The processing of Beach Minerals by means of an InLine Pressure Jig

A. B. Nesbitt, W. Breytenbach, M. Z. Macingwane, P. van der Plas

Gravity Research Unit, Department of Chemical Engineering, Cape Peninsula University of Technology,
P.O. Box 652, 8000, Cape Town, South Africa

Abstract

The processing of beach sands for the recovery of magnetite, ilmenite, titanium, rutile, zircon
Leucoxene garnet and quartz, is common on the South African coastline. Particulate sizes are
typically in the sub 500-micron range, because of the nature of the geology of beach sands. The
separation of the magnetic from the non-magnetic species is relatively straightforward. However,
the relative densities of the non-magnetic mineral species are usually between 2.7 and 5.0 and are
normally clustered between 4.0 and 5.0. The classification of these mineral species therefore
presents a challenge for modern gravity separation techniques. In addition the relatively low value
of non-magnetic beach minerals dictates that the process of writing off the capital cost of
purchased gravity separation equipment be carefully planned. In this paper we report on a study
into the classification of non-magnetic beach sands, using an InLine Pressure Jig.

1. Introduction
The capacity to beneficiate mineral deposits is probably one of the most important
considerations when evaluating the feasibility of an ore deposit. Important physical
methods applied to concentrate ore are; sorting, froth flotation, gravity concentration,
magnetic separation, and high-tension separation (Wills, 1997).

In recent years the application of gravity concentration has become more topical as more
innovative gravity-concentration equipment has become available. These include Mozley
gravity separators, centrifugal separators, and various types of jigs. Jig operation has
improved considerable in the last 20 years due in part to, advances in engineering and
recent innovations. A typical jig uses a pulse action to generate hindered settling systems
that effectively separate particulate material of different densities. These units are used as
pre-concentrators as well as for treatment of waste streams. Presently, common fields of
application include coal, gold, ferro-metals and diamonds.

Gravity concentration and especially jigging lends itself very well to the recovery of
ferrochrome from slag dump material. Slag material contains significant amounts of
entrained ferro-metal and can be an extra source of income for a ferro-metal producing
operation. Other marginally profitable processes in which jigging has been applied are
listed by Weiss (1985). These include the recovery and concentration of cassiterite,
scheelite, manganese, lead-zinc and iron

A recently developed invention, i.e. the InLine Pressure Jig (IPJ), has been successfully
used in the recovery of gold and diamonds (Heins, 2003). The IPJ was originally designed
for this purpose, more specifically, the recovery of coarser gold, before the cyanidation
process. As with other gravity separators and particularly jigging units, the IPJ can also be
applied in, higher mass pull, marginally profitable processes, as is found in industrial
mineral recovery operations. In this paper we examine its effectiveness in the recovery of
different types of beach sands. Mineral beach sands are common on the coastlines of
countries abutting the Indian Ocean and the processing thereof results in the production of
titanium, zircon, steel, and garnet among other commodities. An IPJ is characterized by
having a large number of operational variables. The stroke nature can be substantially
modified and is described in detail in the theory section. It is this variability that
distinguishes the IPJ from other gravity equipment. Although, other gravity separation
devices have been adapted to give this greater variability, this has only been at the bench
scale level thus far. (Chernet et al., 1999)

To suitably test the IPJ’s classification abilities in this particular duty, an existing pilot
plant facility Figure 3, had to be marginally adapted to accommodate the fine particle sizes
and slurry feed densities. The IPJ pilot plant circuit consists of two circuits; one containing
suspended solids for classification, and the other solids free, for the addition of hutch water
to the IPJ. The circuit was designed with the intention of preventing loss of material from
the system.

