Institute of Mineral Processing Machines (IAM) Mining. Crushing, Milling, Screening, Sorting, Agglomerating, Sorting, Transporting

Transcription

1 Institute of Mineral Processing Machines (IAM) Mining Crushing, Milling, Screening, Sorting, Agglomerating, Sorting, Transporting

2 Research for the future Addressing today s challenges Such as - Diminishing ore grades - Rising costs - Price drop - Labour shortage TU Bergakademie Freiberg

3 Research for the future Addressing today s challenges By - New Crushing Technologies - New Milling Technologies - Training Local People Starting from the core. Starting with the ore. TU Bergakademie Freiberg

4 Identification of Suitable Raw Material Parameters 4 Quelle: TAKRAF, Diss. Schmidt

5 Procedure of numerical Mineral Analysis Mine Thin-Section Microscopy Sample Collection Thin-Section Preparation Thin-Section Library a b c

6 Quantitative Mineral Analysis

7 DEM-Modeling of Comminution Processes 7 Quelle: Jeschke, Katterfeld

8 Target of DEM-Modeling Crushing tool geometry and material Comminution process parameters Selective comminution But: Calibration of DEM models still a challenge! 8 Quelle: Diss. Schmidt

9 Principle of DEM- Modeling DEM-Model Rheological Model 9 Quelle: Scholtés et all

10 Polyeder vs. Ball based DEM Modelling 10 Quelle: Konietzky

11 Comminution in Sizers primäre sekundär e terziäre Brechphase

12 Comminution Mechanism in Sizers 12 Quelle: Diss. Schmidt

13 Conpressive vs. Tensile Strength of Rocks Zugfestigkeit / MPa Quarzsandstein mittelharter Sandstein 5 Tonschiefer Granulit 0 Anhydrit Druckfestigkeit / MPa 13 Quelle: Jabs

14 Basics of Comminution 14

15 Crushing Tool Geometry Geometry influences: Nip Angle Throughput Wear Energy Consumption Finish Product 15 Quelle: TAKRAF

16 Crushing Forces Calculation of Crushing Forces with DEM

17 Single Particle Impact Analysis Schnittbil d

18 Selective Comminution Ore Deposit Variety Rock, σ D [MPa] d P [mm] 16/ 20 v P [m/s] 60 n 50 Copper Chile Breccia Diorite Mineral Content [M-%] Hardness [HM] Fissility Oremineral Chalcopyrite ; Bornite 0,8 3,5-4; 3 2; 2 Wastemineral Feldspar; Quartz 99,2 6; Masseanteil [%] Zerkleinerungsprodukt Kupfer Berge Key Figure Select. Comminut. I SZ,1 [-] 0,49 ρ SZ [-] 0,56 Maximum value I SZ,2 [mm] 0,3; 4,7; 12,5; 20 I SZ,3 [-] 1 I SZ,4 [-] 0,02 η SZ [-] 0,02 1 0/0,1 0,1/0,2 0,2/0,315 0,315/0,5 0,5/0,8 0,8/1,25 1,25/2 2/3,15 3,15/5 5/8 Fraktion [mm] 8/12,5 12,5/20 f E 2,25 Evaluation of Selective Comminution + 18

19 Horizontal Impact Mill Particle Movement Quelle: BHS

20 Quelle: Köppern HPGR Load on Grinding Roll Surface

21 SAG Mill Impact Loads on Structures Flow Chart of Mill Circuit Quelle: C. Pfeiffer

22 Particle Movement (DEM-Model) Partikelgeschwindigkeit in Y-Richtung [m/s] >0 (0;-1> (-1;-2> (-2;-3> (-3;-4> <-4

23 Vertical Roller Mills 23 Quelle: Loesche

24 VRM application in Cement 24 Quelle: Loesche

25 VRM application in Cement Quelle: Loesche Quelle: Loesche Grinding bed before compression Grinding bed during compression 25

26 VRM application in Mineral Processing Crushing & Grinding Replacement through VRM 150 0,020mm Benefication & Dewatering

27 VRM application in Mineral Processing 27 Quelle: Loesche

28 Smart Screens

29 Particle Motion on Screen

30 Wendelrinne (Humphreys-Scheider) Sorting by Centrifugal Forces

31 Material Motion in Spiral Chutes

32 Material Motion in Spiral Chutes Particle Speed

33 Material Separation in Jigs

34 Material Movement in a Jig (DEM) Original Postion of Particles Average Height of Particles

35 Mechanisms of Pelletizing 35

36 Example of production scale Diameter: 7500 mm Side panel height: mm Total weight: t Capacity: ~ 150 t /h Production rate: ~ 70 % Recycling load: ~ 30 % Inclination: Rotation speed: 1 10 rpm Liners: autogenously / PE plates Scrapers: static Installed power: kw 36

37 Pelletizing process 37

38 Pelletizing process 38

39 Pelletizing process 39

40 Examples of Pelletizing new Materials 40

41 No more dust! 41

42 The Perspective Raw Material identify relevant material characteristics DEM-modeling Tools Optimization by linking with DEM-model) (energy consumption, material, wear) Drive Concept Optimum between power and inertia (DRC) Optimum fit of drive component characteristics etc. System Overload behaviour Capacity increase powerful, reliable, economical 42

43 Combination of Material and Machine-Simulation 43 Quelle: Dr. Gubsch

44 Freiberg is located in an old mining area but today the old dumps raise new interest!

45 Research for the future LARGE SCALE PLANT TECHNOLOGY Exploration Extraction Preparation Processing/ Veredelung / Finishing Processing Recycling TU Bergakademie Freiberg

46 In Situ Leaching, (Design, Test in Reicher Zeche) The Kruger Kolleg was just started -To investigate the economic recovery of value minerals contained in old tailing dumps and low grade deposits Tailings, Dumps Freiberg Deposit Selective reclaimation from, characterisation of old dumps Slags, Dusts Ore + Ground Ore International Deposits Selection, characterisation ore Microscopy Crushing, grinding, sorting Synthetic Ore Minerals Geochemical analysis of traces in complex samples Recycling Material Bio-Leaching, Bio-Mining Mineral synthesis by doping, mineral analytics (FEREM, qrdx) Metal in diluted aqueous solution + Solid phase after leaching 46

47 The Kruger Kolleg was just started -To investigate the economic recovery of value minerals contained in old tailing dumps and low grade deposits Metal in diluted aqueous solution Metal in concentrated Phase diagram solution Precipitation Crystallisation Reactive separation Selective concentration, Membrane separation, Separation of chelates Chelating agent for solvent extraction Quantum chemical design Chemical fractioning, development reactive separation Enriched Metal Refining Design and synthesis of selective chelating agents Electrolysis, Thermal processing Pure Metal 47

48 Institute of Mineral Processing Machines (Lab 1)

49 Institute of Mineral Processing Machines Full Scale Testing Facilities in Nearby Quarry

50 Research for the Future Collaboration in Education and Research Collaboration in Education and Training: PhD student exchange Post-Doc Programs Collaboration in Research: Mine planning Process design Environmetal Protection Universidad Oropreto 50

51 Prof. Dr.-Ing. Holger Lieberwirth TU Mining University Freiberg Institute of Mineral Processing Machines 51

52 52