Cbt Syl Lab Us Intro Stable

7/31/2019 Cbt Syl Lab Us Intro Stable

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Introduction to Metallurgical Plant Unit Operations and Process Control

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FundamentalsPressure and Pressure Drops

Definition of Force, Area, and PressureEngineering Units of Force and Pressure

Pressure in a Container

Molecular View of Pressure

Measuring Pressure with a Manometer

Effect of the Liquid Density of Manometer ReadingsPressure Caused by GravityStatic Head

Gauge, Absolute Pressures, and Pressure DropTemperature, Heat Flow, and Heat Exchangers

Definition of Temperature and Thermometers

Temperature as Kinetic Energy of MoleculesThe Absolute Temperature Scale

Relationship Between Temperature and Pressure

Definition of Heat and Heat CapacityEngineering Units of HeatIntroduction to Heat Exchangers

Heat Exchanger Types: Shell and Tube and Plate and Frame

Acids, Bases, and pHDefinition of Ions

Definition and Examples of the pH Scale

Hydrochloric Acid as an ExampleSlurries and Slurry Density

Typical Metallurgical Plant SlurriesExamples of Typical Slurries with Photographs

How to Calculate Slurry Percent Solids

Definition of Slurry Specific GravityIntroduction to Slurry Pumps

Sampling and Measuring Slurry Specific Gravity

Measuring Size Distribution with Standard Sieves


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Solutions and Solution ConcentrationDefinition of a Solution

Solids that Form Ions in a Water Solution

Solids that Do Not Form Ions in a Water Solution

Definition of Solvents and SolutesDefinition of Solution Concentration

Saturate Solutions

Ore, Metal Values, Gangue, and TailingsDefinitions of Terms

Sulphide and Oxide OresHost Rock

Mineral Liberation

Example Types of OresTailings Disposal and Impoundments

Tailings Dam and Beach

Atypical Means of Disposal Such as UndergroundRecovery and Concentrate Grade

Recovery as a Function of Feed, Concentrate, and Tails Grade

Definition of Recovery

Effect of Recovery on Concentrate GradeDistribution of Gangue Components in Concentrate and Tails

Simple Calculations

Inverse Grade/Recovery Relationship

AgitationRetention Time


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Plant Safety

IntroductionGeneral Safety

Personal Protective EquipmentEmergencies and General Rules

Housekeeping

Maintenance WorkGeneral Housekeeping

Safe Lifting Technique

Conveyors and Belt Feeders

Bins and HoppersV-Belt Drives

High-Pressure Air

Radiation Devices

Safety Showers and Eyewash StationsReagents

Sulfuric AcidFire

Classifications

Fire Extinguishers

Job Safety Analysis

Hazard TypesConducting the Analysis

Safe Job Procedures

Material Safety Data Sheets (MSDS)


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Crushing and Conveying

Gyratory Crushers, Hydroset, and Lubrication

Objective of Primary CrushingRun of Mine Ore and Truck Dumping

Gyratory Crusher Components

Gyrating Action of a Gyratory Crusher

Gyrator Crusher LubricationComponents of the Main Shaft

Eccentric Bushing

Oil Heating and CoolingOil Filters

Spider Assembly and Lubrication

Hydraulic Adjustment SystemRaising and Lowering the Mantle

Shock Absorbing

Clearing the Crusher

Symons Cone CrushersPrinciples of Operation and Description of Components

Animation

Gap adjustmentHydraulic System Controls

Tramp Metal Release MechanismHydraulic release MechanismLubrication System


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Jaw Crushers

Principle of Operation Including and Animation

Description of Crushing Action

ComponentsSingle Toggle

Hydraulic Rock Breaker

Principle of Operation, Description, and OperatingMethodology

Apron FeederPrinciple of Operation

Components

AnimationStockpiles and Reclaim Belt Feeders

Crushed Ore Stockpiles

Live and Dead StorageDraw Holes

Angle of Repose

Effects of Reclaim on Size Classification

Belt Feeder Components and Safety FeaturesDefinitions and Examples of Feeder Components

Belt Scales

Belt Cleaners and Scrapers

Safety Concerns and Emergency Pull CordsConveyor Belts

Manufacture of Conveyor Belting IncludingBelt Conveyor Components and Safety Features

Definitions and Examples of Conveyor Components

Different Types of Idlers, Including Return and Training

Idlers, Belt Scales, Belt Cleaners, and ScrapersSafety Concerns and Emergency Pull Cords


