7 MP Flowsheets

MINERAL PROCESSING COURSE
Flowsheets
Click to edit Master subtitle style
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Mineral Engineering Technical Services Pty Ltd ©
COPYRIGHT © 2011. MINERAL ENGINEERING TECHNICAL SERVICES. THESE NOTES ARE NOT TO BE COPIED OR REPRODUCED WITHOUT
PERMISSION. ALL RIGHTS RESERVED
> Mineral Processing > Engineering Design > Specialist Services > Simulation & Optimisation > Construction Management > Risk Management > Training
Flowsheets
> Graphical representation of a process

― Consist of major processing units
― Shows direction of flow
― Instrumentation
PROCESS WATER
FIT FCV
OPERATOR SET POINT

FRIC FM
- ORE/WATER RATIO
WE
MILL MOTOR
FEEDER VSD
DRIVE VSD M
CONVEYOR INTERLOCKS WITH

MILL POWER DRAW
WEIGHTOMETER
WIT
SAG
MILL
SP
SC WIC
OPERATOR
SP
WE
Block Flow Diagram
> Made up of a series of blocks and lines
> Each block represents a particular unit process
> Each line shows the direction of flow
ROM
CRUSHING SCREENING GRINDING SCREENING
LEACHING
BULLION PURIFYING ELECTRO ADSORPTION

ELUTION
WINNING
Schematic Flow Diagram
> Similar to Block Flow Diagram

― Has equipment symbols instead of process blocks
― Lacks in detail
Pulp Flow
M
Carbon
Flow
UFG Mill
M
Stripping Tailings
Column Dam
Leach Tanks
Regeneration
Kiln
Bullions
Electrowinning
Cell
Process Flowsheet
CYCLONE O/F
CYCLONE
WATER
STATIC
GRIZZLY CLEANER
LIMS
ROCK LIMS
BREAKER CLEANER
REGRIND RE DRUMS
MILL
DSM
SCREEN
JAW
CRUSHER M
RE DRUMS
SUMP
TAILS
MAGNETITE
WATER
CONCENTRATE
THICKENER
TAILS
CONVEYORS THICKENER M
SUMP
ALUMINIUM BELT FILTER

SULPHURIC MAGNETITE
SULPHATE SAG MILL SUMP
ACID CONCENTRATE
STOCKPILE MAGNETITE
CONCENTRATE
STORAGE
TAILING DAM
SULPHURIC DESILICATE
ACID NATURAL
VACUUM WATER
FILTER CALCINE GAS
SODIUM
SALT
ROAST KILN
DEAMMONIATOR
SCRUBBER VAT LEACH SOLIDS
PREGNANT
AMMONIUM
LIQUOR SOLUTION
SULPHATE CAUSTIC TITANIUM
SODA RICH RESIDUE
ALUMINIUM FUSION & FLAKING VANADIUM PENTOXIDE (V2O5)
SILICATE WASTE FINAL PRODUCT
OFF GAS
BARREN
LIQUOR
AMMONIUM
META-VANADATE (AMV)
PRECIPITATION DEAMMONIATION KILN
FLAKING
FILTER TABLE
DRA CHK’ SCALE SHEET
REV DATE REVISION APP MINERAL ENGINEERING CLIENT
WN D NTS 1 OF 1
28/11/ TECHNICAL SERVICES REED RESOURCES LTD DRAWN DATE
H CHANGE NAMES YHW Resource Projects •
05
18/11/ MODIFIED DIMMONIATOR Technology
PROJECT NHL 07/04/05
G YHW
F
05
14/10/ SCRUBBER
VAT LEACH, FIX RE
MDU • Integrated Services J87 – BARRAMBIE PROJECT APPROVED DATE
05
12/09/ DRUM
SPIRALSTAILS
REMOVED MAG
ABN 66 009 357 171
TITLE
DC
E NHL DC PO BOX 1728 DWG NO. REV
05
20/07/ SEPN ADDED
D WHIMS added NHL DC WEST PERTH, WA 6005 OVERALL VANADIUM FLOWSHEET J87-P-001 H
05
FILENAME: J87-P-001 REV H.VSD
Conventional Copper Flowsheet
Copper Moly Flotation
Downstream Processing
> Complex Copper Sulphide ore
― Multiple-product Circuit
Mixed Oxide Sulphide Copper Flotation
Uranium Flowsheet
Copper SXEW Options
Nickel Options
Value Adding
Cost of Not Getting it Right Up Front
Process Units
Major process units:-

