Mineral Processing Technology: A Concise Introduction

Cover
Half Title
Title
Copyright
Dedication
Contents
About the Author
Preface
Chapter 1 General Introduction
1.1 Introduction
1.2 Locations of Minerals
1.3 Mineral Deposits
1.4 Categories of Solid Minerals
1.5 Chemical States of Mineral Occurrence
1.5.1 Oxides
1.5.2 Sulphides
1.5.3 Carbonates
1.5.4 Arsenides
1.5.5 Native Noble Metals
1.6 The Purpose of Mineral Processing
1.7 Geological Exploration
1.8 The Earth’s Core and Ore Mineral Formation
1.9 Formation of Accessible Ore Deposits
1.10 Mechanisms of Accessible Ore Deposit Formation
1.11 Formation of Ore Deposits
1.12 Igneous Deposits
1.12.1 Magmatic Deposits
1.12.2 Segregations
1.12.3 Disseminations
1.12.4 Magmatic Injections
1.13 Specific Ore Formations
1.13.1 Gold Nuggets Formation
1.13.2 Formation of Spinel Group of Minerals
1.13.3 Magmatic Mineral Deposit by Crystal Settling
1.13.4 Ore Formation from Magmas by Liquid Immiscibility
1.13.5 Pegmatite Deposits
1.13.6 Hydrothermal Deposits
1.13.7 Marine Hydrothermal Deposits
1.13.8 Sedimentary Deposits
1.13.8.1 Weathering
1.13.8.2 Sedimentary Genesis
1.13.8.3 Placer Deposits
1.13.9 Metamorphic Deposits
1.14 Ore Formation Mechanisms that Involve Oxidation State in Water
1.15 Spread of Solid Minerals in Nigeria
1.15.1 The Benue Trough of Nigeria
1.15.2 Sedimentary Rock Iron Deposits
1.15.3 The Minor Sedimentary Basin
1.15.4 Magmatic Ore Deposits
1.15.5 The Metamorphic Rock Deposits
1.15.6 The Carbonate Province
1.15.7 Coastal Deposits
1.15.8 Erosion Deposits
1.16 Notable Mineral Resources of Africa
1.17 Notable Mineral Resources of the United States
1.18 Notable Ore Deposits of India
1.19 Notable Ore Deposits in Canada
1.20 Introduction to Ore Processing
References
Chapter 2 Ore Handling
2.1 Introduction
2.2 Harmful Materials Separation from Ore
2.2.1 Steel Scrap
2.2.2 Wood
2.2.3 Clays and Slimes
2.3 Transportation of Ore
2.3.1 The Challenge of Ore Transport in the Plant
2.4 Ore Storage
2.5 Ore Feeding
2.6 Ore Handling in the Laboratory
2.6.1 Ground Survey
2.7 Laboratory Sample Preparation
2.7.1 Jones Riffle Splitter
2.7.2 Coning and Quartering
2.7.3 Application of Gy Sampling Theory
2.8 Determination of Moisture Content
2.8.1 The Karl­Fischer Titration Method
2.8.2 Drying Oven Method
2.8.3 Microwave Oven Drying
2.8.4 Inline Methods
2.8.5 Determination of Loss on Ignition
2.9 Ore Roasting
References
Chapter 3 Ore Crushing
3.1 Introduction
3.2 Primary Crushers
3.2.1 Jaw Crushers
3.2.2 Blake Jaw Crusher
3.2.3 Jaw Crushers Feeding
3.3 Gyratory Crusher
3.4 Secondary Crushers
3.4.1 Roll Crusher
3.4.2 Cone Crusher
3.4.3 Impact Crusher
3.4.4 Hammer Mills
3.5 High Pressure Grinding Rolls (HPGR)
3.6 Horizontal Shaft Impact (HSI) Crusher
3.7 Vertical Shaft Impact (VSI) Crusher
References
Chapter 4 Ore Grinding
4.1 Introduction
4.2 Comparison of Crushing and Grinding
4.3 The Concept of Correct Grinding
4.4 Mechanisms of Grinding in Tumbling Mills
4.5 The Motion of the Charge in a Tumbling Mill
4.6 Type of Tumbling Mills
4.6.1 Rod Mills
4.6.2 Ball Mills
4.7 Stirred Mills
4.8 Autogenous (AG) and Semi­autogenous (SAG) Mills
4.9 Pebble Mill
4.10 Development of Milling Curves
4.11 Open and Closed Circuit Grinding
