Introduction to Metallurgical Plant Unit Operations and Process Control

Fundamentals Pressure and Pressure Drops Definition of Force, Area, and Pressure Engineering Units of Force and Pressure Pressure in a Container Molecular View of Pressure Measuring Pressure with a Manometer Effect of the Liquid Density of Manometer Readings Pressure Caused by GravityStatic Head Gauge, Absolute Pressures, and Pressure Drop Temperature, Heat Flow, and Heat Exchangers Definition of Temperature and Thermometers Temperature as Kinetic Energy of Molecules The Absolute Temperature Scale Relationship Between Temperature and Pressure Definition of Heat and Heat Capacity Engineering Units of Heat Introduction to Heat Exchangers Heat Exchanger Types: Shell and Tube and Plate and Frame Acids, Bases, and pH Definition of Ions Definition and Examples of the pH Scale Hydrochloric Acid as an Example Slurries and Slurry Density Typical Metallurgical Plant Slurries Examples of Typical Slurries with Photographs How to Calculate Slurry Percent Solids Definition of Slurry Specific Gravity Introduction to Slurry Pumps Sampling and Measuring Slurry Specific Gravity Measuring Size Distribution with Standard Sieves
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Introduction to Metallurgical Plant Unit Operations and Process Control

Solutions and Solution Concentration Definition of a Solution Solids that Form Ions in a Water Solution Solids that Do Not Form Ions in a Water Solution Definition of Solvents and Solutes Definition of Solution Concentration Saturate Solutions Ore, Metal Values, Gangue, and Tailings Definitions of Terms Sulphide and Oxide Ores Host Rock Mineral Liberation Example Types of Ores Tailings Disposal and Impoundments Tailings Dam and Beach Atypical Means of Disposal Such as Underground Recovery and Concentrate Grade Recovery as a Function of Feed, Concentrate, and Tails Grade Definition of Recovery Effect of Recovery on Concentrate Grade Distribution of Gangue Components in Concentrate and Tails Simple Calculations Inverse Grade/Recovery Relationship Agitation Retention Time

Introduction to Metallurgical Plant Unit Operations and Process Control

Plant Safety Introduction General Safety Personal Protective Equipment Emergencies and General Rules Housekeeping Maintenance Work General Housekeeping Safe Lifting Technique Conveyors and Belt Feeders Bins and Hoppers V-Belt Drives High-Pressure Air Radiation Devices Safety Showers and Eyewash Stations Reagents Sulfuric Acid Fire Classifications Fire Extinguishers Job Safety Analysis Hazard Types Conducting the Analysis Safe Job Procedures Material Safety Data Sheets (MSDS)

Introduction to Metallurgical Plant Unit Operations and Process Control

Crushing and Conveying Gyratory Crushers, Hydroset, and Lubrication Objective of Primary Crushing Run of Mine Ore and Truck Dumping Gyratory Crusher Components Gyrating Action of a Gyratory Crusher Gyrator Crusher Lubrication Components of the Main Shaft Eccentric Bushing Oil Heating and Cooling Oil Filters Spider Assembly and Lubrication Hydraulic Adjustment System Raising and Lowering the Mantle Shock Absorbing Clearing the Crusher Symons Cone Crushers Principles of Operation and Description of Components Animation Gap adjustment Hydraulic System Controls Tramp Metal Release Mechanism Hydraulic release Mechanism Lubrication System

Introduction to Metallurgical Plant Unit Operations and Process Control

Jaw Crushers Principle of Operation Including and Animation Description of Crushing Action Components Single Toggle Hydraulic Rock Breaker Principle of Operation, Description, and Operating Methodology Apron Feeder Principle of Operation Components Animation Stockpiles and Reclaim Belt Feeders Crushed Ore Stockpiles Live and Dead Storage Draw Holes Angle of Repose Effects of Reclaim on Size Classification Belt Feeder Components and Safety Features Definitions and Examples of Feeder Components Belt Scales Belt Cleaners and Scrapers Safety Concerns and Emergency Pull Cords Conveyor Belts Manufacture of Conveyor Belting Including Belt Conveyor Components and Safety Features Definitions and Examples of Conveyor Components Different Types of Idlers, Including Return and Training Idlers, Belt Scales, Belt Cleaners, and Scrapers Safety Concerns and Emergency Pull Cords
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Introduction to Metallurgical Plant Unit Operations and Process Control