In this study we concentrated on the separation of non-magnetic ores, specifically the

upgrading and recovery of Zircon (R.D. 4.6 – 4.8) from mainly non-magnetic beach sands
i.e., Rutile (R.D. 4.5), Leucoxene (4.3 – 4.6) and Quartz (R.D. 2.65). Another important
system variable is that of the ragging that assists in bed formation and stability. As the
average particle feed size used in this test work was approximately 150 microns with a
narrow distribution, the ragging would have to be chosen carefully with respect to size and
density. A ragging with an R.D. of 4.2 and a particle size of 650 microns was chosen for
this study. Fine particle sizes are not uncommon in beach sands making for a complex
classification challenge.

2. Theory

Normally the motion of the piston that drives the fluidizing water will determine the time
displacement profile of the created pulse. If the piston is connected to an eccentric, a
sinusoidal movement results. Consider the wave created by an eccentric driven piston,
Figure 1. The extent of dilation and compaction of a mixture of particles is modulated by
the amplitude and frequency of the jigging stroke. The pulse can be divided into two
regions, namely the pulsation stroke and the suction stroke. During the former, the water
moves upwards through the bed resulting in the dilation of the bed (Point 2). During the
suction stroke, discrete particles undergo differential, initial-acceleration due to differences
in particle and fluid densities (Point 3), ultimately causing stratification, with particles of
varying size and density reporting to different strata. During hindered settling, both size
and density of the particles influence the rate of displacement. The larger, heavier particles
settle faster than the lighter smaller particles. During the consolidation stage the bed starts
to compact with the larger particles interlocking. The smaller particles “trickle” through
the interstitial spaces between the larger particles, Wills (1997).
 Pulsion Suction

2 3
Displacement

1
5

0
4.7

Time

Figure 1: Pulse Created By Eccentric Driven Jig

In addition to the traditional pulsing that is normally found in any jigging system, the IPJ
possesses extra qualities. Here the pulse is controlled by a hydraulic circuit, which causes
the ram to extend, cyclically, in a saw-tooth manner. This ram is connected to the IPJ’s
screen that then pulses accordingly. As this system causes the screen to move – unlike a
water pulse where the screen is static - it differs substantially from conventional jigs and
therein allows for vastly better control of both the dilation and compaction stroke.
Upward Displacement

Pulse Frequency Compaction Rate = Dilation Rate

Compaction Rate < Dilation Rate
Compaction Rate > Dilation Rate

Figure 2:Various types of saw tooth pulses created by an IPJ

Normally, the compaction stroke occurs under gravity alone, but in the IPJ its rate can be
controlled by the speed of the upward movement of the screen. It can be said that the
upstroke of the IPJ represents the suction stroke whereas the down stroke the pulsation
stroke. It has been shown (Nesbitt et al., 2005) that by changing the characteristics of the
pulse, the efficiency of separation could be altered and therefore optimized. The nature of
the pulse can be altered via three interacting variables in the hydraulic circuit that require a
pulse characterization value i.e. NPB factor (Nesbitt et al., 2005). The grade efficiency
term used in this paper is calculated using the following relationship

ρ M (ρ C − ρ C ρ T )
grade eff . = ⋅ 100 ..1
ρ M (ρ C − ρ T )
where
ρ M is the specific gravity of the concentrate mixture
ρ C is the specific gravity of the desirable dense material
ρ T is the specific gravity of the less dense material

3. Experimental

During all test work, steady-state conditions were achieved in a relatively short span of
time after start-up of the closed circuit. Sampling the tails and concentrate streams at
steady state, investigated the effect of different operating parameters on the separation
process. A synthetic feed of mainly non-magnetic beach sands was assembled consisting
of silica (27 %), zircon (21 %), rutile (19 %), kyanite (3.3 %), ilminite (4.6 %) with the
balance begin leucoxene and garnet. As all the minerals present contained the same
frequency of particle size distribution - spanning from 75 to 25 microns - and zircon had
the highest specific gravity, separation was theoretically deemed possible by hindered
settling means. Efficiency of separation was calculated from the solids density of the
concentrate and tailings, determined via helium pycnometer (AccuPyc 1330).

