Australia Technical Mining Conference 2015 PROCESS …€¦ · Africa Australia Technical Mining...

Presenter: Herman Oosthuysen- Process Manager, DRA11-12 June 2015, Adelaide Convention Centre

Africa Australia Technical Mining Conference 2015

PROCESS REVIEW FOR IRON ORE BENEFICIATION

• OVERVIEW

• FLOW DIAGRAM

• COMMINUTION/ LIBERATION

• BENEFICIATION

• SOLID LIQUID SEPARATION

• PRODUCT HANDLING

• CONCLUSION


CONTENT

0

200

400

600

800

1,000

1,200

Chi

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ion

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D

eman

d

YearsChina Iron Ore demand Source: Morgan Stanley

020406080

100120140160180200

US

Dol

lor p

er d

ry m

etric

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April 2005 to March 2015China import Iron Ore Fines 62% Fe spot price

Source: Mundi Index Africa Australia Technical Mining Conference 2015

OVERVIEW‐IRON ORE DEMAND & SUPPLY


OVERVIEW OF WEST AFRICAN IRON ORE

ROM Size ReductionSize

ClassificationBeneficiation

by Size Fraction

Product

Rejects

Crushing

Milling

Scrubbing

Screening

Primary Beneficiation

Secondary Beneficiation

Tertiary Beneficiation

Mining - BlastingROM BlendingIn Pit

Product Blending

ROM BlendingCrushed ROM

Product Transport

Tails/ Rejects Storage


PROCESS MODEL FOR IRON ORE

• Mineralogy

• Liberation characteristics

• Product size and grade suite

• Yield & grade

• Energy efficiency

• Equipment selection

• CAPEX & OPEX

• SHE

• Risk


FLOWSHEET BUILDING BLOCKS & CONSIDERATIONS

Scr

ubbi

ng &

Scr

eeni

ng

PrimaryBeneficiation

TertiaryBeneficiation

Secondary Beneficiation

• JAW CRUSHER – Low Capex

• MINERAL SIZER- High clay in feed

• HPGR- High throughput and high reduction ratio required

• CONE CRUSHER- Minimising fines generation

• AG MILLING-Combined comminution and scrubbing steps


Primary Gyrator and Secondary Cone Crushing

LIBERATION & COMMINUTION‐EQUIPMENT'S SELECTION

Wet screening and Coarse & Fine Jig

• OVERVIEW

• FLOW DIAGRAM


• BENEFICIATION



• CONCLUSION


CONTENT

Sorter Plant (DRA, 2015)

SORTER: Material can be sorted based on

1. According to Color (CCD)

2. According to Material (NIR)

3. According to Element

Composition (XRF/XRT)


SECONDARY BENEFICIATION ‐ SORTER

Labrador Iron Ore Plant (DRA, 2011)

(Khumani Jig Plant (DRA, 2008)

• Operating size range

• Particle shape effects

• Can cut at higher density

• Different capacities per size fraction

• Optimised using on-line analyser

• Key aspect to design a jig plant


SECONDARY BENEFICIATION‐ JIG

Modular plant

• High NGM

• Pilot-scale test operating density 4.2 g/cm3.

• Gas atomised FeSi

• Separation efficiency – Lower D50 & Yield benefit


SECONDARY BENEFICIATION‐ DMS/ UHDMS

• Separating sizes range: 2.0 - 0.1 mm

• Capacities: up to 7 t/h

• Configured 5 - 7 turns; can accommodate 4 starts per column

• Iron Ore specific developments over the years:

o Improved materials, feed box, splitter & trough design

o Improved water addition, capacity, re-pulpers, product

boxes

• Recent trends: high capacity units; automate splitter

adjustments


SECONDARY BENEFICIATION‐SPIRAL

Factors influencing performance & operation:

o Volume concentration of solids

o Particle size & shape

o Bed level control

Three product classifier

Reflux Classifier

•Reflux Classifier Incorporates ‘laminar high

shear rate’ mechanism

•Result in higher capacity per area and

Efficiency

• Test and pilot plant proves easily upgrade

to >60%Fe in a single stage


SECONDARY BENEFICIATION‐ UP‐FLOW CLASSIFIERS

Design Consideration

• Oversize protection screen

• LIMS before WHIMS

• Magnetic field Intensity and Matrix size at each stage in WHIMS

• Consider two stage beneficiation to ensure product grade

Classification

• LIMS, MIMS and HIMS

• LIMS- Co-current, counter-rotation or

counter-current.

• WHIMS- Vertical and Horizontal carousel

Magnetite Beneficiation Plant ( DRA, 2014)

Khumani WHIMS Plant (DRA, 2013) Africa Australia Technical Mining Conference 2015

TERTIARY BENEFICIATION‐MAGNETIC SEPARATION

Chemistry Component

CollectorFrother

ActivatorDepressant

pH

Operation Component

Feed rateMineralogy

Particle SizePulp densityTemperature

Equipment Component

Cell DesignAgitationAir Flow

Cell bank ConfigurationCell bank control

FLOTATION SYSTEM

• Mineralogy

• Gangue and Mineral liberation size

• Flotation reagent suite

• Mixed flotation circuit- Combination of

MagSep and Flotation

Source: Flotation system (Klimpel, 1995)


TERTIARY BENEFICIATION‐ FLOTATION

Filter selection requires due consideration of;

o Product/tailings moisture requirement (TML).

o Downstream material handling

o Auxiliary requirements

o Capex and Opex

o Trade-off studies equipment type ie:

o Vacuum Disk or horizontal belt

o Plate & Frame

o HyperbaricBelt filters Magnetite Beneficiation Plant ( DRA, 2014)

Plate & Frame Filter Building design


SOLID‐LIQUID SEPARATION

Product stockpiles

• OVERVIEW

• FLOW DIAGRAM


• BENEFICIATION



• CONCLUSION


CONTENT

PRODUCT HANDLING AND BLENDING

• Product storage / Surge capacity

• Blending / homogenisation

• Weather protection

• Normall large footprint and high Capital requirements

• Dynamic simulation is recommended to accurately assess

o The stockpile capacity

o Logistics to port or siding

o Ship turnaround and ship

sizes

o Port consideration


PROCESS REVIEW FOR IRON ORE BENEFICIATION

• Cost of production is a key focus area

• Coarser beneficiation = typically lower cost

• Liberation is a driving factor

• Flowsheet design requires test work

• Relevant equipment selection to maximise exploitation

of specific material characteristics

• New process technologies available and continuously

improving

• Fit for purpose designs Africa Australia Technical Mining Conference 2015

CONCLUSION

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Australia Technical Mining Conference 2015 PROCESS …€¦ · Africa Australia Technical Mining...

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