Innovative Process Sampling Solutions for the Mining Industry

Transcription

1 Innovative Process Sampling Solutions for the Mining Industry IMP Group Australia 34 Hasler Road, Osborne Park, WA 6017 PO Box 1183 Osborne Park WA 6916 Australia Tel: +61 (8) Fax: +61 (8) IMP Africa Cnr Commissioner & Christopher Street, Boksburg East, 1459 PO Box 1110 Boksburg, 1460, South Africa Tel: +27 (11) Fax: +27 (11) IMP Brazil R. Fernandes Tourinho, 147 Sala Savassi Belo Horizonte-MG Brazil Tel: +55 (31) Fax: +55 (31) IMP Canada Suite 103 / 2902 Sth. Sheridan Way Oakville, ON, L6J7L6 Tel: Fax: Cell: info@impautomation.ca IMP has been providing complete solutions from sampling to analysis for the mining and metallurgical industries since 1987

2 Index Challenging Conventional Sample Processing Many of the major global mining and engineering companies have chosen IMP to provide them with quality state of the art, sampling and analytical solutions on a turnkey basis. IMP challenges conventional systems and works with likeminded customers to engineer robust, application adept, reliable and efficient systems. IMP has an impeccable safety record and has earned an excellent reputation for on time delivery of complex high value turnkey sampling and automated robotic laboratory projects. Continuous improvement in plant /process efficiency requires smarter and faster sampling and analysis systems. IMP is setting the benchmark in the integration of online analysis, sampling systems and automated laboratories to deliver fast and accurate data to the plant to facilitate rapid decision-making. This enables and empowers production personnel to better control and monitor the plant and achieve improved plant efficiencies. Trust IMP s team of sampling experts, metallurgists, engineers and chemists to assist you with your feasibility study, conceptual design, detailed engineering, final project delivery and ongoing after sales support. From Sampling to Analysis Dry Bulk Sampling Port integrated systems, Mine integrated systems Pg 6-8 Integrated sample station connected to laboratory Pg 9 Truck and train integrated sampling Pg 10 Bulk bag sampling, Primary samplers, Secondary samplers Pg Powder Sampling Integrated powder sampling systems Pg 14 Powder samplers Pg l Feasibility studies l Concept designs l Detailed engineering l Lump sum turnkey delivery of entire systems l Audits of brownfield installations l Design improvements for existing installations l Integration of sampling systems to automated robotic laboratories l Project management and more IMP robotic systems replace very tall vertical sample towers. Instead of having very tall sample stations, IMP's designs incorporate many of the splitting, comminution, drying and analysis steps into innovative robotic cells. Slurry Sampling and Analysis Integrated slurry sampling systems Pg Slurry samplers Pg Online and Inline Analysers P Rapid Inline Sample Dryers Pg 29 Automated Sample Transport Systems Pg 30 Pyro Metallurgical Integrated System Pg 31 Other Equipment Pg 32 Ancillary Equipment Pg 33 1

3 Conceptual Design Our teams employ the latest digital design and modelling tools for providing pre-evaluation feasibility studies and detailed designs. Factory Testing Comprehensive quality control during the manufacturing process ensures there are no surprises on site and facilitates a quick, safe installation and commissioning process. Detailed Engineering IMP's design team is equipped with the latest tools and technologies which aid them in employing digital prototypes, process models and integrating design data to deliver world class projects. Project Management On site and office based teams co-ordinate and manage every aspect of the project to ensure all document, safety and project deliverables are met. 2 3

4 Complete Turnkey Sampling Stations Besides providing individual samplers, IMP also provides the complete sample station as a turnkey solution. IMP's engineers ensure that the sample station meets all the relevant sampling criteria and international standards. The sample station can be linked to an IMP automated sample preparation and analysis laboratory. Controlling software integrates the sample station, online and inline analyses and the laboratory to facilitate production control. Site Installation IMP's skilled site teams have experience working with large companies and EPCM's safely delivering turnkey projects that work, on time and within budget. Automated Slurry Sampling to Analysis IMP has provided systems for integrating the sampling to analysis on several concentrators. This type of automation is typically used where online systems cannot deliver the accuracy of analysis required to control the plant. Samples are automatically taken from the slurry streams, automatically filter pressed, automatically dried, pulverized and analysed with results presented back to the plant quickly for plant control. The system processes 4 feed lines, 4 concentrator lines and 4 tailing streams giving the plant metallurgists a picture of the process every few minutes. Automated Bulk Sampling to Analysis IMP has provided a complete solution where the sampling station is directly linked to automated analysis. This was for an iron ore application where automated moisture content, automated particle size analysis, automated sample drying, automated crushing, splitting and pulverizing and automated chemical analysis were required. After-Sales Support IMP has a dedicated team of skilled service technicians and engineers that provide 24 hour after sales service and support. Automated density determination and samples for manual jigging tests are also included. 4 5

