041018 mineral processing nimal he 1
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INTRODUCTION TO MINERAL PROCESSING
Dr. Nimal Subasinghe
Senior Lecturer in Mineral ProcessingMurdoch University
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Mineral production worth $17 billion in 2000Mineral production worth $17 billion in 2000--2020
(Agriculture $4.4 billion(Agriculture $4.4 billion
nnWA a worldWA a world--rankedrankedproducer ofproducer of – –
-- AluminaAlumina 20%20%
-- Iron oreIron ore 14%14%-- NickelNickel 14%14%
-- RutileRutile 38%38%
-- TantalumTantalum 25%25%-- ZirconZircon 32%32%
-- DiamondsDiamonds 38%38%
-- GoldGold 8%8%
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Where do metallurgists fit in
mining industry?• Exploration and discovery -
Geologists.
• Mine Planning & Mining operations -Mining engineers and mine geologists.
• Ore-to-metal Process Development -
Extractive metallurgists.
• Financial specialists - Construction andcapital expenditure; sale of product.
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Metallurgists add value to mineral
resources
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Extractive metallurgy is
about processing ores to …• Liberate and concentrate valuable
minerals.
• Chemically break down minerals textract and refine contained metal
Extractive metallurgy bridge
science and engineering
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Ore-to-metal path involves -
• Mineralogical studies
• Mineral processing
• Metal extraction & refining
- Pyrometallurgy
- Hydrometallurgy
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Ore-to-metal
Mineralogy
Pentlandite
(Ni,Fe)(Ni,Fe)99SS88
Chalcopyrite
CuFeSCuFeS22
Pyrrhotite ~~ FeSFeS
PyriteFeSFeS22Ore Ore
grade grade 3% Ni 3% Ni
Ore Minerals
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STAGES IN MINERAL PROCESSING
RUN-OF MINE
MATERIAL
COMMINUTION (MINERAL LIBERATION)
SEPARATION PROCESSES
(CONCENTRATION)
PRODUCT HANDLING
PROCESS
CONTROL
CONCENTRATE
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Mineral Liberation
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Comminution Circuits
Primary
Crushing
Secondary
Crushing
Screening /
Classification
Jaw Crushers
Gyratory Crushers
Cone Crushers
Hammer mills
Grinding Rod mills, Ball
mills
SAG
milling
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Schematic Diagram of a Gyratory Crusher
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Schematic Diagram of a Ball mill
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Separation Processes
GravityConcentration
Hydro-
metallurgy
CIP/CIL
Electrowinning
Solvent Extraction
Dense medium Vessels
Dense Medium Cyclones
Jigs
Spirals
Reichert Cones
Wilfley TablesSluices
Knudson Bowls
Knelson Concentrators
SurfaceProperties
Froth Flotation
Pyro-
Metallurgy
Smelting
Electostatic
separation
Conductivity
Magnetic
Magnetic
separators
Coloursortin
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FROTH FLOTATION
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Schematic diagram of flotation machines
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Ore-to-metal
Metal extraction - Hydro
Hydrometallurgical processes involve -
• Leaching – aqueous, acid, alkaline.
• Solid-liquid separation - filtration.
• Concentration – ion exchange, solvent
extraction.
• Metal recovery – precipitation, electro-winning, metal reduction.
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Ore-to-metal
Metal extraction - Pyro
• Pyrometallurgy - high-temperaturereactions on concentrate.
• Removal of S (as SO2) and Fe inslag.
• Melt cools as metal-rich matte.
• Ni matte comprises Ni-Fe alloy andminor sulphide phases.
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Ore-to-metal
Pouring Ni matte
WMC photoMatte Grade ~ 70% Ni.Matte Grade ~ 70% Ni.
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What metallurgists do …
• At mines - control mineral processingplants, manage waste, safety.
• In labs – evaluate ores, develop new
processes, computer modelling.
• Design and commission new processingplants.
• Manage operations, people, companies.
• Research and development work.
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What you will study - Yrs 2-4
Chemistry
Mineralogy
Mineral ProcessingHydrometallurgy
Pyrometallurgy
Process control
Process design
Research Project
Other units in …
Maths and Statistics
Engineering units
Computer modelling
Financial management
Environment
Challenges for 21st century
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Challenges for 21st centurymetallurgists …
• Find ways to -- process more-complex ores
- treat lower grade ores
- extract more metal from ores- reduce pollution
- rehabilitate waste dumps
- improve energy efficiency- reduce costs.
• Maximise economic benefit to Australiain a competitive global market.
S i th t
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Some companies thatemploys mets …
Many graduates
ki