Department of Materials and Metallurgical Engineering, FTI-ITS

(1)

Sungging PintowantoroDepartment of Materials and Metallurgical

Engineering,Faculty of Industrial Technology (FTI),

Sepuluh Nopember Institute of Technology Surabaya (ITS), Kampus ITS, Keputih Sukolilo, Surabaya 60111,

Telp/Fax : 031-5997026

Teknologi Pengolahan Material

Department of Materials and Metallurgical Engineering, FTI-ITS

(2)

Department of Materials and Metallurgical Engineering, FTI-ITS

(3)

PETA PERSEBARAN SDA INDONESIA

Department of Materials and Metallurgical Engineering, FTI-ITS

(4)

PETA PERSEBARAN SDA INDONESIA

Mineral Processing OverviewMineral Processing Overview Mineral Processing Mineral Processing

Terminology, EconomicsTerminology, Economics

Comminution and ClassificationComminution and Classification

Physical processing methodsPhysical processing methods

Chemical processing methodsChemical processing methods

Waste products Waste products treatment and treatment and disposaldisposal

Process plant Process plant flow sheets: flow sheets: uranium and potashuranium and potash

Importance of Mineral ProcessingImportance of Mineral Processing

““No substance has been as important as metal in the No substance has been as important as metal in the story of man's control of his environment. Advances story of man's control of his environment. Advances in agriculture, warfare, transport, even cookery are in agriculture, warfare, transport, even cookery are impossible without metal. So is the entire Industrial impossible without metal. So is the entire Industrial

Revolution, from steam to electricity.”Revolution, from steam to electricity.”

Read more: Read more: http://www.historyworld.net/wrldhis/PlainTextHistories.asp?historyid=ab16#ixzz13XSEyvNz

Importance of Mineral ProcessingImportance of Mineral Processing

Bronze Age- Bronze is in use in Bronze Age- Bronze is in use in Sumer, at Ur, in around 2800 Sumer, at Ur, in around 2800 BCBC

Iron Age - from the 11th century BC - from the 11th century BC onwards, steel replaces bronze onwards, steel replaces bronze weapons. It becomes essential, from weapons. It becomes essential, from now on, to have a good steel blade now on, to have a good steel blade rather than a soft and indifferent one.rather than a soft and indifferent one.

Lecture 8

Mineral Processing Overview:

Geology-Mining-Processing Relationship

Mineral Processing Terms Definitions

Mineral Economics review

Project Stages

Lecture 9

Comminution & classification circuits

Comminution Methods Principles Crushing Grinding

Classification Methods Principles Hydrocyclone Screening

Assignment

Lecture # 10

Physical Processing MethodsGravityMagneticElectrostaticRadiometricFroth FlotationSolid/liquid separation

Assignment

Lecture 11Lecture 11

Chemical ProcessingBasic CircuitsLeachingSolvent ExtractionPrecipitationDrying

Downstream – Purified ProductElectrowinningSmelting

Assignment

Lecture #12Lecture #12

Waste Stream Management:

Tailings DisposalSurfaceUnderground

Effluent TreatmentChemical PrecipitationMembrane Technology

Assignment

Lecture # 13 Lecture # 13

Saskatchewan Mill Saskatchewan Mill Process FlowsheetsProcess Flowsheets

UraniumUranium

PotashPotash

AssignmentAssignment

Geology – Mining – Processing

•All 3 aspects must be favorable to make a deposit economically viable

• Geology: Find it. Is it big enough to be economic?•Mining: Dig it. Is it economically recoverable from the ground?•Processing: Extract it. Is it economically separable from the host rock?

Prevalence of mineral processing

In Saskatchewan as of 2009 there were: 3 uranium mills8 potash mine/mills1 gold mine/mill coal mines (thermal)Salt mineAn identified diamond deposit (Fort a la Corne)An identified rare earth element deposit (Hoidas

Lake)

Prevalence of mineral processingPrevalence of mineral processing

Mining is all around us! In Alberta there are:

Oil sands process plants (uses mining and mineral processing techniques)

Coal plants Industrial minerals (limestone) Nickel/cobalt metallurgical complex

In Manitoba there are: Many copper/zinc mines and mills, feeding the Flin Flon

metallurgical complex Nickel mines nearby Thompson smelter

In the Northwest Territories there are: 3 operating diamond mines Gold mines

Scope of mineral

processing

Definitions

Economics

Project Stages

Introduction to Mineral Introduction to Mineral ProcessingProcessing

Mining Terminology - Mining Terminology - Review Review

Miners send their products to their customer – the mill. Ore : Rock that contains a mineral or minerals in sufficient

quantities as to make commercial extraction (mining – milling) profitable.

