GeoE 498-8

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Teknologi Pengolahan Material

• Sungging Pintowantoro
• Department of Materials and Metallurgical
  Engineering,Faculty of Industrial Technology
  (FTI),
• Sepuluh Nopember Institute of Technology Surabaya
  (ITS), Kampus ITS, Keputih Sukolilo, Surabaya
  60111,
• Telp/Fax [phone]

• Department of Materials and Metallurgical
  Engineering, FTI-ITS

• (1)

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• Department of Materials and Metallurgical
  Engineering, FTI-ITS

• (2)

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• PETA PERSEBARAN SDA INDONESIA

• Department of Materials and Metallurgical
  Engineering, FTI-ITS

• (3)

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• PETA PERSEBARAN SDA INDONESIA

• Department of Materials and Metallurgical
  Engineering, FTI-ITS

• (4)

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Mineral Processing Overview

• Mineral Processing Terminology, Economics
• Comminution and Classification
• Physical processing methods
• Chemical processing methods
• Waste products treatment and
  disposal
• Process plant flow
  sheets uranium and potash

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Importance of Mineral Processing

• No substance has been as important as metal in
  the story of man's control of his environment.
  Advances in agriculture, warfare, transport, even
  cookery are impossible without metal. So is the
  entire Industrial Revolution, from steam to
  electricity.Read more http//www.historyworld
  .net/wrldhis/PlainTextHistories.asp?historyidab16
  ixzz13XSEyvNz

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Importance of Mineral Processing

• Bronze Age- Bronze is in use in Sumer, at Ur, in
  around 2800 BC

• Iron Age - from the 11th century BC onwards,
  steel replaces bronze weapons. It becomes
  essential, from now on, to have a good steel
  blade rather than a soft and indifferent one.

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Lecture 8

• Mineral Processing Overview
• Geology-Mining-Processing Relationship
• Mineral Processing Terms
• Definitions
• Mineral Economics review
• Project Stages

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Lecture 9

• Comminution classification circuits
• Comminution Methods
• Principles
• Crushing
• Grinding
• Classification Methods
• Principles
• Hydrocyclone
• Screening
• Assignment

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Lecture 10

• Physical Processing Methods
• Gravity
• Magnetic
• Electrostatic
• Radiometric
• Froth Flotation
• Solid/liquid separation
• Assignment

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Lecture 11

• Chemical Processing
• Basic Circuits
• Leaching
• Solvent Extraction
• Precipitation
• Drying
• Downstream Purified Product
• Electrowinning
• Smelting
• Assignment

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Lecture 12

• Waste Stream Management
• Tailings Disposal
• Surface
• Underground
• Effluent Treatment
• Chemical Precipitation
• Membrane Technology
• Assignment

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Lecture 13

• Saskatchewan Mill Process Flowsheets
• Uranium
• Potash
• Assignment

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• Geology Mining Processing
• All 3 aspects must be favorable to make a deposit
  economically viable
• Geology Find it. Is it big enough to be
  economic?
• Mining Dig it. Is it economically recoverable
  from the ground?
• Processing Extract it. Is it economically
  separable from the host rock?

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Prevalence of mineral processing

• In Saskatchewan as of 2009 there were
• 3 uranium mills
• 8 potash mine/mills
• 1 gold mine/mill
• coal mines (thermal)
• Salt mine
• An identified diamond deposit (Fort a la Corne)
• An identified rare earth element deposit (Hoidas
  Lake)

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Prevalence of mineral processing

• Mining is all around us!
• In Alberta there are
• Oil sands process plants (uses mining and mineral
  processing techniques)
• Coal plants
• Industrial minerals (limestone)
• Nickel/cobalt metallurgical complex
• In Manitoba there are
• Many copper/zinc mines and mills, feeding the
  Flin Flon metallurgical complex
• Nickel mines nearby Thompson smelter
• In the Northwest Territories there are
• 3 operating diamond mines
• Gold mines

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Introduction to Mineral Processing

• Scope of mineral processing
• Definitions
• Economics
• Project Stages

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Mining Terminology - Review

• Miners send their products to their customer
  the mill.
• Ore Rock that contains a mineral or minerals in
  sufficient quantities as to make commercial
  extraction (mining milling) profitable.
• Grade A measure of concentration of a
  mineral/metal contained in rock (or ore). Gold
  and other precious metals g/t or oz/t, base
  metals - , uranium kg/tonne, rare earth
  elements ppm
• Cut off Grade The minimum concentration or
  grade of mineral that is required for rock to be
  considered ore.
• Waste Not Ore.
• Ore Body A mineralized deposit (resource) whose
  characteristics have been examined and found to
  be commercially viable. The extents of the ore
  body are determined by the cut-off grade.
• Host Rock The rock containing an ore deposit.
  Typically composed of 2 or more minerals.
• Gangue Minerals in the ore body that are not of
  economic interest

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Mineral Processing

• Is the recovery of valuable minerals from ore
• Takes place in a mill, aka concentrator -
  because it concentrates valuable minerals by
  removing unwanted material.
• The two main products are the concentrate streams
  (valuable minerals) and the tailings streams
  (rejects).

