Microwave Energy Aided

Mineral Comminution

Presented by:
Ashish Kumar, Bala P Kamath, V V Ramarao (Speaker), D B Mohanty
Central Research & Development Laboratory,
Hindustan Zinc Limited
 Introduction
ƒ Comminution in Mineral Beneficiation
is an energy hungry process. Flotation &
Filteration

• About 50 % of the total energy is 32.3 %

consumed during Comminution.

• Measures to improve grindability of 43.6
Milling
%
Tailing disposal
10 %
ore & attain energy savings were on Crushing
Others
0.9 %

trial since early 1900s;Thermally 13.2 %

Assisted Liberation (T.A.L.) based on

conventional heating was explored.
ƒ Conventional T.A.L. was un-
economical on commercial scale.
ƒ Recent researches in MICROWAVE &
RF pioneered Microwave energy as
an EFFECTIVE solution for Heating
source.
 Microwaves & Mineral Processing
ƒ Percy Le Baron Spancer – 1st to provide the idea of Heating by Microwaves in 1946.

ƒ Microwave energy is a form of Electro Magnetic Radiation having frequency between

3000 MHz to 3000 GHz.
– Common applications of microwaves: communication; heating;
– Frequency bands for microwave heating application in India is 2450±50MHz.

ƒ Ore constituents have different thermal & mechanical properties (thermal expansion
coefficients, microwave absorption coefficients);
Microwave irradiation Differential heating of ore minerals Developing stress

Increased ore grindabilty to create trans-granular & inter-granular cracks / micro-fractures

ƒ Absorption of microwave is Characteristic phenomenon of respective Mineral. For

example, presence of sulphides, oxides and graphitic carbon enhances fracture
formation.

ƒ Breakthrough concept for various industries that consume large amounts of energy
including mineral processing, cement etc.
MICROWAVES
 Applications of Microwave

ƒ Variety of applications of microwave heat in several

industries are in practice like:

– Drying of food items (Tea leaves, seeds, edible items)

– Hospital sanitation
– Sprouting
– Vulcanization of rubber
– Carbon reactivation
– Pressure leaching
– Roasting
– Sintering
– Rocks & Ore comminution
Background for Present Work

• Hindustan Zinc Limited is a

Vedanta Group company; COPPER
SIIL
KCM
• CRDL is for HZL’s R&D;

• Technology cell at CRDL has

decided to adopt microwave
energy use as a step change VEDANTA
technology in its road map. M
UM INIU ZIN
C&
AL CO
/
LE
BAL CO R& HZL AD
MAL CR D
DL
• Work on Microwave aided
comminution project started during
2005; benefits targeted are
– Increased mill throughput
– Reduced grinding energy
through reduction in the ore work index.
 Rampura Agucha Beneficiation Plant
EXISTING RAMPURA AGUCHA – 6100 T.P.D. LEAD/ZINC CONCENTRATOR FLOWSHEET
additional fine ore bin
Pri.Cyc.D20
R.O.M. Sec.Cyc.D15

Primary Fine Crush Plant

Crusher
3 Rod Mills
3 Ball Mills 115

Fine Ore Bin

110
7 Lead Roughers OK-16
Coarse Ore Stock Pile Active 4,500T (Each)
Active less than 9,000T 10 Lead Scavengers OK-16
2 Zn. Conditioners Pb Conditioner

2 Zinc Roughers
8 Zinc Roughers OK-38
9 Zinc Scavengers OK-38

140
139

153
177
181 178
Pb 3-Stage Cleaning

Zn 4-Stage Cleaning

Regrind Cyclones 151

148
D15
145
196
193
Pb Conc.Thickener
190
14 M Dia
Regrind Mill
To 187 162 Pb Stock Tank
Reclaim
Water 224 222
To
Reclaim
Zn Conc. Thickener Water
14 M Dia
249 7 Zn Filter Presses Tailing Thickener
PF25 55 M Dia 1 Pb Filter Press
252 To Reclaim Water PF25
288 Pb Conc. Stock Pile
16 M Dia