Grade : A measure of concentration of a mineral/metal contained in rock (or ore). Gold and other precious metals – g/t or oz/t, base metals - %, uranium – kg/tonne, rare earth elements – ppm…

Cut off Grade : The minimum concentration or grade of mineral that is required for rock to be considered ore.

Waste : Not Ore. Ore Body: A mineralized deposit (resource) whose

characteristics have been examined and found to be commercially viable. The extents of the ore body are determined by the cut-off grade.

Host Rock: The rock containing an ore deposit. Typically composed of 2 or more minerals.

Gangue: Minerals in the ore body that are not of economic interest

Mineral ProcessingMineral Processing

Is the recovery of valuable minerals from oreIs the recovery of valuable minerals from ore

Takes place in a mill, aka concentrator - because it Takes place in a mill, aka concentrator - because it concentrates valuable minerals by removing unwanted concentrates valuable minerals by removing unwanted material. material.

The two main products are the concentrate streams The two main products are the concentrate streams (valuable minerals) and the tailings streams (rejects).(valuable minerals) and the tailings streams (rejects).

Disciplines related to mineral processingDisciplines related to mineral processing

Fields of Metallurgical EngineeringFields of Metallurgical EngineeringField

Description Example of topics

Mineral Processing

Beneficiation or Mineral Dressing

Theory and practice of liberation of minerals from ores and their separation by physical methods at ambient conditions

Crushing and grinding, magnetic and electrical methods, flotation, etc.

Extractive metallurgy

Chemical methods sometimes at high temperature and pressure for treating ores to recover their metal values in a pure form

Leaching, precipitation, electrolysis, oxidation, reduction, etc.

Metal Processing

Physical metallurgy

Study of physical properties of metals and alloys, preparation of alloys

Crystal structure, effect of impurities, metallography, heat treatment, etc.

Engineering metallurgyProcessing of metals in the molten state

Casting, welding, etc.

Mechanical metallurgyProcessing of metals in the solid state

Forging, rolling, extrusion, piercing

Powder metallurgyProcessing of metal powders into finished products

Preparation of metals in powder form, hot pressing, etc.

Engineering Terminology in Engineering Terminology in Mineral ProcessingMineral Processing

Circuit:Circuit: The path that the ore that is being The path that the ore that is being processed takes as it proceeds from one processed takes as it proceeds from one processing point to another.processing point to another.

Flow SheetFlow Sheet - Drawing that indicates the - Drawing that indicates the path that the mineral takes within a path that the mineral takes within a process. Several circuits are often process. Several circuits are often contained within a flow sheetcontained within a flow sheet

RecoveryRecovery Rate Rate – The percentage of – The percentage of valuable metal/mineral, by mass, in the valuable metal/mineral, by mass, in the concentrate from the feed concentrate from the feed

Mineral ProcessingMineral Processing

The goals of mineral processing are to:The goals of mineral processing are to:

separate economic mineral particles from separate economic mineral particles from waste or ganguewaste or gangue

subject minerals to processes in order to subject minerals to processes in order to concentrate them or to extract metals from concentrate them or to extract metals from themthem

Many forms of mineral processing

Depends on feed material and desired product

Mineral Processing Mineral Processing Terminology Terminology

Concentration:Concentration: Another word for grade Another word for grade Heads:Heads: A term that is used to denote the mineral A term that is used to denote the mineral

found in the FEED to a circuit.found in the FEED to a circuit. Head Grade:Head Grade: aka feed concentration aka feed concentration Concentrate:Concentrate: a purified mineral. May require a purified mineral. May require

further downstream processing to convert for end further downstream processing to convert for end uses. Examples: Copper and nickel sulfidesuses. Examples: Copper and nickel sulfides

TailingsTailings - Material rejected from a mill - Material rejected from a mill after the recoverable valuable minerals after the recoverable valuable minerals have been extracted.have been extracted.

