>Mining - ore digging
>Metallurgy - ore processing
2. What is metallurgy?
It is the science and art
of extracting,
refining, and
adopting
metals from minerals,
at a PROFIT,
for human use,
with the utmost care for the environment.
3. Basic terms and concepts:
MINERALS - chemical compounds in the earth's crust containing metals
ORE - a rock which contains minerals from which metals may be profitably recovered
ORE DRESSING - the preparation required before the extraction process
EXTRACTION - the recovery of the metal from the ore (or mineral)
UNIT OPERATIONS - the individual sequential steps in producing metal
from the ore involving purely physical changes
UNIT PROCESSES - the individual sequential steps in producing a metal
involving chemical reactions and/or changes in the state of aggregation
WINNING - the processes involved in removing and collecting the metals from ore
CONCENTRATE - the valuable minerals obtained from the recovery process
GANGUE - the minerals of no value
4. GEOLOGY>MINING>METALLUGY>MINERAL PROCESSING
MINERAL PROCESSING: HYDROMETALLURGY, PYROMETALLURGY, ELECTROMETALLURGY
HPE > METALS FORMING PROCESSES > PROPERTY MODIFICATION PROCESSES
METALS FORMING PROCESSES
-mechanical metallurgy
-foundry metallurgy
-powder metallurgy
PROPERTY MODIFICATION PROCESSES
-physical metallurgy
-microscopic characterization
-mAcroscopic characterization
-alloying
-heat treatment
5. Branches of Metallurgy
- MINERAL PROCESSING
- EXTRACTIVE METALLURGY
- PHYSICAL METALLURGY
- ADAPTIVE METALLURGY
-extraction of the valuable mineral from the ore
EXTRACTIVE METALLURGY
-extraction of metal from the metal from the mineral
PHYSICAL METALLURGY
-deals with the relationship of properties and structures of metals and alloys
ADAPTIVE METALLURGY
-making metal conform to application
6. ORE DRESSING
Perspective in metallurgy: WE NEED METALS, PRIMARY SOURCE OF MINERALS
GOLD PROJECTS:
-MASBATE
-NORTH DAVAO
-APEX
-NRMDC's DIWATA
COPPER PROJECTS:
-BATONG-BUHAY
-FAR SOUTH EAST
-DIDIPIO
-MARCOPPER
-ATLAS
-MARICALUM
-PHILEX's BAYONGAN
-COLET
-KINGKING
-TAMPAKAN
NICKEL PROJECTS:
ERAMEN
MINDORO
RIO TUBA EXPANSION
PHILNICO
ADLAY-CAGDIANNAO-TANDAWA
TAGANITO EXPANSION
PUJADA
7. TECHNOLOGY
*GOLD
MILLER PROCESS
- CHLORINE GAS IS PASSED THROUGH MOLTEN GOLD TO PRECIPITATE OTHER METALS
- >99.5 % Au
WOHLWILL PROCESS
- SELECTIVE DEPOSITION OF GOLD USING REDOX
- >99.99% Au
CIP / CIL / CIC
- SELECTIVE DISSOLUTIONS OF GOLD USING CYANIDE
- >0.3% Au FEED
Direct Smelting - Slag formation for removal of Au impurities
Merrill-Crowe Process: Zinc-Dust Precipitation of Au impurities
*NICKEL
HPAL: H2SO4 Leaching of Ni into sulfate at ↑T, ↑P 0.8% Ni → 57% Ni
Moa Bay Process: H2SO4 Leaching of Ni into sulfate
Sherritt Gordon Process: NH3 Leaching of Ni
Direct Smelting: Slag formation for removal of Ni impurities
*COPPER
Heap Leaching: H2SO4 Leaching of Cu into sulfate >0.1% Cu Feed
Flash Smelting: Autogenous Fine particle smelting of Cu >30% Cu feed
Mitsubishi Process: Continuous Furnace Smelting of Cu
Electro-Refining: Selective deposition of Cu by winning 99.99% Cu product
*IRON
Blast Furnace Smelting: Iron Smelting
Midrex / COREX Process: Direct Iron Oxide Reduction
Basic Oxygen Furnace Smelting: Selective oxidation of Fe Impurities
8. PROBLEM
TECHNICAL: Sensitivity of the processes!
ECONOMIC: Cut-off Grades!
Bridging the Gap
Mineral Processing “de-stresses” the transition between the mineral source, to the final metal product!
8. MINERAL PROCESSING/ MINERAL BENEFICIATION/ ORE DRESSING
The mechanical separation of valuable minerals from the valueless material of an ore
The valuable mineral is collected into a smaller bulk WITHOUT altering the physical and chemical identity of the minerals
Treatments applied to the ore containing valuable metallic or nonmetallic minerals prior to recovery and separation
9. RATIONALE
Virtually, no mineral, AS MINED, is suitable for conversion to final product
Rather, it requires preparation of ores by physical methods
10. Objectives of Ore Dressing
Technical
To bring the valuable mineral or the final product into suitable technical condition as required by the process
Undesired constituents of the original ore must be removed or reduced below the specified units
Economic
To provide the cheapest way to eliminate the unwanted minerals
Reduce unit material handling costs
11. Economic Criteria
Mineral Processing must be cost efficient!
