, a laboratory batch

sedimentation experiment is usually conducted. Calculations follow on the basis
of the results of this test. The sedimentation set-up consists of a series of
graduated cylinders in which the suspension or fine slurry is allowed to settle for a
given time. The time rate of the decrease in height of the visible interface between
supernatant clear liquid and slurry containing the particles is the sedimentation
rate. It is imperative that the experiment be conducted at a uniform temperature all
throughout the experiment and that all conditions in the surrounding environment
are in equilibrium in order to get meaningful results from this experiment.

Objective: This experiment aims to familiarize the student with the calculations
for the area of a thickener using materials and equipment readily available in nay
laboratory.

Materials and Equipment: 1000-ml graduated cylinder, rubber stoppers fit for
the graduated cylinders, stopwatch, ground ore, wash bottle.

Procedure:

1. Prepare a pulp of about 10% solids by mixing 100 gms. of the ore with 800 ml
of water in a 1000 ml graduated cylinder. Place the stopper and shake the
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mixture thoroughly. Dilute to the 1000-ml mark with wash bottle, making sure
all the ore at the sides are washed down.

2. Again shake the mixture very well and using a stopwatch, note down the
height of both clear liquid and the solids at varied time intervals. Take
readings at 5-minute intervals for the first ½ hour, 10-minute intervals for the
1 hour, and 15-minute intervals for the next 1-1/2 hour. Then take hourly
readings up to the 8th hour. Let settle overnight or at least 24 hours and take the
final reading.

3. Repeat the test, this time using pulp densities of 15%, 20%, 25% and 30%.
Note down the final consistency of the pulp.

4. Determine the depth of the compression zone by finding the time it takes to
reach the underflow dilution by extending the settling test over a period of
time (24 hours). During this part of the test, remove the excess water above the
mudline periodically.

5. The minimum depth of the compression zone can be calculated from:

d = t (x + 1)
24 Aρ
where d = depth of compression zone,m
t = retention time of pulp in the compression zone
A = thickener area required (m2/TPD)
Ρ = ave. dilution of the pulp in compression zone corresponding
to x
x = ave. dilution of the pulp in compression zone between the
time the pulp enters the zone and the time at
which the final underflow dilution is reached.

GUIDE FOR DISCUSSIONS:

1. Calculate the thickener area and the depth of the compression zone. (see sample
calculations given)

2. How does a thickener compare with a bowl classifier?

3. The underflow of a thickener is usually pumped using a diaphragm pump and not
by conventional sand pump. Why?

4. List down the parts of a thickener and state its functions.

5. Name non-mechanical methods to improve the efficiency of a thickener. Explain

these concepts.

SAMPLE CALCULATIONS
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A typical settling data is presented in the table below, for a feed pulp
containing 180 gm/L. This pulp is to be thickened to 60% solids by weight slurry
using a thickener. The specific gravity of the solid is 2.7. Calculate the thickener area
needed using Kynch’s formula, and find the depth of the compression zone.

Height of 1000-ml mark: 7.47 cm

Initial Feed Consistency: 180 gm
Specific Gravity of Solids: 180 gm/l
Weight of dry solids: 2.7 gm/ml
Pulp Density of Feed Pulp: 16.2% solids by weight

Time Height of Volume, C, gm H - Hα H - Ho

(T, hrs) Interface ml. solid/li Ho - Hα
(H, cm) pulp
0.0 40.0 1000 180 35.5 1
0.2 34.7 868 207.4 30.0 0.85
0.4 29.2 730 246.6 24.5 0.694
0.6 23.8 595 302.5 19.1 0.541
1.0 15.8 395 455.7 11.1 0.314
1.4 11.7 293 614.3 7.0 0.198
2.0 8.4 210 857.1 3.7 0.105
3.0 6.3 158 1139.2 1.6 0.045
4.0 5.6 140 1285.7 0.9 0.025
5.0 5.2 130 1384.6 0.5 0.014
5.5 5.1 128 1406.3 0.4 0.011
6.0 5.0 125 1440.9 0.3 0.118
4.7 118 1525.4 0 0

Hα is the final height of the interface after settling

a. Thickener Area:

From the settling curve in Figure 1 below, calculate the thickener area as
follows:

weight of solids in the feed 180 gms

final pulp density desired 60% solids
final pulp will have 180 gms. solids and (168 X 40/60) gms. water
volume of pulp is (180/2.7 + 120/1) = 186.7 ml.
height of pulp is 186.7 x (40/1000) = 7.47 cm.

From Kynch’s formula, we can calculate the thickener area as:

A = ___ tu__
H o C0

where A = thickener area in m2/tpd

 21

tu = the value of settling time axis of the intersection of a tangent

to the settling curve and an ordinate representing the
pulp height in the cylinder at underflow density,
expressed din days
Ho = initial height of slurry in the cylinder, m
Co =initial feed consistency, tons of solid / m3

Figure 1. Settling Time Vs. Height of Interface

From the figure, we can calculate the area as:

A = 0.0844 = 1.1722
(0.4)(0.18)

b. Depth of Compression Zone

The critical time at which the pulp enters the compression zone is calculated
using Robert’s Method. Figure 2 shows a semi-log plot of the Data obtained in the
Table above. From this figure, we see that the time at which the horizontal line at Hc
cuts the curve, tc is at 0.5 hr, while the time needed to attain the desired underflow
density is at 2.25 hr. (from Fig.1)

Figure 2. Settling Time vs. Log H – Ha / Ho - Ha

 22

Retention time in the compression zone = time needed to attain desired

underflow density or critical time:

t = T - Tc = 2.25 - 0.5 = 1.75 hr.

During this period, the average dilution and the average pulp density is
calculated. The relevant data are shown in the following table.

