Mineral Processing - Introduction - MCU - 2011 - Luis Magne PDF

1
Mill Circuit University

Weir Minerals
Weir Minerals
Mineral Processing Mineral Processing
Mineral Processing: Introduction Mineral Processing: Introduction Luis Magne Luis Magne
1
Extractive Metallurgy:
Crushing
Metals Extraction:
Example Copper
Metals Extraction:
Example Copper
Process:
Exploration (Geology)
Extraction (Minning)
Extractive Metallurgy:
Crushing
g
Grinding
Classification
Concentration
Dewatering
Smelting
Electro refinery
Crushing
Leaching
Solvent Extraction
Electro winning
Materials Process
Earth Earth
Elements in the Earth Crust Elements in the Earth Crust
Elements Quantity, %
Oxygen (O) 46,6
Silicon (Si) 27,7
Aluminum (Al) 8,1
Iron (Fe) 5,0
Calcium (Ca) 3,6
Sodium (Na) 2,8
Potassium (K) 2,6
Magnesium (Mg) 2,1
Titanium (Ti) 0,5
99,0
Copper: 0,006%
Molibdenum: 0,00025%
2
Copper in the Earth Crust Copper in the Earth Crust
Ore Ore
An ore is a type of rock that contains minerals with
important elements including metals. The ore is formed
through geological processes and it has a characteristic
chemical composition.
An economic definition is: Ore is a mineral that can be
mined at a profit. For example:
Calcopirita Calcopirita
CuFeS
2
Galena Galena
PbS
Esfalerita Esfalerita
ZnS
Ore Ore
MoS
2
Molibdenita Molibdenita
Fe
2
O
3
Hematita Hematita
Magnetita Magnetita
Fe
3
O
4
Cuprita Cuprita
FeS
2
Pirita Pirita
Azurita Azurita
Cu
2
3(CO
3
)2(OH)
2
pp
Cu
2
O
Gold Gold
Au
Silver Silver
Ag
3
Ore Deposites Ore Deposites
An ore deposit is a portion of the earths crust from
which some industrial raw material can be extracted at a
profit.
The interest elements concentration is called grade.
- Copper: % (bigger than 0,4%)
- Molybdenum: % (bigger than 0,05%)
- Iron: % (bigger than 25%)
- Gold: g/t (bigger than 0,8 g/t or ppm)
- Silver: g/t (bigger than 15 g/t or ppm)
Grade Variation of Copper in Main Chiles
Plants
Grade Variation of Copper in Main Chiles
Plants
Recovery Recovery
Is the mass of element of interest obtained trough a
concentration process.
Mineral Processing Plant
Feed: 150 t/h
G
F
: 1,2% feed in interest of element of mass
e concentrat in interest of element of mass
R =
tph
100
1,2
tph feed in interest of element of Mass 8 , 1 150 = =
Mineral Processing Plant
Concentrate: 6,5 t/h
G
C
: 25,0%
Tails: 143,5 t/h
G
T
: 0,122%
tph
100
25,0
tph e concentrat in interest of element of Mass 625 , 1 5 , 6 = =
% 3 , 90
8 , 1
625 , 1
100 = =
tph
tph
R
4
Copper Production in Chile Copper Production in Chile
Mineral processing parameters for sulphur (concentration):
