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Transcript of _kürestajjoo
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Abstract
This summer practice was done in ET Copper Inc., Kre. The main object of the
practice was understanding and witnessing the mineral processing operations by the
first eye. Kre has got one of the best processing plants in Turkey and it is operated
by an important company. There was also another choice in ET Copper Inc., which
covers the underground mining operations, but after doing the first summer practice
about surface mining, my second choice became mineral processing in order to see
also the development and enrichment of the extracted materials in the mines before
sending them to the market. The practice is basically about five different stages of the
processing operations. These are primary crushing, secondary crushing, grinding,
flotation and dewatering. In every part, besides operations, also the used machinesor materials etc. were studied. There is also a personal study part of this report which
is about a series of flotation experiments. They were real processing experiments
and the management used some of the results and informations that we found. In
conclusion, the 20 days spent in the management were full of learning, practice,
examining and surprising.
Acknowledgement
The company has changed its vision a bit during the past couple of years. They are
working with a young and dynamic team nowadays. We have met with four engineer
(one of them was the plant manager) and they were under 33-34 years old. The
relationship with the engineers or workers is very important for the trainees. It can be
said that this relationships can effect all the summer practice and can be the reason
of learning something from it or not. The Black Sea Region people were very kind
and hospitable, they deserve special thanks. The trainees were sharing the dorms
with that people (generally workers of the management) and the relations both during
schedule hours and after work were extremely joyful. As a trainee, we didnt come up
with any problems about this subject. As mentioned, there was a young team of
engineers in the processing operations. They did their best for teaching us something
new or showing the operations by the first eye. Their help was not only about the
management or about mineral processing, but also about the job, mining engineering
and its problem sor benefits etc. ET Copper Inc. is an important management and
the trainees of it were the lucky ones. All the clothes, equipment etc. were ready for
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the trainees, they were new and helpful for the whole summer practice. Also, the
content of the personal study in this report is about some flotation experiments and
Ar-Ge engineers helped us while experiencing them.
Introduction
The word mining refers to extracting the valuable minerals, rocks etc. from the
earths crust in many persons mind. But mining doesnt end after extracting the
minerals from the earth, the operations after getting the minerals outside are as
important as the first part. This summer practice report is about the second part
mining, namely mineral processing. Mineral processing is the enrichment of the
minerals by crushing them, grinding them or floating them, shortly liberating them. It
is about the gaining of the valuable and useful pieces in the extracted material.
Mineral processing is kind of bridge between the mines and the marketing. It is the
area of which the financial considerations are directly affecting the decisions. The aim
of this practice and report is witnessing these operations and learning some of the
details or key points fort he job. If an engineer candidate wants to work in the mineral
processing field after graduation, he/she has to make one of his/her practices in a
processing plant. This report is examining the operations step by step, from starting
with the primary crushing and ending at the dewatering unit. The management has a
lot of building for the operations of course, there was not a single building in which all
the works can be done easily and at one time. Therefore, besides the operations, this
report also examines the machines which are directly or indirectly affects the
operations. For example, crushers are the major objects for the crushing and
downsizing works in the first stage, but it is also very important to observe and report
the conveyors which are some kind of vehicles and they carry the material between
each unit. This is just one example. The machines and their properties are also
placed in this report. At the beginning of the report, the structure of the ore is studied
in detail. Of course we have to know what we are dealing with before starting to
processing it. After observing the whole processing plant and works, in the final part
of the report, a personal study takes place. This study is the result of a series of
flotation experiments. The flotation part is counted as the most important and difficult
part of the processing operations. The personal study asks the question of: Which
one will be more effective? The experiments are covering the addition of lime to thematerial before flotation. There are three experiments and in each of them, lime was
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added to the material in different times. The aim is observing the results according to
the behaviour of flotation. The report is ending with a conclusion part, and then the
references of some informations. Some photographs taken by myself is taking place
in Appendix.