References
Chapter 5 Theory of Comminution
5.1 Introduction
5.2 The Theory and Principles of Comminution
5.3 Comminution Theory
5.4 Crack Propagation in Minerals
5.5 Worked Examples
References
Chapter 6 Particle Size Analysis
6.1 Introduction
6.2 Importance of Particle Size Analysis in Mineral Processing
6.3 Particle Size and Shape
6.4 Methods of Particle Size Analysis
6.4.1 Method of Test Sieving
6.4.2 Test Sieving Procedure
6.4.3 Presentation of Results
6.4.4 Construction of Test Sieve Graphs
6.4.5 Deductions from the Curves
6.5 Determination of Stokes’ Equivalent Diameter
6.6 Dynamic Image Analysis
6.7 Laser Diffraction
6.8 Determination of Particle Shape and Size
References
Chapter 7 Ore Mineralogy and Chemical Analyses
7.1 Ore Mineralogy
7.2 Transmitted Light Microscope
7.2.1 Color
7.2.2 Pleochroism
7.2.3 Habit
7.2.4 Cleavage
7.3 Reflected Light Microscope
7.4 Thin Section Transmitted Light Experiment
7.5 Ore Chemical Analyses
7.5.1 Inductively Coupled Plasma and Atomic Absorption Spectroscopy (ICP & AAS)
7.5.2 X­ray Fluorescence and X­ray Diffraction Techniques
7.5.3 Electron Probe Microanalysis (EPMA)
7.5.4 Scanning Electron Microscope (SEM)
7.5.5 Transmission Electron Microscope
7.5.6 Mass Spectrometry
7.6 Visible and Infrared Spectroscopy
References
Chapter 8 Ore Screening
8.1 Introduction
8.2 Main Purposes of Industrial Screening
8.3 Screen Performance
8.4 Efficiency or Partition Curve or Tromp Curve
8.5 Screen Types
8.6 Grizzly Screens
8.7 Industrial Screening
References
Chapter 9 Ore Classification
9.1 Introduction
9.2 The Principles of Classification
9.3 Settling of Ore Particles in Carrier Fluids
9.3.1 Conditions for Particles Settling
9.3.2 The Forces Acting on a Particle
9.4 Conditions for Equal Settling Rate of Particles
9.4.1 Free Settling Conditions
9.4.2 Hindered Settling Conditions
9.5 Worked Examples
9.6 Types of Classifiers
9.6.1 Hydraulic Classifier
9.6.2 Hydrocyclone
9.7 The d50 Cut Point
9.8 Worked Example
References
Chapter 10 Metallurgical Accounting Analyses
10.1 Slurry Streams Analysis
10.2 Determination of Volumetric Flow Rate of Slurry
10.3 The Composition of a Slurry
10.4 Worked Examples
10.5 Mass Balancing Methods
10.6 Slurry Pump Calculations
References
Chapter 11 Mineral Processing Methods
11.1 Introduction
11.2 Gravity Concentration Methods
11.2.1 Introduction
11.2.2 Advantages of Gravity Methods
11.2.3 Principles of Gravity Separation
11.3 Factors that Affect Gravity Concentration’s Efficiency
11.3.1 Density of Ore Minerals
11.3.2 Ore Particle Size
11.3.3 Slimes
11.3.4 Correct Water Ratio
11.3.5 Presence of Sulphide Minerals
11.3.6 The Presence of Useful Valuable Contaminants
11.4 Gravity Concentrators
11.4.1 Jigging: Gravity Separation
11.4.2 The Jigging Process
11.4.3 Shaking Tabling
11.4.4 Humphrey Spiral
11.4.5 Falcon Gravity Concentrator
11.5 Knelson Gravity Concentrator
11.6 Industrial Spiral Concentration
References
Chapter 12 Dense Medium Separation
12.1 Introduction
12.2 The Principles of Dense Medium Separation
12.3 Types of Heavy Liquids
12.3.1 Dense Organic Liquid Chemicals
12.3.2 Dense Inorganic Aqueous Solution
12.3.3 Suspensions of Ore Particles in Water
12.4 Coal Sink and Float Test
