Mineral Processing Technology: A Concise Introduction

Description

Mineral processing technology is a branch of applied science that deals with the principles and practice of separating useful minerals from primary solid ore mineral resources obtained from the earth crust. This book introduces science and technology of processing solid minerals to concentrates of grades suitable for industrial extraction of metal values and other non-metallic products. It also includes case studies, typical process flowsheets, aspects on processing of tailings arising from mineral processing plants, worked examples, and practice questions. Features: Includes science and technology of processing solid minerals to concentrates of grades, suitable for industrial extraction of metal values and other non-metallic products.Provides a logical progression from basic to advanced concepts in mineral processing.Designed to stimulate students to think as mineral processing engineers in training.Explores sustainable mineral processing and circular economy in mineral processing.Contains worked examples that clearly illustrates the various theories presented and help readers develop problem solving skills in mineral processing. This book is aimed at professionals and senior undergraduate students in metallurgy and mineral processing. Cover Half Title Title Copyright Dedication Contents About the Author Preface Chapter 1 General Introduction 1.1 Introduction 1.2 Locations of Minerals 1.3 Mineral Deposits 1.4 Categories of Solid Minerals 1.5 Chemical States of Mineral Occurrence 1.5.1 Oxides 1.5.2 Sulphides 1.5.3 Carbonates 1.5.4 Arsenides 1.5.5 Native Noble Metals 1.6 The Purpose of Mineral Processing 1.7 Geological Exploration 1.8 The Earth’s Core and Ore Mineral Formation 1.9 Formation of Accessible Ore Deposits 1.10 Mechanisms of Accessible Ore Deposit Formation 1.11 Formation of Ore Deposits 1.12 Igneous Deposits 1.12.1 Magmatic Deposits 1.12.2 Segregations 1.12.3 Disseminations 1.12.4 Magmatic Injections 1.13 Specific Ore Formations 1.13.1 Gold Nuggets Formation 1.13.2 Formation of Spinel Group of Minerals 1.13.3 Magmatic Mineral Deposit by Crystal Settling 1.13.4 Ore Formation from Magmas by Liquid Immiscibility 1.13.5 Pegmatite Deposits 1.13.6 Hydrothermal Deposits 1.13.7 Marine Hydrothermal Deposits 1.13.8 Sedimentary Deposits 1.13.8.1 Weathering 1.13.8.2 Sedimentary Genesis 1.13.8.3 Placer Deposits 1.13.9 Metamorphic Deposits 1.14 Ore Formation Mechanisms that Involve Oxidation State in Water 1.15 Spread of Solid Minerals in Nigeria 1.15.1 The Benue Trough of Nigeria 1.15.2 Sedimentary Rock Iron Deposits 1.15.3 The Minor Sedimentary Basin 1.15.4 Magmatic Ore Deposits 1.15.5 The Metamorphic Rock Deposits 1.15.6 The Carbonate Province 1.15.7 Coastal Deposits 1.15.8 Erosion Deposits 1.16 Notable Mineral Resources of Africa 1.17 Notable Mineral Resources of the United States 1.18 Notable Ore Deposits of India 1.19 Notable Ore Deposits in Canada 1.20 Introduction to Ore Processing References Chapter 2 Ore Handling 2.1 Introduction 2.2 Harmful Materials Separation from Ore 2.2.1 Steel Scrap 2.2.2 Wood 2.2.3 Clays and Slimes 2.3 Transportation of Ore 2.3.1 The Challenge of Ore Transport in the Plant 2.4 Ore Storage 2.5 Ore Feeding 2.6 Ore Handling in the Laboratory 2.6.1 Ground Survey 2.7 Laboratory Sample Preparation 2.7.1 Jones Riffle Splitter 2.7.2 Coning and Quartering 2.7.3 Application of Gy Sampling Theory 2.8 Determination of Moisture Content 2.8.1 The Karl­Fischer Titration