1. Crushing
2. Grinding
3. Flotation
4. Gravity Concentration
5. Thickening
6. Filtering and Drying
7. Roasting
8. Leaching
9. Solvent Extraction
10.Adsorption of Gold
11.Stripping
12.Smelting
Material Balance Diagram
> Block flow diagram representing the material flow of:

― Mass
― Components
― Water
> Input must be equal to output
> Must be updated with every change in the process
Mass Balance
Feed Tailings
10 t/h 9 t/h
PROCESS
Concentrate
1 t/h
Feed = Tailings + Concentrate

10 = 9 + 1
10 = 10
Components Balance
Feed Tailings
10 t/h 9 t/h
2% Cu PROCESS 0.10% Cu
Concentrate
1 t/h
?% Cu
Metallurgical Balance
Solid and Water Balance
> Water volume required to make up pulp of 65% solids
ms
0.65 
ms  mw
0.65ms  0.65mw  ms
0.65mw  (1  0.65) ms
0.65mw  0.35 ms
mw  0.538 ms
Process Flow Diagram
> Shows:-
― Process equipment
― Major process pipes
― Essential process control circuits
― Major process requirements
> The drawing is not to scale and the equipment items are
represented by symbols
> Pre-requisite for P&ID
Process Flow Sheet
FAYALALA PLANT SITE LERO KARTA MINESITE

4
NO. 2 ROM BIN
CRUSHED ORE
CHUTE NO 1. ROM BIN
NO 2. VIBRATING
21 GRIZZLY NO 2. JAW
CRUSHER ROCK
22 BREAKER
METAL
DETECTOR 1
NO.2 ROM
APRON FEEDER
2 NO 1. ROM
CRUSHED ORE APRON FEEDER
CONVEYOR
23 SELF-CLEANING NO 1. JAW
MAGNET CV005 NO 1. VIBRATING
CRUSHER
GRIZZLY
24
PRIMARY CRUSHER SELF-CLEANING 3
DISCHARGE CONVEYOR MAGNET
CV002
PRIMARY CRUSHER CONVEYOR
WEIGHTOMETER
STOCKPILE FEED CONVEYOR CV001
METAL
CV003 DETECTOR
OVERLAND
EMERGENCY CONVEYOR CV004
STOCKPILE
CHANGEOVER ROUTE
CHANGEOVER ROUTE
STOCKPILE
RECLAIM
MAIN ROUTE
MAIN ROUTE
RECLAIM BIN
APRON FEEDER
CRUSHEDORE
J151-P-011
MILL FEED CONVEYOR WEIGHTOMETER
CV006
CRUSHEDORE
J151-P-011
MILL FEED CONVEYOR WEIGHTOMETER
CV007
Area Codes
Area Code General Description

040 Crushing and Screening
050 Grinding
060 Thickening
070 Flotation/Concentrates
080 Bacterial Oxidation, Leach and Filtration
090 Oxide Leach and Adsorption
100 Gold Room and Elution
110 Tailings
120 Reagents
130 Buildings
140 Utilities - Power/Water/Air (Source Supplies)
150 Services:-
Plant Supply of Power
Water
Fire Water
Sewerage
Fuel
LP Gas
160 Mining
Lettering System
> No official standardized lettering system for the designation of equipment

although there are some obvious choices
> Ambiguity or repetition should be avoided
> For instance:

– AG = Agitator
– B = Blower
– C = Compressor
– CT = Cooling tower
– CV = Conveyor
– CY = Cyclone
– D = Drum or Tank
– DR = Dryer
– E = Heat exchanger
– F = Fan
– Fi = Filter
– M = Motor
– P = Pump
– R = Reactor
– RV = Rotary valve
– S = Separator
Sequential Numbering
Pump PP 01 to PP 140
Crushers CR 01 to CR 03
Feeders FE 01 to FE 03
Cyclones CY 01 to CY 15
Equipment List
EQUIPMENT REV QUANTITY DESCRIPTION kW STATUS