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Belt Scales, Magnets, and Metal DetectorsBelt Sale Components and Principles

How the Scale Computes Weight Over the Belt

Belt MagnetsTypes and PrinciplesMetal DetectorsTypes and Principles

Screw Conveyors

Construction, Components, and PrinciplesSafety Concerns

Dust Control and Bag-Type Dust Collectors

Introduction to Methods of Dust ControlBaghouse Components and Principles

Simple Dust Collection Ductwork and Hood Example

Description of Bags and Bag CagesViews and Descriptions of Baghouse Internals

Methods for Removing Collected Dust from the Bags

Setting Pulse Times Based on Pressure DropRotary Valves to Maintain the Dust Seal

Types of Dust Collector Fans

Dust Suppression Sprays and Techniques


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Pumping

Horizontal Centrifugal PumpsIntroduction

Pump Components and PrinciplesPacking and Packing Gland Including Gland Seal Water

Variables to Consider in Pumping Applications

Total Head, Flowrate, and Power RelationshipsStatic, Friction, and Velocity Head

Typical Pumping System

Effect of Piping System and Fittings on Friction HeadFlowrate and Total Head RelationshipSimple Curve

Flowrate and Power RelationshipSimple Curve

Cavitation

Pumping Slurries

Vertical Centrifugal PumpsDry and Wet Pit Pumps

Pump Stages or BowlsPositive Displacement Pumps

Introduction to Positive Displacement Pumps

Differences Between Positive Displacement and CentrifugalPumps

Progressive Cavity Pumps, Components, and Principles

Reciprocating Pumps, Components, and PrinciplesDiaphragm Pumps, Components, and PrinciplesThree-Way Air Valve to Control Reciprocating Pumps

Reagent Metering Pumps

IntroductionPeristaltic Metering Pumps, Components, and Principles

Diaphragm Metering Pumps, Components, and Principles

Cam Drives


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Grinding

Introduction to Grinding Technology

Introduction to Grinding

How Particles are Broken

Grinding ParametersTypes of Grinding Mills

Types of Grinding Circuits

SAG and Ball Mills

Introduction and General Description of CircuitsSAG Mills, Components, and Principles

SAG Mill Volumetric Loading of Charge Components

Cataracting Action in the Rotating SAG MillSAG Mill Liner Components

Semi-Autogenous Grinding MillsDrive Gears and Motors

Mill Lubrication SystemsGear Teeth, Pinions, and Trun-nion BearingsMill ClutchesTypes, Function, and Objectives

Operating Considerations

Ball Mill Description, Objectives, and PrinciplesBall Mill Grinding


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Classification

Cyclones

Introduction to Screening Technology

Zones and MotionEfficiency Factors

Components, Function, and Principles; Clusters

Variables Affecting PerformanceCyclone Operation Troubleshooting

Heavy Media Drums

Principles and DescriptionAnimation

Heavy Media Hydrocyclones

Principles and Description

SpiralsPrinciples and Description

Vibrating Screens

Introduction to Screening

Screen Function and PrinciplesVibration Techniques

Screen Slopes

Screening efficiencyMaterials of Construction

Grizzlies, Components, and Principles

Double- and Triple-Deck Screens


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Flotation

Introduction to Flotation Technology

Introduction

Phases, Reagent Classes, and FunctionsBubble Formation and Dynamics

Froth Dynamics and Management

Conventional and Tank Flotation CellsIntroduction and Brief Explanation of the Flotation Process

Introduction to Hydrophilic and HydrophobicAgitation and Air Introduction to Flotation Cells

Introduction to Simple Flow Diagrams Showing Feed,

Concentrate, and TailsExplanation of Flotation StagesRougher, Scavenger,

Cleaner Cells and Various Combinations

Construction, Components, and Principles of Tank CellsConstruction, Components, and Principles of Conventional

