mining & mineral refining
Post on 29-Dec-2021
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Slide 1 / 241
Mining & Mineral Refining Field Instrumentation Solutions
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 2 / 241
Your robust and reliable choice for the Mining industry
Offering cost reduction solutions
- to save energy and raw material
- to reduce downtime
- to reduce maintenance
Environmental protection using e.g. pH analysis systems
for emission reduction and process water treatment
Wireless solutions optimizing bulk storage and supply
processes
Increasing productivity and quality
Maintenance reduced to a minimum due to equipment
with non contact or no moving parts
Time and cost saving due to uniform operating
philosophy
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Demographic Change
Need for Energy
Need for Water
MEGATRENDS influencing Primaries
Environmental protection
Slide 3
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Mass balance of Energy and Raw Materials Getting more from your ore boosts the value of your company
Global Trend
Worldwide demand for resources such as crude oil, coal,
natural gas, water, iron ore and copper is rising, driven by
population growth and greater purchasing power. Resources
are limited and extraction is getting more expensive. Efficient
and effective use of resources is an overriding challenge for
future growth.
See comments from leading Metals and mining companies
Arcelor Mittal and BHP Billiton
SOURCE :
http://www.sika.com/en/group/sustainability/megatrends/energy_and_raw_materials.html
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Urbanization and industrialization driving current and future Chinese commodity demand
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Rising urbanization in developing countries Comment from Arcelor Mittal
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Mass balance of Energy and Raw Materials Getting more from your ore boosts the value of your company
There are still vast reserves of most resources to explore, but they
are becoming more and more expensive to mine and unearth.
The stock market value of a company is not only linked to current
and future reserves and output (exploration & production) but also
to the valuation of precious metals caught up in the individual
processes.
Internal process auditing (metal accounting)
and optimization increase stock values and has
become an economic necessity.
SOURCE :
http://www.amira.com.au/
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Groupcon 2011 Primaries & Metal
Primaries & Metal industry segments Customers in EVERY country have common topics
SAVING of ENERGY
W.A.G.E.S & PRIMARY FUEL
as well as
RAW MATERIAL
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Mass balance of Energy and Raw Materials Getting more from your ore boosts the value of your company
Worldwide demand for resources such as crude oil, coal, natural gas,
water, iron ore and copper is rising, driven by population growth
and greater purchasing power. Resources are limited and extraction
is getting more expensive. Efficient and effective use of resources is
an overriding challenge for future growth.
Production levels cannot cope with demand. There are still vast
reserves of most resources to explore, but they are becoming more
and more expensive to mine and unearth. The stock market value of
a company is not only linked to current and future reserves and
output (exploration & production) but also to the valuation of precious
metals caught up in the individual processes. Internal process auditing
and optimization has become an economic necessity.
Rising energy and raw material prices in Europe and USA have
propelled investment in energy and resource efficiency and renewable
energy technologies like wind and solar power.
http://www.amira.com.au/
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Summary of trends in Primaries & Metal The driving forces behind process automation
Process optimization taking safety aspects into account e.g. Mine ventilation or cooling water leakage detection e.g LDS solutions
Urban Mining - a new term which stands for the re-use of urban waste in order to extract useful materials.
Manufacturing, Optimization, use of alternative fuels and raw material (AFR) – e.g. bunker fuel oil flow and stock value
Waste Heat Recovery Power Generation
Environmental protection e.g. - emission reduction with SNCR treatment for exhaust gas or methane monitoring in coal plant e.g. Clean Development Mechanism (CDM) - process and waste water treatment
Optimizing bulk and liquid storage and supply processes based on Inventory Management
Wireless sensors are anticipated to continue to make inroads in a number of end-user applications
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 11 / 241
Measurement Technology by process
Click blue for an application example
Product proven in use for this application
Click green for utilities examples
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 12 / 241
Endress+Hauser products & services
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 13 / 241
Typical field instruments in mining processes
Free space
Level radar
Ceraphire®
Pressure
Guages
Guided
Microwave
Level
Ultrasonic
Level
Temperature transmitters
Gas flow
meters
Slurry flow meters
Web servers/
Wireless
Gateways
Heavy duty level
switches
Density Sensors
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Environmental protection
Wastewater treatment and disinfection
• Sludge levels
• Chlorine control
• Suspended solids
Effluent analysis + water sampling
• TOC
• BOD
• Static or portable
Heavy metals analysis
• Copper
• Iron
• Aluminium
• Chromate
• ….
Sensors, panels, stations
or containers
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 15 / 241
Open System integration/Field Communication
W@M
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 16 / 241
Common Mining Processes
W@M
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 17 / 241
Typical Mining Processes
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Barrick Gold Operations Dominican Republic
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Xstrata Nickel– Falcando operations Dominican Republic
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
E+H & Xstrata Process Support Current Position
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 21 / 241
Mining and Minerals Processing Automation solutions
Recovery
• Flotation
• Gravity separation
• Magnetic separation
Materials Handling
• Loading
• Conveying
• Stocking
• Pumping
• Filtering
• De-watering
• Waste/overburden handling
• Drying/Pyro processing
Rock Size Reduction
• Drilling
• Blasting
• Crushing
• Screening
• Grinding
• Cyclones
®
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 22 / 241
Crushing, Grinding & Screening
Extraction & Ore storage
Flotation & Thickening
Roasting & Autoclaving
Smelting
Refining
Environmental Issues
Common Mining Processes
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 23 / 241
Slurry pumping with a Promag S Meter
Problem
Pumps cavitate or dry run if drills are not working efficiently
Drill speed & pump rate optimized against slurry volume output
Medium : Bentonite slurry and stones
Features
Soft rubber pipe liner, Screw in wire brush electrodes
4-20mA slurry volume output to pump or drill drives
Benefits
Pumps and drills speed up or slow down in direct proportion to their output
Instrument Insensitive to high slurry solids content (even for large stones) and abrasive media
Brush electrodes give 50% longer life in abrasive media
Measurement in slurries with 30% solids
Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Leach pad design
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Heap Leaching Measurement considerations
Pregnant solution production
rate analysis
Acid consumption & metering
and pipe line distribution / time
Leakage detection of leachate
collection pipes
Pressure monitoring of under
floor airlines - agitation
Level control of ore heaps
(7-10 meters) during stacking
and reclaiming
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 26 / 241
Mobile leaching pipeline stations Sulphuric acid leach control
Monitoring of pressure and flow in a leaching field
Location of station in the field after 150 day leach cycle
Wireless network
44 Adapters SWA70 non-Ex and 2 Fieldgates SWG70 (prototypes), i.e.
2 networks with about 22 adapters each
All adapters are arranged in one line
Budget USD 75.000 for wireless;
in addition SC-US sold site survey
and installation
Installation: Week 4/2009
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 27 / 241
Mobile leaching pipeline stations Sulphuric acid leach control
2 WirelessHART
networks along line
One of the network nodes with
2 adapters:
one for flow, one for pressure
6000 feet
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 28 / 241
Wireless Monitors Mobile Operations
Benefits to the customer
• The use of robust wireless field network
reduces costs in implementation and
relocation
• The availability of reliable flow and
pressure information allows leach field
operators to optimize operation resulting
in a ROI of about 2 months
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 31 / 241
Stockpile inventory monitoring Ore storage, stacking and reclaiming
Problem
Planning your ore deliveries & extraction process against real ROM inventory levels
Features
Sensors range from 5m to 80m
Volumetric stock pile calculations based on 10 level readings possible
Remote stock visualization with FieldGate® and P View software package
Benefits
Accurate monitoring and delivery of raw material inventory
Makes ore delivery to process plant smoother e.g. no stock outs
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 32 / 241
Bulk Logistics optimization Fieldgate® data access via ethernet, telephone lines or GSM
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 33 / 241
Typical Mining Process Copper, Nickel, Zinc, Gold…
W@M
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 34 / 241
Typical Gold Mining Process Circuits
Crushing & Milling /
Grinding
Acidulation
Autoclaving
Neutralization
CIL Carbon in leach circuit
Carbon strip circuit
Refinery
W@M
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 35 / 241
Crushing, Grinding & Screening
Extraction & Ore storage
Flotation & Thickening
Roasting & Autoclaving
Smelting
Refining
Environmental Issues
Common Mining Processes Key Stages
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 36 / 241
Milling & Crushing circuits
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 37 / 241
Common crusher units include :
Vertical shaft impactors (Impact)
Hammer (shear + attrition)
Gyratories and cone crushers (compression + attrition)
Jaw crushers (compression)
Mobile plant
Crushing circuit process
Mechanical reduction methods
Impact
Attrition
Shear
Compression
Metso crushers
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 38 / 241
Key Crushing, screen & feed requirements
Considerations in crusher circuit design
What is the crusher power demand per ton per hour of crushed product?
What is its capacity? Optimum speeds of belt feeders? Screen size?
Will it accept the largest input size expected?
