Beneficiation of Industrial Minerals using a ...

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Beneficiation of Industrial Minerals using a Triboelectrostatic Belt

Separator

1 Who are we…… What we do

Agenda

2 General Principals

3 STET Belt Separator = Dry Flotation ?

4 STET Elektrostatic Capex/Opex Comparison

5 Preview and Next Steps

ST Equipment & Technology is a Developer and Manufacturer of triboelectrostatic Separators for the Mineral and Fly Ash industries

Global staffing including France, Germany, Chile, UK, South Korea, Vietnam, Peru, Kazakhstan, Australia, Colombia and Central America.

Wholly owned by Titan Group

Titan Cement Group

A vertically-integrated, multiregional building materials company generating more than billion Euros of annual sales

Core Business;

Concrete, Aggregates, Mortars and Fly Ash

Who we are…

Startup founded by MIT engineer to develop Triboelectric Belt Separator

Titan America acquires ST. First international project in Scotland

Fly ash installations at 14 power plants.22 separators in 6 countries: US, UK,Canada, Poland, South Korea, Philipines

ST begins commercial fly ash processing.

1989 1995 2002 2011

History of ST Equipment &Technology

ST Equipment & Technology was chosen as a key supplier in the construction of the the New World Trade Center and produced thousands of tons of high quality ProAsh, thereby creating high strength, durability, workability and reduced heat of hyration

What we do…

Design and manufacture unique patented mineral separators

Customer advocate by providing separation deployment expertise

Assist customers on a global basis to extract valuable products from feed and waste streams

Beneficiation of minerals with an environmentally responsible and water-free process

Lean Manufacturing, including utilization of 3 D printing

Reliability – Production Tested Equipment

Proven Separation Applcations Barite Talc Calicum Carbonate Fly Ash (16 million ton processed)

ST Equipment & Technology was chosen as a key supplier in the construction of the the New World Trade Center and produced thousands of tons of high quality ProAsh, thereby, creating high strength, durability, workability and reduced heat of hydration.


Agenda





Principle - Contact charging and the Triboelectric Series

Triboelectrostatic charging of particles

A) particle-particle contact

neutral particles charging by friction charged particles

B) particle-wall contact

Wall

+ + +

++ +

+

-- - -

- --

+++

Source: Ullmann‘s Encyclopedia of Industrial Chemistry

Principle - Contact charging and the TriboelectrostaticSeries

Work Function = energy to remove most loosely held electron from surface to infinity in a vacuum

Work Function

Contact

Series

+_

_

_

+

+

+_

>

Apparent Triboelectrostatic Series for selected minerals based on inductive separation

Mineral Name Recovery difference(%)

Charge acquired(apparent)

Comment

ApatiteCarbonatesMonaziteTitan magnetiteIlmeniteRutileLeucoxeneMagnetite /haematiteSpinelsGarnetStauroliteAltered ilmeniteGoethiteZirconEpidoteTremoliteHydrous silicatesAluminosilicatesTourmalineActinolitePyroxeneTitaniteFeldsparQuartz

-70,00- 40,2- 38,4

0,40,82,02,43,23,45,16,6

13,314,420,420,921,322,523,624,826,029,739,143,066,8

+++++++++++++++

----------

- -- -- -- -- -- -- -

- - -- - - -- - - -

- - - - - - -

Strong positiveModerate positiveModerate positive

NeutralNeutralNeutralNeutralNeutralNeutralNeutralNeutral

v. weak negativev. weak negativeWeak negativeWeak negativeWeak negative Weak negative Weak negative Weak negativeWeak negativeWeak negative

Moderate negativeModerate negative

Strong negative

Source: D.DN. Ferguson, 7th Intl Heavy Minerals Conference 2009

Separates conductors from non-conductors

All particles must contact drum surface

Lower particle size limit: ~75μm

Source: Elder and Yan, 2003

Example: Corona Charging

Existing Drum Electrostatic Separators can only separate Conductors from Non-Conductors

