Process Systems

Process System Introduction

A machine working in a mineral process flow cannot perform better then the process environment will allow it to. Parameters like type, size and amount of feed, % solids in slurries, additives, discharge conditions etc. will always guide equipment performance and operation economy. There is a strong trend amongst both suppliers and users to work in terms of systems, meaning solutions to various operation problems more than installing equipment. This will effectively increase the operation values as presented in section 2.9 Examples covering systems levels and system modules are shown in this section.

System Levels in Ore / Minerals Processing

Mineral concentrate production

Complete systems Process systems

Comminution circuits Separation circuits Dewatering circuits

Crushing

Grinding

Separation

Thickening

Filtration

Product systems Products

Crushers Grinding mills Separators Thickeners Filters

System Levels in Rock Processing (Quarrying)

Aggregate production

Complete systems

Crushing

Screening

Conveying

Product systems
Crushers Screens Conveyors

Products

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Process System

Process systems

Crushing and screening circuits

Added operation values

Added operation values

Process Systems

System Modules Aggregates

A good way to understand and work with process systems is to use system modules in various combinations. Primary crushing module
From rock front Feeding Screening

Intermediate crushing module

Closed 1

7:5

4:2
Crushing II, III or IV

Closed II

3:8
Crushing Scalping Screening

3:3

Open

4:2

Final products module

Slurry handling module

Classification Recycled process water

Washing

5:1

4:6
Sedimentation Sand Product screening

6:2
Filtration

To slurry circuit

4:2

6:19

System Modules Sand and Gravel

Sand and gravel module
Screening Coarse Medium coarse Washing (Aquamator) Fines

Sand and gravel module

Water Washing (Aquamator)

Process System

4:2

5:1
Classifiying

5:1
Washing (Log washer)

4:6
Sandtrap

5:1
To sand module To slurry handling Slurry module

= option or alternative

7:5

= refering to actual chapters and pages

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Process Systems

System Modules Ore and Minerals

Crushing module
Options
ROM Primary crushing Secondary crushing Screening Grinding

3:3

3:8 Grinding module

4:2

Primary grinding

Secondary grinding

Classification

Tertiary grinding

3:13

3:3

4:6

3:13

Enrichment module
Wet Tailings Primary separation

Upgrading module

Sedimentation

Sedimentation

5:5
Secondary separaton

6:2

6:2
Dewatering

5:5
Final separation

Tailings dry

Tailings disposal

6:2
Drying

Wet Concentrate Optional

5:5

6:47

Dry conc.

Dry tailings

Conc.

= option or alternative

7:5

= refering to actual chapters and pages

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Process System

Process Systems

Process system Railway Ballast

Primary crushing module Secondary crushing module

Feeder (Grizzly)

Primary crusher

7:6
Scalping

3:3

Screen 18 mm

4:2

Secondary crusher

3:8

Screen 35 - 64 mm

4:2

0 - 18 mm

0 - 35 mm

Primary crushing module

35 - 64 mm Water recovery

Washing screen

Wash water

5:2

Slurry handling

5:4
Chips & fines

RW-ballast

Washing module

Process Systems Asphalt / Concrete Ballast

Primary crushing module Secondary crushing module

Feeder (Grizzly)

7:6
Scalping

Primary crusher

Screen

3:3

Secondary crusher

Screen

4:2

3:8

4:2

Process System

Tertiary crusher

Screen Final products

Screen Final products

3:10

4:2
0 - 2 mm

4:2

12 - 16 mm 16 - 22 mm + 22 mm

2 - 4 mm 4 - 8 mm 8 - 12 mm

Tertiary crushing module

= option or alternative

Final products module

7:5

= referring to actual chapters and pages

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Process Systems

Process System Ferrous Ore (hosting apatite)

SIZE REDUCTION
Optional

ROM

Primary crushing

Secondary crushing

Screening

3:3

3:8

4:2

Primary grinding

3:13

Secondary grinding

Classification

3:13

4:6
Spiral/Cyclone

Gyr. jaw

Cone

AG, SAG, Rod

Ball, Pebble

ENRICHMENT & UPGRADING

LIMS wet
Tailings

HGMS

Sedimentation

5:24
Fe Apatite removal conc.

5:31
Fe conc.

6:3
Conventional.

Tailing disposal

Flotation

Flotation

Sedimentation

5:13
Fe conc. final

Dewatering

5:18
Fe conc. final

6:11
Inclined plate

6:30
Pressure filtration

Apatite conc.