Copper Production in Chile Copper Production in Chile
2007 2008 2009 2010 2011
CopperGrade,% 1,09 1,10 1,05 0,97 0,94
Recovery,% 87,9 87,7 88,1 87,6 87,8
Mineral processing parameters for oxides (leaching):
2007 2008 2009 2010 2011
CopperGrade,% 0,69 0,67 0,66 0,61 0,60
Recovery,% 63,67 63,43 63,35 59,09 58,90
Total Mineral for Process Total Mineral for Process
5
Mine Material Remove Mine Material Remove
Minning Proyects in Chile Minning Proyects in Chile
Mineral Processing Mineral Processing e l ocess g e l ocess g
6
Unit process:
- Size reduction process
- Size classification
Size classification
- Ore Concentration
- Dewatering
Minerals Conminution Minerals Conminution
Size reduction process:
- Blast
- Crushing
- Conventional grinding
- Autogenous grinding
- Semiautogenous grinding (SAG)
- Semiautogenous grinding (SAG)
Size classification:
- Screens
- Hydrocyclones
Minerals Concentration Minerals Concentration
Ore concentration:
- Gravitational concentration
- Magnetic concentration
- Flotation
Dewatering:
- Thickening
- Filtration
- Drying
7
Minerals Processing Minerals Processing
Minerals Processing Minerals Processing
Slurry or Pulp Slurry or Pulp
8
Slurry or Pulps Slurry or Pulps
Homogenous mixture between solids
particles and a liquid
A slurry can be described as a two phase
medium (liquid/solid).
In mineral processing, the solid particles are
ores and the liquid is industrial water.
Pulp volume = Solid volume + Liquid volume
Vp = Vs + Vl
Pulp Mass = Solid mass + Liquid mass
Mp = Ms + Ml
Mineral Pulps Mineral Pulps
Pulp in movement: if is the resident time of
the pulp in a control volume
Volumetric flow rate: is the volume of fluid
which passes through the control volume in
the resident time, .
V
t
t
t
t
p
p
l s
l s p
l
l
s
s
V
Q
V V
Q Q Q
V
Q
V
Q
=
+
= + =
=
=
Solids:
Liquid:
Pulp:
Mass flow rate: is the mass of fluid which
passes through the control volume in the
resident time, .
t
s
s
M
G = Solids:
t
t
t
p
p
l s
l s p
l
l
M
G
M M
G G G
M
G
=
+
= + =
= Liquid:
Pulp:
9
Pulp density :
l s
l s
p
p
p
p
V V
M M
V
M
+
+
=
=
In a static system:
l s
l s
p
p
p
p
Q Q
G G
Q
G
+
+
=
=
In a dynamic system:
Solid Concentration in Pulps Solid Concentration in Pulps
Solid concentration in
volume C
v
: it is the fraction
of volume of solid that there
is in the total volume of
pulp
v
s
p
s
s l
v
s
p
s
s l
C =
V
V
=
V
V +V
C =
Q
Q
=
Q
Q +Q
Solid concentration in
weight C
p
: it is the fraction
of mass of solid that there is
in the total mass of pulp
p
s
p
s
s l
p
s
p
s
s l
C =
M
M
=
M
M + M
C =
G
G
=
G
G +G
C
p
in function of C
v
:
C
C
C
p
v s
l v s l
=
+
100
100