Banks of Cells Connected by Transition Boxes

Key Variables and Their Control

Dart ValvesDefinition of Froth and Slurry Levels

Mixing Zones and Flotation Cells

Column Flotation Cells

IntroductionColumn Flotation Cells Construction, Components, and

Principles of Column CellsWhere Column Cells are Typically Used in Circuits and

Why

Control of Froth Depth on Column Cells

Column Cell Air InjectionWash Water and Air Dispersion


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Flocculants

Introduction to Flocculants and Long-Chain Molecules

Principles of How Flocculants Work

Effect of pH and Types of FlocculantsEffects of Dilution and Why it is Important

Flocculant Makeup Systems

Filters Introduction to Filters and Characteristics Common to All

FiltersDefinitions: Feed, Filtrate, Filter Cake, Filter Media

Filer Media Pressure Drop

Types of Filter MediaMethods of Forcing Feed Through Filter Media

Pressure and Vacuum Filters

Methods of Filter Cake RemovalMethods of Cleaning or Replacing the Filter Media

Types of Filters: Drum, Disc, Belt, Plate and Frame, and

Vertical

Larox Filters


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Gold and SilverCyanide Leaching

Introduction and Objectives

ChemistryLeach Tanks

Carbon In Pulp

ChemistryCIP TanksCarbon Advance

Screens

Counter-Current DecantationIntroduction and Objectives

Concept of Washing

Example Three-Stage Circuit

Factors Affecting RecoveryElution and Acid Wash

Introduction and ObjectivesChemistry

Typical Circuits

Carbon Reactivation

Introduction and ObjectivesKilns and Combustion Controls

ChemistryTypical Circuits


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Merrill Crowe Precipitation

Introduction and Objectives

Clarification Filters

ChemistryDeaeration and Zinc Addition

Precipitation Filters

Mercury RetortRetort Oven

CondensersCarbon Adsorption

Vacuum Pump

Gold ElectrowinningIntroduction and Objectives

Electro-Chemistry

Rectifiers and ControlsMaterial Handling

Typical Circuits

Dor Smelting

FluxingSmelting Furnace

Casting

Tailings Detoxification

Introduction and ObjectivesChemistry

Typical Circuits


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Reagents and Sampling

Flotation Reagents MakeupTypical Flotation Reagent Makeup Circuit

Flocculant Makeup

Typical Flocculant Reagent Makeup Circuit

Lime and Lime Slaking

Introduction to Limestone, Quick Lime, and Slaked LimeQuick Lime Production Methods

Safety ConcernsLime Slaking and Slakers

Lime Bin Activators

Slaking System ScrubbersTypical Lime Slaking Circuit

Sampling Theory and Automatic Samplers

Introduction to SamplingWhy Obtaining a Representative Sample is DifficultObjectives of Sampling

Metallurgical Accounting

Process ControlProduct Quality Measurement

Sampling MethodsPrimary and Secondary Samplers

Manual Sampling

Types of Automatic Samplers:


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Air Compressors

Air CompressorsIntroduction and Typical Plant Air Compressors

Operation of a Pneumatic CylinderBasic Types:

Reciprocating Compressors Rotary CompressorsReciprocating Compressors, Components, and PrinciplesRotary Compressors, Components, and Principles

Air ReceiversLubrication and Cooling

Air Filters

Air Dryers

Air Blowers

Introduction to Air Blowers and FansUses

Centrifugal Fans, Components, and PrinciplesAxial Fans and Dampers

Engineering Units Used for Fans and Blowers

Typical Fan Performance CurvesPressure, Flow, and Power Relationships

Types of Centrifugal FansAdvantages and Disadvan-

tages:

Backward Curved/Airfoil Blades Radial Blades Forward Curved BladesPositive Displacement Blowers, Components, and Princi-ples


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Combustion and Offgas Handling

Burners, Combustion, and Heaters

Types of Fuels

Fuel Air MixtureStoichiometry

Flue Gas Products and Excess OxygenGas, Oil, and Pulverized Coal Burners

Combustion Air and Atomizing Air

Primary air and Secondary AirTypical Burner Safety Interlocks

Gas Handling Cyclone

IntroductionPrinciples

Components

Flues Cross Section

Dust Handling

Draft

Dew Point of Air, Water, and SO2 MixturesDew Point as a Function of SO2 Content

Chemistry

Corrosive Problems

Drag Chain ConveyorIntroduction

Principles

ComponentsEductor

Principles

Components


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Boilers and Steam Generation