Conventional

Sedimentation

6:2

Sedimentation

6:2
Dewatering

Pressure filtration

Dewatering

6:30

6:30
Pelletizing (optional)

6:55

Iron conc.

Process System Base Metal Ore

SIZE REDUCTION
Optional

ROM

Primary crushing

Secondary crushing

Screening

3:3

3:8
Cone

4:2

Primary grinding

Secondary grinding

Classification

3:13
AG, SAG, Rod

3:13
Ball, Pebble

4:6
Spiral/Cyclone

Gyr. jaw

Primary Cu flot.

ENRICHMENT & UPGRADING

Tailings

5:13
Fe conc.

Primary Pb flot.

Regrind

5:13
Regrind

Fe conc. final

5:13
Regrind Sedimentation

Final flotation

3:13
Final flotation

5:17
Conventional

3:13
Final flotation

6:3
Tailings disposal

Conventional

Sedimentation

5:13
Pb conc. final

5:3
Dewatering

Sedimentation

5:13
Zn conc. final

Pressure filtration

6:3
Dewatering

6:30
Cu conc.

Sedimentation

Dewatering

6:30

6:3
Conventional.
Pb conc.

6:30
Pressure filtration

Pressure filtration

Zn conc.

= option or alternative

:5 = referring to actual chapters and pages

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Chap 11 Process System.p65 5

Process System

3:13

Primary Zn flot

Process Systems

Process System Gold Bearing Ore

SIZE REDUCTION
Optional

ROM

Primary crushing

Secondary crushing

Screening

3:3

3:8

4:2

Primary grinding

3:13

Secondary grinding

Classification

3:13

4:6
Spiral/Cyclone

Gyr. jaw

Cone

AG, SAG, Rod

Ball, Pebble

ENRICHMENT & UPGRADING

Recovery by flotation

Coarse free gold

Gravity separation

5:8

Recovery by flotation

Primary flot.

Tailings

Lime Carbon Cyanide

5:13

Sedimentation Regrind

Leaching stages

6:3

5:43
Mixers

Gold contained in loaded carbon

3:13
Disposal

Final flot.

Adsorption stages

5:13
Conc. final

5:43
Mixers

Tailings

Sedimentation

Dewatering

Sedimentation

Dewatering

Final tailings

6:3

6:30
Pressure filter Gold contained in bulk concentre

6:11
Inclined plate

6:23

Process System Coal

ROM Separation Dense Media
Float

Media Screen

Sizing Screen

12 - 125 mm

5:6

5:12

4:2
0 - 12 mm

Sink

Media Screen
Coarse tailings

5:12
Heavy media recovery

Dewatering Screen

0.5 - 12 mm

6:21

- 0.5 mm

Blending and storage

Process System

Recycle water

Fine tailings

Flotation

5:13
Sedimentation
- 0.5 clean coal

Dewatering

6:3
Tailings

6:23
Vacuum filter

Drying

6:48
Indirect

- 0.5 mm

= option or alternative

7:5

= referring to actual chapters and pages

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Process Systems

Process System Industrial Mineral Fillers

SIZE REDUCTION
Fine grinding (small tonnages)

ROM

Primary crushing

3:3

Secondary crushing

Screening

3:8

4:2
15 30 mm

2 - 6 mm

Grinding

Classifying

3:3
AG, SAG, Ball, Rod VTM, SAM; VBM

4:17

Jaw

Cone Dry processing

Wet processing

ENRICHMENT & UPGRADING

Grinding tumbling
Optional

Grinding tumbling

3:13

3:13

Classification

4:6
Classification

4:17
Magnetic Sep. HGMS
Fe rejects

Flotation

Magnetic separation

Fe rejects

5:31

5:13

Other rejects

5:28

Optional

Sedimentation

5:3
Dewatering

6:38

Tube press

Process System Glass Sand

SIZE REDUCTION

Silica rock Silica sand

Primary crushing

3:3
Jaw

Secondary crushing

Screening

Grinding

Screening

3:8

3:2
Dry processing

3:13
AG, SAG, Rod, Ball

3:2

Cone

-750 micron

ENRICHMENT & UPGRADING

Classification spiral Polishing scrubber Classification spiral Magnetic separation Flotation