If an ore or mineral is not marketable w/o MP, the processing operation will not be justified unless the product has a selling price GREATER than all the costs involved in producing it
PROFIT = (Metal Price) – (Mining + MinProc + Others) = if (+), OK!
12. Benefits from Mineral Processing
Concentration of desired mineral = Freight Savings!
Since little or no waste is being shipped in the concentrate, quite considerable freight savings can be realized
Waste Rock Minimization = Improved Metal Purity!
Since the waste in the shipment has been considerably reduced, metal losses in slag or leaching residues are correspondingly reduced
Effective Material Reduction = Reduced Treatment Charges!
The reduced tonnage of materials to be treated, either by smelting or leaching, results in drastic reductions of treatment charges
When concentration methods are both efficient and cheap, it is often possible to take advantage of low-cost, high tonnage mining methods to produce ores of lower grade than would normally be produced by high-cost selective mining methods
Efficient and low-cost mineral processing plants make it possible to treat material which, without the availability of cheap concentrating methods, could never be classed as ores
13. Minerals
An INorganically formed, naturally occurring homogeneous solid having a definite chemical composition and an orderly crystal structure
Ore Is a mineral deposit w/c can be ECONOMICALLY EXPLOITED to become a source or supply of a particular material
Gangue Mineral All minerals having NO ECONOMIC VALUE to the recovery process under consideration
14. Unit Operations in Ore Dressing
ComMINUtion
14. Unit Operations in Ore Dressing
ComMINUtion
Sizing
Concentration
Dewatering
Auxiliary Operations
Comminution
particle size reduction by breaking, crushing, or grinding of ore, rock, coal, or other materials
It is a critical component in most mineral processing flow sheets and can serve several purposes
Goals: LIBERATION and SEPARATION
Done either wet or dry
Consumes a lot of energy (>40% of total Mine/Mill consumption)
Sizing
Segregation of Materials into products characterized by difference in size
Screening and Classification
Concentration
Separation of valuable minerals
Based on the physical characteristics of minerals
Dewatering
Solid/liquid separation by thickeners and filters
Auxiliary Operations
Bins, conveyors, feeders, pumps, etc.
Process Flowsheet
A diagrammatic representation showing the individual treatments, or unit operations in a process, and the order by which these are carried out
Process Integration and Flowsheet Analysis
Two factors are particularly significant in a Mineral Processing Circuit:
Each ore is Unique
Interrelation of various process operations (one unit affects the behavior of subsequent operations)
Basic Problems in Process-Flow Metallurgy
Choosing possible products or suitable final products of operation
Source (raw material) > Product 1 Product 2 Product 3...
The ways in which these products should be produced
Source (raw material) > Route 1 Route 2 Route 3 . . . > Product 1
15. Logical Framework for examining process selection problems:
Raw mat’ls: pure or associated
Valuable and unwanted Minerals
Separability: Chemical or Physical
Treatment: Single vs. multi-step process
To be able to select a suitable separation process route, a number of important characteristics of the ore should be defined
16. Mineral Characteristics
The mineral phases which are present in the ore and their composition should be fully identified
The volume and mass fraction of each minerals
The grain sizes and size distribution
Shape of the grains
Orientation of the grains
Distribution of the grains within the ore
17. Mineralogy
MINERAL CHARACTERISTIC
> PROPERTY UTILIZED
> TYPE OF OPERATION
Color and Luster
> Optical response
> Hand Sorting of ore or automatic device triggered by reflected light
Texture, Hardness
> Difference in the response to crushing, grinding, screening, classification
>Air separation of fibers like asbestos; Separation of diamonds
Radioactivity
>Gamma Ray Emission
>Automatic device triggered by scintillation counter
Specific Gravity and Mass
>Differential Displacement in a fluid due to difference in buoyant effect
>Gravity separation of heavies and Lights by HMS, Jig, Table, Spiral
Shape
>Frictional force developed in a stream flow
>Flowing film table separators
Ferromagnetism
>Magnetic
>Magnetic fields used to recover wanted mineral
Surface Conductivity
>Mobility of electrons on the Particle Surface
>High voltage separator
Surface Activity
>ADsorption of specific cations & anions to modify surface tensions
>Froth flotation, flocculation or agglomeration
FROM:
https://lookaside.fbsbx.com/file/INTRODUCTION%20prin%20of%20met%20rev.pdf?token=AWzm37HOha8q5SxoD0sEtD9p5yTIJRsw32qHLR7iGYHtmUKK23fJ8mbvKm6KJTKcW5jdporvQRd3FOdcaKAVJHg5y1vP5ht__vdYWQI5UpFfISrKLLyTvr5zAOyMiTHN3r2i2tLnarrQduWsRScpW59BqoAAXvix8E-5FxhmyJqYENR1mUZ1grR3kL4zVTFRGsjCMeBxZAqOxsUK1VQKmcgU
https://lookaside.fbsbx.com/file/mineral%20processing%20intro.pdf?token=AWxikDNyc_g5CbtFzc7nTszDjkM1eF0GC78cMOimI91vp-ugtWvf6SFp5QdZaKOqzOIhzl1e7Ko9ckIUKoxn7gnPhMk4LrSA91grfXomAk3saLGHLVZtpvBvQyf2zY29usltm5iuwotxSVdp0e0aaN6nb-OpHiBHcvmayKQRZ2oOjCUlsF4z2PwSiyLABQjsa4BC9XvFrlkAx-NJoIv7JpKX4bk8B76r6-oE_6Zm7fRMeA
#################################################################################
DISCLAIMER: please don't sue me, i just reformatted the slides for easier study, I don't mint money, this is for study notes, PEACE!