Ave. dilution pulp in the compression zone = 1.96 / 3.6 = 1.1 kg water / kg solid

e.g. at X = 1.1 ρ = (1.1 + 1/2.7) = 1.429

The depth of the compression zone therefore can be calculated as:

D = t (X + 1) = 1.75(2.1) = 0.09441 m
24 A 24(1.135)(1.429)

Time Volume Dilution Average Time Time

(T, hrs) (V, ml.) kg. water Dilution intervals, Interval x
kg solid hrs. Average
Dilution
0.0 1000 5.19
0.2 868 4.45 4.07
0.4 730 3.69 3.32 .02 0.664
0.6 595 2.94 2.38 0.4 0.952
1.0 395 1.82 1.54 0.4 0.616
 23

1.4 293 1.26 1.03 0.6 0.618

2.0 210 0.80 0.65 1.0 0.650
3.0 158 0.51 0.46 1.0 0.460
4.0 140 0.41
5.0 130 0.35 3.6 3.96
5.5 128 0.34
6.0 125 0.32
 24

THE JAW CRUSHER(M)

The jaw crusher is the most commonly used equipment for cutting down the
size of an ore to a size suitable for further grinding. Since most of the minerals
contained in an ore do not occur as liberated particles, this part of mineral processing
plays an important role in liberating the minerals, making them more easily recovered
by concentration methods.

The Jaw Crusher consists of two crusher plates set nearly vertically, one fixed
and the other movable. There are essentially two types of jaw crushers, the Blake type
and the Dodge type, classified according to the point of minimum amplitude of
motion on the moving face and according to the way in which the motion of the
movable face is transmitted.

Objectives: This experiment aims to familiarize the student with the operation of a
laboratory sized jaw crusher.

Materials and Equipment: Set of sieves; jaw crusher, ore consisting of at least 4”
top size, aluminum pans, balance, broom.

Procedure:

1. Clean the crusher area thoroughly with a broom.

2. Adjust the movable jaw of the crusher so that the final product size is at least
½”.

3. Take the screen analysis of the feed sample, by finding the 80% passing size
of the original feed material.

4. Place enough ore feed and collect the product in an aluminum tray.

5. If the product size passes through ½”, continue the crushing until all of the
sample has been processed.

6. Take the 80% passing size of the final product.

GUIDE FOR DISCUSSIONS

1. Calculate the reduction ratio obtained.

2. Differentiate a Blake crusher from a Dodge crusher. What type of crusher was
used for our purposes?

3. What are the factors which may affect the size of the product?

4. Taggart gives the empirical formula for calculating the capacity of crushers as:
 25

T = 0.6LS

T = tonnage capacity
L = the length of the receiving opening, in.
S = the width of the discharge opening, in.

Calculate the tonnage capacity of the crusher used.

 26

BOND WORK INDEX (O)

The Bond Work Index of a material is a measure of its hardness or its

resistance to crushing or grinding. This is sometimes referred to as the Hardgrove
Grindability Index based on the design of the rod mill being used.

Objective: The experiment aims to familiarize the students with the procedure for
the determination of the Bond Work Index of a given ore.

Materials and Equipment: 8” x 10” Ball Mill; Splitter; set of sieves, graduated
cylinder, mechanical counter.

Procedure:

A. Sample Preparation

1. Prepare sample to –6 mesh by stage crushing and grinding. Use coning and
quartering or the Jones Splitter to obtain a representative sample.

2. Determine the screen analysis of the sample, then obtain the 80% passing size.
Also determine the bulk density in grams per liter by packing sample in 1000 ml
graduated cylinder, and then taking the equivalent weight.

3. Take the weight of 700 ml of sample and place in the mill. Grind at 250 %
circulating load. Calculate the IPP (Intended Product Passing or Ideal Potential
Product) for 250% circulating load.

IPP(grams)= [Wt. Of material charge/3.5]

B. Grinding

1. The grinding charge consists of 191 steel balls weighing 20,125 grams. The
ball combinations are 43 – 1.45 “  balls, 67 – 1.17 “  balls, 10 – 1.0 “  balls, and
71 – 0.75 “  balls. The calculated surface area is 842 in2.

2. Place the material charge and the balls in the mill. Run x revolutions, where x
can be 50, 100, 150, and 200 but usually 100 (no. of revolution based on estimate of
work index). **Be sure that the ball mill and steel balls are thoroughly clean before
starting the experiment. To do this, place a small amount of the ore in the mill and run
for about five or ten minutes, and then throw out this material.

3. Dump the mill charge onto a large pan. Separate the balls from the material
charge. Screen all the materials at the mesh of grind assigned to your group with
coarser protective screens, e.g. if –48 mesh is assigned to your group, weigh product
minus or passing 48 mesh. Mesh of grind (MOG) is the optimum grind at which
valuable minerals are liberated from one another.
 27

Product = weight of material charge – weight of screen oversize.

Net Product = Product – the Weight of undersize in the feed.
Net grams per revolution = (Net product)/ (No. of Revolutions)

4. Add more feed to screen oversize (circulating load) to bring up to original

weight of material charge using the segregated samples and taking into consideration
the original fraction of each particle size.
Example:

wt. of product undersize = 349.19

wt. of new feed = 349.19 (.2288) = 79.89
= 349.19 (.1983) = 69.24
= 349.19 (.1357) = 47.38
= 349.19 (.0719) = 25.11
= 349.19 (.0785) = 27.41
= 349.19 (.0442) = 15.43
= 349.19 (.0446) = 15.57
= 349.19 (.0366) = 12.78
= 349.19 (.0269) = 9.39
= 349.19 (.1343) = 46.90
-------
349.19

5. Calculate the no. of revolutions for the next period.

IPP – weight undersize in feed

No. of Revolutions = ------------------------------------------------
Net product/revolutions from previous period

6. Repeat steps 2 to 5 until the circulating load equilibriates at 250 % + 2 %.

7. Carry out the screen analysis on the final product and plot the results in the
manner similar to the one used for the feed. From the plot, find the 80 %
passing size of the product. Repeat the grindability test to obtain the
equilibrium grindability values at the number of other sizes such as 35, 60,
80 and 100 mesh. An alternative method is shown in the sample
computations.

