Department of Biochemical- and Chemical Engineering Chair of Mechanical Process Engineering 1...

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Department of Biochemical- and Chemical Engineering Chair of Mechanical Process Engineering 1 Planning and Design of a Process for PGM Ore Dressing

Transcript of Department of Biochemical- and Chemical Engineering Chair of Mechanical Process Engineering 1...

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

1

Planning and Design of a Process for PGM Ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

2

Presentation topics Presented by

Introduction A.Chandan

Process Units

• Size reduction Ramakrishna

• Froth flotation Padala

• Pyrometallurgy Tariq

• Hydrometallurgy Kumar

Water Treatment Selva

Plant Layout B.Ravikumar

Environmental Regulation and Safety Yozi Bastian

Cost Estimation Amar

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

3

TASKTASK

Planning and Design of a Process for PGM ore Dressing

PGM Ore

PROCESS

Merensky-Reef

600 t/h

PGM

Concentrate

PGMs

50-90 %

PGMs

5.5 g/t

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

4

Material %Sand 95

Metal Oxides 2Minerals 3

Planning and Design of a Process for PGM ore Dressing

Mineral %Pyrrhotie(Fe1-xS) 75,61

Pentlandite(Fe,Ni)9S8 12,66Chalcopyrite(CuFeS2) 7,69

Pyrite(FeS2) 4Braggite((Pd,Pt,Ni)S) 0,0073PlatinumSulfide(PtS) 0,0073

Palladium Sulfide(PdS) 0,0044Laurite(RuS2) 0,0024

Erlichmanite(OsS2) 0,0002Irridium disulphide(IrS2) 0,00024

Auricupride(Cu3Au) 0,0012Rhodium Disulfide(RhS2) 0,00089

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

5

PFD3D-layout

Individual unit layout

PGMsApplications

Process block diagram

Fixed capital investmentsWorking capital (p.a)

Breakeven point

Individual process selectionProcess description

Process block diagram

TOPICS

INTRODUCTION

INDIVIDUAL UNITS

PLANT LAYOUT

COST

CONCLUSION

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

6

PERIODIC TABLE

Platinum Group Metals

1. Pt Platinum

2. Pd Palladium

3. Rh Rhodium

4. Ir Iridium

5. Ru Ruthenium

6. Os Osmium

Platinum Group Metals

1. Pt Platinum

2. Pd Palladium

3. Rh Rhodium

4. Ir Iridium

5. Ru Ruthenium

6. Os Osmium

INTRODUCTION

By: A.CHANDAN

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

7

Platinum coated computer hard drive disks.Platinum-based drugs can be used to treat a number of cancers.

Rhodium foils are used in equipment for detecting cancer.

Palladium salts are used in electroplating and in the manufacture of process catalysts.

Platinum jewellery

APPLICATIONS

PGM Ore

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

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PROCESS BLOCK DIAGRAMPROCESS BLOCK DIAGRAM

PROCESS BLOCK DIAGRAM

Froth

Flotation

Froth

Flotation

Crushingand

Grinding

Crushingand

Grinding

Roastingand

Smelting

Roastingand

Smelting

Water

treatment

Water

treatment

Off gas

treatment

Off gas

treatment

Atmospheric and

Pressure Leaching

Atmospheric and

Pressure Leaching

(Fe, Cu, Ni) sulphates

for recovery

(Fe, Cu, Ni) sulphates

for recovery

PGMs to refinery

PGMs to refinery

U’flow

Block diagram of the PGM ore concentration process

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

9

Size Reduction

By

Ramakrishna

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

10Planning and Design of a Process for PGM ore Dressing

FrothFlotation

FrothFlotation

Crushingand

Grinding

Crushingand

Grinding

Roastingand

Smelting

Roastingand

Smelting

Water treatment

Water treatment

Off gas treatment

Off gas treatment

Atmospheric and

Pressure leaching

Atmospheric and

Pressure leaching

(Fe, Cu, Ni) sulphates

for recovery

(Fe, Cu, Ni) sulphates

for recovery

PGMs to refinarey

PGMs to refinarey

U’flow

Block diagram of the PGM ore concentration process

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

11

Contents

Process Options and Selection

Equipment Selection

Crushing

Grinding

Solid-Liquid Separator

Process Flow Diagram

Design Parameters

Process Options and Selection

Equipment Selection

Crushing

Grinding

Solid-Liquid Separator

Process Flow Diagram

Design Parameters

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

12

Process Options and Selection

Run of mine to AG/SAG

Tube mill without any preliminary crushing

SIngle stage run of mine grinding

Options

Planning and Design of a Process for PGM ore Dressing

Purpose of size reduction

To liberate individual minerals trapped in rock crystals (ores) and thereby open up for a subsequent enrichment in the form of separation

