The Laboratories of the Chair of Mineral Processing · Aufbereitung sterreichin Ö iii 257...

7
A UFBEREITUNG IN Ö STERREICH III 257 A UFBEREITUNG IN Ö STERREICH III – D EKADENBERICHT 2005 BIS 2015 n The Laboratories of the Chair of Mineral Processing Andreas Böhm INTRODUCTION Since April 2011 the laboratories of the Chair of Mineral Pro- cessing have been situated on the first and second floor of the so-called Impulszentrum Rohstoffe (IZ-Rohstoffe) Montanuniversitaet Leoben Rosseggerstrasse 11a A-8700 Leoben The laboratories are equipped to experimentally cover all the main aspects of comminution, physical and physico-chemical separation techniques as well as agglomeration related to pri- mary and secondary materials below a particle size of 40 mm. Samples of bigger particle size are prepared at selected crush- ing sites, sampled and transported to the lab. Depending on the units to be used in the technical center the maximum sam- ple mass reaches 1000 kg (for vertical roller mill and electro- static separator; maximum throughput rate mill 200 kg/h). The typical sample size, however, ranges from 20 to 50 kg. The physical laboratories for ore characterization (incoming samples) and efficiency evaluation of separation processes (products of tests and technical processes) are designed to op- erate on average sample masses smaller than 5 kg. Apart from measuring size and specific surface, the main interest focuses on the evaluation of the distributions of physical properties of particle sets (like magnetic susceptibility, density and termi- nal velocity), the viscosity of slurries, optical microscopy in transmitted and reflected light and wet assays (especially iron). Automated mineralogy with respect to intergrowth analysis is done in cooperation with LKAB’s research center in Malmberget. We receive the QEMSCAN raw data and evaluate them by image analysis software at the Chair. Most of the flotation experiments are also performed at small scale of up to 2 l of suspension in order to search for the opti- Figure 1: Left: street view of the IZ-Rohstoffe; looking northeast the reader watches the southern and western front (long side). Right: longitudinal section; yellow-shaded frame indicates the Mineral Processing laboratories mum reagents regime. A large collection of surfactants, froth- ers and activators help to solve scientific and industrial prob- lems. The general technical figures of the technical center and the labs are summarized in table 1. The non-scientific staff comprises three members trained in physical testwork and a mechanic responsible for test rig con- struction, electrics and maintenance. The scientific develop- ment as well as the education on the apparatus of staff mem- bers and also students is mainly the responsibility of the author. This includes selection of methods and new equip- ment as well as calibration of measurement devices. The lab is open to use for all members of the Chair, who are trained in handling the apparatus and in the related safety affairs. Pro- ject partners are welcome to accompany the tests.

Transcript of The Laboratories of the Chair of Mineral Processing · Aufbereitung sterreichin Ö iii 257...

Page 1: The Laboratories of the Chair of Mineral Processing · Aufbereitung sterreichin Ö iii 257 Aufbereitung in Österreich iii – D eK AD enbericht 2005 bis 2015 n The Laboratories of

Aufbereitung in Österreich i i i 257

Aufbereitung in Österreich i i i – DekADenbericht 2005 bis 2015 n

The Laboratories of the Chair of Mineral Processing

Andreas Böhm

INTRODUCTION

Since April 2011 the laboratories of the Chair of Mineral Pro-cessing have been situated on the first and second floor of the so-called

Impulszentrum Rohstoffe (IZ-Rohstoffe)Montanuniversitaet Leoben Rosseggerstrasse 11aA-8700 Leoben

The laboratories are equipped to experimentally cover all the main aspects of comminution, physical and physico-chemical separation techniques as well as agglomeration related to pri-mary and secondary materials below a particle size of 40 mm. Samples of bigger particle size are prepared at selected crush-ing sites, sampled and transported to the lab. Depending on the units to be used in the technical center the maximum sam-ple mass reaches 1000 kg (for vertical roller mill and electro-static separator; maximum throughput rate mill 200 kg/h). The typical sample size, however, ranges from 20 to 50 kg. The physical laboratories for ore characterization (incoming samples) and efficiency evaluation of separation processes (products of tests and technical processes) are designed to op-erate on average sample masses smaller than 5 kg. Apart from measuring size and specific surface, the main interest focuses

on the evaluation of the distributions of physical properties of particle sets (like magnetic susceptibility, density and termi-nal velocity), the viscosity of slurries, optical microscopy in transmitted and reflected light and wet assays (especially iron). Automated mineralogy with respect to intergrowth analysis is done in cooperation with LKAB’s research center in Malmberget. We receive the QEMSCAN raw data and evaluate them by image analysis software at the Chair.Most of the flotation experiments are also performed at small scale of up to 2 l of suspension in order to search for the opti-