C. Sample Computation

Bulk Density : 1637.38 gm/ml

Material Charge : 1146.17 gm
IPP Material Charge : 327.48 gm
Sieve Size Tested : 210 microns (65 mesh)

FEED
 28

Mesh Aperture wt., gm % wt. % wt. % wt.

size, m retained passing cum
Retained
cum
6 3360 0.00 0.00 0.00 100.00
8 2380 112.4 22.88 22.88 77.12
10 1680 97.41 19.83 42.71 57.29
14 1198 66.68 13.57 56.28 43.72
20 821 35.34 7.19 63.47 36.53
28 599 38.58 7.85 71.32 28.68
35 420 21.71 4.42 75.74 24.26
48 297 21.92 4.46 80.20 19.80
65 210 17.97 3.66 83.86 16.14
100 149 13.23 2.69 86.55 13.45
-100 65.97 13.43 100.00 0.00

P80 = 153.38 mm

Period wt. of wt. of no. of wt. of wt. of net wt. of net wt. of %
new feed u’size mill products product product product circulating
new revs. o’size u’size u’size u’size per load
feed mill rev.
1 1146.17 184.99 100 796.98 349.19 164.20 1.64 228.24
2 349.19 56.36 165 781.84 364.33 307.97 1.87 214.60
3 364.33 58.80 144 769.33 376.84 318.04 2.21 204.15
4 376.84 60.82 121 826.77 320.06 259.24 2.14 258.11
5 320.06 51.66 129 824.50 321.67 270.01 2.09 256.32
6 321.67 51.92 132 820.50 325.67 273.75 2.07 251.94

circulating load = wt. of product o’size x 100

wt. of product u’size
grindability = 2.08 gm/rev

PRODUCT
mesh Aperture Wt., gm % wt. %wt. % wt.
size, m retained retained passing cum
cum
65 210 0.00 0.00 0.00 100.00
100 149 71.68 22.01 22.01 77.99
150 105 74.85 22.98 44.99 55.01
200 74 60.82 18.68 63.67 36.33
-200 118.32 36.33 100.00 0.00
325.67

F80 = 2498.68 mm
Work index = 13

GUIDE FOR DISCUSSIONS

1. What is the importance of determining the work index?
 29

2. What is circulating load? What is the usual range of circulating load in closed
circuit grinding?

3. What are the advantages and disadvantages of increasing the circulating load
in closed circuit grinding?

4. Explain how the rod mill grindability test in performed?

5. Can you determine the grindability index using wet grinding? Why?

6. Calculate the Work Index of the ore by using the following formula:

W= 4.45

Pi0.22 G0.82
W is the work index, Pi the MOG in microns, G the grindability in gms/rev, P the
product size and F the feed size in microns, both at 80% passing size.
 30

MESH-OF-GRIND DETERMINATION(I)

The mesh-of-grind of a material is the grinding time at which 80% of the

material passes its set liberation size. The liberation size of the sample is the size at
which most of the minerals are found free from each other. This size is usually found
in the lower levels of a sieve, e.g. 150 mesh or finer. For experimentation purposes,
the liberation size of the sample will be set at 200 mesh.

Objective: This experiment aims to familiarize the student with the operation of a
ball mill and to help the student become adept in testing for the mesh-of-grind of a
sample.

Materials and Equipment: crushed and sampled ore; balance, timer, rod mill or ball
mill, steel balls of varied sizes, 200 mesh sieve, aluminum pans, drying oven, vacuum
filter, old newspapers.

Procedure:

1. Prepare a sample by crushing it to at least –20 mesh size using either a jaw
crusher or the cone crusher. Take a representative sample using any of the techniques
you have just learned.

2. Place the sample in the ball mill or a rod mill, adding the necessary amount of balls
or rods to assure a 250% circulating load. (Refer to the discussion on circulating
loads in the previous experiment).

3. Using the timer let the mill run for 5 minutes.

4. Take a grab sample of the mill product and screen from 20 mesh through 400
mesh. Plot the size analysis and take the 80% passing size. Combine the sized samples
and place back in the mill.

5. Repeat step 4, increasing the time in increments of 5 minutes and taking grab
samples until almost the entire material pass through at least 325 mesh.

6. Plot the 80% passing size versus time. Extrapolate the time needed for grinding the
material to result in an 80% passing size of 104 microns.

GUIDE FOR DISCUSSIONS:

1. Discuss the nature of the grinding action taking place inside the ball mill.

2. Differentiate a ball mill from a rod mil in terms of not only the physico-mechanical
properties but also on energy consumption, grinding action, operating details, etc.
 31

3. Predict the nature of the product when the balls are used as grinding media for a
rod mill. Explain your prediction.

SAMPLE CALCULATIONS

Calculation of Charge Volume:

The charge volume refers to the level of the feed inside a ball or rod mill, and
is generally expressed as a percentage of volume within liners filled with grinding
media. This is measured by taking the diameter of the mill (D) and the distance from
the top of the mill to the top of the charge (H). the percentage loading can be
calculated:

%L =113 – 126 H/D

At 50% loading, the minimum power draw is obtained. However, it has been
observed that with an increase in loading from 45% to 50% only 1% increase in
power draw is noticeable. In most cases, therefore, the increase in power consumption
outweights the increase in power draw. As such, mills are normally charge at levels
less than 45%.