To produce fines from mineral fractions by increasing specific surface

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

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Process Steps

Selection Parameters

Particle size

Reduction ratio

Power requirement

Hardness of the ore

Selection Parameters

Particle size

Reduction ratio

Power requirement

Hardness of the ore

Process steps

Stationary Screening

Primary Crushing

Secondary Crushing

Tertiary Crushing

Screening

Grinding (wet grinding)

Solid-Liquid Seperation

Process steps

Stationary Screening

Primary Crushing

Secondary Crushing

Tertiary Crushing

Screening

Grinding (wet grinding)

Solid-Liquid Seperation

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

14

Equipment Selection Selection of crushers & grinding equipment depends on

Hardness of the ore

Throughput

Operating conditions

Feed size

Capacity

Cost effective alternative

Capital & maintainance

Power

Hardness of the ore

Throughput

Operating conditions

Feed size

Capacity

Cost effective alternative

Capital & maintainance

Power

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

15

Selection of Crushers

Roll, hammer, Impact crushers are suitable for soft ore and for low capacities

For harder feed there is a choice between a gyratory and a jaw crusher

Compared to other crushers the cone crusher has some advantages

Making them very suitable for size reduction and shaping downstream a crushing circuit.

Possibilities to change feed and discharge openings during operation

Equipment Selection

Cone crusherTertiary crusher

Cone crusherSecondary crusher

Jaw crusherPrimary crusher

Crusher typeCrushing stage

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

16

Equipment SelectionSelection of Grinding Equipment

Planning and Design of a Process for PGM ore Dressing

Rod mills usually run open circuit

The selection is in between AG/SAG and ball mill.

Advantages of Ball mill

It can be used for wet or dry, wet grinding facilitates the removal of the product

Installation and power costs are low and the grinding medium is cheap and suitable for hard materials

It can be used for batch or continuous operation and also in open or closed circuit grinding

Rod mills usually run open circuit

The selection is in between AG/SAG and ball mill.

Advantages of Ball mill

It can be used for wet or dry, wet grinding facilitates the removal of the product

Installation and power costs are low and the grinding medium is cheap and suitable for hard materials

It can be used for batch or continuous operation and also in open or closed circuit grinding

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

17

Equipment Selection

Planning and Design of a Process for PGM ore Dressing

Advantages of hydrocyclones over centrifuges

Simple construction & cheaper than centrifuge Low maintenance Less space required Control of speed is easier Low energy consumption Higher efficiency with low cost can be obtained Higher capacity can be handled by operating multiple

hydrocyclones (hydrocyclone battery)

Advantages of hydrocyclones over centrifuges

Simple construction & cheaper than centrifuge Low maintenance Less space required Control of speed is easier Low energy consumption Higher efficiency with low cost can be obtained Higher capacity can be handled by operating multiple

hydrocyclones (hydrocyclone battery)

Selection of Solid-Liquid seperator

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

18

Process Flow Diagram

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

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Design Results

Planning and Design of a Process for PGM ore Dressing

Crushers Results

Crushing stage

Crusher type Particle size (mm) Power (kW)

Inlet Outlet

Primary crusher

Jaw crusher 400 134 364

Secondary crusher

Cone crusher 134 32 597

Tertiary crusher

Cone crusher (2)