Physical footprint

Single stage separation

Must maintain laminar flow

Avoid particle-to-particle contact in separation zone

• Low particle loading

• Large electrode gap

• High applied voltage

• Low throughput / unit volume

Source: Elder and Yan, 2003

LimitationsParticles develop charge by

contact with charger

Particle Size Effects Too large – No separation

Too small – Collects on electrodes

Motion influenced by aerodynamics

Lower particle size limit of ~75μm

Existing Free Fall Triboelectrostatic Separators have particle size limits

Multi-stage STET separations occurs in a sigle pass

Small gap and vigorous agitation

High electric field strength with moderate applied voltage (typ. 8-16 kV)

High efficiency multi-stage separation through charging/recharging & internal recycle

Large particle size range

High Capacity

<1µm to ~500 µm

40 – 50 TPH

Low residence times

~1 sec


Agenda





Schematic of the Separator

Schematic of the Separator and Electrode Gap

STET’s Separator

Multiple parameters available for quality optimization

Feed Conditioning Operational Variables Feed Point Tons per Hour Belt Speed Electrode Gap Electrode Voltage Feed Rate

Enables consistent product from highly variable feed material

O

ptim

izat

ion

STET’s Unique Patented Technology

Charged by particle-to-particle contact (Transfer of electrons based on different surface chemistry – “work function”)

Effective on particles from <1μm to 500μm

Does not depend on electrical conductivity of particles(Separates dielectric materials “corona” separators cannot)

Small physical footprint

Sustainability Benefits Further Benefits

Dry process

Low energy consumption 1-2 kWh/tonModerate applied voltage (8 - 16 kV)Small gap and vigorous agitation

Environmentally friendly

No water / no wastewater treatment

little to no chemicals Easy to permit – single dust

collector

High rate: up to 40-50 TPH

Separates fine to moderately coarse particles: <1μm to ~300μm (liberation size does matter)

Ease of operation

p

Rapid start-up and shut-down Rapid response to feed variability Amenable to feed forward / back

automation Limited qualification of operators

required Easy to produce several grades of

products

STET’s Separator Benefits

Resource Optimization

Beneficate of lower qrade ore Enhance the final product quality Recover value from waste

materials

Very low residence time +/- 1 sec

g g

Multi-stage separation occurs in a single pass through charging and recharging

Feed

Pr

oduc

ts

Calcium Carbonate

9.5% SiO2

< 1% SiO2

89% CaCO3Recovery

Improved Brightness

Talc

58% Talc

42% Magnesite

95% Talc

77% Recovery

88% Talc

82% Recovery

Barite Fly Ash

73%BaSO4

3.75 (SG)

8 % ‐ 25% LOI

92% BaSO4

4.24 SG

69% Recovery

Processed ash:

2.5% LOI

ST Equipment & Technology - Proven Results for minerals

The consistent quality of product Independent from feed variability

Siekierki

Fly Ash Projects

Canada 2 unitsIndia 1 unitAustria 1 unitUnited States 1 unit

5 Units

United States 13 unitsUnited Kingdom 4 unitsCanada 1 unitPoland 2 unitsSouth Korea 1 unitPhilippines 1 unit

22 Units

Mineral separators

Fly ash separators

Current commercial separator locations


Agenda





Comparative study by Soutex Inc of Quebec City, Canada Flow sheet development, mass balances, equipment sized and quoted Capital costs and operating costs

Removal of Silica from Low Grade Barite Basis: 200,000 Tpy feed ~82%BaSO4 3.78 Specific Gravity (SG)

Concentrate product ~92%BaSO4 4.21 SG Concentrate mass yield 74%

Flotation based on Indian National Metallurgucal Laboratory pilot plant study Electrostatic based on ST pilot plant studies with similar ores Battery Limits – Wet or dry grinding through tailings wet conditioned for storage

Did not include cost of process water or water treatment

STET Electrostatic CAPEX and OPEX less than Flotation

Barite Flotation flow sheet is complex

Barite STET Electrostatic flow sheet is simpler

Sector Flotation ST Dry

Grinding CircuitWet pulp ball mill with cycloneclassifier

Dry vertical roller mill with dynamicclassifier

Beneficiation Circuit

Three stage flotation

Single stage triboelectricseparator

Dewatering Circuit Thickeners, press filters and kiln dryer

No equipment required

Barite STET Electrostatic flow sheet is simpler

Cost Comparison

Overall Costs Wet Beneficiation(Flotation)