Belt Scales, Magnets, and Metal Detectors Belt Sale Components and Principles How the Scale Computes Weight Over the Belt Belt MagnetsTypes and Principles Metal DetectorsTypes and Principles Screw Conveyors Construction, Components, and Principles Safety Concerns Dust Control and Bag-Type Dust Collectors Introduction to Methods of Dust Control Baghouse Components and Principles Simple Dust Collection Ductwork and Hood Example Description of Bags and Bag Cages Views and Descriptions of Baghouse Internals Methods for Removing Collected Dust from the Bags Setting Pulse Times Based on Pressure Drop Rotary Valves to Maintain the Dust Seal Types of Dust Collector Fans Dust Suppression Sprays and Techniques

Introduction to Metallurgical Plant Unit Operations and Process Control

Pumping Horizontal Centrifugal Pumps Introduction Pump Components and Principles Packing and Packing Gland Including Gland Seal Water Variables to Consider in Pumping Applications Total Head, Flowrate, and Power Relationships Static, Friction, and Velocity Head Typical Pumping System Effect of Piping System and Fittings on Friction Head Flowrate and Total Head RelationshipSimple Curve Flowrate and Power RelationshipSimple Curve Cavitation Pumping Slurries Vertical Centrifugal Pumps Dry and Wet Pit Pumps Pump Stages or Bowls Positive Displacement Pumps Introduction to Positive Displacement Pumps Differences Between Positive Displacement and Centrifugal Pumps Progressive Cavity Pumps, Components, and Principles Reciprocating Pumps, Components, and Principles Diaphragm Pumps, Components, and Principles Three-Way Air Valve to Control Reciprocating Pumps Reagent Metering Pumps Introduction Peristaltic Metering Pumps, Components, and Principles Diaphragm Metering Pumps, Components, and Principles Cam Drives
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Introduction to Metallurgical Plant Unit Operations and Process Control

Grinding Introduction to Grinding Technology Introduction to Grinding How Particles are Broken Grinding Parameters Types of Grinding Mills Types of Grinding Circuits

SAG and Ball Mills Introduction and General Description of Circuits SAG Mills, Components, and Principles SAG Mill Volumetric Loading of Charge Components Cataracting Action in the Rotating SAG Mill SAG Mill Liner Components Semi-Autogenous Grinding Mills Drive Gears and Motors Mill Lubrication SystemsGear Teeth, Pinions, and Trunnion Bearings Mill ClutchesTypes, Function, and Objectives Operating Considerations Ball Mill Description, Objectives, and Principles Ball Mill Grinding

Introduction to Metallurgical Plant Unit Operations and Process Control

Classification Cyclones Introduction to Screening Technology Zones and Motion Efficiency Factors Components, Function, and Principles; Clusters Variables Affecting Performance Cyclone Operation Troubleshooting Heavy Media Drums Principles and Description Animation Heavy Media Hydrocyclones Principles and Description Spirals Principles and Description Vibrating Screens Introduction to Screening Screen Function and Principles Vibration Techniques Screen Slopes Screening efficiency Materials of Construction Grizzlies, Components, and Principles Double- and Triple-Deck Screens

Introduction to Metallurgical Plant Unit Operations and Process Control

Flotation Introduction to Flotation Technology Introduction Phases, Reagent Classes, and Functions Bubble Formation and Dynamics Froth Dynamics and Management Conventional and Tank Flotation Cells Introduction and Brief Explanation of the Flotation Process Introduction to Hydrophilic and Hydrophobic Agitation and Air Introduction to Flotation Cells Introduction to Simple Flow Diagrams Showing Feed, Concentrate, and Tails Explanation of Flotation StagesRougher, Scavenger, Cleaner Cells and Various Combinations Construction, Components, and Principles of Tank Cells Construction, Components, and Principles of Conventional Banks of Cells Connected by Transition Boxes Key Variables and Their Control Dart Valves Definition of Froth and Slurry Levels Mixing Zones and Flotation Cells Column Flotation Cells Introduction Column Flotation Cells Construction, Components, and Principles of Column Cells Where Column Cells are Typically Used in Circuits and Why Control of Froth Depth on Column Cells Column Cell Air Injection Wash Water and Air Dispersion
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Introduction to Metallurgical Plant Unit Operations and Process Control

Flotation Reagents Importance of Appropriate Reagents and Their Function Collectors/Promoters Frothers Modifiers Vertical Regrind Mills Introduction and Objectives Vertical Mills, Components, and Principles Operation Oil Lubrication Grease Lubrication Dewatering Conventional and High-Rate Thickeners Introduction to Conventional Thickeners Thickener Objectives Use of Flocculants Four Thickener Settling Zones Thickener Drive Systems Including Rake Lifting Mechanisms Explanation of Settling in Thickener Zones Underflow Pumping and Sludge Bed Density Control Slimes Level Interface, Methods of Measurement, and Control Effect of Rake Torque on Thickener Operation Introduction to High-Rate Thickeners Advantage and Disadvantages of High-Rate Thickeners Factors on Which High-Rate Thickening Depend Clarifiers Introduction to Clarifiers Differences as Compared to Thickeners What Applications are Appropriate for Clarifiers