Figure 1: Left: street view of the IZ-Rohstoffe; looking northeast the reader watches the southern and western front (long side). Right: longitudinal section; yellow-shaded frame indicates the Mineral Processing laboratories

mum reagents regime. A large collection of surfactants, froth-ers and activators help to solve scientific and industrial prob-lems. The general technical figures of the technical center and the labs are summarized in table 1.

The non-scientific staff comprises three members trained in physical testwork and a mechanic responsible for test rig con-struction, electrics and maintenance. The scientific develop-ment as well as the education on the apparatus of staff mem-bers and also students is mainly the responsibility of the author. This includes selection of methods and new equip-ment as well as calibration of measurement devices. The lab is open to use for all members of the Chair, who are trained in handling the apparatus and in the related safety affairs. Pro-ject partners are welcome to accompany the tests.

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The challenge in operating a university laboratory is to pro-vide both a fully equipped scientific laboratory with best suit-ed measurement devices of defined accuracy and to educate our young students to make them future experts in mineral processing.

THE VISION

Every material intended for comminution and/or physical separation and/or agglomeration has its special features, pro-viding the link to the unique technical process needed to ob-tain economically successful products. It needs the thorough understanding of intergrown phases locked in irregular shaped particles on one hand and the special behavior of the technical apparatus on the other in order to succeed in the operation of a technical comminution or separation process.Careful experimental work thus forms the base at the begin-ning of all physical processing activities irrespective whether

science, plant/apparatus design or plant/apparatus optimiza-tion of special raw materials are in the focus. Apart from developing experimental methods, the main sci-entific idea behind the lab is to search for unambiguous fig-ures to characterize the material as well as the machinery in order to understand their physical interaction with respect to processing. This should lead to physically based and techni-cally reliable models for the prediction of the separation and comminution results and the selection and design of full scale equipment. Although the Chair also operates equipment at pilot scale size, it is the general intention to use test rigs at the smallest scale possible that allows the physical modelling of the real scale process. The low amount of sample mass needed keeps measurements accurate and cheap, avoids cross-contamina-tion of samples and intensive maintenance, helps to keep the tests safe and reduces efforts for environmental protection. Last but not least this allows accurate work within a reason-able time frame.

AREA, HEIGHT Processing technical center 1. Dry comminution and sample preparation (h: 7.5 m)2. Wet processing (h: 7.5 m)3. Magnetic separation and agglomeration (3.2 m)4. Drying (3.2 m)5. Electrostatic separation (7.5 m)

200 m², h: 7.5 m and 150 m², h: 3.2 m

Processing labs 1. Physical lab 2. Optical microscopy3. Chemical lab and wet assay4. Bentonite lab

166 m², h: 3.2 m

Climate chamber 1(electrostatic separation) 28 m², T: 20–60 °C

Climate room (bentonite lab) 18 m², T: 20–30 °C

SUPPLY Water 2.5 m³/h

Gas (methane) 3.6 m³/h

Pressurized air 6 bar

Direct current 100 V, 10 A

Alternating current 300 kVA

Dedusting 500–1500 m³/h

Travelling crane load capacity 5000 kg

Hoist load capacity 6300 kg

Sedimentation pool 11 m², 2.4 m³

Sample storage 50 m³

Table 1: General technical data of the technical center and the labs

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Apart from the scientific claim, the small scale tests allow a wide variation of parameters from which the most promising test conditions are selected to confine expensive pilot scale tests.

