MMT 111 Introduction to Mineral Processing.pdf

MMT 111 Introduction to Metallurgy Introduction to Metallurgy Engr. Myra V. Cabatingan ❑ Metallurgy is a domain of materials science and engineering that studies the physical and chemical behaviour of metallic elements, their inter-metallic compounds, and their m...

MMT 111 Introduction to Metallurgy Introduction to Metallurgy Engr. Myra V. Cabatingan ❑ Metallurgy is a domain of materials science and engineering that studies the physical and chemical behaviour of metallic elements, their inter-metallic compounds, and their mixtures which are called alloys. ❑ Metallurgy comprises of 3 steps: i. Concentration of Ore ii. Isolation of metal from the concentrated ore iii. Purification of the metal Introduction to Metallurgy Basic Terminologies: ▪ Mineral: A solid, naturally occurring ▪ Tailing: are the materials left over after inorganic substance formed by the process of separating the valuable geological processes. fraction from the uneconomic fraction ▪ Ore: A naturally occurring solid material (gangue) of an ore. from which a metal or valuable mineral ▪ Flux: It is a chemical cleaning agent used for purification of the ores. ▪ Slag: waste matter separated from metals during the extraction of ores. ▪ Gangue: In mining, gangue is commercially worthless material that surrounds, or is closely mixed with, a wanted mineral in an ore deposit. The separation of mineral from the gangue is known as mineral processing. Introduction to Metallurgy Introduction to Metallurgy Branch of Metallurgy Metallurgy Physical Mineral Extractive Metallurgy Processing Metallurgy Pyrometallurgy Hydrometallurgy Electrometallurgy Introduction to Metallurgy  MMT 111 Introduction to Metallurgy Introduction to Mineral Processing and Beneficiation Engr. Myra V. Cabatingan MINERAL naturally occurring, inorganic substance with definite chemical composition and a crystalline structure 4,000 Also often used to include anything of economic value which is extracted from the earth (eg. coal, chalk, clay and granite) ❖ Gold and platinum metals are found in native form ❖ Silver, copper and mercury may be found in native form as well as in sulphides, oxides and carbonates ❖ The rest of the metals are always found in compound forms Quartz, SiO2 Galena, PbS Pyrite, FeS2 Introduction to Metallurgy MINERAL naturally occurring, inorganic substance with definite chemical composition and a crystalline structure 4,000 Also often used to include anything of economic value which is extracted from the earth (eg. coal, chalk, clay and granite) ❖ Gold and platinum metals are found in native form ❖ Silver, copper and mercury may be found in native form as well as in sulphides, oxides and carbonates ❖ The rest of the metals are always found in compound forms Introduction to Metallurgy Introduction to Metallurgy a. Silica mineral – SiO2 ▪ any of the forms of silicon dioxide (SiO2), including quartz, tridymite, cristobalite, coesite, stishovite, lechatelierite, and chalcedony. ▪ Various kinds of silica minerals have been produced synthetically Introduction to Metallurgy  b. Nickel Minerals ▪ Nickel (element #28, symbol Ni) is a silvery shiny, metallic element. ▪ Nickel is usually found in laterite deposits, which are deposits in which strong weathering leaches nickel-rich rock and concentrates nickel at or near the surface of the Earth. Introduction to Metallurgy c. Mica minerals ▪ Mica type minerals make a group of silicates of alumina, with potash, iron, magnesia; ▪ characterized by easy cleavage into thin, flexible, elastic sheets. Mica gives off water when strongly heated. Muscovite, or white mica Phlogopite, or amber mica Biotite, or black mica Lepidolite, or Lithium mica Introduction to Metallurgy c. Mica minerals Introduction to Metallurgy d. Manganese minerals manganite hausmannite pyrolusite romanechite Introduction to Metallurgy e. Iron minerals ▪ Iron ores are rocks and minerals from which metallic iron can be economically extracted. ▪ The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, or deep purple to rusty red. Introduction to Metallurgy  f. Gypsum minerals ▪ Gypsum is a soft sulfate mineral composed of calcium sulfate dihydrate, with the chemical formula CaSO 4·2H₂O. ▪ It is widely mined and is used as a fertilizer and as the main constituent in many forms of plaster, blackboard/sidewalk chalk, and drywall. Introduction to Metallurgy  g. Gold ▪ Native gold is an element and a mineral. ▪ Gold in its natural mineral form almost always has traces of silver, and may also contain traces of copper and iron. Introduction to Metallurgy h. Feldspar ▪ Feldspar is the name given to a group of minerals distinguished by the presence of alumina and silica (SiO2) in their chemistry. ▪ This group includes aluminum silicates of soda, potassium, or lime. ▪ It is the single most abundant mineral group on Earth. Introduction to Metallurgy i. Copper minerals ▪ Most of the world's copper comes from the minerals chalcopyrite and chalcocite. ▪ Chrysocolla and malachite also are mined for copper. ▪ Other copper-bearing minerals include atacamite, azurite, bornite, brochantite, cuprite (copper oxide), dioptase, rosasite and tetrahedrite. Introduction to Metallurgy i. Copper minerals Introduction to Metallurgy j. Chromite minerals ▪ Chromite is an oxide mineral composed of