Ore Microscopy

This is a laboratory investigation wherein the output is

the mineral form (i.e. sulfide, oxide, carbonate, etc.)
of the valuable metal and its liberation size. This
involves identification of the mineral form by
comparison with known samples of minerals and linear
measurements under the microscope.

Equipment that may be used for ore microscopy includes

optical microscope, surface morphology microscope, XRD,
SEM, etc.

Size Distribution Analysis

Refers to the practice adapted in the laboratory to
determine the size distribution of the particles in a
given sample. This is usually expressed in terms of
percentage (%). Useful in computing the work index
Degree of Liberation – refers to the percentage of the mineral as free particles
in the ore in relation to the total content. This may not be necessary at all
especially when a significant characteristics difference can be utilized to
separate the locked valuable mineral from the gangue.

FLOWSHEET - is a shorthand method of telling the story of the routing of a

mineral product in a dressing plant.

Forms of flowsheet:
1.) Line form of flowsheet - the simplest form to write and therefore the one
most commonly used.
2.) Pictorial form of flowsheet - graphical form of flowsheet which is the
draftman's delight and is commonly used in periodicals for its
pictorial value.
3.) Segregated form of flowsheet - it is abbreviated and segregated form, the
same usually as pictorial only it is line with the different
columns or rows of group process/activities.
4.) Condensed flowsheet - it is just using symbolic diagram for the purpose of
comparative and discussion of the different part of the mills.

Example: refer to text book for the other figures

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FIG 1: PLANT FOR DRESSING GRAVEL

RAW GRAVEL (FEED)

+
6 inch -
GRIZZLY _ To
waste

3 _ +
_ Coarse
inc
h gravel

TROMMEL
SCREENS 1½ + Medium gravel
_
inch

3
/8 +
inch Fine
_ gravel

+
1.5 mm To coarse sand
Vibrating screen
_

RAKE
CLASSI- Slime to waste Sand 14 to 100 - mesh
FIER

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I.a CRUSHING: (notes for email)

II. Crushers:

Crushing -maybe define as that operation or that group of operations in a

mineral-dressing plant whose object is to reduce large lumps to
fragments, coarsest particles in the crushed product being 1/20 inch
or more in size. Generally the objective of crushing is size
reduction.
Reduction ratio -is the ratio of the maximum size in the feed and in the
product.
Crushing action-is the result from stresses that is applied to the particles to
be crushed by some moving part in the machine, working against a
stationary part or against some other moving part.

The stresses set up strains within the particle to be broken which

result in fracturing whenever they exceed the elastic limit of the material.
It is therefore clear that if the crushing force is not intense
enough, there maybe no crushing effect.

Crushers can be classified into 4 groups:

I. Coarse or Primary Breaking - known as Primary Crushing (1st stage crushing)
Example: Jaw; Gyratory

Jaw crushers consist of two crushing faces or “jaws” one of which is

stationary being mounted rigidly in the crusher frame, and the other moving
alternately toward the stationary face and away from it by a small throw.

Types of Jaw Crushers:

1. Blake Type - the movable jaw is hinged at the top so that greatest
amplitude of motion is at the bottom of the crushing face.
2. Dodge Crusher - reverse of Blake type: the bottom of the jaw is the
fulcrum, and the top moves by the greater amplitude.
Dodge Crusher is made up only in small sizes, it differs from Blake
crusher in that the fulcrum of the motion of the movable
plate is at the bottom of the plate so that the width of
the discharge opening remains practically constant. This
results in the production of more closely sized product.

Also this crusher has fewer parts: one toggle instead of

two and no pitman.

3. Telsmith Jaw Crusher - resembles the Blake crusher in that motion of

swinging jaw is largest at the bottom, but it differs in
that motion is transmitted to the movable plate, not by
means of toggles and pitman, but directly from eccentric
on the main shaft by means of a horizontal, direct-stroke
pitman.
4. Eimco-Fahrenwald - the principal feature of this machine is that the
"stationary" jaw is mounted against heavy springs. This
allows it to move away from the reciprocating jaw if an
uncrushable object falls in the crusher.
Gape – width of the receiving opening of crusher. (last discussion>>>>)

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Taggart formula: capacity of crusher
T = 0.6LS
Where:
T = capacity in tons
L = lengths of the receiving opening
S = width of the discharge opening

Energy Consumption of crusher depends on following:

A. Size of feed
B. Size of product
C. Capacity of machine
D. Properties of rock
E. Percentage of idling time

2. Intermediate or Secondary Crushing:

Ex. Gyratory crusher, cone crusher, disk crusher, and spring roll crusher

Gyratory crusher have been developed after jaw crusher in order to supply
Machine having an even greater capacity.

Cone Crusher –Simon cone is much like that of the gyratory crusher, but with two
exemptions.

1st-the outside crushing surface, instead of flaring in from top to bottom as

it does in gyratory crusher, flares out so as to provide an increased
area of discharge for the crushed materials.
2nd-the outer crushing surface which become in the cone crusher an upper
crushing surface, can be lifted away from the lower surface when an
uncrushable obstruction enters the machine.