5 Dry Bulk Sampling Port Integrated Systems IMP has designed and delivered a number of integrated port laboratories where the entire process from sampling to analysis and cargo certification is fully automated. IMP has provided solutions for time based sampling as well as mass based sampling. The process of drying, splitting, particle size determination, moisture determination and chemical analysis is automated. Bulk composites are also produced. In the case of iron ore sampling, for example, primary cuts of up to one ton are taken. Each cut is split within the sampling system to produce a sample for the automated laboratory. A portion representing each primary cut is transported automatically to the robotic laboratory via a conveyor system or using IMP s monorail sample transport system. These aliquots are composited and split to produce sub lots. Particle size analyses and moisture are determined on each sub lot. Some clients carry out sub lot chemical analysis while others analyse the final composite. The entire process complies with the guidelines of ISO3082. IMP has provided these automated laboratory facilities on a turnkey basis. Our clients include Anglo American (Kumba), Fortescue Metals, Rio Tinto (Cape Lambert) and Roy Hill. Designs vary from single robot cells to multiple robots operating on a track. Automating the entire process from sampling to analysis results in the fastest possible turnaround times of analytical assay, significant improvements in accuracy and precision and much improved operational health and safety. 6 7

6 Mine Integrated Systems As with the integrated port laboratories described, the mine also requires fast turnaround times of analytical data and information on physical properties of the ore being processed. While tremendous progress has been made with online analysis, sample stations and onsite laboratories still provide the benchmark analysis. IMP has risen to the challenge by integrating the sampling stations with robotic automated laboratories. Integrated Sample Station Connected to Laboratory A further example shown below, sample splitting, crushing and drying happens in the sample station. The final dry aliquot for analysis is transported to the laboratory using a pneumatic capsule transport system. Using iron ore as an example, IMP has provided the entire sample station integrated to a robotic cell to determine particle size and moisture content of the sample as well as a robotic cell to determine the chemical analysis and density of the ore being processed. Additionally samples are also prepared for manual jigging tests and other physical tests. As the entire process is fully automated, accurate results are transmitted to the plant control system instantly allowing better control of the process. The entire process complies with the guidelines of ISO3082. In a different example, the mine site has several sampling stations. One is for lump ore, one is for fines and one is at the train load out station. IMP has designed a system to include automated transport of the samples from the sample station to the automated robotic laboratory using IMP s monorail systems. The monorail system can transport up to 80kg of sample to the automated robotic laboratory. The picture on the right shows the bucket transporting the sample from the sample station to the laboratory. The entire process including sampling, sample transport, moisture determination, size analysis and chemical analysis is fully automated. The process is similar to the port facilities described previously. Primary samples are split, composited and accumulated in the sample station. Aliquots of typically 40kg are transported via the monorail to the automated robotic laboratory. In the laboratory the aliquots are composited and split to produce sub lots. Chemical analysis as well as particle size and moisture analysis is all carried out automatically with data transmitted via IMP s Control Track Lims software to the plant control system. The rapid sample drying is achieved by using the novel IMP vibro dryer which incorporates IR drying as well as an oil heated base. The base is vibrated which results in the sample moving in a circular direction releasing trapped moisture and continually exposing fresh surfaces to the IR lamps for rapid drying. A built in pyrometer monitors the surface temperature and controls the heat within the set limits. This system ensures that the sample is dried rapidly without compromising the sample. After drying, the direction of vibration is changed and the dry sample is automatically discharged into an air tube system and transported to the laboratory. The entire drying process happens in a few minutes. The photograph on the right is of a typical automated plant sample sending station. The sending station can accumulate sample from the dryer, mix the sample and take a representative aliquot of the sample. The aliquot is then automatically transported to the laboratory in a capsule where it is received, manually or automatically processed and analysed. The empty capsule is automatically returned to the plant sample sending station to receive the next sample. VR 5 Vibro Dryer HR BM Automatic plant capsule sending station with mixer 8 9