Industrial mineral:Industrial mineral: is used for end purpose is used for end purpose without chemical alteration. Examples: gravel, coalwithout chemical alteration. Examples: gravel, coal

Mineralogy: Mineralogy: Description of mineral contentsDescription of mineral contents

What is mineral processing?What is mineral processing?

Mineral: Mineral:

a)a)A solid naturally-occurring compound having A solid naturally-occurring compound having a definite chemical composition.a definite chemical composition.

b) b) Inorganic substance that are extracted from Inorganic substance that are extracted from the earth for use by man. the earth for use by man.

c) A naturally occurring inorganic element or c) A naturally occurring inorganic element or compound having an orderly internal structure compound having an orderly internal structure and characteristic chemical composition, and characteristic chemical composition, crystal form, and physical properties.crystal form, and physical properties.

Mineral classificationMineral classification

Nonmetallic processing has some commonalities with metal processing, but lots of differences

Examples of mineralsExamples of minerals

Examples of mineralsExamples of minerals

Mineralogy determines recoverability

Impact of mineralogyImpact of mineralogy

We mine rocks but we concentrate minerals.

Gangue minerals also important

Understanding mineralogy allows design of processes

Important for feasibility studies

What is mineral processing?What is mineral processing?

Processing – Processing –

Extract values, reject wasteExtract values, reject waste

Conversion of mined ore into usable productConversion of mined ore into usable product

More expensive/challenging with lower More expensive/challenging with lower grade oresgrade ores

Numerous processing methodsNumerous processing methods

Mineral Processing Methods = Mineral Processing Methods = beneficiation + extractive metallurgybeneficiation + extractive metallurgy

Beneficiation aka Mineral DressingOverlap of physical and chemical methods, depending on productWhere extractive metallurgy leaves off, metal processing begins

Mineral Processing Mineral Processing Terminology Terminology

BeneficiationBeneficiation: : enrichment of ores and separation of unwanted enrichment of ores and separation of unwanted gangue mineralsgangue minerals

subsequent metals extraction more efficient. subsequent metals extraction more efficient. Can be divided into two distinct steps:Can be divided into two distinct steps: LiberationLiberation: the rock is broken down by mechanical means, : the rock is broken down by mechanical means,

mineral components become independent of each other, mineral components become independent of each other, detached detached SeparationSeparation: valuable minerals are separated by : valuable minerals are separated by means of physical and physico-chemical methods making means of physical and physico-chemical methods making use of differences in specific gravity, magnetic properties, use of differences in specific gravity, magnetic properties, etc.etc.

Extractive metallurgyExtractive metallurgy:: Chemical reactions of the processes Chemical reactions of the processes equipment where reactions take placeequipment where reactions take place Flowsheets – combinations of processesFlowsheets – combinations of processes

Typical Beneficiation Typical Beneficiation StepsSteps

Beneficiation Terminology Beneficiation Terminology

Comminution:Comminution: Reduction of particle size Reduction of particle size

Starts at mine with blastingStarts at mine with blasting

Two basic types of equipment used:Two basic types of equipment used:

Crushing – breakage by compressionCrushing – breakage by compression

Grinding – breakage by abrasion and Grinding – breakage by abrasion and impactimpact

Shaft

Comminution EquipmentComminution Equipment

Shaft

Comminution EquipmentComminution Equipment

Beneficiation Terminology Beneficiation Terminology

ClassificationClassification : Separation based mainly on : Separation based mainly on particle sizeparticle size

Behavior affected by size, shape, and Behavior affected by size, shape, and density of the particlesdensity of the particles

Two common types of classifiers:Two common types of classifiers:

Screens – dry method, coarser particlesScreens – dry method, coarser particles

Hydrocyclones – wet method, finer Hydrocyclones – wet method, finer particlesparticles