How much supervision of the unit is necessary?
Typical problems in a crusher circuit
Feed hopper over fill and chute choking and plugging
Material characteristic change e.g. bulk density, moisture, temperature, hardness
Crusher circuit optimization e.g. re-circulating load measurement
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 39 / 241
Crushing and screening controls
Overfill control
in feed bins Emergency Blockage
microwave detector
High level indicator
Surge pocket minimum
volume, 2 truck loads
Low level indicator
Blockage detection
of Grizzlies or screens
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 40 / 241
FMU 90 Continuous Ultrasonic Controller
Features and benefits
1 / 2 & 10 level sensor input (10 from April 2005)
6 Relays give you 6 freely programmable alarms
Rugged Field or compact panel mount options
24VDc version for mounting on mobile crushers
IP66 (NEMA4X) housing means no dust or water ingress
3 DIN rail sizes means “ready to fit” in crusher control panels
Prosonic S crusher level control package Rock solid around the clock
FDU 90 Series Level Sensors
Features and Benefits
Extremely tough IP68/NEMA6P sensor housing
ATEX Dust approved (ATEX II 2G; 1/2D, FM, CSA)
Level
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 41 / 241
Application
The level in the crusher feed bowl is measured using an
ultrasonic sensor
The continuous level value is transmitted via the 4-20mA
output to the Variable Speed Drive on the feeder
The crusher feeder slows down or speeds up the feed to the
crusher.
A second sensor measures levels on the feeder under the
crusher to detect blockages
Automation of the Crusher feeder Using a level control to optimize crusher feed
TOP TIP ! Make your process visible.
Use bright backlit RIA displays for
added safety
Level
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 42 / 241
Ultrasonic Measurement in Primary Crusher
Unloading into primary crusher
Bright RIA 141 Field Display
FDU sensor plus Prosonic S
transmitter
Level
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 43 / 241
Ultrasonic Measurement in primary crusher
Continuous level measurement
Non contact
Mounted away from any possibility
of mechanical damage.
Correct alignment to product
surface
Sun cover to protect sensor from
the elements
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 44 / 241
Primary crusher in the quarry (1) level control of feeder
contact free ultrasonic measurement pre-feed
bin of the crusher
reduced crusher liner wear due to better feed control
feed bin over spill protection, no observer necessary
level system can link to a traffic light to automate the
crusher truck loading
electronics can be mounted up to 300m ( 915 ft) away
from the sensor
grain size /surface > 4 mm – 0.16 inches
up to 6 free programmable relays
Rail mount Prosonic S
transmitter with FDU
ultrasonic sensor
Level
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 45 / 241
Primary crusher in the quarry (2) Level control of feed bin
continuous level control with contact free
ultrasonics
reduction in crusher liner wear due to controlled
material feed
identification of material clogging in feed bin
recognition of material bridging in feed bin
(combination of signal “max. level” with “min. current
consumption”)
easy installation on a swinging boom or arm
stone sizes > 4 mm – (0.29”)
ultrasonic measuring unit Prosonic S
with sensor FDU
Level
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 46 / 241
Primary crusher in the quarry (3) Direct level control of Jaw Crushers
Jaw crusher control
Use compact 4 wire Prosonic M unit
which is quicker than 2 wire sensors
Select a remote mount FHX40 display and
electronics to allow programming and
monitoring away from the crush zone
Mount the sensor on a movable arm for
ease of crusher maintenance
Level and low power consumption
= blocked crusher
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 47 / 241
Primary crusher in the quarry (4) Level control of feed bin
control with Prosonic S FDU sensor :
(sensor is protected by a cover plate against flying
stones)
control with Prosonic S FDU sensor :
- sensor is mounted on a mobile arm
for protection against vibration and
ease of access
additional application
Level
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 48 / 241
detection of blockages in the discharge chute of
crusher with contact free radiometric
measurement
protection of crusher in discharge zone avoiding
down times
reduction of energy costs due to efficient
material feed control
no contact with the product thus no wear
independent of grain size and grain surface
high reliability with self checking functionality
retrofit installation possible
Crusher discharge Level control
Gammapilot M with source container and
scintillation sensor Radiometrics
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 49 / 241
Crusher discharge Level control
• Gammapilot with source container and scintillation sensor in
protecting housing replacement with compact Gammapilot M
Flow
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 50 / 241
continuous and contact free measurement of
conveyor loads
measuring of conveyor load to control the
upstream feeders
over spill protection of feed bin
no contact with the product thus no wear
display and electronic unit can be mounted
separately up to 300 m (984 ft) away
Discharge conveyor Material flow control
Prosonic S rail mount integrator with FDU Sensor
Level
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 51 / 241
Discharge belt conveyor Loading control
limit detection with Prosonic T
control of material height on the belt with an
ultrasonic probe
prevents over spill avoiding shut downs
belt load monitoring allows control of the
upstream feeders
no contact with the product so no sensor wear &
tear
simple installation with screw connection
two wire version with 4-20 mA output
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 52 / 241
Secondary crusher (1) Level control of feed bin
Solicap M limit detection switch
over spill detection of crusher feed bowl with
a capacitance probe
reduced energy costs due to controlled constant
material feed (ON/OFF – operation of feeder)
simple mounting means lower installation costs
no calibration required
display and electronics can be mounted
separately
Level
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 53 / 241
Capacitance probe on a lignite coal mining site
Level
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 54 / 241
Capacitance probe at bucket wheel reclaimer Avoid collision with pile
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 55 / 241
Conveyor transfer points Over spill detection
over spill protection of conveyor transfer points
with a capacitance probe
increased safety of operation
reduction in energy costs by preventing
overloading
simple mounting means lower installation costs
no moving parts
display and electronic unit can be mounted
separately
Solicap M sensor
Level
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 56 / 241
Raw material storage Continuous level control
continuous level control of silos with ultrasonics
continuous monitoring ensures uninterrupted
material flow
self cleaning sensor
display and electronics can be mounted
separately up to 300 m (984ft) apart
arrangement with Fieldgate module for remote
transmission of data via Ethernet/Internet,
WLAN, modem or GSM for direct inventory
control
measuring range up to 70 m – (230ft)
Prosonic S wall mount integrator
with FDU sensor and alignment device
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 57 / 241
Blocked chute detectors Soliwave M
Problems
The chute under the impactor blocks and the crusher hammers or liners are damaged
Features
Added safety for primary crushing rigs
Two microwave point level sensors
Integrated SPDT relay or 4-20mA
TOP TIP ! A Prosonic T above
screens & belt transfer
points detects material
blockages
Benefits
No contact with media, outside crushing process
Small compact device requires minimal installation space
Robust yet light weight design
Level
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 58 / 241
Benefits
Raw material density is the quality parameter used to optimize the
speed & temp. of the mills
Mass flow control on conveyor belts Raw material density and load measurement
Top TIP ! Add a speed sensor + Memo Graph S.
You get an alternative to a Multi Idler
Belt Scale. (Kg / Hr )
Features
FMG60 Detector is mounted over the belt near the FMU sensor
The source container is mounted under the conveyer
Combined Density & level on the belt gives the meal bulk density
Add a shear gate and you get a fixed material height on the belt
Radiometrics
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 59 / 241
Typical Grinding and Milling Controls
Types of mine mill
Vertical Ball mills for lime stone
grinding
Autogenous mills (SAG) for milling
stone directly from primary crushers
Conical ball mills for wet grinding
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 60 / 241
Problems
Air, ore and grinder ball mix optimisation
Ore feed to mill speed ratio control
Pressure control of the mill hydraulics
Overheating
Getting optimum material dispersion rates
Solutions
DP measurement across the mill
Pneumatic feeder air flow monitoring
Temperature measurement at outlet
Vertical roller ball mills Common problems
Top Tip : Temperature in
Temperature out
The tough TAF 12T ceramic thermocouple for abrasive
media
Nickel coated stainless steel probe
Utilities
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 61 / 241
Mill air pressure package RMA422, Cerabar T/M/S, RIA displays
Cerabar S
Continuous
Differential pressure
Analogue output 2
Incoming pressure
Analogue output 1
Analogue input 1 Analogue input 2
minimum pressure
Limit switch
Ceraphant T
Switch
Pressure
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 62 / 241
Mill air pressure & temperature package ECOGRAPH T & RIA 141 displays
Cerabar S
Differential pressure
with Deltabar S
Analogue output 2
Incoming pressure
& temperature
Analogue output 1
Analogue input 1 Analogue input 2
3 Limit switches
Ceraphant T
Analogue input 3 Analogue input 4
Omnigrad TC10-15 Omnigrad TAF 11-16
Temperature
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 63 / 241
Problems
Mill outlet Chute or screen plugs or buffer tank overfilling
Solutions
High or low level tank alarms, mill pipe outlet flow detectors
Features
Top, side or angle mounting
Self cleaning forks or single rod
Extended rod or fork up to 4m(12ft) or fork 20m (60ft) on a rope
Overfill & blockage of mill buffer tanks Good Vibrations with a Soliphant Fork or Monorod
Benefits
Buffer bin after the mill with temperatures up to150°C (302°F)
Vibration fork FTM 30 measures grain sizes to 10mm (3/8”).