( )
C
p
in function of
p
:
C
p
s p l
p s l
=

100

( )
( )
C
v
in function of
p
:
C
v
p l
s l
=

100

10

p
in function of C
v
:
l p p s
l p
v
C C
C
C

+
=
) 100 (
100
C
v
in function of C
p
:
100
) (
l s v
l p
C

+ =
p
in function of C
p
:
p l p s
l s
p
C C

+
=
) 100 (
100
Example:
A mineral process plant, processes 500 mtph of ore with
density of 2,8 mt/m
3
. In the mill, the pulp has a Cp of
80,0% and in the flotation the Cp is 32,0%. Determine:
o How much water is necessary for grinding process
o How much additional water it should be added in the
flotation process
o Which is the pulp density in both cases?
a) 125 m
3
/h; b) 937,5 m
3
/h; c) 2,06 t/m
3
; 1,26 t/m
3
Water in Mineral Processing Water in Mineral Processing
11
Water in Mineral Processing Water in Mineral Processing
Crushing Plant
ROM
(3 5% humidity)
GrindingPlant
Cp=80%
ConcentrationPlant
Tails
Thickening
Tailsdeposit
FreshWater
Recycled Water
If 60% of water is recovered, then is necessary 1 m
3
of water for 1
t of ore.
Cp=30%
Concentrate
Cp=62%
Thickening
Cp=60%
Filtration
Dryconcentrate(8 10% humidity)
Tailsdeposit
Recycled
Water
Size Reduction Process Size Reduction Process
Size reduction is relevant in mineral
processing, because it have:
High capital cost (investment)
Reduction Size Reduction Size
o Equipment process
High operational cost
o Energy
o Steel consumption
12
Why Size Reduction? Why Size Reduction?
Why Mineral Size Reduction? Why Mineral Size Reduction?
Mineral Size Reduction Target Mineral Size Reduction Target
- To liberate interest minerals of non interest
materials or gangue (concentration)
- To promote fast chemical reactions by a big
superficial area exposition (hydrometallurgy)
Degree of Liberation:
- The degree of liberation of a certain mineral or
phase is the percentage of that mineral or
phase occurring as free particles in relation to
the total of that mineral occurring in the free
and locked forms
13
Usually the first steps are doing in a mine for
transport objective.
The following steps, crushing and grinding, are
doing made to separate the interest minerals of
the gangue.
Size Reduction Steps Size Reduction Steps
The final product have different types of
particles:
Fully liberated
Partially liberated
Non liberated or locked
Fully liberated: more than 80%
is mineral
Partially liberated:
oMixed: between 80 y 50% is
mineral
Asociaciones Mineralgicas y Grados de
Liberacin
Asociaciones Mineralgicas y Grados de
Liberacin
oAssociate: between 50 y 15%
is mineral
Non liberated:
oLess than 15% is mineral
oOccluded: mineral is inside of
gangue
Size Reduction Mechanism Size Reduction Mechanism
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Fracture
Cutting
Cutting
Abrasion
Fracture
by compression
by shearing
by impact
Size Reduction Mechanism and Equipment Size Reduction Mechanism and Equipment
MECHANISM MECHANISM
COMPRESSION COMPRESSION IMPACT IMPACT COMPRESSION COMPRESSION- -IMPACT IMPACT
Jaw Crusher
Giratory Crusher
Cone Crusher
Rolls Crusher
Impact crusher
Impact mill
Bars mill
Balls mill
Autogenous mill
Semiautogenous mill
15
Size Reduction Process Size Reduction Process Size Reduction Process Size Reduction Process
Size Reduction Process Size Reduction Process
Size reduction process depend of product target
Product target depend of the next process:
concentration (flotation, magnetic concentration,
gravitational concentration), cyanuration, leaching,
etc.
If the target is fine product (150 to 300 m):
Conventional grinding circuit: 3 or 4 crushing
Conventional grinding circuit: 3 or 4 crushing
steps and 2 grinding steps
Unitary grinding circuit: 3 crushing steps and 1
grinding step
Semiautogenous grinding circuit: 1 crushing step
and 1 grinding step
If the target is medium size (20 mm): 3 crushing steps.
Conventional Grinding Circuit
Crusher Plant
Conventional Grinding Circuit
Crusher Plant
Primary crusher:
Run of mine material (ROM), with sizes until 60 inch