Method 2.8.2 Drying Oven Method 2.8.3 Microwave Oven Drying 2.8.4 Inline Methods 2.8.5 Determination of Loss on Ignition 2.9 Ore Roasting References Chapter 3 Ore Crushing 3.1 Introduction 3.2 Primary Crushers 3.2.1 Jaw Crushers 3.2.2 Blake Jaw Crusher 3.2.3 Jaw Crushers Feeding 3.3 Gyratory Crusher 3.4 Secondary Crushers 3.4.1 Roll Crusher 3.4.2 Cone Crusher 3.4.3 Impact Crusher 3.4.4 Hammer Mills 3.5 High Pressure Grinding Rolls (HPGR) 3.6 Horizontal Shaft Impact (HSI) Crusher 3.7 Vertical Shaft Impact (VSI) Crusher References Chapter 4 Ore Grinding 4.1 Introduction 4.2 Comparison of Crushing and Grinding 4.3 The Concept of Correct Grinding 4.4 Mechanisms of Grinding in Tumbling Mills 4.5 The Motion of the Charge in a Tumbling Mill 4.6 Type of Tumbling Mills 4.6.1 Rod Mills 4.6.2 Ball Mills 4.7 Stirred Mills 4.8 Autogenous (AG) and Semi­autogenous (SAG) Mills 4.9 Pebble Mill 4.10 Development of Milling Curves 4.11 Open and Closed Circuit Grinding References Chapter 5 Theory of Comminution 5.1 Introduction 5.2 The Theory and Principles of Comminution 5.3 Comminution Theory 5.4 Crack Propagation in Minerals 5.5 Worked Examples References Chapter 6 Particle Size Analysis 6.1 Introduction 6.2 Importance of Particle Size Analysis in Mineral Processing 6.3 Particle Size and Shape 6.4 Methods of Particle Size Analysis 6.4.1 Method of Test Sieving 6.4.2 Test Sieving Procedure 6.4.3 Presentation of Results 6.4.4 Construction of Test Sieve Graphs 6.4.5 Deductions from the Curves 6.5 Determination of Stokes’ Equivalent Diameter 6.6 Dynamic Image Analysis 6.7 Laser Diffraction 6.8 Determination of Particle Shape and Size References Chapter 7 Ore Mineralogy and Chemical Analyses 7.1 Ore Mineralogy 7.2 Transmitted Light Microscope 7.2.1 Color 7.2.2 Pleochroism 7.2.3 Habit 7.2.4 Cleavage 7.3 Reflected Light Microscope 7.4 Thin Section Transmitted Light Experiment 7.5 Ore Chemical Analyses 7.5.1 Inductively Coupled Plasma and Atomic Absorption Spectroscopy (ICP & AAS) 7.5.2 X­ray Fluorescence and X­ray Diffraction Techniques 7.5.3 Electron Probe Microanalysis (EPMA) 7.5.4 Scanning Electron Microscope (SEM) 7.5.5 Transmission Electron Microscope 7.5.6 Mass Spectrometry 7.6 Visible and Infrared Spectroscopy References Chapter 8 Ore Screening 8.1 Introduction 8.2 Main Purposes of Industrial Screening 8.3 Screen Performance 8.4 Efficiency or Partition Curve or Tromp Curve 8.5 Screen Types 8.6 Grizzly Screens 8.7 Industrial Screening References Chapter 9 Ore Classification 9.1 Introduction 9.2 The Principles of Classification 9.3 Settling of Ore Particles in Carrier Fluids 9.3.1 Conditions for Particles Settling 9.3.2 The Forces Acting on a Particle 9.4 Conditions for Equal Settling Rate of Particles 9.4.1 Free Settling Conditions 9.4.2 Hindered Settling Conditions 9.5 Worked Examples 9.6 Types of Classifiers 9.6.1 Hydraulic Classifier 9.6.2 Hydrocyclone 9.7 The d50 Cut Point 9.8 Worked Example References Chapter 10 Metallurgical Accounting Analyses 10.1 Slurry Streams Analysis 10.2 Determination of Volumetric Flow Rate of Slurry 10.3 The Composition of a Slurry 10.4 Worked Examples 10.5 Mass Balancing Methods 10.6 Slurry Pump Calculations References Chapter 11 Mineral Processing Methods 11.1 Introduction 11.2 Gravity Concentration Methods 11.2.1 Introduction 11.2.2 Advantages of Gravity Methods 11.2.3 Principles of Gravity Separation 11.3 Factors that Affect Gravity Concentration’s Efficiency 11.3.1 Density of Ore Minerals 11.3.2 Ore Particle Size 11.3.3 Slimes 11.3.4 