chromium, iron, and oxygen (FeCr2O4). ▪ It is dark gray to black in color with a metallic to submetallic luster and a high specific gravity. Introduction to Metallurgy  k. Calcite ▪ Calcite is a carbonate mineral and the most stable polymorph of calcium carbonate (CaCO3). ▪ The Mohs scale of mineral hardness, based on scratch hardness comparison, defines value 3 as "calcite". ▪ Other polymorphs of calcium carbonate are the minerals aragonite and vaterite. Introduction to Metallurgy l. Sulfur minerals ▪ most common are anhydrite (calcium sulfate), barite (barium sulfate), chalcocite (copper sulfide), chalcopyrite, cinnabar (mercury sulfide), galena (lead sulfide), kieserite (magnesium sulfate), gypsum, sphalerite (zinc sulfide), and stibnite (antimony sulfide). Introduction to Metallurgy Relative abundance of elements found in the earth’s crust (Wills, 2005). Introduction to Metallurgy ORE Refers to a naturally-occurring rock that contains metal or metal compounds. There must be enough metal in the rock to make it worth extracting at a comparatively low cost. Ores are materials that we mine. They contain enough metal to justify mining on a commercial scale. In other words, we must be able to mine it at a profit. ❑ The ore grade is a measurement of the metal content of ore ❑ Deposits are any known quantity of metal ores – not necessarily enough to mine.(if there is, it’s known as resource) ❑ Gangue – extraneous rocky material of no economic value usually entrained in ores Introduction to Metallurgy Ore Classification 1. Native ores – metal is present in the elementary form 2. Sulphide ores – contain the metal as sulphides 3. Oxidized ores – valuable mineral may be present as oxide, sulphate, silicate, carbonate or some hydrated form 4. Complex ores – contain profitable amounts of more than one valuable mineral Introduction to Metallurgy Ore Classification Sulphide ores Oxidized ores Significant examples include: These minerals include argentite (silver sulfide), azurite (Cu3(CO3)2(OH)2) cinnabar (mercury sulfide), galena (lead sulfide), malachite(Cu2(CO3)(OH)2) molybdenite (molybdenum sulfide), gold pentlandite (nickel sulfide), realgar (arsenic silver sulfide), and stibnite (antimony), sphalerite chalcocite (Cu2S) (zinc sulfide), and pyrite (iron disulfide), and chalcopyrite (CuFeS2.) chalcopyrite (iron-copper sulfide). Introduction to Metallurgy Ore Classification Complex ores The major minerals of complex ores are: galena (PbS) sphalerite (ZnS). pyrite (FeS2) chalcopyrite (CuFeS2) arsenopyrite (FeAsS) cassiterite (SnO2) Introduction to Metallurgy Introduction to Metallurgy Introduction to Metallurgy Introduction to Metallurgy MINERAL PROCESSING ▪ Also known as ore dressing, ore beneficiation, mineral dressing, or milling. ▪ It is the process of separating commercially valuable minerals from the ore. ▪ Crushing and separating ore into valuable or waste by any of a variety of techniques. ▪ It is the first process that most ores undergo after mining in order to provide a more concentrated material for the procedures of extractive metallurgy. Introduction to Metallurgy MINERAL PROCESSING Four principal steps: a. Size reduction - to liberate the grains of valuable mineral from gangue minerals Introduction to Metallurgy MINERAL PROCESSING Introduction to Metallurgy MINERAL PROCESSING Introduction to Metallurgy MINERAL PROCESSING Four principal steps: b. Sizing- is the separation of material or product into various fractions characterized by difference in size. Sizing can be performed by screening or classification. c. Concentration- may be regarded as collections of valuable in a small bulk. It is carried out by various means which mainly depend upon the mineral types and it characteristic Introduction to Metallurgy MINERAL PROCESSING Four principal steps: d. Dewatering- after concentration the concentrate is in moist form or in a liquid pulp so it first dewatered before sending it to smelter or for shipment. Introduction to Metallurgy MINERAL PROCESSING Two fundamentals of Mineral Processing 1. Liberation – the release of valuable minerals Locking of mineral and gangue Cross-section of oreparticles Introduction to Metallurgy  MINERAL PROCESSING Two fundamentals of Mineral Processing 2. Concentration - the separation of these values from the gangue 1. Sorting by visual observation 2. Gravity concentration based on density differences 3. Froth flotation based on different surface properties 4. Magnetic separation 5. High tension separation based on electrical conductivity Introduction to Metallurgy MINERAL PROCESSING Factors to consider 1. Processing costs 2. Mineral losses 3. Power and water supply 4. Access roads 5. Tailings disposal 6. Taxes and royalty payments 7. Research and development 8. Medical and safety costs Introduction to Metallurgy Introduction to Metallurgy  PROCESS FLOWSHEET ▪ The flow sheet is the key document in process design. ▪ It shows the arrangement of the equipment selected to carry out the process, the stream connections, stream flow rates and compositions, and the operating conditions. Discard, Enriched portion containing containing most predominantly of the valuable mineral the gangue minerals Introduction to Metallurgy Introduction to Metallurgy Introduction to Metallurgy  End Page Click to edit title style Click to edit subtitle style