7 Truck and Train Integrated Sampling While belt end sampling is always the preferred method of sampling, often plant constraints or certain brownfields projects do not allow for this and may not be practical to sample at the end of a conveyor. It may also be a requirement to be able to do direct truck or train sampling. Typical applications include concentrate deliveries to a toll smelter or raw materials delivery to a steel plant. IMP caters for the design and supply of automated sampling systems to allow full integration of the sampling system to an automated robotic laboratory. Some of the process steps such as compositing, rapid drying, crushing and splitting, may be carried out at the sampling station prior to the sample being automatically transported to the laboratory for analysis. Appropriate samplers such as auger samplers, spoon samplers or vacuum samplers are deployed depending on the ore to be sampled. In the case of truck sampling a gantry or single arm sampler is often used. Dry Product Samplers Primary Samplers Heavy Duty Rotating Sampler This sampler is typically installed at the belt discharge point. It has the advantage that a sample is collected and elevated at the same time which reduces the height of the sample station. IMP tailor the design to suit large or smaller production tonnage rates. The system has a proven reliability and low maintenance cost. It is typically integrated into ship loading systems. The Continuous Reverse Discharge Sampler The Continuous Reverse Discharge Sampler cuts the product stream off the end of the belt. The sample which is collected is discharged by gravity towards the underside of the belt. This design ensures a complete cross sectional cut and representative sampling of the product on the belt. Continuous Forward Discharge Sampler Bulk Bag Sampling Product supplied in bulk bags have to be sampled and certified in batches. The IMP bulk bag sampling system can be integrated into an automated sample analysis laboratory. The automated sampling process is carried out by means of a 6 axis robot or a gantry system, the decision of which to use is often driven by plant restrictions in floor space. The sampler is mounted at the belt end at a transfer point. The sampler traverses the ore stream and the sampled portion is continuously discharged in the same direction as the ore stream by gravity. This sampler typically has less wear when compared to a reverse spoon sampler Front Discharge Cross Belt Sampler The continuous discharge forward sampler moves perpendicular to the stream off the end of the belt. The discharge is done via gravity in front of the belt. This works well for large volumes of sample as the momentum of the sample flow aids in discharge

8 Pendulum Sampler The pendulum sampler crosses perpendicular to the stream and parallel to the belt. It crosses through the entire stream at once. The sampling head moves to the discharge position where the sample is discharged by gravity. Secondary Samplers Vesin Sampler The Vesin Sampler splits or divides a fixed ratio of sample from a falling stream. One or more segments pass through the falling stream diverting the sample split to the output chute. Access doors allow inspection and easy maintenance. This method of supply is used for smaller tonnage systems. VICO Vesin Samplers Rotary Belt End Sampler The rotary belt end sampler cuts across the stream coming off the end of the belt. The cutting edge is angled so that the entry and exit of the cutter is perpendicular to the stream. The VICO Sampler delivers an analytical homogeneous portion and at a constant sample output weight from a variable sample input weight. The sampler design is based on industry standards and complies with all good sampling theories and practices. The mass of the material entering the sampler must be known. A PLC calculates the splitting ratio and delivers a constant mass to the discharge chute. The sampled portion is discharged by gravity through the centre of the sampler. Side Discharge Sampler The side discharge sampler traverses the ore stream collecting sample and discharging the sample on either side of the ore stream from the base of the sampler. Rotating Plate Divider The rotating plate divider will split a fixed percentage of the incoming sample by volume. It works by utilising compartments fitted to a rotating plate. This causes the compartments to rotate under the stream of the sample. The compartments discharge via gravity into a discharge point. The percentage split can be defined in the design stage whereby the amount and/or the size of the compartments will be fitted accordingly. Hammer Cross Belt Sampler The sampler is located directly above the conveyor belt and its installation does not require the conveyor to be either modified or cut. A thick steel spoon rotates and passes just above the conveyor. As it moves it scrapes a representative cross sectional cut of product from the conveyor and it pushes it towards a sample collection and gravity discharge point that is located at the edge of the conveyor. RSDs Multi Output The RSD allows two or more splits from the stream to be taken using a rotating tube mechanism. Different fractions can be obtained from each split. Each aliquot is representative of the primary sample. The VICO software can be installed on the RSD allowing for a constant mass output through each output chute. This type of sampler is ideal for installations where it is not possible to sample at belt end. It is easy to retrofit on existing belts