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Disciplines related to mineral processing
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Fields of Metallurgical Engineering
Field Description Example of topics
Mineral Processing Beneficiation or Mineral Dressing Theory and practice of liberation of minerals from ores and their separation by physical methods at ambient conditions Crushing and grinding, magnetic and electrical methods, flotation, etc.
Mineral Processing Extractive metallurgy Chemical methods sometimes at high temperature and pressure for treating ores to recover their metal values in a pure form Leaching, precipitation, electrolysis, oxidation, reduction, etc.
Metal Processing Physical metallurgy Study of physical properties of metals and alloys, preparation of alloys Crystal structure, effect of impurities, metallography, heat treatment, etc.
Metal Processing Engineering metallurgy Processing of metals in the molten state Casting, welding, etc.
Metal Processing Mechanical metallurgy Processing of metals in the solid state Forging, rolling, extrusion, piercing
Metal Processing Powder metallurgy Processing of metal powders into finished products Preparation of metals in powder form, hot pressing, etc.
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Engineering Terminology in Mineral Processing

• Circuit The path that the ore that is being
  processed takes as it proceeds from one
  processing point to another.
• Flow Sheet - Drawing that indicates the path that
  the mineral takes within a process. Several
  circuits are often contained within a flow sheet
• Recovery Rate The percentage of valuable
  metal/mineral, by mass, in the concentrate from
  the feed

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Mineral Processing

• The goals of mineral processing are to
• separate economic mineral particles from waste or
  gangue
• subject minerals to processes in order to
  concentrate them or to extract metals from them

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• Many forms of mineral processing
• Depends on feed material and desired product

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Mineral Processing Terminology

• Concentration Another word for grade
• Heads A term that is used to denote the mineral
  found in the FEED to a circuit.
• Head Grade aka feed concentration
• Concentrate a purified mineral. May require
  further downstream processing to convert for end
  uses. Examples Copper and nickel sulfides
• Tailings - Material rejected from a mill after
  the recoverable valuable minerals have been
  extracted.
• Industrial mineral is used for end purpose
  without chemical alteration. Examples gravel,
  coal
• Mineralogy Description of mineral contents

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What is mineral processing?
Mineral a)A solid naturally-occurring compound
having a definite chemical composition. b)
Inorganic substance that are extracted from the
earth for use by man. c) A naturally occurring
inorganic element or compound having an orderly
internal structure and characteristic chemical
composition, crystal form, and physical
properties.
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Mineral classification
Nonmetallic processing has some commonalities
with metal processing, but lots of differences
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Examples of minerals
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Examples of minerals
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• Mineralogy determines recoverability

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Impact of mineralogy

• We mine rocks but we concentrate minerals.
• Gangue minerals also important
• Understanding mineralogy allows design of
  processes
• Important for feasibility studies

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What is mineral processing?

• Processing
• Extract values, reject waste
• Conversion of mined ore into usable product
• More expensive/challenging with lower grade ores
• Numerous processing methods

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Mineral Processing Methods beneficiation
extractive metallurgy
Beneficiation aka Mineral Dressing Overlap of
physical and chemical methods, depending on
product Where extractive metallurgy leaves off,
metal processing begins
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Mineral Processing Terminology

• Beneficiation enrichment of ores and separation
  of unwanted gangue minerals
• subsequent metals extraction more efficient.
• Can be divided into two distinct steps
• Liberation the rock is broken down by mechanical
  means, mineral components become independent of
  each other, detached Separation valuable
  minerals are separated by means of physical and
  physico-chemical methods making use of
  differences in specific gravity, magnetic
  properties, etc.
• Extractive metallurgy
• Chemical reactions of the processes
• equipment where reactions take place
• Flowsheets combinations of processes

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Typical Beneficiation Steps
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Beneficiation Terminology

• Comminution Reduction of particle size
• Starts at mine with blasting
• Two basic types of equipment used
• Crushing breakage by compression
• Grinding breakage by abrasion and impact

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Comminution Equipment
Shaft
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Comminution Equipment
Shaft
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Beneficiation Terminology

• Classification Separation based mainly on
  particle size
• Behavior affected by size, shape, and density of
  the particles
• Two common types of classifiers
• Screens dry method, coarser particles
• Hydrocyclones wet method, finer particles

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Classification Equipment
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Beneficiation Terminology