NUMBER
310BIN01 1 ROM ore Bin suitable for truck or FEL tipping 0.00
Mild Steel Plate c/w Wear Plate Liners
Fabricated Cap: 180t live capacity
310CHU01 1 Primary Crusher Feed Chute Cap: 400tph 0.00
Mild Steel Plate Wear Plate Liners
Fabricated
310CHU03 1 Primary Crusher Discharge Chute Cap: 400tph 0.00
Fabricated Size: 1200 wide belt
310CHU03 1 CVR 01 Head Chute Cap: 100 tph 0.00
Fabricated Size: 1200 wide belt
310CRJ01 1 Primary Crusher Cap: 400 tph 1850.00 C
Jaw - Single Toggle Size: 1050 x 1400 mm feed opening

CSS 150 mm
310CVR01 1 Primary Conveyor Design 1300 tph/Actual 852 tph 30.00 C
Size: 1200 mm Len: 25.3 m
Lift: 2.8 m Speed:2.0m/s
310CWR10 1 Crusher Water Chiller 0.00
310FDP01 F 1 Plate Feeder Cap: 400 tph Type: BVS 1655 45.00 C
Size: 5500 x 1600 mm Construction: V/S hydraulic drive
310HST01 G 1 Crusher Overhead Crane Cap: 8 tonne SWL 20.80 C
Electric Lift and Travel
Size:
310MGT01 F 1 Tramp Metal Magnet Cap: 7.00 P
Electromagnetic Stationary
Size: 1200 mm wide Head 310-CVR-01
310PED01 F 1 Pedestal for Primary Crusher Motor 0.00 C
310PPD102 1 Jaw Crusher Lube Pump 3.70 C
310SCR01 1 Product Screen Cap: 1000 tph 75.00 C
Banana Screen Sized for rubber decks
Size: 2400 x 7100 double deck Aperture: 55/22
2031.50
P&ID
> Piping and Instrumentation Diagram (P&ID)
> Definitive and comprehensive diagrams, showing

― All control loops
― Equipment
― Piping
― Valves
― Instrumentation
> P&ID has all items identified
P&ID (cont.)
Recleaner Concentrate 47
J183-C-006
II
IT Concentrate
Thickener
M
280-TH-810
ProcessWater
48
II
Density Control
Manual Input
IT
S/P
40V4 03
03 40V4 FIC
VSD
100v801 100V801
M WT
40V403
280-002-SC-RL-100
80x100 280-004-SC-RL-100 XS
MH
40V403
40V403 40V403 WIR
100V901
200V801
280-PP-811
MS FAL FIR DIT DAH
PE IT II
40V403 25V301
40V301
Disc Filter
VSD FI DT 280-FL-820
WashdownWater 25V301
GlandWater M XS MH
40V403
280-005-SC-RL-100
280-003-SC-RL-100
Concentrate Distribution
80x100 100x904
280-001-SC-RL-100
Conveyors
280-007-CS-RL-150
100V901
280-PP-812 FE DC
280-006-CS-RL-150
Concentrate Thickener IT II
280-CV-831
M
Underflow Pumps
280-CV-832
280-CV-833 280-SP-803
II
25V301
28
Filtrate Moisture 280-TP-834
Concentrate
280-PP-821
Receivers Traps Stockpile
IT Recirculation
28
Pump RC RC MT MT
Filtrate Return
M
1 2 1 2
Filtrate Tank
Pump 100V904 280-010-PW-MS-100
280-AR-840 280-AR-841 280-MT-842 280-MT-843
II IT 80x100
M 80x100 80V801 280-008-PW-MS-80
280-009-PW-MS-80
280-PP-845
II IT PE
280-013-PW-MS-200 180x200 II IT M
280-012-PW-MS-200 28 28 M
25V301
280-TK-850
280-PP-851
280-011-PW-MS-100 80x100
280-014-DW-PE-090-010-SB 80V705
80x100 80V801
25V301
280-PP-844 280-PP-871
II IT
Filtrate Recovery M
PE
MH Pumps Silencer
MS
80V705
LSHH LSHL
25V301
28 28 50V403
LAHH M 280-PP-872
LE
28 25V403
28
II IT
M
280-PS-852
80V705
Concentrate Area
25V301
Sump Pump 280-PP-873
Vacuum Pumps
II
27
P&ID (cont.)
IT
27
Process
Water II
27
300V801 IT
27
N3 N1
40 V 4 N2 03
03 40 V 4
VSD
300v352 300V352
40V403
350x300
350x352 A
TF
100x200
40V403
350x250
XS MH
40V403 40V403
100V901
200V801
IT II
MS
27 27
PC
40V403 25V301
40V301
VSD
25V301
WASHDOWN M XS MH
40V403
WATER
B
TF
100x200 350x904
350x250
100V901
Thickener Underflow
Pump
271-PP-711/712
Gland Water
P&ID (cont.)
Final P&IDs should include:-
― Mechanical equipment with names and numbers
― Instruments with identification and necessary interfaces