Classification EquipmentClassification Equipment

Beneficiation Terminology Beneficiation Terminology

Separation Techniques Separation Techniques take advantage of the take advantage of the

differences in characteristics between mineralsdifferences in characteristics between minerals::Flotation: Flotation: Attachment of minerals to air Attachment of minerals to air

bubbles - hydrophibicitybubbles - hydrophibicityMagnetic Separation: Magnetic Separation: Apply magnetic Apply magnetic

fieldfieldGravity Separation:Gravity Separation: differences in specific differences in specific

gravity of materialsgravity of materials

Electrostatic Separation:Electrostatic Separation: Apply Apply electrostatic polarityelectrostatic polarity

Particle size distribution has large influence on Particle size distribution has large influence on resultsresults

Separation EquipmentSeparation Equipment

Flotation cellFlotation cell

Separation EquipmentSeparation Equipment

Magnetic Magnetic separatorseparator

Separation EquipmentSeparation Equipment

Gravity separation - jigGravity separation - jig

Separation EquipmentSeparation Equipment

Electrostatic Electrostatic separatorseparator

Beneficiation Terminology Beneficiation Terminology

Dewatering:Dewatering: To remove water from a substance. To remove water from a substance. Also refers to the circuit where this takes place. Also refers to the circuit where this takes place.

Dewatering Techniques:Dewatering Techniques:Thickener: Thickener: Allow gravity settlingAllow gravity settlingFilter: Filter: Apply air pressure to draw water Apply air pressure to draw water

outoutCentrifuge: Centrifuge: Apply centrifugal forceApply centrifugal forceDryer: Dryer: Apply heat to evaporateApply heat to evaporate

Slurry Density:Slurry Density: The amount of solids in a slurry, The amount of solids in a slurry, expressed as a percentage by weight.expressed as a percentage by weight.

Dewatering EquipmentDewatering Equipment

ThickenerThickener

Dewatering EquipmentDewatering Equipment

Disc filterDisc filter

Dewatering EquipmentDewatering Equipment

Rotary kiln dryerRotary kiln dryer

Beneficiation Terminology Beneficiation Terminology

Waste Disposal - Waste Disposal - "Mining is waste management ..." "Mining is waste management ..." The majority of tonnage mined must be disposed of The majority of tonnage mined must be disposed of

as tailingsas tailings Water used must be treated and released Water used must be treated and released

Tailings Dam:Tailings Dam: Built from ground waste rock discharged after Built from ground waste rock discharged after processing from the mill processing from the mill

Acid Mine Drainage: Acid Mine Drainage: produced by exposing sulfide minerals to produced by exposing sulfide minerals to air and water, resulting in oxidation that generates acid.air and water, resulting in oxidation that generates acid.

Waste Rock: Waste Rock: Unprocessed non-mineralized / low grade Unprocessed non-mineralized / low grade mined materialmined material

Water Balance: Water Balance: Accounting of water inputs and outputs Accounting of water inputs and outputs from a mine/mill site.from a mine/mill site.

Water Treatment:Water Treatment: The removal of harmful contaminants from The removal of harmful contaminants from waterwater

Waste DisposalWaste Disposal

Tailings DamTailings Dam

Waste DisposalWaste Disposal Waste Rock PileWaste Rock Pile

Waste DisposalWaste Disposal Acid Mine DrainageAcid Mine Drainage

Waste DisposalWaste Disposal

Water BalanceWater Balance

Mineral Processing Methods = Mineral Processing Methods = beneficiation + extractive metallurgybeneficiation + extractive metallurgy

Beneficiation aka Mineral DressingOverlap of physical and chemical methods, depending on productWhere extractive metallurgy leaves off, metal processing begins

Extractive Metallurgy Extractive Metallurgy Terminology Terminology

HydrometallurgyHydrometallurgy Leaching - the process of extracting a soluble Leaching - the process of extracting a soluble

constituent from a solid by means of a (water based) constituent from a solid by means of a (water based) solventsolvent

• Water changes solubility, by making it acidic or basic, oxidizing or reducing

Solvent Extraction – transfer between immiscible Solvent Extraction – transfer between immiscible fluidsfluids

Ion Exchange – solid resins that adsorb/desorb Ion Exchange – solid resins that adsorb/desorb dissolved chemical speciesdissolved chemical species