9 Dry Powder Sampling Integrated Systems IMP has a complete range of samplers for sampling powders including hot powders. These include screw samplers, piston samplers, slot samplers, swivel samplers etc. From these samplers the sample needs to be collected and in some cases re-split in order to secure a representative sample that can be transported to the sample preparation and analytical instrument. Besides the samplers IMP provides solutions to transport the samples to a containerised laboratory or a central laboratory via a pneumatic air tube system. Inside the container or laboratory IMP can provide the equipment to automatically carry out particle size analysis, C and S analysis, XRF or XRD analysis, TGA and any other related instrumental analysis specific to the sample type. These sampling facilities are designed to run largely unattended and complement the IMP range of online analysers such as online XRF, XRD, particle size and Neutron Activation systems. The picture above shows a sampling station near the SAG mill. At this sampling point the automatic sampler collects a number of sub-samples from the process. Within the sampling station these sub-lots are combined into a composite, homogenised and sub-divided into an analytical portion which is automatically loaded into a capsule and transported to the laboratory via pneumatic air tube. The pneumatic transport system delivers the sample capsule into the receiving station connected to a mill press and XRD. The entire process from sampling to analysis is fully automated and operates largely unattended with analytical results being transmitted to the plant automatically. Powder Samplers HR-SN Screw Sampler The HR-SN screw sampler is designed for the sampling of powder and fine-grained materials from vertical or inclined drop chutes. The threads are rotated for a given time while exposed to the product stream. Sample is collected at the base of the thread. HR-RN-Air Slide Sampler The HR-RN air slide sampler is designed for the sampling of powder and fine-grained materials from horizontal air conveyor troughs. A perforated collecting tube located vertically in the air conveyor trough retrieves the sample from the material flow. Once a sample is collected the tube is rotated trapping the sample. The sample is then discharged by pneumatically moving the collector over the discharge. S-FLP Slot Vessel Sampler The S-FLP down pipe vessel sampler utilizes a spoon with a fixed volume to sample at set intervals from a falling stream. The spoon is presented to the sample stream at a constant speed. The spoon is then rotated over the discharge chute. S-FSP Swivel Sampler The S-FSP Swivel sampler produces representative samples from a stream by swivelling a slotted vessel through the stream. The sample is discharged into a separate sample chute

10 HR-KN Clinker Sampler Slurry Sampling and Analysis The HR-KN Clinker Sampler is designed for the sampling of coarse-grain material from vertical falling stream. A hydraulically operated sampling chute is swivelled upon demand into the material flow, and retrieves a precise sample quantity defined by the chute volume. The sample is then transported by tube systems or a vibratory chute to the downstream components (e.g. a jaw-crusher). The sampling cycle is controlled by a programmable controller. HR-PN piston sampler is designed for the sampling of powder and finegrain material from vertical or inclined product streams. A pneumatically operated sample piston is moved into the material flow, and retrieves a precise sample quantity defined by the volume of the piston. The aliquot is discharged into the discharge chute. HR-PN Piston Sampler HR-KNH Hot Powder Sampler The HR-KNH sampler is designed for the sampling of hot powder and fine-grain material from inclined drop shafts falling product streams. An air cooled spoon is driven into the hot product and a sample is taken on the spoon. Several successive samples can be taken to increase the volume of the sample. Once sufficient sample has been taken the sample can be automatically transported to the laboratory or container facility for analysis