Calculation of Motor Size;

We have seen that the power required to grind a material can be calculated using the
equation:

W =11.15Wi (1/P1/2- 1/F1/2)

where W is the power consumption in kwh / MT for wet grinding. This formula,
however, applies inly to wet grinding in a closed circuit. For other conditions,
calculate the gross power consumption (G) as follows:
a. Wet grinding, open circuit, product top size limited: G = W to 1.25W
b. Dry grinding, closed circuit: G = 1.30W
c. Dry grinding, open circuit, product top size not limited: G = 1.30W
d. Dry grinding, open circuit, product top size limited: G = 1.30W to 2.0W
e. Fro P less than 80% passing 70 microns:

W(P + 10.3)
G = --------------------
1.145 P

Example: A dry grinding ball mill in closed circuit is to be fed 100 metric tons / hr. of
a material with a Work Index of 15 and a size distribution of 80% passing 0.8 cm. The
 32

required product size is 80% passing 60 microns. If the feed is to be prepared in a

cone crusher, what is the power required for this?

Solution: Calculate W from the equation:

W = 11.15(15) (1/601/2 – 1/80001/2) = 19.74 kwh / MT

Then calculate G for dry grinding, closed circuit, with P grater than 70 μ

1.3 * 19.74 (60 + 10.3)

G = ----------------------------------- = 26.26 kwh / MT
1.145 * 60

Therefore the power rate of new feed is: 26.26 x 100 = 2.626 Kw

Calculation of Mill size to Match Required Power

The calculated power is the power that must be applied to the mill drive in
order to grind the tonnage of feed from one size distribution to a finer size
distribution. The size of the mill required to draw this power can be calculated as the
following. The power input required to maintain the condition in the figured shown is
theoretically calculated as:

MC sin α (2 π n)
Pinput = -------------------------
12,400

where M = weight of charge in Metric Tons

C = distance of center of gravity of charge from the center of mill in
meters
α = dynamic angle of repose of the charge
n = mill speed in rpm

For more detailed computations, refer to S.K. Jain, Ore Processing, pp 134 – 141.
 33

MINERAL DRESSING LABORATORY

A. BASIC

1. Exercise Title: Hand Sampling and Screen Testing

Objectives:

1. To study particle paths and behaviors during various hand-sampling

procedures.

2. To test the relation between particle size and the sample weight that
will give reproducible sizing analyses.

3. To investigate different methods of graphical analyses of size

distribution.

Procedure Abstract:

1. Study and sketch the particle size on the shovel load. Sketch the size distribution
of the material which has been suddenly dropped on the floor from the shovel.

2. Transfer the materials from the original heap to a cone and observe the behavior
of particles of different sizes as they are dropped onto the growing cone. Make a
sketch of the finished cone.

3. Split the cone into three parts by shoveling. Sift each split separately on 2 nd down
to 20 mesh screens. Dump the -1 st material into a rough cone and split into three
parts by shoveling. Sift the fractions by 3/8th down to 200-mesh sieve screens.

4. Shovel the -1” material into a rough cone and make a pancake of about 3 or 4
inches deep with its center along the original cone axis. Mark off the pancake into
quarters and shovel out opposite quarters and combine them into halves. Weigh
the halves.

5. Cone and quarter one of the halves. Weigh and sift the product of each one and
quartering stage in 3/8” down to 20-mesh.

6. Riffle the other -1” half five times. Weigh the product of each stage and get the
screen analysis of the last two riffling stages.

7. Screen out the -10 mesh material and riffle five times. Weigh the product of each
stage and get the screen analysis of the last two riffling stages.
 34

Equipment Required:

Smooth sampling floor

Straight-edged, D-handled shovels, 2 pcs.
Floor brush
Platform balance
Beam balance
Jones riffles, 1/3” slot; 2” slot with fitting pans and scoops
Tyler sieve screens, complete set from 3-mesh to 200-mesh
Screens with 3/8”; 1”; 1 ½” square
Sample tins
Buckers and cans
Dust masks
50 kg of minus 2-inch siliceous ore

2. Exercise Title: Hand Methods of Concentration

Objective: To make observations which will furnish factual evidence for the
explanation of the causes and effects of particle movements in panning, vanning and
hand jigging.

Procedure Abstract

1) Panning

i) Deslime the feed.

ii) Charge the pan with a weighted fraction of the feed (about 1 kg), dip up
enough water to fill three-fourths of the pan. Agitate the pan following a
horizontal circular motion at a rate sufficient to partially suspend the
material in water. Tilt the pan and rock it back and forth so that the water
splashes across the surface of the settled solids. Examine the toe for
galena; if galena free, wash the toe. Observe the order in which the
different sizes of quartz leave the pan during washing.

iii) Restratify and reskim until the concentrate is clean except for some fine
sand. Then remove the fine sand under a continuous stream of water.

iv) Wash the concentrate into a rust-proof pan.

v) Repan the tailings and collect the concentrate separately. Collect tailings in
rust-proof pans.

vi) Dry and weigh separate concentrates, combine and label.

vii) Recharge the pan, after drying, with a dry charge, place on a table top and
move in a horizontal circle as in the stratification with a wet charge.

2) Vanning
 35

i) Wet down the sample on the plaque first as a thick mud then dilute.

ii) Give the plaque a gentle rotary motion that causes sand to collect at the
center of bottom and keeps slime in suspension, then pour off the slime.
Continue doing this until pulp is slime-free.

iii) Move the plaque along a small vertical circle with a sharp downward
movement and relatively slow upward movement. This stratifies and
collects the heavy minerals near the far side of the plaque.

iv) Collect tailings for rewashing, collect concentrate, rewash tailings, dry and
weigh the products and set aside for assay.

v) Stratify another charge on the plaque using horizontal swirling, then still
swirling slowly, incline plaque slightly and bump upper edge sharply
against heel of free hand some twenty or thirty times.

3) Hand Jigging of Coal

i) Charge the sieve (with aperture smaller than the diameter of the finest
grain in the feed) with the gravel-sized raw coal sample to a depth of 8 or
10 to 40 or more grains depending on the size of the sieve of the particles
but not closer than an inch of the rim.

ii) Submerge the charged sieve in water till the water just covers the charge.
Push down quickly enough to drop the screen from beneath the charge
such that the bed loosen but does not boil at the center. Raise more slowly.

iii) After 40 to 60 strokes, skim off the tailing layer, charge more feed and
repeat.

iv) As the middling layer builds up, skim middling separately. Remove the
tailing and return the middling as nucleus for a new bed.

v) Proceed until the entire sample has been jigged then make a final
separation of clean coal from the middling of the last sieve load by hand
pickling.

vi) Weigh the clean coal and the tailing wet.