Precipitation – convert dissolved into solidPrecipitation – convert dissolved into solid• Crystallization via evaporation• Ionic precipitation - addition of a reagent to a

solution creates a metal compound whose solubility is so low that precipitation takes place immediately

Hydrometallurgy EquipmentHydrometallurgy Equipment

Tank leach circuitTank leach circuit

Hydrometallurgy EquipmentHydrometallurgy Equipment

Solvent extraction mixer-settlersSolvent extraction mixer-settlers

Hydrometallurgy EquipmentHydrometallurgy Equipment

Ion ExchangeIon Exchange

Hydrometallurgy EquipmentHydrometallurgy Equipment

Vacuum Vacuum crystallizercrystallizer

Extractive Metallurgy Extractive Metallurgy Terminology Terminology

Pyrometallurgy – use of heat to induce a Pyrometallurgy – use of heat to induce a chemical transformationchemical transformation

Roasting – convert to oxide form. Roasting – convert to oxide form. Example: 2 CuS2 + 5 O2 → 2 CuO + 4 Example: 2 CuS2 + 5 O2 → 2 CuO + 4 SO2SO2

Smelting - uses reducing substances Smelting - uses reducing substances that will combine with those oxidized that will combine with those oxidized elements to free the metal. Example: elements to free the metal. Example: 2 Fe2O3 + 3 C → 4 Fe + 3 CO2 2 Fe2O3 + 3 C → 4 Fe + 3 CO2

Pyrometallurgy EquipmentPyrometallurgy Equipment

SmelterSmelter

Extractive Metallurgy Extractive Metallurgy Terminology Terminology

Electrometallurgy – use of electrical Electrometallurgy – use of electrical energy to induce a chemical energy to induce a chemical transformationtransformation

Electrowinning – to precipitate a metal Electrowinning – to precipitate a metal from solution using electric potentialfrom solution using electric potential

Electrorefining – to purify a metal by Electrorefining – to purify a metal by dissolving it, then re-precipitating it dissolving it, then re-precipitating it

Electrometallurgy EquipmentElectrometallurgy Equipment

Alternating anodes and cathodes in a Alternating anodes and cathodes in a tankhouse for electrowinningtankhouse for electrowinning

Flowsheet examplesFlowsheet examples

Aluminum:Aluminum: from bauxitefrom bauxite

Copper:Copper: from chalcopyritefrom chalcopyrite

Iron:Iron: from hematitefrom hematite

GoldGold – – Placer, sulphide and oxide Placer, sulphide and oxide

Oil SandsOil Sands – – Fort McMurrayFort McMurray

AluminumAluminum

CopperCopper

IronIron

GoldGold

Oil SandsOil Sands

Mineral Processing Mineral Processing Recovery Recovery

Recovery : Recovery : Potential for loss every step of the way, Potential for loss every step of the way, in each circuit!in each circuit!

Tonnage vs. Recovery: Tonnage vs. Recovery: A processing circuit pushed A processing circuit pushed beyond its capacity will induce recovery lossbeyond its capacity will induce recovery loss

Feed Grade vs. Recovery Feed Grade vs. Recovery : : A higher feed grade tends A higher feed grade tends to have higher processing recoveryto have higher processing recovery

Concentrate Grade vs. Recovery: Concentrate Grade vs. Recovery: A higher A higher concentrate grade tends to result in lower processing concentrate grade tends to result in lower processing recovery (= rejection of lower quality minerals to recovery (= rejection of lower quality minerals to tailings)tailings)

Concentrate Grade vs. Price:Concentrate Grade vs. Price: A higher quality A higher quality concentrate will fetch a higher price (have lower concentrate will fetch a higher price (have lower impurity penalties) impurity penalties)

Revenue = Production (tonnes) x grade x recovery Revenue = Production (tonnes) x grade x recovery x pricex price

Milling Operating CostsMilling Operating Costs

Typical relative cost of beneficiating an ore

Operation%

Crushing 5 - 20

Grinding 25 - 75

Flotation 25 -45

Dewatering and drying

10 -20

Other operations 5 - 10