Mineral Processing (MINE 342) 2023 Course Outline PDF

King Abdulaziz University Mining Engineering Department Mineral Processing (MINE 342) 2023 1  Class / lab. schedule Lectures: 3 hours/week, two meetings each of 1.5 hour What days ? At what time? At what c...

King Abdulaziz University Mining Engineering Department Mineral Processing (MINE 342) 2023 1  Class / lab. schedule Lectures: 3 hours/week, two meetings each of 1.5 hour What days ? At what time? At what class? What is required from you in lectures? Lab exercises: 2 hours/week, 1 meeting what days ? At what time? What is required from you in laboratories? COURSE CONTENT 1. Course Introduction 2. Safety in Mineral Processing plants 3. Sampling, Liberation and Metallurgical Balance 4. Size distribution (screening) and Classification 5. Comminution (Crushing and Grinding) 6. Sorting and Gravity Separation 7. Magnetic and Electrostatic Separation 8. Flotation 9. Dewatering and Tailing Disposal 10. Local Ore processing Flowsheets: Bauxite ore 11. Local Ore processing Flowsheets: Gold ores  Define mineral processing and its methods Mention the fundamental operations in mineral processing and their accomplishments Distinguish between the different types of flowsheets Course Learning Outcomes Determine the metallurgical balance in mineral processing Compare the different methods for particle size analyses in mineral processing List the different sample division methods in mineral processing and determine accuracy (C.L.O.) Mention equipments used in primary crushing of ores and their design and operating aspects List equipments used in secondary and tertiary crushing of ores and their specifications Design multi-stage crushing circuits List the different types of grinding mills and their design specifications Design different multi-stage grinding circuits Differentiate between the different types of gravity separators Categorize the different equipments used in separation of minerals of different magnetic properties Mention principles of materials separation according to electric conductivity Design a flowsheet involving combination and separation stages  References *Barry A. Wills, Tim Napier-Munn, "Mineral Processing Technology: An Introduction to the Practical Aspects of Ore Treatment and Mineral Recovery," 7th Edition, Amsterdam, [Netherlands]: Butterworth-Heinemann, 2016 * Ashok Gupta and Denis Yan, "Introduction to Mineral Processing Design and Operation" Elsevier, 16th May 2016, eBook ISBN: 9780444635891, Hardcover ISBN: 9780444635891 * Instructor notes  Assessment tools Tests & Mid Exam Laboratory Report and Final Exam poster Log in to the system download course calendar and Let us have a tour to completely understand it. Mentioned dates and activities cannot be changed Formation of minerals and rocks (Big Bang theory) Matter Evolution Since Big Bang Dimensions of Atom and Smaller Components 9 Oxygen and Elements Concentrations in Earth’s Crust Elements Associations in Earth’s Crust What is a mineral? A solid naturally-occurring, non-organic compound having a definite chemical composition Examples: quartz - SiO2 (an oxide) hematite - Fe2O3 (oxide) covelite - CuS (a sulphide) Wollastonite CaSiO3 Calcite CaCO3 Dolomite CaMg(CO3)2 Silica sand SiO2 Diopside CaMgSi2O6 More examples of minerals 13 Mineral Classification Minerals are classified by their chemical composition and internal crystal structure. There are 7 Major Mineral Groups:  Silicates  Native Elements  Halides  Carbonates  Oxides  Sulfates  Sulfides There are also 7 Major crystal structures: 14 Minerals Crystalline forms System Elemental cell (lattice) Examples of Minerals 1 2 3 1. Regular (C ) halite (NaCl) galena (PbS) a=b=c fluorite (CaF2)  =  =  = 90o sphalerite (ZnS) 2. Tetragonal (Q) rutile (TiO2) zyrkon (ZrSiO4) a=bc hausmanite (Mn3O4)  =  =  = 90o cassiterite (SnO2) 3. Rombic (O) sulfur (S) barite (BaSO4) abc stibnite (Sb2S3)  =  =  = 90o anhydrite (CaSO4) 4. Hexagonal (H) graphite (C) wurzite (ZnS) a=bc corundum (Al2O3)  =  = 90o,  = 120o covellite (CuS) 5. Trigonal (T ) (romboedric) -quartz (SiO2) calcite (CaCO3) a=b=c dolomite (MgCa(CO3)2)  =  =   90o hematite (Fe3O4) 6. Monoclinic (M) arsenopyrite (FeSAs) gipsum (CaSO4 ·2H2O) abc kriolite (Na3AlF6)  =  = 90o,   120o diopside (CaMgSi2O6) 7.Triclinic (A) albite (NaAlSi3O8) abc microcline (KAlSi3O8)       90o anortite (CaAl2Si2O8) kaolinite (Al4Si4O10(OH)8) Common metallic ores / sources Fe Hematite - Fe2O3 Magnetite - Fe3O4 Ilmenite - FeTiO3 Limonite - FeO(OH) / HFeO2 Al Canada, Russia, New Bauxites Caldonia, Cuba, United Gibbsite - Al2O3 3H2O States, South Africa Böhmite/diaspore - Al2O3 H2O Cu Chile, Peru, Mexico, Europe, South Africa, chalcopyrite – CuFeS2 several USA bornite – Cu5FeS4 Sn Malaysia, Thailand, and Bolivia Cassiterite – SnO2 Stannite –SnCu2(Fe.Zn)4 Caribbean area, Ni South America, Pentlandite [(Ni,Fe)9S8]. Australia and Africa 16 What is an ore and what is grade? An ore An occurrence of minerals or metals in sufficiently high concentration to be profitable to mine and process using current technology and under current economic conditions. Ore grade Grade is the concentration of economic mineral or metal in an ore deposit. It is expressed in ·Weight percentage, % (base metals) ·Grams/tonne or oz/ton (precious metals) ·ppm (rare elements and minor elements) Equivalent Metal Grade In polymetallic ores there is a grade called metal equivalent. As per class explanation Solve example in next slide for 2 extra marks i.e. student who solve it will get 2 marks Metal equivalent grade Find the grade of this block as Ag equivalent Base metal Ore Cu equivalent block Ag = 1.5% Zn equivalent Cu = 3.5 % Au equivalent Au = 1.9 g/t Zn = 8.9 % Use today metal price and assume you were able to extract all the metals in the ore i.e (recovery of 100 %) 18 Typical Grades of Ore Deposits Typical Grade Metal (% by weight) Aluminum 35 Iron 45 Copper 0.5-4 Nickel 1 Zinc 4 Uranium 0.3 Lead 5 Silver 0.01 Gold 0.0001-0.001 What does it take to be an ore deposit? 2 10 Iron Aluminum 1 10 Lead Zinc Typical Orebody Concentration Copper 0 10 Nickel Uranium -1 y=x 10 -2 10 Silver -3 10 Gold -4 10 -7 -5 -3 -1 1 3 10 10 10 10 10 10 Crustal Concentration  Solid chemical compounds occurring in Nature are called minerals Presently we know about 4 000 minerals See B. A. Wills “Mineral Processing Technology” 2003 7th ed. Appendix of names of minerals and their properties Understand how to calculate concentration of metal in mineral See bauxite example excel sheet  Understanding Saudi bauxite ore 27 16 1 55 56 24 28 Molecular weight Al2O3, % Al, % Al, % Mineral Al O H Mn Fe Mg Si 102 27 Al2O3, % Gibbsite Al(OH)3 1 3 3 78 65.38 34.61538 0.529412 Boehmite, γ-AlO(OH) 1 2 1 60 85.00 45 0.529412 Diaspore, α-AlO(OH) 1 2 1 60 85.00 45 0.529412 Corundum, Al2O3 2 3 102 100.00 52.94118 0.529412 Spinel, MgAl2O4 2 4 1 142 71.83 38.02817 0.529412 Hercynite, FeAl2O4 2 4 1 174 58.62 31.03448 0.529412 Galaxite, MnAl2O4 2 4 1 173 58.96 31.21387 0.529412 Kaolin Al2Si2O5(OH)4 2 9 4 2 258 39.53 20.93023 0.529412 All gamgue minerals 0 variable 0 Bauxite Analyses ore Mineral Al2O3, % Mineralogy Gibbsite Al(OH)3 33 Boehmite, γ-AlO(OH) 35 Diaspore, α-AlO(OH) 0 Kaolin Al2Si2O5(OH)4 14.64 All gangues 17.4 Goethite (FeO(OH)), 57.1 Hematite Fe2O3 Anatase TiO2 quartz SiO2 Calcite CaCO3 Others 17.36 100 22 Mineral Processing Methods = beneficiation + extractive metallurgy Mineral Dressing Overlap of physical and chemical methods, depending on product Where extractive metallurgy leaves off, metal processing begins 23  mining raw post-mining secondary raw materials raw materials materials MINERAL PROCESSING metallurgy chemical construction wastes industry materials Disciplines related to mineral processing 25