Equipment Required:

Miner’s pans
Vanning plaque
Tyler sieve screens, complete set
 36

Drum
Hand lens
Skimmer for sieve
Minus 20-mesh quartz-galena mixture with 5% galena
Minus 65-mesh quartz-galena mixture with 5% galena
5 kg of raw coal (1 – 1/1 inch size)

3. Exercise Title: Introduction to Flotation

Objectives:

1) To determine qualitatively by the method of difference, the probable functions of

the various reagents and treatments of the pulp in a simple flotation operation.

2) To set up a qualitative material balance of a flotation operation.

Procedure Abstract:

a) Fill the cell, after thorough cleaning, to about half-full with water. Start the
agitator and half open the air valve. Add sufficient ground ore so that with
proper operating pulp level the % solids will be between 20% and 25%. Adjust
the pH of the pulp to 8.5 using the lime solution.

b) Add 0.1 to 0.15 lb per ton of ore of sodium (or potassium ethyl xanthate).
Observe what happens.

c) Add 0.5 to 0.15 per ton of ore of pine oil (or cresol). Observe.

d) Remove froth by overflow or by skimming until effective separation ceases.

Thereupon explore in order the effect of:
i) increased air introduction,
ii) further addition of ethyl xanthate,
iii) further addition of pine oil (or cresol),
iv) addition of one drop of wood creosote.

e) Draw off tailings and examine samples of concentrates and tailings under
water on a watch glass with a binocular microscope or hand lens.

f) Return the concentrate to the cleaned machine and with the addition of
sufficient water, refloat.

g) Examine microscopically the refloated concentrates and cleaner tailings.

h) Place the products in rust-proof pans, weigh and assay.

Equipment Required:

Laboratory flotation machine, 2-li volume, having at least one transparent wall
 37

Binocular microscope or high power hand lens

Beakers
Watch glasses
pH meter
Oven
1 ml pipettes
Medicine droppers or syringes
Rust-proof pans
Sieve screens: 48 mesh
Simple galena preferably with a siliceous gangue dry ground to pass 48 mesh
Flotation reagents:
lime
sodium or potassium ethyl xanthate
pine oil or cresol
wood creosote

4. Exercise Title: Wet Grinding in Tumbling Mills

Objectives:

1) To determine the effects of changes in the operation of a batch-type ball mill is

indicated by the size distribution of the ground products.

2) To determine the operational work index using Bond’s equation.

Procedure Abstract:

a) Preparation of the Sample

i) Determine the density of the ore by volume displacement.

ii) Sample the 30 kg of ore to get a 500 gram lot and weigh the sample. Wet
screen the sample in 200-mesh, filter, and dry both screening fractions.
Dry screen the oversized fraction up to 8 mesh using the Rotap sieve
shaker.

b) Preparation of the Ball Mill

i) Determine the volume of the ball mill, the volume of the interstices
between the season ball charge and the weight of ore and water to be used
to have a pulp which is 60% solids by weight.

ii) Clean the ball mill.

c) Determine the effect of the following factors on the size distribution of the
ground product: grinding time, pulp density, ratio of volume of interstices to
 38

volume of pulp, scalping of the feed and percentage loading. For each run
measure the power requirement using the wattmeter.

Equipment Required:

Laboratory ball mill, batch type

Season charge steel balls
Rotap sieve shaker
Wattmeter
Beam balance, up to 4 kg
Tyler sieve screen, complete set
Vacuum filter
Buckets
Beakers
Graduated cylinder
Timer
Minus 8-mesh crushed siliceous ore, 30 kgs

5. Exercise Title: Continuous Thickener Design

Objectives:

1) To determine, through batch sedimentation tests, the area and depth of a

continuous type thickener under steady state condition and set slurry inflow
and outflow rates.

2) To determine the effects of flocculation on settling rates brought about by

the addition of time.

Procedure Abstract:

a) Wet grind the ore sample in the tumbling mill such that it can pass 10 mesh
sieve. Dry the ground ore. Mix the dry round ore and weigh out three 250-
gram lots by increments sampling.

b) Determine the density of the ore by the volume displacement method using a
50 gram sample from one 250-gram lots.

c) Place one 250-gram lot in one graduated cylinder and add enough water to
make one liter slurry. Place the other lot in the other graduated cylinder, make
a one liter slurry and add 3 grams of lime per ton or ore.

d) Mix each slurry separately for a few minutes, immediately place the graduated
cylinder on a stable platform. Read the height of the clear liquid-settling
particle zone interface at intervals of 5 minutes for the first two hours and at a
longer time intervals after the second hour. Stop reading after four hours.
 39

e) For each condition, determine the thickener dimensions following the method
suggested by Foust (Unit Operations).

Equipment Required:

One-liter graduated cylinder, 2 pcs.

Ball mill or rod mill
Mettler balance
Mechanical mixer
Beam balance
One-ml pipette
Tyler sieve screen, 10-mesh siliceous ore
Lime

B. OPTIONAL

1. Exercise Title: Shaking Table

Objectives:

1. To study the structure and motion of a shaking table.

2. To study the particle movement on an operating shaking table.

3. To study the cause of the effects of changes in the operation of the shaking
table on the recovery and grade of the concentrate.