(1,5 m). Product of 6 to 8 inch (15 to 20 cm)
Secondary crusher:
Work with product of the primary crusher. Product of
2 to 3 inch (5 to 8 cm)
Tertiary crusher:
Work with product of the secondary crusher. Product
minus of inch (12 mm) for mill circuit.
Primary mill:
The crusher plant product is grinding until 6 to 4 mm.
Normally is wet.
Secondary mill:
The product of primary mill is grinding for produce
particles of 200 m (may be 100 to 300 m or more).
16
Unitary Grinding Circuit
Crusher Plant
Unitary Grinding Circuit
Crusher Plant
Primary crusher:
Run of mine material, with sizes until 60 inch (1,5
m). Product of 6 to 8 inch (15 to 20 cm)
Secondary crusher:
Work with product of the primary crusher.
Product of 2 to 3 inch (5 to 8 cm)
Tertiary crusher:
Work with product of the secondary crusher.
Product minus of inch (12 mm) for mill circuit.
Milling:
The crusher plant product is grinding for produce
particles of 200 m (may be 100 to 300 m or
more).
Semiautogenous Grinding Circuit Semiautogenous Grinding Circuit
Primary crusher:
Run of mine material, with sizes until
60 inch (1,5 m). Product of 6 to 8 inch
(15 to 20 cm)
Semiautogenous mill:
Work directly with the crusher product
o d ec y e c us e p oduc
and produce material with 12 mm.
Normally is wet.
Secondary mill:
The product of primary mill is grinding
for produce particles of 200 m (may be
100 to 300 m or more).
FAG o SAG FAG o SAG
Size Control Size Control Size Control Size Control
17
Size Distribution of Mineral Particles Size Distribution of Mineral Particles
The sizes distribution of the mineral
particles can be represented by a set of
numbers representing the cumulative weight
fraction below size x
i
versus x
i
: F(x
i
) vs x
i
100
10 100 1000 10000 100000
1
10
A
c
u
m
u
l
a
d
o
P
a
s
a
n
t
e
, %
Tamao de partcula, m
Ro-Tap
Sieves Sieves
Mesh number is the slots number by one
lineal inch.
Abertura Serie ASTM
N de tamiz
Serie Tyler
N de tamiz
107.6 mm
101.6 mm
90.5 mm
76.1 mm
64.0 mm
4.24"
4.00"
31/2"
3"
21/2"
53.8 mm
50.8 mm
45.3 mm
38.1 mm
32.0 mm
26.9 mm
2.12"
2"
13/4"
11/2"
11/4"
1.06"
25.4 mm 1"
22.6 mm
19.0 mm
16.0 mm
13.5 mm
7/8"
3/4"
5/8"
0.530"
0.883"
0.742"
0.624"
0.525"
12.7 mm
11.2 mm
9.51 mm
8.0 mm
6.73 mm
6.35 mm
1/2"
7/16"
3/8"
5/16"
0.265"
1/4"
0.441"
0.371"
2.172"
3
5.55 mm
4760 m
4000 m
3360 m
2830 m
2380 m
3 1/2
4
5
6
7
8
3 1/2
4
5
6
7
8
18
Abertura Serie ASTM
N de tamiz
Serie Tyler
N de tamiz
2000 m
1680 m
1410 m
1190 m
1000 m
10
12
14
16
18
9
10
12
14
16
841 m
707 m
595 m
500 m
420 m
20
25
30
35
40
20
24
28
32
35
354 45 42
354 m
297 m
250 m
210 m
45
50
60
70
42
48
60
65
177 m
149 m
125 m
105 m
80
100
120
140
80
100
115
150
88 m
74 m
63 m
53 m
44 m
37 m
170
200
230
270
325
400
170
200
250
270
325
400
Total mass 537,6 g
Interval Representative Particle Mass Partial Cummulative
Mesh Mesh size, m g fraction, % fraction, %
10 - 14 10 1680
14 - 20 14 1190
20 - 28 20 841
28 - 35 28 595
35 - Bottom 35 420
10 - 14 10 1680 65,4
14 - 20 14 1190 93,0
20 - 28 20 841 145,4
28 - 35 28 595 122,6
35 - Bottom 35 420 110,9
537,3
10 - 14 10 1680 65,4
14 - 20 14 1190 93,0
20 - 28 20 841 145,4
28 - 35 28 595 122,6
35 - Bottom 35 420 111,2
537,6
10 - 12 10 2380 65,4 12,17
12 - 30 12 2000 93,0 17,30
30 - 270 30 595 145,4 27,05
270 - 400 270 53 122,6 22,81
400 -(-400) 400 37 111,2 20,68
537,6 100,00
10 - 12 10 2380 65,4 12,17 100,00
12 - 30 12 2000 93,0 17,30 87,83
30 - 270 30 595 145,4 27,05 70,54
270 - 400 270 53 122,6 22,81 43,49
400 -(-400) 400 37 111,2 20,68 20,68
537,6 100,00
80% size (F
80
) is the 80% passing size in the
distribution.
Which is the F
80
of this distribution size?
19
Size Reduction Definitions Size Reduction Definitions Size Reduction Definitions Size Reduction Definitions
Size Reduction Caracterization Size Reduction Caracterization
Size Reduction
Power consumption
Pot in kW
Feed Product
F
80
F, mtph
P
80
P=F, mtph
100
10 100 1000 10000 100000 1000000
0.1
1
10
A
c
u
m
u
la
d
o