with control loops
― Interconnecting piping, sizes and identification
― Valves with identifications
― Vents, drains, special fittings, sampling lines, reducers and

increasers
― Flow directions
P&ID (cont.)
> Control interfaces, inputs and outputs
> Interface tags to other P&ID's
> Main plant interlocks
> Identification of symbols used
> Reference list including identification of relevant PFD's
Pipe Identification
23-182-PW-MS-150
23 = area number
182 = unique pipe number within the area
PW = pipe line contents, process water in this case
MS = piping specification, (mild steel)
150 = pipe line size
General P&ID Identification
PIPELINE IDENTIFICATION
PIPELINE NUMBERING AS FOLLOWS
AA-BBB-CCC-DDD-EEE-FF-GG
> WHERE AA IS THE AREA NUMBER (FIRST TWO DIGITS)
> BBB IS THE UNIQUE PIPE NUMBER WITHIN THE AREA.
> CCC IS THE PIPELINE CONTENTS (SEE FLUID IDENTIFICATION)
> DDD IS PIPING SPECIFICATION.
> EEE IS THE PIPELINE SIZE (HPS OR DO)
> FF IS CLASS OF PLASTIC PIPING.
> GG IS SWEPT BENDS WHERE SPECIFIED
General P&ID Identification (cont.)
FLUID IDENTIFICATION
AS ANTISCALANT HD HYDRAULIC OIL

BS BARREN SOLUTION IA INSTRUMENTATION AIR
CA CAUSTIC SOLUTION LA LEACH AIR
CC CAUSTIC CYANIDE SOLUTION LM LIME
CN CYANIDE SOLUTION LO LUBRICATION OIL
CS CYANIDE SLURRY MS MILL SLURRY
DW DIRTY WATER NA NITRIC ACID
EF EXHAUST FUMES PA PLANT AIR
EW ELUTION WATER POT POTABLE WATER
FL FLOCCULANT PS PREGNANT SOLUTION
FO FUEL OIL PW PROCESS WATER
FW FILTERED WATER RW RAW WATER
GL GLYCOL SC CARBON SLURRY
GW GLAND WATER TW TAILINGS WATER
HCL HYDROCHLORIC ACID WW WASHDOWN WATER
PIPING SPECIFICATION
PVC UNPLASTICISED POLYVINYLCHLORIDE

BL BUTYL LINED MILD STEEL
RL RUBBER LINED MILD STEEL
FH FLEXIBLE HOSE
SS STAINLESS STEEL
MH MINING HOSE
XS EXTRA STRONG
MS MILD STEEL
MSG MILD STEEL GALVANISED
PE POLYETHYLENE
PP POLYPROPYLENE
LINE IDENTIFICATION
MAIN PROCESS LINE OR UTILITIES HYDRAULICS
CARBON FLOW
HOSE (FLOWSHEET ONLY)
BYPASS FLOW (OR STANDBY)

(FLOWSHEETS ONLY)
ELECTRO MAGNETIC, SONIC, NUCLEAR
OR LIGHT SIGNAL
BY HAND
INTERNAL SYSTEM LINK

PNEUMATIC SIGNAL OR (SOFTWARE OR DATA LINK)
AIR SUPPLY TO INSTRUMENTATION
P&ID REFERENCE FLAG

CAPILLARY TUBING A C
A – DESCRIPTION OF FLOW STREAM
B B – REFERENCE DRAWING NUMBER
C – UNIQUE CROSS REFERENCE NUMBER
VALVE & ACTUATOR SYMBOLS
TECH-TAYLOR VALVE NEEDLE VALVE KNIFE GATE VALVE DIAPHRAGM WITH POSITIONER
PRESSURE REDUCING REGULATOR