32 9 373

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

20

Results

Planning and Design of a Process for PGM ore Dressing

Hydrocyclone

Number of hydrocyclones = 11

Cone angle = 20°

D50C = 92.5µ

Ball mill

7.0MWPower required

17.64rpmNc

11.47rpmN

0.65N/Nc

5.74 mD

11.48 mL

2L/d Ratio

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

21

Froth Flotation

by

Padala Subrahmanyeswara Reddy

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

22Planning and Design of a Process for PGM ore Dressing

FrothFlotation

FrothFlotation

Crushingand

Grinding

Crushingand

Grinding

Roastingand

Smelting

Roastingand

Smelting

Water treatment

Water treatment

Off gas treatment

Off gas treatment

Atmospheric and

Pressure leaching

Atmospheric and

Pressure leaching

(Fe, Cu, Ni) sulphates

for recovery

(Fe, Cu, Ni) sulphates

for recovery

PGMs to refinarey

PGMs to refinarey

U’flow

Block diagram of the PGM ore concentration process

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

23

Froth Flotation

Process Selection

Purpose

Flotation Reagents And Amounts

Flotation Machines - Selection

Flotation Circuit

Flotation Process Flow Sheet

Results

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

24

Processes

Gravity Separation or Flotation

Selection

Froth Flotation

Purpose

Minerals – 3%

Metal Oxides – 2%

Gangue(Sand) – 95%

Concentrating minerals

Froth Flotation

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

25

Froth Flotation

Flotation Reagents And Amounts

Reagent Name Amount

Collector Sodium Ethyl Xanthate

1 kg/ton of feed

Frother Pine Oil 1 kg/ton of feed

Activator Copper Sulfate 1kg/ton of feed

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

26

Froth Flotation

Flotation Machines

Outokumpu Flotation Machines

Basic Inventory is 20% lower than in a conventional plant

Low space requirements

A simple design with low maintenance cost

Low power requirements

Easy performance control

Fast froth removal

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

27

Froth FlotationFlotation Circuit

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

28

Froth FlotationFlotation Tanks Details

Equipment Time Required (min)

Percentage

Recovery

No. of cells

Rougher 15 76 5

Scavenger-1

25 50 7

Scavenger-2

25 30 7

Scavenger-3

25 15 7

Cleaner 10 66 4

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

29

Froth FlotationProcess Flow Sheet

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

30

Froth Flotation

Results

PGMs in feed = 3.28 kg/hr

PGMs in Concentrate = 2.94 kg/hr

PGMs in Tailings = 0.34 kg/hr

Percentage of Extraction = 89.5

Percentage Purity = 90

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

31

Pyrometallurgy

By

Tariq Anwar

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

32Planning and Design of a Process for PGM ore Dressing

FrothFlotation

FrothFlotation

Crushingand

Grinding

Crushingand

Grinding

Roastingand

Smelting

Roastingand

Smelting

Waste water treatment

Waste water treatment

Off gas treatment

Off gas treatment

Atmospheric and

Pressure leaching

Atmospheric and

Pressure leaching

(Fe, Cu, Ni) sulphates

for recovery

(Fe, Cu, Ni) sulphates

for recovery

PGMs to refinarey

PGMs to refinarey

U’flow

Block diagram of the PGM ore concentration process

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

3333

Contents

Roasting

Smelting

Atomization

Process flow diagram

Results

Pyrometallurgy

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

34

Roasting

Converts sulphides to oxides or sulphates

Why ?

Ore is rich in sulphides

Eliminates fugitive SO2 emissions from smelter

Produces SO2 of high concentration for Sulphuric acid production

Reduced energy consumption for smelting

Roasting eliminates drying

Roasting

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

35

Reactions

  2FeS2 + 11 O2 Fe2O3 + 4SO2 

2FeS + 3O2 2FeO + 2SO2 

2CuFeS2 + 13/2O2 2CuO + 4SO2 + Fe2O3

Feed size ~ 74 microns Operating temperature & pressure ~ 1000 °C & 1bar

Considerations

Involves gas-solid reactions

Reactions begin at the outer layer of the solid particle

Outer layers are converted into new compounds

“Ash layer” diffusion controls reaction

Roasting

)/(41 molkcal)/(3.22 molkcal)/(2.44 molkcal

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

36

Options

Multiple hearth roaster

Fluidized bed roaster

Fluidized bed advantages

Easy handling and transport of solids

 Large throughput possible        

Uniform temperature distribution

Large solid gas exchange area

Suitable for handling smaller particles

Roasting

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

37

Reduction with carbon, forming, two layers – metallic layer & slag layer

Reductant & fluxes are added to reduce metal oxides to metals

Why ?

PGM‘s are conveniently “collected” in iron based alloy

PGM losses are very low

Base metals of high purity are formed

High reaction rates

Well established process

Smelting

      

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

38

Options

A.C. (alternating current) arc furnace

D.C. (direct current) plasma arc furnace

D.C. Plasma arc furnace advantages

Can handle fines

 Dc arc is more stable than ac arc      

Simple construction (single electrode) - easy gas sealing

Very high temperatures can be attained  

Little off gas volume - less losses

Can process chromite bearing PGM ore(UG2 ore)

Planning and Design of a Process for PGM ore Dressing

Smelting

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

39

Temperatures

Off gases ~ 1100 °C

Metal & slag ~ 1600 °C

Plasma column ~ 20000 °C

Arc attachment zone ~ 2500°CRoof & walls are water cooled !