11 Slurry Sampling Integrated Slurry Sampling Systems IMP provides inline automated analytical and particle size measurement techniques. Inline analysis provides very fast feedback for plant control. There are, however, applications where offline sampling and analysis is required. Examples include metal accounting or cases where the analytes cannot be measured by online techniques or where online techniques do not achieve the detection limits required. Applications include phosphate ore and precious metals. In order to solve the problem of sampling and fast reliable result feedback from the laboratory, IMP has pioneered the integration of sampling systems with automated robotic laboratories. Direct transport to the laboratory. Once dried the sample is automatically presented to a robotic sample preparation cell where the sample is milled and analysed. In some applications such as phosphate ores, the sample is analysed using XRF techniques. In the case of precious metals, IMP s patented Fast (FIFA) inline fire assay system is used to provide rapid turnaround of assay. Particle size measurement on the dry powder is also available. Note that the automated filter presses discussed above can be used manually or automatically, located in the plant or in the laboratory. Typical turnaround times are 20 minutes from slurry to result for XRF techniques and 50 minutes for IMP s patented Fast (FIFA) inline fire assay techniques. IMP has provided a number of automated systems on a turnkey basis that include the automated processing and analysis of the slurry using an automated robotic laboratory. IMP has a novel solution to transport the slurry aliquots taken from the samplers at various points in the plant to a central laboratory. These aliquots can be processed manually or by means of an automated system. In the case of an automated system, once these slurry aliquots arrive at the laboratory they are automatically filtered using an automated filter press designed by IMP in The filter press automatically filters the slurry sample presenting the filter cake to the robot. The liquor can also be captured for analysis. The filter press automatically selfcleans. The robot in turn places the filter cake in a microwave where the sample is automatically dried. The microwave has a built in load cell which is used to determine the end point of the drying process. In the photograph above you can see four feed, four concentrate and four tailings lines that carry the slurry aliquots into the automated filter dryer system. The lower photograph shows another example which uses a 6 axis robot instead of a gantry robot as above. Plant drying and transport to the laboratory IR Belt sample dryer In some applications it is more practical to dry the slurry sample in the plant prior to transporting the sample to the laboratory. In these cases the slurry sample is reduced to a trickle and dribbled onto a continuous belt IR dryer which dries the sample on a stainless steel belt. The dry powder is then scraped off the belt end into a capsule. The capsule is then automatically transported to the laboratory by means of a pneumatic sample transport system. Once in the laboratory the capsule is automatically opened and the sample is discharged from the capsule. This sample is then prepared and analysed using the appropriate technique automatically

12 Slurry Samplers IMP provides a complete range of innovative slurry sampling systems. These components can be purchased individually or as part of an integrated automated system from sampling to analysis. The range includes: Primary samplers l Gravity sampler l Linear cross-cut l Rotary cross-cut l Pipe off-take sampler Secondary samplers l Gravity samplers l Launder (cross-cut) Samplers l Primary (in-line) Slurry Samplers l Two-in-one samplers l Pipe take-off samplers l Timed and Continuous Vezin samplers Two-In-One Samplers These robust samplers have the advantage that there is no secondary reject stream. The units can be easily retrofitted into existing slurry streams. The cutter gaps are usually three times the nominal top size of the material being sampled. These units are compact and easy to install and access. The cutter hood is situated at 90% of the slurry trajectory with sharp tapered blades. Manual Cross Steam Sampler The economical manually operated cross stream sampler can be installed as a backup system or in applications where sampling frequency does not warrant automated systems. These manual Cross Stream Samplers are easy to install. Inspection ports allow easy inspection and maintenance. Pipe Take-off Samplers Pipe take off samplers are available for certain applications. These units can be sized to suit. Slurry discharged from the piped samples are collected, thoroughly mixed, dewatered by filter pressing and analysed. Primary Inline Slurry Sampler This sampler is ideal for pipe diameters typically up to 900mm ID. Typical throughput of 4600 m3/hr Material size typically <6 mm Slurry Velocity <2m/s Moisture value (W/W) >45% Pulp Density <1.55 t/m3 (gold slurry) Launder Sampler Sample Collection and Multiplexing Units The sample collection and multiplexing units are used in applications where samples from multiple slurry lines need to be collected and diverted to one or more analysers. This system is typically used to save costs by sharing one analyser across multiple slurry lines. The slurry is kept in suspension in the sample collected until required by the analyser. The sampler crosses the stream diverting the required amount of slurry to the sample discharge. A range of launders samples to suit most applications is available on request