Sensors not affected by heavy build-up.
No calibration necessary.
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 64 / 241
Application Example
FTE Paddle switches are mounted as high alarms
A Prosonic FMU electronics + FDU sensor provide
a reliable level measurement of the crushed raw slurry
The ultrasonic sensor is mounted using the “easy aimer”
or top target positioner FAU40
Pictures: Lafarge Aluminates, China
Continuous or switch level protection Overfill protection in holding bins with paddle switches
Level
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 65 / 241
Features
High or low level alarm
Grain size up to 50mm (2”), ATEX II 1/3D
Bulk density as low as 100g/l
Compact, extended and cable versions
Benefits
Easy installation through 1¼” process hole
No calibration required
Pictures: Lafarge Aluminates, China
Dry running protection Paddle with the current with a Soliswitch FTE30
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 66 / 241
Mill circuit optimization Promag S Slurry meter
Problems
Optimum mill speed rotation
Application:
Flow meter installed vertically on mill discharge and input.
Line size: 450 mm.
Flow rate: 1300 m3/h. (Velocity 2.2 m/s)
Features
Liner : Natural rubber
Electrodes: 316 SS Brush Electrodes.
Benefits
Long electrode/ liner life
Helps optimize mill efficiency
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 67 / 241
Alluvial Diamond Project mobile recovery + DMS plant
Flow measurement with Promag S
Industry Trend: jet line system with water as a carrier including IPJ (Inline
pressure Jig) and DMS (Dense Medium Separation) with FeSi (Ferrous Silicone)
to make water denser
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 68 / 241
Alluvial Diamond Projects mobile recovery + DMS plant
Pressure measurement with a Cerabar M with ceramic membrane
on an IPJ (Inline pressure Jig)
and at the slurry pump
Pressure
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 69 / 241
Alluvial Diamond Projects mobile recovery + DMS plant
Detection of solids under water
with Soliphant
installed from the side
and from the top
Level
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 70 / 241
Crushing, Grinding & Screening
Extraction & Ore storage
Flotation & Thickening
Roasting & Autoclaving
Smelting
Refining
Environmental Issues
Common Mining Processes Key Stages
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 71 / 241
Flotation
Froth Flotation is a selective process for separating
minerals from gangue by using surfactants and wetting
agents. The flotation process is used for the separation
of a large range of sulfides, carbonates and oxides prior
to further refinement
Other commonly used separation processes include
crystallisation, distillation, electrostatic methods and
gravity separation
The process was first successfully operated on a
commercial scale in Australia in the early 1900’s
Today it is the most widely separation process in the
base and precious metal processes
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 72 / 241
Flotation process
After the ore has been
ground to a fine paste it is
mixed with water and
stirred to form a
homogenous mixture
Upon entering the first
flotation cells the mineral
content of the mixture can
be as low as 1/10th of a
percent
By the time the concentrate
emerges from the flotation
circuit it is 95 percent pure
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 73 / 241
Flotation process
Particles are made Hydrophobic
through the addition of reagents
Air is bubbled through the mixture
Metals attach to the air bubbles and
are floated to the top of the vessel
and are harvested
Gangue settles to the bottom of the
vessel and are discarded
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 74 / 241
Flotation
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 77 / 241
Brush electrodes
and thick natural rubber
lining
Primary slurry in grinding
processes, tunnel digging
machines, dredging
Rocky slurry, grain size
> 0.02 in (0.5 mm)
Typical flow speed over
3…13 ft/s (1…4 m/s)
Extremely high abrasion
resistance due to softness of
the lining and the
electrodes
Linatex avail. as special
Solution for Rocky slurry
sensor robustness for extended
lifetime of measuring point
high signal stability in noisy
application
increased process reliability
increased operational reliability
cost reduction
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 80 / 241
TOP TIP : View tank levels from your PC?
Schedule tank refill orders automatically?
Install FieldGate® and PC Java Applets
Flotation Cell Solutions
Cell Control parameters include :
Level & Interface
Dosing of xanthate frothers
PH
Air Flow
Frothing chemicals “frothers” are made of
glycol and aliphatic alcohols and their waste
should be disposed of responsibly
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Waste treatment and analysis From sensor, to analyser panel to drop in container
Tailor made mobile effluent control
solutions
Analysers for every environmental
concern
Limit value monitoring in mine
wastewater inflow and outflow
River toxicity monitoring
Internal monitoring of wastewater
Monitoring of cooling water and
steam e.g. boilers
Production loss monitoring
Analysis
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 82 / 241
Levels of foam and slurry in flotation tanks Ultrasonics with ball & float system
Prosonic Ultrasonic
sensor measures top level of foam
Metal target & ball float gives level
of the slurry
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Safety first
Picture courtesy of Phil Thwaites of Xstrata XPS, Sudbury, Ontario
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 84 / 241
Levels of foam and slurry in flotation tanks
Mechanical plate & ball solution up close
Top TIP ! Measure injected air
for agitation using a
Prowirl 72 Vortex mass
flow meter
Level
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Xstrata float innovation
The XPSFloat™
Less prone to build up
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Install to maintain
Float and rod should be easy
to remove from the process
Simple remove and clean
installation means sound
measurment
Build up on the rod means
inaccurate measurement
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 87 / 241
Compact ultrasonic sensor Separate instrumentation
Prosonic T Prosonic (S)
Flotation cell level & interface controls
Rio Tinto’s Palabora mine, South Africa
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 88 / 241
Level of slurries with ultrasonic Prosonic S
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 89 / 241
Flotation cells
Slurry level & foam interface measurement
Features:
Prosonic M FMU ultrasonic level device, optional without display
2-Wire, Hart® programmable
Compact IP68 aluminum housing
Benefits:
Simple operation / setup without manual
Excellent 2mm accuracy
Robust non plastic housing
Measures from 25cm (10”) to 15m (50 ft)
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 90 / 241
Dosing of flotation cell flocculants Flow metering with worlds smallest mass meter - CUBEMASS
precise online metering of xanthates with
a coriolis mass flow meter
• Measurment output links digitally to spray head
& dosing controller
• measurement accuracy not affected by pipe
vibrations
• standard industry outputs such as Ethernet,
4-20 mA HART®,PROFIBUS® or Foundation
Fieldbus™
Digital Wall mount
or compact display
& electronics
In line coriolis mass Meter and dosing
panel
Utilities
Slide 91 / 241
BHP Billiton Cannington
Silver & Lead Mine, Queensland Australia
Flotation Cell Project
Slide 91
09.07.2004
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 92 / 241
Cannington Project Charter
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 93 / 241
Flotation Tank control philosophy
Switch room cabinet
PLC rack and ALL I/O
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 94 / 241
Control Panel Segments
PROFIgate
(Ethernet – PROFIbus DP
Link modules / Siemens
Segment couplers
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 95 / 241
Instrumentation setup using E+H PC
Tools & Software
PROFIgate
(Ethernet – PROFIbus DP
Link modules / Segment
couplers
Endress+Hauser Instrument
setup on the ProfiBus network
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 96 / 241
Allen Bradley
PLC 5
SST PROFIbus DP
Scanner
Cannington Flotation Cell PLC System
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 97 / 241
Lead concentrate metering to flotation cells
• Lead Concentrate
• High solids content
• Very abrasive media
• Low conductivity
• Promag 55S Magnetic
Flow Meter
• Natural Rubber lining
• Brush electrode
•
Flow Provides solids content, mass flow
and slurry density when linked to a
radiometric gamma meter
r
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 98 / 241
Valve control using E+H Flow Meters
Flow
Promass 80 Mass Flow
Meter dosing acids and
xanthates
Promag 55S magnetic slurry
meter
Samson 3785 valve
positioners
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 99 / 241
Flow control using a Promass 80 Coriolis Flow Meter
• Remote Promass Flow Meter
Transmitter with display
• Note ProfiBus T box
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 100 / 241
Acid Flow Control to the Flotation Tanks
• Acid valve installation with
Samson 3785 positioner
• Note Profibus T box
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 101 / 241
Profibus instrument network cabling
• T box couplers
• High and safe
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 102 / 241
PH Control in the tanks using the TopClean System
• TopClean pH system with
full PROFIbus integration
• Remote cleaning actuation
• Remote control of measuring
system
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 103 / 241
Level control of foam and slurry in the flotation tanks
using Ultrasonic sensors and ball & float system
• Prosonic T Compact Ultrasonic
sensor measures level of foam
• Metal target for level device
• Ball float in the tank
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 104 / 241
Flotation tank level control up close
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 106 / 241