Company Information
Kre concentrating facility was founded in 1973 in order to benefit from the copper
orebodies in Black Sea Region. 1.000.000 tonnes of copper aggregate (touvenant
copper), 90.000 tonnes of copper concentrate, 400.000 tonnes of pyrite concentrate
are produced in this facility in a single year. There are 3 surface and 1 underground
mining operations which are now active. Nearly 250 employees are placed in the
facility. Workings such as modernization, increasing the capacity and finding new
orebodies are continuing.
Kre Mining Areas passed to MTA in 1939 and then coppered pyrite (chalcopyrite,
CuFeS2) orebody was discovered in the area by the geological and geophysical
drilling methods by Etibank in 1963. In 1968, the area this time passed to Black Sea
Copper Managements. Firstly, the produced copper ore was being delivered as only
raw material but later, after the foundation of Etibank Coppered Pyrite Managements
in 1987, it started to be delivered as copper and pyrite concentrations seperately.
Following, area was passed to Etibank Coppered Pyrite Managements in 1991.
Between 1991-1998, the management kept working under that name, but in 1998 it
turned out to Eti Copper Inc. Finally, it was bought by Cengiz Holding in 2004 inside
the privatization project.
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http://www.etibakir.com.tr/default.asp
Physical Properties
Bulk Density =2,2 gr/cm3
Particle Size
+ 200 mesh =% 4,00
-200 + 270 mesh =% 5,00-270 + 400 mesh =% 16,00
- 400 mesh =% 75,00
Delivery Conditions
Kre Copper Concentrate can be transported as bulk load. The material is
transported to nebolu Port according to the contracts made.
Pyrite Concentrate
http://www.etibakir.com.tr/default.asphttp://www.etibakir.com.tr/default.asphttp://www.etibakir.com.tr/default.asp -
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Physical Properties
Bulk Density =2,4 gr/cm3
Particle Size
-75 mikron : 78-82 %
-53 mikron : 68-72 %
-38 mikron : 50-55 %
Delivery Conditions
Kre Pyrite Concentrate can be transported as bulk load. The material is transported
to nebolu Port according to the contracts made.
Structure of the Ore
The main ore minerals are pyrite and chalcopyrite in Kre. Many other rock types can
also be seen but they are generally not in large amounts. Some examples are
hematite, sphalerite, limonite, marcasite, galenite, bornite, basalt, fahlerz, bravoyite,
rutile, chromit, magnetite and digenite. Naturally, the grades of these minerals are
changing from drilling to drilling because the structure is changing from location to
location. But it is for sure that the actual aim of the facility is producing pyrite and
chalcopyrite. Copper (Cu) and Pyrite (FeS2) are obtained from Chalcopyrite (CuFeS2)
at the end of many liberating and concentrating processes. The extracted and
concentrated pyrite and copper are stocked separately and then sent to nebolu Port
by trucks for transporting to Samsun by the seaway.
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Quartz, chlorite, carbonate minerals are the main gangue minerals extracted
from the mine.
Once upon a time, there was a very efficient surface mine in the area called
Bakibaba and the extracted material had a grade of 16-18 %. But the ore here ran
out in 2009 so the management cant benefit from Bakibaba now. Drilling operations
are continueing in order to find a new vein. Also, Aky surface mine ran out two
years ago and today reclamation works are taking place. Nowadays, from the
surface, three types of ore are fed to the primary crushers; 2-4 % graded wooded
ore, 0.8-1 % graded impregnated ore (oxidization can be seen because the high
rates of Fe), 4-8 % graded massive ore.
Today, the actual source of the management is an underground mine called
Mara. The ore coming from here has a grade of 2-2.2 %. Cyprus type orebody
formation can be seen in underground mine. There are stil 10 million tonnes of
reserve takes place in Mara mine, this means the mine life will be nearly 10 years
from today. Daily 1500-2000 tonnes of production is done in the management.
However, the facility capacity is about 4000 tonnes.
