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Wills Concentracao SelecaoAutomatica
Wills Concentracao SelecaoAutomatica
Wills Concentracao SelecaoAutomatica
four basic subsystems (Arvidson, 1987; Salter and Wyatt, Various sensing technologies that are available and
1991; von Ketelhodt, 2012; Robben et al., 2013): common industrial sensors are listed in Table 14.1.
Electronic processing involves analysis of the data
1. Particle presentation
acquired by the detector. A wide range of site-specific
2. Sensing (particle examination/detection)
algorithms are used, depending on the sensor type and
3. Electronic processing (data analysis)
ore characteristics. Physical separation is typically
4. Separation
achieved using an array of about 200 high speed air
Robben et al. (2013) include a material conditioning valves. Mechanical ejectors are installed in low through-
stage prior to particle presentation. Most important for put units, for example, single particle XRL (X-ray lumi-
successful operation is the presentation of a carefully nescence) diamond or XRF (X-ray fluorescence) sorters.
selected and screened particle size range that shows both Water jets have been discussed and trialed, but have not
liberation and a minimum amount of fine material which found their way into today’s industrial scale sorters
is detrimental for high availability. For photometric sort- (Fickling, 2011; Robben et al., 2013).
ing, particle surfaces sometimes must be moistened or
washed, so that blurring of the signal by a covering layer
does not occur. The upper size limit is technically
350 mm, but nonetheless liberation of barren waste is
14.3 HISTORICAL DEVELOPMENT
often experienced below 100 mm. The lower size limit is First patents for SBS technology originated in the 1920s
technically 0.5 mm for most detection technologies, but (Sweet, 1928). During the 1950s Kelly and Hunter
as the operating costs are inversely proportional to the (K 1 H) developed the Model 6 (M6) photometric sorter,
average particle size (and weight), the economically fea- which was subsequently installed at the Mary Kathleen
sible lower size limit is often in the range of 10 20 mm. uranium mine in Australia (Salter and Wyatt, 1991;
Separation efficiency decreases when a wide range of Stewart, 1967). In 1966, Gold Fields of South Africa
particle sizes is fed to a single machine, the ratio undertook a joint project with Rio Tinto-Zinc (RTZ)
between maximum and minimum particle size (size (through their subsidiary Ore Sorters) to develop sorting
range coefficient) typically should not exceed three technology for use in South African gold-mining opera-
(Robben et al., 2013). tions (Barton and Peverett, 1980). The project culminated
Particle presentation can be achieved via two system with the installation of a Model 13 prototype photometric
types: chute or belt-type systems (shown in Figure 14.3). sorter at the Doornfontein Gold Mine in 1972 (Keys
The chute system senses the particles as they free-fall et al., 1974; Barton and Peverett, 1980). The sorters were
after being guided on a high-incline chute. For the belt the first to use laser technology and are considered the
system, the sensor is mounted above or below the con- first high tonnage sorters (Salter and Wyatt, 1991). The
veyor belt, which feeds a monolayer of particles. The Gunson’s Sortex MP80 machine was probably the first
ore must be fed in a monolayer, as individual particles sorter to employ microprocessor technology (Anon.,
must be displayed to the sorting device for effective 1980). The sorter handled minerals in the size range
separation. 10 150 mm at feed rates of up to 150 t h21.
412 Wills’ Mineral Processing Technology
FIGURE 14.3 Schematics of (a) Belt-type, and (b) Chute-type sorting systems (NIR is near infra-red) (Courtesy Tomra Sorting Solutions).
Rocks having white or gray quartz pebbles in a darker up to 4,000 times per second, and the reflection analyzed
matrix were accepted, while quartzite ranging from light in less than 0.25 μs by photomultiplier tubes and high
green through olive green to black, were rejected. Most of speed parallel processors. One or more of 120 air ejectors
the gold occurred in rocks which reported to the “accept” are fired to divert the value or waste past a cutter and into
category. Uniform distribution of the ore entering the the accept/reject bins. As the position of the rock is accu-
sorter was achieved by the use of tandem vibrating fee- rately identified, and the ejector firing duration is less
ders and the ore was washed on a second feeder to than 1 ms, the sorter can operate very selectively.
