Crushing Screening and conveying In- House Workshop

Transcription

1 Crushing Screening and conveying In- House Workshop Intermediate to Senior level for Active Plant Operators and Maintenance Staff Mr Basdew Rooplal Metallurgical and Business Consultant Mr Basdew Rooplal is a Mineral Processing Engineer with over 20 years of experience gained in the mining, mineral processing and related industries in the operational, research and development, project management (plant design and commissioning) business development and consultation fields in the Gold and Diamond industries. His experience spans over hard rock underground mining of the Witwatersrand, large open cast mining of Botswana and alluvial mining of the west coast of Southern Africa. During his career Basdew has facilitated several workshops for the Mineral Processing environment. He is currently working together with international partners (ex JKMRC) on the development and distribution of user friendly (excel based) plant monitoring and optimisation software for the minerals industry. He holds a HND in extractive metallurgy and a Post Graduate Diploma in Management Studies (SAQA NQF level 8)

2 Overview of Workshop Once valuable minerals have been identified it is first blasted to liberate it from the mother rock and then transported via rail or trucks for subsequent beneficiation. Depending of the grade of product required the material is processed via a crushing and screening plant or subjected to run of mine milling. The prior option is chosen when run of mine milling is not suitable and a coarse product is required. The course covers the essential process of extraction and design of comminution circuits with emphasis on crushing and screening; Essential aspects of proper sampling of deposits and ore characterisation which play a vital role for design and plant trouble shooting are also covered. A practical approach is followed throughout the workshop where participants learn to relate work related practice to theoretical aspects of the job. A hands on approach is followed where delegates learn to trouble shoot, draw up routine checklists and audit and develop corrective actions for their plant. Key Learning areas: The delegate will learn the essential elements involved in the design of a comminution circuit. Having covered this aspect plant trouble shooting to enhance plant efficiencies and production become easier. Issues related to plant optimisation and control is also covered. The basics of plant design i.e. sampling and bench scale testwork is often neglected but forms an important basis for proper operation and control of most crushing circuits. This stage becomes pertinent when reviewing crusher operation and solving optimisation issues. Profitable and efficient operation involves the identification and planning from the source, i.e. mining and this stage is often neglected in most crusher plant operations. The basic issues of conveyor belt installation and safety forms the basis for good plant operations. Neglect in this area can be a source of several accidents and lead to poor plant control. The delegates will learn to draw up routine checklists, conduct and audit and develop a proactive corrective system for their operations.

3 Topics under discussion. 1. Sampling a Mineral deposit for metallurgical testwork and design of a comminution circuit. 2. The basics of laboratory testwork for crushing operations. a. The various bench scale testwork that can be performed for trouble shooting and design analysis b. Ore characterization analysis c. Ore dressing studies 3. Factors that influence the selection of crushing circuits a. Outline of the various circuits under consideration b. Identification of factors c. General cost consideration of various circuits 4. Types and characteristics of crushing equipment and circuit flow sheets. a. Plant throughput and ore delivery schedules b. Feed Size c. Product Size d. Ore characteristics e. Climate Conditions f. Downstream factors g. Primary Secondary and tertiary crushing h. Description of the various crushers i. Applications 5. The basics of layout and design of a crushing plant a. Design parameters b. Ore characteristics c. Safety and environment d. Operational consideration e. Maintenance requirements f. Climatic conditions g. Upper supporting structure h. Receiving hopper area i. Crusher floor level j. Surge bin Area k. Crusher lubrication l. Feeder area from Surge bin m. Maintenance items n. Take away conveyor o. Dust collection suppression p. Stockpiles

4 Instrumentation and control of a crusher circuit. q. System optimisation diagram r. Standard equipment for crusher design s. Level sensing t. Conveyor weightometer u. Cameras v. Proximity switches w. Metal detectors x. Vibration sensors y. Control strategies z. Optimisation control 6. Coarse screening in mineral processing operations a. Coarse vibrating screens b. The working principle of vibratory screens c. Vibrating screen application d. Common measures of screen performance e. Traditional sizing methods f. Optimising performance and wear cost 7. Fine Screening in mineral processing operations a. Wet fine screening b. Factors effecting wet screening c. Types of wet screens d. Dry fine screens e. Types of dry fines screens f. Factors effecting dry screening g. Benefits of fine screening

5 8. Conveyor safety and preventative maintenance a. Precautions for operating and maintenance personnel b. Basic Conveyor maintenance i. Conveyor maintenance check list ii. Preventative maintenance iii. Techniques for preventing drive belt misalignment problems iv. Tips for aligning drives v. Chain conveyor inspections 9. Installation, Operation and maintenance of conveyor belt idlers a. Establishing the conveyor belt centreline b. Idler installation checklist c. Return idlers d. Self-aligning troughing idlers e. Conveyor start-up f. Belt training g. Training and empty belt h. Training a loaded belt i. Idler maintenance 10. Training problems associated with conveyors. 11. Crusher Plant optimisation a. Increasing the energy efficiency of process plants b. Optimising crusher performance c. Blasting for improved comminution performance d. Production planning for improved mine and plant performance

6 Crushing Screening and Conveying 3 day schedule for in-house training Day 1 8 H 30 Plant management team to lead discussion. Plant flowsheet and Key problem areas of Crushing and Screening Plant. Highlight areas for improvement in respect of maintenance and Plant Design Highlight process flow limitations and bottle necks. Highlight major areas of breakdown and production loss. High risk hazards for maintenance and production personnel. 10 H 00 Tea Break 10 H 30 Sampling, ore characterisation and flowsheet development for a crushing and screening plant. Relevant testwork that can be performed when evaluating a sample for feasibility and plant design. 13 H 00 Lunch Break 14 H 00 Group Discussion and Brain Storming session Possible Design solutions to problematic areas of Crushing and screening plant. 16 H 00 End of Day 1 Day 2 8 H 00 Crushing and Screening Presentation Plant Design and Layout considerations Selection and sizing of secondary and tertiary cone crushers. Cone crusher Installation 10 H 00 Tea Break 10 H 30 Crushing and Screening Continued. Principles of Screening Screen optimisation and Trouble shooting Preventative maintenance 13 H 00 Lunch Break 14 H 00 Group Discussion Review of Safe working procedures and other relevant issues related to Crushing and Screening plant. Preventative maintenance schedules and checklists. 16 H 00 End of Day 2 Day 3 8 H 00 Plant Hazards and Conveyor Belts General Plant Hazards Conveyor belt safety Conveyor belt installation and key design areas. Conveyor belt Trouble shooting and maintenance 10 H 00 Tea Break 10 H 30 Plant walk about. Plant inspection. Risk assessments and hazard identifications. Review of checklists. 13 H 00 Lunch Break 14 H 00 Plant Optimisation and Control 16 H 00 End of Session and handing over of certificates.

7 Fees and Contact Details Our Fees: R for workshop facilitation only. This excludes travel, accommodation and workshop material. Contact our consultant: Basdew Rooplal Cell No. : Telephone: rooplalba@yahoo.com