TWO TYPES OF SYMONS:

1. Standard crusher for the reduction of coarser feeds
2. Short-head crusher for the reduction of finer feeds.

Telsmith gyrasphere-introduced later, it feature spherical steel head instead

of truncated cone, roller bearing instead of a main spherical bearing and
compression-yielding instead of tension–yielding coil spring.

Crushing rolls-consist of cylinders revolving toward each other as to rip a

falling ribbon of rock and discharge it, crushed below.

Types;
1. Rigid rolls - both rolls shafts are revolving in fixed bearing.
2. Spring rolls – the crushing surface consist of a suitably heat–treated
steel shell shrunk of the main-roll casting.

3. Fine Crushing-
Ex. Gravity stamps mills;

Gravity Stamps Mills - are one of the oldest intermediate and fine crushing
devices known. They operate on the principal of mortar and pestle. It is
used to handle small tonnage of coarse feed; to make fine product,
especially if it is for amalgamation.

4. Special Crushers –include the steam stamp .Bradford coal breaker, disk
crusher ,toothed rolls, and hammer crusher.
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 Steam Stamp-resembles gravity stamps in that a large weight strikes the ore.

Steam Stamp - have been used for treatment of native copper ore.

Bradford breaker - this machine is a combination of a crushing machine and

screen which have been used for the elimination of coarse waste from coal. It
resembles the ball mill without the balls.

Disk Crushers – consist of a pair of saucer-shaped disks revolving at

substantially the same speed and in the same direction. One of the disks has,
also, a slight gyrating motion. Centrifugal force throws out the rock toward
the periphery, where it is nipped and crushed.

Toothed rolls – are used extensively in coal preparation. It consist of a

heavy frame in which two rolls are mounted. These rolls are driven so they
rotate one another. Rock feed in the above is nipped between the moving
rolls, crushed, and discharged at the bottom.

Swing-hammer crushers and pulverizers – This consists of four heavy blocks or

hammers fastened by pins to a revolving disk, inside a crushing chamber. The
centrifugal force of hammer is employed to deliver the blow that reduces the
rock in size. The rock remains in the crushing chamber until fine enough to
drop through the openings in the bottom. ( exam next meeting July 17)

I.b.) GRINDING:

Difference of Grinding from Crushing:

1.) In crushing rapture of particles was affected through the application of
compressive stresses.
2.) Whereas in grinding rapture was affected through the application of
shearing stress.

Other concept:
1.) Crushing relatively on coarse material
2.) While grinding on relatively fine material.

Crushing has been considered as resulting from impact and grinding from rubbing.

Definition:
Grinding – is the method of comminution in which a heavy surface is caused to
slide or roll over another surface, the material to be ground being
caught between the two moving surfaces.
- is the breaking down to the ultimate fineness to which comminution is
conducted of the relatively coarse [particles made by crushing.

Ball mill – is characterized by the use of steel or iron ball as the grinding
medium. This is a continuous machines, crushed rock being taken in at
one end through a feeder and ground rock being discharged at the other
end or through the periphery. Laboratory machines are either
intermittent or continuous.
Working Principle:
The ball mill is a horizontal rotating device transmitted by the
outer gear. The materials are transferred to the grinding chamber through
the quill shaft uniformly. There are ladder liner and ripple liner and
different specifications of steel balls in the chamber. The centrifugal
force caused by rotation of barrel brings the steel balls to a certain
height and impact and grind the materials. The ground materials are
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 discharged through the discharging board thus the grinding process is
finished.
Ball Mill Application:
The ball mill is a key equipment for regrinding. It is widely
used for the cement, the silicate product, new type building material,
fire-proof material, chemical fertilizer, black and non-ferrous metal,
glass, ceramics and etc. Our ball mill can grind ore or other materials
that can be grinded either by wet process or by dry process.

Critical Speed – defined as the speed which causes the steel balls to
centrifuge. It is the speed wherein the balls or rods will no longer do
the grinding action the charged material. The rotational speed is equal
to the numerical value of the natural vibration.

CS = 76.63 / D

Where:
CS = Critical Speed
D = Inside diameter of the mill

Ball mill – Classifier circuits:

The sizing action required to regulate the performance of the ball

mills is obtained by operating the mill in close circuit with the classifier.

100 T per 24 hrs.

400 T per 24 hrs. 500 T per 24 hrs.

Ball mill-classifier circulating load 400%

Capacity of the ball mills depends upon:

1.) the size of the mills
2.) the hardness of the ore
3.) the reduction in size attempted
4.) and the efficiency of the operation

Two types of Grinding:

1. Dry grinding – grinding without water, air is the classifying medium.
Usually pneumatic classifier is usually attached to it.
2. Wet Grinding – grinding with water as a classifying medium. Hydraulic
classifier attached to it.

Rod Mills- are similar to ball mills in appearance and in general principle.
They maybe defined as rotating cylindrical shells loaded with rods that grind
the ore by tumbling within the shell. Rod mill are made of a length greater than
their diameter in order to avoid jamming of the rods in the mill.

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