remove slimes which could affect light-reflecting quali- SBS has been employed in diamond recovery since
ties. The successful implementation of the Model 13 the 1960s, initially using simple optical sorters and more
sorter led to the development of the RTZ Ore Sorters recently machines based on the fact that diamonds lumi-
Model 16 photometric sorter, which has been used since nesce when irradiated by X-rays (Anon, 1971; Rylatt and
1976 on a wide range of ore types (e.g., magnesite, wol- Popplewell, 1999a,b; Damjanović and Goode, 2000). X-
framite, gold) (Anon., 1981a; Barton and Peverett, 1980). ray luminescence sorters are used in almost all diamond
A subsequent development to the RTZ Ore Sorters operations for the final stages of recovery after the ore
Model 16 is the Ultrasort UFS120 photometric sorter, has been concentrated by DMS (Chapter 11). They replace
which is used in the processing of magnesite, feldspar, grease separation (Taggart, 1945), which exploits the
limestone, and talc. Ore passes from a vibrating feeder to natural hydrophobicity (oleophilicity) of diamonds and is
high pressure water sprays and counterweight feeder now used only in rare cases where the diamonds luminesce
where water is removed and the rocks are accelerated to weakly or to audit the X-ray sorter tailings. Luminescence
form a monolayer. They drop onto a short conveyor mov- is a more consistent diamond property than oleophilicity,
ing at 2 m s21 where they pass via a high speed 5 m s21 and sorters are more secure than grease belts or tables.
“slinger” conveyor into free fall, now well separated. The Figure 14.4 shows an early dry X-ray sorter, in which
rock layer, 0.8 1.2 m wide, is scanned by a laser beam at the DMS concentrates are exposed to a beam of X-rays in
Sensor-based Ore Sorting Chapter | 14 413
FIGURE 14.5 Left: Internals of a RADOS XRF sorter (modified from Fickling, 2011), Right: Rados XRF sorter installation at Ural Mountains
Mining Company’s Svyatogor Cu/Zn Mine (Courtesy RADOS International Technologies).
concentrate and discard streams. Typically, feed grade now benefiting from those developments, with proven
must exceed 0.1 wt% for effective detection, although the detection and data processing being available for applica-
system can also use a matrix of elements as the criteria tion on mining proof machines.
for separation in low grade ore systems (e.g., gold, ura-
nium or PGM) (RADOS, 2014).
Microwave attenuation has been used to sort diamond- 14.4 EXAMPLE FLOWSHEET AND
bearing kimberlite from waste rock (Salter et al., 1989).
The development was notable for the first use of high
ECONOMIC DRIVERS
speed pulsed water ejectors. Equipment to sort asbestos SBS installations typically consist of: crusher, screen,
ore has also been developed (Collier, 1972). The detection sorter, and compressor. Because of the often large parti-
technique was based on the low thermal conductivity of cle sizes and low concentrations of valuables, it is
asbestos fibers and used sequential heating and infrared advised to install mechanical sampling, size reduction
scanning to detect the asbestos seams. The use of micro- and splitting equipment to enable determination of plant
wave heating coupled with infrared-thermography has performance.
been tested on a wide range of minerals (e.g., cop- Figure 14.6 shows an example flowsheet for a multi-
per molybdenum ore, iron ore) for sorting purposes stage, multi-machine stage operation. Machines are com-
(Sivamohan and Forssberg, 1991; van Weert et al., 2009; monly operated in parallel for high throughput opera-
Ghosh et al., 2013). tions. Cascading circuit arrangements enhance
A machine was installed at King Island Scheelite separation efficiency and allow for redundancy and the
in Tasmania, where the scheelite was sensed by its potential for multiple detection technologies to be
fluorescence under ultraviolet radiation. XRT (X-ray combined.
transmission) has proven to be superior to UV fluores- Capital and operating costs are typically roughly half
cence. Mittersill Mine currently operates XRT sorters the costs of dense-media systems. Since SBS is a single
for waste elimination where ca. 25% of the 130 t h21 particle technology, the throughput is inversely propor-
run-of-mine stream grading 0.03% WO3 is rejected tional to the average particle size fed to the machine.
before milling and sold as aggregate (Mosser and Both types of specific costs are thus inversely dependent
Gruber, 2010). upon the average particle size. The upper particle size is
Rapid developments in sensing and computing tech- determined by the liberation characteristics of the ore and
nology have increased the capabilities of today’s SBS the lower particle size limit by the economically viable
machines significantly. In addition, industrial food proces- specific costs per ton of product.
sing and recycling industries have openly adopted the Typically, the highest economic benefit is obtained
technology and tens of thousands of sorters are installed when eliminating deleterious waste that hinders down-
for numerous separation tasks. The mining industry is stream processes. In such cases, the overall recovery
Sensor-based Ore Sorting Chapter | 14 415
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