MINERAL PROCESSING TECHNOLOGY CONTENT 1. Introduction Basic definitions Minerals by value The process frame of minerals Mineral processing and hardness Size and hardness The stress forces of rock mechanics 2. Minerals in operation Operation stages Operation – dry or wet? Mining and quarry fronts _ Natural fronts Size reduction Size control Enrichment – washing Enrichment – separation Upgrading Materials handling Wear in operation Operation and environment Operation values 3. Size reduction The size reduction process Feed material Reduction ratio The art of crushing Crushing of rock and gravel Crushing of ore and minerals Crushing – calculation of reduction ratio Selection of crushers Primary crusher – type Primary crusher – sizing Secondary crusher – type Cone crusher – a powerful concept Secondary crusher – sizing Final crushing stage – more than just crushing VSI – a rock protected impactor High Pressure Grinding Rolls (HPGRs) - HRC™ Final crusher – sizing Wet crushing prior to grinding Technical data: Gyratory crusher – SUPERIOR® MK-II PrimaryTechnical data: Jaw crusher – C series Technical data: Impact crusher – NP series Technical data: Cone crusher – GPS series Technical data: Cone crusher – HP series Technical data: Cone crushers – HP 3, 4 and 5 series Technical data: Cone crusher – MP series Technical data: Cone crusher – GP-series Technical data: Vertical shaft impactor (VSI) Technical data: High pressure grinding rolls (HPGRs) - HRC™ Grinding – introduction Grinding methods _ Grinding mills – reduction ratios Grinding – tumbling mills _ Grinding – stirred mills Grinding – vibrating mills Cost of grinding – typical Mill linings – basic Grinding mills – sizing Grinding circuits _ Vertimill circuits Stirred media detritors (SMD) circuits Grinding – power calculation Grinding – bonds work index Pulverizing of coal Vertimill more than a grinding mill _ Vertimill as lime slaker Grinding vs enrichment and upgrading _ Technical data: AG and SAG mills Technical data: Ball mills Technical data: Spherical roller bearing supported ball mills Technical data: Conical ball mills technical data: SRR mill __ Technical data: Vertimill (wide body) Technical data: Vertimill Technical data: Vertimill (lime slaking) Technical data: Stirred media grinding mills Technical data: Vibrating ball mill 4. Size control Size control – introduction Size control by duties Size control by methods Screens Screening by stratification Screening by free fall Screen types Screen capacities Selection of screening media Particle size – mesh or micron? Technical data: Single inclination screen – circular motion Technical data: Double inclination screen – linear motion Technical data: Triple inclination screen – linear motion Classification – introduction Wet classification – fundamentals Hydrocyclone Spiral classifiers Dry classification – introduction Static classifiers Dynamic classifiers Ancillary air solutions Dry grinding Size control in crushing and grinding circuits 5. Enrichmen Enrichment – introduction _ Enrichment – processes Wash water treatment Separation – introduction Separation by gravity Separation in water Separation by jigs Separation by spiral concentrators Separation by shaking tables Separation in dense media Separation by flotation Flotation circuit layout _ Reactor cell flotation system (RCS) Reactor cell flotation system (RCS) – sizing Technical data: Flotation machines RCS DR flotation cell system Technical data: Flotation machine DR, metric Technical data: Flotation machine DR, US Column flotation cell system _ Column flotation – features Magnetic separation – introduction Magnetic separation – methods Magnetic separation – separator types _ Magnetic separation – equipment Dry LIMS, belt drum separator BS Technical data: Dry LIMS, belt separator BSA and BSS Dry LIMS, drum separator DS Technical data: Dry LIMS, drum separator DS Wet LIMS – Wet magnetic separators Wet LIMS – concurrent (CC) Wet LIMS – counter rotation (CR) and (CRHG) Wet LIMS – countercurrent (CTC) and CTCHG Wet LIMS – froth separator (DWHG Wet LIMS – dense media recovery (DM) (DMHG) Technical data: Wet LIMS – concurrent (CC) Technical data: Wet LIMS – counter rotation (CR) and (CRHG Technical data: Wet LIMS – countercurrent (CTC) and CTCHG Technical data: Wet LIMS – froth separator (DWHG) Technical data: Wet LIMS – dense media recovery (DM) (DMHG) Wet HGMS/F – magnet design Wet HGMS, HGMF – separator types Wet cyclic HGMS Wet cyclic HGMS – process system Wet cyclic HGMS – operation Wet cyclic