Minerals Testing & Research Center

Transcription

1 Minerals Testing & Research Center Offering metallurgical, ore characterization, analytical, and separation testing capabilities

2 2 FLSmidth Mineral Testing Laboratories In an effort to continue improving services to our clients, FLSmidth has constructed a new Minerals Testing and Research Center. Opened in August 2010, this facility has expanded services for ore characterization, equipment selection, process testing, plant trouble-shooting, and research. The Minerals Testing Center houses the: 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 brand new, fully-equipped building and up-to-date instruments 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 Chemical Analysis ICP-MS ICP-OES AA+LECO S+C Bulk Mineralogy Optical Microscopy XRD CEC+NIR Ore Profiling Metallurgy Plant Products Optimization Mineral/Particle Analysis SEM EMPA ToF-SIMS Quantitative Mineralogy Automated Mineral Analyzers FLSmidth has added state-of-the-art Ore Characterization and Process Mineralogy Labs to support our metallurgical services, engineering and plant construction. The labs also serve mining companies for exploration, mine site geology, expansions, feasibility studies, plant support optimization, and environmental work. The OCPM laboratories started up during the 1st quarter of They are staffed with highly experienced process mineralogists and encompass the most advanced laboratory technology. Capabilities include: Quantitative XRD Rietveld mineralogy SEM and optical microscopy Automated mineral analysis NIR data base development Clay analysis

5 5 Mineralogical laboratory services will include Ore characterization & process mineralogy Plant surveys Lab technology development Lab design Lab automation Training in geo-metallurgy Ore characterization for exploration, mine geology, resource control Drill core, cuttings, pulps Bulk ore samples Ore profiling of drill campaigns in support of logging Quantitative XRD & NIR mineralogy Quantitative sulfide & oxide mineralogy Environmental support work Chain-of-custody soil-slag-ash-residue analyses Tailings characterization Contamination source allocation Dust profiling using state-of-theart automated mineral analyses Beneficial reuse and re-processing assessments Process mineralogy services - automated mineral analysis Bulk modal analysis Liberation/Locking analyses of feeds, tails and concentrates Particle size profiles & dust analysis Grinding circuit surveys Analyses of leach ores When & where to use our Ore Characterization Labs - Project planning Geo-Metallurgy program development Review mineralogical sampling & lab work Lab automation for mineralogy & chemical labs Exploration & mine site geology Drilling projects Metals deportment Alteration zone analysis New ore body & plant development Future plant design Pre-feasibility & feasibility studies Support of metallurgical testing + pilot plants Alteration zone analysis mineralogy & geochemistry Preliminary process mineralogy of new ore types Preparation of spectral NIR data bases Geo-metallurgical ore profiling programs Characterization of refractory ores Lab technology development & lab automation* On-line & downhole chemistry & mineralogy Automated sample preparation systems design for mineralogy & chemistry Advanced automation of production mineralogy/chemistry labs in mining *In cooperation with FLSmidth s Automation Team Production support Assist with overflow work from company facilities Optimizing ore blending, routing & forecasting Plant re-starts, expansions & optimization Complex metallurgy or refractory ores Gold/Copper/Uranium leach support Bio leach solids characterization Environmental characterization

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. FLSmidth s Analytical capabilities are tailored to support the mining industry by providing prompt, quality driven analyses. This reliable information allows our clients to make fully informed decisions regarding the development of future projects or the optimization of existing operations.

9 9 Hot Plate Acid Digestion Traditional acid digestion procedures utilize a combination of concentrated acids to dissolve solid samples in preparation for elemental analyses by AA or ICP. Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES) ICP-OES is an analytical technique which introduces a sample to a plasma source to produce excited atoms and ions that emit electromagnetic radiation at wavelengths characteristic of an element. This technique provides a sensitive and rapid multi-element analysis for a variety of sample matrices. Fire Assay Fire assaying is one of the oldest and most reliable methods for the quantitative analysis of gold and silver. The method is used for both ores and process products. This method is accepted as the industry standard. Microwave Digestion Systems For complicated sample matrices or for samples where the volatile elements need to be preserved, microwave digestion is a preferred dissolution technique. Using a specially-designed laboratory microwave system, the temperature and pressure within each sample vessel can be monitored to ensure a proper digestion. Microwave digestion provides reproducible results while maintaining a high degree reliability and safety. LECO Carbon and Sulfur Analyzer Carbon and sulfur concentrations are determined by the use of infrared detectors following the combustion of the sample in an induction furnace. Inductively Coupled Plasma- Mass Spectroscopy (ICP-MS) - NexIon 300 ICP-MS is an analytical technique which introduces a sample to a plasma source to produce singly charged ions. These ions are separated according to their mass-tocharge ratio and measured to determine elemental concentrations. This technique is highly sensitive and capable of detecting several elements at concentrations as low as one part per trillion. Laser Particle Size Analyzer The particle size distribution of samples can be determined with the use of laser diffraction technology. Particles ranging from submicron to a few millimeters can be measured rapidly and accurately either as dry material or in solution. Flame Atomic Absorption Spectroscopy (FAAS) FAAS is a spectroanalytical procedure for the quantitative determination of chemical elements (metals and metalloids) employing the absorption of optical radiation (light) by free atoms in the gaseous state. Metal ions in a solution are converted to atomic state by means of a flame. Light of the appropriate wavelength is supplied and the amount of light absorbed is measured against a standard curve. Typical concentrations range in the low mg/l (ppm) range.

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 By sending your samples to an FLSmidth laboratory, you will benefit from 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 From the results of this testing, the optimal conditions can be selected to provide the most efficient results that will also help reduce costs. The FLSmidth Separation Laboratory in Salt Lake City, Utah provides extensive facilities for bench and pilot scale testing, as well as 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 also a valuable resource for the Separation Technology Group engineers. Arranging for test work Requests can be made through your FLSmidth sales representative. Information about the process will be requested to allow preparation of a detailed proposal specifying job scope, estimated time and cost. An MSDS and application data sheet is required with the sample when the work is 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 equipmentfocused 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 Pilot Operations functions include: Design Data collection Installation Report production Operation and maintenance Equipment decommissioning 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. FLSmidth engineers and technicians can work at your site or at our fully equipped Minerals Testing and Research Center. Our Salt Lake City based full-service analytical laboratory provides quick and efficient analysis of pilot samples. FLSmidth s heavy investments both 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. FLSmidth s Pilot Operations team delivers products, processes, and technical expertise anywhere in the world. Our equipment is modern. Our staff is professional and highly trained. In short, FLSmidth ensures you receive first-class service.

14 14 Research & Development The Non-Ferrous 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 Non-Ferrous 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 nonferrous 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, biochemistry and physics. 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. 9/17/2012 al-us