GATE VALVE (SELF CONTAINED) DUMP VALVE ROTARY (90°)
BALL VALVE PISTON OPERATED RETURN DART VALVE

(SINGLE ACTING) ROTARY (90°) WITH POSITIONER
PLUG VALVE
GLOBE VALVE PISTON OPERATED
(DOUBLE ACTING)
PINCH VALVE M MOTORISED
BUTTERFLY VALVE PISTON OPERATED
(DOUBLE ACTING) SPECTACLE VALVE
WITH POSITIONER (OPEN TO FLOW) SOLENOID
CHECK VALVE S
SPECTACLE VALVE
(CLOSED TO FLOW) DIAPHRAGM MANUAL (ABSENCE OF OPERATOR
DIAPHRAGM VALVE IMPLIES MANUAL OPERATION)
PRESSURE RELIEF VALVE
THREE WAY VALVE
PIPING SYMBOLS
PIPE LINE RO AUTO DRAIN FILTER

RESTRICTION PLATE
VICTAULIC JOINT
SPRAY
FLANGED JOINT FLANGED RUBBER ELBOW OR BEND
INSULATED PIPE WASHDOWN WATER UTILITY-STATION SAFETY SHOWER WITH EYEWASH

1
(NUMERAL INDICATES NUMBER OF OUTLETS)
(BALL VALVE + MINSUP)
END CAP SP
POTABLE WATER STATION SPECIAL EQUIPMENT
HOSE CONNECTION
MINSUP COUPLING HOSE REEL STATION FLOW ELEMENT

(ELECTROMAGNETIC)
LAUNDER GATE PLANT AIR UTILITY-STATION FLOW ELEMENT -

(NUMERAL INDICATES NUMBER OF OUTLETS) DIFFERENTIAL PRESSURE
1 (PLANT AIR + MINSUP) V CONE
REDUCER (CONCENTRIC)
FIRE WATER STATION SURGE ALLEVIATOR/
BF REDUCER (ECCENTRIC) (C/W FIRE HYDRANT, HOSE NOZZLE AND HOSE BOX) PRESSURE VESSEL
BOTTOM FLAT
TF REDUCER (ECCENTRIC) ORIFICE PLATE
TOP FLAT Y STRAINER
DRESSER COUPLING
FILTER A
AUTO BACKWASHING STRAINER
Equipment
HOIST/CRANE STOCKPILE
JAW CRUSHER
BELT CONVEYOR
(WITH DRIVE PULLEY)
GRINDING MILL ROCKBREAKER
VARIABLE SPEED DRIVE

VSD (VVVF)
M
AGITATOR (SINGLE) THICKENER
PISTON PUMP
CLASSIFYING
CYCLONE
FAN TRUCK
Equipment
M
OIL FAN COOLER

LIME SILO WITH TWO FEEDERS
BAG BREAKER AND FILTER
M M
BELT WASH STATION
R D L
THICKENER
HYDRAULIC MOTOR
WINCH
M
GYRATORY OR
CONE CRUSHER
LOAD CELL
M M
KNELSON CONCENTRATOR
KEMIX INTERSTAGE
SCREEN
Equipment
M
SIEVE BEND VERTICAL SPINDLE
PUMP
HELICAL ROTOR PUMP M
MOTORISED DRUM PUMP
APRON FEEDER
VIBRATING SCREEN
VIBRATING GRIZZLY
BAG BREAKER
BUCKET
INTERSTAGE SCREEN
CENTRIFUGAL PUMP
DUST COLLECTOR
Other Deliverables
> Equipment list

> Process Description
> Process Design Criteria
> Process Control Design philosophy
> Operating Cost
> Capital Cost
> General Arrangement drawings
> Section drawings
> Implementation plan
> Project schedule
> Financial Model
> Risk Assessment
Final Flow Sheet Analysis
Continuous Improvement
> Identify problem
> Look for alternatives
> Discuss with others
> Research
> Equipment manuals
> Cost effective
> Feasibility
> Implement plans
Flow Sheet Modification
Focus on:
> The original design criteria
― Is this design criteria still applicable to the ore currently

being treated?
> The original equipment list
― Is the equipment being fully utilised?
― What scope exists for increasing throughput?
― Are there mechanical limitations?
― Where are the bottlenecks in the plant?
― How can these bottlenecks be overcome?
Example Design Criteria
> Information required in order to set up a process flow

diagram or P&ID:-
― Equipment specification
― Development of the plant layout
― Plant specification
― Performance specification
― Ore specification
Example Design Criteria (cont.)
> Plant capacity 500,000 tpa.