Procedure Abstract:

a) Observe the structure and motion of the shaking table. Learn how to adjust the
stroke length, speed and angle.

b) Feeding at a rate of 1 lb per minute with 3 lbs of water, vary the length of the
stroke, slope, quantity of wash water and speed until visual inspection of
concentrate and vanning tests on tailings indicate optimum results.
c) With the table in best operating condition, take simultaneous position samples
around the table and set aside for screen analysis.

d) Stop the feed, wash water and shake mechanism simultaneously. Examine
with a binocular microscope, the distribution of material on the deck vertically
and horizontally, considering both size and mineral composition. Record the
results in sketches.

Equipment Required:

Shaking table, with Wilfley-type riffling, variable speed drive, quick controls
of water, feed and movement
Three-product collecting troughs
 40

Tyler sieve screen series

Beam balance, ±1 g
Binocular microscope
5 kg of minus 20-mesh artificial mixture of quartz and galena

2. Exercise Title: The Bubble-Pick-Up Method

Objectives:
1. To familiarize the students with the use, applicability and limitations of the
bubble-pick-up apparatus.

2. To construct the critical contact curves for three minerals using the bubble-
pick-up method.

Procedure Abstract:

1) Sample Preparation

Clean the -48-mesh minerals separately by first boiling in dilute NaOH then
washing with distilled water. Then boil in dilute sodium chloride and then wash
with distilled water. Check for completeness of cleaning.

2) Critical Contact Curve Determination

a) Assemble the bubble pick-up apparatus. Fill each of the three burets with
collector solution, dilute sulfuric acid and dilute sodium hydroxide solutions.

b) Place about one gram of cleaned galena in a 500-ml beaker with a known
volume of distilled water. Acidity up to pH 4.

c) From an air bubble at the end of the bubble holder, add collector solution until
the bubble begins to pick up galena particles while the pH is held fairly
constant with measured sulfuric acid additions. Increase pH to 5 by adding the
base. Determine collector volume needed to effect bubble pick-up. Carry out
the same procedure up to pH 9. Record all volumes of additions. For
chalcopyrite, test from pH 8 to 11 while for pyrite from pH 4 to 6. Determine
mine collector concentration required for pick-up for each pH level.

d) Prepare 300 ml of collector solution with 25 mg of collector per liter of

solution. Place clean galena in the solution and lower pH to 6.5. Add aqueous
solution of sodium sulfide (depressant) until air ceases to pick-up the galena
particles. Lower the pH by half a unit and repeat the above procedure down to
pH 3.5. Do the tests for chalcopyrite from pH 9 to 6 while for pyrite, from pH
10 to 5. Determine the concentration of sodium sulfide necessary to depress at
each pH level.

Equipment Required:
 41

pH meter
Mettler balance
Bubble pick-up tube (glass tube, rubber tubing and pinch cock)
Burets, 3 pcs.
Buret stands
Magnetic stirrer or mechanical stirrer
Graduated cylinder
High-purity dry-ground galena, chalcopyrite and pyrite
Sulfuric acid
Sodium hydroxide
Sodium sulfide
Collector: ethyl xanthate
Distilled water
Sodium chloride
 42

CRUSHING AND GRINDING

The ore coming from most mines are usually in the form of rocks, the
largest size of which can be as large as 6 ft. in diameter. The machines which break
down these boulders into smaller, more manageable pieces of about 6” diameter are
called coarse crushers. Intermediate crushers are those that break down these 6”
pieces into still smaller diameters of about ½”. Finally, these crushed material are
made finer, around 0.05 mm what are known as fine crushers or grinders.

This part of the mineral processing operation takes up the most cost and
should therefore be given the attention it deserves.

This section of the course will familiarize the students with the operation
of crushers and grinders which are of laboratory size and will instruct the students in
methods by which the efficiency of crushing can be calculated.

THE JAW CRUSHER(M)

The jaw crusher is the most commonly used equipment for cutting down the
size of an ore to a size suitable for further grinding. Since most of the minerals
contained in an ore do not occur as liberated particles, this part of mineral processing
plays an important role in liberating the minerals, making them more easily recovered
by concentration methods.

The Jaw Crusher consists of two crusher plates set nearly vertically, one
fixed and the other movable. There are essentially two types of jaw crusher, the Blake
type and the Dodge type, classified according to the point of minimum amplitude of
motion on the moving face and according to the way in which the motion of the
movable faces is transmitted.

Objective: This experiment aims to familiarize the student with the operation of a
laboratory sized jaw crusher.

Materials and Equipment: Set of sieves; jaw crusher, ore consisting of at least 4”
top size, aluminum pans, balance, broom.

Procedure:

1. Clean the crusher area thoroughly with a broom.

2. Adjust the movable jaw of the crusher so that the final product size is at least ½”.

3. Take the screen analysis of the feed sample, by finding the 80% passing size of the
original feed material.

4. Place enough ore feed and collect the product in an aluminum tray.
 43

5. If the product size passes through ½”, continue the crushing until the entire
sample has been processed.

6. Take the 80% passing size of the final product.

GUIDE FOR DISCUSSIONS:

1. Calculate the reduction ratio obtained.

2. Differentiate a Blake crusher from a Dodge crusher. What

type of crusher was used for our purposes?

3. What are the factors which may affect the size of the
product?

4. Taggart gives the empirical formula for calculating the

capacity of crushers as:

T = 0.6LS

T = tonnage capacity
L = the length of the receiving opening, in.
S = the width of the discharge opening, in.

Calculate the tonnage capacity of the crusher used.

THE CONE CRUSHER (O)

The cone crusher consists of a fixed crushing surface in the form of a fulcrum
of an inverted cone around the axis of which revolves a movable crushing surface in
the shape of an upright cone. The outside crushing surface flares in from top to
bottom to provide an increased are of discharge for the crushed material.

This crusher is built in three types, the suspended spindle type, the supported
spindle type and the fixed spindle type. This is usually recognized from the equipment
model where a K indicates a suspended spindle type and a D indicates the supported
one. Fixed spindles are relatively new and therefore carries only the size in its model
number.

