UNIVERSITY OF WITWATERSRAND ‘SCHOOL OF CHEMICAL AND METALLURGICAL ENGINEERING INTRODUCTION TO EXTRACTIVE METALLURGY (CHMT 2017A) CLASS TEST 8" MAY 2017 TIME: 2 HOURS, RW 231 INSUTRCUTIONS: Answer all questions in the booklets provided SECTION A Question 1A [20 MARKS] Ves {a) Briefly outine the essential diferences between autogenous, ball and rod mils, [15 Marks} {b) Which one ofthe three is the most cost effective in primary grinding stage? [5 Marks] Solution (a) The essential differences between Autogenous, ball and rod mill ae the media type and the particle size, Large rocks, steel balls and steel rods are used. 2s-media respectively. Rod and 15 mills are used for coarse oF primary, grinding whereas.bal mills are,uasdalorfinesst autogenou: ous al sggondary.grinding, [ 15 Marks] (b) Autogenous mills are the most cost effective [ 5 Marks] Question 2A [15 MARKS) Explain briefly the following concepts {a) Comminution [5 Marks] [5 Marks} (b) Reduction ratio(c) Fracture by compression [5 Marks} Solution (2) Comminution ja size reduction process consisting of rushipa anc. arnding (5 Marks] (b) The reduction ratio is the extent of size reduction achieved by a comminution device [5 (c) Fracture by compression is when a particle is caught between 2 crushing surfaces that apply Marks] compressive forces resulting in fracture. [5 Marks] Question 3A [20 MARKS] You are given the following closed crushing circuit Sercen Crusher 2{ crusher? Sereen 3 The feed rate to the above circuit (stream 1) is 600 tph and the apertures on the three screens are respectively 150, 25 and 15mm. (a) Identity which ofthe product streams from the screen are the O/S and UIS streams (ie. the oversize and undersize streams). [5 Marks] (b) What isthe size distribution of the feed to screen 2 if screen 1 is working perfectly and the size distributions of the feed (stream 1), and the product from the crusher 1 (stream 4) are as follows. (20 Marks} Size (mm) 200 150 100 50 2 10 ‘Cum % passing for stream 1 @ | 8 | & | 30 | o | 10 ‘Cum % passing for stream 4 100 65 55. 45 35 25TOTAL MARKS Fo, R SECTION a: Solution (a) 1ON A: 60 MARKS Screen 1 15 Marks} Solution (b) ‘Screen ‘Size (mm) 200) 150 | 100 ac 10 0 | ‘Cum % passing for stream 1 s fs [sles bo] cnrouinwrinne [wo] « [= [ole fs % Retaveam 7 % MO 8 0 a % Ret steam 4 9 3 10 1 1 1 OS ie 15 Marks} Gol ee Oo 0 ooo oe tons of steam 3 in size classes fo oe [5Marksy [OTS MSweamAinsizedasses | a7 es 20 Combined stream 3 and 4 0 45 67 87 87 87 1575 600 y Ue rremAiperceniage | srs us As 6 45 2625 100 [5 Marks}SECTIONB Question 1B [10 MARKS] a) In not more than three sentences each, briefly discuss briefly the effect of the following factors on the design of leaching processes: (1) Ore type and mineralogy [2 MARKS), (2) Selectivity of leaching reagent [3 MARKS] ‘SOLUTION D} ii) Ore type: Ore type determines the mineralogical characteristics [1 mark] and the grade/ composition (ie. either high or low grade) [1 mark] and textural properties (affects liberation) of the mineral to be leached [1 mark], which in tums determines the selection of leaching reagent [1 MARKY]. The grade of mineral determines the selection of leaching processes, vis-a-vis, agitate leaching systems for high rade ores [1 mark] vs. non-agitaive leaching systems for relatively low grade ores [1 MARK]. The Bresence of other minerals that can be’ codeached together with the target mineral determines the nature and extent of sideeaching reactions, and hence, the overall reagent consumption and the complexity of purification ofthe leach liquor before metal recovery. This i typically so in polymetallic. minerals [TMARK], Some minerals, 9. suphides, tend to be refractory under conventional leaching Conditions, and as such require some pretreatment Conditions such as pressure leaching (1 MARK] Ore mineralogy: Basically, Processing or the use of more aggressive leaching the Fesponses are so much inked to ore type and marks willbe awarded for any responses that are repeated under both () and (i). Mineralogical Characteristics determines the compostion/grade [1 mark] and textual properties (which affect liberation) [1 mark] of the mineral {oe leached, which in tums determines the selection of leaching reagent [1 MARK] Selectivity: Leaching reagent must be selective tothe targeted mineral in the ore, especially in the ‘ase of polymetalic minerals [MARK], Non-selectve leaching reagents tend fo result in high reagent consumption due to side-eactions [1 MARK], and also resulls in the increase in costs and complexity Of purifying the leach liquor before metal recovery processes. [1 MARK] Based on any leaching mode! of your choice, discuss the effect of the {olowing factors on the leaching Process of typical mineral ore in hydrometalurgy,() Particle size, and (2 MARKS) prom Gulls PUB, (i) Degree of agitation [3 MARKS} deh ow g leddug & obetOregeHOns mij inwbiig oSrenger oF rep 4 