041018 Mineral Processing Nimal he 1

8/2/2019 041018 Mineral Processing Nimal he 1

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INTRODUCTION TO MINERAL PROCESSING

Dr. Nimal Subasinghe

Senior Lecturer in Mineral ProcessingMurdoch University



Mineral production worth $17 billion in 2000Mineral production worth $17 billion in 2000--2020

(Agriculture $4.4 billion(Agriculture $4.4 billion

nnWA a worldWA a world--rankedrankedproducer ofproducer of – –

-- AluminaAlumina 20%20%

-- Iron oreIron ore 14%14%-- NickelNickel 14%14%

-- RutileRutile 38%38%

-- TantalumTantalum 25%25%-- ZirconZircon 32%32%

-- DiamondsDiamonds 38%38%

-- GoldGold 8%8%



Where do metallurgists fit in

mining industry?• Exploration and discovery -

Geologists.

• Mine Planning & Mining operations -Mining engineers and mine geologists.

• Ore-to-metal Process Development -

Extractive metallurgists.

• Financial specialists - Construction andcapital expenditure; sale of product.



Metallurgists add value to mineral

resources



Extractive metallurgy is

about processing ores to …• Liberate and concentrate valuable

minerals.

• Chemically break down minerals textract and refine contained metal

Extractive metallurgy bridge

science and engineering



Ore-to-metal path involves -

• Mineralogical studies

• Mineral processing

• Metal extraction & refining

- Pyrometallurgy

- Hydrometallurgy



Ore-to-metal

Mineralogy

Pentlandite

(Ni,Fe)(Ni,Fe)99SS88

Chalcopyrite

CuFeSCuFeS22

Pyrrhotite ~~ FeSFeS

PyriteFeSFeS22Ore Ore

grade grade 3% Ni 3% Ni

Ore Minerals



STAGES IN MINERAL PROCESSING

RUN-OF MINE

MATERIAL

COMMINUTION (MINERAL LIBERATION)

SEPARATION PROCESSES

(CONCENTRATION)

PRODUCT HANDLING

PROCESS

CONTROL

CONCENTRATE



Mineral Liberation



Comminution Circuits

Primary

Crushing

Secondary

Crushing

Screening /

Classification

Jaw Crushers

Gyratory Crushers

Cone Crushers

Hammer mills

Grinding Rod mills, Ball

mills

SAG

milling



Schematic Diagram of a Gyratory Crusher



Schematic Diagram of a Ball mill



Separation Processes

GravityConcentration

Hydro-

metallurgy

CIP/CIL

Electrowinning

Solvent Extraction

Dense medium Vessels

Dense Medium Cyclones

Jigs

Spirals

Reichert Cones

Wilfley TablesSluices

Knudson Bowls

Knelson Concentrators

SurfaceProperties

Froth Flotation

Pyro-

Metallurgy

Smelting

Electostatic

separation

Conductivity

Magnetic

Magnetic

separators

Coloursortin



FROTH FLOTATION



Schematic diagram of flotation machines



Ore-to-metal

Metal extraction - Hydro

Hydrometallurgical processes involve -

• Leaching – aqueous, acid, alkaline.

• Solid-liquid separation - filtration.

• Concentration – ion exchange, solvent

extraction.

• Metal recovery – precipitation, electro-winning, metal reduction.


http://slidepdf.com/reader/full/041018-mineral-processing-nimal-he-1 32/38Process control WMC ph



Ore-to-metal

Metal extraction - Pyro

• Pyrometallurgy - high-temperaturereactions on concentrate.

• Removal of S (as SO2) and Fe inslag.

• Melt cools as metal-rich matte.

• Ni matte comprises Ni-Fe alloy andminor sulphide phases.



Ore-to-metal

Pouring Ni matte

WMC photoMatte Grade ~ 70% Ni.Matte Grade ~ 70% Ni.



What metallurgists do …

• At mines - control mineral processingplants, manage waste, safety.

• In labs – evaluate ores, develop new

processes, computer modelling.

• Design and commission new processingplants.

• Manage operations, people, companies.

• Research and development work.



What you will study - Yrs 2-4

Chemistry

Mineralogy

Mineral ProcessingHydrometallurgy

Pyrometallurgy

Process control

Process design

Research Project

Other units in …

Maths and Statistics

Engineering units

Computer modelling

Financial management

Environment

Challenges for 21st century



Challenges for 21st centurymetallurgists …

• Find ways to -- process more-complex ores

- treat lower grade ores

- extract more metal from ores- reduce pollution

- rehabilitate waste dumps

- improve energy efficiency- reduce costs.

• Maximise economic benefit to Australiain a competitive global market.

S i th t



Some companies thatemploys mets …

Many graduates

ki

041018 Mineral Processing Nimal he 1

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