Mineral Processing

Beneficiation Operations and Process Optimization through Modeling

1st Edition - January 21, 2023
Imprint: Elsevier
Editors: Rajendran Sripriya, Ch VGK Murty
Language: English
Paperback ISBN:
9 7 8 - 0 - 1 2 - 8 2 3 1 4 9 - 4
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 2 3 1 5 0 - 0

Mineral Processing: Beneficiation Operations and Process Optimization through Modeling is written for both individuals working in industry as well as students. Processing technique… Read more

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Mineral Processing: Beneficiation Operations and Process Optimization through Modeling is written for both individuals working in industry as well as students. Processing techniques for the recovery or extraction of a particular mineral are largely dictated by the physical, chemical, and mineral characteristics of that particular mineral. The design of the process flow sheet and the configuration of the circuit can vary from situation to situation, as well, and this book guides readers in formulating those flow sheets for various minerals in order to assist in selecting the right equipment for the process. The book serves as a guide to mineral processing plant engineers for flow sheet development of various minerals, including coal and steel plant waste. It additionally includes alternative flow sheets and process routes for plant design.

Cover Image
Title page
Table of Contents
Copyright
Dedication
List of contributors
Foreword
Preface
Acknowledgment
Chapter 1. Coal beneficiation: theory and practice
Abstract
1.1 Introduction
1.2 Geology and occurrence of coal
1.3 Formation of coal
1.4 Coal rank
1.5 Coal beds
1.6 Coking and noncoking coal
1.7 Metallurgical coal blends
1.8 Coal mining and the environment
1.9 Modes of coal transport
1.10 General testing procedure for coal pertaining to beneficiation
1.11 Coal beneficiation
1.12 Generic description of coal preparation plant
1.13 Broad input and output design parameters in coal washery
1.14 Brief system description of high/medium coking coal washery
1.15 Environment management
1.16 Quality monitoring and control
1.17 Instrumentation and control systems
1.18 Guideline to plant availability, material and power consumption in a coal beneficiation plant
1.19 Operational problems and mitigating measures in a coal washing plant
1.20 Conclusions
References
Chapter 2. Iron ore beneficiation: an overview
Abstract
2.1 Introduction
2.2 Geology and occurrence
2.3 Mining methods
2.4 Beneficiation methods
2.5 Operating practices
2.6 Summary
References
Chapter 3. Chromite ore beneficiation: prospects and challenges
Abstract
3.1 Introduction
3.2 Ore genesis
3.3 Mining
3.4 Characterization
3.5 Beneficiation
3.6 Research & development
3.7 Effluent treatment processes
3.8 Cost structure for the chromite ore beneficiation plant
References
Further reading
Chapter 4. Beneficiation of bauxite ores
Abstract
4.1 Introduction
4.2 Refining of bauxite ore for alumina production
4.3 Bauxite ore resources
4.4 Bauxite mining practices
4.5 Geology of bauxite deposits
4.6 Characterization of bauxite ores
4.7 Beneficiation of bauxite ores
4.8 Pilot trials for developing beneficiation flowsheet
4.9 Impact of different bauxites on the Bayer process
4.10 Major alumina refinery plants in India and abroad
4.11 Bayer process technology
4.12 Capital investments, Operating cost, and techno-economical viability for green-field refinery
4.13 Sustainability challenges
4.14 Concluding remarks
Acknowledgments
References
Chapter 5. Beneficiation of mineral sands: a practical outlook
Abstract
5.1 Introduction
5.2 Geology
5.3 Mining
5.4 Processing
5.5 Processing of heavy mineral ore
5.6 Factors influencing mineral sand processing
5.7 Tailing’s disposal
5.8 Metallurgical accounting system
5.9 Data collection, validation, and management
5.10 Reconciliation, balancing and reporting
5.11 Metal accounting system
5.12 Record keeping
5.13 Methodology to develop a mineral sands project
5.14 Economic uses
5.15 Resource characteristics
5.16 Availability and cost of utilities
5.17 Conclusion
Acknowledgements
Further reading
Chapter 6. Addressing an inverse problem of classifier size distributions
Abstract
6.1 Introduction
6.2 Analytical solution to the Classifier product size distributions
6.3 Validation of the proposed analytical expressions
6.4 Pivot phenomenon and difference similarity of the classifier distributions
6.5 Classifier inverse problem
6.6 Parameter sensitivity analysis
6.7 Conclusions
Acknowledgments
References
Chapter 7. Numerical methods in mineral processing: an overview
Abstract
7.1 Introduction
7.2 Discrete Element Modeling (DEM)
7.3 Population Balance Modeling (PBM)
7.4 Computational Fluid Dynamics (CFD) modeling
7.5 Conclusions
References
Chapter 8. Computational fluid dynamic modeling of hydrocyclones
Abstract
8.1 Introduction
8.2 Computational methodology
8.3 Two-phase flow predictions
8.4 Multiphase flow predictions
8.5 Conclusions
Acknowledgements
Abbreviations
References
Chapter 9. Numerical modeling of dense medium cyclones
Abstract
9.1 Introduction
9.2 Computational fluid dynamics approach for dense medium cyclone modeling
9.3 Rheology modeling
9.4 Numerical modeling
9.5 Results and discussion
9.6 Using computational fluid dynamics to improve dense medium cyclone performance
9.7 Conclusions
Acknowledgments
Abbreviations
References
Chapter 10. Froth flotation and its modeling aspects
Abstract
10.1 Introduction
10.2 A brief description of flotation reagents
10.3 Concepts of grade and recovery
10.4 Smelter contract and economic sustenance
10.5 Flotation kinetics
10.6 Some standard flotation testing procedures
10.7 Data reconciliation
10.8 Residence time distribution
10.9 Entrainment
10.10 Industrial mechanical cells
10.11 Effect of mechanism profile on the mineral upgradation
10.12 Brief description on flotation circuit process modeling
10.13 Final remarks
Acknowledgments
References
Chapter 11. Mathematical modeling of mineral jigs
Abstract
11.1 Introduction
11.2 Test work and grade-yield-recovery curves
11.3 Effect of head grade on the jig performance
11.4 Timed batch jig tests and attainment of dynamic equilibrium of particles in the jig bed
11.5 Jig Stratification Index
11.6 Jig bed kinetics and bed assay evolution
11.7 Kinetics of particle size segregation in a batch jig
11.8 Jig types
11.9 Jig wave forms
11.10 King's stratification model
11.11 Application of King's stratification model to the continuous performance of an industrial jig
11.12 Simulation studies of King’s stratification model for batch jig operation
11.13 Simulation studies of King’s stratification model for continuous jig operation
11.14 Partition surface
11.15 Size-density bivariate distributions and their characteristics
11.16 Extended King’s stratification model
11.17 Control of industrial Batac jig performance
11.18 Challenges ahead
Acknowledgments
References
Index