Reactions

FeO + C Fe + CO

NiO + C Ni + CO

CuO + C Cu + CO

Fe2O3 + C 2Fe + 3CO

Planning and Design of a Process for PGM ore Dressing

Smelting

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

40

Convert the hot molten metal coming from DC arc furnace into solid particles

of appropriate size for subsequent leaching step

Options

Water atomizer

Gas atomizer

Water atomizer advantages

Widely used for powders of Au, Pd, Pt, Co, Cu, Ni, & Fe

Particle size from 10 microns to few millimeters

The particles are irregular in shape

Cost effective as compared to granulation & milling

Atomization

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

41

Process flow diagram

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

42

Results

Planning and Design of a Process for PGM ore Dressing

Roaster

Height ~ 12.6 m

Diameter ~ 8.2 m

Fluidization velocity ~ 0.8 m/s

Smelter

Power consumption ~ 15.2 MW

Operating current ~ 33.6 kA

Electrode diameter ~ 473 mm

Capacity ~ 45 tonnes

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

43

Results

Planning and Design of a Process for PGM ore Dressing

Atomizer

Height ~ 3 m

Diameter ~ 1.2 m

Water flow rate ~ 16.6 Kg/s

Product size ~ 14 microns

Roastingand

Smelting

Roastingand

Smelting

0.016 % PGM’s 0.03 % PGM’s

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

44

Hydrometallurgy

by

Kumar

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

45Planning and Design of a Process for PGM ore Dressing

FrothFlotation

FrothFlotation

Crushingand

Grinding

Crushingand

Grinding

Roastingand

Smelting

Roastingand

Smelting

Waste water treatment

Waste water treatment

Off gas treatment

Off gas treatment

Atmospheric and

Pressure leaching

Atmospheric and

Pressure leaching

(Fe, Cu, Ni) sulphates

for recovery

(Fe, Cu, Ni) sulphates

for recovery

PGMs to refinarey

PGMs to refinarey

U’flow

Block diagram of the PGM ore concentration process

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

46

ContentsLeaching

Process classification

Selection of process

Block diagram

Considerations

Reactions

Equipment selection

Process flow diagram

Design parameters

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

47

Leaching

Two main steps are involved is

Contact of liquid solvent with the solid to effect transfer of solute from the solid to the solvent.

Separation of resulting solution from the residual solid.

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

48

Process Classification

Insoluble PGM residue

The base metal is dissolved leaving the PGMs in a highly concentrated residue suitable for refining

Dissolved PGM

The base metal and PGMs are dissolved together, and then subsequent separation of each metals in a sequence of hydrometallurgical operations

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

49

Selection of processAtmospheric leach

simpler to operate

cheaper

most reliable to leach the bulk

Pressure leach

To speed the dissolution of all values into the leach solution

improve the solubility rate of solids that are at best only slowly soluble at atmospheric leach.

Atmospheric leach - Iron and Nickel

Pressure oxidative leach - Copper

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

50

Considerations

Physical characterstics of the solids

Process and operating conditions

Choice of solvent

Temperature

Leaching cycle and contact method

Type of reactor

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

51

Block diagram

Planning and Design of a Process for PGM ore Dressing

Atmospheric Leaching

60°C & 1atm

Liquid/Solidseparator

PressureLeaching

110°C & 7 bar

Liquid/Solidseparator

Liquid by-product

Solid product

14 µm from

atmoizer

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

52

First step leaching

Ni(s) + H2SO4 (aq) NiSO4 (sol) + H2 (g)

)/(27.19 molkcal

Fe(s) + H2SO4 (aq) FeSO4(sol)+ H2 (g)

)/(17.24 molkcal

)/( 06.57 molkcal

Second step leaching

Planning and Design of a Process for PGM ore Dressing

Cu(s) + H2SO4(aq) + 0.5O2(g) CuSO4 (sol) + H2O (l)

Reactions

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

53

Equipment Selection

Selection Basis

Good solid-liquid mixing

High conversion

Easy to install and control

Atmospheric leach

Continous stirred tank reactor

Pressure leach

Autoclave reactor

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

54

Process flow diagram

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

55

Design parameters

Parameter C.S.T.R Autoclave

Residence time (hours)