Neutralization Tank
254
247 282
Zn Conc. Stock Pile
Zn Stock Tank TAILING DAM
 Microwave Experimental Work
™ Preparation of sample: 3 kg representative samples from plant rod mill
feed were prepared mixing ore size fraction in the range –19 mm to + 2
mm in the same size proportion as in plant rod mill feed. (minus 2 mm
size fraction discarded in accordance with previous observations)

™ Grindability studies: Laboratory ball mill was used for wet grinding with
3 kg sample each time at a pulp density of 60% solids (by wt); ground
material size distribution is known through wet sieving; Observations are:
o Effect of microwave on particle size distribution under water quenched &
unquenched conditions w.r.t. unexposed samples.

o Effect of microwave on work index of ore. The relative work index of the ore
was calculated using Berry & Bruce formula.

– Wi : work index kW.h/t; r and t refer

for reference and test samples;
– P and F refer to 80% passing of the
product and feed stream.
Experimental Work ….contd.

o Effect of microwave on the grinding time, which is directly proportional

to the saving in grinding energy of the ore.

™ Simulation studies – Prediction of mill throughput increase for

reduction in ore work index;

o JKSimMet comminution software

o Microwave irradiation (with quenching) at different time/intensity
ranges for using different work index values.

o Simulations predicted Throughput changes for same P-80 size;

 (more finer size for same grinding)
94
Average of cumulative wt% passing

92
y = -0.9646Ln(x) + 95.346
90

88 y = -0.8184Ln(x) + 91.935

y = -0.9906Ln(x) + 92.559
86

84
0 50 100 150 200 250 300 350 400 450
Sieve size (in mesh)

Blank UQ AVG Q AVG Log. (UQ AVG) Log. (Q AVG) Log. (Blank)

Trend line (semi log) for average particle size distribution of R A Mine samples
under water quenched, unquenched & unexposed conditions
 60

(more grindability with more exposure)

50
% reduction in work index

40

30

20

10

0
0 10 20 30 40 50 60 70
Unexposed Exp osure time (min)

% Reduction in work index

Effect of microwave exposure for different time intervals on work index of ore
Microwave &

% cumulative pass by 200 mesh

100
90
80

Grinding Time 70
60
50
0 10 20 30 40 50 60 70
Time of grinding (min)

• Plot of % passing fraction at Unexposed Exposed

different particle sizes in ground

product for different grinding 100

times 90

% cumulative pass by 150 mesh

80
– Irradiated & quenched 70

– Non-irradiated 60

50
0 10 20 30 40 50 60 70
Time of grinding (min)

• More finer fraction generated for Unexposed Expos ed

irradiated & quenched fractions

than non-irradiated (normal)

% cumulative pass by 100 mesh

100

fractions 90

– 100 #, 150 # & 200 #

80

70

60
(for same grinding time more 50

finer product & for same 0 10 20 30 40

Time of grinding (min)
50 60 70

product size reduced residence Unexposed Exposed

time)
 10

8
% increase in plant throughput

0
10 20 30 40 50
% reduction in work index

Percent increase in plant throughput

Simulation studies to estimate the increased plant throughput rate

with percent reduction in work index
Conclusion
ƒ Lead-Zinc sulphide ore of R A Mine is responsive to
microwave radiation.

ƒ Water quenching immediately after microwave exposure

causes substantial reduction in work index of the ore.

ƒ Reduced work index results in reduction in grinding

residence time that reflects grinding energy reduction.

ƒ Increased grindability of ore causes increased plant

throughput rate (predicted by simulation studies).

ƒ Microwave energy has a potential role in commercial scale

comminution and other mineral / metallurgical operations;

ƒ Strong need for developing appropriate technology.

R.O.M.
F F
Crusher
Fine Crush Plant O O
Pri. Crusher Coarse Ore B B
Stock Pile

Microwave

To Flotation
Pri. Cyclone

Sec. Cyclone

Applicator
Cavity

Rod Mill
Ball Mill

Typical Flow Sheet For Microwave Aided Ore Milling(Proposed )

Thank You !