Minerals Testing & Research Center

Transcription

1 Minerals Testing & Research Center Offering mineralogy, metallurgical, liquid/solid separation, and analytical testing capabilities

2 2 FLSmidth Mineral Testing Laboratories FLSmidth continues to expand services for mineralogy, metallurgical testing, equipment selection, process review, plant trouble-shooting, and research. Our Salt Lake City Minerals Testing & Research Center houses: Ore Characterization & Process Mineralogy Laboratory Dawson Metallurgical Laboratories Separations Laboratory Analytical Laboratories Pilot Operations Group Research Group

3 3 FLSmidth strives to provide the best possible data on which to base future projects. The data from our labs form the cornerstone of proper plant design or optimization projects. The FLSmidth Minerals Testing and Research Center delivers the data you need. We are continuously expanding the capabilities of our laboratories to serve your needs more completely. Our state-of-the-art facility ensures that we maintain the integrity of your samples without contamination, loss, or delay. The best available equipment and instruments provide rapid turnaround, quality results and accurate data. We have the capability to bench-test complete flowsheets in most mineral processes. Our fully-equipped building and up-to-date equipment ensure clients and visitors the highest quality of products and services. Adding to that value is our technical staff, which includes some of the best recognized names in mineralogy and mineral processing. They are backed by an unprecedented depth of personnel and world-class breadth of knowledge, making FLSmidth the preferred choice when customers encounter a one-of-a-kind process challenge. FLSmidth s commitment to safety and quality is the underpinning which ensures personnel are safe, data is sound, and equipment is used properly. We take safety seriously, whether working in our laboratories or doing tests at your site. Our quality assurance programs are designed to provide the accuracy and precision in test results required by the most demanding clients. This combination of facility, equipment, personnel, and procedures means that FLSmidth is your One Source for robust minerals testing and process development.

4 4 Ore Characterization & Process Mineralogy Labs X-ray diffraction NIR & FT-NIR spectroscopy Automated mineral analyzer Expand margins, increase returns and reduce your risk FLSmidth s Ore Characterization & Process Mineralogy Labs are your best single source for mineralogical support services related to geo-metallurgy, heap leaching, concentrator optimization and characterization of other materials. Our mineralogy work is high quality, cost efficient, reliable and performed by a team with decades of mining and production experience. The new 200-samplesper-day QCX RoboLab can complete larger sample loads in the shortest possible time in support of the your geometallurgy modeling and ore profiling. Lab capabilities FLSmidth s Ore Characterization & Process Mineralogy Labs is one of the most advanced integrated mineralogy labs in the service business. Staffed with a senior team representing more than 77 years of combined lab experience in mining, our staff and laboratories can assist you and your operation with any mineralogical challenges from the exploration site to the tailings pond. NIR & FT-NIR Optical microscopy SEM-EDS/WDS analysis XRD Rietveld and clay analysis QEMSCAN/TIMA mineralogy D-SIMS & electron microprobe

5 5 Mineralogy for exploration & mine-site geology In the future, ore deposit development will require larger amounts of quantitative mineralogy data related to ore control and processing. As part of the continuous effort to optimize exploration, mine site geology and ore profiling (geo-metallurgy), FLSmidth has established the most advanced commercial mineralogy service center available. Our commitment is to provide customers with the best ore characterization during early, advanced and feasibility phases. For existing operations, our services are focused on assisting in best practices and reducing variance inherent in ore bodies. A robust mineralogical analysis is the best risk-reduction method. Metals deportment Alteration mineralogy Quantitative XRD & FT NIR Leach residue mineralogy FT-NIR spectral data bases Quantitative clay mineralogy Geo-metallurgy - ore profiles Bulk mineralogy - core/cuttings/blast holes Plant & process support With changing, deeper and lower-grade ore bodies, current and future plants are required to continuously optimize their circuits and/or troubleshoot unexpected metallurgical problems. That effort applies to both heap leaching and concentrator operations. Mineralogical work is targeted to optimize ore routing, better hardness control and forecasting of problem minerals, such as reagent consumers and/or minerals impacting flotation. Surveys for heaps, grinding and flotation circuits are critical to improved processing. The FLSmidth mineralogy labs provide extensive production experience from mining operations in mineralogical plant survey projects. Heap leach mineralogy Mineralogy for MET testing Acid consumption forecasts Concentrator & heap surveys Optimize ore blending/routing Plant de-bottlenecking, re-starts and expansions Automated mineral analysis QEMSCAN & TIMA Our labs operate some of the most advanced automated mineral analysis capabilities in the mining industry. The supervisory staff has mine-site process mineralogy experience for both daily concentrator and heap leach support. The QEMSCAN and TIMA labs are linked to a state-of-the-art robotics sample preparation lab. In 2013, they received one the first automated sample load systems for 24/7 sample exchanges in mining. Metal deportment Liberation/locking Bulk model mineralogy Leach residue mineralogy Material balanced mineralogy Lab technology-lab design / automation QCX mineralogy RoboLab Mineralogy staff training Robotics lab module design Large geo-metallurgical programs Automated mineralogy samples per day Design of sample prep, mineralogy and chem labs Mill throughput / BWi-SPI mineralogy correlations Elemental analysis Pathfinder trace elements for mineralizations, impurities in ores, residual metal values in process materials, surface contaminations and environmental speciation work require micro chemical, elemental analysis. FLSmidth s Ore Characterization Labs are highly experienced in this type of work as it relates to exploration, concentrators, smelting, refining and remediation. Elemental concentrations Elemental distribution (maps) Mineral classifications Characterization of slags, filter material, crud, sludge, precipitates and residues Environmental speciation

