Mineral Processing Design and Operation

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Introduction to Mineral Processing Design and Operation PREFACE In nature minerals of interest exist physically and chemically combined with the host rock. Removal of the unwanted gangue to increase the concentration of mineral in an economicallyviable manner is the basis of mineral processing operations. This book treats the strategy ofbeneficiation as a combination of unit operations. Each unit process and its operation is therefore treated separately. Integration of these units leading to the development of viableflow sheets that meets the final objective, is then indicated. The greatest challenge to a mineral processor is to produce high grade concentrates consistently at maximum recovery from the ore body. To quantify recovery a reasonable ideaof the initial concentration of mineral in a lode is required. Proper sampling representing theore body is therefore essential. The book therefore commences with the techniques of sampling of ore followed by the design and operation of unit processes of comminution thathelp to release the mineral from the associated rocks. Separation and concentration processesusing techniques involving screening, classification, solid-liquid separations, gravityseparation and flotation then follow. In the book some early methods of operation have been included and the modern methods highlighted.The design and operation of each unit process is a study by itself. Over the years, improvements in the understanding of the complexities of these processes have resulted in increased efficiency, sustained higher productivity and grades. Mathematical modeling has helped in this direction and hence its use is emphasized. However, the models at best serve as guides to most processes operations that invariably involve complex interdependent variableswhich are not always easily assessed or manipulated. To solve the dilemma, plants areincreasingly being equipped with instruments and gadgets that respond to changes much faster than humans can detect. Dynamic mathematical models are the basis of operations ofthese gadgets which are usually well developed, sophisticated, electronic equipment. In thisbook therefore, the basics of instrumental process control is introduced the details of whichbelong to the province of instrument engineers. This book is written after several years on plant operation and teaching. The book is biasedtowards practical aspects of mineral processing. It is expected to be of use to plantmetallurgist, mineral processors, chemical engineers and electronics engineers who are engaged in the beneficiation of minerals. It is pitched at a level that serves as an introductionto the subject to graduate students taking a course in mineral processing and extractivemetallurgy. For a better understanding of the subject solved examples are cited and typicalproblems are set. Most problems may be solved by hand-held calculators. However most plants are now equipped with reasonable numbers of computers hence solution to problemsare relatively simple with the help of spreadsheets. The authors are grateful for the help received from numerous friends active in the field of mineral processing who have discussed the book from time to time. Particular thanks are due