Ore Beneficiation at Eramet Research

Transcription

1 Ore Beneficiation at Eramet Research Comminution Sizing Density separation Magnetic separation Flotation Sampling Mineral characterization Chemical analysis Services for each of your project phases: LABORATORY DESIGN PILOT INDUSTRIALIZATION

2 We provide high quality, innovative solutions 40 years of experience in extractive metallurgy of nonferrous metals For all steps of processing: - Conceptualization, including documentation - Numerical modeling and simulation - Laboratory and pilot testing: Ore beneficiation, Hydrometallurgy, Pyrometallurgy - Industrial plant start-up assistance - Continuous quality control at all steps using physico-chemical material characterization A tight collaboration with ERAMET Engineering guaranties the successful industrialization of your project For further information on ore beneficiation facilities and services, please contact us at : eramet.research@erametgroup.com

3 Comminution Commin ution Crushing and grinding consume the most energy in mining installations. Therefore developing an energy-saving process is one of the key-features for profitable projects. Equipment Brand Feed size Output size Throughput Teethed-roll crusher Mecaroanne < 200 mm 0-20 mm 0-2 t/h 200 mm Jaw crusher Dragon < 100 mm 0-10 mm 0-1 t/h Retsch < 10 mm 0-2 mm kg/h Cone crusher Siebtechnick < 25 mm 0-2 mm kg/h Ball mill Glen Creston < 5 mm < 100 µm Volumes : 10L, 27L Rod mill Minemet < 5 mm < 200 µm Volume : 8L Vibratory mill Retsch <1 mm <10 µm 100 g Attrition cells Minemet < 10 mm 0-10 mm 1 kg SMD Metso < 10 mm 0-10 mm 1 kg 1 mm Industrial attrition of lateritic ores (Ni, Mn, REE, Nb) Crushing of sticky lateritic ores with the Teethed-Roll Crusher Teethed-roll crusher Vibratory mill Ball mill

4 Sizing Efficiency in grain size separation using vibrational sieving and screening requires a proper evaluation of operating parameters. e.g. attractive forces, media Equipment Brand Particle size Cut size Throughput Scrubber + double trommel MPM 0-80 mm 1mm / 4mm / 10mm <2 t/h Siebtechnik mm 10 à 90 mm 100 kg/h Sieving Siebtechnik 2 Retsch 2 Chauvin 0-80 mm 32 µm to 40 mm 2 kg/h Chauvin 0-2 mm 100 µm to 1 mm < 100 kg/h Screens Dewatering screen Somatrap mm 10 mm <1 t/h Chauvin 0-80 mm 40 mm <2 t/h Chauvin 0-2 mm 315 µm <1 t/h Cyclones KHG <500 µm <100 µm <8 m 3 /h Scrubbing and particle classification of Mn-laterite ore during pilot operations Particle size distributions of ores and intermediate metallurgical products: Lateritic ores (Ni, Mn, REE, Nb, Ta), heavy mineral sands (Ti, Zr), slags, salts Chauvin sieving Scrubber and trommel

5 Density separation Efficient gravity separation requires development of particle size and specific density indicators in order to define cost efficient operating conditions and feed preparation. Multi gravity separation techniques can enrich the concentrates by up to 10%. Equipment Brand Particle size Wet / Dry Throughput Shaking table Holman- Wilfley <1 mm Wet <70 kg/h Pneumatic table Jig Tecmachine >100 µm Dry 500 kg/h Denver mm Wet 3 kg batches Tenova - Batac mm Wet 500 kg/h Spiral Mineral Deposits mm Wet 1-4 t/h Dense media separation Eramet Research lab >300 µm Organic medium <1 kg/h Laboratory and pilot tests: elimination of quartz from lateritic ores using a shaking table and spirals Continuous beneficiation pilot by jigging of Mn-lateritic ore Industrial separation of heavy mineral sands (Ti, Zr) by spirals Slag/metal separation using a pneumatic table Jig Heavy sands dredging Shaking tables