Rajendran Sripriya

Dr R.Sripriya holds a doctorate in Minerals Engineering. She joined R&D, Tata Steel India as a Research Engineer trainee in 1990. At R&D, her work focussed on the investigation of multiphase flow in industrial processes, combining experimental work and numerical modelling as a tool for equipment evaluation and design. She is presently a Principal Scientist in Tata Steel Europe, Netherlands. In her 25 years of professional career spread across India and Europe, Dr. Sripriya has developed a number of process flow-sheets for iron and steelmaking processes and solid waste utilisation. The body of her work aggregates into seven registered patents, apart from several international papers and publications. In the area of numerical modelling, her research focus has been on multiphase modelling of industrial processes like the galvanising bath, the continuous caster, the hydrocyclones and the dense medium cyclones. Most recently, she has been involved in developing a new industrial scale design for the HIsarna Plant using CFD in the Ijmuiden operations in Netherlands, a new iron making technology that reduces the carbon footprint,and produces hot metal directly from coal and iron ore fines. In the process, it bypasses the conventional use of coke and sinter in an integrated steel plant.

Affiliations and expertise

Principal Scientist, Tata Steel Europe, The Netherlands

Ch VGK Murty

Dr.Ch.V.G.K.Murty is the Director (Projects) at M/s.Saraf Agencies Private Limited. Dr. Murty holds a doctorate in Chemical Engineering, and post grad degree in Mineral Process Engineering. He served for 3 years in Hindusthan Zinc Limited as an Engineer (Ore Dressing) in the area of Lead – Zinc beneficiation, before joining Ferro Alloys Corporation (FACOR) as an Assistant Plant Superintendent and working in the area of Chrome Ore Beneficiation. He joined Tata Steel in 1988 as an R&D Engineer where he was involved in various activities in the area of beneficiation of raw materials with particular reference to iron ore, limestone, coal, chromite, manganese, steel plant wastes, etc.. After working for almost 20 years with Tata Steel at various levels, Dr.Murty joined M/s.Trimex Sands Pvt Limited as CEO to lead a green field project starting from erection to commissioning. He was also involved in the development of another green field project starting from the concept to Bankable feasibility including detailed engineering. He has published approximately 50 papers and has 2 patents to his credit.

Affiliations and expertise

Director (Projects), M/s.Saraf Agencies Private Limited, India

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