12.5 Dense Medium Industrial Separation
12.6 Liquid Mixing Equation
References
Chapter 13 Froth Flotation
13.1 Introduction
13.2 The General Principle of Froth Flotation
13.3 Collectors
13.4 The Operating Technique
13.5 The Flotation Stages
13.5.1 Roughing
13.5.2 Cleaning
13.5.3 Scavenging
13.6 The Science of Flotation
13.7 Theory of Flotation
13.8 Polar and Non­polar Minerals
13.9 Grease Tabling of Diamond
13.10 Polar Minerals
13.11 Frothers, Activators and Depressants
13.12 Mechanisms of Froth Flotation
13.13 Column Flotation
13.14 Flotation Conditioning
13.14.1 Air Control
13.14.2 Level Control
13.14.3 Feed Rate
13.14.4 Overdosing of Reagents
13.14.5 Procedure for Laboratory Froth Flotation Test
13.15 Typical Laboratory­scale Froth Flotation Tests
13.16 Pilot-scale Froth Flotation Test
References
Chapter 14 Magnetic Separation
14.1 Introduction
14.2 Principles of Magnetism
14.3 Type of Materials Based on Magnetism
14.3.1 Ferromagnetic Materials
14.3.2 Paramagnetic Materials
14.3.3 Diamagnetic Materials
14.4 Principle of Magnetic Separation
14.5 Categories of Magnetic Separators
14.6 Design in Magnetic Separation
14.7 Wet Drum Magnetic Separation
14.8 Operation of a Wet High­intensity Magnetic Separator (WHIMS)
14.9 A Laboratory Bench WHIMS Practice
14.10 Wet Magnetic Separation with BOXMAG Rapid Equipment
14.11 Permanent Drum Magnetic Separator
14.12 Low­intensity Magnetic Separator (LIMS)
14.13 Laboratory­scale Magnetic Concentration of Ores
14.14 Pilot­scale Magnetic Concentration of Ores
14.15 Magnetizing Roasting Experiment
14.16 Electrostatic Separation
References
Chapter 15 Ore Sorting
15.1 Introduction
15.2 The Principles of Electronic Sorting
15.3 Mechanism of Operation
15.4 Types of Ore Sorters
15.5 The Model 16 Photometric Sorter
15.6 The Belt Sorter
15.7 Industrial Ore Sorting
References
Chapter 16 Dewatering and Tailings Disposal
16.1 Introduction
16.2 Filtration
16.3 Sedimentation
16.4 Thermal Drying
16.5 The Principles and Operation of a Thickener
16.6 Coagulation and Flocculation
16.7 Tailings Disposal
16.8 Laboratory Testing for Thickener Design
16.9 Industrial Thickener
16.10 Talmadge and Fitch Method
16.11 Worked Example
References
Chapter 17 Automatic Control in Mineral Processing Plants
17.1 Introduction
17.2 Principles of Automatic Control
17.3 Identification of Process Variables
17.4 Process Modeling
17.5 In­line Instrumentation
17.6 Overall Control Architecture
17.6.1 Control Objectives
17.7 General Control Scheme
17.8 In­line Instrumentation for Automatic Control in Mineral Processing Plants
17.8.1 A Mass Flow Meter
17.8.2 The Magnetic Flow Meter
17.8.3 Ultrasonic Flow Meter
17.8.4 Nucleonic Density Gauge
17.8.5 Non­nuclear Density Gauge
17.8.6 On­line Chemical Analysis
References
Chapter 18 Introduction to Flowsheets Design
18.1 Introduction
18.2 Quantified Flow Data Derivation
18.2.1 Worked Example
References
Chapter 19 Assessment of Metallurgical Efficiency of Mineral Processing Operations
19.1 Parameters to Assess the Quality of Concentrates
19.1.1 Grade or Assay of the Concentrate
19.1.2 Recovery
19.1.3 Ratio of Concentration (R)
19.1.4 The Enrichment Ratio (RC)
19.2 Relationship between Recovery and Grade