Dosing of additives for flotation process
Mass flow measurement with Promass A coriolis meter
Flow
Slide 107 / 241
Optimising Tailings Thickener Control Begins with Optimised Process Measurement
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 108 / 241
Thickening
The production of a concentrated slurry from a dilute suspension of
solid particles in a liquid
In practices thickeners are also used to produce clear liquids therefore
clarification is a concurrent process
Both thickening and clarification are outcomes of sedimentation
(mechanical separation)
Thickening can be carried out either batch wise or continuously but
the more common method utilised in industry is continuous
The product produced is either rejected (tailings) or used as an input
for the next stage of processing (concentrate)
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 109 / 241
Thickening control loop
Slide 110 / 241
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 112 / 241
Tailings thickener operation, conventional
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 113 / 241
Tailings thickener operation, conventional
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 114 / 241
Tailings thickener operation, High Compression/ Paste
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 115 / 241
Tailings thickener operation, High Compression/ Paste
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 116 / 241
Time (hrs)
Underf
low
% s
olids
Tailings thickener operation, Control Strategy
Without appropriate sensing technology
With appropriate sensing technology
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 118 / 241
Process Measurement in Tailings Thickeners
PT
LT
LT
PT
DT
FT
FT
DT
AT
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 119 / 241
PT
Process Measurement in Tailings Thickeners Rake torque control with Cerabar pressure sensors
Rake Torque
Hydraulic lift control
Protect damage to drives
Initiate rake lift
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 120 / 241
Process Measurement in Tailings Thickeners
Cerabar PMC51 or 71 Pressure sensor
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 121 / 241
Commodity item YES – Stock item at most vendors
Operating Principle Strain gauge semiconductor bridge
Sizing required YES – Consider pressure peaks
Life cycle maintenance None - if sized correctly
On site calibration None
Vendor assistance Not needed
Process Measurement in Tailings Thickeners
[Pa] P = [N]
[m²] F A
A
F
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 122 / 241
PT
Process Measurement in Tailings Thickeners
Prosonic Ultrasonic level sensor
Rake Torque
To control rake lift and actual rake depth
LT Rake Lift
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 123 / 241
Process Measurement in Tailings Thickeners
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 124 / 241
Process Measurement in Tailings Thickeners
Commodity item YES – Stock item at most vendors
Operating Principle Non contact Ultrasonic
Sizing required No – base entry model is enough
Life cycle maintenance None
On site calibration Zeroing for reference and lift span
Vendor assistance Not needed
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 125 / 241
PT
Process Measurement in Tailings Thickeners
Rake Torque
Position of compressed bed (fluidised bed)
LT Rake Lift
LT Bed Level
Feedback flocculant dosing effect
Early warning for solids carry over to overflow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 126 / 241
Process Measurement in Tailings Thickeners
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 127 / 241
Process Measurement in Tailings Thickeners
Commodity item No – Only specific vendors
Operating Principle Submersible Sonar
Sizing required No – one model cover all ranges
Life cycle maintenance YES – Periodical cleaning
On site calibration YES - In situ, after installation
Vendor assistance YES
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 128 / 241
CUS 70: Rinsing Pump for Sensor cleaning
Option
mounting bracket
pump
sensor
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 129 / 241
Process Measurement in Tailings Thickeners
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 130 / 241
Process Measurement in Tailings Thickeners
Commodity item No – Only specific vendors
Operating Principle Infrared Light Adsorption
Sizing required No – one model cover all ranges
Life cycle maintenance YES – Periodical cleaning
On site calibration YES – In site, After installation
Vendor assistance YES
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 131 / 241
Process Measurement in Tailings Thickeners
Fill the float with 3Kg of bottom slurry
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 132 / 241
Process Measurement in Tailings Thickeners
Commodity item No – Only specific vendors
Operating Principle Electromechanical Displacement
Sizing required No – one model cover all ranges
Life cycle maintenance No
On site calibration YES – Fill sensing body with slurry
Vendor assistance No
Careful Tape cleaning
Microprocessor controlled
with English text menus
Electronically controlled
Powerful motor Tape wipers Separate tape compartment
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 133 / 241
PT
Process Measurement in Tailings Thickeners
Rake Torque
Solids inventory
LT Rake Lift
LT Bed Height
Feed forward to underflow pump PT
Bed Mass
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 134 / 241
Process Measurement in Tailings Thickeners
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 135 / 241
Hot tap insertion with water purge
Process Measurement in Tailings Thickeners
Commodity item No – Special connection required
Operating Principle Ceramic capacitance bridge
Sizing required YES – Consider height and Bed SG
Life cycle maintenance YES – Flushing against blockage
On site calibration No
Vendor assistance No
atmospheric pressure
pressure
substrate
diaphragm
gauge pressure cell
Conventional PT with separate valve
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 136 / 241
PT
Process Measurement in Tailings Thickeners
Rake Torque
Dry solids flow discharge
LT Rake Lift
LT Bed Height
PT
Bed Mass
DT Underflow Density
FT
Volumetric flow
Control underflow slurry pump
Total slurry volume discharge
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 137 / 241
Process Measurement in Tailings Thickeners
Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 138 / 241
Process Measurement in Tailings Thickeners
Commodity item No – Only specific vendors
Operating Principle Nucleonic Gamma Ray Attenuation
Sizing required YES – Vendor to advise
Life cycle maintenance None – Except legislation directives
On site calibration YES – Vendor to advise
Vendor assistance YES
r
µSv/h
mCi
X-ray in Medicare
• Dental 0.01 mSv
• Head 0.1 mSv
• Mammogram 0.5 mSv
• Spinal column 1 mSv
• Stomach 10 mSv
High sensitivity 0,1 µSv/h gamma scintillator detector
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 139 / 241
Process Measurement in Tailings Thickeners
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 140 / 241
Process Measurement in Tailings Thickeners
Commodity item YES – Select liner & electrodes with care
Operating Principle Magnetic Inductive in line flow meter
Sizing required YES – Diameter dependant
Life cycle maintenance None
On site calibration No
Vendor assistance No
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 141 / 241
PT
Process Measurement in Tailings Thickeners
Rake Torque
Dry solids feed
LT Rake Lift
LT Bed Height
PT
Bed Mass
DT Underflow Density
FT
Volumetric flow
Feed forward to flocculant dosing
FT
Volumetric flow
DT Underflow Density
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 142 / 241
PT
Process Measurement in Tailings Thickeners
Rake Torque
Quality assurance of clarified water in ppm
LT Rake Lift
LT Bed Height
PT
Bed Mass
DT Underflow Density
FT
Volumetric flow
Register excess carry over of solids
FT
Volumetric flow
DT Underflow Density
AT Clarity
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 143 / 241
Process Measurement in Tailings Thickeners
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 144 / 241
Process Measurement in Tailings Thickeners
Commodity item No – Certain vendors only
Operating Principle 90 degree scattered infrared light
Sizing required No – Same sensor fits all
Life cycle maintenance Periodical cleaning
On site calibration YES
Vendor assistance YES
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 145 / 241
Process Measurement in Tailings Thickeners
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
John Immelman
Slide 146 / 241
Process Measurement in Tailings Thickeners
PT
LT
LT
PT
DT
FT
FT
DT
AT
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 147 / 241
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 148 / 241
Jindal Steel Vijaynagar Ltd. India Ore sludge package solution
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 149 / 241
Density measurement of ore slurry with a compact Gammapilot M
Abrasive slurry, flowing
with high velocity
Field housing FHX40
with display VU331
Use of NaJ crystal due to
high stability of
+/-0,1%.
Integrated detector and
transmitter plus
source container
Radiometric
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 150 / 241
Slurry measurement at final concentrator
Process Specification:
Fluid: Platinum Slurry, 60%, fine particles
Pressure: 7 bar
Temperature: Ambient
Instrument:
Model: Promag 35S
Size/Lining: DN 300 DIN PN 10
Company: Lonmin Platinum Ref:
Location: Rustenburg, South Africa
PHOTO
Process:
Platinum slurry density measurement
Process problems included :
Slurry has a high settling velocity
Solution:
Vertical installation, as long a straight runs as
possible
Pitfalls to avoid: Don’t forget back pressure!
Key Success Factors:
High accuracy, abrasive resistant liner Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 152 / 241
Density measurement in thickeners and clarifiers pumping the sludge dependent on density/sludge level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 153 / 241
Sludge level in thickening tanks Is the slurry thick enough?
