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> M i n e r a l P r o c e s s i n g > E n g i n e e r i n g D e s i g n > T r a i n i n g > S p e c i a l i s t S e r v i c e s > RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
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4th Annual FeTech Conference 2013
Criteria for Selecting a Jig or DMS
Presented by John Visser
Mineral Engineering Technical Services
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> DISCLAIMER With respect to all the information contained herein, neither Mineral Engineering Technical Services Pty Ltd, nor any officer, servant, employee, agent or consultant thereof make any representations or give any warranties, expressed or implied, as to the accuracy, reliability or completeness of the information contained herein, including but not limited to opinions, information or advice which may be provided to users of the document. No responsibility is
accepted to users of this document for any consequence of relying on the contents hereof.
> COPYRIGHT © Passing of this document to a third party, duplication or re-use of this document, in whole or part, electronically or otherwise, is not permitted without the expressed written consent of Mineral Engineering Technical Services Pty Ltd.
> ACKNOWLEDGEMENTS This document is a dynamic record of the knowledge and experience of personnel at Mineral Engineering Technical Services. As such it has been built upon over the years and is a collaborative effort by all those involved. We are thankful for the material supplied by and referenced from various equipment manufacturers, vendors, industry research and project
partners.
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Key Attributes
> Working globally since 1988
> Dynamic and innovative niche consultancy
> Dedicated team providing customised service
> Specialist in Mineral Processing & Engineering Projects
> Unique solution finder
Pragmatic, efficient, complete engineering through quality, personalised & exceptional service delivery
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Overview
> Introduction
> Criteria for selection
> Jig Setup
> DMS Setup
> Case studies
> Capex and Opex
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Introduction
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Criteria For Selection
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Criteria for selection
Criteria Jigs DMS
Particle size Narrower sizing Broader sizing
Density cut No restriction Max limit of 3.8
Density difference
between float and sinks
> 1.0 0.5 to 0.8
Efficiency Less sharp Sharper
Efficiency Dependant on small size
Near density material Less of a problem
More of a problem
Yield and recovery Less optimisation Better optimisation
Tailings grades Higher Lower
Seperation Density Density
Capex Higher Lower
Opex Lower Higher
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Separation of Iron Ores
Iron Oxides
(Hematite)
Magnetite
Coarse (-32+8mm) DMS
Jigging
Cobbing
LIMS Medium (-8+1mm)
Fine (-1mm+212/75µm) Spirals
WHIMS
Flotation
LIMS
Flotation Slimes (-212µm)
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Efficiency comparison
0.00
20.00
40.00
60.00
80.00
100.00
120.00
F 2.7 2.7 - 2.85 2.85 - 3 3 - 3.15 3.15 - 3.3 3.3 - 3.45 3.45 - 3.6 3.6 - 3.75 3.75 - 3.9 3.9 - 4.05 4.05 - 4.2 S 4.2
DMS vs. Jig partition curve
DMS
Jig (Interpolated)
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JIG SETUP
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Gravity Separation Performance
> Concentration Criterion = SG of heavy mineral − SG of fluidSG of light mineral − SG of fluid
Concentration Criterion (CC) Gravity Separation
CC>2.5 Easy down to 75 µm
1.75<CC<2.5 Possible down to 150 µm
1.5<CC<1.75 Possible down to 1.7 mm
1.25<CC<1.5 Possible down to 6.35 mm
CC<1.25 Impossible at any size
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Jigging
> Size classes for iron ore
― – 32 +8mm
― – 8 +3mm
― – 3 +1mm
> Size classes for coal
― – 100 + 35mm
― 35 + 10mm
― – 10 + 3mm
> Capacity Batak Style Jig
― 65 t/h per meter width of jig to max of 4 m wide jig
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Jigging Operation
> The oscillating motion causes pulsations that will dilate the bed of
material
> This makes the particles settle as the larger and denser particles forming
the lower layers with the finer and lighter particles on the top
> During the suction stroke, differential initial acceleration occurs followed
by hindered settling and finally consolidation trickling
Start Dilation
Differential
Initial
acceleration Hindered
settling
Consolidated
trickling
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Jigging Action
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Jig Variations
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Under bed (Batac®) pulsed machines
> Examples
> Alljig from Allmineral
> Batac® from Humboldt Wedag
> Apic jigs from Bateman
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AllJig
> Side pulsed or under bed pulsed machines
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Slimes Dam
Lumpy Product
Fines Product
2 x Double deck
-80 mm
554 tph
-8 +. 5
188 tph
3718 m3ph
1400 m3ph
849 m3ph
1592 m3ph 1296 m3ph
-8 + . 5
129 tph
-32 + 8
80 tph
10 tph
1382 m3ph
2 x Single deck
-32 +8
264 tph
-8 +.5
51 tph
-32 +8
182 tph
+ 32 mm
231 tph
Crusher
Discard
407 tph
-80 mm
785 tph
Lumpy
Fines
From W &S 2960 m3ph
Jig Plant
Preparation
Plant
Water Reclamation Plant
Jig Process Flowsheet
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DMS SETUP
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DMS described
> Dense Media Separation (DMS) is a physical separation technology
which relies on the difference in material densities to separate
different materials
> The mixed solids are placed in a liquid denser than one and less
dense than others
> The denser material sinks while the less dense material floats