THE PERMANENT EQUIPMENT

The following section shall give a short overview over the main permanently installed test rigs as of September 2015. Additionally, a special area in the main hall is reserved for non-persistent test rig installations combining the permanent apparatus of the Chair with rented or borrowed units from industrial partners.The technical center is equipped for dry comminution test-work with focus on the elaboration of the crushing and grind-ing characteristics of the material. As far as the stress condi-tions impact and compression are dominant, lab scale equipment is sufficient, whereas for compression and friction we had to change to pilot scale to simulate industrial condi-tions on a vertical roller mill. In all cases the scientific evalu-ation is based on the mechanical measurement of the energy input from grinding tools into the material via torque with the most suitable equipment. Special test routines combined with dispersity evaluation at analytical accuracy allow for commi-nution at highest energy efficiency. The energy and dispersity data thus are clearly defined and traceable in order to provide a reproducible base for ore characterization, intergrowth analysis and benchmarking of the efficiency of industrial comminution tools. Screening and classification at pilot scale are done by a tum-bling screen (Allgaier; particle size: –14 +0.063 mm), an air cross flow separator (CEMTEC; top cuts between 150 µm and 20 µm) and cyclone test rigs (40 µm to 2 µm cut-size).The separation equipment at the technical center focuses on density separation as well as magnetic and electrical separa-tion. Flotation at pilot scale recently started by the implemen-tation of a flotation column. There are jigs for sizes below 15 mm available as well as a drum separator for heavy media separation and a HMS cy-clone test rig for feed size range between 8 mm and 0.5 mm in cooperation with VA Erzberg GmbH. Lab scale shaking

tables and (ore) spirals at technical scale close the gap for density separation in the size range between 0.04 mm and 2 mm.Magnetic separators for dry magnetic separation operate from low intensity (size range: –5 +0.04 mm; 0.01–0.08 T), variable intensity (two induction roll separators by Wedag and Carpco; –2 mm +0.1 mm; 0.1–1.8 T) and high intensity (IFE roll separator: 0.8 T; size range –8 mm +0.2 mm; IFE drum separator: 0.35 T; size range –20 mm +0.2 mm). Tests for wet low intensity magnetic separation can be committed with a lab scale Sala drum separator. Recently research work on a lab scale matrix separator in dry and wet mode including prototype development has begun. The electrostatic free fall separator by Hamos with an elec-trode area of 2 m² is located in a special climate chamber for temperature and moisture control.As the trend in mineral processing goes to ever more chal-lenging raw materials (low grade and/or heavily intergrown ores, slags) that cannot be utilized in the fine state they have to be ground to for upgrading, research interest is also put on agglomeration. The lab is equipped with lab scale apparatus for binder research comprising an Eirich high shear mixer (10 l), pelletizing discs and drums (up to 0.62 m diameter), equipment for quality testing of the green pellets (e.g. poros-ity, water saturation) and a load cell for testing the compres-sive strength of green, dry and hardened pellets. A prototype of a down draft mini pellet pot (2 kg of pellets, temperature range from ambient to 1500 °C, electrical and gas power sup-ply) for material testing of pellets at temperature conditions close to industrial rates was developed. Tables 2 to 5 summarize the majority of the standard tests available. Nevertheless there are numerous additional test procedures that can be especially tailored to the needs of the customer to solve specific problems. A discussion with the scientists of the Chair of Mineral Processing helps to reveal the best fitting approach.

Figure 2: View into the physical lab (left); VRM 200 in the technical center (right)

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n Aufbereitung in Österreich i i i – DekADenbericht 2005 bis 2015

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Aufbereitung in Österreich i i i – DekADenbericht 2005 bis 2015 n

Tabl

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Sta

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II: G

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Size

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[mm

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15 m

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set

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coo

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tion

with

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nly

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mm

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tatio

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was

te m

ater

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Siz

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strib

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Pel

lets

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size

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Dro

p te

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siz

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Com

pres

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siz

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Por

osity

in s

ize

clas

ses

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0 (M

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mer

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®)

Wat

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atur

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Net

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ace(

" sin

gle

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n")

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i pel

let p

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ts, t

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re p

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cord

ing

to in

dust

rial p

lant

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test

ing

of b

inde

rs a

nd a

dditi

ves

at v

aryi

ng te

mpe

ratu

res,

pre

para

tion

of re

gula

r pot

te

sts

Load

cel

l, fo

rce

and

spee

d co

ntro

lled;

max

imum

looa

d 50

00 N

, mes

sphy

sik

*) c

alcu

late

d m

eans

: der

ivat

ion

of B

ond´

s in

dex

from

mea

sure

d en

ergy

val

ues

and

size

val

ues.