6 Magnetic separation A powerful tool to extract ferrous contaminants in polymetallic laterite ores, or concentrate magnetic particles in mineral sands. Careful adjustment of process parameters including particle magnetic susceptibility, magnetic field, effective medium viscosity and particle velocity is required. Equipment Scale Brand Feed size Wet / Dry Throughput Low intensity separator Laboratory Eriez >100 µm Wet 1-10 m 3 /h Pilot FCB 100 µm 100 mm Dry t/h High intensity separator Laboratory Downer Mining 40 µm 5 mm Dry <100 kg/h High intensity magnetic beneficiation of Mn-rich sands Elimination of Fe oxides of polymetallic laterite ore Numerical modeling of the particle behavior in a magnetic field Dry high intensity magnetic separator Wet low intensity magnetic separator

7 Froth flotation It uses hydrophobic and hydrophilic properties for the separation of valuable minerals and tailings. Process efficiency depends on the configuration of the flotation circuit, the equipment design, and the physical and chemical nature of the treated pulp. Equipment Brand Particle size Volume Throughput Laboratory cells Outotec L Batch <5 kg mm Outotec L Batch <1kg 2 Minemet L Batch 300 g 4 Minemet H180 3 * 5 L kg/h Pilot cells 4 Minemet H300 4 Minemet H µm 5 mm 3*25 L kg/h 2*20 L kg/h 4 Minemet H300 2*25 L kg/h More than 30 years-experience in flotation of sulphide ores, salts, barite, coal Flotation of metal-bearing phases in laterite ores (REE, Nb, Ta) and black shales (Mn) Lab cell Outotec Flotation pilot Lab cell Minemet

8 Sampling Precise and accurate sampling is the base of a successful project. Compliance with sampling theory and application of testing standards ensures the representativity and validity of analyses. Equipment Brand Feed Output Capacity Big-Bag divider Laarmann 1 t (1 Big-Bag) 8 futs 200 L 1 t/h Sampling tower Laarmann 200 kg (1 fut) <80 mm sample <500 g & <2 mm 500 kg/h Riffle splitter 4 Metaleurop <10 mm à <100 mm 2 samples <500 kg/h Rotary splitter Klupp <5 mm 8 samples <50 kg/h Pulp divider 2 Minemet Pulps 12 samples <8 m 3 /h Standardized sampling procedures applied to all pilot operations Design of automated sampling tools Echantillonnage Rotary splitter Big-bag divider Sampling tower

9 Mineral characterization Mineral characterization at each process step allows an optimization of laboratory, pilot and industrial operations. Continous quality control ensures a certified customer product. Equipment Type Model Tools Interets Optical microscopy Electronic microscopy Laser particle sizer DRX Binocular Optical microscope Metallographic microscope Electronic microprobe SEM-FEG Environnemental SEM-FEG Wild Heerbrugg LEICA DM2500P Olympus PMG3 CAMECA SX100 Zeiss Supra 55 FEI Quanta 650F Numerical camera Numerical camera 4 WDS, 1 EDS 2 EDS, EBSD, Esprit, Multiscan 2 EDS, Esprit, Qemscan Macroscopic observations Phases definition + textural information Metallic microstructures Precise phases chemistry Morphological and textural information Phases quantification + textural information Wet CILAS 1064L Grain size distribution On powder PANanalytica l X Pert PRO Domed sample holder Phases identification Phosphorus mapping in lateritic ores Low intensity magnetic separation followed by mineral characterization for process validation Geometallurgy of Ni-lateritic ores Qemscan mineralogical mapping Grain size and density map

10 Chemical analyses Chemical analyses of ores and processed products at each step give a measure of the concentration process efficiency and product quality. Technology Type Model Applications X-ray fluorescence spectrometry Energy dispersion PANalytical AXIOS Quantitative analysis of beads and semi-quantitative analysis (OMNIAN) ICP-MS Analytik Jena Ultra-traces : PGM, REE, U, Th, etc. Plasma spectrometry ICP-OES Agilent Vista Pro, 720 & 730 Trace elements and minors MP-AES Agilent 4200 Na, K, major elements Elemental analyzer C-S HORIBA EMIA 320 V C-S on ores, metals and slags Atomic adsorption spectrometry Mineralizers GFAAS Agilent AA220Z Trace elements (Cd, As, & Pb) Mercury analyzer CETAC M6100 Mercury in trace Fluxer Claisse TheOx Automatized borate mergers, 6 posts Microwave Milestone UltraWave Under pressure acid mineralizations, 5 posts Chemical control of a jigging pilot on Mn-lateritic Quantification of Fe 2+ Fe 3+ in lateritic ores REE analyses during a polymetallic lateritic ore beneficiation pilot