6 6 Dawson Metallurgical Laboratories FLSmidth s Dawson Metallurgical Laboratories provide metallurgical testing for ore amenability, process development, flowsheet layout and plant design. Our facilities include crushing, grinding (including ultra-fine grinding capabilities), comminution sizing, gravity separation, wet high- and low-intensity magnetic separation, size classification, hydrometallurgical processing (ambient and autoclave technologies, column and stirred reactor leaching), and flotation. Flotation equipment includes mechanical test cells from 50- to 20,000-gram capacity. Our laboratory also offers in-plant consultation services and plant auditing.

7 7 Process Development Testing Capabilities Flotation Grind/Liberation Rougher/Cleaner Batch ( L) Locked Cycle Sulfide Ores Oxide/Transition Ores Industrial Minerals Attrition Scrubbing Hydrometallurgy Cyanidation (CIP, CIL, CIC) Pressure/ Oxidation Leach Bottle Rolls Mixed Reactor Column Leach Chemical Oxidation Gold Diagnostic Leach Copper Diagnostic Leach Comminution J-K Drop Weight Test SAGDESIGN (Starkey Method) Abrasion Index Crusher Impact Index HPGR UCS Bond Ball/Rod Mill Indices VXPmill Vertical Mill Gravity Concentration Deister Table Mozley Table Knelson Bowl Falcon Bowl Duplex Jig Reichert Spiral Magnetic Concentration Wet Low-Intensity Wet Hi-Intensity Davis Tube Classification Wet/Dry Sieves (4-10μ) Hydrocyclone Cyclosizer Malvern Size Analysis (to 0.02μ) Hydrometallurgical Testing Our laboratory also has extensive experience in hydrometallurgical testing of precious metals and base metals. Leaching can be conducted at different sizes from small-scale shaker tests to 500, 1000 or 5000 gram bottle roll tests; agitation leaches of up to 40 gallons have been conducted. Bench scale Parr autoclaves (2 liter) are also used for pressure oxidation test work. Flotation Concentration Laboratory bench-scale rougher through cleaner flotation use combinations of 2000, 1000, 500 or 250 gram cells. Larger scale flotation tests (up to 20 kilograms of material) can be conducted in a 1.3 cubic foot Agitair cell. Process development tests generally apply test series to establish the primary grind size, reagents and cleaner (regrind) requirements to characterize ore response. Locked cycle tests recirculate water and intermediate products to simulate closed-circuit process operation. Our laboratory has extensive experience with different mineral separation procedures. Frequently, nonselective bulk sulfide flotation tests are used to recover precious metals associated with pyrite or other sulfides. Gravity pre-concentration and magnetic separation can also be incorporated into any test program. Selective flotation tests can separate different mineral combinations such as copper from pyrite or copper from molybdenum. Other mineral separations conducted include: copper-lead-zinc-pyrite, silver-lead-zinc-pyrite, silver from sulfosalts, enargite-pyrite, lead-zincpyrrhotite, nickel-pyrrhotite, cobaltpyrrhotite and iron ore processing. Bench scale flotation tests can also target the recovery of industrial minerals such as cassiterite, potash, phosphates, talc, silica frac sands, silicates, barite; and energy minerals such as coal, resin-coal and tar sands.