19.3 Metallurgical Efficiency of Separation Processes
19.4 The Schulz Separation Efficiency
19.5 Worked Examples
19.6 The Net Smelter Return (NSR) Curve
19.7 Practical Factors that Affect Metallurgical Efficiency
19.7.1 Liberation of Mineral Value
19.7.2 Particle Size
References
Chapter 20 Sustainable Mineral Processing
20.1 Introduction
20.2 Approaches for Sustainable Mineral Processing
20.2.1 The Application of Improved Ore Comminution
20.2.2 Improved Ore Processing
20.2.3 The Geometallurgy Approach
20.3 Analytical Methods for Geometallurgy
20.3.1 The Transmitted Light Microscope
20.3.2 Description of Minerals in Thin Sections in Plane­polarized Light
20.3.3 Description of Minerals in Thin Sections in Cross­polar Light
20.3.4 The Reflecting Microscope
20.3.5 Rietveld Analysis
20.3.6 Quantitative Evaluation of Minerals by Scanning Electron Microscopy (QEMSCAN)
20.3.7 Mineral Liberation Analysis (MLA)
20.3.8 Scanning Electron Microscopy (SEM)
20.3.9 Sustainable Circularity in Mineral Processing
References
Chapter 21 Processing of Rare Earth Minerals
21.1 Introduction
21.2 Beneficiation Methods for REE Minerals
21.3 Pyrometallurgy and Hydrometallurgy in REE Processing
21.4 Hydrometallurgy
21.4.1 Leaching of Eudialyte
21.5 Secondary Resources of REEs
21.6 Supercritical Fluids Applications
21.7 Recovery of REEs from Coal Resources
References
Chapter 22 Applications of Leaching and Microorganisms in Mineral Processing
22.1 Introduction
22.2 Application of Microorganisms
References
Chapter 23 Tailings Re-treatment
23.1 Introduction
23.2 Approaches for Tailings Re­treatment
23.2.1 Industry Re­treatment of Tailings
23.2.2 Retreatment through Heap Leaching
23.2.3 Tailings Re­concentration
23.2.4 Microbial Treatment and Leaching Technology
23.2.5 Tailings Dewatering Process
23.2.6 Filling of the Mined­out Areas
23.3 Tailings Sand Cement Filling Technology
23.4 Water Consolidation Sand Filling Technology
23.4.1 Production of Geo­polymers
References
Chapter 24 Mineral Processing of Beach Sand Minerals
24.1 Introduction
24.2 Processing of Beach Ores
References
Chapter 25 Processing of Battery Minerals
25.1 Introduction
25.2 Beneficiation Methods
25.2.1 Beneficiation of Nickel Ores
25.3 Leaching Recovery of Cobalt and Nickel
25.4 Processing of a Nickel­copper Sulphide Ore
25.4.1 Flotation Concentration
25.4.2 Roasting
25.4.3 Leaching and Solution Recovery
25.4.4 Copper Solvent Extraction
25.4.5 Processing of Lithium Ores
References
Chapter 26 Processing of Refractory Ores
26.1 Introduction
26.2 Pre­treatment Methods
References
Chapter 27 Processing of Non-metallic
Ores
27.1 Introduction
27.2 Geochemical Classification of Minerals
27.3 Classes of Non­metallic Minerals
27.3.1 Chemical Raw Material
27.3.2 Metallurgical Raw Materials
27.3.3 Construction Non­metallic Materials
27.3.4 Non­metallic Ore Raw Materials
27.4 Processing of Non­metallic Minerals
27.4.1 Processing of Phosphate Ores
27.4.2 Processing of Diamond Ores
27.4.3 Tar Sands
27.4.4 Processing of Fluorite Ores
References
Chapter 28 The Operation of a Quarry
28.1 Introduction
28.2 Mining the Rocks
28.3 Crushing the Rocks
28.4 Storage
28.5 Environmental Protection
28.6 Aggregates
References
Index