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Introduction to Metallurgical Plant Unit Operations and Process Control

Flocculants Introduction to Flocculants and Long-Chain Molecules Principles of How Flocculants Work Effect of pH and Types of Flocculants Effects of Dilution and Why it is Important Flocculant Makeup Systems Filters Introduction to Filters and Characteristics Common to All Filters Definitions: Feed, Filtrate, Filter Cake, Filter Media Filer Media Pressure Drop Types of Filter Media Methods of Forcing Feed Through Filter Media Pressure and Vacuum Filters Methods of Filter Cake Removal Methods of Cleaning or Replacing the Filter Media Types of Filters: Drum, Disc, Belt, Plate and Frame, and Vertical Larox Filters

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Introduction to Metallurgical Plant Unit Operations and Process Control

Gold and Silver Cyanide Leaching Introduction and Objectives Chemistry Leach Tanks Carbon In Pulp Chemistry CIP Tanks Carbon Advance Screens Counter-Current Decantation Introduction and Objectives Concept of Washing Example Three-Stage Circuit Factors Affecting Recovery Elution and Acid Wash Introduction and Objectives Chemistry Typical Circuits Carbon Reactivation Introduction and Objectives Kilns and Combustion Controls Chemistry Typical Circuits

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Introduction to Metallurgical Plant Unit Operations and Process Control

Merrill Crowe Precipitation Introduction and Objectives Clarification Filters Chemistry Deaeration and Zinc Addition Precipitation Filters Mercury Retort Retort Oven Condensers Carbon Adsorption Vacuum Pump Gold Electrowinning Introduction and Objectives Electro-Chemistry Rectifiers and Controls Material Handling Typical Circuits Dor Smelting Fluxing Smelting Furnace Casting Tailings Detoxification Introduction and Objectives Chemistry Typical Circuits

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Introduction to Metallurgical Plant Unit Operations and Process Control

Reagents and Sampling Flotation Reagents Makeup Typical Flotation Reagent Makeup Circuit Flocculant Makeup Typical Flocculant Reagent Makeup Circuit Lime and Lime Slaking Introduction to Limestone, Quick Lime, and Slaked Lime Quick Lime Production Methods Safety Concerns Lime Slaking and Slakers Lime Bin Activators Slaking System Scrubbers Typical Lime Slaking Circuit Sampling Theory and Automatic Samplers Introduction to Sampling Why Obtaining a Representative Sample is Difficult Objectives of Sampling Metallurgical Accounting Process Control Product Quality Measurement Sampling MethodsPrimary and Secondary Samplers Manual Sampling Types of Automatic Samplers:

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Introduction to Metallurgical Plant Unit Operations and Process Control

Air Compressors Air Compressors Introduction and Typical Plant Air Compressors Operation of a Pneumatic Cylinder Basic Types: Reciprocating Compressors Rotary Compressors Reciprocating Compressors, Components, and Principles Rotary Compressors, Components, and Principles Air Receivers Lubrication and Cooling Air Filters Air Dryers Air Blowers Introduction to Air Blowers and Fans Uses Centrifugal Fans, Components, and Principles Axial Fans and Dampers Engineering Units Used for Fans and Blowers Typical Fan Performance Curves Pressure, Flow, and Power Relationships Types of Centrifugal FansAdvantages and Disadvantages: Backward Curved/Airfoil Blades Radial Blades Forward Curved Blades Positive Displacement Blowers, Components, and Principles

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Introduction to Metallurgical Plant Unit Operations and Process Control

Combustion and Offgas Handling Burners, Combustion, and Heaters Types of Fuels Fuel Air Mixture Stoichiometry Flue Gas Products and Excess Oxygen Gas, Oil, and Pulverized Coal Burners Combustion Air and Atomizing Air Primary air and Secondary Air Typical Burner Safety Interlocks Gas Handling Cyclone Introduction Principles Components Flues Cross Section Dust Handling Draft Dew Point of Air, Water, and SO2 Mixtures Dew Point as a Function of SO2 Content Chemistry Corrosive Problems Drag Chain Conveyor Introduction Principles Components Eductor Principles Components
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Introduction to Metallurgical Plant Unit Operations and Process Control

Boilers and Steam Generation Steam Characteristics Saturated and superheated steam Heat of vaporization Water Tube Boiler Construction Steam drum Tubes Thermal circulation Burner assembly Insulation Blowdown