Comminution
particle size reduction by breaking, crushing, or grinding of ore, rock, coal, or other materials
It is a critical component in most mineral processing flow sheets and can serve several purposes
Goals: LIBERATION and SEPARATION
Done either wet or dry
Consumes a lot of energy (>40% of total Mine/Mill consumption)
Sizing
Segregation of Materials into products characterized by difference in size
Screening and Classification
Concentration
Separation of valuable minerals
Based on the physical characteristics of minerals
Dewatering
Solid/liquid separation by thickeners and filters
Auxiliary Operations
Bins, conveyors, feeders, pumps, etc.
Process Flowsheet
A diagrammatic representation showing the individual treatments, or unit operations in a process, and the order by which these are carried out
Process Integration and Flowsheet Analysis
Two factors are particularly significant in a Mineral Processing Circuit:
Each ore is Unique
Interrelation of various process operations (one unit affects the behavior of subsequent operations)
Basic Problems in Process-Flow Metallurgy
Choosing possible products or suitable final products of operation
Source (raw material) > Product 1 Product 2 Product 3...
The ways in which these products should be produced
Source (raw material) > Route 1 Route 2 Route 3 . . . > Product 1
15. Logical Framework for examining process selection problems:
Raw mat’ls: pure or associated
Valuable and unwanted Minerals
Separability: Chemical or Physical
Treatment: Single vs. multi-step process
To be able to select a suitable separation process route, a number of important characteristics of the ore should be defined
16. Mineral Characteristics
The mineral phases which are present in the ore and their composition should be fully identified
The volume and mass fraction of each minerals
The grain sizes and size distribution
Shape of the grains
Orientation of the grains
Distribution of the grains within the ore
17. Mineralogy
MINERAL CHARACTERISTIC
> PROPERTY UTILIZED
> TYPE OF OPERATION
Color and Luster
> Optical response
> Hand Sorting of ore or automatic device triggered by reflected light
Texture, Hardness
> Difference in the response to crushing, grinding, screening, classification
>Air separation of fibers like asbestos; Separation of diamonds
Radioactivity
>Gamma Ray Emission
>Automatic device triggered by scintillation counter
Specific Gravity and Mass
>Differential Displacement in a fluid due to difference in buoyant effect
>Gravity separation of heavies and Lights by HMS, Jig, Table, Spiral
Shape
>Frictional force developed in a stream flow
>Flowing film table separators
Ferromagnetism
>Magnetic
>Magnetic fields used to recover wanted mineral
Surface Conductivity
>Mobility of electrons on the Particle Surface
>High voltage separator
Surface Activity
>ADsorption of specific cations & anions to modify surface tensions
>Froth flotation, flocculation or agglomeration
FROM:
https://lookaside.fbsbx.com/file/INTRODUCTION%20prin%20of%20met%20rev.pdf?token=AWzm37HOha8q5SxoD0sEtD9p5yTIJRsw32qHLR7iGYHtmUKK23fJ8mbvKm6KJTKcW5jdporvQRd3FOdcaKAVJHg5y1vP5ht__vdYWQI5UpFfISrKLLyTvr5zAOyMiTHN3r2i2tLnarrQduWsRScpW59BqoAAXvix8E-5FxhmyJqYENR1mUZ1grR3kL4zVTFRGsjCMeBxZAqOxsUK1VQKmcgU
https://lookaside.fbsbx.com/file/mineral%20processing%20intro.pdf?token=AWxikDNyc_g5CbtFzc7nTszDjkM1eF0GC78cMOimI91vp-ugtWvf6SFp5QdZaKOqzOIhzl1e7Ko9ckIUKoxn7gnPhMk4LrSA91grfXomAk3saLGHLVZtpvBvQyf2zY29usltm5iuwotxSVdp0e0aaN6nb-OpHiBHcvmayKQRZ2oOjCUlsF4z2PwSiyLABQjsa4BC9XvFrlkAx-NJoIv7JpKX4bk8B76r6-oE_6Zm7fRMeA
#################################################################################
DISCLAIMER: please don't sue me, i just reformatted the slides for easier study, I don't mint money, this is for study notes, PEACE!
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