P
a
s
a
n
t
e
,

%
Tamao de Partcula, m
AlimentacinMolino SAG
Descarga Molino Sag
Reduction Ratio Reduction Ratio
Ratio of feed size to product size for a
crushing or grinding operation:
R
F
P
r
=
80
80
R
F
P
r
=
max
max
Inefficient process:
R
r
= 1
20
Consumed Specific Energy (CSE) Consumed Specific Energy (CSE)
CSE is the necesary energy to reduce a ton of
mineral:
| |
| | t h F
kW Pot
CSE =
Inefficient process:
F = 0 mtph
| | mtph F
Reduction Ratio and SEC Reduction Ratio and SEC
The ideal condition is to obtain the
maximum reduction ratio and minimum
CSE:
0 CSE R
r

Sizing and
Size Classification
Sizing and
Size Classification Size Classification Size Classification
21
Sizing and Size Classification Sizing and Size Classification
Sizing is the general term for separation of
particles according to their size. The simplest
sizing process is screening.
Classification refers to sizing operations that
exploit the differences in settling velocities
exhibited by particles of different size.
Classification equipment may include
hydrocyclones and rotating trommels.
hydrocyclones and rotating trommels.
Feed
Fine
Coarse
Sizing and Size Clasification Sizing and Size Clasification
D P A + =
Global mass balance:
coarse in flow Mass fine in flow Mass feed in flow Mass + =
Mass balance by size:
Feed
A t h
Fine
P, mtph
p
i
Cp
R
i i i
Dd Pp Aa + =
Mass balance of water:
D
D
P
P
A
A
Cp
Cp
D
Cp
Cp
P
Cp
Cp
A
) 100 ( ) 100 ( ) 100 (
+
A, mtph
a
i
Coarse
D, mtph
d
i
Cp
A
Cp
D
10
100
p
a
s
a
n
t
e
,

%
Sizing and Size Classification Sizing and Size Classification
10 100 1000 10000 100000
1
Granulometras:
Alimentacin
Descarga
Rebalse
A
c
u
m
u
l
a
d
o

