Department of Materials and Metallurgical Engineering, FTI-ITS

1. Teknologi Pengolahan Material Sungging Pintowantoro Department of Materials and Metallurgical Engineering,Faculty of Industrial Technology (FTI), Sepuluh Nopember Institute of Technology Surabaya (ITS), Kampus ITS, Keputih Sukolilo, Surabaya 60111, Telp/Fax : 031-5997026 • Department of Materials and Metallurgical Engineering, FTI-ITS • (1)

2. Department of Materials and Metallurgical Engineering, FTI-ITS • (2)

3. PETA PERSEBARAN SDA INDONESIA • Department of Materials and Metallurgical Engineering, FTI-ITS • (3)

4. PETA PERSEBARAN SDA INDONESIA • Department of Materials and Metallurgical Engineering, FTI-ITS • (4)

5. Mineral Processing Overview • Mineral Processing Terminology, Economics • Comminution and Classification • Physical processing methods • Chemical processing methods • Waste products treatment and disposal • Process plant flow sheets: uranium and potash

6. Importance of Mineral Processing “No substance has been as important as metal in the story of man's control of his environment. Advances in agriculture, warfare, transport, even cookery are impossible without metal. So is the entire Industrial Revolution, from steam to electricity.”Read more: http://www.historyworld.net/wrldhis/PlainTextHistories.asp?historyid=ab16#ixzz13XSEyvNz

7. Importance of Mineral Processing Bronze Age- Bronze is in use in Sumer, at Ur, in around 2800 BC Iron Age - from the 11th century BC onwards, steel replaces bronze weapons. It becomes essential, from now on, to have a good steel blade rather than a soft and indifferent one.

8. Lecture 8 Mineral Processing Overview: • Geology-Mining-Processing Relationship • Mineral Processing Terms • Definitions • Mineral Economics review • Project Stages

9. Lecture 9 • Comminution & classification circuits • Comminution Methods • Principles • Crushing • Grinding • Classification Methods • Principles • Hydrocyclone • Screening • Assignment

10. Lecture # 10 • Physical Processing Methods • Gravity • Magnetic • Electrostatic • Radiometric • Froth Flotation • Solid/liquid separation • Assignment

11. Lecture 11 • Chemical Processing • Basic Circuits • Leaching • Solvent Extraction • Precipitation • Drying • Downstream – Purified Product • Electrowinning • Smelting • Assignment

12. Lecture #12 Waste Stream Management: • Tailings Disposal • Surface • Underground • Effluent Treatment • Chemical Precipitation • Membrane Technology • Assignment

13. Lecture # 13 Saskatchewan Mill Process Flowsheets • Uranium • Potash • Assignment

14. Geology – Mining – Processing • All 3 aspects must be favorable to make a deposit economically viable • Geology: Find it. Is it big enough to be economic? • Mining: Dig it. Is it economically recoverable from the ground? • Processing: Extract it. Is it economically separable from the host rock?

15. Prevalence of mineral processing • In Saskatchewan as of 2009 there were: • 3 uranium mills • 8 potash mine/mills • 1 gold mine/mill • coal mines (thermal) • Salt mine • An identified diamond deposit (Fort a la Corne) • An identified rare earth element deposit (Hoidas Lake)

16. Prevalence of mineral processing • Mining is all around us! • In Alberta there are: • Oil sands process plants (uses mining and mineral processing techniques) • Coal plants • Industrial minerals (limestone) • Nickel/cobalt metallurgical complex • In Manitoba there are: • Many copper/zinc mines and mills, feeding the Flin Flon metallurgical complex • Nickel mines nearby Thompson smelter • In the Northwest Territories there are: • 3 operating diamond mines • Gold mines

17. Scope of mineral processing Definitions Economics Project Stages Introduction to Mineral Processing

18. Mining Terminology - Review Miners send their products to their customer – the mill. Ore : Rock that contains a mineral or minerals in sufficient quantities as to make commercial extraction (mining – milling) profitable. Grade :A measure of concentration of a mineral/metal contained in rock (or ore). Gold and other precious metals – g/t or oz/t, base metals - %, uranium – kg/tonne, rare earth elements – ppm… Cut off Grade : The minimum concentration or grade of mineral that is required for rock to be considered ore. Waste : Not Ore. Ore Body: A mineralized deposit (resource) whose characteristics have been examined and found to be commercially viable. The extents of the ore body are determined by the cut-off grade. Host Rock:The rock containing an ore deposit. Typically composed of 2 or more minerals. Gangue: Minerals in the ore body that are not of economic interest

19. Mineral Processing Is the recovery of valuable minerals from ore Takes place in a mill, aka concentrator - because it concentrates valuable minerals by removing unwanted material. The two main products are the concentrate streams (valuable minerals) and the tailings streams (rejects).