13 An Automated X-ray Diffraction System for Controlling Metallurgical Plant Performance All mining metallurgical plants require analyses of plant in-process streams to monitor plant performance. Typically automated cross-stream cutters are used to provide shift or daily composites which are then sent to an analytical laboratory for analysis. The turn-around time for plant personnel to receive the analytical data is typically 24 to 48 hours after receipt of the samples at the laboratory. The XRD system has been designed in such a way that the XRD tube is lying flat, and the two sample cells are positioned on either side of the tube. This enables two sample streams to be analysed simultaneously and to accomplish this both shutters are operated with the same signal. Sample preparation and presentation, therefore, also have to be synchronised. The X-ray tube, sample cell and detector of one circulating system are shown in the photo. Thus the data reports the past performance of the plant and cannot be used as a real time tool to control plant performance. They only have historical value. Obviously plant managers would like as near on-line analyses as possible to monitor plant performance to minimise value mineral loss and optimise use of reagents. To keep a plant running at optimal performance is mainly dependent on the skill and experience of plant operators who will notice changes, such as the absence of bubbles being produced in a flotation circuit, and will then immediately apply corrective measures. On-line analyzers are available for slurry streams but typically require high maintenance, are not very accurate due to calibration difficulties and have high detection limits due to the high dilution factor in the slurry streams. Near on-line analysis for metallurgical plants is also available from IMP Automation for fire assay (Precious Metals) and X-ray Fluorescence Spectrometry (XRFS) using fusion discs for major elements and pressed pellets for minor and trace elements as described before. However, these analytical methods give data for individual elements. If a process in a metallurgical plant involves the separation of phases containing the same element/s then these analytical methods produce less useful data. Such a situation occurs in heavy mineral beach sand plants where Ti occurs in several phases of which some are not recoverable. Ilmenite, Rutile and Leucoxene are the main value-bearing Ti minerals whereas sphene (a Ca, Ti silicate) and Ti-bearing amphiboles and spinels are not. An analytical method which quantifies phases (or minerals) instead of elements would be useful in such a case. Such a method is X-ray Diffraction (XRD). Automated XRD at the Foskor Mineral Separation Plant A near on-line XRD method to quantify the minerals occurring in the process streams has been developed at Foskor in South Africa. The minerals determined are apatite, phlogopite, forsterite, dolomite, diopside and calcite. Apatite is a Ca phosphate, phlogopite a K, Mg, Al mica, forsterite a Mg olivine, dolomite a Ca, Mg carbonate, diopside a Ca, Mg clino-pyroxene and calcite a Ca carbonate. Samples are collected from the process streams and pumped a short distance to the laboratory which is adjacent to the plant. Technical Description of XRD System A Cu-anode tube is used in the Foskor application. The sample cell window is made of 20µ BOP (Bi-axially Oriented Polypropylene) film which has no interfering peaks in the range theta, which is the scanning area of importance for the minerals being determined. Braun PSDs (Position Sensitive Detectors) are used with fixed geometry, resulting in an effective 10 2 theta working range. A Cu anode is used as it gives good peak resolution. If high Fe-bearing minerals have to be determined, a Coanode would be used. Lower angles would result in losses of peak intensity and, therefore, much higher detection limits. But higher angles should not be a problem (dependent on available film material) if they should be required for any particular minerals

14 Sample Preparation and Methodology A specific volume of sample is collected for the XRD analysis, which is then milled to nominally 38mm, and held at readiness in a mixer tank situated just before the XRD circulating system. The sample must be milled, as tests have indicated that the slime fraction, often representing as low as 10% of the sample, can contribute up to 80% of the mineral peak intensities. This results in biased, erroneous data. Thus it is essential for a sample to be analysed to have a narrow range of particle sizes. Analytical method For feed samples the method has to compensate for the dilution factor, and a method of using relative intensities is used to correlate the Apatite, Diopside, Forsterite, Phlogopite, Dolomite and Calcite to the wet chemical P2O 5 analysis. The dilution is calculated by measuring a clean area on the diffractogram while scanning water, and then expressing all other mineral peak intensities as a percentage of the dilution when compared to the same area with sample. Water is then not only used as part of the measure of dilution but also as a very important drift corrector for tube intensities. Tube standardisations with clean water are done after every 10 reading cycles. Integration time for the samples is 5 minutes. To determine the mineral concentrations is more difficult. At Foskor the product is sometimes upgraded to 40% P O 2 5 which calculates to 94.4% Apatite. At this level the absorption of x-rays by apatite results in no increase in peak intensity for increasing amounts of apatite (for the same dilution). A circulating system is used for the movement of sample, one placed on either side of the XRD tube. A circulating system consists of:- 1. A sample holding tank This tank has a stirrer and while the current sample is being analysed, the next sample is already being collected in this tank to be ready for analysis in the sample cell as soon as the previous sample has been analysed and flushed out. The cycle time for sample collection and preparation needs to be shorter than 7 minutes. 2. Sump and Pump After being collected in the holding tank, the sample falls into the sump, from where it can be pumped to a point above the XRD from where it can be gravitated to the sample cell. After analysis while in the sample cell, the sample gravitates back to the sump from where it can be pumped away to a drain. Sample volumes are too small to justify pumping back to the plant. For this reason the measurement of the gangue minerals becomes important. As the apatite percentage of a sample increases, the proportion of gangue minerals decreases, and vice versa. A multiple linear regression clearly shows the relationship of gangue minerals to the actual P2O 5%. Thus, for concentrates, the proportion of apatite is calculated by difference