8 8 Analytical Laboratories FLSmidth s Analytical Laboratories provide quantitative chemical analyses on a variety of minerals related materials utilizing classical methods and modern analytical instrumentation. Analytical instrumentation includes: Flame Atomic Absorption Spectroscopy (AA) Inductively Coupled Plasma- Optical Emission Spectroscopy (ICP-OES) Inductively Coupled Plasma- Mass Spectroscopy (ICP-MS) Leco combustion furnace Laser Ablation

9 9 Fusion Fire assay gold and silver with lead oxide collection and gravimetric, AA or ICP finish Fire assay platinum group metals with nickel sulfide collection and ICP finish Lithium borate fusion followed by ICP for refractory minerals Sodium peroxide fusion followed by ICP for refractory minerals Acid digestion Four acid hot plate digestion Microwave assisted digestion Hydrofluoric acid digestion for silicon Aqua regia digestion at low temperature for volatile elements including Hg, As, Sb and Se Concentrates Iodide titration for copper Molybdenum concentrate digestion with AA or ICP finish Molybdenum concentrate with gravimetric finish Acid insoluble content Carbon and Sulfur Total Carbon and/or Sulfur by Leco induction furnace Sulfide sulfur by Leco following sodium carbonate leach Sulfide sulfur by Leco following HCl leach Sulfate sulfur by Leco following roast Sulfate sulfur with gravimetric finish following HCl leach Elemental Sulfur by UV-Vis following chloroform leach Total sulfur by ICP following microwave digestion Selective leach test Acid soluble copper (oxide copper) Ferric soluble copper (Quick Leach Test) Cyanide soluble copper Water soluble copper Cyanide soluble gold Cyanide soluble gold with preg-rob Molybdenum oxide Chloride Water soluble chloride with ion selective electrode (ISE) Total chloride by nitric acid digestion and ISE, titration or gravimetric finish Other Methods Acid base accounting (ABA) Meteoric water mobility procedure (MWMP) Acid consumption Loss on ignition Moisture Free acid in solutions Phosphorous

10 10 Separations Laboratory FLSmidth s Separation Technology Group has experienced engineers available to assist you in the evaluation of new or existing processes, either to optimize operation or to determine design criteria for new equipment selection. Our services include contract testing, process engineering, bench testing, pilot testing and research and development. Our laboratory engineers are highly educated, holding at least bachelor degrees, and have continued their training in the specific testing needed for separation technology. The FLSmidth Separation Technology Group performs testing in the laboratory and in the field. The engineers also certify and optimize full scale FLSmidth equipment.

11 11 FLSmidth laboratories, are backed by testing methodology refined in thousands of studies, combined with an encyclopedic database reflecting over five decades of solid-liquid separation experience. Bench Testing Particle size analysis Sedimentation Vacuum filtration Pressure filtration Pilot Testing Thickeners Clarifiers Vacuum filtration Pressure filtration Sedimentation Typical analysis for sedimentation includes bench scale testing to simulate Clarification Thickening (high rate, high density, paste, & CCD applications) MaxR Particle Growth to enhance separations Hydroseparation Filtration Typical filtration analysis includes bench scale testing to simulate: Horizontal belt filters Drum filters Disc filters Pressure filters The results of these tests will offer material and process specific conditions, which will concurrently provide efficacy throughout a plant system and a reduction in costs. The FLSmidth Separation Laboratory in Salt Lake City, Utah provides expansive facilities for bench and pilot scale testing, including analytical laboratory support services. Field Service Most of the services of the Separation Technology Group can be provided in the field. In many cases, an on site assessment of existing systems and process conditions is advantageous in achieving maximum operating efficiency. Services include both testing and equipment evaluation. Research and Development Also included in the Separations Laboratory facility are some of the most experienced and knowledgeable people in the separation industry. Working in research and development, these employees are a valuable resource for the Separation Technology Group engineers. Arranging for test work Requests can be made through your FLSmidth sales representative. Process information will be requested to enable preparation of a detailed proposal specifying job scope, estimated time, and its cost. An MSDS and application data sheet are required with the sample s arrival for work to being done at the Separation Laboratory. References FLSmidth has performed testing and developmental services for most large mineral, chemical, energy, and engineering firms worldwide. A list of relevant references is available upon request.

12 12 Pilot Operations Combining multiple disciplines and the complete range of FLSmidth products, Pilot Operations can handle your pilot testing needs. With Safety as a watchword, FLSmidth designs, installs, operates, and decommissions pilot plants. The strong process and equipment competencies of the One Source model, provides answers, which equipment focused suppliers miss. We deliver a variety of equipment combinations for plug-and-play installations. These process islands include the major pieces of process equipment, control panels, and ancillary equipment; all skid mounted. The group bridges the gap between the bench-top testing and full-scale operations.