Correct Water Ratio 11.3.5 Presence of Sulphide Minerals 11.3.6 The Presence of Useful Valuable Contaminants 11.4 Gravity Concentrators 11.4.1 Jigging: Gravity Separation 11.4.2 The Jigging Process 11.4.3 Shaking Tabling 11.4.4 Humphrey Spiral 11.4.5 Falcon Gravity Concentrator 11.5 Knelson Gravity Concentrator 11.6 Industrial Spiral Concentration References Chapter 12 Dense Medium Separation 12.1 Introduction 12.2 The Principles of Dense Medium Separation 12.3 Types of Heavy Liquids 12.3.1 Dense Organic Liquid Chemicals 12.3.2 Dense Inorganic Aqueous Solution 12.3.3 Suspensions of Ore Particles in Water 12.4 Coal Sink and Float Test 12.5 Dense Medium Industrial Separation 12.6 Liquid Mixing Equation References Chapter 13 Froth Flotation 13.1 Introduction 13.2 The General Principle of Froth Flotation 13.3 Collectors 13.4 The Operating Technique 13.5 The Flotation Stages 13.5.1 Roughing 13.5.2 Cleaning 13.5.3 Scavenging 13.6 The Science of Flotation 13.7 Theory of Flotation 13.8 Polar and Non­polar Minerals 13.9 Grease Tabling of Diamond 13.10 Polar Minerals 13.11 Frothers, Activators and Depressants 13.12 Mechanisms of Froth Flotation 13.13 Column Flotation 13.14 Flotation Conditioning 13.14.1 Air Control 13.14.2 Level Control 13.14.3 Feed Rate 13.14.4 Overdosing of Reagents 13.14.5 Procedure for Laboratory Froth Flotation Test 13.15 Typical Laboratory­scale Froth Flotation Tests 13.16 Pilot-scale Froth Flotation Test References Chapter 14 Magnetic Separation 14.1 Introduction 14.2 Principles of Magnetism 14.3 Type of Materials Based on Magnetism 14.3.1 Ferromagnetic Materials 14.3.2 Paramagnetic Materials 14.3.3 Diamagnetic Materials 14.4 Principle of Magnetic Separation 14.5 Categories of Magnetic Separators 14.6 Design in Magnetic Separation 14.7 Wet Drum Magnetic Separation 14.8 Operation of a Wet High­intensity Magnetic Separator (WHIMS) 14.9 A Laboratory Bench WHIMS Practice 14.10 Wet Magnetic Separation with BOXMAG Rapid Equipment 14.11 Permanent Drum Magnetic Separator 14.12 Low­intensity Magnetic Separator (LIMS) 14.13 Laboratory­scale Magnetic Concentration of Ores 14.14 Pilot­scale Magnetic Concentration of Ores 14.15 Magnetizing Roasting Experiment 14.16 Electrostatic Separation References Chapter 15 Ore Sorting 15.1 Introduction 15.2 The Principles of Electronic Sorting 15.3 Mechanism of Operation 15.4 Types of Ore Sorters 15.5 The Model 16 Photometric Sorter 15.6 The Belt Sorter 15.7 Industrial Ore Sorting References Chapter 16 Dewatering and Tailings Disposal 16.1 Introduction 16.2 Filtration 16.3 Sedimentation 16.4 Thermal Drying 16.5 The Principles and Operation of a Thickener 16.6 Coagulation and Flocculation 16.7 Tailings Disposal 16.8 Laboratory Testing for Thickener Design 16.9 Industrial Thickener 16.10 Talmadge and Fitch Method 16.11 Worked Example References Chapter 17 Automatic Control in Mineral Processing Plants 17.1 Introduction 17.2 Principles of Automatic Control 17.3 Identification of Process Variables 17.4 Process Modeling 17.5 In­line Instrumentation 17.6 Overall Control Architecture 17.6.1 Control Objectives 17.7 General Control Scheme 17.8 In­line Instrumentation for Automatic Control in Mineral Processing Plants 17.8.1 A Mass Flow Meter 17.8.2 The Magnetic Flow Meter 17.8.3 Ultrasonic Flow Meter 17.8.4 Nucleonic Density Gauge 17.8.5 Non­nuclear Density Gauge 17.8.6 On­line Chemical Analysis References Chapter 18 Introduction to Flowsheets Design 18.1 Introduction 18.2 Quantified Flow Data Derivation 18.2.1 Worked Example