15 Results Typical calibration data and analytical results are shown in the following graphs. Online and Inline Analysers NITA II Nita II on belt product analyser uses advanced neutron-gamma technology to provide elemental composition measurements that are both rapid and accurate. It utilises the penetrating power of neutron radiation to interrogate a large volume of material flowing on the conveyor belt. When neutrons interact with the material, gamma radiation is emitted promptly with energy signatures that are characteristic of elements present in the material. Dry Powder XRD Analyser Comment Although the quantitative XRD system described here covers the minerals apatite, phlogopite, dolomite, forsterite, diopside and calcite, the same principles would apply to any assemblage of minerals. The actual methodology and choice of XRD tube would depend on the composition of minerals to be determined. If Fe-bearing minerals are important then a Co tube would be most appropriate but for most mineral assemblages a Cu tube would be the best. Quantitative mineralogy becomes important if elements of interest occur in more than one phase. In that situation quantitative analysis by XRF or ICP is not appropriate. For example, at a local heavy mineral beach sand operation XRF analysis showed that appreciable Ti was being lost in the mag-others fraction. It was only shown by XRD that this Ti occurred in the mineral lamprobolite, a Ti-bearing amphibole, and was irrecoverable anyway. A very effective quantitative XRD programme is now available commercially. IMP has the expertise and experience to design and implement a quantitative XRD system for mining plant and laboratory applications. Online XRD provides information on the mineralogy of the product. Inline rapid mineralogical analysis can significantly improve process control. IMP can integrate the XRD system to IMP sampling and sample preparation equipment presenting the analyser with dry representative product for analyses. IMP MD100 On-belt Moisture Analyser The IMP MD100 On-belt moisture measurement system allows for the accurate measurement of moisture in real time. This readily available moisture information allows proactive process control and closed loop process control. OD Online Oversize Detection System The OD (Oversize Detection) system features a camera with onboard ultra-fast processing power to analyse the product on the Conveyer at a suitable point in the process. Illumination of the material enables the camera to capture crisp images of the product up to a rate of 75 fps (frames per second rate is dependent on the tools being utilized on the system)

16 Dry Powder Disperser and Laser Diffraction Sensor The unit is suitable to measure particle sizes from 0.25 to 3500 microns on dry powders utilizing laser diffraction technology. Modular components are available for optimum adaptation to the process. Inline solutions cover pipe diameters from 100 to 200 mm. Though representative sampling is of crucial importance, sometimes different kinds of samplers (e.g. screw-samplers) are already installed. The unit can then be adapted directly to existing samplers or operate as a wall mounted standalone on-line solution. Image Analysis Sensor with Flow Cell and Auto-focus The dry particle size analyser is suitable to analyse particles in a range of 5 microns through to 10mm. The unit utilizes image analysis techniques so information about the particle shape is also available. Rapid Inline Sample Dryers VR5 Vibro Dryer The VR5 Vibro dryer is a high speed dryer that can dry 8kgs of sample in a matter of minutes. The dryer incorporates a vibrating oil heated base with infrared heating from above. The sample is vibrated and tumbled during the drying process. The continuous movement of product and exposure of all surfaces of the sample aids the speed of drying. A pyrometer monitors and controls the surface temperature of the sample ensuring that the sample is not compromised during the drying process. The direction of vibration is reversed to guide the sample into sample collection cup. Continuous Belt IR Dryer The continuous Belt IR dryer is used to dry slurry samples. The units are usually fitted after a slurry sampler and are used to dry the final sample that is used for chemical and other analysis. The units are often connected to pneumatic sample transport systems that transport the dry sample in a capsule to the laboratory. Ultrasonic Slurry Particle Size Analyser The unit is suitable for use in highly concentrated suspensions and emulsions. It utilizes ultrasonic extinction method to determine the particle size. The probe can measure particles from 0.1 micron up to 3mm in suspensions with a pulp density up to 70%. Unlike laser techniques the slurry or emulation does not need to be diluted. Slurry is dribbled onto the stainless steel belt where the slurry is slowly transported under IR lamps that drive off the moisture. The dry powder is collected at the end of the belt for analysis. The dryer is typically installed in the plant. Vibe Feeder Dyers The vibration feeder dryers are specifically designed for large samples. Samples are placed on the input side of the dryer and they are slowly passed through to the output. Slurry On-line Laser Diffraction with Auto-Dilution Suitable for use in low concentration slurries or where the slurry can be diluted. Particle size and shape analysis from 2 µm to 6820 µm in five measuring ranges is possible. As they pass through, the samples are exposed to the infra-red lamps above the vibration feeder. The size of the sample is not limited as the sample can be continuously fed into the input. Pyrometers monitor and control the surface temperature of the sample to ensure that the sample is not overheated and compromised during the drying process. Samples as large as 1 ton can be dried on these dryers