There is an important situation in primary crushing unit. It is impossible to
liberate the wooden ore into wood and ore separately. Because they lie under the
ground for many years and in a sense their formation has changed, they sticked
together and act as a whole. Therefore, it becomes a different structure. They dont
sink into water for example, also other techniques dont work. But the management
realized that this new formation is harmful for the facility. Especially in the flotation
process, the resin of that woods causes over-frothing. So, the engineers found a
solution that, if they mix the wooden ore with the ore coming from underground mine
(Mara) and do not put it directly into processes, the problem vanishes. Finally, the
ore fed directly to the primary crushers has a grade of 1.5-1.6 %.
The facility can be divided into five parts in order to analyze and understand the
process. This dividing is also helpful for the directors of the management. Each of theparts can be said self-governing but also they are all bonded. These parts are;
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1 Primary Crushing Unit
2 Secondary Crushing Unit
3 Grinding Unit
4 Flotation
5 Dewatering
Lets examine all of this parts of the facility separately:
1 Primary Crushing Unit
This unit consists of the very first stages of processing operations. The newlyextracted ore directly comes to primary crushing. Here, it is exposed to the first
downsizing. But this downsizing rate is not enough for further operations such as
flotation, so after primary crushing there is a similar unit called secondary crushing
and it continues to decrease the particle size.
Machines and Their Properties
There are three trucks in primary crushing unit and they are responsible for the
feeding of the crusher. Actually, in general they dont feed the crusher directly, they
empty their material at a kind of stockpile near the crusher and the loaders use this
stockpile for the feeding. But sometimes also the trucks are used for this job directly.
These are two Volvo (34 DA 8942 34 TU 4650) an done Mercedes (37 NA 499)
model trucks. A hydraulic shovel makes the loading to these trucks. It has six
cylinder. The shovel capacity is 2.5 m3 and it can load or carry 5-6 tonnes of material
at one time. The loading time of the Mercedes truck is 2.75 minutes (it is loaded by 8
dipper), total cycle time is 22 minutes. Volvo (34 DA 8942) truck has a loading time of
about 3.5 minutes and a total cycle time of 21.5 minutes. The other Volvo truck (34
TU 4650) has a loading time of 3.25 minutes and a total cycle time of 17.5 minutes.
Four loaders are used for the feeding of primary crusher (966 G (two item), 938 G,
980 G CAT). Their shovel capacity is about 3.5-4 m3. The machines have a weight of
nearly 23 tonnes and they need experienced drivers for handling. During the feeding
into primary crusher, in order to balance the grade of the material, the loaders take 3
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shovels from impregnated (low-graded) ore, 1 shovel from wooded ore and 1 shovel
from massive (high-graded) ore. This balancing detail is an important one.
Crusher and Conveyor Properties
Previously there was a crusher which is used for ramble production (upper jaw width :
90 cm) and another primary jaw crusher (C 160 model) which is placed after K1
conveyor -it comes from underground- but today they are not in use and a jaw
crusher called new crusher is responsible for the operations. This one is a bit far
from K1 conveyor and there are many other conveyors which helps to collect their
output material into one stockpile. The new crusher is (MEM model) has an upper
jaw width of 130 cm, bottom jaw width of 15-16 cm. It has a motor power of 130 kW
and its capacity is 300 t/h. In jaw crushers, the materials are downsized by both the
impact of the dynamic jaws and the compression between each other.
The important parts of the crusher are steady cloth, dynamic cloth, the big pulley
called flywheel - it provides the movement - , and helix (spiral) strings. These helix
springs absorb the vibration of the crusher and they help to balance the crusher
during optimum feeding.
Generally in jaw crushers, the cloths are the parts that most prone to damaging. Main
reasons of this situation are the impact force of the material, friction, and feeding of
the moist material. This problem can be handled by changing the cloths regularly or
adding a metal plate behind the cloths. Besides, sometimes tough and big particles
can be stucked between the two jaws and it causes the loss of time and of course
money. In this case, the crusher is stopped and with the help of the lifters, the big
rocks are removed.
The dust problem occuring in the primary crusher is solved by four dust fans (filters)
placed in four different places around the crusher. These dust fans have 224 cloths
and works with 37 kW motor power.
Reduction gear is used for the purpose of arranging the speed of the conveyors.