Steam Characteristics

Saturated and superheated steam

Heat of vaporizationWater Tube Boiler Construction

Steam drumTubes

Thermal circulation

Burner assemblyInsulation

Blowdown

Steam Transmission

SafetySteam leaks

Safety relief valves

Energy conservationInsulation

Pressure drops through fittings

Valve usageGate valveGlobe valve

Ball valve

Check valveCondensate removal and steam traps


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Electrostatic Precipitators

Introduction

Principles

ComponentsElectrodes, Collecting Plates, and Insulators

Hoppers and Dust CollectionIsolating Units

Rappers

Stack EffectIntroduction

Effect of Heat

Simple Equation for Calculating Pressure DifferentialInduced vs. Natural Draft

Overcoming System Resistance

Stack Opacity DetectorPrinciples

Components

Pneumatic Conveying

TypesPrinciple of Dense-Phase and Dilute-Phase Systems

Advantages and Disadvantages of each Type

Principle of Pod-Type Dense-Phase Systems

Fuller Kinyon PumpsIntroduction

PrinciplesContinuous Dense-Phase Operation

Air Slide

Introduction

PrinciplesComponents


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ElectricityIntroduction

Atomic Nature of Electricity, Ions, Free Electrons

Conductors and Insulators

Voltage, Electric Current, and ResistanceEngineering Units for Voltage and Analogies

Definition and Units for Current and Resistance

Analogies for Resistance

Simple Direct Current CircuitsSimple Electrical Relationships

Electrical Safety IssuesPower

Engineering Units; Power Relationship to Current and

VoltagePower Analogies

InsulationApplications and Potential Problems and Abuse

Direct CurrentAlternating Current

Simple AC GeneratorFactors that Affect Voltage Generated by a Generator

Concept of a Conductor Cutting Magnetic Field Flux Lines

More Complex AC Generators and Simple Animation

Simple AnimationsMultiple Pole AC Generators

Industrial Revolving Field Generators, Components, and

Principles


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TransformersIntroduction and Objectives

Transformer Definitions, Components, and Principles

Simple Equations for Determining Primary and SecondaryVoltage and Affect on Power.

AC Motors

Induction Motors, Components, and PrinciplesAction of an Induction Motor.

Squirrel Cage Motors and AssemblySynchronous Motors, Components, and Principles

Characteristics of Synchronous Motors

Formula to Calculate Synchronous Motor SpeedVariable Frequency Motors

Multiple Phase AC Power

Single-Phase Revolving Field Generator

Two-Phase AC Generator

Electrical Distribution SystemsHigh, Low, and Medium Voltage

Substations and Load Centres


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Process Controllers

Introduction to Process Controllers

Introduction and Examples

TermsAutomatic Control

Advantages of Automatic ControlIntroduction to a Simple Control Loop

Functions of Sensors, Transmitters, and Controllers

Example of a Controller Face PlateExplanations of Automatic and Manual

Definitions of Process Variable, Set Point, and Output

Definition of Direct and Reverse ControlSimple Examples

Illustrations of Control Loops Using Symbols or Block

DiagramsManual Control

Descriptions and Examples of Manual Control

Example of Manual Level Control

Block Diagram Illustrating Pure Manual ControlControl Modes

Introduction to the Various Control Modes:

Binary Proportional Proportional Plus Integral Proportional Plus Integral Plus DerivativeBinary Control and Factors to Consider

Proportional Control and Factors to ConsiderDefinition of Proportional Gain and Error


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Control Modes

Definition of Proportional Band

Affect of Proportional Gain on System Response

Example of a Control Loop Using Proportional ControlExplanation of Offset and its Affect on a Control Loop

Proportional Plus Integral Control (PI) and How itRemoves Offset

PI Control and Factors to Consider

Example PI Loop and How Offset is RemovedProportional Plus Integral Plus Derivative Control (PID)

Advantages of PID Control and Factors to Consider

Example PID Loop and its Response

Types of Automatic ControlLocal Automatic (Local Set Point)

Cascade (Automatic Remote Set Point)Dead BandControl Loop Tuning

Interlocks

Introduction to Interlocks

Definitions

Examples

SensorsIntroduction to SensorsPressure Sensors

Flow Sensors

Level SensorsTemperature Sensors

Density Sensors


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Control Devices

Introduction to Control DevicesControl Valves

Gate Valve

Globe ValveButterfly Valve

Plug ValveBall ValveDiaphragm

Vanes

Troubleshooting

Troubleshooting Controllers and Control Devices

Methodologies

Process Problems

Distinction Between Process Control Problems and Process

ProblemsRealistic Examples

Introduction to P&IDs

Identify Various Types of instruments

Identify Various Types of signal linesRead P&IDs.

Read P&ID Legends

Instrument SymbolsMeanings of Letters

Line Symbols

P&ID ExamplesReading the Legend

Cbt Syl Lab Us Intro Stable

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