17 Automated Sample Transport Systems HR-HSK Manual Sample Sending Station Unit for sending a sample via pneumatic tube as well as for receiving the returning carrier The sample material, which is collected manually, is transported to the nearby manual station and inserted into a pneumatic tube capsule. The capsule is closed by means of the integral manual capsule opener, and then placed in the insertion point of the manual station. The manual station is open and closed manually. When the pneumatic tube capsule has been inserted, it can be dispatched to the laboratory at the touch of a button. A light on the receiving station indicates that a capsule has been received. The manual station can be employed in the laboratory to return empty pneumatic dispatch capsules to the plant. HR BM Automatic Plant Capsule Sending Station with Mixer This unit is used to collect sample increments, mix the increments, remove a representative sample, place the sample in a capsule and send the sample to the laboratory for analysis. The unit can also be used in conjunction with the dryers described previously. Automatically transporting samples from the sample station to the laboratory ensures rapid turnaround times of results. In the laboratory the sample can be manually or automatically processed. The empty capsule is automatically transported back to the plant station for reuse. Pyro Metallurgical Integrated Sampling IMP s pyro metallurgists in conjunction with the IMP project team have designed, developed, installed and commissioned an automated converter sampling system. The system was designed to sample an Ausmelt converter with a hearth depth of 17 metres. The system collects either slag or matte, cools the samples and automatically transports the samples to a robotic l a b o r a t o r y f o r s a m p l e preparation and XRF analysis. In order to provide meaningful feedback to the smelter, analytical results are reported within 12 minutes. In order to achieve this IMP invented and patented a molten metal sampler that allows automatic sampling of either slag or matte using capillary action. The sampling head is designed such that the sample can be automatically removed. The process works as follows: A water-cooled lance traveling at 10 metres per second enters the converter, takes a sample of either matte or slag. Note that the slag and matte layers are only a few hundred millimetres. The lance is retracted and the sample is automatically removed and separated from the smouldering sampler. The sample is then automatically crushed and transported to the laboratory in a capsule via a pneumatic sample transport system. In the laboratory the robotic system automatically removes the sample form the capsule, pulverizes the sample and presses it in a steel ring before analysing the sample in an XRF. Results are returned to the plant within 12 minutes. Monorail The IMP Monorail system is used to automatically transport bulk samples from the sampling stations to the laboratory for further processing of the sample using one of IMP's automated robotic facilities or, alternatively, samples can be manually processed

18 Other Equipment IMP has a range of Jaw, Cone and Rolls crushers that are used in the sample stations to crush the sample prior to further splitting. Based on the size and type of ore IMP will recommend the correct crusher for your application. Crushers Ancillary Equipment Composite Sample Collector The collector collects sample increments over a set period building a composite sample for analysis. These are used where the sample is not automatically transferred to the laboratory. Diverters Jaw Crusher CM20 A complete range of diverters are available with two or three way position diverters. Diverters are appropriately lined to reduce wear. The units are sized to suit most applications. Automated Mortar Crusher Twin Roller Mill Rotary Sample Dividers Linear Indexers Linear indexers dispense samples into two or more containers. Indexers can be used to multiplex slurry lines or for collecting samples into containers. A range of RSD's and RSDR units are available that can be integrated into the sample station or operate as standalone machines in your comminution process of laboratory samples. Bucket Carousel Sample bucket carousel for 2-8 buckets of various sizes are available. Buckets ranging from 5kg to 200 litres are available. Typically the 200 litre drum carousel holds 4 x 200 litre drums