Objective: The experiment aims to familiarize the students with the use of the cone
crushers.
 44

Materials and Equipment: Set of sieves, cone crusher, ore consisting of at least 4”
top size, aluminum pans, balance, broom.

Procedure:

1. Clean the area of the crusher thoroughly with a broom.

2. Weigh out the sample to be used for the experiment.

3. Run a screen analysis and take the 80% passing size.

4. Proceed as in experiment 4, taking care not to put in too much ore to prevent
choking. In case of blockages, use a stick to push the sample through. Be very
careful not to get your hands in between the plates.

5. Run a screen analysis on the product and take the 80% passing size.

GUIDE FOR DISCUSSIONS:

1. What are the factors which may affect the size of the product?

2. Compare the products from a jaw crusher and a cone crusher.

3. What reduction ratio was achieved using this method?

4. Why is it necessary to use cone crushers in closed circuit with screens?

 45

BOND WORK INDEX (O)

The Bond Work Index of a material is a measure of its hardness or its

resistance to crushing or grinding. This is sometimes referred to as the Hardgrove
Grindability Index based on the design of the rod mill being used.

Objective: The experiment aims to familiarize the students with the procedure for the
determination of the Bond Work Index of a given ore.

Materials and Equipment: 8” x 10” Ball Mill; balance; Splitter; set of sieves;
graduated cylinder, mechanical counter

Procedure:

A. Sample Preparation

a. Prepare sample to -6 meshes by stage crushing and grinding. Use

coning and quartering or the Jones Splitter to obtain a representative
sample.

b. Determine the screen analysis of the sample, and then obtain the 80%
passing size. Also determine the bulk density in grams per liter by
packing sample in 1000 ml graduated cylinder, and then taking the
equivalent weight.
c. Take the weight of 700 ml of sample in the mill. Grind at 250%
circulating load. Calculate the IPP (Intended Product Passing or Ideal
Potential Product) for 250% circulating load.

IPP(grams) = [ Wt. of material charge / 3.5]

B. Grinding

a. The grinding charge consists of 191 steel balls weighing 20,125 grams.
The ball combinations are: 43 – 1.45 “ ø balls, 67 – 1.17 “ ø balls, 10 –
1.0 “ ø balls, and 71 – 0.75 “ ø balls. The calculated surface area is 842
in2.

b. Place the material charge and the balls in the mill. Run x revolutions,
where x can be 50, 100, 150, and 200 but usually 100 (no. of
revolution based on estimate of work index). ** Be sure that the ball
mill and steel balls are thoroughly clean before starting the experiment.
To do this, place a small amount of the ore in the mill and run for about
five or ten minutes, and then throw out this material.

c. Dump the mill charge onto a large pan. Separate the balls from the
material charge. Screen all the materials at the mesh of grind assigned
to your group with coarser protective screens, e.g. if -48 mesh is
 46

assigned to your group, weigh product minus or passing 48 mesh.

Mesh of grind (MOG) is the optimum grind at which valuable minerals
are liberated from one another.

Product = weight of material charge – weight of screen oversize

Net Product = Product – the weight of undersize in the feed.
Net grams per revolution = (Net product)/ (No. of revolutions)

d. Add more feed to screen oversize (circulating load) to bring up to

original weight of material charge using the segregated samples and
taking into consideration the original fraction of each particle size.

Example:

Wt. of product undersize = 349.19

Wt. of new feed = 349.19 (.2288) = 79.89
= 349.19 (.1983) =
69.24
= 349.19 (.1357) = 47.38
= 349.19 (.0719) = 25.11
= 349.19 (.0785) =
27.41 = 349.19 (.0442)
= 15.43 = 349.19
(.0446) = 15.57
= 349.19 (.0366) = 12.78
= 349.19 (.0269) = 9.39
= 349.19 (.1343) = 46.90
--------
349.19

e. Calculate the no. of revolutions for the next period.

IPP – weight undersize in feed
No. of revolutions = -------------------------------------------------
Net product / revolutions from previous period

f. Repeat steps 2 to 5 until circulating load equilibrates at 250% ± 2 %.

g. Carry out the screen analysis on the final product and plot the results in
the manner similar to the one used for the feed. From the plot, find the
80% passing size of the product. Repeat the grindability test to obtain
the equilibrium grindability values at the number of other sizes such as
35, 60, 80, and 100 mesh. An alternative method shown in the sample
computations.

C. Sample Computation

Bulk Density : 1637.38 gm / ml

Material Charge : 1146.17 gm
 47

IPP Material Charge : 327.48 gm

Sieve Size Tested : 210 microns (65 mesh)

FEED
Mesh Aperture Wt., gm % wt. % wt. % wt.
size, µm Retained retained passing cum
cum
6 3360 0.00 0.00 0.00 100.00
8 2380 112.4 22.88 22.88 77.12
10 1680 97.41 19.83 42.71 57.29
14 1198 66.68 13.57 56.28 43.72
20 821 35.34 7.19 63.74 36.53
28 599 38.58 7.85 71.32 28.68
35 420 21.71 4.42 75.74 24.26
48 297 21.92 4.46 80.20 19.80
65 210 17.97 3.66 83.86 16.14
100 149 13.23 2.69 86.55 13.45
-100 65.97 13.43 100.00 0.00

P80 = 153.38 mm

Period Wt. of Wt. of No. Wt. of Wt. of Net wt. Net wt. %
new u’size of products product of of Circulating
feed new mill o’size u’size product product load
feed revs. u’size u’size
per mill
rev.
1 1146.17 184.99 100 796.98 349.19 164.20 1.64 228.24
2 349.19 56.36 165 781.84 364.33 307.97 1.87 214.60
3 364.33 58.80 144 769.33 376.84 318.04 2.21 204.15
4 376.84 60.82 121 826.77 320.06 259.24 2.14 258.11
5 320.06 51.66 129 824.50 321.67 270.01 2.09 256.32
6 321.67 51.92 132 820.50 325.67 273.75 2.07 251.94

circulating load = wt. of product o’size x 100

wt. of product u’size

grindability = 2.08 gm /rev.