5.15 5

Volume (m3) 40 5

L/D 1 5

Diameter (m) 3.7 5

Length (m) 3.7 1

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

56

Water treatment

By

Selva kumar

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

57Planning and Design of a Process for PGM ore Dressing

FrothFlotation

FrothFlotation

Crushingand

Grinding

Crushingand

Grinding

Roastingand

Smelting

Roastingand

Smelting

Water treatment

Water treatment

Off gas treatment

Off gas treatment

Atmospheric and

Pressure leaching

Atmospheric and

Pressure leaching

(Fe, Cu, Ni) sulphates

for recovery

(Fe, Cu, Ni) sulphates

for recovery

PGMs to refinarey

PGMs to refinarey

U’flow

Block diagram of the PGM ore concentration process

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

58

Contents

Planning and Design of a Process for PGM ore Dressing

Process selection

Block diagram

Screening

Sedimentation

Ion exchange

Process Flow Diagram

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

59

Water Treatment

Purpose of water treatment

Water conservation

reuse water

control water pollution

Purification of water

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

60

Preliminary treatment includes screening, comminution, grit

removal, oil and grease removal etc.

Primary treatment includes gravity separation, flotation, filtration,

thickener etc

Secondary treatment includes ion exchange, reverse osmosis,

adsorption etc

Tertiary treatment includes biological treatment, chemical treatment

Planning and Design of a Process for PGM ore Dressing

Process selection

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

61

Block diagram

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

62

Chair of Mechanical Process Engineering

Screening

Sedimentation

Solid-liquid separation - utilizes gravity (size and specific weight) to

remove suspended solid

Here most of gangue materials from froth tailings are removed

Sedimentation Processes - Thickening and clarification

Removing the floatable solids

Vibration screen is preferred, because

It can handle high capacity per unit area

increased accuracy of sizing & low maintenance cost

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

63

Chair of Mechanical Process Engineering

Clarification Process to remove relative amount of fine suspended particles and

produce clear effluent

For better separation of colloidal particles by gravity, it is necessary to

agglomerate them by addition of coagulants and flocculants.

Coagulants and flocculants

Coagulants- destabilization of colloidal suspension

Flocculants- agglomeration of the neutralized colloids

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

64

Inorganic coagulants

increases coagulation

But modifies the physical-chemical characteristic of the water

(conductivity, pH) and increases sludge volume.

Organic Coagulant

Polyelectrolyte is used because it reduces sludge volume and does not alter pH.

Sedimentation Unit

Tank, Drive unit, Lifting device, Rake mechanism

and Overflow and underflow arrangements

Planning and Design of a Process for PGM ore Dressing

Water Treatment

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

65

Ion Exchange

Ion exchange is a reversible chemical reaction wherein an ion from solution is exchanged for a similarly charged ion attached to an immobile solid particle

Structure of Ion –Exchange resins Ion exchange resins are made of synthetic polymer matrix

Styrene-divinylbenzene (DVB) is used as base polymer because it has well defined structure and are fully ionized over entire pH range

The organic -swellable copolymer is converted to water swellable material by the introduction of functional ionic sites

Planning and Design of a Process for PGM ore Dressing

Water Treatment

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

66

Classification of ion exchange resin

Cation exchange resins

Strong-acid exchange resins (SAC)

Weak-acid exchange resins (WAC)

Anion exchange resins

Strong-base exchange resins (SBA)

Weak-acid exchange resins (WBA)

Strong-acid cation exchange resins are prepared by sulfonating the benzene ring in the polymer

Strong -base resins are produced by amination or by

chloromethylation

Planning and Design of a Process for PGM ore Dressing

Water Treatment

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

67

Operating mode

Fixed-bed countercurrent ion exchange is preferred over co-current because,

lower leakage of ions during service

lower consumption of regenerants

decreased quantity of regenerant wastes

lower consumption of water for rinsing and backwash

Planning and Design of a Process for PGM ore Dressing

Water Treatment

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

68

Service-exchange reaction occurs, the hardness-producing ions are equally exchanged by ions,until operating capacity is reached

Back washing-prepare resin for regeneration

Regeneration-displaces exchanged ions during service run and returns the resin to desired capacity

Rinsing-ion exchange resin is rinsed free of excess regenerate before being put back into operation

