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Mineral Processing 2 L11

The document describes mineral processing operations for several types of ores and minerals including gravel, rock, coal, tin ore, magnetite ore, hematite-magnetite iron ore, and beach sands. Specific unit operations discussed include crushing, screening, magnetic and gravity separation, grinding, and filtering. Flowsheets are provided for each example to illustrate the processing steps.

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ahmed kishk
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17 views

Mineral Processing 2 L11

The document describes mineral processing operations for several types of ores and minerals including gravel, rock, coal, tin ore, magnetite ore, hematite-magnetite iron ore, and beach sands. Specific unit operations discussed include crushing, screening, magnetic and gravity separation, grinding, and filtering. Flowsheets are provided for each example to illustrate the processing steps.

Uploaded by

ahmed kishk
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Mineral Industry

Mineral Processing 2 ME 365

Prof.Dr. Ahmed A.S. Seifelnassr


Professor of Mineral Processing
Dept. of Mining Engineering
Faculty of Petroleum and Mining Engineering
Suez University
Suez, Egypt
E-mail:[email protected]
Lecture 11- Examples Of Mineral Processing Operations
In this chapter brief- descriptions are given to illustrate representative
industrial treatment of a number of common ores.
1- Dressing gravel
• Figure 1 represents a dressing plant for the preparation of concrete
aggregate .
• It consists essentially of screens and classifiers ,the screens(trommels)
making coarse, medium and fine gravel ,and the classifier making sand .
• In addition a vibration screen removes coarse sand, the oversize from the
coarsest screen and the fine over flow from the classifier (clay) are waste
products .
• The sizing exerted by the various screens is useful as it permits the
subsequent blending of aggregate of various sizes and of sand according to
definite specifications.
2- Crushing and grading rock
• Figure 2 shows a typical flowsheet for crushing and sizing rock in a
quarrying operation.
• Run-of-mine ore can be present as lumps as large as 1.5 m (5 ft) in
diameter.
• In this figure's example, 91.4-cm (3-ft) lumps of rock are fed to a crusher
that reduces the material to 20.3 cm (8 in.) or less in diameter.
• After screening to remove rock that is less than 57.2 mm (2 1/4 in.) in size,
rock between the sizes of 57.2 mm (2 1/4 in.) and 20.3 cm (8 in.) is further
reduced in size by a gyratory crusher.
• The product from this step is then classified by screening to the desired
product for sale.
• Note that neither of the flowsheets outlined in Figs.1 and 2 involves a
concentration operation.
FIGURE 2 Flowsheet for crushing and grading rock
3- Coal plants
• Figure 3 represents a plant for the cleaning and preparation of bituminous
coal .
• Concentration is by hand picking for the two coarse sizes ,viz, the 6 – 10 in.
, lump and 3 – 6 in. stove sizes, and by jigging for the minus 3 in. sizes.
• Coarse sizing is done by shaking screens.
• Fine sizing is done by means of vibration screens.
• Figure 4 represents an anthracite preparation plant.
• Heavy media separation is used for cleaning coarse sizes and shaking table
for fine sizes.
• Toothed rolls are used for size reduction, shaking and vibrating screens for
sizing and centrifugal filter for dewatering -10 mesh anthracite.
4- concentration of a tin ore
• Figure 5 shows an integrated circuit demonstrating crushing, grinding,
size separation, and gravity concentration of a tin ore.
• Initial size separation is effected with a grizzly set at 1 1/2-in.
• Oversize material is fed to a jaw crusher set at 1 1/2-in., and the
crushed product is, then, further reduced in size to 20 mesh by ball
milling.
• The -20-mesh material is classified to several grades by hydraulic
classifier, each grade being concentrated on a shaking table.
• The middlings in this process receive additional treatment.
• The concentrate from this operation is reground and sized at 200
mesh.
• Two-stage vanning is used to produce a fine tin concentrate.
5- Iron ores
Magnetite ore
Figure 6 shows a Plant for the treatment of a magnetite ore . The unit operations involved
are:
A- Crushing in 3 stages from 42 inch to ¾ inch.
B- Dry magnetic concentration is carried out on three sizes , 3/8 to ¾ inch ,3/16 to 3/8
inch and 1/16 to 3/16 inch.
C- The middllings from dry magnetic separators are crushed in roll crusher and returned
to the multiple deck vibrating screen.
D- The minus 3/16 inch middllings and 1/16 inch ,undersize from the multiple deck
vibrating screen are ground to 65 mesh in a ball mill controlled by a rake classifier.
E- The minus 65 mesh is concentrated by wet magnetic separators in roughing and
cleaning stages.
F- A demagnetizer precedes the classifier to prevent magnetic flocculation in the classifier
as well as cleaning step order to eliminate the waste occluded mechanically within
magnetic flocs .
G- Filtering completes the dressing operation and the concentrate is ready for sintering .
Figure 6 Plant for the treatment of a magnetite ore .
Hematite-Magnetite iron ore
Figure7, below presents the processing flowsheet.
Processing of Beach (black) sands
Figure 8(below) shows a typical beach sand treatment flowsheet.

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