> Approximate feed grade 4.5 g/tonne.
> Overall recovery 95 %.
Ore Specification Characteristics
Bulk density
> Range 1.3 to 1.6 t/m3
> Design 1.4
Specific gravity
> Oxide ore 2.0
> Sulphide ore 3.0
> Design 2.13
Moisture content
> Maximum 12.0 %.
> Average 8.0 %
ROM sizing
> 100 % minus, mm 800
> 80 % minus, mm 450
> 20 % minus, mm 150
BOND Work Index.

> Oxide ore 8.3 kWh/tonne
> Secondary Pyrite 13.0 " "
> Primary Ore 18.5 " "
> Laterite 19.9 " "
> Design basis 13.0 " “
Abrasive Index.
> Oxide ore 0.0139
> Secondary Pyrite 0.3005
Chemical composition
> Oxide ore - grade

– Copper (ppm) 50 to 600 ppm
– Nickel (ppm) 90 to 300 ppm
> Sulphide ore – grade

– Copper (ppm) 300 to 1200 ppm
– Nickel (ppm) 100 to 300 ppm
Plant General Arrangement
Plant Layout
Layout
THANK YOU
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MINERAL PROCESSING COURSE

Click to edit Master subtitle style

> Graphical representation of a process

OPERATOR SET POINT

CONVEYOR INTERLOCKS WITH

> Made up of a series of blocks and lines

> Each block represents a particular unit process

> Each line shows the direction of flow

BULLION PURIFYING ELECTRO ADSORPTION

> Similar to Block Flow Diagram

ALUMINIUM BELT FILTER

Major process units:-

6. Filtering and Drying

> Block flow diagram representing the material flow of:

> Input must be equal to output

> Must be updated with every change in the process

Feed = Tailings + Concentrate

> Water volume required to make up pulp of 65% solids

― Major process pipes

― Essential process control circuits

― Major process requirements

> Pre-requisite for P&ID

FAYALALA PLANT SITE LERO KARTA MINESITE

NO. 2 ROM BIN

MILL FEED CONVEYOR WEIGHTOMETER

MILL FEED CONVEYOR WEIGHTOMETER

Area Code General Description

> No official standardized lettering system for the designation of equipment

> Ambiguity or repetition should be avoided

> For instance:

EQUIPMENT REV QUANTITY DESCRIPTION kW STATUS

Jaw - Single Toggle Size: 1050 x 1400 mm feed opening

> Piping and Instrumentation Diagram (P&ID)

> Definitive and comprehensive diagrams, showing

> P&ID has all items identified

Final P&IDs should include:-

― Mechanical equipment with names and numbers

― Instruments with identification and necessary interfaces

― Interconnecting piping, sizes and identification

― Valves with identifications

― Vents, drains, special fittings, sampling lines, reducers and

> Control interfaces, inputs and outputs

> Interface tags to other P&ID's

> Main plant interlocks

> Identification of symbols used

> Reference list including identification of relevant PFD's

182 = unique pipe number within the area

PW = pipe line contents, process water in this case

MS = piping specification, (mild steel)

150 = pipe line size

> WHERE AA IS THE AREA NUMBER (FIRST TWO DIGITS)

> BBB IS THE UNIQUE PIPE NUMBER WITHIN THE AREA.

> CCC IS THE PIPELINE CONTENTS (SEE FLUID IDENTIFICATION)

> DDD IS PIPING SPECIFICATION.

> EEE IS THE PIPELINE SIZE (HPS OR DO)

> FF IS CLASS OF PLASTIC PIPING.

> GG IS SWEPT BENDS WHERE SPECIFIED

AS ANTISCALANT HD HYDRAULIC OIL

PVC UNPLASTICISED POLYVINYLCHLORIDE

MAIN PROCESS LINE OR UTILITIES HYDRAULICS

BYPASS FLOW (OR STANDBY)

INTERNAL SYSTEM LINK

P&ID REFERENCE FLAG

VALVE & ACTUATOR SYMBOLS