3.1 Test work with Silica ragging (2.65 SG)

Test work was done on the beach sands, using silica particles of 2 to 3 mm in diameter, as
ragging. A successful split was achieved at a constant hutch water rate of 1.5 m3.h-1. Pulse
rates were varied from 90 to 150 pulses per minute and stroke lengths were varied from
20% to 30% of maximum. It was found that the best results were obtained between these
constricting ranges. When exceeding these ranges the dynamics of the ragging bed became
un-stable. A schematic representation of the test circuit is shown in Figure 3.

3.2 Test work using denser ragging (3.6 SG)

For this test work a denser ragging was chosen (S.G. = 3.6) that consisted of smaller
particles approximately (600 - 500 Microns). This resulted in an improvement in
performance compared to the silica ragging, in addition to a firmer bed and hence more
stable operating conditions. Experience with previous test work indicated that the system
would be able to sustain higher hutch water rates if a denser ragging was used. As a result
it was decided to improve the potential for increased hutch water delivery by incorporating
a larger hydrocyclone with a larger higher pressure feed pump. The other system
parameters were altered to achieve stability within the system. A constant hutch water rate
of 2.5 m3.h-1 was used with pulse rates once again being varied between 90 to 150 pulses
per minute. The higher density ragging now allowed for stroke lengths of between 20%
and 40%, of maximum and faster down stroke displacement rates, without incurring bed
collapse.

Feed tank over flow

Slurry supply to Feed Tank

Air Outlet
Feed
Tank

Slurry Feed into Inline Concentrate Stream

Pressure Jig Hydrocyclone
Underflow
Tailing Stream

Inline De-watering Main Pump

Hutch Pressure Jig Cyclone recycle
Hutch Sump
water
Cyclone Pump
water Tank
tank
addition

Hydrocyclone Overflow

Figure 3: Schematic Diagram of Pilot Plant used to process Beach Sands

4. Discussions and Results

4.1 The silica ragging system

The silica ragging system resulted in the rejection of silica from the feed, to the tailings
with more-dense material reporting to the concentrate. From Figure 4, it is observed that
there is a significant density difference between the solid mixtures in the concentrate and
tailing streams. However, it is clear from the closeness of the density between the feed
and concentrate that in effect, most of the feed passes through to the concentrate with only
small amounts of less dense material being elutriated to tailings. The highest stroke
lengths in the range used, reduced the mass pull to the tailings stream and this was
attributed to bed collapse. From qualitative investigations, it was observed that the down
stroke velocity (DSV) has a significant effect on the stability of the jigging bed for the
silica ragging system. The full results of the preliminary tests are given in Table 1 and 2,
showing the recoveries and grade efficiency for different down stroke displacement rates
(DSV) and stroke lengths respectively.

3.70

3.65

3.60

3.55

3.50

3.45 Concentrate
Tailings
3.40 Feed
3.35

3.30

3.25

3.20
90 100 110 120 130 140 150

Figure 4: Effect of pulse rate on density profile silica ragging system

Table 1 effect of Down Stroke velocity on recovery and grade, silica ragging system

Conditions Recovery Grade Density

Pulse rate
DSV Recovery % Grade eff. Tailings Concentrate
min-1
1.5 90 86.8 62.9 3.154 3.606
2.5 90 96.1 62.5 3.053 3.615

1.5 110 88.2 63.8 3.354 3.685

2.5 110 96.4 61.9 3.152 3.585

1.5 130 86.3 64.9 3.292 3.648

2.5 130 98.3 64.1 3.082 3.632

1.5 150 87.0 62.9 3.262 3.605

2.5 150 98.6 63.4 3.058 3.615
Table 2: Effect of stroke length on recovery and grade, silica ragging system

Stroke
Pulse rate min-1 Recovery % Grade eff.
Length
20 130 88.99 62.93
25 130 88.96 63.09
30 130 95.86 63.38