Tamao de partcula, m
22
Size Reduction Circuits Size Reduction Circuits Size Reduction Circuits Size Reduction Circuits
Open Circuit Open Circuit
Size Reduction
Feed, F Product, P
F
80
P
80
P F =
product in flow Mass feed in flow Mass =
Direct Closed Circuit Direct Closed Circuit
Size
Reduction
Feed, F
Classification
F
80
Water
Water
Coarse
Product, D
G
A
M fl b l
Fine Product, P
P
80
G D F = +
P D A + =
G A =
Mass flow balance
i i i
Gg Dd Ff = +
i i i
Pp Dd Aa + =
F P =
23
Inverse Closed Circuit Inverse Closed Circuit
Size Reduction
Feed, F
Classification
F
80
P
Water
Water
Coarse
Product, D
A
G
Fine Product, P
P
80
A G F = +
P D A + =
G D =
Mass flow balance
F P =
i i i
Aa Gg Ff = +
i i i
Pp Dd Aa + =
Circulating Load Ratio Circulating Load Ratio
Equipo de F G FF
Circulating Load, C, is the ratio of the mass
flowrate of solids in the classifier discharge
stream to the mass flowrate of solid in the
classifier overflow stream:
Equipo de
Reduccin de
Tamaos
F
Producto
final
Clasificador
Q
D
A
G
Equipo de
Reduccin de
Tamaos
Q
Clasificador
D
A
G Equipo de
Reduccin de
Tamaos
Q
Clasificador
D
A
G
P
D
C 100 =
P
D
C 100 =
P
R
Feed
A, mtph
a
i
Fine
P, mtph
p
i
Cp
A
Cp
R
D P A + =
i i i
Dd Pp Aa + =
D
D
P
P
A
A
Cp
Cp
D
Cp
Cp
P
Cp
Cp
A
) 100 ( ) 100 ( ) 100 (
+
) (
) (
100
i i
i i
a d
p a
C
=
Coarse
D, mtph
d
i
Cp
D
P D A
D A P
Cp Cp Cp
Cp Cp Cp
C
) (
) (
100
=
Since mass balance by size:
Since mass balance of water:
24
Feed
A, mtph
a
i
Fine
P, mtph
p
i
Cp
A
Cp
R
P D A
D A P
Cp Cp Cp
Cp Cp Cp
C
) (
) (
100
=
Example 1:
Cp
A
= 60%
Cp
D
= 80%
Cp
P
= 30%
Coarse
D, mtph
d
i
p
A
Cp
D
p
P
Example 2:
Cp
A
= 60%
Cp
D
= 78%
Cp
P
= 35%
R: Example 1=400%: Example 2=309,5%
Size Reduction Circuit Evolution Size Reduction Circuit Evolution
Size Reduction Circuit Evolution:
60s Decade
Transporte
a Proceso
Chancado
Primario
(Mandbulas)
Chancado
Secundario
(Cono
estndar)
Molino
e Bo s
A Flotacin
Conventional circuit:
Conventional blast
Jaw primary crusher
Symons cone crusher, secondary and terciary
Mills of 12 ft, 950 kW
The same power in both mill steps
Ball mill circuit is direct
Classification in spirals
Chancado
Terciario
(Cono
C. corta)
Tolva de Finos
Molino
de Barras
de Bolas
25
Transporte
a Proceso
Chancado
Primario
(Mandbulas)
Chancado
Secundario
(Cono Molino
A Flotacin
70s Decade
Unitary circuit:
Conventional blast
Jaw primary crusher
Symons cone crusher, secondary and terciary
Ball mills of 16,5 ft, 3.000 kW
Ball mill circuit is inverse
Classification in small hydrocyclon
estndar)
Chancado
Terciario
(Cono
C. corta)
Tolva de Finos
Molino
de Bolas
SAG mill Circuit:
Conventional blast
Giratory primary crusher
SAG mills of 36 ft, 11.200 kW
Balls mills of 18 ft, 4.800 kW
Power of primary mill is bigger than
secondary mill
Cl t f h d l f 20 i h
Transporte
a Proceso
Chancado
Primario
(Giratorio)
Stock
Pile
80s Decade
Cluster of hydrocyclons of 20 inch
Molino
de Bolas
A Flotacin
Pile
Clasificador
MolinoSAG
Pebbles
SAG mill circuit:
Conventional blast
Power of primary mill iqual to secondary mill
Pebbles crusher
Cluster of hydrocyclon of 26 inch
Transporte
a Proceso
Chancado
Primario
(Giratorio)
Stock Stock
Pile Pile
90s Decade
Pebbles
y y
Molino
de Bolas
A Flotacin
Clasificador
Molino SAG
26
SAG mill circuit:
Selective blast
Pre crushing
Power of primary mill less than secondary
mill
Pebbles crusher
Secundary circuit is inverse
Circuitos de Reduccin de Tamaos:
Dcada del 2000
Transporte
a Proceso
Chancado
Primario
(Giratorio)
Stock
Pile
Secundary circuit is inverse
Pebbles crushed to ball mills
Cluster of hydrocyclons de 33 inch
Molino
de Bolas
A Flotacin
Clasificador
MolinoSAG
Prechancado
(Cono
serie moderna)
Pebbles
