Introduction to

Mineral Processing Design and Operation

PREFACE

In nature minerals of interest exist physically and chemically combined with the host rock.
Removal of the unwanted gangue to increase the concentration of mineral in an economically
viable manner is the basis of mineral processing operations. This book treats the strategy of
beneficiation as a combination of unit operations. Each unit process and its operation is
therefore treated separately. Integration of these units leading to the development of viable
flow sheets that meets the final objective, is then indicated.
The greatest challenge to a mineral processor is to produce high grade concentrates
consistently at maximum recovery from the ore body. To quantify recovery a reasonable idea
of the initial concentration of mineral in a lode is required. Proper sampling representing the
ore body is therefore essential. The book therefore commences with the techniques of
sampling of ore followed by the design and operation of unit processes of comminution that
help to release the mineral from the associated rocks. Separation and concentration processes
using techniques involving screening, classification, solid-liquid separations, gravity
separation and flotation then follow. In the book some early methods of operation have been
included and the modern methods highlighted.
The design and operation of each unit process is a study by itself. Over the years,
improvements in the understanding of the complexities of these processes have resulted in
increased efficiency, sustained higher productivity and grades. Mathematical modeling has
helped in this direction and hence its use is emphasized. However, the models at best serve as
guides to most processes operations that invariably involve complex interdependent variables
which are not always easily assessed or manipulated. To solve the dilemma, plants are
increasingly being equipped with instruments and gadgets that respond to changes much
faster than humans can detect. Dynamic mathematical models are the basis of operations of
these gadgets which are usually well developed, sophisticated, electronic equipment. In this
book therefore, the basics of instrumental process control is introduced the details of which
belong to the province of instrument engineers.
This book is written after several years on plant operation and teaching. The book is biased
towards practical aspects of mineral processing. It is expected to be of use to plant
metallurgist, mineral processors, chemical engineers and electronics engineers who are
engaged in the beneficiation of minerals. It is pitched at a level that serves as an introduction
to the subject to graduate students taking a course in mineral processing and extractive
metallurgy. For a better understanding of the subject solved examples are cited and typical
problems are set. Most problems may be solved by hand-held calculators. However most
plants are now equipped with reasonable numbers of computers hence solution to problems
are relatively simple with the help of spreadsheets.
The authors are grateful for the help received from numerous friends active in the field of
mineral processing who have discussed the book from time to time. Particular thanks are due
vi

to Dr Lutz Elber and Dr H. Eren who painfully went through the chapter on process control.
Authors are also grateful for permission received from various publishers who own material
that we have used and acknowledged in the text. And lastly and more importantly to our
respective families who have helped in various ways and being patient and co-operative.

A.Gupta and D.S.Yan

Perth, Australia, January 2006