• Separation Techniques take advantage of the
  differences in characteristics between minerals
• Flotation Attachment of minerals to air bubbles
  - hydrophibicity
• Magnetic Separation Apply magnetic field
• Gravity Separation differences in specific
  gravity of materials
• Electrostatic Separation Apply electrostatic
  polarity
• Particle size distribution has large influence on
  results

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Separation Equipment

• Flotation cell

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Separation Equipment

• Magnetic separator

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Separation Equipment

• Gravity separation - jig

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Separation Equipment

• Electrostatic separator

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Beneficiation Terminology

• Dewatering To remove water from a substance.
  Also refers to the circuit where this takes
  place.
• Dewatering Techniques
• Thickener Allow gravity settling
• Filter Apply air pressure to draw water out
• Centrifuge Apply centrifugal force
• Dryer Apply heat to evaporate
• Slurry Density The amount of solids in a slurry,
  expressed as a percentage by weight.

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Dewatering Equipment

• Thickener

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Dewatering Equipment

• Disc filter

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Dewatering Equipment

• Rotary kiln dryer

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Beneficiation Terminology

• Waste Disposal - "Mining is waste management ..."
  
• The majority of tonnage mined must be disposed
  of as tailings
• Water used must be treated and released
• Tailings Dam Built from ground waste rock
  discharged after processing from the mill
• Acid Mine Drainage produced by exposing sulfide
  minerals to air and water, resulting in oxidation
  that generates acid.
• Waste Rock Unprocessed non-mineralized / low
  grade mined material
• Water Balance Accounting of water inputs and
  outputs from a mine/mill site.
• Water Treatment The removal of harmful
  contaminants from water

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Waste Disposal

• Tailings Dam

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Waste Disposal

• Waste Rock Pile

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Waste Disposal

• Acid Mine Drainage

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Waste Disposal

• Water Balance

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Mineral Processing Methods beneficiation
extractive metallurgy
Beneficiation aka Mineral Dressing Overlap of
physical and chemical methods, depending on
product Where extractive metallurgy leaves off,
metal processing begins
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Extractive Metallurgy Terminology

• Hydrometallurgy
• Leaching - the process of extracting a soluble
  constituent from a solid by means of a (water
  based) solvent
• Water changes solubility, by making it acidic or
  basic, oxidizing or reducing
• Solvent Extraction transfer between immiscible
  fluids
• Ion Exchange solid resins that adsorb/desorb
  dissolved chemical species
• Precipitation convert dissolved into solid
• Crystallization via evaporation
• Ionic precipitation - addition of a reagent to a
  solution creates a metal compound whose
  solubility is so low that precipitation takes
  place immediately

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Hydrometallurgy Equipment

• Tank leach circuit

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Hydrometallurgy Equipment

• Solvent extraction mixer-settlers

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Hydrometallurgy Equipment

• Ion Exchange

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Hydrometallurgy Equipment

• Vacuum crystallizer

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Extractive Metallurgy Terminology

• Pyrometallurgy use of heat to induce a chemical
  transformation
• Roasting convert to oxide form. Example 2
  CuS2 5 O2 ? 2 CuO 4 SO2
• Smelting - uses reducing substances that will
  combine with those oxidized elements to free the
  metal. Example
• 2 Fe2O3 3 C ? 4 Fe 3 CO2

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Pyrometallurgy Equipment

• Smelter

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Extractive Metallurgy Terminology

• Electrometallurgy use of electrical energy to
  induce a chemical transformation
• Electrowinning to precipitate a metal from
  solution using electric potential
• Electrorefining to purify a metal by dissolving
  it, then re-precipitating it

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Electrometallurgy Equipment

• Alternating anodes and cathodes in a tankhouse
  for electrowinning

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Flowsheet examples

• Aluminum from bauxite
• Copper from chalcopyrite
• Iron from hematite
• Gold Placer, sulphide and oxide
• Oil Sands Fort McMurray

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Aluminum
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Copper
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Iron
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Gold
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Oil Sands
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Mineral Processing Recovery

• Recovery Potential for loss every step of the
  way, in each circuit!
• Tonnage vs. Recovery A processing circuit pushed
  beyond its capacity will induce recovery loss
• Feed Grade vs. Recovery A higher feed grade
  tends to have higher processing recovery
• Concentrate Grade vs. Recovery A higher
  concentrate grade tends to result in lower
  processing recovery ( rejection of lower quality
  minerals to tailings)
• Concentrate Grade vs. Price A higher quality
  concentrate will fetch a higher price (have lower
  impurity penalties)
• Revenue Production (tonnes) x grade x recovery
  x price

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Milling Operating Costs
Typical relative cost of beneficiating an ore
Operation
Crushing 5 - 20
Grinding 25 - 75
Flotation 25 -45
Dewatering and drying 10 -20
Other operations 5 - 10