Concentration Process Concentration Process
Feed
M
f
, G
f
Tail
M
t
, G
t
Concentrate
M
c
, G
c
t t
27
Concentration Circuit Concentration Circuit
Rougher o Bulk:
Is the first concentration step. Their objective is to
maximize the recovery. Produce a rougher concentrate
and rougher tails.
Scavenger:
W k ith h t il th i bj ti i t
Work with rougher tails, their objective is to
supplement the recovery. Produce a scavenger
concentrate and scavenger tails.
Cleaner:
Work with rougher concentrate, their objective is to
maximize the concentrate grade. Produce a cleaner
concentrate and cleaner tails.
Alimentacin
fresca
Relave
final
Rougher
Scavenger
Rougher
Feed
Tail
Concentrado
final
Scavenger
cleaner
Cleaner
Concentrate
Alimentacin
fresca
Relave
final
Rougher
Scavenger
Cleaner
Feed
Tail
Concentrado
final
Scavenger
cleaner
Recleaner
Scavenger
recleaner
Concentrate
28
Recovery, R (%):
100
feed in interest of element of mass
e concentrat in interest of element of mass
R =
Feed
Concentrate
MF , GF
MC, GC
Tail
MT, GT
100
F F
C C
G M
G M
R =
Concentration Ratio, K (%):
mass e Concentrat
mass Feed
K =
C
F
M
M
K =
Example:
A mineral process plant, processes 1000 mtpd of ore
with copper feed grade of 1,3%. The concentrate grade is
28% and the tail grade is 0,10%. If the plant produces 43
mtpd of concentrates and 957 mtpd of tails, determine:
C i h fl
o Copper mass in each flow
o Recovery
o Concentration ratio
a) 13,0, 12,04, 0,96 mtpd; b) 92,6%; c) 23,25
Material balance:
tail in flow Mass e concentrat in flow Mass feed in flow Mass + =
Ore balance:
M
f
= M
c
+M
t
Feed
MF , GF
Tail
M G
Element balance:
M
f
G
a
= M
c
G
c
+ M
t
G
t
Concentrate
MC, GC
MT, GT
29
Concentrate mass:
Recovery:
Feed
MF , GF
Tail
M G
F
T C
T F
C
M
G G
G G
M
=
C T F
G G G
R
) (
=
Concentration Ratio:
Concentrate
MC, GC
MT, GT
F T C
G G G
R
) (
=
T F
T C
G G
G G
K
=
Alimentacin
fresca
Relave
final
R h
Feed
Tail
2605 tph
1,29% Cu
0 12% Cu
Example:
Which is the flow mass in each point?
Concentrado
final
Rougher
Scavenger
cleaner
Cleaner
Concentrate
0,12% Cu
13,57% Cu
7,88% Cu
5,22% Cu
30,93% Cu
10,63% Cu
0,22% Cu
0,12% Cu
Relationship Between
Consumed Energy and Particle
Relationship Between
Consumed Energy and Particle
Size Size
30
Size Reduction and
Consumed Specific Energy
Size Reduction and
Primary crushing: < 1 kWh/t
Secondary crushing: Between 1 to 2 kWh/t
Tertiary crushing: Between 1,5 to 3 kWh/t
Tertiary crushing: Between 1,5 to 3 kWh/t
Primary mill: Between 4 to 8 kWh/t
Secondary mill: Between 6 to 20 kWh/t
Bond Bond s law s law (Bond (Bonds third theory) s third theory) Bond Bond s law s law (Bond (Bonds third theory) s third theory)
Energy Energy Particle Size Particle Size Energy Energy Particle Size Particle Size
(
(
1 1
10WI CSE
The Bonds law assumes that the total work useful in
breakage is inversely proportional to the square root
of the size of the product particles:
WI is the work index (kWh/t) which expresses he
resistance of the material to crushing and grinding;
and F
80
and P
80
are the 80% passing size of the feed
and the product (m), respectively.
(
(
=
80 80
1 1
10
F P
WI CSE
WI depend:
Ore (resistance at comminution)
The machine used
Energy Energy Particle Size Particle Size Energy Energy Particle Size Particle Size
WI is determined in a standard laboratory test
31
Reduction Ratio and
Reduction Ratio and
The balance between capacity and reduction
ratio is:
(
(
=
1 1
10W CSE
| | kW Pot
CSE =
Capacity Reduction ratio
(
(
=
80 80
10
F P
W CSE
i
| | t/h A
CSE =
In a first evaluation, we need:
CSE
Wi
Circulating Load
F
80
and P
80
Solid bypass in classification
Weir Minerals
Weir Minerals

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