PRODUCT
Mesh Aperture Wt., gm % wt. % wt. % wt.
size, µm retained retained passing cum
cum
 48

65 210 0.00 0.00 0.00 100.00

100 149 71.68 22.01 22.01 77.99
150 105 74.85 22.98 44.99 55.01
200 74 60.82 18.68 63.67 36.33
-200 118.32 36.33 100 0.00
325.67

F80 = 2498.68 mm
Work Index = 13

GUIDE FOR DISCUSSIONS:

1. What is the importance of determining the work index?

2. What is circulating load? What is the usual range of circulating load in closed
circuit grinding?

3. What are the advantages and disadvantages of increasing the circulating load in
closed circuit grinding?

4. Explain how the rod mill grindability test is performed?

5. Can you determine the grindability index using wet grinding? Why?

6. Calculate the Work Index of the ore by using the following formula:

4.45
W = ───────────────
Pi0.22 G 0.82 ( 1/ P1/2 – 1/ F1/2)

W is the work index, Pi the MOG in microns, G the grindability in gms / rev, P the
product size and the F the feed size in microns, both at 80% passing size.

MESH-OF-GRIND DETERMINATION

The mesh-of-grind of a material is the grinding time at which 80% of the

material passes its set liberation size. The liberation size of the sample is the size at
which most of the minerals are found free from each other. This size is usually found
in the lower levels of a sieve, e.g. 150 mesh or finer. For experimentation purposes,
the liberation size of the sample will be set at 200 mesh.

Objective: This experiment aims to familiarize the student with the operation of a
ball mill and to help the student become adept in testing for the mesh-of-grind of a
sample.
 49

Materials and Equipment: crushed and sampled ore; balance, timer, rod mill or ball
mill, steel balls of varied sizes, 200 mesh sieve, aluminum pans, drying oven, vacuum
filter, old newspapers.

Procedure:

1) Prepare a sample by crushing it to at least -20 mesh size using either a jaw crusher
or the cone crusher. Take a representative sample using any of the techniques you
have just learned.

2) Place the sample in a ball mill or a rod mill, adding the necessary amount of balls
or rods to assure a 250% circulating load. (Refer to the discussion on circulating
loads in the previous experiment).

3) Using the timer let the mill run for 5 minutes.

4) Take a grab sample of the mill product and screen from 20 mesh through 400
mesh. Plot the size analysis and take the 80% passing size. Combine the sized
samples and place back in the mill.

5) Repeat step 4, increasing the time in increments of 5 minutes and taking grab
samples until almost the entire material pass through at least 325 mesh.

6) Plot the 80% passing size versus time. Extrapolate the time needed for grinding
the material to result in an 80% passing size of 104 microns.

GUIDE FOR DISCUSSIONS:

1. Discuss the nature of the grinding action taking place inside the ball mill.

2. Differentiate a ball mill from a rod mil in terms of not only the physico-
mechanical properties but also on energy consumption, grinding action, operating
details, etc.

3. Predict the nature of the product when the balls are used as grinding media for a
rod mill. Explain your prediction.

SAMPLE CALCULATIONS

Calculation of Charge Volume:

The charge volume refers to the level of the feed inside a ball or rod mill, and
is generally expressed as a percentage of volume within liners filled with grinding
media. This is measured by taking the diameter of the mill (D) and the distance from
 50

the top of the mill to the top of the charge (H).The percentage loading can be
calculated:

H
%L = 113 – 126 ───
D

At 50% loading, the maximum power draw is obtained. However, it has been
observed that with an increase in loading from 45% to 50% only a 1% increase in
power draw is noticeable. In most cases, therefore, the increase in power consumption
outweights the increase in power draw. As such, mills are normally charged at levels
less than 45%.

Calculation of Motor Size;

We have seen that the power required to grind a material can be calculated
using the equation:

W = 11.15Wi ( 1/ P1/2 – 1/ F1/2)

where W is the power consumption in kwh / MT for wet grinding. This formula,
however, applies only to wet grinding in a closed circuit. For other conditions,
calculate the gross power consumption (G) as follows:
a. Wet grinding, open circuit, product top size limited: G = W to 1.25W
b. Dry grinding, closed circuit: G = 1.30W
c. Dry grinding, open circuit, product top size not limited: G = 1.30W
d. Dry grinding, open circuit, product top size limited: G = 1.30W to 2.0W.
e. Fro P less than 80% passing 70 microns:

W (P + 10.3)
G = ──────────
1.145 P

Example: A dry grinding ball mill in closed circuit is to be fed 100 metric tons / hr. of
a material with a Work Index of 15 and a size distribution of 80% passing 0.8 cm. The
required product size is 80% passing 60 microns. If the feed is to be prepared in a
cone crusher, what is the power required for this?

Solution: Calculate W from the equation:

1 1
W = 11.15(15) ── - ──── = 19.74 kwh / MT
601/2 80001/2

Then calculate G for dry grinding, closed circuit, with P grater than 70 µ
 51

1.3 * 19.74 (60 + 10.3)

G = ─────────────────── = 26.26 kwh / MT
1.145 * 60

Therefore the power rate of new feed is: 26.26 x 100 = 2.626 kw

Calculation of Mill size to Match Required Power

The calculated power is the power that must be applied to the mill drive in
order to grind the tonnage of feed from one size distribution to a finer size
distribution. The size of the mill required to draw this power can be calculated as the
following. The power input required to maintain the condition in the figure shown is
theoretically calculated as:

MC sin α (2 π n )
Pinput = ────────────
12,400

where M = weight of charge in Metric Tons

C = distance of center of gravity of charge from the center of mill in
meters
α = dynamic angle of repose of the charge
n = mill speed in rpm

For more detailed computations, refer to S. K. Jain, Ore Processing, pp 134 -141.
52