rele, tle " digpusio. op miass + the Jager te particle, lor te dig rato “is (ogous SOLUTION: frawsey to te unrecard| gbre hee eed lie ¥ The Fine LE particle sive greater te oun eTR gr ee 1) Ore particle size: Leaching is a heterogeneous reaction (sod-id) and is governed by mass transfer -2L the leaching reagent from the bulk of solution tothe reaction intertage (1 MARK for linking with mass transfer phenomena], The, larger the parce size, the larger the. cifusion-conglled, mass \tansterof reactants to the reaction interface, and hence the longer it takes for complet leaching of ‘he-parile, and vce versa [1 MARK]. Finer particles are associated with a larger suface.area..and - Peter the tends to increase te lacing at due to ennanced const between the reacting guage and 'e bulk of leaching reagent (1 MARK for linking particle size to the classical rate phenomena) ') Degree of agitation: nceases the degree of ming in he bulk lian andthe mass transfer. of reagents, to feacton interface surface [1 MARK]. By continuously breaking do Ceoiucl ay nhances the rat of chemical reaction a the intrace ofthe unreacted core, enfiancing the [ass lranserof eacton products away tom the reaction joterace suface (1 MARK, KEY WORDS: MIXING, MASS-TRANSFER, BRESKDOWN.OF REACTIONPRODUCT BARRIER ) Explain briefly the purpose of any three (3) of the unit processes highlighted in (@) above. The planation for each unit process must not be more than three (3) sentences long (6 MARKS}, FLOWSHEET: Many possible Variations- marks awarded de Process flowsheet proposed by student ‘Pending on the reasonableness of the Primary and secondary ctushing with screens and showing Circulating load * Milling (ball or rod) with classifier and showing ciculating load, Marks deducted for using screens with fine grinding processes Flotation of U/S from ball/ rod Physicochemical separation of sulphides from gangue into NiS and CuFeS2 sulphide-rich concentrates and Cu20-enrched gangue. Sulphide Concentrates and gangue- oxide streams should be shown Roasting (oxidative roasting of sulphides concenirales to produce NiO + Cu20 + Fe208 which is more amenable {o sulphuric acid leaching). Marks were awarded for further separating the products of roasting by magnetic methods (based magnetic suscepiibilties of Fe) into NiO and CuO (non-mags) and Fe203/Fe304 (as mags). The NiO + Cuz0 stream is then leaching as a high grade concentrate, Electro-ecovery (Ni2+ & Cu from solution to Ni & Cu metal using elecrowinning process), * _ Regrind of Cu20-enriched gangue (flotation tails from the scavenger cell to further Iberate the Cu20 from the Al203-Si02 gangue before leaching, Leaching (rect leaching of Cu20-enriched gangue)- residue streams (SiO2 + Al203) need to be shown from the SIL separation process. Electroecovery (Cu from solution to Cu metal using electrowinning process, NB: Negative marking on non-coherent processes (e9. roasting unit process after leaching!) QUESTION 3B [10 MARKS]‘The R&D Manager has commissioned a laboratory scale test to evaluate the efficacy of the copper ‘covery in the electrowinning plant you have described in (a). The test involve connecting an external ect current power supply to two platinum electrodes immersed in a beaker containing 1.0M CuSOs at 25°C as shown in the figure below, Ws e zy is ve Powersupply Pet we Cu (agye 2e=cu (o ideation SPRL Fara Ph Proce, As the cell operates, copper metal {s deposited onto ane-electrode and O2 (9) is produced at the other Glecrode The two reduction hal reaction forthe overall reaction that occurs in he cell are shown in the table below: Half Reaction Ev) 02 () +a (aq) 4e= 2D (p Ta | Cu (aq) ¥2e =Cu(@) O34 Qe 3) Write balanced net ionic equation Tor the eleclolysis reaction thal ocours the celi[T MARKS} 5) Calculate the Gibbs free energy change for the reaction and comment on [2 MARKS} sy . ¢) Anelectrc current of 1.60amps passes through the cell for 40 minutes, u ') Calculate the mass. in grams, of the Cu (s) tha is deposited on the electrode [3 MARKS} ') Calculate the dry volume, in itres measured at 25%C and 1.16atm, ofthe O; (9) that is produced [4 MARKS], the feasibility of the reaction Data: Faraday's Constant: 96500 Coulombs/mol Universal gas constant, R: 0.0821 L alm K-mol*‘SOLUTION 8D 2Cu yy +2H Oy) = 2Cthyy + Orr) #4 ahs BP 4034 (1.230) = 0.897 [1 MARK} b) AG? = =n*F =(~4)(96500)(~0.89) = +3404 ; AG > 0 —-Non-spontaneous (2 MARKS] ‘c) Mass of copper deposited: 19¢Cu OR [3 MARKS] ( 1.Samp x 40 minx 60s/ min 196500) ) Mass(g)= (4} M,(Cu Charge= (1.Samps X 40min X 60simin) = 3600 Imole_, lmol Cu, 63.552 96500C” 2mole —Imol Cu d) 1.18 of Cu= 0.0187 mols of Cu, Using 2:1 (from balanced equation), this gives 0.00933mols 02. From ideal gas equation, V = s = MnossmeiNh 28) = 0.197 [4MARKS] 3600Cx: 119g Cu © UNIVERSITY OF WITWATERSRAND, JOHANNESBURG TOTAL MARKS FOR SECTION B: 40 MARKS ‘UNIVERSITY OF WITWATERSRAND, JOHANNESBURG