References Chapter 19 Assessment of Metallurgical Efficiency of Mineral Processing Operations 19.1 Parameters to Assess the Quality of Concentrates 19.1.1 Grade or Assay of the Concentrate 19.1.2 Recovery 19.1.3 Ratio of Concentration (R) 19.1.4 The Enrichment Ratio (RC) 19.2 Relationship between Recovery and Grade 19.3 Metallurgical Efficiency of Separation Processes 19.4 The Schulz Separation Efficiency 19.5 Worked Examples 19.6 The Net Smelter Return (NSR) Curve 19.7 Practical Factors that Affect Metallurgical Efficiency 19.7.1 Liberation of Mineral Value 19.7.2 Particle Size References Chapter 20 Sustainable Mineral Processing 20.1 Introduction 20.2 Approaches for Sustainable Mineral Processing 20.2.1 The Application of Improved Ore Comminution 20.2.2 Improved Ore Processing 20.2.3 The Geometallurgy Approach 20.3 Analytical Methods for Geometallurgy 20.3.1 The Transmitted Light Microscope 20.3.2 Description of Minerals in Thin Sections in Plane­polarized Light 20.3.3 Description of Minerals in Thin Sections in Cross­polar Light 20.3.4 The Reflecting Microscope 20.3.5 Rietveld Analysis 20.3.6 Quantitative Evaluation of Minerals by Scanning Electron Microscopy (QEMSCAN) 20.3.7 Mineral Liberation Analysis (MLA) 20.3.8 Scanning Electron Microscopy (SEM) 20.3.9 Sustainable Circularity in Mineral Processing References Chapter 21 Processing of Rare Earth Minerals 21.1 Introduction 21.2 Beneficiation Methods for REE Minerals 21.3 Pyrometallurgy and Hydrometallurgy in REE Processing 21.4 Hydrometallurgy 21.4.1 Leaching of Eudialyte 21.5 Secondary Resources of REEs 21.6 Supercritical Fluids Applications 21.7 Recovery of REEs from Coal Resources References Chapter 22 Applications of Leaching and Microorganisms in Mineral Processing 22.1 Introduction 22.2 Application of Microorganisms References Chapter 23 Tailings Re-treatment 23.1 Introduction 23.2 Approaches for Tailings Re­treatment 23.2.1 Industry Re­treatment of Tailings 23.2.2 Retreatment through Heap Leaching 23.2.3 Tailings Re­concentration 23.2.4 Microbial Treatment and Leaching Technology 23.2.5 Tailings Dewatering Process 23.2.6 Filling of the Mined­out Areas 23.3 Tailings Sand Cement Filling Technology 23.4 Water Consolidation Sand Filling Technology 23.4.1 Production of Geo­polymers References Chapter 24 Mineral Processing of Beach Sand Minerals 24.1 Introduction 24.2 Processing of Beach Ores References Chapter 25 Processing of Battery Minerals 25.1 Introduction 25.2 Beneficiation Methods 25.2.1 Beneficiation of Nickel Ores 25.3 Leaching Recovery of Cobalt and Nickel 25.4 Processing of a Nickel­copper Sulphide Ore 25.4.1 Flotation Concentration 25.4.2 Roasting 25.4.3 Leaching and Solution Recovery 25.4.4 Copper Solvent Extraction 25.4.5 Processing of Lithium Ores References Chapter 26 Processing of Refractory Ores 26.1 Introduction 26.2 Pre­treatment Methods References Chapter 27 Processing of Non-metallic Ores 27.1 Introduction 27.2 Geochemical Classification of Minerals 27.3 Classes of Non­metallic Minerals 27.3.1 Chemical Raw Material 27.3.2 Metallurgical Raw Materials 27.3.3 Construction Non­metallic Materials 27.3.4 Non­metallic Ore Raw Materials 27.4 Processing of Non­metallic Minerals 27.4.1 Processing of Phosphate Ores 27.4.2 Processing of Diamond Ores 27.4.3 Tar Sands 27.4.4 Processing of Fluorite Ores References Chapter 28 The Operation of a Quarry 28.1 Introduction 28.2 Mining the Rocks 28.3 Crushing the Rocks 28.4 Storage 28.5 Environmental Protection 28.6 Aggregates References Index