HGMS – application Wet cyclic HGMS – sizing Technical data: Wet cyclic HGM Wet cyclic high gradiant magnetic filter HGMF HGMF – applications HGMF – process data HGMF – sizing Technical data: Wet cyclic high gradiant magnetic filter HGMF Wet continuous HGMS Wet continuous HGMS – process system Wet continuous HGMS – applications Wet continuous HGMS – sizing and selection Technical data: Wet continuous HGMS Leaching of metals Gold leaching Gold leaching- carbon adsorption Gold leaching – CIP 6. Upgrading Upgrading – introduction Upgrading by methods Upgrading by operation costs _ Sedimentation Flocculation Conventional clarifier Conventional clarifier – sizing Conventional thickener Conventional thickener – sizing Conventional clarifier/thickener – design Conventional clarifier/thickener – drive system Conventional clarifier/thickener – drive sizing Lamella or inclined plate sedimentation – introduction Inclined plate settler (IPS) Inclined plate settler – drives Inclined plate settler – product range Technical data: Inclined plate settler (LT) Technical data: Inclined plate settler (LTS) Technical data: Inclined plate settler (LTK) Technical data: Inclined plate settler (LTE) Technical data: Inclined plate settler (LTE/C) Technical data: Inclined plate settler (LTC) Mechanical dewatering – introduction _ Mechanical dewatering – introduction _ Mechanical dewatering – methods and products Gravimetric dewatering Spiral dewaterer Technical data: Spiral dewaterer Sand screw Dewatering screen Dewatering wheel Mechanical dewatering by pressure – introduction Drum vacuum filters __ Belt drum filters Top feed filters Vacuum filters – vacuum requirements _ Vacuum plant – arrangement Vertical plate pressure filter – introduction _ Vertical plate pressure filter – design Pressure filter VPA – operation Pressure filter VPA – sizes Pressure filter VPA – chamber data Pressure filter VPA – nomenclature Pressure filter VPA – sizing Pressure filter VPA – moisture in filter cake Pressure filter VPA – compressor sizing Pressure filter VPA – compressor power Pressure filter VPA – feed pump selection Pressure filter VPA – feed pump power Pressure filter VPA – product system Technical data: Pressure filter VPA 10 Technical data: Pressure filter VPA 15 Technical data: Pressure filter VPA 20 Tube press – introduction Tube press – design Tube press – operation Tube press – applications Tube press – material of construction _ Tube press – sizes Tube press – sizing Tube press – cycle times and cake moisture Tube press – capacity Tube press – product system Tube press – booster system Tube press – mechanical description Technical data: Tube press _ Thermal processing – introduction _ Direct heat rotary dryer (cascade type) Indirect heat rotary dryer (kiln) Fluidized bed Indirect heat screw dryer (Holo-flite) Holo-fliteprocess syste Technical data: Indirect heat screw dryer (Holo-flite) Fluidized bed Something about cooling Iron ore pelletizing _ Pellet plant schematic Feed preparation Grate Kiln technology Major process equipment components of iron ore pellet plant Design criteria and plant sizing Comparisons of indurating technologies _ Lime calcining system Coke calcining system Tire pyrolysis 7. Materials handling Introduction Loading and unloading Railcar dumpers Train positioners Unloaders Storage buffering Stacker reclaimer Scraper reclaimer Barrel reclaimer Feeding Technical data sheets Technical data: Feeder – Apron Technical data: Feeder – Vibration Technical data: Feeder – Unbalanced motor Technical data: Feeder – Belt Technical data: Feeder – Electromagnetic _ Technical data: Feeder – Wobbler Conveying Conveying systems Conveyor capacities Volume weight and angle of inclination _ Conveyor - more than a rubber belt Technical data: Conveyor – Standard belt Vertical conveyor system 8. Slurry handling Slurry handling – introduction Basic definitions Slurry pump range MD Technical data: MD Slurry pumps – range XM Technical data: XM Slurry pumps – range XR and VASA HD Technical data: XR and VASA HD Dredge pumps – range Thomas Technical data: Thomas Slurry pumps – range HR and HM Technical data: HR and HM Slurry pumps – range MR and MM Technical data: MR and MM Slurry pumps – range VS Technical data: VS Slurry pumps – range VSHM and VSMM Technical data: VSHM and VSMM Slurry pumps – range VT Technical data: VT Slurry pumps – range VF Technical data: VF Application guide for slurry pumps _ Selection – by solids Selection – by head and volume Selection – by slurry type Selection – by industrial application Minerals Construction _ Coal Waste and recycling Power and FGD Pulp and paper Metallurgy Chemical Mining Agitation – Attrition scrubber Attrition scrubber – Sizing “The slurry line” Technical data: Material handling hoses _ Technical data: Rubber lined steel pipes Technical data: 3xD bends 45 Technical data: 3xD bends 90 Technical data: Branch pipes Technical data: Gaskets Technical data: Couplings Technical data: Reducers, rubber lined steel Technical data: Compensators Technical data: Tailing compensators / bends Technical data: Tailing pipes 9. Wear in operation Introduction Wear in operation – caused by Wear by compression Wear by impaction (high) Wear by impaction (low) Wear by sliding Wear protection and products Wear products – application Heavy impact – selection Impact and sliding – selection (modules) Impact and sliding – selection (sheeting) Sliding and build up – selection Wear protection – wear parts Wear parts – slurry pumps Something about ceramic liners Wear in slurry pipelines 10. Operation and environment Operation and environment – introduction _ Dust control – basic Noise _ Noise reduction Ear protection 11. Process system Process system – Introduction System modules – aggregates System modules – sand & gravel System modules – ore & minerals Process system – railway ballast Process system – asphalt / concrete ballast Process system – ferrous ore Process system – base metal ore Process system – gold bearing ore Process system – coal Process system – industrial mineral fillers Process system – glass sand Process system – diamond (kimberlite) Process system – kaolin Mobile systems Technical data: Primary jaw crusher + grizzly Technical data: Primary impact crusher + grizzly Metso simulation tools _ Consulting business Process Technology and Innovation 12. Miscellaneous Conversion factors Tyler standard scale Density of solids Water and solids – pulp density data (metric and imperial) _
MINERAL PROCESSING TECHNOLOGY
CONTENT
1. Introduction
Basic definitions
Minerals by value
The process frame of minerals
Mineral processing and hardness
Size and hardness
The stress forces of rock mechanics
2. Minerals in operation
Operation stages
Operation – dry or wet?
Mining and quarry fronts _
Natural fronts
Size reduction
Size control
Enrichment – washing
Enrichment – separation
Upgrading
Materials handling
Wear in operation
Operation and environment
Operation values
3. Size reduction
The size reduction process
Feed material
Reduction ratio
The art of crushing
Crushing of rock and gravel
Crushing of ore and minerals
Crushing – calculation of reduction ratio
Selection of crushers
Primary crusher – type
Primary crusher – sizing
Secondary crusher – type
Cone crusher – a powerful concept
Secondary crusher – sizing
Final crushing stage – more than just crushing
VSI – a rock protected impactor
High Pressure Grinding Rolls (HPGRs) - HRC™
Final crusher – sizing
Wet crushing prior to grinding
Technical data: Gyratory crusher – SUPERIOR® MK-II PrimaryTechnical data: Jaw crusher – C series
Technical data: Impact crusher – NP series
Technical data: Cone crusher – GPS series
Technical data: Cone crusher – HP series
Technical data: Cone crushers – HP 3, 4 and 5 series
Technical data: Cone crusher – MP series
Technical data: Cone crusher – GP-series
Technical data: Vertical shaft impactor (VSI)
Technical data: High pressure grinding rolls (HPGRs) - HRC™
Grinding – introduction
Grinding methods _
Grinding mills – reduction ratios
Grinding – tumbling mills _
Grinding – stirred mills
Grinding – vibrating mills
Cost of grinding – typical
Mill linings – basic
Grinding mills – sizing
Grinding circuits _
Vertimill circuits
Stirred media detritors (SMD) circuits
Grinding – power calculation
Grinding – bonds work index
Pulverizing of coal
Vertimill more than a grinding mill _
Vertimill as lime slaker
Grinding vs enrichment and upgrading _
Technical data: AG and SAG mills
Technical data: Ball mills
Technical data: Spherical roller bearing supported ball mills
Technical data: Conical ball mills
technical data: SRR mill __
Technical data: Vertimill (wide body)
Technical data: Vertimill
Technical data: Vertimill (lime slaking)
Technical data: Stirred media grinding mills
Technical data: Vibrating ball mill
4. Size control
Size control – introduction
Size control by duties
Size control by methods
Screens
Screening by stratification
Screening by free fall
Screen types
Screen capacities
Selection of screening media
Particle size – mesh or micron?