20 150 89.60 64.35

25 150 89.52 60.49
30 150 96.81 62.06

4.2 The 3.6 SG ragging system

The 3.6 SG ragging system, allowed for longer stroke lengths, greater hutch water addition
rates and down stroke displacement rates (DSV) that resulted in improved beneficiation.
This we attribute to a more stable bed, the denser ragging causing a higher-pressure drop.
The greater stability allowed for an increase in variable ranges and showed a real upgrade
in the concentrate compared to the feed, shown in Figure 5. The recoveries are therefore
less, as shown in Tables 3 and 4. Unlike in the silica system the stroke length could be
increased to 40% of maximum and the displacement rates to 45% of maximum.
3.80

3.75 Concentrate
Tailings
3.70 Feed

3.65
Specific gravity

3.60

3.55

3.50

3.45

3.40
90 100 110 120 130 140 150
Pulse rate

Figure 5: Effect of pulse rate on density profile 3.6 SG ragging system

Table 3: effect of Down Stroke displacement rate on recovery and grade in the 3.6 SG
ragging system

Conditions Recovery Grade Density

DSV Stroke length RecoveryGrade eff. Tailings Concentrate
2.5 30 35.4 69.2 3.466 3.742
4.5 30 34.8 67.3 3.617 3.700

2.5 40 27.5 66.9 3.520 3.691

4.5 40 59.9 64.5 3.619 3.639

Table 4: Effect of stroke length on recovery and grade in the 3.6 SG ragging system

Conditions Recovery vs Grade Density

Pulse rateStroke length Grade eff. RecoveryTailings Concentrate
90 30 69.2 35.4 3.466 3.742
110 30 66.2 33.6 3.482 3.676
130 30 64.4 18.4 3.481 3.637

90 40 66.9 27.5 3.520 3.691

110 40 69.6 36.4 3.486 3.750
130 40 64.4 30.3 3.476 3.637
150 40 63.6 27.0 3.426 3.620

The increase in down stroke displacement has the effect of causing the bed to dilate to a
greater extent. When this is combined with a longer stroke length and higher pulse rates,
the effect is to cause the bed to be dilated for a longer period of time, per cycle. It is
apparent from Table 3 and 4 that improved upgrade of the concentrate is achieved by
increasing the bed voidage through a higher down stroke displacement rate and longer
stroke lengths. Another variable that will shed light on the extent of bed dilation effect will
be that of hutch water with in this case was limited to 1.5 m3.hr-1 for the silica ragging
system and 2.5 m3.hr-1 for the 3.6 SG ragging but variation was not considered in this test
work.

5. Conclusion

It would appear from the results that the performance of the IPJ can be optimised to
achieve classification in this particular duty after one pass and with more passes could
successfully achieve a desirable level of beneficiation. Clearly the use of ragging, of the
correct density and size is extremely important in high mass pull, near density applications
as is the case in beach sand processing. The denser ragging gave a better performance with
respect to product beneficiation, than the lighter silica ragging and also increased stability
of the system allowing for a greater deviation of system variables during the optimisation
process. This in turn allows for an increase in stable bed dilation, which would appear to
improve product grade.
References

Heins, R., 2003. Private communication. Gekko, Systems RSA.

Weiss, N.L, (1985) SME Mineral Processing Handbook, Volume 1, pp 4-1 to 4-55

Wills, B.A., (1997), Mineral Processing Technology, Sixth Edition, pp 214-236

Chernet T, Marom J. and Nissinen A, 1999. Significantly improved recovery of slightly

heavy minerals from quaternary samples using GTK Modified 3’’ Knelson
preconcentrator. Minerals Engineering 12, 1521-1526

Nesbitt, A.B., Breytenbach, W., van der Plas, P.J., 2005 Characterization of the pulse wave
of an InLine Pressure Jig in a near density application. Minerals Engineering, 18, 1-7.