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A DESIGN MODEL OF A WASTE

WATER TREAMENT PLANT

IN A MINERAL PROCESSING MILL

USING PLANT DESIGN MANAGEMENT

SYSTEM ( PDMS )

A DESIGN MODEL OF A WASTE

WATER TREAMENT PLANT

IN A MINERAL PROCESSING MILL

USING PLANT DESIGN MANAGEMENT

SYSTEM ( PDMS )

SHEU A. BASHARU,SHEU A. BASHARU,

M. N. S. USAINIM. N. S. USAINI

AND AND

M. ALIM. ALI

ABSTRACT

INTRODUCTION

Water (HWater (H22O) O) is the most abundant compound, covering about 

70% 70% of the earth surface.

Therefore,

when water is contaminated, it is said

to be polluted.

Water is essential to life on our

planet; a prerequisite of

sustainable development

must be to ensure uncontaminated streams, rivers,

lakes and oceans.

(Nigerians Minerals and Mining Act, 2007);

Mining and Mineral Processing activities constitute the major causes of water Pollution through large amounts of water utilized in the processing of ores in mills, which when discharged pollute environmental water bodies.Because of these problems and assertions raised by NMMA, 2007; this then call for a research on a design model of a Waste Water Treatment Plant in a Mineral Processing mill using PDMS in order to tackle the problem caused by water pollution from Mining and Mineral Processing Activities.

Therefore,

Aims and Objectives of the Research

recovery and reuse of mineral processing mill waste water;

removing the pollutants from the waste water; recovery of some saleable products from mill

waste water; the treatment plant to supply fresh water to

the host community;

Specifically, the research will provide design for:

Types of Water Pollution from Mining/Mineral Processing Activities

Acid Mine Drainage Heavy Metal Contamination & Leaching Processing Chemicals Pollution Erosion and Sedimentation

History of Water Treatment EngineeringHistory of Water Treatment EngineeringHistory of Water Treatment EngineeringHistory of Water Treatment EngineeringHistory of Water Treatment EngineeringHistory of Water Treatment EngineeringHistory of Water Treatment Engineering

Development of Water Treatment Design Projects

The period before construction commences can generally be divided into the following phases:

Master planning Process train selection Preliminary design Final design

Multidiscipline Teams for Design of Mill Waste Water Treatment Plant

• Process engineers• Plant operations specialists• Structural Engineers• Piping Engineers• Civil Engineers• Instrumentation and control engineers• Health and safety specialists• Environmental scientists

For a water treatment plant in a mineral processing mill, the following engineers are added to the team;

• Mineral Processing Engineers• Metallurgists

INTRODUCING INTRODUCING VANTAGE PDMSVANTAGE PDMS

• PDMS means Plant Design Management System. It is therefore the accepted CAD software for all engineering designs as it allows for all forms of configurations.

• The PDMS login form looks like this,

Project: WATER TEATMENT PLANT Username: SYSTEM PASSWORD: XXXXXX MDB: SAMPLE Module: DESIGN Load from: Macro files

INTRODUCING VANTAGE PDMS

(CONTD) The PDMS Startup Display, when PDMS has loaded the screen

looks like this,

THE DESIGN MODEL OF THE PLANT

For the purpose of this research work, two design models were compared, as shown below;

DESIGN MODEL 1

THE DESIGN MODEL OF THE PLANT (CONTD)

THE DESIGN MODEL OF THE PLANT (CONTD)

DESIGN MODEL 2

THE DESIGN MODEL OF THE PLANT (CONTD)

DESIGN MODEL 2

DESIGN MODEL OF THE PLANT (CONTD)

Design model 2 involves the following steps:

from the mill Pollution prevention at all sources from the mill

Minimization of potential impacts by mitigation measures

Recovery and beneficial use of water on mill complex

Treatment of mill water for beneficial use and dischargeTreatment of mill water for beneficial use and discharge