In B

ond´

s m

etho

ds e

nerg

y is

not

mea

sure

d bu

t dep

ends

on

the

stric

t ap

para

tus

setu

p. O

ur m

ills a

re n

ot s

trict

Bon

d m

ills

Indu

ratio

nTe

sts

Ener

gy c

ontr

olle

d gr

indi

ng te

sts

(dry

),

Com

pres

sive

stre

ngth

of i

ndur

ated

pel

lets

Test

Gre

en P

elle

tizin

gTe

sts

grin

dabi

lity,

Grin

ding

B

ehav

ior

Pelletizing Tests

Quality Evaluation

Met

hod

2.00

0 to

50.

000

0.63

m d

iam

eter

pel

letiz

ing

disc

or d

rum

; adj

suta

ble

spee

d

Ene

rgy

valu

es fo

r mill

desi

gn: i

n co

oper

atio

n w

ith s

uppl

iers

rolle

r mill

VR

M 2

00 C

EMTE

C w

ith e

nerg

y m

easu

rem

ent b

y to

rque

rod,

and

3 m

odes

of

ope

ratio

n: K

olle

r Gan

g, c

lass

ic ro

ller m

ill w

ith in

tern

al a

ir cl

asss

ifier

and

byp

ass

of

coar

se m

ater

ial o

f the

cla

ssifi

er

Indu

ratio

n of

dry

pel

lets

acc

ordi

ng to

a te

mpe

ratu

re p

rofil

e

Ela

bora

tion

of th

e su

rface

dev

elop

men

t vs.

Cum

ulat

ive

ener

gy s

uppl

ied

Page 6: The Laboratories of the Chair of Mineral Processing · Aufbereitung sterreichin Ö iii 257 Aufbereitung in Österreich iii – D eK AD enbericht 2005 bis 2015 n The Laboratories of

262 Aufbereitung in Österreich i i i

n Aufbereitung in Österreich i i i – DekADenbericht 2005 bis 2015

Sam

ple

Size

Gra

in S

ize

[g]

[mm

]

Sw

ellin

g in

dex

(I.B

.O F

P-0

3/20

03)

wat

er a

dsor

ptio

n, E

nslin

Nef

f - te

st (I

.B.O

. FP

-02/

2003

)

Met

hyle

ne b

lue

test

(VD

G P

35, I

.B.O

. 02/

2003

, I.B

.O. 0

3/20

03)

OC

MA

Test

, vis

cosi

tyA

PI S

Pec

13A

/Iso

1350

0)

moi

stur

e co

nten

t

Haa

ke R

heos

tress

600

Rhe

owin

VT

550

capi

llary

vis

osim

eter

for s

uspe

nsio

ns

perm

anen

t ava

ilabl

e S

EPA

RA

TIO

N e

quip

men

t

labo

rato

ry d

rum

test

s up

to 5

0 l

20.0

00 g

- 30

mm

heav

y m

ediu

m c

yclo

n te

strig

, cy

clon

e: D

6B-1

2 -8

39, 1

90 m

m d

iam

eter

, 18

- 30

m³/h

vol

ume

stre

am, s

tirre

d su

mp

50.0

00 g

+ 0,

3 - 1

5 m

m

jig, S

iebt

echn

ik- 1

6 m

m

lab

shak

ing

tabl

es1)

