Criteria for Selecting a Jig or DMS

Transcription

1 4th Annual FeTech Conference 2013 Criteria for Selecting a Jig or DMS Ph: Fax: info@metsengineering.com Web: PO Box 3211, ST GEORGES TCE, WA 6831 AUSTRALIA Presented by John Visser Mineral Engineering Technical Services > Mineral > RESOURCE M iprocessing n e r aprojects l P r o c e s s i n g > > EEngineering g i n e edesign > r itechnology n g D e s i g n > T r a> i Training n i n g > S p e> cintegrated i a l i s> t Specialist S e SERVICES r v i cservices e s

2 > DISCLAIMER With respect to all the information contained herein, neither Mineral Engineering Technical Services Pty Ltd, nor any officer, servant, employee, agent or consultant thereof make any representations or give any warranties, expressed or implied, as to the accuracy, reliability or completeness of the information contained herein, including but not limited to opinions, information or advice which may be provided to users of the document. No responsibility is accepted to users of this document for any consequence of relying on the contents hereof. > COPYRIGHT Passing of this document to a third party, duplication or re-use of this document, in whole or part, electronically or otherwise, is not permitted without the expressed written consent of Mineral Engineering Technical Services Pty Ltd. > ACKNOWLEDGEMENTS This document is a dynamic record of the knowledge and experience of personnel at Mineral Engineering Technical Services. As such it has been built upon over the years and is a collaborative effort by all those involved. We are thankful for the material supplied by and referenced from various equipment manufacturers, vendors, industry research and project partners.

3 Key Attributes Pragmatic, efficient, complete engineering through quality, personalised & exceptional service delivery > Working globally since 1988 > Dynamic and innovative niche consultancy > Dedicated team providing customised service > Specialist in Mineral processing & engineering projects > Unique solution finder

4 Overview > Introduction > Criteria for selection > Jig setup > DMS setup > Case studies > Capex and opex

5 Criteria for selection Criteria Jigs DMS Particle size Narrower sizing Broader sizing Density cut No restriction Max limit of 3.8 Density difference between float and sinks > to 0.8 Efficiency Less sharp Sharper Efficiency Dependent on small size Near density material Less of a problem More of a problem Yield and recovery Less optimisation Better optimisation Tailings grades Higher Lower Separation Density Density Capex Higher Lower Opex Lower Higher

6 Separation of Iron Ores Iron Oxides (Hematite) Magnetite Coarse (-32+8mm) Medium (-8+1mm) DMS Jigging Cobbing LIMS Fine (-1mm+212/75µm) Slimes (-212µm) Spirals WHIMS Flotation LIMS Flotation

7 Efficiency Comparison DMS vs. Jig partition curve DMS Jig (Interpolated) F S 4.2

8 Gravity Separation Performance > Concentration Criterion = SG of heavy mineral SG of fluid SG of light mineral SG of fluid Concentration Criterion (CC) Gravity Separation CC>2.5 Easy down to 75 µm 1.75<CC<2.5 Possible down to 150 µm 1.5<CC< <CC<1.5 CC<1.25 Possible down to 1.7 mm Possible down to 6.35 mm Impossible at any size

9 Jigging > Size classes for iron ore 32 +8mm 8 +3mm 3 +1mm > Size classes for coal mm mm mm > Capacity Batak Style Jig 65 t/h per meter width of jig to max of 4 m wide jig

10 Jigging Operation > The oscillating motion causes pulsations that will dilate the bed of material > This makes the particles settle as the larger and denser particles forming the lower layers with the finer and lighter particles on the top > During the suction stroke, differential initial acceleration occurs followed by hindered settling and finally consolidation trickling Consolidated trickling Start Dilation Differential Initial acceleration Hindered settling

11 Jigging Action

12 Jig Variations

13 Under Bed (Batac ) pulsed machines > Examples > Alljig from Allmineral > Batac from Humboldt Wedag > Apic jigs from Bateman

14 AllJig > Side pulsed or under bed pulsed machines

15 Jig Process Flowsheet + 32 mm 231 tph Lumpy Jig Plant 1400 m 3 ph -80 mm 554 tph tph tph Crusher -80 mm 785 tph 2 x Double deck tph Fines tph Lumpy Product Preparation Plant 2 x Single deck tph 10 tph 1382 m3ph Discard tph Fines Product 1296 m 3 ph 1592 m3ph From W &S 2960 m3ph 3718 m 3 ph 849 m 3 ph Slimes Dam 407 tph Water Reclamation Plant

16 DMS Described > Dense Media Separation (DMS) is a physical separation technology which relies on the difference in material densities to separate different materials > The mixed solids are placed in a liquid denser than one and less dense than others > The denser material sinks while the less dense material floats > DMS is the most straight forward technique for separating particles based on their densities > Also known as Heavy Media Separation (HMS)