Planning and Design of a Process for PGM ore Dressing

Water TreatmentSystem Operation

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

69

Process flow diagram

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

70

Process Flow Diagram & Plant Layout

By

Bolishetti

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

71

Process Flow Diagram & Plant Layout

By

Bolishetti

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

72

Process Flow DiagramProcess Flow Diagram

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

73

 

Plant Layout

The basis for 3D Layout design is

Process flow diagram

Pipe lists

Drafts of process and instrumentation diagrams

Data sheets of the main equipment

Dimensions of the construction site

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

74

Factors influencing arrangement of equipment

Process demands

safety

Pipe routing

Operability

Access to the equipment

Maintenance

Cost

Planning and Design of a Process for PGM ore Dressing

Plant Layout

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

75

Iterative sequence of plant layout

-PFD-P&ID

-Technical data sheets

-PFD-P&ID

-Technical data sheets

Placement-Design

-Optimization

Placement-Design

-Optimization

Analysis-Pipeing studies

-safety-Steel structure

-Operability-Etc.

Analysis-Pipeing studies

-safety-Steel structure

-Operability-Etc.

-Layout model-Plant layout-Pipe plan

-Layout model-Plant layout-Pipe plan

Planning and Design of a Process for PGM ore Dressing

Plant Layout

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

76

Free space

Free space

Sedimentation Tanks

Space for collecting ore

Buildings(Mensa, firestation etc)

Flotation Unit

Crushing Unit

LeachingUnit

SmeltingUnit

Control room

Storageroom

2D Layout

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

77

Flotation section 3D design

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

78

Leaching section 3D design

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

79

Environment & Safety

By

Yozi Bastian

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

80

Chair of Mechanical Process Engineering

Contents

Environmental Regulations

Off - Gas Treatment

Safety

Results

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

81

Chair of Mechanical Process Engineering

Environmental Regulations

BImSchG

Principles

remove any damage caused by air polution

any harm must be avoid

Aims

Protection against harmful effects to the environment

Licensible installation

Prevention

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

82

Environment Regulations

Pollution Types

Air Pollutants

SO2

CO

Particulates Matter

Noise Pollution

Water Pollution

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

83

Environmental Regulations

MAK-Value

Pollutants 10-min avg (g/m3)

15-min avg (g/m3)

30-min avg (g/m3)

1-h avg (g/m3)

8-h avg (g/m3)

24-h avg (g/m3)

CO   100,000 60,000 30,000 10,000  

SO2 500     250    

Dusts           120

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

84

Gas Treatment

Planning and Design of a Process for PGM ore Dressing

SO2 Treatment

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

85

Chair of Mechanical Process Engineering

Gas Treatment

Planning and Design of a Process for PGM ore Dressing

CO Treatment

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

86

Environmental Regulations

Sources of noise and vibration

Furnaces

Electric motors

Belt conveyors

Pumps

Compressors

Crushers and mills

Fan

Typical Sound Levels at the Workplace limit 85 dB

Planning and Design of a Process for PGM ore Dressing

Regulation of noise

By constructing the equipment in a closed buildings

Making insulation

Maintenance

Grinders are arranged in a special building.