Problem :
Slurry solids content needs to be increased and excess water pumped off to save heating
costs
Solution :
Ultrasonic CUM750 transmitter with CUS70 sensor
Features
Multi channel version for parallel measurement in 4 tanks
Sensor cable run length up to 100m
Temperature to 153°C (307°F)
Benefits
No moving parts
Insensitive to floating sludge
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 154 / 241
Sludge level measurement example East Driefontein Gold Mine
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 155 / 241
Rate control and dosage of flocculent in wet processes
Photos: Ciba Spezialitätenchemie Lampertheim GmbH, Lampertheim
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 156 / 241
Density monitoring in thickeners
Optoelectronic solid content measurement
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 157 / 241
Guided radar measurement in thickeners
Benefits:
Plain language display -time and cost saving due to uniform operating philosophy
Reduced stocking costs by modularity : highest flexibility even for different silo
Pre-calibration of device minimises the effort for set-up: mount and measure
High reliability of rod probe, not influenced by large nozzle or changes in density
Features:
Rod probe modular and exchangeable
Single rod probe with highest sensitivity, no danger of bridge formation
Measuring range up to 4 m (12ft) maximum with rod probe
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 158 / 241
Acidulation circuit control
Slurry thickness & concentration measurement
Problem :
Sludge level Blanket measure
Solution :
CUC101 see SI 026C
Features
Opto-electrical turbidity sensor
Sludge level to 11m
Measuring range 0..12g/l
Accuracy at 1% of measured value
Repeatability 0.5%
2 x 4-20mA output, level and concentration
Benefits
Direct continuous concentration level measurement
Sensor replaceable without re-calibration
Concentration & level for slurry profile evaluation
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 159 / 241
Application :
Sulphuric acid addition to gold slurry.
Level Solution :
FMR 245 radar plus low level silo alarm
Features
suitable for use in a safety instrumented system to SIL2 for
overspill protection according to IEC61511-1
Benefits
2 Wire instruments for easy installation
Non contact level technology
DIN or ANSI flange process connection options for highest
degree of chemical protection
Acidulation circuit control parameters Level in sulphuric acid tanks
TOP TIP : View tank levels from your PC?
Schedule tank refill orders automatically?
Install FieldGate® and PC Java Applets
W@M
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 160 / 241
Acidulation circuit acid control parameters Sulphuric acid concentration of ore slurry
Problem :
Sulphuric acid concentration of the carbonate rich slurry
needs to be measured
Conductivity solution :
Liquiline CM42 with CLS50D PFA Inductive sensor ,
compact field transmitter and built in Pt 100 temperature
sensor
Features
Pre set H2S04 concentration curves
Self monitoring safety function; ageing, moisture ingress, short circuit
Smallest most compact transmitter available
Benefits
Self checking extends the sensor life
Measures concentration and temperature
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 161 / 241
Acidulation circuit flow control parameters
Sulphuric acid mass flow / dosing control
Problems :
Accurate metering of concentrated acids
Application :
Sulphuric Acid Metering
Flow solution :
In Line Promass 80F Coriolis mass flow meter
TOP TIP !
Make your process visible.
Use bright backlit displays
for added safety
Features
Mass flow, temperature and density parameters
Hart®, Profibus PA and FF protocols
Benefits
Three in one measurement solution
High process temperatures to 210°C/410°F
Accurate to 0.15% of flow range, 1000 : 1 turndown
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 162 / 241
Acidulation circuit control parameters From acid surge tanks into the Autoclave circuit
Locations :
Rouyn-Noranda, PQ, Canada
Application :
Mass flow and density control. Gold Slurry 5%
solids, bulk density 2 t/m3, particle size @
50…250 mesh, 40 PSIG, Ambient Temperature.
Flow Solution :
Promass 80F with remote display and transmitter.
Features
Accuracy 0.15% of flow span
Turndown 1000 to 1
Benefits
3 in 1 solution : Mass flow, temperature & density
Compact device means simple installation
Process Temperatures from -60 to +210°C
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 163 / 241
Typical flow sheet mineral separation
continuous level metering in agitator bin 1.2 & 3.0
density metering with pressure differential device in bin 1.2 & 3.0
volume control in transfer piping
plus
level measurement bin 1.0 & 1.1 either with ultrasonic
or limit vibration limit switches
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 164 / 241
Solid-liquid separation by sedimentation
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 165 / 241
Material discharge dependent on sludge density with 2 pressure measurements PMC with flush mounted membrane
Pressure
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 166 / 241
Solid content + differential pressure measurement in thickeners in wet processes
Pressure
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 167 / 241
Optical turbidity measurement for rate control and dosage of flocculent
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 168 / 241
Optical turbidity measurement for rate control and dosage of flocculent
Installation of the sensor CUS 41
in inlet of thickener in pipe filled
with process water
Promag 53H
volumetric flocculent
dosing of Fe3Chlorid
Analytical
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 169 / 241
Flow measurement of water with 50W in closed circuits in wet process
Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 170 / 241
Pressure measurements with Cerabar S und Deltapilot S
Measuring of the conveying
pressure with Cerabar S
PMC 71
Hydrostatic level
measurement in tank with
Deltapilot S DB 50
Pressure
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 171 / 241
for friction bearing lubrication with 4 x Promass F in total
predictive maintenance purpose
in combination with temperature
measurement at bearing
Mass flow measurement of lubricating oil
Installation point
of the mass flow
meter
Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 172 / 241
Recognising solids under water
Soliphant T/M
Both Soliphant families can recognise
solids under water. I.e. they do not
switch when the probe is covered by
liquid but when the probe is covered
by sand or sludge.
Sludge level needs to be recognised in
alumina sedimentation tanks.
Customers can set this in Soliphant M
using the sensitivity.
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 173 / 241
Pressure measurement of lubricating oil
Cerabar S installed at various points using manometer connection
Pressure
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 174 / 241
Crushing, Grinding & Screening
Extraction & Ore storage
Flotation & Thickening
Roasting & Autoclaving
Smelting
Refining
Environmental Issues
Common Mining Processes Key Stages
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Schematic courtesy of Phil Thwaites, Xstrata Sudbury
Roaster automation Promass coriolis meters for slurry handling
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Roaster Feed - Multivariable metering Digital output control with Ethernet
Roaster Feed – Coriolis combined
Mass Flow, temperature and
Density Meter
Four 4” Promass 83F installed, one
on each feed line
Controls mass feed rate and density
to 2 roasters
Measurements required for
regulatory compliance (sulphur
balance) and mass balance
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Promass 83I straight tube coriolis
required due to poor screening of
slurry
Diagnostics with a FieldXpert HHC
Roaster feed preparation Simple Profibus control philosophy + Bluetooth
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 178 / 241
Refractory Ore Processing Autoclaving circuits, pressure oxidisation
Sulphide Ore slurry is oxidized at
high pressure and temperatures
Important parameters in the
oxidation of refractory gold ores
under oxygen pressure are the
fineness of grinding; the pressure,
temperature, density and pH of the
slurry in the autoclave; and the
total retention time.
autoclave at Barrick's Goldstrike Plant, USA
Radiometrics
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 179 / 241
Refractory Ore Processing Acid Matte Copper Leaching Process
TOP TIP ! Always make a backup?
Install a MEMOGRAPH S
Secure your process data.
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 180 / 241
Refractory Ore Processing Copper leaching process description
Locations :
Murrin Murrin Nickel Cobalt Plant Leonora, Australia
Application :
The PAL area receives slurried feed, heats it to 225oC
and mixes it with hot concentrated sulphuric acid
inside four titanium-lined autoclaves.
Nickel and cobalt are leached into solution.
Precipitated iron and aluminum tailings are washed
and stored in the tailings dam.
The autoclaves discharge leached slurry to the counter-
current decantation (CCD) washing area, where it is
mixed with flush-steam heated water, producing a
clear solution of nickel and cobalt in preparation for
hydrogen sulphide precipitation of mixed nickel/cobalt
Process circuit :
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 181 / 241
Level measurement in the autoclave Radiometric measurement with Gammapilot M
Application
Level measurement and limit detection
in flush tanks in autoclaves
Features
Functional safety to IEC 61508 (SIL2)
Level, interface or density functionality
Hart®, Profibus PA & FF output protocols
Benefits
Non-invasive measurement through
the tank wall and thick brick lining
High temperatures and high pressure
have no influence on measurement
Thick brick
lining
Detector
Murrin Murrin / Australia
Source
container
Radiometrics
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 182 / 241
Gammapilot M Product line Radiometric level and density transmitter
Radiometric system components :
Source
Source container
Compact transmitter / detector
Remote display
More details:
Radiometrics
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 183 / 241
Autoclave & Neutralization circuits Oxygen or air metering package
Application
Air is pumped in the circuit tanks to speed up the lime
acid mixing
Flow solution
Promass 80 Coriolis Mass Flow Meter
Features
Mass flow and temperature measurement
Benefits
Quick on-site setup via a plain language display
- time and cost saving due to uniform operating
philosophy
Compact multivariable device may reduce the number of
measuring points
Maintenance reduced to a minimum due to no moving
parts
Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 184 / 241
Oxygen or air control Differential pressure transmitter used for gas flow measurement
• Deltatop is an all in one device,
differential pressure transmitter,
valve block and orifice plate in one
order code!
Endress+Hauser
is the second biggest supplier of
pressure transmitters world-wide.