. 1 K

rupp

: K 1

794

250

x 50

0 m

m; 2

).1 7

50 x

100

0 m

m 1

0.00

0 g

- 1 m

m +

0,04

mm

spira

ls1

Kre

bs o

re s

pira

l, m

ediu

m, 1

org

inal

Hum

phre

ys s

pira

l- 2

mm

+0,

2 m

m

lab

drum

sep

arat

or, a

djus

tabl

e fie

ld v

ia c

oil c

urre

nt 0

,005

- 0,

06 T

dry

som

e 10

.000

- 5 m

m

lab

drum

sep

arat

or, S

ALA

TU 1

488/

0 20

0 m

m d

rum

dia

met

erw

etso

me

10.0

00- 1

mm

indu

ctio

n ro

ll se

para

tor s

; Car

pco

MIH

(13)

111

-5; 0

,1 -

1 T

dry

som

e 10

.000

- 2 m

m +

0,1

mm

indu

ctio

n ro

ll se

para

tors

Wed

AG i-

1-15

0, 0

,1 -

1,4

Tdr

yso

me

10.0

00- 2

mm

+ 0

,1 m

m

dry

som

e 10

.000

- 8 m

m +

0,1

mm

dry

- 20

mm

+ 0

,1 m

m

wet

depe

nds

on m

atrix

type

lab

scal

e ro

ll se

para

tor,

Car

pco

HP

-167

-MC

arpc

odr

y- 2

0 kV

Ham

osdr

y- 1

00 k

V

Den

ver D

-1 la

b ce

ll, re

agen

t tes

ting

elab

orat

ion

of re

agen

t sys

tem

in 1

- 3 l

cells

lab

colu

mn

cell:

D =

80

mm

; L =

2,5

m

Zeta

pot

entia

l m

easu

rem

ent

stre

amin

g po

tent

ial;

EK

A An

ton

Paa

r ; e

lect

roph

ores

is

bent

onite

ch

arac

teriz

atio

n

Test

Met

hod

perm

anen

t mag

netic

roll

sepa

rato

r, ro

ll di

amet

er: 0

,08

m; w

idth

: 0,2

5 m

IFE

KP

250

-1, 0

,7 T

perm

anen

t mag

netic

dru

m s

para

tor;

0,6

x 0,

6 m

, 0,3

5 T

mat

rix s

epar

ator

rese

arch

dry

mag

netic

mat

rix s

epar

ator

EM

S 5

00, f

ree

fall

sepa

rato

r, cl

imat

e ch

ambe

r

elec

tros

tatic

se

para

tion

visc

osity

flota

tion

+1m

m

HIM

S

Mag

netic

sep

arat

ion

LIM

S

-1 m

m

dens

ity s

epar

atio

n

Tabl

e 4:

Sta

ndar

d te

sts II

I: B

ento

nite

testi

ng a

nd se

para

tion

tests

Page 7: The Laboratories of the Chair of Mineral Processing · Aufbereitung sterreichin Ö iii 257 Aufbereitung in Österreich iii – D eK AD enbericht 2005 bis 2015 n The Laboratories of

Aufbereitung in Österreich i i i 263

Aufbereitung in Österreich i i i – DekADenbericht 2005 bis 2015 n

Tabl

e 5:

Add

ition

al e

quip

men

t

Sam

ple

Size

Gra

in S

ize

[g]

[mm

]

dryi

ngm

ini p

elle

t pot

test

rig

for d

own

draf

t dry

ing

mix

ing

high

inte

nsity

mix

er, E

irich

R 0

2 E

, 5 l

< 10

.000

- 5

mm

tube

furn

ace

used

for h

eate

d pe

rmea

ted

parti

cle

bed

test

s w

ith o

ff ga

s co

mpo

sitio

n m

easu

rem

ent

muf

fle fu

rnca

e, N

aber

ther

m L

/15/

12

mea

sure

men

t sys

tem

sel

ectri

cal p

ower

; off

gas

com

posi

tion

Test

o 35

0 M

(SO

2, O

2, C

O, C

O2,

NO

x),

clim

ate

cham

bers

Test

Met

hod

2 cl

imat

e ch

ambe

rs/ r

oom

s: 1

. P

A-O

CA

71a-

H/R

407

150

m³;

moi

stur

e: 1

0 - 6

0 %

, Tem

pera

ture

: 5 -

60 °

C;2

. 32

m³,

defin

ed m

oist

ure

for e

.g. p

elle

tizin

g te

sts

addi

tiona

l fur

nace

s