Recovery and beneficial use of water on mill complex

Treatment of mill water for beneficial use and discharge

Minimization of potential impacts by mitigation measures

Recovery and beneficial use of water on mill complex

Treatment of mill water for beneficial use and discharge

Pollution prevention at all sources from the mill

Minimization of potential impacts by mitigation measures

Recovery and beneficial use of water on mill complex

Treatment of mill water for beneficial use and discharge

Pollution prevention at all sources from the mill

Minimization of potential impacts by mitigation measures

Recovery and beneficial use of water on mill complex

Pollution prevention at all sources from the mill

Minimization of potential impacts by mitigation measures

Treatment of mill water for beneficial use and discharge

Recovery and beneficial use of water on mill complex

Pollution prevention at all sources from the mill

Minimization of potential impacts by mitigation measures

Treatment of mill water for beneficial use and discharge

Recovery and beneficial use of water on mill complex

Treatment of mill water for beneficial use and discharge

Minimization of potential impacts by mitigation measures

Recovery and beneficial use of water on mill complex

Treatment of mill water for beneficial use and discharge

Pollution prevention at all sources from the mill

Minimization of potential impacts by mitigation measures

Recovery and beneficial use of water on mill complex

Treatment of mill water for beneficial use and discharge

DESIGN MODEL OF THE PLANT (CONTD)

Treatment Plant technology involved in Design 2 Treatment Plant technology involved in Design 2 Treatment Plant technology involved in Design 2 Treatment Plant technology involved in Design 2 Treatment Plant technology involved in Design 2 Treatment Plant technology involved in Design 2

Mine waste water treatment plant technology

Mine waste water treatment plant technology

DISCUSSIONThe major processes involved in the treating of mill waste water

due to harmful contaminants in it, these processes are: Aeration and Air Stripping Process Mixing Coagulation and Flocculation Sedimentation Process Filtration Process (High Rate Granular Media) Oxidation and Disinfection Lime Softening Ionic Exchange Processes Membrane Processes Activated Carbon Processes Ultra – Violent Light Process

The design 1 carryout processes such as aeration, coagulation, sedimentation, filtration, backwashing and disinfection due to limitations in it design parameters.

DISCUSSION (Contd)From the foregoing, we can deduce that the costs involved in constructing and operating a waste water treatment plant from mineral processing mill can be broadly divided into two categories:

(1) investment costs and

(2) operating expenses.

The investment costs include following under – listed costs:

Preliminary studies; Acquisition of site and building planning; Project costs such as design, EIA etc; Civil work, equipment & instrumentation costs,

Construction and installation; Commissioning (i.e. testing and accepting the

installation) and start-up costs.

Operating costs generally includes items such as:

Personnel; Maintenance costs; Operational costs: chemicals, utilities, lab

supplies, office supplies etc.; Aeration costs (electricity); Sludge disposal costs.

DISCUSSION (Contd)DESIGN 1 It is a model for a small scale

mill, where simple ore is processed. Its configuration is such that it allows for particle size of contaminants in micro meter. The design model is therefore affected by physical nature, chemical composition and type of contaminants. It is cost effective for a small scale mill.

DESIGN 2 It explains a model for a large

scale mill that can process all sort of ores particularly complex ore. Its configuration is such that it allows for varying sizes of contaminants. It is not affected by the type of contaminants, chemical composition and physical nature of the contaminants. It is restricted to large scale mill that can pay for its maintenance cost and other miscellaneous expenses.

CONCLUSION Plant Design Management System (PDMS) is the

only Computer – Aided – Design (CAD) Software that allows for any type of configuration in the design of any process plant as it was pointed out from above. It gives room for all designers working on a project to work simultaneously without interfering with each other’s work. The designers includes; structural engineers, civil engineers, process engineers, electrical engineers, mechanical engineers and piping engineers, hence it can adequately be applied in Mineral Process Mill Waste Water Treatment Plant .

This is not the same with other design software like CADWORX , the entire work is designed by a designer because it not a management system as a result such design is not perfected and does not allow for varying configuration types as the PDMS does.

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