There is a small part between the reduction gear and conveyor drum and it gives the
hydraulic pushing to the reduction gear. There is also another part which provides the
steadiness between the conveyor and conveyor drum during the movement. The
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switch button is needed for emergency cases, in such situations we can stop the
conveyor system by pushing it.
There is a sample taker after the K8 conveyor which comes from underground. This
is also called feed hopper. In the management, in every 20 minutes samples aretaken from the 35 cm crusher (jaw) and every morning at 7 a.m it is taken to the
laboratory for analyzing (K8 conveyor carries the particles which are smaller than 10
cm, this materials come from the 90 cm crusher which is placed at underground).
Under the buffer stock, there are five reciprocating feeders (one armed) called F1,
F2, F3, F4 and F5. Today, only F2, F3 and F4 feeders are working. The material is
feeded to K6 conveyor from these feeders, then K6 drops its load to K7 conveyor and
K7 carries the material to the secondary crushing unit, this point is the end of
primary crushing operations. In the management, like some other conveyors, this K6
and K7 conveyors are also have magnetic separators in order to separate harmful or
unnecessary iron particles (F2 works in a schedule of 10 minutes (underground) and
F3, F4 works in a schedule of 5 minutes (impregnated)).
2 Secondary Crushing Unit
The extracted material is supposed to downsizing process firstly in the primary
crushing unit, and then it comes to secondary crushing, in which it will also exposed
to further sizing operations. The next step for the material will be grinding (mills).
Therefore, the materials size is tried to be suitable for the flotation unit.
We can say that this unit starts with the feeding of K6 conveyor by the reciprocating
feeders F2, F3, and F4 which are under the buffer stock. Then the material comes to
the 370-metered-long K7 conveyor (which has a slope of 15%) and goes to
secondary crushing plant. It passes through the 500 tonnes capacitied (250 m3
volumed) SB1 silo and with the help of F6 banded feeder, the material falls to the F1
doubledeck screen. The upper deck has the aperture size of 60x60 mm2 and the
lower deck has the aperture size of 15x30 mm2, the screen has made of a flexible but
hard material; polyurethane. It has the length of 5 meters and width of 1.6 meters. It
consists of 4 equal pieces which are bonded end to end, each has a 1.25 meters
length. The particles can not passed under the screen are sent to the seconder
crusher (G4214 Lokomo). The particles passed from the apertures of the screen are
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directly sent to the next unit, grinding, by K11 conveyor. The particles crushed in the
seconder crusher (cone type) are sent to the other silo SB2 (800 tonnes capacitied,
400 m3 volume by the conveyors (in order) K8, K9 and K10 conveyors for the
purpose of screening or, if necessary, crushing again. They are fed from SB2 silo to
F2 screen by F7 feeder and to F3 screen by F8 feeder. These screens have the
aperture size of 52x12 mm2. This time, the particles bigger than the aperture size
(oversize material) are sent to tertiary crusher (HP 300 Metso). There are two of them
but today, just the second one is working because the material amount comes to
secondary crusher is not enough to fill both of them, the capacity can not be met. The
small particles passing through the screens F2 and F3 are sent to grinding unit by
K11 conveyor. The particles crushed by the tertiary crusher are dropped into SB2 silo
by K8, K9 and K10 conveyors and the same processes continue in a closed circuit till
the required particle size is obtained. In conclusion, the particles downsized by this
system reach to three cylindirical silos (each has a volume of 2500 m3 and a capacity
of 5000 tonnes) by K11 and then K12 conveyors. From here, with the help of the
feeders F9, F10, F11, F12, F13 and F14, again they are dropped to K13 and K14
conveyors, and finally K15 conveyor and sent to grinding unit by this conveyor. So,
the secondary crushing unit ends up here.