Measuring ranges from
0.5 mbar to 400 bar
• Absolute, relative or differential
pressure, all available with Hart as
standard, Profibus PA or Fieldbus
Foundation as option. Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 185 / 241
Deltatop / Deltaset
• Deltatop = compact device • Deltaset = modular solution
Without impulse pipes With impulse pipes
from DN 10 to DN 2000
Complete pre-mounted measuring unit
Optimized and ready to be installed
Flow measurement with differential pressure
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 186 / 241
Deltatop / Deltaset Pressure flow kits just for the mine
• Complete solution for every measuring point
• Pitot tubes from DN 50 to DN 12000
• Quick commissioning with the new Quick Setup
menu
• Diagnostics functions
• Orifice plate versions from DN 10 to DN 1000
• Functional safety up to SIL 2
• Customized pre-mounting and configuration
Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 187 / 241
Deltatop
Tough flow kits for the mine environment
Flow
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 188 / 241
Deltaset In mine waste water recycling
Electrically
heated
Deltaset Pitot tube DN 800
with heated
impulse piping
Flow measurement in a bio filter
chimney
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 189 / 241
Steam recycling from the autoclave Mass flow of steam with Deltatop
Steam calculation is done via
energy manager
Software specific for steam
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 190 / 241
Energy Manager RMC 621 Compact solution for steam in the autoclave circuit
Error handling (I)
DP measurement in RMS 621 according to DIN EN ISO 5167-1
Online calculation of all parameters of the flow equation
Discharge coefficient
Velocity of approach factor
Expansion coefficient
Input signals
DP
Temperature
Pressure
Utilities
Mining overview
Extraction & Ore
storage
Crushing, Grinding
& Screening
Flotation
Roasting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 191 / 241
Neutralization Circuit Process overview
The slurry on discharge from the
autoclave has 15 to 20 grams per
liter of sulphuric acid. The acid is
neutralized with milk of lime.
Slurry changed from pH 1.5 to 10.5
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 192 / 241
Acid Neutralization Circuit
Avoid exposure to acid . Install automatic pH Controllers
Problems :
Repeated contact with low concentrations may cause dermatitis.
Lime milk addition increases slurry pH from 1.5 to 10.5
PH Control solution
Liquisys M CPM 253 with CPS11 or CPF81 electrode
Features
Compact IP65 / NEMA4X field housing
Measures pH -2 to 16 ; Hart®, Profibus PA and DP outputs
Benefits
Memosens sensor calibration is done in the lab meaning a safer process
Manual pH sampling can dangerous. This is now removed.
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 193 / 241
Carbon adsorption recovery processes Cyanidation & Carbon in Pulp (CIP)
Ore is crushed to 200
mesh/75µM
2lb of sodium cyanide is added
per ton of Ore & water
Lime is added to keep pH level
at 11
Slurry at 50% solids is pumped
through 4 or 5 air agitated tanks
Granular carbon is added and
gold is adsorbed
Screens between the tanks trap
the carbon and gold
Gold is washed from carbon and
recovered by electrolysis
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 194 / 241
Carbon adsorption recovery
Air addition for agitation in CIP tanks using a Prowirl Vortex Meter
Features:
Large turndown of 40 to 1 for gas flows to 75 m/s
DN15 to 150 process connection to PN 160
Accuracy across flow range of better than 1%
Benefits:
Compact device which is easy to install in compressed air line
Reduces the use of compressed air on site by optimizing the compressors
Increased safety with self-monitoring functions
Cost effective – short return on investment
Tek Cominco
Williams Mine,
Ontario, Canada
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 195 / 241
Problems
Blowing any powder around a mine can be a nightmare. Pipe blocks and tank over
filling can cause explosions and dust clouds and gas can attract environmentalists or worse.
Solutions
The Soliphant vibration switch for solids with grain sizes up to 10mm (3\8”) is fitted in
many mines as an over spill alarm.
The Cerabar S pressure gauge will warn against powder or gas build up & plugs in
pneumatic conveyer lines
Pneumatic conveying of coal or lime powder Dust cloud and explosion concerns ?
Features
Long term pressure stability at 0.1% deviation/ year
Over pressure resistant ceramic cell
Benefits
Bins protected from overfilling and potential explosions from over
pressurization
Barakov miner in Luhansk
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 196 / 241
Crushing, Grinding & Screening
Extraction & Ore storage
Flotation & Thickening
Roasting & Autoclaving
Smelting
Refining
Environmental Issues
Common Mining Processes Key Stages
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 197 / 241
Chemical or refractory processes Tanks, silos, bins and vessels on the plant
Acid Wash Vessels
Agitators
Boilers
Carbon Columns
Carbon Conditioning
Tanks
Carbon Sizing Screens
Carbon Stripping
Vessels
Cathode Wash Boxes
Chemical Mixing Tanks
Chemical Storage Tanks
Dart Valves
De-aeration Vessels
Drying Ovens
Electro winning Cells,
Polypropylene
Electro winning Cells,
Stainless Steel
Carbon Regeneration Kilns
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 198 / 241
Air & steam flow metering using Prowirl 72 Vortex Meters to 400°C
SO2 Gas pressure monitoring with Deltabar S
H2S04 concentration control in the boiler’s venturi circuit with ConduMax W
CLS 13
Roasting Circuits Sulphuric dioxide converted in to sulphuric acid
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 199 / 241
Typical Refining Process Copper, Nickel, Zinc, Gold Mine
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 200 / 241
Electro winning Processes
Commercially available systems
Electro winning involves placing an anode and cathode
into a bath of slowly circulating electrolyte.
Metal ions move to the cathode to be plated.
EMEW®, the electrolyte is circulated rapidly past the
anode and cathode at a higher flow rate, allowing for
improvements in efficiency and recovery.
The ANODE runs through the centre of the cell. The
Inside surface of the pipe is the CATHODE.
There are two types of EMEW® cell. One produces metal
plate, the other produces metal powder
Electrolyte is pumped through the cell from the bottom.
Power is applied. Metal begins to plate, or powders on the
CATHODE.
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 201 / 241
Electrolytic Copper Process Crushing, stockpiling and rinsing
• The first Step will always be to have
the mineral ore in an appropriated size
for either, Floatation, or extraction by
solvents, therefore, the rocks are
brought from the pit to the crushers by
truck.
• Right after the rocks are properly sized
they are dumped into the acid bath
area, using mechanical conveyors.
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 202 / 241
• Lubricant Oil flow to mills.
• Oil Pressure for mills and belt clutch systems.
• Lubricant Oil temperature.
• Chute overflow detection.
• Water flow measurement for milling and dilution.
• Mill discharge flow measurement.
• Cyclone separation pressure measurement.
• pH Measurement.
• Reactive high level detection.
• Air flow to flotation tanks.
• Interface measurement in flotation baths.
Electrolytic Copper Process
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 203 / 241
Electrolytic Copper Process Copper ore rinsing
• The rock piles are now being washed by a constant flow of sulphuric acid and a mixture of an extracting compound.
• This weak acid solution washes stones all the way down, diluting the copper and bringing it to the lagoons where the solution now called “head” is concentrated for further pumping to the electrowinning plant.
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 204 / 241
• Extractant solution flow measurement
going to irrigation area.
• Level measurement in lagoons.
• Flow measurement of head return to
the transfer process.
• Pressure measurement in the pumping
stations.
Electrolytic Copper Process Copper ore rinsing
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 205 / 241
• Once the head reaches the plant, it is filtered, to remove solids and then mixed with kerosene and “LIX®”. (ion exchange reagent). The copper is transferred then from the acidic solution to the organic one.
• Separation by density is then carried out with very large static separators.
• After that, the organic solution is mixed again, but now with the electrolyte that is going to form the copper plates as it takes place at refinery in the previous process.
Electrolytic Copper Process Copper recovery and extraction
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 206 / 241
• Kerosene flow measurement.
• Conductivity measurement in agitation
bath.
• Temperature in heat exchanger inlet
and oulet.
• Electrolyte flow measurement.
• Concentrated acid flow measurement.
Electrolytic Copper Process Copper recovery and extraction
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 207 / 241
• Copper is now diluted into the
electrolite.A DC current is applied
between SS anode and cathode.
• Current means that only copper ions
travel in the direction of the cathode.
• Copper is now 99.99 to 99.999 % pure,
and the main contaminant up to this
point is just Oxygen.
Electrolytic Copper Process Copper recovery and extraction
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 208 / 241
• H2SO4 Level Measurement (20% by weight, 60ºC )
• Water flow measurement for all the plant services.
• Condensate recovery system flow measurement, level measurement, Conductivity
• Level in various containers with reactive for electrolyte conditioning.
• Electrolite flow to the separation cells.