> DMS is the most straight forward technique for separating particles
based on their densities
> Also known as Heavy Media Separation (HMS)
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DMS Medium
> Heavy Liquids
> Response of a given feed to a DMS process and be accurately
established in a laboratory by testing with various heavy liquids
Name Specific Gravity, 25oC
Methylene iodide 3.33
Tetrabromoethane 2.96
Bromoform 2.86
Tribromoethane 2.61
Methylene bromide 2.48
Ethylene dibromide 2.17
Methylene chlorobromide 1.92
Pentachlorethane 1.67
Carbon tetrachloride 1.59
Trichloroethylene 1.46
Ethylene dichloride 1.26
Liquids Used to Test Feeds
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DMS Medium
> Heavy Liquids
> Aim is to separate the ore samples into a series of fractions
according to density
> May be used to assess the efficiency of an existing dense
medium circuit
> Heavy liquids give off toxic fumes and must be used with proper
ventilation
> The use of pure liquids has not been found to be practicable on
a commercial scale
> Industrial processes employ finely ground solids suspended in
water
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DMS Medium
> Finely ground or atomised Ferro Silicon (FeSi) and water are
commonly used as the heavy media
> Specific gravity is adjusted by addition or removal of FeSi
> Would not work where solids have similar densities, nor those that
are soluble in the fluid media
> Magnetic materials must be removed before this step
> Separated materials may have to be dried for further processing
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DMS Medium
> FeSi SG: 6.7-6.9
> Milled FeSi produced in different size ranges
– 30-95% –45µm
– Coarser, low viscosity grades achieve medium densities of up
to 3.3
> Atomised FeSi
– More spherical particles
– Medium is of lower viscosity
– Used to achieve densities as high as 4
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DMS Medium Ferrosilicon
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Gravity DMS – Drum Separator
> Drum Separator
> Side view
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Gravity DMS – Drum Separator
> Drum Separator
> End view
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Gravity DMS – Drum Separator
WEMCO® Heavy Media Drum Separator
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Centrifugal DMS – DSM Cyclone
> Dutch State Mines (DSM) Cyclone Separator
> Used for finer feeds, 0.04 to 0.0005 m
> Separation is made by the action of centrifugal and centripetal forces.
> The heavier portion of the feed leaves the cyclone at the apex opening (5), and the lighter portion leaves at the overflow top orifice
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Centrifugal DMS – DSM Cyclone
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Dense Media Separation on Iron Ore
> Cut SG of 3.6-3.8
> Not considered at SG 4 due to impact of high FeSi viscosity
> Ferrosilicon is used in water atomised, gas atomised or finely
milled forms
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Typical DMS Flowsheet
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DMS PFD
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Case Studies
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DMS results: Operation A
> The operation’s product grades are – > 65% Fe
– Density cut point for achieving grade is considered to be 4.2
– So, no chance
Description Weight (g) Weight (%) Fe (%)
+3.8sg 7.3 3.8 61.54
-3.8+3.6sg 28.6 15.0 57.11
-3.6+3.3sg 146.0 76.9 55.95
-3.3sg 4.0 2.1 52.19
Total (+1.18mm) 185.9 97.8 56.27
-1.18mm 4.1 2.2 46.47
Calculated Head 190.0 100.0 56.05
Head Assay 55.67
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Jig results: Operation A
> Notice grade is achieved
> Notice also the mass yield
Lump product Pilot plant – results for 11 test runs
Product – (32-62mm)
Weight (%) % Fe Grade Fe Recovery (%)
Feed Run 1 100 60.1 101.2
Conc. Run 1 85 65.4 92.5
Reject Run 1 15 34.6 8.6
Feed Run 4 100 62.1 99.3
Conc Run 4 86.8 66.5 93
Reject Run 4 13.2 29.7 6.3
Feed Run 7 100 59.7 99.9
Conc. Run 7 85.4 65.3 93.4
Reject Run 14.6 26.4 6.5
Jigging Test Runs
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Jig results: Operation B
Fe Grade % Pilot plant – overall results
Laboratory tests - average
Product (32-6mm)
Conc 63.4 63.1
Rejects 53.2 53.5
Feed 58.8 60.2
Products (6-1mm)
Conc 63.2 63.1
Rejects 52.8 53.2
Feed 59.6 59.9
Design % Actual %
Product (32-6mm)
Weight Fe Grade %
Fe Recovery %
Weight Fe Grade %
Fe Recovery %
Conc. 67 63.5 70.1 72.2 63.5 74.8
Mids. 1320 57.3 18.9 19.4 58.8 18.6
Rejects 10013 47 10.1 8.4 47.7 6.5
Feed 100 60.7 100 61.3
Product (6-1mm)
Weight Fe Grade %
Fe Recovery %
Weight Fe Grade %
Fe Recovery %
Conc. 63.4 63.5 66.3 64.1 63.4 66.3
Mids. 25.6 61.6 26 28.1 58.6 26.9
Feed 11 47 8.5 7.8 44.7 5.7
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Costing
Capex and Opex
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Process Design Criteria
> Haematite
> Plant throughput: 900 tph
> Minus 2 mm rejected
> Lump/fines split 60/40 = 540/260 t/h
> Jig unit: lump and fines: under bed pulsed: Batac®
> DMS unit: Lump & Fines: Cyclones
> Lump size: +8 -32 mm/Fines +2 -8 mm
Parameter Jig DMS
Number: lump 2 1
Number: fines 2 2
Medium None FeSi
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Capex and Opex
> Capex
> Opex
Direct Costs Equipment Installed
Bulk Earthworks & Civils
Platework, Structural & Piping
Electrical & Instrumentation
Buildings Design Contingency
Freight Total Costs
DMS $16,01M $3,13M $3,65M $2,55M $0.58M $2,59M $1.00M $29.51M
Jigs $16,71M $3,27M $3,81M $2,66M $0.61M $2,71M $1,04M $30.81M
Area Fixed Variable Misc. Total % Total
Labour Power Reagents &
Consumables
Maintenance $/tonne Costs
DMS plant $0.56 $0.73 $4.41 $0.34 $0.04 $6.08 35.5%
Jig plant
$0.56 $1.04 $0.75 $0.35 $0.00 $2.70 12.5%
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