17 DMS Medium Heavy Liquids > Response of a given feed to a DMS process and be accurately established in a laboratory by testing with various heavy liquids Liquids used to test feeds Name Specific Gravity, 25oC Methylene iodide 3.33 Tetrabromoethane 2.96 Bromoform 2.86 Tribromoethane 2.61 Methylene bromide 2.48 Ethylene dibromide 2.17 Methylene chlorobromide 1.92 Pentachlorethane 1.67 Carbon tetrachloride 1.59 Trichloroethylene 1.46 Ethylene dichloride 1.26

18 DMS Medium Heavy Liquids > Aim is to separate the ore samples into a series of fractions according to density > May be used to assess the efficiency of an existing dense medium circuit > Heavy liquids give off toxic fumes and must be used with proper ventilation > The use of pure liquids has not been found to be practicable on a commercial scale > Industrial processes employ finely ground solids suspended in water

19 DMS Medium > Finely ground or atomised Ferro Silicon (FeSi) and water are commonly used as the heavy media > Specific gravity is adjusted by addition or removal of FeSi > Would not work where solids have similar densities, nor those that are soluble in the fluid media > Magnetic materials must be removed before this step > Separated materials may have to be dried for further processing

20 DMS Medium > FeSi SG: > Milled FeSi produced in different size ranges 30-95% 45µm Coarser, low viscosity grades achieve medium densities of up to 3.3 > Atomised FeSi More spherical particles Medium is of lower viscosity Used to achieve densities as high as 4

21 DMS Medium Ferrosilicon

22 Gravity DMS Drum Separator Drum separator > Side view

23 Gravity DMS Drum Separator Drum separator > End view

24 Gravity DMS Drum Separator WEMCO heavy media drum separator

25 Centrifugal DMS DSM Cyclone > Dutch State Mines (DSM) Cyclone Separator > Used for finer feeds, 0.04 to m > Separation is made by the action of centrifugal and centripetal forces > The heavier portion of the feed leaves the cyclone at the apex opening (5), and the lighter portion leaves at the overflow top orifice

26 Centrifugal DMS DSM Cyclone

27 Dense Media Separation on Iron Ore > Cut SG of > Not considered at SG 4 due to impact of high FeSi viscosity > Ferrosilicon is used in water atomised, gas atomised or finely milled forms

28 Typical DMS Flowsheet

29 DMS PFD

30 DMS results: Operation A > The operation s product grades are > 65% Fe Density cut point for achieving grade is considered to be 4.2 So, no chance Description Weight (g) Weight (%) Fe (%) +3.8sg sg sg sg Total (+1.18mm) mm Calculated Head Head Assay 55.67

31 Jig Results: Operation A > Notice grade is achieved > Notice also the mass yield Jig test runs Lump product Pilot plant results for 11 test runs Product (32-62mm) Weight (%) % Fe Grade Fe Recovery (%) Feed Run Conc. Run Reject Run Feed Run Conc Run Reject Run Feed Run Conc. Run Reject Run

32 Fe Grade % Product (32-6mm) Jig results: Operation B Pilot plant overall results Conc Rejects Feed Products (6-1mm) Conc Rejects Feed Laboratory tests - average Product (32-6mm) Design % Actual % Weight Fe Grade % Fe Recovery % Weight Fe Grade % Conc Mids Rejects Feed Product (6-1mm) Weight Fe Grade % Fe Recovery % Weight Fe Grade % Conc Mids Feed Fe Recovery % Fe Recovery %

33 Process Design Criteria > Haematite > Plant throughput: 900 tph > Minus 2 mm rejected > Lump/fines split 60/40 = 540/260 t/h > Jig unit: lump and fines: under bed pulsed: Batac > DMS unit: lump & fines: Cyclones > Lump size: mm/fines +2-8 mm Parameter Jig DMS Number: lump 2 1 Number: fines 2 2 Medium None FeSi

34 Capex and Opex Capex Direct Costs Equipment Installed Bulk Earthworks & Civils Platework, Structural & Piping Electrical & Instrumentation Buildings Design Freight Total Contingency Costs DMS $16,01M $3,13M $3,65M $2,55M $0.58M $2,59M $1.00M $29.51M Jigs $16,71M $3,27M $3,81M $2,66M $0.61M $2,71M $1,04M $30.81M Opex Area Fixed Variable Misc. Total % Total Labour Power Reagents & Consumables Maintenance $/tonne Costs DMS plant $0.56 $0.73 $4.41 $0.34 $0.04 $ % Jig plant $0.56 $1.04 $0.75 $0.35 $0.00 $ %

35 Acknowledgements > METS Staff > FeTech for the opportunity to present

36 THANK YOU