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

87

Safety

Introduction

Chemical plants contain a large variety of hazards

Safety layer

Automatic actions

Automatic actions

Physicalprotection

Physicalprotection

Plant emergency response

Plant emergency responsecommunity emergency

response

community emergency response

Controls and alarms

Controls and alarms

Processdesign

Processdesign

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

88

Safety

Planning and Design of a Process for PGM ore Dressing

C.S.T.R

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

89

Pressure across bag house

2000 Pa

Superficial gas velocity

0.05 m/s

Area required for filtration

2130 m2

Length of one bag 5 m

Number of chambers

22

Vertical height of plates

5 m

Horizontal length of plates

5 m

Wire Diameter 0,0025 m

Distance plate to plate

0,3 m

Collection Area 454,78 m2

Number of plates 11 plates

Gas Treatment Results

Planning and Design of a Process for PGM ore Dressing

Baghouse Filter ESP

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

90

Cost Estimation and Overall Review

By

Amarnath Reddy

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

91

Cost Estimation

Contents

Estimating Fixed capital cost

Estimating Total production cost/annum

Income incurred per year

Pay back period

Analysis

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

92

Cost Estimation

Total Capital Investment

Fixed Capital Investment Working Capital Investment

Direct Costs Indirect Costs

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

93

Total capital investment

Fixed capital investment = P.E.C+O.D.C+I.D.C+Contingencies

P.E.C=Purchases Equipment Cost

O.D.C=Other Direct Costs

I.D.C=Indirect Cost

Planning and Design of a Process for PGM ore Dressing

Total capital investment=Fixed Capital investment+Total production costs

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

94

Purchased Equipment costUnits Purchased Equipment cost

Million $

Communition 10.55

Flotation 8.49

Pyrometallurgy 6

Hydrometallurgy 1.72

Thickening and filtering 0.89

water treatment 6.3

Conveying 0.23

Pumps 0.74

Total P.E.C 35,8

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

95

Other Direct CostsPurchased EquipmentInstallationInsulation

Instrumentation and Controls

Piping

Electrical Installations

Building Including Services

Yard Improvements

Service Facilities

Land

45% PEC

9%PEC

13%PEC

31%PEC

13%PEC

47%PEC

15% PEC

30%PEC6%PEC

O.D.C=$118million

Other Direct costs

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

96

Production Costs

Manufacturing Costs = Direct Production Costs + Fixed Charges +

Plant Overhead Costs

Total Product Cost = Manufacturing Cost + General Expenses

Direct Production Costs million $/year

Raw Materials 206,4Operating Labor 10

Supervisory & clerical labor 1,5Electricity 22,5

Maintenance and Repairs 9,8Operating Supplies 1,46

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

97

Fixed Chargesmillion $/year

Depreciation Rate 16,30Local Taxes 4,80

Insurance 1,60

Plant Overhead Costs

Plant Overhead Costs 12,80

General Expenses

Administrative Costs 2,50Research and Development 15,20

Production Costs

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

98

Production Costs

Raw Materials (58.4 %)

Other Direct ProductionCosts(21.5%)

Fixed Charges (6.5%)

Plant Overhead Costs (7.9%)

General Expenses (5.7%)

58.4%

21.5%6.5%7.9%

5.7%

Total Production cost =$305million

Working capital/annum

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

99

SUMMARY

Details Costs in $ millions

Purchased Equipment cost 35.8

Other Direct Costs 118.1

Indirect Costs 29.3

Fixed capital investment 163

Manufacturing costs 287.8

General Expenses 17.2

Total Production Costs 305

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

100

Income incurred /year

Number of kgs Produced/year = 22817 kg/year

Selling price Per Kg = $ 17000 per kg

Gross Earnings = Total Income – Total Product Cost = $ 82.6 million

Net Profit = Gross Earnings – Taxes = $ 61,9 million/year

Cost analysis

maintenance cost increases every year by 5%

50% of the initial investment is from banks

30% from the share holders

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

101

Analysis

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

102

Analysis

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

103

Analysis

Planning and Design of a Process for PGM ore Dressing

The Pgms Price is expected to be 2005

The pay back period

The pay back period for share holder

Bank installment clearence

= $25000 per kg

= 3 years for the owners

= 4 years

= 5 years

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

104

Overall Review Overall Review

Planning and Design of a Process for PGM ore Dressing

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

105

Overall review

Planning and Design of a Process for PGM ore Dressing

Advantages of our process

It can handle Chromite bearing ores too.

Off gas can be directly sold with minimum treatment

it is an economically feasible plant because break even point is just around 3 years

99Hydrometallurgy

96Pyrometallurgy

89.5Concentration

% Pgms RecoveryUnit

Final Concentration of PGM is 57%

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

106

Planning and Design of a Process for PGM ore Dressing

Tutors

Dr.-Ing. Helmut Wiggers

Dipl.-Ing. Frank Landwehr

Dipl.-Ing. Daniel Feggeler

Dipl.-Ing. Sascha Groom

Tutors

Dr.-Ing. Helmut Wiggers

Dipl.-Ing. Frank Landwehr

Dipl.-Ing. Daniel Feggeler

Dipl.-Ing. Sascha Groom

Thankyou very much

Reference

Prof. Dr. techn. Peter Walzel

Co-reference

Prof. Dr. Gabriele Sadowski

Reference

Prof. Dr. techn. Peter Walzel

Co-reference

Prof. Dr. Gabriele Sadowski

Department of Biochemical- and Chemical Engineering

Chair of Mechanical Process Engineering

107

Planning and Design of a Process for PGM ore Dressing