Steam Transmission Safety Steam leaks Safety relief valves Energy conservation Insulation Pressure drops through fittings Valve usage Gate valve Globe valve Ball valve Check valve Condensate removal and steam traps

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Introduction to Metallurgical Plant Unit Operations and Process Control

Electrostatic Precipitators Introduction Principles Components Electrodes, Collecting Plates, and Insulators Hoppers and Dust Collection Isolating Units Rappers Stack Effect Introduction Effect of Heat Simple Equation for Calculating Pressure Differential Induced vs. Natural Draft Overcoming System Resistance Stack Opacity Detector Principles Components Pneumatic Conveying Types Principle of Dense-Phase and Dilute-Phase Systems Advantages and Disadvantages of each Type Principle of Pod-Type Dense-Phase Systems Fuller Kinyon Pumps Introduction Principles Continuous Dense-Phase Operation Air Slide Introduction Principles Components
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Introduction to Metallurgical Plant Unit Operations and Process Control

Electricity Introduction Atomic Nature of Electricity, Ions, Free Electrons Conductors and Insulators Voltage, Electric Current, and Resistance Engineering Units for Voltage and Analogies Definition and Units for Current and Resistance Analogies for Resistance Simple Direct Current Circuits Simple Electrical Relationships Electrical Safety Issues Power Engineering Units; Power Relationship to Current and Voltage Power Analogies Insulation Applications and Potential Problems and Abuse Direct Current Alternating Current Simple AC Generator Factors that Affect Voltage Generated by a Generator Concept of a Conductor Cutting Magnetic Field Flux Lines More Complex AC Generators and Simple Animation Simple Animations Multiple Pole AC Generators Industrial Revolving Field Generators, Components, and Principles

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Introduction to Metallurgical Plant Unit Operations and Process Control

Transformers Introduction and Objectives Transformer Definitions, Components, and Principles Simple Equations for Determining Primary and Secondary Voltage and Affect on Power. AC Motors Induction Motors, Components, and Principles Action of an Induction Motor. Squirrel Cage Motors and Assembly Synchronous Motors, Components, and Principles Characteristics of Synchronous Motors Formula to Calculate Synchronous Motor Speed Variable Frequency Motors Multiple Phase AC Power Single-Phase Revolving Field Generator Two-Phase AC Generator Electrical Distribution Systems High, Low, and Medium Voltage Substations and Load Centres

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Introduction to Metallurgical Plant Unit Operations and Process Control

Process Controllers Introduction to Process Controllers Introduction and Examples Terms Automatic Control Advantages of Automatic Control Introduction to a Simple Control Loop Functions of Sensors, Transmitters, and Controllers Example of a Controller Face Plate Explanations of Automatic and Manual Definitions of Process Variable, Set Point, and Output Definition of Direct and Reverse Control Simple Examples Illustrations of Control Loops Using Symbols or Block Diagrams Manual Control Descriptions and Examples of Manual Control Example of Manual Level Control Block Diagram Illustrating Pure Manual Control Control Modes Introduction to the Various Control Modes: Binary Proportional Proportional Plus Integral Proportional Plus Integral Plus Derivative Binary Control and Factors to Consider Proportional Control and Factors to Consider Definition of Proportional Gain and Error

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Introduction to Metallurgical Plant Unit Operations and Process Control

Control Modes Definition of Proportional Band Affect of Proportional Gain on System Response Example of a Control Loop Using Proportional Control Explanation of Offset and its Affect on a Control Loop Proportional Plus Integral Control (PI) and How it Removes Offset PI Control and Factors to Consider Example PI Loop and How Offset is Removed Proportional Plus Integral Plus Derivative Control (PID) Advantages of PID Control and Factors to Consider Example PID Loop and its Response Types of Automatic Control Local Automatic (Local Set Point) Cascade (Automatic Remote Set Point) Dead Band Control Loop Tuning Interlocks Introduction to Interlocks Definitions Examples Sensors Introduction to Sensors Pressure Sensors Flow Sensors Level Sensors Temperature Sensors Density Sensors
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Introduction to Metallurgical Plant Unit Operations and Process Control

Control Devices Introduction to Control Devices Control Valves Gate Valve Globe Valve Butterfly Valve Plug Valve Ball Valve Diaphragm Vanes Troubleshooting Troubleshooting Controllers and Control Devices Methodologies Process Problems Distinction Between Process Control Problems and Process Problems Realistic Examples Introduction to P&IDs Identify Various Types of instruments Identify Various Types of signal lines Read P&IDs. Read P&ID Legends Instrument Symbols Meanings of Letters Line Symbols P&ID Examples Reading the Legend
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