Dry Beneficiation (ST Triboelectrostatic)

CAPEX Equipment 100% 94.5%Total CAPEX 100% 63.2%Annual OPEX 100% 75.8%Unitary OPEX ($/ton conc.) 100% 75.8%Total Cost of Ownership 100% 70.0%

CAPEX and OPEX of crushing are the same for both processes and are not includedTotal Cost of Ownership over 10 year period; Discount Rate = 8%

STET Electrostatic CAPEX and OPEX are less than Flotation

Sustainability Benefits Further BenefitsSmall physical footprintSmall physical footprint

Dry processDry process

Low energy 1‐2 kWh/tonLow energy 1‐2 kWh/ton

Environmentally friendlyEnvironmentally friendly

No water / no wastewater little or no chemicals Easy to permit – single dust

collector

Resource OptimizationResource Optimization

Use of lower quality ore

High rate: up to 40‐50 TPHHigh rate: up to 40‐50 TPH

Separates particles <1μm to ~300μm

Ease of operationEase of operation

Rapid start‐up and shut‐down Rapid response to feed variability Amenable to automation Limited qualification of operators

required Produce several grades of

product easily

STET Separator BenefitsA sustainable separation process

Questions

Could Valuable Products be recovered from what is considered waste today?

Can we lower Production Cost and Increase recovery?

Are you interested in the recovery of Ultra-Fine minerals without the cost of water?

Are you searching for a Technological Innovation that provide sustainable, cost-effective and reliable solution in an effort to drive toward Water-Free processes?

How important is Comprehensive Extraction and Beneficiation of Fly Ash & Minerals?


Agenda





Drinking water is one of the world‘s most valuable resources Unfortunately it gets

more and more scarce each year

Source: Reuters / photo: Danish Siddiqui

Source: science.how.stuffworks.com

Therefore we should deal with water very carefully

YOUR LOGO

Pilot Plant Separator New applications must be

investigated empirically

Performance Factors• Particle surface chemistry

• Size distribution

• Shape

• Surface moisture

• Aging

• ContaminantsIdentical to full-sized separatorexcept 1/7 width for reduced rateTest feed rate 1 to 8 TPH10 Kg (25 lb) batch runs2 to 4 Ton sample of dry feed required

Pilot-scale Equipment for Process Development

YOUR LOGO

Feed Storage Area Feed Conditioning Equipment

Pilot Plant SeparatorsChemical Testing Lab

Technical Center in Needham MA USA – Pilot Plant and Laboratory

AFM – charging methods

F

x

y

F

FRubbing

the tip is dragged over a chosen surface area

Static chargingthe tip is brought into

contact at a fix position

Matrix of static chargingthe tip is brought into contact at a defined set of points on a chosen

surface areaMontanuniversitaet LeobenChair of Mineral Processing ©

AFM – influence of charging methods

RUBBING STATIC CHARGINGMATRIX OF STATIC

CHARGING

CP

D s

igna

l

tip bias 0 V contact force 1 µNrubbed area 4 x 4 µm2

speed of rubbing 1.2 µm/sNo. of lines 256

tip bias -10 Vcontact force 0.01 µNtime of contact 10 min

tip bias 0 V contact force 1 µNnumber of points 4 x 4charged area 4 x 4 µm2

calcite single crystal; 30 °C; in air; rel. humidity 40 %

Montanuniversitaet LeobenChair of Mineral Processing ©

AFM – Charging at low humidity

Contact force: 1 µN; Rubbing 0 V; at 50°C in dry nitrogen

Conclusions

STET Belt Separator is successfully used in commercial operation

First successes for minerals have been achieved Five triboelectric separators installed Additional applications will follow

Increasing interest noticeable Currently: focus on industrial minerals

We will consequently continue our way as a reliable and well equipped partner for our industry

Thank you for your attention

Please visit us at the booth no. 11

Mr. Rodger Butler – Director Contract AdministrationMr. Laddy Lewandowski – Business Development Manager

for Europe

are there for your disposal

Website: www.steqtech.com

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