20. Disciplines related to mineral processing

21. Fields of Metallurgical Engineering

22. Engineering Terminology in Mineral Processing Circuit:The path that the ore that is being processed takes as it proceeds from one processing point to another. Flow Sheet - Drawing that indicates the path that the mineral takes within a process. Several circuits are often contained within a flow sheet RecoveryRate – The percentage of valuable metal/mineral, by mass, in the concentrate from the feed

23. Mineral Processing The goals of mineral processing are to: • separate economic mineral particles from waste or gangue • subject minerals to processes in order to concentrate them or to extract metals from them

24. Many forms of mineral processing • Depends on feed material and desired product

25. Mineral Processing Terminology Concentration: Another word for grade Heads: A term that is used to denote the mineral found in the FEED to a circuit. Head Grade: aka feed concentration Concentrate:a purified mineral. May require further downstream processing to convert for end uses. Examples: Copper and nickel sulfides Tailings - Material rejected from a mill after the recoverable valuable minerals have been extracted. Industrial mineral:is used for end purpose without chemical alteration. Examples: gravel, coal Mineralogy: Description of mineral contents

26. What is mineral processing? Mineral: a)A solid naturally-occurring compound having a definite chemical composition. b) Inorganic substance that are extracted from the earth for use by man. c) A naturally occurring inorganic element or compound having an orderly internal structure and characteristic chemical composition, crystal form, and physical properties.

27. Mineral classification Nonmetallic processing has some commonalities with metal processing, but lots of differences

28. Examples of minerals

29. Examples of minerals

30. Mineralogy determines recoverability

31. Impact of mineralogy • We mine rocks but we concentrate minerals. • Gangue minerals also important • Understanding mineralogy allows design of processes • Important for feasibility studies

32. What is mineral processing? • Processing – • Extract values, reject waste • Conversion of mined ore into usable product • More expensive/challenging with lower grade ores • Numerous processing methods

33. Mineral Processing Methods = beneficiation + extractive metallurgy Beneficiation aka Mineral Dressing Overlap of physical and chemical methods, depending on product Where extractive metallurgy leaves off, metal processing begins

34. Mineral Processing Terminology Beneficiation: enrichment of ores and separation of unwanted gangue minerals subsequent metals extraction more efficient. Can be divided into two distinct steps: Liberation: the rock is broken down by mechanical means, mineral components become independent of each other, detached Separation: valuable minerals are separated by means of physical and physico-chemical methods making use of differences in specific gravity, magnetic properties, etc. Extractive metallurgy: Chemical reactions of the processes equipment where reactions take place Flowsheets – combinations of processes

35. Typical Beneficiation Steps

36. Beneficiation Terminology Comminution: Reduction of particle size Starts at mine with blasting Two basic types of equipment used: Crushing – breakage by compression Grinding – breakage by abrasion and impact

37. Comminution Equipment Shaft

38. Comminution Equipment Shaft

39. Beneficiation Terminology Classification : Separation based mainly on particle size Behavior affected by size, shape, and density of the particles Two common types of classifiers: Screens – dry method, coarser particles Hydrocyclones – wet method, finer particles

40. Classification Equipment

41. Beneficiation Terminology Separation Techniques take advantage of the differences in characteristics between minerals: Flotation: Attachment of minerals to air bubbles - hydrophibicity Magnetic Separation: Apply magnetic field Gravity Separation: differences in specific gravity of materials Electrostatic Separation: Apply electrostatic polarity Particle size distribution has large influence on results

42. Separation Equipment • Flotation cell

43. Separation Equipment • Magnetic separator

44. Separation Equipment • Gravity separation - jig

45. Separation Equipment • Electrostatic separator

46. Beneficiation Terminology Dewatering:To remove water from a substance. Also refers to the circuit where this takes place. Dewatering Techniques: Thickener: Allow gravity settling Filter: Apply air pressure to draw water out Centrifuge: Apply centrifugal force Dryer: Apply heat to evaporate Slurry Density:The amount of solids in a slurry, expressed as a percentage by weight.

47. Dewatering Equipment • Thickener

48. Dewatering Equipment • Disc filter

49. Dewatering Equipment • Rotary kiln dryer

50. Beneficiation Terminology Waste Disposal - "Mining is waste management ..." The majority of tonnage mined must be disposed of as tailings Water used must be treated and released Tailings Dam:Built from ground waste rock discharged after processing from the mill Acid Mine Drainage: produced by exposing sulfide minerals to air and water, resulting in oxidation that generates acid. Waste Rock: Unprocessed non-mineralized / low grade mined material Water Balance: Accounting of water inputs and outputs from a mine/mill site. Water Treatment:The removal of harmful contaminants from water