Machines and Their Properties
K6 conveyor has a length of 75 meters, a width of 1200 mm, velocity of 1 m/s and it
works with 30 kW motor power. K7 conveyor has a length of 370 meters, a width of
1000 mm, velocity of 1.5 m/s and it works with 160 kW motor power. The entering
particle size of the ore to the SB1 silo is between 0-12 cm. F6 feeder (banded) has a
width of 1200 mm and it works with 7.5 kW motor power. The upper deck (60x60
mm2)of the doubledeck screen was put in order to protect the lower deck (15x30
mm2). K8 conveyor has a length of 85 meters, a width of 1000 mm and it works with
55 kW motor power. K9 conveyor has a length of 20 meters, a width of 1000 mm and
it works with 7.5 kW motor power. K10 conveyor has a length of 85 meters and it
works with 75 kW motor power. K11 conveyor has a length of 115 meters and it
works with 75 kW motor power. K12 conveyor has a length of 25 meters and it works
with 7.5 kW motor power. Secondary crusher works with 132 kW and tertiary crusher
works with 200 kW motor powers. F7 and F8 feeders also work with 7.5 kW motorpower. Screen motor works with 22 kW. Dust fan cleans the air of the secondary
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crushing unit with its 21 pipes placed different points around the unit and this fan
works with 132 kW motor power. This dust fan is 11 years old and sometimes one of
its air valves get broken (blow-out etc.) and this valve can be changed with another in
15-20 minutes, so the problem can easily be solved.
Secondary crusher has a capacity of about 400 t/h. Its cloth has a useful life of 6000
hours. The cloth is made of cast iron. The actual capacity is 400 t/h but during the
fine or mixed feeding, it can decrease to 200 t/h because of the limited extraction. It
works with open circuit system and it is repulsive from both upper and lower sides.
The upper opening (mouth) is about 10 cm but after 9-10 months, it gets wider and
reaches 11-11.5 cm. The working ampere ranges from 150 A to 200 A.
Tertiary crusher is standard (head) cone crusher and it is available for possible
blockages. It is repulsive from just the lower side, it works with closed circuit system.
The crusher cloth is again made of cast iron and it has a useful life of about 1000
hours. Grease temperature changes between 36C and 40C. The hose temperature
changes between 27C and 38C. Its reduction ratio is 5:1. The secondary crushers
reduction ratio is between 10:1 and 3:1. Before starting to work, tertiary crusher waits
120 seconds for greasing, 60 seconds for feeding and 10 seconds for increasing the
ampere to high degrees from low degrees. The cutting action is arranged by the
stroke, therefore the particles supposed to downsizing and finally folieceous products
are obtained. Because of this reason, the screen apertures are rectangular-shaped.
Tertiary crushers motors engine rpm is 1500 revolution per minute. The wood and
rock pieces which hinder the circuit are cleaned daily.
In secondary crusher, if the feeding is hindered by a hard object (like iron), the
crusher may be stucked. The problem is solved by stopping the crusher, lowering the
conical head and taking that object out. For raising the head again, some grease is
pumped. In tertiary crusher, at the moment of stucking, the nitrogen tanks
automatically gives pressure to the stucked area and lower the conical head by this
way.
A heavy, protective plate made by lead is placed at the lower part of the crushers.
This is a very important part and it can be called as the heart of the crusher.
Because, after the abrasion or broken of this plate, you have to pay serious money inorder to compensate.
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3 Grinding Unit
The grinding unit is the last unit for particle downsizing after the primary and second
crushing. The required sized product of this unit is sent to flotation after classification.
The main elements of grinding unit are mills (rod and ball type) and hydrocyclones.
The grinding takes place in both rod and ball mills, it is wet grinding type. The
material taken from the secondary crushings stocked silos (-20 mm) is mixed with
lime and enters the grinding unit with 140-180 tph capacity. The reason for the
addition of lime is to increase the pH range for the flotation process because the main
purpose is to depress pyrite. The material firstly enters to rod mill. Rod mill operates
in open circuit and the material grinded here directly goes to cyclones (Before going
to cyclones, it visites Tank 1 and then it is sent to cyclones by sludge pump). After
classified in here, overflow is sent to flotation and underflow is sent to ball mills.