4:6

5:3

Slime -100 micron

Slime -100 micron Iron removal Fe, Al, Cr bearing with minerals Reject water

Dewatering

6:21
Sedimentation

6:3
Tilings disposal

Clean sand 100-750 micron

= option or alternative

7:5

= referring to actual chapters and pages

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Process System

4:6

5:22

5:13

Process Systems

Process System Diamonds (Kimberlite)

Primary crushing

Scrubber

Screen

3:3

5:3
Tumbling

4:2

Secondary crusher

3:8

Jaw

Cone

Screen
Diamond sorting

Sink
2-3%

5:12

Gravity sep. Dense media

Float

Screen

5:10

5:12

After treatment

Drying

Recovery of heavy media

6:48
Screen Magnetic separation
Iron reject Fines 1-6 mm Non iron reject

4:12
Recrushing VSI

5:22

X-ray separation

3:10

Alternatively - AG milling - no crushing

Diamonds

Process System Kaolin

H20

Dry mining

Scrubbing (blunging)

5:3

Wet hydraulic mining

Classification spiral

4:6

Classification cyclones

Thickening

4:6

6:2

Coarse waste sand, mica a.o. Medium waste sand, mica a.o.

Fine waste

Flotation

Process System

sand, mica a.o. Tailings 17% H2O

5:13

Ultra fine grinding

3:17

Optional for increasing the percentage of -2 micron material

Dewatering tube press

6:38

Products:

Kaolin Filler, 45% -2 micron Kaolin Coating, 90% -2 micron

17% H2O

= option or alternative

7:5

= referring to actual chapters and pages

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Process Systems

Mobile Systems
In modern quarrying, mining, tunnelling and recycling operations the use of mobile process systems is increasing dramatically. Particularly at rock front operations the technique of moving the process equipment closer to the front end using mobile crushing and screening units in many cases gives remarkable cost savings. These mobile units represent one or more complete machine functions including materials handling, power supply etc. Advanced process control secures the intelligence of the system.

Mobile Crushing and Conveying System

Key arguments for mobile equipment vs stationary equipment and damp truck haulage are:
Process System

Less hauling less costs Less front road maintenance Less exhaust gas and dust emissions Improved working safety Improved flexibility

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Process Systems

Primary Jaw Crusher + Grizzly (typical)

Type* LT110 LT125 LT140 LT160

Max feed/product size mm (in) 670 / 250 (26/10) 800 / 300 (31/12) 900 / 350 (35/14) 1040/ 400 (41/16)

Cap. tph 700 800 1200 2000

H/W/L m (ft) 4.4/3.0/17.4 (14.5/9.1/57.0) 5.7/4.0/15.8(18.6/15.2/51.1) 6.3/4.3/16.4(20.8/14.1/53.1) 7.6/5.9/20.2(25.0/19.3/66.7)

Weight ton 60 86 110 220

*LT110 refers to Jaw crusher type C110, LT125 to Jaw crusher type C125 etc. see further section 3.

Primary Impact Crusher + Grizzly (typical)

Process System

Type* LT1415 LT1620

Max feed/product size mm (in) 1000/200 (40/8) 1300/200 (52/8)

Cap. thp 800 1200

H/W/L m (ft) 5.4/4.0/15.8 (17.7/13.1/51.1) 6.5/4.8/18.5 (21.3/15.7/60.7)

Weight ton 73 170

*LT 1415 refers to Impact crusher type NP1415, LT 1620 to Impact crusher type NP1620 etc. see further section 3.

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Process Systems

Caravan Mill A pre-assembled Ore Concentrating Plant

1 5 2 3 4

Typical units at approx. 10 t/h capacity

1.Crushing unit
Jaw- and cone crusher in closed circuit with a double deck screen Weight app. 19 ton, transportation measures W= 2,6m, H= 4.2m

2. Grinding unit
Grinding mill (ball or rod), pump and hydrocyclone Weight app. 25 ton, transportation measures W= 3,0m, H= 3,8m

3.Separation unit (flotation)

Process System

Rougher, scavenger and cleaner cells together with conditioners, reagent feeding systems and air blower. Weight app.14ton, transportation measures W= 2,5m, H= 4.2m Units for leaching and gravity separation (dense media, tables and spirals) also available

4.Dewatering unit
Compact sedimentation (lamella unit) and vacuum filter with auxiliary equipment

5. Power unit
Diesel driven generator including connection terminal Transportation measures W= 2,5m, H= 3.8m BASICS IN MINERAL PROCESSING
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Process Systems

Process System

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