Electrolytic Copper Process Copper recovery and extraction
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 209 / 241
Mineral refinery processes Electrolyte Flow Controls
Application
Electrolyte flow control through a 2” plastic pipe
Solution :
Prosonic 90/93W clamp on pipe ultrasonic flow meter
Valleyfield Zinc Refinery,
Canada
Features
Flow range 0...15m/s (49 ft/sec) with 150 to 1 turndown
Typical repeatability of ±0.3% for flows > 0.3m/s (
Benefits :
Simple to install and retro- fit with direct clamp-on-pipe fitting
High accuracy electrolyte pump flow controL
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 210 / 241
Mineral refinery processes Valve control of electrolyte flow to electro winning tanks
Open and close valves against
specific flow set points with a
Promag Magnetic Flow Meter
Remote transmitter for convenient
programming and visualization
Meters have a wide range of ANSI
or DIN flange connections to fit
your existing pipes
You can link the meter to existing
PLC or SCADA using standard
industry connectivity such as 4-
20mA Hart, Profibus PA and
Fieldbus Foundation
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 211 / 241
Control the flow thru the filters
with a Promag Flow Meter
Valve, meter and piping is usually
separate from the filter tank on a
skid to ease transport
Mineral refinery processes Electrolyte filter tank measurement
Flow
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 212 / 241
Mineral refinery processes Electrolyte storage tank level monitoring
Monitor tank levels and prevent
over spills with a Prosonic M
compact Ultrasonic Level sensor
Separate display for easier setup
and programming
Install on a moving boom or arm for
ease of maintenance or
programming
Relay outputs to switch pumps on
or off
Level
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 213 / 241
Mineral Extraction from natural brine deposits
Evaporation ponds
Salar Brine
Salar de Atacama's process diagram
Carnallite deposits
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 214 / 241
Flow product
Promass 83F
Features
Density measurement
Temperature
Mass and volumetric flow
Customer: SQM Salar, Chile
Material : Lithium brine solution
Uses : Ceramics, aluminium, battery
Mineral Extraction from natural brine deposits Density and Flow Measurement
Benefits
Brine is pumped from ponds to tanks and for further refining only when set
density is confirmed
Actual brine densities match stipulated quality standards
Brine quality consistency better than with just lab density testing
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 215 / 241
Fertilizer production process Ammonium phosphate
beneficiation plant
phosphoric acid plant
ammonia plant
granulation plant
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 216 / 241
Ammonium Phosphate Granulation pH value as a mix controller
Phosphoric acid mixed with ammonia
Topclean S, Topcal S auto clean, auto
calibrating pH meter
Features
Auto retractable pH sensors
Calibration buffer solutions
MemoSens® means initial lab calibration
Benefits
Automated maintenance
No need for manual dipping meaning a
much safer work environment
Calibration data saved in sensor
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 217 / 241
Phosphoric Acid Plant Bi Products Selling off gypsum to concrete or plaster board producers
Opportunity
Deliver gypsum against your customer’s production requirements
Solution
Offer your customer a just in time delivery based on his actual silo levels.
Install a FieldGate, remote silo visualization and level control system
Features
View your own gypsum stock levels and match these with levels in customer tanks
Benefits
Offer your customer a just in time delivery based on his actual silo levels.
Install a FieldGate, remote silo visualization and level control system
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 218 / 241
Phosphoric Acid Plant Bi -Products Selling off gypsum to concrete or plaster board producers
Opportunity
Deliver gypsum against your customer’s production requirements
Solution
Offer your customer a just in time delivery based on his actual silo levels.
Install a FieldGate, remote silo visualisation and level control system
Features
View your own gypsum stock levels and match these with levels in customer tanks
Benefits
Offer your customer a just in time delivery based on his actual silo levels.
Install a FieldGate, remote silo visualization and level control system
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 219 / 241
Crushing, Grinding & Screening
Extraction & Ore storage
Flotation & Thickening
Roasting & Autoclaving
Smelting
Refining
Environmental Issues
Common Mining Processes Key Stages
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 220 / 241
The mine life cycle Impacts on the water environment
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 221 / 241
Features:
Silo Guard consists of a continuous guided level radar Levelflex M, Cerabar T
pressure sensor, remote displays with integral alarm relays
Optional Remote data access and control with Fieldgate® inside, sends you
an SMS message or E-Mail in an overfill emergency
Visual and audible high level & pressure overfill alarms in pneumatically
filled powder bins
Environmental Protection Packages Silo Guard Overfill Protection System
Benefits:
Eliminate the prospect of silo damage
Meet requirements of local Health and Safety for over filling
Prevent environmental emission issues
Assist you in preventative maintenance
Air & Powder
Inlet Valve
% Level
High Relays
mBar, relays
Over & under
Relays close inlet valve
when in alarm state
W@M
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 223 / 241
Measurement in tailings dam overflow wells
Waterpilot FMX with remote data transmission
RIA45 + TMT181
Temperature
RIA46
Level
RMA422
Monitoring
Power
Display
Monitoring
Transmitting
Controlling
FMX21
Level, Pressure +
Temperature
Pressure
HAW
Surge Arrestor
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 228 / 241
Remote monitoring of effluent water Analytical parameters and flow
Remote data transfer in case of heavy
rain
measuring
- conductivity
- pH
- turbidity
plus
flow across a v-notch weir with
ultrasonics
Pressure
Mining overview
Extraction, leaching
& ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaving
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 231 / 241
Quarrying Process Solution Kaolin clay settling ponds
Ammonia measurement in effluent using a
CA 70AM and a CA 50 and CA 30
CA 70AM-Stamolys ammonia analyzer
CA 30-submersible sampling system
CA 50-sedimentation unit
China clay pools are natural or fabricated holding tanks where,
the ammonia solution is allowed to slowly dissipate to
atmosphere and the pH of the resulting wastewater is allowed
to stabilize to a range of 6.0 - 10.5 standard pH units
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 233 / 241
Recycled process water quality How dirty is your water?
Problem :
If you drain your waste water to land or river then it must meet local environmental
standards for cleanliness and chemical content e.g. EU IPPC law,
Solution :
Measure the turbidity of your treated water with a Turbimax CUS 41
Features :
Integrated sensor cleaner wiper for lime build up
Benefits :
Measure the solid content of your treated water and
BOD
Comply with local discharge legislation
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
Autoclaves
Refining
Enviromental
Issues
Thickening
Milling & Grinding
Slide 234 / 241
Effluent water quality How safe is the water?
Problem :
Waste water from your plant may meet local emission limit values for certain chemicals
but will your effluent affect river oxygen levels
Solution :
Simple dissolved oxygen sensor at the point of discharge will check oxygen levels
Features :
Flow through, retractable and immersion assembly options
Measuring ranges from 0.001 to 60 mg/l of 02
Benefits :
Factory calibrated system means fit and forget
Ensures survival of river live stock
Analytical
Mining overview
Extraction, Leaching
& Ore storage
Crushing, Grinding
& Screening
Flotation
Smelting &
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Slide 236 / 241
Silo Guard Systems Remote viewing and multi silo monitoring
The “Remote Guard” with FieldGate® inside will send your maintenance crew a mobile
SMS or E-Mail in an emergency situation.
A “Multi Guard” Silo protection system will link all your silos in to one control panel and
record every fill as it happens
Local guidance information for the Mining and Quarrying Industry states a requirement for
:
Prevention against over-filling of silos with a high level device
Silo operating conditions must not exceed manufacturers specifications
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Slide 237 / 241
“Silo Guard” Panel & Component Examples
SILO GUARD
Levelflex FMP51 Continuous Level
Soliphant FTM / Minicap FTC High Level Alarm
Cerabar T PMC 131 Pressure switch
RIA 250/450 Pressure display
RIA 250/450 Level display
SILO GUARD - Multi
ECOGRAPH /Memograph S
Prosonic S Ultrasonic transmitter
SILO GUARD - Remote
Field Gate Unit (Ethernet/GSM/Analogue)
Java Applets
P View
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Slide 238 / 241
Problem :
Environmental Laws require that extraction systems are
monitored to ensure certain levels of dust emissions are
not exceeded.
Solutions :
The Soliwave M is mounted on the filter outlet pipe. The
microwaves detect any dust particles passing through the
wave from a torn filter. Buildup on the pipe walls can also be
monitored
DCE
Filter
System
Exhaust
D to 100m
Dust build up & blockage detector in an air filter system Soliwave M
FAN
Soliwave M
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Slide 239 / 241
Filter dust in collecting box Soliphant T Monorod Switch
Pump
Application
FTM20-AA42A
• Filter dust from cleaning
dry (500 g/l) in the
collecting tank
• Controls box discharge as
max alarm to start up a
pneumatic pump
Problems
• Strong external vibration
from pneumatic system
• Build up on sensor
Alternative solutions
• Minicap
• Soliswitch
• Soliphant M
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Slide 240 / 241
Technology Tip Common Dust Filter Modules
Filter envelopes
with shake clean
motor & gear
mechanism
Filter types :
Envelope
Cartridge
Dust collection
box or silo
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Slide 241 / 241
Problem :
Dust from the plant filter system is collected and recycled. A level system that can
measure through thick dust clouds is required
Solution :
Levelflex FMP50 guided radar
Dust Levels in the bag house Measuring through dust clouds?