Technical data: Single inclination screen – circular motion
Technical data: Double inclination screen – linear motion
Technical data: Triple inclination screen – linear motion
Classification – introduction
Wet classification – fundamentals
Hydrocyclone
Spiral classifiers
Dry classification – introduction
Static classifiers
Dynamic classifiers
Ancillary air solutions
Dry grinding
Size control in crushing and grinding circuits
5. Enrichmen
Enrichment – introduction _
Enrichment – processes
Wash water treatment
Separation – introduction
Separation by gravity
Separation in water
Separation by jigs
Separation by spiral concentrators
Separation by shaking tables
Separation in dense media
Separation by flotation
Flotation circuit layout _
Reactor cell flotation system (RCS)
Reactor cell flotation system (RCS) – sizing
Technical data: Flotation machines RCS
DR flotation cell system
Technical data: Flotation machine DR, metric
Technical data: Flotation machine DR, US
Column flotation cell system _
Column flotation – features
Magnetic separation – introduction
Magnetic separation – methods
Magnetic separation – separator types _
Magnetic separation – equipment
Dry LIMS, belt drum separator BS
Technical data: Dry LIMS, belt separator BSA and BSS
Dry LIMS, drum separator DS
Technical data: Dry LIMS, drum separator DS
Wet LIMS – Wet magnetic separators
Wet LIMS – concurrent (CC)
Wet LIMS – counter rotation (CR) and (CRHG)
Wet LIMS – countercurrent (CTC) and CTCHG
Wet LIMS – froth separator (DWHG
Wet LIMS – dense media recovery (DM) (DMHG)
Technical data: Wet LIMS – concurrent (CC)
Technical data: Wet LIMS – counter rotation (CR) and (CRHG
Technical data: Wet LIMS – countercurrent (CTC) and CTCHG
Technical data: Wet LIMS – froth separator (DWHG)
Technical data: Wet LIMS – dense media recovery (DM) (DMHG)
Wet HGMS/F – magnet design
Wet HGMS, HGMF – separator types
Wet cyclic HGMS
Wet cyclic HGMS – process system
Wet cyclic HGMS – operation
Wet cyclic HGMS – application
Wet cyclic HGMS – sizing
Technical data: Wet cyclic HGM
Wet cyclic high gradiant magnetic filter HGMF
HGMF – applications
HGMF – process data
HGMF – sizing
Technical data: Wet cyclic high gradiant magnetic filter HGMF
Wet continuous HGMS
Wet continuous HGMS – process system
Wet continuous HGMS – applications
Wet continuous HGMS – sizing and selection
Technical data: Wet continuous HGMS
Leaching of metals
Gold leaching
Gold leaching- carbon adsorption
Gold leaching – CIP
6. Upgrading
Upgrading – introduction
Upgrading by methods
Upgrading by operation costs _
Sedimentation
Flocculation
Conventional clarifier
Conventional clarifier – sizing
Conventional thickener
Conventional thickener – sizing
Conventional clarifier/thickener – design
Conventional clarifier/thickener – drive system
Conventional clarifier/thickener – drive sizing
Lamella or inclined plate sedimentation – introduction
Inclined plate settler (IPS)
Inclined plate settler – drives
Inclined plate settler – product range
Technical data: Inclined plate settler (LT)
Technical data: Inclined plate settler (LTS)
Technical data: Inclined plate settler (LTK)
Technical data: Inclined plate settler (LTE)
Technical data: Inclined plate settler (LTE/C)
Technical data: Inclined plate settler (LTC)
Mechanical dewatering – introduction _
Mechanical dewatering – methods and products
Gravimetric dewatering
Spiral dewaterer
Technical data: Spiral dewaterer
Sand screw
Dewatering screen
Dewatering wheel
Mechanical dewatering by pressure – introduction
Drum vacuum filters __
Belt drum filters
Top feed filters
Vacuum filters – vacuum requirements _
Vacuum plant – arrangement
Vertical plate pressure filter – introduction _
Vertical plate pressure filter – design
Pressure filter VPA – operation
Pressure filter VPA – sizes
Pressure filter VPA – chamber data
Pressure filter VPA – nomenclature
Pressure filter VPA – sizing
Pressure filter VPA – moisture in filter cake
Pressure filter VPA – compressor sizing
Pressure filter VPA – compressor power
Pressure filter VPA – feed pump selection
Pressure filter VPA – feed pump power
Pressure filter VPA – product system
Technical data: Pressure filter VPA 10
Technical data: Pressure filter VPA 15
Technical data: Pressure filter VPA 20