Overflow is 90 % ( - 74 ), 70 % ( - 38 ). Underflow is ( - 2 mm). Underflow is
grinded again at ball mills (BM1, BM2), and then pumped to cyclones by the sludge
pumps. The maximum particle size entering to cyclones becomes 2 mm. Ball mills
operate with closed circuit, so, while the overflow samely sent to flotation, underflow
continues to downsizing operation until the required particle size is obtained. The
floating particles in the copper flotation comes to BM3 ball mill for re-grinding. The
entering to BM3 is 80-90 % ( - 23 ) (overflow). The particles grinded in here are sent
to another small cyclone by Tank 2 in order to classification. Again overflow is sent to
flotation and underflow comes to BM3 by closed circuit principle. Grinding unit ends
up here.
By the formula ( Nc = (42.3) / (D-d) ) (D : 3,4 m) (d: it can be neglected because the
diameter is too small)
42,3/3,4 = 23 .
Revolution per minute is 14. So;
14/23 = 0.608 0.608 x 100 = 60.8 % 60-65 % critical speed
(rod mill).
Similarly, the diameter of the ball mill : 4 m. Nc= 42.3/ D = 21.2
Revolution per minute is 16. So;
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16/21.2 = 0.75 0.75 x 100 = 75 % 75 % critical speed (ball mill).
140 tonnes ; BM1 BM2 : 7.14 kW/ton
RM : 3.21 kW/ton
BM3 : 2.5 kW/ton
170 tonnes ; BM1 - BM2 : 7.05 kW/ton
RM : 2.94 kW/ton
BM3 : 2.17 kW/ton
The ball used for each tonnes is 1500 gr/ton. The rod used for each tonnes is 450gr/ton. In the rod mill, there are 640 (80 mm sized) body cloth, and 384 (160 mm
sized) lifting cloth. In the ball mills, the body cloth is 160 cm sized and the lifting cloth
is 80 cm sized. The entrance protectors have a usage life of nearly 8500 hours. The
body cloths have a usage life of nearly 1700 hours. The ball mill has a flow rate of
210 t/h.
If the pressure of the hydrocyclone increases, the cutting size decreases. If the length
of the body cone increases, the cutting size decreases. If the apex increases, the
cutting size also increases. If the vortex corrodes (increasing width), the cutting size
increases.
Machines and Their Properties
The rod mill has the diameter of 3400 mm, and the length of 5000 mm. The rods
inside are sized 70 x 4625 mm. The capacity of the machine can change between
140-180 t/h. The particle size enters to the mill is 20 mm. The cloth is cast iron (withmanganese). The solid rate of the machine is 70 %. The rod mill is Reoma Repola
type and it works with 850 kW motor power (1000 rpm).
BM1 and BM2 ball mills have the same properties. They have the diameter of 4000
mm and the length of 6000 mm. The balls are sized 30 mm and the solid rate of the
mill is 60 %. The material feeding to the mill has a particle size of averagely 2mm.
They are also Reoma Repola type mills and their cloth is also cast iron (with
manganese). While BM1 works with 170 kW (1000 rpm) motor power, BM2 works
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with 1700 kW (1000 rpm). BM3 ball mill (re-grinding) has a smaller size compared to
the others. It has a diameter of 2700 mm and a length of 4500 mm. The balls are
sized 30 mm diameter. The solid rate can change between 60-65 % and the feeding
material has a particle size of -38 . Averagely 65 tonnes of material is fed to BM3
which is a model of Reoma Repola. Electric motor works with 450 kW (1000 rpm).
BM1 battery has 4 cyclones ( 2 (500), 1 (350) and 1 (250) ). There were previously 6
ones. BM2 battery has got 6 cyclones ( 5 (350) and 1 (250) ). BM3 battery has 8
cyclones ( 4 (150) and 4 (250) ). The 500 cyclones have upper aperture diameter of
210 mm and lower aperture diameter of 105 mm. 350 cyclones have upper aperture
diameter of 130 mm and lower aperture diameter of 65 mm. 250 cyclones have upper
aperture diameter of 100 mm and lower aperture diameter of 45 mm. The conicalparts of the cyclones are made of polyethylene and the cylindirical parts are made of
rubber.