13 13 We see projects through, from start to finish. The team composed of engineers, technicians, and logistic specialists possesses extensive experience in mining, mineral processing, metallurgy, chemical engineering, mechanical engineering and mine and plant operations. These industry experts utilize the best industry practices, promote safety and adhere to strict environmental protocols. Services include: Develop action and test plans Ensure complete engineering Manage resources and utilities Develop project schedule Procure materials and equipment Construct system or process island Develop operating and safety procedures Operate equipment Supervise pilot plants Provide On Call technical support Manage laboratory support Generate reports Functioning as an independent organization, the Pilot Operations group maintains accountability by using a single project manager who serves as the point of contact through all project stages. The Pilot Operations group also includes multiple engineering disciplines. This allows us to respond quickly and reliably. Access to a wide variety of other resources further bolsters the disciplines to include those below: Process Piping and Instrumentation Control Layout Electrical Mechanical The Pilot Operations team offers a full range of testing services from bench-top test units to pilot-scale equipment.our Salt Lake City based full-service analytical laboratory provides quick and efficient analysis of pilot samples. FLSmidth s investments in equipment and in people ensure that you receive the latest technology. Areas of expertise include: Comminution HPGR Mills Crushers Flotation Wemco Dorr-Oliver Xcell Classification Krebs Thickening Eimco Dorr-Oliver Vacuum Filtration Drum Disk Belt Pressure filtration Shriver AFP IV Pneumapress The Pilot Operations group delivers turnkey pilot systems for operation in applications from base and precious metals to coal. The department s full range of services confidently transforms bench-top tests into full-scale operations. Our staff is professional and highly trained. In short, FLSmidth ensures you receive first-class service.

14 14 Research & Development The Mineral Processing Research and Development Group is headquartered in the Minerals Testing and Research Center (MTRC) and is part of FLSmidth Group Research and Product Review. Primary research activities are conducted in laboratories and pilot areas within the MTRC, and the execution of projects involves interaction with other FLSmidth research and testing facilities in Bethlehem, PA (USA), Dania and Valby (Denmark) and Chennai (India). Some research, at a fundamental level, is contracted to universities and outside research institutes depending on the topic under study.

15 15 The Mineral Processing R&D group focuses its efforts on improving existing process and unit operations technologies and also in developing ideas and proving concepts that will take FLSmidth into new technology areas. Our goals are to provide our customers with sustainable, innovative and environmentally responsible operations. The group s research is aligned with the primary technology centers located in Salt Lake City: concentrators, hydrometallurgical processing, and pyrometallurgical processing; the group also conducts process research supporting coal, iron ore, and fertilizer minerals. Concentrators research investigates technologies affiliated with minerals concentrators. This includes comminution operations, classification, value concentration (e.g., flotation, heavy media, magnetic separations, etc.), liquid/ solids separations (sedimentation and filtration), and tailings treatment and disposal. The technologies include unit operations (machine optimization and new machine technology) and processing research. Hydrometallurgy research focuses on the technologies affiliated with leaching of mineral ores and concentrates and the subsequent isolation and recovery of value from the leach solutions while managing and disposing non-value elements. This includes research into leaching systems and kinetics enhancements, value recovery systems (e.g., solvent extraction, activated carbon, ion exchange, electrowinning, selective precipitation and membrane technologies) and non-value precipitation for disposal and discharge water treatment. Pyrometallurgical research investigates high temperature thermal processing technologies in extractive metallurgy that bring about physical and chemical transformations. This research is primarily conducted at testing facilities near Bethlehem, PA (USA) and in conjunction with the Cement Research facilities in Denmark. The research facilities at the MRTC consist of three laboratories fully dedicated to research in the Mineral Processing focus areas, and a 1,000m 2 pilot area. The other laboratories in the MRTC provide support services to the research projects in addition to serving FLSmidth customers. The pilot plant area is dedicated to scaled-up research in equipment optimization, prototype testing, and process research. The research staff consists of well trained researchers/scientists with background in relevant areas including minerals processing, metallurgical, chemical, mechanical and mining engineering, and specialists in CFD, chemistry and biochemistry. Dedicated men and women with great cultural diversity and industry experience encompassing recent graduates to seasoned professionals with decades of experience and expertise are a hallmark of FLSmidth s customer centric research group.

16 Minerals Testing & Research Center FLSmidth Salt Lake City, Inc S. FLSmidth Dr. Midvale, UT USA Tel: Fax: Copyright 2012 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. Rev. 1/9/2014 al-us