Tube press – introduction
Tube press – design
Tube press – operation
Tube press – applications
Tube press – material of construction _
Tube press – sizes
Tube press – sizing
Tube press – cycle times and cake moisture
Tube press – capacity
Tube press – product system
Tube press – booster system
Tube press – mechanical description
Technical data: Tube press _
Thermal processing – introduction _
Direct heat rotary dryer (cascade type)
Indirect heat rotary dryer (kiln)
Fluidized bed
Indirect heat screw dryer (Holo-flite)
Holo-fliteprocess syste
Technical data: Indirect heat screw dryer (Holo-flite)
Something about cooling
Iron ore pelletizing _
Pellet plant schematic
Feed preparation
Grate Kiln technology
Major process equipment components of iron ore pellet plant
Design criteria and plant sizing
Comparisons of indurating technologies _
Lime calcining system
Coke calcining system
Tire pyrolysis
7. Materials handling
Introduction
Loading and unloading
Railcar dumpers
Train positioners
Unloaders
Storage buffering
Stacker reclaimer
Scraper reclaimer
Barrel reclaimer
Feeding
Technical data sheets
Technical data: Feeder – Apron
Technical data: Feeder – Vibration
Technical data: Feeder – Unbalanced motor
Technical data: Feeder – Belt
Technical data: Feeder – Electromagnetic _
Technical data: Feeder – Wobbler
Conveying
Conveying systems
Conveyor capacities
Volume weight and angle of inclination _
Conveyor - more than a rubber belt
Technical data: Conveyor – Standard belt
Vertical conveyor system
8. Slurry handling
Slurry handling – introduction
Slurry pump range MD
Technical data: MD
Slurry pumps – range XM
Technical data: XM
Slurry pumps – range XR and VASA HD
Technical data: XR and VASA HD
Dredge pumps – range Thomas
Technical data: Thomas
Slurry pumps – range HR and HM
Technical data: HR and HM
Slurry pumps – range MR and MM
Technical data: MR and MM
Slurry pumps – range VS
Technical data: VS
Slurry pumps – range VSHM and VSMM
Technical data: VSHM and VSMM
Slurry pumps – range VT
Technical data: VT
Slurry pumps – range VF
Technical data: VF
Application guide for slurry pumps _
Selection – by solids
Selection – by head and volume
Selection – by slurry type
Selection – by industrial application
Minerals
Construction _
Coal
Waste and recycling
Power and FGD
Pulp and paper
Metallurgy
Chemical
Mining
Agitation – Attrition scrubber
Attrition scrubber – Sizing
“The slurry line”
Technical data: Material handling hoses _
Technical data: Rubber lined steel pipes
Technical data: 3xD bends 45
Technical data: 3xD bends 90
Technical data: Branch pipes
Technical data: Gaskets
Technical data: Couplings
Technical data: Reducers, rubber lined steel
Technical data: Compensators
Technical data: Tailing compensators / bends
Technical data: Tailing pipes
9. Wear in operation
Wear in operation – caused by
Wear by compression
Wear by impaction (high)
Wear by impaction (low)
Wear by sliding
Wear protection and products
Wear products – application
Heavy impact – selection
Impact and sliding – selection (modules)
Impact and sliding – selection (sheeting)
Sliding and build up – selection
Wear protection – wear parts
Wear parts – slurry pumps
Something about ceramic liners
Wear in slurry pipelines
10. Operation and environment
Operation and environment – introduction _
Dust control – basic
Noise _
Noise reduction
Ear protection
11. Process system
Process system – Introduction
System modules – aggregates
System modules – sand & gravel
System modules – ore & minerals
Process system – railway ballast
Process system – asphalt / concrete ballast
Process system – ferrous ore
Process system – base metal ore
Process system – gold bearing ore
Process system – coal
Process system – industrial mineral fillers
Process system – glass sand
Process system – diamond (kimberlite)
Process system – kaolin
Mobile systems
Technical data: Primary jaw crusher + grizzly
Technical data: Primary impact crusher + grizzly
Metso simulation tools _
Consulting business
Process Technology and Innovation
12. Miscellaneous
Conversion factors
Tyler standard scale
Density of solids
Water and solids – pulp density data (metric and imperial) _
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