Features :
Reliable level measurement in powder and dust to 45 meters (115ft)
Approved for use in potential dust explosion areas e.g. ATEX II 1/3D
Benefits :
Fit and forget in the silo.
Remote programming and data visualization
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Slide 242 / 241
Fuel supply Storage and handling
Each type of fuel has be stored and
controlled with different measurement
systems.
Depending on the fuel type, gaseous,
liquid or solid and whether it is the
primary or secondary fuel the following
measurement systems will be used:
• level control
• pressure control
• control of volume
• control of waste oil viscosity (for example waste oil - measurement
installed to save energy in heating)
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Slide 243 / 241
Fuel supply (1) Level control of tank for heavy oils
level control of tanks with pressure
measurement devices
• easy setup reduces installation costs
• extra safe due to metallic measuring cell
• second process barrier for highest safety
• direct mounting at discharge point
• standard industry outputs such as 4-20 mA
HART®, PROFIBUS® or Foundation
Fieldbus™
Cerabar S pressure measurement Pressure
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Slide 244 / 241
Fuel supply (2) Level control of oil tank
continuous level control of oil tanks with free space
time of flight radar
• helps optimise the fuel supply and materials
logistics process
• no contact with media – measurement
independent of product properties
• change the product in the tank and there is no
need to recalibrate the radar
• easy setup via display or PC-program ToF-Tool
• For all materials with DK-value 1.4
radar measurement
Micropilot M Level
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Slide 245 / 241
Fuel supply (3) Level control in tank
Over spill or empty detection of oil tanks with
a vibrating sensor
• sensor is self monitoring and will check for
malfunction; safe and reliable
• operation of limit switch not affected by flow,
turbulence, air bubbles, foam, vibration, solid
constituents or built-up
• no mechanical moving parts
• no adjustment: rapid and economical
commissioning
Liquiphant FTL vibration fork limit switch
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Slide 246 / 241
Fuel supply (4) Waste oil
Promass F mass flow measurement system
online mass metering of waste oil at the
feeding station
• precise metering of delivered oil
• not affected by pipe vibrations
• no mechanical moving parts
• maintenance free in comparison to mechanical
flow meters
• standard industry outputs such as 4-20 mA
HART®, PROFIBUS® or Foundation Fieldbus™
Flow
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Slide 247 / 241
Fuel supply (5) Mass flow- and density measurement of waste oil
online mass metering with density measure-
ment of waste oil of fuel supply for rotary kiln
• optimised control of burning process and
reduction of discharge gas emissions
• not affected by pipe vibrations
• maintenance free in comparison to mechanical
flow meters,
• three in one solution of mass flow, density and
temperature
• standard industry outputs such as 4-20 mA
HART®, PROFIBUS® or Foundation Fieldbus™
Promass F mass flow measurement system
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Slide 248 / 241
Fuel supply (6) Viscosity control of waste oil
online measurement of viscosity for changing
qualities of waste oil
• control improvement of burning process
• slashes the cost of utility bills by saving energy
in heating up the waste oil
• measurement accuracy not affected by pipe
vibrations
• standard industry outputs such as 4-20 mA
HART®, PROFIBUS® or Foundation Fieldbus™
Promass I
the 4 in 1 Mass Flow Solution
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Slide 249 / 241
Fuel supply with coal dust Level control of silos
Levelflex M radar measurement unit
continuous level control with guided radar
measurement in coal dust silos
• continuous level measurement ensures
uninterrupted material flow
• minimum process down time due to radar’s
quick setup procedure
• reliable measurement, even during pneumatic
filling when thick dust clouds are common
• measurement principle independent of moisture
content or product changes
• recommended installation for powder and
products with a grain size up to max.
20 mm – 0.79 inches
• measuring range up to 45 m/147 ft - please
consider pulling forces -
Level
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Slide 250 / 241
Fuel supply with coal dust Level control in silos
point level detection in coal dust silo for max.
detection with a capacitance probe
• no calibration required, fit and forget
• simple mounting means lower installation costs
• integrated active compensation of built-up
• maintenance free – no moving parts
• long expected life time
• temperature range up to 60 °C – 140 °F
• grain size up to 50 mm – (2”)
Minicap measurement unit
Level
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Slide 251 / 241
Coal mill Pressure control
monitoring material flow by air pressure
control of coal mill
• fully configurable calibration and easy setup due
to modular concept reduces commissioning
costs
• extra safe due to ceramic measuring cell
• high overload protection up to a factor of 40
• second process barrier for highest safety
• quick an comfortable commissioning with PC-
program Commuwin II
• standard industry outputs such as 4-20 mA
HART®, PROFIBUS® or Foundation Fieldbus™
Cerabar S pressure sensor
ATEX
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Slide 252 / 241
Levelflex M with rod probe to 4 m /13ft
continuous level control with guided radar
measurement in sampler vessel with agitator
• Level devices when mounting space is at a
premium
• operation not affected by turbulence and foam
build up
• pre-adjusted setup: rapid and economical
commissioning
• measurement principle independent of density
or product change
• rod probe for for small liquid tanks
• coaxial probe for low DK liquids
• cable probe for solids to 35m / 115ft
• for materials with DK-value 1.6
ATEX
Secondary fuel supply with solvent (1) Continuous level control in sampler vessels
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Slide 253 / 241
point level measurement with vibration fork in
sampler vessel with agitator
• sensor has function monitoring to check for
damage; safe and reliable
• operation of limit switch not affected by flow,
turbulence, air bubbles, foam, vibration, solid
particles or build-up
• reliable long term operation due to integrated
corrosion protection
• suitable for mounting in restricted spaces
• product temperature up to +150 °C –
(302 °F)
• solid particles up to max. 5 mm – (0.2”)
Liquiphant FTL measurement unit
Secondary fuel supply with solvent (2) Limit detection in sampler vessel
ATEX
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Slide 254 / 241
Secondary fuel supply with solvent (3) Pressure control in conveyor piping -
pressure control in conveyor piping
• extra safe due to metallic measuring cell
• start and end of measuring range freely
adjustable
• easy setup via push buttons or digital interface to
PC
• long term stability of 0.1 % drift/year
• standard industry outputs such as 4-20 mA
HART®, PROFIBUS® or Foundation Fieldbus™
additional temperature measurement TER at
sample vessel
Cerabar M pressure sensor
ATEX
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Slide 255 / 241
Secondary fuel supply with waste tyres Level control of pre-burning chamber
maintenance and contact free level control
with radiometric measurement
• density profiling for otherwise difficult products
• no contact with the product thus no wear
• high reliability with self checking functionality
• low radiation due to scintillator sensor
• standard industry outputs such as 4-20 mA
HART®, PROFIBUS® or Foundation Fieldbus™
Gammapilot M with source container
and scintillation sensor Radiometrics
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Slide 256 / 241
Secondary fuel supply with waste plastic Level control of storage bin
maintenance and contact free point level
control with microwave measurement
• no contact, independent to media, there-fore
recommended for burning paper, plastic and
wood chips
• no maintenance costs caused by wear
• robust design – long expected life time
• sealed construction, dust and water tight
• Integrated 4-20mA or relay output
• max. range 100m – (300 ft)
• ambient temperature up to 70 °C – (129 °F)
Soliwave M FQR/FDR
Microwave measurement unit
Level
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Slide 257 / 241
Secondary fuel supply with waste plastic Continuous level control
Prosonic Sensor S / FDU measurement unit
continuous level measurement with ultrasonic
probe to control of screw conveyor
• no contact with media means low maintenance
costs
• low installation costs
• self cleaning sensor
• 6 free programmable relays
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Slide 258 / 241
overspill protection with electromechanical
paddle switch at bucket elevator feed
• ready to operate without calibration
• easy setup
• high operational safety due to internal non slip
coupling
• optional integrated switch signal light
Secondary fuel supply with waste plastic Limit detection at bucket elevator
Soliswitch FTE paddle switch
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Slide 259 / 241
Fuel supply using animal carcasses and bone meal(1) Limit detection at conveyors
Minicap capacitance probe
overspill protection of conveyors using point
level capacitance measurement
• simple mounting means lower installation costs
• no calibration required
• maintenance free – no moving parts
• available in compact or with cable probe to 6m
– 20ft
• grain sizes up to 30 mm – (1.8”)
Level
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Slide 260 / 241
Air line controls
Cerabar T pressure transmitter
pressure and temperature control of pneumatic
conveyors
• increase in site safety by monitoring potentially
hazardous fuel / air flow conditions
• overload protected and designed for vacuum
operation (pressure sensor)
• tough housing completely made of stainless steel
• reliable and long term stable
• small and compact means easy to install
• long term stability < 0.15 % drift/year (pressure
sensor)
• measuring range adjustable with PC program
compact Easytemp TSM thermometer
Pressure
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