INTRODUCTION TO MINERAL PROCESSING Dr.

Nimal Subasinghe Senior Lecturer in Mineral Processing Murdoch University

Mineral production worth $17 billion in 2000-200 (Agriculture $4.4 billion nWA a world-ranked producer of
Alumina Iron ore Nickel Rutile Tantalum Zircon Diamonds Gold 20% 14% 14% 38% 25% 32% 38% 8%

Where do metallurgists fit in mining industry?

Exploration and discovery Geologists. Mine Planning & Mining operations Mining engineers and mine geologists. Ore-to-metal Process Development Extractive metallurgists. Financial specialists - Construction and capital expenditure; sale of product.

Metallurgists add value to mineral resources

Extractive metallurgy is about processing ores to

Liberate and concentrate valuable minerals.

Chemically break down minerals to extract and refine contained metals

Extractive metallurgy bridges science and engineering

Ore-to-metal path involves Mineralogical studies Mineral processing Metal extraction & refining Pyrometallurgy Hydrometallurgy

Ore Minerals

Ore-to-metal

Mineralogy
Pyrrhotite ~ FeS Pyrite FeS2 Chalcopyrite CuFeS2

Ore grade 3% Ni
Pentlandite (Ni,Fe)9S8

STAGES IN MINERAL PROCESSING

RUN-OF MINE MATERIAL COMMINUTION (MINERAL LIBERATION) PRODUCT HANDLING SEPARATION PROCESSES (CONCENTRATION) PROCESS CONTROL

CONCENTRATE

Mineral Liberation

Comminution Circuits
Jaw Crushers Gyratory Crushers

Primary Crushing

Secondary Crushing Grinding

Cone Crushers Hammer mills Rod mills, Ball mills

SAG milling

Screening / Classification

Schematic Diagram of a Gyratory Crusher

Schematic Diagram of a Ball mill

Separation Processes Gravity Concentration

Dense medium Vessels Dense Medium Cyclones Jigs Spirals Reichert Cones Wilfley Tables Sluices Knudson Bowls Knelson Concentrators Magnetic separators Smelting

Surface Properties
Froth Flotation

Hydrometallurgy
CIP/CIL Electrowinning

Conductivity
Electostatic separation

Solvent Extraction

Magnetic

PyroMetallurgy

Colour
sorting

FROTH FLOTATION

Schematic diagram of flotation machines

Ore-to-metal

Metal extraction - Hydro

Hydrometallurgical processes involve Leaching aqueous, acid, alkaline. Solid-liquid separation - filtration. Concentration ion exchange, solvent extraction. Metal recovery precipitation, electrowinning, metal reduction.

Process control

WMC pho

Ore-to-metal

Metal extraction - Pyro

Pyrometallurgy - high-temperature reactions on concentrate. Removal of S (as SO2) and Fe in slag. Melt cools as metal-rich matte. Ni matte comprises Ni-Fe alloy and minor sulphide phases.

Ore-to-metal

Pouring Ni matte

Matte Grade ~ 70% Ni.

WMC photo

What metallurgists do
At mines - control mineral processing plants, manage waste, safety. In labs evaluate ores, develop new processes, computer modelling. Design and commission new processing plants. Manage operations, people, companies. Research and development work.

What you will study - Yrs 2-4

Chemistry Mineralogy Mineral Processing Hydrometallurgy Pyrometallurgy Process control Process design Research Project Other units in Maths and Statistics Engineering units Computer modelling Financial management Environment

Challenges for 21st century metallurgists

Find ways to - process more-complex ores - treat lower grade ores - extract more metal from ores - reduce pollution - rehabilitate waste dumps - improve energy efficiency - reduce costs. Maximise economic benefit to Australia in a competitive global market.

Some companies that employs mets

Many graduates working overseas